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Lennox International Inc. ML193UH Gas Heater User Manual

1. rap at coil is optional Drain Pan Piping from furnace and evaporator coil must slope down a minimum 1 4 per ft toward trap FIGURE 53 Page 32 TRAP DRAIN ASSEMBLY USING 1 2 PVC OR 3 4 PVC Optional Condensate Drain Connection Adapter 3 4 inch slip X 3 4 inch mpt not furnished 90 Street Elbow 3 4 inch PVC not furnished R Condensate Drain Connection In Unit 1 25 mm Min 2 50 mm Max Above Top Of 90 Street Elbow 3 4 inch PVC l furnished 1 2 inch PVC Pipe Optional Drain Piping From Trap Not Furnished Drain Assembly for 1 2 inch Drain Pipe ane 1 2 inch PVC Pipe Not Furnished V 90 Elbow m 1 2 inch PVC To Not Furnished Drain Drain Assembly for 3 4 inch Drain Pipe LiL 3 4 inch mpt not furnished Condensate Drain Connection In Unit 90 Elbow 3 4 inch PVC T Not Furnished Adapter 3 4 inch slip X Condensate Drain Connection In Unit Vent 5 Feet a WE 3 4 inch PVC Pipe Not Furnished Coupling 3 4 inch slip X slip Not Furnished Drain Trap Assembly Furnished Drain Trap raf Clean Out 90 Elbow 90 Elbow 3 4 inch PVC y 3 4 inch PVC Not Furnished Not Furnished I To Coupling 3 4 inch slip X slip Drain Not Furnished Drain Trap Assembly with 1 2 inch Piping 1 25 mm Min 2 50 mm Max Above Top Of Condensate Drain Connection In Unit Drain Trap
2. o RETURN AIR Contractor s Name Telephone Checklist Completed Job Address Technician s Name Page 49 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 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 vic
3. 43 04 39 64 36 81 34 55 32 56 2 1 2 2 469 6300 4350 3520 3000 2650 2400 2250 2050 1950 1850 63 5 67 713 178 39 123 17 99 67 84 95 75 04 67 96 63 71 58 05 55 22 52 38 3 3 068 11000 7700 6250 5300 4750 4300 3900 3700 3450 3250 76 2 77 927 311 48 218 03 176 98 150 07 134 50 121 76 110 43 104 77 97 69 92 03 4 4 026 23000 15800 12800 10900 9700 8800 8100 7500 7200 6700 101 6 102 260 651 27 447 39 362 44 308 64 274 67 249 18 229 36 212 37 203 88 189 72 1 2 622 175 120 12 7 17 799 4 96 3 40 3 4 824 360 250 19 05 20 930 10 19 7 08 1 1 049 680 465 25 4 26 645 19 25 13 17 1 114 1 380 1400 950 31 75 35 052 39 64 26 90 a NOTE Capacity given in cubic feet of gas per hour kilo liters of gas per hour and based on 0 60 specific gravity gas 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 prop erly 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 vent ing system has been installed improperly you must correct the system as indicated in the general ven
4. oOo Coupling or i 7 p 3 in to 2 in Intake Debris Screen Provided Transition Field Provided See table 6 for maximum vent lengths 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 7 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 communicate di rectly or by ducts with the outdoors or spaces crawl or at tic that freely communicate with the outdoors or indirectly 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 en closure See figures 5 and 8 When communicating with the outdoors through horizontal ducts each opening shall have a minimum free area of 1 square inch 645 mm per 2 000 Btu 56 kW per total input rating of all equipment in the enclosure See figure 9 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
5. 3 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 located and other spaces of the building 4 Close fireplace dampers 5 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 6 Follow the lighting instruction to place the appliance being inspected into operation Adjust thermostat so appliance will operate continuously 7 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 9 After determining that each appliance remaining con nected to the common venting system properly vents when tested as indicated in
6. Count all elbows inside and outside house Desired pipe size 2 2 1 2 3 What is the altitude of 6 the furnace installation Use table 5 or 6 to find O max intake or exhaust pip length Includes all vent pipe and elbows inside and outside the house FIGURE 23 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 TABLE 5 Maximum Allowable Intake or Exhaust Vent Length in Feet NOTE Size intake and exhaust pipe length separately Values in table are for Intake OR Exhaust not combined total Both Intake and Exhaust must be same pipe size NOTE Additional vent pipe and elbows used to terminate the vent pipe outside the structure must be included in the total vent length calculation Standard Termination at Elevation 0 10 000 Number Of 2 1 2 Pipe 3 Pipe 90 Elbows Used i I CAL a7 Fah 107 118 113 108 103 11 114 11 109 104 03 27 722 a7 772 32 La ERa ro a gt N N A Go f wo NI z OO Go Go CO CO wl oo N Ny NI N o A amp g o Ao gt oO O N N S on ECA Termination Elevation 0 10 000 Number Of 2 1 2 Pipe 90 Elbows Usedl o J o oO J o NI NI o oe A AY oy oy o o A o gt o gt o A o gt nA co oa ojl o A
7. DIRECT VENT CONCENTRIC ROOFTOP TERMINATION 71M80 69M29 or 60L46 US 44W92 or 44W93 Canada FIGURE 38 FIELD PROVIDED REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION OUTSIDE 1 1 2 38mm accelerator provided on 71M80 amp 44W92 kits for ML193UH045P24B 070P24B amp 070P36B INTAKE EXHAUST EXHAUST WALL AIR NY ve c 12 305mm Min above grade or average snow accumulation GRADE DIRECT VENT CONCENTRIC WALL TERMINATION 71M80 69M29 or 60L46 US 44W92 or 44W93 Canada FIGURE 39 Page 27 EXHAUST VENT INTAKE AIR 457mm Front View gt EXHAUST VENT LZ f 12 305mm Min gea o above grade or Tio average snow INTAKE accumulation Inches mm optional intake elbo 7 gt Side View OPTIONAL VENT TERMINATION FOR MULTIPLE UNIT INSTALLATION OF DIRECT VENT WALL TERMINATION KIT 30G28 or 81J20 FIGURE 40 2 EXTENSION FOR 2 PVC PIPE1 EXTENSION FOR 3 PVC PIPE FURNACE EXHAUST FURNACE GLUE EXHAUST END FLUSH INTO TERMINATION 1 1 2 ACCELERATOR all 45 070 and 090 units FLUSH MOUNT SIDE WALL TERMINATION KIT 51W11 US or 51W12 Canada FIGURE 41 FIELD FABRICATED WALL TERMINATION NOTE FIELD PROVIDED REDUCER MAY BE 7 7 See OO ae LARGER VENT PIPE SIZE TO TERMINATION Vent Pipe Vent Pipe A Minimum clearance above grade or average 12 305 mm 12 305 mm snow
8. LINE Input 120VAC XFMR Transformer 120VAC EAC Indoor Air Qality Accessory Air Cleaner 120VAC COOL Blower Cooling Speed 120VAC HEAT Blower Heating Speed 120VAC PARK Dead terminals to park alternate spd taps CONT Continuous blower NEUT TWIN Neutral terminals 120VAC Twinning Terminal 24VAC RALS 3sni_div_S d oood DOOO OOO dj PUSH BUTTON BLOWER OFF DELAY JUMPER FIGURE 1 Integrated Control Diagnostic Codes DIAGNOSTIC CODES LED Status DESCRIPTION LED Off No power to control or control harware fault detected LED On Normal operation 4 Flash Flame present with gas vavle de energized Pressure switch closed with combustion 2 Flashes he f air inducer de energized Pressure switch open with combus 3 Flashes feet tion air inducer energized 4 Flashes Primary limit switch open 5 Flashes Rollout switch open 6 Flashes Pressure switch cycle lockout 7 Flashes Lockout burners fail to light Lockout buners lost flame too many times 9 Flashes Line voltage polarity incorrect 8 Flashes Page 39 Note This control is equipped with a push button switch for diagnostic code recall The control stores the last 5 fault codes in non volatile memory The most recent fault code is flashed first the oldest fault code is flashed last There is a 2 second pause between codes When the push button switch is press
9. 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 prelubricated 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 1 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 3 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 co
10. per 1 17kW per hour of the total input rating of all other equipment in the enclosure FIGURE 9 Shipping Bolt Removal Units with 1 2 hp blower motor are equipped with three flex ible 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 10 The bolt and washer must be re moved before the furnace is placed into operation Af ter the bolt and washer have been removed the rigid leg will not touch the blower housing ML193UH090P48C and ML193UH110P48C with 1 2 HP Blower Motor RIGID LEG Remove shipping bolt P and washer FIGURE 10 AWARNING Do not connect the return air duct to the back of the furnace Doing so will adversely affect the operation of the safety control devices which could result in personal injury or death A WARNING Blower access panel must be securely in place when blower and burners are operating Gas fumes which could contain carbon monoxide can be drawn into living space resulting in personal injury or death Upflow Applications The ML193UH gas furnace can be installed as shipped in the upflow position Refer to figure 12 for clearances Se lect a location that allows for the required clearances that are listed on the unit nameplate Also consider gas supply connections electrical supply vent connection conden sate trap and drain connect
11. 2 Air Filter Return Air Plenum Transition FIGURE 13 Page 10 Optional Return Air Base Upflow Applications Only TRAP ae i CONDENSATE O a IF BASE 123 584 IS USED a Overall t WITHOUT Maximum 1 Minimum 11 279 IAQ CABINET INDOOR AIR ASINGLE 2 Maximum 1997 16 QUALITY RETURN AIR 1 Unit side return air 14 356 570 CABINET PLENUM Opening Eek PCO Filter MUST i aes epi etc COVER BOTH ven UNIT AND RETURN 5 5 3 SIDE RETURN AIR BASE 143 AIR OPENINGS OPENINGS Either Side 23 17 1 2 446 B Width ae RETIENS 584 21 533 C Width 50W99 AIR BASE 26 7 8 24 1 2 622 D Width 51W00 683 FRONT VIEW SIDE VIEW NOTE Optional side return air filter kits are not for use with return air base 1 Both the unit return air opening and the base return air opening must be covered by a single plenum or IAQ cabinet Minimum unit side return air opening dimensions for units requiring 1800 cfm of air and over W x H 23 x 11 in 584 x 279 mm The opening can be cut as needed to accommodate plenum or IAQ cabinet while maintaining dimensions shown Side return air openings must be cut in the field There are cutting guides stenciled on the cabinet for the side return air opening The size of the opening must not extend beyond the markings on the furnace cabinet 2 To minimize pressure drop the largest opening height possible up to 14 i
