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© 2022 Lennox Industries Inc.
Dallas, Texas USA
INSTALLATION
INSTRUCTIONS
ML193UHE
MERIT ® SERIES GAS FURNACE
UPFLOW / HORIZONTAL AIR DISCHARGE
507863-02
03/2022
Supersedes 10/2021
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.
CAUTION
As with any mechanical equipment, contact with sharp sheet metal edges can result in personal injury. Take care while handling this equipment and wear gloves and protective clothing.
WARNING
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 HVAC installer (or equivalent), service agency, or the gas supplier.
Contents
Unit Dimensions - inches (mm) ......................................2
ML193UHEGas Furnace ................................................3
Shipping and Packing List ..............................................3
Safety .............................................................................3
Use of Furnace as a Construction Heater ......................4
General ...........................................................................5
Combustion, Dilution, Ventilation Air...............................5
Setting Equipment ..........................................................8
Filters ............................................................................13
Duct System .................................................................13
Pipe Fittings Specifications ...........................................14
Joint Cementing Procedure ..........................................15
Venting Practices ..........................................................16
Gas Piping ....................................................................33
Electrical .......................................................................36
Integrated Control .........................................................39
Unit Start-Up .................................................................41
Gas Pressure Measurement.........................................42
Proper Combustion.......................................................43
High Altitude .................................................................43
Testing For Combustion Air Non-Direct Vents ..............44
Other Unit Adjustments.................................................45
Service..........................................................................46
Repair Parts List ...........................................................46
Start Up Checklist .........................................................48
Blower Data ..................................................................52
Page 1
Unit Dimensions - inches (mm)
1 NOTE - 60C size units that require air volumes over
1800 cfm must have one of the following:
1. Single side return air and Optional Return Air Base
with transition that must accommodate required
20 x 25 x 1 inch (508 x 635 x 25 mm) air filter to
maintain proper velocity.
2. Bottom return air.
3. Return air from both sides.
4. Bottom and one side return air.
See Blower Performance Tables for additional information.
2 Optional Side Return Air Filter Kit is not for use with the Optional Return Air Base.
2 (51)
D
COMBUSTION
AIR INTAKE
Flue Condensate Trap Assembly
Furnished for external field installation on either side of unit.
(See installation instructions for additional information.)
7
(178)
2
OPTIONAL
SIDE RETURN
AIR FILTER KIT
(Either Side)
3-3/8
(86)
2-7/8
(73)
EXHAUST AIR
OUTLET
SUPPLY AIR
OPENING
23-3/4
(603)
25
(635)
TOP VIEW
3/4
(19)
Model No.
030XE36B
045XE36B
070XE36B
090XE36C
090XE48C
110XE48C
110XE60C
A
B
AIR FLOW
C
1
Bottom Return
Air Opening
FRONT VIEW
1 (25)
Front Panel
9/16 (14)
2 OPTIONAL
SIDE RETURN
AIR FILTER KIT
(Either Side)
33
(838)
6-9/16 (167)
Left
9 (229)
Right
12-5/8 (321)
(Either Side)
ELECTRICAL
INLET
(Either Side)
14-3/4
(375)
16
(406)
3/4
(19)
5/8
(16) 3-1/4
(83)
A in - mm
17-1/2 - 446
B in - mm
16-3/8 - 416
21 - 533 19-7/8 - 505
27-3/4
(705)
19-7/16
(494)
2 (51)
(Either Side)
GAS PIPING INLET
(Either Side)
CONDENSATE
TRAP CONNECTION
(Either Side)
6-1/2 (165)
(Either Side)
23
(584)
1 Side Return
Air Opening
(Either Side)
14
(356)
1-15/16 (49)
23-1/2
(597)
1
Bottom Return
Air Opening
SIDE VIEW
9/16
(14)
1-1/2
(38)
C in - mm
16 - 406
D in - mm
7-5/8 - 194
19-1/2 - 495 9-3/8 - 238
Page 2
ML193UHE Gas Furnace
The ML193UHE Category IV gas furnace is shipped ready for installation in the upflow or horizontal position. The fur nace is shipped with the bottom panel in place. The bottom panel must be removed if the unit is to be installed in horizontal or upflow applications with bottom return air.
or a Non-Direct Vent gas central furnace.
The furnace is equipped for installation in natural gas applications. 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 FIGURE 1 and FIGURE 2
for applications involving roof termination.
DIRECT VENT INSTALLATION
EXHAUST OUTLET
COMBUSTION
AIR INTAKE OUTSIDE
OF HOUSE
NON-DIRECT VENT
INSTALLATION
EXHAUST
OUTLET
COMBUSTION
AIR INTAKE
INSIDE
OF HOUSE
Shipping and Packing List
Package 1 of 1 contains
1 - Assembled ML193UHE 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 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
WARNING
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 HVAC installer (or equivalent), service agency, or the gas supplier.
FIGURE 1
NON-DIRECT VENT
INSTALLATION
EXHAUST
OUTLET
NON-DIRECT VENT
INSTALLATION
EXHAUST
OUTLET
COMBUSTION
AIR INTAKE INSIDE
VENTILATED
ATTIC SPACE
COMBUSTION
AIR INTAKE INSIDE
VENTILATED
CRAWL SPACE
Danger of explosion.
DANGER
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.
ML193UHE 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).
FIGURE 2
Page 3
The National Fuel Gas Code is available from the following address:
American National Standards Institute, Inc.
11 West 42nd Street
New York, NY 10036
In Canada, installation must conform with current National
Standard of Canada CSA-B149 Natural Gas and Propane
Installation Codes, local plumbing or waste water codes and other applicable local codes.
In order to ensure proper unit operation in non-direct vent applications, combustion and ventilation air supply must be provided according to the current National Fuel Gas
Code or CSA-B149 standard.
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 protection 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 atmosphere, the furnace must be installed ac cording to recommended good practice requirements and current National Fuel Gas Code or CSA B149 standards.
NOTE - Furnace 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 ML193UHE furnace must be installed so that its electrical 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 compartment. 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 manually 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 address:
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 I (CSA Standard C22.1) and/or local codes.
Heating Unit Installed Parallell to Air Handler Unit
Dampers
(open during heating operation only)
Gas Unit
Air Handler Unit
Dampers
(open during cooling operation only)
Heating Unit Installed Upstream of Cooling Unit
Gas Unit
Evaporator
FIGURE 3
NOTE - This furnace is designed for a minimum continu ous return air temperature of 60°F (16°C) or an intermittent operation 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 ML193UHE furnace may be installed in alcoves, closets, attics, basements, garages, crawl spaces and utility rooms in the upflow or horizontal position. This furnace design has not been CSA certified for installation in mobile homes, recreational vehicles, or outdoors.
Use of Furnace as Construction Heater
Units may be used for heating of buildings or structures under construction, if the following conditions are met to ensure proper operation:
DO NOT USE THE UNIT FOR CONSTRUCTION HEAT
UNLESS ALL OF THE FOLLOWING CRITERIA ARE
MET :
• Furnace must be in its final location. The vent system must be permanently installed per these installation instructions.
• Furnace must be installed as a two pipe system and one hundred percent (100%) outdoor air must be provided for combustion air requirements during construction.
• A room thermostat must control the furnace. The use of fixed jumpers that will provide continuous heating is prohibited.
• The input rate and temperature rise must be set per the furnace rating plate.
• Supply and Return air ducts must be provided and sealed to the furnace. Return air must be terminated outside of the space where furnace is installed.
Page 4
• Return air temperature range between 60°F (16°C) and
80°F (27°C) must be maintained.
• MERV 11 or greater air filters must be installed in the system and must be regularly inspected and maintained
(e.g., regular static checks and replaced at end of life) during construction.
• Blower and vestibule access panels must be in place on the furnace at all times.
• The furnace heat exchanger, components, duct system, and evaporator coils must be thoroughly cleaned following final construction clean−up.
• Air filters must be replaced upon construction comple tion.
• All furnace operating conditions (including ignition, input rate, temperature rise and venting) must be verified in accordance with these installation instructions.
EQUIPMENT MAY EXPERIENCE PREMATURE COM-
PONENT FAILURE AS A RESULT OF FAILURE TO FOL-
LOW THE ABOVE INSTALLATION INSTRUCTIONS.
FAILURE TO FOLLOW THE ABOVE INSTALLATION IN-
STRUCTIONS VOIDS THE MANUFACTURER’S EQUIP-
MENT LIMITED WARRANTY. LENNOX DISCLAIMS
ALL LIABILITY IN CONNECTION WITH INSTALLER’S
FAILURE TO FOLLOW THE ABOVE INSTALLATION IN-
STRUCTIONS .
NOTWITHSTANDING THE FOREGOING, INSTALLER
IS RESPONSIBLE FOR CONFIRMING THAT THE USE
OF CONSTRUCTION HEAT IS CONSISTENT WITH THE
POLICIES AND CODES OF ALL REGULATING ENTI-
TIES. ALL SUCH POLICIES AND CODES MUST BE AD-
HERED TO.
General
These instructions are intended as a general guide and do not supersede local codes in any way. Consult authorities having jurisdiction before installation.
In addition to the requirements outlined previously, the following general recommendations must be considered when installing a ML193UHE furnace:
• Place the furnace as close to the center of the air distribution system as possible. The furnace should also be located close to the vent termination point.
• When the furnace is installed in non-direct vent applications, do not install the furnace where drafts might blow directly into it. This could cause improper combustion and unsafe operation.
• When the furnace is installed in non-direct vent applications, do not block the furnace combustion air opening with clothing, boxes, doors, etc. Air is needed for proper combustion and safe unit operation.
• When the furnace is installed in an attic or other insulated space, keep insulation away from the furnace.
• When the furnace is installed in an unconditioned space, consider provisions required to prevent freezing of condensate drain system.
• Please consult the manufacturer of your evaporator coil for their recommendations on distance required between the heat exchanger and their drain pan. Adequate space must be provided between the drain pan and the furnace heat exchanger.
Page 5
CAUTION
ML193UHE unit should not be installed in areas normally subject to freezing temperatures.
WARNING
Insufficient combustion air can cause headaches, nausea, dizziness or asphyxiation. It will also cause excess water in the heat exchanger resulting in rusting 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 combustion air supply:
Permanent wave solutions
Chlorinated waxes and cleaners
Chlorine base swimming pool chemicals
Water softening chemicals
De-icing salts or chemicals
Carbon tetrachloride
Halogen type refrigerants
Cleaning solvents (such as perchloroethylene)
Printing inks, paint removers, varnishes, etc.
Hydrochloric acid
Cements and glues
Antistatic fabric softeners for clothes dryers
Masonry acid washing materials
Combustion, Dilution & Ventilation Air
If the ML193UHE is installed as a Non-Direct Vent Furnace, follow the guidelines in this section.
NOTE - In Non-Direct Vent installations, combustion air is taken from indoors or ventilated attic or crawlspace and flue gases are discharged out-doors.
In the past, there was no problem in bringing in sufficient outdoor air for combustion. Infiltration provided all the air that was needed. In today’s homes, tight construction practices make it necessary to bring in air from outside for combustion. Take into account that exhaust fans, appliance vents, chimneys, and fireplaces force additional air that could be used for combustion out of the house. Unless outside air is brought into the house for combustion, negative pressure (outside pressure is greater than inside pressure) will build to the point that a downdraft can occur in the furnace vent pipe or chimney. As a result, combustion gases enter the living space creating a potentially dangerous situation.
In the absence of local codes concerning air for combustion and ventilation, use the guidelines and procedures in this section to install ML193UHE furnaces to ensure effi cient 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 permission from the National Fuel Gas Code (AN-
SIZ223.1/ NFPA 54).
This reprinted material is not the complete and official po sition of the ANSI on the referenced subject, which is represented only by the standard in its entirety.
In Canada, refer to the CSA B149 installation codes.
CAUTION
Do not install the furnace in a corrosive or contaminated atmosphere. Meet all combustion and ventilation air requirements, as well as all local codes.
All gas-fired appliances require air for the combustion process. If sufficient combustion air is not available, the furnace or other appliance will operate inefficiently and unsafely. Enough air must be provided to meet the needs of all fuel-burning appliances and appliances such as exhaust fans which force air out of the house. When fireplac es, exhaust fans, or clothes dryers are used at the same time as the furnace, much more air is required to ensure proper combustion and to prevent a downdraft. Insuffi cient air causes incomplete combustion which can result in carbon monoxide.
In addition to providing combustion air, fresh outdoor air dilutes contaminants in the indoor air. These contaminants may include bleaches, adhesives, detergents, solvents and other contaminants which can corrode furnace components.
The requirements for providing air for combustion and ventilation depend largely on whether the furnace is installed in an unconfined or a confined space.
Unconfined Space
An unconfined space is an area such as a basement or large equipment room with a volume greater than 50 cubic feet (1.42 m3) per 1,000 Btu (.29 kW) per hour of the combined 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 unconfined, it might be necessary to bring in outdoor air for combustion if the structure does not provide enough air by infiltration. If the furnace is located in a building of tight construction with weather stripping and caulking around the windows and doors, follow the procedures in the Air from Outside section.
