Lennox MERIT ML193DF, ML195DF MERIT SERIES Installation Instructions Manual
Page 1
06/12
*2P0612*
507011−01
*P507011-01*
2012 Lennox Industries Inc.
Dallas, Texas, USA
AIR FLOW
DOWNFLOW
INSTALLATION
INSTRUCTIONS
ML193DF
MERIT
®
SERIES GAS FURNACE
DOWNFLOW AIR DISCHARGE
507011−01
06/2012
Supersedes 506475−01
THIS MANUAL MUST BE LEFT WITH THE
HOMEOWNER FOR FUTURE REFERENCE
This is a safety alert symbol and should never be ignored.
When you see this symbol on labels or in manuals, be alert
to the potential for personal injury or death.
CAUTION
As with any mechanical equipment, personal injury
can result from contact with sharp sheet metal
edges. Be careful when you handle this equipment.
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.
Table of Contents
Unit Dimensions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ML193DF Gas Furnace 3. . . . . . . . . . . . . . . . . . . . . . . . . .
Shipping and Packing List 3. . . . . . . . . . . . . . . . . . . . . . . .
Safety Information 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Use of Furnace as a Construction Heater 4. . . . . . . . . . .
General 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Combustion, Dilution and Ventilation Air 5. . . . . . . . . . . .
Setting Equipment 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filters 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duct System 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pipe and Fittings Specifications 12. . . . . . . . . . . . . . . . . . .
Joint Cementing Procedure 14. . . . . . . . . . . . . . . . . . . . . . .
Venting Practices 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vent Piping Guidelines 15. . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Piping 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Start Up 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Pressure Measurement 38. . . . . . . . . . . . . . . . . . . . . .
Proper Combustion 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Altitude 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing Non Direct Appliances for Proper Air 40. . . . . . . .
Other Unit Adjustments 41. . . . . . . . . . . . . . . . . . . . . . . . . .
Twinning the ML193DF Furnace 42. . . . . . . . . . . . . . . . . .
Service 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Parts List 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start Up Checklist 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Litho U.S.A.
Page 2
ML193DF Unit Dimensions − inches (mm)
AIR
EXHAUST AIR
OUTLET
COMBUSTION
AIR INTAKE
FLOW
2−1/16 (52)
GAS PIPING INLET
(Either Side)
ELECTRICAL INLET
(Either Side)
RETURN AIR
OPENING
FRONT VIEW SIDE VIEW
TOP VIEW
A
B
C
3/4
(19)
27−3/4
19−1/4
(489)
9−1/8 (232) Right
6−9/16 (167) Left
2 (51)
Either Side
33
(838)
3/4
(19)
B
Supply
Air
Supply
Air
9/16
(14)
9/16
(14)
9/16
(14)
9/16
(14)
19−7/16
(494)
3/4
(19)
CONDENSATE
TRAP CONNECTION
5
(127)
6−1/2 (165)
Either Side
2−1/4
(57)
(Either Side)
1 (25)
Front Panel
(705)
ML193DF
Model No.
A B C
in. mm in. mm in. mm
045XP36B
070XP6B
17−1/2 446 16−3/8 416 16 406
090XP48C
110XP60C
21 533 19−7/8 504 19−1/2 495
Page 3
ML193DF Gas Furnace
The ML193DF Category IV gas furnace is shipped ready
for installation in the downflow position.
The furnace is equipped for installation in natural gas applications. A conversion kit (ordered separately) is required for use in propane/LP gas applications.
The ML193DF can be installed as a Direct Vent or Non−
Direct Vent gas central furnace.
NOTE − In Direct Vent installations, combustion air is taken
from outdoors and flue gases are discharged outdoors. In
Non−Direct Vent installations, combustion air is taken from
indoors or ventilated attic or crawlspace and flue gases are
discharged outdoors. See figures 1 and 2 for applications involving roof termination.
