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Report MeC2r c XD 141-150 SW 2iver`Ix.P LENNOX (�l 'l 1J'�rFORMATION M L1 H E Corp 1911-L7 Service Literature ° 07/2020 V RFCEI ML196UHE SERIES UNITS APR 18 2022 CITY OF TIGARD ML196UHE series units are high-efficiency gas fur- r -- It ,_ I ION Arta. naces manufactured with Lennox DuralokPlus"" alumi- 1 , I , , , nized steel clamshell-type heat exchangers,with a stainless . ` 1 steel condensing coil. ML196UHE units are available in , heating input capacities of 30,000 to 135,000 Btuh and , =;, cooling applications from 1.5 through 5 tons. Refer to Engi- 'A -.1 neering Handbook for proper sizing. A Units are factory equipped for use with natural gas.A kit is available for conversion to LP/Propane operation. All ' ML196UHE units are equipped with a hot surface ignition zr J' system. The gas valve is redundant to assure safety st °4K shut-off as required by C.S.A. 7 The heat exchanger, bumers and manifold assembly can be removed for inspection and service. The maintenance section gives a detailed description on how this is done. - All specifications are subject to change. Procedures outlined in this manual are presented as a recommendation only I I' , 1111 I and do not supersede or replace local or state codes. \' !I, • « I J AWARNING Y.. Electric shock hazard. Can cause injury or death. Before attempting to perform any service or maintenance, turn thelir t•' electrical power to unit OFF at discon- nect switch(es). Unit may have multiple power supplies. Table of Contents AWARNING Specifications 2 Improper installation, adjustment, alteration, service or maintenance can cause property damage, person- Optional Accessories 3 al injury or loss of life. Installation and service must Blower Performance Data 4 be performed by a licensed professional HVAC I-Unit Components 7 in- staller(or equivalent), service agency or the gas sup- plier. II Placement and Installation 21 III-Start-Up 42 A CAU T I O N IV-Heating System Service Checks 43 V-Typical Operating Conditions 47 As with any mechanical equipment, contact with sharp sheet metal edges can result in personal in- VI-Maintenance 48 jury. Take care while handling this equipment and VII-Sequence of Operation and Flow Charts 51 wear gloves and protective clothing. ' lJ Technical ©2020 Lennox Industries Inc. Publications Page 1 Lino US A. SPECIFICATIONS _ Gas Model No. ML196UH ML196UH ML196UH ML196UH ML196UH Heating 030XE36B 045XE36B 070XE36B 070XE48B 090XE36C Performance 'AFUE 96% 96% 96% 96% 96% - Input-Btuh 30,000 44,000 66,000 66,000 88,000 Output-Btuh 29,000 42,800 63,900 63,900 85,600 Temperature rise range-°F 25-55 35-65 35-65 30-60 45-75 Gas Manifold Pressure(in.w.g.) 3.5/ 10 3.5/ 10 3.5/ 10 3.5/10 3.5/ 10 Nat.Gas/LPG/Propane High static-in.w.g. 0.5 0.5 0.5 0.5 0.5 Energy Star®Certified Yes Yes Yes Yes Yes Connections Intake/Exhaust Pipe(PVC) 2/2 2/2 2/2 2/2 2/2 in. Gas pipe size IPS 1/2 1/2 1/2 1/2 1/2 Condensate Drain Trap (PVC pipe)-i.d. 3/4 3/4 3/4 3/4 3/4 with furnished 90°street elbow 3/4 slip x 3/4 Mipt with field supplied(PVC coupling)-o.d. 3/4 slip x 3/4 MPT Indoor Wheel nom.dia.x width-in. 10 x 8 10 x 8 10 x 8 11-1/2 x 10 10 x 8 Blower Motor Type DC Brushless DC Brushless DC Brushless DC Brushless DC Brushless Motor output-hp 1/2 1/2 1/2 3/4 1/2 Tons of add-on cooling 1.5-3 1.5-3 1.5-3 2-4 1.5-3 Air Volume Range-cfm 175- 1435 520-1345 550-1380 500- 1710 460-1470 Electrical Data Voltage 120 volts-60 hertz-1 phase Blower motor full load amps 6.8 6.8 6.8 8.4 6.8 Maximum overcurrent protection 15 15 15 15 15 Shipping Data lbs.-1 package 120 124 129 XXX XXX NOTE-Filters and provisions for mounting are not furnished and must be field provided. 'Annual Fuel Utilization Efficiency based on DOE test procedures and according to FTC labeling regulations.Isolated combustion system rating for non-weatherized furnaces. SPECIFICATIONS Gas Model No. ML196UH ML196UH ML196UH ML196UH Heating 090XE48C 090XE60C 110XE60C 135XE60D Performance 'AFUE 96% 96% 96% 96% Input-Btuh 88,000 88,000 110,000 132,000 Output-Btuh 85,600 85,600 107,200 127,000 Temperature rise range-°F 50-80 35-65 45-75 45-75 Gas Manifold Pressure(in.w.g.) 3.5/10 3.5/10 3.5/10 3.5/10 Nat. Gas/LPG/Propane High static-in.w.g. 0.5 0.5 0.5 0.5 Energy Star'®Certified Yes Yes Yes Yes Connections Intake/Exhaust Pipe(PVC) 2/2 2/2 2/2 2/2 in. Gas pipe size IPS 1/2 1/2 1/2 1/2 Condensate Drain Trap (PVC pipe)-i.d. 3/4 3/4 3/4 3/4 with furnished 90°street elbow 3/4 slip x 3/4 Mipt with field supplied (PVC coupling)-o.d. 3/4 slip x 3/4 MPT Indoor Wheel nom.dia.x width-in. 10 x 10 11 x 11 11-1/2 x 10 11 x 11 Blower Motor Type DC Brushless DC Brushless DC Brushless DC Brushless Motor output-hp 3/4 1 1 1 Tons of add-on cooling 2.5-4 3-5 3-5 3-5 Air Volume Range-cfm 760-1740 XXX 1055-2220 1310-2400 Electrical Data Voltage 120 volts-60 hertz- 1 phase Blower motor full load amps 8.4 10.9 10.9 10.9 Maximum overcurrent protection 15 15 15 15 Shipping Data lbs.- 1 package 152 XXX 164 XXX NOTE-Filters and provisions for mounting are not furnished and must be field provided. 