Lennox International Inc Electric Heater MERIT SERIES GAS FURNACE DOWNFLOW AIR DISCHARGE User Manual

INSTALLATION  
INSTRUCTIONS  
ML193DF  
E 2010 Lennox Industries Inc.  
Dallas, Texas, USA  
®
MERIT SERIES GAS FURNACE  
DOWNFLOW AIR DISCHARGE  
506475−01  
01/2011  
Supersedes 10/2010  
Litho U.S.A.  
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.  
DOWNFLOW  
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.  
AIR FLOW  
Table of Contents  
Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
ML193DF Parts Arrangement . . . . . . . . . . . . . . . . . . . . . 3  
ML193DF Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
Shipping and Packing List . . . . . . . . . . . . . . . . . . . . . . . . 4  
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
Use of Furnace as a Construction Heater . . . . . . . . . . . 5  
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
Combustion, Dilution and Ventilation Air . . . . . . . . . . . . 6  
Vent Piping Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . 15  
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30  
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32  
Unit Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36  
Gas Pressure Measurement . . . . . . . . . . . . . . . . . . . . . 38  
Proper Combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38  
High Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38  
Testing Non Direct Appliances for Proper Air . . . . . . . 39  
Other Unit Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 40  
Blower Motor Performance . . . . . . . . . . . . . . . . . . . . . . . 41  
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42  
Planned Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44  
Integrated Control Diagnostic Codes . . . . . . . . . . . . . . 44  
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45  
Repair Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49  
Start Up Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50  
Setting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9  
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12  
Duct System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12  
Pipe and Fittings Specifications . . . . . . . . . . . . . . . . . . . 12  
Joint Cementing Procedure . . . . . . . . . . . . . . . . . . . . . . 14  
Venting Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14  
01/11  
506475−01  
Page 1  
*2P0111*  
*P506475-01*  
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ML193DF Parts Arrangement  
CONTROL BOX  
(Includes integrated control,  
transformer and door switch)  
BAG ASSEMBLY  
BLOWER MOTOR  
(hidden)  
BLOWER  
ACCESS  
PANEL  
COMBUSTION  
AIR INDUCER  
BLOWER DECK  
PRIMARY LIMIT  
COLD END HEADER BOX  
BURNER  
ACCESS  
PANEL  
HEAT EXCHANGER  
GAS VALVE  
BURNER BOX ASSEMBLY  
(includes sensor, rollout switches and ignitor)  
FIGURE 1  
Page 3  
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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  
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 ap-  
plications. A conversion kit (ordered separately) is re-  
quired for use in propane/LP gas applications.  
1 − Propane/LP changeover kit  
Safety Information  
The ML193DF can be installed as a Direct Vent or Non−  
Direct Vent gas central furnace.  
WARNING  
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 and flue gases are discharged outdoors. See figure  
2 for applications involving roof termination.  
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.  
DIRECT VENT INSTALLATION  
NON−DIRECT VENT  
INSTALLATION  
CAUTION  
As with any mechanical equipment, personal injury  
can result from contact with sharp sheet metal  
edges. Be careful when you handle this equipment.  
EXHAUST  
OUTLET  
EXHAUST  
OUTLET  
COMBUSTION  
AIR INTAKE  
OUTSIDE OF  
HOUSE  
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.  
COMBUSTION  
AIR INTAKE INSIDE  
OF HOUSE  
Building Codes  
In the USA, installation of gas furnaces must conform with lo-  
cal 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:  
ML193DF  
ML193DF  
American National Standards Institute, Inc.  
11 West 42nd Street  
New York, NY 10036  
FIGURE 2  
Shipping and Packing List  
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.  
Package 1 of 1 contains  
1 − Assembled ML193DF unit  
1 − Bag assembly containing the following:  
3 Wire nuts  
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.  
1 Snap bushing  
1 Snap plug  
Locations and Clearances  
1 − Wire tie  
This furnace is CSA International certified for installation  
clearances to combustible material as listed on the unit  
nameplate and in the table in figure 11. Accessibility and ser-  
vice clearances must take precedence over fire protection  
clearances.  
1 Condensate trap  
1 Condensate trap cap  
1 Condensate trap clamp  
1 2" diameter Air intake screen  
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 apublic garage, hangar, or other building that has a haz-  
ardous atmosphere, the furnace must be installed accord-  
ing to recommended good practice requirements and cur-  
rent National Fuel Gas Code or CSA B149 standards.  
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.  
Page 4  
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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.  
tent operation down to 55°F (13°C) dry bulb for cases  
where a night setback thermostat is used. Return air tem-  
perature 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 ML193DF furnace must be installed so that its electri-  
cal components are protected from water.  
Installation in Combination with a Cooling Coil  
This furnace design has not been CSA certified for installa-  
tion in mobile homes, recreational vehicles, or outdoors.  
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 compart-  
ment. 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 manu-  
ally operated, it must be equipped to prevent operation of ei-  
ther the heating or the cooling unit, unless it is in the full  
HEAT or COOL setting.  
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 op-  
eration of the unit with clogged or misplaced filters will dam-  
age the unit.  
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 ad-  
dress:  
ML193DF units may be used for heating of buildings or  
structures under construction, if the following conditions  
are met:  
National Fire Protection Association  
1 Battery March Park  
Quincy, MA 02269  
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.  
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.  
The return air duct must be provided and sealed to the  
furnace.  
Heating Unit Installed Parallell to Air Handler Unit  
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.  
Air filters must be replaced upon construction comple-  
tion.  
AIR HANDLER  
GAS UNIT  
The input rate and temperature rise must be set per the  
furnace rating plate.  
One hundred percent (100%) outdoor air must be pro-  
vided for combustion air requirements during construc-  
tion. 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.  
Dampers  
(open during cooling  
operation only)  
Dampers  
(open during heating  
operation only)  
The furnace heat exchanger, components, duct system,  
air filters and evaporator coils must be thoroughly  
cleaned following final construction clean−up.  
FIGURE 3  
All furnace operating conditions (including ignition, in-  
put rate, temperature rise and venting) must be verified  
according to these installation instructions.  
NOTE − This furnace is designed for a minimum continu-  
ous return air temperature of 60°F (16°C) or an intermit-  
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General  
WARNING  
These instructions are intended as a general guide and do  
not supersede local codes in any way. Consult authorities  
having jurisdiction before installation.  
Insufficient combustion air can cause headaches,  
nausea, dizziness or asphyxiation. It will also cause  
excess water in the heat exchanger resulting in rust-  
ing 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 com-  
bustion air supply:  
In addition to the requirements outlined previously, the fol-  
lowing general recommendations must be considered  
when installing a ML193DF furnace:  
Place the furnace as close to the center of the air dis-  
tribution system as possible. The furnace should also be  
located close to the chimney or vent termination point.  
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  
When the furnace is installed in non−direct vent applica-  
tions, 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 applica-  
tions, do not block the furnace combustion air opening  
with clothing, boxes, doors, etc. Air is needed for proper  
combustion and safe unit operation.  
Cements and glues  
Antistatic fabric softeners for clothes dryers  
Masonry acid washing materials  
When the furnace is installed in an attic or other insu-  
lated 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.  
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-  
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 combus-  
tion, 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 po-  
tentially dangerous situation.  
CAUTION  
ML193DF unit should not be installed in areas nor-  
mally 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 Cal-  
ifornia to cause cancer.)  
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 effi-  
cient 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 com-  
plete and official position of the ANSI on the referenced  
subject, which is represented only by the standard in its  
entirety.  
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  
In Canada, refer to the CSA B149 installation codes.  
Combustion, Dilution & Ventilation Air  
If the ML193DF is installed as a Non−Direct Vent Fur-  
nace, follow the guidelines in this section.  
CAUTION  
Do not install the furnace in a corrosive or contami-  
nated atmosphere. Meet all combustion and ventila-  
tion air requirements, as well as all local codes.  
NOTE − In Non−Direct Vent installations, combustion air  
is taken from indoors and flue gases are discharged out−  
doors.  
Page 6  
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All gas-fired appliances require air for the combustion pro-  
cess. If sufficient combustion air is not available, the fur-  
nace or other appliance will operate inefficiently and un-  
safely. 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, ex-  
haust 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.  
dangerous negative pressure condition. Air for combustion  
and ventilation can be brought into the confined space ei-  
ther 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  
2
square inch (645 mm ) 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  
2
In addition to providing combustion air, fresh outdoor air di-  
lutes contaminants in the indoor air. These contaminants  
may include bleaches, adhesives, detergents, solvents  
and other contaminants which can corrode furnace compo-  
nents.  
(64516 mm ). One opening shall be within 12 inches (305  
mm) of the top of the enclosure and one opening within 12  
EQUIPMENT IN CONFINED SPACE − ALL AIR FROM INSIDE  
The requirements for providing air for combustion and ven-  
tilation depend largely on whether the furnace is installed in  
an unconfined or a confined space.  
ROOF TERMINATED  
EXHAUST PIPE  
Unconfined Space  
An unconfined space is an area such as a basement or  
large equipment room with a volume greater than 50 cubic  
3
OPENINGS  
(To Adjacent  
feet (1.42 m ) per 1,000 Btu (.29 kW) per hour of the com-  
SIDE WALL  
TERMINATED  
EXHAUST PIPE  
(ALTERNATE  
LOCATION)  
Unconfined  
Space)  
bined 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 un-  
confined, 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.  
NOTE − Each opening shall have a free area of at least one square  
2
inch per 1,000 Btu (645mm per .29kW) per hour of the total input  
rating of all equipment in the enclosure, but not less than 100 square  
2).  
inches (64516mm.  
FIGURE 4  
Confined Space  
Air from Outside  
If air from outside is brought in for combustion and ventila-  
tion, 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 mini-  
A confined space is an area with a volume less than 50 cubic  
3
feet (1.42 m ) 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 con-  
taining 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  
2
mum free area of 1 square inch per 4,000 Btu (645mm  
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 mini-  
2
mum free area of 1 square inch per 2,000 Btu (645mm  
per .59kW) per total input rating of all equipment in the en-  
closure (See figure 5).  
Page 7  
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EQUIPMENT IN CONFINED SPACE − ALL AIR FROM OUTSIDE  
(Inlet Air from Crawl Space and Outlet Air to Ventilated Attic)  
EQUIPMENT IN CONFINED SPACE − ALL AIR FROM OUTSIDE  
(All Air Through Ventilated Attic)  
VENTILATION LOUVERS  
(Each end of attic)  
ROOF TERMINATED  
EXHAUST PIPE  
VENTILATION LOUVERS  
(Each end of attic)  
ROOF TERMINATED  
EXHAUST PIPE  
OUTLET  
AIR  
OUTLET  
AIR  
INLET AIR  
(Ends 12" above  
bottom)  
SIDE WALL  
TERMINATED  
EXHAUST PIPE  
(ALTERNATE  
LOCATION)  
SIDE WALL  
TERMINATED  
VENTILATION  
EXHAUST PIPE  
LOUVERS  
(ALTERNATE  
LOCATION)  
INLET  
AIR  
(For unheated  
crawl space)  
NOTE−The inlet and outlet air openings shall each have a free area of  
2
at least one square inch per 4,000 Btu (645mm per 1.17kW) per  
hour of the total input rating of all equipment in the enclosure.  
NOTE−The inlet and outlet air openings shall each have a free area  
2
of at least one square inch per 4,000 Btu (645mm 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  
FIGURE 5  
ROOF TERMINATED  
EXHAUST PIPE  
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 enclosure and one opening within 12 inches  
(305 mm) of the bottom. These openings must communi-  
cate directly or by ducts with the outdoors or spaces (crawl  
or attic) that freely communicate with the outdoors or indi-  
rectly through vertical ducts. Each opening shall have a  
OUTLET AIR  
SIDE WALL  
TERMINATED  
EXHAUST PIPE  
(ALTERNATE  
LOCATION)  
INLET AIR  
2
minimum free area of 1 square inch (645 mm ) per 4,000  
NOTE−Each air duct opening shall have a free area of at least one  
2
Btu (1.17 kW) per hour of total input rating of all equipment  
in the enclosure. See figures 5 and 6. When communicat-  
ing with the outdoors through horizontal ducts, each open-  
ing shall have a minimum free area of 1 square inch (645  
square inch per 2,000 Btu (645mm 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 communi-  
cate directly with the outdoors, each opening shall have a free area  
2
of at least 1 square inch per 4,000 Btu (645mm per 1.17kW) per  
hour of the total input rating of all other equipment in the enclosure.  
2
mm ) per 2,000 Btu (.56 kW) per total input rating of all  
equipment in the enclosure. See figure 7.  
FIGURE 7  
When ducts are used, they shall be of the same cross−sec-  
tional 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 protec-  
tive 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.  
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  
The bolt and washer must be removed before the fur-  
nace is placed into operation. After the bolt and washer  
have been removed, the rigid leg will not touch the blower  
housing.  
Page 8  
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Allow for clearances to combustible materials as indicated  
on the unit nameplate. Minimum clearances for closet or al-  
cove installations are shown in figure 11.  
ML193DF09048C BLOWER MOTOR  
RIGID LEG  
remove shipping bolt and washer  
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 8  
Installation − Setting Equipment  
WARNING  
SETTING EQUIPMENT  
Do not install the furnace on its front, back or in the  
horizontal position. See figure 10. Do not connect the  
return air ducts to the back of the furnace. Doing so  
will adversely affect the operation of the safety con-  
trol devices, which could result in personal injury or  
death.  
AIR FLOW  
AIR FLOW  
AIR FLOW  
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 9.  
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 9  
Front  
Horizontal  
Back  
NOTE − Do not install the furnace on its front, back or in the horizontal position  
FIGURE 10  
Page 9  
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WARNING  
1 − Cut floor opening keeping in mind clearances listed on  
unit rating plate. Also keep in mind gas supply connec-  
tions, 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.  
Improper installation of the furnace can result in per-  
sonal 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 fur-  
nace should be sealed airtight to the return air ple-  
num. 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. Al-  
low absolutely no sagging, cracks, gaps, etc.  
3 − Set the unit over the plenum and seal the plenum to  
the unit.  
4 − Ensure that the seal is adequate.  
For no reason should return and supply air duct sys-  
tems ever be connected to or from other heating de-  
vices such as a fireplace or stove, etc. Fire, explo-  
sion, carbon monoxide poisoning, personal injury  
and/or property damage could result.  
NON−COMBUSTIBLE FLOOR OPENING SIZE  
Front to Rear  
Side to Side  
Cabinet Width  
in.  
mm  
502  
502  
in.  
mm  
422  
511  
The unit may be installed three ways in downflow applica-  
tions: 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.  
