Lennox ML193DF Installation Instructions Manual
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Lennox ML193DF Installation Instructions Manual

Merit series gas furnace downflow air discharge
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E 2015 Lennox Industries Inc.
Dallas, Texas, USA
AIR FLOW
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Page 1
INSTALLATION
INSTRUCTIONS
ML193DF
®
MERIT
SERIES GAS FURNACE
DOWNFLOW AIR DISCHARGE
507279-02
10/2015
Supersedes 02/2015
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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  • Page 1: Table Of Contents

    INSTALLATION INSTRUCTIONS E 2015 Lennox Industries Inc. Dallas, Texas, USA ML193DF ® MERIT SERIES GAS FURNACE DOWNFLOW AIR DISCHARGE 507279-02 10/2015 Supersedes 02/2015 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.

  • Page 2: Unit Dimensions

    ML193DF Unit Dimensions - inches (mm) 9/16 (14) COMBUSTION AIR INTAKE RETURN AIR OPENING EXHAUST AIR OUTLET 2−1/16 (52) 9/16 2−1/4 (14) (57) (127) TOP VIEW 27−3/4 1 (25) Front Panel (705) 19−7/16 9/16 9/16 (14) (494) (14) FLOW ELECTRICAL INLET...

  • Page 3: Ml193Df Gas Furnace

    A conversion kit (ordered separately) is required for use in propane/LP gas applications. 1 - Snap plug The ML193DF can be installed as a Direct Vent or Non- 1 - Wire tie Direct Vent gas central furnace. 1 - Condensate trap...

  • Page 4: Use Of Furnace As Construction Heater

    This ML193DF furnace must be installed so that its electri­ Never use an open flame to test for gas leaks. Check all cal components are protected from water.

  • Page 5: General

    Combustion, Dilution & Ventilation Air If the ML193DF is installed as a Non-Direct Vent Fur­ General nace, follow the guidelines in this section. NOTE - In Non-Direct Vent installations, combustion air is...
  • Page 6 This definition includes furnace closets or small this section to install ML193DF furnaces to ensure efficient equipment rooms. and safe operation. You must consider combustion air When the furnace is installed so that supply ducts carry air needs and requirements for exhaust vents and gas pip-ing.
  • Page 7 Air from Outside If air from outside is brought in for combustion and ventila­ tion, the confined space must have two permanent open­ If air from outside is brought in for combustion and ventila­ ings. One opening shall be within 12 inches (305 mm) of the tion, the confined space shall be provided with two perma­...

  • Page 8: Setting Equipment

    Shipping Bolt Removal EQUIPMENT IN CONFINED SPACE - ALL AIR FROM OUTSIDE (All Air Through Ventilated Attic) NOTE - The ML193DF09048C is equipped with a 1/2 hp blower motor which has three flexible legs and one rigid leg. The rigid leg is equipped with a shipping bolt and a flat ROOF TERMINATED VENTILATION LOUVERS EXHAUST PIPE...
  • Page 9 Allow for clearances to combustible materials as indicated SETTING EQUIPMENT on the unit nameplate. Minimum clearances for closet or al­ cove installations are shown in figure 13. WARNING AIR FLOW AIR FLOW AIR FLOW Blower access panel must be securely in place when blower and burners are operating.
  • Page 10 Installation on Non-Combustible Flooring Figure 14 WARNING 1 - Cut floor opening keeping in mind clearances listed on Improper installation of the furnace can result in per­ unit rating plate. Also keep in mind gas supply connec­ sonal injury or death. Combustion and flue products tions, electrical supply, flue and air intake connections must never be allowed to enter the return air system and sufficient installation and servicing clearances.
  • Page 11 TABLE 2 COMBUSTIBLE FLOORING BASE OPENING SIZE Front to Rear Side to Side Cabinet Catalog FURNACE Width Number B Cabinet 11M60 18 - 3/4 (17.5”) C Cabinet COOLING COIL 11M61 22 - 3/4 (21”) PROPERLY SIZED FLOOR OPENING PLENUM FURNACE SUPPLY AIR PLENUM PROPERLY...

  • Page 12: Filters

    Lennox tion and the formation of carbon monoxide gas. This raw Product Specifications bulletin. Additional informa­...
  • Page 13 CAUTION IMPORTANT Solvent cements for plastic pipe are flammable liq­ ML193DF exhaust and intake connections are made uids and should be kept away from all sources of of PVC. Use PVC primer and solvent cement when ignition. Do not use excessive amounts of solvent using PVC vent pipe.

