Lennox MERIT ML193DF Installation Instructions Manual
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Lennox MERIT ML193DF Installation Instructions Manual

Lennox MERIT ML193DF Installation Instructions Manual

Gas furnace downflow air discharge
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E 2012 Lennox Industries Inc.
Dallas, Texas, USA
AIR FLOW
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06/12
*2P0612*
DOWNFLOW

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INSTALLATION
INSTRUCTIONS
ML193DF
®
MERIT
SERIES GAS FURNACE
DOWNFLOW AIR DISCHARGE
507011−01
06/2012
Supersedes 506475−01
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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CAUTION
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Summary of Contents for Lennox MERIT ML193DF

  • Page 1: Table Of Contents

    INSTALLATION INSTRUCTIONS E 2012 Lennox Industries Inc. Dallas, Texas, USA ML193DF ® MERIT SERIES GAS FURNACE DOWNFLOW AIR DISCHARGE 507011−01 06/2012 Supersedes 506475−01 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) 2−1/4 9/16 (14) (57) (127) TOP VIEW 27−3/4 1 (25) Front Panel (705) 9/16 19−7/16 9/16 (14) (494) (14) FLOW ELECTRICAL INLET (Either Side) 2 (51) Either Side...

  • Page 3: Ml193Df Gas Furnace

    ML193DF Gas Furnace Shipping and Packing List Package 1 of 1 contains The ML193DF Category IV gas furnace is shipped ready 1 − Assembled ML193DF unit for installation in the downflow position. 1 − Bag assembly containing the following: The furnace is equipped for installation in natural gas ap- plications.

  • Page 4: Use Of Furnace As Construction Heater

    Lennox does not recommend the use of ML193DF units as ment. With a parallel flow arrangement, a damper (or other a construction heater during any phase of construction.

  • Page 5: General

    Lennox Industries Inc. • All furnace operating conditions (including ignition, in- P.O. Box 799900 Dallas, TX 75379−9900 put rate, temperature rise and venting) must be verified according to these installation instructions.
  • Page 6 pliance vents, chimneys, and fireplaces force additional combustion if the structure does not provide enough air by air that could be used for combustion out of the house. infiltration. If the furnace is located in a building of tight Unless outside air is brought into the house for combus- construction with weather stripping and caulking around tion, negative pressure (outside pressure is greater than the windows and doors, follow the procedures in the air...
  • 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 tion, the confined space shall be provided with two perma- the top of the enclosure and one opening within 12 inches nent openings.

  • 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

    Filters Pipe & Fittings Specifications All pipe, fittings, primer and solvent cement must conform This unit is not equipped with a filter or rack. A field−pro- with American National Standard Institute and the Ameri- vided filter is required for the unit to operate properly. Table can Society for Testing and Materials (ANSI/ASTM) stan- 3 lists recommended filter size.
  • Page 13 Low temperature solvent cement is recommended during IMPORTANT cooler weather. Metal or plastic strapping may be used for vent pipe hangers. Uniformly apply a liberal coat of PVC ML193DF exhaust and intake connections are made primer for PVC or use a clean dry cloth for ABS to clean in- of PVC.

  • Page 14: Joint Cementing Procedure

    Venting Practices Joint Cementing Procedure All cementing of joints should be done according to the Piping Suspension Guidelines specifications outlined in ASTM D 2855. SCHEDULE 40 NOTE − A sheet metal screw may be used to secure PVC − 5’ the intake pipe to the connector, if desired.

  • Page 15: Vent Piping Guidelines

    NOTE − All horizontal runs of exhaust pipe must slope back used. Contact Lennox’ Application Department for assis- toward unit. A minimum of 1/4" (6mm) drop for each 12"...
  • Page 16 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 −...
  • Page 17 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 18 Intake Piping 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 19 CSA−B149 Natural Gas and Propane Installation Codes in EQUIPMENT IN CONFINED SPACE Canada for details. (Inlet Air from Ventilated Crawlspace and Outlet Air to Outside) Position termination according to location given in figure 27 or 28. In addition, position termination so it is free from any Roof Terminated obstructions and 12"...

  • Page 20: 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 27...
  • Page 21 ‡ 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 21...
  • Page 22 Details of Intake and Exhaust Piping Terminations for NOTE − Care must be taken to avoid recirculation of exhaust back into intake pipe. Direct Vent Installations NOTE − In Direct Vent installations, combustion air is tak- Exiting Exhaust and Intake Vent en from outdoors and flue gases are discharged to out- (no common pressure zone) doors.
  • Page 23 When exhaust and intake piping must be run up an 8 − A multiple furnace installation may use a group of up to outside wall, the exhaust piping must be terminated four terminations assembled together horizontally, as with pipe sized per table 10.The intake piping may be shown in figure 37.
  • Page 24 FIELD FABRICATED WALL TERMINATION OR FIELD FABRICATED WALL TERMINATION 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 25 EXHAUST VENT Front View 1−1/2" (38mm) accelerator provided on 71M80 & 44W92 SIZE kits for ML193DF045P36B− & TERMINATION 070P36B PIPE PER INTAKE TABLE 10. FLASHING 12” (305mm) (Not Furnished) INTAKE Minimum Above Average Top View Snow Accumulation 1/2" (13mm) Foam Insulation in Unconditioned Space SHEET METAL STRAP EXHAUST VENT...
  • Page 26 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 exhause pipe is less than 12 in. (305 mm) above snow accumulation or other obstructions, field− fabricated piping must be installed.
  • Page 27 ML193DF DIRECT VENT APPLICATION SIZE TERMINATION STRAIGHT−CUT OR USING EXISTING CHIMNEY ANGLE−CUT IN DIRECTION PIPE PER TABLE OF ROOF SLOPE * 12" (305mm) ABOVE AVE. SNOW 1/2" (13mm) FOAM 8" − 12" 3" − 8" EXHAUST VENT ACCUMULATION (76mm− INSULATION 1/2"...
  • Page 28 12" (305mm) MAX. for 2" (51mm) CONDENSATE TRAP AND PLUG LOCATIONS 20" (508mm) MAX. for 3" (76mm) UNCONDITIONED SPACE 6" (152mm) SIZE TER- MINATION *WALL SUPPORT PIPE PER TABLE 10. OUTSIDE WALL FIELD−PROVIDED 12" (305mm) REDUCER MAY BE ABOVE GRADE OR REQUIRED TO AVERAGE SNOW ADAPT LARGER...
  • 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; 24 ft. (7.3m) − kit no. 26K69; and 50 ft. (15.2m) − kit no. 26K70.
  • Page 30 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 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- dards of the National Fuel Gas Code ANSI Z223.1.
  • Page 34 Before connecting the thermostat or the power wiring, ing. Any humidifier rated up to one amp can be connected check to make sure the wires will be long enough for servic- to this terminal with the neutral leg of the circuit being con- ing at a later date.
  • Page 35 TYPICAL ML193DF WIRING DIAGRAM FIGURE 57 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

    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 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 check- 2 −...

  • 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

    Testing of Non−Direct Vent Applications for Proper Venting and Sufficient Combustion Air 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 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

    between the "C" and "Twin" terminals of the two controls. Twinning the ML193DF 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 43: Service

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

  • Page 44: 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: ML193DF045XP36B. All service must be performed by a licensed professional installer (or equivalent), service agency, or gas supplier.

  • 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 AMPS______ Supply Duct Temperature _______ 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- For all side wall, horizontally vented, gas−fueled equipment...

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Ml195df merit series

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