B Cabinet (17.5")  
C Cabinet (21")  
19 − 3/4  
19 − 3/4  
16 − 5/8  
20−1/8  
NOTE − Floor opening dimensions listed are 1/4 inch (6 mm) larger than  
the unit opening. See dimension drawing on page 2.  
Refer to figure 11 for clearances in downflow applica-  
tions.  
Downflow Application Installation Clearances  
Top  
FURNACE  
PROPERLY  
SIZED FLOOR  
OPENING  
SUPPLY AIR  
PLENUM  
Left Side  
Right Side  
Bottom  
FIGURE 12  
Top  
*Front  
Back  
Sides  
Vent  
0
0
0
1 − When unit is installed on a combustible floor, a down-  
flow combustible flooring base must be installed be-  
tween the furnace and the floor. The base must be or-  
dered separately. See table 2 for opening size to cut in  
floor.  
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.  
The furnace may be installed on a combustible wood floor if an op-  
tional additive base is installed between the furnace and the com-  
bustible floor.  
CAUTION  
The furnace and combustible flooring base shall not  
be installed directly on carpeting, tile, or other com-  
bustible material other than wood flooring.  
FIGURE 11  
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COMBUSTIBLE FLOORING BASE OPENING SIZE  
Front to Rear  
Side to Side  
Cabinet  
Width  
Catalog  
Number  
FURNACE  
in.  
22  
mm  
559  
in.  
mm  
476  
B Cabinet  
(17.5")  
11M60  
11M61  
18 − 3/4  
C Cabinet  
(21")  
COOLING COIL  
PLENUM  
22  
559  
22 − 3/4  
578  
PROPERLY  
SIZED FLOOR  
OPENING  
FURNACE  
SUPPLY AIR  
PLENUM  
PROPERLY  
SIZED FLOOR  
OPENING  
COMBUSTIBLE  
FLOORING BASE  
FIGURE 14  
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  
FIGURE 13  
2 − Sealing strips should be used to ensure an airtight seal  
between the cabinet and the plenum.  
2 − After opening is cut, set the combustible flooring base  
into opening.  
3 − In all cases, plenum should be secured to top of fur-  
nace using sheet metal screws.  
3 − Check fiberglass strips on the combustible flooring  
base to make sure they are properly glued and posi-  
tioned.  
4 − Make certain that an adequate seal is made.  
PLENUM  
SECURE FROM  
4 − Lower supply air plenum into the combustible flooring  
base until plenum flanges seal against fiberglass  
strips.  
(Field Provided)  
OUTSIDE CABINET  
NOTE − Be careful not to damage fiberglass strips.  
CABINET  
Check for a tight seal.  
SEALING STRIP  
SIDE PANEL  
(Field Provided)  
5 − Set the furnace over the plenum.  
Side View  
6 − Ensure that the seal between the furnace and plenum  
is adequate.  
FIGURE 15  
PLENUM  
NOTE − Downflow combustible flooring kit is not used..  
(Field Provided)  
SEALING STRIP  
1 − Refer to reverse−flow coil installation instructions for  
correctly sized opening in floor and installation of cabi-  
net.  
(Field Provided)  
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.  
SIDE PANEL  
SECURE FROM  
INSIDE CABINET  
Side View  
FIGURE 16  
3 − Seal the cabinet and check for air leaks.  
Page 11  
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Filters  
Pipe & Fittings Specifications  
All pipe, fittings, primer and solvent cement must conform  
with American National Standard Institute and the Ameri-  
can Society for Testing and Materials (ANSI/ASTM) stan-  
dards. The solvent shall be free flowing and contain no  
lumps, undissolved particles or any foreign matter that ad-  
versely 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. Re-  
fer to the table 4 below for approved piping and fitting ma-  
terials.  
This unit is not equipped with a filter or rack. A field−pro-  
vided 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  
17−1/2"  
21"  
16 x 25 x 1 (1)  
CAUTION  
Duct System  
Solvent cements for plastic pipe are flammable liq-  
uids 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.  
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.  
TABLE 4  
PIPING AND FITTINGS SPECIFICATIONS  
Schedule 40 PVC (Pipe)  
D1785  
F891  
Schedule 40 PVC (Cellular Core Pipe)  
Schedule 40 PVC (Fittings)  
Supply Air Plenum  
D2466  
F441  
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 al-  
ways be in place when the furnace is operating and it must  
not allow leaks into the supply air duct system.  
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)  
F438  
D2241  
F442  
F628  
D1527  
D2468  
Schedule 40 ABS (Fittings)  
Return Air Plenum  
ABS−DWV (Drain Waste & Vent)  
(Pipe & Fittings)  
D2661  
D2665  
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 de-  
vice (i.e., wood fireplace) is installed.  
PVC−DWV (Drain Waste & Vent)  
Pipe & Fittings)  
ASTM  
SPECIFICATION  
PRIMER & SOLVENT CEMENT  
PVC & CPVC Primer  
PVC Solvent Cement  
CPVC Solvent Cement  
ABS Solvent Cement  
F656  
D2564  
F493  
When return air is drawn from a room, a negative pres-  
sure 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 through-  
out the house by the furnace duct system.  
D2235  
PVC/CPVC/ABS All Purpose Cement For  
Fittings & Pipe of the same material  
D2564, D2235, F493  
D3138  
ABS to PVC or CPVC Transition Solvent  
Cement  
CANADA PIPE & FITTING & SOLVENT  
CEMENT  
MARKING  
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.  
PVC & CPVC Pipe and Fittings  
PVC & CPVC Solvent Cement  
ULCS636  
ABS to PVC or CPVC Transition Cement  
Page 12  
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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 in-  
side socket surface of fitting and male end of pipe to depth  
of fitting socket.  
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.  
Canadian Applications Only − Pipe, fittings, primer  
and solvent cement used to vent (exhaust) this ap-  
pliance must be certified to ULC S636 and supplied by a  
single manufacturer as part of an approved vent (ex-  
haust) system. In addition, the first three feet of vent  
pipe from the furnace flue collar must be accessible for  
inspection.  
Use PVC primer and solvent cement or ABS solvent cement  
meeting ASTM specifications, refer to Table 4. As an alter-  
nate, use all purpose cement, to bond ABS, PVC, or CPVC  
pipe when using fittings and pipe made of the same materi-  
als. Use transition solvent cement when bonding ABS to ei-  
ther PVC or CPVC.  
TABLE 5  
OUTDOOR TERMINATION KITS USAGE  
STANDARD  
CONCENTRIC  
Outdoor  
Exhaust  
Accelerator  
(Dia. X  
Outdoor  
Flush-  
Mount  
Kit  
1−1/2"  
Concentric Concentric Concentric  
2"  
3"  
Exhaust  
Accelerator  
(Dia. X  
2" Wall Plate 3" Wall Plate  
Kit  
2" Wall  
Ring Kit  
VENT  
PIPE  
DIA.  
Kit  
ML193  
UNIT  
Kit  
Kit  
Kit  
Length)  
Length)  
(in.)  
71M80 69M29  
or or  
44W92†† †44W92††  
22G44  
or 30G28†  
44J40  
or 81J20†  
60L46  
or 44W93†  
1−1/2" X 12"  
2" X 12"  
15F74  
51W11**  
2
YES  
YES  
YES  
YES  
YES  
YES  
YES  
YES  
YES  
YES  
YES  
YES  
YES*  
YES*  
YES*  
YES*  
YES*  
YES*  
YES  
YES  
YES  
YES  
YES  
YES  
YES  
YES  
YES  
YES  
YES  
YES  
YES  
YES  
YES  
YES  
YES  
YES  
YES  
YES  
YES  
YES  
2−1/2  
YES  
YES  
YES  
YES  
YES  
YES  
YES  
YES  
YES  
045  
070  
3
2
2−1/2  
3
2
YES  
YES  
YES  
YES  
YES  
YES  
YES  
YES  
2−1/2  
3
YES  
090  
110  
YES  
3
YES  
*Requires field−provided and installed 1−1/2" exhaust accelerator.  
** Kit 51W11 is provided with a 1−1/2" accelerator which must be used for all ML193DF−045, −070 and −090 installations.  
Termination kits 44W92, 44W93, 30G28 and 81J20 approved for use in Canadian installations to meet CSAB149.  
†† The 44W92 Concentric kit is provided with a 1−1/2" accelerator which must be installed on the exhaust outlet when this kit is used with the ML193DF045P36B and  
ML193DF070P36B furnaces.  
Page 13  
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Venting Practices  
Joint Cementing Procedure  
All cementing of joints should be done according to the  
specifications outlined in ASTM D 2855.  
Piping Suspension Guidelines  
SCHEDULE 40  
PVC − 5’  
all other pipe* − 3’  
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!  
NOTE − Isolate piping at the point where it exits the outside wall or  
roof in order to prevent transmission of vibration to the structure.  
Fumes from PVC glue may ignite during system  
check. Allow fumes to dissipate for at least 5 minutes  
before placing unit into operation.  
Wall Thickness Guidelines  
24" maximum  
3/4" minimum  
1 − Measure and cut vent pipe to desired length.  
Wall  
inside  
outside  
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.  
FIGURE 17  
REPLACING FURNACE THAT  
WAS PART OF A COMMON  
VENT SYSTEM  
CHIMNEY  
OR GAS  
VENT  
(Check sizing  
for water  
heater only)  
6 − Promptly apply solvent cement to end of pipe and in-  
side socket surface of fitting. Cement should be ap-  
plied lightly but uniformly to inside of socket. Take  
care to keep excess cement out of socket. Apply sec-  
ond coat to end of pipe.  
FURNACE  
(Replaced  
by ML193)  
WATER  
HEATER  
NOTE − Time is critical at this stage. Do not allow prim-  
er 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 dur-  
ing assembly (but not after pipe is fully inserted) to dis-  
tribute cement evenly. DO NOT turn ABS or cellular  
core pipe.  
OPENINGS  
(To Adjacent  
Room)  
If an ML193DF furnace replaces a furnace which was com-  
monly vented with another gas appliance, the size of the ex-  
isting 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.  
NOTE − Assembly should be completed within 20 sec-  
onds 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 indi-  
cate an improper assembly due to insufficient sol-  
vent.  
FIGURE 18  
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.  
9 − Handle joints carefully until completely set.  
Page 14  
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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 conden-  
sate collection trap and lines.  
Use the following steps to correctly size vent pipe diameter.  
045, 070,  
090, 110  
or 135 btuh  
1
Route piping to outside of structure. Continue with installa-  
tion following instructions given in piping termination sec-  
tion.  
Furnace capacity?  
Which termination?  
Standard or  
Concentric?  
CAUTION  
2
Do not discharge exhaust into an existing stack or  
stack that also serves another gas appliance. If verti-  
cal discharge through an existing unused stack is re-  
quired, insert PVC pipe inside the stack until the end  
is even with the top or outlet end of the metal stack.  
Which needs  
most elbows?  
Intake or  
exhaust  
3
CAUTION  
The exhaust vent pipe operates under positive pres-  
sure and must be completely sealed to prevent leak-  
age of combustion products into the living space.  
Vent Piping Guidelines  
How many?  
4
5
The ML193DF can be installed as either a Non−Direct  
Vent or a Direct Vent gas central furnace.  
NOTE − In Non-Direct Vent installations, combustion air is  
taken from indoors and flue gases are discharged outdoors.  
In Direct Vent installations, combustion air is taken from out-  
doors and flue gases are discharged outdoors.  
2", 2−1/2"  
or 3"  
Desired pipe size?  
Intake and exhaust pipe sizing −− Size pipe according to  
tables 6 and 7. Table 6 lists the minimum vent pipe lengths  
permitted. Table 7 lists the maximum pipe lengths per-  
mitted.  
TABLE 6  
MINIMUM VENT PIPE LENGTHS  
6
7
What is the altitude?  
ML193DF  
MODEL  
MIN. VENT LENGTH*  
15 ft. or  
5 ft plus 2 elbows or  
10 ft plus 1 elbow  
045, 070, 090, 110  
max intake or exhaust  
pipe length.  
*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 8.  
FIGURE 19  
NOTE − It is acceptable to use any pipe size which fits within  
the guidelines allowed in table 7.  
In some applications which permit the use of several differ-  
ent sizes of vent pipe, a combination vent pipe may be  
used. Contact Lennox’ Application Department for assis-  
tance in sizing vent pipe in these applications.  
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  
IMPORTANT  
Do not use screens or perforated metal in exhaust or  
intake terminations. Doing so will cause freeze−ups  
and may block the terminations.  
fittings.  
NOTE − Exhaust piping should be checked carefully to  
make sure there are no sags or low spots.  
Page 15  
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TABLE 7  
Maximum Allowable Intake or Exhaust Vent Length in Feet  
*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.  
Standard Termination at Elevation 0 − 10,000 ft.  
2" Pipe  
Model  
2−1/2" Pipe  
Model  
3" Pipe  
Model  
Number  
Of 90°  
Elbows  
Used  
045  
61  
56  
51  
46  
41  
36  
31  
26  
21  
16  
070  
46  
41  
36  
31  
26  
21  
16  
11  
090  
24  
110  
045  
100  
95  
90  
85  
80  
75  
70  
65  
60  
55  
070  
090  
43  
38  
33  
28  
23  
18  
13  
110  
045  
127  
122  
117  
112  
107  
102  
97  
070  
127  
122  
117  
112  
107  
102  
97  
090  
108  
103  
98  
110  
108  
103  
98  
1
2
80  
75  
70  
65  
60  
55  
50  
45  
40  
35  
19  
3
14  
4
93  
93  
5
88  
88  
n/a  
n/a  
6
83  
83  
7
78  
78  
n/a  
8
92  
92  
73  
73  
9
87  
87  
68  
68  
n/a  
n/a  
10  
82  
82  
63  
63  
Concentric Termination Elevation 0 − 10,000 ft.  
2" Pipe  
Model  
2−1/2" Pipe  
Model  
3" Pipe  
Model  
Number  
Of 90°  
Elbows  
Used  
045  
53  
48  
43  
38  
33  
28  
23  
18  
13  
n/a  
070  
38  
33  
28  
23  
18  
13  
090  
22  
110  
045  
90  
85  
80  
75  
70  
65  
60  
55  
50  
45  
070  
70  
65  
60  
55  
50  
45  
40  
35  
30  
25  
090  
39  
34  
29  
24  
19  
14  
110  
045  
111  
106  
101  
96  
070  
111  
106  
101  
96  
090  
104  
99  
94  
89  
84  
79  
74  
69  
64  
59  
110  
104  
99  
94  
89  
84  
79  
74  
69  
64  
59  
1
2
17  
3
12  
4
5
91  
91  
n/a  
n/a  
6
86  
86  
7
81  
81  
n/a  
8
76  
76  
n/a  
n/a  
9
71  
71  
10  
66  
66  
Page 16  
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TYPICAL EXHAUST PIPE CONNECTIONS  
Pipe size determined in table 7.  
