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E 2011 Lennox Industries Inc.
Dallas, Texas, USA
INSTALLATION
INSTRUCTIONS
EL195UH
ELITE ® SERIES GAS FURNACE
UPFLOW / HORIZONTAL AIR DISCHARGE
506596−01
03/2011
Supersedes 02/2011
Litho U.S.A.
THIS MANUAL MUST BE LEFT WITH THE
HOMEOWNER FOR FUTURE REFERENCE
This is a safety alert symbol and should never be ignored.
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.
AIR FLOW
UPFLOW
HORIZONTAL LEFT HORIZONTAL RIGHT
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Installation and service must be performed by a licensed professional installer (or equivalent), service agency or the gas supplier.
Unit Dimensions
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Use of Furnace as a Construction Heater . . . . . . . . . . .
General
Table of Contents
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EL195UH Parts Arrangement
EL195UH Gas Furnace
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . .
Shipping and Packing List . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Combustion, Dilution, Ventilation Air . . . . . . . . . . . . . . .
2
3
4
4
4
5
6
6
Setting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duct System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
13
Pipe and Fittings Specifications
Joint Cementing Procedure
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
13
15
Venting Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vent Piping Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
17
Gas Piping
Electrical
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
37
Unit Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Pressure Measurement
Proper Combustion
. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
42
42
High Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Other Unit Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . .
42
44
Blower Motor Performance
Service
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45
47
Planned Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Integrated Control Diagnostic Codes . . . . . . . . . . . . . . .
49
49
Troubleshooting
Repair Parts List
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start Up Checklist
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50
53
54
03/11
*2P0311*
Page 1
506596−01
*P506596-01*
EL195UH Unit Dimensions − inches (mm)
1 NOTE − 60C size units that require air volumes
1800 cfm or over (850 L/s) must have one of the following
1. Single side return air with transition, to accommodate
20 x 25 x 1 in. (508 x 635 x 25 mm) cleanable air filter. Required to maintain proper air velocity.
2. Single side return air with optional Return Air Base
3. Bottom return air.
4. Return air from both sides.
5. Bottom and one side return air.
See Blower Performancetables for additional information.
2 Optional External Side Return Air Filter Kit is not for use with the optional Return Air Base.
3/4
(19)
A
B 9/16 (14)
1 − 7/8 (48)
3 − 1/4
(83)
D
COMBUSTION
AIR INTAKE
2 OPTIONAL
SIDE RETURN
AIR FILTER KIT
(Either Side)
1 − 1/2 (38)
Front Panel
EXHAUST AIR
OUTLET
SUPPLY AIR
OPENING
23 − 3/4
(603)
25
(635)
TOP VIEW
27 − 3/4
(705)
19 − 7/16
(494)
9/16
(14)
2 OPTIONAL
SIDE RETURN
AIR FILTER KIT
(Either Side)
33
(838)
6 − 9/16 (167)
Left
9 (229)
Right
12 − 5/8 (321)
(Either Side)
ELECTRICAL
INLET
(Either Side)
14 − 3/4
(375)
16
(406)
AIR FLOW
C
1 Bottom Return
Air Opening
FRONT VIEW
Model No.
EL195UH045P24B
EL195UH045P36B
EL195UH070P36B
EL195UH070P48B
EL195UH090P36C
EL195UH090P48C
EL195UH090P60C
EL195UH110P48C
EL195UH110P60C
EL195UH135P60D
3/4
(19)
5/8
(16) in.
A mm
17 − 1/2
21
24 − 1/2
446
533
622 in.
B mm
16 − 3/8
19 − 7/8
23 − 3/8
3 − 1/4
(83)
416
505
594
2 (51)
(Either Side)
GAS PIPING INLET
(Either Side)
CONDENSATE
TRAP CONNECTION
(Either Side)
6 − 1/2 (165)
(Either Side)
23
(584)
1 Side Return
Air Opening
(Either Side) in.
C mm
1
23 − 1/2
(597)
Bottom Return
Air Opening
SIDE VIEW
D in.
mm
16 406
19 − 1/2 495
23 584
7 − 5/8
9 − 3/8
11 − 1/8
14
(356)
1 − 15/16 (49)
194
238
283
1 − 1/2
(38)
Page 2
EL195UH Parts Arrangement
GAS VALVE
EL195UH PARTS IDENTIFICATION
BURNER BOX
ASSEMBLY
FLEXIBLE NO−HUB
EXHAUST COLLAR
TOP CAP
DuralokPlus TM
HEAT EXCHANGER
ASSEMBLY
COMBUSTION AIR
INDUCER
PRIMARY LIMIT
BAG ASSEMBLIES
(shipping location)
OUTER
COLD END
ACCESS
PANEL
HEADER BOX
COMBUSTION
AIR PRESSURE
SWITCH
BLOWER
ASSEMBLY
CONTROL BOX
(includes integrated ignition control, transformer and interlock switch)
FIGURE 1
Page 3
EL195UH Gas Furnace
The EL195UH Category IV gas furnace is shipped ready for installation in the upflow or horizontal position. The furnace is shipped with the bottom panel in place. The bottom panel must be removed if the unit is to be installed in horizontal or upflow applications with bottom return air.
The EL195UH can be installed as either a Direct Vent or a Non−Direct Vent gas central furnace.
The furnace is equipped for installation in natural gas applications. A conversion kit (ordered separately) is required for use in propane/LP gas applications.
NOTE − In Direct Vent installations, combustion air is taken from outdoors and flue gases are discharged outdoors. In
Non−Direct Vent installations, combustion air is taken from indoors and flue gases are discharged outdoors. See figure
2 for applications involving roof termination.
DIRECT VENT INSTALLATION
COMBUSTION
AIR INTAKE
OUTSIDE OF
HOUSE
EXHAUST
OUTLET
NON−DIRECT VENT
INSTALLATION
EXHAUST
OUTLET
EL195UH EL195UH
COMBUSTION
AIR INTAKE INSIDE
OF HOUSE
FIGURE 2
Shipping and Packing List
Package 1 of 1 contains
1 − Assembled EL195UH 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 debris screen
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 − Return air base kit
1 − Horizontal suspension kit
1 − High altitude pressure switch
Safety Information
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal 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.
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.
Use only the type of gas approved for use with this furnace.
Refer to unit nameplate.
EL195UH 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 local 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 non−direct vent applications, combustion and ventilation air supply must be provided according to the current National Fuel Gas Code or CSA-B149 standard.
Page 4
Installation Locations
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.
NOTE − For installation on combustible floors, the furnace shall not be installed directly on carpeting, tile, or other combustible material other than wood flooring.
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 in a public garage, hangar, or other building that has a hazardous atmosphere, the furnace must be installed according to recommended good practice requirements and current 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 EL195UH furnace must be installed so that its electrical components are protected from water.
Installed in Combination with a Cooling Coil
When this furnace is used with cooling coils (figure 3), it shall
be installed in parallel with, or on the upstream side of, cooling coils to avoid condensation in the heating compartment.
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 manually operated, it must be equipped to prevent operation of either 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 address:
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.
Heating Unit Installed Parallel to Air Handler Unit
Dampers
(open during heating operation only)
Gas Unit
AIR FLOW
Air Handler Unit
Dampers
(open during cooling operation only)
AIR FLOW
Heating Unit Installed Upstream of Cooling Coil
AIR FLOW
Gas Unit
AIR FLOW
Cooling Coil
FIGURE 3
NOTE − This furnace is designed for a minimum continuous return air temperature of 60°F (16°C) or an intermittent operation down to 55°F (13°C) dry bulb for cases where a night setback thermostat is used. Return air temperature must not exceed 85°F (29°C) dry bulb.
The EL195UH furnace may be installed in alcoves, closets, attics, basements, garages, crawl spaces and utility rooms in the upflow or horizontal position.
This furnace design has not been CSA certified for installation in mobile homes, recreational vehicles, or outdoors.
Use of Furnace as Construction Heater
Lennox does not recommend the use of EL195UH units as a construction heater during any phase of construction.
Very low return air temperatures, harmful vapors and operation of the unit with clogged or misplaced filters will damage the unit.
EL195UH units may be used for heating of buildings or structures under construction, if the following conditions are met:
D The vent system must be permanently installed per these installation instructions.
D A room thermostat must control the furnace. The use of fixed jumpers that will provide continuous heating is not allowed.
D The return air duct must be provided and sealed to the furnace.
D Return air temperature range between 60°F (16°C) and
80°F (27°C) must be maintained.
Page 5
D Air filters must be installed in the system and must be maintained during construction.
D Air filters must be replaced upon construction completion.
D The input rate and temperature rise must be set per the furnace rating plate.
D One hundred percent (100%) outdoor air must be provided for combustion air requirements during construction. 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.
D The furnace heat exchanger, components, duct system, air filters and evaporator coils must be thoroughly cleaned following final construction clean−up.
D All furnace operating conditions (including ignition, input rate, temperature rise and venting) must be verified according to these installation instructions.
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 following general recommendations must be considered when installing a EL195UH furnace:
•
Place the furnace as close to the center of the air distribution system as possible. The furnace should also be located close to the vent termination point.
•
When the furnace is installed in non−direct vent applications, 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 non−direct vent applications, 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 insulated 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
EL195UH unit should not be installed in areas normally 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 California 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 75379−9900
WARNING
Insufficient combustion air can cause headaches, nausea, dizziness or asphyxiation. It will also cause excess water in the heat exchanger resulting in rusting 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 combustion air supply:
Permanent wave solutions
Chlorinated waxes and cleaners
Chlorine base swimming pool chemicals
Water softening chemicals
De−icing 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
Combustion, Dilution & Ventilation Air
If the EL195UH is installed as a Non−Direct Vent Furnace, follow the guidelines in this section.
NOTE − In Non−Direct Vent installations, combustion air is taken from indoors and flue gases are discharged out− doors.
In the past, there was no problem in bringing in sufficient outdoor air for combustion. Infiltration provided all the air that was needed. In today’s homes, tight construction practices make it necessary to bring in air from outside for combustion. Take into account that exhaust fans, appliance 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-
Page 6
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 potentially 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 EL195UH furnaces to ensure efficient 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 complete 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 contaminated atmosphere. Meet all combustion and ventilation air requirements, as well as all local codes.
All gas-fired appliances require air for the combustion process. If sufficient combustion air is not available, the furnace or other appliance will operate inefficiently and unsafely. Enough air must be provided to meet the needs of all fuel−burning appliances and appliances such as exhaust fans which force air out of the house. When fireplaces, exhaust 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 dilutes contaminants in the indoor air. These contaminants may include bleaches, adhesives, detergents, solvents and other contaminants which can corrode furnace components.
The requirements for providing air for combustion and ventilation 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 m
3
) per 1,000 Btu (.29 kW) per hour of the combined 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 unconfined, it might be necessary to bring in outdoor air for combustion if the structure does not provide enough air by infiltration. If the furnace is located in a building of tight construction with weather stripping and caulking around the windows and doors, follow the procedures in the Air from Outside section.
Confined Space
A confined space is an area with a volume less than 50 cubic feet (1.42 m
3
) 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 containing 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 either from inside the building or from outside.
Air from Inside
If the confined space that houses the furnace adjoins a space categorized as unconfined, air can be brought in by providing two permanent openings between the two spaces. Each opening must have a minimum free area of 1 square inch (645 mm 2 ) per 1,000 Btu (.29 kW) per hour of total input rating of all gas−fired equipment in the confined space. Each opening must be at least 100 square inches
(64516 mm 2 ). 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.
EQUIPMENT IN CONFINED SPACE − ALL AIR FROM INSIDE
ROOF TERMINATED
EXHAUST PIPE
SIDE WALL
TERMINATED
EXHAUST PIPE
(ALTERNATE
LOCATION)
EL195UH
OPENINGS
(To Adjacent
Unconfined
Space)
NOTE − Each opening shall have a free area of at least one square inch per 1,000 Btu (645mm 2 per .29kW) per hour of the total input rating of all equipment in the enclosure, but not less than 100 square inches
(64516mm.
2).
FIGURE 4
Page 7
Air from Outside
If air from outside is brought in for combustion and ventilation, the confined space shall be provided with two permanent 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 minimum free area of 1 square inch per 4,000 Btu (645mm 2 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 minimum free area of 1 square inch per 2,000 Btu (645mm
2 per .59kW) per total input rating of all equipment in the en-
EQUIPMENT IN CONFINED SPACE − ALL AIR FROM OUTSIDE
(Inlet Air from Crawl Space and Outlet Air to Ventilated Attic)
VENTILATION LOUVERS
(Each end of attic)
ROOF TERMINATED
EXHAUST PIPE
When ducts are used, they shall be of the same cross−sectional 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 protective 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.
EQUIPMENT IN CONFINED SPACE − ALL AIR FROM OUTSIDE
(All Air Through Ventilated Attic)
ROOF TERMINATED
EXHAUST PIPE
OUTLET
AIR
VENTILATION LOUVERS
(Each end of attic)
SIDE WALL
TERMINATED
EXHAUST PIPE
(ALTERNATE
LOCATION)
FURNACE
INLET
AIR
OUTLET
AIR
VENTILATION
LOUVERS
(For unheated crawl space)
NOTE −The inlet and outlet air openings shall each have a free area of at least one square inch per 4,000 Btu (645mm 2 per 1.17kW) per hour of the total input rating of all equipment in the enclosure.
FIGURE 5
If air from outside is brought in for combustion and ventilation, the confined space must have two permanent openings. 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 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 minimum free area of 1 square inch (645 mm 2 ) 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 opening shall have a minimum free area of 1 square inch (645 mm 2 ) per 2,000 Btu (.56 kW) per total input rating of all equipment in the enclosure. See
SIDE WALL
TERMINATED
EXHAUST PIPE
(ALTERNATE
LOCATION)
FURNACE
INLET AIR
(Ends 12" above bottom)
NOTE −The inlet and outlet air openings shall each have a free area of at least one square inch per 4,000 Btu (645mm 2 per 1.17kW) per hour of the total input rating of all equipment in the enclosure.
