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Lennox International Inc. MERIT SERIES GAS FURNACE DOWNFLOW AIR DISCHARGE Electric Heater User Manual

1. ENECS C 08 3 AMP 32 VAC FUSE FIGURE 53 ES A WARNING FOR YOUR SAFETY READ BEFORE OPERATING AWARNING Do not use this furnace if any part has been under water A flood damaged furnace is extremely dan gerous Attempts to use the furnace can result in fire or explosion Immediately call a qualified ser vice technician inspect the furnace to replace all gas controls control system parts and electrical parts that have been wet or to replace the furnace if deemed necessary Danger of explosion Can cause injury or product or property damage Should the gas supply fail to shut off or if overheating occurs shut off the gas valve to the furnace before shutting off the electrical supply BEFORE LIGHTING the unit smell all around the fur nace area for gas Be sure to smell next to the floor be cause some gas is heavier than air and will settle on the floor ACAUTION The gas valve on the ML193DF is equipped with a gas control switch Use only your hand to move switch Never Before attempting to perform any service or mainte nance turn the electrical power to unit OFF at dis connect switch use tools If the switch will not move by hand do not try to repair it Force or attempted repair may result in a fire or explosion Page 36 Placing the furnace into operation ML193DF units are equipped with an automatic hot sur face ignition system Do not attemp
2. 1 2 inch PVC Pipe Not Furnished Coupling 1 2 inch slip X slip Not Furnished Not Furnished 90 Elbow 1 2 inch PVC To Not Furnished Drain Drain Assembly for 3 4 inch Drain Pipe 1 2 inch PVC Furnished Y 1 90 Elbow 3 4 inch PVC Not Furnished To p COVPling 3 4 inch slip X slip Not Furnished 90 Elbow Y 3 4 inch PVC Not Furnished Drain Trap Assembly with 1 2 inch Piping 1 inch 25mm Minimum Above Top of Condensate Drain Connection In Unit Drain Trap Assembly Vent Furnished Condensate Drain Connection In Unit Drain Trap Assembly Furnished Drain Trap Clean Out Drain Trap Assembly with 3 4 inch Piping 1 inch 25mm Minimum Above Top of Condensate Drain Connection In Unit Vent Condensate Drain Connection In Unit A CAUTION If a flexible gas connector is required or allowed by the authority that has jurisdiction black iron pipe shall be installed at the gas valve and extend outside the furnace cabinet The flexible connector can then be added between the black iron pipe the gas supply line AWARNING Do not exceed 600 in Ibs 50 ft lbs torque when at taching the gas piping to the gas valve 1 Gas piping may be routed into the unit through either the left or right hand side Supply piping enters into th
3. SUPPLY Supe gt Line Voltage 1 GAS SUPPLY C Natural Gas _ LP Propane Gas C Piping Connections Tight L Leak Tested Flter L Supply Line Pressure W C N RETURN AIR DUCT SYSTEM SUPPLY AIR DUCT Sealed L Insulated if necessary INTAKE EXHAUST PIPE RETURN DUCT Sealed L All Joints Primed and Glued Filter Installed and Clean L Terminations Installed Properly Grilles Unobstructed G VOLTAGE CHECK L Condensate Trap Primed Line Sloped Supply Voltage LJ Electrical Connections Tight L Horizontal Pipes Sloped if applicable O Pipes Supported L Heat Cable Installed and Operable if applicable Page 50 UNIT OPERATION HEATING MODE COOLING MODE GAS MANIFOLD PRESSURE W C Q INDOOR BLOWER AMPS 2 COMBUSTION SAMPLE CO CO PPM 4 TEMPERATURE DROP Return Duct Temperature BLOWER Supply Duct Temperature 4 TEMPERATURE RISE Temperature Drop Supply Duct Temperature 5 TOTAL EXTERNAL STATIC dry coil Supply External Static Return External Static Total External Static TOTAL EXTERNAL STATIC DRAIN LINE Supply External Static Return External Static Total External Static CONDENSATE LINE THERMOSTAT E Leak
4. 2 1 Clearance under veranda porch 12 inches 305mm t 12 inches 305mm t deck or balcony 1 In accordance with the current ANSI Z223 1 NFPA 54 Natural Fuel Gas Code For clearances not specified ANSI Z223 1 NFPA 54 or CSA B149 1 clear 2 n accordance with the current CSA B149 1 Natural Gas and Propane Installation Code ance will be in accordance with local installation codes and the requirements A vent shall not terminate directly above a sidewalk or paved driveway that is located Of the gas supplier and these installation instructions between two single family dwellings and serves both dwellings t 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 24 Page 20 Details of Intake and Exhaust Piping Terminations for Direct Vent Installations NOTE In Direct Vent installations combustion air is tak en from outdoors and flue gases are discharged to out doors NOTE Flue gas may be slightly acidic and may adversely affect some building materials If any vent termination is used and the flue gasses may impinge on the building ma terial a corrosion resistant shield minimum 24 inches square should be used to protect the wall surface If the optional tee is used the protective shield is recommended The shield should be constructed using wood plastic sheet metal or other suitable ma
5. ML193DF NON DIRECT VENT APPLICATION USING EXISTING CHIMNEY SIZE TERMINATION PIPE PER TABLE 8 Minimum 12 305 above chimney top plate or average snow accumulation SHEET METAL TOP PLATE INSULATE TO FORM SEAL STRAIGHT CUT OR 1 ANGLE CUT IN DIRECTION OF ROOF SLOPE EXHAUST VENT 1 2 13mm WEATHERPROOF INSULATION HOULDER OF FITTINGS PROVIDE SUPPORT OF PIPE ON TOP PLATE EXTERIOR PORTION OF CHIMNEY NOTE Do not discharge exhaust gases directly into any chimney or vent stack If ver tical discharge through an existing unused chimney or stack is required insert piping inside chimney until the pipe open end is above top of chimney and terminate as illus trated In any exterior portion of chimney the exhaust vent must be insulated FIGURE 41 Condensate Piping This unit is designed for either right or left side exit of con densate piping Refer to figure 42 for condensate trap loca tions Page 27 NOTE If necessary the condensate trap may be installed up to 5 away from the furnace Use PVC pipe to connect trap to furnace condensate outlet Piping from furnace must slope down a minimum of 1 4 per ft toward trap CONDENSATE TRAP AND PLUG LOCATIONS Trap same on right side Plug same on left side di 1 1 2 in FIGURE 42 1 Determine which side condensate piping will exit the unit location of trap field provided fittings and len
6. 4 026 23000 15800 12800 10900 9700 8800 8100 7500 7200 6700 1 i 6 102 260 651 27 447 39 362 44 308 64 274 67 249 18 229 36 212 37 203 88 189 72 NOTE Capacity given in cubic feet of gas per hour kilo liters of gas per hour and based on 0 60 specific gravity gas Page 31 Removal of the Furnace from Common Vent In the event that an existing furnace is removed from a venting system commonly run with separate gas ap pliances the venting system is likely to be too large to properly vent the remaining attached appliances Conduct the following test while each appliance is operat ing and the other appliances which are not operating re main connected to the common venting system If the venting system has been installed improperly you must correct the system as indicated in the general venting re quirements section A WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result carbon mon oxide poisoning or death The following steps shall be followed for each ap pliance connected to the venting system being placed into operation while all other appliances connected to the venting system are not in operation 1 Seal any unused openings in the common venting sys tem 2 Inspect the venting system for proper size and horizontal pitch Determine that th
7. Reinstall pressure switches and reconnect pressure switch wiring 27 Carefully connect combustion air pressure switch hosing from pressure switches to proper stubs on cold end header collector box 28 Reinstall condensate trap 29 Reconnect exhaust piping and exhaust drain tubing 30 Reinstall burner box assembly in vestibule area 31 Reconnect flame roll out switch wires 32 Reconnect sensor wire and reconnect 2 pin plug from ignitor 33 Secure burner box assembly to vestibule panel using four existing screws Make sure burners line up in center of burner ports 34 Reinstall gas valve manifold assembly Reconnect gas supply line to gas valve 35 Reconnect 2 wires to gas valve 36 Replace the blower compartment access panel 37 Refer to instruction on verifying gas and electrical con nections when re establishing supplies Page 43 38 Follow lighting instructions to light and operate fur nace for 5 minutes to ensure that heat exchanger is clean and dry and that furnace is operating properly 39 Replace heating compartment access panel Cleaning the Burner Assembly 1 Turn off electrical and gas power supplies to furnace Remove upper and lower furnace access panels 2 Disconnect the 2 pin plug from the gas valve 3 Remove the burner box cover 4 Disconnect the gas supply line from the gas valve Re move gas valve manifold assembly 5 Mark and disconnect sensor wire from the sensor Di
8. intake and exhaust 8 203MM D Maximum exhaust pipe length 12 305MM 20 508MM E Maximum wall support distance from top of each 6 152MM 6 152MM pipe intake exhaust FIGURE 28 C Minimum from end of exhaust to inlet of intake Page 23 FIELD SUPPLIED WALL TERMINATION OR 15F74 WALL RING TERMINATION KIT With INTAKE ELBOW NOTE FIELD PROVIDED REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION 1 2 13mm ARMAFLEX INSULATION IN UN CONDITIONED SPACE SIZE TERMINATION PER TABLE 8 STRAIGHT APPPLICATION 1 2 13mm ARMAFLEX INSULATION IN UNCONDITIONED SPACE WALL SUPPORT EXTENDED APPLICATION See venting table 7 for maximum venting lengths with this arrangement Use wall support every 24 610 mm Use two wall supports if extension is greater than 24 610 mm but less than 48 1219 mm NOTE One wall support must be 6 152 mm from top of each pipe intake and exhaust 2 51mm 3 76mm Vent Pipe Vent Pipe A Minimum clearance above grade or average 12 508MM 12 508MM snow accumulation 6 152MM 6 152MM 6 152MM 6 152MM D Maximum exhaust pipe length 12 305MM 20 508MM E Maximum wall support distance from top of each 6 152MM 6 152MM pipe intake exhaust FIGURE 29 B Maximum horizontal separation between intake and exhaust C Minimum from end of exhaust to inlet intake 1 1 2 38mm accelerato
9. IS NOT PERMITTED Canadian Installations 12 inches 305mm or 12 in 305mm above average snow accumulation 6 inches 152mm for appliances 10 000 Btuh 3kw 12 inches 305mm for appliances 10 000 Btuh 3kw and 100 000 Btuh 30kw 36 inches 9m for appliances gt 100 000 Btuh 30kw 5127 Equal to or greater than soffit depth Equal to or greater than soffit depth No minimum to outside corner 3 feet 9m within a height 15 feet 4 5m 3 feet 9m within a height 15 feet 4 5m above the meter regulator assembly 3 feet 9m 4 feet 1 2 m below or to side of opening 1 foot 30 cm above opening above the meter regulator assembly 3 feet 9m 6 inches 152mm for appliances 10 000 Btuh 3kw 12 inches 305mm for appliances gt 10 000 Btuh 3kw and 100 000 Btuh 30kw 36 inches 9m for appliances 100 000 Btuh 30kw Clearance to mechanical air sup ply inlet Clearance above paved sidewalk or paved driveway located on public property Clearance under veranda porch deck or balcon 1 In accordance with the current ANSI Z223 1 NFPA 54 Natural Fuel Gas Code 2 n accordance with the current CSA B149 1 Natural Gas and Propane Installation Code T A vent shall not terminate directly above a sidewalk or paved driveway that is located 3 feet 9m above if within 10 feet 3m horizontally 7 feet 2 1 12 inches 305mm t between two single family dwe
10. ML193DF Model No 04536B 07036B 09048C 2 11060C Page 2 ML193DF Parts Arrangement CONTROL BOX Includes integrated control transformer and door switch BAG ASSEMBLY BLOWER MOTOR ze BLOWER ACCESS BLOWER DECK PRIMARY LIMIT BURNER ACCESS COLD END HEADER BOX PANEL HEAT EXCHANGER GAS VALVE BURNER BOX ASSEMBLY includes sensor rollout switches and ignitor FIGURE 1 Page 3 ML193DF Gas Furnace The ML193DF Category IV gas furnace is shipped ready for installation in the downflow position The furnace is equipped for installation in natural gas ap plications A conversion kit ordered separately is re quired for use in propane LP gas applications The ML193DF can be installed as a Direct Vent or Non Direct Vent gas central furnace NOTE In Direct Vent installations combustion air is taken from outdoors and flue gases are discharged outdoors In Non Direct Vent installations combustion air is taken from indoors and flue gases are discharged outdoors See figure 2 for applications involving roof termination DIRECT VENT INSTALLATION NON DIRECT VENT INSTALLATION EXHAUST OUTLET EXHAUST COMBUSTION OUTLET AIR INTAKE OUTSIDE OF COMBUSTION AIR INTAKE INSIDE OF HOUSE ML193DF Shipping and Packing List Pac
11. On field supplied terminations for side wall exit ex haust piping may extend a maximum of 12 inches 305mm for 2 PVC and 20 inches 508mm for 3 76mm PVC beyond the outside wall Intake piping should be as short as possible See figures 28 and 29 NOTE Care must be taken to avoid recirculation of exhaust back into intake pipe 6 On field supplied terminations a minimum distance Page 21 Inches mm 12 305mm ABOVE AVERAGE SNOW between the end of the exhaust pipe and the end of the intake pipe without a termination elbow is 8 and a minimum distance of 6 with a termination elbow See figures 28 and 29 3 76mm MAX SIZE TERMINATION PIPE PER TABLE 8 UNCONDITIONED 8 203mm MIN ATTIC SPACE 1 2 13mm FOAM aa INSULATION IN UNCONDITIONED ACCUMULATION 2 EXTENSION FOR 2 PVC PIPE 3 76mm O 2 51mm PVC PROVIDE SUPPORT FOR INTAKE AND EXHAUST LINES DIRECT VENT ROOF TERMINATION KIT 15F75 or 44J41 FIGURE 25 FURNACE EXHAUST 1 EXTENSION FOR PIPE 3 PVC PIPE FURNACE N 1 GLUE EXHAUST END FLUSH INTO TERMINATION 1 1 2 ACCELERATOR all 070 and 090 units FLUSH MOUNT SIDE WALL TERMINATION KIT 51W11 FIGURE 26 If intake and exhaust piping must be run up a side wall to position above snow accumulation or other ob structions piping must be supported every 24 610mm as shown in figures 28 and 29 In addition close coupled wall
12. tions on non combustible flooring on combustible flooring using an additive base or on a reverse flow cooling coil cabinet Do not drag the unit across the floor in the downflow position Floor and furnace flange damage will result Refer to figure 11 for clearances in downflow applica tions Downflow Application Installation Clearances Top Left Side Right Side Front clearance in alcove installation must be 24 in 610 mm Maintain a minimum of 24 in 610 mm for front service access TAllow proper clearances to accommodate condensate trap and vent pipe installation furnace be installed on a combustible wood floor if an op tional additive base is installed between the furnace and the com bustible floor FIGURE 11 Installation on Non Combustible Flooring Figure 12 1 Cut floor opening keeping mind clearances listed on unit rating plate Also keep in mind gas supply connec tions electrical supply flue and air intake connections and sufficient installation and servicing clearances See table 1 for correct floor opening size 2 Flange warm air plenum and lower the plenum into the opening 3 Set the unit over the plenum and seal the plenum to the unit 4 Ensure that the seal is adequate TABLE 1 NON COMBUSTIBLE FLOOR OPENING SIZE Front to Rear Cabinet Width Side to Side B Cabinet 17 5 19 3 4 16 5 8 422 Cabinet 21 19 3 4 20 1 8 511 NOTE Floor opening
