- Home
- Domestic appliances
- Large home appliances
- Water heaters & boilers
- Lennox
- ML196DFE Series Units
- Installation instructions
advertisement
© 2022 Lennox Industries Inc.
Dallas, Texas USA
INSTALLATION
INSTRUCTIONS
ML196DFE
MERIT ® SERIES GAS FURNACE
DOWNFLOW AIR DISCHARGE
507968-03
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.
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.
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.
Contents
Unit Dimensions - inches (mm) ......................................2
ML196DFE Gas Furnace................................................3
Shipping and Packing List ..............................................3
Safety .............................................................................3
Use of Furnace as a Construction Heaterl .....................4
General ...........................................................................5
Combustion, Dilution, Ventilation Air...............................5
Setting Equipment ..........................................................8
Filters ............................................................................ 11
Duct System .................................................................12
Pipe Fittings Specifications ...........................................12
Joint Cementing Procedure ..........................................14
Venting Practices ..........................................................15
Page 1
Gas Piping ....................................................................33
Electrical .......................................................................35
Unit Start Up .................................................................40
Gas Pressure Measurement.........................................41
Proper Combustion.......................................................42
High Altitude .................................................................42
Testing Non Direct Vent Appliances for Proper Air .......43
Other Unit Adjustments.................................................43
Service..........................................................................44
Repair Parts List ...........................................................46
Start Up Check List.......................................................48
Blower Data ..................................................................50
Unit Dimensions - inches (mm)
Flue Condensate Trap Assembly
Furnished for external field installation on either side of unit.
(See installation instructions for additional information.)
A
AIR
B
FLOW
9/16
(14)
9/16
(14)
7
(178)
COMBUSTION
AIR INTAKE
EXHAUST AIR
OUTLET
B
RETURN AIR
OPENING
2-1/16 (52)
1 (25)
Front Panel
5
(127)
2-1/4
(57)
9/16
(14)
TOP VIEW
27-3/4
(705)
19-7/16
(494)
9/16
(14)
33
(838)
2 (51)
Either Side
GAS PIPING INLET
(Either Side)
9-1/8 (232) Right
6-9/16 (167) Left
3/4
(19)
C
Supply
Air
FRONT VIEW
3/4
(19)
Model No.
ML196DF045XE36B
ML196DF070XE48B
ML196DF090XE48C
ML196DF110XE60C
A in - mm
17-1/2 - 446
21 - 533
B in - mm
16-3/8 - 416
19-7/8 - 505
ELECTRICAL INLET
(Either Side)
CONDENSATE
TRAP CONNECTION
(Either Side)
6-7/16 (163)
Either Side
9 (229)
Either Side
19-1/4
(489)
SIDE VIEW
Supply
Air
3/4
(19)
C in - mm
16 - 406
19-1/2 - 495
Page 2
ML196DFE Gas Furnace
The ML196DFE Category IV gas furnace is shipped ready for installation in the downflow position.
The furnace is equipped for installation in natural gas applications. A conversion kit (ordered separately) is required for use in propane/LP gas applications.
The ML196DFE can be installed as a Direct Vent or
Non- Direct Vent gas central furnace.
NOTE - In Direct Vent installations, combustion air is taken from outdoors and flue gases are discharged outdoors.
In Non-Direct Vent installations, combustion air is taken from indoors 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
Figure 1
NON-DIRECT VENT
INSTALLATION
EXHAUST
OUTLET
COMBUSTION
AIR INTAKE INSIDE
VENTILATED
ATTIC SPACE
NON-DIRECT VENT
INSTALLATION
EXHAUST
OUTLET
Figure 2
COMBUSTION
AIR INTAKE
INSIDE
OF HOUSE
COMBUSTION
AIR INTAKE INSIDE
VENTILATED
CRAWL SPACE
Page 3
Shipping and Packing List
Package 1 of 1 contains
1 - Assembled ML196DFE unit
1 - Bag assembly containing the following:
1 - Snap bushing
1 - 1/2” diameter threaded street elbow
1 - Snap plug
1 - Wire tie
1 - Condensate trap
1 - Condensate trap cap
1 - Condensate trap clamp
1 - 2” diameter Air intake 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 - LP/Propane changeover kit
1 - High altitude pressure switch
Safety Information
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.
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 installer (or equivalent), service agency or the gas supplier.
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.
Use only the type of gas approved for use with this furnace.
Refer to unit nameplate.
ML196DFE 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 (AN-
SI-Z223.1/NFPA 54). The National Fuel Gas Code is available from the following address:
American National Standards Institute, Inc.
11 West 42nd Street
New York, NY 10036
In Canada, installation must conform with current National
Standard of Canada CSA-B149 Natural Gas and Propane
Installation Codes, local plumbing or waste water codes and other applicable local codes.
In order to ensure proper unit operation in non-direct vent applications, combustion and ventilation air supply must be provided according to the current National Fuel Gas
Code or CSA-B149 standard.
Locations and Clearances
This furnace is CSA International certified for installation clearances to combustible material as listed on the unit
nameplate and in the table in Figure 13. Accessibility and
service clearances must take precedence over fire protec tion clearances.
For installation in a residential garage, the furnace must be installed so that the burner(s) and the ignition source are located no less than 18 inches (457 mm) above the floor. The furnace must be located or protected to avoid physical damage by vehicles. When a furnace is installed in a public garage, hangar, or other building that has a hazardous atmosphere, the furnace must be installed according 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 premature heat exchanger failure.
This ML196DFE furnace must be installed so that its electrical components are protected from water.
Installation in Combination with a Cooling Coil
When this furnace is used with cooling units (Figure 3),
it shall be installed in parallel with, or on the upstream side of, cooling units to avoid condensation in the heating 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.
GAS UNIT
Dampers
(open during heating operation only)
AIR HANDLER
Dampers
(open during cooling operation only)
Page 4
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 ML196DFE furnace may be installed in alcoves, closets, attics, basements, garages, utility rooms and crawl spaces.
This furnace design has not been CSA certified for instal lation in mobile homes, recreational vehicles, or outdoors.
Never use an open flame to test for gas leaks. Check all connections using a commercially available soap solution made specifically for leak detection.
Use of Furnace as Construction Heater
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.
• 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 ML196DFE 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 chimney or 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.
CAUTION
ML196DFE unit should not be installed in areas normally subject to freezing temperatures.
Combustion, Dilution & Ventilation Air
If the ML196DFE 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.