'Annual Fuel Utilization Efficiency based on DOE test procedures and according to FTC labeling regulations.Isolated combustion system rating for non-weatherized furnaces. Page 2 OPTIONAL ACCESSORIES "B" Width Models I "C"Width Models I "D"Width Models CABINET ACCESSORIES Horizontal Suspension Kit-Horizontal only 51W10 51W10 51W10 Return Air Base-Upflow only 50W98 50W99 50W99 High Performance Economizer(Commercial Only) 10U53 10U53 10U53 CONDENSATE DRAIN KITS Condensate Drain Heat Cable 6 ft. 26K68 26K68 26K68 24 ft. 26K69 26K69 26K69 Crawl Space Vent Drain Kit US 51W18 51W18 51W18 Canada 15Z70 15Z70 15Z70 CONTROLS Blower Relay Kit (for two-stage outdoor units) 85W66 85W66 85W66 iComfort®M30 Smart Wi-Fi Thermostat 15Z69 15Z69 15Z69 Remote Outdoor Temperature Sensor X2658 X2658 X2658 Twinning Kit 16W72 16W72 16W72 FILTER KITS 'Air Filter and Horizontal(end) Size of filter-in. 87L96- 18 x 25 x 1 87L97-20 x 25 x 1 87L98-25 x 25 x 1 Rack Kit Side Return Single 44J22 44J22 44J22 Ten Pack 66K63 66K63 66K63 Size of filter-in. 16x25x1 16x25x1 16x25x1 NIGHT SERVICE KIT Night Service Kit 84W48 I 84W48 84W48 TERMINATION KITS See Installation Instructions for specific venting information. Termination Kits- Concentric US-2 in. 71M80 69M29 --- Direct Vent 3 in. --- 60L46 60L46 Applications Only Canada-2 in. 44W92 44W92 --- 3 in. --- 44W93 44W93 Flush-Mount US-2, 2-1/2 or 3 in. 51W11 51W11 51W11 Canada-2,2-1/2 or 3 in. 51W12 51W12 51W12 Wall-Close US-2 in. 22G44 --- --- Couple 3 in. 44J40 44J40 44J40 Wall-Close Canada-2 in. 30G28 --- --- Couple WTK 3 in. 81J20 81J20 81J20 Termination Kits- Roof 2 in. 15F75 15F75 --- Direct or Non- Wall Ring Kit 2 in. 15F74 '15F74 --- Direct vent 2 Roof Termination Flashing Kit-Direct or 2 in. 44J41 44J41 44J41 Non-Direct Vent(2 fleshings) VENTING Flue Coupling 2 in. I 17H92 I 17H92 I 17H92 'Cleanable polyurethane frame type filter. 'Kits contain enough parts for two,non-direct vent installations. 'Non-direct vent only. NOTE-Termination Kits(44W92,44W93,30G28,51W12,51W19,81J20)and Crawl Space Vent Drain Kit(15Z7D)are certified to ULC S636 standard for use in Canada only. Page 3 BLOWER DATA _ ML196UH030XE36B PERFORMANCE (Less Filter) External Air Volume/Watts at Various Blower Speeds Static High Medium-High Medium Medium-Low Low Pressure in.w.g. cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts 0.00 1435 346 1170 191 1000 127 775 62 705 45 0.10 1400 351 1130 199 955 132 735 71 635 48 0.20 1360 358 1085 207 905 137 680 81 515 50 0.30 1325 370 1055 217 865 148 625 84 445 55 0.40 1300 382 1020 227 815 157 570 91 380 61 0.50 1265 387 990 231 785 161 515 95 310 66 0.60 1235 402 945 244 735 168 475 104 265 68 0.70 1200 411 910 253 710 175 425 107 215 72 0.80 1160 420 885 260 660 183 355 114 175 75 ML196UH045XE36B PERFORMANCE(Less Filter) External Air Volume/Watts at Various Blower Speeds Static High Medium-High Medium Medium-Low Low Pressure in.w.g. cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts 0.00 1460 335 1285 235 1190 170 910 85 870 75 0.10 1430 350 1260 245 1155 185 885 95 830 85 0.20 1405 365 1235 255 1125 200 860 105 800 90 0.30 1375 370 1205 265 1090 210 825 115 755 95 0.40 1350 380 1175 275 1055 215 780 125 710 105 0.50 1315 385 1145 285 1020 230 735 130 665 115 0.60 1245 375 1110 295 980 240 685 140 620 125 0.70 N/A N/A 1070 305 940 250 640 145 575 135 0.80 N/A N/A 1020 310 905 260 600 155 530 140 ML196UH070XE36B PERFORMANCE(Less Filter) External Air Volume/Watts at Various Blower Speeds Static High Medium-High Medium Medium-Low Low Pressure in.w.g. cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts 0.00 1445 315 1315 215 1215 165 930 85 925 75 0.10 1445 335 1275 230 1170 180 905 94 860 80 0.20 1415 345 1240 240 1125 190 870 101 800 85 0.30 1380 355 1205 250 1090 200 830 109 760 95 0.40 1345 370 1175 265 1055 210 790 117 710 105 0.50 1315 385 1150 280 1020 220 735 129 665 115 0.60 1275 390 1110 290 985 230 685 137 625 125 0.70 1210 395 1075 300 950 240 640 146 565 130 0.80 N/A N/A 1030 305 915 250 595 148 535 135 ML196UH070XE48B PERFORMANCE(Less Filter) External Air Volume 1 Watts at Various Blower Speeds Static High Medium-High Medium Medium-Low Low Pressure in.w.g. cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts 0.00 1710 466 1510 305 1330 209 1240 164 1005 104 0.10 1685 477 1485 317 1305 220 1200 178 965 112 0.20 1675 486 1445 331 1250 232 1150 190 885 113 0.30 1640 498 1400 347 1210 246 1095 203 835 123 0.40 1590 518 1370 360 1170 260 1045 215 765 130 0.50 1550 532 1315 374 1135 274 995 225 700 140 0.60 1515 545 1270 392 1070 287 940 238 635 150 0.70 1475 554 1240 402 1015 300 895 247 570 156 0.80 _ 1420 551 1195 419 965 305 835 259 500 172 Page 4 BLOWER DATA ML196UH090XE36C PERFORMANCE(Less Filter) External Air Volume/Watts at Various Blower Speeds Static High Medium-High Medium Medium-Low Low - Pressure in.w.g. cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts 0.00 1470 313 1355 233 1195 171 975 92 895 50 0.10 1445 325 1330 249 1170 184 940 101 855 63 0.20 1430 335 1300 270 1150 196 885 109 735 75 0.30 1385 350 1265 275 1110 206 870 122 680 82 0.40 1370 365 1230 287 1085 217 815 126 640 91 0.50 1340 376 1200 298 1055 226 790 137 595 96 0.60 1300 384 1170 305 1015 231 735 146 565 103 0.70 1280 394 1150 317 985 245 700 152 505 108 0.80 1230 395 