13. COOLING MODE ABNORMAL COOLING MODE POWER ON IGNITION CONTROL MAIN POWER ON GAS VALVE OFF COMBUSTION AIR INDUCER OFF CONTROL SELF DIAGNOSTIC CHECK INDOOR BLOWER OFF WITH NORMAL DELAY IS CONTROL OPERATING NORMALLY SIGNAL CIRCUIT BOARD FAILURE AT LED INTERRUPT MAIN POWER TO RESET CONTROL SIGNAL IMPROPER GROUND AT LED IS THERE A PROPER GROUND e CONTROL WILL CONTINUE TO CALL FOR COOLING IN THIS CONDITION SIGNAL POLARITY REVERSED AT LED CONTROL IS POLARITY CORRECT WILL CONTINUE TO CALL FOR COOLING IN THIS CONDITION IS VOLTAGE LED SIGNALS LOW VOLTAGE CONTROL WILL ABOVE 90 VOLTS CONTINUE TO CALL FOR COOLING IN THIS CONDITION GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER ON ROLLOUT SWITCH MONITORED CONTINUOUSLY SIGNAL ROLL OUT SWITCH OPEN AT LED IS ROLLOUT SWITCH CLOSED SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES AND MAIN POWER IS INTERRUPTED OR THERMOSTAT IS CYCLED OFF ON FOR 1 SEC MINIMUM LED SLOW FLASH RATE REMAINS UNCHANGED THROUGHOUT COOLING CYCLE THERMOSTAT CALLS FOR COOLING COMPRESSOR CONTACTOR AND SYSTEM FAN ENERGIZED WITH 2 SECOND DELAY COOLING SPEED EAC TERM ENERGIZED THERMOSTAT OPENS COMPRESSOR OFF SYSTEM FAN AND EAC TERM OFF WITH 45 SECOND DELAY Page 47 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
14. FITTINGS INSULATION optional above chimney top OF PIPE ON TOP PLATE late or average snow SHEET _ ALTERNATE accumulation PLATE INTAKE PIPE 3 76mm OR UNCONDITIONED 2 51mm PVC ATTIC SPACE PROVIDE SUPPORT FOR EXHAUST LINES INSULATE TO FORM NON DIRECT VENT ROOF TERMINATION KIT 15F75 or 44J41 FIGURE 38 SIZE TERMINATION PIPE PER TABLE 8 NOTE Do not discharge exhaust gases directly into any chimney or vent stack If ver tical discharge through an existing unused chimney or stack is required insert piping inside chimney until the pipe open end is above top of chimney and terminate as illus trated In any exterior portion of chimney the exhaust vent must be insulated 12 305mm MAX for 2 51mm 20 508mm MAX for 3 76mm 1 2 13mm ARMAFLEX FIGURE 37 INSULATION IN UNCONDITIONED SPACE 4 2 13mm ARMAFLEX FIELD PROVIDED INSULATION REDUCER MAY Details of Exhaust Piping Terminations for Non Direct BE REQUIRED TO EA ADAPT LARGER EZ Se Vent Applications VENT PIPE SIZE PVC REDUCER TO TERMINATION Exhaust pipes may be routed either horizontally through an SIZE TERMINATION ea outside wall or vertically through the roof In attic or closet PIPE PER TABLE 6 installations vertical termination through the roof is pre accumulation ferred Figures 38 through 41 show typical terminations 15F74 WALL TERMINATION KIT shown The termination
15. In addition the first three feet of vent pipe from the furnace flue collar must be accessible for inspection TABLE 5 OUTDOOR TERMINATION KITS USAGE STANDARD Outdoor Exhaust Accelerator Dia X Length Outdoor Exhaust Accelerator Dia X Length 22G44 1 4 2 X 12 or 306281 2 Wall Plate 3 Wall Plate CONCENTRIC 2 Wall Ring Kit 44940 60146 15 74 51W11 se Sas e epI L es Peps 0 Peps 20 E m o9 e eje ee 9 L ESENES EJES w e 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 ML193DF 045 070 and 090 installations T Termination kits 44W92 44W93 30G28 and 81J20 approved for use in Canadian installations to meet CSAB149 tt The 44W92 Concentric kit is provided with a 1 1 2 accelerator which must be installed on the exhaust outlet when this kit is used with the ML193DF045P36B and ML193DF070P36B furnaces Page 13 Joint Cementing Procedure All cementing of joints should be done according to the specifications outlined in ASTM D 2855 NOTE A sheet metal screw may be used to secure the intake pipe to the connector if desired Use a drill or self tapping screw to make a pilot hole A DANGER DANGER OF EXPLOSION Fumes from PVC glue may ignite during system check Allow fumes to dissipate for at le
16. TO PREVENT MOTOR BURNOUT NEVER CONNECT PRIMARY GAS MORE THAN ONE LEAD TO ANY ONE CONNECTION LIMIT Z PARK TERMINALS ARE UNPOWERED TERMINALS GAS VALVE J159 ALL UNUSED MOTOR LEADS MUST BE WIRED CONDUGTORSONEY ais EM P159 S47 TO A PARK TERMINAL FLAME FLAME 81 FAME ei IGNITER FLAME ZAN FIELD SUPPLIED ACC WIRE SWITCH SWITCH ZA 914519 USED WITH HONEYWELL GAS NOTE USE COPPER VALVE WHEN APPLIED IN LP GAS UNITS BURNERS 78 DENOTES OPTIONAL COMPONENTS LINE VOLTAGE FIELD INSTALLED CLASS II VOLTAGE FIELD WIRING LINE H XFMR H EQUIPMENT GROUND i PURPLE ORANGE YELLOW SEE BLOWER SPEED CHART SENSOR WHITE PINK FLAME YELLOW Jt6 0156 ANT BLOWER MOTOR WHITE COMMON FIGURE 52 Page 35 INTEGRATED CONTROL Automatic Hot Surface Ignition System O NN gt NN NNEUTRALS N SATS IL RED GR Bowe R 6 O BLOWER OFF DELAY JUMPER TERMINAL DESIGNATIONS HUM Humidifier 120VAC LINE Input 120VAC XFMR Transformer 120VAC EAC Electronic Air Cleaner 120VAC COOL Blower Cooling Speed 120VAC HEAT Blower Heating Speed 120VAC PARK Dead terminals to park alternate spd taps FLAME Flame sensor NEUTRALS Neutral terminals 120VAC
17. Turn on clothes dryers and any appliances not con nected to the venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Follow the lighting instruction to place the appliance being inspected into operation Adjust thermostat so appliance will operate continuously Use the flame of match or candle to test for spillage of flue gases at the draft hood relief opening after 5 min utes of main burner operation If improper venting is observed during any of the above tests the venting system must be corrected or sufficient combustion make up air must be provided The venting system should be re sized to approach the minimum size as determined by using the ap propriate tables in appendix G in the current standards of the National Fuel Gas Code ANSI Z223 1 NPFA 54 in the U S A and the appropriate Natural Gas and Propane appliances venting sizing tables in the cur rent standard of the CSA B149 Natural Gas and Pro pane Installation Codes in Canada After determining that each appliance remaining connected to the common venting system properly vents when tested as indicated in step 3 return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous condition of use Other Unit Adjustments NOTE See troubleshooting flow charts if any safety switches are found to be open Primary Limit Th
18. air out of the house When fireplaces ex haust fans or clothes dryers are used at the same time as the furnace much more air is required to ensure proper combustion and to prevent a downdraft Insufficient air causes incomplete combustion which can result in carbon monoxide In addition to providing combustion air fresh outdoor air di lutes contaminants in the indoor air These contaminants may include bleaches adhesives detergents solvents and other contaminants which can corrode furnace compo nents The requirements for providing air for combustion and ven tilation depend largely on whether the furnace is installed in an unconfined or a confined space Unconfined Space An unconfined space is an area such as a basement or large equipment room with a volume greater than 50 cubic feet 1 42 m3 per 1 000 Btu 29 kW per hour of the com bined input rating of all appliances installed in that space This space also includes adjacent rooms which are not separated by a door Though an area may appear to be un confined it might be necessary to bring in outdoor air for combustion if the structure does not provide enough air by infiltration If the furnace is located in a building of tight construction with weather stripping and caulking around the windows and doors follow the procedures in the air from outside section Confined Space A confined space is an area with a volume less than 50 cubic feet 1 42 m per 1 000 Btu 29
19. blower is de ener gized Longer off delay settings provide lower return air temperatures shorter settings provide higher return air temperatures See figure 55 Thermostat Heat Anticipation Set the heat anticipator setting if adjustable according to the amp draw listed on the wiring diagram that is attached to the unit Electrical 1 Check all wiring for loose connections 2 Check for the correct voltage at the furnace furnace operating 3 Check amp draw on the blower motor Motor Nameplate Actual HEAT FAN OFF TIME IN SECONDS HEAT OFF JUMPER POSITION DELAY PINI PIN2 60 PIN2 PIN3 90 PIN3 PIM 120 PIN4 PINS 80 NO JUMPER 180 To adjust fan off timing reposition jumper across pins to achieve desired setting 60 Second off Time 90 Second off Time 120 Second off Time 180 Second off Time Blower Speeds Follow the steps below to change the blower speeds 1 Turn off electrical power to furnace 2 Remove blower access panel 3 Disconnect existing speed tap at integrated control speed terminal NOTE Termination of any unused motor leads must be insulated 4 Place unused blower speed tap on integrated control PARK terminal or insulate 5 Refer to blower speed selection chart on unit wiring dia gram for desired heating or cooling speed See Blower performance data beginning on the next page 6 Connect selected speed tap at integrated control sp
20. cal building codes In the absence of local codes units must be installed according to the current National Fuel Gas Code ANSI Z223 1 NFPA 54 The National Fuel Gas Code is available from the following address American National Standards Institute Inc 11 West 42nd Street New York NY 10036 In Canada installation must conform with current National Standard of Canada CSA B149 Natural Gas and Propane Installation Codes local plumbing or waste water codes and other applicable local codes In order to ensure proper unit operation in non direct vent applications combustion and ventilation air supply must be provided according to the current National Fuel Gas Code or CSA B149 standard Locations and Clearances This furnace is CSA International certified for installation clearances to combustible material as listed on the unit nameplate and in the table in figure 11 Accessibility and ser vice clearances must take precedence over fire protection clearances For installation in a residential garage the furnace must be installed so that the burner s and the ignition source are located no less than 18 inches 457 mm above the floor The furnace must be located or protected to avoid physical damage by vehicles When a furnace is installed in a public garage hangar or other building that has a haz ardous atmosphere the furnace must be installed accord ing to recommended good practice requirements and cur rent National Fuel Gas Code or CS
21. connected to this termi nal it is necessary to use an external relay Install the room thermostat according to the instruc ML193DF and CONDENSING UNIT tions provided with the thermostat See figure 50 for THERMOSTAT DESIGNATIONS Refer to specific thermostat and outdoor unit thermostat designations If the furnace is being matched with a heat pump refer to the FM21 installa tion instruction or appropriate dual fuel thermostat in Thermostat Furnace Condensing Unit structions n Indoor Blower Speeds POWER ONT 1 When the thermostat is set to FAN ON the indoor blower will run continuously on the heating speed when there is no cooling or heating demand 2 When the ML193DF is running in the heating mode the indoor blower will run on the heating speed INDOOR BLOWER A CONDENSING i i j SONON MMC 3 When there is a cooling demand the indoor blower will run on the cooling speed HEAT CONDENSING UNIT COOLING NOTE R REQUIRED ON SOME OUTDOOR UNITS FIGURE 50 TYPICAL ML193DF FIELD WIRING DIAGRAM FLAME FLAME 120V ACC ROLLOUT FLAME IGNITOR ROLLOUT K43 ECON SWITCH SENSOR J159 SWITCH FUSED COMBUSTION AIR E INDUCER MOTOR 10 PRIMARY GAS WARNING LIMIT ELECTRIC SHOCK HAZARD CAN CAUSE INJURY OR DEATH UNIT MUST BE GROUNDED IN ACCORDANCE 145 LOW GAS WITH NATIONAL AND LOCAL CODES PRESSURE NOTE SWITCH GAS VALVE IF ANY WIRE IN THIS APPLIANC
22. detector with an alarm and battery backup is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery oper ated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwell ing building or structure served by the side wall hori zontally vented gas fueled equipment It shall be the responsibility of the property owner to secure the ser vices of qualified licensed professionals for the instal lation of hard wired carbon monoxide detectors a In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detec tor with alarm and battery back up may be installed on the next adjacent floor level b In the event that the requirements of this subdivi sion cannot be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided however that during said thirty 30 day period a battery operated carbon monoxide detec tor with an alarm shall be installed 2 APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accor dance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and IAS certi fied 3 SIGNAGE A metal or plastic identification plate shall be permanently mounted to
23. gas This raw gas or toxic fumes might then be distributed through out the house by the furnace duct system Use fiberglass sealing strips caulking or equivalent seal ing method between the plenum and the furnace cabinet to ensure a tight seal If a filter is installed size the return air duct to fit the filter frame Pipe amp Fittings Specifications All pipe fittings primer and solvent cement must conform with American National Standard Institute and the Ameri can Society for Testing and Materials ANSI ASTM stan dards The solvent shall be free flowing and contain no lumps undissolved particles or any foreign matter that ad versely affects the joint strength or chemical resistance of the cement The cement shall show no gelation stratifica tion or separation that cannot be removed by stirring Re fer to the table 4 below for approved piping and fitting ma terials A CAUTION Solvent cements for plastic pipe flammable liq uids and should be kept away from all sources of ignition Do not use excessive amounts of solvent cement when making joints Good ventilation should be maintained to reduce fire hazard and to minimize breathing of solvent vapors Avoid contact of cement with skin and eyes TABLE 4 PIPING AND FITTINGS SPECIFICATIONS SDR 21 PVC or SDR 26 PVC Pipe Schedule 40 ABS Pipe D1527 Waste amp Vent PVC amp CPVC Primer PVC Solvent Cement D2564 CPVC Solvent Cement F493
24. in Non Direct Vent applications where combustion air is taken from indoors and flue gases are discharged outdoors 1 Use field provided materials and the factory provided air intake screen to route the intake piping as shown in figure 22 Maintain a minimum clearance of 3 76mm around the air intake opening The air intake opening with the protective screen should always be directed forward or sideways 2 Use cement to secure the intake pipe to the connector if desired General Guidelines for Vent Terminations In Non Direct Vent applications combustion air is taken from indoors and the flue gases are discharged to the out doors The ML193DF is then classified as a non direct vent Category IV gas furnace In Direct Vent applications combustion air is taken from outdoors and the flue gases are discharged to the out doors The ML193DF is then classified as a direct vent Category IV gas furnace In both Non Direct Vent and Direct Vent applications the vent termination is limited by local building codes In the absence of local codes refer to the current National Fuel Gas Code ANSI Z223 1 NFPA 54 in U S A and current CSA B149 Natural Gas and Propane Installation Codes in Canada for details Position termination according to location given in figure 23 or 24 In addition position termination so it is free from any obstructions and 12 above the average snow accumula tion At vent termination care must be taken to mai