WARNING
I nsufficient 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
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 ML196DFE 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 (ANSIZ223.1/
NFPA 54). This reprinted material is not the complete and official position of the ANSI on the referenced subject, which is represented only by the standard in its entirety. In
Canada, refer to the CSA B149 installation codes.
Page 5
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. Insufficient 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 irculated 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
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
(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)
*Intake Debris
Screen
(Provided)
Furnace
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 6
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
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 5
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 7 and Figure 8. When com-
municating 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 rat-
ing of all equipment in the enclosure. See Figure 9.
SIDE WALL
TERMINATED
EXHAUST PIPE
(ALTERNATE
LOCATION)
FURNACE
INLET
AIR
OUTLET
AIR
Page 7
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
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.
EQUIPMENT IN CONFINED SPACE - ALL AIR FROM OUTSIDE
(All Air Through Ventilated Attic)
ROOF TERMINATED
EXHAUST PIPE
VENTILATION LOUVERS
(Each end of attic)
OUTLET
AIR
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 washer (rather than the rubber mounting grommet used
with a 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
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
RIGID LEG remove shipping bolt and washe
Figure 10
Installation - Setting Equipment
WARNING
Do not install the furnace on its front, back or in the
horizontal position. See Figure 12. Do not connect the
return air ducts 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.
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. Minimum clearances for closet or
alcove installations are shown in Figure 13.
Page 8
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.
SETTING EQUIPMENT
AIR FLOW
AIR FLOW
AIR FLOW
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.
1/2” max.
FRONT VIEW SIDE VIEW SIDE 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
Back Front
NOTE - Do not install the furnace on its front, back or in the horizontal position
Figure 12
Horizontal
Page 9
The unit may be installed three ways in downflow applica tions: on non-combustible flooring, on combustible floor ing using an additive base, or on a reverse-flow cooling coil cabinet. Do not drag the unit across the floor in the downflow position. Floor and furnace flange damage will result.
Refer to Figure 13 for clearances in downflow appli
cations .
Downflow Application Installation Clearances
Top
TABLE 1
NON-COMBUSTIBLE FLOOR OPENING SIZE
Cabinet
Width
Front to Rear in.
mm
Side to Side in mm
B (17.5”) 19-3/4 502 16-5/8 422
C (21”) 19-3 4 502 20-1/8 511
NOTE Floor opening dimensions listed are 1/4 inch (6 mm) larger than the unit opening. See dimension drawing on page 2.
FURNACE
Left Side Right Side
PROPERLY
SIZED FLOOR
OPENING
SUPPLY AIR
PLENUM
Bottom
Top
*Front
Back
0
0
0
Sides
Vent
0†
0
Floor NC
‡
*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 and vent pipe installation.
‡ tional base is installed between the furnace and the combustible floor.
Figure 13
Installation on Non-Combustible Flooring Figure 14
1 - Cut floor opening keeping in mind clearances listed on unit rating plate. Also keep in mind gas supply connections, electrical supply, flue and air intake connections and sufficient installation and servicing
clearances. See TABLE 1 for correct floor opening
size.
2 - Flange warm air plenum and lower the plenum into the opening.
3 - Set the unit over the plenum and seal the plenum to the unit.
4 - Ensure that the seal is adequate.
Figure 14
Installation on Combustible Flooring Figure 15
1 - When unit is installed on a combustible floor, a downflow combustible flooring base must be installed between the furnace and the floor. The base must be ordered separately.
CAUTION
The furnace and combustible flooring base shall not be installed directly on carpeting, tile, or other combustible material other than wood flooring.
TABLE 2
COMBUSTIBLE FLOORING BASE OPENING SIZE
Cabinet
Width
Catalog
Number
Front to Rear in mm
Side to Side in mm
B (17.5”) 11M60
C (21”) 11M61
22
22
559
559
18-3/4
22-3/4
476
578
Page 10
FURNACE
PROPERLY
SIZED FLOOR
OPENING
SUPPLY AIR
PLENUM
COMBUSTIBLE
FLOORING BASE
PROPERLY
SIZED FLOOR
OPENING
FURNACE
COOLING COIL
PLENUM
Figure 15
2 - After opening is cut, set the combustible flooring base into opening.
3 - Check fiberglass strips on the combustible flooring base to make sure they are properly glued and positioned.
4 - Lower supply air plenum into the combustible flooring base until plenum flanges seal against fiberglass strips.
NOTE - Be careful not to damage fiberglass strips.
Check for a tight seal.
5 - Set the furnace over the plenum.
6 - Ensure that the seal between the furnace and plenum is adequate.
Installation on Cooling Coil Cabinet Figure 16
NOTE - Downflow combustible flooring kit is not used.
1 - Refer to reverse-flow coil installation instructions for correctly sized opening in floor and installation of cabinet.
2 - When cooling cabinet is in place, set and secure the furnace according to the instructions that are provided with the cooling coil. Secure the furnace to the cabinet.
3 - Seal the cabinet and check for air leaks.
Return Air Opening -- Downflow Units
Return air may be brought in only through the top opening of a furnace installed in the downflow position. The follow ing steps should be taken when installing plenum:
1 - Bottom edge of plenum should be flanged with a
hemmed edge (See Figure 17 or Figure 18).
2 - Sealing strips should be used to ensure an airtight seal between the cabinet and the plenum.
3 - In all cases, plenum should be secured to top of furnace using sheet metal screws.
4 - Make certain that an adequate seal is made.
PLENUM
(Field Provided)
Figure 16
SECURE FROM
OUTSIDE CABINET
SEALING STRIP
(Field Provided)
CABINET
SIDE PANEL
Side View
Figure 17
PLENUM
(Field Provided)
SEALING STRIP
(Field Provided)
SECURE FROM
INSIDE CABINET Side View
Figure 18
CABINET
SIDE PANEL
Filters
This unit is not equipped with a filter or rack. A field-provid -
ed filter is required for the unit to operate properly. TABLE
3 lists recommended minimum filter size.
A filter must be in place whenever the unit is operating.
TABLE 3
Furnace Cabinet Width Minimum Filter Size
17-1/2”
21”
16 x 25 x 1 (1)
Page 11
IMPORTANT
If a highefficiency filter is being installed as part of this system to ensure better indoor air quality, the filter must be properly sized. Highefficiency filters have a higher static pressure drop than standardefficiency 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).
Duct System
Use industry-approved standards to size and install the
supply and return air duct system. Figure 19 shows the
correct supply and return duct installation. Refer to ACCA
Manual D. This will result in a quiet and low-static system that has uniform air distribution.
