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Lennox MERIT ML193UH Installation Instructions Manual

Gas furnace upflow / horizontal air discharge
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E 2012 Lennox Industries Inc.
Dallas, Texas, USA
HORIZONTAL LEFT
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08/12
*2P0812*
AIR FLOW
UPFLOW
HORIZONTAL RIGHT

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INSTALLATION
INSTRUCTIONS
ML193UH
®
MERIT
SERIES GAS FURNACE
UPFLOW / HORIZONTAL AIR DISCHARGE
507010−01
08/2012
Supersedes 06/2012
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.
As with any mechanical equipment, personal injury
can result from contact with sharp sheet metal
edges. Be careful when you handle this equipment.
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.
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507010−01
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Litho U.S.A.
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Summary of Contents for Lennox MERIT ML193UH

  • Page 1: Table Of Contents

    INSTALLATION INSTRUCTIONS E 2012 Lennox Industries Inc. Dallas, Texas, USA ML193UH ® MERIT SERIES GAS FURNACE UPFLOW / HORIZONTAL AIR DISCHARGE 507010−01 Litho U.S.A. 08/2012 Supersedes 06/2012 THIS MANUAL MUST BE LEFT WITH THE HOMEOWNER FOR FUTURE REFERENCE This is a safety alert symbol and should never be ignored.

  • Page 2: Unit Dimensions

    ML193UH Unit Dimensions − inches (mm) EXHAUST AIR NOTE − 60C and 60D size units that require air 3−3/8 OUTLET volumes 1800 cfm or over (850 L/s) must have (86) one of the following 1. Single side return air with transition, to accommodate 2 (51) 20 x 25 x 1 in.

  • Page 3: Ml193Uh Gas Furnace

    ML193UH Gas Furnace Shipping and Packing List Package 1 of 1 contains The ML193UH Category IV gas furnace is shipped ready for installation in the upflow or horizontal position. The fur- 1 − Assembled ML193UH unit nace is shipped with the bottom panel in place. The bot- 1 −...

  • Page 4: Use Of Furnace As Construction Heater

    Installed in Combination with a Cooling Coil Lennox does not recommend the use of ML193UH units as a construction heater during any phase of construction. When this furnace is used with cooling coils (figure 3), it shall...

  • Page 5: General

    Air filters must be replaced upon construction comple- WARNING tion. The input rate and temperature rise must be set per the The State of California has determined that this prod- furnace rating plate. uct may contain or produce a chemical or chemicals, One hundred percent (100%) outdoor air must be pro- in very low doses, which may cause serious illness or death.
  • Page 6 with permission from the National Fuel Gas Code (ANSI− Confined Space Z223.1/NFPA 54). This reprinted material is not the com- A confined space is an area with a volume less than 50 cubic plete and official position of the ANSI on the referenced feet (1.42 m ) per 1,000 Btu (.29 kW) per hour of the com−...
  • Page 7 Air from Outside EQUIPMENT IN CONFINED SPACE If air from outside is brought in for combustion and ventila- (Inlet Air from Ventilated Crawlspace and Outlet Air to Outside) tion, the confined space shall be provided with two perma- nent openings. One opening shall be within 12" (305mm) of the top of the enclosure and one within 12"...
  • Page 8 leg). See figure 10. The bolt and washer must be re- EQUIPMENT IN CONFINED SPACE − ALL AIR FROM OUTSIDE moved before the furnace is placed into operation. Af- (All Air Through Ventilated Attic) ter the bolt and washer have been removed, the rigid leg will not touch the blower housing.

  • Page 9: Setting Equipment

    SETTING EQUIPMENT UPFLOW APPLICATION UNIT UNIT FRONT FRONT AIR FLOW AIR FLOW 1/2" max. FRONT VIEW SIDE VIEW SIDE VIEW HORIZONTAL APPLICATION 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 11 Page 9...
  • Page 10 Return Air Guidelines WARNING Return air can be brought in through the bottom or either Improper installation of the furnace can result in per- side of the furnace installed in an upflow application. If the sonal injury or death. Combustion and flue products furnace is installed on a platform with bottom return, make must never be allowed to enter the return air system an airtight seal between the bottom of the furnace and the...
  • Page 11 Optional Return Air Base CONDENSATE (Upflow Applications Only) TRAP FURNACE FRONT 23 (584) IF BASE 3−1/4 Overall IS USED (83) (Maximum) WITHOUT Minimum 11 (279) IAQ CABINET, INDOOR AIR A SINGLE Maximum 22−7/16 QUALITY Unit side return air RETURN AIR 14 (356) (570) CABINET...
  • Page 12 19. A horizontal suspension 4 − Route auxiliary drain line so that water draining from kit (51W10) may be ordered from Lennox or use equiva- lent. this outlet will be easily noticed by the homeowner.