25. include 1 Detailed instructions for the installation of the venting System design or the venting system components and 2 A complete parts list for the venting system design or venting system MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas fueled equipment does not pro vide the parts for venting the flue gases but identifies spe cial venting systems the following requirements shall be satisfied by the manufacturer 1 The referenced special venting system instructions shall be included with the appliance or equipment installation instructions and 2 special venting systems shall be Product Ap proved by the Board and the instructions for that sys tem shall include a parts list and detailed installation instructions A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment all venting instructions all parts lists for venting instructions and or all venting design instruc tions shall remain with the appliance or equipment at the completion of the installation Page 52
26. kW per hour of the com bined input rating of all appliances installed in that space This definition includes furnace closets or small equipment rooms When the furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space con taining the furnace the return air must be handled by ducts which are sealed to the furnace casing and which terminate outside the space containing the furnace This is especially important when the furnace is mounted on a platform in a confined space such as a closet or small equipment room Even a small leak around the base of the unit at the platform or at the return air duct connection can cause a potentially Page 7 dangerous negative pressure condition Air for combustion and ventilation can be brought into the confined space ei ther from inside the building or from outside Air from Inside If the confined space that houses the furnace adjoins a space categorized as unconfined air can be brought in by providing two permanent openings between the two spaces Each opening must have a minimum free area of 1 square inch 645 mm per 1 000 Btu 29 kW per hour of total input rating of all gas fired equipment in the confined space Each opening must be at least 100 square inches 64516 mm One opening shall be within 12 inches 305 mm of the top of the enclosure and one opening within 12 inches 305 mm of the bottom See figure 4 EQUIPMENT IN CONFINED SPACE
27. lowing test should be conducted to ensure proper venting and sufficient combustion air has been provided to the ML193DF as well as to other gas fired appliances which are separately vented If a ML193DF furnace replaces a Category furnace which was commonly vented with another gas appliance the size of the existing vent pipe for that gas appliance must be checked Without the heat of the original furnace flue prod ucts the existing vent pipe is probably oversized for the single water heater or other appliance The vent should be checked for proper draw with the remaining appliance The test should be conducted while all appliances both in operation and those not in operation are connected to the venting system being tested If the venting system has been installed improperly or if provisions have not been made for sufficient amounts of combustion air corrections must be made as outlined in the previous section 1 Seal any unused openings in the venting system Page 39 2 4 5 c 1 Visually inspect the venting system for proper size and horizontal pitch Determine there is no blockage or re striction leakage corrosion or other deficiencies which could cause an unsafe condition To the extent that it is practical close all building doors and windows and all doors between the space in which the appliances connected to the venting system are lo cated and other spaces of the building Close fireplace dampers
28. out of the house Unless outside air is brought into the house for combus tion negative pressure outside pressure is greater than inside pressure will build to the point that a downdraft can occur in the furnace vent pipe or chimney As a result combustion gases enter the living space creating a po tentially dangerous situation In the absence of local codes concerning air for combus tion and ventilation use the guidelines and procedures in this section to install ML193DF furnaces to ensure effi cient and safe operation You must consider combustion air needs and requirements for exhaust vents and gas pip ing A portion of this information has been reprinted with permission from the National Fuel Gas Code ANSI Z223 1 NFPA 54 This reprinted material is not the com plete and official position of the ANSI on the referenced subject which is represented only by the standard in its entirety In Canada refer to the CSA B149 installation codes CAUTION Do not install the furnace in a corrosive or contami nated atmosphere Meet all combustion and ventila tion air requirements as well as all local codes Page 6 All gas fired appliances require air for the combustion pro cess If sufficient combustion air is not available the fur nace or other appliance will operate inefficiently and un safely Enough air must be provided to meet the needs of all fuel burning appliances and appliances such as exhaust fans which force
29. size opening required it may be assumed that wood louvers will have 20 to 25 percent free area and metal louvers and grilles will have 60 to 75 percent free area Louvers and grilles must be fixed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation EQUIPMENT IN CONFINED SPACE ALL AIR FROM OUTSIDE All Air Through Ventilated Attic ROOF TERMINATED VENTILATION LOUVERS EXHAUST PIPE Each end of attic E Pd TERMINATED EXHAUST PIPE ALTERNATE LOCATION INLET AIR Ends 12 above bottom NOTE The inlet and outlet air openings shall each have a free area of at least one square inch per 4 000 Btu 645mm per 1 17kW per hour of the total input rating of all equipment in the enclosure FIGURE 6 EQUIPMENT IN CONFINED SPACE ALL AIR FROM OUTSIDE ROOF TERMINATED EXHAUST PIPE ZZ OUTLET AIR SIDE WALL TERMINATED EXHAUST PIPE ALTERNATE LOCATION NOTE Each air duct opening shall have a free area of at least one square inch per 2 000 Btu 645mm per 59kW per hour of the total input rating of all equipment in the enclosure If the equipment room is located against an outside wall and the air openings communi cate directly with the outdoors each opening shall have a free area of at least 1 square inch per 4 000 Btu 645mm per 1 17kW per hour of the total input rating of all other equipment in the enclosure FIGURE 7 S
30. the exterior of the building at a minimum height of eight 8 feet above grade di rectly in line with the exhaust vent terminal for the hori zontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECT LY BELOW KEEP CLEAR OF ALL OBSTRUC TIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspec tion the inspector observes carbon monoxide detec tors and signage installed in accordance with the pro visions of 248 CMR 5 08 2 a 1 through 4 EXEMPTIONS The following equipment is exempt from 24 CMR 5 08 2 a 1 through 4 1 The equipment listed in Chapter 10 entitled Equip ment Not Required to Be Vented in the most current edition of NFPA 54 as adopted by the Board and 2 Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure sepa rate from the dwelling building or structure used in whole or in part for residential purposes MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas fueled equipment provides a vent ing system design or venting system components with the equipment the instructions provided by the manufacturer for installation of the equipment and the venting system shall
31. 0 1090 405 920 345 0 40 1930 775 1705 630 1495 575 1235 455 0 50 1300 545 1170 450 1035 380 875 335 0 50 1845 740 1645 610 1450 530 1215 450 0 60 1195 500 1095 425 990 365 840 320 0 60 1745 700 1525 550 1380 505 1185 430 0 70 1140 485 1020 400 895 345 780 300 0 70 1620 650 1460 535 1315 480 1110 405 0 80 1025 450 920 370 840 330 695 275 0 80 1450 585 1340 505 1220 445 1020 375 0 90 945 435 800 335 700 295 605 250 0 90 1320 555 1130 450 1010 385 920 345 ML193DF070P36B PERFORMANCE Less Filter ML193DF110P60C PERFORMANCE Less Filter Air Volume Watts at Various Blower Speeds Air Volume Watts at Various Blower Speeds External External Static High Medium Medium Low Static High Medium Medium Low Pressure High Low Pressure High Low in W 9 cfm Watts cfm Watts cfm Watts cfm Watts in W9 cfm Watts cfm Watts cfm Watts cfm watts 0 00 1505 660 1310 570 1090 455 940 390 0 00 2410 1390 2190 1080 1860 910 1560 735 0 10 1480 625 1295 550 1070 435 935 365 0 10 2405 1385 2180 1070 1855 905 1555 730 0 20 1405 585 1255 515 1055 425 930 350 0 20 2285 1345 2120 1030 1850 865 1540 720 0 30 1355 580 1225 475 1045 405 900
32. 330 0 30 2220 1315 2015 1005 1770 840 1535 705 0 40 1305 540 1165 470 1010 385 890 325 0 40 2185 1295 1950 955 1750 815 1530 685 0 50 1270 525 1110 425 975 370 835 305 0 50 2045 1240 1830 925 1680 790 1500 660 0 60 1175 500 1080 415 925 345 815 290 0 60 1965 1220 1710 890 1575 755 1445 640 0 70 1105 460 1000 395 855 320 745 270 0 70 1820 1165 1610 850 1495 720 1370 615 0 80 1040 440 925 365 790 300 670 250 0 80 1625 1155 1510 820 1400 695 1315 595 0 90 920 400 825 335 680 270 560 225 0 90 1455 1110 1390 790 1350 660 1210 565 41 AWARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in dangerous operation serious injury death or property damage Improper servicing could result dangerous opera tion serious injury death or property damage Before servicing disconnect all electrical power to furnace When servicing controls label all wires prior to dis connecting Take care to reconnect wires correctly Verify proper operation after servicing At the beginning of each heating season system should be checked as follows by a qualified service technician Blower Check the blower wheel for debris and clean if necessary The blower motors are prelubri
33. A B149 standards Page 4 NOTE Furnace must be adjusted to obtain a temperature rise within the range specified on the unit nameplate Failure to do so may cause erratic limit operation and premature heat exchanger failure This ML193DF furnace must be installed so that its electri cal components are protected from water Installation in Combination with a Cooling Coil When this furnace is used with cooling units figure 3 it shall be installed in parallel with or on the upstream side of cooling units to avoid condensation in the heating compart ment With a parallel flow arrangement a damper or other means to control the flow of air must adequately prevent chilled air from entering the furnace If the damper is manu ally operated it must be equipped to prevent operation of ei ther the heating or the cooling unit unless it is in the full HEAT or COOL setting When installed this furnace must be electrically grounded according to local codes In addition in the United States installation must conform with the current National Electric Code ANSI NFPA No 70 The National Electric Code ANSI NFPA No 70 is available from the following ad dress National Fire Protection Association 1 Battery March Park Quincy MA 02269 In Canada all electrical wiring and grounding for the unit must be installed according to the current regulations of the Canadian Electrical Code Part CSA Standard C22 1 and or local codes Heati
34. ABS Solvent Cement D2235 PVC CPVC ABS All Purpose Cement For Fittings amp Pipe of the same material D2564 D2235 F493 ABS to PVC or CPVC Transition Solvent Cement D3138 CANADA PIPE amp FITTING amp SOLVENT CEMENT MARKING PVC amp CPVC Pipe and Fittings PVC amp CPVC Solvent Cement ULCS636 ABS to PVC or CPVC Transition Cement Page 12 A IMPORTANT ML193DF exhaust intake connections made of PVC Use PVC primer and solvent cement when using PVC vent pipe When using ABS vent pipe use transitional solvent cement to make connections to the PVC fittings in the unit Use PVC primer and solvent cement or ABS solvent cement meeting ASTM specifications refer to Table 4 As an alter nate use all purpose cement to bond ABS PVC or CPVC pipe when using fittings and pipe made of the same materi als Use transition solvent cement when bonding ABS to ei ther PVC or CPVC Low temperature solvent cement is recommended during cooler weather Metal or plastic strapping may be used for vent pipe hangers Uniformly apply a liberal coat of PVC primer for PVC or use a clean dry cloth for ABS to clean in side socket surface of fitting and male end of pipe to depth of fitting socket Canadian Applications Only Pipe fittings primer and solvent cement used to vent exhaust this ap pliance must be certified to ULC S636 and supplied by a single manufacturer as part of an approved vent ex haust system
35. AL 1 5 MICROAMPS OR GREATER e LED 1 SLOW FLASH INDUCER AND INDOOR BLOW YES LED 2 FAST FLASH ER OFF LEDs SIGNAL LIMIT SWITCH OPEN UNTIL MAIN INDOOR BLOWER ON POWER IS AFTER SES COND DE GAS VALVE DE ENERGIZED INTERRUPTED OR YES COMBUSTION AIR INDUCER DE ENERGIZED T STAT IS CYCLED INDOOR BLOWER ON UNTIL SWITCH CLOSES OFF ON FOR 1 SEC PRIMARY AND SECONDARY LIMIT LED 1 SLOW FLASH LED 2 ON MINIMUM 60 MINUTE SWITCHES CLOSED IS LIMIT SWITCH CLOSED WATCHGUARD PE RIOD STARTS AT TIME LIMIT CLOSES IS 60 MIN PERIOD HAS PRIMARY LIMIT RESET COMPLETE TIME EXCEEDED 3 MINUTES GAS VALVE POWER OFF COMBUSTION AIR INDUCER POWER ON ROLLOUT SWITCH CLOSED INDOOR BLOWER ON LED 1 ON LED 2 SLOW FLASH SEQUENCE HOLDS UNTIL ROLLOUT SWITCH IS RESET AND MAIN POWER IS INTERRUPTED OR COMBUSTION AIR PRESSURE THERMOSTAT IS CYCLED OFF ON FOR 1 SEC MINIMUM SWITCH CLOSED YES GAS VALVE DE ENERGIZED COMBUSTION AIR INDUCER ON THERMOSTAT DEMAND SATISFIED INDOOR BLOWER OFF WITH DELAY YES LED 1 OFF LED 2 SLOW FLASH HAS CAB SWITCH CLOSED IN 2 5 MINUTES LED 1 amp 2 SIMULTANEOUS SLOW FLASHES COMB AIR INDUCER CONTINUES 5 SECOND 5 MINUTE PRESSURE SWITCH POST PURGE AFTER T STAT DEMAND IS SATISFIED WATCHGUARD MODE INDOOR AIR BLOWER COMPLETES SELECTED DELAY BEFORE SHUTTING OFF Page 46 Troubleshooting Cooling Sequence of Operation COOLING SEQUENCE OF OPERATION NORMAL
36. ALL AIR FROM INSIDE SIDE WALL TERMINATED EXHAUST PIPE ALTERNATE LOCATION NOTE Each opening shall have a free area of at least one square inch per 1 000 Btu 645mm per 29kW per hour of the total input rating of all equipment in the enclosure but not less than 100 square inches 64516mm 2 FIGURE 4 Air from Outside If air from outside is brought in for combustion and ventila 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 305mm of the bottom These openings must communicate directly or by ducts with the outdoors or spaces crawl or attic that freely communicate with the outdoors or indirectly through vertical ducts Each opening shall have a mini mum free area of 1 square inch per 4 000 Btu 645mm per 1 17kW per hour of total input rating of all equipment in the enclosure When communicating with the outdoors through horizontal ducts each opening shall have a mini mum free area of 1 square inch per 2 000 Btu 645mm per 59kW per total input rating of all equipment in the en closure See figure 5 EQUIPMENT IN CONFINED SPACE ALL AIR FROM OUTSIDE Inlet Air from Crawl Space and Outlet Air to Ventilated Attic VENTILATION LOUVERS Each end of attic ROOF TERMINATED EXHAUST PIPE ZZ BH SIDE WALL TERMINATED EXHAUST PIPE ALTERNATE LOCATION VENTILATION LOUVERS For unheated crawl spac
