Page 2 - FRONT VIEW
Page 2 ML193DF Unit Dimensions − inches (mm) AIR EXHAUST AIR OUTLET COMBUSTION AIR INTAKE FLOW 2 − 1/16 (52) GAS PIPING INLET (Either Side) ELECTRICAL INLET (Either Side) RETURN AIR OPENING FRONT VIEW SIDE VIEW TOP VIEW A B C 3/4 (19) 27 − 3/4 19 − 1/4 (489) 9 − 1/8 (232) Right 6 − 9/16 (167) Left 2...
Page 3 - ML193DF Parts Arrangement; FIGURE 1
Page 3 ML193DF Parts Arrangement FIGURE 1 CONTROL BOX (Includes integrated control, transformer and door switch) BAG ASSEMBLY BLOWER MOTOR (hidden) BLOWER ACCESS PANEL BURNER ACCESS PANEL COMBUSTIONAIR INDUCER BURNER BOX ASSEMBLY (includes sensor, rollout switches and ignitor) GAS VALVE BLOWER DECK ...
Page 4 - Shipping and Packing List; Package 1 of 1 contains; DANGER; Safety Information; WARNING; Building Codes
Page 4 ML193DF Gas Furnace The ML193DF Category IV gas furnace is shipped readyfor 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. The ML193DF can ...
Page 5 - Heating Unit Installed Parallell to Air Handler Unit; NOTE; Use of Furnace as Construction Heater
Page 5 NOTE − Furnace must be adjusted to obtain a temperature rise within the range specified on the unit nameplate. Failureto do so may cause erratic limit operation and premature heatexchanger failure. This ML193DF furnace must be installed so that its electri-cal components are protected from wa...
Page 6 - General; Product contains fiberglass wool.; In Canada, refer to the CSA B149 installation codes.; CAUTION
Page 6 General These instructions are intended as a general guide and donot supersede local codes in any way. Consult authoritieshaving jurisdiction before installation.In addition to the requirements outlined previously, the fol-lowing general recommendations must be consideredwhen installing a ML1...
Page 7 - Air from Outside
Page 7 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 allfuel−burning appliances and appliances such as exhaust...
Page 8 - FIGURE 5; equipment in the enclosure. See; FIGURE 7; Shipping Bolt Removal
Page 8 FIGURE 5 EQUIPMENT IN CONFINED SPACE − ALL AIR FROM OUTSIDE (Inlet Air from Crawl Space and Outlet Air to Ventilated Attic) NOTE −The inlet and outlet air openings shall each have a free area of at least one square inch per 4,000 Btu (645mm 2 per 1.17kW) per hour of the total input rating of ...
Page 9 - Installation − Setting Equipment; The unit must be level from side to side. Unit may
Page 9 FIGURE 8 RIGID LEG remove shipping bolt and washer ML193DF09048C BLOWER MOTOR Installation − Setting Equipment WARNING Do not install the furnace on its front, back or in thehorizontal position. See figure 10. Do not connect thereturn air ducts to the back of the furnace. Doing sowill adverse...
Page 10 - Do not drag the unit across the floor in the; Downflow Application Installation Clearances; Installation on Non−Combustible Flooring Figure 12; Installation on Combustible Flooring Figure 13
Page 10 WARNING Improper installation of the furnace can result in per-sonal injury or death. Combustion and flue productsmust never be allowed to enter the return air systemor air in the living space. Use sheet metal screws andjoint tape to seal return air system to furnace.In platform installation...
Page 12 - Filters; TABLE 3; Furnace; Duct System; Pipe & Fittings Specifications; TABLE 4
Page 12 Filters This unit is not equipped with a filter or rack. A field−pro-vided filter is required for the unit to operate properly. Table3 lists recommended filter size.A filter must be in place whenever the unit is operating. TABLE 3 Furnace Cabinet Width Filter Size 16 x 25 x 1 (1) 17−1/2"...