FIGURE 1
DIRECT VENT INSTALLATION NON−DIRECT VENT
INSTALLATION
EXHAUST
OUTLET
COMBUSTION
AIR INTAKE OUTSIDE
OF HOUSE
COMBUSTION
AIR INTAKE
INSIDE
OF HOUSE
EXHAUST OUTLET
FIGURE 2
NON−DIRECT VENT
INSTALLATION
NON−DIRECT VENT
INSTALLATION
COMBUSTION
AIR INTAKE INSIDE
VENTILATED
CRAWL SPACE
COMBUSTION
AIR INTAKE INSIDE
VENTILATED
ATTIC SPACE
EXHAUST
OUTLET
EXHAUST
OUTLET
Shipping and Packing List
Package 1 of 1 contains
1 − Assembled ML193DF unit
1 − Bag assembly containing the following:
1 − Snap bushing
1 − Snap plug
1 − Wire tie
1 − Condensate trap
1 − Condensate trap cap
1 − Condensate trap clamp
1 − 2" diameter Air intake screen
1 − 1/2" Threaded street elbow
DANGER
Danger of explosion.
There are circumstances in which odorant used with
LP/propane gas can lose its scent. In case of a leak,
LP/propane gas will settle close to the floor and may
be difficult to smell. An LP/propane leak detector
should be installed in all LP applications.
Check equipment for shipping damage. If you find any
damage, immediately contact the last carrier.
The following items may also be ordered separately:
1 − Thermostat
1 − Propane/LP changeover kit
Safety Information
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, personal injury
can result from contact with sharp sheet metal
edges. Be careful when you handle this equipment.
Use only the type of gas approved for use with this furnace.
Refer to unit nameplate.
ML193DF units are CSA International certified to ANSI
Z21.47 and CSA 2.3 standards.
Building Codes
In the USA, installation of gas furnaces must conform with local building codes. In the absence of local codes, units must
be installed according to the current National Fuel Gas Code
(ANSI-Z223.1/NFPA 54). The National Fuel Gas Code is
available from the following address:
Page 4
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 protection
clearances.
For installation in a residential garage, the furnace must
be installed so that the burner(s) and the ignition source
are located no less than 18 inches (457 mm) above the
floor. The furnace must be located or protected to avoid
physical damage by vehicles. When a furnace is installed
in a public garage, hangar, or other building that has a 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. Failure
to do so may cause erratic limit operation and premature heat
exchanger failure.
This ML193DF 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.
FIGURE 3
Heating Unit Installed Parallell to Air Handler Unit
AIR HANDLER
GAS UNIT
Dampers
(open during cooling
operation only)
Dampers
(open during heating
operation only)
NOTE − This furnace is designed for a minimum continuous 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 ML193DF furnace may be installed in alcoves, closets,
attics, basements, garages, utility rooms and crawl
spaces.
This furnace design has not been CSA certified for installation in mobile homes, recreational vehicles, or outdoors.
Never use an open flame to test for gas leaks. Check all
connections using a commercially available soap solution
made specifically for leak detection.
Use of Furnace as Construction Heater
Lennox does not recommend the use of ML193DF units as
a construction heater during any phase of construction.
Very low return air temperatures, harmful vapors and operation of the unit with clogged or misplaced filters will damage the unit.
ML193DF units may be used for heating of buildings or
structures under construction, if the following conditions
are met:
• The vent system must be permanently installed per
these installation instructions.
• A room thermostat must control the furnace. The use of
fixed jumpers that will provide continuous heating is not
allowed.
• The return air duct must be provided and sealed to the
furnace.
• Return air temperature range between 60°F (16°C) and
80°F (27°C) must be maintained.
• Air filters must be installed in the system and must be
maintained during construction.
Page 5
• Air filters must be replaced upon construction completion.
• The input rate and temperature rise must be set per the
furnace rating plate.
• One hundred percent (100%) outdoor air must be provided for combustion air requirements during construction. Temporary ducting may supply outdoor air to the
furnace. Do not connect duct directly to the furnace.
Size the temporary duct following these instructions in
section for Combustion, Dilution and Ventilation Air in a
confined space with air from outside.
• The furnace heat exchanger, components, duct system,
air filters and evaporator coils must be thoroughly
cleaned following final construction clean−up.
• All furnace operating conditions (including ignition, input rate, temperature rise and venting) must be verified
according to these installation instructions.
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 ML193DF 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
ML193DF unit should not be installed in areas normally subject to freezing temperatures.
WARNING
Product contains fiberglass wool.
Disturbing the insulation in this product during
installation, maintenance, or repair will expose you
to fiberglass wool. Breathing this may cause lung
cancer. (Fiberglass wool is known to the State of California to cause cancer.)
Fiberglass wool may also cause respiratory, skin,
and eye irritation.
To reduce exposure to this substance or for further
information, consult material safety data sheets
available from address shown below, or contact your
supervisor.
Lennox Industries Inc.