2”  
2”  
2”  
2”  
2”  
or  
3”  
TRANSITION  
*2”  
INTAKE  
EXHAUST  
DO NOT transition from smaller  
to larger pipe size in horizontal  
runs of exhaust pipe.  
TOP VIEW  
* 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 20  
TYPICAL INTAKE PIPE CONNECTIONS  
2”  
2”  
Pipe size determined in table 7.  
2”  
2”  
2”  
or  
TRANSITION  
3”  
3”  
*2”  
*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 21  
Page 17  
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Intake Piping  
General Guidelines for Vent Terminations  
In Non-Direct Vent applications, combustion air is taken  
from indoors and the flue gases are discharged to the out-  
doors. The ML193DF is then classified as a non-direct  
vent, Category IV gas furnace.  
The ML193DF 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.  
In Direct Vent applications, combustion air is taken from  
outdoors and the flue gases are discharged to the out-  
doors. The ML193DF is then classified as a direct vent,  
Category IV gas furnace.  
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).  
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.  
1 − Use cement to secure the intake pipe to the inlet air  
connector.  
or 24. In addition, position termination so it is free from any  
obstructions and 12" above the average snow accumula-  
tion.  
2 − Route piping to outside of structure. Continue with  
installation following instructions given in general  
guide lines for piping terminations and intake and ex-  
haust piping terminations for direct vent sections. Re-  
fer to table 7 for pipe sizes.  
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 a condensing unit because  
the condensate can damage the painted coating.  
TYPICAL AIR INTAKE PIPE CONNECTIONS  
NONDIRECT VENT APPLICATIONS  
AIR  
NOTE − If winter design temperature is below 32°F (0°C),  
exhaust piping should be insulated with 1/2" (13mm), Ar-  
maflex or equivalent when run through unheated space.  
Do not leave any surface area of exhaust pipe open to out-  
side air; exterior exhaust pipe should be insulated with  
1/2" (13mm) Armaflex or equivalent. In extreme cold cli-  
mate areas, 3/4" (19mm) Armaflex or equivalent may be  
necessary. Insulation on outside runs of exhaust pipe  
must be painted or wrapped to protect insulation from de-  
terioration. Exhaust pipe insulation may not be necessary  
in some specific applications.  
INTAKE  
SCREEN  
(Provided)  
NOTE − During extremely cold temperatures, below  
approximately 20°F (6.7°C), units with long runs of vent  
pipe through unconditioned space, even when insulated,  
may form ice in the exhaust termination that prevents the  
unit from operating properly. Longer run times of at least 5  
minutes will alleviate most icing problems. Also, a heating  
cable may be installed on exhaust piping and termination  
to prevent freeze−ups. Heating cable installation kit is  
available from Lennox. See Condensate Piping section  
for part numbers.  
NOTE − Air intake screen and elbow may be rotated, so that  
screen may be positioned to face forward or to either side.  
FIGURE 22  
IMPORTANT  
Do not use screens or perforated metal in exhaust  
terminations. Doing so will cause freeze−ups and  
may block the terminations.  
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 22. 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.  
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).  
2 − Use cement to secure the intake pipe to the connector,  
if desired.  
Page 18  
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VENT TERMINATION CLEARANCES  
FOR NON−DIRECT VENT INSTALLATIONS IN THE USA AND CANADA  
INSIDE CORNER  
DETAIL  
G
H
A
D
E
B
L
B
Fixed  
Closed  
B
B
I
C
Operable  
Fixed  
Closed  
M
F
Operable  
K
J
A
B
AREA WHERE TERMINAL  
IS NOT PERMITTED  
AIR SUPPLY INLET  
VENT TERMINAL  
1
2
US Installations  
Canadian Installations  
A =  
Clearance above grade, veranda,  
porch, deck or balcony  
12 inches (305mm) or 12 in. 305mm)  
above average snow accumulation.  
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  
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)  
4 feet (1.2 m) below or to side of opening;  
1 foot (30 cm) above opening  
C =  
D =  
Clearance to permanently  
closed window  
* 12"  
* 12"  
Vertical clearance to ventilated soffit  
located above the terminal within a  
horizontal distance of 2 feet (mm)  
from the center line of the terminal  
* Equal to or greater than soffit depth.  
* Equal to or greater than soffit depth.  
* Equal to or greater than soffit depth.  
E =  
F =  
Clearance to unventilated soffit  
Clearance to outside corner  
* Equal to or greater than soffit depth.  
* No minimum to outside corner  
* No minimum to outside corner  
*
G = Clearance to inside corner  
*
H = Clearance to each side of center line ex-  
tended above meter / regulator assembly  
3 feet (.9m) within a height 15 feet (4.5m) 3 feet (.9m) within a height 15 feet (4.5m)  
above the meter / regulator assembly  
*
above the meter / regulator assembly  
I =  
Clearance to service regulator  
vent outlet  
3 feet (.9m)  
* 3 feet (.9m)  
J =  
Clearance to non−mechanical air  
supply inlet to building or the com-  
bustion air inlet to any other ap-  
pliance  
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)  
4 feet (1.2 m) below or to side of opening;  
1 foot (30 cm) above opening  
K =  
L =  
Clearance to mechanical air sup-  
ply inlet  
3 feet (.9m) above if within 10 feet  
(3m) horizontally  
6 feet (1.8m)  
Clearance above paved sidewalk or  
paved driveway located on public property  
7 feet (2.1m)ꢀ  
7 feet (2.1m)ꢀ  
M =  
Clearance under veranda, porch,  
deck or balcony  
12 inches (305mm)ꢁ  
*12 inches (305mm)ꢁ  
1
In accordance with the current ANSI Z223.1/NFPA 54 Natural Fuel Gas Code  
*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 re-  
quirements of the gas supplier and these installation instructions."  
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.  
FIGURE 23  
Page 19  
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VENT TERMINATION CLEARANCES  
FOR DIRECT VENT INSTALLATIONS IN THE USA AND CANADA  
INSIDE CORNER  
DETAIL  
G
H
A
D
E
B
L
B
Fixed  
Closed  
B
B
I
C
Operable  
Fixed  
Closed  
M
F
Operable  
K
J
A
B
AREA WHERE TERMINAL  
IS NOT PERMITTED  
AIR SUPPLY INLET  
VENT TERMINAL  
1
2
US Installations  
Canadian Installations  
A =  
Clearance above grade, veranda,  
porch, deck or balcony  
12 inches (305mm) or 12 in. 305mm)  
above average snow accumulation.  
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 6 inches (152mm) for appliances <10,000  
Btuh (3kw), 9 inches (mm) for appliances  
> 10,000 Btuh (3kw) and <50,000 Btuh  
(15 kw), 12 inches (305mm) for ap-  
pliances > 50,000 Btuh (15kw)  
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 =  
D =  
Clearance to permanently  
closed window  
* 12"  
Vertical clearance to ventilated soffit  
located above the terminal within a  
horizontal distance of 2 feet (mm)  
from the center line of the terminal  
* Equal to or greater than soffit depth  
* 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  
* No minimum to outside corner  
E =  
F =  
G =  
Clearance to unventilated soffit  
Clearance to outside corner  
Clearance to inside corner  
*
*
H = Clearance to each side of center line ex-  
tended above meter / regulator assembly  
3 feet (.9m) within a height 15 feet (4.5m) 3 feet (.9m) within a height 15 feet (4.5m)  
above the meter / regulator assembly  
above the meter / regulator assembly  
I =  
Clearance to service regulator  
vent outlet  
3 feet (.9m)  
* 3 feet (.9m)  
J =  
Clearance to non−mechanical air  
supply inlet to building or the com-  
bustion air inlet to any other ap-  
pliance  
6 inches (152mm) for appliances <10,000 6 inches (152mm) for appliances <10,000  
Btuh (3kw), 9 inches (mm) for appliances  
> 10,000 Btuh (3kw) and <50,000 Btuh  
(15 kw), 12 inches (305mm) for ap-  
pliances > 50,000 Btuh (15kw)  
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)  
K =  
L =  
Clearance to mechanical air sup-  
ply inlet  
3 feet (.9m) above if within 10 feet  
(3m) horizontally  
6 feet (1.8m)  
Clearance above paved sidewalk or  
paved driveway located on public property  
7 feet (2.1m)ꢀ  
* 7 feet (2.1m)  
M =  
Clearance under veranda, porch,  
deck or balcony  
*12 inches (305mm)ꢁ  
12 inches (305mm)ꢁ  
1
In accordance with the current ANSI Z223.1/NFPA 54 Natural Fuel Gas Code  
*For clearances not specified in ANSI Z223.1/NFPA 54 or CSA B149.1, clear-  
ance will be in accordance with local installation codes and the requirements  
of the gas supplier and these installation instructions."  
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.  
FIGURE 24  
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Details of Intake and Exhaust Piping Terminations for  
Direct Vent Installations  
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. See  
figures 28 and 29.  
NOTE − In Direct Vent installations, combustion air is tak-  
en from outdoors and flue gases are discharged to out-  
doors.  
3"(76mm) MAX.  
SIZE TERMINATION  
PIPE PER TABLE 8.  
Inches(mm)  
NOTE − Flue gas may be slightly acidic and may adversely  
affect some building materials. If any vent termination is  
used and the flue gasses may impinge on the building ma-  
terial, 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 recommended.  
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 27.  
UNCONDITIONED  
ATTIC SPACE  
8" (203mm) MIN  
1/2" (13mm) FOAM  
INSULATION IN  
UNCONDITIONED  
SPACE  
12" (305mm) ABOVE  
AVERAGE SNOW  
ACCUMULATION  
3" (76mm) OR  
2" (51mm) PVC  
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. Figures 25 through 37 show typical termina-  
tions.  
PROVIDE SUPPORT  
FOR INTAKE AND  
EXHAUST LINES  
DIRECT VENT ROOF TERMINATION KIT  
(15F75 or 44J41)  
1 − Exhaust and intake exits must be in same pressure  
zone. Do not exit one through the roof and one on the  
side. Also, do not exit the intake on one side and the  
exhaust on another side of the house or structure.  
FIGURE 25  
2 − Intake and exhaust pipes should be placed as close  
together as possible at termination end (refer to il-  
lustrations). Maximum separation is 3" (76mm) on roof  
terminations and 6" (152mm) on side wall termina-  
tions.  
2" EXTENSION FOR  
2" PVC PIPE  
1" EXTENSION FOR  
3" PVC PIPE  
FURNACE  
EXHAUST  
PIPE  
4’’  
GLUE EXHAUST  
END FLUSH INTO  
TERMINATION  
FURNACE  
INTAKE  
PIPE  
3 − On roof terminations, the intake piping should termi-  
nate straight down using two 90° elbows (See figure  
25).  
1−1/2" ACCELERATOR  
(all −070 and −090 units)  
4 − Exhaust piping must terminate straight out or up as  
shown. A reducer may be required on the exhaust pip-  
ing at the point where it exits the structure to improve  
the velocity of exhaust away from the intake piping.  
FLUSH−MOUNT SIDE WALL TERMINATION KIT 51W11  
FIGURE 26  
TABLE 8  
EXHAUST PIPE TERMINATION SIZE REDUCTION  
ML193  
MODEL  
Termination  
Pipe Size  
7 − If intake and exhaust piping must be run up a side wall  
to position above snow accumulation or other ob-  
structions, piping must be supported every 24"  
(610mm) as shown in figures 28 and 29. In addition,  
close coupled wall termination kits must be extended  
for use in this application. See figures 35 and 36.  
When exhaust and intake piping must be run up an  
outside wall, the exhaust piping must be terminated  
with pipe sized per table 8.The intake piping may be  
equipped with a 90° elbow turndown. Using turndown  
will add 5 feet (1.5m) to the equivalent length of the  
pipe.  
Exhaust Pipe Size  
1−1/2" (38mm)  
2" (51mm), 2−1/2" (64mm),  
3" (76mm)  
*045 and *070  
*090  
2" (51mm)  
2" (51mm)  
3" (76mm)  
110  
*ML193DF−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, ex-  
haust 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  
NOTE − Care must be taken to avoid recirculation of  
exhaust back into intake pipe.  
8 − A multiple furnace installation may use a group of up to  
four terminations assembled together horizontally, as  
6 − On field supplied terminations, a minimum distance  
Page 21  
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B
B
D
D
C
3
Intake  
C
1
Front View of  
Intake and Exhaust  
A
Exhaust  
A
2
Intake  
Exhaust  
D
TABLE 9  
2" (51mm)  
Vent Pipe  
1
E
3" (76mm)  
Vent Pipe  
B
A− Clearance above  
grade or average snow  
accumulation  
12" (508MM) Min.  
12" (508MM) Min.  
12"  
B−Horizontal  
separation between  
intake and exhaust  
6" (152MM) Min. 6" (152MM) Min.  
24" (610 MM) Max 24" (610 MM) Max  
C
2
C−Minimum from  
end of exhaust to  
inlet of intake  
A
9" (227MM) Min. 9" (227MM) Min.  
12" (305MM) Min.  
16" (405 MM) Max.  
12" (305MM) Min.  
20" (508MM) Max.  
D−Exhaust pipe length  
E−Wall support distance  
from top of each pipe  
(intake/exhaust)  
6" (152MM) Max. 6" (152MM) Max.  
1
The exhaust termination tee should be connected to the 2" or 3" PVC flue pipe as shown in the illustration. Do  
not use an accelerator in applications that include an exhaust termination tee. The accelerator is not required.  
As required. Flue gas may be acidic and may adversely affect some building materials. If a side wall vent  
2
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 recom-  
mended. 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.  
3
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 27  
Page 22  
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FIELD SUPPLIED WALL TERMINATION OR  
(15F74) WALL RING TERMINATION KIT  
With INTAKE ELBOW  
FIELD SUPPLIED WALL TERMINATION OR  
(15F74) WALL RING TERMINATION KIT  
NOTE − FIELD PROVIDED  
REDUCER MAY BE  
NOTE − FIELD PROVIDED  
REDUCER MAY BE  
1/2" (13mm) ARMAFLEX  
REQUIRED TO ADAPT  
1/2" (13mm) ARMAFLEX  
REQUIRED TO ADAPT  
INSULATION IN UN-  
INSULATION IN UN-  
LARGER VENT PIPE SIZE  
LARGER VENT PIPE SIZE  
CONDITIONED SPACE  
TO TERMINATION  
CONDITIONED SPACE  
TO TERMINATION  
SIZE TERMINATION  
SIZE TERMINATION  
D
B
D
B
STRAIGHT  
APPPLICATION  
A
STRAIGHT  
APPPLICATION  
C
C
A
1/2" (13mm) ARMAFLEX INSULATION  
IN UNCONDITIONED SPACE  
1/2" (13mm) ARMAFLEX INSULATION  
IN UNCONDITIONED SPACE  
D
D
E
* WALL  
SUPPORT  
E
* WALL  
SUPPORT  
B
B
A
A
EXTENDED  
C
APPLICATION  
C
EXTENDED  
APPLICATION  
See venting table 7 for maximum venting lengths with this  
arrangement.  