Page 13 - IMPORTANT; Canadian Applications Only
Page 13 IMPORTANT ML193DF exhaust and intake connections are madeof PVC. Use PVC primer and solvent cement whenusing PVC vent pipe. When using ABS vent pipe, usetransitional solvent cement to make connections tothe PVC fittings in the unit. Use PVC primer and solvent cement or ABS solvent cementmeet...
Page 14 - Joint Cementing Procedure; Venting Practices; Piping Suspension Guidelines; Wall Thickness Guidelines
Page 14 Joint Cementing Procedure All cementing of joints should be done according to thespecifications outlined in ASTM D 2855. NOTE − A sheet metal screw may be used to secure the intake pipe to the connector, if desired. Use a drillor self tapping screw to make a pilot hole. DANGER DANGER OF EXPL...
Page 15 - Vent Piping Guidelines
Page 15 2 − When furnace is installed in a residence where unit is shut down for an extended period of time, such as avacation home, make provisions for draining conden-sate collection trap and lines. Exhaust Piping (Figures 20 and 21) Route piping to outside of structure. Continue with installa-tio...
Page 17 - Pipe size determined in table 7.; TOP VIEW; TOP VIEW
Page 17 FIGURE 20 TYPICAL EXHAUST PIPE CONNECTIONS TRANSITION 2” 2” 2” 3” Pipe size determined in table 7. 2” 2” or DO NOT transition from smaller to larger pipe size in horizontal runs of exhaust pipe. TOP VIEW EXHAUST INTAKE * When transitioning up in pipe size, use the shortest length of 2” PVC p...
Page 18 - TYPICAL AIR INTAKE PIPE CONNECTIONS; NON
Page 18 Intake Piping 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 furnacefrom the surrounding space, the indoor air quality must beconsidered. Guidelines listed in Combustion, Dilu...
Page 21 - EXHAUST PIPE TERMINATION SIZE REDUCTION
Page 21 Details of Intake and Exhaust Piping Terminations forDirect Vent Installations NOTE − In Direct Vent installations, combustion air is tak- en from outdoors and flue gases are discharged to out-doors. NOTE − Flue gas may be slightly acidic and may adversely affect some building materials. If ...
Page 25 - WALL TERMINATION KITS (CLOSE
Page 25 FIGURE 35 ÉÉÉÉÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉÉÉÉÉ 12” (305 mm) Minimum Above Grade or Average Snow Accumulation 1/2” (13 mm) FOAM INSULATION (Field Furnished) 5” (127 mm) 5 − 1/2” (140 mm) EXHAUST AIR INTAKE AIR GRADE 12” (305 mm) INTAKE AIR EXHAUST AIR GRADE 12” (305 mm) Max. fo...
Page 26 - − Exhaust piping must terminate straight out or up as; − If exhaust piping must be run up a side wall to position
Page 26 ML193DF DIRECT VENT APPLICATION USING EXISTING CHIMNEY 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 pipinginside chimney until the pipe open end is above top of chimney an...
Page 27 - ML193DF NON−DIRECT VENT APPLICATION; Condensate Piping; CONDENSATE TRAP AND PLUG LOCATIONS
Page 27 FIGURE 40 12" (305mm) ABOVE GRADE OR AVERAGE SNOW ACCUMULATION UNCONDITIONED SPACE 1/2" (13mm) FOAM INSULATION 1/2" (13mm) FOAM INSULATION IN UNCONDITIONED SPACE *WALL SUPPORT OUTSIDE WALL SIZE TER-MINATION PIPE PER TABLE 8. FIELD−PROVIDED REDUCER MAY BE REQUIRED TO ADAPT LARGER ...
Page 28 - − If unit will be started immediately upon completion of; CONDENSATE TRAP LOCATION; to drain; ML193DF with Evaporator Coil; Do
Page 28 5 − If unit will be started immediately upon completion of installation, prime trap per procedure outlined in UnitStart−Up section.Condensate line must slope downward away from thetrap to drain. If drain level is above condensate trap,condensate pump must be used. Condensate drainline should...