1125 328 960 256 665 162 460 117 ML196UH090XE48C PERFORMANCE(Less Filter) External Air Volume/Watts at Various Blower Speeds Static High Medium-High Medium Medium-Low Low Pressure in.w.g. cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts 0.00 1765 375 1535 250 1410 180 1315 155 1155 115 0.10 1735 390 1500 260 1365 200 1270 165 1130 125 0.20 1700 405 1465 275 1330 215 1230 175 1095 135 0.30 1660 425 1435 290 1295 225 1195 190 1055 145 0.40 1640 435 1400 300 1265 235 1165 200 1010 155 0.50 1615 450 1370 315 1230 250 1125 215 965 165 0.60 1575 465 1340 325 1190 265 1080 230 925 180 0.70 1530 470 1305 340 1150 280 1045 235 885 190 0.80 N/A N/A 1260 345 1115 285 1000 245 845 195 ML196UH090XE60C PERFORMANCE (Less Filter) External Air Volume/Watts at Various Blower Speeds Static High Medium-High Medium Medium-Low Low Pressure - in.w.g. cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts 0.00 2105 63B 1860 431 1705 327 1585 274 1425 203 0.10 2075 652 1820 449 1675 344 1550 287 1380 213 0.20 2050 672 1790 470 1630 363 1505 295 1335 218 0.30 2005 694 1765 485 1590 375 1475 314 1300 233 0.40 1975 701 1715 496 1565 392 1425 325 1230 242 0.50 1960 714 1700 514 1510 405 1395 339 1195 256 0.60 1925 738 1650 530 1480 419 1355 351 1145 268 0.70 1865 745 1610 541 1435 434 1300 366 1110 282 0.80 1830 739 1580 554 1400 445 1270 383 1050 293 Page 5 BLOWER DATA ML196UH110XE60C PERFORMANCE (Less Filter) Air Volume/Watts at Different Blower Speeds Single Side Return Air-Air volumes in bold(over 1800 External Bottom Return Air, Side Return Air with Return Air from cfm)require Optional Return Air Base and field fabricated Static Both Sides or Return Air from Bottom and One Side. transition to accommodate 20 x 25 x 1 in.air filter in order to Pressure maintain proper air velocity. in.w.g. High Med-High Medium Med-Low Low High Med-High Medium Med-Low Low cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts 0.00 2220 655 1975 440 1800 325 1665 390 1050 180 2180 685 1910 460 1750 345 1660 285 1430 195 0.10 2185 680 1925 460 1750 345 1625 285 1440 200 2155 705 1885 480 1720 360 1610 295 1415 205 0.20 2150 705 1880 480 1710 365 1590 300 1390 220 2130 725 1855 495 1685 380 1565 305 1380 220 0.30 2110 720 1850 495 1680 380 1560 320 1350 230 2085 745 1825 510 1655 390 1535 325 1335 230 0.40 2080 735 1810 520 1650 405 1515 330 1310 245 2060 760 1795 530 1625 405 1495 340 1295 245 0.50 2045 755 1785 530 1610 415 1470 350 1265 255 2030 775 1765 545 1585 425 1450 355 1255 265 0.60 2010 775 1740 545 1575 430 1440 370 1220 270 1995 785 1725 565 1550 435 1420 370 1205 275 0.70 1980 790 1705 565 1525 450 1400 375 1170 280 1960 795 1690 575 1505 455 1385 385 1165 290 0.80 1950 795 1670 580 1485 460 1360 390 1140 293 1895 790 1650 590 1465 470 1335 395 1120 295 ML196UH135XE6OD PERFORMANCE(Less Filter) Air Volume/Watts at Different Blower Speeds Single Side Return Air-Air volumes in bold(over 1800 External Bottom Return Air,Side Return Air with Return Air from cfm)require Optional Return Air Base and field fabricated Static Both Sides or Return Air from Bottom and One Side. transition to accommodate 20 x 25 x 1 in.air filter in order to Pressure maintain proper air velocity. in.w.g. High Med-High Medium Med-Low Low High Med-High Medium Med-Low Low cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts 0.00 2400 920 2205 709 2035 513 1800 363 1625 268 2280 929 2100 703 1935 531 1720 368 1550 269 0.10 2370 930 2170 718 1985 524 1760 375 1585 279 2245 941 2075 720 1910 543 1700 380 1530 280 0.20 2345 937 2150 723 1960. 552 1725 385 1535 291 2210 957 2050 745 1895 558 1695 396 1500 295 0.30 2305 958 2120 744 1920 565 1690 404 1505 305 2200 978 2030 757 1850 569 1675 408 1475 308 0.40 2275 974 2070 763 1885. 576 1665 419 1475 323 2175 990 2015 774 1845 584 1640 427 1450 326 0.50 2230 986 2055 779 1845 593 1620 433 1435 330 2145 989 2010 783 1820 603 1605 446 1410 332 0.60 2195 988 2030 796 1810. 614 1590 451 1385 348 2125 980 1990 809 1785 618 1580 455 1375 351 0.70 2125 961 1985 806 1780 626 1545 468 1355 359 2060 937 1960 819 1765 635 1545 474 1340 366 0.80 2065 931 1965 822 1760 642 1500 479 1310 377 1980 912 1925 825 1730 646 1510 491 1295 379 Page 6 ML196UHE PARTS IDENTIFICATION FLEXIBLE NO-HUB EXHAUST COLLAR BURNER BOX ASSEMBLY TOP CAP GAS VALVE • r • DuralokPlusTM �i' r\ HEAT EXCHANGER �� 1 ASSEMBLY 010 COMBUSTION AIR\Ifi INDUCER tom- " BURNER ACCESS e�j 'toia PANEL ► I 1pt,� 044k 106,4‘-i;p4 it:*•-•;0-. _*Ikt1:%:.:0-0:0;-.11111111..11 I..J.1,'-"----- lo 0 ------ • . r ll'' 44.4p4.,‘...' Abli111111111114114.-'''''' fpx%.t a•,•0 0......1°..°... ..: 11,14- 0 _Tyl ;,� BAG ASSEMBLIES P-IMARY LIMIT (shipping location) ......„,,,, ,, ( / v -----..„.,44 ,i., s.....,,, i to ;111111jPi'',.. I ''.