Confined Space
A confined space is an area with a volume less than 50 cubic feet (1.42 m3) per 1,000 Btu (.29 kW) per hour of the combined 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 containing 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 either 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 kW) per hour of total input rating of all gas-fired equipment in the confined space. Each opening must be at least 100 square inches
(64516 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
ROOF TERMINATED
EXHAUST PIPE
SIDE WALL
TERMINATED
EXHAUST PIPE
(ALTERNATE
LOCATION)
OPENINGS
(To Adjacent
Unconfined
Space)
NOTE - Each opening shall have a free area of at least one square inch per 1,000 Btu (645mm 2 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 ventilation, the confined space shall be provided with two perma nent openings. One opening shall be within 12” (305mm) of the top of the enclosure and one within 12” (305mm) of the bottom. These openings must communicate directly or by ducts with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors or indirectly through vertical ducts. Each opening shall have a minimum free area of 1 square inch per 4,000 Btu (645mm2 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 (645mm2 per .59kW) per total input rating of all equipment in the enclosure (See
EQUIPMENT IN CONFINED SPACE - ALL AIR FROM OUTSIDE
(Inlet Air from Crawl Space and Outlet Air to Outside)
VENTILATION LOUVERS
(Each end of attic)
ROOF TERMINATED
EXHAUST PIPE
SIDE WALL
TERMINATED
EXHAUST PIPE
(ALTERNATE
LOCATION)
FURNACE
INLET
AIR
OUTLET
AIR
FIGURE 5
*Intake Debris
Screen
(Provided)
Furnace
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 2 per 1.17kW) per hour of the total input rating of all equipment in the enclosure.
EQUIPMENT IN CONFINED SPACE
(Inlet Air from Ventilated Attic and Outlet Air to Outside)
Roof Terminated
Exhaust Pipe
Ventilation Louvers
Inlet Air
(Minimum
12 in.(305mm) Above attic floor)
EQUIPMENT IN CONFINED SPACE
(Inlet Air from Ventilated Crawlspace and Outlet Air to Outside)
Roof Terminated
Exhaust Pipe
Ventilation
Louvers
(Crawl space)
Furnace
Inlet Air
(Minimum
12 in.(305mm)
Above crawl space floor)
Coupling or
3 in. to 2 in.
Transition
(Field Provided)
*Intake Debris Screen Provided)
NOTE-The inlet and outlet air openings shall each have a free area of at least one square inch per 4,000 Btu (645mm 2 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 ventilation, 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 directly or by ducts with the outdoors or spaces
(crawl or attic) that freely communicate with the outdoors or indirectly through vertical ducts. Each opening shall have a minimum free area of 1 square inch (645 mm2) per 4,000 Btu (1.17 kW) per hour of total input rating of
all equipment in the enclosure. See FIGURE 5 and FIG-
URE 8. When communicating with the outdoors through
horizontal ducts, each opening shall have a minimum free area of 1 square inch (645 mm2) per 2,000 Btu (.56 kW) per total input rating of all equipment in the enclosure. See
When ducts are used, they shall be of the same cross-sectional area as the free area of the openings to which they connect. The minimum dimension of rectangular air ducts shall be no less than 3 inches (75 mm). In calculating free area, the blocking effect of louvers, grilles, or screens must be considered. If the design and free area of protective covering is not known for calculating the size opening required, it may be assumed that wood louvers will have
20 to 25 percent free area and metal louvers and grilles will have 60 to 75 percent free area. Louvers and grilles must be fixed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation.
NOTE-The inlet and outlet air openings shall each have a free area of at least one square inch per 4,000 Btu (645mm 2 per 1.17kW) per hour of the total input rating of all equipment in the enclosure.
FIGURE 6
Page 7
EQUIPMENT IN CONFINED SPACE - ALL AIR FROM OUTSIDE
(All Air Through Ventilated Attic)
flexible mounting leg). See FIGURE 10.
The bolt and washer must be removed before the furnace is placed into operation. After the bolt and washer have been removed, the rigid leg will not touch the blower housing.
Units with 1/2 or 3/4 HP Blower Motor
ROOF TERMINATED
EXHAUST PIPE
VENTILATION LOUVERS
(Each end of attic)
OUTLET
AIR
RIGID LEG remove shipping bolt and washe
SIDE WALL
TERMINATED
EXHAUST PIPE
(ALTERNATE
LOCATION)
FURNACE
INLET AIR
(Ends 12” above bottom)
NOTE-The inlet and outlet air openings shall each have a free area of at least one square inch per 4,000 Btu (645mm 2 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
OUTLET AIR
SIDE WALL
TERMINATED
EXHAUST PIPE
(ALTERNATE
LOCATION)
FURNACE
INLET AIR
NOTE-Each air duct opening shall have a free area of at least one square inch per 2,000 Btu (645mm 2 per .59kW) per hour of the total input rating of all equipment in the enclosure. If the equipment room cate directly with the outdoors, each opening shall have a free area of at least 1 square inch per 4,000 Btu (645mm 2 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 and 3/4 hp blower motor are equipped with three flexible legs and one rigid leg. The rigid leg is equipped with a shipping bolt and a flat white plastic wash er (rather than the rubber mounting grommet used with a
FIGURE 10
Installation - Setting Equipment
WARNING
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.
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 ML193UHE gas furnace can be installed as shipped in the upflow position. Refer to figure 12 for clearances.
Select a location that allows for the required clearances that are listed on the unit nameplate. Also consider gas supply connections, electrical supply, vent connection, condensate trap and drain connections, and installation and service 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
Allow for clearances to combustible materials as indicated on the unit nameplate.
Page 8
SETTING EQUIPMENT
UPFLOW APPLICATION
Place level on the front blower deck to check side to side
Place level on blower deck screws to check forward tilt
UNIT
FRONT
AIR FLOW
1/2” max.
SIDE VIEW
HORIZONTAL APPLICATION
UNIT
FRONT
AIR FLOW 1/2” max.
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
WARNING
Improper installation of the furnace can result in personal 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 furnace should be sealed airtight to the return air plenum.
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. Allow absolutely no sagging, cracks, gaps, etc. For no reason should return and supply air duct systems ever be connected to or from other heating devices such as a fireplace or stove, etc. Fire, explosion, carbon monoxide poisoning, personal injury and/or property damage could result.
Installation Clearances
Top
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.
ML193UHE 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.) require either a return air base or field-fabricated transition to accommodate an optional IAQ accessory taller than 14.5”. See figure 13.
Side Return Air
(with transition and filter)
Left Side Right Side
20” X 25” X 1”
(508mmX635mmX 25mm)
Air Filter
Bottom (Floor)
Top/Plenum
*Front
Back
Sides
1 in. (25 mm)
0
0
0
†
Vent
Floor 0
0
‡
*Front clearance in alcove installation must be 24 in. (610 mm).
Maintain a minimum of 24 in. (610 mm) for front service access.
†
Allow proper clearances to accommodate condensate trap.
‡
For installations on a combustible floor, do not install the furnace directly on carpeting, tile or other combustible materials other than wood flooring.
FIGURE 12
Transition
FIGURE 13
Return
Air
Plenum
Page 10
CONDENSATE
TRAP
FURNACE
FRONT
Optional Return Air Base
(Upflow Applications Only)
AIR FLOW
INDOOR AIR
QUALITY
CABINET
(PCO, Filter
Cabinet, etc.)
IF BASE
IS USED
WITHOUT
IAQ CABINET,
A SINGLE
RETURN AIR
PLENUM
MUST
COVER BOTH
UNIT AND
RETURN
AIR BASE
OPENINGS
3−1/4
(83)
7−1/4
(184)
1 23 (584)
Overall
(Maximum)
1 Unit side return air
Opening
1 Minimum
11 (279)
2 Maximum
14 (356)
5−5/8
(143)
SIDE RETURN
AIR OPENINGS
(Either Side)
1 22−7/16
(570)
Overall
(Maximum)
17−1/2 (446) B Width (50W98)
21 (533) C Width (50W99)
24−1/2 (622) D Width (51W00)
FRONT VIEW
OPTIONAL
RETURN
AIR BASE
23
(584)
26−7/8
(683)
SIDE VIEW
3/4
(19)
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 or more of air (W x H): 23 x 11 in. (584 x 279 mm).
2
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.
To minimize pressure drop, the largest opening height possible (up to 14 inches) is preferred.
Removing the Bottom Panel
FIGURE 14
Removing the Bottom Panel
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
WARNING
Do not install the furnace on its front or back. See
See figure 4.
Screw
Bottom Panel
FIGURE 15
Bottom Cap
Front
FIGURE 16
Back
Page 11
The ML193UHE furnace can be installed in horizontal ap plications with either right- or left-hand air discharge.
Refer to FIGURE 17 for clearances in horizontal applica
tions.
Horizontal Application
Installation Clearances
Right-Hand Discharge
L e f t E n d R i g h t E n d
AIR FLOW
Air
Flow
Air
Flow
Bottom (Floor)**
Left-Hand Discharge
Top
L e f t E n d R i g h t E n d
AIR FLOW
Bottom (Floor)**
Top
Front*
Back
Ends
0
0
0
0
Vent
Floor 0
0
‡
*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 furnace directly on carpeting, tile or other combustible materials other than wood flooring.
FIGURE 17
Suspended Installation of Horizontal Unit
This furnace may be installed in either an attic or a crawlspace. Either suspend the furnace from roof rafters or
floor joists, as shown in FIGURE 18, or install the furnace
on a platform, as shown in FIGURE 19. A horizontal sus
pension 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 interfere with the plenum or exhaust piping installation.
Cooling coils and supply and return air plenums must be supported separately.
HORIZONTAL SUSPENSION KIT
Metal Strap
(typical)
Internal Brace
(provided with kit)
Bracket
(typical)
Air
Flow
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 installing the unit in a crawl space, a proper support platform may be created using 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 condensate 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
INTAKE PIPE
EXHAUST PIPE
*Gas connector may be used for Canadian able by local authority having jurisdiction.
*GAS CONNECTION
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. See FIGURE 20 for proper duct
installation.
SUPPLY
AIR
SERVICE PLATFORM
RAISED
PLATFORM
FIGURE 19
Return Air -- Horizontal Applications
Return air may be brought in only through the end of a furnace installed in the horizontal position. The furnace is equipped with a removable bottom panel to facilitate in-
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
operate properly. TABLE 1 lists recommended filter sizes.
A filter must be in place whenever the unit is operating.
WARNING
If a high efficiency filter is being installed as part of this system to ensure better indoor air quality, the filter must be properly sized. High efficiency filters have a higher static pressure drop than standard efficiency glass/foam filters. If the pressure drop is too great, system capacity and performance may be reduced. 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 information is provided in Service and Application Note ACC002 (August 2000).
Furnace
Cabinet Width
17-1/2”
21”
TABLE 1
Side Return
Filter Size
Bottom Return
16 X 25 X 1 (1)
16 X 25 X 1 (1)
16 X 25 X 1 (1)
20 X 25 X 1 (1)
Install self tapping screws to seal any potential air leaks
SUPPLY
AIR
UPFLOW UNIT
HORIZONTAL UNIT
FIGURE 20
NOTE - This furnace is not certified for operation in heat ing 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 always be in place when the furnace is operating and it must not allow leaks. For horizontal units, in stall self tapping screws in the three evaporator coil screw holes made for horizontal applications to seal the top cap to the vestibule panel.
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 device (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 reverse flow of the flue gas may result in incomplete combustion 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 furnace 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 fiberglass sealing strips, caulking, or equivalent seal ing method between the plenum and the furnace cabinet to ensure a tight seal. If a filter is installed, size the return air duct to fit the filter frame.
Page 13
Pipe & Fittings Specifications
All pipe, fittings, primer and solvent cement must conform with American National Standard Institute and the American Society for Testing and Materials (ANSI/ASTM) standards. The solvent shall be free flowing and contain no lumps, undissolved particles or any foreign matter that adversely affects the joint strength or chemical resistance of the cement. The cement shall show no gelation, stratification, or separation that cannot be removed by stirring.
Refer to the TABLE 2 below for approved piping and fitting
materials
TABLE 2
PIPING AND FITTINGS SPECIFICATIONS
Schedule 40 PVC (Pipe) D1785
Schedule 40 PVC (Cellular Core Pipe)
Schedule 40 PVC (Fittings)
Schedule 40 CPVC (Pipe)
Schedule 40 CPVC (Fittings)
SDR-21 PVC or SDR-26 PVC (Pipe)
SDR-21 CPVC or SDR-26 CPVC (Pipe)
Schedule 40 ABS Cellular Core DWV
(Pipe)
Schedule 40 ABS (Pipe)
Schedule 40 ABS (Fittings)
ABS-DWV (Drain Waste & Vent) (Pipe &
Fittings)
PVC-DWV (Drain Waste & Vent) Pipe &
Fittings)
F891
D2466
F441
F438
D2241
F442
F628
D1527
D2468
D2661
D2665
PRIMER & SOLVENT CEMENT
PVC & CPVC Primer
PVC Solvent Cement
CPVC Solvent Cement
ABS Solvent Cement
PVC/CPVC/ABS All Purpose Cement
For Fittings & Pipe of the same material
ABS to PVC or CPVC Transition Solvent
Cement
CANADA PIPE & FITTING & SOLVENT
CEMENT
PVC & CPVC Pipe and Fittings
PVC & CPVC Solvent Cement
ABS to PVC or CPVC Transition
Cement
POLYPROPYLENE VENTING SYSTEM
PolyPro® by Duravent
ASTM
SPECIFICATION
F656
D2564
F493
D2235
D2564, D2235,
F493
D3188
MARKING
ULCS636
InnoFlue® by Centrotherm
UL 1738 CERTIFIED GAS VENTING SYSTEM
PEX System1738 Schedule 40 PVC
Pipes and Fittings
IPEX System1738 PVC FGV Cement &
Primer
UL1738
CAUTION
Solvent cements for plastic pipe are flammable liquids and should be kept away from all sources of ignition.