12. Assembly Furnished Condensate Drain Connection In Unit FIGURE 54 Page 33 Drain Trap Assembly with 3 4 inch Piping 1 25 mm Min 2 50 mm Max Above Top Of Condensate Drain Connection In Unit Vent Condensate Drain Connection In Unit Gas Piping ACAUTION 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 and the gas supply line AWARNING Do not exceed 600 in lbs 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 the gas valve from the side of the valve as shown in figure 57 Move Bellows grommet to side which gas line enters Ensure opposite gas line hole is plugged with supplied plug A IMPORTANT When converting the ML193 unit from natural gas to LP propane install the field provided low pressure switch See figure 55 LOW INLET PRESSURE SWITCH S145 LOCATION Orange Yellow Gas Valve Shown In Off Position FIGURE 55 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 9 li
13. Configurations MANUAL MAIN SHUT OFF MANUAL Horizontal Application MAIN SHUT OFF Left Side Air Discharge VALVE GROUND JOINT UNION GROUND Bellows Grommet JOINT DRIP LEG gt UNION Bellows Grommet DRIP LEG gt Gas Valve Horizontal Application RTT A VANUA Right Side Air Discharge MAIN SHUT OFF VALVE Gas Valve GROUND FIELD Bellows Grommet JOINT PROVIDED UNION AND INSTALLED NOTE BLACK IRON PIPE ONLY TO BE ROUTED INSIDE OF CABINET DRIR EEG FIGURE 58 Page 35 TABLE 9 GAS PIPE CAPACITY FT3 HR kL HR Internal Length of Pipe Feet m Diameter 10 20 30 40 50 60 70 80 90 100 Inches mm 3 048 6 096 9 144 12 192 15 240 18 288 21 336 24 384 27 432 30 480 82 73 66 61 57 53 Nominal Iron Pipe Size Inches mm 2 75 2 32 2 07 1 87 1 73 1 61 1 50 1 42 200 170 151 138 125 118 110 103 5 66 4 81 4 28 3 91 3 54 3 34 3 11 2 92 375 320 285 260 240 220 205 195 10 62 9 06 8 07 7 36 6 80 6 23 5 80 5 52 770 660 580 530 490 460 430 400 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 21 24 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
14. GAS METER CLOCKING CHART Seconds for One Revolution ML193 Natural J P Unit 1 cu ft 2 cu ft Dial DIAL o o f eo 200 00 E a a a 20 e a Ooi 2 0a Oe OS Natural 1000 btu cu ft LP 2500 btu cu ft Page 41 Furnace should operate at least 5 minutes before checking gas flow Determine time in seconds for two revolutions of gas through the meter Two revolutions assures a more accurate time Divide by two and compare to time in table 10 below If manifold pressure matches table 11 and rate is incorrect check gas orifices for proper size and restriction Remove temporary gas meter if installed NOTE To obtain accurate reading shut off all other gas appliances connected to meter Supply Pressure Measurement When testing supply gas pressure use the 1 8 N P T plugged tap or pressure post located on the gas valve to facilitate test gauge connection See figure 61 Check gas line pressure with unit firing at maximum rate Low pres sure may result in erratic operation or underfire High pres sure can result in permanent damage to gas valve or over fire On multiple unit installations each unit should be checked separately with and without units operating Supply pres sure must fall within range listed in table 11 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 measure manifold pres s
15. OF PIPE ON TOP PLATE ALTERNATE INTAKE PIPE EXTERIOR PORTION OF CHIMNEY 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 FIGURE 43 Details of Exhaust Piping Terminations for Non Direct Vent Applications 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 pre ferred Figures 44 through 45 show typical terminations 1 Exhaust piping must terminate straight out or up as shown The termination 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 building 2 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 Page 29 SIZE TERMINATION 12 305mm PIPE PER TABLE 8 ABOVE AVE SNOW ACCUMULATIO 3 76mm OR UNCONDITIONED 2 51mm PVC ATTIC SPACE PROVIDE SUPPORT FOR EXHAUST LINES NON DIRECT VENT ROOF TERMINATION KIT 15F75
16. be re duced The pressure drop may also cause the limit to trip more frequently during the winter and the indoor coil to freeze in the summer resulting in an increase in the number of service calls Before using any filter with this system check the specifications provided by the filter manufacturer against the data given in the appropriate Lennox Product Specifications bulletin Additional informa tion is provided in Service and Application Note ACC 00 2 August 2000 TABLE 1 Furnace Cabinet Width Side Return Bottom Return 17 1 2 16 X 25 X 1 1 16 X 25 X 1 1 16 X 25 X 1 1 20 X 25 X 1 1 24 1 2 16 X 25 X 1 2 24 X 25 X1 1 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 l
17. distance from top of each pipe 6 152 mm Max 6 152 mm Max intake exhaust 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 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 recommended 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 3 Exhaust 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 42 Page 28 ML193UH DIRECT VENT APPLICATION USING EXISTING CHIMNEY STRAIGHT CUT OR 3 8 ANGLE CUT IN DIRECTION 76 203 OF ROOF SLOPE mm mm Pa 1 H 8 12 E 203mm 305mm Minimum 12 305MM INTAKE PIPE a above chimney top INSULATION optional plate or average snow SHEET METAL TOP accumulation PLATE SHOULDER OF FITTINGS PROVIDE SUPPORT
18. 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 1 Return air base kit 1 Horizontal suspension kit Safety Information AWARNING Improper installation adjustment alteration service or maintenance can cause property damage personal injury or loss of life Installation and service must be performed by a licensed professional in staller or equivalent service agency or the gas sup plier 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 A DANGER Danger of 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 Use only the type of gas approved for use with this furnace Refer to unit nameplate ML193UH 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 local 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 ad
19. 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 ML193UH gas furnace has been started the fol lowing test should be conducted to ensure proper venting and sufficient combustion air has been provided to the ML193UH as well as to other gas fired appliances which are separately vented If a ML193UH 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 2 Visually inspect the venting system for proper size and Page 43 horizontal pitch Determine there is no blockage or re striction leakage corrosion or other deficiencies which could cause an unsafe condition
20. necessary the conden sate line from the furnace and evaporator coil can drain together See figures 50 52 and 53 Upflow furnace figure 52 In upflow furnace applica Page 30 Condensate line must slope downward away from the trap to drain If drain level is above condensate trap condensate pump must be used Condensate drain 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 Heating cable kit is available from Lennox in various lengths 6 ft 1 8m kit no 26K68 24 ft 7 3m kit no 26K69 and 50 ft 15 2m kit no 26K70 CONDENSATE TRAP LOCA UniT BON in upflow position with remote trap Field Provided Vent Min 1 Above Condensate Drain Connection To Dran Piping from furnace must slope down a minimum of 1 4 per ft toward trap FIGURE 48 ML193UH With Evaporator Coil Using A Separate Drain Evaporator drain line required Trap at coil is optional Field Provided Vent 1 min 2 max above condensate connec tion Condensate Drain Connection FIGURE 49 Page 31 Condensate Trap With Optional Overflow Switch From Evaporator Coil Field Provided Vent Upflow Furnace 1 Min to 2 Max Horizontal Furnace4 Min t
21. of louvers grilles or screens must be considered If the design and free area of protective cov ering is not known for calculating the size opening required it may be assumed that wood louvers will have 20 to 25 per cent 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 opera tion EQUIPMENT IN CONFINED SPACE ALL AIR FROM OUTSIDE All Air Through Ventilated Attic ROOF TERMINATED EXHAUST PIPE VENTILATION LOUVERS Each end of attic INLET AIR Ends 12 above TERMINATED bottom EXHAUST PIPE ALTERNATE LOCATION Ld 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 8 EQUIPMENT IN CONFINED SPACE ALL AIR FROM OUTSIDE ROOF TERMINATED EXHAUST PIPE ZZ 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
22. setting 3 Turn off all electrical power to the unit 4 This furnace is equipped with an ignition device 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 61 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 supplier s instruc tions If you do not smell gas go to next step 8 Move gas valve switch to ON See figure 61 MANIFOLD PRESSURE OUTLET MANIFOLD PRESSURE PRESSURE PORT GAS VALVE SHOWN IN ON POSITION FIGURE 61 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 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 Page 40 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
23. soffit depth Equal to or greater than soffit depth No minimum to outside corner 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 AREA WHERE TERMINAL IS NOT PERMITTED Canadian Installations2 12 inches 305mm or 12 in 305mm above average snow accumulation 6 inches 152mm for appliances lt 10 000 Btuh 3kw 12 inches 305mm for appliances gt 10 000 Btuh 3kw and lt 100 000 Btuh 30kw 36 inches 9m for appliances gt 100 000 Btuh 30kw 12 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 above the meter regulator assembly 3 feet 9m 6 inches 152mm for appliances lt 10 000 Btuh 3kw 12 inches 305mm for appliances gt 10 000 Btuh 3kw and lt 100 000 Btuh 30kw 36 inches 9m for appliances gt 100 000 Btuh 30kw Clearance to mechanical air sup ply inlet Clearance above paved sidewalk or 3 feet 9m above if within 10 feet 3m horizontally 7 feet 2 1m t 6 feet 1 8m 7 feet 2 1m t paved driveway located on public property Clearance under veranda porch deck or balcony 12 inches 305mm M 42 inches 305mm 1In accordance with the current ANSI Z223 1 NFPA 54 Natural Fuel Gas Code 2 In accordan
24. 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 material All seams joints cracks etc in the affected area should be sealed using an appropriate sealant See figure 42 Intake and exhaust pipes may be routed either horizontally through an outside wall or vertically through the roof In at tic or closet installations vertical termination through the roof is preferred Figures 35 through 43 show typical terminations 1 Intake and exhaust terminations are not required to be in the same pressure zone You may exit the intake on one side of the structure and the exhaust on another side figure 36 You may exit the exhaust out the roof and the intake out the side of the structure figure 37 NOTE When venting in different pressure zones maximum separation of intake and exhaust pipe DO NOT apply 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 NOTE When venting in different pressure zones the maximum separation requirement of intake and ex haust pipe DOES NOT apply On roof terminations the intake piping should termi nate straight down using two 90 elbows See figure 35 Exhaust piping must terminate straight out or up as shown A red