See venting table 7 for maximum 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 6" (152 mm) from top of each pipe  
(intake and exhaust)  
* 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 6" (152 mm) from top of each pipe  
(intake and exhaust)  
2" (51mm)  
Vent Pipe  
3" (76mm)  
Vent Pipe  
2" (51mm)  
Vent Pipe  
3" (76mm)  
Vent Pipe  
A−Minimum clearance  
above grade or average  
snow accumulation  
A−Minimum clearance  
above grade or average  
snow accumulation  
12" (508MM)  
12" (508MM)  
12" (508MM)  
6" (152MM)  
8" (203MM)  
12" (508MM)  
6" (152MM)  
8" (203MM)  
B−Maximum horizontal  
separation between  
intake and exhaust  
B−Maximum horizontal  
separation between  
intake and exhaust  
6" (152MM)  
6" (152MM)  
C−Minimum from  
end of exhaust to  
inlet of intake  
C−Minimum from  
end of exhaust to  
inlet of intake  
6" (152MM)  
20" (508MM)  
6" (152MM)  
6" (152MM)  
12" (305MM)  
6" (152MM)  
D−Maximum exhaust  
pipe length  
D−Maximum exhaust  
pipe length  
12" (305MM)  
6" (152MM)  
20" (508MM)  
6" (152MM)  
E−Maximum wall support  
distance from top of each  
pipe (intake/exhaust)  
E−Maximum wall support  
distance from top of each  
pipe (intake/exhaust)  
FIGURE 29  
FIGURE 28  
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1−1/2" (38mm) accelerator  
provided on 71M80 & 44W92  
kits for ML193DF045P36B− &  
070P36B  
EXHAUST VENT  
Front View  
SIZE  
TERMINATION  
PIPE PER  
INTAKE  
AIR  
FLASHING  
12” (305mm)  
Minimum  
Above Average  
Snow  
(Not Furnished)  
INTAKE  
Accumulation  
Top View  
1/2" (13mm) Foam Insulation  
in Unconditioned Space  
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 LARGER  
VENT PIPE SIZE  
TO TERMINATION  
EXHAUST VENT  
INTAKE AIR  
CLAMP  
FIELD−PROVIDED  
REDUCER MAY BE REQUIRED  
TO ADAPT LARGER VENT  
PIPE SIZE TO TERMINATION  
6 (152mm) MIN.  
OUTSIDE WALL  
DIRECT VENT WALL TERMINATION KIT  
(30G28 or 81J20)  
DIRECT VENT CONCENTRIC ROOFTOP TERMINATION  
71M80, 69M29 or 60L46 (US)  
41W92 or 41W93 (Canada)  
FIGURE 30  
FIGURE 33  
1−1/2" (38mm) accelerator  
provided on 71M80 &  
FIELD−PROVIDED  
44W92 kits for  
ML193DF045P36B− &  
EXHAUST VENT  
Front View  
REDUCER MAY BE  
REQUIRED TO ADAPT  
SIZE  
070P36B  
LARGER VENT PIPE  
SIZE TO TERMINATION  
TERMINATION  
PIPE PER  
OUTSIDE  
WALL  
INTAKE  
INTAKE  
AIR  
AIR  
EXHAUST  
AIR  
EXHAUST  
AIR  
Top View  
12" (305mm) Min.  
above grade or  
average snow ac-  
cumulation.  
INTAKE  
AIR  
1/2" (13mm) Foam Insulation  
in Unconditioned Space  
INTAKE  
AIR  
CLAMP  
(Not Furnished)  
FIELD−PROVIDED  
REDUCER MAY  
BE REQUIRED TO  
ADAPT LARGER  
VENT PIPE SIZE  
TO TERMINATION  
GRADE  
EXHAUST VENT  
INTAKE AIR  
DIRECT VENT CONCENTRIC WALL TERMINATION  
71M80, 69M29 or 60L46 (US)  
41W92 or 41W93 (Canada)  
FIGURE 31  
8" (206mm) MIN.  
OUTSIDE WALL  
12"  
DIRECT VENT WALL TERMINATION KIT  
(22G44 or 44J40)  
EXHAUST  
VENT  
(305mm)  
5−1/2"  
(140mm)  
5"  
(127mm)  
FIGURE 34  
INTAKE  
AIR  
18" MAX.  
(457mm)  
Front View  
EXHAUST VENT  
12" (305mm) Min.  
above grade or  
average snow ac-  
cumulation.  
Inches (mm)  
INTAKE  
AIR  
Side View  
optional intake elbow  
OPTIONAL VENT TERMINATION FOR MULTIPLE UNIT  
INSTALLATION OF DIRECT VENT WALL TERMINATION KIT  
(22G44, 44J40, 30G28 or 81J20)  
FIGURE 32  
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WALL TERMINATION KITS (CLOSECOUPLE)  
EXTENDED VENT FOR GRADE CLEARANCE  
2 inch (51 mm) 22G44 (US)  
3 inch (76 mm) 44J40 (US)  
If intake and exhause pipe is less than 12 in. (305 mm)  
above snow accumulation or other obstructions, field−  
FIELD−PROVIDED  
REDUCER MAY BE REQUIRED TO ADAPT  
LARGER VENT PIPE SIZE TO TERMINATION  
fabricated piping must be installed.  
8” (203 mm) Min. for 2” (51 mm) & 3” (76 mm) DIA. pipe  
between the end of the exhaust pipe and intake pipe  
12” (305 mm) Max. for 2” (51 mm) Dia. Exhaust  
20” (508 mm) Max. for 3” (76 mm) Dia. Exhaust  
WALL SUPPORT*  
12”  
(305 mm)  
EXHAUST  
AIR  
1/2” (13 mm)  
FOAM INSULATION  
(Field Furnished)  
6” (152 mm)  
Maximum  
INTAKE  
AIR  
EXHAUST  
AIR  
INTAKE  
AIR  
5” (127 mm)  
12” (305 mm) Minimum  
8” (203 mm) Min.  
12” (305 mm) Minimum  
Above Grade or Average  
Snow Accumulation  
Above Grade or Average  
51/2”  
Snow Accumulation  
(140 mm)  
GRADE  
GRADE  
*Use wall support every 24" (610). Use two supports if  
extension is greater than 24" but less than 48".  
12” (305 mm) Max. for 2” (51 mm) Dia. Exhaust  
20” (508 mm) Max. for 3” (76 mm) Dia. Exhaust  
FIGURE 35  
WALL TERMINATION KITS (CLOSECOUPLE)  
EXTENDED VENT FOR GRADE CLEARANCE  
2 inch (51 mm) 30G28 (WTK Canada)  
3 inch (76 mm) 81J20 (WTK Canada)  
See Installation Instructions for additional information.  
If intake and exhause pipe is less than 12 in. (305 mm)  
FIELD−PROVIDED  
REDUCER MAY BE REQUIRED TO ADAPT  
LARGER VENT PIPE SIZE TO TERMINATION  
above snow accumulation or other obstructions, field−  
fabricated piping must be installed.  
WALL SUPPORT*  
12” (305 mm) Max. for 2” (51 mm) Dia. Exhaust  
20” (508 mm) Max. for 3” (76 mm) Dia. Exhaust  
12”  
(305 mm)  
EXHAUST  
AIR  
1/2” (13 mm)  
FOAM INSULATION  
(Field Furnished)  
6” (152 mm)  
Maximum  
INTAKE  
AIR  
6” (152 mm)  
Minimum  
EXHAUST  
AIR  
INTAKE  
AIR  
5” (127 mm)  
12” (305 mm) Minimum  
6” (152 mm)  
Minimum  
12” (305 mm) Minimum  
Above Grade or Average  
Snow Accumulation  
GRADE  
Above Grade or Average  
51/2”  
(140 mm)  
Snow Accumulation  
GRADE  
*Use wall support every 24" (610). Use two supports if  
extension is greater than 24" but less than 48".  
12” (305 mm) Max. for 2” (51 mm) Dia. Exhaust  
20” (508 mm) Max. for 3” (76 mm) Dia. Exhaust  
FIGURE 36  
Page 25  
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ML193DF DIRECT VENT APPLICATION  
USING E
SIZE TERMINATION  
PIPE PER TABLE 8.  
STRAIGHT−CUT OR  
ANGLE−CUT IN DIRECTION  
OF ROOF SLOPE *  
12" (305mm)  
ABOVE AVE.  
SNOW  
1/2" (13mm) FOAM  
INSULATION  
3" − 8"  
(76mm−  
203mm)  
EXHAUST VENT  
1/2" (13mm)  
WEATHERPROOF  
INSULATION  
8" − 12"  
(203mm − 305mm)  
ACCUMULATION  
SHOULDER OF FITTINGS  
PROVIDE SUPPORT  
OF PIPE ON TOP PLATE  
Minimum 12" (305MM)  
INTAKE PIPE  
INSULATION (optional)  
3" (76mm) OR  
2" (51mm) PVC  
above chimney top  
plate or average snow  
accumulation  
UNCONDITIONED  
ATTIC SPACE  
SHEET  
METAL TOP  
PLATE  
ALTERNATE  
INTAKE PIPE  
PROVIDE SUPPORT  
FOR EXHAUST LINES  
3" − 8"  
(76mm−  
203mm)  
INSULATE  
TO FORM  
SEAL  
EXTERIOR  
PORTION OF  
CHIMNEY  
NON−DIRECT VENT ROOF TERMINATION KIT  
(15F75 or 44J41)  
*SIZE TERMINATION  
PIPE PER TABLE 8.  
FIGURE 38  
NOTE − Do not discharge exhaust gases directly into any chimney or vent stack. If ver-  
tical discharge through an existing unused chimney or stack is required, insert piping  
inside chimney until the pipe open end is above top of chimney and terminate as illus-  
trated. In any exterior portion of chimney, the exhaust vent must be insulated.  
12" (305mm) MAX. for 2" (51mm)  
20" (508mm) MAX. for 3" (76mm)  
1/2" (13mm) ARMAFLEX  
INSULATION IN  
UNCONDITIONED SPACE  
FIGURE 37  
1/2" (13mm)  
ARMAFLEX  
INSULATION  
FIELD−PROVIDED  
REDUCER MAY  
BE REQUIRED TO  
ADAPT LARGER  
VENT PIPE SIZE  
TO TERMINATION  
Details of Exhaust Piping Terminations for Non-Direct  
Vent Applications  
PVC REDUCER  
12" MIN.  
(305mm)  
Above Grade or  
average snow  
accumulation  
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 pre-  
ferred. Figures 38 through 41 show typical terminations.  
SIZE TERMINATION  
PIPE PER TABLE 8.  
NON−DIRECT VENT FIELD SUPPLIED WALL TERMINATION OR  
(15F74) WALL TERMINATION KIT  
1 − Exhaust piping must terminate straight out or up as  
shown. The termination pipe must be sized as listed in  
table 8.The specified pipe size ensures proper veloc-  
ity required to move the exhaust gases away from the  
building.  
FIGURE 39  
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) as  
up an outside wall, any reduction in exhaust pipe size  
must be done after the final elbow.  
2 − On field supplied terminations for side wall exit, ex-  
haust piping may extend a maximum of 12 inches  
(305mm) for 2" PVC and 20 inches (508mm) for 3"  
(76mm) PVC beyond the outside wall. See figure 39.  
Page 26  
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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.  
12" (305mm) MAX. for 2" (51mm)  
20" (508mm) MAX. for 3" (76mm)  
UNCONDITIONED  
SPACE  
6" (152mm)  
Max  
SIZE TER-  
MINATION  
PIPE PER  
CONDENSATE TRAP AND PLUG LOCATIONS  
*WALL SUPPORT  
OUTSIDE WALL  
FIELD−PROVIDED  
REDUCER MAY BE  
REQUIRED TO  
ADAPT LARGER  
VENT PIPE SIZE TO  
TERMINATION  
12" (305mm)  
ABOVE GRADE OR  
AVERAGE SNOW  
ACCUMULATION  
1/2" (13mm) FOAM  
INSULATION IN  
UNCONDITIONED  
SPACE  
Trap  
(same on  
right side)  
1/2" (13mm) FOAM  
INSULATION  
*Use wall support every 24" (610). Use  
two supports if extension is greater  
than 24" but less than 48".  
Plug  
(same on left  
side)  
1−1/2 in.  
NON−DIRECT VENT FIELD SUPPLIED WALL TERMINATION EX-  
TENDED OR (15F74) WALL TERMINATION VENT PIPE EXTENDED  
FIGURE 40  
ML193DF NON−DIRECT VENT APPLICATION  
USING EXISTING CHIMNEY  
STRAIGHT−CUT OR  
ANGLE−CUT IN DIRECTION  
OF ROOF SLOPE  
SIZE TERMINATION  
PIPE PER TABLE 8.  
3" − 8"  
(76mm−  
203mm)  
EXHAUST VENT  
1/2" (13mm)  
WEATHERPROOF  
INSULATION  
Minimum 12" (305MM)  
above chimney top  
FIGURE 42  
plate or average snow  
accumulation  
SHOULDER OF FITTINGS  
PROVIDE SUPPORT  
OF PIPE ON TOP PLATE  
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.  
SHEET  
METAL TOP  
PLATE  
2 − Remove plug (figure 42) from the cold end header box  
at the appropriate location on the side of the unit. Install  
field−provided 1/2" NPT male fitting into cold end head-  
er box. Use teflon tape or appropriate pipe dope.  
3" − 8"  
(76mm−  
203mm)  
INSULATE  
TO FORM  
SEAL  
EXTERIOR  
PORTION OF  
CHIMNEY  
3 − Install the cap over the clean out opening at the base of  
NOTE − Vinyl tubing may be used for condensate drain.  
Tubing must be 1−1/4" OD X 1" ID and should be attached to  
the drain on the trap using a hose clamp.  
NOTE − Do not discharge exhaust gases directly into any chimney or vent stack. If ver-  
tical discharge through an existing unused chimney or stack is required, insert piping  
inside chimney until the pipe open end is above top of chimney and terminate as illus-  
trated. In any exterior portion of chimney, the exhaust vent must be insulated.  