FIGURE 6
EQUIPMENT IN CONFINED SPACE −
ALL AIR FROM OUTSIDE
ROOF TERMINATED
EXHAUST PIPE
FURNACE
OUTLET AIR
SIDE WALL
TERMINATED
EXHAUST PIPE
(ALTERNATE
LOCATION)
INLET AIR
NOTE −Each air duct opening shall have a free area of at least one square inch per 2,000 Btu (645mm 2 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 communicate directly with the outdoors, each opening shall have a free area of at least 1 square inch per 4,000 Btu (645mm 2 per 1.17kW) per hour of the total input rating of all other equipment in the enclosure.
FIGURE 7
Page 8
Shipping Bolt Removal
Units with 1/2 hp blower motor are equipped with three flexible legs and one rigid leg. The rigid leg is equipped with a shipping bolt and a flat white plastic washer (rather than the rubber mounting grommet used with a flexible mounting
The bolt and washer must be removed before the furnace is placed into operation.
After the bolt and washer have been removed, the rigid leg will not touch the blower housing.
EL195UH090P48C
EL195UH110P48C with 1/2 HP Blower Motor
RIGID LEG
(Remove shipping bolt and washer)
FIGURE 8
Installation − Setting Equipment
WARNING
Do not connect the return air duct to the back of the furnace. Doing so will adversely affect the operation of the safety control devices, which could result in personal injury or death.
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.
Upflow Applications
The EL195UH gas furnace can be installed as shipped
in the upflow position. Refer to figure 10 for clearances.
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. The unit may be positioned from level to ½" toward the front. See
Allow for clearances to combustible materials as indicated on the unit nameplate.
SETTING EQUIPMENT
UPFLOW APPLICATION
AIR FLOW
FRONT VIEW
UNIT
FRONT
AIR FLOW
SIDE VIEW
HORIZONTAL APPLICATION
1/2" max.
UNIT
FRONT
SIDE VIEW
UNIT
FRONT
AIR FLOW
1/2" max.
END VIEW
FRONT VIEW
Unit must be level side−to−side. Unit may be positioned from level to 1/2" toward the front to aid in draining.
FIGURE 9
Page 9
WARNING
Improper installation of the furnace can result in personal 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 furnace should be sealed airtight to the return air plenum. 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. Allow absolutely no sagging, cracks, gaps, etc.
For no reason should return and supply air duct systems ever be connected to or from other heating devices such as a fireplace or stove, etc. Fire, explosion, carbon monoxide poisoning, personal injury and/or property damage could result.
Installation Clearances
Top
Return Air Guidelines
Return air can be brought in through the bottom or either side of the furnace installed in an upflow application. If the furnace is installed on a platform with bottom return, make an airtight seal between the bottom of the furnace and the platform to ensure that the furnace operates properly and safely. The furnace is equipped with a removable bottom panel to facilitate installation.
Markings are provided on both sides of the furnace cabinet for installations that require side return air. Cut the furnace cabinet at the maximum dimensions shown on page 2.
Refer to Engineering Handbook for additional information.
EL195UH applications which include side return air and a condensate trap installed on the same side of the cabinet (trap can be installed remotely within 5 ft.) require either a return air base or field−fabricated transition to accommodate an optional IAQ accessory taller
Left Side Right Side
Side Return Air
(with transition and filter)
20" X 25" X 1"
(508mm X635mm X 25mm)
1−1/2 in.
Air Filter Bottom (Floor)
Top/Plenum
*Front
Back
Sides
Vent
1 in. (25 mm)
0
0
0 †
0
Floor 0 ‡
*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.
‡ For installations on a combustible floor, do not install the furnace directly on carpeting, tile or other combustible materials other than wood flooring.
FIGURE 10
Return
Air
Plenum
Transition
FIGURE 11
Page 10
FURNACE
FRONT
Optional Return Air Base
(Upflow Applications Only)
AIR FLOW
INDOOR AIR
QUALITY
CABINET
(PCO, Filter
Cabinet, etc.)
IF BASE
IS USED
WITHOUT
IAQ CABINET,
A SINGLE
RETURN AIR
PLENUM
MUST
COVER BOTH
UNIT AND
RETURN
AIR BASE
OPENINGS
3 − 1/4
(83)
1 23 (584)
Overall
(Maximum)
1 Unit side return air
Opening
1 Minimum
11 (279)
2 Maximum
14 (356)
1 22 − 7/16
(570)
Overall
(Maximum)
7 − 1/4
(184)
5 − 5/8
(143)
SIDE RETURN
AIR OPENINGS
(Either Side)
17 − 1/2 (446) B Width (50W98)
21 (533) C Width (50W99)
24 − 1/2 (622) D Width (51W00)
FRONT VIEW
OPTIONAL
RETURN
AIR BASE
23
(584)
26 − 7/8
(683)
SIDE VIEW
3/4
(19)
NOTE− Optional side return air filter kits are not for use with return air base.
1 Both the unit return air opening and the base return air opening must be covered by a single plenum or IAQ cabinet.
Minimum unit side return air opening dimensions for units requiring 1800 cfm of air and over (W x H): 23 x 11 in. (584 x 279 mm).
2
The opening can be cut as needed to accommodate plenum or IAQ cabinet while maintaining dimensions shown.
Side return air openings must be cut in the field. There are cutting guides stenciled on the cabinet for the side return air opening. The size of the opening must not extend beyond the markings on the furnace cabinet.
To minimize pressure drop, the largest opening height possible (up to 14 inches) is preferred.
Removing the Bottom Panel
FIGURE 12
Removing the Bottom Panel
Remove the two screws that secure the bottom cap to the furnace. Pivot the bottom cap down to release the bottom panel. Once the bottom panel has been removed, reinstall
the bottom cap. See figure 13.
Horizontal Applications
WARNING
Do not install the furnace on its front or back.
Screw
Bottom Cap
Bottom Panel
Front Back
FIGURE 13
FIGURE 14
Page 11
The EL195UH furnace can be installed in horizontal applications with either right− or left−hand air discharge.
Refer to figure 15 for clearances in horizontal applications.
Horizontal Application
Installation Clearances
Right−Hand Discharge
Left End Right End
Air
Flow
Air
Flow
Bottom (Floor)**
Left−Hand Discharge
Top
Left End Right End
NOTE − Heavy−gauge sheet metal straps may be used to suspend the unit from roof rafters or ceiling joists. When straps are used to suspend the unit in this way, support must be provided for both the ends. The straps must not interfere with the plenum or exhaust piping installation.
Cooling coils and supply and return air plenums must be supported separately.
TYPICAL HORIZONTAL APPLICATION
Metal Strap
(typical)
Internal Brace
(provided with kit)
Bracket
(typical)
Air
Flow
Air
Flow
Bottom (Floor)**
Top
Front*
Back
Ends
Vent
Floor
0
0
0
0
0
0 ‡
*Front clearance in alcove installation must be 24 in. (610 mm).
Maintain a minimum of 24 in. (610 mm) for front service access.
**An 8" service clearance must be maintained below the unit to provide for servicing of the condensate trap.
‡ For installations on a combustible floor, do not install the furnace directly on carpeting, tile or other combustible materials other than wood flooring.
FIGURE 15
Suspended Installation of Horizontal Unit
This furnace may be installed in either an attic or a crawlspace. Either suspend the furnace from roof rafters or
floor joists, as shown in figure 16, or install the furnace on a
platform, as shown in figure 17. A horizontal suspension
kit (51W10) may be ordered from Lennox or use equivalent.
FIGURE 16
Air
Flow the horizontal suspension kit in a crawlspace, it must be elevated enough to avoid water damage, accommodate drain trap and to allow the evaporator coil to drain.
Platform Installation of Horizontal Unit
1 − Select location for unit keeping in mind service and
other necessary clearances. See figure 15.
2 − Construct a raised wooden frame and cover frame with a plywood sheet. If unit is installed above finished space, fabricate an auxiliary drain pan to be installed
under unit. Set unit in drain pan as shown in figure 17.
Leave 8 inches for service clearance below unit for condensate trap.
3 − Provide a service platform in front of unit. When installing the unit in a crawl space, a proper support platform may be created using cement blocks.
4 − Route auxiliary drain line so that water draining from this outlet will be easily noticed by the homeowner.
Page 12
5 − If necessary, run the condensate line into a condensate pump to meet drain line slope requirements. The pump must be rated for use with condensing furnaces.
Protect the condensate discharge line from the pump to the outside to avoid freezing.
6 − Continue with exhaust, condensate and intake piping installation according to instructions.
INTAKE PIPE
EXHAUST PIPE
*GAS
CONNECTOR
*Gas connector may be used for Canadian installation if acceptable by local authority having jurisdiction.
RAISED
PLATFORM
SERVICE PLATFORM
FIGURE 17
Return Air −− Horizontal Applications
Return air may be brought in only through the end of a furnace installed in the horizontal position. The furnace is equipped with a removable bottom panel to facilitate
Filters
This unit is not equipped with a filter or rack. A field−provided high velocity rated filter is required for the unit to oper-
ate properly. Table 1 lists recommended filter sizes.
A filter must be in place whenever the unit is operating.
TABLE 1
Furnace
Cabinet Width
17−1/2"
21"
24−1/2"
Side Return
16 X 25 X 1 (1)
16 X 25 X 1 (1)
16 X 25 X 1 (2)
Filter Size
Bottom Return
16 X 25 X 1 (1)
20 X 25 X 1 (1)
24 X 25 X 1 (1)
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 always be in place when the furnace is operating and it must not allow leaks.
Return Air Plenum
NOTE − Return air must not be drawn from a room where this furnace, or any other gas−fueled appliance
(i.e., water heater), or carbon monoxide−producing device (i.e., wood fireplace) is installed.
When return air is drawn from a room, a negative pressure 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 combustion and the formation of carbon monoxide gas. This raw gas or toxic fumes might then be distributed throughout the house by the furnace duct system.
Return air can be brought in through the bottom or either side of the furnace. If a furnace with bottom return air is installed on a platform, make an airtight seal between the bottom of the furnace and the platform to ensure that the unit operates properly and safely. Use fiberglass sealing strips, caulking, or equivalent sealing 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 American Society for Testing and Materials (ANSI/ASTM) standards. The solvent shall be free flowing and contain no lumps, undissolved particles or any foreign matter that adversely affects the joint strength or chemical resistance of the cement. The cement shall show no gelation, stratification, or separation that cannot be removed by stirring. Re-
fer to the table 2 below for approved piping and fitting ma-
terials.
Page 13
CAUTION
Solvent cements for plastic pipe are flammable liquids 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 2
PIPING AND FITTINGS SPECIFICATIONS
Schedule 40 PVC (Pipe)
Schedule 40 PVC (Cellular Core Pipe)
Schedule 40 PVC (Fittings)
D1785
F891
D2466
Schedule 40 CPVC (Pipe)
Schedule 40 CPVC (Fittings)
SDR−21 PVC or SDR−26 PVC (Pipe)
SDR−21 CPVC or SDR−26 CPVC (Pipe)
Schedule 40 ABS Cellular Core DWV (Pipe)
Schedule 40 ABS (Pipe)
Schedule 40 ABS (Fittings)
ABS−DWV (Drain Waste & Vent)
(Pipe & Fittings)
PVC−DWV (Drain Waste & Vent)
Pipe & Fittings)
F441
F438
D2241
F442
F628
D1527
D2468
D2661
D2665
PRIMER & SOLVENT CEMENT
ASTM
SPECIFICATION
PVC & CPVC Primer
PVC Solvent Cement
CPVC Solvent Cement
ABS Solvent Cement
PVC/CPVC/ABS All Purpose Cement For
Fittings & Pipe of the same material
ABS to PVC or CPVC Transition Solvent
Cement
CANADA PIPE & FITTING & SOLVENT
CEMENT
PVC & CPVC Pipe and Fittings
PVC & CPVC Solvent Cement
ABS to PVC or CPVC Transition Cement
F656
D2564
F493
D2235
D2564, D2235, F493
D3138
MARKING
ULCS636
IMPORTANT
EL195UH 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 2. As an alter-
nate, use all purpose cement, to bond ABS, PVC, or CPVC pipe when using fittings and pipe made of the same materials. Use transition solvent cement when bonding ABS to either 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 inside 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 appliance must be certified to ULC S636 and supplied by a single manufacturer as part of an approved vent (exhaust) system. In addition, the first three feet of vent pipe from the furnace flue collar must be accessible for inspection.
Page 14
EL195
UNIT
VENT
PIPE
DIA.
(in.)
2
Outdoor
Exhaust
Accelerator
(Dia. X
Length)
1−1/2" X 12"
YES
TABLE 3
OUTDOOR TERMINATION KITS USAGE
STANDARD
Outdoor
Exhaust
Accelerator
(Dia. X
Length)
2" Wall Plate
Kit
3" Wall Plate
Kit
2" Wall
Ring Kit
Flush-
Mount
Kit
2" X 12"
22G44 or 30G28
44J40 or 81J20
15F74 51W11**
YES YES* YES YES
71M80 or
44W92
YES
CONCENTRIC
1−1/2"
Concentric
Kit
2"
Concentric
Kit
3"
Concentric
Kit
69M29 or
44W92
60L46 or 44W93
045 2−1/2
3
2
YES
YES
YES
YES
YES
YES
YES*
YES*
YES*
YES
YES
YES
YES
YES
YES
YES
YES
YES
2−1/2 YES YES YES* YES YES YES 070
090
110
3
2
2−1/2
3
2
2−1/2
3
YES
YES
YES
YES
YES
YES
YES
YES YES*
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
135 3 YES YES YES YES
*Requires field−provided and installed 1−1/2" exhaust accelerator.
** Kit 51W11 is provided with a 1−1/2" accelerator which must be used for all EL195UH−045, −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 1−1/2" accelerator which must be installed on the exhaust outlet when this kit is used with theEL195UH045P24B and
EL195UH070P36B furnaces.
4 − Test fit joint and mark depth of fitting on outside of pipe.
Joint Cementing Procedure
All cementing of joints should be done according to the specifications outlined in ASTM D 2855.
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.
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.
NOTE − Time is critical at this stage. Do not allow primer to dry before applying cement.