25. IPMENT GROUND SEE BLOWER SPEED CHART IGNITOR J159 45 P159 Pon 3 P156 P156 74 J156 J156 FLAME BLOWER MOTOR COMMON BLOWER SPEED SELECTION haon o SPEED TAPS _ BLACK BROWN YELLOW RED THERMOSTAT HEAT ANTICIPATION SETTINGS 65 AMP__ HONEYWELL VALVE 50 AMP__ WHITE RODGERS VALVE ___ _JACKPLUGCHART__ ee ELECTRIC SHOCK HAZARD CAN CAUSE INJURY OR DEATH UNIT MUST BE GROUNDED IN ACCORDANCE WITH NATIONAL AND LOCAL CODES NOTE IF ANY WIRE IN THIS APPLIANCE IS REPLACED IT MUST BE REPLACED WITH WIRE OF LIKE SIZE RATING INSULATION THICKNESS AND TERMINATION IMPORTANT TO PREVENT MOTOR BURNOUT NEVER CONNECT MORE THAN ONE LEAD TO ANY ONE CONNECTION Z PARK TERMINALS ARE UNPOWERED TERMINALS ALL UNUSED MOTOR LEADS MUST BE WIRED TO A PARK TERMINAL FIELD SUPPLIED ACC WIRE DO NOT USE RED LOW SPD MOTOR LEAD FOR HEATING LEAVE ON PARK TERMINAL FOR 070P24B 090P36C 110P48C AND 135P60D UNITS AX 5145 IS USED WITH HONEYWELL GAS VALVE WHEN APPLIED IN LP GAS UNITS AA HEATICOOL JUMPER PRESENT ON SOME MODELS I90P48C 10P48C 10P60C 135P60D YELLOW BLACK RED BROWN g BROWN 145 YELLOW S1 ROOM THERMOSTAT YELLOW DENOTES OPTIONAL COMPONENTS LINE VOLTAGE FIELD INSTALLED CLASS II VOLTAGE FIELD WIRING FIGURE 60 Page 38 Integrated Control INTEGRATED CONTROL ce Ignition System Automatic Hot Surfa TERMINAL DESIGNATIONS HUM Humidifier 120VAC
26. LENNOX J 2013 Lennox Industries Inc Dallas Texas USA 9 bell lt HORIZONTAL LEFT UPFLOW Di fo HORIZONTAL RIGHT INSTALLATION INSTRUCTIONS ML193UH MERIT SERIES GAS FURNACE UPFLOW HORIZONTAL AIR DISCHARGE Meran Publications 507121 01 08 2013 Litho U S A Supersedes 06 2013 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 licensed professional HVAC in staller or equivalent service agency or the gas sup plier Table of Contents Unit Dimensions 2 02000 eee eee 2 ML193UH Gas Furnace 00 002005 3 Shipping and Packing List 000 3 Safety Information 00 00 cece eee 3 Use of Furnace as a Construction Heater 4 Genefal cick iach agadi ia ip hen wieataaon hh eaan t 5 Combustion Dilution Ventilation Air 5 Setting Equipment 00000 eee
27. NECTIONS IN HORIZONTAL DIRECT OR NON DIRECT VENT APPLICATIONS RIGHT HAND DISCHARGE SHOWN i TRANSITION nie SIDE VIEW DO NOT transition from smaller to larger pipe in horizontal runs of exhaust pipe EXHAUST 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 25 Page 19 TYPICAL AIR INTAKE PIPE CONNECTIONS IN UPFLOW DIRECT VENT APPLICATIONS Pipe size determined in table 5 TRANSITION When transitioning up in pipe size use the shortest length of 2 PVC pipe possible NOTE Intake and exhaust pipe must be the same diameter FIGURE 26 TYPICAL AIR INTAKE PIPE CONNECTIONS IN HORIZONTAL DIRECT VENT APPLICATIONS RIGHT HAND DISCHARGE SHOWN L TRANSITION xo AIR INTAKE When transitioning up in pipe size use the shortest length of 2 PVC pipe possible NOTE Intake and exhaust pipe must be the same diameter FIGURE 27 Page 20 Intake Pip
28. Oy o o ny N o OW OF OF oy oj OF oa 135 045 070 zi 776 m 705 701 14 T 04 114 109 105 100 gt NI N j oe gt A N NIN N NNN N N N N N oj N S7 NENES A oO gt BR x x amp co o gt o gt gt R x N 0 a on a a gt N N A o A o A nee N CT ol BY BY Oa oy oA N Co Coy CO Co Co CO wo o gt NI NI Ce A BP Oy on Co j CO CO Co Co f Go CO TABLE 6 Maximum Allowable Exhaust Vent Lengths With Furnace Installed in a Closet or Basement Using Ventilated Attic or Crawl Space For Intake Air in Feet NOTE Additional vent pipe and elbows used to terminate the vent pipe outside the structure must be included in the total vent length calculation Standard Termination at Elevation 0 10 000 Number Of 2 1 2 Pipe 90 Elbows Page 18 TYPICAL EXHAUST PIPE CONNECTIONS IN UPFLOW DIRECT OR NON DIRECT VENT APPLICATIONS Pipe size determined in table 5 3 TRANSITION EXHAUST o DO NOT transition from smaller to larger pipe in horizontal runs of exhaust pipe When transitioning up in pipe size use the shortest length of 2 PVC pipe possible NOTE Exhaust pipe and intake pipe must be the same diameter FIGURE 24 TYPICAL EXHAUST PIPE CON
29. W 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 mm2 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 ALL AIR FROM INSIDE OPENINGS To Adjacent SIDE WALL Unconfined TERMINATED Space 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 Page 6 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 verti cal ducts Each opening shall have a minimum 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 minimum free area of 1 square inch per 2 000 Btu 645mm per 59kW per total inp
30. XHAUST RETURN DUCT PIFE E Sealed _ All Joints Primed and Glued L Filter Installed and Clean C Terminations Installed Properly L Grilles Unobstructed G VOLTAGE CHECK L Condensate Trap Primed Line Sloped Supply Voltage L Horizontal Pipes Sloped if applicable O pi s L Electrical Connections Tight ipes Sup ported L Heat Cable Installed and Operable if applicable Page 48 HEATING MODE GAS MANIFOLD PRESSURE W C COMBUSTION SAMPLE CO2 CO PPM INDOOR BLOWER AMPS TEMPERATURE RISE Supply Duct Temperature Return Duct Temperature Temperature Rise TOTAL EXTERNAL STATIC Supply External Static Return External Static Total External Static CONDENSATE LINE L Leak Free VENT PIPE L Leak Free Combustion CO Thermostat oe UNIT OPERATION COOLING MODE INDOOR BLOWER AMPS G TEMPERATURE DROP Return Duct Temperature Supply Duct Temperature Temperature Drop TOTAL EXTERNAL STATIC dry coil Supply External Static Return External Static Total External Static DRAIN LINE L Leak Free THERMOSTAT L Adjusted and Programmed L Explained Operation to Own er Blower Motor Amps Temperatures Gas Manifold Pressure
31. a i Pipe Furnace Minimum 12 in p 305 MM above grade or snow accumulation FIGURE 36 Exiting Exhaust and Intake Vent different pressure zones A Roof Terminated Exhaust Pipe inlet Air Minimum 12 in 305 MM above grade or snow accumulation Furnace FIGURE 37 Page 26 7 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 At least one bracket must be used within 6 from the top of the el bow and then every 24 610mm as shown in figure 42 to prevent any movement in any direction 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 8 A multiple furnace installation may use a group of up to four terminations assembled together horizontally as shown in figure 40 1 1 2 38mm accelerator provided on 71M80 amp 44W92 EXHAUST kits for ML193UH045P24B VENT H 070P24B amp 070P36B _ 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 TT REDUCER MAY BE REQUIRED bJ bJ TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION
32. a pressure switch change which can be ordered separately Table 13 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 essary to convert this unit Refer to the changeover kit installation instruction for the conversion procedure TABLE 13 Conversion Kit and Pressure Switch Requirements at Varying Altitudes High Altitude Natural Burner Orifice Kit Natural to LP Propane to kri LP Propane Natural Burner Orifice Kit nit 0 7500 ft 7501 10 000 ft 0 7500 ft 0 2286m 2286 3038m 0 2286m 69W73 73W37 73W81 68 W68 93W87 93W88 High Altitude LP Propane High Altitude Pressure Switch 4501 7500 ft 7501 10 000 ft 1373 2286m 2286 3048m 7501 10 000 ft 2286 3038m 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 Page 42 Testing for Proper Venting and Sufficient Combustion Air for Non Direct Vent Applications 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
33. accumulation B Maximum horizontal separation between 6 152 mm 6 intake and exhaust C1 Minimum from end of _ exhaust to inlet of intake 8 203 mm 152 mm 8 203 mm Elbow C2 Minimum from end of _ 2 STRAIGHT PS A exhaust to inlet of intake 6 152mm 6 152 mm APPPLICATION NN D Maximum exhaust pipe length 12 305 mm 20 508 mm E Maximum wall support WALL distance from top of each 6 152 mm 6 152 mm SUPPORT pipe intake exhaust See venting table 5 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 p NOTE One wall support must be within 6 152 mm NY NY from top of each pipe intake and exhaust to prevent EXTENDED movement in any direction APPLICATION 2 51MM 3 76MM Vent Pipe Vent Pipe A Clearance above grade or average snow 12 305 mm Min 12 305 mm Min accumulation B Horizontal i separation between 87 152 mm Min 6 152 mm Min intake and exhaust 24 610 mm Max 24 610 mm Max C Minimum from end of exhaust to 9 227 mm Min 9 227 mm Min inlet of intake 12 305 mm Min 12 305 mm Min A i D Exhaust pipe length 46 405 mm Max 20 508 mm Max Front View of Intake and Exhaust E Wall support
34. ace into operation ML193UH units are equipped with an automatic hot sur face ignition system Do not attempt to manually light burn ers 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 Set the 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 5 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 61 1 STOP Read the safety information at the beginning of this section 2 Set the thermostat to the lowest
35. base trap assembly of the trap Secure with clamp See figure 54 Appropriately sized tubing and barbed fitting f the t S ith cl See fi 54 NOTE A jately sized tubi d barbed fitti 4 Install drain trap using appropriate PVC fittings glue may be used for condensate drain Attach to the drain same on right side all joints Glue the provided drain trap as shown in fig ure 54 Route the condensate line to an open drain Condensate line must maintain a 1 4 downward slope from the furnace to the drain CONDENSATE TRAP AND PLUG LOCATIONS Unit shown in upflow position Trap 1 1 2 in i Plug same on left side on the trap using a hose clamp See figure 47 If unit will be started immediately upon completion of installation prime trap per procedure outlined in Unit Start Up section Field Provided Drain Components Barbed Fitting Hose Clamp FIGURE 47 A CAUTION Lo NOTE In upflow applications where side return Do not use copper tubing or existing copper conden sate lines for drain line air filter is installed on same side as the conden sate trap filter rack must be installed beyond condensate trap or trap must be re located to avoid interference FIGURE 46 Figures 49 and 51 show the furnace and evaporator coil using a separate drain If