37. ANSI Z223 1 ELECTROSTATIC DISCHARGE ESD Precautions and Procedures ACAUTION Electrostatic discharge can affect electronic com ponents precautions during furnace installa tion and service to protect the furnace s electronic controls Precautions will help to avoid control ex posure to electrostatic discharge by putting the fur nace the control and the technician at the same electrostatic potential Neutralize electrostatic charge by touching hand and all tools on an un painted unit surface such as the gas valve or blower deck before performing any service procedure The unit is equipped with a field make up box on the left hand side of the cabinet A field provided make up box can be installed on the exterior of the right side of the furnace to facilitate installation If the make up box is moved to the right side clip the wire ties that bundle the wires together and install on the outside of the cabinet See figure 49 The excess wire must be pulled into the blower compartment Secure the excess wire to the existing harness to protect it from damage Page 32 INTERIOR MAKE UP BOX FACTORY INSTALLED LEFT SIDE MAKE UP BOX INSIDE CABINET Left side FIGURE 48 EXTERIOR MAKE UP BOX FIELD PROVIDED RIGHT SIDE DN KC MAKE UP N BOX OUTSIDE CABINET Right Side FIGURE 49 Refer to figure 51 for field wiring and figure 52 for schematic wi
38. E IS REPLACED IT MUST BE REPLACED WITH WIRE OF LIKE SIZE 18 RATING INSULATION THICKNESS AND TERMINATION COMBUSTION AIR PROVING NOTE USE COPPER SWITCH A FIELD SUPPLIED ACC WIRE CONDUCTORS ONLY A 145 IS USED WITH HONEYWELL GAS TRANSFORMER VALVE WHEN APPLIED IN LP GAS UNITS UR NOTE R REQUIRED ON SOME OUTDOOR UNITS INTERLOCK 1 92 ROOM THERMOSTAT IGNITION BLOWER CONTROL INDOOR C4 BLOWER MOTOR CAPACITOR OUTDOOR UNIT FIGURE 51 Page 34 TYPICAL ML193DF WIRING DIAGRAM BLOWER SPEED CHART FACTORY CONNECTED SPEED TAPS MOTOR 045P36B x YELLOW BROWN RED INDOOR c4 070P36B BROWN YELLOW RED BLOWER CAPACITOR 090P48C BROWN YELLOW RED MOTOR 110P60C BROWN YELLOW RED BLOWER SPEED SELECTION sO TAPS _ BLACK BROWN YELLOW RED IGNITION BLOWER CONTROL THERMOSTAT HEAT ANTICIPATION SETTINGS 1 SOM ERER AT 65 AMP HONEYWELL VALVE m 50AMP WHITE RODGERS VALVE DOOR TRANSFORMER JACKPLUG CHART INTERLOCK J P58 JACK PLUG BURNER CONTROL 120V ACC JACK PLUG INDUCER IGNITER OR ECON JACK PLUG IGNITER IF USED WARNING ELECTRIC SHOCK HAZARD CAN CAUSE INJURY OR DEATH UNIT MUST BE GROUNDED IN ACCORDANCE COMBUSTION COMBUSTION AIR AIR PROVING 62 WITH NATIONAL AND LOCAL CODES SWITCH NOTE S145 IF ANY WIRE IN THIS APPLIANCE IS REPLACED IT Lowcas LD MUST BE REPLACED WITH WIRE OF LIKE SIZE RATING PRESSURE D INSULATION THICKNESS AND TERMINATION SWITCH 18 IMPORTANT S10
39. Free Adjusted Programmed Return Duct Temperature Temperature Rise Leak Free 7 VENT PIPE L Explained Operation to Owner Leak Free Combustion SUPPLY AIR Thermostat Temperatures D Gas Manifold Pressure Blower Motor Amps gt RETURN AIR Contractor s Name Telephone Checklist Completed Job Address Technician s Name Page 51 Requirements for Commonwealth of Massachusetts Modifications to NFPA 54 Chapter 10 Revise NFPA 54 section 10 8 3 to add the following re quirements For all side wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven 7 feet above the finished grade in the area of the venting in cluding but not limited to decks and porches the following requirements shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETEC TORS At the time of installation of the side wall hori zontally vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide
40. LENNOX 2010 Lennox Industries Inc Dallas Texas USA DOWNFLOW AIR FLOW Unit Dimensions ML193DF Parts Arrangement ML193DF Gas Furnace Shipping and Packing List Safety Information Use of Furnace as a Construction Heater General Combustion Dilution and Ventilation Air Setting Equipment I LTD Duct System Pipe and Fittings Specifications Joint Cementing Procedure Venting Practices 01 11 INSTALLATION INSTRUCTIONS ML193DF MERIT SERIES GAS FURNACE DOWNFLOW AIR DISCHARGE 506475 01 01 2011 Supersedes 10 2010 Technical Publications 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 When you see this symbol on labels or in manuals be alert to the potential for personal injury or death ACAUTION As with any mechanical equipment personal injury can result from contact with sharp sheet metal edges Be careful when you handle this equipment AWARNING 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 l
41. N AIR INDUCER OFF POWER ON INDOOR BLOWER DELAY OFF CONTROL SELF CHECK OKAY LED 1 ON LED 2 ON RESET CONTROL BY TURNING MAIN POWER OFF POLARITY REVERSED IS POLARITY CORRECT LED 1 FAST FLASH LED 2 SLOW FLASH IMPROPER GROUND IS THERE A PROPER GROUND LED 1 ALTERNATING FAST FLASH YES LED 2 ALTERNATING FAST FLASH NO LEDs SIGNAL FAST ALTERNATING FLASH I IS VOLTAGE CONTROL WILL NOT RESPOND TO A CALL FOR ABOVE 90 VOLTS HEATING UNTIL VOLTAGE RISES ABOVE 95 VOLTS YES NO GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER ON ROLLOUT SWITCH CLOSED LED 1 ON LED 2 SLOW FLASH SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES YES AND POWER IS RESET OR T STAT IS INTERRUPTED FOR MINIMUM OF 1 SECOND GAS VALVE OFF COMBUSTION AIR INDUCER ON BURNER OFF NO INDOOR BLOWER ON HEATING SPEED Flame sensed without gas valve energized LED 1 SLOW FLASH LED 2 OFF YES i NORMAL OPERATION LED 1 SLOW FLASH LED 2 SLOW FLASH COMBUSTION AIR INDUCER OFF INDOOR BLOWER ON LED 1 SLOW FLASH RATE LED 2 ON THERMOSTAT CALLS FOR HEAT LED 1 FAST FLASH LED 2 FAST FLASH YES PRIMARY LIMIT SWITCH CLOSED GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF WITH DELAY IS COMBUSTION AIR LED 1 OFF PRESSURE SWITCH OPEN LED 2 SLOW FLASH YES Sequence holds until pressure switch opens or thermostat resets control IS COMBUSTION AIR I
42. NDUCER ENERGIZED YES PRESSURE SWITCH IS IN WATCHGUARD MODE HAS COMBUSTION AIR PRESSURE O GAS VALVE OFF COMBUSTION AIR INDUCER OFF SWITCH CLOSED IN 2 5 MINUTES INDOOR BLOWER OFF WITH DELAY YES i LED 1 OFF LED 2 SLOW FLASH IS 5 MINUTE RESET PERIOD COMPLETE CONTINUED NEXT PAGE Page 45 Troubleshooting Heating Sequence of Operation Continued HEATING SEQUENCE CONTINUED NORMAL HEATING MODE ABNORMAL HEATING MODE 15 SECOND COMBUSTION AIR INDUCER PREPURG INITIATED BY CLOSED PRESSURE SWITCH LEDS SIGNAL YES NO ALTERNATING IGNITOR WARM UP 20 SECONDS I VOLTAGE ABOVE 90 VOLTS NO MO MEI ne YES YES 95 VOLTS THEN RESTARTS HEATING 4 SECOND TRIAL FOR IGNITION SEQUENCE GAS VALVE OPENS IGNITOR ENERGIZED FOR FIRST 3 SECONDS OF THE TRIAL GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER OFF NO HAS CONTROL FAILED TO SENSE FLAME FOR FLAME STABILIZATION PERIOD FIVE CONSECUTIVE TRIES DURING A SINGLE 4 SECONDS HEAT DEMAND FLAME RECTIFICATION CURRENT WATCHGUARD MODE GAS VALVE OFF CHECK CAN FLAME BE PROVEN WITHIN COMBUSTION AIR INDUCER OFF 4 SECONDS AFTER GAS VALVE OPENS INDOOR BLOWER OFF WITH DELAY 0 5 microamps LEDs SIGNAL WATCHGUARD FAILURE CODE IS 60 MINUTE RESET PERIOD COMPLETE YES FLAME PRESENT HAS CONTROL RESET IGNITION SEQUENCE FOUR TIMES LOW FLAME SIGNAL LIMIT SWITCH WATCHGUARD Does not affect operation of control MODE GAS VALVE COMB AIR FLAME SIGN
43. THERMOSTAT CONTROL G ENERGIZES SYSTEM FAN AT HEAT SPEED EAC TERMINAL IS ENERGIZED HUM TERM ENERGIZES THERMOSTAT CALLS FOR HEAT W WITH COMB AIR INDUCER YES THERMOSTAT CALLS FOR COOLING SYSTEM FAN REMAINS ON YES HEATING SPEED SYSTEM FAN SWITCHED TO COOL SPEED EAC TERM REMAINS ON THERMOSTAT OPENS THERMOSTAT OPENS HUM TERM DE ENERGIZES WITH COMB AIR INDUCER MANUAL FAN SELECTION MADE AT THERMOSTAT CONTROL G ENERGIZES SYSTEM FAN AT HEAT SYSTEM FAN REMAINS ON SPEED EAC TERM ENERGIZED HEATING SPEED Page 48 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 ML193DF04536B All service must be performed by a licensed pro fessional installer or equivalent service agency or gas supplier Cabinet Parts Upper access panel Blower access panel Top Cap Control Panel Parts Transformer Integrated control board Door interlock switch Blower Parts Blower wheel Motor Motor mounting frame Motor capacitor Blower housing cutoff plate Page 49 Heating Parts Flame Sensor Heat exchanger assembly Gas manifold Combustion air inducer Gas valve Main burner cluster Main burner orifices Pressure switch Ignitor Primary limit control Flame rollout switches Start Up amp Performance Check List UNIT SET UP Furnace Model Number Serial Number
44. ast 5 minutes before placing unit into operation 1 Measure and cut vent pipe to desired length 2 Debur and chamfer end of pipe removing any ridges or rough edges If end is not chamfered edge of pipe may remove cement from fitting socket and result in a leaking joint 3 Clean and dry surfaces to be joined 4 Test fit joint and mark depth of fitting on outside of pipe 5 Uniformly apply a liberal coat of PVC primer for PVC or use a clean dry cloth for ABS to clean inside socket surface of fitting and male end of pipe to depth of fitting socket 1 Promptly apply solvent cement to end of pipe and in side socket surface of fitting Cement should be ap plied lightly but uniformly to inside of socket Take care to keep excess cement out of socket Apply sec ond coat to end of pipe NOTE Time is critical at this stage Do not allow prim er to dry before applying cement N 1 Immediately after applying last coat of cement to pipe and while both inside socket surface and end of pipe are wet with cement forcefully insert end of pipe into socket until it bottoms out Turn PVC pipe 1 4 turn dur ing assembly but not after pipe is fully inserted to dis tribute cement evenly DO NOT turn ABS or cellular core pipe NOTE Assembly should be completed within 20 sec onds after last application of cement Hammer blows should not be used when inserting pipe 8 After assembly wipe excess cement from pipe at
45. ate DRIP LEG AND INSTALLED Bellows Grommet NOTE BLACK IRON PIPE ONLY TO BE ROUTED INSIDE OF CABINET Bellows Grommet FIGURE 47 TABLE 10 GAS PIPE CAPACITY FT3 HR kL HR Nominal Internal Length of Pipe Feet m Iron Pipe Size Diameter 10 20 30 50 60 70 80 90 100 Inches mm Inches mm 3 048 6 096 9 144 15 240 18 288 21 336 024 384 27 432 30 480 1 2 622 175 120 97 82 73 66 53 50 12 7 17 799 4 96 3 40 2 75 2 32 2 07 1 87 1 uS 1 Gat 1 50 1 42 3 4 824 360 250 200 170 151 138 125 118 110 103 19 05 20 930 10 19 7 08 5 66 4 81 4 28 3 91 3 54 3 34 3 11 2 92 1 1 049 680 465 375 320 285 260 240 220 205 195 25 4 26 645 19 25 13 17 10 62 9 06 8 07 7 36 6 80 6 23 5 80 5 52 1 1 4 1 380 1400 950 770 660 580 530 490 460 430 400 31 75 35 052 39 64 26 90 21 80 18 69 16 42 15 01 13 87 13 03 12 18 11 33 1 1 2 1 610 2100 460 1180 990 900 810 750 690 650 620 38 1 40 894 59 46 41 34 33 41 28 03 25 48 22 94 2124 19 54 18 41 17 56 2 2 067 3950 2750 2200 1900 1680 1520 1400 1300 1220 1150 50 8 52 502 111 85 77 87 62 30 53 80 47 57 43 04 39 64 36 81 34 55 32 56 6300 178 39 3 068 11000 7700 6250 5300 4750 4300 3900 3700 3450 3250 S a 77 927 311 48 218 03 176 98 150 07 134 50 121 76 110 43 104 77 97 69 92 03
46. bution system as possible The furnace should also be located close to the chimney or vent termination point e When the furnace is installed in non direct vent applica tions do not install the furnace where drafts might blow directly into it This could cause improper combustion and unsafe operation e When the furnace is installed in non direct vent applica tions do not block the furnace combustion air opening with clothing boxes doors etc Air is needed for proper combustion and safe unit operation e When the furnace is installed in an attic or other insu lated space keep insulation away from the furnace e When the furnace is installed in an unconditioned space consider provisions required to prevent freezing of condensate drain system CAUTION ML193DF unit should not be installed in areas nor mally subject to freezing temperatures AWARNING Product contains fiberglass wool Disturbing the insulation in this product during installation maintenance or repair will expose you to fiberglass wool Breathing this may cause lung cancer Fiberglass wool is known to the State of Cal ifornia to cause cancer Fiberglass wool may also cause respiratory skin and eye irritation To reduce exposure to this substance or for further information consult material safety data sheets available from address shown below contact your supervisor Lennox Industries Inc P O Box 799900 Dallas TX 75379 9900 Combu
47. cated for extended bearing life No further lubrication is needed AWARNING The blower access panel must be securely in place when the blower and burners are operating Gas fumes which could contain carbon monoxide can be drawn into living space resulting in personal inju ry or death Filters All air filters are installed external to the unit Filters should be inspected monthly Clean or replace the filters when necessary to ensure proper furnace operation Table 3 lists recommended filter sizes Exhaust and air intake pipes Check the exhaust and air intake pipes and all connections for tightness and to make sure there is no blockage NOTE After any heavy snow ice or frozen fog event the furnace vent pipes may become restricted Always check the vent system and remove any snow or ice that may be obstructing the plastic intake or exhaust pipes Electrical 1 Check all wiring for loose connections 2 Check for the correct voltage at the furnace furnace operating Check amp draw on the blower motor Motor Nameplate Actual Winterizing and Condensate Trap Care 1 Turn off power to the furnace 2 Have a shallow pan ready to empty condensate water 3 Remove the clean out cap from the condensate trap and empty water Inspect the trap then reinstall the drain plug Cleaning Heat Exchanger If cleaning the heat exchanger becomes necessary follow the below procedures and refer to figure 1 when disassem bl
48. dimensions listed are 1 4 inch 6 mm larger than the unit opening See dimension drawing on page 2 FURNACE PROPERLY SIZED FLOOR v SUPPLY AIR OPENING PLENUM ne A e ee FIGURE 12 Installation on Combustible Flooring Figure 13 1 When unit is installed on a combustible floor a down flow combustible flooring base must be installed be tween the furnace and the floor The base must be or dered separately See table 2 for opening size to cut in floor A CAUTION The furnace and combustible flooring base shall not be installed directly on carpeting tile or other com bustible material other than wood flooring Page 10 TABLE 2 COMBUSTIBLE FLOORING BASE OPENING SIZE Cabinet Catalog Front to Rear Side to Side B Cabinet COOLING COIL PROPERLY 2 SIZED FLOOR OPENING ms PLENUM FURNACE 24 me SUPPLY AIR PLENUM p ee VA PROPERLY COMBUSTIBLE SIZED FLOOR FLOORING BASE FIGURE 14 OPENING Return Air Opening Downflow Units Return air may be brought in only through the top opening of a furnace installed in the downflow position The follow ing steps should be taken when installing plenum 1 Bottom edge of plenum should be flanged with a hemmed edge See figure 15 or 16 FIGURE 13 2 Sealing strips should be used to ensure an airtight seal 2 After opening is cut set the combustible flooring base between the cabinet and the plenum i