NOTE - This furnace is not certified for operation in 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 into the supply air duct system.
Duct Installation
Down-Flow Unit
Figure 19
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 com bustion and the formation of carbon monoxide gas. This raw gas or toxic fumes might then be distributed throughout the house by the furnace duct system.
Use fiberglass sealing strips, caulking, or equivalent seal ing method between the plenum and the furnace cabinet to ensure a tight seal. If a filter is installed, size the return air duct to fit the filter frame.
Pipe & 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, stratifica tion, or separation that cannot be removed by stirring.
Refer to the TABLE 4 below for approved piping and fitting
materials.
Page 12
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.
TABLE 4
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
IPEX System1738 Schedule 40 PVC
Pipes and Fittings
IPEX System1738 PVC FGV Cement &
Primer
UL1738
IMPORTANT
ML196DFE 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 cement meeting ASTM specifications, refer to Table 4. 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 13
TABLE 5
OUTDOOR TERMINATION USAGE*
STANDARD CONCENTRIC
Input Size
045
Vent Pipe
Dia. in.
6 1-1/2
2
2-1/2
Flush Mount
Kit
51W11 (US)
51W12 (CA)
3 YES
3 YES
3 YES
Wall Kit
2 inch
22G44 (US)
30G28
(CA)
YES
YES
YES
4
3 inch
44J40 (US)
81J20 (CA)
1 YES
1 YES
1 YES
Field
Fabricated
5 YES
5 YES
5 YES
1-1/2 inch
71M80 (US)
44W92
(CA)
2 YES
2 YES
2 YES
2 inch
69M29 (US)
44W92
(CA)
3 inch
60L46 (US)
444W93
(CA)
070
6
3
1-1/2
2
2-1/2
3 YES
3YES
3YES
3 YES
YES
YES
YES
YES
1
1
1
1
YES
YES
YES
YES 5
5
5
5
YES
YES
YES
YES
2
2
2
2
YES
YES
YES
YES
N/A N/A
090
3
2
2-1/2
3
2
3
3
3
3
YES
YES
YES
YES
YES
YES
N/A
1 YES
YES
YES
YES
YES
5
5
5
5
YES
YES
YES
YES
5 YES
2 YES
N/A
YES
YES
YES
YES
YES
YES
YES
YES
110 2-1/2 YES YES 5 YES YES YES
3 YES YES 5 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
1Requires field-provided outdoor 1-1/2” exhaust accelerator.
2Concentric kits 71M80 and 44W92 include 1-1/2” outdoor accelerator, when used with 045 and 070 input models. When using 1-1/2 in. piping, the pipe must transition to
2in. pipe when used with the concentrci kit.
3 Flush mount kits 51W11 and 51W12 includes 1-1/2 in. outdoor exhaust accelerator, required when used with 045, 070 and 090 input models. When using 1-1/2 in. piping, the pipe must transition to 2in. pipe when used with the flush mount kit.
4 Termination kits 30G28, 44W92, 44W93 and 81J20 are certified to ULC S636 for use in Canada only.
5 See table 10 for vent accelerator requirements
6 2inch to 1-1/2 inch reducer required. must be fied required.
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.
NOTE - Check the inside of vent pipe thoroughly for any obstruction that may alter furnace operation.
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.
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.
NOTE - Time is critical at this stage. Do not allow primer to dry before applying cement.
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.
Page 14
Venting Practices
Piping Suspension Guidelines
SCHEDULE 40
PVC - 5' all other pipe* - 3'
* 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 20
REPLACING FURNACE THAT WAS PART OF A
COMMON VENT SYSTEM
CHIMNEY
OR GAS
VENT
(Check sizing for water heater only)
WATER
HEATER
FURNACE
(Replaced)
OPENINGS
(To Adjacent
Room)
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 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.
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.
Page 15
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.
Exhaust Piping (Figure 23 and Figure 24)
Route piping to outside of structure. Continue with installation following instructions given in piping termination section.
WARNING
Carbon Monoxide Poisoning Hazard
Cutting or altering exhaust or air intake pipes, which are located in the blower compartment, could result in
Carbon Monoxide Poisoning or Death.
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
The ML196DFE can be installed as either a Non-Direct
Vent or a Direct Vent gas central furnace.
NOTE - In Direct Vent installations, combustion air is taken from outdoors and flue gases are discharged outdoors. In
Non-Direct Vent installations, combustion air is taken from indoors or ventilated attic or crawlspace and flue gases are discharged outdoors.
Intake and exhaust pipe sizing -- Size pipe according to-
TABLE 6 (minimum) and TABLE 7 (maximum). Count all
elbows inside and outside the home.
NOTE - Lennox offers a glueless vent adapter kit 17H92 as an option for exhaust exiting at the furnace top cap coupling.
TABLE 6
MINIMUM VENT PIPE LENGTHS
ML196DFE MODEL
045, 070, 090, 110
MIN. VENT LENGTH*
15 ft or 5ft 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 equivalent to one 90 degree elbow .
Regardless of the diameter of pipe used, the standard roof and wall terminations described in section Exhaust Piping
Terminations should be used. Exhaust vent termination pipe is sized to optimize the velocity of the exhaust gas as it exits the termination. Refer to table 10. 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.
Use the following steps to correctly size vent pipe diameter.
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 22
NOTE - It is acceptable to use any pipe size which fits within the guide lines allowed in table 7.
NOTE - All horizontal runs of exhaust pipe must slope back toward unit.
A minimum of 1/4” (6mm) drop for each 12” (305mm) of horizontal run is mandatory for drainage.
NOTE - Exhaust pipe MUST be glued to furnace exhaust fittings.
NOTE - Exhaust piping should be checked carefully to make sure there are no sags or low spots.
Page 16
No. Of
90°
Elbows
7
8
5
6
3
4
1
2
9
10
7
8
5
6
9
10
3
4
1
2
TABLE 7
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.