4 − Install drain trap using appropriate PVC fittings, glue  
all joints. Glue the provided drain trap as shown in fig-  
FIGURE 41  
Condensate Piping  
This unit is designed for either right- or left-side exit of con-  
densate piping. Refer to figure 42 for condensate trap loca-  
tions.  
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.  
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5 − If unit will be started immediately upon completion of  
installation, prime trap per procedure outlined in Unit  
Start−Up section.  
ML193DF with Evaporator Coil  
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 avail-  
able 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 and  
evaporator coil must drain  
separately as shown.  
Field−Provided Vent  
CONDENSATE TRAP LOCATION  
(shown with right side exit of condensation)  
Drain  
Field Provided Vent  
min. 1" Above  
Condensate Drain  
FIGURE 44  
Trap can be installed a  
maximum of 5 ft. from furnace.  
(*PVC Only)  
CAUTION  
Do not use copper tubing or existing copper  
condensate lines for drain line.  
1" min.  
5’ max.  
CAUTION  
to drain  
*Piping from furnace must slope down a minimum of  
1/4" per ft. toward trap.  
A separate drain line must be run to the drain  
from the condensate trap to ensure proper  
drainage and pressure switch operation. DO  
NOT connect the condensate trap drain into the  
drain line from the evaporator coil.  
FIGURE 43  
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TRAP / DRAIN ASSEMBLY USING 1/2" PVC OR 3/4" PVC  
OPTIONAL Condensate Drain Connection  
Adapter 1/2 inch slip X  
Adapter 1/2 inch slip X  
1/2 inch mpt (Not Furnished)  
Condensate Drain  
Connection In Unit  
1/2 inch mpt (Not Furnished)  
Vent  
90° Street Elbow  
1 (25) Minimum  
1/2 inch PVC  
5 Feet  
Maximum  
(Not Furnished)  
Above Top of Condensate Drain  
Connection In Unit  
90° Elbow 1/2 inch PVC  
Condensate Drain  
Connection In Unit  
(Not Furnished)  
1/2 inch PVC Pipe  
(Not Furnished)  
1/2 inch PVC Pipe  
(Not Furnished)  
OPTIONAL Drain Piping  
Drain Assembly for 1/2 inch Drain Pipe  
Coupling 1/2 inch slip X slip  
(Not Furnished)  
1/2 inch PVC Pipe  
(Not Furnished)  
Drain Trap  
Assembly  
(Furnished)  
1/2 inch PVC  
(Furnished)  
90° Elbow  
1/2 inch PVC  
(Not Furnished)  
To  
Drain  
To  
Drain  
Drain Assembly for 3/4 inch Drain Pipe  
Drain Trap  
Clean Out  
90° Elbow  
90° Elbow  
3/4 inch PVC  
(Not Furnished)  
3/4 inch PVC  
(Not Furnished)  
To  
Drain  
To  
Drain  
Coupling 3/4 inch slip X slip  
(Not Furnished)  
Drain Trap Assembly with 3/4 inch Piping  
Drain Trap Assembly with 1/2 inch Piping  
1 inch (25mm) Minimum Above Top of  
Condensate Drain Connection In Unit  
1 inch (25mm) Minimum Above Top of  
Condensate Drain Connection In Unit  
Vent  
Drain Trap Assembly  
(Furnished)  
Vent  
7
Condensate Drain  
Connection In Unit  
Condensate Drain  
Connection In Unit  
(178)  
To  
Drain  
To  
Drain  
FIGURE 45  
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Gas Piping  
IMPORTANT  
Compounds used on threaded joints of gas piping  
must be resistant to the actions of liquified petro-  
leum gases.  
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.  
Leak Check  
After gas piping is completed, carefully check all piping  
connections (factory− and field−installed) for gas leaks. Use  
a leak detecting solution or other preferred means.  
The furnace must be isolated from the gas supply system  
by closing its individual manual shut-off valve during any  
pressure testing of the gas supply system at pressures less  
than or equal to 1/2 psig (3.48 kPa, 14 inches w.c.).  
WARNING  
Do not exceed 600 in−lbs (50 ft−lbs) torque when at-  
taching the gas piping to the gas valve.  
MANUAL MAIN SHUT−OFF  
VALVE WILL NOT HOLD  
NORMAL TEST PRESSURE  
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 47.  
FURNACE  
ISOLATE  
GAS VALVE  
1/8" N.P.T. PLUGGED TAP  
CAP  
2 − When connecting gas supply, factors such as length of  
run, number of fittings and furnace rating must be con-  
sidered to avoid excessive pressure drop. Table 10  
lists recommended pipe sizes for typical applications.  
FIGURE 46  
NOTE − Use two wrenches when connecting gas pip-  
ing 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 eleva-  
tor shafts. Center gas line through piping hole. Gas  
IMPORTANT  
When testing pressure of gas lines, gas valve must  
valves can be damaged if subjected to pressures  
greater than 1/2 psig (3.48 kPa).  
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, ev-  
ery 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.  
WARNING  
FIRE OR EXPLOSION HAZARD  
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 54.  
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.  
6 − In some localities, codes may require installation of a  
manual main shut-off valve and union (furnished by in-  
staller) external to the unit. Union must be of the  
ground joint type.  
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Left Side Piping  
(Standard)  
MANUAL  
MAIN SHUT−OFF  
VALVE  
(With 1/8 in. NPT  
Plugged Tap  
Shown)  
GROUND  
JOINT  
UNION  
AUTOMATIC  
GAS VALVE  
(with manual  
shut−off valve)  
MANUAL  
MAIN SHUT−OFF  
VALVE  
(With 1/8 in. NPT  
Plugged Tap Shown)  
AUTOMATIC  
GAS VALVE  
(with manual  
shut−off valve)  
Plug  
Plug  
GROUND  
JOINT  
UNION  
DRIP LEG  
Right Side Piping  
(Alternate)  
FIELD  
PROVIDED  
AND INSTALLED  
DRIP LEG  
Bellows Grommet  
Bellows Grommet  
NOTE − BLACK IRON PIPE ONLY TO BE ROUTED INSIDE OF CABINET  
FIGURE 47  
TABLE 10  
GAS PIPE CAPACITY − FT3/HR (kL/HR)  
Length of Pipe−Feet(m)  
Nominal  
Iron Pipe Size  
−Inches(mm)  
Internal  
Diameter  
−Inches(mm)  
10  
(3.048)  
20  
(6.096)  
30  
(9.144)  
40  
50  
60  
70  
80  
90  
100  
(12.192) (15.240) (18.288) (21.336) (24.384) (27.432) (30.480)  
1/2  
(12.7)  
.622  
(17.799)  
175  
(4.96)  
120  
(3.40)  
97  
(2.75)  
82  
(2.32)  
73  
(2.07)  
66  
(1.87)  
61  
(1.73)  
57  
(1.61)  
53  
(1.50)  
50  
(1.42)  
3/4  
(19.05)  
.824  
(20.930)  
360  
(10.19)  
250  
(7.08)  
200  
(5.66)  
170  
(4.81)  
151  
(4.28)  
138  
(3.91)  
125  
(3.54)  
118  
(3.34)  
110  
(3.11)  
103  
(2.92)  
1
(25.4)  
1.049  
(26.645)  
680  
(19.25)  
465  
(13.17)  
375  
(10.62)  
320  
(9.06)  
285  
(8.07)  
260  
(7.36)  
240  
(6.80)  
220  
(6.23)  
205  
(5.80)  
195  
(5.52)  
1−1/4  
(31.75)  
1.380  
(35.052)  
1400  
(39.64)  
950  
(26.90)  
770  
(21.80)  
660  
(18.69)  
580  
(16.42)  
530  
(15.01)  
490  
(13.87)  
460  
(13.03)  
430  
(12.18)  
400  
(11.33)  
1−1/2  
(38.1)  
1.610  
(40.894)  
2100  
(59.46)  
460  
(41.34)  
1180  
(33.41)  
990  
(28.03)  
900  
(25.48)  
810  
(22.94)  
750  
(21.24)  
690  
(19.54)  
650  
(18.41)  
620  
(17.56)  
2
(50.8)  
2.067  
(52.502)  
3950  
(111.85)  
2750  
(77.87)  
2200  
(62.30)  
1900  
(53.80)  
1680  
(47.57)  
1520  
(43.04)  
1400  
(39.64)  
1300  
(36.81)  
1220  
(34.55)  
1150  
(32.56)  
2−1/2  
(63.5)  
2.469  
(67.713)  
6300  
(178.39)  
4350  
(123.17)  
3520  
(99.67)  
3000  
(84.95)  
2650  
(75.04)  
2400  
(67.96)  
2250  
(63.71)  
2050  
(58.05)  
1950  
(55.22)  
1850  
(52.38)  
3
(76.2)  
3.068  
(77.927)  
11000  
(311.48)  
7700  
(218.03)  
6250  
(176.98)  
5300  
(150.07)  
4750  
(134.50)  
4300  
(121.76)  
3900  
(110.43)  
3700  
(104.77)  
3450  
(97.69)  
3250  
(92.03)  
4
(101.6)  
4.026  
(102.260)  
23000  
(651.27)  
15800  
(447.39)  
12800  
(362.44)  
10900  
(308.64)  
9700  
(274.67)  
8800  
(249.18)  
8100  
(229.36)  
7500  
(212.37)  
7200  
(203.88)  
6700  
(189.72)  
NOTE − Capacity given in cubic feet of gas per hour (kilo liters of gas per hour) and based on 0.60 specific gravity gas.  
Page 31  
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Removal of the Furnace from Common Vent  
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.  
In the event that an existing furnace is removed from a  
venting system commonly run with separate gas ap-  
pliances, the venting system is likely to be too large to  
properly vent the remaining attached appliances.  
6 − After determining that each appliance connected to the  
common venting system is venting properly, (step 3)  
return all doors, widows, exhaust fans, fireplace damp-  
ers, and any other gas−burning appliances to their pre-  
vious mode of operation.  
Conduct the following test while each appliance is operat-  
ing and the other appliances (which are not operating) re-  
main 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 re-  
quirements section.  
7 − If a venting problem is found during any of the preced-  
ing tests, the common venting system must be modi-  
fied 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 stan-  
dards of the National Fuel Gas Code ANSI Z223.1.  
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 mon-  
oxide poisoning or death.  
The following steps shall be followed for each ap-  
pliance connected to the venting system being  
placed into operation, while all other appliances  
connected to the venting system are not in  
operation:  
Electrical  
ELECTROSTATIC DISCHARGE (ESD)  
Precautions and Procedures  
CAUTION  
Electrostatic discharge can affect electronic com-  
ponents. Take precautions during furnace installa-  
tion and service to protect the furnace’s electronic  
controls. Precautions will help to avoid control ex-  
posure to electrostatic discharge by putting the fur-  
nace, the control and the technician at the same  
electrostatic potential. Neutralize electrostatic  
charge by touching hand and all tools on an un-  
painted unit surface, such as the gas valve or blower  
deck, before performing any service procedure.  
1 − Seal any unused openings in the common venting sys-  
tem.  
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.  
3 − Close all building doors and windows and all doors be-  
tween the space in which the appliances remaining  
connected to the common venting system are located  
and other spaces of the building. Turn on clothes dry-  
ers 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 oper-  
ate at maximum speed. Do not operate a summer ex-  
haust fan. Close fireplace dampers.  
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 49. The  
excess wire must be pulled into the blower compartment.  
Secure the excess wire to the existing harness to protect it  
from damage.  
4 − Follow the lighting instructions. Turn on the appliance  
that is being inspected. Adjust the thermostat so that  
the appliance operates continuously.  
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Complete the wiring connections to the equipment. Use the  
provided unit wiring diagram and the field wiring diagram  
shown in figure 51. Use 18−gauge wire or larger that is suit-  
able for Class II rating for thermostat connections.  
INTERIOR MAKE−UP BOX  
(FACTORY− INSTALLED LEFT SIDE)  
Electrically ground the unit according to local codes or, in  
the absence of local codes, according to the current Na-  
tional 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.  
MAKE−UP  
BOX INSIDE  
CABINET  
Left side  
NOTE − The ML193DF furnace contains electronic compo-  
nents that are polarity sensitive. Make sure that the furnace  
is wired correctly and is properly grounded.  
Generator Use − Voltage Requirements  
The following requirements must be kept in mind when  
specifying a generator for use with this equipment:  
FIGURE 48  
D The furnace requires 120 volts + 10% (Range: 108  
volts to 132 volts)  
EXTERIOR MAKE−UP BOX  
(FIELD PROVIDED RIGHT SIDE)  
D The furnace operates at 60 Hz + 5% (Range: 57 Hz to  
63 Hz)  
D 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  
D Generator should have a wave form distortion of less  
than 5% RHD  
MAKE−UP  
BOX  
OUTSIDE  
CABINET  
Accessory Terminals  
Right Side  
One line voltage ꢂEAC" 1/4" spade terminal is provided on  
control configuration. 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 exter-  
nal relay.  
FIGURE 49  
wiring diagram and troubleshooting.  
The power supply wiring must meet Class I restrictions.  
Protected by either a fuse or circuit breaker, select circuit  
protection and wire size according to unit nameplate.  
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.  
One line voltage ꢂHUM" 1/4" spade terminal is provided on  
control configuration. This terminal is energized in the  
heating mode when the combustion air inducer is operat-  
ing. Any humidifier rated up to one amp can be connected  
to this terminal with the neutral leg of the circuit being con-  
nected to one of the provided neutral terminals. If a humidi-  
fier rated at greater than one amp is connected to this termi-  
nal, it is necessary to use an external relay.  
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 servic-  
ing at a later date. Remove the blower access panel to  
check the length of the wire.  
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Install the room thermostat according to the instruc-  
tions provided with the thermostat. See figure 50 for  
thermostat designations. If the furnace is being  
matched with a heat pump, refer to the FM21 installa-  
tion instruction or appropriate dual fuel thermostat in-  
structions.  
ML193DF and CONDENSING UNIT  
THERMOSTAT DESIGNATIONS  
(Refer to specific thermostat and outdoor unit.)  
Thermostat  
Furnace  
Condensing  
Unit  
Indoor Blower Speeds  
*CONDENSING  
UNITꢃ  
1 − When the thermostat is set to ꢂFAN ON," the indoor  
blower will run continuously on the heating speed  
when there is no cooling or heating demand.  
POWER  
R
R
W1  
Y
HEAT  
W
Y
CONDENSING  
UNITꢃ  
COOLING  
2 − When the ML193DF is running in the heating mode,  
the indoor blower will run on the heating speed.  
INDOOR BLOWER  
G
G
C
CONDENSING  
UNITꢃ COMMON  
3 − When there is a cooling demand, the indoor blower will  
run on the cooling speed.  
