Lennox EL195DF SERIES User manual

Page 1 ©2012 Lennox Industries Inc.
Litho U.S.A.
Corp. 1102−L1 EL195DF
Service Literature Revised 02/2012
EL195DF SERIES UNITS
EL195DF series units are high−efficiency gas furnaces
manufactured with Lennox DuralokPlustaluminized
steel clamshell−type heat exchangers, with a stainless steel
condensing coil. EL195DF units are available in heating
input capacities of 44,000 to 110,000 Btuh (13 to 32.2 kW)
and cooling applications from 2 through 5 tons (7.0 through
17.6 kW). Refer to Engineering Handbook for proper sizing.
Units are factory equipped for use with natural gas. A kit is
available for conversion to LP/Propane operation. All
EL195DF units are equipped with a hot surface ignition
system. The gas valve is redundant to assure safety
shut−off as required by C.S.A.
The heat exchanger, burners and manifold assembly can be
removed for inspection and service. The maintenance section
gives a detailed description on how this is done.
All specifications are subject to change. Procedures outlined
in this manual are presented as a recommendation only
and do not supersede or replace local or state codes.
WARNING
Electric shock hazard. Can cause injury
or death. Before attempting to perform
any service or maintenance, turn the
electrical power to unit OFF at discon-
nect switch(es). Unit may have multiple
power supplies.
Table of Contents
Specifications 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Accessories 3. . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Performance Data 4. . . . . . . . . . . . . . . . . . . . . .
I−Unit Components 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
II Placement and Installation 16. . . . . . . . . . . . . . . . . . . .
III−Start−Up 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IV−Heating System Service Checks 37. . . . . . . . . . . . . .
V−Typical Operating Conditions 40. . . . . . . . . . . . . . . . . .
VI−Maintenance 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VII−Wiring and Sequence of Operation 43. . . . . . . . . . . .
VIII−Troubleshooting 44. . . . . . . . . . . . . . . . . . . . . . . . . . .
WARNING
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, person-
al injury or loss of life. Installation and service must
be performed by a licensed professional installer (or
equivalent), service agency or the gas supplier.
WARNING
Sharp edges.
Be careful when servicing unit to avoid sharp edges
which may result in personal injury.

Page 2
SPECIFICATIONS
Gas
Heating
Performance
Model No. EL195DF045P36B EL195DF070P48B EL195DF090P60C EL195DF110P60C
1AFUE 95% 95% 95% 95%
Input - Btuh 44,000 66,000 88,000 110,000
Output - Btuh 42,000 64,000 85,000 106,000
Temperature rise range - °F 25 - 55 25 - 55 30 - 60 40 - 70
Gas Manifold Pressure (in. w.g.)
Nat. Gas / LPG/Propane
3.5 / 10 3.5 / 10 3.5 / 10 3.5 / 10
High static - in. w.g. 0.5 0.5 0.5 0.5
Connections
in.
Intake / Exhaust Pipe (PVC) 2 / 2 2 / 2 2 / 2 2 / 2
Gas pipe size IPS 1/2 1/2 1/2 1/2
Condensate Drain Trap (PVC pipe) - i.d. 1/2 1/2 1/2 1/2
with furnished 90° street elbow 1/2 slip x 1/2 Mipt 1/2 slip x 1/2 Mipt 1/2 slip x 1/2 Mipt 1/2 slip x 1/2 Mipt
with eld supplied (PVC coupling) - o.d. 1/2 slip x 1/2 Npt 1/2 slip x 1/2 Npt 1/2 slip x 1/2 Npt 1/2 slip x 1/2 Npt
Indoor
Blower
Wheel nom. dia. x width - in. 10 x 8 11-1/2 x 10 11-1/2 x 10 11-1/2 x 10
Motor output - hp 1/3 3/4 1 1
Tons of add-on cooling 2 - 3 3 - 4 4 - 5 4 - 5
Air Volume Range - cfm 605-1615 1090-1885 1270-2305 1330-2375
Electrical
Data
Voltage 120 volts - 60 hertz - 1 phase
Blower motor full load amps 6.1 10.0 11.5 11.5
Maximum overcurrent protection 12 12 15 15
Shipping Data lbs. - 1 package 121 134 154 164
NOTE - Filters and provisions for mounting are not furnished and must be eld provided.