-•-•1%....4.4..,-.e // COLD END ' �f. BLOWER ACCESS HEADER BOX v 01 0 PANEL '1 `iN. BLOWER COMBUSTION y1 ASSEMBLY AIR PRESSURE SWITCH CONTROL BOX (includes integrated ignition control,trans- former,circuit breaker and interlock switch) FIGURE 1 Page 7 I-UNIT COMPONENTS 3. Circuit Breaker(CBS) - A 24V circuit breaker is also located in the control box. The switch provides overcurrent protection to the transformer ELECTROSTATIC DISCHARGE (ESD) (T1). The breaker is rated at 3A at 32V. If the current ex- Precautions and Procedures ceeds this limit the breaker will trip and all unit operation will shutdown. The breaker can be manually reset by pressing A CAUTION the button on the face. 4. Integrated Ignition Control (A92) pmElectrostatic discharge can affect elec- tronic components. Take precautions to neutralize electrostatic charge by A WARNING touching your hand and tools to metal prior to handling the control. Shock hazard. Disconnect power before servicing. Control is not ML196UHE unit components are shown in figure 1. The field repairable. If control is inoperable, simply re- combustion air inducer, gas valve and burners can be ac- cessed by removing the outer access panel. The blower Can cause injury or death. Unsafe operation will re and control box can be accessed by removing the blow- suit if repair is attempted. er access panel. The hot surface ignition control system consisting of an in- A-Control Box Components (Figure 2) Unit transformer(T1)and integrated ignition control (A92) tegrated control (figure 3 with control terminal designa- are located in the control box. In addition, a door interlock tions in tables 1,2 and 3),sensor and ignitor(figure 5).The switch (S51) is located in the control box. integrated control and ignitor work in combination to en- sure furnace ignition and ignitor durability.The integrated control, controls all major furnace operations. The inte- ML196UHE Control Box grated control also features a RED LED for troubleshoot- ing and two accessory terminals rated at(1)one amp.See Transformer table 4 for troubleshooting diagnostic codes. The nitride iignitor is made from a non-porous, high strength propri- li1111rfk etary ceramic material that provides long life and trouble atO• free maintenance. Circuit Breaker , t`, TABLE 1 -or. '� • 4-Pin Terminal Designation 1,1 \ %.• O Q ; PIN# FUNCTION Door Interlock 1 Combustion Air Inducer Line ' ;jam,. Switch 2 Ignitor Line 411110;,-, —• 3 Combustion Air Inducer Neutral � �,�y 1'ti 11 4 Ignitor Neutral �. TABLE 2 Integrated Control 12-Pin Terminal Designations FIGURE 2 PIN # FUNCTION 1 High Limit Output 2 Not Used 1. Transformer(T1) 3 24V Line A transformer located in the control box provides power to 4 Not Used the low voltage section of the unit.The transformers on all 5 Rollout Switch Out models are rated at 40VA with a 120V primary and 24V 6 24V Neutral secondary. High Limit Input 2. Door Interlock Switch (S51) 8 Ground A door interlock switch rated 14A at 120VAC is located on 9 Gas Valve Common the control box.The switch is wired in series with line volt- 10 Pressure Switch In age. When the blower door is removed the unit will shut 11 Rollout Switch In down. 12 Gas Valve Out Page 8 TABLE 3 1l4"QUICK CONNECT TERMINALS 120HUM Humidifier 120VAC ' LINE 120VAC XFMR Transformer 120VAC CIRC Indoor blower 120VAC EAC Indoor air quality accessory 120VAC NEUTRALS Common 120VAC HUM24 Humidifier 24VAC 3116"QUICK CONNECT TERMINALS COOL Cooling tap 24VAC HEAT Heating tap 24VAC FAN Continuous blower 24 VAC PARK(no power) Park terminal for unused speed taps FS Flame sense 24 COM Common 24VAC TABLE 4 The integrated control is equipped with an LED light for troubleshooting. The diagnostic codes are listed below in table 4. RED LED 2 Diagnostic Codes/Status of Furnace Flash Code Off No power to control or board fault detected Heartbeat) Normal Operation- Idle, Continuous Fan, Cool Continuous Rapid Call For Heat/Burner Opertation Flash 1 Reverse Line Voltage Polarity 2 Improper Earth Ground 3 Burner failed to light, or lost flame during heat demand 4 Low Flame Signal- check flame sensor 5 Watchguard - burner failed to light, exceeded maximum number of retries or recycles. 6 Not Used 7 Primary or Secondary Limit Open or Watchguard Mode-Limit Switch Open longer than 3 min- utes 8 Rollout Switch Open 9 Pressure Switch failed to close or opened during heat demand 10 Watchguard - Pressure Switch opened 5 times during one heat demand 11 Pressure Switch stuck closed prior to activation of combustion air inducer 12 Flame Sensed without gas valve energized 13 Low Line Voltage Notes Note 1 A"Heartbeat" is indicated by a "Slow Flash"- 1 sec on 1 sec off, repeating Note 2 Error codes are indicated by a "Rapid Flash" - the LED flashes X times at 1/2 sec on 1/2 sec off, remains off for 3 sec, then repeats Last 10 error codes are stored in memory including when power is shut off to the unit.