Do not use excessive amounts of solvent cement when making joints. Good ventilation should be maintained to reduce fire hazard and to minimize breathing of solvent vapors. Avoid contact of cement with skin and eyes.
IMPORTANT
ML193UHE 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 the 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 inside 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 manu facturer as part of an approved vent (exhaust) system. In addition, the first three feet of vent pipe from the furnace flue collar must be accessible for inspection.
Page 14
Input Size
030,
045
070
090
110
Vent Pipe
Dia. in.
6 1-1/2
2
2-1/2
3
6 1-1/2
2
2-1/2
3
2
2-1/2
3
2
2-1/2
3
Flush
Mount Kit
51W11
(US)
51W12
(CA)
3
3
3
3
3
3 YES
3 YES
3 YES
3 YES
3 YES
3 YES
YES
YES
YES
YES
YES
YES
YES
YES
TABLE 3
OUTDOOR TERMINATION USAGE*
STANDARD
Wall Kit
3 inch 2 inch
22G44
(US)
4 30G28
(CA)
44J40 (US)
4 81J20
(CA)
Field
Fabricated
YES
YES
YES
YES
YES
YES
YES
YES
1
1
1
1
1
1
1
1
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
5
5
5
5
5
5
5
5
5
5
YES
YES
YES
YES
YES
YES
YES
YES
5 YES
5 YES
YES
YES
5 YES
5 YES
1-1.2 inch
4
71M80
44W92
2
2
2
2
2
2
2
2
(US)
(CA)
YES
YES
YES
YES
YES
YES
YES
YES
CONCENTRIC
4
2 inch
69M29
(US)
44W92
(CA)
YES
YES
YES
YES
YES
YES
4
3 inch
60L46 (US)
44W93
(CA)
YES
YES
YES
YES
YES
YES
NOTE - Standard Terminations do not include any vent pipe or elbows 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 030, 045 and 070 input models. When using 1-1/2 inch vent pipe, transistion to 2” pipe before installing concentric kit.
3 Flush mount kits 51W11 and 51W12 includes 1-1/2 in. outdoor exhaust accelerator, required when used with 030, 045, 070 and 090 input models.When using 1-1/2” vent pipe, transition to 2” pipe before installing flushmount kit.
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.
6 Requires field provided 2” to 1-1/2” reducer.
Joint Cementing Procedure
All cementing of joints should be done according to the specifications outlined in ASTM D 2855.
NOTE - A sheet metal screw may be used to secure the intake pipe to the connector, if desired. Use a drill or self tapping screw to make a pilot hole.
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 outside of pipe.
5 - Uniformly apply a liberal coat of PVC primer for PVC or use a clean dry cloth for ABS to clean inside socket surface of fitting and male end of pipe to depth of fitting socket.
NOTE - Time is critical at this stage. Do not allow primer to dry before applying cement.
6 - Promptly apply solvent cement to end of pipe and inside socket surface of fitting. Cement should be applied lightly but uniformly to inside of socket. Take care to keep excess cement out of socket. Apply second coat to end of pipe.
Page 15
7 - 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 during assembly (but not after pipe is fully inserted) to distribute cement evenly. DO NOT turn
ABS or cellular core pipe.
NOTE - Assembly should be completed within 20 seconds 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'
Exhaust Piping (FIGURE 25 and FIGURE 26)
Route piping to outside of structure. Continue with installation following instructions given in piping termination section.
REPLACING FURNACE THAT WAS PART OF A
COMMON VENT SYSTEM
CHIMNEY
OR GAS
VENT
(Check sizing for water heater only)
FURNACE
(Replaced)
WATER
HEATER
OPENINGS
(To Adjacent
Room)
* See Piping and Fittings Specifications table
NOTE - Isolate piping at the point where it exits the outside wall or roof in order to prevent transmission of vibration to the structure.
i n s i d
Wall Thickness Guidelines
24” maximum
3/4” minimum e
Wall o u t s i d e
FIGURE 21
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 condensate collection trap and lines.
If replacing a 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 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 22
CAUTION
Do not discharge exhaust into an existing stack or stack that also serves another gas appliance. If vertical discharge through an existing unused stack is required, insert PVC pipe inside the stack until the end is even with the top or outlet end of the metal stack.
CAUTION
The exhaust vent pipe operates under positive pressure and must be completely sealed to prevent leakage of combustion products into the living space.
Vent Piping Guidelines
NOTE - Lennox has approved the use of DuraVent® and
Centrotherm manufactured vent pipe and terminations as an option to PVC. When using the PolyPro ® by Du raVent or InnoFlue® by Centrotherm venting system the vent pipe requirements stated in the unit installation in struction – minimum & maximum vent lengths, termination clearances, etc. – apply and must be followed. Follow the instructions provided with PoyPro by DuraVent and Inno -
Flue by Centrotherm venting system for assembly or if re quirements are more restrictive. The PolyPro by Duravent and InnoFlue by Centrotherm venting system must also follow the uninsulated and unconditioned space criteria
Page 16
The ML193UHE 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
TABLE 4 and TABLE 5. Count all elbows inside and outside
the home. TABLE 4 lists the minimum vent pipe lengths
permitted. TABLE 5 lists the maximum pipe lengths per-
mitted. Regardless of the diameter of pipe used, the standard roof and wall terminations described in section Ex haust 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 different sizes of vent pipe, a combination vent pipe may be used. Contact Lennox’ Application Department for assistance in sizing vent pipe in these applications.
NOTE - The exhaust collar on all models is sized to ac commodate 2” Schedule 40 vent pipe. In horizontal ap plications, 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 Application Department for more information concerning sizing of vent systems which include multiple pipe sizes.
Horizontal Installation Offset Requirements
Exhaust Pipe
12” Max.
12” Min.
Horizontal
Gas Furnace
NOTE 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 fitting, unless the optional glueless vent adapter kit 17H92 is used..
NOTE - Exhaust piping should be checked carefully to make sure there are no sags or low spots.
FIGURE 23
NOTE - Lennox offers a glueless vent adapter kit 17H92 as an option for exhaust exiting at the furnace top cap coupling. If the kit is not used then the exhaust pipe MUST be glued to the furnace exhaust fitting.
Piping Size Process
1
What is the furnace capacity?
2
Which style termination being used?
Standard or concentric?.
3
Which needs most elbows?
Intake or exhaust?
4
How many elbows?
Count all elbows inside and outside house.
5
Desired pipe size?
6
What is the altitude of the furnace installation?
7
Find max intake or exhaust pipe length.
Includes all vent pipe and elbows inside and outside the house.
FIGURE 24
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 4
MINIMUM VENT PIPE LENGTHS
ML193UHE Model
030, 045, -070, -090, 110
MIN. VENT LENGTH*
15 ft. or 5 ft. plus 2 elbows or 10 ft. plus 1 elbow
*Any approved termination may be added to the minimum length listed. Two 45 degree elbows are the equivalent to one
90 degree elbow.
Page 17
Number
Of 90°
Elbows
Used
6
7
4
5
1
2
3
8
9
10
Number
Of 90°
Elbows
Usedl
5
6
7
8
9
10
3
4
1
2
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.
030/
045
25
20
15
10 n/a
030/
045
20
15
10 n/a
1-1/2” Pipe
Model
070
Standard Termination at Elevation 0 - 10,000
2” Pipe
Model
2-1/2” Pipe
Model
090 110 030/ 070 090 110
030/
045
070 090
20 81 66 44 24 115 100 68
15
10 n/a n/a
56
51
46
41
76
71
66
61
41
36
31
26
61
56
51
46
39
34
29
24
19
14 n/a
19
14 n/a
90
85
80
75
110
105
100
95
75
70
65
60
95
90
85
80
43
38
33
28
63
58
53
48
36 21 70 55 23
1-1/2” Pipe
Model
070
Concentric Termination Elevation 0 - 10,000
2” Pipe
Model
2-1/2” Pipe
Model
090 110 030/ 070 090 110
030/
045
070 090
15 73 58 42 22 105 90 64
10 68 53 37 17 100 85 59
12 n/a n/a n/a
63
58
53
48
43
38
33
28
48
43
38
33
28
23
18
13
32
27
22
17
12 n/a n/a
95
90
85
80
75
70
65
60
80
75
70
65
60
55
50
45
54
49
44
39
34
29
24
19
110
28
23
18
13
43
38
33 n/a
110
39
34
29
24
19
14 n/a
030/
045
137
112
107
102
97
92
132
127
122
117
030/
045
121
116
111
106
101
96
91
86
81
76
3” Pipe
Model
070 090 110
101
96
91
86
121
116
111
106
81
76
137
132
127
122
117
112
107
102
97
92
3” Pipe
Model
94
89
84
79
114
109
104
99
74
69
118
113
108
103
98
93
88
83
78
73
94
89
84
79
114
109
104
99
74
69
118
113
108
103
98
93
88
83
78
73
070 090 110
TABLE 6
VENT LENGTHS (EXHAUST) - VENTILATED ATTIC OR CRAWLSPACE INTAKE AIR - FEET
STANDARD TERMINATION AT ELEVATION 0 - 10,000 ft.
Pipe Size
1 20
1-1/2 in.
070 090 110 030/
045
070
2 in.
090 110 030/
045
2-1/2 in.
070 090 110 030/
045
070
3 in.
090 110
15 N/A N/A 71 56 34 14 100 100 78 43 118 117 98 98
No. of
90 ELL
2
3
4
5
6
7
8
9
10
15 10 N/A N/A 66 51 29 9 95 95 73 38 113 112 93 93
10 N/A N/A N/A 61 46 24 4 90 90 68 33 108 107 88 88
N/A N/A N/A N/A 56 41 19 N/A 85 85 63 28 103 102 83 83
N/A N/A N/A N/A 51 36 14 N/A 80 80 58 23 98 97 78 78
N/A N/A N/A N/A 46 31 9 N/A 85 75 63 18 93 92 73 73
N/A N/A N/A N/A 41 26 4 N/A 70 70 48 13 88 87 68 68
N/A N/A N/A N/A 36 21 N/A N/A 65 65 43 8 83 82 63 63
N/A N/A N/A N/A 31 16 N/A N/A 60 60 38 3 78 77 58 58
N/A N/A N/A N/A 26 11 N/A N/A 55 55 33 N/A 73 72 53 53
NOTES - Additional vent pipe and elbows used to terminate vent pipe outside the structure must be included in the total vent length calculation.
Page 18
Exhaust
DO NOT transition from larger to smaller pipe in horizontal runs of exhaust pipe.
TYPICAL EXHAUST AND INTAKE PIPE CONNECTIONS IN UPFLOW
DIRECT OR NON-DIRECT VENT APPLICATIONS
EXHAUST INTAKE EXHAUST INTAKE
2”
2”
2” or
2”
2” 3” 3”
Exhaust
DO NOT transition from smaller to larger pipe in horizontal runs of exhaust pipe.
2”
030/045/070 Only
1−1/2”
TRANSITION
2” 6” Min
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
TYPICAL EXHAUST AND INTAKE PIPE CONNECTIONS IN HORIZONTAL DIRECT OR
NON-DIRECT VENT APPLICATIONS (RIGHT HAND DISCHARGE SHOWN)
12” max.
45°
MAX
EXHAUST
2” or 2”
Exhaust
2”
2”
INTAKE
2”
2”
2” or
2”
2”
2”
DO NOT transition from smaller to larger pipe in horizontal runs of exhaust pipe.
SIDE VIEW
45°
MAX
3”
Exhaust
EXHAUST
*2”
*2”
3”
*2”
DO NOT transition from larger to smaller pipe in horizontal runs of exhaust pipe.
030/045/070 Only
1−1/2”
TRANSITION
*2”
INTAKE
*2”
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.
*2”
FIGURE 26
Page 19
Intake Piping
The ML193UHE 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 exhaust piping terminations for direct vent sections.
Refer to TABLE 5 for pipe sizes.
TYPICAL AIR INTAKE PIPE CONNECTIONS
UPFLOW NON−DIRECT
VENT APPLICATIONS
INTAKE
DEBRIS
SCREEN
(Provided)
Min 2”
NOTE - Debris screen and elbow may be rotated, so that screen may be positioned to face forward or to either side.
FIGURE 27
TYPICAL AIR INTAKE PIPE CONNECTIONS
HORIZONTAL NON−DIRECT VENT APPLICATIONS
(Horizontal Right−Hand Air Discharge Application Shown)
PVC pipe coupling
Min 2”
OR
INTAKE
DEBRIS
SCREEN
(Provided)
NOTE - Debris screen may be positioned straight out
(preferred) or with an elbow rotated to face down.
FIGURE 28
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 factoryprovided air intake screen to route the intake piping
as shown in FIGURE 27 or FIGURE 28. 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
29) or ventilated crawlspace (FIGURE 30) the exhaust
vent length must not exceed those listed in TABLE 7.
If 3” diameter pipe is used, reduce to 2” diameter pipe at the termination point to accommodate the debris screen. Use a sheet metal screw 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.
Page 20
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 inlet 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)
Roof Terminated
Exhaust Pipe
Ventilation Louvers
Inlet Air
(Minimum
12 in.(305mm) Above attic floor)
NOTE-The inlet and outlet air openings shall each have a free area of at least one square inch per 4,000 Btu (645mm 2 per 1.17kW) per hour of the total input rating of all equipment in the enclosure.