1 Annual Fuel Utilization Efciency based on DOE test procedures and according to FTC labeling regulations. Isolated combustion system rating for non-weatherized
furnaces.

Page 3
OPTIONAL ACCESSORIES - MUST BE ORDERED EXTRA
“B” Width Models “C” Width Models
CABINET ACCESSORIES
Downow Combustible Flooring Base 11M60 11M61
CONDENSATE DRAIN KITS
Condensate Drain Heat Cable 6 ft. 26K68 26K68
24 ft. 26K69 26K69
50 ft. 26K70 26K70
Heat Cable Tape Fiberglass - 1/2 in. x 66 ft. 36G53 36G53
Aluminum foil - 2 in. x 60 ft. 16P89 16P89
Crawl Space Vent Drain Kit 51W18 51W18
CONTROLS
DOWNFLOW FILTER KITS
Downow Air Filter and Rack Kit 51W07 51W08
No. and Size of lter - in. (2) 20 x 20 x 1 (2) 20 x 20 x 1
NIGHT SERVICE KITS
Night Service Kit 51W03 51W03
Safety Service Kit 89W20 89W20
TERMINATION KITS
See Installation Instructions for specic venting information.
Termination Kits -
Direct Vent Applications
Only
Concentric US - 2 in. 71M80 69M29
3 in. - - - 60L46
Canada - 2 in. 44W92 44W92
3 in. - - - 44W93
Flush-Mount 2, 2-1/2 or 3 in. 51W11 51W11
Wall - Close
Couple
US - 2 in. 22G44 - - -
3 in. 44J40 44J40
Wall - Close
Couple WTK
Canada - 2 in. 30G28 - - -
3 in. 81J20 81J20
Termination Kits -
Direct or Non-Direct vent
Roof 2 in. 15F75 15F75
Wall Ring Kit 2 in. 15F74 315F74
Roof Termination Flashing Kit - Direct or Non-Direct
Vent (2 ashings)
2 in. 44J41 44J41
1 Cleanable polyurethane frame type lter.
2Kits contain enough parts for two, non-direct vent installations.
3 Non-direct vent only.
NOTE - Termination Kits 44W92, 44W93, 30G28, 81J20 are certied to ULC S636 standard for use in Canada only.
GAS HEAT ACCESSORIES
Input
High Altitude
Pressure Switch Kit
Natural Gas to
LPG/Propane Kit
LPG/Propane
to Natural Gas Kit
Natural Gas
High Altitude
Orice Kit
LPG/Propane
High Altitude
Orice Kit
4501 - 7500 ft. 7501 - 10,000 ft. 0 - 7500 ft. 0 - 7500 ft. 7501- 10,000 ft. 7501- 10,000 ft.
045 No Change 74W90 69W73 73W81 73W37 68W68
070 77W43 73W22 69W73 73W81 73W37 68W68
090 77W43 73W22 69W73 73W81 73W37 68W68
110 77W43 73W22 69W73 73W81 73W37 68W68

Page 4
BLOWER DATA
EL195DF070P48B PERFORMANCE (Less Filter)
External
Static
Pressure
in. w.g.
Air Volume / Watts at Various Blower Speeds
High Medium-
High
Medium-
Low Low
cfm Watts cfm Watts cfm Watts cfm Watts
0.00 1885 935 1830 815 1810 720 1700 640
0.10 1850 910 1805 795 1785 705 1680 630
0.20 1775 890 1750 775 1710 690 1620 610
0.30 1715 870 1685 755 1640 660 1575 595
0.40 1645 855 1620 735 1595 650 1495 575
0.50 1575 835 1525 715 1485 625 1440 555
0.60 1505 815 1450 690 1425 610 1360 540
0.70 1390 790 1360 675 1340 590 1270 525
0.80 1280 770 1270 650 1255 570 1210 505
0.90 1200 740 1185 635 1160 550 1090 485
EL195DF110P60C PERFORMANCE (Less Filter)
External
Static
Pressure
in. w.g.