49. e NOTE The inlet and outlet air openings shall each have a free area of at least one square inch per 4 000 Btu 645mm per 1 17kW per hour of the total input rating of all equipment in the enclosure FIGURE 5 If air from outside is brought in for combustion and ventila tion the confined space must have two permanent open ings One opening shall be within 12 inches 305 mm of the top of the enclosure and one opening within 12 inches 305 mm of the bottom These openings must communi cate directly or by ducts with the outdoors or spaces crawl or attic that freely communicate with the outdoors or indi rectly through vertical ducts Each opening shall have a minimum free area of 1 square inch 645 mm per 4 000 Btu 1 17 kW per hour of total input rating of all equipment in the enclosure See figures 5 and 6 When communicat ing with the outdoors through horizontal ducts each open ing shall have a minimum free area of 1 square inch 645 mm 2 2 000 Btu 56 kW per total input rating of all equipment in the enclosure See figure 7 When ducts are used they shall be of the same cross sec tional area as the free area of the openings to which they connect The minimum dimension of rectangular air ducts shall be no less than 3 inches 75 mm In calculating free area the blocking effect of louvers grilles or screens must be considered If the design and free area of protec tive covering is not known for calculating the
50. e gas valve from the side of the valve as shown in figure 47 2 When connecting gas supply factors such as length of run number of fittings and furnace rating must be con sidered to avoid excessive pressure drop Table 10 lists recommended pipe sizes for typical applications NOTE Use two wrenches when connecting gas pip ing to avoid transferring torque to the manifold 3 Gas piping must not run in or through air ducts clothes chutes chimneys or gas vents dumb waiters or eleva tor shafts Center gas line through piping hole Gas line should not touch side of unit See figures 47 4 Piping should be sloped 1 4 inch per 15 feet 6mm per 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 or straps Install a drip leg in vertical pipe runs to serve as a trap for sediment or condensate 5 1 8 N P T plugged tap or pressure post is located on the gas valve to facilitate test gauge connection See figure 54 In some localities codes may require installation of a manual main shut off valve and union furnished by in staller external to the unit Union must be of the ground joint type 1 AIMPORTANT Compounds used threaded joints of gas piping must be resistant to the actions of liquified petro leum gases Leak Check After gas piping is completed carefully check all piping connections
51. e primary limit is located on the heating compartment vestibule panel This limit is factory set and requires no ad justment Flame Rollout Switches Two These manually reset switches are located on the front of the burner box Pressure Switch The pressure switch is located in the heating compartment on the cold end header box This switch checks for proper combustion air inducer operation before allowing ignition trial The switch is factory set and must not be adjusted Temperature Rise After the furnace has been started and supply and return air temperatures have been allowed to stabilize check the temperature rise If necessary adjust the blower speed to maintain the temperature rise within the range shown on the unit nameplate Increase the blower speed to decrease the temperature Decrease the blower speed to increase the temperature rise Failure to adjust the temperature rise may cause erratic limit operation Fan Control The fan on time of 30 seconds is not adjustable The fan off delay amount of time that the blower operates after the heat demand has been satisfied may be adjusted 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 comfort and is adjustable to satisfy individual applications Adjust the fan off delay to achieve a supply air temperature between 90 and 110 F at the moment that the
52. e which automatically lights the burners Do not try to light the burners by hand 5 Remove the upper access panel 6 Move gas valve switch to OFF See figure 54 7 Wait five minutes to clear out any gas If you then smell gas STOP Immediately call your gas supplier from a neighbor s phone Follow the gas suppliers instruc tions If you do not smell gas go to next step 8 Move gas valve switch to ON See figure 54 9 Replace the upper access panel 10 Turn on all electrical power to to the unit 11 Set the thermostat to desired setting NOTE When unit is initially started steps 1 through 11 may need to be repeated to purge air from gas line MANIFOLD PRESSURE ADJUSTMENT SCREW MANIFOLD PRESSURE OUTLET INLET A PRESSURE PORT GAS VALVE SHOWN IN ON POSITION FIGURE 54 12 If the appliance will not operate follow the instructions Turning Off Gas to Unit and call your service techni cian or gas supplier Turning Off Gas to Unit 1 Set the thermostat to the lowest setting 2 Turn off all electrical power to the unit if service is to be performed 3 Remove the upper access panel 4 Move gas valve switch to OFF 5 Replace the upper access panel Failure To Operate If the unit fails to operate check the following 1 Is the thermostat calling for heat 2 Are access panels securely in place 3 Is the main disconnect switch closed 4 Is there a blown fuse or tripped b
53. ed carefully to make sure there are no sags or low spots Page 15 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 Standard Termination at Elevation 0 10 000 ft Of 90 Model Model Model Elbows Used 045 070 090 110 045 070 090 110 1 61 46 24 127 127 108 108 2 56 41 19 122 122 103 103 3 36 14 117 117 98 31 16 n a Concentric Termination Elevation 0 10 000 ft Number 2 Pipe 2 1 2 Pipe 3 Pipe Of 90 Model Model Model Elbows eee NS s 5 eee ee ee eee 90 70 39 aa N wo m 5 91 91 84 84 n a 6 28 13 86 86 79 79 7 23 n a 81 81 74 74 8 18 76 76 69 69 n a 9 71 71 64 64 zx 16 Pipe size determined in table 7 81 mE Ca Pipe size determined in table 7 TYPICAL EXHAUST PIPE CONNECTIONS TRANSITION DO NOT transition from smaller INTAKE EXHAUST to larger pipe size in horizontal runs of exhaust pipe TOP VIEW o When transitioning up in pipe size use the shortest length of 2 PVC pipe possible NOTE Exhaust pipe and intake pipe must be the same diameter FIGURE 20 C TRANSITION 11 TRANSITION 2 INTAKE EXHAUST TOP VIEW When tra
54. eed terminal 7 Resecure blower access panel 8 Turn on electrical power to furnace 9 Recheck temperature rise Exhaust and Air Intake Pipe 1 Check exhaust and air intake connections for tightness and to make sure there is no blockage 2 pressure switch closed Obstructed exhaust pipe will cause unit to shut off at pressure switch Check ter mination for blockages 3 Obstructed pipe or termination may cause rollout switches to open Reset manual flame rollout switches on burner box assembly if necessary Page 40 BLOWER DATA ML193DF045P36B PERFORMANCE Less Filter ML193DF090P48C PERFORMANCE Less Filter Air Volume Watts at Various Blower Speeds Air Volume Watts at Various Blower Speeds External External Static High Medium Medium Low Static High Medium Medium L w Pressure High Low Pressure High Low W 9 cfm Watts cfm Watts cfm Watts cfm Watts in W9 cfm Watts cfm Watts cfm Watts cfm Watts 0 00 1615 650 1385 555 1205 465 1045 390 0 00 2145 900 1865 740 1545 635 1295 530 0 10 1605 640 1375 545 1195 455 1035 380 0 10 2135 890 1855 730 1540 625 1290 520 0 20 1500 620 1340 525 1165 445 1015 370 0 20 2065 845 1815 710 1525 600 1285 500 0 30 1450 590 1290 490 1125 420 975 365 0 30 2010 825 1760 685 1510 580 1275 485 0 40 1350 560 1235 48
55. end of fitting socket A properly made joint will show a bead around its entire perimeter Any gaps may indi cate an improper assembly due to insufficient sol vent 9 Handle joints carefully until completely set Venting Practices Piping Suspension Guidelines SCHEDULE 40 PVC 5 all other pipe 3 See table 4 for allowable pipe NOTE Isolate piping at the point where it exits the outside wall or roof in order to prevent transmission of vibration to the structure Wall Thickness Guidelines 24 maximum 3 4 minimum Wall outside REPLACING FURNACE THAT WAS PART OF A COMMON CHIMNEY LAS VENT SYSTEM VENT Check sizing for water heater only FURNACE Replaced by ML193 OPENINGS To Adjacent If an ML193DF furnace replaces a furnace which was com monly vented with another gas appliance the size of the ex isting vent pipe for that gas appliance must be checked Without the heat of the original furnace flue products the existing vent pipe is probably oversized for the single water heater or other appliance The vent should be checked for proper draw with the remaining appliance FIGURE 18 In areas where piping penetrates joists or interior walls hole must be large enough to allow clearance on all sides of pipe through center of hole using a hanger 1 14 2 When furnace is installed in a residence where unit is shut down for an extended period of time such as a vacati
56. er deck 14 Remove the primary limit from the vestibule panel 15 Remove two screws from the front cabinet flange at the blower deck Spread cabinet sides slightly to allow clearance for removal of heat exchanger 16 Remove screws along vestibule sides and bottom which secure vestibule panel and heat exchanger as sembly to cabinet Remove two screws from blower rail which secure bottom heat exchanger flange Re move heat exchanger from furnace cabinet 17 Back wash heat exchanger with soapy water solution or steam If steam is used it must be below 275 F 135 C 18 Thoroughly rinse and drain the heat exchanger Soap solutions can be corrosive Take care to rinse entire assembly 11 Page 42 19 Reinstall heat exchanger into cabinet making sure that the clamshells of the heat exchanger assembly are resting on the support located at the rear of the cabi net Remove the indoor blower to view this area through the blower opening 20 Re secure the supporting screws along the vestibule sides and bottom to the cabinet Reinstall blower and mounting screws 21 Reinstall cabinet screws on front flange at blower deck 22 Reinstall the primary limit on the vestibule panel 23 Route heating component wiring through hole in blow er deck and reinsert strain relief bushing 24 Reinstall electrical junction box 25 Reinstall the combustion air inducer Reconnect the combustion air inducer to the wire harness 26
57. ere is no blockage restriction leakage corrosion or other deficiencies which could cause an unsafe condition 99 1 Close all building doors and windows and all doors be tween the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dry ers and any appliances not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will oper ate at maximum speed Do not operate a summer ex haust fan Close fireplace dampers Follow the lighting instructions Turn on the appliance that is being inspected Adjust the thermostat so that the appliance operates continuously 1 5 After the main burner has operated for 5 minutes test for leaks of flue gases at the draft hood relief opening Use the flame of a match or candle 6 After determining that each appliance connected to the common venting system is venting properly step 3 return all doors widows exhaust fans fireplace damp ers and any other gas burning appliances to their pre vious mode of operation 7 If a venting problem is found during any of the preced ing tests the common venting system must be modi fied to correct the problem Resize the common venting system to the minimum vent pipe size determined by using the appropriate tables in Appendix G These are in the current stan dards of the National Fuel Gas Code
58. factory and field installed for gas leaks Use a leak detecting solution or other preferred means The furnace must be isolated from the gas supply system by closing its individual manual shut off valve during any pressure testing of the gas supply system at pressures less than or equal to 1 2 psig 3 48 kPa 14 inches w c MANUAL MAIN SHUT OFF VALVE WILL NOT HOLD FURNACE NORMAL TEST PRESSURE 1 8 N P T PLUGGED TAP GAS VALVE FIGURE 46 AIMPORTANT When testing pressure of gas lines gas valve must be disconnected and isolated See figure 46 Gas valves can be damaged if subjected to pressures greater than 1 2 psig 3 48 kPa AWARNING FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in serious injury death or property damage Never use an open flame to test for gas leaks Check all connections using a commercially available soap solution made specifically for leak detection Some soaps used for leak detection are corrosive to certain metals Carefully rinse piping thoroughly after leak test has been completed Page 30 Left Side Piping MANUAL AUTOMATIC Standard GAS VALVE 2 JAIN SHUT OFF AUTOMATIC with manual _ VALVE GAS VALVE 2 With 1 8 in NPT with manual Plugged Tap B Shown GROUND JOINT UNION MANUAL MAIN SHUT OFF VALVE With 1 8 in NPT Plugged Tap Shown n t GROUND JOINT UNION DRIP LEG FIELD Right Side Piping PROVIDED Altern
59. g is not allowed The return air duct must be provided and sealed to the furnace Return air temperature range between 60 F 16 C and 80 F 27 C must be maintained Air filters must be installed in the system and must be maintained during construction Air filters must be replaced upon construction comple tion The input rate and temperature rise must be set per the furnace rating plate One hundred percent 10096 outdoor air must be pro vided for combustion air requirements during construc tion Temporary ducting may supply outdoor air to the furnace Do not connect duct directly to the furnace Size the temporary duct following these instructions in section for Combustion Dilution and Ventilation Air in a confined space with air from outside The furnace heat exchanger components duct system air filters and evaporator coils must be thoroughly cleaned following final construction clean up All furnace operating conditions including ignition in put rate temperature rise and venting must be verified according to these installation instructions These instructions are intended as a general guide and do not supersede local codes in any way Consult authorities having jurisdiction before installation In addition to the requirements outlined previously the fol lowing general recommendations must be considered when installing ML193DF furnace e Place the furnace as close to the center of the air dis tri