FIGURE 29
EQUIPMENT IN CONFINED SPACE
(Inlet Air from Ventilated Crawlspace and Outlet Air to Outside)
Roof Terminated
Exhaust Pipe
Ventilation
Louvers
(Crawl space)
Furnace
*Intake Debris
Screen
(Provided)
Furnace
Inlet Air
(Minimum
12 in.(305mm)
Above crawl space floor)
Coupling or
3 in. to 2 in.
Transition
(Field Provided)
*Intake Debris Screen Provided)
NOTE-The inlet and outlet air openings shall each have a free area of at least one square inch per 4,000 Btu (645mm 2 per 1.17kW) per hour of the total input rating of all equipment in the enclosure.
FIGURE 30
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 ML193UHE 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 ML193UHE is then classified as a direct vent,
Category IV gas furnace.
In both Non-Direct Vent and Direct Vent applications, the vent termination is limited by local building codes. In the absence of local codes, refer to the current National Fuel
Gas Code ANSI Z223-1/NFPA 54 in U.S.A., and current
CSA-B149 Natural Gas and Propane Installation Codes in
Canada for details.
Position termination according to location given in FIG-
URE 32 or FIGURE 33. In addition, position termination so
it is free from any obstructions and 12” above the average snow accumulation.
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 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) Ar maflex or equivalent. In extreme cold climate areas, 3/4”
(19mm) Armaflex or equivalent may be necessary. Insu lation 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.
IMPORTANT
Do not use screens or perforated metal in exhaust terminations. Doing so will cause freeze-ups and may block the terminations.
IMPORTANT
For Canadian Installations Only:
In accordance to CSA International B149 installation codes, the minimum allowed distance between the combustion air intake inlet and the exhaust outlet of other appliances shall not be less than 12 inches (305mm).
Page 21
Maximum Allowable Exhaust Vent Pipe Length (in ft.) Without Insulation In Unconditioned Space For
Winter Design Temperatures Single - Stage High Efficiency Furnace
Winter Design
Temperatures1 °F
(°C)
Vent Pipe
Diameter 030
TABLE 7
045
Unit Input Size
070 090 110
PVC 2 PP PVC 2 PP PVC 2 PP PVC 2 PP PVC 2 PP
32 to 21
(0 to -6)
20 to 1
(-7 to -17)
1-1/2”
2 in
2-1/2 in
3 in
1-1/2”
2 in
2-1/2 in
3 in
1-1/2”
N/A N/A
25
18
13
9
15
9
5
1
10
N/A
16
N/A
9
N/A
8
N/A
1
N/A
20
31
24
18
20
18
13
8
15
N/A
28
N/A
18
N/A
16
N/A
8
N/A
N/A
50
42
35
N/A
32
24
19
N/A
N/A
48
N/A
35
N/A
29
N/A
19
N/A
N/A
30
56
47
N/A
30
34
26
N/A
0 to -20
(-18 to -29)
2 in
2-1/2 in
5
1
3
N/A
12
7
10
N/A
22
15
19
N/A
30
22
27
N/A
3 in N/A N/A 2 2 10 10 16 16
1Refer to 99% Minimum Design Temperature table provided in the current edition of the ASHRAE Fundamentals Handbook.
2 Poly-Propylene vent pipe (PP) by Duravent and Centrotherm.
NOTE - Concentric terminations are the equivalent of 5’ and should be considered when measuring pipe length.
NOTE - Maximum uninsulated vent 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.
N/A
30
N/A
47
N/A
30
N/A
26
N/A
Conditioned
Space
Conditioned
Space
Pipe Insulation
Unconditioned
Space
FIGURE 31
Page 22
Exhaust
Pipe
Intake
Pipe
VENT TERMINATION CLEARANCES
FOR NON-DIRECT VENT INSTALLATIONS IN THE US AND CANADA
INSIDE CORNER
DETAIL
G
A
H
D
E
B
L
F
C
Fixed
Closed
Operable
B
Operable
B
Fixed
Closed
I
M
B
A
J
K
B
A =
VENT TERMINAL
Clearance above grade, veranda, porch, deck or balcony
AIR SUPPLY INLET
US Installations 1
12 inches (305mm) or 12 in. (305mm) above average snow accumulation.
AREA WHERE TERMINAL
IS NOT PERMITTED
Canadian Installations 2
12 inches (305mm) or 12 in. (305mm) above average snow accumulation.
B = Clearance to window or door that may be opened
4 feet (1.2 m) below or to side of opening;
1 foot (30cm) above opening
6 inches (152mm) for appliances <10,000
Btuh (3kw), 12 inches (305mm) for appliances > 10,000 Btuh (3kw) and
<100,000 Btuh (30kw), 36 inches (.9m) for appliances > 100,000 Btuh (30kw)
* 12” C = Clearance to permanently closed window
* 12”
D =
E =
F =
G =
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
* Equal to or greater than soffit depth.
* Equal to or greater than soffit depth.
* No minimum to outside corner
*
* Equal to or greater than soffit depth.
* Equal to or greater than soffit depth.
* No minimum to outside corner
*
H =
I = tended above meter / regulator assembly
Clearance to service regulator vent outlet
Clearance to non-mechanical air
* 3 feet (.9m) within a height 15 feet (4.5m) above the meter / regulator assembly
* 3 feet (.9m)
3 feet (.9m) within a height 15 feet (4.5m) above the meter / regulator assembly
3 feet (.9m)
J = pliance
4 feet (1.2 m) below or to side of opening;
1 foot (30 cm) above opening
6 inches (152mm) for appliances <10,000
Btuh (3kw), 12 inches (305mm) for appliances > 10,000 Btuh (3kw) and
<100,000 Btuh (30kw), 36 inches (.9m) for appliances > 100,000 Btuh (30kw)
6 feet (1.8m) K =
L = ply inlet
Clearance above paved sidewalk or paved driveway located on public property
3 feet (.9m) above if within 10 feet
(3m) horizontally
7 feet (2.1m)† 7 feet (2.1m)†
M = Clearance under veranda, porch, deck or balcony
*12 inches (305mm)‡
1
In 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
† 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.
12 inches (305mm)‡
*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 lation instructions.”
FIGURE 32
Page 23
VENT TERMINATION CLEARANCES
FOR DIRECT VENT INSTALLATIONS IN THE US AND CANADA
INSIDE CORNER
DETAIL
G
A
H
D
E
B
L
F
C
Fixed
Closed
Operable
B
Operable
B
Fixed
Closed
I
M
B
J
K
A
B
A =
B =
VENT TERMINAL
Clearance above grade, veranda, porch, deck or balcony
Clearance to window or door that may be opened
AIR SUPPLY INLET
US Installations 1
12 inches (305mm) or 12 in. (305mm) above average snow accumulation.
AREA WHERE TERMINAL
IS NOT PERMITTED
Canadian Installations 2
12 inches (305mm) or 12 in. (305mm) above average snow accumulation.
6 inches (152mm) for appliances <10,000 pliances > 10,000 Btuh (3kw) and <50,000 pliances > 50,000 Btuh (15kw)
* 12”
6 inches (152mm) for appliances <10,000
Btuh (3kw), 12 inches (305mm) for appliances > 10,000 Btuh (3kw) and
<100,000 Btuh (30kw), 36 inches (.9m) for appliances > 100,000 Btuh (30kw)
* 12” C = Clearance to permanently closed window
D =
E =
F =
G =
H =
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
* 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
* 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) I = tended above meter / regulator assembly
Clearance to service regulator vent outlet
Clearance to non-mechanical air
* 3 feet (.9m)
J = 6 inches (152mm) for appliances <10,000
K =
L =
M = pliances > 10,000 Btuh (3kw) and <50,000 pliance ply inlet
Clearance above paved sidewalk or paved driveway located on public property
Clearance under veranda, porch, deck or balcony pliances > 50,000 Btuh (15kw)
3 feet (.9m) above if within 10 feet
(3m) horizontally
* 7 feet (2.1m)
*12 inches (305mm)‡
1
In 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
† 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.
6 inches (152mm) for appliances <10,000
Btuh (3kw), 12 inches (305mm) for appliances > 10,000 Btuh (3kw) and
<100,000 Btuh (30kw), 36 inches (.9m) for appliances > 100,000 Btuh (30kw)
6 feet (1.8m)
7 feet (2.1m)†
12 inches (305mm)‡
*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 installation instructions.”
FIGURE 33
Page 24
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 adverse ly affect some building materials. If any vent termination is used and the flue gases may impinge on the building material, a corrosion-resistant shield (minimum 24 inches square) should be used to protect the wall surface. If the optional tee is used, the protective shield is recommend ed. 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 41.
Intake and exhaust pipes may be routed either horizontal ly through an outside wall or vertically through the roof. In attic or closet installations, vertical termination through the
roof is preferred. FIGURE 34 through FIGURE 42 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 35). You may exit the
exhaust out the roof and the intake out the side of
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 illustrations). Maximum separation is 3” (76mm) on roof terminations and 6” (152mm) on side wall terminations.
NOTE - When venting in different pressure zones, the maximum separation requirement of intake and exhaust pipe DOES NOT apply.
3 - terminate straight down using two 90° elbows (See
4 - Exhaust piping must terminate straight out or up as shown. A reducer may be required on the exhaust piping at the point where it exits the structure to improve the velocity of exhaust away from the intake
5 - On field supplied terminations for side wall exit, exhaust 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.
6 - 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.
NOTE - Care must be taken to avoid recirculation of exhaust back into intake pipe.
TABLE 8
Exhaust Pipe Termination Size Reduction
ML193UHE Model Termination Pipe Size
1-1/2” (38mm) *030, *045, *070
*090
110
2” (51mm)
*Use the provided 1-1/2” accelerator if matched with the flushmount termination.
Inches(mm)
3”(76mm) MAX.
UNCONDITIONED
ATTIC SPACE
8” (203mm) MIN
12” (305mm) ABOVE
AVERAGE SNOW
ACCUMULATION
Exhaust
Pipe
3” (76mm) OR
2” (51mm) PVC
PROVIDE SUPPORT
FOR INTAKE AND
EXHAUST LINES
DIRECT VENT ROOF TERMINATION KIT
(15F75 or 44J41)
FIGURE 34
Exiting Exhaust and Intake Vent
(different pressure zone)
Furnace
Inlet Air
(Minimum 12 in.
305 MM) above grade or snow accumulation
FIGURE 35
Exiting Exhaust and Intake Vent
(different pressure zone)
Roof Terminated
Exhaust Pipe
Furnace
Inlet Air
(Minimum 12 in.
305 MM) above grade or snow accumulation
FIGURE 36
Page 25
7 - If intake and exhaust piping must be run up a side wall to position above snow accumulation or other obstructions, piping must be supported. At least one bracket must be used within 6” from the top of the elbow and then every 24” (610mm) as shown
in FIGURE 41, 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 turn-down 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,
12” (305mm)
Minimum
Above Average
Snow
Accumulation
Accelerator not required for
3” concentric
INTAKE
FLASHING
(Not Furnished)
CLAMP
SHEET METAL STRAP
(Clamp and sheet metal strap must be field installed to support the weight of the termination kit.)
FIELD-PROVIDED
REDUCER MAY BE REQUIRED
TO ADAPT DIFFERENT VENT
PIPE SIZE TO TERMINATION
DIRECT VENT CONCENTRIC ROOFTOP TERMINATION
71M80, 69M29 or 60L46 (US)
44W92 or 44W93 (Canada)
FIGURE 37
EXHAUST
VENT
INTAKE
AIR
5”
(127mm)
(305mm)
5-1/2”
(140mm)
12”
Inches (mm)
18” MAX.
(457mm)
EXHAUST VENT
Front View
INTAKE
AIR
12” (305mm) Min.
above grade or cumulation.
optional intake elbow
Side View
OPTIONAL VENT TERMINATION FOR MULTIPLE UNIT
INSTALLATION OF DIRECT VENT WALL TERMINATION KIT
(30G28 or 81J20)
FIGURE 39
2” EXTENSION FOR 2” PVC
PIPE1” EXTENSION FOR 3”
PVC PIPE
4''
FURNACE
EXHAUST
PIPE
FURNACE
INTAKE
PIPE
GLUE EXHAUST
END FLUSH INTO
TERMINATION
FLAT
SIDE 1-1/2” ACCELERATOR
FLUSH-MOUNT SIDE WALL TERMINATION KIT
51W11 (US) or 51W12 (Canada)
FIGURE 40
FIELD-PROVIDED
REDUCER MAY BE
REQUIRED TO ADAPT
DIFFERENT VENT PIPE
SIZE TO TERMINATION
OUTSIDE
WALL
EXHAUST
AIR
Accelerator not required for 3” concentric
EXHAUST
AIR
INTAKE
AIR
CLAMP
(Not Furnished)
12” (305mm) Min.
above grade or average snow ac cumulation.