Air Volume / Watts at Various Blower Speeds
High Medium-
High
Medium-
Low Low
cfm Watts cfm Watts cfm Watts cfm Watts
0.00 2375 1250 2205 915 1975 785 1630 640
0.10 2365 1235 2195 905 1960 775 1625 635
0.20 2275 1200 2125 890 1950 760 1635 625
0.30 2200 1180 2060 880 1900 735 1620 610
0.40 2115 1150 1995 850 1845 710 1620 600
0.50 2040 1115 1940 835 1795 695 1585 580
0.60 1955 1090 1855 810 1745 670 1540 565
0.70 1860 1070 1730 765 1640 650 1515 550
0.80 1735 1030 1620 740 1590 620 1415 535
0.90 1640 1010 1535 715 1480 600 1330 510
EL195DF045P36B PERFORMANCE (Less Filter)
External
Static
Pressure
in. w.g.
Air Volume / Watts at Various Blower Speeds
High Medium-
High
Medium-
Low Low
cfm Watts cfm Watts cfm Watts cfm Watts
0.00 1615 650 1385 555 1205 465 1045 390
0.10 1605 640 1380 545 1195 455 1035 380
0.20 1500 620 1345 525 1165 445 1015 370
0.30 1450 590 1290 490 1125 420 975 365
0.40 1350 560 1235 480 1090 405 920 345
0.50 1300 545 1170 450 1035 380 880 330
0.60 1195 500 1095 425 990 365 840 320
0.70 1140 480 1020 395 895 345 780 300
0.80 1025 450 920 370 840 330 695 270
0.90 945 430 800 335 700 290 605 250
EL195DF090P60C PERFORMANCE (Less Filter)
External
Static
Pressure
in. w.g.
Air Volume / Watts at Various Blower Speeds
High Medium-
High
Medium-
Low Low
cfm Watts cfm Watts cfm Watts cfm Watts
0.00 2305 1255 2145 950 1900 810 1515 670
0.10 2295 1240 2135 940 1885 795 1500 665
0.20 2200 1220 2085 915 1865 775 1525 655
0.30 2160 1210 1990 875 1830 755 1545 640
0.40 2055 1170 1935 865 1790 725 1530 620
0.50 1970 1130 1855 835 1705 700 1500 600
0.60 1890 1105 1765 805 1635 675 1495 580
0.70 1775 1075 1680 785 1565 655 1430 560
0.80 1690 1050 1590 760 1485 630 1370 540
0.90 1580 1010 1485 735 1405 610 1270 510

Page 5
FIGURE 1
CONTROL BOX
(Includes integrated control,
transformer and door switch) BAG ASSEMBLY
(shipping location)
BLOWER MOTOR
(hidden)
OUTER
ACCESS
PANEL
COMBUSTION
AIR INDUCER
BURNER BOX ASSEMBLY
(includes sensor, rollout switches and ignitor) GAS VALVE
BLOWER DECK
COLD END HEADER BOX
PRIMARY LIMIT
DuralokPlusTM
HEAT EXCHANGER
ASSEMBLY
COMBUSTION AIR INDUCER
PRESSURE SWITCH
PARTS ARRANGEMENT

Page 6
I−UNIT COMPONENTS
ELECTROSTATIC DISCHARGE (ESD)
Precautions and Procedures
CAUTION
Electrostatic discharge can affect elec-
tronic components. Take precautions to
neutralize electrostatic charge by
touching your hand and tools to metal
prior to handling the control.
EL195DF unit components are shown in figure 1. The com-
bustion air inducer, gas valve and burners can be accessed
by removing the burner access panel. The blower and con-
trol box can be accessed by removing the blower access
door.
A−Control Box Components (Figure 2)
Unit transformer (T1) and integrated ignition control (A92)
are located in the control box. In addition, a door interlock
switch (S51) is located in the control box.
FIGURE 2
DOOR INTERLOCK
SWITCH (S51)
INTEGRATED IGNITION
CONTROL
(A92)
TRANSFORMER
(T1)
EL195DF Control Box
1. Transformer (T1)
A transformer located in the control box provides power to
the low voltage section of the unit. The transformers on all
models are rated at 40VA with a 120V primary and 24V
secondary.
