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 2015 Lennox Industries Inc.

Dallas, Texas, USA

AIR FLOW

DOWNFLOW

INSTALLATION
INSTRUCTIONS
ML193DF

MERIT

® 

SERIES GAS FURNACE

DOWNFLOW AIR DISCHARGE

507279-02
10/2015
Supersedes 02/2015

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, person­
al 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

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ML193DF Gas Furnace

3

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Shipping and Packing List

3

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Safety Information

3

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Use of Furnace as a Construction Heater

4

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General

5

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Combustion, Dilution and Ventilation Air

5

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Setting Equipment

8

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Filters

12

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Duct System

12

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Pipe and Fittings Specifications

12

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Joint Cementing Procedure

15

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Venting Practices

15

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Vent Piping Guidelines

15

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Gas Piping

31

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Electrical

33

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Unit Start Up

37

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Gas Pressure Measurement

38

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Proper Combustion

39

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High Altitude

39

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Testing Non Direct Appliances for Proper Air

40

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Other Unit Adjustments

41

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Twinning the ML193DF Furnace

42

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Service

43

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Repair Parts List

44

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Start Up Checklist

45

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Litho U.S.A.

Содержание ML193DF

Страница 1: ...nance can cause property damage person al 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...

Страница 2: ...IEW 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...

Страница 3: ...ap cap 1 Condensate trap clamp 1 2 diameter Air intake screen 1 3 4 Threaded street elbow DANGER Danger of explosion There are circumstances in which odorant used with LP propane gas can lose its scen...

Страница 4: ...oling 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 w...

Страница 5: ...quired to prevent freezing of condensate drain system CAUTION ML193DF unit should not be installed in areas nor mally subject to freezing temperatures WARNING Product contains fiberglass wool Disturbi...

Страница 6: ...h a volume greater than 50 cubic feet 1 42 m3 per 1 000 Btu 29 kW per hour of the com bined input rating of all appliances installed in that space This space also includes adjacent rooms which are not...

Страница 7: ...um vent lengths If air from outside is brought in for combustion and ventila tion the confined space must have two permanent open ings One opening shall be within 12 inches 305 mm of the top of the en...

Страница 8: ...ON 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 p...

Страница 9: ...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...

Страница 10: ...aintain 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...

Страница 11: ...instructions for correctly sized opening in floor and installation of cabi net 2 When cooling cabinet is in place set and secure the furnace according to the instructions that are provided with the c...

Страница 12: ...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 h...

Страница 13: ...e and Fittings ULCS636 PVC CPVC Solvent Cement ABS to PVC or CPVC Transition Cement POLYPROPYLENE VENTING SYSTEM ULC S636 PolyPro by Duravent InnoFlue by Centrotherm ULC S636 IMPORTANT ML193DF exhaust...

Страница 14: ...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...

Страница 15: ...ompartment 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 verti cal discharge through an...

Страница 16: ...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 Standa...

Страница 17: ...pe 3 Pipe Model Model Model 045 070 090 110 045 070 090 110 045 070 090 110 1 53 38 22 n a 90 70 39 n a 111 111 104 104 2 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...

Страница 18: ...transitioning up in pipe size use the shortest length of 2 PVC pipe possible NOTE Exhaust pipe and intake pipe must be the same diameter 2 FIGURE 23 TYPICAL INTAKE PIPE CONNECTIONS 2 2 TRANSITION 2 3...

Страница 19: ...erials and the factory provided air intake screen to route the intake piping as shown in figure 24 Maintain a minimum clearance of 3 76mm around the air intake opening The air intake opening with the...

Страница 20: ...r details Position termination according to location given in figure 28 or 29 In addition position termination so it is free from any obstructions and 12 above the average snow accumula tion At vent t...

Страница 21: ...in N A N A 7 N A 15 N A 22 N A N A N A 3 in N A N A N A N A 10 10 16 16 18 18 1Refer to 99 Minimum Design Temperature table provided in the current edition of the ASHRAE Fundamentals Handbook 2 Poly P...

Страница 22: ...y inlet Clearance above paved sidewalk or paved driveway located on 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...

Страница 23: ...ve paved sidewalk or paved driveway located on public property Clearance under veranda 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...

Страница 24: ...ement of intake and ex haust pipe DOES NOT apply 3 On roof terminations the intake piping should termi nate straight down using two 90 elbows See figure 32 4 Exhaust piping must terminate straight out...

Страница 25: ...OUTSIDE WALL GRADE CLAMP Not Furnished FIELD PROVIDED REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINA TION 1 1 2 38mm accelerator provided on 71M80 44W92 kits for ML193DF045P36B 070...