GRADE
DIRECT VENT CONCENTRIC WALL TERMINATION
71M80, 69M29 or 60L46 (US)
44W92 or 44W93 (Canada)
FIGURE 38
Page 26
* WALL
SUPPORT
C1
NOTE − FIELD−PROVIDED
REDUCER MAY BE
REQUIRED TO ADAPT
LARGER VENT PIPE SIZE
TO TERMINATION
C1
E
A
D
B
A
FIELD FABRICATED WALL TERMINATION
Intake
Elbow
C2
D
B
2” (51mm)
Vent Pipe
A − Minimum clearance above grade or average snow accumulation
B − Maximum horizontal
separation between
intake and exhaust
C1 -
Minimum from end of exhaust to inlet of intake
12” (305 mm)
6” (152 mm)
8” (203 mm)
STRAIGHT
APPPLICATION
A
C2 -
Minimum from end of exhaust to inlet of intake
6” (152 mm)
D
B
EXTENDED
APPLICATION
C2
E
A
B
D
3” (76mm)
Vent Pipe
12” (305 mm)
6” (152 mm)
8” (203 mm)
6” (152 mm)
D − Maximum exhaust pipe length
E − Maximum wall support distance from top of each pipe (intake/exhaust)
12” (305 mm)
6” (152 mm)
20” (508 mm)
6” (152 mm)
See maximum allowable venting tables for venting lengths with this arrangement.
* Use wall support every 24” (610 mm). Use two wall supports if extension is greater than
24” (610 mm) but less than 48” (1219 mm).
NOTE − One wall support must be within 6” (152 mm) from top of each pipe (intake and exhaust) to prevent movement in any direction.
2
2
B
B
A
E
C
C
ALTERNATE TERMINATIONS (TEE & FORTY−FIVE DEGREE ELBOWS ONLY)
D
1
Intake
Elbow
B
A
C
D
3
1
A
- Clearance above
Grade or average snow accumulation
B
- Horizontal separation between intake and exhaust
2” (51mm)
Vent Pipe
6” (152mm)min
24” (610mm )Max
C
- Minimum from end of exhaust to inlet of intake
D
- Exhaust pipe length
9” (227mm)
12” (305mm)min
16” (405mm )Max
E
- Wall support distance from top of each pipe
(intake/exhaust)
6” (152mm) Max
3” (76mm)
Vent Pipe
12” (305 mm) Min 12” (305 mm) Min
6” (152mm)min
24” (610mm )Max
9” (227mm)
12” (305mm)min
16” (405mm )Max
6” (152mm) Max
D
E
D
Exhaust
D
1
B
E
B
Front View of
Intake and Exhaust
12”
C
12” 2
A
A
C
Intake
Exhaust
A
1 The exhaust termination tee should be connected to the 2” or 3” PVC flue pipe as shown in the illustration. In horizontal tee applications there must be be a minimum of 3 ft away from covered patios or any living ares and cannot be within 3 ft of a window. Do not use an accelerator in applications that include an exhaust termination tee. The accelerator is not required.
2
3
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.
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 41
Page 27
DIRECT VENT APPLICATION
USING EXISTING CHIMNEY
STRAIGHT-CUT OR
ANGLE-CUT IN DIRECTION
OF ROOF SLOPE *
8” - 12”
(203mm - 305mm)
Minimum 12” (305MM) above chimney top plate or average snow accumulation
INTAKE PIPE
INSULATION (optional)
SHEET
METAL TOP
PLATE
3” - 8”
(76mm-
203mm)
INSULATE
TO FORM
SEAL
SHOULDER OF FITTINGS
PROVIDE SUPPORT
OF PIPE ON TOP PLATE
ALTERNATE
INTAKE PIPE
3” - 8”
(76mm-
203mm)
EXTERIOR
PORTION OF
CHIMNEY
3 - If exhaust piping must be run up a side wall to position above snow accumulation or other obstructions, piping 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.
Distance between exhaust pipe terminations on multiple furnaces must meet local codes.
NON-DIRECT VENT APPLICATION
USING EXISTING CHIMNEY
STRAIGHT-CUT OR
ANGLE-CUT IN DIRECTION
OF ROOF SLOPE
NOTE - Do tical discharge through an existing unused chimney or stack is required, insert piping inside trated. In any exterior portion of chimney, the exhaust vent must be insulated.
FIGURE 42
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
preferred. FIGURE 43 and FIGURE 44 show typical ter-
minations.
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
velocity required to move the exhaust gases away from the building.
2 - On field supplied terminations for side wall exit, exhaust piping may extend a maximum of 12 inches
(305mm) for 2” PVC and 20 inches (508mm) for 3”
(76mm) PVC beyond the outside wall.
12” (305mm)
ABOVE AVE.
SNOW
ACCUMULATION
Minimum 12” (305MM) above chimney top plate or average snow accumulation
SHEET
METAL TOP
PLATE
INSULATE
TO FORM
SEAL
SHOULDER OF FITTINGS
PROVIDE SUPPORT
OF PIPE ON TOP PLATE
EXTERIOR
PORTION OF
CHIMNEY
NOTE - Do tical discharge through an existing unused chimney or stack is required, insert piping inside trated. In any exterior portion of chimney, the exhaust vent must be insulated.
FIGURE 44
Crawl Space and Extended Horizontal Venting
Lennox provides kit 51W18 (USA) kit 15Z70 (Canada) to install 2” or 3” PVC exhaust piping through the floor joists and into the crawl space. See figure below.
This kit can also be used as a supplemental drain for installations with condensate run back in the vent pipe (ie. long horizontal runs, unconditioned spaces, etc.).
Venting In A Crawl Space
3” (76mm) OR
2” (51mm) PVC
PROVIDE SUPPORT
FOR EXHAUST LINES
UNCONDITIONED
ATTIC SPACE
NON-DIRECT VENT ROOF TERMINATION KIT
(15F75 or 44J41)
FIGURE 43
Page 28
Basement Floor
KIT 51W18
(USA)
KIT 15Z70
(CANADA)
Condensate Piping
This unit is designed for either right- or left-side exit of condensate piping in upflow applications. In horizontal applications, the condensate trap must extend below the unit. An 8” service clearance is required for the conden-
sate trap. Refer to figures FIGURE 45 and FIGURE 47
for condensate trap locations. FIGURE 53 shows trap as-
sembly 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.
1 - Determine which side condensate piping will exit the unit, location of trap, field-provided fittings and length of PVC pipe required to reach available drain.
NOTE - Do not remove the rubber grommet used to seal the cabinet on the side not used when installing the condensate trap.
2 - Use a large flat head screw driver or a 1/2” drive
socket extension and remove plug (FIGURE 45)
from the cold end header box at the appropriate location on the side of the unit. Install provided 3/4
NPT street elbow fitting into cold end header box.
Use Teflon tape or appropriate pipe dope.
NOTE - Cold end header box drain plugs are facto ry installed. Check the unused plug for tightness to prevent leakage.
3 - Install the cap over the clean out opening at the base
of the trap. Secure with clamp. See FIGURE 53.
4 - Install drain trap using appropriate PVC fittings, glue all joints. Glue the provided drain trap as shown
in FIGURE 53. 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
(same on right side)
1-1/2 in.
Plug
(same on left side)
NOTE - In upflow applications where side return sate trap, filter rack must be installed beyond condensate trap or trap must be re-located to avoid interference.
FIGURE 45
5 - FIGURE 48 and FIGURE 50 show the furnace and
evaporator coil using a separate drain. If necessary the condensate line from the furnace and evaporator
coil can drain together. See FIGURE 49, FIGURE 51 and FIGURE 52.
- In upflow furnace applications the field provided vent must be a mini mum 1” to a maximum 2” length above the conden sate drain outlet connection. Any length above 2” may result in a flooded heat exchanger if the com bined primary drain line were to become restricted.
Horizontal furnace (FIGURE 52)
- In horizontal fur nace applications the field provided vent must be a minimum 4” to a maximum 5” length above the con densate drain outlet connection. Any length above
5” may result in a flooded heat exchanger if the com bined primary drain line were to become restricted.
NOTE - In horizontal applications it is recommended to install a secondary drain pan underneath the unit and trap assembly.
NOTE - Appropriately sized tubing and barbed fit ting may be used for condensate drain. Attach to the
drain on the trap using a hose clamp. See FIGURE
CAUTION
Do not use copper tubing or existing copper condensate lines for drain line.
6 - If unit will be started immediately upon completion of installation, prime trap per procedure outlined in Unit
Start-Up section.
Field Provided Drain Components
Elbow
Tubing
Barbed Fitting
Hose Clamp
FIGURE 46
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 and 24 ft.
(7.3m) - kit no. 26K69.
Page 29
CONDENSATE TRAP LOCATIONS
(Unit shown in upflow position with remote trap)
FieldProvidedVent
Min. 1” AboveCondensate
DrainConnection
1” Min.
2” Max.
*5’ max.
PVCPipeOnly
Trap Can Be Installed a
Maximum 5’ From Furnace
To Drain
*Piping from furnace must slope down a minimum 1/4” per ft. toward trap
FIGURE 47
Furnace 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 connection)
Condensate
DrainConnection
Condensate Trap With Optional Overflow Switch
From Evaporator Coil
HorizontalFurnace4” Min. to 5” Max.above
condensatedrain connection)
FurnaceCondensate
DrainConnection
Optional
FIGURE 49
FIGURE 48
Page 30
Furnace with Evaporator Coil Using a Separate Drain
(Unit shown in horizontal left-hand discharge position)
Evaporator
Coil
Field Provided Vent
(4” min. to 5” max. above condensate connection)
Condensate
DrainConnection
4”min
5”max
5’ max.
PVC Pipe Only
Drain Pan
(Trap at coil is optional)
Piping from furnace and evaporator coil must slope down a minimum 1/4” per ft. toward trap
.
Furnace with Evaporator
Coil Using a Common Drain
(Trap at coil is optional)
Evaporator drain line required
FIGURE 50
IMPORTANT
When combining the furnace and evaporator coil drains together, the A/C condensate drain outlet must be vented to relieve pressure in order for the furnace pressure switch to operate properly.
(1” min. to 2” Max.above
condensatedrain connection)
Condensate
DrainConnection
FIGURE 51
Furnace with Evaporator Coil Using a Common Drain
(Unit shown in horizontal left−hand discharge position)
Drain Pan
Evaporator
Coil
Condensate Drain
Connection
4”min
5”max
5’ max.
PVC Pipe Only
(Trap at coil is optional)
Piping from furnace and evaporator coil must slope down a minimum 1/4” per ft. toward trap
(4” min. to 5” Max.above
condensatedrain connection)
FIGURE 52
Page 31
TRAP / DRAIN ASSEMBLY USING 1/2” PVC OR 3/4” PVC
Optional Condensate Drain Connection
Adapter 3/4 inch slip X
3/4 inch mpt (not furnished)
90
°
Street Elbow
3/4 inch PVC
(not furnished)
Adapter 3/4 inch slip X
3/4 inch mpt (not furnished)
Condensate Drain
Connection In Unit
1 (25 mm) Min.
2 (50 mm) Max.
Above Top Of
Condensate Drain
Connection In Unit
Vent
5 Feet
Maximum
90
°
Street Elbow
3/4 inch PVC
( furnished) 90 ° Elbow 3/4 inch PVC
(Not Furnished)
To
Trap
Optional DrainPipingFromTrap
Drain Assembly for 1/2 inch Drain Pipe
1/2 inch PVC Pipe
(Not Furnished)
Condensate Drain
Connection In Unit
3/4 inch PVC Pipe
(Not Furnished)
Coupling 3/4 inch slip X slip
(Not Furnished)
1/2 inch PVC Pipe
(Not Furnished)
To
Drain
90 ° Elbow
1/2 inch PVC
(Not Furnished)
Drain Assembly for 3/4 inch Drain Pipe
Drain Trap
Assembly
(Furnished)
Drain Trap
Clean Out
To
Drain
90 ° Elbow
3/4 inch PVC
(Not Furnished)
90 ° Elbow
3/4 inch PVC
(Not Furnished)
To
Drain
Coupling 3/4 inch slip X slip
(Not Furnished)
DrainTrap Assembly
(Furnished)
DrainTrap Assembly with 1/2 inch Piping
1 (25 mm) Min. 2 (50 mm) Max. Above Top
Of Condensate Drain Connection In Unit
Vent
DrainTrap Assembly with 3/4 inch Piping
1 (25 mm) Min. 2 (50 mm) Max. Above Top
Of Condensate Drain Connection In Unit
Vent
3/4 inch
7
(178)
1/2 inch
Condensate Drain
Connection In Unit
Condensate Drain
Connection In Unit
To
Drain
To
Drain
FIGURE 53
Page 32
Gas Piping
CAUTION
If a flexible gas connector is required or allowed by the authority that has jurisdiction, black iron pipe shall be installed at the gas valve and extend outside the furnace cabinet. The flexible connector can then be added between the black iron pipe and the gas supply line.
WARNING
Do not over torque (800 in-lbs) or under torque (350 inlbs) when attaching 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 56. Connect the gas supply piping into the
gas valve. The maximum torque is 800 in lbs and minimum torque is 350 in lbs when attaching the gas piping to the gas valve.
IMPORTANT
When converting the ML193 unit from natural gas to LP/ propane install the field provided low pressure switch.
switch. See figure 55.
LOW INLET PRESSURE SWITCH
(S145) LOCATION
Orange
White
Orange
Yellow
Gas Valve Shown In Off Position
FIGURE 54
2 - When connecting gas supply, factors such as length of run, number of fittings and furnace rating must be considered to avoid excessive pressure drop.
TABLE 9 lists recommended pipe sizes for typical
applications.
NOTE - Use two wrenches when connecting gas piping 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 elevator shafts. Center gas line through piping hole. Gas line should not touch side of unit. See
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, every 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.
6 - In some localities, codes may require installation of a manual main shut-off valve and union (furnished by installer) external to the unit. Union must be of the ground joint type.
IMPORTANT
Compounds used on threaded joints of gas piping must be resistant to the actions of liquified petroleum gases.