N o.Of
90°
Elbows
1-1/2” Pipe
Model
Standard Termination at Elevation 0 - 2000 ft
2” Pipe
Model
2-1/2” Pipe
Model
3” Pipe
Model
045 070 090 110 045 070 090 110 045 070 090 110 045 070 090 110
15 15 61 46 24 100 80 43 127 127 108 108
10 10 56
51
41
36
19
14
95
90
75
70
38
33
122 122 103 103
117 117 98 98 n/a n/a n/a n/a
46
41
36
31
26
21
16
31
26
21
16
11 n/a n/a n/a
85
80
75
70
65
60
55
65
60
55
50
45
40
35
28
23
18
13 n/a n/a
112 112
107 107
102 102
97
92
97
92
93
88
83
78
73
93
88
83
78
73
87 87 68 68
82 82 63 63
045
35
30
25
20
15
10 n/a
25
20
15
10
2” Pipe
Model
070 090
Standard Termination Elevation 2001 - 10,000 ft
2-1/2” Pipe
Model
110 045 070 090 110
15
10
100
95
90
85
73
68
63
58
43
38
33
28 n/a n/a n/a
80
75
70
65
60
55
53
48
43
38
33
28
23
18
13 n/a n/a
045
127
122
117
112
107
102
97
92
87
82
3” Pipe
Model
070
127
122
117
112
107
102
97
92
87
82
090
108
103
98
93
88
83
78
73
68
63
110
108
103
98
93
88
83
78
73
68
63
Page 17
No, Of
90°
Elbows
7
8
5
6
3
4
1
2
9
10
7
8
5
6
3
4
1
2
9
10
TABLE 7 continued
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.
No. Of
90°
Elbows
1-1/2” Pipe
Models
Concentric Termination at Elevation 0 - 2000 ft
2” Pipe
Model
2-1/2” Pipe
Model
3” Pipe
Model
045 070 090 110 045 070 090 110 045 070 090 110 045 070 090 110
10 10 53 38 22 90 70 39 111 111 104 104
48
43
33
28
17
12
85
80
65
60
34
29
106
101
106
101
99
94
99
94 n/a n/a n/a n/a
38
33
28
23
23
18
13 n/a n/a
75
70
65
60
55
50
45
40
24
19
14
9 n/a
96
91
86
81
96
91
86
81
89
84
79
74
89
84
79
74
18
13 n/a n/a
55 35
50 30
45 25 n/a
76
71
66
76 69 69
71 64 64
66 59 59
045
35
30
25
20
15
10 n/a
070
25
2” Pipe
Model
090
15
Concentric Termination Elevation 2001 - 10,000 ft
2-1/2” Pipe
110 045
90
070
Model
090
63 39
110
20
15
10 85
80
58
53
34
29
10 n/a n/a n/a
75
70
65
60
48
43
38
33
24
19
14
9 n/a
55
50
45
28
23
18 n/a
96
91
86
81
045
111
106
101
76
71
66
070
111
3” Pipe
Model
090
104
106
101
96
91
86
81
76
71
66
99
94
89
84
79
74
69
64
59
89
84
79
74
110
104
99
94
69
64
59
Page 18
7
8
9
10
5
6
1
2
3
4
TABLE 8
Maximum Allowable Exhaust Vent Lengths With Furnace Installed in a Closet or
Basement Using Ventilated Attic or Crawl Space For Intake Air in Feet
NOTE - Additional vent pipe and elbows used to terminate the vent pipe outside the structure must be included in the total vent length calculation.
Number
Of 90°
Elbows
1-1/2” Pipe
Model
Standard Termination at Elevation 0 - 2000 ft
2” Pipe
Model
2-1/2” Pipe
Model
3” Pipe
Model
045 070 090 110 045 070 090 110 045 070 090 110 045 070 090 110
10 10 51 36 14 85 65 28 107 107 88 88
9
N/A N/A
N/A N/A
46
41
36
31
26
21
16
11 n/a
31
26
21
16
11 n/a n/a
N/A
80
75
70
65
60
55
50
45
40
60
55
50
45
40
35
30
25
20
23
18
13
8 n/a n/a
77
72
67
62
102 102 83 83
97
92
97
92
78
73
78
73
87
82
87
82
68 68
63 63
77
72
67
62
58 58
53 53
48 48
43 43
Number
Of 90°
Elbows
6
7
4
5
1
2
3
8
9
10
1-1/2” Pipe
Model
Standard Termination at Elevation 2001 - 10,000 ft
2” Pipe
Model
2-1/2” Pipe
Model
3” Pipe
Model
045 070 090 110 045 070 090 110 045 070 090 110 045 070 090 110
30 20 10 80 53 28 107 107 88 88
N/A N/A N/A N/A
25
20
15
10 n/a
15
10 n/a n/a
N/A
55
50
45
40
35
75
70
65
60
28
23
18
13 n/a
48
43
38
33
23
18
13 n/a n/a
82
77
72
67
62
102 102 83 83
97 97 78 78
92
87
92
87
73
68
73
68
82
77
72
67
62
63
58
63
58
53 53
48 48
43 43
Page 19
Exhaust
DO NOT transition from larger to smaller pipe in horizontal runs of exhaust pipe.
045/070 Only
1−1/2”
TRANSITION
2”
TYPICAL EXHAUST PIPE CONNECTIONS
2”
2”
2” or
2”
2”
Exhaust
3”
TRANSITION
*2”
DO NOT transition from smaller to larger pipe size in horizontal runs of exhaust pipe.
INTAKE EXHAUST
TOP VIEW
045/070 Only
1−1/2”
TRANSITION
2”
* 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 23
TYPICAL INTAKE PIPE CONNECTIONS
2”
2”
2” or
2”
2”
TRANSITION
3”
*2” 3”
*2”
TRANSITION
*2” INTAKE
EXHAUST
TOP VIEW
* When transitioning up in pipe size, use the shortest length of 2” PVC pipe possible.
NOTE − Intake pipe and exhaust pipe must be the same diameter.
Figure 24
Page 20
Intake Piping
The ML196DFE furnace may be installed in either direct vent or non-direct vent applications.
In non-direct vent applications, when intake air will be drawn into the furnace from the surrounding space, the indoor air quality must be considered. Guidelines listed in Combustion, Dilution and
Ventilation Air section must be followed.
Follow the next two steps when installing the unit in Direct
Vent applications, where combustion air is taken from outdoors and flue gases are discharged outdoors. The provided air intake screen must not be used in direct vent applications (outdoors).
1 - Use cement to secure the intake pipe to the inlet air connector.
2 - Route piping to outside of structure. Continue with installation following instructions given in general guide lines for piping terminations and intake and exhaust piping terminations for direct vent sections.
Refe to TABLE 7 for pipe sizes.
Follow the next two steps when installing the unit in Non-
Direct Vent applications where combustion air is taken from indoors and flue gases are discharged outdoors.
1 - Use field-provided materials and the factory-provided air intake screen to route the intake piping as shown
in Figure 25. Maintain a minimum clearance of
3” (76mm) around the air intake opening. The air intake opening (with the protective screen) should always be directed forward, or sideways.
