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Page 21

TABLE 11 

OUTDOOR TERMINATION USAGE*

Input Size

Vent Pipe 

Dia. in.

STANDARD

CONCENTRIC

Flush Mount 

Kit

Wall Kit

Field

 

Fabricated

1-1/2 inch

2 inch

3 inch

51W11 (US) 

51W12 (CA)

2 inch

3 inch

71M80 (US) 

4

44W92 

(CA)

69M29 (US) 

4

44W92 

(CA)

60L46 (US) 

4

444W93 

(CA)

22G44 (US) 

4

30G28 

(CA)

44J40 (US) 

4

81J20 (CA)

045

6

1-1/2

3

YES

YES

1

YES

5

 YES

2

 YES

N/A

N/A

2

3

YES

YES

1

YES

5

 YES

2

 YES

2-1/2

3

YES

YES

1

YES

5

 YES

2

 YES

3

3

YES

YES

1

YES

5

 YES

2

 YES

070

6

1-1/2

3YES

YES

1

YES

5

 YES

2

 YES

2

3YES

YES

1

YES

5

 YES

2

 YES

2-1/2

3

YES

YES

1

YES

5

  YES

2

 YES

3

3

YES

YES

1

YES

5

 YES

2

 YES

090

2

3

YES

N/A

YES

5

 YES

N/A

YES

YES

2-1/2

3

YES

YES

5

 YES

YES

YES

3

3

YES

YES

5

 YES

YES

YES

110

2

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.* Kits must be properly installed according to kit instructions.

1Requires field-provided outdoor 1-1/2” exhaust accelerator.

2Concentric kits 71M80 and 44W92 include 1-1/2” outdoor accelerator, when 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.

Summary of Contents for ML196DF045XE36B

Page 1: ...ctory equipped for use with natural gas A kit is available for conversion to LP Propane operation All ML196DFE units are equipped with a hot surface ignition system The gas valve is redundant to assur...

Page 2: ...pt 3 4 slip x 3 4 Mipt with field supplied PVC coupling o d 3 4 slip x 3 4 MPT 3 4 slip x 3 4 MPT 3 4 slip x 3 4 MPT 3 4 slip x 3 4 MPT Indoor Blower Wheel nom diameter x width in 10 x 8 11 1 2 x 10 1...

Page 3: ...of filter in 2 16 x 20 x 1 2 16 x 20 x 1 NIGHT SERVICE KIT Night Service Kit 84W48 84W48 TERMINATION KITS See Installation Instructions for specific venting information Direct Vent Concentric US 2 in...

Page 4: ...640 150 0 70 N A N A 1255 430 1040 315 910 255 585 160 0 80 N A N A 1215 445 990 320 865 265 525 170 ML196DF045XE36B PERFORMANCE Less Filter External Static Pressure in w g Air Volume Watts at Various...

Page 5: ...cation BLOWER MOTOR hidden BURNER ACCESS PANEL COMBUSTION AIR INDUCER BURNER BOX ASSEMBLY includes sensor rollout switches and ignitor GAS VALVE BLOWER DECK COLD END HEADER BOX PRIMARY LIMIT DuralokPl...

Page 6: ...transformer T1 The breaker is rated at 3A at 32V If the current exceeds this limit the breaker will trip and all unit operation will shutdown The breaker can be manually reset by pressing the button...

Page 7: ...sor 5 Watchguard burner failed to light exceeded maximum number of retries or recycles 6 Not Used 7 Primary or Secondary Limit Open or Watchguard Mode Limit Switch Open longer than 3 minutes 8 Rollout...

Page 8: ...es into Watchguard Flame Failure mode After a 60 minute reset period the integrat ed control will begin the ignition sequence again Fan Time Control Ignition Control 103217 03 Heating Fan On Time The...

Page 9: ...rtbeat is indicated by 1s on 1s off It is used for idle continuous fan and cool modes Note 2 Error codes are indicated by a rapid flash the LED flashes X times at second on second off remains off for...

Page 10: ...See table 4 flash code 8 for troubleshooting 2 Heat Exchanger FIGURE 7 ML196DFE units use an aluminized steel primary and stainless steel secondary heat exchanger assembly Heat is transferred to the a...

Page 11: ...nd sensing electrode The ignition control allows the gas valve to remain open as long as flame signal is sensed NOTE The ML196DFE is polarity sensitive Make sure that the furnace is wired correctly an...