6 − Promptly apply solvent cement to end of pipe and inside socket surface of fitting. Cement should be applied lightly but uniformly to inside of socket. Take care to keep excess cement out of socket. Apply second coat to end of pipe.
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.
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 during assembly (but not after pipe is fully inserted) to distribute cement evenly. DO NOT turn ABS or cellular core pipe.
Page 15
NOTE − Assembly should be completed within 20 seconds 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 indicate an improper assembly due to insufficient solvent.
9 − Handle joints carefully until completely set.
Venting Practices
CHIMNEY
OR GAS
VENT
(Check sizing for water heater only)
FURNACE
(Replaced by EL195)
REPLACING FURNACE THAT
WAS PART OF A COMMON
VENT SYSTEM
WATER
HEATER
OPENINGS
(To Adjacent
Room)
Piping Suspension Guidelines
SCHEDULE 40
PVC − 5’ all other pipe* − 3’
* See table 2 for allowable pipe.
NOTE − Isolate piping at the point where it exits the outside wall or roof in order to prevent transmission of vibration to the structure.
Wall Thickness Guidelines
24" maximum
3/4" minimum inside
Wall outside
If an EL195UH furnace replaces a 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 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 19 insulation
(if required)
FIGURE 18
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.
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 condensate collection trap and lines.
Exhaust Piping (Figures 22 and 23)
Route piping to outside of structure. Continue with installation following instructions given in piping termination section.
CAUTION
Do not discharge exhaust into an existing stack or stack that also serves another gas appliance. If vertical discharge through an existing unused stack is required, 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 pressure and must be completely sealed to prevent leakage of combustion products into the living space.
Page 16
Vent Piping Guidelines
The EL195UH can be installed as either a Non−Direct
Vent or a Direct Vent gas central furnace.
NOTE − In Non-Direct Vent installations, combustion air is taken from indoors and flue gases are discharged outdoors.
In Direct Vent installations, combustion air is taken from outdoors and flue gases are discharged outdoors.
Intake and exhaust pipe sizing −− Size pipe according to
minimum vent pipe lengths permitted. Table
lists the maximum pipe lengths permitted.
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 6.
In some applications which permit the use of several different sizes of vent pipe, a combination vent pipe may be used. Contact Lennox’ Application Department for assistance in sizing vent pipe in these applications.
NOTE − The exhaust collar on all models is sized to accommodate 2" Schedule 40 vent pipe. In horizontal applications, any transition to exhaust pipe larger than 2" must be made in vertical runs of the pipe. Therefore a 2" elbow must be added before the pipe is transitioned to any size larger than 2". This elbow must be added to the elbow count used to determine acceptable vent lengths.
Contact the Application Department for more information concerning sizing of vent systems which include multiple pipe sizes.
Exhaust Pipe
12" Min.
12" max of straight pipe
Use the following steps to correctly size vent pipe diameter.
1
Furnace capacity?
2
Which termination?
3
4
Which needs most elbows?
How many?
5
Desired pipe size?
045, 070,
090, 110 or 135 btuh
Standard or
Concentric?
Intake or exhaust
2", 2 1/2",
3" or 4"
6
What is the altitude?
Horizontal Application
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.
EL195UH
MODEL
FIGURE 20
TABLE 4
MINIMUM VENT PIPE LENGTHS
MIN. VENT LENGTH*
045, 070, 090, 110, 135
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.
7
Use table 5 to find max intake or exhaust pipe length.
FIGURE 21
IMPORTANT
Do not use screens or perforated metal in exhaust or intake terminations. Doing so will cause freeze−ups and may block the terminations.
Page 17
TABLE 5
Maximum Allowable Intake or Exhaust Vent Length in Feet
*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.
Number Of
90° Elbows
Used
8
9
6
7
10
3
4
1
2
5
Number Of
90° Elbows
Used
6
7
4
5
8
1
2
3
9
10
71
66
61
045
81
76
56
51
46
41
36
66
61
56
51
46
045
81
76
71
41
36
51
46
41
36
31
070
66
61
56
26
21
2" Pipe
Model
090
44
39
34
29
24
19
14 n/a
56
51
46
070
66
61
41
36
31
26
21
2" Pipe
Model
090
44
39
34
29
24
19
14 n/a
110
24
19
14 n/a
Standard Termination at Elevation 0 − 4500 ft
135 045 070
2−1/2" Pipe
Model
090 110 135
115
110
105
100
95
115
110
105
100
95
93
88
83
78
73
58
53
48
43
38 n/a n/a
90
85
80
75
90
85
80
75
68
63
58
53
33
28
23
18
110
70 70 48 13
Standard Termination Elevation 4500 − 10,000 ft
135 045 070
2−1/2" Pipe
Model
090 110 135
115
110
105
115
110
105
93
88
83
58
53
48 n/a n/a
100
95
90
85
80
75
70
100
95
90
85
80
75
70
78
73
68
63
58
53
48
43
38
33
28
23
18
13 n/a
070
137
132
127
122
117
112
107
102
97
92
045
138
133
128
123
118
113
108
103
98
93
122
117
112
107
102
070
137
132
127
97
92
123
118
113
108
103
045
138
133
128
98
93
103
98
93
88
83
78
73
3" Pipe
Model
090
118
113
108
3" Pipe
Model
090
118
113
108
103
98
93
88
83
78
73
135
114
109
104
99
94
89
84
79
74
69
110
118
113
108
103
98
93
88
83
78
73
99
94
89
84
79
135
114
109
104
74
69
103
98
93
88
83
110
118
113
108
78
73
Page 18
TABLE 5 Continued
Maximum Allowable Intake or Exhaust Vent Length in Feet
*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.
Number Of
90° Elbows
Used
6
7
4
5
8
1
2
3
9
10
Number Of
90° Elbows
Used
5
6
3
4
7
1
2
8
9
10
070
43
38
33
28
23
58
53
48
18
13
045
58
53
48
43
38
73
68
63
33
28
23
18
13
38
33
28
070
58
53
48
43
38
33
28
53
48
43
045
73
68
63
58
2" Pipe
Model
090
27
22
17
12
42
37
32 n/a
2" Pipe
Model
090
42
37
32
27
22
17
12 n/a
Concentric Termination at Elevation 0 − 4500 ft
2−1/2" Pipe
110 135 045 070
Model
090 110 135
22
17
12 n/a n/a
90
85
80
75
70
105
100
95
105
100
95
90
85
80
75
70
89
84
79
74
69
64
59
54
54
49
44
39
34
29
24
19 n/a
65
60
65
60
49
44
14 n/a
Concentric Termination Elevation 4501 − 10,000 ft
2−1/2" Pipe
Model
110 n/a
135 n/a
70
65
60
85
80
75
045
105
100
95
90
70
65
60
85
80
75
070
105
100
95
90
54
49
44
69
64
59
090
89
84
79
74
19
14 n/a
34
29
24
110
54
49
44
39
135 n/a
045
121
116
111
106
101
96
91
86
81
76
101
96
91
86
81
76
045
121
116
111
106
070
121
116
111
106
101
96
91
86
81
76
3" Pipe
Model
090
99
94
89
84
79
114
109
104
74
69
101
96
91
86
81
76
070
121
116
111
106
3" Pipe
Model
79
74
69
94
89
84
090
114
109
104
99
135
90
85
80
75
70
105
100
95
65
60
110
99
94
89
84
79
114
109
104
74
69
70
65
60
85
80
75
135
105
100
95
90
79
74
69
94
89
84
110
114
109
104
99
Page 19
TYPICAL EXHAUST AND INTAKE PIPE CONNECTIONS IN UPFLOW DIRECT OR
NON−DIRECT VENT APPLICATIONS
EXHAUST INTAKE EXHAUST INTAKE
2”
2” or
2”
3”
2” 2”
3”
TRANSITION
*2” *2”
TRANSITION
DO NOT transition from smaller to larger pipe in horizontal runs of exhaust pipe .
2”
* When transitioning up in pipe size, use the shortest length of 2” PVC pipe possible.
FIGURE 22
TYPICAL EXHAUST AND INTAKE PIPE CONNECTIONS IN HORIZONTAL DIRECT OR NON−DIRECT VENT
APPLICATIONS (RIGHT HAND DISCHARGE SHOWN)
EXHAUST
12" max.
2”
2”
2” or
2”
2”
2”
2”
2” or
2”
2”
*2”
45°
MAX
SIDE VIEW
45°
MAX
INTAKE
3”
EXHAUST
*2"
*2"
TRANSITION
3”
DO NOT transition from smaller to larger pipe in horizontal runs of exhaust pipe .
*2"
*2"
INTAKE
* When transitioning up in pipe size, use the shortest length of 2” PVC pipe possible.
FIGURE 23
Page 20
Intake Piping
The EL195UH furnace may be installed in either direct vent or non−direct vent applications. In non−direct vent applications, when intake air will be drawn into the furnace from the surrounding space, the indoor air quality must be considered and 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 transition solvent cement or a sheet metal screw 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 guidelines for piping terminations and intake and exhaust piping terminations for direct vent sections. Refer to table
for pipe sizes.
TYPICAL AIR INTAKE PIPE CONNECTIONS
UPFLOW NON − DIRECT
VENT APPLICATIONS
INTAKE
DEBRIS
SCREEN
(Provided)
TYPICAL AIR INTAKE PIPE CONNECTIONS
HORIZONTAL NON − DIRECT VENT APPLICATIONS
(Horizontal Right − Hand Air Discharge Application Shown)
PVC pipe coupling
OR
INTAKE
DEBRIS
SCREEN
(Provided)
NOTE − Debris screen may be positioned straight out
(preferred) or with an elbow rotated to face down.
FIGURE 25
Follow the next two steps when installing the unit in Non-
Direct Vent applications where combustion air is taken from indoors and flue gases are discharged outdoors .
1 − Use field−provided materials and the factory−provided air intake screen to route the intake piping as shown in
figure 24 or 25. 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 to either side in the upflow position, and either straight out or downward in the horizontal position.
The air intake piping must not terminate too close to the flooring or a platform. Ensure that the intake air inlet will not be obstructed by loose insulation or other items that may clog the debris screen.
2 − Use a sheet metal screw to secure the intake pipe to the connector, if desired.
NOTE − Debris screen and elbow may be rotated, so that screen may be positioned to face forward or to either side.
FIGURE 24
Page 21
General Guidelines for Vent Terminations
In Non-Direct Vent applications, combustion air is taken from indoors and the flue gases are discharged to the outdoors. The EL195UH 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 outdoors. The EL195UH 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 Z223−1/NFPA 54 in U.S.A., and current
CSA−B149 Natural Gas and Propane Installation Codes in
Canada for details.
Position termination according to location given in figure 26
or 27. In addition, position termination so it is free from any
obstructions and 12" above the average snow accumulation.
At vent termination, care must be taken to maintain protective coatings over building materials (prolonged exposure to exhaust condensate can destroy protective coatings). It is recommended that the exhaust outlet not be located within 6 feet (1.8m) of a condensing unit because the condensate can damage the painted coating.
NOTE − If winter design temperature is below 32°F (0°C), exhaust piping should be insulated with 1/2" (13mm), Armaflex or equivalent when run through unheated space.
Do not leave any surface area of exhaust pipe open to outside air; exterior exhaust pipe should be insulated with
1/2" (13mm) Armaflex or equivalent. In extreme cold climate 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 deterioration. Exhaust pipe insulation may not be necessary in some specific applications.
NOTE − During extremely cold temperatures, below approximately 20°F (6.7°C), units with long runs of vent pipe through unconditioned space, even when insulated, may form ice in the exhaust termination that prevents the unit from operating properly. Longer run times of at least 5 minutes will alleviate most icing problems. Also, a heating cable may be installed on exhaust piping and termination to prevent freeze−ups. Heating cable installation kit is available from Lennox. See Condensate Piping section for part numbers.
IMPORTANT
Do not use screens or perforated metal in exhaust terminations. Doing so will cause freeze−ups and may block the terminations.
IMPORTANT
For Canadian Installations Only:
In accordance to CSA International B149 installation codes, the minimum allowed distance between the combustion air intake inlet and the exhaust outlet of other appliances shall not be less than 12 inches
(305mm).
Page 22
D
E
VENT TERMINATION CLEARANCES
FOR NON−DIRECT VENT INSTALLATIONS IN THE USA AND CANADA
INSIDE CORNER
DETAIL
G
H
A
B
L
F
C
Fixed
Closed
Operable
B
Operable
B
Fixed
Closed
I
M
B
K
J
A
B
A =
B =
VENT TERMINAL
Clearance above grade, veranda, porch, deck or balcony
Clearance to window or door that may be opened
AIR SUPPLY INLET
US Installations 1
12 inches (305mm) or 12 in. 305mm) above average snow accumulation.
AREA WHERE TERMINAL
IS NOT PERMITTED
Canadian Installations 2
12 inches (305mm) or 12 in. 305mm) above average snow accumulation.
4 feet (1.2 m) below or to side of opening;
1 foot (30 cm) above opening
* 12"
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)
* 12"
C = Clearance to permanently closed window
D =
E =
F =
G =
H =
I =
J =
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 extended above meter / regulator assembly
Clearance to service regulator vent outlet
Clearance to non−mechanical air supply inlet to building or the combustion air inlet to any other appliance
*
* Equal to or greater than soffit depth.
* Equal to or greater than soffit depth.
* No minimum to outside corner
*
3 feet (.9m) within a height 15 feet (4.5m) above the meter / regulator assembly
* 3 feet (.9m)
4 feet (1.2 m) below or to side of opening;
1 foot (30 cm) above opening
3 feet (.9m) above if within 10 feet
(3m) horizontally
7 feet (2.1m)
* Equal to or greater than soffit depth.
* Equal to or greater than soffit depth.
* No minimum to outside corner
*
3 feet (.9m) within a height 15 feet (4.5m) above the meter / regulator assembly
3 feet (.9m)
6 inches (152mm) for appliances <10,000
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)
6 feet (1.8m) K =
L =
Clearance to mechanical air supply inlet
Clearance above paved sidewalk or paved driveway located on public property
7 feet (2.1m)
M = Clearance under veranda, porch, deck or balcony
*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
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 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.