2 - If intake air is drawn from a ventilated attic (Figure
26) or ventilated crawlspace (Figure 27) the exhaust
vent length must not exceed those listed in TABLE
8. If 3” diameter pipe is used, reduce to 2” diameter
pipe at the termination point to accommodate the debris screen.
3 - Use cement to secure the intake pipe to the connector, if desired.
TYPICAL AIR INTAKE PIPE CONNECTIONS
NON−DIRECT VENT APPLICATIONS
AIR
INTAKE
SCREEN
(Provided)
NOTE - Air intake screen and elbow may be rotated, so that screen may be positioned to face forward or to either side.
Figure 25
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.
Page 21
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 26
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 27
General Guidelines for Vent Terminations
In Non-Direct Vent applications, combustion air is taken from indoors or ventilated attic or crawlspace and the flue gases are discharged to the outdoors. The ML196DFE is then classified as a non-direct vent, Category IV gas fur nace.
In Direct Vent applications, combustion air is taken from outdoors and the flue gases are discharged to the out doors. The ML196DFE is then classified as a direct vent,
Category IV gas furnace.
In both Non-Direct Vent and Direct Vent applications, the vent termination is limited by local building codes. In the absence of local codes, refer to the current National Fuel
Gas Code ANSI Z223-1/NFPA 54 in U.S.A., and current
CSA-B149 Natural Gas and Propane Installation Codes in
Canada for details.
Position termination according to location given in Figure
29 or Figure 30. 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 9 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 22
TABLE 9
Maximum Allowable Exhaust Vent Pipe Length (in ft.) 3 Without Insulation In Unconditioned Space For
Winter Design Temperatures Single - Stage High Efficiency Furnace
Winter Design
Temperatures 1 °F (°C)
Vent Pipe
Diameter
045 070
Unit Input Size
090
PVC 2 PP PVC 2 PP PVC 2 PP
32 to 21
(0 to -6)
20 to 1
(-7 to -17)
1-1/2 in
2 in
2-1/2 in
3 in
1-1/2in.
2 in
2-1/2 in
3 in
1-1/2 in
20
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
0 to -20
(-18 to -29)
2 in
2-1/2 in
5
1
3
N/A
12
7
10
N/A
22
15
3 in N/A N/A 2 2 10
1
Refer to 99% Minimum Design Temperature table provided in the current edition of the ASHRAE Fundamentals Handbook.
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
19
N/A
10
2
Poly-Propylene vent pipe (PP) by Duravent and Centrotherm.
PVC
18
12
7
N/A
30
36
29
N/A
27
20
14
N/A
110
2 PP
N/A
30
N/A
29
N/A
24
N/A
14
N/A
15
N/A
7
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 7 or 8 which ever is less.
NOTE -
3 Vent length in the table is equivalent length. Each elbow is equivalent to 5ft of straight pipe and should be included when measuring total length.
Conditioned
Space
Conditioned
Space
Pipe Insulation
Unconditioned
Space
Figure 28
Exhaust
Pipe
Intake
Pipe
Page 23
D
E
B
VENT TERMINATION CLEARANCES
FOR NON-DIRECT VENT INSTALLATIONS IN THE US AND CANADA
INSIDE CORNER
DETAIL
G
A
H
L
F
C
Fixed
Closed
Operable
B
Operable
B
Fixed
Closed
I
M
B
J
K
A
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 =
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
* 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
G =
H =
I =
Clearance to inside corner 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 29
Page 24
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 =
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
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 30
Page 25
Details of Intake and Exhaust Piping Terminations for
Direct Vent Installations
NOTE - In Direct Vent installations, combustion air is taken from outdoors and flue gases are discharged to outdoors.
NOTE - Flue gas may be slightly acidic and may adverse ly affect some building materials. If any vent termination is used and the flue gasses 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 39.
Intake and exhaust pipes may be routed either horizontally through an outside wall or vertically through the roof.
In attic or closet installations, vertical termination through
the roof is preferred. Figure 31 through Figure 38 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 32). You may exit the
exhaust out the roof and the intake out the side of
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
TABLE 10
EXHAUST PIPE TERMINATION SIZE REDUCTION
ML196 Model Exhaust Pipe Size
Termination
Pipe Size
*045 and 070 2” (51mm), 2-1/2” (64mm),
*090, 110
3” (76mm)
1-1/2”
(38mm)
2” (51mm)
*ML196DFE-045, -070 and -090 units with the flush-mount termination must use the 1-1/2”accelerator supplied with the kit.
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. See Figure 39.
NOTE - Care must be taken to avoid recirculation of ex haust back into intake pipe.
Page 26
Inches(mm)
Exhaust
Pipe
8” (203mm) MIN
12” (305mm) ABOVE
AVERAGE SNOW
ACCUMULATION
3” (76mm) OR
2” (51mm) PVC
PROVIDE SUPPORT
FOR INTAKE AND
EXHAUST LINES
DIRECT VENT ROOF TERMINATION KIT
(15F75 or 44J41)
Figure 31
Roof Terminated
Exhaust Pipe
3”(76mm) MAX.
UNCONDITIONED
ATTIC SPACE
Exiting Exhaust and Intake Vent
(different pressure zone)
Furnace
Figure 32
Inlet Air
(Minimum 12 in.
305 MM) above grade or snow accumulation
Exiting Exhaust and Intake Vent
(different pressure zone)
Furnace
Inlet Air
(Minimum 12 in.
305 MM) above grade or snow accumulation
Figure 33
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.
7 - If intake and exhaust piping must be run up a side wall to position above snow accumulation or other obstructions, iping 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 39, 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 10.The intake piping may be equipped with a 90° elbow turndown. Using turndown will add 5 feet (1.5m) to the equivalent length of the pipe.
8 - A multiple furnace installation may use a group of up to four terminations assembled together horizontally,
Accelerator not required for
3” concentric
INTAKE
FLASHING
(Not Furnished)
12” (305mm)
Minimum
Above Average
Snow
Accumulation
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 34
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)
INTAKE
AIR
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 35
EXHAUST
VENT
INTAKE
AIR
5”
(127mm)
12”
(305mm)
5-1/2”
(140mm)
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 36
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 37
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
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 38
Page 27
* 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
STRAIGHT
APPPLICATION
C2
A
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)
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
12” (305 mm) 20” (508 mm)
E − Maximum wall support distance from top of each pipe (intake/exhaust)
6” (152 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
1
B
E
D
B
Front View of
Intake and Exhaust
12”
C
12” 2
A
C
Intake Exhaust
A
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 39
Page 28
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 40, Figure 41 and Figure 42 show typical
terminations.