  • Page 14: Joint Cementing Procedure

    TABLE 5 OUTDOOR TERMINATION USAGE* STANDARD CONCENTRIC Flush­ Wall Kit Wall Ring Kit Mount 1-1/2 inch 2 inch 3 inch Vent 2 inch 3 inch 2 inch Pipe Input Size Field Dia. in. 51W11 71M80 69M29 Fabricated 44J40 (US) 22G44 (US) (US) (US) 60L46 (US)

  • Page 15: Venting Practices

    9. The ML193DF can be installed as either a Non-Direct If an ML193DF furnace replaces a furnace which was com­ monly vented with another gas appliance, the size of the ex­ Vent or a Direct Vent gas central furnace.
  • Page 16 In some applications which permit the use of several differ­ most elbows? ent sizes of vent pipe, a combination vent pipe may be Intake or used. Contact Lennox' Application Department for assis­ exhaust? tance in sizing vent pipe in these applications. IMPORTANT...
  • Page 17 TABLE 7 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. NOTE - Additional vent pipe and elbows used to terminate the vent pipe outside the structure must be included in the total vent length calculation. Standard Termination at Elevation 0 - 10,000 ft.
  • Page 18 TYPICAL EXHAUST PIPE CONNECTIONS Pipe size determined in table 7. 2” 2” 2” 2” 2” 3” TRANSITION INTAKE DO NOT transition from smaller EXHAUST *2” to larger pipe size in horizontal TOP VIEW runs of exhaust pipe. * When transitioning up in pipe size, use the shortest length of 2” PVC pipe possible. NOTE −...
  • Page 19 1 - Use field-provided materials and the factory-provided air intake screen to route the intake piping as shown in The ML193DF furnace may be installed in either direct figure 24. Maintain a minimum clearance of 3” (76mm) vent or non-direct vent applications. In non-direct vent around the air intake opening.
  • Page 20 In Direct Vent applications, combustion air is taken from IMPORTANT outdoors and the flue gases are discharged to the out­ doors. The ML193DF is then classified as a direct vent, For Canadian Installations Only: Category IV gas furnace. In accordance to CSA International B149 installation In both Non‐Direct Vent and Direct Vent applications, the...
  • Page 21 TABLE 9 Maximum Allowable Exhaust Vent Pipe Length (in ft.) 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 (0 to -6) 2-1/2 in.

  • Page 22: 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 28...
  • Page 23 ‡ 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 29 Page 23...
  • Page 24 *045 and *070 ACCUMULATION *090 2” (51mm) 2” (51mm) *ML193DF-045, -070 and -090 units with the flush-mount termination 3” (76mm) OR must use the 1-1/2”accelerator supplied with the kit. 2” (51mm) PVC PROVIDE SUPPORT 5 - On field-supplied terminations for side wall exit, ex­...
  • Page 25 51W11 (US) or 51W12 (Canada) DIRECT VENT CONCENTRIC ROOFTOP TERMINATION 71M80, 69M29 or 60L46 (US) FIGURE 36 41W92 or 41W93 (Canada) FIGURE 33 ML193DF DIRECT VENT APPLICATION STRAIGHT-CUT OR USING EXISTING CHIMNEY ANGLE-CUT IN DIRECTION OF ROOF SLOPE * 1-1/2” (38mm) accelerator 8”...
  • Page 26 FIELD FABRICATED WALL TERMINATION NOTE − FIELD−PROVIDED REDUCER MAY BE 2” (51mm) 3” (76mm) REQUIRED TO ADAPT LARGER VENT PIPE SIZE Vent Pipe Vent Pipe TO TERMINATION A− Minimum clearance above grade or average 12” (305 mm) 12” (305 mm) snow accumulation B−...
  • Page 27 The termination pipe must be sized as listed in table 10.The specified pipe size ensures proper ve­ locity required to move the exhaust gases away from ML193DF NON-DIRECT VENT APPLICATION the building. USING EXISTING CHIMNEY 2 - On field supplied terminations for side wall exit, ex­...
  • Page 28 Condensate Piping 2 - Use a large flat head screw driver or a 1/2” drive socket extension and remove plug (figure 41) from the cold This unit is designed for either right‐ or left‐side exit of con­ end header box at the appropriate location on the side densate piping.
  • Page 29 Heat cable kit is avail­ Coil Using a Common Drain able from Lennox in various lengths; 6 ft. (1.8m) - kit no. 26K68 and 24 ft. (7.3m) - kit no. 26K69. CONDENSATE TRAP LOCATION Field Provided Vent 1”...
  • Page 30 TRAP / DRAIN ASSEMBLY USING 1/2” PVC OR 3/4” PVC Optional Condensate Drain Connection Adapter 3/4 inch slip X 3/4 inch mpt (not furnished) 90° Street Elbow 3/4 inch PVC (not furnished) Adapter 3/4 inch slip X 3/4 inch mpt (not furnished) Condensate Drain Connection In Unit 1 (25 mm) Min.