FIGURE 26
Page 23
VENT TERMINATION CLEARANCES
FOR DIRECT VENT INSTALLATIONS IN THE USA AND CANADA
INSIDE CORNER
DETAIL
G
H
A
D
E
B
L
F
C
Fixed
Closed
Operable
B
Operable
B
Fixed
Closed
I
M
B
K
J
A
B
A =
B =
VENT TERMINAL
Clearance above grade, veranda, porch, deck or balcony
Clearance to window or door that may be opened
AIR SUPPLY INLET
US Installations 1
12 inches (305mm) or 12 in. 305mm) above average snow accumulation.
AREA WHERE TERMINAL
IS NOT PERMITTED
Canadian Installations 2
12 inches (305mm) or 12 in. 305mm) above average snow accumulation.
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 appliances > 50,000 Btuh (15kw)
* 12"
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)
* 12" C = Clearance to permanently closed window
D =
E =
F =
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
* Equal to or greater than soffit depth
* Equal to or greater than soffit depth
* No minimum to outside corner
*
* Equal to or greater than soffit depth
* Equal to or greater than soffit depth
* No minimum to outside corner
G =
H =
I =
J =
Clearance to inside corner
Clearance to each side of center line extended above meter / regulator assembly
Clearance to service regulator vent outlet
Clearance to non−mechanical air supply inlet to building or the combustion air inlet to any other appliance
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 appliances > 50,000 Btuh (15kw)
3 feet (.9m) above if within 10 feet
(3m) horizontally
*
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)
6 feet (1.8m) K =
L =
Clearance to mechanical air supply inlet
Clearance above paved sidewalk or paved driveway located on public property
* 7 feet (2.1m)
7 feet (2.1m)
M = Clearance under veranda, porch, deck or balcony
*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
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 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.
FIGURE 27
Page 24
Details of Intake and Exhaust Piping Terminations for
Direct Vent Installations
NOTE − In Direct Vent installations, combustion air is taken from outdoors and flue gases are discharged to outdoors.
NOTE − Flue gas may be slightly acidic and may adversely affect some building materials. If any vent termination is used and the flue gasses may impinge on the building material, a corrosion−resistant shield (minimum 24 inches square) should be used to protect the wall surface. If the optional tee is used, the protective shield is recommended.
The shield should be constructed using wood, plastic, sheet metal or other suitable material. All seams, joints, cracks, etc. in the affected area should be sealed using an
appropriate sealant. See figure 29.
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 28 through 40 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 illustrations). Maximum separation is 3" (76mm) on roof terminations and 6" (152mm) on side wall terminations.
3 − On roof terminations, the intake piping should terminate straight down using two 90° elbows (See figure
4 − Exhaust piping must terminate straight out or up as shown. A reducer may be required on the exhaust piping at the point where it exits the structure to improve the velocity of exhaust away from the intake piping.
3"(76mm) MAX.
Inches(mm) SIZE TERMINATION
8" (203mm) MIN
12" (305mm) ABOVE
AVERAGE SNOW
ACCUMULATION
UNCONDITIONED
ATTIC SPACE
1/2" (13mm) FOAM
INSULATION IN
UNCONDITIONED
SPACE
TABLE 6
EXHAUST PIPE TERMINATION SIZE REDUCTION
EL195UH
MODEL
Exhaust Pipe Size
Termination
Pipe Size
*045 and 070
*090
110
135
2" (51mm), 2−1/2" (64mm),
3" (76mm)
3" (76mm)
1−1/2" (38mm)
2" (51mm)
2" (51mm)
2" (51mm)
*EL195UH−045, −070 and −090 units with the flush mount termination must use the 1−1/2"accelerator supplied with the kit.
NOTE − Care must be taken to avoid recirculation of exhaust back into intake pipe.
5 − On field−supplied terminations for side wall exit, exhaust 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 30 and 31.
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
7 − If intake and exhaust piping must be run up a side wall to position above snow accumulation or other obstructions, piping must be supported every 24"
(610mm) as shown in figures 30 and 31. In addition,
close coupled wall termination kits must be extended
for use in this application. See figures 38 and 39.
When exhaust and intake piping must be run up an outside wall, the exhaust piping must be terminated
with pipe sized per table 6.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
3" (76mm) OR
2" (51mm) PVC
PROVIDE SUPPORT
FOR INTAKE AND
EXHAUST LINES
DIRECT VENT ROOF TERMINATION KIT
(15F75 or 44J41)
FIGURE 28
Page 25
B
B
D
D
Intake
C
3
C
1
A
Exhaust
Front View of
Intake and Exhaust
2
A
Intake Exhaust
D
TABLE 7
2" (51mm)
Vent Pipe
3" (76mm)
Vent Pipe
2
B
A
E
C
1
12"
A − Clearance above grade or average snow accumulation
B −Horizontal
separation between
intake and exhaust
C −Minimum from end of exhaust to inlet of intake
D −Exhaust pipe length
E −Wall support distance from top of each pipe
(intake/exhaust)
12" (508MM) Min.
6" (152MM) Min.
24" (610 MM) Max
9" (227MM) Min.
12" (305MM) Min.
16" (405 MM) Max.
6" (152MM) Max.
12" (508MM) Min.
6" (152MM) Min.
24" (610 MM) Max
9" (227MM) Min.
12" (305MM) Min.
20" (508MM) Max.
6" (152MM) Max.
NOTE − See unit installation instructions for proper exhaust pipe termination size reduction.
1 The exhaust termination tee should be connected to the 2" or 3" PVC flue pipe as shown in the illustration. Do not use an accelerator in applications that include an exhaust termination tee. The accelerator is not required.
2 As required. Flue gas may be acidic and may adversely affect some building materials. If a side wall vent termination is used and flue gases will impinge on the building materials, a corrosion−resistant shield (24 inches square) should be used to protect the wall surface. If optional tee is used, the protective shield is recommended. 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.
3 Exhaust pipe 45° elbow can be rotated to the side away from the combustion air inlet to direct exhaust away from adjacent property. The exhaust must never be directed toward the combustion air inlet.
FIGURE 29
Page 26
FIELD−SUPPLIED WALL TERMINATION OR
(15F74) WALL RING TERMINATION KIT
NOTE − FIELD−PROVIDED
REDUCER MAY BE
REQUIRED TO ADAPT
LARGER VENT PIPE SIZE
TO TERMINATION
D
1/2" (13mm) ARMAFLEX
INSULATION IN UN-
CONDITIONED SPACE
SIZE TERMINATION
C
A
B
STRAIGHT
APPPLICATION
1/2" (13mm) ARMAFLEX INSULATION
IN UNCONDITIONED SPACE
D
* WALL
SUPPORT
E
B
A
C
EXTENDED
APPLICATION
See venting table
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)
A −Minimum clearance above grade or average snow accumulation
B −Maximum horizontal
separation between
intake and exhaust
C −Minimum from end of exhaust to inlet of intake
D −Maximum exhaust pipe length
E −Maximum wall support distance from top of each pipe (intake/exhaust)
2" (51mm)
Vent Pipe
12" (508MM)
6" (152MM)
8" (203MM)
12" (305MM)
6" (152MM)
3" (76mm)
Vent Pipe
12" (508MM)
6" (152MM)
8" (203MM)
20" (508MM)
6" (152MM)
FIGURE 30
FIELD−SUPPLIED WALL TERMINATION OR
(15F74) WALL RING TERMINATION KIT
With INTAKE ELBOW
NOTE − FIELD−PROVIDED
REDUCER MAY BE
REQUIRED TO ADAPT
LARGER VENT PIPE SIZE
TO TERMINATION
1/2" (13mm) ARMAFLEX
INSULATION IN UN-
CONDITIONED SPACE
SIZE TERMINATION
D
C
A
B
STRAIGHT
APPPLICATION
1/2" (13mm) ARMAFLEX INSULATION
IN UNCONDITIONED SPACE
D
* WALL
SUPPORT
E
C
B
A
EXTENDED
APPLICATION
See venting table 5 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
A −Minimum clearance above grade or average snow accumulation
B −Maximum horizontal
separation between
intake and exhaust
C −Minimum from end of exhaust to inlet of intake
D −Maximum exhaust pipe length
E −Maximum wall support distance from top of each pipe (intake/exhaust)
12" (508MM)
6" (152MM)
6" (152MM)
12" (305MM)
6" (152MM)
12" (508MM)
6" (152MM)
6" (152MM)
20" (508MM)
6" (152MM)
FIGURE 31
Page 27
2" EXTENSION FOR 2" PVC
PIPE1" EXTENSION FOR 3"
PVC PIPE
4’’
FURNACE
EXHAUST
PIPE
FURNACE
INTAKE
PIPE
GLUE EXHAUST
END FLUSH INTO
TERMINATION
FLAT
SIDE 1−1/2" ACCELERATOR
( all −45, −070 and −090 units)
FLUSH−MOUNT SIDE WALL TERMINATION
51W11
FIGURE 32
EXHAUST
VENT
INTAKE
AIR
Inches (mm)
5"
(127mm)
18" MAX.
(457mm)
12"
(305mm)
5−1/2"
(140mm)
Front View
EXHAUST VENT
INTAKE
AIR
12" (305mm) Min.
above grade or average snow accumulation.
EXHAUST
VENT
12” (305mm)
Minimum
Above Average
Snow
Accumulation
INTAKE
AIR
1 1/2" (38mm) accelerator provided on 71M80 & 44W92 kits for EL195UH045P24B,
070P24B & 070P36B
FLASHING
(Not Furnished) optional intake elbow
Side View
OPTIONAL VENT TERMINATION FOR MULTIPLE UNIT
INSTALLATION OF DIRECT VENT WALL TERMINATION KIT
(22G44, 44J40, 30G28 or 81J20)
FIGURE 35
Front View
INTAKE
AIR
EXHAUST VENT
SIZE
TERMINATION
PIPE PER
Top View
1/2" (13mm) Foam Insulation
in Unconditioned Space
FIELD−
PROVIDED
REDUCER MAY
BE REQUIRED
TO ADAPT
LARGER VENT
PIPE SIZE TO
TERMINATION
EXHAUST VENT
INTAKE AIR
6 (152mm) MIN.
CLAMP
SHEET METAL STRAP
(Clamp and sheet metal strap must be field installed to support the weight of the termination kit.)
FIELD−PROVIDED
REDUCER MAY BE REQUIRED
TO ADAPT LARGER VENT
PIPE SIZE TO TERMINATION
DIRECT VENT CONCENTRIC ROOFTOP TERMINATION
71M80, 69M29 or 60L46 (US)
44W92 or 44W93 (Canada)
FIGURE 33
FIELD−PROVIDED
REDUCER MAY BE REQUIRED
TO ADAPT LARGER VENT
PIPE SIZE TO TERMINATION
OUTSIDE
WALL
EXHAUST
VENT
INTAKE
AIR
CLAMP
(Not Furnished)
12" (305mm) Min.
above grade or average snow accumulation.
GRADE
DIRECT VENT CONCENTRIC WALL TERMINATION
71M80, 69M29 or 60L46 (US)
44W92 or 44W93 (Canada)
FIGURE 34
1−1/2" (38mm) accelerator provided on 71M80 & 44W92 kits for EL195UH045P24B,
070P24B & 070P36B
INTAKE
AIR
EXHAUST
VENT
OUTSIDE WALL
DIRECT VENT WALL TERMINATION KIT
(30G28 or 81J20)
FIGURE 36
Front View EXHAUST VENT
SIZE
TERMINATION
PIPE PER
INTAKE
AIR
1/2" (13mm) Foam Insulation
in Unconditioned Space
FIELD−
PROVIDED
REDUCER MAY
BE REQUIRED
TO ADAPT
LARGER VENT
PIPE SIZE TO
TERMINATION
Top View
EXHAUST VENT
INTAKE AIR
8" (206mm) MIN.
OUTSIDE WALL
DIRECT VENT WALL TERMINATION KIT
(22G44 or 44J40)
FIGURE 37
Page 28
WALL TERMINATION KITS (CLOSE − COUPLE)
EXTENDED VENT FOR GRADE CLEARANCE
2 inch (51 mm) 22G44 (US)
3 inch (76 mm) 44J40 (US)
If intake and exhaust pipe is less than 12 in. (305 mm) above snow accumulation or other obstructions, field − fabricated piping must be installed.
FIELD−PROVIDED
REDUCER MAY BE REQUIRED TO ADAPT
LARGER VENT PIPE SIZE TO TERMINATION
WALL SUPPORT*
8” (203 mm) Min. for 2” (51 mm) & 3” (76 mm) DIA. pipe between the end of the exhaust pipe and intake pipe
12” (305 mm) Max. for 2” (51 mm) Dia. Exhaust
20” (508 mm) Max. for 3” (76 mm) Dia. Exhaust
12”
(305 mm)
6” (152 mm)
Maximum
EXHAUST
AIR
1/2” (13 mm)
FOAM INSULATION
(Field − Furnished)
INTAKE
AIR
INTAKE
AIR EXHAUST
AIR
5” (127 mm)
8” (203 mm) Min.
12” (305 mm) Minimum
Above Grade or Average
Snow Accumulation
GRADE
ÉÉÉÉÉÉÉÉÉÉÉÉ
12” (305 mm) Max. for 2” (51 mm) Dia. Exhaust
ÉÉÉÉÉÉÉÉÉÉÉÉ 20” (508 mm) Max. for 3” (76 mm) Dia. Exhaust
5 − 1/2”
(140 mm)
12” (305 mm) Minimum
Above Grade or Average
Snow Accumulation
ÉÉÉÉÉÉÉÉÉÉÉÉ
GRADE
*Use wall support every 24" (610). Use two supports if
ÉÉÉÉÉÉÉÉÉÉÉÉ extension is greater than 24" but less than 48".
FIGURE 38
WALL TERMINATION KITS (CLOSE − COUPLE)
EXTENDED VENT FOR GRADE CLEARANCE
2 inch (51 mm) 30G28 (WTK Canada)
3 inch (76 mm) 81J20 (WTK Canada)
See Installation Instructions for additional information.