1 - Exhaust piping must terminate straight out or up as shown. The termination pipe must be sized as listed
in TABLE 10.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
Venting In A Crawl Space
Basement Floor
KIT 51W18
(USA)
KIT 15Z70
(CANADA)
3” (76mm) OR
2” (51mm) PVC
PROVIDE SUPPORT
FOR EXHAUST LINES
UNCONDITIONED
ATTIC SPACE
Figure 41
NON-DIRECT VENT APPLICATION
USING EXISTING CHIMNEY
STRAIGHT-CUT OR
ANGLE-CUT IN DIRECTION
OF ROOF SLOPE
NON-DIRECT VENT ROOF TERMINATION KIT
(15F75 or 44J41)
Figure 40
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.
Crawl Space and Extended Horizontal Venting
Lennox provides kit 51W18 (USA) and kit 15Z70 (Canada) to install 2” or 3” PVC exhaust piping through the floor
joists and into the the crawl space. See Figure 41.
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.).
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 42
Condensate Piping
This unit is designed for either right- or left-side exit of
condensate piping. Refer to Figure 43 for condensate trap
locations.
Page 29
NOTE - If necessary the condensate trap may be installed up to 5’ away from the furnace. Use PVC pipe to connect trap to furnace condensate outlet. Piping from furnace must slope down a minimum of 1/4” per ft. toward trap.
CONDENSATE TRAP AND PLUG LOCATIONS
NOTE - If necessary the condensate trap may be installed up to 5 feet away from the furnace. Piping from furnace must slope down a minimum of 1/4” per ft. toward trap.
NOTE - Appropriately sized tubing and barbed fitting may be used for condensate drain. Attach to the drain on the
trap using a hose clamp. See Figure 44.
Field Provided Drain Components
Trap
(same on right side)
Elbow
Plug
(same on left side) Tubing
Barbed Fitting
Hose Clamp
1-1/2 in.
Figure 43
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.
2 - Use a large flat head screw driver or a 1/2” drive
socket extension and remove plug (Figure 43) 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 49.
4 - Install drain trap using appropriate PVC fittings, glue all joints. Glue the provided drain trap as shown in
Figure 49. Route the condensate line to an open
drain.
5 - Figure 46 shows 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 47 and Figure 48. The field
provided vent must be a minimum 1” to a maximum 2” length above the condensate drain outlet connection.
6 - If unit will be started immediately upon completion of installation, prime trap per procedure outlined in Unit
Start-Up section.
Figure 44
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. Heat cable kit is available from Lennox in various lengths; 6 ft. (1.8m) - kit no. 26K68; 24 ft. (7.3m) - kit no.
26K69; and 50 ft. (15.2m) - kit no. 26K70.
CONDENSATE TRAP LOCATION
(shown with right side exit of condensation)
Trap can be installed a maximum of 5ft. from furnace (*PVC only)
Field Provided Vent
1” min. 2” max. above condensate drain.
1” min.
2” max.
5’ max.
to drain
*Piping from furnace must slope down a minimum 1/4” per ft. toward trap
Figure 45
Page 30
Furnace with Evaporator Coil
Using a Separate Drain
Field Provided Vent
1” min. 2” max. above condensate drain.
Condensate
Drain Connection
Condensate Trap With Optional Overflow Switch
From Evaporator Coil
HorizontalFurnace4” Min. to 5” Max.above
condensatedrain connection)
FurnaceCondensate
DrainConnection
Optional
Evaporator Drain Line
(vent required)
Drain
Figure 46
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.
Furnace with Evaporator
Coil Using a Common Drain
Figure 48
CAUTION
Do not use copper tubing or existing copper condensate lines for drain line.
Field Provided Vent
1” min. 2” max. above condensate drain.
Condensate
Drain Connection
Evaporator Drain Line
(vent required)
Figure 47
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 49
Page 32
Gas Piping
Gas supply piping should not allow more than 0.5”W.C. drop in pressure between gas meter and unit. Supply gas pipe must not be smaller than unit gas connection.
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 51. Connect the gas supply piping into the
gas valve. The maximum torque is 800 in lbs and minimum torque is 350 in lbs when when attaching the gas piping to the gas valve.
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 11 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.
1/8” N.P.T. PLUGGED TAP
CAP
Figure 50
FURNACE
IMPORTANT
When testing pressure of gas lines, gas valve must be
disconnected and isolated. See Figure 50. Gas valves
can be damaged if subjected to pressures greater than
1/2 psig (3.48 kPa).
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.
Page 33
MANUAL
MAIN SHUT-OFF
VALVE
(1/8 in. NPT plugged tap shown)
Left Side Piping
(Standard)
AUTOMATIC
GAS VALVE
(with manual shut-off valve)
AUTOMATIC
GAS VALVE
(with manual shut-off valve)
MANUAL
MAIN SHUT-OFF
VALVE
(1/8 in. NPT plugged tap shown)
GROUND
JOINT
UNION
GROUND
JOINT
UNION
DRIP LEG
FIELD
PROVIDED
AND INSTALLED
NOTE - BLACK IRON PIPE
ONLY
TO BE ROUTED INSIDE OF CABINET
DRIP LEG
Right Side Piping
(Alternate)
Figure 51
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 11
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)
Page 34
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.
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.
The unit is equipped with a field make-up box on the left hand side of the cabinet. A field-provided make-up box can be installed on the exterior of the right side of the furnace to facilitate installation. If the make-up box is moved to the right side, clip the wire ties that bundle the wires together
and install on the outside of the cabinet. See Figure 52.
The excess wire must be pulled into the blower compartment. Secure the excess wire to the existing harness to protect it from damage.
Refer to Figure 53 for field wiring and troubleshooting.
EXTERIOR MAKE-UP BOX
(FIELD PROVIDED RIGHT SIDE)
MAKE-UP
BOX
OUTSIDE
CABINET
Right Side
Figure 52
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.
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.
Page 35
Install a separate (properly sized) disconnect switch near the furnace so that power can be turned off for servicing.
Before connecting the thermostat or the power wiring, check to make sure the wires will be long enough for servicing at a later date. Remove the blower access panel to check the length of the wire.
Complete the wiring connections to the equipment. Use the provided unit wiring diagram and the field wiring dia -
gram shown in Figure 53. 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 ML196DFE furnace contains electronic com ponents that are polarity sensitive. Make sure that the fur nace is wired correctly and is properly grounded.
