Lennox ML195UH Installation Instructions Manual
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Lennox ML195UH Installation Instructions Manual

Merit ml195uh series gas furnace upflow / horizontal air discharge
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E 2011 Lennox Industries Inc.
Dallas, Texas, USA
HORIZONTAL LEFT
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07/11
*2P0711*
AIR FLOW
UPFLOW
HORIZONTAL RIGHT

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INSTALLATION
INSTRUCTIONS
ML195UH
®
MERIT
SERIES GAS FURNACE
UPFLOW / HORIZONTAL AIR DISCHARGE
506723−01
07/2011
Supersedes 506533−01
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 2011 Lennox Industries Inc. Dallas, Texas, USA ML195UH ® MERIT SERIES GAS FURNACE UPFLOW / HORIZONTAL AIR DISCHARGE 506723−01 Litho U.S.A. 07/2011 Supersedes 506533−01 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

    ML195UH Unit Dimensions − inches (mm) EXHAUST AIR NOTE − 60C size units that require air volumes 3−3/8 OUTLET 1800 cfm or over (850 L/s) must have one of the (86) following 1. Single side return air with transition, to accommodate 2 (51) 20 x 25 x 1 in.

  • Page 3: Ml195Uh Parts Arrangement

    ML195UH Parts Arrangement ML195UH PARTS IDENTIFICATION FLEXIBLE NO−HUB EXHAUST COLLAR TOP CAP MANIFOLD BURNER BOX ASSEMBLY GAS VALVE DuralokPlus HEAT EXCHANGER ASSEMBLY COMBUSTION AIR INDUCER BURNER ACCESS PANEL CABINET BAG ASSEMBLIES COMBUSTION (shipping location) PRIMARY LIMIT AIR PRESSURE SWITCH SIGHT...

  • Page 4: Ml195Uh Gas Furnace

    Safety Information horizontal or upflow applications with bottom return air. The ML195UH can be installed as either a Direct Vent or WARNING a Non−Direct Vent gas central furnace.

  • Page 5: Use Of Furnace As Construction Heater

    60°F (16°C) or an intermit- exchanger failure. tent operation down to 55°F (13°C) dry bulb for cases This ML195UH furnace must be installed so that its electri- where a night setback thermostat is used. Return air tem- cal components are protected from water.

  • Page 6: General

    Combustion, Dilution & Ventilation Air tions, do not block the furnace combustion air opening If the ML195UH is installed as a Non−Direct Vent Fur- with clothing, boxes, doors, etc. Air is needed for proper nace, follow the guidelines in this section.
  • Page 7 (1.42 m ) per 1,000 Btu (.29 kW) per hour of the com− this section to install ML195UH furnaces to ensure effi- bined input rating of all appliances installed in that space. This cient and safe operation. You must consider combustion definition includes furnace closets or small equipment rooms.
  • Page 8 Air from Outside When ducts are used, they shall be of the same cross−sec- tional area as the free area of the openings to which they If air from outside is brought in for combustion and ventila- connect. The minimum dimension of rectangular air ducts tion, the confined space shall be provided with two perma- shall be no less than 3 inches (75 mm).

  • Page 9: Setting Equipment

    1/2 HP Blower Motor living space resulting in personal injury or death. Upflow Applications RIGID LEG The ML195UH gas furnace can be installed as shipped (Remove shipping bolt in the upflow position. Refer to figure 10 for clearances. and washer) Select a location that allows for the required clearances that are listed on the unit nameplate.
  • Page 10 Fire, explo- ML195UH applications which include side return air sion, carbon monoxide poisoning, personal injury and a condensate trap installed on the same side of the and/or property damage could result.
  • 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 The ML195UH furnace can be installed in horizontal ap- NOTE − Heavy−gauge sheet metal straps may be used to suspend the unit from roof rafters or ceiling joists. When plications with either right− or left−hand air discharge. straps are used to suspend the unit in this way, support Refer to figure 15 for clearances in horizontal applications.