36. ce 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 between two single family dwellings and serves both dwellings 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 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 requirements of the gas supplier and these instal lation instructions FIGURE 33 Page 24 VENT TERMINATION CLEARANCES FOR DIRECT VENT INSTALLATIONS IN THE USA AND CANADA SS ES 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 610mm 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 Clearance to mechanical air sup ply inlet Clearance above paved sidewalk or pa
37. chloroethylene e Place the furnace as close to the center of the air dis Printing inks paint removers varnishes etc tribution system as possible The furnace should also be Hydrochloric acid located close to the vent termination point Cements and glues 3 Antistatic fabric softeners for clothes dryers e When the furnace is installed in non direct vent applica Masonry acid washing materials tions do not install the furnace where drafts might blow directly into it This could cause improper combustion Combustion Dilution amp Ventilation Air and unsafe operation e When the furnace is installed in non direct vent applica tions do not block the furnace combustion air opening If the ML193UH is installed as a Non Direct Vent Fur nace follow the guidelines in this section with clothing boxes doors etc Air is needed for proper NOTE In Non Direct Vent installations combustion air is combustion and safe unit operation taken from indoors or ventilated attic or crawlspace and e When the furnace is installed in an attic or other insu flue gases are discharged out doors lated space keep insulation away from the furnace In the past there was no problem in bringing in sufficient e When the furnace is installed in an unconditioned outdoor air for combustion Infiltration provided all the air space consider provisions required to prevent freezing that was needed In today s homes tight construction prac of condensate dra
38. de 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 cu bic 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 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 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 mm2 per 1 000 Btu 29 k
39. de of pipe 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 o1 1 NOTE Time is critical at this stage Do not allow prim er to dry before applying cement 6 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 second coat to end of pipe 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 Page 15 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 end of fitting socket A properly made joint will show a bead around its entire perimeter Any gaps may indicate an improper assembly due to insufficient solvent 9 Handle joints carefully until completely set Venting Practices Piping Suspension Guidelines SCHEDULE 40 PVC 5 all other pipe 3 See table 2 for allowable pipe NOTE Isolate pipi
40. dler Unit Dampers open during heating operation only V7 i Gas Unit lt OTE Sn Air Handler Unit N Dampers open during cooling operation only Heating Unit Installed Upstream of Cooling Coil Cooling Coil FIGURE 3 NOTE This furnace is designed for a minimum continuous return air temperature of 60 F 16 C or an intermittent op eration down to 55 F 13 C dry bulb for cases where a night setback thermostat is used Return air temperature must not exceed 85 F 29 C dry bulb The ML193UH furnace may be installed in alcoves clos ets attics basements garages crawl spaces and utility rooms in the upflow or horizontal position This furnace design has not been CSA certified for installa tion in mobile homes recreational vehicles or outdoors Use of Furnace as Construction Heater Lennox does not recommend the use of ML193UH 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 ML193UH units may be used for heating of buildings or structures under construction if the following conditions are met e 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 heating is not allowed e The return air duct must be provided and sealed to t
41. dress 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 Installation Locations This furnace is CSA International certified for installation clearances to combustible material as listed on the unit nameplate and in the table in figure 12 Accessibility and service clearances must take precedence over fire protec tion clearances NOTE For installation on combustible floors the furnace shall not be installed directly on carpeting tile or other combustible material other than wood flooring 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 hazardous at mosphere the furnace must be installed according to rec ommended good practice requirements and current Na tional Fuel Gas Code or CSA B149 standards NOTE Furnac
42. e Product Specifications bulletin for blower perfor mance tables 6 Connect selected speed tap at integrated control speed terminal 7 Resecure blower access panel 8 Turn on electrical power to furnace 9 Recheck temperature rise Electronic Ignition The integrated control has an added feature of an internal Watchguard control The feature serves as an automatic reset device for integrated control lockout caused by igni tion failure This type of lockout is usually due to low gas line pressure After one hour of continuous thermostat de mand for heat the Watchguard will break and remake ther mostat demand to the furnace and automatically reset the integrated control to begin the ignition sequence Exhaust and Air Intake Pipe 1 Check exhaust and air intake connections for tightness and to make sure there is no blockage 2 Is pressure switch closed Obstructed exhaust pipe will cause unit to shut off at pressure switch Check ter mination for blockages Obstructed pipe or termination may cause rollout switches to open Reset manual flame rollout switches on burner box assembly if necessary ow 1 Page 44 Twinning the ML193UH The control board in this furnace is equipped with a provi sion to twin interconnect two 2 adjacent furnaces with a common plenum such that they operate as one 1 large unit When twinned the circulating blower speeds are synchro nized between the furnaces If either furnace has a
43. e Blower Performancetables for additional information Optional External Side Return Air Filter Kit is not for use with the optional Return Air Base EXHAUST AIR OUTLET SUPPLY AIR OPENING COMBUSTION AIR INTAKE 2 ie SIDE RETURN ns 3 AIR FILTER KIT Either Side 635 TOP VIEW A 1 25 27 3 4 Front Panel 705 i B 9 16 14 9 16 14 ry 6 9 16 167 9 629 Either Side 2 OPTIONAL Right GAS PIPING INLET SIDE RETURN 12 5 8 321 N Either Side AIR FILTER KIT Either Side CONDENSATE Either Side A TRAP CONNECTION Cs O7 Either Side w ELECTRICAL epee o 4 INLET Either Side 23 1 1 2 D are 584 38 46 1 Side Return ne Air Opening 406 Either Side AIR FLOW 5 8 A 3 4 3 4 16 3 1 4 23 1 2 a ig c 19 83 597 1 Bottom Return 1 Bottom Return Air Opening Air Opening FRONT VIEW SIDE VIEW ML193UH Cc D Model No in mm in mm 045XP24B 045XP36B 070XP24B 16 406 7 5 8 194 070XP36B 090XP36C 090XP48C 110XP48C 19 1 2 495 9 3 8 238 110XP60C 135XP60D 23 584 11 1 8 283 Page 2 ML193UH Gas Furnace The ML193UH Category IV gas furnace is shipped ready for installation in the upflow or horizontal position The fur nace is shipped with the bottom pane
44. e 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 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 sys
45. e must be adjusted to obtain a temperature rise within the range specified on the unit nameplate Fail ure to do so may cause erratic limit operation and prema ture heat exchanger failure This ML193UH furnace must be installed so that its electri cal components are protected from water Installed in Combination with a Cooling Coil When this furnace is used with cooling coils figure 3 it shall be installed in parallel with or on the upstream side of cooling coils 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 either 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 Heating Unit Installed Parallell to Air Han
46. eaks 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 pressure 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 re verse flow of the flue gas may result in incomplete com bustion and the formation of carbon monoxide gas This raw gas or toxic fumes might then be distributed throughout the house by the furnace duct system Return air can be brought in through the bottom or either side of the furnace return air brought into either side fur nace allowed in upflow applications only If a furnace with bottom return air is installed on a platform make an airtight seal between the bottom of the furnace and the platform to ensure that the unit operates properly and safely Use fi berglass sealing strips caulking or equivalent sealing method between the plenum and the furnace cabinet to en sure 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
47. ed for less than 5 seconds the control will flash the stored fault codes when the switch is released The fault code history may be cleared by pressing the push button switch for more than 5 seconds Unit Start Up 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 service technician to inspect the furnace and to replace all gas controls control system parts and electrical parts that have been wet or to replace the furnace if deemed necessary the gas supply fail to shut off or if overheating occurs shut off the gas Danger of explosion Can cause injury valve to the furnace before shutting off the electrical supply or product or property damage Should ACAUTION Before attempting to perform any service or mainte nance turn the electrical power to unit OFF at dis connect switch BEFORE LIGHTING the unit smell all around the furnace area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor The gas valve on the ML193UH is equipped with a gas con trol switch lever Use only your hand to move switch Nev er use tools If the the switch will not move by hand do not try to repair it Force or attempted repair may result in a fire or explosion Placing the furn