Leak Check
After gas piping is completed, carefully check all field-in stalled piping connections for gas leaks. Use a commercially available leak detecting solution specifically manu factured for leak detection. Never use an open flame to test for gas leaks.
The furnace must be isolated from the gas supply sys tem by closing the individual manual shut-off valve during any gas supply system at pressures greater than or equal to ½ psig. (3.48 kPa, 14 inches w.c.). This furnace and its components are designed, manufactured and inde pendently certified to comply with all applicable ANSI/CSA standards. A leak check of the furnace and its components is not required.
CAP
FURNACE
VALVE WILL NOT HOLD
NORMAL TEST PRESSURE
1/8” N.P.T. PLUGGED TAP
FIGURE 55
IMPORTANT
When testing pressure of gas lines, gas valve must be
disconnected and isolated. See FIGURE 55. Gas valves
can be damaged if subjected to pressures greater than
1/2 psig (3.48 kPa).
Page 33
WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warnings exactly could result in serious injury, death, or property damage. Never use an open flame to test for gas leaks. Check all connections using a commercially available soap solution made specifically for leak detection. Some soaps used for leak detection are corrosive to certain metals. Carefully rinse piping thoroughly after leak test has been completed.
Upflow Application
Left Side Piping
(Standard)
MANUAL
MAIN SHUT-OFF
VALVE
GROUND
JOINT
UNION
DRIP LEG
1/2” NPT
FIELD
PROVIDED
AND INSTALLED
NOTE - BLACK IRON PIPE
ONLY
TO BE ROUTED INSIDE OF CABINET
Upflow Application
Right Side Piping
(Alternate)
1/2” NPT
MANUAL
MAIN SHUT-OFF
VALVE
GROUND
JOINT
UNION
DRIP LEG
FIGURE 56
Horizontal Applications
Possible Gas Piping Configurations
MANUAL
MAIN SHUT-OFF
VALVE
Horizontal Application
Left-Side Air Discharge
MANUAL
MAIN SHUT-OFF
VALVE
GROUND
JOINT
UNION
DRIP LEG
GROUND
JOINT
UNION
DRIP LEG
Horizontal Application
Right-Side Air Discharge
FIELD
PROVIDED
AND INSTALLED
NOTE - BLACK IRON PIPE
ONLY
TO BE ROUTED INSIDE OF CABINET
FIGURE 57
MANUAL
MAIN SHUT-OFF
VALVE
GROUND
JOINT
UNION
DRIP LEG
Page 34
Nominal
Iron Pipe
Size Inches
(mm)
1/2
(12.7)
3/4
(19.05)
1
(25.4)
1-1/4
(31.75)
1-1/2
(38.1)
2
(50.8)
2-1/2
(63.5)
3
(76.2)
Internal
Diameter inches
(mm)
.622
(17.799)
.824
(20.930)
1.049
(26.645)
1.380
(35.052)
1.610
(40.894)
2.067
(52.502)
2.469
(67.713)
3.068
(77.927)
10
(3.048)
172
(4.87)
360
(10.19)
678
(19.19)
1350
(38.22)
2090
(59.18)
4020
(113.83)
6400
(181.22)
11300
(319.98)
20
(6.096)
118
(3.34)
247
(7.000)
466
(13.19)
957
(27.09)
1430
(40.49)
2760
(78.15)
4400
(124.59)
7780
(220.30)
TABLE 9
Gas Pipe Capacity - ft3/hr (m3/hr)
Length of Pipe - feet (m)
30
(9,144)
95
(2.69)
199
(5.63)
374
(10.59)
768
(22.25)
1150
(32.56)
2220
(62.86)
3530
(99.95)
6250
(176.98)
40
(12,192)
81
(2.29)
170
(4.81)
320
(9.06)
657
(18.60)
985
(27.89)
1900
(53.80)
3020
(85.51)
5350
(151.49)
50
(15.240)
72
(2.03)
151
(4.23)
284
(8.04)
583
(16.50)
873
(24.72)
1680
(47.57)
2680
(75.88)
4740
(134.22)
60
(18.288)
65
(1.84)
137
(3.87)
257
(7.27)
528
(14.95)
791
(22.39)
1520
(43.04)
2480
(70.22)
4290
(121.47)
70
(21.336)
60
(1.69)
126
(3.56)
237
(6.71)
486
(13.76)
728
(20.61)
1400
(39.64)
2230
(63.14)
3950
(111.85)
80
(24.384)
NOTE Capacity given in cubic feet (m3 ) of gas per hour and based on 0.60 specific gravity gas.
56
(1.58)
117
(3.31)
220
(6.23)
452
(12.79)
677
(19.17)
1300
(36.81)
2080
(58.89)
3670
(103.92)
90
(27.432)
635
(17.98)
1220
(34.55)
1950
(55.22)
3450
(97.69)
52
(1.47)
110
(3.11)
207
(5.86)
424
(12.00)
100
(30,480)
50
(1.42)
104
(2.94)
195
(5.52)
400
(11.33)
600
(17.00)
1160
(32.844)
1840
(52.10)
3260
(92.31)
Removal of the Furnace from Common Vent
In the event that an existing furnace is removed from a venting system commonly run with separate gas appliances, the venting system is likely to be too large to properly vent the remaining attached appliances. Conduct the following test while each appliance is operating and the other appliances (which are not operating) remain connected to the common venting system. If the venting system has been installed improperly, you must correct the system as indicated in the general venting requirements section.
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 monoxide poisoning or death.
The following steps shall be followed for each appliance 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 system.
2 - Inspect the venting system for proper size and horizontal pitch. Determine that there is no blockage, restriction, leakage, corrosion, or other deficiencies which could cause an unsafe condition.
Close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers 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 operate at maximum speed. Do not operate a summer exhaust 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 flame of a match or candle.
6 - After determining that each appliance connected to the common venting system is venting properly, (step
3) return all doors, widows, exhaust fans, fireplace dampers, and any other gas-burning appliances to their previous mode of operation.
7 - If a venting problem is found during any of the preceding tests, the common venting system must be modified 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 standards of the National Fuel Gas Code ANSI Z223.1.
Page 35
Electrical
ELECTROSTATIC DISCHARGE (ESD)
Precautions and Procedures
CAUTION
Electrostatic discharge can affect electronic components. Take precautions to neutralize electrostatic charge by touching your hand and tools to metal prior to handling the control.
WARNING
Electric Shock Hazard. Can cause injury or death. Unit must be properly grounded in accordance with national and local codes.
WARNING
Fire Hazard. Use of aluminum wire with this product may result in a fire, causing property damage, severe injury or death. Use copper wire only with this product.
INTERIOR MAKE-UP BOX INSTALLATION
MAKE-UP
BOX
Right Side
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 facilitate installation . Secure the excess wire to the existing harness to protect it from damage.
Refer to FIGURE 59 for schematic wiring diagram and
troubleshooting.
The power supply wiring must meet Class I restrictions.
Protected by either a fuse or circuit breaker, select circuit protection and wire size according to unit nameplate.
CAUTION
Failure to use properly sized wiring and circuit breaker may result in property damage. Size wiring and circuit breaker(s) per Product Specifications bulletin (EHB) and unit rating plate.
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 59. 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
National 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 ML193UHE furnace contains electronic com ponents that are polarity sensitive. Make sure that the fur nace is wired correctly and is properly grounded.
FIGURE 58
Page 36
Accessory Terminals See pages 39 and 40 for igntion control illustration.
One line voltage “EAC” 1/4” spade terminal is provided on the furnace integrated control. This terminal is energized when the indoor blower is operating. Any accessory rated up to one amp can be connected to this terminal with the neutral leg of the circuit being connected to one of the provided neutral terminals. If an accessory rated at greater than one amp is connected to this terminal, it is necessary to use an external relay.
One line voltage 120V “HUM” 1/4” spade terminal is provided on the furnace integrated control. This terminal is energized in the heating mode when the combustion air inducer is operating. Any humidifier 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 a humidifier rated at greater than one amp is connected to this terminal, it is necessary to use an external relay relay
One 24V ”HUM” 1/4” spade terminal is provided on the furnace integrated control. The terminal is energized in the heating mode when the combustion air inducer is operating and the pressure switch is closed. Any humidifier rated up to 0.5 amp can be connected to this terminal with the ground leg of the circuit connected to ground or the ”C” terminal.
Thermostat
Install the room thermostat according to the instructions
provided with the thermostat. See FIGURE 59 for thermo-
stat designations. If the furnace is being matched with a heat pump, refer to the thermostat installation instruction for set up.
Indoor Blower Speeds
1 - When the thermostat is set to “FAN ON,” the indoor blower will run continuously on the (FAN) speed when there is no cooling or heating demand. See table below for for allowable circulation speeds.
2 - When the ML193UHE is running in the heating mode, the indoor blower will run on the heating speed (HEAT).
See table below for allowable heating speeds.
3 - When there is a cooling demand, the indoor blower will run on the cooling speed (COOL).
Generator Use - Voltage Requirements
The following requirements must be kept in mind when specifying a generator for use with this equipment:
• The furnace requires 120 volts + 10% (Range: 108 volts to 132 volts)
• The furnace operates at 60 Hz + 5% (Range: 57
Hz to 63 Hz)
• 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
• Generator should have a wave form distortion of less than 5% THD (total harmonic distortion).
ML193UHE
Model Number
-030
-045
-070
-09036C
-09048C
-11048C
-11060C
Red
Allowed
Not Allowed
Allowable Heating Speeds
Yellow Blue
Factory Setting
Allowed
Not Allowed
Allowed
Not Allowed
Allowed
Allowed
Factory Setting
Allowed
Factory Setting
Allowed
Factory Setting
Brown
Allowed
Factory Setting
Allowed
Factory Setting
Allowed
Model Number
All Models
Red
Factory Setting
Allowable Circulation Speeds
Yellow Blue
Not Allowed Not Allowed
Brown
Not Allowed
Black
Not Allowed
Allowed
Not Allowed
Black
Not Allowed
Page 37
FIGURE 59
Page 38
Integrated Control 103217-03
IGNITION CONTROL 103217-03
120V HUM
LINE
XFMR
CIRC
EAC
HUM24
NEUTRALS (5) NEUTRAL
3/16” QUICK CONNECT TERMINALS
COOL COOL SPEED FROM INDOOR BLOWER
MOTOR (24 VAC)
HEAT
FAN
HEAT SPEED FROM INDOOR BLOWER
MOTOR (24 VAC)
CONTINUOUS FAN SPEED FROM
INDOOR BLOWER MOTOR (24 VAC)
PARK (3)
FS
24 COM
TABLE 10
1/4” QUICK CONNECT TERMINALS
POWER FOR HUMIDIFIER (120 VAC
INCOMING POWER LINE (120 VAC)
TRANSFORMER PRIMARY (120 VAC)
INDOOR BLOWER MOTOR (120 VAC)
ELECTRONIC AIR CLEANER (120 VAC)
POWER FOR HUMIDIFIER (24 VAC)
TERMINALS FOR UNUSED MOTOR
SPEED TAPS
FLAME SENSOR ELECTRODE (120 VAC)
COMMON (24 VAC) RED LED RECALL BUTTON
BLOWER OFF DELAY
FIGURE 60
RED LED Flash Code 2
Off
Heartbeat 1
Continuous Rapid Flash
1
2
3
4
7
10
11
8
9
12
13
5
6
Note - 1
Note - 2
Note - 3
Diagnostic Codes / Status
No power to control or board fault detected
Normal Operation - Idle, Continuous Fan, Cool
Call For Heat / Burner Operation
Reverse Line Voltage Polarity
Improper Earth Ground
Burner failed to light, or lost flame during heat demand
Low Flame Signal - check flame sensor
Watchguard - burner failed to light, exceeded maximum number of retries or recycles.
Not Used
Primary or Secondary Limit Open or Watchguard Mode - Limit Switch Open longer than 3 minutes
Rollout Switch Open
Pressure Switch failed to close or opened during heat demand
Watchguard - Pressure Switch opened 5 times during one heat demand
Pressure Switch stuck closed prior to activation of combustion air inducer
Flame Sensed without gas valve energized
Low Line Voltage
Notes
A ”Heartbeat” is indicated by a ”Slow Flash” - 1 sec on 1 sec off, repeating
Error codes are indicated by a “rapid flash” - the LED flashes X times at ½ second on ½ second off, remains off for 3 seconds then repeats.
Last 10 error codes are stored in memory including when power is shut off to the unit. - To recall, press and release button, most recent will be displayed first, LED off for 3 sec, then next error code is displayed, etc. To clear error codes, depress and hold button longer than 5 seconds.
Page 39
Integrated Control 107163-01
IGNITION CONTROL 107163-01
PARKS
Push Button
Error Recall
Diagnostic LED
RED LED Flash Code
Off
On
Fast Heartbeat 3
Slow Heartbeat 1
1 Flash 2
2 Flashes 2
3 Flashes 2
4 Flashes 2
5 Flashes 2
6 Flashes 2
7 Flashes 2
8 Flashes 2
9 Flashes 2
10 Flashes 2
11 Flashes 2
12 Flashes 2
13 Flashes 2
Note - 1
Note - 2
Note - 3
Note - 4
Heating Blower Off
Delay Selector Switch
Diagnostic Codes / Status of Furnace Ignition Control 107163-01
No Power to Control or Board Fault Detected
Board Fault Detected
Call for Heat / Burner Operation
Normal Operation – Idle, Continuous Fan, or Cool
Reverse Line Voltage Polarity or Phasing of 120V power
Improper earth ground
Burner failed to light, or lost flame during heat demand
Low flame signal – check flame sensor
Watchguard – burner failed to light, exceeded maximum number of retries/recycles, 1 hour lockout
Not used
Primary or Secondary limit switch open or Watchguard mode – Limit Switch open longer than 3 minutes
Roll-out Switch Open
Pressure Switch failed to close or opened during heat demand, inducer on
Watchguard - Pressure switch opened 5 times during a single heating demand
Pressure switch stuck closed prior to activation of Combustion Air Inducer
Flame sensed without gas valve energized
Low line voltage
Notes
A slow heartbeat is indicated by 1s on / 1s off. It is used for idle, continuous fan and cool modes.