Page 12: ...s Multi Meter To Control Sensor T erminal T o Flame Terminal Remove Sensor Wire from Intergrated Control and Connect Alligator Clip to Terminal on Control Flame Sensor Terminal Flame Sensor Wire Remov...

Page 13: ...rect voltage Insert meter probes into terminals 2 and 4 use small diameter probes in order not to damage plug Check voltage during 20 second ignitor warm up period Voltage should read 120 volts 10 If...

Page 14: ...er flow through the heat exchanger The switch is a SPST N O prove switch electrically con nected to the integrated control The purpose of the switch is to prevent burner operation if the combustion ai...

Page 15: ...d end header box are negative How sure than the port 4 Operate unit and observe manometer reading Readings will change as heat exchanger warms a Take one reading immediately after start up b Take a se...

Page 16: ...tial pressure across the pressure switch Check for restricted inlet vent Remove all block age Check for proper vent sizing and run length See table 13 Wrong pressure switch installed in the unit or pr...

Page 17: ...s present in tests 1 and 2 and motor is not operating properly replace motor The motor is not field repairable If replacing the indoor blower motor or blower wheel is necessary placement is critical T...

Page 18: ...peed tap used for continuous fan 1 2 3 4 or 5 on input plug P49 If 24 volts is not present problem may be up stream of plug P49 Proceed to test 4 Multi Meter set to VAC 12 0 12 0 24 Multi Meter set to...

Page 19: ...imately the same resistance within an ohm 13 Check to see if the blower wheel spins freely Motor Test FIGURE 19 TABLE 9 Scale Measurement range in words ohms 2 M two megohm two million ohms 0 2 000 00...

Page 20: ...VENTING SYSTEM PolyPro by Duravent InnoFlue by Centrotherm UL 1738 CERTIFIED GAS VENTING SYSTEM IPEX System1738 Schedule 40 PVC Pipes and Fittings UL1738 IPEX System1738 PVC FGV Cement Primer IMPORTA...

Page 21: ...g 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...

Page 22: ...ng 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...

Page 23: ...TABLE 12 minimum and TABLE 13 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...

Page 24: ...127 108 108 2 10 10 56 41 19 95 75 38 122 122 103 103 3 n a n a 51 36 14 90 70 33 117 117 98 98 4 46 31 n a 85 65 28 112 112 93 93 5 41 26 80 60 23 107 107 88 88 6 36 21 75 55 18 102 102 83 83 7 31 16...

Page 25: ...a 90 70 39 n a 111 111 104 104 2 n a n a 48 33 17 85 65 34 106 106 99 99 3 43 28 12 80 60 29 101 101 94 94 4 38 23 n a 75 55 24 96 96 89 89 5 33 18 70 50 19 91 91 84 84 6 28 13 65 45 14 86 86 79 79 7...

Page 26: ...7 88 88 2 N A N A 46 31 9 80 60 23 102 102 83 83 3 41 26 n a 75 55 18 97 97 78 78 4 36 21 70 50 13 92 92 73 73 5 31 16 65 45 8 87 87 68 68 6 26 11 60 40 n a 82 82 63 63 7 21 n a 55 35 77 77 58 58 8 16...

Page 27: ...pipe and intake pipe must be the same diameter 2 TRANSITION 2 1 1 2 045 070 Only DO NOT transition from larger to smaller pipe in horizontal runs of exhaust pipe Exhaust Exhaust FIGURE 24 TYPICAL INTA...

Page 28: ...eld provided materials and the factory provided air intake screen to route the intake piping as shown in FIGURE 26 Maintain a minimum clearance of 3 76mm around the air intake opening The air intake o...

Page 29: ...ted 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 Ca...

Page 30: ...2 2 10 10 7 7 1 Refer to 99 Minimum Design Temperature table provided in the current edition of the ASHRAE Fundamentals Handbook 2 Poly Propylene vent pipe PP by Duravent and Centrotherm NOTE Concentr...

Page 31: ...public property Clearance under veranda porch deck or balcony 12 Equal to or greater than soffit depth 3 feet 9m 12 3 feet 9m within a height 15 feet 4 5m above the meter regulator assembly 3 feet 9m...

Page 32: ...anda porch deck or balcony 12 7 feet 2 1m 3 feet 9m within a height 15 feet 4 5m above the meter regulator assembly 3 feet 9m 6 inches 152mm for appliances 10 000 pliances 10 000 Btuh 3kw and 50 000 p...