Accessory Terminals
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 “120 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.
One 24V ”H” 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.
Install the room thermostat according to the instructions
provided with the thermostat. See Figure 53 for thermo-
stat designations. If the furnace is being matched with a heat pump, refer to thermostat installation instructions 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 (FAN) when there is no cooling or heating demand. See
TABLE 19 on page 51 for allowable circulation
speeds.
2 - When the ML196DFE is running in the heating mode, the indoor blower will run on the heating speed
(HEAT). See TABLE 18 on page 51 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)
Page 36
Figure 53
Page 37
IGNITION CONTROL 103217-03
RED LED RECALL BUTTON
Note - 1
Note - 2
BLOWER OFF DELAY
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 12
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)
Figure 54
IGNITION CONTROL 103217-03
RED LED Flash Code 2
Off
Heartbeat 1
Continuous Rapid Flash
1
2
3
4
5
6
7
8
9
10
11
12
13
Note - 3
Diagnostic Codes / Status of Furnace
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, pressand 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 38
IGNITION CONTROL 107163-01
PARKS
Push Button
Error Recall
Diagnostic LED
IGNITION CONTROL 107163-01
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
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 39
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.
CAUTION
Before attempting to perform any service or maintenance, turn the electrical power to unit OFF at disconnect switch.
WARNING
Danger of explosion. Can cause injury or product or property damage. If overheating occurs or if gas supply fails to shut off, shut off the manual gas valve to the appliance before shutting off electrical supply.
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 ML196DFE is equipped with a gas control switch. 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:
ML196DFE 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 55)
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 access panel.
6 - Move gas valve switch to OFF. See Figure 55.
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 55.
9 - Replace the access panel.
10- Turn on all electrical power to to the unit.
11- Set the thermostat to desired setting.
NOTE - When unit is initially started, steps 1 through 11 may need to be repeated to purge air from gas line.
MANIFOLD
PRESSURE
ADJUSTMENT
SCREW
MANIFOLD
PRESSURE
OUTLET
PORT
INLET
PRESSURE
PORT GAS VALVE SHOWN IN ON POSITION
Figure 55
12- If the appliance will not operate, follow the instructions
“Turning Off Gas to Unit” and call your service technician or gas supplier.
Turning Off Gas to Unit
1 - Set the thermostat to the lowest setting.
2 - Turn off all electrical power to the unit if service is to be performed.
3 - Remove the access panel.
4 - Move gas valve switch to OFF.
5 - Replace the access panel.
Page 40
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)
TABLE 13
GAS METER CLOCKING CHART
ML196
Unit
-045
-070
-090
-110
Seconds For One Revolution
Natuarl
1 cu ft
Dial
80
2 cu ft
Dial
160
LP/Propane
1 cu ft
Dial
200
2 cu ft
Dial
400
55
41
33
110
82
66
136
102
82
272
204
164
Natural-1000 btu/cu ft LP-2500 btu/cu ft
NOTE - To obtain accurate reading, shut off all other gas appliances connected to meter.
Furnace should operate at least 5 minutes before 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 13. If manifold pressure matches TABLE 14 and
rate is incorrect, check gas orifices for proper size and restriction. Remove temporary gas meter if installed.
Supply Pressure Measurement
A threaded plug on the inlet side of the gas valve provides access to the supply pressure tap. Remove the threaded plug, install a field-provided barbed fitting and connect a
manometer to measure supply pressure. See TABLE 14
for proper supply line pressure. Replace the threaded plug after measurements have been taken.
TABLE 14
Supply Line and Manifold Pressure (inches w.c.)
Unit Fuel
Manifold
Pressure
Line Pressure
All
All
Nat
LP/Propane
Check Manifold Pressure
3.5
10.0
4.5 - 10.5
11.0 - 13.0
After supply pressure has been checked and adjusted, check manifold pressure. Move pressure gauge to outlet pressure tap located on unit gas valve (GV1). Checks of manifold pressure are made as verification of proper reg ulator adjustment.
IMPORTANT
For safety, connect a shut-off valve between the manometer and the gas tap to permit shut off of gas pressure to the manometer.
Follow the steps below. Gas manifold Kit 10L34 provides additional components if needed.
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 table 15.
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.
Page 41
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. The maximum carbon monoxide reading should not exceed 100 ppm.
TABLE 15
CO
2
% Nat CO
2
% LP ML196 Unit
-045
-070
-090
-110
7.2 - 8.2
8.6 - 9.6
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. SeeTABLE 16 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 17 lists conversion kit and pressure
switch requirements at varying altitudes. The combustion air pressure switch is factory-set and requires no adjustment.
TABLE 16
Manifold and Supply Line Pressure 0-10,000ft.
Manifold Pressure in. wg.
ML196
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 17
Conversion Kit and Pressure Switch Requirements at Varying Altitudes
Natural to LP/
Propane
High Altitude
Natural Burner
Orifice Kit
High Altitude
LP/Propane Burner
Orifice Kit
High Altitude Pressure Switch
ML196
Unit
0 - 7500 ft
(0 - 2286m)
7501 - 10,000 f t
(2286 - 3038m)
7501 - 10,000 ft
(2286 - 3038m)
4501 - 7500 ft
(1373 - 2286m)
7501 -10,000 ft
(2286 - 3048m)
-045
-070
11U65
11U70
11U66
11U68
-090
-110
11K49 73W37 11K44
11U71
11U70
11U68
11U68
Pressure switch is factory set. No adjustment necessary. All models use the factory-installed pressure switch from 0-4500 feet (0-
1370 m).
Page 42
Testing of Non-Direct Vent Applications for Proper
Venting and Sufficient Combustion Air
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 ML196 gas furnace has been started, the following test should be conducted to ensure proper venting and sufficient combustion air has been provided to the ML196 as well as to other gas-fired appliances which are sepa rately vented.
If a ML196 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.
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 TABLE 18 on page 51 for
allowable heating speeds. 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 heat fan off delay (amount of time that the blower operates after the heat demand has been satisfied) may be adjusted by changing the jumper position across the five pins on the integrated control. The unit is shipped with a factory fan off setting of 90 seconds. The fan off delay affects comfort and is adjustable to satisfy individual ap plications. 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 pro vide lower return air temperatures; shorter settings provide higher return air temperatures. See Figure 56.The cool fan off delay (amount of time that the blower operates after the cool demand has been satisfied) is 45 seconds and not adjustable.
Page 43
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 56
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
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
TABLE 18 on page 51 for allowable heating
speeds.