Error codes are indicated by a “rapid flash” - the LED flashes X times at ½ second on ½ second off, remains off for 3 seconds then repeats.
A fast heartbeat is indicated by 0.5s on / 0.5s off. It is only used during a heat call.
Last 10 error codes are stored in memory including when power is shut off to the unit. - To recall, press, and release button, most recent will be displayed first, LED off for 3 sec, then next error code is displayed, etc. To clear error codes, depress and hold button longer than 5 seconds.
Page 40
Unit Start-Up
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING
Do not use this furnace if any part has been underwater. A flood-damaged furnace is extremely dangerous. 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.
WARNING
Danger of explosion. Can cause injury or product or property damage. Should the gas supply fail to shut off or if overheating occurs, shut off the gas valve to the furnace before shutting off the electrical supply.
CAUTION
Before attempting to perform any service or maintenance, turn the electrical power to unit OFF at disconnect 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 ML193UHE is equipped with a gas control switch (lever). Use only your hand to move switch.
Never use tools. If the switch will not move by hand, do not try to repair it. Force or attempted repair may result in a fire or explosion.
Placing the furnace into operation:
ML193UHE units are equipped with an automatic hot surface ignition system. Do not attempt to manually light burners on this furnace. Each time the thermostat calls for heat, the burners will automatically light. The ignitor does not get hot when there is no call for heat on these units.
Priming Condensate Trap
The condensate trap should be primed with water prior to start-up to ensure proper condensate drainage. Either pour 10 fl. oz. (300 ml) of water into the trap, or follow these steps to prime the trap:
1 - Follow the lighting instructions to place the unit into operation.
2 - Set the thermostat to initiate a heating demand.
3 - Allow the burners to fire for approximately 3 minutes.
Adjust the thermostat to deactivate the heating demand.
5 - Wait for the combustion air inducer to stop. Set the thermostat to initiate a heating demand and again allow the burners to fire for approximately 3 minutes.
Adjust the thermostat to deactivate the heating demand 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.
WARNING
. 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 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 instructions. If you do not smell gas go to next step.
8 - Move gas valve switch to ON. See FIGURE 61
MANIFOLD
PRESSURE
ADJUSTMENT
SCREW
MANIFOLD
PRESSURE
OUTLET
PORT
INLET
PRESSURE
PORT GAS VALVE SHOWN IN ON POSITION
FIGURE 61
9 - Replace the upper access panel.
10- Turn on all electrical power 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”
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 41
4 - Move gas valve switch to OFF.
5 - Replace the upper access panel.
Failure To Operate
If the unit fails to operate, check the following:
1 - Is the thermostat calling for heat?
2 - Are access panels securely in place?
3 - Is the main disconnect switch closed?
4 - Is there a blown fuse or tripped 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.
Combustion air pressure switch proves blower operation. Switch is factory set and requires no adjustment.
3 - After a 15-second prepurge, the hot surface ignitor energizes.
4 - After a 20-second ignitor warm-up period, the gas valve solenoid opens. A 4-second Trial for Ignition period begins.”
5 - Gas is ignited, flame sensor proves the flame, and the combustion process continues.
6 - If flame is not detected after first ignition trial, the ignition 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 automatically 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
Gas Flow (Approximate)
ML193
Unit
-030
-045
-070
-090
-110
TABLE 11
GAS METER CLOCKING CHART
Seconds for One Revolution
120
Natural
1 cu ft
Dial
2 cu ft
Dial
240
1 cu ft
Dial
300
LP
2 cu ft
Dial
600
80
55
160
110
200
136
41
33
82
66
102
82
Natural-1000 btu/cu ft LP-2500 btu/cu ft
400
272
204
164
Furnace should operate at least 5 minutes before checking gas flow. Determine time in seconds for two revolu tions of gas through the meter. (Two revolutions assures a more accurate time.) Divide by two and compare to time
in TABLE 11. If manifold pressure matches TABLE 12 and
rate is incorrect, check gas orifices for proper size and 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 pressure may result in erratic operation or underfire. High pressure can result in permanent damage to gas valve or overfire.
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 12.
Manifold Pressure Measurement
1 - Connect the test gauge positive side “+“ to manifold pressure tap on gas valve.
2 - Tee into the gas valve regulator vent hose and connect to test gauge negative “-”.
3 - Start unit and let run for 5 minutes to allow for steady state conditions.
4 - After allowing unit to stabilize for 5 minutes, record manifold pressure and compare to value given in
5 - Shut unit off and remove manometer as soon as an accurate reading has been obtained. Take care to replace pressure tap plug.
6 - Start unit and perform leak check. Seal leaks if found.
TABLE 12
Supply Line and Manifold Pressure (inches w.c.)
Unit Fuel
Manifold
Pressure
Line Pressure
All
All
Nat. Gas
L.P. Gas
3.5
10.0
4.5 - 10.5
11.0 - 13.0
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.
Page 42
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 table below.
ML193 Unit
030
045
070
090
110
TABLE 13
CO
2
Nat
6.5 - 7.5
7.0 - 9.0
CO
2
LP
7.5 - 8.5
8.0 - 10.0
The maximum carbon monoxide reading should not exceed 100 pm.
High Altitude Information
NOTE - In Canada, certification for installations at eleva tions over 4500 feet (1372 m) is the jurisdiction of local authorities.
Units may be installed at altitudes up to 10,000 ft. above
sea level. See TABLE 14 for de-rate manifold values. Units
installed at altitude of 7501 - 10,000 feet require an orifice change. Units installed at altitude of 4501 - 10,000 feet require a pressure switch change which can be ordered
separately. TABLE 15 lists conversion kit and pressure
switch requirements at varying altitudes.
The combustion air pressure switch is factory-set and requires no adjustment.
NOTE - A natural to LP/propane gas changeover kit is necessary to convert this unit. Refer to the changeover kit installation instruction for the conversion procedure.
TABLE 14
Manifold and Supply Line Pressure 0-10,000ft.
Manifold Pressure in. wg.
ML193
Unit
Gas
0 - 4500 ft 4501 - 5500 ft 5501 - 6500 ft 6501 - 7500 ft 7501 - 10,000 ft
Supply Line Pressure in. w.g.
0 - 10000 ft.
All
Models
Natural
L.P. Propane
3.5
10.0
3.3
9.4
3.2
9.1
3.1
8.9
3.5
10.0
4.5
11.0
13.0
13.0
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.
TABLE 15
Conversion Kit and Pressure Switch Requirements at Varying Altitudes
Natural to LP/
Propane
High Altitude
Natural Burner
Orifice Kit
LP/Propane to
Natural
High Altitude LP/
Propane Burner
Orifice Kit
High Altitude Pressure Switch
ML193 Model
0 - 7500 ft
(0 - 2286m)
17H63
7501 - 10,000 ft
(2286 - 3038m)
14C90
0 - 7500 ft
(0 - 2286m)
N/A
7501 - 10,000 ft
(2286 - 3038m)
17H66
4501 - 7500 ft
(1373 - 2286m)
7501 -10,000 ft
(2286 - 3048m)
-030
-045
-070
-090
-110
*11K49 73W37 *73W81 *11K44
11U65 11U66
* 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 43
Testing for Proper Venting and Sufficient Combustion Air for Non-Direct Vent Applications
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 monoxide poisoning or death.
The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation.
After the ML193UHE gas furnace has been started, the following test should be conducted to ensure proper venting and sufficient combustion air has been provided to the
ML193UHE as well as to other gas-fired appliances which are separately vented.
If a ML193UHE furnace replaces a Category I 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 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.
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 horizontal pitch. Determine there is no blockage or restriction, leakage, corrosion, or other deficiencies which could cause an unsafe condition.
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 connected 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 minutes of main burner operation.
8 - 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 appropriate 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 current standard of the
CSA-B149 Natural Gas and Propane Installation
Codes in Canada.
9 - After determining that each appliance remaining connected to the common venting system properly vents when tested as indicated in step 3, return doors, windows, exhaust fans, fireplace dampers and any other gas-burning appliance to their previous condition of use.
Page 44
Other Unit Adjustments
Primary Limit.
The primary limit is located on the heating compartment vestibule panel. This limit is factory set and requires no adjustment.
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. See ‘Allowable Heating Speeds” table on page 37. 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
Ignition Control 103217-03
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 off delay affects com fort and is adjustable to satisfy individual applications. Adjust the fan off delay to achieve a supply air temperature between 90° and 110°F at the moment that the blower is de-energized. Longer off delay settings provide lower return air temperatures; shorter settings provide higher re-
turn air temperatures. See FIGURE 62.
Ignition Control 107163-01
The heat fan-on time of 30 seconds is not adjustable The heat fan-off delay (amount of time that the blower oper ates after the heat demand has been satisfied) may be adjusted by changing the two position dip switch on the integerated control, to one of four slections. Blower off de lay is factory set at 90 seconds. For other blower off delay settings, please refer to the following chart:
60
90
120
180
Blower Delay Select
SW2-1
OFF
OFF
ON
ON
Factory Setting is 90
SW2-2
ON
OFF
OFF
ON
HEAT FAN ‐ OFF TIME IN SECONDS
NO JUMPER
To adjust fan-off timing, reposition jumper across pins to achieve desired setting.
60 Second off Time
90 Second off Time
120 Second off Time
180 Second off Time
FIGURE 62
Electrical
1 - Check all wiring for loose connections.
2 - Check for the correct voltage at the furnace operating).
Correct voltage is 120VAC + 10%
3 - Check amp-draw on the blower motor with blower access panel in place.
Motor Nameplate__________Actual__________
Blower Speeds
Follow the steps below to change the blower speeds.
1 - Turn off electrical power to furnace.
2 - Remove blower access panel.
3 - Disconnect existing speed tap at integrated control speed terminal.
NOTE - Termination of any unused motor leads must be insulated.
4 - Place unused blower speed tap on integrated control
“PARK” terminal or insulate.
5 - Refer to blower speed selection chart on unit wiring diagram for desired heating or cooling speed.
See Product Specifications bulletin for blower
performance tables. See for allowable heating
speeds.
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.
Page 45
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 ignition failure. This type of lockout is usually due to low gas line pressure. After one hour of continuous thermostat demand for heat, the Watchguard will break and remake thermostat demand to the furnace and automatically reset the integrated control to begin the ignition sequence.
Exhaust and Air Intake Pipe
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 termination for blockages.
3 - Obstructed pipe or termination may cause rollout switches to open. Reset manual flame rollout switches on burner box assembly if necessary.
Service
WARNING
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 operation, serious injury, death, or property damage.
Before servicing, disconnect all electrical power to furnace. When servicing controls, label all wires prior to disconnecting. Take care to reconnect wires correctly.
Verify proper operation after servicing.
WARNING
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 injury or death.
Annual Furnace Maintenance
At the beginning of each heating season, and to comply with the Lennox Limited Warranty, your system should be checked as follows:
1 - Check wiring for loose connections, voltage at indoor unit and amperage of indoor motor.
2- Check the condition of the belt and shaft bearings if applicable.
3- Inspect all gas pipe and connections for leaks.
4- Check the cleanliness of filters and change if necessary (monthly).
5- Check the condition and cleanliness of burners and heat exchanger and clean if necessary.
Check the cleanliness of blower assembly and clean the housing, blower wheel and blower motor if necessary .
7- Inspect the condensate drain and trap for leaks and cracks. The drain and trap must also be cleaned and the trap must be primed with water. Inspect the rubber hoses connected to the pressure switches for cracks or loose connections, replace as necessary.
Remove the rubber hoses from the cold end header box and inspect for any blockage, clean as needed.
If strainers are installed in the hoses remember to remove and clean before reinstalling the hoses.
8- Evaluate the heat exchanger integrity by inspecting the heat exchanger per the AHRI heat exchanger inspection procedure. This procedure can be viewed at www.ahrinet.org
9- Ensure sufficient combustion air is available to the furnace. Fresh air grilles and louvers (on the unit and in the room where the furnace is installed) must be properly sized, open and unobstructed to provide combustion air.
10- Inspect the furnace intake and exhaust pipes to make sure they are in place, structurally sound, without holes, blockage or leakage and the exhaust pipe is sloped toward the furnace. Inspect terminations to ensure they are free of obstructions and are structurally sound. Inspect the furnace return air duct connection to ensure the duct is sealed to the furnace. Check for air leaks on supply and return ducts and seal where necessary.
11- Inspect the furnace return air duct connection to ensure the duct is sealed to the furnace. Check for air leaks on supply and return ducts and seal where necessary.
12- Check the condition of the furnace cabinet insulation and repair if necessary.
13- Perform a complete combustion analysis during the furnace inspection to ensure proper combustion and operation. Consult Service Literature for proper combustion values.
Verify operation of CO detectors and replace batteries as required.