  • Page 13: Filters

    5 − If necessary, run the condensate line into a conden- Supply Air Plenum sate pump to meet drain line slope requirements. The If the furnace is installed without a cooling coil, a removable pump must be rated for use with condensing furnaces. access panel should be installed in the supply air duct.
  • Page 14 TABLE 2 IMPORTANT PIPING AND FITTINGS SPECIFICATIONS Schedule 40 PVC (Pipe) D1785 ML193UH exhaust and intake connections are made Schedule 40 PVC (Cellular Core Pipe) F891 of PVC. Use PVC primer and solvent cement when Schedule 40 PVC (Fittings) D2466 using PVC vent pipe.

  • Page 15: Joint Cementing Procedure

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

  • Page 16: Venting Practices

    8 − After assembly, wipe excess cement from pipe at end REPLACING FURNACE THAT of fitting socket. A properly made joint will show a CHIMNEY WAS PART OF A COMMON OR GAS bead around its entire perimeter. Any gaps may indi- VENT VENT SYSTEM (Check sizing...

  • Page 17: Vent Piping Guidelines

    In some applications which permit the use of several differ- Which needs ent sizes of vent pipe, a combination vent pipe may be most elbows? used. Contact Lennox’ Application Department for assis- Intake or tance in sizing vent pipe in these applications. exhaust? NOTE −...
  • Page 18 TABLE 5 Maximum Allowable Intake or Exhaust Vent Length in Feet NOTE − Size intake and exhaust pipe length separately. Values in table are for Intake OR Exhaust, not combined total. Both Intake and Exhaust must be same pipe size. NOTE −...
  • Page 19 TYPICAL EXHAUST PIPE CONNECTIONS IN UPFLOW DIRECT OR NON−DIRECT VENT APPLICATIONS Pipe size determined in table 5 2” 3” 2” 2” 2” 2” TRANSITION *2” EXHAUST DO NOT transition from smaller to larger pipe in horizontal runs of exhaust pipe. * When transitioning up in pipe size, use the shortest length of 2”...
  • Page 20 TYPICAL AIR INTAKE PIPE CONNECTIONS IN UPFLOW DIRECT VENT APPLICATIONS Pipe size determined in table 5 2” 3” TRANSITION 2” *2” AIR INTAKE 2” 2” 2” * When transitioning up in pipe size, use the shortest length of 2” PVC pipe possible. NOTE −...
  • Page 21 Intake Piping TYPICAL AIR INTAKE PIPE CONNECTIONS The ML193UH furnace may be installed in either direct HORIZONTAL NON−DIRECT VENT APPLICATIONS (Horizontal Right−Hand Air Discharge Application Shown) 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 PVC pipe...
  • Page 22 General Guidelines for Vent Terminations CAUTION In Non-Direct Vent applications, combustion air is taken If this unit is being installed in an application with from indoors and the flue gases are discharged to the out- combustion air coming in from a space serviced by doors.
  • Page 23 TABLE 7 Maximum Allowable Exhaust Vent Pipe Length Without Insulation In Unconditioned Space For Winter Design Temperatures Single − Stage High Efficiency Furnace Unit Input Size Winter Design Vent Pipe Temperatures °F (°C) Diameter 2 in. 32 to 21 2−1/2 in. 0 to −6) 3 in.