Page 30 - Gas Piping; Leak Check; FIRE OR EXPLOSION HAZARD
Page 30 Gas Piping CAUTION If a flexible gas connector is required or allowed bythe authority that has jurisdiction, black iron pipeshall be installed at the gas valve and extend outsidethe furnace cabinet. The flexible connector can thenbe added between the black iron pipe and the gassupply line. W...
Page 31 - GAS PIPE CAPACITY − FT
Page 31 GROUND JOINT UNION AUTOMATIC GAS VALVE (with manual shut−off valve) FIELD PROVIDED AND INSTALLED GROUND JOINT UNION Left Side Piping (Standard) Right Side Piping (Alternate) AUTOMATIC GAS VALVE (with manual shut−off valve) DRIP LEG DRIP LEG MANUAL MAIN SHUT−OFF VALVE (With 1/8 in. NPT Plugge...
Page 32 - Electrical; Precautions and Procedures; outside
Page 32 Removal of the Furnace from Common Vent In the event that an existing furnace is removed from aventing system commonly run with separate gas ap-pliances, the venting system is likely to be too large toproperly vent the remaining attached appliances. Conduct the following test while each appl...
Page 34 - Indoor Blower Speeds
Page 34 Thermostat Furnace Condensing Unit ML193DF and CONDENSING UNIT THERMOSTAT DESIGNATIONS (Refer to specific thermostat and outdoor unit.) COMMON POWER HEAT INDOOR BLOWER Y C R G W1 Y C R G W COOLING FIGURE 50 CONDENSING UNIT CONDENSING UNIT COMMON *CONDENSING UNIT *NOTE − R" REQUIRED ON SO...
Page 35 - TYPICAL ML193DF WIRING DIAGRAM
Page 36 - INTEGRATED CONTROL; TERMINAL DESIGNATIONS; Unit Start−Up; FOR YOUR SAFETY READ BEFORE OPERATING; BEFORE LIGHTING
Page 36 FIGURE 53 INTEGRATED CONTROL (Automatic Hot Surface Ignition System) TERMINAL DESIGNATIONS HUMLINEXFMREACCOOLHEATPARKFLAMENEUTRALS Humidifier (120VAC)Input (120VAC)Transformer (120VAC)Electronic Air Cleaner (120VAC)Blower − Cooling Speed (120VAC)Blower − Heating Speed (120VAC)Dead terminals ...
Page 38 - Gas Pressure Adjustment; Fuel; Manifold; All sizes; Proper Combustion; High Altitude Information
Page 38 Gas Pressure Adjustment Gas Flow (Approximate) TABLE 11 GAS METER CLOCKING CHART ML193 Unit Seconds for One Revolution Natural LP 1 cu ft Dial 2 cu ft Dial 1 cu ft Dial 2 cu ft DIAL −045 80 160 200 400 −070 55 110 136 272 −090 41 82 102 204 −110 33 66 82 164 Natural−1000 btu/cu ft LP−2500 bt...
Page 39 - CARBON MONOXIDE POISONING HAZARD!
Page 39 TABLE 14 Conversion Kit and Pressure Switch Requirements at Varying Altitudes ML193 Unit Natural to LP/Propane High Altitude Natural Burner Orifice Kit LP/Propane to Natural High Altitude LP/Propane Burner Orifice Kit High Altitude Pressure Switch 0 − 7500 ft (0 − 2286m) 7501 − 10,000 ft (22...
Page 40 - Other Unit Adjustments
Page 40 Other Unit Adjustments NOTE − See troubleshooting flow charts if any safety switches are found to be open. Primary Limit The primary limit is located on the heating compartmentvestibule panel. This limit is factory set and requires no ad-justment. Flame Rollout Switches (Two) These manually ...
Page 41 - BLOWER DATA
Page 41 BLOWER DATA ML193DF070P36B PERFORMANCE (Less Filter) External Static Pressure in. w.g. Air Volume / Watts at Various Blower Speeds High Medium- High Medium- Low Low cfm Watts cfm Watts cfm Watts cfm Watts 0.00 1505 660 1310 570 1090 455 940 390 0.10 1480 625 1295 550 1070 435 935 365 0.20 14...