Perform a general system test. Turn on the furnace to check operating functions such as the start-up and shutoff operation.
1 - Check the operation of the ignition system, inspect and clean flame sensor. Check microamps before and after. Check controls and safety devices (gas valve, flame sensor, temperature limits). Consult
Service Manual for proper operating range. Thermal
Limits should be checked by restricting airflow and not disconnecting the indoor blower. For additional details, please see Service and Application Note
H049.
2 - Verify that system total static pressure and airflow settings are within specific operating parameters.
3 - Clock gas meter to ensure that the unit is operating at the specified firing rate. Check the supply pressure and the manifold pressure. If manifold pressure adjustment is necessary, consult the Service
Literature for unit specific information on adjusting gas pressure. Not all gas valves are adjustable.
Verify correct temperature rise.
Page 46
Winterizing and Condensate Trap Care
1 - Turn off power to the furnace.
2 - Have a shallow pan ready to empty condensate water.
3 - Remove the clean out cap from the condensate trap and empty water. Inspect the trap then reinstall the clean out cap.
Cleaning the Burner Assembly
1 - Turn off gas and electrical power to the furnace.
Remove 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.
Disconnect and label ground wire from burner/ manifold assembly.
8 - Remove four screws that secures burner/manifold assembly to vestibule. Remove the assembly and make note not to allow ignitor plate to dislodge from the assembly.
9 - Gently clean the face of the burners using the soft brush attachment on a vacuum cleaner. Visually inspect 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 existing four screws. Burners are self aligning to center 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 burners are clean and operating correctly.
19 - Replace heating compartment access panel.
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: ML193UH045XE36B-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
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
Page 47
Start-Up & Performance Check List
2
2
UNIT SET UP
(typical)
Furnace:
Model Number_______________
Serial Number_________________
Line Voltage
4
1 GAS SUPPLY
Natural Gas LP Propane Gas
Piping Connections Tight
Leak Tested
Supply Line Pressure “W.C.________
1
Gas Supply Pressure
1
SUPPLY
AIR
3
Flter
RETURN AIR
2 INTAKE / EXHAUST PIPE
All Joints Primed and Glued
Terminations Installed Properly
Horizontal Pipes Sloped (if applicable)
Condensate Trap Primed / Line Sloped
Pipes Supported
Heat Cable Installed and Operable (if applicable)
3
DUCT SYSTEM
SUPPLY AIR DUCT
Sealed
Insulated (if necessary)
RETURN DUCT
Sealed
Filter Installed and Clean
4
Grilles Unobstructed
VOLTAGE CHECK
Supply Voltage _____
Electrical Connections Tight
Page 48
1
HEATING MODE
GAS MANIFOLD PRESSURE “W.C._____
UNIT OPERATION
2 COMBUSTION SAMPLE CO
2
%
______
CO PPM_______
3
INDOOR BLOWER AMPS______
4
5
TEMPERATURE RISE
Supply Duct Temperature ________
Return Duct Temperature _ _____
Temperature Rise = ________
TOTAL EXTERNAL STATIC
Supply External Static _______
Return External Static + ______
Total External Static = _______
6
7
CONDENSATE LINE
Leak Free
VENT PIPE
Leak Free
Combustion CO
2
2
7
SUPPLY
AIR
3
COOLING MODE
INDOOR BLOWER AMPS______
4 TEMPERATURE DROP
Return Duct Temperature _________
Supply Duct Temperature _ _______
Temperature Drop = _________
5
8
TOTAL EXTERNAL STATIC (dry coil)
Supply External Static _______
Return External Static + ______
Total External Static = _______
DRAIN LINE
Leak Free
9 THERMOSTAT
Adjusted and Programmed
Explained Operation to Owner
Thermostat
9
Blower Motor Amps
3
6
8
Gas Manifold Pressure
1
Temperatures
4
Duct Static
High +
5
RETURN AIR
Low -
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 requirements:
For all side wall, horizontally vented, gas-fueled equip ment 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:
INSTALLATION OF CARBON MONOXIDE
DETECTORS. At the time of installation of the side wall, horizontally 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-operated or hard-wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall, horizontally vented, gas-fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation 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 hardwired carbon monoxide detector with alarm and battery backup may be installed on the next adjacent floor level.
b. In the event that the requirements of this subdivision 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 detector with an alarm shall be installed.
2 - APPROVED CARBON MONOXIDE DETECTORS.
Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
3 - 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 directly in line with the exhaust vent terminal for the horizontally 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 DIRECTLY BELOW. KEEP CLEAR OF ALL
OBSTRUCTIONS.”4
4 - INSPECTION. The state or local gas inspector of the side wall, horizontally vented, gas-fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions 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:
The equipment listed in Chapter 10 entitled
“Equipment 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, gasfueled equipment installed in a room or structure separate 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 venting 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
“special venting systems,” the following requirements shall be satisfied by the manufacturer:
1 - The referenced “special venting system” instructions shall be included with the appliance or equipment installation instructions; and
The “special venting systems” shall be Product
Approved by the Board, and the instructions for that system 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 instructions 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” reducer for 2” venting at the point where the exhaust pipe exits the structure is not required in direct or non-direct vent applications in the Province of Ontario. In these applications, the vent should be oriented such that the exhaust plume is unobjectionable. If the installation requires more separation between the flue gases and the building struc ture, a reducer may be installed on the exhaust pipe to increase the flue gas velocity.
ADDENDUM FOR ALL PROVINCES OF CANADA
See below for venting in all provinces of Canada. Lennox approves the following termination for use in all provinces of Canada.
B
D
C
12”
A
A − Clearance above grade or average snow accumulation
2” (51MM)
Vent Pipe
3” (76MM)
Vent Pipe
12” (305 mm) Min. 12” (305 mm) Min.
B − Horizontal separation between intake and exhaust
6” (152 mm) Min.
24” (610 mm) Max.
6” (152 mm) Min.
24” (610 mm) Max.
C − Exhaust pipe length Per: Saskatchewan Code of Practice
D − Wall support distance from top of each pipe (intake/exhaust)
6” (152 mm) Max.
6” (152 mm) Max.
NOTE − Flue gas may be acidic and may adversely affect some building materials. If flue gases impinge on the building materials, a corrosion−resistant shield should be used to protect the wall surface. 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.
Page 51
Blower Data
ML193UH030XE36B PERFORMANCE (Less Filter)
External
Static
Pressure in. w.g.
cfm
High
(Black)
Watts
Air Volume / Watts at Various Blower Speeds
Medium-High cfm
(Brown)
Watts cfm
Medium
(Blue)
Watts
Medium-Low cfm
(Yellow)
Watts
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
1435
1400
1360
1325
1300
1265
1235
1200
1160
346
351
358
370
382
387
402
411
420
1170
1130
1085
1055
1020
990
945
910
885
191
199
207
217
227
231
244
253
260
1000
955
905
865
815
785
735
710
660
127
132
137
148
157
161
168
175
183
775
735
680
625
570
515
475
425
355
91
95
104
107
114
62
71
81
84 cfm
705
635
515
445
380
310
265
215
175
Low
(Red)
Watts
61
66
68
72
75
45
48
50
55
ML193UH045XE36B PERFORMANCE (Less Filter)
External
Static
Pressure in. w.g.
cfm
High
(Black)
Watts
Air Volume / Watts at Various Blower Speeds
Medium-High cfm
(Brown)
Watts cfm
Medium
(Blue)
Watts
Medium-Low cfm
(Yellow)
Watts
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
1420
1390
1355
1330
1295
1265
1240
1210
1160
343
348
349
368
378
386
402
411
420
1305
1270
1230
1205
1180
1140
1100
1065
1030
264
271
280
291
298
310
316
331
340
1170
1135
1100
1060
1025
995
955
920
880
191
199
207
220
226
233
242
253
262
930
885
850
795
755
720
670
615
580
102
109
119
126
134
140
148
157
160 cfm
780
735
680
625
570
515
475
425
355
Low
(Red)
Watts
91
95
104
107
114
66
71
81
84
Page 52
Blower Data
ML193UH070XE36B PERFORMANCE (Less Filter)
External
Static
Pressure in. w.g.
cfm
High
(Black)
Watts
Air Volume / Watts at Various Blower Speeds
Medium-High cfm
(Brown)
Watts cfm
Medium
(Blue)
Watts
Medium-Low cfm
(Yellow)
Watts
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
1430
1395
1365
1340
1305
1270
1250
1210
1185
330
337
344
357
367
377
393
401
412
1300
1270
1245
1215
1180
1145
1110
1080
1045
249
256
269
275
285
296
305
316
325
1170
1145
1100
1080
1040
1005
970
930
885
185
192
199
210
219
230
237
247
255
955
910
865
815
760
720
685
635
600
101
107
115
123
133
139
147
152
158 cfm
750
705
655
600
550
505
455
405
355
Low
(Red)
Watts
93
95
100
109
114
67
71
76
82
ML193UH090XE36C PERFORMANCE (Less Filter)
External
Static
Pressure in. w.g.
cfm
High
(Black)
Watts
Air Volume / Watts at Various Blower Speeds
Medium-High cfm
(Brown)
Watts cfm
Medium
(Blue)
Watts
Medium-Low cfm
(Yellow)
Watts
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
1410
1375
1340
1310
1275
1240
1210
1170
1135
280
289
301
314
326
340
347
362
368
1340
1315
1285
1260
1225
1190
1160
1130
1105
230
239
249
261
269
279
288
299
304
1160
1125
1090
1055
1015
965
920
885
855
160
168
175
180
195
201
211
221
229
835
885
840
780
730
675
620
580
535
90
95
104
112
117
126
133
138
144 cfm
770
730
685
645
590
535
495
455
405
Low
(Red)
Watts
87
91
98
102
107
64
70
74
81
Page 53
Blower Data
ML193UH090XE48C PERFORMANCE (Less Filter)
External
Static
Pressure in. w.g.
cfm
High
(Black)
Watts
Air Volume / Watts at Various Blower Speeds
Medium-High cfm
(Brown)
Watts cfm
Medium
(Blue)
Watts
Medium-Low cfm
(Yellow)
Watts
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
1710
1675
1655
1615
1595
1560
1525
1490
1445
373
381
392
408
416
429
439
453
464
1500
1475
1460
1410
1365
1335
1295
1260
1230
256
263
273
282
295
308
315
325
332
1395
1365
1315
1290
1245
1200
1160
1105
1085
200
206
219
225
236
246
255
268
275
1315
1275
1230
1195
1155
1105
1060
1015
980
164
173
185
192
203
214
221
229
240 cfm
1205
1160
1110
1065
1010
965
915
875
830
Low
(Red)
Watts
129
135
142
151
160
167
176
184
195
ML193UH110XE48C PERFORMANCE (Less Filter)
External
Static
Pressure in. w.g.
cfm
High
(Black)
Watts
Air Volume / Watts at Various Blower Speeds
Medium-High cfm
(Brown)
Watts cfm
Medium
(Blue)
Watts
Medium-Low cfm
(Yellow)
Watts
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
1750
1715
1680
1640
1615
1580
1540
1515
1470
372
380
391
405
418
433
445
450
467
1535
1495
1470
1425
1395
1345
1315
1285
1230
254
262
272
284
296
305
315
325
334
1410
1380
1355
1300
1260
1225
1180
1135
1095
200
208
220
230
239
249
258
268
278
1330
1295
1255
1220
1170
1130
1080
1035
995
169
176
184
194
206
212
223
230
240 cfm
1220
1175
1135
1085
1025
975
935
895
850
Low
(Red)
Watts
128
135
145
154
162
170
179
186
192
Page 54
Blower Data
ML193UH110XE60C PERFORMANCE (Less Filter)
Air Volume / Watts at Different Blower Speeds
External
Static
Pressure in. w.g.
Bottom Return Air, Side Return Air with Return Air from
Both Sides or Return Air from Bottom and One Side.
Single Side Return Air − Air volumes in bold require
Optional Return Air Base and field fabricated transition to accommodate 20 x 25 x 1 in. air filter in order to maintain proper air velocity.
High
(Black)
Med-High
(Brown)
Medium
(Blue)
Med-Low
(Yellow)
Low
(Red)
High
(Black)
Med-High
(Brown)
Medium
(Blue)
Med-Low
(Yellow)
Low
(Red) cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts
0.00 2150 624 1915 436 1755 345 1650 280 1480 201 2175 607 1930 412 1760 330 1645 271 1475 199
0.10 2120 633 1880 441 1715 353 1605 288 1435 210 2135 614 1885 421 1705 342 1595 280 1415 207
0.20 2085 648 1830 455 1665 362 1560 298 1360 220 2085 628 1830 437 1670 351 1545 293 1370 218
0.30 2040 663 1795 468 1630 374 1515 317 1325 229 2035 647 1790 451 1625 364 1500 308 1315 227
0.40 2005 675 1760 482 1585 386 1470 327 1270 244 1995 657 1755 469 1590 378 1460 319 1275 240
0.50 1965 688 1710 496 1540 399 1425 336 1230 251 1985 674 1725 478 1545 391 1410 329 1225 250
0.60 1935 705 1680 507 1510 408 1390 347 1180 263 1925 687 1675 494 1495 401 1375 343 1170 257
0.70 1885 715 1635 521 1485 425 1345 359 1140 271 1900 698 1635 506 1450 413 1330 351 1125 270
0.80 1855 735 1600 534 1440 426 1305 367 1085 279 1850 711 1605 520 1415 430 1285 363 1075 281
Page 55
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