Page 33: ...irement of intake and exhaust pipe DOES NOT apply 3 On roof terminations the intake piping should terminate straight down using two 90 elbows See FIGURE 32 4 Exhaust piping must terminate straight out...

Page 34: ...ATION 71M80 69M29 or 60L46 US 44W92 or 44W93 Canada INTAKE AIR EXHAUST AIR INTAKE AIR INTAKE AIR EXHAUST AIR OUTSIDE WALL GRADE CLAMP Not Furnished FIELD PROVIDED REDUCER MAY BE REQUIRED TO ADAPT DIFF...

Page 35: ...ective 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 seala...

Page 36: ...Distance between exhaust pipe terminations on multiple furnaces must meet local codes NON DIRECT VENT ROOF TERMINATION KIT 15F75 or 44J41 UNCONDITIONED ATTIC SPACE 3 76mm OR 2 51mm PVC PROVIDE SUPPOR...

Page 37: ...n 5 FIGURE 47 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 48 The field provided ven...

Page 38: ...ve condensate drain Evaporator Drain Line vent required Condensate Drain Connection FIGURE 48 IMPORTANT When combining the furnace and evaporator coil drains together the A C condensate drain outlet m...

Page 39: ...ction In Unit Condensate Drain Connection In Unit Vent To Drain Condensate Drain Connection In Unit Optional Condensate Drain Connection OptionalDrainPipingFromTrap DrainTrapAssembly Furnished DrainTr...

Page 40: ...he trap should be primed with sufficien 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...

Page 41: ...m mended It is available through Lennox under part number 31B2001 See Corp 8411 L10 for further details WARNING Do not use matches candles flame or any other source of ignition to check for gas leaks...

Page 42: ...TABLE 17 Manifold and Supply Line Pressure 0 10 000ft ML196 Unit Gas Manifold Pressure in wg Supply Line Pressure in w g 0 10000 ft 0 4500 ft 4501 5500 ft 5501 6500 ft 6501 7500 ft 7501 10 000 ft All...

Page 43: ...stallations at eleva tions over 4500 feet 1372 m is the jurisdiction of local authorities ML196DFE 1 2 and 3 units require no manifold pres sure adjustments for operation at altitudes up to 10 000 fee...

Page 44: ...a function of load indicates a poor or partial ground Compare the readings to the table below If the readings exceed the maximum shown in TABLE 21 make repairs before operating the furnace 2 In addit...

Page 45: ...return air plenums Insert manometer hose flush with inside edge of hole or insulation Seal around the hose with permagum Connect the zero end of the manometer to the discharge supply side of the syste...

Page 46: ...he 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...

Page 47: ...e two screws which secure combustion air inducer to collector box Remove combustion air inducer assembly Remove ground wire from vest panel 13 Remove electrical junction box from the side of the furna...

Page 48: ...er sources of ignition to check for gas leaks Cleaning the Burner Assembly if needed 1 Turn off electrical and gas power supplies to furnace Remove upper and lower furnace access panels 2 Disconnect t...

Page 49: ...or heat can continue 5 A92 integrated control energizes B6 combustion air inducer S18 combustion air pressure switch closes Once S18 closes a 15 second pre purge follows 6 A92 integrated control energ...

Page 50: ...ALVE ENERGIZED GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER ON HEATING SPEED LED FLASHES CODE 11 PRESSURE SWITCH CLOSED GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF WITH DELAY S...

Page 51: ...RESET IGNITION SEQUENCE FOUR TIMES FLAME SIGNAL 1 5 MICROAMPS OR GREATER YES YES YES ROLLOUT SWITCH CLOSED LED FLASHES CODE 8 ROLLOT SWITCH OPEN GAS VALVE POWER OFF COMBUSTION AIR INDUCER POWER ON IND...

Page 52: ...ITCH CLOSED LED SLOW FLASH RATE REMAINS UNCHANGED THROUGHOUT COOLING CYCLE THERMOSTAT CALLS FOR COOLING COMPRESSOR CONTACTOR AND SYSTEM FAN ENERGIZED WITH 2 SECOND DELAY COOLING SPEED EAC TERM ENERGIZ...

Page 53: ...AN SWITCHED TO COOL SPEED EAC TERM REMAINS ON THERMOSTAT OPENS MANUAL FAN SELECTION MADE AT THERMOSTAT CONTROL G ENERGIZES SYSTEM FAN AT FAN SPEED EAC TERM ENERGIZED NO YES YES NO SYSTEM FAN SWITCHES...

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