48. eee 8 FCT ac cade ns borscht a ote act i ketene g dee eS eh 13 Duct SYSIOM 2 isa pee dadect ase heehee ee ees 13 Pipe and Fittings Specifications 13 Joint Cementing Procedure 00 ee eee 15 Venting Practices 0 cece eee eee 16 08 13 Page 1 Vent Piping Guidelines 0 eee eee 17 Gas PIPING lt 2 cescaie lc ted cm trie ete em alae aad 34 EIS CIHICAl vi uie cans enamat eens ede eee nea eh bean 37 Integrated Control 0 cee eee eee 39 Unit Start Up oe ceea 0 00 c eee 40 Gas Pressure Measurement 00000 41 Proper Combustion 2 00200eeeeeeeee 42 High Altitude 0 0 2 c ee eee 42 Testing For Combustion Air Non Direct Vents 44 Other Unit Adjustments 22 00 eee 45 Twinning the ML193UH 0 eee eee 45 Service 200 eens 46 Repair Parts List 0 0200 eee eeeee 47 Start Up Checklist 00 00 20005 48 507121 01 ML193UH Unit Dimensions inches mm INOTE 60C and 60D size units that require air volumes 1800 cfm or over 850 L s must have one of the following 1 Single side return air with transition to accommodate 20 x 25 x 1 in 508 x 635 x 25 mm cleanable air filter Required to maintain proper air velocity 2 Single side return air with optional Return Air Base 3 Bottom return air 4 Return air from both sides 5 Bottom and one side return air Se
49. es 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 SIGNAGE A metal or plastic identification plate shall be permanently mounted to 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 Oo 1 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve th
50. ew to secure the intake pipe to the connector if desired 3 Use a sheet metal screw to secure the intake pipe to the connector if desired A CAUTION If this unit is being installed in an application with combustion air coming in from a space serviced by an exhaust fan power exhaust fan or other device which may create a negative pressure in the space take care when sizing the inlet air opening The in iet air opening must be sized to accommodate the maximum volume of exhausted air as well as the maximum volume of combustion air required for all gas appliances serviced by this space EQUIPMENT IN CONFINED SPACE Inlet Air from Ventilated Attic and Outlet Air to Outside Ventilation Louvers Roof Terminated Inlet Air j Minimum A SN 12 in 305mm Above Gite floor Intake Debris Screen Provided Furnace See table 6 for maximum vent lengths 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 30 EQUIPMENT IN CONFINED SPACE Inlet Air from Ventilated Crawlspace and Outlet Air to Outside Roof Terminated Exhaust Pipe Inlet Air Minimum 12 in 305mm Above crawl space floor Ventilation Louvers Crawl space oOo Coupling or i A 3 in to 2 in Intake Debris Screen Provided Transition Field Provided See table 6 for maxi
51. g cement blocks 4 Route auxiliary drain line so that water draining from this outlet will be easily noticed by the homeowner 5 If necessary run the condensate line into a conden sate pump to meet drain line slope requirements The pump must be rated for use with condensing furnaces Protect the condensate discharge line from the pump to the outside to avoid freezing 6 Continue with exhaust condensate and intake piping installation according to instructions Page 12 GAS CONNECTION INTAKE PIPE EXHAUST RRES Za V A Ves SERVICE PLATFORM PLATFORM FIGURE 19 Return Air Horizontal Applications Return air may be brought in only through the end of a fur nace installed in the horizontal position The furnace is equipped with a removable bottom panel to facilitate instal lation See figure 15 Filters This unit is not equipped with a filter or rack A field pro vided high velocity rated filter is required for the unit to oper ate properly Table 1 lists recommended filter sizes A filter must be in place whenever the unit is operating A IMPORTANT If a high efficiency filter is being installed as part of this system to ensure better indoor air quality the fil ter must be properly sized High efficiency filters have a higher static pressure drop than standard ef ficiency glass foam filters If the pressure drop is too great system capacity and performance may
52. he furnace e Return air temperature range between 60 F 16 C and 80 F 27 C must be maintained e Air filters must be installed in the system and must be maintained during construction Page 4 e Air filters must be replaced upon construction comple tion e The input rate and temperature rise must be set per the furnace rating plate e One hundred percent 100 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 sys tem 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 The A coil drain pan is high quality engineering poly mer with a maximum service temperature of 500 F However adequate space must be provided between the drain pan and the furnace heat exchanger At least 2 space is required for sectionalized heat exchanger and and 4 for drum type or oil fired furnace exchanger Closer spacing may damage the drain pan and cause leaking AWARNING Product contains fibe
53. he unit Use PVC primer and solvent cement or ABS solvent ce ment meeting ASTM specifications refer to Table 2 As an alternate use all purpose cement to bond ABS PVC or CPVC pipe when using fittings and pipe made of the same materials Use transition solvent cement when bonding ABS to either 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 appliance must be certified to ULC S636 and supplied by a single manufacturer as part of an approved vent exhaust sys tem In addition the first three feet of vent pipe from the fur nace flue collar must be accessible for inspection Page 14 TABLE 3 OUTDOOR TERMINATION USAGE STANDARD 3 inch 22G44 US 430G28 CA 44J40 US 481J20 CA Flush Mount Input Size Pipe Kit 2 1 2 3 2 070 2 1 2 fe 3 Wall Kit CONCENTRIC Field Fabricated Wall Ring Kit 2 inch 60L46 US 15F74 444W93 CA 1YES 5YES 1YES 5YES 1YES 5YES 1YES 5YES 1YES 5YES 1YES 5YES lt lt m m n n lt m n lt m n NOTE Standard Terminations do not include any vent pipe or elbow
54. igure 54 shows trap assembly using 1 2 PVC or 3 4 PVC 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 tions the field provided vent must be a minimum 1 toa maximum 2 length above the condensate drain outlet connection Any length above 2 may result in a flooded heat exchanger if the combined primary drain 1 Determine which side condensate piping will exit the line were to become restricted l unit location of trap field provided fittings and length Horizontal furnace figure 53 In horizontal furnace of PVC pipe required to reach available drain applications the field provided vent must be a mini mum 4 to a maximum 5 length above the condensate 2 Use a large flat head screw driver or a 1 2 drive socket drain outlet connection n above 5 may re extension and remove plug figure 46 from the cold sult in a flooded heat exchanger if the combined pri end header box at the appropriate location on the side mary drain line were to become restricted of the unit Install provided 3 4 NPT street elbow fitting or ro i into cold end header box Use Teflon tape or appropri NOTE In horizontal applications it is recommended to ate pipe dope install a secondary drain pan underneath the unit and 3 Install the cap over the clean out opening at the
55. in system tices make it necessary to bring in air from outside for com bustion Take into account that exhaust fans appliance ACAUTION vents chimneys and fireplaces force additional air that could be used for combustion out of the house Unless out ML193UH unit should not be installed in areas nor side air is brought into the house for combustion negative mally subject to freezing temperatures pressure outside pressure is greater than inside pressure Page 5 will build to the point that a downdraft can occur in the fur nace vent pipe or chimney As a result combustion gases enter the living space creating a potentially dangerous situ ation In the absence of local codes concerning air for combus tion and ventilation use the guidelines and procedures in this section to install ML193UH furnaces to ensure efficient and safe operation You must consider combustion air needs and requirements for exhaust vents and gas piping A portion of this information has been reprinted with per mission 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 en tirety In Canada refer to the CSA B149 installation codes A 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 code
56. inal 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 HUM 1 4 spade terminal is provided on the furnace integrated control See figure 1 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 connected to this termi nal it is necessary to use an external relay relay Thermostat Install the room thermostat according to the instructions provided with the thermostat See figure 60 for thermostat designations If the furnace is being matched with a heat pump refer to the FM21 installation instruction or appropri ate dual fuel thermostat instructions Indoor Blower Speeds 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 ML193UH is running in the heating mode the indoor blower will run on the heating speed 3 When there is a coo
57. ing The ML193UH 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 and 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 transition solvent cement or a sheet metal screw 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 5 for pipe sizes TYPICAL AIR INTAKE PIPE CONNECTIONS UPFLOW NON DIRECT VENT APPLICATIONS INTAKE DEBRIS SCREEN Provided NOTE Debris screen and elbow may be rotated so that screen may be positioned to face forward or to either side FIGURE 28 Page 21 TYPICAL AIR INTAKE PIPE CONNECTIONS HORIZONTAL NON DIRECT VENT APPLICATIONS Horizon
58. ions and installation and ser vice clearances 24 inches 610 mm at unit 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 draining See figure 11 Allow for clearances to combustible materials as indicated on the unit nameplate Page 8 SETTING EQUIPMENT UPFLOW APPLICA TION AIR FLOW FRONT VIEW SIDE VIEW f SIDE VIEW HORIZONTAL APPLICATION AIR FLOW FRONT VIEW END VIEW Unit must be level side to side Unit may be positioned from level to 1 2 toward the front to aid in draining FIGURE 11 Page 9 AWARNING 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 num A door must never be used as a portion of the 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 Installation Clearances To