If intake and exhaust pipe is less than 12 in. (305 mm) above snow accumulation or other obstructions, field − fabricated piping must be installed.
WALL SUPPORT*
6” (152 mm)
Maximum
INTAKE
AIR
FIELD−PROVIDED
REDUCER MAY BE REQUIRED TO ADAPT
LARGER VENT PIPE SIZE TO TERMINATION
12” (305 mm) Max. for 2” (51 mm) Dia. Exhaust
20” (508 mm) Max. for 3” (76 mm) Dia. Exhaust
12”
(305 mm)
EXHAUST
AIR
1/2” (13 mm)
FOAM INSULATION
(Field − Furnished)
6” (152 mm)
Minimum
INTAKE
AIR EXHAUST
AIR
5” (127 mm)
6” (152 mm)
Minimum
12” (305 mm) Minimum
Above Grade or Average
Snow Accumulation
GRADE
5 − 1/2”
(140 mm)
12” (305 mm) Minimum
Above Grade or Average
Snow Accumulation
GRADE
ÉÉÉÉÉÉÉÉÉÉÉÉ
12” (305 mm) Max. for 2” (51 mm) Dia. Exhaust
20” (508 mm) Max. for 3” (76 mm) Dia. Exhaust
ÉÉÉÉÉÉÉÉÉÉÉÉ
*Use wall support every 24" (610). Use two supports if extension is greater than 24" but less than 48".
FIGURE 39
Page 29
EL195UH DIRECT VENT APPLICATION
USING EXISTING CHIMNEY
3"−8"
(76mm−203mm)
STRAIGHT−CUT OR
ANGLE−CUT IN DIRECTION
OF ROOF SLOPE *
8" − 12"
(203mm − 305mm)
Minimum 12" (305MM) above chimney top plate or average snow accumulation
INTAKE PIPE
INSULATION (optional)
SHEET
METAL TOP
PLATE
INSULATE
TO FORM
SEAL
EXHAUST VENT
1/2" (13mm)
WEATHERPROOF
INSULATION
SHOULDER OF FITTINGS
PROVIDE SUPPORT
OF PIPE ON TOP PLATE
ALTERNATE
INTAKE PIPE
3" − 8"
(76mm−
203mm)
EXTERIOR
PORTION OF
CHIMNEY
*SIZE TERMINATION
NOTE − Do not discharge exhaust gases directly into any chimney or vent stack. If vertical 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 illustrated. In any exterior portion of chimney, the exhaust vent must be insulated.
FIGURE 40
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 41 through 44 show typical terminations.
1 − Exhaust piping must terminate straight out or up as shown. The termination pipe must be sized as listed in
table 6.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, exhaust 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 42.
SIZE TERMINATION
12" (305mm)
ABOVE AVE.
SNOW
ACCUMULATION
1/2" (13mm) FOAM
INSULATION
1/2" (13mm) ARMAFLEX
INSULATION IN
UNCONDITIONED SPACE
FIELD−PROVIDED
REDUCER MAY
BE REQUIRED TO
ADAPT LARGER
VENT PIPE SIZE
TO TERMINATION
SIZE TERMINATION
12" (305mm) MAX. for 2" (51mm)
20" (508mm) MAX. for 3" (76mm)
1/2" (13mm)
ARMAFLEX
INSULATION
PVC REDUCER
12" MIN.
(305mm)
Above Grade or average snow accumulation
NON−DIRECT VENT FIELD SUPPLIED WALL TERMINATION OR
(15F74) WALL TERMINATION KIT
FIGURE 42
3 − If exhaust piping must be run up a side wall to position above snow accumulation or other obstructions, piping must be supported every 24 inches (610mm) as
shown in figure 43. When exhaust piping must be run
up an outside wall, any reduction in exhaust pipe size must be done after the final elbow.
12" (305mm) MAX. for 2" (51mm)
20" (508mm) MAX. for 3" (76mm)
UNCONDITIONED
SPACE
6" (152mm)
Max
*WALL SUPPORT
OUTSIDE WALL
FIELD−PROVIDED
REDUCER MAY BE
REQUIRED TO
ADAPT LARGER
VENT PIPE SIZE TO
TERMINATION
SIZE TER-
MINATION
PIPE PER
12" (305mm)
ABOVE GRADE OR
AVERAGE SNOW
ACCUMULATION
1/2" (13mm) FOAM
INSULATION IN
UNCONDITIONED
SPACE
1/2" (13mm) FOAM
INSULATION
NON−DIRECT VENT FIELD SUPPLIED WALL TERMINATION
EXTENDED OR (15F74) WALL TERMINATION VENT PIPE
EXTENDED
*Use wall support every 24" (610). Use two supports if extension is greater than 24" but less than 48".
FIGURE 43
3" (76mm) OR
2" (51mm) PVC
PROVIDE SUPPORT
FOR EXHAUST LINES
UNCONDITIONED
ATTIC SPACE
NON−DIRECT VENT ROOF TERMINATION KIT
(15F75 or 44J41)
FIGURE 41
Page 30
EL195UH NON−DIRECT VENT APPLICATION
USING EXISTING CHIMNEY
SIZE TERMINATION
STRAIGHT−CUT OR
ANGLE−CUT IN DIRECTION
OF ROOF SLOPE
Minimum 12" (305MM) above chimney top plate or average snow accumulation
SHEET
METAL TOP
PLATE
EXHAUST VENT
1/2" (13mm)
WEATHERPROOF
INSULATION
SHOULDER OF FITTINGS
PROVIDE SUPPORT
OF PIPE ON TOP PLATE
INSULATE
TO FORM
SEAL
EXTERIOR
PORTION OF
CHIMNEY
CONDENSATE TRAP AND PLUG LOCATIONS
(Unit shown in upflow position)
Trap
(same on right side)
1−1/2 in.
Plug
(same on left side)
NOTE − Do not discharge exhaust gases directly into any chimney or vent stack. If vertical 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 illustrated. In any exterior portion of chimney, the exhaust vent must be insulated.
FIGURE 44
Condensate Piping
This unit is designed for either right- or left-side exit of condensate piping in upflow applications. In horizontal applications, the condensate trap must extend below the unit. An
8" service clearance is required for the condensate trap.
Refer to figure 45 for condensate trap locations. Figure 49
shows trap assembly using 1/2" PVC or 3/4" PVC.
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.
1 − Determine which side condensate piping will exit the unit, location of trap, field−provided fittings and length of
PVC pipe required to reach available drain.
2 − Remove plug (figure 45) from the cold end header box
at the appropriate location on the side of the unit. Install field−provided 1/2 NPT male fitting into cold end header box. Use Teflon tape or appropriate pipe dope.
3 − Install the cap over the clean out opening at the base of
the trap. Secure with clamp. See figure 49.
NOTE − In upflow applications where side return air filter is installed on same side as the condensate trap, filter rack must be installed beyond condensate trap or trap must be re−located to avoid interference.
FIGURE 45
4 − Install drain trap using appropriate PVC fittings, glue all joints. Glue the provided drain trap as shown in fig-
ure 49. Route the condensate line to an open drain.
Condensate line must maintain a 1/4" downward slope from the furnace to the drain.
NOTE − Vinyl tubing may be used for condensate drain.
Tubing must be 1−1/4" OD X 1" ID and should be attached to the drain on the trap using a hose clamp.
CAUTION
Do not use copper tubing or existing copper condensate lines for drain line.
5 − If unit will be started immediately upon completion of installation, prime trap per procedure outlined in Unit
Start−Up 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
Page 31
on the condensate trap and line. Heating cable kit is available 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.
CONDENSATE TRAP LOCATIONS
(Unit shown in upflow position with remote trap)
Field Provided Vent
Min. 1" Above Condensate
Drain Connection
1" Min.
*5’ max.
PVC Pipe Only
Trap Can Be Installed a
Maximum 5’ From Furnace
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.
EL195UH with Evaporator Coil
Condensate trap and evaporator coil must be drained separately as shown.
To Drain
*Piping from furnace must slope down a minimum of 1/4" per ft. toward trap.
FIGURE 46
CONDENSATE TRAP LOCATIONS
(Unit shown in horizontal right − hand discharge position)
FIGURE 47
Field−Provided Vent
Must Not Interfere With
Service To The Unit to drain
4−1/2"
Min.
5’ max.
*PVC Pipe Only
*Piping from furnace must slope down a minimum of 1/4" per ft. toward trap.
FIGURE 48
Page 32
TRAP / DRAIN ASSEMBLY USING 1/2" PVC OR 3/4" PVC
OPTIONAL Condensate Drain Connection
Adapter 1/2 inch slip X
1/2 inch mpt (Not Furnished)
Adapter 1/2 inch slip X
1/2 inch mpt (Not Furnished)
90 ° Street Elbow
1/2 inch PVC
(Not Furnished)
1 (25) Minimum
Vent
5 Feet
Maximum
Condensate Drain
Connection In Unit
Condensate Drain
Connection In Unit
90 ° Elbow 1/2 inch PVC
(Not Furnished)
OPTIONAL Drain Piping
Drain Assembly for 1/2 inch Drain Pipe
1/2 inch PVC Pipe
(Not Furnished)
1/2 inch PVC Pipe
(Not Furnished)
Coupling 1/2 inch slip X slip
(Not Furnished)
To
Drain
90 ° Street Elbow
1/2 inch PVC
(Furnished)
To
Drain
1/2 inch PVC Pipe
(Not Furnished)
90 ° Elbow
1/2 inch PVC
(Not Furnished)
Drain Assembly for 3/4 inch Drain Pipe
Drain Trap
Assembly
(Furnished)
Drain Trap
Clean Out
To
Drain
90 ° Elbow
3/4 inch PVC
(Not Furnished)
90 ° Elbow
3/4 inch PVC
(Not Furnished)
To
Drain
Coupling 3/4 inch slip X slip
(Not Furnished)
Drain Trap Assembly
(Furnished)
Drain Trap Assembly with 1/2 inch Piping
1 inch (25mm) Minimum Above Top of
Condensate Drain Connection In Unit
Vent
Drain Trap Assembly with 3/4 inch Piping
1 inch (25mm) Minimum Above Top of
Condensate Drain Connection In Unit
Vent
7
(178)
Condensate Drain
Connection In Unit
Condensate Drain
Connection In Unit
To
Drain
To
Drain
FIGURE 49
Page 33
Gas Piping
Gas supply piping should not allow more than 0.5"W.C. drop in pressure between gas meter and unit. Supply gas pipe must not be smaller than unit gas connection.
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 in−lbs (50 ft−lbs) torque when attaching 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 51. Move Bellows grommet to side which gas
line enters. Ensure opposite gas line hole is plugged with supplied plug.
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 8 lists
recommended pipe sizes for typical applications.
NOTE − Use two wrenches when connecting gas piping 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 elevator shafts. Center gas line through piping hole. Gas
line should not touch side of unit. See figures 51 and
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, every 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.
6 − In some localities, codes may require installation of a manual main shut-off valve and union (furnished by installer) 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 petroleum gases.
Leak Check
After gas piping is completed, carefully check all piping connections (factory− and field−installed) for gas leaks. Use a leak detecting solution or other preferred means.
Never use an open flame to test for gas leaks. Check all connections using a commercially available soap solution made specifically for leak detection.
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 greater than or equal to 1/2 psig (3.48 kPa, 14 inches w.c.).
MANUAL MAIN SHUT−OFF
VALVE WILL NOT HOLD
NORMAL TEST PRESSURE
1/8" N.P.T.
PLUGGED TAP
CAP
FURNACE
ISOLATE
GAS VALVE
FIGURE 50
IMPORTANT
When testing pressure of gas lines, gas valve must
be disconnected and isolated. See figure 50. 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 34
Left Side Piping
(Standard)
MANUAL
MAIN SHUT−OFF
VALVE
GROUND
JOINT
UNION
Plug Plug
Right Side Piping
(Alternate)
Bellows Grommet
MANUAL
MAIN SHUT−OFF
VALVE
GROUND
JOINT
UNION
DRIP LEG
DRIP LEG
Gas Valve
Bellows Grommet
FIELD
PROVIDED
AND INSTALLED
NOTE − BLACK IRON PIPE ONLY TO BE ROUTED INSIDE OF CABINET
FIGURE 51
Gas Valve
MANUAL
MAIN SHUT−OFF
VALVE
Horizontal Applications
Possible Gas Piping Configurations
MANUAL
MAIN SHUT−OFF
VALVE Horizontal Application
Left−Side Air Discharge
GROUND
JOINT
UNION
DRIP LEG
Bellows Grommet
GROUND
JOINT
UNION
DRIP LEG
Bellows Grommet
Gas Valve
Horizontal Application
Right−Side Air Discharge
Gas Valve
MANUAL
MAIN SHUT−OFF
VALVE
GROUND
JOINT
UNION
DRIP LEG
Plug
FIELD
PROVIDED
AND INSTALLED
Bellows Grommet
NOTE − BLACK IRON PIPE ONLY TO BE ROUTED INSIDE OF CABINET
FIGURE 52
Page 35
Nominal
Iron Pipe Size
−Inches(mm)
1/2
(12.7)
3/4
(19.05)
1
(25.4)
1−1/4
(31.75)
1−1/2
(38.1)
2
(50.8)
2−1/2
(63.5)
3
(76.2)
4
(101.6)
Internal
Diameter
−Inches(mm)
.622
(17.799)
.824
(20.930)
1.049
(26.645)
1.380
(35.052)
1.610
(40.894)
2.067
(52.502)
2.469
(67.713)
3.068
(77.927)
4.026
(102.260)
10
(3.048)
175
(4.96)
360
(10.19)
680
(19.25)
1400
(39.64)
2100
(59.46)
3950
(111.85)
6300
(178.39)
11000
(311.48)
23000
(651.27)
TABLE 8
GAS PIPE CAPACITY − FT 3 /HR (kL/HR)
20
(6.096)
120
(3.40)
250
(7.08)
465
(13.17)
950
(26.90)
460
(41.34)
2750
(77.87)
4350
(123.17)
7700
(218.03)
15800
(447.39)
30
(9.144)
97
(2.75)
200
(5.66)
375
(10.62)
770
(21.80)
1180
(33.41)
2200
(62.30)
3520
(99.67)
6250
(176.98)
12800
(362.44)
40
(12.192)
82
(2.32)
Length of Pipe−Feet(m)
50
(15.240)
73
(2.07)
60
(18.288)
66
(1.87)
70
(21.336)
61
(1.73)
170
(4.81)
320
(9.06)
660
(18.69)
990
(28.03)
1900
(53.80)
3000
(84.95)
5300
(150.07)
10900
(308.64)
151
(4.28)
285
(8.07)
580
(16.42)
900
(25.48)
1680
(47.57)
2650
(75.04)
4750
(134.50)
9700
(274.67)
138
(3.91)
260
(7.36)
530
(15.01)
810
(22.94)
1520
(43.04)
2400
(67.96)
4300
(121.76)
8800
(249.18)
125
(3.54)
240
(6.80)
490
(13.87)
750
(21.24)
1400
(39.64)
2250
(63.71)
3900
(110.43)
8100
(229.36)
NOTE − Capacity given in cubic feet of gas per hour (kilo liters of gas per hour) and based on 0.60 specific gravity gas.