2. Door Interlock Switch (S51)
A door interlock switch rated 14A at 120VAC is located on
the control box. The switch is wired in series with line volt-
age. When the blower door is removed the unit will shut
down.
3. Integrated Ignition Control (A92)
WARNING
Shock hazard.
Disconnect power before servicing. Control is not
field repairable. If control is inoperable, simply re-
place entire control.
Can cause injury or death. Unsafe operation will
result if repair is attempted.
The ignition control system consists of an integrated con-
trol (figure 4) ignitor (figure 5) and flame sensor (figure 5).
The integrated control and ignitor work in combination to
ensure furnace ignition and ignitor durability. The inte-
grated control, controls all major furnace operations. The
integrated control also features a RED LED light for trou-
bleshooting and two accessory terminals rated at (1) one
amp. Tables 1 and 2 show jack plug terminal designations.
See table 3 for troubleshooting diagnostic codes. The ni-
tride ignitor is made from a non−porous, high strength pro-
prietary ceramic material that provides long life and
trouble free maintenance. The integrated control continu-
ously monitors line voltage and maintains the ignitor pow-
er at a consistent level to provide proper lighting and maxi-
mum ignitor life.
TABLE 1
4−Pin Terminal Designation
PIN # FUNCTION
1Combustion Air Inducer Line
2Ignitor Line
3Combustion Air Inducer Neutral
4Ignitor Neutral
TABLE 2
12−Pin Terminal Designations
PIN # FUNCTION
1High Limit Output
2Not Used
324V Line
4Not Used
5Rollout Switch Out
624V Neutral
7High Limit Input
8 Ground
9Gas Valve Common
10 Pressure Switch In
11 Rollout Switch In
12 Gas Valve Out

Page 7
Electronic Ignition
On a call for heat the integrated control monitors the com-
bustion air inducer prove switch. The integrated control will
not begin the heating cycle if the pressure switch is closed
(by−passed). Once the pressure switch is determined to be
open, the combustion air inducer is energized. When the
differential in the pressure switch is great enough, the pres-
sure switch closes and a 15−second pre−purge begins. If
the pressure switch is not proven within 2−1/2 minutes, the
integrated control goes into Watchguard−Pressure Switch
mode for a 5−minute re−set period.
After the 15−second pre−purge period, the ignitor warms up
for 20 seconds during which the gas valve opens at 19 sec-
onds for a 4−second trial for ignition. The ignitor remains
energized for the first 3 seconds during the 4 second trial. If
ignition is not proved during the 4−second period, the inte-
grated control will try four more times with an inter purge
and warm−up time between trials of 35 seconds. After a to-
tal of five trials for ignition (including the initial trial), the inte-
grated control goes into Watchguard−Flame Failure mode.
After a 60−minute reset period, the integrated control will
begin the ignition sequence again.
The integrated control has an added feature of ignitor pow-
er regulation to maintain consistent lighting and longer igni-
tor life under all line voltage conditions.
Fan Control
Heating Fan On Delay
The heating fan on time of 30 seconds is not adjustable.
Heating Fan Off Delay
The heat fan off delay (amount of time that the blower oper-
ates after the heat demand has been satisfied) may be ad-
justed by changing the jumper position across the five pins
on the integrated control. The unit is shipped with a factory
fan off setting of 90 seconds. The fan off delay affects com-
fort and is adjustable to satisfy individual applications. Ad-
just the fan off delay to achieve a supply air temperature be-
tween 90° and 110°F at the moment that the blower is
de−energized. Longer off delay settings provide lower re-
turn air temperatures; shorter settings provide higher re-
turn air temperatures. See figure 3.
Cooling Fan On Delay
The cool fan on delay is 2 seconds and not adjustable.
Cooling Fan Off Delay
The cool fan off delay (amount of time that the blower oper-
ates after the cool demand has been satisfied) is 45 sec-
onds and not adjustable.
HEAT FAN-OFF TIME IN SECONDS
To adjust fan−off timing, reposition jumper across pins to
achieve desired setting.