60. gth of PVC pipe required to reach available drain 2 Remove plug figure 42 from the cold end header box at the appropriate location on the side of the unit Install field provided 1 2 NPT male fitting into cold end head er box Use teflon tape or appropriate pipe dope 3 Install the cap over the clean out opening at the base of the trap See figure 45 NOTE Vinyl tubing may be used for condensate drain Tubing must be 1 1 4 OD X 1 ID and should be attached to the drain on the trap using a hose clamp 4 Install drain trap using appropriate PVC fittings glue all joints Glue the provided drain trap as shown in fig ure 45 Route the condensate line to an open drain NOTE If necessary the condensate trap may be installed up to 5 feet away from the furnace Piping from furnace must slope down a minimum of 1 4 per ft toward trap 5 If unit will be started immediately upon completion of installation prime trap per procedure outlined in Unit Start Up section Condensate line must slope downward away from the Condensate trap and trap to drain If drain level is above condensate trap Field Provided Vent evaporator coil must drain condensate pump must be used Condensate drain separately as shown line should be routed within the conditioned space to avoid freezing of condensate and blockage of drain line If this is not possible a heat cable kit may be used on the condensate trap and line Heat cable kit is avail able fro
61. he diameter of pipe used the standard roof and wall terminations described in section Exhaust Piping Terminations should be used Exhaust vent termination pipe is sized to optimize the velocity of the exhaust gas as it exits the termination Refer to table 8 In some applications which permit the use of several differ ent sizes of vent pipe a combination vent pipe may be used Contact Lennox Application Department for assis tance in sizing vent pipe in these applications A IMPORTANT Do not use screens or perforated metal in exhaust or intake terminations Doing so will cause freeze ups and may block the terminations Use the following steps to correctly size vent pipe diameter 090 110 or 135 btuh Furnace capacity Which termination a Which needs most elbows Intake or exhaust How many Desired pipe size gt o What is the altitude Use table 7 to find max intake or exhaust pipe length 7 FIGURE 19 NOTE It is acceptable use any pipe size which fits within the guidelines allowed in table 7 NOTE All horizontal runs of exhaust pipe must slope back toward unit A minimum of 1 4 6mm drop for each 12 305mm of horizontal run is mandatory for drainage NOTE Exhaust pipe MUST be glued to furnace exhaust fittings NOTE Exhaust piping should be check
62. hipping Bolt Removal 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 white plastic washer rather than the rubber mounting grommet used with a flexible mounting leg See figure 8 The bolt and washer must be removed before the fur nace is placed into operation After the bolt and washer have been removed the rigid leg will not touch the blower housing Page 8 ML193DF09048C BLOWER MOTOR Allow for clearances to combustible materials as indicated RIGID L on the unit nameplate Minimum clearances for closet or al cove installations are shown in figure 11 A WARNING remove shipping bolt and washer Blower access panel must be securely in place when blower and burners are operating Gas fumes which FIGURE 8 could contain carbon monoxide can be drawn into living space resulting in personal injury or death Installation Setting Equipment AWARNING Do not install the furnace on its front back or in the horizontal position See figure 10 Do not connect the return air ducts to the back of the furnace Doing so will adversely affect the operation of the safety con trol devices which could result in personal injury or death SETTING EQUIPMENT AIR FLOW AIR FLOW Select a location that allows for the required clearances that are listed on the unit nameplate Also consider gas supply connections elec
63. icensed professional installer or equivalent service agency or the gas supplier Table of Contents Page 1 Vent Piping Guidelines 15 Gas PIPING cde eere ke ee ee 30 Electrical ice cese e mee Ras 32 Unit Start Up eere eta e ERE RE Rv 36 Gas Pressure Measurement 38 Proper Combustion 38 High Altitude 38 Testing Non Direct Appliances for Proper Air 39 Other Unit Adjustments 40 Blower Motor 41 NIE 42 Planned Service 44 Integrated Control Diagnostic Codes 44 Troubleshooting 45 Repair Parts List 49 Start Up Checklist 50 506475 01 ML193DF Unit Dimensions inches mm COMBUSTION AIR INTAKE RETURN AIR EXHAUST AIR OPENING OUTLET t 9 16 14 TOP VIEW A 27 3 4 Front Panel 705 B 19 7 16 9 16 494 14 AIR FLOW i ELECTRICAL INLET om Either Side a 2 51 Either Side CONDENSATE EE Sur cds TRAP CONNECTION Gj Either Side 9 1 8 232 Right 6 9 16 167 Left 6 1 2 165 Either Side Suppl L 19 1 4 Supply P 489 Air FRONT VIEW SIDE VIEW
64. impinge on the building materials a corrosion resistant shield 24 inches square should be used to protect the wall surface If optional tee is used the protective shield is recom mended The shield should be constructed using wood sheet metal or other suitable material All seams joints cracks etc in affected area should be sealed using an appropriate sealant 3Exhaust pipe 45 elbow can be rotated to the side away from the combustion air inlet to direct exhaust away from adjacent property The exhaust must never be directed toward the combustion air inlet FIGURE 27 Page 22 FIELD SUPPLIED WALL TERMINATION OR 15F74 WALL RING TERMINATION KIT NOTE FIELD PROVIDED REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION 1 2 13mm ARMAFLEX INSULATION IN UN CONDITIONED SPACE SIZE TERMINATION PER TABLE 8 STRAIGHT APPPLICATION 1 2 13mm ARMAFLEX INSULATION IN UNCONDITIONED SPACE WALL SUPPORT EXTENDED APPLICATION See venting table 7 for maximum venting lengths with this arrangement Use wall support every 24 610 mm Use two wall supports if extension is greater than 24 610 mm but less than 48 1219 mm NOTE One wall support must be 6 152 mm from top of each pipe intake and exhaust 3 76mm 2 51mm Vent Pipe Vent Pipe A Minimum clearance above grade or average 12 508MM 12 508MM snow accumulation B Maximum horizontal separation between 6 152MM 6 152MM
65. ing unit Use papers or protective covering in front of fur nace while removing heat exchanger assembly 1 Turn off electrical and gas supplies to the furnace 2 Remove the furnace access panels 3 Disconnect the 2 wires from the gas valve 4 Remove gas supply line connected to gas valve Re move gas valve manifold assembly 5 Remove sensor wire from sensor Disconnect 2 pin plug from the ignitor 6 Disconnect wires from flame roll out switches 7 Loosen clamps at vent elbow Disconnect condensate drain tubing from flue collar and remove the vent el bow 8 Remove four burner box screws at the vestibule panel and remove burner box Set burner box assembly aside NOTE If necessary clean burners at this time Follow procedures outlined in Burner Cleaning section 9 Mark and disconnect all combustion air pressure tub ing from cold end header collector box 10 Mark and remove wires from pressure switches Re move pressure switches Keep tubing attached to pressure switches Disconnect the plug from the combustion air inducer Remove two screws which secure combustion air in ducer to collector box Remove combustion air induc er assembly Remove ground wire from vest panel 12 Remove electrical junction box from the side of the fur nace 13 Mark and disconnect any remaining wiring to heating compartment components Disengage strain relief bushing and pull wiring and bushing through the hole in the blow
66. kage 1 of 1 contains 1 Assembled ML193DF unit 1 Bag assembly containing the following 3 Wire nuts 1 Snap bushing 1 Snap plug 1 Wire tie 1 Condensate trap 1 Condensate trap cap 1 Condensate trap clamp 1 2 diameter Air intake screen A DANGER Danger explosion There are circumstances in which odorant used with LP propane gas can lose its scent In case of a leak LP propane gas will settle close to the floor and may be difficult to smell An LP propane leak detector should be installed in all LP applications Check equipment for shipping damage If you find any damage immediately contact the last carrier The following items may also be ordered separately 1 Thermostat 1 Propane LP changeover kit Safety Information AWARNING 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 A CAUTION As with any mechanical equipment personal injury can result from contact with sharp sheet metal edges Be careful when you handle this equipment Use only the type of gas approved for use with this furnace Refer to unit nameplate ML193DF units are CSA International certified to ANSI Z21 47 and CSA 2 3 standards Building Codes In the USA installation of gas furnaces must conform with lo
67. llings and serves both dwellings t 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 23 Page 19 6 feet 1 8m 7 feet 2 1m T 12 inches 305mm t For clearances not specified in ANSI Z223 1 NFPA 54 or CSA B149 1 clearance will be in accordance with local installation codes and the re quirements of the gas supplier and these installation instructions VENT TERMINATION CLEARANCES FOR DIRECT VENT INSTALLATIONS IN THE USA AND CANADA INSIDE CORNER DETAIL x AREA WHERE TERMINAL IS NOT PERMITTED G9 AIR SUPPLY INLET VENT TERMINAL Canadian Installations 12 inches 305mm or 12 in 305mm above average snow accumulation US Installations 12 inches 305mm or 12 in 305mm above average snow accumulation Clearance above grade veranda porch deck or balcony Clearance to window or door that may be opened 6 inches 152mm for appliances 10 000 6 inches 152mm for appliances 10 000 Btuh 3kw 9 inches mm for appliances Btuh 3kw 12 inches 305mm for gt 10 000 Btuh 3kw and 50 000 Btuh appliances gt 10 000 Btuh 3kw and 15 kw 12 inches 305mm for ap 100 000 Btuh 30kw 36 inches 9m pliances gt 50 000 Btuh 15kw for appliances gt 100 000 Btuh 30kw Clearance to permanently 12 12 closed window Vertical clearance to ventilated soffit located abo
68. m 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 ML193DF with Evaporator Coil CONDENSATE TRAP LOCATION shown with right side exit of condensation Field Provided Vent min 1 Above Condensate Drain FIGURE 44 Trap can be installed a maximum of 5 ft from furnace PVC Only A CAUTION Do not use copper tubing or existing copper condensate lines for drain line A CAUTION A separate drain line must be run to the drain from the condensate trap to ensure proper drainage and pressure switch operation DO NOT connect the condensate trap drain into the FIGURE 43 drain line from the evaporator coil to drain Piping from furnace must slope down a minimum of 1 4 per ft toward trap Page 28 TRAP DRAIN ASSEMBLY USING 1 2 PVC OR 3 4 PVC OPTIONAL Condensate Drain Connection Adapter 1 2 inch slip X Adapter 1 2 inch slip X 1 2 inch mpt EN Furnished Vent 90 Street Elbow 1 2 inch PVC Not Furnished 1 25 Minimum 90 Elbow 1 2 inch PV Condensate Drain Not Furnished Connection In Unit 1 2 inch PVC OPTIONAL Drain Piping Not Furnished Drain Assembly for 1 2 inch Drain Pipe 1 2 inch PVC Pipe Above Top of Condensate Drain Connection In Unit 1 2 inch mpt Not Furnished Condensate Drain Connection In Unit 5 Feet Maximum
69. nditioned Space REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION DIRECT VENT WALL TERMINATION KIT 30G28 or 81J20 FIGURE 33 EXHAUST VENT SIZE TERMINATION O O PIPE PER INTAKE TABLE 8 AIR Front View Top View 1 2 13mm Foam Insulation in Unconditioned Space REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION 8 206mm MIN OUTSIDE WALL DIRECT VENT WALL TERMINATION KIT 22G44 or 44J40 FIGURE 34 Page 24 WALL TERMINATION KITS CLOSE COUPLE EXTENDED VENT FOR GRADE CLEARANCE 2 inch 61 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 FIELD PROVIDED REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION 203 mm Min for 2 51 mm amp 3 76 mm DIA pipe between the end of the exhaust pipe and intake pipe WALL SUPPORT 305 mm Max for 2 51 mm Dia Exhaust cds mm Max for 3 76 mm Dia Exhaust EXHAUST 1 2 13 6 1 mm Maximum FOAM INSULATION Field Furnished INTAKE INTAKE AIR EXHAUST AIR 2 305 mm Minimum 12 305 mm Minimum 8 203 mm Min Above Grade or Average Above Grade or Average Snow Accumulation Snow Accumulation IU SPNO 77 GRADE 305 mm Max for 2 51 mm Dia Exhaust Use wall support ever
70. ng Unit Installed Parallell to Air Handler Unit GAS UNIT AIR HANDLER Dampers open during cooling operation only Dampers open during heating operation only FIGURE 3 NOTE This furnace is designed for a minimum continu ous return air temperature of 60 F 16 C or an intermit Page 5 tent operation down to 55 F 13 C dry bulb for cases where a night setback thermostat is used Return air tem perature must not exceed 85 F 29 C dry bulb The ML193DF furnace may be installed in alcoves closets attics basements garages utility rooms and crawl spaces This furnace design has not been CSA certified for installa tion in mobile homes recreational vehicles or outdoors Never use an open flame to test for gas leaks Check all connections using a commercially available soap solution made specifically for leak detection Use of Furnace as Construction Heater Lennox does not recommend the use of ML193DF units as a construction heater during any phase of construction Very low return air temperatures harmful vapors and op eration of the unit with clogged or misplaced filters will dam age the unit ML193DF units may be used for heating of buildings or structures under construction if the following conditions are met The vent system must be permanently installed per these installation instructions e A room thermostat must control the furnace The use of fixed jumpers that will provide continuous heatin
71. nsitioning up in pipe size use the shortest length of 2 PVC pipe possible NOTE Intake pipe and exhaust pipe must be the same diameter Page 17 Intake Piping The ML193DF furnace may be installed in either direct 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 Guidelines listed in Combustion Dilution and Ventilation Air section must be followed Follow the next two steps when installing the unit in Direct Vent applications where combustion air is taken from outdoors and flue gases are discharged outdoors The provided air intake screen must not be used in direct vent applications outdoors 1 Use cement to secure the intake pipe to the inlet air connector 2 Route piping to outside of structure Continue with installation following instructions given in general guide lines for piping terminations and intake and ex haust piping terminations for direct vent sections Re fer to table 7 for pipe sizes TYPICAL AIR INTAKE PIPE CONNECTIONS NON DIRECT VENT APPLICATIONS y AIR INTAKE SCREEN Provided DIS 5 i i CHEER i WS NOTE Air intake screen and elbow be rotated so that screen may be positioned to face forward or to either side FIGURE 22 Follow the next two steps when installing the unit
72. ntain protective coatings over building materials prolonged exposure to exhaust condensate can destroy protective coatings It is recommended that the exhaust outlet not be located within 6 feet 1 8m of a condensing unit because the condensate can damage the painted coating NOTE If winter design temperature is below 32 F 0 C exhaust piping should be insulated with 1 2 13mm Ar maflex or equivalent when run through unheated space Do not leave any surface area of exhaust pipe open to out side air exterior exhaust pipe should be insulated with 1 2 13mm Armaflex or equivalent In extreme cold cli mate areas 3 4 19mm Armaflex or equivalent may be necessary Insulation on outside runs of exhaust pipe must be painted or wrapped to protect insulation from de terioration Exhaust pipe insulation may not be necessary in some specific applications NOTE During extremely cold temperatures below approximately 20 F 6 7 C units with long runs of vent pipe through unconditioned space even when insulated may form ice in the exhaust termination that prevents the unit from operating properly Longer run times of at least 5 minutes will alleviate most icing problems Also a heating cable may be installed on exhaust piping and termination to prevent freeze ups Heating cable installation kit is available from Lennox See Condensate Piping section for part numbers IMPORTANT Do not use screens or perforated metal in exhau