-To recall, Note 3 press and release button, most recent will be displayed first, LED off for 3 sec, then next error code is displayed, etc. To clear error codes, depress and hold button longer than 5 seconds. Page 9 tal of five trials for ignition (including the initial trial), the inte- _ INTEGRATED CONTROL grated control goes into Watchguard-Flame Failure mode. (Automatic Hot Surface Ignition System) After a 60-minute reset period, the integrated control will 10N 110A 021 IIO10N NA t2 ° 0 begin the ignition sequence again. O Fan Time Control G TOO OO IIII0 @ @ Heating Fan On Time G<0 @ The fan on time of 30 seconds is not adjustable. Heating Fan Off Time '0 0_ Fan off time (time that the blower operates after the heat o 0 81FL 0 00 0 _ demand has been satisfied)can be adjusted by moving the 0o DO 01 jumper to a different setting. The unit is shipped with a fac- �� g tory fan off setting of 90 seconds. For customized comfort, - 8 1 7)ci- I monitor the supply air temperature once the heat demand 88 o u 0 is satisfied. Note the supply air temperature at the instant — O 0 0 70©®©Q the blower is de-energized. iD® s0® Adjust the fan-off delay to achieve a supply air temperature o o ®®04 Q between 90° - 110° at the instant the blower is de-ener- - 0 0, gri-1 8 0 gized. (Longer delay times allow for lower air temperature, 0 too - - shorter delay times allow for higher air temperature). See 0 0 0 0 g ® a ® ® a figure 4. oED Q 07 WCRG Y 0 Cooling Fan On Time RED LED / BLOWER OFF DELAY The fan on time is 2 seconds and is not adjustable. RECALL BUTTON Cooling Fan Off Time FIGURE 3 The control has a 45 second fan off delay after cooling de- mand has been met. This delay is factory set and not ad- Electronic Ignition justable. On a call for heat the integrated control monitors the com- bustion air inducer pressure switch. The control board will HEAT FAN-OFF TIME IN SECONDS not begin the heating cycle if the pressure switch is closed JUMPER POSITION U DELAY E (by-passed). Once the pressure switch is determined to be PIN P I N2 60 PIN2 PIN3 90 open, the combustion air inducer is energized. When the PIN3 P I N4 120 differential in the pressure switch is great enough, the pres- P 1 N4 P Ns 80 NO JUMPFR 180 sure switch closes and a 15-second pre-purge begins. If the pressure switch is not proven within 2-1/2 minutes, the To adjust fan-off timing,reposition jumper across pins toachieve desired setting. integrated control goes into Watchguard-Pressure Switch 60 Second 90 Second 120 Second 180 Second mode for a 5-minute re-set period. off Time off Time off Time off Time After the 15-second pre-purge period,the ignitor warms up � for 20 seconds during which the gas valve opens at 19 sec- ;+_I ��11/I !?11I NI onds for a 4-second trial for ignition. The ignitor remains Y�i i - !WI 1 i i y'i _ ._ ��% �u�- ��Cy� �. energized for the first 3 seconds during the 4 second trial. If 0 0 0 0 0 0 000 ignition is not proved during the 4-second period, the inte- `O° N `°° NCO° N ° N grated control will try four more times with an inter purge and warm-up time between trials of 35 seconds.After a to- FIGURE 4 Page 10 ML196UHE Burner Box Assembly 1 ° • \---.-:;-p i A.,-`/''-.•-,•,,,.4.4, j Burner Assembly Al l ''' /- 1- vim. A -. Rollout Switch(s) / 4 / � / A/ s� . lir � J gar% 0 Flame Sensor '=; !, 1 }410 �r� Ignitor `- Gas Valve I( Burner Box Front �� FIGURE 5 B-Heating Components 2. Heat Exchanger(Figure 6) Combustion air inducer(B6), primary limit control (S10), ig- ML196UHE units use an aluminized steel primary and nitor, burners, flame rollout switch (S47), gas valve (GV1), stainless steel secondary heat exchanger assembly. combustion air pressure switch(S18), and heat exchangers Heat is transferred to the air stream from all surfaces of are located in the heating compartment. The heating the heat exchanger.The shape of the heat exchanger en- compartment can be accessed by removing the outer ac- sures maximum efficiency. cess panel. The combustion air inducer pulls fresh air through the burn- er box. This air is mixed with gas in the burners. The gas I air mixture is then burned at the entrance of each clam- shell. Combustion gases are then pulled through the primary 1. Flame Rollout Switches (Figure 5) and secondary heat exchangers and exhausted out the ex- Flame rollout switches S47 are SPST N.C. high temperature haust vent pipe. limits located on the left and right of the front buner box plate. 3. Primary Limit Control (Figure 6) S47 is wired to the burner ignition control A92.When ei- Primary limit(S10) used on ML196UHE units is located in the they of the switches sense flame rollout (indicating a heating vestibule panel. When excess heat is sensed in the blockage in the combustion passages),the flame rollout heat exchanger,the limit will open.Once the limit opens, the switch trips,and the ignition control immediately closes furnace control energizes the supply air blower and de-en- the gas valve. Switch S47 in all ML196UHE units is factory ergizes the gas valve. The limit automatically resets when preset to open at 210°F+ 12°F (99°C +6.7°C)on a tern unit temperature returns to normal. The switch is factory set and cannot be adjusted. For limit replacement remove re rise.All flame rollout switches are manual reset. See wires from limit terminals, remove mounting screws, rotate table 4 table 4 flash code 8 for troubleshooting. limit switch 90 degrees and slowly remove from the vesti- bule panel. Install replacement limit with same care.See table 4 flash code 7 for troubleshooting if limit switch opens during operation. Page 11 5. Flame Sensor(Figure 5) Primary Limit Location and Heat Exchanger A flame sensor is located on the left side of the burner sup- �' , port. The sensor is mounted on the front burner box plate �� o �4 4 and the tip protrudes into the flame envelope of the left- most burner. The sensor can be removed for service (use ��- steel wool only to clean) without removing any part of the burners. During operation, flame is sensed by current passed through the flame and sensing electrode. The igni- tion control allows the gas valve to remain open as long as ® flame signal is sensed. ;� ®%'t ,� NOTE- The ML196UHE is polarity sensitive. Make sure ® ; that the furnace is wired correctly and is properly grounded. �� A microamp DC meter is needed to check the flame signal 40 on the integrated control. �� Flame (microamp) signal is an electrical current which passes from the integrated control to the sensor during unit operation. 