NO JUMPER
FIGURE 3
60 90
120
180
60 90
120
180
60 90
120
180
60 90
120
180
60 Second
off Time
90 Second
off Time
120 Second
off Time
180 Second
off Time
FIGURE 4
INTEGRATED CONTROL
(Automatic Hot Surface Ignition System)
TERMINAL DESIGNATIONS
HUM
LINE
XFMR
EAC
COOL
HEAT
PARK
FLAME
FAN
Humidifier (120VAC)
Input (120VAC)
Transformer (120VAC)
Indoor Air Quality Accessories (120VAC)
Blower − Cooling Speed (120VAC)
Blower − Heating Speed (120VAC)
Dead terminals to park alternate speed taps
Flame sensor
Continuous blower
Blower off delay
jumper
HUM Humidifier (24VAC)
Red LED Recall

Page 8
TABLE 3
RED LED
Flash Code Diagnostic Codes / Status of Furnace
Off No power to control or board fault detected.
ON Board Fault Detected.
Heartbeat1Control powered − displayed during all modes of operation if no errors are detected.
1
Reverse Line Voltage.
Corrective Action − Check the 120V line and neutral connections and reverse the connection if
necessary.
2Improper Earth Ground.
Corrective Action − Check for proper unit ground and install if necessary.
3
Burner failed to light, or lost flame during heat demand.
Corrective Action − Check condition of flame sensor and clean if necessary using steel wool.
Check flame sensor signal and replace if necessary.
Check flame sensor wiring and replace if necessary.
4
Low Flame Signal.
Corrective Action − Check flame sensor micro amp reading. Normal reading is 1.5. Replace
sensor if lower than 0.5.
5Watchguard − burner failed to light, exceeded maximum number of retries or recycles.
6Ignitor Circuit Failure − not available on this control.
7
Primary or Secondary Limit Open or Watchguard Mode − Limit Switch Open longer than
3 minutes.
Corrective Action
Check for restriction on blower inlet air and outlet air. Remove restrictions.
Check unit rate, rise and static. Make adjustments if necessary and run unit until equilarium.
Check continuity across switch and replace if necessary.
8
Rollout Switch Open.
Corrective Action − Check continuity across switch and replace switch if necessary.
Check for restriction in vent pipe, combustion air inlet and heat exchanger. Determine cause of
restriction before placing furnace back inoperation.
9
Pressure Switch failed to close or opened during heat demand.
Corrective Action − Check the differential in the pressure switch. See figure 11.
Check for restricted vent pipe and remove all blockage.
Check vent pipe sizing. See table 10.
10
Watchguard − Pressure Switch opened 5 times during one heat demand.
Corrective Action − Check for restricted vent pipe and remove all blockage.
Check the condensate line for proper drainage and correct as necessary.
Check for proper vent termination and replace if necessary. See table 8.
11
Pressure Switch stuck closed prior to activation of combustion air inducer.
Corrective Action − Check that the pressure switch is open without the combustion air inducer
operating. Replace switch if defective.
12 Flame Sensed without gas valve energized.
Corrective Action − Check that the gas valve is stuck open. Replace gas valve.
13
Low Line Voltage.
Corrective Action − Check line voltage to unit. Voltage should be 120V + 10%. Contact power
company if necessary.
Notes
Note 1 A "Heartbeat" is indicated by a "Slow Flash" − 1 sec on 1 sec off, repeating
Note Error codes are indicated by a "Rapid Flash" − the LED flashes X times at 1/2 sec on 1/2 sec
off, remains off for 3 sec, then repeats
Note
Last 10 error codes are stored in memory including when power is shut off to the unit. − 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 9
FIGURE 5
EL195DF Burner Box Assembly
SENSOR
ROLLOUT SWITCHES
GAS VALVE
IGNITOR
BURNERS
FRONT BURNER BOX PLATE
B−Heating Components
Combustion air inducer (B6), primary limit control (S10),
SureLight ignitor, burners, flame rollout switch (S47), gas
valve (GV1), combustion air prove switch (S18), and clam-
shell heat exchangers are located in the heating compart-
ment. The heating compartment can be accessed by re-
moving the burner access panel.