P.O. Box 799900
Dallas, TX 75379−9900
Combustion, Dilution & Ventilation Air
If the ML193DF 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
Insufficient combustion air can cause headaches,
nausea, dizziness or asphyxiation. It will also cause
excess water in the heat exchanger resulting in rusting and premature heat exchanger failure. Excessive
exposure to contaminated combustion air will result
in safety and performance related problems. Avoid
exposure to the following substances in the combustion air supply:
Permanent wave solutions
Chlorinated waxes and cleaners
Chlorine base swimming pool chemicals
Water softening chemicals
De−icing salts or chemicals
Carbon tetrachloride
Halogen type refrigerants
Cleaning solvents (such as perchloroethylene)
Printing inks, paint removers, varnishes, etc.
Hydrochloric acid
Cements and glues
Antistatic fabric softeners for clothes dryers
Masonry acid washing materials
In the past, there was no problem in bringing in sufficient
outdoor air for combustion. Infiltration provided all the air
that was needed. In today’s homes, tight construction
practices make it necessary to bring in air from outside
for combustion. Take into account that exhaust fans, ap-
Page 6
pliance 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 combus−
tion and ventilation, use the guidelines and procedures in
this section to install ML193DF furnaces to ensure efficient and safe operation. You must consider combustion
air needs and requirements for exhaust vents and gas
pip−ing. A portion of this information has been reprinted
with permission from the National Fuel Gas Code (ANSI−
Z223.1/NFPA 54). This reprinted material is not the 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.
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 fireplaces, 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 m
3
) 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 m
3
) per 1,000 Btu (.29 kW) per hour of the com−
bined input rating of all appliances installed in that space. This
definition includes furnace closets or small equipment rooms.
When the furnace is installed so that supply ducts carry air
circulated by the furnace to areas outside the space 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 mm
2
) per 1,000 Btu (.29 kW) per hour of
total input rating of all gas−fired equipment in the confined
space. Each opening must be at least 100 square inches
(64516 mm
2
). 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.
FIGURE 4
EQUIPMENT IN CONFINED SPACE − ALL AIR FROM INSIDE
OPENINGS
(To Adjacent
Unconfined
Space)
NOTE − Each opening shall have a free area of at least one square
inch per 1,000 Btu (645mm
2
per .29kW) per hour of the total input
rating of all equipment in the enclosure, but not less than 100 square
inches (64516mm.
2).
ROOF TERMINATED
EXHAUST PIPE
SIDE WALL
TERMINATED
EXHAUST PIPE
(ALTERNATE
LOCATION)
Page 7
Air from Outside
If air from outside is brought in for combustion and ventilation, the confined space shall be provided with two permanent 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 (645mm
2
per 1.17kW) per hour of total input rating of all equipment
in the enclosure. When communicating with the outdoors
through horizontal ducts, each opening shall have a minimum free area of 1 square inch per 2,000 Btu (645mm
2
per .59kW) per total input rating of all equipment in the enclosure (See figure 5). It is also permissible to bring in air
for combustion from a ventilated attic (figure 6) or ventilated crawl space (figure 7).
FIGURE 5
EQUIPMENT IN CONFINED SPACE − ALL AIR FROM OUTSIDE
(Inlet Air from Crawl Space and Outlet Air to Outised)
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.
OUTLET
AIR
INLET
AIR
VENTILATION
LOUVERS
(For unheated
crawl space)
ROOF TERMINATED
EXHAUST PIPE
VENTILATION LOUVERS
(Each end of attic)
SIDE WALL
TERMINATED
EXHAUST PIPE
(ALTERNATE
LOCATION)
FIGURE 6
EQUIPMENT IN CONFINED SPACE
(Inlet Air from Ventilated Attic and Outlet Air to Outside)
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.
Ventilation Louvers
Inlet Air
(Minimum
12 in.(305mm) Above
attic floor)
Roof Terminated
Exhaust Pipe
Furnace
*Intake Debris
Screen
(Provided)
* See table 8 for maximum vent lengths
If air from outside is brought in for combustion and ventilation, the confined space must have two permanent openings. 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 mm
2
) per 4,000
Btu (1.17 kW) per hour of total input rating of all equipment
in the enclosure. See figures 5 and 8. When communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 square inch (645
mm
2
) per 2,000 Btu (.56 kW) per total input rating of all
equipment in the enclosure. See figure 9.
FIGURE 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.