Page 42 - Service
Page 42 Service WARNING ELECTRICAL SHOCK, FIRE, OR EXPLOSION HAZARD. Failure to follow safety warnings exactly could resultin dangerous operation, serious injury, death orproperty damage.Improper servicing could result in dangerous opera-tion, serious injury, death, or property damage.Before servici...
Page 44 - DIAGNOSTIC CODES
Page 44 Planned Service A service technician should check the following items dur-ing an annual inspection. Power to the unit must be shut offfor safety. 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 ...
Page 45 - Troubleshooting: Heating Sequence of Operation; HEATING SEQUENCE OF OPERATION; NORMAL HEATING MODE; (Flame sensed without gas valve energized)
Page 45 Troubleshooting: Heating Sequence of Operation HEATING SEQUENCE OF OPERATION NORMAL HEATING MODE ABNORMAL HEATING MODE CONTROL SELF−CHECK OKAY? BURNER OFF? (Flame sensed without gas valve energized) NORMAL OPERATION: LED #1 −− SLOW FLASHLED #2 −− SLOW FLASH NO YES YES GAS VALVE OFF. COMBUSTI...
Page 46 - HEATING SEQUENCE CONTINUED
Page 46 Troubleshooting: Heating Sequence of Operation (Continued) HEATING SEQUENCE CONTINUED NORMAL HEATING MODE ABNORMAL HEATING MODE FLAME RECTIFICATION CURRENT CHECK. CAN FLAME BE PROVEN WITHIN 4 SECONDS AFTER GAS VALVE OPENS? (0.5 microamps) FLAME PRESENT? INDOOR BLOWER ON AFTER 30−SECOND DELAY...
Page 47 - Troubleshooting: Cooling Sequence of Operation; COOLING SEQUENCE OF OPERATION; NORMAL COOLING MODE
Page 47 Troubleshooting: Cooling Sequence of Operation COOLING SEQUENCE OF OPERATION NORMAL COOLING MODE ABNORMAL COOLING MODE IGNITION CONTROL MAIN POWER ON. CONTROL SELF DIAGNOSTIC CHECK. IS CONTROL OPERATING NORMALLY? YES SIGNAL POLARITY REVERSED AT LED. CONTROL WILL CONTINUE TO CALL FOR COOLING ...
Page 48 - Troubleshooting: Continuous Fan Sequence of Operation; CONTINUOUS HEAT SPEED FAN SEQUENCE OF OPERATION
Page 48 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. THERMOSTAT CAL...
Page 49 - Repair Parts List; All service must be performed by a licensed pro-
Page 49 Repair Parts List The following repair parts are available through Lennox dealers. When ordering parts, include the complete furnace modelnumber listed on the CSA nameplate −− Example: ML193DF04536B. All service must be performed by a licensed pro- fessional installer (or equivalent), servic...
Page 50 - Start−Up & Performance Check List; Gas Supply Pressure; Line Voltage; Flter
Page 50 Start−Up & Performance Check List Gas Supply Pressure SUPPLY AIR Line Voltage GAS SUPPLY Natural Gas LP Propane Gas Piping Connections Tight Leak Tested Supply Line Pressure W.C.________ 1 INTAKE / EXHAUST PIPE All Joints Primed and Glued Terminations Installed Properly Pipes Supported C...
Page 51 - Combustion CO; UNIT OPERATION
Page 51 Contractor’s: Name_________________________Telephone_____________Checklist Completed____________________ Job Address_____−________________________________Technician’s Name___________________________________ 1 HEATING MODE GAS MANIFOLD PRESSURE W.C._____ COMBUSTION SAMPLE CO 2 % ______ CO PPM...
Page 52 - Requirements for Commonwealth of Massachusetts; Modifications to NFPA−54, Chapter 10
Page 52 Requirements for Commonwealth of Massachusetts Modifications to NFPA−54, Chapter 10 Revise NFPA−54 section 10.8.3 to add the following re-quirements: For all side wall, horizontally vented, gas−fueled equipmentinstalled in every dwelling, building or structure used inwhole or in part for res...
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