1. Flame Rollout Switches (Figure 5)
Flame rollout switches S47 are SPST N.C. high temperature
limits located on the top left and bottom right of the front buner
box plate. S47 is wired to the burner ignition control A92.
When either of the switches sense flame rollout (indicat-
ing a blockage in the combustion passages), the flame
rollout switch trips, and the ignition control immediately
closes the gas valve. Switch S47 in all EL195DF units is
factory preset to open at 210_F + 12_F (99_C + 6.7_C) on a
temperature rise. All flame rollout switches are manual reset.
2. Heat Exchanger (Figure 6)
EL195DF units use an aluminized steel primary and
stainless steel secondary heat exchanger assembly.
Heat is transferred to the air stream from all surfaces of
the heat exchanger. The shape of the heat exchanger en-
sures maximum efficiency.
The combustion air inducer pulls fresh air through the burn-
er box. This air is mixed with gas in the burners. The gas /
air mixture is then burned at the entrance of each clam-
shell. Combustion gases are then pulled through the primary
and secondary heat exchangers and exhausted out the ex-
haust vent pipe.
3. Primary Limit Control (Figure 6)
Primary limit (S10) used on EL195DF units is located in the
heating vestibule panel. When excess heat is sensed in the
heat exchanger, the limit will open. Once the limit opens, the
furnace control energizes the supply air blower and de−en-
ergizes the gas valve. The limit automatically resets when
unit temperature returns to normal. The switch is factory
set and cannot be adjusted. For limit replacement remove
wires from limit terminals and rotate limit switch 90 de-
grees. Slowly remove from the vestibule panel. Install re-
placement limit with same care.

Page 10
FIGURE 6
Primary Limit Location and Heat Exchanger
Install limit face down
4. Gas Valve (GV1)
The EL195DF uses an internally redundant to valve to assure
safety shut-off. If the gas valve must be replaced, the same
type valve must be used.
24VAC terminals and gas control switch are located on
top of the valve. All terminals on the gas valve are con-
nected to wires from the ignition control. 24V applied to the
terminals opens the valve.
Inlet and outlet pressure taps are located on the valve. A
manifold adjustment screw is also located on the valve. An
LP/Propane changeover kit is available.
FIGURE 7
Gas Valve
MANIFOLD
PRESSURE
OUTLET
PORT
INLET
PRESSURE
PORT
MANIFOLD
PRESSURE
ADJUSTMENT
SCREW
(under
barbed
fitting)
5. Flame Sensor (Figure 5)
A flame sensor is located on the left side of the burner sup-
port. The sensor is mounted on the bottom burner box plate
and the tip protrudes into the flame envelope of the left−
most burner. The sensor can be removed for service with-
out removing any part of the burners. During operation,
flame is sensed by current passed through the flame and
sensing electrode. The ignition control allows the gas valve
to remain open as long as flame signal is sensed.
NOTE − The EL195DF is polarity sensitive. Make sure that
the furnace is wired correctly and is properly grounded.
A microamp DC meter is needed to check the flame signal
on the integrated control.
Flame (microamp) signal is an electrical current which passes
from the integrated control to the sensor during unit operation.
Current passes from the sensor through the flame to ground to
complete a safety circuit.
To Measure Flame Signal − Integrated Control:
Use a digital readout meter capable of reading DC micro-
amps. See figure 8 for flame signal check.
1 − Set the meter to the DC amps scale.
2 − Turn off supply voltage to control.
3 − Disconnect integrated control flame sensor wire from
the flame sensor.
4 − Connect (−) lead to flame sensor.
5 − Connect (+) lead to the ignition control sensor wire.
6 − Turn supply voltage on and close thermostat contacts to
cycle system.
7 − When main burners are in operation for two minutes, take
reading.
6. Ignitor (Figure 5)
EL195DF units use a mini−nitride ignitor made from a pro-
prietary ceramic material. To check ignitor, measure its re-
sistance and voltage. A value of 39 to 70 ohms indicates a
good ignitor. Voltage to the ignitor should be 102VAC −
132VAC. See figure 9 for resistance and voltage checks.