59. l in place The bottom panel must be removed if the unit is to be installed in hori zontal or upflow applications with bottom return air The ML193UH can be installed as either a Direct Vent or a Non Direct Vent gas central furnace The furnace is equipped for installation in natural gas ap plications A conversion kit ordered separately is required for use in propane LP gas applications 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 or ventilated attic or crawlspace and flue gases are discharged outdoors See figures 1 and 2 for applications involving roof termination DIRECT VENT INSTALLATION EXHAUST OUTLET NON DIRECT VENT INSTALLATION s COMBUSTION EXHAUST AIR INTAKE OUTSIDE J OUTLET OF HOUSE COMBUSTIO AIR INTAKE INSIDE OF HOUSE FIGURE 1 NON DIRECT VENT INSTALLATION NON DIRECT VENT INSTALLATION EXHAUST EXHAUST ra OUTLET OUTLET COMBUSTION AIR INTAKE INSIDE VENTILATED COMBUSTION AIR INTAKE INSID VENTILATED ATTIC SPACE FIGURE 2 Page 3 Shipping and Packing List Package 1 of 1 contains 1 Assembled ML193UH unit 1 Bag assembly containing the following 1 Snap bushing 1 Snap plug 1 Wire tie 1 Condensate trap 1 Condensate trap cap 1 Condensate trap clamp 1 2 diameter debris screen 1 3 4 Threaded street elbow Check
60. lar on all models is sized to accom modate 2 Schedule 40 vent pipe In horizontal applica tions any transition to exhaust pipe larger than 2 must be made in vertical runs of the pipe Therefore a 2 elbow must be added before the pipe is transitioned to any size larger than 2 This elbow must be added to the elbow count used to determine acceptable vent lengths Contact the Applica tion Department for more information concerning sizing of vent systems which include multiple pipe sizes Exhaust Pipe Exhaust Pipe Horizontal Gas Furnace NOTE All horizontal runs of exhaust pipe must slope back to ward 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 checked carefully to make sure there are no sags or low spots FIGURE 22 TABLE 4 MINIMUM VENT PIPE LENGTHS ML193UH MIN VENT LENGTH MODEL 15 ft or 5 ft plus 2 elbows or 10 ft plus 1 elbow 045 070 090 110 Any approved termination may be added to the minimum length listed Page 17 Use the following steps to correctly size vent pipe diameter Piping Size Process What is the furnace capacity G4 045 070 090 110 or 135 Which style termination being used Standard or concentric See table 3 Which needs 3 most elbows Intake or exhaust How many elbows
61. lengths listed may include the termination vent pipe exterior to the structure and cannot exceed 5 linear feet or the maximum allowable intake or exhaust vent length listed in table 5 or 6 which ever is less NOTE If insulation is required in an unconditioned space it must be located on the pipe closest to the furnace See figure32 Conditioned Exhaust DY wa Intake Pipe Conditioned z Space Unconditioned Space FIGURE 32 Page 23 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 610 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 amp 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 30cm above opening 12 Equal to or greater than
62. ling demand the indoor blower will run on the cooling speed Page 37 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 THD total harmonic distortion Generator Use Voltage Requirements o The following requirements must 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 TYPICAL ML193UH WIRING DIAGRAM BLOWER SPEED CHART BURNERS UNIT FACTORY CONNECTED SPEED TAPS cenon ES e Ee el S47 O S47 YELLOW BLACK RED ROLLO FLAME RED BLACK YELLOW 4 veya ROLLOUT A FLAME IGNITER ROLLOUT RED __ Of SENSOR BLACK YELLOW RED 4 K43 ECON SWITCH J159 SWITCH IF USED P159 MOTOR A lt 3 zh ro Qa 045P24B 045P36B 070P24B 70P36B 90P36C COMBUSTION AIR INDUCER MOTOR s10 PRIMARY GAS ON Q LIMIT OFF 145 LOW GAS O 5 PRESSURE D GV1 SWITCH GAS VALVE s18 COMBUSTION AIR PROVING SWITCH e 3 156 a Ye DOOR INTERLOCK NOTE USE COPPER CONDUCTORS ONLY A92 IGNITION BLOWER CONTROL S1 ROOM THERMOSTAT INDOOR c4 BLOWER MOTOR CAPACITOR x zZ a uw E I x O D Z wW N OUTDOOR UNIT LINE H XFMR H EQU
63. ly for leak detection 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 ISOLATE PLUGGED TAP FIGURE 56 AIMPORTANT When testing pressure of gas lines gas valve must be disconnected and isolated See figure 56 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 cer tain metals Carefully rinse piping thoroughly after leak test has been completed Page 34 Left Side Piping ee Right Side Piping Standard with manual Alternate shut off valve Bellows Grommet MANUAL MAIN SHUT OFF amp VALVE l MANUAL XE OMAIN SHUT OFF VALVE GROUND i GROUND JOINT JOINT UNION x UNION DRIP LEG Gas Valve DRIP LEG Bellows Grommet FELD PROVIDED AND INSTALLED NOTE BLACK IRON PIPE ONLY TO BE ROUTED INSIDE OF CABINET FIGURE 57 Horizontal Applications Possible Gas Piping
64. me 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 ANSI 2223 1 Page 36 ELECTROSTATIC DISCHARGE ESD Precautions and Procedures CAUTION Electrostatic discharge can affect elec tronic components Take precautions to neutralize electrostatic charge by touching your hand and tools to metal prior to handling the control INTERIOR MAKE UP BOX INSTALLATION remove and relocate plug to unused opening on left side O Right Side FIGURE 59 The unit is equipped with a field make up box The make up box may be moved to the right side of the furnace to fa cilitate installation Seal unused openings on left side with plugs removed from right side Secure the excess wire to the existing harness to protect it from damage Refer to figure 60 for schematic wiring diagram and trou bleshooting The power supply wiring must meet Class restrictions Protected by ei
65. mum vent lengths NOTE The inlet and outlet air openings shall each have a free area of at least one square inch per 4 000 Btu 645mm2 per 1 17kW per hour of the total input rating of all equipment in the enclosure 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 ML193UH 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 ML193UH 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 ab sence 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 Can ada for details Position termination according to location given in figure 33 or 34 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 maintain 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 an outdoor AC unit because the condensate can damage
66. nches 9m pliances 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 1m 7 feet 2 1m t M Clearance under veranda porch deck or balcony 12 inches 305mm t 12 inches 305mm t 1In accordance with the current ANSI Z223 1 NFPA 54 Natural Fuel Gas Code 2 In accordance with the current CSA B149 1 Natural Gas and Propane Installation Code For clearances not specified in ANSI Z223 1 NFPA 54 or CSA B149 1 clearance will be in accordance with local installation t A vent shall not terminate directly above a sidewalk or paved driveway that is located codes and the requirements of the gas supplier and these between two single family dwellings and serves both dwellings installation instructions 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 34 Page 25 Details of Intake and Exhaust Piping Terminations for Direct Vent Installations NOTE In Direct Vent installations combustion air is taken from outdoors and flue gases are discharged to outdoors 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
67. nches is preferred FIGURE 14 z Removing the Bottom Panel Removing the Bottom Panel R Remove the two screws that secure the bottom cap to the furnace Pivot the bottom cap down to release the bottom panel Once the bottom panel has been removed reinstall the bottom cap See figure 15 Horizontal Applications AWARNING Do not install the furnace on its front or back See figure 16 Bottom Cap Bottom Panel FIGURE 15 FIGURE 16 Page 11 The ML193UH furnace can be installed in horizontal ap plications with either right or left hand air discharge Refer to figure 17 for clearances in horizontal applications Horizontal Application Installation Clearances Right Hand Discharge Left End Right End Air ie ip Air Flow Flow Bottom Floor Left Hand Discharge Right End a Air Flow Front clearance in alcove installation must be 24 in 610 mm Maintain a minimum of 24 in 610 mm for front service access An 8 service clearance must be maintained below the unit to provide for servicing of the condensate trap For installations on a combustible floor do not install the fur nace directly on carpeting tile or other combustible materials oth er than wood flooring FIGURE 17 Suspended Installation of Horizontal Unit This furnace may be installed in either an attic or a crawl space Either suspend the furnace from roof rafters or floo
68. ndensate trap and empty water Inspect the trap then reinstall the clean out cap Cleaning the Burner Assembly 1 Turn off gas and electrical power to the furnace Re move heating compartment access panel 2 Disconnect the gas supply line from the gas valve 3 Disconnect and label wires from gas valve 4 Disconnect ignitor wiring at 2 circuit plug 5 Disconnect and label wires from rollout switch 6 Disconnect and label flame sensor wire 7 Disconnect and label ground wire from burner man ifold assembly 8 Remove four screws that secures burner manifold as sembly to vestibule Remove the assembly and make note not to allow ignitor plate to dislodge from the as sembly 9 Gently clean the face of the burners using the soft brush attachment on a vacuum cleaner Visually in spect the inside of the burners and crossovers for any blockage caused by foreign matter Remove any blockage 10 Reinstall the burner manifold assembly using the ex isting four screws Burners are self aligning to cen ter of clam shells 11 Reconnect ground wire 12 Reconnect flame sensor wire 13 Reconnect rollout switch wires 14 Reconnect ignitor wires 15 Reconnect gas valve wires 16 Reconnect gas supply line to gas valve 17 Refer to instructions on verifying gas and electrical connections when re establishing supplies 18 Follow instructions to place furnace in operation Run furnace 5 minutes to ensure burner
69. need to run the blower both furnaces will run the blower on the same speed The cooling speed has highest priority fol lowed by heating speed and fan speed Field installation of twinning consists of connecting wires between the C and Twin terminals of the two controls The 24 VAC secondary of the two systems must be in phase All thermostat connections are made to one control only Figure 2 show wiring for two stage and single stage thermostats The twinned furnace without thermostat connections is to have the call for heat supplied by an external 24VAC isola tion relay to prevent its rollout switch from being bypassed by the other twinned furnace The coil of the isolation relay connects from the thermostat W to 24 VAC common The contacts of the relay connect R to W on the non thermo stat twin FIELD WIRING FOR TWINNING Call For 1st Stage Heat Call For 2nd StageHeat O FIGURE 2 Page 45 Service 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 in 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
