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Lennox Merit ML193UH

Lennox Merit ML193UH
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Page 1
08/12
*2P0812*
507010−01
*P507010-01*
E 2012 Lennox Industries Inc.
Dallas, Texas, USA
AIR FLOW
UPFLOW
AIR FLOW
AIR FLOW
HORIZONTAL RIGHT
HORIZONTAL LEFT
INSTALLATION
INSTRUCTIONS
ML193UH
MERIT
®
SERIES GAS FURNACE
UPFLOW / HORIZONTAL AIR DISCHARGE
507010−01
08/2012
Supersedes 06/2012
THIS MANUAL MUST BE LEFT WITH THE
HOMEOWNER FOR FUTURE REFERENCE
This is a safety alert symbol and should never be ignored.
When you see this symbol on labels or in manuals, be alert
to the potential for personal injury or death.
CAUTION
As with any mechanical equipment, personal injury
can result from contact with sharp sheet metal
edges. Be careful when you handle this equipment.
WARNING
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, person-
al injury or loss of life. Installation and service must
be performed by a licensed professional installer (or
equivalent), service agency or the gas supplier.
Table of Contents
Unit Dimensions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ML193UH Gas Furnace 3. . . . . . . . . . . . . . . . . . . . . . . . . .
Shipping and Packing List 3. . . . . . . . . . . . . . . . . . . . . . . .
Safety Information 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Use of Furnace as a Construction Heater 4. . . . . . . . . . .
General 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Combustion, Dilution, Ventilation Air 5. . . . . . . . . . . . . . . .
Setting Equipment 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filters 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duct System 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pipe and Fittings Specifications 13. . . . . . . . . . . . . . . . . . .
Joint Cementing Procedure 15. . . . . . . . . . . . . . . . . . . . . .
Venting Practices 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vent Piping Guidelines 17. . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Piping 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Integrated Control 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Start Up 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Pressure Measurement 43. . . . . . . . . . . . . . . . . . . . .
Proper Combustion 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Altitude 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Other Unit Adjustments 46. . . . . . . . . . . . . . . . . . . . . . . . . .
Twinning the ML193UH 47. . . . . . . . . . . . . . . . . . . . . . . . . .
Service 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Parts List 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start Up Checklist 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Litho U.S.A.
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Lennox Merit ML193UH Specifications

General IconGeneral
EfficiencyUp to 93% AFUE
Heating StagesSingle-stage
Blower MotorPSC
Gas ValveSingle-stage
Energy Star CertifiedNo
Fuel TypeNatural Gas or Propane
Cabinet TypeUpflow/Horizontal
Ignition TypeHot Surface Ignition
Heat ExchangerAluminized Steel
Heating Capacity44, 000-132, 000 BTU/h

Summary

INSTALLATION INSTRUCTIONS ML193 UH

ML193 UH Unit Dimensions

ML193 UH Gas Furnace Overview

Shipping and Packing List

Lists contents of the furnace package and optional items.

Safety Information

Crucial safety warnings and precautions for installation and operation.

Building Codes

Mentions conformance to local and national building codes for installation.

Installation Locations

Installed in Combination with a Cooling Coil

Guidance on installing the furnace with a cooling coil.

Use of Furnace as Construction Heater

Conditions and recommendations for using the furnace as a construction heater.

General Installation Practices

Combustion, Dilution & Ventilation Air

Guidelines for ensuring proper air supply for combustion and ventilation.

Unconfined Space Requirements

Confined Space Requirements

Details requirements for confined spaces and air intake.

Air Intake for Confined Spaces

Air from Outside

Details requirements for bringing outside air into a confined space.

Air from Inside

Details requirements for bringing inside air into a confined space.

Furnace Installation Setup

Shipping Bolt Removal

Instructions for removing shipping bolts from the blower motor.

Setting Equipment

Guidance on selecting a location and setting the furnace unit.

Equipment Setting Diagrams

Installation Clearances and Air Returns

Installation Clearances

Minimum required clearances for furnace installation from combustible materials.

Return Air Guidelines

How to properly connect the return air system to the furnace.

Return Air and Horizontal Installation

Optional Return Air Base

Information on installing an optional return air base for upflow applications.

Removing the Bottom Panel

Step-by-step guide to removing the furnace's bottom panel.

Horizontal Applications Notes

Notes regarding furnace installation in horizontal configurations.

Horizontal Installation Details

Horizontal Application Installation Clearances

Clearances required for horizontal furnace installations.

Suspended Installation of Horizontal Unit

Instructions for suspending the furnace in attics or crawlspaces.

Platform Installation of Horizontal Unit

Guidelines for installing the furnace on a platform.

Piping and Component Installation

Condensate Piping

Guidance on installing condensate piping, including trap and drain connections.

Filters

Information on required air filters and recommended sizes.

Duct System

Guidance on sizing and installing supply and return air duct systems.

Pipe & Fittings Specifications

Standards and materials for PVC/CPVC/ABS piping and cement.