EQUIPMENT IN CONFINED SPACE
(Inlet Air from Ventilated Crawlspace and Outlet Air to Outside)
Roof Terminated
Exhaust Pipe
Furnace
Ventilation
Louvers
(Crawl space)
*Intake Debris Screen Provided)
Inlet Air
(Minimum
12 in.(305mm)
Above crawl
space floor)
Coupling or
3 in. to 2 in.
Transition
(Field Provided)
* See table 8 for maximum vent lengths
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.
Page 8
FIGURE 8
EQUIPMENT IN CONFINED SPACE − ALL AIR FROM OUTSIDE
(All Air Through Ventilated Attic)
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.
OUTLET
AIR
VENTILATION LOUVERS
(Each end of attic)
INLET AIR
(Ends 12" above
bottom)
ROOF TERMINATED
EXHAUST PIPE
SIDE WALL
TERMINATED
EXHAUST PIPE
(ALTERNATE
LOCATION)
FIGURE 9
EQUIPMENT IN CONFINED SPACE −
ALL AIR FROM OUTSIDE
OUTLET AIR
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
is located against an outside wall and the air openings communicate 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.
ROOF TERMINATED
EXHAUST PIPE
SIDE WALL
TERMINATED
EXHAUST PIPE
(ALTERNATE
LOCATION)
Shipping Bolt Removal
NOTE − The ML193DF09048C is equipped with a 1/2 hp
blower motor which has three flexible legs and one rigid
leg. The rigid leg is equipped with a shipping bolt and a flat
white plastic washer (rather than the rubber mounting
grommet used with a flexible mounting leg). See figure 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.
FIGURE 10
RIGID LEG
remove shipping bolt and washer
ML193DF09048C BLOWER MOTOR
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
draining.
See figure 11.
Page 9
Allow for clearances to combustible materials as indicated
on the unit nameplate. Minimum clearances for closet or alcove installations are shown in figure 13.
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.
FIGURE 11
SETTING EQUIPMENT
FRONT VIEW SIDE VIEW
AIR FLOW
AIR FLOW
1/2"
max.
AIR FLOW
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 12
Front
NOTE − Do not install the furnace on its front, back or in the horizontal position
Back
Horizontal
Page 10
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.
The unit may be installed three ways in downflow applications: on non−combustible flooring, on combustible flooring
using an additive base, or on a reverse−flow cooling coil
cabinet. Do not drag the unit across the floor in the
downflow position. Floor and furnace flange damage
will result.
Refer to figure 13 for clearances in downflow applica-
tions.
Downflow Application Installation Clearances
Top
Bottom
Left Side Right Side
Top 0
*Front 0
Back 0
Sides 0†
Vent 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.
‡The furnace may be installed on a combustible wood floor if an optional additive 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.
TABLE 1
NON−COMBUSTIBLE FLOOR OPENING SIZE
Cabinet Width
Front to Rear Side to Side
in. mm in. mm
B Cabinet (17.5") 19 − 3/4 502 16 − 5/8 422
C Cabinet (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.
FIGURE 14
SUPPLY AIR
PLENUM
PROPERLY
SIZED FLOOR
OPENING
FURNACE
Installation on Combustible Flooring Figure 15
1 − When unit is installed on a combustible floor, a down-
flow combustible flooring base must be installed between the furnace and the floor. The base must be ordered separately. See table 2 for opening size to cut in
floor.
CAUTION
The furnace and combustible flooring base shall not
be installed directly on carpeting, tile, or other combustible material other than wood flooring.
Page 11
TABLE 2
COMBUSTIBLE FLOORING BASE OPENING SIZE
Cabinet
Width
Catalog
Number
Front to Rear Side to Side
in. mm in. mm
B Cabinet
(17.5")
11M60
22 559 18 − 3/4 476
C Cabinet
(21")
11M61
22 559 22 − 3/4 578
FIGURE 15
FURNACE
SUPPLY AIR
PLENUM
COMBUSTIBLE
FLOORING BASE
PROPERLY
SIZED FLOOR
OPENING
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.
FIGURE 16
COOLING COIL
PLENUM
PROPERLY
SIZED FLOOR
OPENING
FURNACE
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 following steps should be taken when installing plenum:
1 − Bottom edge of plenum should be flanged with a
hemmed edge (See figure 17 or 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 fur-
nace using sheet metal screws.
4 − Make certain that an adequate seal is made.