70. ng 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 outside lt inside Wall ae FIGURE 20 1 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 2 When furnace is installed in a residence where unit is shut down for an extended period of time such as a vacation home make provisions for draining conden sate collection trap and lines REPLACING FURNACE THAT AS PART OF A COMMON VENT SYSTEM CHIMNEY ZN OR GAS VENT Check sizing for water heater only FURNACE Replaced by ML193 OPENINGS To Adjacent Room If an ML193UH furnace replaces a furnace which was commonly vented with another gas appliance the size of the existing vent pipe for that gas ap pliance 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 21 Exhaust Piping Figures 24 and 25 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 ga
71. o 5 Max above condensate drain connection SS Furnace Condensate Drain Connection Optional Overflow Switch FIGURE 50 ML193UH with Evaporator Coil Using a Separate Drain Unit shown in horizontal left hand discharge position Field Provided Vent Evaporator 4 min to 5 max above Coil condensate connection 4 min 5 max lt 9 max PVC Pipe Only Condensate Drain Connection Drain M es at coil is optional Piping from furnace and evaporator coil must slope down a minimum 1 4 per ft toward trap FIGURE 51 ML193UH with Evaporator Coil Using a Common Drain A IMPORTAN Evaporator drain line required T Trap at coil is optional E When combining the furnace and evaporator coil drains together the A C condensate drain Field Provided Vent outlet must be vented to relieve pressure in or 1 min to 2 Max above der for the furnace pressure switch to operate condensate drain connection properly Condensate Drain Connection FIGURE 52 ML193UH with Evaporator Coil Using a Common Drain Unit shown in horizontal left hand discharge position Field Provided Vent Evaporator 4 min to 5 Max above Coil condensate drain connection 4 min 5 max lt 5 max PVC Pipe Only Condensate Drain Connection
72. off delay affects comfort and is adjustable to satisfy individual applications Adjust the fan off delay to achieve a supply air temperature be tween 90 and 110 F at the moment that the blower is de energized Longer off delay settings provide lower re turn air temperatures shorter settings provide higher re turn air temperatures See figure 62 Electrical 1 Check all wiring for loose connections 2 Check for the correct voltage at the furnace furnace operating Correct voltage is 120VAC 10 Check amp draw on the blower motor with blower ac cess panel in place Motor Nameplate Blower Speeds Follow the steps below to change the blower speeds 1 Turn off electrical power to furnace o 1 Actual 2 Remove blower access panel 3 Disconnect existing speed tap at integrated control speed terminal HEAT FAN OFF TIME IN SECONDS HEAT OFF DELAY JUMPER POSITION PINI PIN PIN2 PIN3 PIN3 PIN4 PIN4 PINS 80 NO JUMPER 180 To adjust fan off timing reposition jumper across pins to achieve desired setting 90 Second 120 Second off Time off Time 60 Second off Time 180 Second off Time FIGURE 62 NOTE Termination of any unused motor leads must be in sulated 4 Place unused blower speed tap on integrated control PARK terminal or insulate 5 Refer to blower speed selection chart on unit wiring diagram for desired heating or cooling speed Se
73. or 44J41 FIGURE 44 3 If exhaust piping must be run up a side wall to position above snow accumulation or other obstructions pip ing must be supported every 24 inches 610mm When exhaust piping must be run up an outside wall any reduction in exhaust pipe size must be done after the final elbow 4 Distance between exhaust pipe terminations on mul tiple furnaces must meet local codes ML193UH NON DIRECT VENT APPLICATION USING EXISTING CHIMNEY SIZE TERMINATION PIPE PER TABLE 8 Minimum 12 305MM above chimney top plate or average snow accumulation STRAIGHT CUT OR ANGLE CUT IN DIRECTION OF ROOF SLOPE SHOULDER OF FITTINGS PROVIDE SUPPORT OF PIPE ON TOP PLATE SHEET METAL TOP PLATE INSULATE TO FORM EXTERIOR SEAL E 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 45 Condensate Piping This unit is designed for either right or left side exit of con densate piping in upflow applications In horizontal applica tions the condensate trap must extend below the unit An 8 service clearance is required for the condensate trap Refer to figures 46 and 48 for condensate trap locations F
74. p 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 For installations on a combustible floor do not install the fur nace directly on carpeting tile or other combustible materials oth er than wood flooring FIGURE 12 Return Air Guidelines Return air can be brought in through the bottom or either side of the furnace installed in an upflow application If the furnace is installed on a platform with bottom return make an airtight seal between the bottom of the furnace and the platform to ensure that the furnace operates properly and safely The furnace is equipped with a removable bottom panel to facilitate installation Markings are provided on both sides of the furnace cabinet for installations that require side return air Cut the furnace cabinet at the maximum dimensions shown on page 2 Refer to Engineering Handbook for additional information ML193UH applications which include side return air and a condensate trap installed on the same side of the cabinet trap can be installed remotely within 5 ft re quire either a return air base or field fabricated transi tion to accommodate an optional IAQ accessory taller than 14 5 See figure 13 Side Return Air with transition and filter 20 X 25 X 1 508mmX635mmX 25mm 1 1
75. place 3 Is the main disconnect switch closed 4 Is there a blown fuse or tripped breaker 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 Gas is 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 Gas Pressure Adjustment o 1 Gas Flow Approximate TABLE 10
76. r joists as shown in figure 18 or install the furnace on a plat form as shown in figure 19 A horizontal suspension kit 51W10 may be ordered from Lennox or use equivalent NOTE Heavy gauge sheet metal straps may be used to suspend the unit from roof rafters or ceiling joists When straps are used to suspend the unit in this way support must be provided for both the ends The straps must not in terfere with the plenum or exhaust piping installation Cool ing coils and supply and return air plenums must be supported separately HORIZONTAL SUSPENSION KIT 3 Internal Brace 3 provided with kit Metal Strap Ja typical Bracket FIGURE 18 NOTE When the furnace is installed on a platform or with the horizontal suspension kit in a crawlspace it must be elevated enough to avoid water damage accommodate drain trap and to allow the evaporator coil to drain Platform Installation of Horizontal Unit 1 Select location for unit keeping in mind service and other necessary clearances See figure 17 2 Construct a raised wooden frame and cover frame with a plywood sheet If unit is installed above finished space fabricate an auxiliary drain pan to be installed under unit Set unit in drain pan as shown in figure 19 Leave 8 inches for service clearance below unit for condensate trap 3 Provide a service platform in front of unit When instal ling the unit in a crawl space a proper support platform may be created usin
77. rglass 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 or contact your supervisor Lennox Industries Inc P O Box 799900 Dallas TX 75379 9900 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 Permanent wave solutions These instructions are intended as a general guide and do Chlorinated waxes and cleaners not supersede local codes in any way Consult authorities Chlorine base swimming pool chemicals having jurisdiction before installation Water softening chemicals n i i De icing salts or chemicals In addition to the requirements outlined previously the fol Carbon tetrachloride lowing general recommendations must be considered Halogen type refrigerants when installing a ML193UH furnace Cleaning solvents such as per
78. s 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 ex haust fans which force air out of the house When fire places exhaust fans or clothes dryers are used at the same time as the furnace much more air is required to en sure proper combustion and to prevent a downdraft Insuf ficient 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 m 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 provi
79. s 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 Page 16 Vent Piping Guidelines The ML193UH 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 out doors In Direct Vent installations combustion air is taken from outdoors and flue gases are discharged outdoors Intake and exhaust pipe sizing Size pipe according to tables 4 and 5 Count all elbows inside and outside the home Table 4 lists the minimum vent pipe lengths per mitted Table 5 lists the maximum pipe lengths permitted Regardless of the 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 NOTE The exhaust col
80. s are clean and op erating correctly 19 Replace heating compartment access panel Page 46 Repair Parts List The following repair parts are available through Lennox dealers When ordering parts include the complete furnace model number listed on the CSA nameplate Example ML193UH045XP36B 01 All service must be performed by a licensed professional installer or equivalent service agency or gas supplier 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 47 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 SUPPLY sure Line Voltage GAS SUPPLY C Natural Gas _ LP Propane Gas C Piping Connections Tight L Leak Tested Fiter L Supply Line Pressure W C Sh RETURN AIR Duct sys GUPey air puct L Sealed L Insulated if necessary INTAKE E
81. s external to the structure Any vent pipe or elbows external to the structure must be included in total vent length calculations See vent length tables Kits must be properly installed according to kit instructions 1Requires field provided outdoor 1 1 2 exhaust accelerator 2Concentric kits 71M80 and 44W92 include 1 1 2 outdoor accelerator when uses with 045 and 070 input models 3 Flush mount kits 51W11 and 51W12 includes 1 1 2 in outdoor exhaust accelerator required when used with 045 070 and 090 input models 4 Termination kits 30G28 44W92 4493 and 81J20 are certified to ULC S636 for use in Canada only 5 See table 8 for vent accelerator requirements 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 in take pipe to the connector if desired Use a drill or self tap ping 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 least 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 outsi