  • Page 13: Filters

    5 − If necessary, run the condensate line into a conden- NOTE − This furnace is not certified for operation in heating mode (indoor blower operating at selected heating speed) sate pump to meet drain line slope requirements. The with an external static pressure which exceeds 0.8 inches pump must be rated for use with condensing furnaces.
  • Page 14 CAUTION IMPORTANT Solvent cements for plastic pipe are flammable liq- ML195UH 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 15: Joint Cementing Procedure

    *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 ML195UH−045, −070 and −090 installations. † Termination kits 44W92, 44W93, 30G28 and 81J20 approved for use in Canadian installations to meet CSAB149.

  • Page 16: Venting Practices

    (To Adjacent Room) Piping Suspension Guidelines SCHEDULE 40 If an ML195UH furnace replaces a furnace which PVC − 5’ was commonly vented with another gas appliance, all other pipe* − 3’ the size of the existing vent pipe for that gas ap- pliance must be checked.

  • Page 17: Vent Piping Guidelines

    Use the following steps to correctly size vent pipe diameter. Vent Piping Guidelines The ML195UH 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 045, 070, taken from indoors and flue gases are discharged outdoors.
  • Page 18 TABLE 5 Maximum Allowable 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. Standard Termination at Elevation 0 − 4500 ft 2"...
  • Page 19 TABLE 5 Continued Maximum Allowable Vent Length in Feet Concentric Termination at Elevation 0 − 4500 ft 2" Pipe 2−1/2" Pipe 3" Pipe Number Of 90° Elbows Model Model Model Used Concentric Termination Elevation 4501 − 10,000 ft 2" Pipe 2−1/2"...
  • Page 20 TYPICAL EXHAUST AND INTAKE PIPE CONNECTIONS IN UPFLOW DIRECT OR NON−DIRECT VENT APPLICATIONS EXHAUST INTAKE EXHAUST INTAKE Pipe size determined in table 5 2” 2” 2” 2” 2” 2” 3” 3” TRANSITION TRANSITION 2” 2” DO NOT transition from smaller to larger pipe in horizontal runs of exhaust pipe.
  • Page 21 Intake Piping TYPICAL AIR INTAKE PIPE CONNECTIONS The ML195UH 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...
  • Page 22 20°F (6.7°C), units with long runs of vent doors. The ML195UH is then classified as a direct vent, pipe through unconditioned space, even when insulated, Category IV gas furnace.

  • Page 23: Vent Termination Clearances

    VENT TERMINATION CLEARANCES FOR NON−DIRECT VENT INSTALLATIONS IN THE USA AND CANADA INSIDE CORNER DETAIL Fixed Operable Fixed Closed Closed Operable AREA WHERE TERMINAL AIR SUPPLY INLET VENT TERMINAL IS NOT PERMITTED US Installations Canadian Installations Clearance above grade, veranda, 12 inches (305mm) or 12 in.
  • Page 24 VENT TERMINATION CLEARANCES FOR DIRECT VENT INSTALLATIONS IN THE USA AND CANADA INSIDE CORNER DETAIL Fixed Operable Fixed Closed Closed Operable AREA WHERE TERMINAL AIR SUPPLY INLET VENT TERMINAL IS NOT PERMITTED US Installations Canadian Installations Clearance above grade, veranda, 12 inches (305mm) or 12 in.
  • Page 25 SUPPORT the velocity of exhaust away from the intake piping. See table 6. TABLE 6 EXHAUST PIPE TERMINATION SIZE REDUCTION EXTENDED ML195UH Termination Exhaust Pipe Size MODEL Pipe Size APPLICATION 1−1/2" (38mm) *045 and 070 2"...
  • Page 26 5 − On field−supplied terminations for side wall exit, ex- FIELD−SUPPLIED WALL TERMINATION OR haust piping may extend a maximum of 12 inches (15F74) WALL RING TERMINATION KIT (305mm) for 2" PVC and 20 inches (508mm) for 3" With INTAKE ELBOW (76mm) PVC beyond the outside wall.