COMMON  
C
*NOTE − ꢀR" REQUIRED ON SOME OUTDOOR UNITS  
FIGURE 50  
TYPICAL ML193DF FIELD WIRING DIAGRAM  
IGNITOR  
*NOTE − ꢀR" REQUIRED ON SOME OUTDOOR UNITS  
*R  
FIGURE 51  
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TYPICAL ML193DF WIRING DIAGRAM  
FIGURE 52  
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INTEGRATED CONTROL  
(Automatic Hot Surface Ignition System)  
TERMINAL DESIGNATIONS  
Humidifier (120VAC)  
HUM  
LINE  
XFMR  
EAC  
Input (120VAC)  
Transformer (120VAC)  
Electronic Air Cleaner (120VAC)  
Blower − Cooling Speed (120VAC)  
Blower − Heating Speed (120VAC)  
Dead terminals to park alternate spd taps  
Flame sensor  
COOL  
HEAT  
PARK  
FLAME  
NEUTRALS  
Neutral terminals (120VAC)  
3 AMP, 32 VAC FUSE  
BLOWER OFF  
DELAY JUMPER  
FIGURE 53  
Unit Start−Up  
WARNING  
FOR YOUR SAFETY READ BEFORE OPERATING  
Danger of explosion. Can cause injury  
or product or property damage. Should  
the gas supply fail to shut off or if  
overheating occurs, shut off the gas  
valve to the furnace before shutting off  
the electrical supply.  
WARNING  
Do not use this furnace if any part has been under-  
water. A flood−damaged furnace is extremely dan-  
gerous. Attempts to use the furnace can result in  
fire or explosion. Immediately call a qualified ser-  
vice 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.  
BEFORE LIGHTING the unit, smell all around the fur-  
nace area for gas. Be sure to smell next to the floor be-  
cause some gas is heavier than air and will settle on the  
floor.  
The gas valve on the ML193DF 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.  
CAUTION  
Before attempting to perform any service or mainte-  
nance, turn the electrical power to unit OFF at dis-  
connect switch.  
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Placing the furnace into operation:  
MANIFOLD  
PRESSURE  
ADJUSTMENT  
SCREW  
MANIFOLD  
PRESSURE  
OUTLET  
ML193DF units are equipped with an automatic hot sur-  
face 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  
INLET  
PRESSURE  
PORT  
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:  
GAS VALVE SHOWN IN ON POSITION  
FIGURE 54  
12− If the appliance will not operate, follow the instructions  
ꢂTurning Off Gas to Unit" and call your service techni-  
cian or gas supplier.  
1 − Follow the lighting instructions to place the unit into op-  
eration.  
2 − Set the thermostat to initiate a heating demand.  
Turning Off Gas to Unit  
3 − Allow the burners to fire for approximately 3 minutes.  
1 − Set the thermostat to the lowest setting.  
4 − Adjust the thermostat to deactivate the heating de-  
mand.  
2 − Turn off all electrical power to the unit if service is to be  
performed.  
5 − Wait for the combustion air inducer to stop. Set the  
thermostat to initiate a heating demand and again al-  
low the burners to fire for approximately 3 minutes.  
3 − Remove the upper access panel.  
4 − Move gas valve switch to OFF.  
5 − Replace the upper access panel.  
6 − Adjust the thermostat to deactivate the heating de-  
mand 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.  
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?  
WARNING  
If you do not follow these instructions exactly, a fire  
or explosion may result causing property damage,  
personal injury or death.  
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.  
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.  
Heating Sequence Of Operation  
1 − When thermostat calls for heat, combustion air inducer  
starts.  
4 − This furnace is equipped with an ignition device which  
automatically lights the burners. Do not try to light the  
burners by hand.  
2 − Combustion air pressure switch proves blower opera-  
tion. Switch is factory−set and requires no adjustment.  
3 − After a 15−second prepurge, the hot surface ignitor en-  
ergizes.  
5 − Remove the upper access panel.  
6 − Move gas valve switch to OFF. See figure 54.  
4 − After a 20−second ignitor warm−up period, the gas  
valve solenoid opens. A 4−second Trial for Ignition peri-  
od begins."  
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 instruc-  
tions. If you do not smell gas go to next step.  
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 igni-  
tion control will repeat steps 3 and 4 four more times  
before locking out the gas valve (ꢂWATCHGUARD"  
flame failure mode). The ignition control will then auto-  
matically repeat steps 1 through 6 after 60 minutes.  
To interrupt the 60−minute ꢂWATCHGUARD" period,  
move thermostat from ꢂHeat" to ꢂOFF" then back to  
ꢂHeat". Heating sequence then restarts at step 1.  
8 − Move gas valve switch to ON. See figure 54.  
9 − Replace the upper 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.  
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Manifold Pressure Measurement  
Gas Pressure Adjustment  
1 − Remove the threaded plug from the outlet side of the  
gas valve and install a field−provided barbed fitting.  
Connect to a manometer to measure manifold pres-  
sure.  
Gas Flow (Approximate)  
TABLE 11  
GAS METER CLOCKING CHART  
Seconds for One Revolution  
Natural LP  
2 − Start unit and allow 5 minutes for unit to reach steady  
state.  
ML193  
Unit  
3 − While waiting for the unit to stabilize, notice the flame.  
Flame should be stable and should not lift from burner.  
Natural gas should burn blue.  
1 cu ft  
Dial  
80  
2 cu ft  
Dial  
1 cu ft  
Dial  
2 cu ft  
DIAL  
−045  
−070  
−090  
−110  
160  
110  
82  
200  
136  
102  
82  
400  
272  
204  
164  
4 − After allowing unit to stabilize for 5 minutes, record  
manifold pressure and compare to value given in table  
12.  
55  
41  
33  
66  
NOTE − Shut unit off and remove manometer as soon as an  
accurate reading has been obtained. Take care to remove  
barbed fitting and replace threaded plug.  
Natural−1000 btu/cu ft  
LP−2500 btu/cu ft  
NOTE To obtain accurate reading, shut off all other gas  
appliances connected to meter.  
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 tables below. The maximum carbon  
Furnace should operate at least 5 minutes before check-  
ing gas flow. Determine time in seconds for two revolu-  
tions of gas through the meter. (Two revolutions assures a  
more accurate time). Divide by two and compare to time  
in table 11. If manifold pressure matches table 12 and rate  
is incorrect, check gas orifices for proper size and restric-  
tion. Remove temporary gas meter if installed.  
monoxide reading should not exceed 50 ppm.  
TABLE 13  
ML193  
CO %  
2
CO %  
For L.P.  
For Nat  
2
Unit  
−045  
−070  
−090  
−110  
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 12 for  
proper supply line pressure. Replace the threaded plug af-  
ter measurements have been taken.  
7.2 − 7.9  
8.6 − 9.3  
High Altitude Information  
NOTE − In Canada, certification for installations at eleva-  
tions over 4500 feet (1372 m) is the jurisdiction of local au-  
thorities.  
TABLE 12  
Manifold and Supply Pressure (Outlet) inches w.c.  
ML193DF units require no manifold pressure adjustments  
for operation at altitudes up to 10,000 feet (3048 m) above  
sea level. Units installed at altitude of 4501 − 10,000 feet  
(1373 to 3048m) require a pressure switch change which  
can be ordered separately. Table 14 lists conversion kit and  
pressure switch requirements at varying altitudes.  
Supply  
Pressure in.wg.  
Model  
Input Sizes  
Manifold  
Pressure in.wg.  
Fuel  
Min.  
Max.  
Nat. Gas  
L.P. Gas  
All sizes  
All sizes  
4.5  
10.0  
3.5  
11.0  
13.0  
The combustion air pressure switch is factory−set and re-  
quires no adjustment.  
10.0  
NOTE − A natural to L.P. propane gas changeover kit is nec-  
essary to convert this unit. Refer to the changeover kit  
installation instruction for the conversion procedure.  
NOTE − A natural to LP/propane gas changeover kit is nec-  
essary to convert this unit. Refer to the changeover kit  
installation instruction for the conversion procedure.  
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TABLE 14  
Conversion Kit and Pressure Switch Requirements at Varying Altitudes  
High Altitude  
Natural Burner  
Orifice Kit  
High Altitude  
LP/Propane  
Burner Orifice Kit  
Natural to  
LP/Propane  
LP/Propane  
to Natural  
High Altitude Pressure  
Switch  
ML193  
Unit  
4501 − 7500 7501 −10,000  
ft  
0 − 7500 ft  
(0 − 2286m)  
7501 − 10,000 ft  
(2286 − 3038m)  
0 − 7500 ft  
(0 − 2286m)  
7501 − 10,000 ft  
(2286 − 3038m)  
ft  
(1373 −  
2286m)  
(2286 −  
3048m)  
−045  
−070  
−090  
−110  
*69W73  
73W37  
*73W81  
*68W68  
74W90  
74W91  
* Conversion requires installation of a gas valve manifold spring which is provided with the gas conversion kit.  
Pressure switch is factory set. No adjustment necessary. All models use the factory−installed pressure switch from 0−4500 feet (0−1370 m).  
2 − Visually inspect the venting system for proper size and  
Testing of Non−Direct Vent Applications  
horizontal pitch. Determine there is no blockage or re-  
for Proper Venting and Sufficient  
Combustion Air  
striction, 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  
WARNING  
CARBON MONOXIDE POISONING HAZARD!  
the appliances connected to the venting system are lo-  
cated and other spaces of the building.  
Failure to follow the steps outlined below for each  
appliance connected to the venting system being  
placed into operation could result in carbon monox-  
ide poisoning or death.  
The following steps shall be followed for each ap-  
pliance connected to the venting system being  
placed into operation, while all other appliances con-  
nected to the venting system are not in operation.  
4 − Close fireplace dampers.  
5 − Turn on clothes dryers and any appliances not con-  
nected 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.  
After the ML193DF gas furnace has been started, the fol-  
lowing test should be conducted to ensure proper venting  
and sufficient combustion air has been provided to the  
ML193DF as well as to other gas-fired appliances which  
are separately vented.  
7 − Use the flame of match or candle to test for spillage of  
flue gases at the draft hood relief opening after 5 min-  
utes 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 ap-  
propriate 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 cur-  
rent standard of the CSA−B149 Natural Gas and Pro-  
pane Installation Codes in Canada.  
If a ML193DF 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 prod-  
ucts, 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.  
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.  
1 − Seal any unused openings in the venting system.  
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Other Unit Adjustments  
HEAT FAN-OFF TIME IN SECONDS  
NOTE − See troubleshooting flow charts if any safety  
switches are found to be open.  
Primary Limit  
The primary limit is located on the heating compartment  
vestibule panel. This limit is factory set and requires no ad-  
justment.  
NO JUMPER  
To adjust fan−off timing, reposition jumper across pins to  
achieve desired setting.  
Flame Rollout Switches (Two)  
60 Second  
off Time  
90 Second  
off Time  
120 Second  
off Time  
180 Second  
off Time  
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.  
FIGURE 55  
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. 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.  
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.  
Fan Control  
The fan on time of 30 seconds is not adjustable. The fan off  
delay (amount of time that the blower operates after the  
heat demand has been satisfied) may be adjusted by  
changing the jumper position across the five pins on the  
integrated control. The unit is shipped with a factory fan off  
setting of 90 seconds. The fan off delay affects comfort and  
is adjustable to satisfy individual applications. Adjust the  
fan off delay to achieve a supply air temperature between  
90° and 110°F at the moment that the blower is de−ener-  
gized. Longer off delay settings provide lower return air  
temperatures; shorter settings provide higher return air  
temperatures. See figure 55.  
4 − Place unused blower speed tap on integrated control  
ꢂPARK" terminal or insulate.  
5 − Refer to blower speed selection chart on unit wiring dia-  
gram for desired heating or cooling speed. See Blower  
performance data beginning on the next page.  
6 − Connect selected speed tap at integrated control  
speed terminal.  
7 − Resecure blower access panel.  
8 − Turn on electrical power to furnace.  
9 − Recheck temperature rise.  
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 − Check exhaust and air intake connections for tightness  
and to make sure there is no blockage.  
Electrical  
2 − Is pressure switch closed? Obstructed exhaust pipe  
will cause unit to shut off at pressure switch. Check ter-  
mination for blockages.  
1 − Check all wiring for loose connections.  
2 − Check for the correct voltage at the furnace (furnace  
operating).  
3 − Obstructed pipe or termination may cause rollout  
switches to open. Reset manual flame rollout switches  
on burner box assembly if necessary.  
3 − Check amp-draw on the blower motor.  
Motor Nameplate__________Actual__________  
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BLOWER DATA  
ML193DF045P36B PERFORMANCE (Less Filter)  
ML193DF090P48C PERFORMANCE (Less Filter)  
Air Volume / Watts at Various Blower Speeds  
Air Volume / Watts at Various Blower Speeds  
External  
Static  
Pressure  
in. w.g.  
External  
Medium-  
Medium-  
Medium-  
Medium-  
Static  
Pressure  
in. w.g.  
High  
Low  
High  
Low  
High  
Low  
High  
Low  
cfm Watts cfm Watts cfm Watts cfm Watts  
1615 650 1385 555 1205 465 1045 390  
1605 640 1375 545 1195 455 1035 380  
1500 620 1340 525 1165 445 1015 370  
1450 590 1290 490 1125 420 975 365  
1350 560 1235 480 1090 405 920 345  
1300 545 1170 450 1035 380 875 335  
1195 500 1095 425 990 365 840 320  
1140 485 1020 400 895 345 780 300  
1025 450 920 370 840 330 695 275  
945 435 800 335 700 295 605 250  
cfm Watts cfm Watts cfm Watts cfm Watts  
2145 900 1865 740 1545 635 1295 530  
2135 890 1855 730 1540 625 1290 520  
2065 845 1815 710 1525 600 1285 500  
2010 825 1760 685 1510 580 1275 485  
1930 775 1705 630 1495 575 1235 455  
1845 740 1645 610 1450 530 1215 450  
1745 700 1525 550 1380 505 1185 430  
1620 650 1460 535 1315 480 1110 405  
1450 585 1340 505 1220 445 1020 375  
1320 555 1130 450 1010 385 920 345  
0.00  
0.10  
0.20  
0.30  
0.40  
0.50  
0.60  
0.70  
0.80  
0.90  
0.00  
0.10  
0.20  
0.30  
0.40  
0.50  
0.60  
0.70  
0.80  
0.90  
ML193DF070P36B PERFORMANCE (Less Filter)  
ML193DF110P60C PERFORMANCE (Less Filter)  
Air Volume / Watts at Various Blower Speeds  
Air Volume / Watts at Various Blower Speeds  
External  
External  
Medium-  
High  
Medium-  
Low  
Medium-  
High  
Medium-  
Low  
Static  
Pressure  
in. w.g.  