FIGURE 17
SECURE FROM
OUTSIDE CABINET
PLENUM
(Field Provided)
SEALING STRIP
(Field Provided)
Side View
CABINET
SIDE PANEL
SECURE FROM
INSIDE CABINET
PLENUM
(Field Provided)
SEALING STRIP
(Field Provided)
Side View
CABINET
SIDE PANEL
FIGURE 18
Page 12
Filters
This unit is not equipped with a filter or rack. A field−provided filter is required for the unit to operate properly. Table
3 lists recommended filter size.
A filter must be in place whenever the unit is operating.
TABLE 3
Furnace
Cabinet Width
Filter Size
16 x 25 x 1 (1)
17−1/2"
21"
Duct System
Use industry-approved standards to size and install the
supply and return air duct system. Refer to ACCA Manual
D. This will result in a quiet and low-static system that has
uniform air distribution.
NOTE − This furnace is not certified for operation in heating
mode (indoor blower operating at selected heating speed)
with an external static pressure which exceeds 0.5 inches
w.c. Operation at these conditions may result in improper
limit operation.
Supply Air Plenum
If the furnace is installed without a cooling coil, a removable
access panel should be installed in the supply air duct. The
access panel should be large enough to permit inspection
of the heat exchanger. The furnace access panel must always be in place when the furnace is operating and it must
not allow leaks into the supply air duct system.
Return Air Plenum
NOTE − Return air must not be drawn from a room
where this furnace, or any other gas−fueled appliance
(i.e., water heater), or carbon monoxide−producing device (i.e., wood fireplace) is installed.
When return air is drawn from a room, a negative pressure is created in the room. If a gas appliance is operating
in a room with negative pressure, the flue products can
be pulled back down the vent pipe and into the room. This
reverse flow of the flue gas may result in incomplete combustion and the formation of carbon monoxide gas. This
raw gas or toxic fumes might then be distributed throughout the house by the furnace duct system.
Use fiberglass sealing strips, caulking, or equivalent sealing 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, stratification, or separation that cannot be removed by stirring. Refer to the table 4 below for approved piping and fitting materials.
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) F891
Schedule 40 PVC (Fittings) D2466
Schedule 40 CPVC (Pipe) F441
Schedule 40 CPVC (Fittings) F438
SDR−21 PVC or SDR−26 PVC (Pipe) D2241
SDR−21 CPVC or SDR−26 CPVC (Pipe) F442
Schedule 40 ABS Cellular Core DWV (Pipe) F628
Schedule 40 ABS (Pipe) D1527
Schedule 40 ABS (Fittings) D2468
ABS−DWV (Drain Waste & Vent)
(Pipe & Fittings)
D2661
PVC−DWV (Drain Waste & Vent)
Pipe & Fittings)
D2665
PRIMER & SOLVENT CEMENT
ASTM
SPECIFICATION
PVC & CPVC Primer F656
PVC Solvent Cement D2564
CPVC Solvent Cement F493
ABS Solvent Cement D2235
PVC/CPVC/ABS All Purpose Cement For
Fittings & Pipe of the same material
D2564, D2235, F493
ABS to PVC or CPVC Transition Solvent
Cement
D3138
CANADA PIPE & FITTING & SOLVENT
CEMENT
MARKING
PVC & CPVC Pipe and Fittings
ULCS636
PVC & CPVC Solvent Cement
ABS to PVC or CPVC Transition Cement
Page 13
IMPORTANT
ML193DF 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 manufacturer 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.
TABLE 5
OUTDOOR TERMINATION USAGE
Input Size
Vent
Pipe
Dia. in.
STANDARD CONCENTRIC
FlushMount
Kit
Wall Kit Wall Ring Kit
Field
Fabricated
1−1/2 inch 2 inch 3 inch
2 inch 3 inch 2 inch
51W11
22G44 (US)
4
30G28 (CA)
44J40
(US)
4
81J20 (CA)
15F74
71M80
(US)
4
44W92
(CA)
69M29
(US)
4
44W92
(CA)
60L46 (US)
4
44W93 (CA)
045
2
3
YES YES
1
YES
1
YES
5
YES
2
YES
2−1/2
3
YES YES
1
YES
1
YES
5
YES
2
YES
3
3
YES YES
1
YES
1
YES
5
YES
2
YES
070
2
3
YES YES
1
YES
1
YES
5
YES
2
YES
2−1/2
3
YES YES
1
YES
1
YES
5
YES
2
YES
3
3
YES YES
1
YES
1
YES
5
YES
2
YES
090
2
3
YES YES YES
5
YES YES YES
2−1/2
3
YES YES YES
5
YES YES YES
3
3
YES YES YES
5
YES YES YES
110
2 YES YES YES
5
YES YES YES
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 length
calculations. See vent length tables.