  • Page 27: Front View

    1 1/2" (38mm) accelerator EXHAUST VENT Front View provided on 71M80 & 44W92 EXHAUST kits for ML195UH045P24B, SIZE VENT 070P24B & 070P36B TERMINATION PIPE PER INTAKE FLASHING TABLE 6. 12” (305mm) INTAKE (Not Furnished) Minimum Above Average Snow Accumulation Top View 1/2"...
  • 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.
  • Page 29 ML195UH DIRECT VENT APPLICATION 12" (305mm) MAX. for 2" (51mm) 20" (508mm) MAX. for 3" (76mm) USING EXISTING CHIMNEY 1/2" (13mm) ARMAFLEX STRAIGHT−CUT OR INSULATION IN ANGLE−CUT IN DIRECTION 3"−8" UNCONDITIONED SPACE 1/2" (13mm) OF ROOF SLOPE * (76mm−203mm) ARMAFLEX FIELD−PROVIDED...
  • Page 30 CONDENSATE TRAP AND PLUG LOCATIONS ML195UH 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 6. OF ROOF SLOPE right side) 1−1/2 in. EXHAUST VENT 1/2"...
  • Page 31 To Drain *Piping from furnace must slope down a minimum of 1/4" per ft. toward trap. FIGURE 45 ML195UH with Evaporatoir Coil Using a Separate Drain (Unit shown in horizontal left−hand discharge position) Field−Provided Vent Evaporator (4" min. to 5" Max. above...
  • Page 32 Furnace Condensate Drain Connection Optional Overflow Switch FIGURE 49 To Drain FIGURE 48 ML195UH with Evaporator Coil Using a Common Drain (Unit shown in horizontal left−hand discharge position) Field−Provided Vent (4" min. to 5" Max. above Evaporator condensate drain connection) Coil 4”min...
  • Page 33 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 34: 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 Leak Check the authority that has jurisdiction, black iron pipe shall be installed at the gas valve and extend outside After gas piping is completed, carefully check all piping the furnace cabinet.
  • Page 35 Left Side Piping Right Side Piping (Standard) (Alternate) 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 AND INSTALLED NOTE −...
  • Page 36 TABLE 7 GAS PIPE CAPACITY − FT /HR (kL/HR) Nominal Length of Pipe − feet (m) Internal Iron Pipe Diameter Size inches inches (mm) (3.048) (6.096) (9.144) (12.192) (15.240) (18.288) (21.336) (24.384) (27.432) (30.480) (mm) .622 (12.7) (17.799) (4.87) (3.34) (2.69) (2.29) (2.03)

  • Page 37: Electrical

    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 ML195UH furnace contains electronic compo- nents that are polarity sensitive. Make sure that the furnace FIGURE 55 is wired correctly and is properly grounded.
  • Page 38 Thermostat Furnace Condensing 2 − When the ML195UH is running in the heating mode, Unit the indoor blower will run on the heating speed. *CONDENSING 3 − When there is a cooling demand, the indoor blower will...
  • Page 39 TYPICAL ML195UH WIRING DIAGRAM FIGURE 59 Page 39...

  • Page 40: Unit Start Up

    Immediately call a qualified ser- floor. vice technician to inspect the furnace and to replace The gas valve on the ML195UH is equipped with a gas all gas controls, control system parts, and electrical control switch (lever). Use only your hand to move parts that have been wet or to replace the furnace, switch.
  • Page 41 Priming Condensate Trap 9 − Replace the upper access panel. The condensate trap should be primed with water prior to 10− Turn on all electrical power to to the unit. start−up to ensure proper condensate drainage. Either 11− Set the thermostat to desired setting. pour 10 fl.