80
(24.384)
57
(1.61)
118
(3.34)
220
(6.23)
460
(13.03)
690
(19.54)
1300
(36.81)
2050
(58.05)
3700
(104.77)
7500
(212.37)
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 appliances, the venting system is likely to be too large to properly vent the remaining attached appliances.
Conduct the following test while each appliance is operating and the other appliances (which are not operating) remain 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 requirements 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 monoxide poisoning or death.
The following steps shall be followed for each appliance 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 system.
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.
90
(27.432)
53
(1.50)
110
(3.11)
205
(5.80)
430
(12.18)
650
(18.41)
1220
(34.55)
1950
(55.22)
3450
(97.69)
7200
(203.88)
100
(30.480)
50
(1.42)
103
(2.92)
195
(5.52)
400
(11.33)
620
(17.56)
1150
(32.56)
1850
(52.38)
3250
(92.03)
6700
(189.72)
3 − Close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers 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 operate at maximum speed. Do not operate a summer exhaust 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 dampers, and any other gas−burning appliances to their previous mode of operation.
7 − If a venting problem is found during any of the preceding tests, the common venting system must be modified 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 standards of the National Fuel Gas Code ANSI Z223.1.
Page 36
Electrical
ELECTROSTATIC DISCHARGE (ESD)
Precautions and Procedures
CAUTION
Electrostatic discharge can affect electronic components. Take precautions to neutralize electrostatic charge by touching your hand and tools to metal prior to handling the control.
INTERIOR MAKE−UP BOX INSTALLATION
Left side
MAKE−UP
BOX
FIGURE 53
INTERIOR MAKE−UP BOX INSTALLATION
MAKE−UP
BOX remove and relocate plug to unused opening on left side
Right Side
FIGURE 54
The unit is equipped with a field make−up box. The make− up box may be moved to the right side of the furnace to facilitate installation. Seal unused openings on left side with plugs removed from right side. Secure the excess wire to the existing harness to protect it from damage.
Refer to figure 56 for field wiring and figure 57 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 Over−Current 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 check to make sure the wires will be long enough for servicing at a later date. Make sure that thermostat wire is long enough to facilitate future removal of blower for service.
Complete the wiring connections to the equipment. Use the provided unit wiring diagram and the field wiring diagram
shown in figure 56. Use 18−gauge wire or larger that is suit-
able for Class II rating for thermostat connections.
Electrically ground the unit according to local codes or, in the absence of local codes, according to the current National 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 make−up box.
NOTE − The EL195UH furnace contains electronic components that are polarity sensitive. Make sure that the furnace is wired correctly and is properly grounded.
Accessory Terminals
One line voltage EAC" 1/4" spade terminal is provided on
the furnace integrated control. See figure 58 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 external relay.
One line voltage HUM" 1/4" spade terminal is provided on
the furnace integrated control. See figure 58 for integrated
control configuration. This terminal is energized in the heating mode when the combustion air inducer is operating. Any humidifier 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 a humidifier rated at greater than one amp is connected to this terminal, it is necessary to use an external relay relay.
Page 37
One 24V "H" 1/4" spade terminal is provided on the furnace
integrated control. See figure 58 for integrated control con-
figuration. The terminal is energized in the heating mode when the combustion air inducer is operating and the pressure 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.
EL195UH and CONDENSING UNIT
THERMOSTAT DESIGNATIONS
(Refer to specific thermostat and outdoor unit.)
Thermostat Furnace Condensing
Unit
POWER
*CONDENSING
UNIT
R R
HEAT
W1 W
COOLING
CONDENSING
UNIT
Y Y
INDOOR BLOWER
G G
C
COMMON
C
CONDENSING
UNIT COMMON
*NOTE − R" REQUIRED ON SOME OUTDOOR UNITS
FIGURE 55
Install the room thermostat according to the instruc-
tions provided with the thermostat. See figure 55 for
thermostat designations. If the furnace is being matched with a heat pump, refer to the FM21 installation instruction or appropriate dual fuel thermostat instructions.
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 EL195UH 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.
Generator Use − Voltage Requirements
The following requirements must be kept in mind when specifying a generator for use with this equipment:
D The furnace requires 120 volts + 10% (Range: 108 volts to 132 volts).
D
The furnace operates at 60 Hz + 5% (Range: 57 Hz to
63 Hz).
D
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.
D
Generator should have a wave form distortion of less than 5% THD (total harmonic distortion).
TYPICAL EL195UH FIELD WIRING DIAGRAM
IGNITOR
*R
*NOTE − R" REQUIRED ON SOME OUTDOOR
UNITS
FIGURE 56
Page 38
TYPICAL EL195UH WIRING DIAGRAM
FIGURE 57
Page 39
INTEGRATED CONTROL
(Automatic Hot Surface Ignition System)
HUM
LINE
XFMR
EAC
COOL
HEAT
PARK
FLAME
FAN
HUM
TERMINAL DESIGNATIONS
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
Humidifier (24VAC)
Red LED Recall
Blower off delay jumper
FIGURE 58
Unit Start−Up
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING
Do not use this furnace if any part has been underwater. A flood−damaged furnace is extremely dangerous. Attempts to use the furnace can result in fire or explosion. Immediately call a qualified service 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.
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.
CAUTION
Before attempting to perform any service or maintenance, turn the electrical power to unit OFF at disconnect switch.
BEFORE LIGHTING the unit, smell all around the furnace area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.
The gas valve on the EL195UH is equipped with a gas control switch (lever). Use only your hand to move switch. Never use tools. If the the switch will not move by hand, do not try to repair it. Force or attempted repair may result in a fire or explosion.
Placing the furnace into operation:
EL195UH units are equipped with an automatic hot surface 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.
Page 40
Priming Condensate Trap
The condensate trap should be primed with water prior to start−up to ensure proper condensate drainage. Either pour 10 fl. oz. (300 ml) of water into the trap, or follow these steps to prime the trap:
1 − Follow the lighting instructions to place the unit into operation.
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 demand.
5 − Wait for the combustion air inducer to stop. Set the thermostat to initiate a heating demand and again allow the burners to fire for approximately 3 minutes.
6 − Adjust the thermostat to deactivate the heating demand 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 59)
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.
7 − Wait five minutes to clear out any gas. If you then smell gas, STOP! Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions. If you do not smell gas go to next step.
8 − Move gas valve switch to ON.
MANIFOLD PRESSURE
ADJUSTMENT SCREW
(under barbed fitting)
MANIFOLD
PRESSURE
OUTLET
PORT
INLET
PRESSURE
PORT
GAS VALVE SHOWN IN ON POSITION
FIGURE 59
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.
12− If the appliance will not operate, follow the instructions
Turning Off Gas to Unit" and call your service technician 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 operation. Switch is factory set and requires no adjustment.
3 − After a 15−second prepurge, the hot surface ignitor energizes.
4 − After a 20−second ignitor warm−up period, the gas valve solenoid opens. A 4−second trial for ignition period 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 ignition 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 automatically repeat steps 1 through 6 after 60 minutes.
To interrupt the 60−minute WATCHGUARD" period, move thermostat from Heat" to OFF" then back to
Heat". Heating sequence then restarts at step 1.
Page 41
Gas Pressure Adjustment
Gas Flow (Approximate)
EL195
Unit
−045
−070
−090
−110
−135
TABLE 9
GAS METER CLOCKING CHART
Seconds for One Revolution
Natural LP
1 cu ft
Dial
2 cu ft
Dial
1 cu ft
Dial
2 cu ft
DIAL
80
55
41
33
27
160
110
82
66
54
200
136
102
82
68
Natural−1000 btu/cu ft LP−2500 btu/cu ft
400
272
204
164
136
Furnace should operate at least 5 minutes before checking gas flow. Determine time in seconds for two revolutions of gas through the meter. (Two revolutions assures a more accurate time.) Divide by two and compare to time
in table 9 below. If manifold pressure matches table 10
and rate is incorrect, check gas orifices for proper size and restriction. Remove temporary gas meter if installed.
NOTE − To obtain accurate reading, shut off all other gas appliances connected to meter.
Supply Pressure Measurement
When testing supply gas pressure, use the 1/8" N.P.T.
plugged tap or pressure post located on the gas valve to
facilitate test gauge connection. See figure 59. Check gas
line pressure with unit firing at maximum rate. Low pressure may result in erratic operation or underfire. High pressure can result in permanent damage to gas valve or overfire.
On multiple unit installations, each unit should be checked separately, with and without units operating. Supply pres-
sure must fall within range listed in table 10.
Manifold Pressure Measurement
1 − Remove the threaded plug from the outlet side of the gas valve and install a field−provided barbed fitting.
Connect to a manometer to measure manifold pressure.
2 − Start unit and allow 5 minutes for unit to reach steady state.
3 − While waiting for the unit to stabilize, observe the flame. Flame should be stable and should not lift from burner. Natural gas should burn blue.
4 − After allowing unit to stabilize for 5 minutes, record manifold pressure and compare to value given in table
NOTE − Shut unit off and remove manometer as soon as an accurate reading has been obtained. Take care to remove barbed fitting and replace threaded plug.
TABLE 10
Supply Line and Manifold Pressure (inches w.c.)
Unit Fuel
Manifold
Pressure
Line Pressure
All
All
Nat
LP/Propane
3.5
10.0
4.5 − 10.5
11.0 − 13.0
Proper Combustion
Furnace should operate minimum 15 minutes with correct manifold pressure and gas flow rate before checking combustion. Take combustion sample beyond the flue outlet and compare to the tables below.
TABLE 11
EL195
Unit
CO
2
%
For Nat
CO
2
%
For LP
−045
−070
−090
−110
7.2 − 8.2
8.6 − 9.6
−135
The maximum carbon monoxide reading should not exceed 50 ppm.
High Altitude Information
NOTE − In Canada, certification for installations at elevations over 4500 feet (1372 m) is the jurisdiction of local authorities.
Units installed at altitude of 4501 − 10,000 feet (1373 to
3048m) may require a pressure switch change which can
be ordered separately. Table 12 lists conversion kit and
pressure switch requirements at varying altitudes.
The combustion air pressure switch is factory−set and requires no adjustment.
Page 42
EL195
Unit
−045
−070
−090
−110
−135
TABLE 12
LP/Propane Conversion Kit and Pressure Switch Requirements at Varying Altitudes
Natural to
LP/Propane
0 − 7500 ft
(0 − 2286m)
High Altitude
Natural Burner
Orifice Kit
7501 − 10,000 ft
(2286 − 3038m)
High Altitude
LP/Propane Burner
Orifice Kit
7501 − 10,000 ft
(2286 − 3038m)
High Altitude Pressure Switch
*69W73 73W37 *68W68
4501 − 7500 ft
(1373 − 2286m)
No Change
77W43
77W42
77W43
77W42
7501 −10,000 ft
(2286 − 3048m)
74W90
73W22
73W22
73W22
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 factory−installed pressure switch from 0−4500 feet (0−1370 m).
Testing for Proper Venting and Sufficient Combustion Air for Non−Direct Vent Applications
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 monoxide poisoning or death.
The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation.
After the EL195UH gas furnace has been started, the following test should be conducted to ensure proper venting and sufficient combustion air has been provided to the
EL195UH as well as to other gas-fired appliances which are separately vented.
If a EL195UH 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 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.
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 restriction, 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 located and other spaces of the building.
4 − Close fireplace dampers.
5 − Turn on clothes dryers and any appliances not connected 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 minutes 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 appropriate tables in appendix G in the current standards of the National Fuel Gas Code ANSI−Z223.1/NPFA 54 in the U.S.A., and the appropriate Natural Gas and
Propane appliances venting sizing tables in the current standard of the CSA−B149 Natural Gas and Propane 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.
Page 43
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 adjustment.
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 factory−set 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 operates after the heat demand has been satisfied) may be adjusted 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 comfort and is adjustable to satisfy individual applications. Adjust the fan off delay to achieve a supply air temperature between 90° and 110°F at the moment that the blower is de−energized. Longer off delay settings provide lower return air temperatures; shorter settings provide higher re-
turn air temperatures. See figure 60.
The cool fan off delay (amount of time that the blower operates after the cool demand has been satisfied) is 45 seconds 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). Correct voltage is 120VAC + 10%
3 − Check amp−draw on the blower motor with blower access panel in place.
Motor Nameplate__________Actual__________
HEAT FAN-OFF TIME IN SECONDS
NO JUMPER
To adjust fan−off timing, reposition jumper across pins to achieve desired setting.
60 Second off Time
90 Second off Time
120 Second off Time
180 Second off Time
FIGURE 60
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 diagram 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.
Electronic Ignition
The integrated control has an added feature of an internal
Watchguard control. The feature serves as an automatic reset device for integrated control lockout caused by ignition failure. This type of lockout is usually due to low gas line pressure. After one hour of continuous thermostat demand for heat, the Watchguard will break and remake thermostat demand to the furnace and automatically reset the integrated control to begin the ignition sequence.
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 termination 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 44
BLOWER DATA
EL195UH045P24B PERFORMANCE (Less Filter)
External
Static
Pressure in. w.g.