Страница 26: ...227 mm Min 12 305 mm Min 16 405 mm Max 6 152 mm Max 6 152 mm Min 24 610 mm Max 9 227 mm Min 12 305 mm Min 20 508 mm Max 6 152 mm Max Intake Elbow WALL SUPPORT B A D E B D E A ALTERNATE TERMINATIONS TE...

Страница 27: ...TION PIPE PER TABLE 10 3 If exhaust piping must be run up a side wall to position above snow accumulation or other obstructions pip ing must be supported every 24 inches 610mm When exhaust piping must...

Страница 28: ...nd header box drain plugs are factory in stalled 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 figur...

Страница 29: ...y Field Provided Vent 1 min 2 max above condensate drain Piping from furnace must slope down a minimum of 1 4 per ft toward trap FIGURE 44 ML193DF with Evaporator Coil Using a Separate Drain Drain Fie...

Страница 30: ...rain Connection In Unit Condensate Drain Connection In Unit Vent To Drain Condensate Drain Connection In Unit Optional Condensate Drain Connection OptionalDrainPipingFromTrap DrainTrapAssembly Furnish...

Страница 31: ...sediment or condensate 5 A 1 8 N P T plugged tap or pressure post is located on the gas valve to facilitate test gauge connection See figure 53 6 In some localities codes may require installation of a...

Страница 32: ...50 1 42 3 4 19 05 824 20 930 360 10 19 247 7 00 199 5 63 170 4 81 151 4 28 137 3 87 126 3 56 117 3 31 110 3 11 104 2 94 1 25 4 1 049 26 645 678 19 19 466 13 19 374 10 59 320 9 06 284 8 04 257 7 27 23...

Страница 33: ...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...

Страница 34: ...door 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 accessor...

Страница 35: ...Page 35 TYPICAL ML193DF WIRING DIAGRAM FIGURE 51...

Страница 36: ...Pressure switch closed with combustion air inducer de energized 3 Flashes Pressure switch open with combus tion air inducer energized 4 Flashes Primary limit switch open 5 Flashes Rollout switch open...

Страница 37: ...tat to initiate a heating demand 3 Allow the burners to fire for approximately 3 minutes 4 Adjust the thermostat to deactivate the heating de mand 5 Wait for the combustion air inducer to stop Set the...

Страница 38: ...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 se...

Страница 39: ...to convert this unit Refer to the changeover kit installation instruction for the conversion procedure TABLE 15 Manifold and Supply Line Pressure 0 10 000ft ML193 Unit Gas Manifold Pressure in wg Sup...

Страница 40: ...ly inspect the venting system for proper size and horizontal pitch Determine there is no blockage or re striction leakage corrosion or other deficiencies which could cause an unsafe condition 3 To the...

Страница 41: ...res shorter settings provide higher return air temperatures See figure 54 Thermostat Heat Anticipation Set the heat anticipator setting if adjustable according to the amp draw listed on the wiring dia...

Страница 42: ...terminals of the two controls The 24 VAC secondary of the two systems must be in phase All thermostat connections are made to one control only Figure 55 show wiring for two stage and single stage ther...

Страница 43: ...t www ahrinet org 9 Ensure sufficient combustion air is available to the fur nace Fresh air grilles and louvers on the unit and in the room where the furnace is installed must be properly sized open a...

Страница 44: ...that the burners line up in the center of the burner ports 10 Reinstall the gas valve manifold assembly Reconnect the gas supply line to the gas valve Reinstall the burn er box cover 11 Reconnect 2 pi...

Страница 45: ...stalled Properly Pipes Sup ported Condensate Trap Primed Line Sloped Heat Cable Installed and Operable if applicable 2 2 2 1 Horizontal Pipes Sloped if applicable UNIT SET UP 3 4 Flter RETURN AIR Furn...

Страница 46: ...TIC 5 Supply External Static _______ Return External Static ______ Total External Static _______ CONDENSATE LINE 6 Leak Free VENT PIPE 7 Leak Free COOLING MODE INDOOR BLOWER AMPS______ 3 TEMPERATURE D...

Страница 47: ...eight 8 feet above grade di rectly in line with the exhaust vent terminal for the hori zontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half...

Страница 48: ...e province of Saskatchewan Lennox approves the following termination for use in Saskatchewan Canada C 12 D B A 2 51MM Vent Pipe 3 76MM Vent Pipe 12 305 mm Min 12 305 mm Min 6 152 mm Min 24 610 mm Max...

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