  • Page 42: Gas Pressure Measurement

    4 − After allowing unit to stabilize for 5 minutes, record Gas Pressure Adjustment manifold pressure and compare to value given in table Gas Flow (Approximate) TABLE 8 NOTE − Shut unit off and remove manometer as soon as an GAS METER CLOCKING CHART accurate reading has been obtained.
  • Page 43 Do not operate a summer exhaust fan. After the ML195UH 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 44: 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 45: Blower Motor Performance

    BLOWER DATA ML195UH045XP24B PERFORMANCE (Less Filter) ML195UH090XP36C PERFORMANCE (Less Filter) Air Volume / Watts at Various Blower Speeds Air Volume / Watts at Various Blower Speeds External External Medium- Medium- Static Static High Medium-Low High Medium-Low High High Pressure Pressure in.
  • Page 46 BLOWER DATA ML195UH110XP60C PERFORMANCE (Less Filter) Air Volume / Watts at Different Blower Speeds Bottom Return Air, Side Return Air with Optional Return Air Single Side Return Air − Air volumes in bold require field External Base, Return Air from Both Sides or Return Air from Bottom fabricated transition to accommodate 20 x 25 x 1 in.

  • Page 47: Service

    3 − Remove the clean out cap from the condensate trap Service and empty water. Inspect the trap then reinstall the clean out cap. WARNING Cleaning Heat Exchanger If cleaning the heat exchanger becomes necessary, follow ELECTRICAL SHOCK, FIRE, the below procedures and refer to figure 1 when disassem- OR EXPLOSION HAZARD.
  • Page 48 21 − Remove two screws from the front cabinet flange at 41 − Reconnect gas supply line to gas valve. the blower deck. Spread cabinet sides slightly to allow 42 − Reconnect flame roll−out switch wires. clearance for removal of heat exchanger. 43 −...

  • Page 49: Planned Service

    Return air duct − Must be properly attached and provide Planned Service an air seal to the unit. A service technician should check the following items dur- Operating performance − Unit must be observed during ing an annual inspection. Power to the unit must be shut off operation to monitor proper performance of the unit and the for safety.

  • Page 50: Troubleshooting

    Troubleshooting: Heating Sequence of Operation HEATING SEQUENCE OF OPERATION ABNORMAL HEATING MODE NORMAL HEATING MODE POWER ON GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER DELAY OFF. CONTROL SELF−CHECK OKAY? LED #1 ON LED #2 ON (RESET CONTROL BY TURNING MAIN POWER OFF.) POLARITY REVERSED.
  • Page 51 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. LEDS SIGNAL ALTERNATING FAST FLASH UNTIL IGNITOR WARM-UP −− 20 SECONDS. IS VOLTAGE ABOVE 90 VOLTS? VOLTAGE IS ABOVE 95 VOLTS, THEN RESTARTS HEATING...

  • Page 52: Troubleshooting: Cooling Sequence Of Operation

    Troubleshooting: Cooling Sequence of Operation COOLING SEQUENCE OF OPERATION NORMAL COOLING MODE ABNORMAL COOLING MODE POWER ON IGNITION CONTROL MAIN POWER ON. GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER OFF WITH NORMAL DELAY. CONTROL SELF DIAGNOSTIC CHECK. SIGNAL CIRCUIT BOARD FAILURE AT LED. IS CONTROL OPERATING NORMALLY? INTERRUPT MAIN POWER TO RESET CONTROL.

  • Page 53: Repair Parts List

    Troubleshooting: Continuous Fan Sequence of Operation CONTINUOUS HEAT SPEED FAN SEQUENCE OF OPERATION LED: SLOW FLASH RATE REMAINS UNCHANGED THROUGHOUT SEQUENCE. MANUAL FAN SELECTION MADE AT THERMOSTAT. CONTROL (G) ENERGIZES SYSTEM FAN AT HEAT SPEED. EAC TERMINAL IS ENERGIZED. HUM TERM. ENERGIZES THERMOSTAT CALLS FOR HEAT (W).

  • Page 54: 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 55 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 56 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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