Static  
Pressure  
in. w.g.  
High  
Low  
High  
Low  
cfm Watts cfm Watts cfm Watts cfm Watts  
1505 660 1310 570 1090 455 940 390  
1480 625 1295 550 1070 435 935 365  
1405 585 1255 515 1055 425 930 350  
1355 580 1225 475 1045 405 900 330  
1305 540 1165 470 1010 385 890 325  
1270 525 1110 425 975 370 835 305  
1175 500 1080 415 925 345 815 290  
1105 460 1000 395 855 320 745 270  
1040 440 925 365 790 300 670 250  
920 400 825 335 680 270 560 225  
cfm Watts cfm Watts cfm Watts cfm Watts  
2410 1390 2190 1080 1860 910 1560 735  
2405 1385 2180 1070 1855 905 1555 730  
2285 1345 2120 1030 1850 865 1540 720  
2220 1315 2015 1005 1770 840 1535 705  
2185 1295 1950 955 1750 815 1530 685  
2045 1240 1830 925 1680 790 1500 660  
1965 1220 1710 890 1575 755 1445 640  
1820 1165 1610 850 1495 720 1370 615  
1625 1155 1510 820 1400 695 1315 595  
1455 1110 1390 790 1350 660 1210 565  
0.00  
0.10  
0.20  
0.30  
0.40  
0.50  
0.60  
0.70  
0.80  
0.90  
0.00  
0.10  
0.20  
0.30  
0.40  
0.50  
0.60  
0.70  
0.80  
0.90  
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3 − Remove the clean out cap from the condensate trap  
and empty water. Inspect the trap then reinstall the  
drain plug.  
Service  
Cleaning Heat Exchanger  
WARNING  
ELECTRICAL SHOCK, FIRE,  
OR EXPLOSION HAZARD.  
If cleaning the heat exchanger becomes necessary, follow  
the below procedures and refer to figure 1 when disassem-  
bling unit. Use papers or protective covering in front of fur-  
nace while removing heat exchanger assembly.  
Failure to follow safety warnings exactly could result  
in dangerous operation, serious injury, death or  
property damage.  
Improper servicing could result in dangerous opera-  
tion, serious injury, death, or property damage.  
Before servicing, disconnect all electrical power to  
furnace.  
1 − Turn off electrical and gas supplies to the furnace.  
2 − Remove the furnace access panels.  
3 − Disconnect the 2 wires from the gas valve.  
4 − Remove gas supply line connected to gas valve. Re-  
move gas valve/manifold assembly.  
When servicing controls, label all wires prior to dis-  
connecting. Take care to reconnect wires correctly.  
Verify proper operation after servicing.  
5 − Remove sensor wire from sensor. Disconnect 2-pin  
plug from the ignitor.  
6 − Disconnect wires from flame roll−out switches.  
7 − Loosen clamps at vent elbow. Disconnect condensate  
drain tubing from flue collar. and remove the vent el-  
bow.  
At the beginning of each heating season, system should be  
checked as follows by a qualified service technician:  
Blower  
8 − Remove four burner box screws at the vestibule panel  
and remove burner box. Set burner box assembly  
aside.  
Check the blower wheel for debris and clean if necessary.  
The blower motors are prelubricated for extended bearing  
life. No further lubrication is needed.  
NOTE − If necessary, clean burners at this time. Follow  
procedures outlined in Burner Cleaning section.  
9 − Mark and disconnect all combustion air pressure tub-  
ing from cold end header collector box.  
WARNING  
10 − Mark and remove wires from pressure switches. Re-  
move pressure switches. Keep tubing attached to  
pressure switches.  
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 inju-  
ry or death.  
11 − Disconnect the plug from the combustion air inducer.  
Remove two screws which secure combustion air in-  
ducer to collector box. Remove combustion air induc-  
er assembly. Remove ground wire from vest panel.  
Filters  
All air filters are installed external to the unit. Filters should  
be inspected monthly. Clean or replace the filters when  
necessary to ensure proper furnace operation. Table 3  
lists recommended filter sizes.  
12 − Remove electrical junction box from the side of the fur-  
nace.  
13 − Mark and disconnect any remaining wiring to heating  
compartment components. Disengage strain relief  
bushing and pull wiring and bushing through the hole in  
the blower deck.  
Exhaust and air intake pipes  
Check the exhaust and air intake pipes and all connections  
for tightness and to make sure there is no blockage.  
14 − Remove the primary limit from the vestibule panel.  
15 − Remove two screws from the front cabinet flange at  
the blower deck. Spread cabinet sides slightly to allow  
clearance for removal of heat exchanger.  
NOTE − After any heavy snow, ice or frozen fog event the  
furnace vent pipes may become restricted. Always check  
the vent system and remove any snow or ice that may be  
obstructing the plastic intake or exhaust pipes.  
16 − Remove screws along vestibule sides and bottom  
which secure vestibule panel and heat exchanger as-  
sembly to cabinet. Remove two screws from blower  
rail which secure bottom heat exchanger flange. Re-  
move heat exchanger from furnace cabinet.  
Electrical  
1 − Check all wiring for loose connections.  
2 − Check for the correct voltage at the furnace (furnace  
operating).  
17 − Back wash heat exchanger with soapy water solution  
or steam. If steam is used it must be below 275°F  
(135°C) .  
3 − Check amp−draw on the blower motor.  
Motor Nameplate__________Actual__________  
Winterizing and Condensate Trap Care  
1 − Turn off power to the furnace.  
18 − Thoroughly rinse and drain the heat exchanger. Soap  
solutions can be corrosive. Take care to rinse entire  
assembly.  
2 − Have a shallow pan ready to empty condensate water.  
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19 − Reinstall heat exchanger into cabinet making sure that  
the clamshells of the heat exchanger assembly are  
resting on the support located at the rear of the cabi-  
net. Remove the indoor blower to view this area  
through the blower opening.  
38 − Follow lighting instructions to light and operate fur-  
nace for 5 minutes to ensure that heat exchanger is  
clean and dry and that furnace is operating properly.  
39 − Replace heating compartment access panel.  
Cleaning the Burner Assembly  
20 − Re-secure the supporting screws along the vestibule  
sides and bottom to the cabinet. Reinstall blower and  
mounting screws.  
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.  
21 − Reinstall cabinet screws on front flange at blower  
deck.  
4 − Disconnect the gas supply line from the gas valve. Re-  
move gas valve/manifold assembly.  
22 − Reinstall the primary limit on the vestibule panel.  
23 − Route heating component wiring through hole in blow-  
er deck and reinsert strain relief bushing.  
24 − Reinstall electrical junction box.  
5 − Mark and disconnect sensor wire from the sensor. Dis-  
connect 2-pin plug from the ignitor at the burner box.  
6 − Remove four screws which secure burner box assem-  
bly to vest panel. Remove burner box from the unit.  
25 − Reinstall the combustion air inducer. Reconnect the  
combustion air inducer to the wire harness.  
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 block-  
age caused by foreign matter. Remove any blockage.  
26 − Reinstall pressure switches and reconnect pressure  
switch wiring.  
27 − Carefully connect combustion air pressure switch  
hosing from pressure switches to proper stubs on  
cold end header collector box.  
8 − Reconnect the sensor wire and reconnect the 2−pin  
plug to the ignitor wiring harness.  
28 − Reinstall condensate trap.  
9 − Reinstall the burner box assembly using the existing  
four screws. Make sure that the burners line up in the  
center of the burner ports.  
29 − Reconnect exhaust piping and exhaust drain tubing.  
30 − Reinstall burner box assembly in vestibule area.  
31 − Reconnect flame roll−out switch wires.  
10 − Reinstall the gas valve manifold assembly. Reconnect  
the gas supply line to the gas valve. Reinstall the burn-  
er box cover.  
32 − Reconnect sensor wire and reconnect 2−pin plug from  
ignitor.  
33 − Secure burner box assembly to vestibule panel using  
four existing screws. Make sure burners line up in  
center of burner ports.  
11 − Reconnect 2−pin plug to gas valve.  
12 − Replace the blower compartment access panel.  
34 − Reinstall gas valve manifold assembly. Reconnect  
gas supply line to gas valve.  
13 − Refer to instruction on verifying gas and electrical con-  
nections when re−establishing supplies.  
35 − Reconnect 2 wires to gas valve.  
14 − Follow lighting instructions to light and operate fur-  
nace for 5 minutes to ensure that heat exchanger is  
clean and dry and that furnace is operating properly.  
36 − Replace the blower compartment access panel.  
37 − Refer to instruction on verifying gas and electrical con-  
nections when re−establishing supplies.  
15 − Replace heating compartment access panel.  
Page 43  
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Return air duct − Must be properly attached and provide  
Planned Service  
an air seal to the unit.  
A service technician should check the following items dur-  
ing an annual inspection. Power to the unit must be shut off  
for safety.  
Operating performance − Unit must be observed during  
operation to monitor proper performance of the unit and the  
vent system.  
Fresh air grilles and louvers (on the unit and in the room  
where the furnace is installed) − Must be open and unob-  
structed to provide combustion air.  
Combustion gases − Flue products must be analyzed and  
compared to the unit specifications.  
Problems detected during the inspection may make it nec-  
essary to temporarily shut down the furnace until the items  
can be repaired or replaced.  
Burners − Must be inspected for rust, dirt, or signs of water.  
Vent pipe − Must be inspected for signs of water, cracked,  
damaged or sagging pipe, or disconnected joints.  
Instruct the homeowners to pay attention to their  
furnace. Situations can arise between annual furnace in-  
spections that may result in unsafe operation. For instance,  
items innocently stored next to the furnace may obstruct  
the combustion air supply. This could cause incomplete  
combustion and the production of carbon monoxide gas.  
Unit appearance − Must be inspected for rust, dirt, signs  
of water, burnt or damaged wires, or components.  
Blower access door − Must be properly in place and pro-  
vide a seal between the return air and the room where the  
furnace is installed.  
Ignition Control Board Diagnostic Codes  
DIAGNOSTIC CODES  
Make sure to Identify LED’S Correctly.  
LED #1 (Red)  
LED #2 (Green)  
DESCRIPTION  
SIMULTANEOUS  
SLOW FLASH  
SIMULTANEOUS  
SLOW FLASH  
Power on − Normal operation.  
Also signaled during cooling and continuous fan.  
SIMULTANEOUS  
FAST FLASH  
SIMULTANEOUS  
FAST FLASH  
Normal operation − signaled when heating demand initiated at thermostat.  
Primary limit switch open. Limit must close within 3 minutes or unit goes into 1  
hour Watchguard.  
SLOW FLASH  
OFF  
ON  
Pressure prove switch open.  
SLOW FLASH  
OR: Blocked inlet/exhaust vent;  
OR: Pressure switch closed prior to activation of combustion air inducer.  
ALTERNATING  
SLOW FLASH  
ALTERNATING  
SLOW FLASH  
Watchguard 1 hour −− burners failed to ignite or lost flame 5 times during single  
heating demand.  
SLOW FLASH  
ON  
OFF  
Flame sensed without gas valve energized.  
SLOW FLASH  
Rollout switch open. OR: 12-pin connector improperly attached.  
ON  
ON  
ON  
OFF  
Circuit board failure or control wired incorrectly.  
OFF  
ON  
FAST FLASH  
SLOW FLASH  
Main power polarity reversed. Switch line and neutral.  
SLOW FLASH  
FAST FLASH  
Low flame signal. Measures below 1.5 microamps. Replace flame sense rod.  
ALTERNATING  
FAST FLASH  
ALTERNATING  
FAST FLASH  
Improper main ground.  
OR: Line voltage below 90 volts.  
NOTE − Slow flash rate equals 1 Hz (one flash per second). Fast flash rate equals 3 Hz (three flashes per second).  
Minimum flame sense current = 0.5 microAmps.  
Page 44  
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Troubleshooting: Heating Sequence of Operation  
HEATING SEQUENCE OF OPERATION  
ABNORMAL HEATING MODE  
NORMAL HEATING MODE  
POWER ON  
GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.  
INDOOR BLOWER DELAY OFF.  
LED #1 ON  
NO  
CONTROL SELF−CHECK OKAY?  
LED #2 ON  
(RESET CONTROL BY TURNING MAIN POWER OFF.)  
YES  
NO  
POLARITY REVERSED.  
LED #1 −− FAST FLASH  
LED #2 −− SLOW FLASH  
IS POLARITY CORRECT?  
YES  
NO  
IMPROPER GROUND.  
LED #1 −− ALTERNATING FAST FLASH  
LED #2 −− ALTERNATING FAST FLASH  
IS THERE A PROPER GROUND?  
YES  
NO  
LEDs SIGNAL FAST ALTERNATING FLASH.  
CONTROL WILL NOT RESPOND TO A CALL FOR  
HEATING UNTIL VOLTAGE RISES ABOVE 95 VOLTS.  
IS VOLTAGE  
ABOVE 90 VOLTS?  
GAS VALVE OFF. COMBUSTION AIR INDUCER ON.  
INDOOR BLOWER ON.  
LED #1 −− ON. LED #2 −− SLOW FLASH.  
YES  
NO  
ROLLOUT SWITCH CLOSED?  
SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES  
AND POWER IS RESET OR T’STAT IS INTERRUPTED  
FOR MINIMUM OF 1 SECOND.  
YES  
GAS VALVE OFF. COMBUSTION AIR INDUCER ON.  
INDOOR BLOWER ON HEATING SPEED.  
LED #1 −− SLOW FLASH  
NO  
BURNER OFF?  
(Flame sensed without gas valve energized)  
LED #2 −− OFF  
YES  
NO  
NORMAL OPERATION:  
LED #1 −− SLOW FLASH  
LED #2 −− SLOW FLASH  
YES  
COMBUSTION AIR INDUCER OFF.  
INDOOR BLOWER ON  
LED #1 SLOW FLASH RATE  
LED #2 −− ON  
THERMOSTAT CALLS FOR HEAT:  
LED #1 −− FAST FLASH  
LED #2 −− FAST FLASH  
NO  
YES  
PRIMARY LIMIT SWITCH. CLOSED?  
GAS VALVE OFF.  
COMBUSTION AIR INDUCER OFF.  
YES  
INDOOR BLOWER OFF WITH DELAY.  
LED #1 OFF  
LED #2 SLOW FLASH  
NO  
IS COMBUSTION AIR  
PRESSURE SWITCH OPEN?  
(Sequence holds until pressure switch  
opens or thermostat resets control.)  
YES  
IS COMBUSTION AIR INDUCER  
ENERGIZED?  
YES  
PRESSURE SWITCH IS IN WATCHGUARD MODE.  
GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.  
INDOOR BLOWER OFF WITH DELAY.  