6 - Connect selected speed tap at integrated control speed terminal.
7 - Re-secure blower access panel.
8 - Turn on electrical power to furnace.
9 - Recheck temperature rise.
Thermostat Heat Anticipation
Set the heat anticipator setting (if adjustable) according to the amp draw listed on the wiring diagram that is attached to the unit
Exhaust and Air Intake Pipe
1 - 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.
Page 44
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 shut-off 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.
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
If cleaning the burners becomes necessary, follow the steps below:
1 - Turn off electrical and gas power supplies to furnace.
Remove upper and lower furnace access panels.
2 - Disconnect the 2-pin plug from the gas valve.
3 - Remove the burner box cover (if equipped).
4 - Disconnect the gas supply line from the gas valve.
Remove gas valve/manifold assembly.
5 - Loosen clamps and remove combustion air intake flexible connector (if equipped).
5 - Mark and disconnect sensor wire from the sensor.
Disconnect plug from the ignitor at the burner box.
Remove four screws which secure burner box assembly to vest panel. Remove burner box from the unit.
7 - Use the soft brush attachment on a vacuum cleaner to gently clean the face of the burners. Visually inspect the inside of the burners and crossovers for any blockage caused by foreign matter. Remove any blockage.
8 - Reinstall the burner box assembly using the existing four screws. Make sure that the burners line up in the center of the burner ports.
9 - Reconnect the sensor wire and reconnect the 2-pin plug to the ignitor wiring harness.
10 - Reinstall combustion air intake flexible connector (if equipped), secure using existing clamps.
11 Reinstall the gas valve manifold assembly.
Reconnect the gas supply line to the gas valve.
Reinstall the burner box cover.
12 - Reconnect plug to gas valve.
13 - Replace the blower compartment access panel.
14 - Refer to instruction on verifying gas and electrical connections when re-establishing supplies.
15 - Follow lighting instructions to light and operate furnace for 5 minutes to ensure that heat exchanger is clean and dry and that furnace is operating properly.
16 - Replace access panel.
Page 45
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: ML196DF045XE36B-01.
All service must be performed by a licensed professional installer (or equivalent), service agency, or gas supplier.
Cabinet Parts
Outer 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
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
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 nondirect 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 structure, a reducer may be installed on the exhaust pipe to increase the flue gas velocity.
ADDENDUM FOR ALL THE PROVINCES OF CANADA
See below for venting in all the provinces of Canada. Lennox approves the following termination for use in all the provinces of Canada.
C
D
B
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 46
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 equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above the finished grade in the area of the venting, in cluding but not limited to decks and porches, the following requirements shall be satisfied:
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 - 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 provide 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 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
Blower Data
ML196DF045XE36B 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
1455
1425
1395
1365
1325
1245
1180
N/A
N/A
370
375
380
385
385
370
360
N/A
N/A
1275
1250
1225
1195
1170
1130
1095
1045
1000
255
260
265
275
290
300
305
310
290
1175
1145
1115
1085
1045
1010
970
935
895
190
200
210
220
230
240
245
255
260
920
885
850
815
770
720
675
615
580
90
100
110
115
130
135
140
150
155
ML196DF070XE48B 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
1720
1700
1675
1640
1600
1560
1500
N/A
N/A
510
530
545
555
565
570
565
N/A
N/A
1545
1505
1465
1420
1380
1340
1300
1255
1215
355
360
370
380
395
400
420
430
445
1340
1310
1275
1230
1180
1140
1095
1040
990
235
245
255
270
280
290
305
315
320
1240
1195
1155
1120
1060
1015
965
910
865
190
200
205
215
225
235
245
255
265 cfm
865
830
795
750
700
660
605
560
505
Low
(Red)
Watts cfm
1020
955
895
835
785
715
640
585
525
Low
(Red)
Watts
95
110
115
125
135
145
150
160
170
85
90
95
105
110
120
125
130
135
ML196DF090XE48C 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
1760
1730
1700
1670
1640
1590
1530
N/A
N/A
435
445
455
465
480
485
465
N/A
N/A
1555
1515
1475
1445
1410
1380
1340
1315
1280
280
300
315
330
340
345
360
370
375
1405
1375
1350
1310
1265
1225
1195
1150
1115
230
240
250
265
275
285
295
305
315
1315
1280
1245
1200
1160
1125
1085
1065
1015
175
190
205
220
230
235
245
255
265 cfm
1190
1150
1115
1070
1025
985
945
895
860
Low
(Red)
Watts
135
145
155
165
175
185
195
200
210
Page 50
Blower Data
ML196DF110XE60C 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
2115
2090
2060
2020
1980
1935
1895
1830
1765
669
686
701
711
734
740
749
738
723
1895
1845
1790
1760
1715
1690
1625
1600
1550
466
476
487
498
511
525
536
548
564
1710
1670
1630
1590
1545
1500
1460
1410
1370
356
368
375
393
403
418
423
438
456
1605
1570
1520
1470
1420
1370
1335
1280
1240
285
299
315
324
342
347
358
367
387
Red
TABLE 18
Allowable Heating Speeds
Yellow Blue
ML196DF Model
Number
045XE36B
070XE48B
090XE48C
110XE60C
Allowed
Factory Setting
Allowed
Allowed
Brown
Not Allowed
Allowed
Factory Setting cfm
1415
1380
1320
1280
1220
1170
1110
1080
1010
Low
(Red)
Watts
209
217
222
236
247
264
269
286
290
Black
Not Allowed
Model Number
All Models
Red
Factory Setting
TABLE 19
Allowable Circulation Speeds
Yellow
Not Allowed
Blue
Not Allowed
Brown
Not Allowed
Black
Not Allowed
Page 51
advertisement
Related manuals
advertisement
Table of contents
- 2 Unit Dimensions - inches (mm)
- 3 ML196DFE Gas Furnace
- 3 Shipping and Packing List
- 3 Safety
- 4 Use of Furnace as a Construction Heaterl
- 5 General
- 5 Combustion, Dilution, Ventilation Air
- 8 Setting Equipment
- 11 Filters
- 12 Duct System
- 14 Joint Cementing Procedure
- 15 Venting Practices
- 33 Gas Piping
- 35 Electrical
- 40 Unit Start Up
- 41 Gas Pressure Measurement
- 42 Proper Combustion
- 42 High Altitude
- 43 Testing Non Direct Vent Appliances for Proper Air
- 43 Other Unit Adjustments
- 44 Service
- 46 Repair Parts List
- 48 Start Up Check List
- 50 Blower Data