1
Requires field−provided outdoor 1−1/2" exhaust accelerator.
2
Concentric kits 71M80 and 44W92 include 1−1/2" outdoor accelerator, when used with 045 and 070 input models.
3
Flush mount kit 51W11 includes 1−1/2 in. outdoor exhaust accelerator, required when used with 045, 070 and 090 input models.
4
Termination kits 30G28, 44W92, 4493 and 81J20 are certified to ULC S636 for use in Canada only.
5
See table 10 for vent accelerator requirements.
Page 14
Joint Cementing Procedure
All cementing of joints should be done according to the
specifications outlined in ASTM D 2855.
NOTE − A sheet metal screw may be used to secure
the intake pipe to the connector, if desired. Use a drill
or self tapping screw to make a pilot hole.
DANGER
DANGER OF EXPLOSION!
Fumes from PVC glue may ignite during system
check. Allow fumes to dissipate for at least 5 minutes
before placing unit into operation.
1 − Measure and cut vent pipe to desired length.
2 − Debur and chamfer end of pipe, removing any ridges
or rough edges. If end is not chamfered, edge of pipe
may remove cement from fitting socket and result in a
leaking joint.
3 − Clean and dry surfaces to be joined.
4 − Test fit joint and mark depth of fitting on outside of pipe.
5 − Uniformly apply a liberal coat of PVC primer for PVC or
use a clean dry cloth for ABS to clean inside socket
surface of fitting and male end of pipe to depth of fitting
socket.
6 − Promptly apply solvent cement to end of pipe and in-
side 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.
Venting Practices
FIGURE 19
* See table 4 for allowable pipe.
Piping Suspension Guidelines
NOTE − Isolate piping at the point where it exits the outside wall or
roof in order to prevent transmission of vibration to the structure.
SCHEDULE 40
PVC − 5’
all other pipe* − 3’
Wall
inside outside
24" maximum
3/4" minimum
Wall Thickness Guidelines
CHIMNEY
OR GAS
VENT
(Check sizing
for water
heater only)
FURNACE
(Replaced
by ML193)
WATER
HEATER
OPENINGS
(To Adjacent
Room)
If an ML193DF furnace replaces 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 20
REPLACING FURNACE THAT
WAS PART OF A COMMON
VENT SYSTEM
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.
Page 15
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.
Exhaust Piping (Figures 22 and 23)
Route piping to outside of structure. Continue with installation following instructions given in piping termination section.
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
The ML193DF 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
tables 6 and 7. Count all elbows inside and outside the
home. Table 6 lists the minimum vent pipe lengths permitted. Table 7 lists the maximum pipe lengths permitted.
TABLE 6
MINIMUM VENT PIPE LENGTHS
ML193DF
MODEL
MIN. VENT LENGTH*
045, 070, 090, 110
15 ft. or
5 ft plus 2 elbows or
10 ft plus 1 elbow
*Any approved termination may be added to the minimum length listed.
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.
IMPORTANT
Do not use screens or perforated metal in exhaust or
intake terminations. Doing so will cause freeze−ups
and may block the terminations.
Use the following steps to correctly size vent pipe diameter.
FIGURE 21
Piping Size Process
1
2
3
4
5
6
Which style termination
being used?
Standard or concentric?
See table 5.
Which needs
most elbows?
Intake or
exhaust?
How many elbows?
Count all elbows inside
and outside house.
Desired pipe size?
2", 2−1/2", 3"
Use table 7 or 8 to find
max intake or exhaust pipe
length. Includes all vent
pipe and elbows inside
and outside the house.
What is the altitude of
the furnace installation?
7
What is the
furnace capacity?
045, 070, 090 or
110?
NOTE − It is acceptable to use any pipe size which fits within
the guidelines allowed in table 7.
NOTE −
All horizontal runs of exhaust pipe must slope back
toward unit. A minimum of 1/4" (6mm) drop for each 12"
(305mm) of horizontal run is mandatory for drainage.
NOTE − Exhaust pipe MUST be glued to furnace exhaust
fittings.
NOTE − Exhaust piping should be checked carefully to
make sure there are no sags or low spots.
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