YES  
NO  
HAS COMBUSTION AIR PRESSURE  
SWITCH CLOSED IN 2.5 MINUTES?  
LED #1 −− OFF. LED #2 −− SLOW FLASH.  
IS 5-MINUTE RESET PERIOD COMPLETE?  
YES  
CONTINUED NEXT PAGE  
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Troubleshooting: Heating Sequence of Operation (Continued)  
HEATING SEQUENCE CONTINUED  
NORMAL HEATING MODE  
ABNORMAL HEATING MODE  
15-SECOND COMBUSTION AIR INDUCER PREPURGE  
INITIATED BY CLOSED PRESSURE SWITCH.  
LEDS SIGNAL  
ALTERNATING  
YES  
NO  
NO  
FAST FLASH UNTIL  
VOLTAGE IS ABOVE  
95 VOLTS, THEN  
RESTARTS HEATING  
SEQUENCE.  
IS VOLTAGE ABOVE 90 VOLTS?  
IGNITOR WARM-UP −− 20 SECONDS.  
YES  
YES  
4-SECOND TRIAL FOR IGNITION.  
GAS VALVE OPENS. IGNITOR ENERGIZED FOR  
FIRST 3 SECONDS OF THE TRIAL.  
GAS VALVE OFF. COMBUSTION AIR INDUCER ON.  
INDOOR BLOWER OFF.  
HAS CONTROL FAILED TO SENSE FLAME FOR  
FIVE CONSECUTIVE TRIES DURING A SINGLE  
HEAT DEMAND?  
YES  
NO  
NO  
FLAME STABILIZATION PERIOD.  
4 SECONDS  
YES  
FLAME RECTIFICATION CURRENT  
CHECK. CAN FLAME BE PROVEN WITHIN  
4 SECONDS AFTER GAS VALVE OPENS?  
(0.5 microamps)  
WATCHGUARD MODE. GAS VALVE OFF.  
COMBUSTION AIR INDUCER OFF.  
INDOOR BLOWER OFF WITH DELAY  
LEDs SIGNAL WATCHGUARD FAILURE CODE.  
IS 60-MINUTE RESET PERIOD COMPLETE?  
YES  
YES  
NO  
NO  
YES  
HAS CONTROL RESET IGNITION  
SEQUENCE FOUR TIMES?  
FLAME PRESENT?  
YES  
LIMIT SWITCH WATCHGUARD  
MODE. GAS VALVE, COMB. AIR  
INDUCER AND INDOOR BLOW-  
ER OFF. LEDs SIGNAL LIMIT  
SWITCH OPEN UNTIL MAIN  
POWER IS  
LOW FLAME SIGNAL  
(Does not affect operation of control)  
LED #1 −− SLOW FLASH  
NO  
FLAME SIGNAL 1.5 MICROAMPS OR GREATER?  
YES  
LED #2 −− FAST FLASH  
INDOOR BLOWER ON  
AFTER 30−SECOND DELAY  
INTERRUPTED OR  
T’STAT IS CYCLED  
GAS VALVE DE−ENERGIZED.  
COMBUSTION AIR INDUCER DE−ENERGIZED.  
YES  
OFF/ON FOR 1 SEC.  
MINIMUM. 60−MINUTE  
WATCHGUARD PE-  
RIOD STARTS AT  
TIME LIMIT CLOSES.  
IS 60−MIN. PERIOD  
COMPLETE?  
INDOOR BLOWER ON UNTIL SWITCH CLOSES.  
LED #1 −− SLOW FLASH. LED #2 −− ON.  
IS LIMIT SWITCH CLOSED?  
NO  
PRIMARY AND SECONDARY LIMIT  
SWITCHES CLOSED?  
YES  
YES  
HAS PRIMARY LIMIT RESET  
TIME EXCEEDED 3 MINUTES?  
YES  
NO  
GAS VALVE POWER OFF.  
NO  
COMBUSTION AIR INDUCER POWER ON.  
INDOOR BLOWER ON  
LED #1 −− ON. LED #2 −− SLOW FLASH.  
ROLLOUT SWITCH CLOSED?  
YES  
SEQUENCE HOLDS UNTIL ROLLOUT SWITCH IS RESET  
AND MAIN POWER IS INTERRUPTED OR  
THERMOSTAT IS CYCLED OFF/ON FOR 1 SEC. MINIMUM.  
NO  
COMBUSTION AIR PRESSURE  
SWITCH CLOSED?  
YES  
GAS VALVE DE−ENERGIZED.  
COMBUSTION AIR INDUCER ON.  
INDOOR BLOWER OFF WITH DELAY  
LED #1 −− OFF. LED #2 −− SLOW FLASH.  
HAS CAB SWITCH CLOSED IN 2.5 MINUTES?  
YES  
THERMOSTAT DEMAND SATISFIED.  
YES  
LED #1 & #2 SIMULTANEOUS SLOW FLASHES.  
NO  
YES  
5-MINUTE PRESSURE SWITCH  
WATCHGUARD MODE.  
COMB. AIR INDUCER CONTINUES 5-SECOND  
POST PURGE AFTER T’STAT DEMAND IS SATISFIED.  
INDOOR AIR BLOWER COMPLETES SELECTED ꢂOFF"  
DELAY BEFORE SHUTTING OFF.  
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Troubleshooting: Cooling Sequence of Operation  
COOLING SEQUENCE OF OPERATION  
NORMAL COOLING MODE  
ABNORMAL COOLING MODE  
POWER ON  
IGNITION CONTROL MAIN POWER ON.  
GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.  
INDOOR BLOWER OFF WITH NORMAL DELAY.  
SIGNAL CIRCUIT BOARD FAILURE AT LED.  
NO  
CONTROL SELF DIAGNOSTIC CHECK.  
IS CONTROL OPERATING NORMALLY?  
INTERRUPT MAIN POWER TO RESET CONTROL.  
YES  
NO  
SIGNAL IMPROPER GROUND AT LED.  
CONTROL WILL CONTINUE TO CALL FOR COOLING  
IN THIS CONDITION.  
IS THERE A PROPER GROUND?  
YES  
SIGNAL POLARITY REVERSED AT LED. CONTROL  
WILL CONTINUE TO CALL FOR COOLING IN THIS  
CONDITION.  
NO  
IS POLARITY CORRECT?  
YES  
NO  
LED SIGNALS LOW VOLTAGE. CONTROL WILL  
CONTINUE TO CALL FOR COOLING  
IN THIS CONDITION.  
IS VOLTAGE  
ABOVE 90 VOLTS?  
YES  
GAS VALVE OFF. COMBUSTION AIR INDUCER ON.  
INDOOR BLOWER ON.  
NO  
ROLLOUT SWITCH MONITORED CONTINUOUSLY.  
IS ROLLOUT SWITCH CLOSED?  
SIGNAL ROLL-OUT SWITCH OPEN AT LED.  
SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES  
AND MAIN POWER IS INTERRUPTED OR THERMOSTAT  
IS CYCLED OFF/ON FOR 1 SEC. MINIMUM.  
YES  
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. ENERGIZED.  
THERMOSTAT OPENS.  
COMPRESSOR OFF.  
SYSTEM FAN AND EAC TERM. OFF  
WITH 45-SECOND DELAY.  
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Troubleshooting: Continuous Fan Sequence of Operation  
CONTINUOUS HEAT SPEED FAN SEQUENCE OF OPERATION  
LED: SLOW FLASH RATE REMAINS  
UNCHANGED THROUGHOUT SEQUENCE.  
MANUAL FAN SELECTION MADE AT THERMOSTAT.  
CONTROL (G) ENERGIZES SYSTEM FAN AT HEAT  
SPEED. EAC TERMINAL IS ENERGIZED.  
HUM TERM. ENERGIZES  
WITH COMB. AIR INDUCER.  
THERMOSTAT CALLS FOR HEAT (W).  
YES  
NO  
SYSTEM FAN REMAINS ON  
HEATING SPEED.  
THERMOSTAT CALLS FOR COOLING.  
YES  
NO  
SYSTEM FAN SWITCHED TO COOL SPEED.  
EAC TERM. REMAINS ON.  
THERMOSTAT OPENS.  
HUM TERM. DE−ENERGIZES  
WITH COMB. AIR INDUCER  
THERMOSTAT OPENS.  
MANUAL FAN SELECTION MADE AT THERMOSTAT.  
CONTROL (G) ENERGIZES SYSTEM FAN AT HEAT  
SPEED. EAC TERM. ENERGIZED.  
SYSTEM FAN REMAINS ON  
HEATING SPEED.  
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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: ML193DF04536B. All service must be performed by a licensed pro-  
fessional installer (or equivalent), service agency, or gas supplier.  
Cabinet Parts  
Upper access panel  
Heating Parts  
Flame Sensor  
Blower access panel  
Top Cap  
Heat exchanger assembly  
Gas manifold  
Control Panel Parts  
Transformer  
Combustion air inducer  
Gas valve  
Integrated control board  
Door interlock switch  
Blower Parts  
Main burner cluster  
Main burner orifices  
Pressure switch  
Blower wheel  
Ignitor  
Motor  
Primary limit control  
Flame rollout switches  
Motor mounting frame  
Motor capacitor  
Blower housing cutoff plate  
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Start−Up & Performance Check List  
UNIT SET UP  
Furnace:  
Model Number_______________  
Serial Number_________________  
SUPPLY  
AIR  
Line Voltage  
2
4
1
GAS SUPPLY  
Natural Gas  
LP Propane Gas  
3
Piping Connections Tight  
Leak Tested  
Flter  
RETURN AIR  
2
Supply Line Pressure ꢀW.C.________  
1
Gas Supply Pressure  
DUCT SYSTEM  
3
1
SUPPLY AIR DUCT  
Sealed  
Insulated (if necessary)  
RETURN DUCT  
Sealed  
2
INTAKE / EXHAUST PIPE  
All Joints Primed and Glued  
Filter Installed and Clean  
Terminations Installed Properly  
Grilles Unobstructed  
Horizontal Pipes Sloped (if applicable)  
Condensate Trap Primed / Line Sloped  
VOLTAGE CHECK  
4
Supply Voltage _____  
Electrical Connections Tight  
Pipes Supported  
Heat Cable Installed and Operable (if applicable)  
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UNIT OPERATION  
HEATING MODE  
COOLING MODE  
GAS MANIFOLD PRESSURE ꢀW.C._____  
1
2
INDOOR BLOWER AMPS______  
3
4
COMBUSTION SAMPLE CO % CO PPM_______  
2 ______  
TEMPERATURE DROP  
Return Duct Temperature _________  
_
INDOOR BLOWER AMPS______  
TEMPERATURE RISE  
3
4
Supply Duct Temperature _______  
Temperature Drop = _________  
5
TOTAL EXTERNAL STATIC (dry coil)  
Supply External Static _______  
Supply Duct Temperature ________  
_
Return Duct Temperature  
_____  
Return External Static + ______  
Total External Static = _______  
Temperature Rise = ________  
TOTAL EXTERNAL STATIC  
5
8
DRAIN LINE  
Leak Free  
Supply External Static _______  
Return External Static + ______  
Total External Static = _______  
THERMOSTAT  
6
7
9
CONDENSATE LINE  
Leak Free  
Adjusted and Programmed  
Explained Operation to Owner  
VENT PIPE  
Leak Free  
Combustion CO  
2
2
7
SUPPLY  
AIR  
Thermostat  
Temperatures  
8
Gas Manifold Pressure  
9
4
1
Blower Motor Amps  
6
3
Duct Static  
5
RETURN AIR  
Contractor’s: Name_________________________Telephone_____________Checklist Completed____________________  
Job Address_____−________________________________Technician’s Name___________________________________  
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Requirements for Commonwealth of Massachusetts  
Modifications to NFPA−54, Chapter 10  
4 − INSPECTION. The state or local gas inspector of the  
side wall, horizontally vented, gas−fueled equipment  
shall not approve the installation unless, upon inspec-  
tion, the inspector observes carbon monoxide detec-  
tors and signage installed in accordance with the pro-  
visions of 248 CMR 5.08(2)(a) 1 through 4.  
Revise NFPA−54 section 10.8.3 to add the following re-  
quirements:  
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:  
EXEMPTIONS: The following equipment is exempt  
from 24 CMR 5.08(2)(a) 1 through 4:  
1 − The equipment listed in Chapter 10 entitled ꢂEquip-  
ment 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, gas−  
fueled equipment installed in a room or structure sepa-  
rate from the dwelling, building or structure used in  
whole or in part for residential purposes.  
1 − INSTALLATION OF CARBON MONOXIDE DETEC-  
TORS. At the time of installation of the side wall, hori-  
zontally 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−oper-  
ated or hard−wired carbon monoxide detector with an  
alarm is installed on each additional level of the dwell-  
ing, building or structure served by the side wall, hori-  
zontally vented, gas−fueled equipment. It shall be the  
responsibility of the property owner to secure the ser-  
vices of qualified licensed professionals for the instal-  
lation of hard−wired carbon monoxide detectors.  
MANUFACTURER REQUIREMENTS −  
GAS EQUIPMENT VENTING SYSTEM PROVIDED.  
When the manufacturer of Product Approved side wall,  
horizontally vented, gas−fueled equipment provides a vent-  
ing 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  
a − In the event that the side wall, horizontally vented,  
gas−fueled equipment is installed in a crawl space  
or an attic, the hard−wired carbon monoxide detec-  
tor with alarm and battery back−up may be installed  
on the next adjacent floor level.  
2 − A complete parts list for the venting system design or  
venting system.  
MANUFACTURER REQUIREMENTS −  
GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED.  
b − In the event that the requirements of this subdivi-  
sion 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 detec-  
tor with an alarm shall be installed.  
When the manufacturer of Product Approved side wall,  
horizontally vented, gas−fueled equipment does not pro-  
vide the parts for venting the flue gases, but identifies ꢂspe-  
cial venting systems," the following requirements shall be  
satisfied by the manufacturer:  
2 − APPROVED CARBON MONOXIDE DETECTORS.  
Each carbon monoxide detector as required in accor-  
dance with the above provisions shall comply with  
NFPA 720 and be ANSI/UL 2034 listed and IAS certi-  
fied.  
1 − The referenced ꢂspecial venting system" instructions  
shall be included with the appliance or equipment  
installation instructions; and  
2
The ꢂspecial venting systems" shall be Product Ap-  
proved by the Board, and the instructions for that sys-  
tem shall include a parts list and detailed installation  
instructions.  
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 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 (1/2) inch in size, ꢂGAS VENT DIRECT-  
LY BELOW. KEEP CLEAR OF ALL OBSTRUC-  
TIONS."  
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 instruc-  
tions shall remain with the appliance or equipment at  
the completion of the installation.  
Page 52  
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