4, 1 e ' Current passes from the sensor through the flame to ground to complete a safety circuit. Install limit face down To Measure Flame Signal - Integrated Control: FIGURE 6 Use a digital readout meter capable of reading DC micro- 4. Gas Valve (Figure 7) amps. See figure 8 for flame signal check. The ML196UHE uses an internally redundant valve to assure 1 Set the meter to the DC amps scale. safety shut-off. If the gas valve must be replaced, the same 2 - Turn off supply voltage to control. type valve must be used. 3- Remove sensor wire from integrated control. 24VAC terminals and gas control switch are located on 4- Connect(-) lead to flame sensor wire. top of the valve. All terminals on the gas valve are con 5- Connect(+) lead to Terminal FS on integrated control. netted to wires from the ignition control. 24V applied to the 6- Turn supply voltage on and close thermostat contacts to cycle system. terminals opens the valve. 7- When main burners are in operation for two minutes,take Inlet and outlet pressure taps are located on the valve. A reading. manifold adjustment screw is also located on the valve.An 6. Ignitor(Figure 5) LP/Propane changeover kit is available. ML196UHE units use a nitride ignitor made from a propri- MANIFOLD PRESSURE etary ceramic material.To check ignitor, measure its resist- ADJUSTMENT SCREW g(under barbed fitting) ance and voltage. A value of 39 to 70 ohms indicates a �Is MANIFOLD good ignitor.Voltage to the ignitor should be 102- 132VAC. OO r PRESSURE ' --4� OUTLET See figure 9 for resistance and voltage checks. •� <<' �Of�i ' 1�. PORT 11 (� / _ INLET wAL G,_I ©11�, PRESSURE �� PORT GAS VALVE SHOWN IN ON POSITION FIGURE 7 Page 12 - Measuring Flame Signal Flame Signal In Microamps . Normal Low Drop Out >1.5 0.5-1.4 <0.4 I � . � Flame I _ Sensor if1�� Wire h� ,_ Oft; il� i Remove sensor from integrated I� ItiSk 4, , control and connect alligator clip Ii.'' � i (-)to flame sensor lead. "r. ) isir .. A oZ I i `-, vl'1 G ,,, 3 ,,,, "co- 0 ., , , , ,i , ,, . ,.. „_,.. 0_,/,..... ,, 11 _,� • ( (—) 1 OC�i *'i �- 0 4::1"0111.kilr ..1 0 5 .�;��1 Multi-Meter Intergrated " 1'.. Control IR U ,;+ 1 I jSet Dial to DC MicroAmps r II 011 I.,''' - 1 Allir Flame Sensor wg ® Terminal ° fill all ® �` �� ( )To Flame / Terminal 1111 (+)To Control Sensor Terminal Remove sensor from integrated control and connect alligator clip (+)to terminal on control. FIGURE 8 Page 13 Test I 1= t Check ignitor circuit for correct resistance. Remove 4-pin plug from control. ® iT l• Check ohms reading across terminals 2 and 4. S.S,Ilrft t Reading should be between 39 and 70 ohms. If `[� 1VI- -- value is correct,this is the only test needed. If the reading on the meter is not correct,(0 or �� infinity)then a second test is needed. "V�� Multi-Meter -i �1 (set to ohms ��"� Vill ifi '�� =� J0 .r OOOO Q 4 3 2 1 A� Ain iv .it.t C%: o° Test 2 Check ignitor for correct resistance. Seperate the 2-pin jack-plug near the manifold and check resistance of ignitor at the plug.Reading should be ® 7 - I�' between 39 and 70 ohms.If the reading is correct,then 'f� H. the problem is with the wiring between the jack-plug and `1;�j Vi- the control. If reading is not correct,the issue is the ignitor. 1. '*1,1 Multi-Meter �., .i�r C.' (set to ohms —" 04, .. ,�y 1-.P15Pa.;rAili O O©©Oc °!r " 'pi ° V;° Pr ° ' / 1*l Test 3 Check ignitorintfor terminals t2 voltaand 4( ® T � Insert meterprobes into 2 and 4 use small ( L \ diameter probes in order not to damage plug). `( IV _1 Check voltage during 20 second ignitor warm up period. Voltage should read 120 volts+ 10%.If voltage reads below = � 'I these values,check for correct supply voltage to furnace. °� Multi-Mrod4eter 14 NEAP (set to VAC) .,,,, I •� :4„, •rfoi0.114,' cr•' rill • El FIGURE 9 Page 14 7. Combustion Air Inducer(B6) Pressure Switch • &Cold End Header Box All ML196UHE units use a combustion air inducer to l' move air through the burners and heat exchanger during I -I heating operation. The blower uses a shaded pole 120VAC motor. The motor operates during all heating op- Ill eration and is controlled by integrated control A92. Blower operates continuously while there is a call for heat. The in- ill Ii rrao tegrated control will not proceed with the ignition sequence I until combustion air inducer operation is sensed by the prov- I =I mi ing switches. The combustion air inducer is installed on the cold end i I-I header box. The cold end header box is a single piece made of hard plastic. The box has an internal channel — where the combustion air inducer creates negative pres- FIGURE 10 sure at unit start