  • Page 31: Gas Piping

    Gas Piping IMPORTANT Compounds used on threaded joints of gas piping CAUTION must be resistant to the actions of liquified petro­ leum gases. If a flexible gas connector is required or allowed by the authority that has jurisdiction, black iron pipe Leak Check shall be installed at the gas valve and extend outside After gas piping is completed, carefully check all piping...
  • Page 32 Left Side Piping MANUAL AUTOMATIC (Standard) MAIN SHUT-OFF GAS VALVE MANUAL VALVE AUTOMATIC (with manual MAIN SHUT-OFF Plug (With 1/8 in. NPT GAS VALVE shut-off valve) VALVE Plugged Tap (with manual Plug (With 1/8 in. NPT Shown) shut-off valve) Plugged Tap Shown) GROUND JOINT UNION...

  • Page 33: Electrical

    Removal of the Furnace from Common Vent Resize the common venting system to the minimum vent pipe size determined by using the appropriate In the event that an existing furnace is removed from a tables in Appendix G. (These are in the current stan­ venting system commonly run with separate gas ap­...
  • Page 34 51. Use 18-gauge wire or larger that is suit­ 2 - When the ML193DF is running in the heating mode, able for Class II rating for thermostat connections. the indoor blower will run on the heating speed.
  • Page 35 TYPICAL ML193DF WIRING DIAGRAM FIGURE 51 Page 35...

  • Page 36: Integrated Control Diagnostic Codes

    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 37: Unit Start Up

    NOTE - When unit is initially started, steps 1 through 11 The gas valve on the ML193DF is equipped with a gas con­ may need to be repeated to purge air from gas line.

  • Page 38: Gas Pressure Measurement

    Failure To Operate NOTE - To obtain accurate reading, shut off all other gas appliances connected to meter. If the unit fails to operate, check the following: 1 - Is the thermostat calling for heat? Furnace should operate at least 5 minutes before checking 2 - Are access panels securely in place? gas flow.

  • Page 39: 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 40: Testing Non Direct Appliances For Proper Air

    Do not operate a summer exhaust fan. After the ML193DF gas furnace has been started, the fol­ 6 - Follow the lighting instruction to place the appliance lowing test should be conducted to ensure proper venting being inspected into operation.

  • Page 41: 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 42: Twinning The Ml193Df Furnace

    Field installation of twinning consists of connecting wires Twinning the ML193DF between the ”C” and ”Twin” terminals of the two controls. The control board in this furnace is equipped with a provi­ The 24 VAC secondary of the two systems must be in sion to ”twin”...

  • Page 43: Service

    At the beginning of each heating season, and to comply 13 Perform a complete combustion analysis during the fur­ with the Lennox Limited Warranty, your system should be checked as follows: nace inspection to ensure proper combustion and oper­...

  • Page 44: Repair Parts List

    1 - Turn off power to the furnace. 2 - Have a shallow pan ready to empty condensate water. The following repair parts are available through Lennox 3 - Remove the clean out cap from the condensate trap dealers. When ordering parts, include the complete fur­...

  • Page 45: 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 46 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 Supply Duct Temperature _______ AMPS______ Temperature Drop = _________ TEMPERATURE RISE TOTAL EXTERNAL STATIC (dry coil) Supply Duct Temperature ________ Supply External Static _______ Return Duct Temperature...
  • Page 47 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...
  • Page 48 ADDENDUM FOR THE PROVINCE OF SASKATCHEWAN See below for venting in the province of Saskatchewan. Lennox approves the following termination for use in Saskatchewan Canada. 12” 3” (76MM) 2”...

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