  • Page 24: Vent Termination Clearances

    ‡ Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor. Lennox recommends avoiding this location if possible. FIGURE 32...
  • Page 25 ‡ 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 33 Page 25...
  • Page 26 Details of Intake and Exhaust Piping Terminations for NOTE − Care must be taken to avoid recirculation of ex- haust back into intake pipe. Direct Vent Installations NOTE − In Direct Vent installations, combustion air is tak- en from outdoors and flue gases are discharged to out- doors.
  • Page 27 FIELD FABRICATED WALLL TERMINATION FIELD FABRICATED WALL TERMINATION OR OR (15F74) WALL RING TERMINATION KIT (15F74) WALL RING TERMINATION KIT With INTAKE ELBOW NOTE − FIELD PROVIDED NOTE − FIELD PROVIDED REDUCER MAY BE REDUCER MAY BE 1/2" (13mm) ARMAFLEX 1/2"...
  • Page 28 7 − If intake and exhaust piping must be run up a side wall with pipe sized per table 8.The intake piping may be to position above snow accumulation or other ob- equipped with a 90° elbow turndown. Using turndown structions, piping must be supported every 24"...
  • Page 29 1 1/2" (38mm) accelerator EXHAUST VENT Front View provided on 71M80 & 44W92 EXHAUST kits for ML193UH045P24B, SIZE VENT 070P24B & 070P36B TERMINATION PIPE PER INTAKE FLASHING TABLE 8. 12” (305mm) INTAKE (Not Furnished) Minimum Above Average Snow Accumulation Top View 1/2"...
  • Page 30 WALL TERMINATION KITS (CLOSE−COUPLE) EXTENDED VENT FOR GRADE CLEARANCE 2 inch (51 mm) 22G44 (US) 3 inch (76 mm) 44J40 (US) If intake and exhaust pipe is less than 12 in. (305 mm) above snow accumulation or other obstructions, field− fabricated piping must be installed.
  • Page 31 ML193UH DIRECT VENT APPLICATION 12" (305mm) MAX. for 2" (51mm) 20" (508mm) MAX. for 3" (76mm) USING EXISTING CHIMNEY 1/2" (13mm) ARMAFLEX INSULATION IN STRAIGHT−CUT OR ANGLE−CUT IN DIRECTION 3"−8" UNCONDITIONED SPACE 1/2" (13mm) OF ROOF SLOPE * (76mm−203mm) ARMAFLEX FIELD−PROVIDED INSULATION REDUCER MAY...
  • Page 32 CONDENSATE TRAP AND PLUG LOCATIONS ML193UH NON−DIRECT VENT APPLICATION (Unit shown in upflow position) USING EXISTING CHIMNEY Trap SIZE TERMINATION STRAIGHT−CUT OR (same on ANGLE−CUT IN DIRECTION PIPE PER TABLE 8. OF ROOF SLOPE right side) 1−1/2 in. EXHAUST VENT 1/2"...
  • Page 33 Heating cable kit is drain separately as condensate drain connection) shown. 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...
  • Page 34 ML193UH with Evaporator IMPORTANT Coil Using a Common Drain Evaporator Drain Line When combining the furnace and evaporator Vent Required coil drains together, the A/C condensate drain outlet must be vented to relieve pressure in or- der for the furnace pressure switch to operate properly.
  • Page 35 TRAP / DRAIN ASSEMBLY USING 1/2" PVC OR 3/4" PVC Optional Condensate Drain Connection Adapter 1/2 inch slip X 1/2 inch mpt (Not Furnished) 90° Street Elbow 1/2 inch PVC (Not Furnished) Adapter 1/2 inch slip X 1/2 inch mpt (Not Furnished) Condensate Drain Connection In Unit 1 (25 mm) Min.

  • Page 36: Gas Piping

    4 − Piping should be sloped 1/4 inch per 15 feet (6mm per Gas Piping 5.6m) upward toward the gas meter from the furnace. The piping must be supported at proper intervals, ev- ery 8 to 10 feet (2.44 to 3.05m), using suitable hangers CAUTION or straps.
  • Page 37 Left Side Piping AUTOMATIC Right Side Piping GAS VALVE (Standard) (Alternate) (with manual shut−off valve) Bellows Grommet MANUAL MAIN SHUT−OFF MANUAL VALVE Plug Plug MAIN SHUT−OFF VALVE GROUND GROUND JOINT JOINT UNION UNION DRIP LEG Gas Valve Gas Valve Bellows Grommet DRIP LEG FIELD PROVIDED...
  • Page 38 TABLE 10 GAS PIPE CAPACITY − FT /HR (kL/HR) Length of Pipe−Feet(m) Nominal Internal Iron Pipe Size Diameter −Inches(mm) −Inches(mm) (3.048) (6.096) (9.144) (12.192) (15.240) (18.288) (21.336) (24.384) (27.432) (30.480) .622 (12.7) (17.799) (4.96) (3.40) (2.75) (2.32) (2.07) (1.87) (1.73) (1.61) (1.50) (1.42)

  • Page 39: Electrical

    Complete the wiring connections to the equipment. Use the Electrical provided unit wiring diagram and the field wiring shown in ELECTROSTATIC DISCHARGE (ESD) figure 66. Use 18−gauge wire or larger that is suitable for Precautions and Procedures Class II rating for thermostat connections. CAUTION Electrically ground the unit according to local codes or, in the absence of local codes, according to the current Na-...
  • Page 40 D The furnace integrated control requires both polarity Generator Use − Voltage Requirements and proper ground. Both polarity and proper grounding The following requirements must be kept in mind when should be checked before attempting to operate the specifying a generator for use with this equipment: furnace on either permanent or temporary power D The furnace requires 120 volts + 10% (Range: 108 D Generator should have a wave form distortion of less...