up.The channel contains an orifice used On start-up, the switch monitors whether the combustion air to regulate flow created by the combustion air inducer. inducer is operating. It closes a circuit to the integrated The box has pressure taps for the combustion air inducer control when the difference in pressure across the com- pressure switch hoses. The pressure switch measures bustion air inducer orifice exceeds a non-adjustable factory the pressure across the combustion air inducer orifice or setting. If the switch does not successfully sense the re- difference in the channel and the box. If replacement is quired differential, the switch cannot close and the fur- necessary the gaskets used to seal the box to the nace cannot operate. If the flue or air inlet become ob- vestibule panel and the combustion air inducer to structed during operation, the switch senses a loss of the box, must also be replaced. pressure differential and opens the circuit to the integrated control. If the condensate line is blocked,water will back up TABLE 5 into the header box and reduce the pressure differential Combustion Air Inducer across the switch. The pressure switch opens if the differ- ML196UHE Unit Orifice Size ential drops below the set point. See table 6. -030 0.525" Checks of pressure differential can aid in troubleshooting. When measuring the pressure differential, readings should be -045 0.618" taken at the pressure switch.See figure 11 and table 7. Lack of -070 0.775" differential usually indicates problems in the intake or exhaust piping, but may indicate problems in the heat exchanger, -090 0.905" condensing coil, header boxes, combustion inducer or -110 1.040" other components. -135 1.235" TABLE 6 Altitude ft. 8. Combustion Air Pressure Switch Unit 0 -4500 4501 -7500 7501 - 10000 (Figure 10) Set Point"w.c. Set Point"w.c Set Point"w.c. ML196UHE series units are equipped with a differential -030 -0.65 -0.65 -0.60 pressure switch located on the cold end header box.The -045 -0.65 -0.65 -0.60 switch monitors across the combustion air inducer orifice to in- -070 -0.95 -0.85 -0.75 sure proper flow through the heat exchanger. -090 -0.90 -0.80 -0.65 The switch is a SPST N.O. pressure switch electrically con- -110 -0.90 -0.85 -0.65 nected to the integrated control.The purpose of the switch is -135 -0.90 -0.80 -0.65 to prevent burner operation if the combustion air inducer is not moving enough air for proper combustion. *Set point is factory set and non-adjustable Page 15 Measuring Pressure Differential ® Black Tubing RED (positive +) luck Red and Black Tubing or Red Tubing (negative -) 117 11)To Cold End Header Box To Cold End Header Box Field Provided Tubing To Pressure Switch isr High Low 1 - Remove thermostat demand and allow unit to cycle off. 4- Operate unit and observe manometer reading. 2- Install a tee inthe negative(-) ine(red and black tubing Readings will change as heat exchanger warms. or red tubing)and a tee in the positive(+) line(black a.Take one reading immediately after start-up. tubing) running from the pressure switch to the cold b. Take a second reading after unit has reached steady state(approximately 5 minutes).This will be end header box. 3- Install a manometer with hose from the negative(-) the pressure differential. side of the manometer to the tee installed in the The pressure differential should be greater negative(-)line and with hose from the positive(+) than those listed in table 6. side of the manometer to the tee in the positive(+) 5- Remove thermostat demand and allow to cycle off. line. NOTE Both sides of the cold end header box are nega- 6- Remove manometer and tee's. Reinstall combustion air sensing hoses to the pressure switch. tive. However the(+)port reads less negative pressure than the (-)port. FIGURE 11 Page 16 TABLE 7 Pressure Switch Troubleshooting Guide Problem Corrective Action Pressure switch stuck closed Check that the pressure switch is open without the combustion air inducer operat- ing. Replace if defective. Pressure switch does not close due to Check for restricted vent. Remove all blockage. obstruction in vent pipe. Check for proper vent sizing. See table 12. Pressure switch does not close due to Check that the pressure switch tubing is correctly routed. Correctly route pressure incorrect routing of the pressure witch line. switch tubing. Pressure switch does not close due to obstructions in the pressure switch Remove any obstructions from the the pressure switch line and/or taps line. Pressure switch tubing damaged. Check pressure switch tubing for leaks. Replace damaged tubing if necessary. Condensate in pressure switch tubing. Check pressure switch tubing for condensate. Remove condensate from tubing. Pressure switch does not close due to Check the differential pressure across the pressure switch. a low differential pressure across the Check for restricted inlet vent. Remove all blockage. pressure switch. Check for proper vent sizing and run length. See tablel2. Wrong pressure switch installed in the Check that the correct pressure switch is installed in the unit. Replace pressure unit, or pressure switch is out of cal- switch if necessary. ibration Miswiring of