73. nto opening 3 In all cases plenum should be secured to top of fur 3 Check fiberglass strips on the combustible flooring base to make sure they are properly glued and posi 4 Make certain that an adequate seal is made tioned PLENUM 4 Lower supply air plenum into the combustible flooring Field Provided 5 base until plenum flanges seal against fiberglass SUSIE SABINET strips NOTE Be careful not to damage fiberglass strips CABINET Check for a tight seal voee disi SIDE PANEL le rovide 5 Set the furnace over the plenum Side View 6 Ensure that the seal between the furnace and plenum is adequate FIGURE 15 Installation on Cooling Coil Cabinet Figure 14 PLENUM NOTE Downflow combustible flooring kit is not used Field Provided SEALING STRIP Field Provided 1 Refer to reverse flow coil installation instructions for correctly sized opening in floor and installation of cabi net CABINET SECURE FROM SIDE PANEL INSIDE CABINET Side View 2 When cooling cabinet is in place set and secure the furnace according to the instructions that are provided with the cooling coil Secure the furnace to the cabinet 3 Seal the cabinet and check for air leaks FIGURE 16 Page 11 This unit is not equipped with a filter or rack A field pro vided filter is required for the unit to operate properly Table 3 lists recommended filter size A filter must be in place whenever the uni
74. on home make provisions for draining conden sate collection trap and lines Exhaust Piping Figures 20 and 21 Route piping to outside of structure Continue with installa tion following instructions given in piping termination sec tion A CAUTION Do not discharge exhaust into an existing stack or stack that also serves another gas appliance If verti cal discharge through an existing unused stack is re quired insert PVC pipe inside the stack until the end is even with the top or outlet end of the metal stack A CAUTION The exhaust vent pipe operates under positive pres sure and must be completely sealed to prevent leak age of combustion products into the living space Vent Piping Guidelines The ML193DF 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 taken from indoors and flue gases are discharged outdoors In Direct Vent installations combustion air is taken from out doors and flue gases are discharged outdoors Intake and exhaust pipe sizing Size pipe according to tables 6 and 7 Table 6 lists the minimum vent pipe lengths permitted Table 7 lists the maximum pipe lengths per mitted TABLE 6 MINIMUM VENT PIPE LENGTHS ML193DF MODEL MIN VENT LENGTH 15 ft or 045 070 090 110 5 ft plus 2 elbows or 10 ft plus 1 elbow Any approved termination may be added to the minimum length listed Regardless of t
75. ous fan SIMULTANEOUS SIMULTANEOUS Normal operation signaled when heating demand initiated at thermostat SLOW FLASH FLASH ow raa v limit switch open Limit must close within 3 minutes or unit goes into 1 Watchguard Pressure prove switch open SLOW FLASH OR Blocked inlet exhaust vent OR Pressure switch closed prior to activation of combustion air inducer ALTERNATING ALTERNATING Watchguard 1 hour burners failed to ignite or lost flame 5 times during single SLOW FLASH SLOW FLASH heating demand SLOW FLASH Flame sensed without gas valve energized 9N SLOW FLASH Rollout switch open OR 12 pin connector improperly attached ON ON ON OFF Circuit board failure or control wired incorrectly OFF ON FAST FLASH SLOW FLASH Main power polarity reversed Switch line and neutral SLOW FLASH FAST FLASH Low flame Low flame signal Measures below 1 5 microamps Replace flame sense rod Measures below 1 5 Low flame signal Measures below 1 5 microamps Replace flame sense rod Replace flame sense rod ALTERNATING ALTERNATING Improper main ground FAST FLASH FAST FLASH OR Line voltage below 90 volts NOTE Slow flash rate equals 1 Hz one flash per second Fast flash rate equals 3 Hz three flashes per second Minimum flame sense current 0 5 microAmps Page 44 Troubleshooting Heating Sequence of Operation HEATING SEQUENCE OF OPERATION NORMAL HEATING MODE ABNORMAL HEATING MODE GAS VALVE OFF COMBUSTIO
76. pipe must be sized as listed in table 8 The specified pipe size ensures proper veloc ity required to move the exhaust gases away from the FIGURE 39 building 3 If exhaust piping must be run up a side wall to position me above snow accumulation or other obstructions pip 2 On field supplied terminations for side wall exit ex ing must be supported every 24 inches 610mm as haust piping may extend a maximum of 12 inches shown in figure 40 When exhaust piping must be run 305mm for 2 PVC and 20 inches 508mm for 3 up an outside wall any reduction in exhaust pipe size 76mm PVC beyond the outside wall See figure 39 must be done after the final elbow Page 26 UNCONDITIONED SPACE WALL SUPPORT OUTSIDE WALL FIELD PROVIDED REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION MN SSSSSSSS NL SSSSSSSNVSRSSSI zZZZZZZZz rh d 12 305mm MAX for 2 b1mm 20 508mm MAX igre 76mm SIZE TER MINATION PIPE PER TABLE 8 SSSSSSS SNS SSE SQ 12 305mm ABOVE GRADE OR AVERAGE SNOW ACCUMULATION 01 SS 277722212 1022222 1 2 13mm FOAM INSULATION IN UNCONDITIONED SPACE 1 2 13mm FOAM INSULATION Use wall support every 24 610 Use two supports if extension is greater than 24 but less than 48 NON DIRECT VENT FIELD SUPPLIED WALL TERMINATION EX TENDED OR 15F74 WALL TERMINATION VENT PIPE EXTENDED FIGURE 40
77. r provided on 71M80 amp 44W92 kits for MLT93DF045P36B amp 070P36B a gt _ FLASHING Not Furnished 12 305mm Minimum Above Average Snow Accumulation SHEET METAL STRAP Clamp and sheet metal strap must be field installed to support the weight of the termination kit FIELD PROVIDED REDUCER MAY BE REQUIRED bJ bJ TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION DIRECT VENT CONCENTRIC ROOFTOP TERMINATION 71M80 69M29 or 60L46 US 41W92 or 41W93 Canada FIGURE 30 1 1 2 38mm accelerator FIELD PROVIDED provided on 71M80 amp 44W92 kits for REDUCER MAY BE REQUIRED TO ADAPT 4 ML193DF045P36B amp LARGER VENT PIPE 070P36B SIZE TO TERMINATION DE EXHAUST 2 305mm Min above grade or average snow ac cumulation GRADE DIRECT VENT CONCENTRIC WALL TERMINATION 71M80 69M29 or 60L46 US 41W92 or 41W93 Canada FIGURE 31 EXHAUST gt VENT s 127mm INTAKE TAKES A EA E EA CD AST Front View EXHAUST VENT y 12 305mm Min poc above grade or average snow ac Inches 777277 INTAKE cumulation v AIR Side View OPTIONAL VENT TERMINATION FOR MULTIPLE UNIT INSTALLATION OF DIRECT VENT WALL TERMINATION KIT 22644 44J40 30628 or 81J20 FIGURE 32 optional intake elbow EXHAUST VENT SIZE TERMINATION PIPE PER id TABLE 8 AIR Front View Top View 1 2 13mm Foam Insulation in Unco
78. re manifold pres sure 2 Start unit and allow 5 minutes for unit to reach steady state 3 While waiting for the unit to stabilize notice the flame Flame should be stable and should not lift from burner Natural gas should burn blue 4 After allowing unit to stabilize for 5 minutes record manifold pressure and compare to value given in table 12 NOTE Shut unit off and remove manometer as soon as an accurate reading has been obtained Take care to remove barbed fitting and replace threaded plug Proper Combustion Furnace should operate minimum 15 minutes with correct manifold pressure and gas flow rate before checking com bustion Take combustion sample beyond the flue outlet and compare to the tables below The maximum carbon monoxide reading should not exceed 50 ppm TABLE 13 ML193 High Altitude Information NOTE In Canada certification for installations at eleva tions over 4500 feet 1372 m is the jurisdiction of local au thorities ML193DF units require no manifold pressure adjustments for operation at altitudes up to 10 000 feet 3048 m above sea level Units installed at altitude of 4501 10 000 feet 1373 to 3048m require a pressure switch change which can be ordered separately Table 14 lists conversion kit and pressure switch requirements at varying altitudes The combustion air pressure switch is factory set and re quires no adjustment NOTE A natural to LP propane gas changeover kit is nec es
79. reaker 5 Is the filter dirty or plugged Dirty or plugged filters will cause the limit control to shut the unit off 6 Is gas turned on at the meter 7 Is the manual main shut off valve open 8 Is the internal manual shut off valve open 9 Is the unit ignition system in lockout If the unit locks out again inspect the unit for blockages Heating Sequence Of Operation 1 When thermostat calls for heat combustion air inducer starts 2 Combustion air pressure switch proves blower opera tion Switch is factory set and requires no adjustment 3 After a 15 second prepurge the hot surface ignitor en ergizes 4 After a 20 second ignitor warm up period the gas valve solenoid opens A 4 second Trial for Ignition peri od begins 5 Gasis ignited flame sensor proves the flame and the combustion process continues 6 If flame is not detected after first ignition trial the igni tion control will repeat steps 3 and 4 four more times before locking out the gas valve WATCHGUARD flame failure mode The ignition control will then auto matically repeat steps 1 through 6 after 60 minutes To interrupt the 60 minute WATCHGUARD period move thermostat from Heat to OFF then back to Heat Heating sequence then restarts at step 1 Page 37 Gas Pressure Adjustment Gas Flow Approximate TABLE 11 GAS METER CLOCKING CHART Seconds for One Revolution Natural J P Unit 2 cu f
80. ring diagram and troubleshooting The power supply wiring must meet Class restrictions Protected by either a fuse or circuit breaker select circuit protection and wire size according to unit nameplate NOTE Unit nameplate states maximum current draw Maximum Over Current Protection allowed is 15 AMP Holes are on both sides of the furnace cabinet to facilitate wiring Install a separate properly sized disconnect switch near the furnace so that power can be turned off for servicing Before connecting the thermostat or the power wiring check to make sure the wires will be long enough for servic ing at a later date Remove the blower access panel to check the length of the wire Page 33 Complete the wiring connections to the equipment Use the provided unit wiring diagram and the field wiring diagram shown in figure 51 Use 18 gauge wire or larger that is suit able for Class II rating for thermostat connections Electrically ground the unit according to local codes or in the absence of local codes according to the current Na tional Electric Code ANSI NFPA No 70 for the USA and current 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 ML193DF furnace contains electronic compo nents that are polarity sensitive Make sure that the furnace is wired correctly and is properly grounded Generator Use Voltage Requirements The following requirements m
81. rners Must be inspected for rust dirt or signs of water Vent pipe Must be inspected for signs of water cracked damaged or sagging pipe or disconnected joints Unit appearance Must be inspected for rust dirt signs of water burnt or damaged wires or components Blower access door Must be properly in place and pro vide a seal between the return air and the room where the furnace is installed Return air duct Must be properly attached and provide an air seal to the unit Operating performance Unit must be observed during operation to monitor proper performance of the unit and the vent system Combustion gases Flue products must be analyzed and compared to the unit specifications Problems detected during the inspection may make it nec essary to temporarily shut down the furnace until the items can be repaired or replaced Instruct the homeowners to pay attention to their furnace Situations can arise between annual furnace in spections that may result in unsafe operation For instance items innocently stored next to the furnace may obstruct the combustion air supply This could cause incomplete combustion and the production of carbon monoxide gas Ignition Control Board Diagnostic Codes DIAGNOSTIC CODES Make sure to Identify LED S Correctly LED 1 Red LED 2 Green DESCRIPTION SIMULTANEOUS SIMULTANEOUS Power on Normal operation SLOW FLASH SLOW FLASH Also signaled during cooling and continu
82. s connect 2 pin plug from the ignitor at the burner box 6 Remove four screws which secure burner box assem bly to vest panel Remove burner box from the unit 7 Use the soft brush attachment on a vacuum cleaner to gently clean the face of the burners Visually inspect the inside of the burners and crossovers for any block age caused by foreign matter Remove any blockage 8 Reconnect the sensor wire and reconnect the 2 pin plug to the ignitor wiring harness 9 Reinstall the burner box assembly using the existing four screws Make sure that the burners line up in the center of the burner ports 10 Reinstall the gas valve manifold assembly Reconnect the gas supply line to the gas valve Reinstall the burn er box cover 11 Reconnect 2 pin plug to gas valve 12 Replace the blower compartment access panel 13 Refer to instruction on verifying gas and electrical con nections when re establishing supplies 14 Follow lighting instructions to light and operate fur nace for 5 minutes to ensure that heat exchanger is clean and dry and that furnace is operating properly 15 Replace heating compartment access panel Planned Service A service technician should check the following items dur ing an annual inspection Power to the unit must be shut off for safety Fresh air grilles and louvers on the unit and in the room where the furnace is installed Must be open and unob structed to provide combustion air Bu
83. sary to convert this unit Refer to the changeover kit installation instruction for the conversion procedure 8 6 9 3 Page 38 TABLE 14 Conversion Kit and Pressure Switch Requirements at Varying Altitudes High Altitude Natural Burner Orifice Kit Natural to LP Propane 0 7500 ft 0 2286m 7501 10 000 ft 2286 3038m LP Propane to Natural 0 7500 ft 0 2286m High Altitude LP Propane Burner Orifice Kit High Altitude Pressure Switch 4501 7500 7501 10 000 7501 10 000 ft ft ft 2286 3038m 1373 2286 2286m 3048m 0 69W73 73W37 73W81 68 W68 74W90 74W91 10 Conversion requires installation of a gas valve manifold spring which is provided with the gas conversion kit Pressure switch is factory set No adjustment necessary All models use the factory installed pressure switch from 0 4500 feet 0 1370 m Testing of Non Direct Vent Applications for Proper Venting and Sufficient Combustion Air A WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monox ide poisoning or death The following steps shall be followed for each ap pliance connected to the venting system being placed into operation while all other appliances con nected to the venting system are not in operation After the ML193DF gas furnace has been started the fol