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
Air Volume / Watts at Various Blower Speeds
High
Medium-
High
Medium-
Low
Low cfm Watts cfm Watts cfm Watts cfm Watts
1140 455 920 365 765 295 710 265
1135 445 900 360 765 290 690 255
1125 430 895 350 755 285 680 255
1090 415 870 340 725 280 660 250
1065 405 870 325 715 270 635 245
1020 390 825 315 675 260 605 235
945 365 780 300 640 250 555 225
910 350 740 295 585 240 505 220
790 325 670 275 510 225 455 205
735 310 575 255 460 220 390 195
EL195UH045P36B PERFORMANCE (Less Filter)
External
Static
Pressure in. w.g.
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
Air Volume / Watts at Various Blower Speeds
High
Medium-
High
Medium-
Low
Low cfm Watts cfm Watts cfm Watts cfm Watts
1605 700 1370 590 1160 475 1010 400
1600 680 1355 565 1155 465 1015 390
1550 645 1330 540 1150 445 1000 380
1480 620 1295 520 1140 430 975 365
1425 590 1280 490 1105 415 975 345
1355 565 1190 460 1085 395 940 335
1320 545 1165 435 1030 380 900 315
1225 500 1110 425 980 355 855 310
1135 480 1050 395 920 330 780 280
1025 445 950 360 795 295 700 255
EL195UH070P36B PERFORMANCE (Less Filter)
External
Static
Pressure in. w.g.
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
Air Volume / Watts at Various Blower Speeds
High
Medium-
High
Medium-
Low
Low cfm Watts cfm Watts cfm Watts cfm Watts
1585 685 1340 585 1095 480 880 380
1560 665 1320 565 1085 470 885 375
1515 630 1300 540 1080 460 880 370
1465 590 1275 520 1065 440 890 360
1410 570 1235 490 1050 420 875 350
1345 540 1195 470 1020 400 840 335
1275 510 1140 440 975 365 830 315
1195 485 1090 410 930 355 780 290
1105 460 995 380 850 325 730 275
985 420 890 345 770 300 650 255
EL195UH070P48B PERFORMANCE (Less Filter)
External
Static
Pressure in. w.g.
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
Air Volume / Watts at Various Blower Speeds
High
Medium-
High
Medium-
Low
Low cfm Watts cfm Watts cfm Watts cfm Watts
2015 1005 1950 840 1870 730 1675 630
1930 985 1915 830 1805 720 1650 615
1880 965 1840 805 1760 695 1620 600
1815 945 1775 790 1700 675 1560 580
1740 925 1700 770 1630 655 1515 565
1680 895 1625 750 1545 635 1455 545
1575 880 1555 720 1485 620 1380 530
1500 860 1450 700 1380 600 1310 515
1400 825 1380 680 1315 580 1230 495
1290 805 1270 655 1235 560 1145 480
EL195UH090P36C PERFORMANCE (Less Filter)
External
Static
Pressure in. w.g.
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
Air Volume / Watts at Various Blower Speeds
High
Medium-
High
Medium-
Low
Low cfm Watts cfm Watts cfm Watts cfm Watts
1630 715 1345 590 1090 475 885 385
1615 700 1320 580 1070 465 890 380
1580 675 1305 570 1070 455 890 370
1525 620 1295 535 1060 435 890 360
1480 615 1275 515 1055 430 885 350
1415 565 1220 485 1030 410 860 330
1350 535 1175 450 1005 390 835 310
1260 505 1115 415 955 360 785 290
1190 480 1010 380 880 325 740 285
1060 435 930 360 795 295 655 250
EL195UH090P48C PERFORMANCE (Less Filter)
External
Static
Pressure in. w.g.
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
Air Volume / Watts at Various Blower Speeds
High
Medium-
High
Medium-
Low
Low cfm Watts cfm Watts cfm Watts cfm Watts
2140 880 1895 780 1590 645 1350 550
2110 850 1880 760 1585 635 1360 545
2060 810 1835 725 1580 620 1360 520
1990 765 1805 690 1550 585 1365 495
1925 750 1755 655 1510 545 1330 470
1830 700 1680 610 1455 525 1285 450
1720 645 1610 575 1390 480 1230 415
1600 615 1525 535 1300 465 1165 390
1455 560 1410 495 1195 430 1035 365
1300 515 1305 465 1100 390 900 320
EL195UH110P48C PERFORMANCE (Less Filter)
External
Static
Pressure in. w.g.
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
Air Volume / Watts at Various Blower Speeds
High
Medium-
High
Medium-
Low
Low cfm Watts cfm Watts cfm Watts cfm Watts
2000 910 1675 765 1360 635 1185 525
1980 895 1650 745 1370 610 1180 505
1935 855 1600 710 1400 590 1170 485
1875 830 1560 680 1370 570 1160 490
1800 785 1490 655 1325 545 1120 455
1725 720 1400 610 1295 515 1080 435
1630 685 1335 585 1185 480 1030 410
1530 665 1290 525 1100 435 940 385
1410 610 1190 485 985 400 790 365
1245 560 1000 430 925 380 715 315
Page 45
BLOWER DATA
EL195UH090P60C PERFORMANCE (Less Filter)
Air Volume / Watts at Different Blower Speeds
External
Static
Pressure in. w.g.
0.00
0.10
Bottom Return Air, Side Return Air with Optional Return
Air Base, Return Air from Both Sides or Return Air from
Bottom and One Side.
High Medium-High Medium-Low Low
Single Side Return Air − Air volumes in bold require field fabricated transition to accommodate 20 x 25 x 1 in. air filter in order to maintain proper air velocity.
High Medium-High Medium-Low Low cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts
2445 1290 2235 1000 1875 840 1495 660 2445 1355 2180 1020 1785 850 1400 665
2430 1270 2220 985 1860 830 1500 650 2425 1335 2160 1010 1775 840 1405 655
0.20
0.30
0.40
0.50
0.60
0.70
0.80
2370 1260 2170
2290 1220 2110
2200 1190 2055
960
935
900
1875
1855
1835
805
785
765
1515
1545
1560
645
640
625
2390 1310 2135
2305 1270 2080
2230 1240 2015
985
960
925
1790
1805
1775
825
805
780
1435
1455
1460
645
640
630
2095 1155 1970 865 1785 735 1520 610 2150 1215 1965 900 1745 755 1460 620
2010 1145 1920 850 1725 715 1495 600 2055 1170 1890 865 1695 730 1440 605
1960 1120 1835 815 1655 690 1455 575 1955 1145 1805 840 1640 705 1415 590
1845 1080 1720 785 1570 665 1390 550 1825 1095 1705 815 1565 675 1360 565
0.90
1725 1040 1620 755 1490 645 1305 530 1715 1065 1590 775 1470 645 1290 540
EL195UH110P60C PERFORMANCE (Less Filter)
Air Volume / Watts at Different Blower Speeds
External
Static
Pressure in. w.g.
0.00
0.10
Bottom Return Air, Side Return Air with Optional Return
Air Base, Return Air from Both Sides or Return Air from
Bottom and One Side.
High Medium-High Medium-Low Low
Single Side Return Air − Air volumes in bold require field fabricated transition to accommodate 20 x 25 x 1 in. air filter in order to maintain proper air velocity.
High Medium-High Medium-Low Low cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts
2485 1515 2090 1070 1835 865 1380 660 2400 1475 2100 1075 1755 870 1320 655
2460 1475 2075 1040 1810 835 1390 650 2370 1440 2090 1060 1735 850 1330 645
0.20
0.30
0.40
0.50
0.60
0.70
2405 1445 2040
2335 1375 1990
995
980
1790
1760
820
790
1405
1460
650
635
2320 1405 2060 1050
2235 1350 2040 1030
1720
1725
835
825
1340
1350
650
645
2215 1355 1935 940 1740 775 1410 630 2165 1330 1975 970 1700 815 1330 632
2185 1310 1865 895 1680 750 1410 625 2040 1290 1920 945 1700 790 1325 620
2060 1270 1805 870 1630 720 1405 610 1960 1260 1845 910 1635 770 1340 620
1945 1235 1700 840 1605 700 1380 590 1865 1215 1750 890 1575 730 1295 600
0.80
0.90
1845 1210 1605 810 1505 670 1305 570 1715 1175 1590 840 1505 710 1280 590
1730 1150 1570 790 1470 660 1250 540 1630 1135 1490 685 1460 685 1235 565
EL195UH135P60D PERFORMANCE (Less Filter)
Air Volume / Watts at Different Blower Speeds
External
Static
Pressure in. w.g.
0.00
0.10
Bottom Return Air, Side Return Air with Optional Return
Air Base, Return Air from Both Sides or Return Air from
Bottom and One Side.
High Medium-High Medium-Low Low
Single Side Return Air − Air volumes in bold require field fabricated transition to accommodate 20 x 25 x 1 in. air filter in order to maintain proper air velocity.
High Medium-High Medium-Low Low cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts
2595 1515 2245 2015 1780 890 1365 700 2540 1500 2185 1095 1715 880 1350 700
2570 1490 2235 1095 1765 875 1370 665 2525 1480 2165 1085 1725 870 1335 675
0.20
0.30
0.40
0.50
0.60
0.70
2440 1465 2135 1075 1745
2340 1405 2075 1060 1755
2255 1370 1995 1005 1680
865
845
825
1395
1365
1370
660
660
660
2440 1445 2120 1090
2345 1400 2060 1060
2220 1345 1955 1015
1725
1715
1685
865
850
820
1345
1345
1370
675
670
660
2095 1320 1915 960 1650 805 1335 650 2100 1310 1895 985 1620 805 1320 650
1995 1270 1840 935 1595 775 1320 630 2005 1285 1780 945 1605 790 1285 635
1900 1225 1755 905 1540 755 1270 615 1845 1235 1700 910 1510 740 1225 610
0.80
0.90
1740 1180 1650 875 1430 725 1190 590 1745 1185 1645 880 1450 720 1175 595
1580 1140 1535 840 1350 695 1145 570 1655 1160 1545 840 1380 705 1135 575
Page 46
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 operation, serious injury, death, or property damage.
Before servicing, disconnect all electrical power to furnace.
When servicing controls, label all wires prior to disconnecting. 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 injury 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 1
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 amp−draw 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 clean out cap.
Cleaning Heat Exchanger
If cleaning the heat exchanger becomes necessary, follow the below procedures and refer to figure 1 when disassembling unit. Use papers or protective covering in front of furnace while removing heat exchanger assembly.
1 − Turn off electrical and gas supplies to the furnace.
2 − Remove the furnace access panels.
3 − Disconnect the 2 wires from the gas valve.
4 − Remove gas supply line connected to gas valve. Remove the burner box cover (if equipped) and remove gas valve/manifold assembly.
5 − Remove sensor wire from sensor. Disconnect 2-pin plug from the ignitor.
6 − Disconnect wires from flame roll−out switches.
7 − Disconnect combustion air intake pipe. It may be necessary to cut the existing pipe to remove burner box assembly.
8 − 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.
9 − Loosen the clamps to the flexible exhaust coupling.
10 − Disconnect condensate drain line from the cold end header box.
11 − Disconnect condensate drain tubing from flue collar.
Remove screws that secures the flue collar into place.
Remove flue collar. It may be necessary to cut the exiting exhaust pipe for removal of the fitting.
12 − Mark and disconnect all combustion air pressure tubing from cold end header collector box.
13 − Mark and remove wires from pressure switch assembly. Remove the assembly. Keep tubing attached to pressure switches.
14 − Disconnect the plug from the combustion air inducer.
Remove two screws which secure combustion air inducer to collector box. Remove combustion air inducer assembly. Remove ground wire from vest panel.
15 − Disconnect the condensate drain line.
16 − Remove cold end header box.
17 − Remove electrical junction box from the side of the furnace.
18 − 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.
19 − Remove the primary limit from the vestibule panel.
20 − 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 47
21 − Remove screws along vestibule sides and bottom which secure vestibule panel and heat exchanger assembly to cabinet. Remove two screws from blower rail which secure bottom heat exchanger flange. Remove heat exchanger from furnace cabinet.
22 − Back wash heat exchanger with soapy water solution or steam.
If steam is used it must be below 275°F
(135°C) .
23 − Thoroughly rinse and drain the heat exchanger. Soap solutions can be corrosive. Take care to rinse entire assembly.
24 − Reinstall heat exchanger into cabinet making sure that the clamshells of the heat exchanger assembly is engaged properly into the support bracket on the blower deck. Remove the indoor blower to view this area through the blower opening.
25 − Re-secure the supporting screws along the vestibule sides and bottom to the cabinet.
26 − Reinstall cabinet screws on front flange at blower deck.
27 − Reinstall the primary limit on the vestibule panel.
28 − Route heating component wiring through hole in blower deck and reinsert strain relief bushing.
29 − Reinstall electrical junction box.
30 − Reinstall the cold end header box.
31 − Reinstall the combustion air inducer. Reconnect the plug to the wire harness.
32 − Reinstall pressure switches and reconnect pressure switch wiring.
33 − Carefully connect combustion air pressure switch tubing from pressure switches to proper ports on cold end header collector box.
34 − Reconnect condensate drain line to the cold end header box.
35 − Use securing screws to reinstall flue collar to the top cap on the furnace. Reconnect exhaust piping and exhaust drain tubing.
36 − Replace flexible exhaust adapter on combustion air inducer and flue collar. Secure using two existing hose clamps.
37 − Reinstall burner box assembly in vestibule area. Secure burner box assembly to vestibule panel using four existing screws. Make sure burners line up in center of burner ports
38 − Reconnect flame roll−out switch wires.
39 − Reconnect sensor wire and reconnect 2−pin plug from ignitor.
40 − Reinstall gas valve manifold assembly. Reconnect gas supply line to gas valve.
41 − Reconnect the combustion air intake pipe.
42 − Reinstall burner box cover.
43 − Reconnect wires to gas valve.
44 − Replace the blower compartment access panel.
45 − Reconnect gas supply piping. Turn on power and gas supply to unit.
46− Follow lighting instructions on unit nameplate to light and operate furnace for 5 minutes to ensure the furnace is operating properly.