Pipe & Fittings Specifications

Joint Cementing Procedure

Venting Practices and Support

Venting Practices

General guidelines and precautions for furnace venting installations.

Piping Suspension Guidelines

Recommendations for supporting vent piping.

Wall Thickness Guidelines

Guidelines for wall thickness when penetrating structures with vent piping.

Vent Piping Guidelines and Sizing

Vent Piping Guidelines

Sizing and installation rules for vent piping based on furnace capacity and termination type.

Piping Size Process

A step-by-step process to determine the correct vent pipe diameter.

Maximum Allowable Vent Lengths

Table 5: Maximum Allowable Intake or Exhaust Vent Lengths

Maximum vent pipe lengths based on termination, altitude, and elbows.

Table 6: Maximum Allowable Exhaust Vent Lengths

Maximum vent lengths for specific installation scenarios.

Typical Exhaust Pipe Connections

Typical Air Intake Pipe Connections

Intake Piping Installation

Vent Termination Guidelines

Maximum Uninsulated Vent Lengths

Vent Termination Clearances (Non-Direct Vent)

Vent Termination Clearances (Direct Vent)

Direct Vent Piping Terminations

Field Fabricated Wall Terminations

Exhaust Piping Run-Up

Direct Vent Termination Kits

Direct Vent Concentric Rooftop Termination

Installation details for concentric rooftop termination kits.

Direct Vent Wall Termination Kits

Diagrams and instructions for various direct vent wall termination kits.

Wall Termination Kits for Grade Clearance

Venting with Existing Chimneys

ML193 UH Direct Vent Application Using Existing Chimney

Specific instructions for using the furnace with an existing chimney.

Exhaust Piping Terminations for Non-Direct Vent

Instructions for routing and terminating exhaust pipes for non-direct vent systems.

Non-Direct Vent with Existing Chimney

Condensate Piping

Guidance on installing condensate piping, including trap and drain connections.

Condensate Trap Locations

Evaporator Coil Separate Drain

Instructions for draining condensate from a separate evaporator coil.

Combined Condensate Drains

Condensate Trap With Optional Overflow Switch

Details on installing a condensate trap with an overflow switch.

Evaporator Coil Common Drain

Instructions for combining furnace and evaporator coil condensate drains.

Condensate TrapDrain Assembly

Gas Piping Installation

Gas Piping Safety Warnings

Critical safety warnings and precautions for gas piping connections.

Leak Check Procedures

Procedures for checking gas piping connections for leaks.

Gas Piping Configurations

Left Side Piping (Standard)

Diagram and notes for standard left-side gas piping connections.

Right Side Piping (Alternate)

Diagram and notes for alternate right-side gas piping connections.

Horizontal Applications Gas Piping

Diagrams showing gas piping setups for horizontal installations.

Gas Pipe Capacity and Common Vent Removal

GAS PIPE CAPACITY Table

Table showing gas pipe capacity based on size and length.

Removal from Common Vent

Steps for safely removing a furnace from a common vent system.

Electrical Connections

ESD Precautions and Procedures

Safety measures to prevent electrostatic discharge damage to electronic components.

Thermostat Installation

Instructions for installing and connecting the room thermostat.

Indoor Blower Speeds

How the indoor blower speed operates in different modes.

Wiring Diagram and Generator Use

Typical ML193 UH Wiring Diagram

Complete wiring diagram for the ML193UH furnace unit.

Generator Use Voltage Requirements

Requirements for generator voltage and waveform when powering the furnace.

Integrated Control System

Integrated Control Overview

Overview of the integrated control board and its terminal designations.

Diagnostic Codes

Explains LED status codes for diagnosing control board issues.

Unit Start-Up Procedures

Unit Start-Up

Step-by-step instructions for safely starting up the furnace.

Gas Valve Operation

Procedures for operating the gas valve and safety checks.

Gas Pressure and Flow Checks

Gas Pressure Adjustment

How to adjust and measure gas pressure for optimal furnace operation.

Supply Pressure Measurement

Procedures for checking gas supply pressure at the unit.

Manifold Pressure Measurement

How to measure and compare manifold pressure to specifications.

Combustion and High Altitude

Proper Combustion Analysis

Guidelines for checking and ensuring proper combustion through CO2 analysis.

High Altitude Information

Adjustments and requirements for furnace operation at high altitudes.

Venting and Combustion Air Testing

Unit Adjustments and Checks

Other Unit Adjustments

Adjustments for fan control, primary limit, and other settings.

Electrical Checks

Checks for wiring, voltage, and amp-draw on furnace components.

Exhaust and Air Intake Pipe Checks

Inspection of vent pipes and connections for tightness and blockages.

Twinning Furnaces

Service Procedures

Blower Maintenance

Instructions for inspecting and cleaning the blower wheel.

Filter Maintenance

Recommendations for filter inspection, cleaning, and replacement.

Exhaust and Air Intake Pipe Inspection

Inspection of vent pipes and connections for tightness and blockages.

Repair Parts List

Start-Up & Performance Check List

Unit Operation Checklist

Massachusetts Installation Requirements

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