  • Page 41: Integrated Control

    Integrated Control INTEGRATED CONTROL (Automatic Hot Surface Ignition System) TERMINAL DESIGNATIONS Humidifier (120VAC) Input (120VAC) LINE Transformer (120VAC) XFMR Indoor Air Qality Accessory Air Cleaner (120VAC) Blower − Cooling Speed (120VAC) COOL Blower − Heating Speed (120VAC) HEAT Dead terminals to park alternate spd taps PARK Continuous blower CONT...

  • Page 42: Unit Start Up

    5 − Wait for the combustion air inducer to stop. Set the Unit Start−Up thermostat to initiate a heating demand and again al- FOR YOUR SAFETY READ BEFORE OPERATING low the burners to fire for approximately 3 minutes. 6 − Adjust the thermostat to deactivate the heating de- WARNING mand and wait for the combustion air inducer to stop.

  • Page 43: Gas Pressure Measurement

    4 − Move gas valve switch to OFF. Furnace should operate at least 5 minutes before check- ing gas flow. Determine time in seconds for two revolu- 5 − Replace the upper access panel. tions of gas through the meter. (Two revolutions assures a Failure To Operate more accurate time.) Divide by two and compare to time If the unit fails to operate, check the following:...

  • Page 44: Proper Combustion

    Proper Combustion High Altitude Information NOTE − In Canada, certification for installations at eleva- Furnace should operate minimum 15 minutes with correct tions over 4500 feet (1372 m) is the jurisdiction of local au- manifold pressure and gas flow rate before checking com- thorities.
  • Page 45 Testing for Proper Venting and Sufficient Combustion Air for Non−Direct Vent Applications horizontal pitch. Determine there is no blockage or re- WARNING striction, leakage, corrosion, or other deficiencies which could cause an unsafe condition. CARBON MONOXIDE POISONING HAZARD! 3 − To the extent that it is practical, close all building doors Failure to follow the steps outlined below for each and windows and all doors between the space in which appliance connected to the venting system being...

  • Page 46: Other Unit Adjustments

    Other Unit Adjustments HEAT FAN-OFF TIME IN SECONDS Primary Limit. The primary limit is located on the heating compartment vestibule panel. This limit is factory set and requires no ad- justment. NO JUMPER Flame Rollout Switches (Two) To adjust fan−off timing, reposition jumper across pins to These manually reset switches are located on the front of achieve desired setting.

  • Page 47: Twinning The Ml193Uh

    between the "C" and "Twin" terminals of the two controls. Twinning the ML193UH The 24 VAC secondary of the two systems must be in The control board in this furnace is equipped with a provi- phase. All thermostat connections are made to one control sion to "twin"...

  • Page 48: Service

    Electrical Service 1 − Check all wiring for loose connections. 2 − Check for the correct voltage at the furnace (furnace operating). WARNING 3 − Check amp−draw on the blower motor. Motor Nameplate__________Actual__________ ELECTRICAL SHOCK, FIRE, Winterizing and Condensate Trap Care OR EXPLOSION HAZARD.

  • Page 49: Repair Parts List

    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: ML193UH045XP36B−01. All service must be performed by a licensed professional installer (or equivalent), service agency, or gas supplier.

  • Page 50: Start Up Checklist

    Start−Up & Performance Check List UNIT SET UP Furnace: Model Number_______________ Serial Number_________________ SUPPLY Line Voltage GAS SUPPLY LP Propane Gas Natural Gas Piping Connections Tight Leak Tested Flter Supply Line Pressure W.C.________ RETURN AIR Gas Supply Pressure DUCT SYSTEM SUPPLY AIR DUCT Sealed Insulated (if necessary)
  • Page 51 UNIT OPERATION HEATING MODE COOLING MODE GAS MANIFOLD PRESSURE W.C._____ INDOOR BLOWER AMPS______ COMBUSTION SAMPLE CO CO PPM_______ TEMPERATURE DROP ______ Return Duct Temperature _________ INDOOR BLOWER AMPS______ Supply Duct Temperature _______ Temperature Drop = _________ TEMPERATURE RISE TOTAL EXTERNAL STATIC (dry coil) Supply Duct Temperature ________ Supply External Static _______ Return Duct Temperature...
  • Page 52 Requirements for Commonwealth of Massachusetts Modifications to NFPA−54, Chapter 10 4 − INSPECTION. The state or local gas inspector of the side wall, horizontally vented, gas−fueled equipment Revise NFPA−54 section 10.8.3 to add the following re- shall not approve the installation unless, upon inspec- quirements: tion, the inspector observes carbon monoxide detec- For all side wall, horizontally vented, gas−fueled equipment...

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