84. st terminations Doing so will cause freeze ups and may block the terminations IMPORTANT For Canadian Installations Only In accordance to CSA International B149 installation codes the minimum allowed distance between the combustion air intake inlet and the exhaust outlet of other appliances shall not be less than 12 inches 305mm Page 18 VENT TERMINATION CLEARANCES FOR NON DIRECT VENT INSTALLATIONS IN THE USA AND CANADA VENT TERMINAL Clearance above grade veranda porch deck or balcony Clearance to window or door that may be opened Clearance to permanently closed window Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet mm from the center line of the terminal Clearance to unventilated soffit Clearance to outside corner Clearance to inside corner Clearance to each side of center line ex tended above meter regulator assembly Clearance to service regulator vent outlet Clearance to non mechanical air supply inlet to building or the com bustion air inlet to any other ap pliance INSIDE CORNER DETAIL G9 AIR SUPPLY INLET US Installations 12 inches 305mm or 12 in 305mm above average snow accumulation 4 feet 1 2 m below or to side of opening 1 foot 30 cm above opening 12 Equal to or greater than soffit depth Equal to or greater than soffit depth No minimum to outside corner AREA WHERE TERMINAL
85. stion Dilution amp Ventilation Air If the ML193DF is installed as a Non Direct Vent Fur nace follow the guidelines in this section NOTE In Non Direct Vent installations combustion air is taken from indoors and flue gases are discharged out doors A WARNING Insufficient combustion air can cause headaches nausea dizziness or asphyxiation It will also cause excess water in the heat exchanger resulting in rust ing and premature heat exchanger failure Excessive exposure to contaminated combustion air will result in safety and performance related problems Avoid exposure to the following substances in the com bustion air supply Permanent wave solutions Chlorinated waxes and cleaners Chlorine base swimming pool chemicals Water softening chemicals De icing salts or chemicals Carbon tetrachloride Halogen type refrigerants Cleaning solvents such as perchloroethylene Printing inks paint removers varnishes etc Hydrochloric acid Cements and glues Antistatic fabric softeners for clothes dryers Masonry acid washing materials In the past there was no problem in bringing in sufficient outdoor air for combustion Infiltration provided all the air that was needed In today s homes tight construction practices make it necessary to bring in air from outside for combustion Take into account that exhaust fans ap pliance vents chimneys and fireplaces force additional air that could be used for combustion
86. t DIAL 80 160 200 400 90 21 8 2 204 82 e Natural 1000 btu cu ft LP 2500 btu cu ft NOTE To obtain accurate reading shut off all other gas appliances connected to meter Furnace should operate at least 5 minutes before check ing gas flow Determine time in seconds for two revolu tions of gas through the meter Two revolutions assures a more accurate time Divide by two and compare to time in table 11 If manifold pressure matches table 12 and rate is incorrect check gas orifices for proper size and restric tion Remove temporary gas meter if installed Supply Pressure Measurement A threaded plug on the inlet side of the gas valve provides access to the supply pressure tap Remove the threaded plug install a field provided barbed fitting and connect a manometer to measure supply pressure See table 12 for proper supply line pressure Replace the threaded plug af ter measurements have been taken TABLE 12 Manifold and Supply Pressure Outlet inches w c Model Fuel Input Sizes Supply Manifold Pressure in wg Pressure in wg NOTE A natural to L P propane gas changeover kit is nec essary to convert this unit Refer to the changeover kit installation instruction for the conversion procedure Manifold Pressure Measurement 1 Remove the threaded plug from the outlet side of the gas valve and install a field provided barbed fitting Connect to a manometer to measu
87. t is operating TABLE 3 Cabinet Width 16 x 25 x 1 1 17 1 2 Duct System Use industry approved standards to size and install the supply and return air duct system Refer to ACCA Manual D This will result in a quiet and low static system that has uniform air distribution NOTE This furnace is not certified for operation in heating mode indoor blower operating at selected heating speed with an external static pressure which exceeds 0 5 inches w c Operation at these conditions may result in improper limit operation Supply Air Plenum If the furnace is installed without a cooling coil a removable access panel should be installed in the supply air duct The access panel should be large enough to permit inspection of the heat exchanger The furnace access panel must al ways be in place when the furnace is operating and it must not allow leaks into the supply air duct system Return Air Plenum NOTE Return air must not be drawn from a room where this furnace or any other gas fueled appliance i e water heater or carbon monoxide producing de vice i e wood fireplace is installed When return air is drawn from a room a negative pres sure is created in the room If a gas appliance is operating in a room with negative pressure the flue products can be pulled back down the vent pipe and into the room This reverse flow of the flue gas may result in incomplete com bustion and the formation of carbon monoxide
88. t to manually light burners on this furnace Each time the thermostat calls for heat the burners will automatically light The ignitor does not get hot when there is no call for heat on these units Priming Condensate Trap The condensate trap should be primed with water prior to start up to ensure proper condensate drainage Either pour 10 fl oz 300 ml of water into the trap or follow these steps to prime the trap 1 Follow the lighting instructions to place the unit into op eration 2 Setthe thermostat to initiate a heating demand 3 Allow the burners to fire for approximately 3 minutes 4 Adjust the thermostat to deactivate the heating de mand Wait for the combustion air inducer to stop Set the thermostat to initiate a heating demand and again al low the burners to fire for approximately 3 minutes 6 Adjust the thermostat to deactivate the heating de mand and wait for the combustion air inducer to stop At this point the trap should be primed with sufficient water to ensure proper condensate drain operation AWARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or death Gas Valve Operation Figure 54 1 STOP Read the safety information at the beginning of this section 2 Setthe thermostat to the lowest setting 3 Turn off all electrical power to the unit 4 This furnace is equipped with an ignition devic
89. terial All seams joints cracks etc in the affected area should be sealed using an appropriate sealant See figure 27 Intake and exhaust pipes may be routed either horizontally through an outside wall or vertically through the roof In attic or closet installations vertical termination through the roof is preferred Figures 25 through 37 show typical termina tions 1 Exhaust and intake exits must be in same pressure zone Do not exit one through the roof and one on the side Also do not exit the intake on one side and the exhaust on another side of the house or structure 2 Intake and exhaust pipes should be placed as close together as possible at termination end refer to il lustrations Maximum separation is 3 76mm on roof terminations and 6 152mm on side wall termina tions On roof terminations the intake piping should termi nate straight down using two 90 elbows See figure 25 4 Exhaust piping must terminate straight out or up as shown A reducer may be required on the exhaust pip ing at the point where it exits the structure to improve the velocity of exhaust away from the intake piping See table 8 TABLE 8 EXHAUST PIPE TERMINATION SIZE REDUCTION ML193 Termination MODEL Exhaust Pipe Size Pipe Size 045 and 070 am 2 1 2 64mm 1 ue 38mm 090 1 m ML193DF 045 070 and 090 units with the flush mount termination must use the 1 1 2 accelerator supplied with the kit 5
90. termination kits must be extended for use in this application See figures 35 and 36 When exhaust and intake piping must be run up an outside wall the exhaust piping must be terminated with pipe sized per table 8 The intake piping may be equipped with a 90 elbow turndown Using turndown will add 5 feet 1 5m to the equivalent length of the pipe A multiple furnace installation may use a group of up to four terminations assembled together horizontally as shown in figure 32 Front View of Intake and Exhaust Exhaust 2 pt Intake Exhaust TABLE 9 Vent Pipe Vent Pipe A Clearance above grade or average snow 12 508MM Min accumulation B Horizontal 152MM Min 6 152MM Min separation between 610 MM Max 24 610 MM Max intake and exhaust C Minimum from end of exhaust to 9 227MM Min 9 227MM Min inlet of intake 12 305MM Min 12 305MM Min D Exhaust pipe length pips eng 16 405 MM Max 20 508MM Max E Wall support distance from top of each pipe 6 152MM Max 6 152MM Max intake exhaust 1 The exhaust termination tee should be connected to the 2 or 3 PVC flue pipe as shown in the illustration Do not use an accelerator in applications that include an exhaust termination tee The accelerator is not required 2 As required Flue gas may be acidic and may adversely affect some building materials If a side wall vent termination is used and flue gases will
91. trical supply vent connection condensate trap and drain connections and installation FRONT VIEW SIDE VIEW SIDE VIEW and service clearances 24 inches 61 0 mm at unit Unit must be level side to side Unit may be positioned from level to 1 2 toward the front to aid in draining front The unit must be level from side to side Unit may be positioned from level to 1 2 toward the front to aid in FIGURE 9 draining See figure 9 NOTE Do not install the furnace on its front back or in the horizontal position FIGURE 10 Page 9 WARNING Improper installation of the furnace can result in per sonal injury or death Combustion and flue products must never be allowed to enter the return air system or air in the living space Use sheet metal screws and joint tape to seal return air system to furnace In platform installations with furnace return the fur nace should be sealed airtight to the return air ple must never be used as portion of return air duct system The base must provide a stable support and an airtight seal to the furnace Al low absolutely no sagging cracks gaps etc For no reason should return and supply air duct sys tems ever be connected to or from other heating de vices such as a fireplace or stove etc Fire explo sion carbon monoxide poisoning personal injury and or property damage could result The unit may be installed three ways in downflow applica
92. ust be kept in mind when specifying a generator for use with this equipment e The furnace requires 120 volts 10 Range 108 volts to 132 volts e The furnace operates at 60 Hz 5 Range 57 Hz to 63 Hz e The furnace integrated control requires both polarity and proper ground Both polarity and proper grounding should be checked before attempting to operate the furnace on either permanent or temporary power e Generator should have a wave form distortion of less than 5 RHD Accessory Terminals One line voltage EAC 1 4 spade terminal is provided on the furnace integrated control See figure 53 for integrated control configuration This terminal is energized when the indoor blower is operating Any accessory rated up to one amp can be connected to this terminal with the neutral leg of the circuit being connected to one of the provided neutral terminals If an accessory rated at greater than one amp is connected to this terminal it is necessary to use an exter nal relay One line voltage 1 4 spade terminal is provided on the furnace integrated control See figure 53 for integrated control configuration This terminal is energized in the heating mode when the combustion air inducer is operat ing Any humidifier rated up to one amp can be connected to this terminal with the neutral leg of the circuit being con nected to one of the provided neutral terminals If a humidi fier rated at greater than one amp is
93. ve the terminal within a horizontal distance of 2 feet mm from the center line of the terminal Equal to or greater than soffit depth Equal to or greater than soffit depth Clearance to unventilated soffit Equal to or greater than soffit depth No minimum to outside corner Equal to or greater than soffit depth Clearance to outside corner No minimum to outside corner Clearance to inside corner 3 feet 9m within a height 15 feet 4 5m feet 9m within a height 15 feet 4 5m above the meter regulator assembly above the meter regulator assembly 8 feet 9m 3 feet 9m Clearance to each side of center line ex tended above meter regulator assembly Clearance to service regulator vent outlet Clearance to non mechanical air supply inlet to building or the com bustion air inlet to any other ap pliance Clearance to mechanical air sup ply inlet Clearance above paved sidewalk or 6 inches 152mm for appliances 10 000 6 inches 152mm for appliances 10 000 Btuh 3kw 9 inches mm for appliances Btuh 3kw 12 inches 305mm for gt 10 000 Btuh 3kw and 50 000 Btuh appliances gt 10 000 Btuh 3kw and 15 kw 12 inches 305mm for ap lt 100 000 Btuh 30kw 36 inches 9m liances gt 50 000 Btuh 15kw for appliances gt 100 000 Btuh 30kw 3 feet 9m above if within 10 feet 6 feet 1 8m 3m horizontally 7 feet 2 1 7 feet 2 1 paved driveway located on public property
94. y 24 610 Use two supports if 508 mm Max for 3 76 mm Dia Exhaust extension is greater than 24 but less than 48 FIGURE 35 WALL TERMINATION KITS CLOSE COUPLE EXTENDED VENT FOR GRADE CLEARANCE 2 inch 61 mm 30G28 WTK Canada 3 inch 76 mm 81J20 WTK Canada See Installation Instructions for additional information If intake and exhause pipe is less than 12 in 305 mm above snow accumulation or other obstructions field REDUCER A EE REQUIRED TOADABT fabricated piping must be installed piping LARGER VENT PIPE SIZE TO TERMINATION WALL SUPPORT 12 305 mm Max for 2 51 mm Dia Exhaust 20 508 mm Max for 3 76 mm Dia Exhaust EXHAUST 6 152 mm AIR Maximum 152 mm INTAKE 6 152 mm 2 305 mm Minimum T 805 mm Minimum Minimum Above Grade or Average Above Grade or Average now Accumulation Snow Accumulation p PAE SPN 12 305 mm Max for 2 51 mm Dia Exhaust Use wall support every 24 610 Use two supports if 20 508 mm Max for 3 76 mm Dia Exhaust extension is greater than 24 but less than 48 FIGURE 36 Page 25 ML193DF DIRECT VENT APPLICATION USING EXISTING CHIMNEY 4G cot IN DIRECTION OF ROOF SLOPE SIZE TERMINATION PIPE PER TABLE 8 12 305mm ABOVE AVE SNOW 1 2 13mm FOAM ACCUMULATION INSULATION 8 12 8 EXHAUST VENT 203mm 305mm WEATHERPROOF INSULATION Minimum 12 305MM INTAKE PIPE SHOULDER OF

Lennox International Inc. MERIT SERIES GAS FURNACE DOWNFLOW AIR DISCHARGE Electric Heater User Manual

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