82. 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 2 below for approved piping and fitting ma terials Page 13 A CAUTION Solvent cements for plastic pipe are 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 ce ment with skin and eyes TABLE 2 PIPING AND FITTINGS SPECIFICATIONS ABS DWYV Drain Waste amp Vent Pipe amp Fittings D2661 PVC DWV Drain Waste amp Vent Pipe amp Fittings pee ASTM PRIMER amp SOLVENT CEMENT SPECIFICATION PVC CPVC ABS All Purpose Cement For Fittings amp Pipe of the same material D2564 D2235 F493 ABS to PVC or CPVC Transition Solvent CANADA PIPE amp FITTING amp SOLVENT CEMENT PVC amp CPVC Pipe and Fittings PVC amp CPVC Solvent Cement ABS to PVC or CPVC Transition Cement ULCS636 A IMPORTANT ML193UH exhaust and intake connections are 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 t
83. step 3 return doors win dows exhaust fans fireplace dampers and any other gas burning appliance to their previous condition of use 1 Other Unit Adjustments Primary Limit The 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 120 seconds The fan
84. sts 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 57 and 58 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 A 1 8 N P T plugged tap or pressure post is located on the gas valve to facilitate test gauge connection See figure 61 6 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 AIMPORTANT Compounds used on 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 factory and field installed for gas leaks Use a leak detecting solution or other preferred means Never use an open flame to test for gas leaks Check all connections using a commercially available soap solution made specifical
85. tal Right Hand Air Discharge Application Shown PVC pipe coupling OR a INTAKE DEBRIS SCREEN Provided NOTE Debris screen may be positioned straight out preferred or with an elbow rotated to face down FIGURE 29 Follow the next two steps when installing the unit 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 28 or 29 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 to either side in the upflow position and either straight out or downward in the horizontal position The air intake piping must not terminate too close to the flooring or a platform Ensure that the intake air inlet will not be obstructed by loose insulation or other items that may clog the debris screen 2 If intake air is drawn from a ventilated attic figure 30 or ventilated crawlspace figure 31 the exhaust vent length must not exceed those listed in table 7 If 3 di ameter pipe is used reduce to 2 diameter pipe at the termination point to accommodate the debris screen Use a sheet metal scr
86. tems 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 The 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 50 FOR THE PROVINCE OF ONTARIO HORIZONTAL SIDEWALL VENT APPLICATIONS ONLY For exterior horizontal venting applications the 2 X 1 5 plume is unobjectionable If the installation requires more reducer for 2 venting at the point where the exhaust pipe separation between the flue gases and the building struc exits the structure is not required in direct or non direct vent ture a reducer may be installed on the exhaust pipe to in applications in the Province of Ontario In these applica crease the flue gas velocity tions the vent should be oriented such that the exhaust Page 51
87. the painted coating NOTE See table 7 for maximum allowed exhaust pipe length without insulation in unconditioned space during winter design temperatures below 32 F 0 C If required exhaust pipe should be insulated with 1 2 13mm Arma flex or equivalent In extreme cold climate areas 3 4 19mm Armaflex or equivalent may be necessary Insula tion must be protected from deterioration Armaflex with UV protection is permissable Basements or other en closed areas that are not exposed to the outdoor ambient temperature and are above 32 degrees F 0 C are to be considered conditioned spaces A IMPORTANT Do not use screens or perforated metal in exhaust terminations Doing so will cause freeze ups and may block the terminations A 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 22 TABLE 7 Maximum Allowable Exhaust Vent Pipe Length in ft Without Insulation In Unconditioned Space For Winter Design Temperatures Single Stage High Efficiency Furnace Winter Design Vent Pipe Temperatures F C Diameter a in 7 to 17 in 18 to 29 1Refer to 99 Minimum Design Temperature table provided in the current edition of the ASHRAE Fundamentals Handbook NOTE Maximum unisulated vent
88. ther 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 check to make sure the wires will be long enough for servicing at a later date Make sure that thermostat wire is long enough to facilitate future removal of blower for service Complete the wiring connections to the equipment Use the provided unit wiring diagram and the field wiring shown in figure 60 Use 18 gauge wire or larger that is suitable 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 ML193UH furnace contains electronic compo nents that are polarity sensitive Make sure that the furnace is wired correctly and is properly grounded Accessory Terminals One line voltage EAC 1 4 spade terminal is provided on the furnace integrated control See figure 1 for integrated control configuration This term
89. ting 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 in 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 horizon tal pitch Determine that there is no blockage restric tion leakage corrosion or other deficiencies which could cause an unsafe condition 3 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 4 Follow the lighting instructions Turn on the appliance that is being inspected Adjust the thermostat so that the appliance operates continuously 5 After the main burner has operated for 5 minutes test for leaks of flue gases at the draft hood relief opening Use the fla
90. ucer 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 oO 1 A Li oa 1 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 On field supplied terminations a minimum distance 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 O 1 NOTE Care must be taken to avoid recirculation of exhaust back into intake pipe TABLE 8 EXHAUST PIPE TERMINATION SIZE REDUCTION ML193UH Termination Pipe Size MODEL 045 and 070 1 1 2 38mm ML193UH 045 070 and 090 units with the flush mount termination must use the 1 1 2 accelerator supplied with the kit unless a tee is used for termination as shown figure 42 3 76mm MAX SIZE TERMINATION PIPE PER TABLE 8 Inches mm 8 203mm MIN 12 305mm ABOVE AVERAGE SNOW ACCUMULATION 3 76mm O 2 51mm PVC e UNCONDITIONED PROVIDE SUPPORT FOR INTAKE AND ATTIC SPACE EXHAUST LINES DIRECT VENT ROOF TERMINATION KIT 15F75 or 44J41 FIGURE 35 Exiting Exhaust and Intake Vent different pressure zones aN Z K Exhaust i gis
91. ure 2 Start unit and allow 5 minutes for unit to reach steady state 3 While waiting for the unit to stabilize observe 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 11 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 TABLE 11 Supply Line and Manifold Pressure inches w c Manifold Line Pressure Pressure NOTE A natural to L P propane gas changeover kit is necessary to convert this unit Refer to the changeover kit installation instruction for the conversion procedure 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 TABLE 12 ML193 090 72 79 8 6 9 3 The maximum carbon monoxide reading should not exceed 50 ppm High Altitude Information NOTE In Canada certification for installations at eleva tions over 4500 feet 1372 m is the jurisdiction of local au thorities ML193UH 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
92. ut rat ing of all equipment in the enclosure See figure 5 It is also permissible to bring in air for combustion from a ventilated attic figure 6 or ventilated crawl space figure 7 EQUIPMENT IN CONFINED SPACE ALL AIR FROM OUTSIDE Inlet Air from Crawl Space and Outlet Air to Ouside VENTILATION LOUVERS Each end of attic ROOF TERMINATED EXHAUST PIPE z SIDE WALL TERMINATED EXHAUST PIPE ALTERNATE LOCATION VENTILATION LOUVERS For unheated crawl space 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 EQUIPMENT IN CONFINED SPACE Inlet Air from Ventilated Attic and Outlet Air to Outside Ventilation Louvers Inlet Air A Minimum SSA 12 in 305mm Above attic floor Roof Terminated Exhaust Pipe Intake Debris Screen Provided Furnace See table 6 for maximum vent lengths 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 Page 7 EQUIPMENT IN CONFINED SPACE Inlet Air from Ventilated Crawlspace and Outlet Air to Outside Roof Terminated Exhaust Pipe Inlet Air Minimum 12 in 305mm Above crawl space floor Ventilation Louvers Crawl space
93. ved driveway located on public property INSIDE CORNER DETAIL Y AREA WHERE TERMINAL N IS NOT PERMITTED amp AIR SUPPLY INLET US Installations Canadian Installations2 12 inches 305mm or 12 in 305mm 12 inches 305mm or 12 in 305mm above average snow accumulation above average snow accumulation 6 inches 152mm for appliances lt 10 000 6 inches 152mm for appliances lt 10 000 Btuh 3kw 9 inches 228mm for ap Btuh 3kw 12 inches 305mm for pliances gt 10 000 Btuh 3kw and lt 50 000 appliances gt 10 000 Btuh 3kw and Btuh 15 kw 12 inches 305mm for ap lt 100 000 Btuh 30kw 36 inches 9m pliances gt 50 000 Btuh 15kw for appliances gt 100 000 Btuh 30kw 42 12 Equal to or greater than soffit depth Equal to or greater than soffit depth Equal to or greater than soffit depth Equal to or greater than soffit depth No minimum to outside corner 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 above the meter regulator assembly 3 feet 9m 3 feet 9m 6 inches 152mm for appliances lt 10 000 6 inches 152mm for appliances lt 10 000 Btuh 3kw 9 inches 228mm for ap Btuh 3kw 12 inches 305mm for pliances gt 10 000 Btuh 3kw and lt 50 000 appliances gt 10 000 Btuh 3kw and Btuh 15 kw 12 inches 305mm for ap lt 100 000 Btuh 30kw 36 i

Lennox International Inc. ML193UH Gas Heater User Manual

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