47− Check all piping connections, factory and field, for gas leaks. Use a leak detecting solution or other preferred means.
48− Replace heating compartment access panel.
CAUTION
Some soaps used for leak detection are corrosive to certain metals. Carefully rinse piping thoroughly after leak test has been completed. Do not use matches, candles, flame or other sources of ignition to check for gas leaks.
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 wires from the gas valve.
3 − Remove the burner box cover (if equipped).
4 − Disconnect the gas supply line from the gas valve. Remove gas valve/manifold assembly.
5 − Mark and disconnect sensor wire from the sensor. Disconnect wires from flame rollout switches.
6 − Disconnect combustion air intake pipe. It may be necessary to cut the existing pipe to remove burner box assembly.
7 − Remove four screws which secure burner box assembly to vest panel. Remove burner box from the unit.
8 − 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 blockage caused by foreign matter. Remove any blockage.
9 − Reinstall the burner box assembly using the existing four screws. Make sure that the burners line up in the center of the burner ports.
10 − Reconnect the sensor wire and reconnect the 2−pin plug to the ignitor wiring harness. Reconnect wires to flame rollout switches.
11 − Reinstall the gas valve manifold assembly. Reconnect the gas supply line to the gas valve. Reinstall the burner box cover.
12 − Reconnect wires to gas valve.
13 − Replace the blower compartment access panel.
14 − Refer to instruction on verifying gas and electrical connections when re−establishing supplies.
15 − Follow lighting instructions to light and operate furnace for 5 minutes to ensure that heat exchanger is clean and dry and that furnace is operating properly.
16 − Replace heating compartment access panel.
Page 48
Planned Service
A service technician should check the following items during 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 unobstructed 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 provide a seal between the return air and the room where the furnace is installed.
Ignition Control Board Diagnostic Codes
RED LED
Flash Code
Off
Heartbeat 1
3
4
1
2
5
6
7
11
12
13
8
9
10
Note 1
Note
Note
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 necessary 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 inspections 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.
Diagnostic Codes / Status of Furnace
No power to control or board fault detected
Control powered − displayed during all modes of operation if no errors are detected
Reverse Line Voltage Polarity
Improper Earth Ground
Burner failed to light, or lost flame during heat demand
Low Flame Signal − check flame sensor
Watchguard − burner failed to light, exceeded maximum number of retries or recycles.
Ignitor Circuit Failure − not available on this control
Primary or Secondary Limit Open or Watchguard Mode − Limit Switch Open longer than 3 minutes
Rollout Switch Open
Pressure Switch failed to close or opened during heat demand
Watchguard − Pressure Switch opened 5 times during one heat demand
Pressure Switch stuck closed prior to activation of combustion air inducer
Flame Sensed without gas valve energized
Low Line Voltage
Notes
A "Heartbeat" is indicated by a "Slow Flash" − 1 sec on 1 sec off, repeating
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
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 49
Troubleshooting: Heating Sequence of Operation
HEATING SEQUENCE OF OPERATION
ABNORMAL HEATING MODE
NORMAL HEATING MODE
POWER ON
CONTROL SELF−CHECK OKAY?
NO
GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.
INDOOR BLOWER DELAY OFF.
LED SLOW FLASH
(RESET CONTROL BY TURNING MAIN POWER OFF.)
YES
IS POLARITY CORRECT?
YES
IS THERE A PROPER GROUND?
YES
NO
NO
LED FLASHES CODE 1 − POLARITY REVERSED.
LED FLASHES CODE 2 − IMPROPER GROUND.
NO
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.
YES
ROLLOUT SWITCH CLOSED?
YES
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 POWER IS RESET OR T’STAT IS INTERRUPTED
FOR MINIMUM OF 1 SECOND.
NO
LED FLASHES CODE 12 − FLAME SENSED
WITHOUT GAS VALVE ENERGIZED.
GAS VALVE OFF. COMBUSTION AIR INDUCER ON.
INDOOR BLOWER ON HEATING SPEED.
NO
BURNER OFF?
( Flame sensed without gas valve energized )
YES
NORMAL OPERATION:
LED SLOW FLASH
YES
THERMOSTAT CALLS FOR HEAT:
LED SLOW FLASH
YES
PRIMARY LIMIT SWITCH. CLOSED?
YES
IS COMBUSTION AIR
PRESSURE SWITCH OPEN?
YES
IS COMBUSTION AIR INDUCER
ENERGIZED?
YES
HAS COMBUSTION AIR PRESSURE
SWITCH CLOSED IN 2.5 MINUTES?
YES
CONTINUED NEXT PAGE
NO
NO
LED FLASHES CODE 7 − PRIMARY LMIT
OPEN. COMBUSTION AIR INDUCER
OFF.INDOOR BLOWER ON
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
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?
YES
Page 50
Troubleshooting: Heating Sequence of Operation (Continued)
HEATING SEQUENCE CONTINUED
NORMAL HEATING MODE ABNORMAL HEATING MODE
15-SECOND COMBUSTION AIR INDUCER PREPURGE
INITIATED BY CLOSED PRESSURE SWITCH.
YES
NO
IGNITOR WARM-UP −− 20 SECONDS.
YES
4-SECOND TRIAL FOR IGNITION.
GAS VALVE OPENS. IGNITOR ENERGIZED FOR
FIRST 3 SECONDS OF THE TRIAL.
YES
FLAME STABILIZATION PERIOD.
4 SECONDS
IS VOLTAGE ABOVE 70 VOLTS?
YES
NO
LED FLASHES CODE 13 −
LOW LINE VOLTAGE.
ONCE VOLTAGE IS ABOVE
75 VOLTS, HEATING
SEQUENCE RESTARTS.
NO
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?
NO
YES
FLAME RECTIFICATION CURRENT
CHECK. CAN FLAME BE PROVEN WITHIN
4 SECONDS AFTER GAS VALVE OPENS?
(0.5 microamps)
YES
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
FLAME PRESENT?
NO
HAS CONTROL RESET IGNITION
SEQUENCE FOUR TIMES?
NO
YES
YES
FLAME SIGNAL 1.5 MICROAMPS OR GREATER?
YES
INDOOR BLOWER ON
AFTER 30−SECOND DELAY
YES
PRIMARY LIMIT SWITCH CLOSED?
YES
ROLLOUT SWITCH CLOSED?
YES
COMBUSTION AIR PRESSURE
SWITCH CLOSED?
YES
NO
LED FLASHES CODE 4 − LOW FLAME
SIGNAL.
(Does not affect operation of control)
NO
LED FLASHES CODE 7 − PRIMARY LIMIT OPEN
GAS VALVE DE−ENERGIZED.
COMBUSTION AIR INDUCER DE−ENERGIZED.
INDOOR BLOWER ON UNTIL SWITCH CLOSES.
LIMIT SWITCH CLOSED?
YES
YES
HAS 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
T’STAT IS CYCLED
OFF/ON FOR 1 SEC.
MINIMUM. 60−MINUTE
WATCHGUARD PE-
RIOD STARTS AT
TIME LIMIT CLOSES.
IS 60−MIN. PERIOD
COMPLETE?
NO
NO
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.
NO
THERMOSTAT DEMAND SATISFIED.
YES
LED SLOW FLASH.
YES
COMB. AIR INDUCER CONTINUES 5-SECOND
POST PURGE AFTER T’STAT DEMAND IS SATISFIED.
INDOOR AIR BLOWER COMPLETES SELECTED OFF"
DELAY BEFORE SHUTTING OFF.
HAS PRESSURE SWITCH OPENED 5 TIMES
IN THE SAME HEAT DEMAND?
NO YES
GAS VALVE DE−ENERGIZED. COMBUSTION AIR
INDUCER ON. INDOOR BLOWER OFF WITH
DELAY. HAS CAB PRESSURE SWITCH CLOSED
WITHIN 2.5 MINUTES?
NO
5-MINUTE PRESSURE SWITCH
WATCHGUARD MODE.
YES
LED FLASHES
CODE 10
1 HR PRESSURE
SWITCH
WATCHGUARD
MODE
Page 51
Troubleshooting: Cooling Sequence of Operation
COOLING SEQUENCE OF OPERATION
NORMAL COOLING MODE
POWER ON
ABNORMAL COOLING MODE
IGNITION CONTROL MAIN POWER ON.
CONTROL SELF DIAGNOSTIC CHECK.
IS CONTROL OPERATING NORMALLY?
YES
IS THERE A PROPER GROUND?
YES
IS POLARITY CORRECT?
YES
IS VOLTAGE
ABOVE 70 VOLTS?
YES
NO
ROLLOUT SWITCH MONITORED CONTINUOUSLY.
IS ROLLOUT SWITCH CLOSED?
YES
NO
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.
NO
NO
LED FLASHES CODE 2 IMPROPER GROUND
CONTROL WILL CONTINUE TO CALL FOR COOLING
IN THIS CONDITION.
LED FLASHES CODE 1 POLARITY REVERSED
CONTROL WILL CONTINUE TO CALL FOR COOLING IN
THIS CONDITION.
NO
LED FLASHES CODE 13 LOW VOLTAGE. CONTROL
WILL CONTINUE TO CALL FOR COOLING
IN THIS CONDITION.
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.
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.
THERMOSTAT OPENS.
COMPRESSOR OFF.
SYSTEM FAN AND EAC TERM. OFF
WITH 45-SECOND DELAY.
Page 52
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).
NO YES
THERMOSTAT CALLS FOR COOLING.
YES
SYSTEM FAN SWITCHED TO COOL SPEED.
EAC TERM. REMAINS ON.
NO
SYSTEM FAN CONTINUES FAN SPEED WITHOUT
INTERRUPTION. EAC TERMINAL REMAIN ON.
HUM TERMINAL IS ENERGIZED WITH COMBUSTION
AIR BLOWER.
THERMOSTAT OPENS.
MANUAL FAN SELECTION MADE AT THERMOSTAT.
CONTROL (G) ENERGIZES SYSTEM FAN AT FAN
SPEED. EAC TERM. ENERGIZED.
SYSTEM FAN SWITCHES TO HEAT SPEAD AFTER 30
SECOND DELAY. EAC AND HUM TERMINAL REMAIN ON.
THERMOSTAT OPENS.
HUM. TERMINAL OFF AFTER POST PURGE
BY COMBUSTION AIR BLOWER. SYTEM FAN
SWITCHES TO FAN SPEED AFTER BLOWER
OFF DELAY. EAC CONTINUES WITHOUT
INTERRUPTION.
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: EL195UH045P24B−01. All service must be performed by a licensed professional 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 53
Start−Up & Performance Check List
UNIT SET UP
Furnace:
Model Number_______________
Serial Number_________________
2
2
Line Voltage
4
1 GAS SUPPLY
Natural Gas LP Propane Gas
Piping Connections Tight
Leak Tested
Supply Line Pressure W.C.________
SUPPLY
AIR
1
Gas Supply Pressure
1
3
Flter
RETURN AIR
3
DUCT SYSTEM
SUPPLY AIR DUCT
Sealed
Insulated (if necessary)
2 INTAKE / EXHAUST PIPE
All Joints Primed and Glued
Terminations Installed Properly
Horizontal Pipes Sloped (if applicable)
Condensate Trap Primed / Line Sloped
Pipes Supported
Heat Cable Installed and Operable (if applicable)
RETURN DUCT
Sealed
Filter Installed and Clean
4
Grilles Unobstructed
VOLTAGE CHECK
Supply Voltage _____
Electrical Connections Tight
Page 54
1
HEATING MODE
GAS MANIFOLD PRESSURE W.C._____
UNIT OPERATION
3
COOLING MODE
INDOOR BLOWER AMPS______
2 COMBUSTION SAMPLE CO
2
%
______
CO PPM_______
3
INDOOR BLOWER AMPS______
4
TEMPERATURE RISE
Supply Duct Temperature ________
Return Duct Temperature _ _____
Temperature Rise = ________
5
TOTAL EXTERNAL STATIC
Supply External Static _______
Return External Static + ______
Total External Static = _______
6
CONDENSATE LINE
Leak Free
7 VENT PIPE
Leak Free
Combustion CO
2
4
TEMPERATURE DROP
Return Duct Temperature _________
Supply Duct Temperature _ _______
Temperature Drop = _________
5 TOTAL EXTERNAL STATIC (dry coil)
Supply External Static _______
Return External Static + ______
Total External Static = _______
8 DRAIN LINE
Leak Free
9
THERMOSTAT
Adjusted and Programmed
Explained Operation to Owner
2
7
SUPPLY
AIR
Thermostat
9
Blower Motor Amps
3
6
8
Gas Manifold Pressure
1
Temperatures
4
Duct Static
5
RETURN AIR
Contractor’s: Name_________________________Telephone_____________Checklist Completed____________________
Job Address_____−________________________________Technician’s Name___________________________________
Page 55
Requirements for Commonwealth of Massachusetts
Modifications to NFPA−54, Chapter 10
Revise NFPA−54 section 10.8.3 to add the following requirements:
For all side wall, horizontally vented, gas−fueled 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, including 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, horizontally vented, gas−fueled equipment, the installing plumber or gasfitter shall observe that a hard−wired 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 battery−operated or hard−wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall, horizontally vented, gas−fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard−wired carbon monoxide detectors.
a − In the event that the side wall, horizontally vented, gas−fueled equipment is installed in a crawl space or an attic, the hard−wired carbon monoxide detector with alarm and battery back−up may be installed on the next adjacent floor level.
b − In the event that the requirements of this subdivision 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 battery−operated carbon monoxide detector with an alarm shall be installed.
2 − APPROVED CARBON MONOXIDE DETECTORS.
Each carbon monoxide detector as required in accordance with the above provisions shall comply with
NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
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 directly in line with the exhaust vent terminal for the horizontally vented, gas−fueled heating appliance or equipment. The sign shall read, in print size no less than one−half (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, gas−fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions 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 Equipment 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 separate 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, gas−fueled equipment provides a venting 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, gas−fueled equipment does not provide the parts for venting the flue gases, but identifies special 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 Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.
A copy of all installation instructions for all Product
Approved side wall, horizontally vented, gas−fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.
Page 56
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