furnace or improper con- Check for correct wiring and loose connections. Correct wiring and/or replace any nections at pressure switch. loose connections. Pressure switch failure. If all the above modes of failure have been checked,the pressure switch may have failed. Replace pressure switch and determine if unit will operate. Damaged condensate trap. Check trap for any cracks or damage and replace if necessary. Cold end header box does not drain Check that the furnace is set properly with a slight tilt(0 - 1/2")towards the front properly. if necessary. See furnace installation instruction. Air leakage around the combustion air Check gasket and replace if necessary. inducer gasket. Air leakage around the cold end head Check gasket and replace if necessary. er box gasket. Damaged cold end header box tubing. Check tubing and replace if necessary. ELECTRONIC IGNITION 1 15 34 38 80 5 SEC I I ON Pre-Purge Ignitor Warm-up Trial for Blower"On"* Post ❑ OFF Ignition Delay Purge DFMAND CAI IGNITOR I GAS VALVE INDOOR BLOWER `Blower on time will be 30 seconds after flame is sensed.Blower off time will depend on"OFF TIME"Setting. FIGURE 12 Page 17 C-Blower Compartment BLOWER WHEEL REPLACEMENT A IMPORTANT Center Blower Wheel Each blower is statically and dynamically balanced in Blower Housing as an assembly before installation in the unit. .Am ML196UHE units are equipped with a constant torque ECM motor. It has a DC motor coupled to an electronic control module both contained in the same motor housing. The mo- tor is programmed to provide constant torque at each of the five selectable speed taps. Each tap requires 24 volts to en- r - ergize. Input Voltage Requirements The circuit is designed to be operated with AC voltage. To ' enable a tap requires 12 to 33VAC. Expected current draw will be less than 20mA. • Troubleshooting the Motor ° 'L� Troubleshooting the motor is an easy process. Follow steps below. 1- Shut off power to unit. FIGURE 13 2- Remove input plugs P48 and P49 from motor. See ALIGN AND TIGHTEN SET SCREW WITH figure 16 for troubleshooting procedure. FLAT SIDE OF MOTOR SHAFT If correct voltage is present in tests 1 and 2 and motor is not operating properly, replace motor. The motor is not field re- pairable. ,'ll� �� If replacing the indoor blower motor or blower wheel is nec- Housing Hub Set Screw 'i essa �� "ry, placement is critical.The blower wheel must be cen- tered in the blower housing as shown in figure 13.When re- Motor placing the indoor blower motor the set screw must be Shaft ( 4� aligned and tightened with the motor shaft as shown in figure 14. 9. 9. Secondary Limit Controls `' The secondary limit is located in the blower compartment on the back side of the blower housing. See figure 15. When ex- cess heat is sensed in the blower compartment, the limit will open. If the limit is open,the furnace control energizes the sup- FIGURE 14 ply air blower and doses the gas valve.The limit automatically resets when unit temperature returns to normal. The secon- SECONDARY LIMIT CONTROL dary limit cannot be adjusted. 7 / \ Z� \ \ � i < 4 plir `' �11111 Secondary Limits FIGURE 15 Page 18 - -�_. O � lONIOA 02 � tl0 �d O (tr, lick., 0'1 1\ O O O g o en ID 1. Multi-Meter ��®OQ ® P49 CD 4/ (set to V•C) o • o U 910a e .3,/,A, �� o oN. Multi-Meter it, 3 z0 0 . 00 lik (set to VAC) vk, . .. 0,,,,,..),„ C' O 0 o❑ W C R G Y 0 1 i tO Test 1 P48 Test 3 (if necessary) .', Turn on power to unit.Check for 120 volts across terminals Check for 120 volts across terminals"CIRC"and"Neutrals" "L"and"N"on input plug P48.If voltage is present continue on the integrated control. If voltage is present, problem is to test 2.If voltage is not present problem may be may be up- with the harness. If voltage is not present problem may be stream of plug P48 and proceed to test 3. may be with the integrated control. 10N 1100 011 tl0J,a 0VA IS _ o O gl 1 n 1 4o• 3 O .o ®000 —i c� e _, o . , , 1„, 1 00 �0 [ri L ri pi / - 0 c' a`'o ©®©a Multi-Meter f D® s0® (set to VAC) _ ®OO +OQ`I Multi-Meter P49 s�fA4 f o $�— 8 0 (set to VAC) I//� ®W l 7+ \�,,,� ° O O ❑a WCRG Y � 2\ s. 4, ,, k. P48 Test 2 Test 4(if necessary) Switch thermostat to CONTINUOUS FAN MODE.Check for Check for 24 volts across terminals"24 COM"and"FAN"ter- 24 volts across terminal"C"on input plug P48and speed tap minals on the integrated control.If voltage is present,prob- used for continuous fan.(1,2,3,4 or 5)on input plug P49.If lem is with the harness. If voltage is not present problem 24 volts is not present problem may be up stream of plug P49. may be may be with the integrated control Proceed to test 4. FIGURE 16 Page 19 Replacing the Motor Module Motor Test 1. Disconnect electrical power to unit. 2. Remove unit access panel. IIIIP 3. Unplug the two harnesses from the motor control mod- ule. See figure 17. Unplug the Two Harness Connection ,r,r CONN ,44k/ ETwO CTIONS OW- 19 TABLE 8 MOTOR Measurement range in MOTOR CONTROL MODULE Scale words ohms two 2 M ohms megohm-two million 0-2,000,000 "C LT'-0 -=I I=n --" two hundred kilo-ohm-two „"„ o „„_a„ 200 K hundred thousand ohms 0-200,000 '" T'-'3 w� I IC' oo„o la a;w!` twenty kilo-ohm-twenty r< o 'oI Hz 0-,,,- 20 K thousand ohms 0-20,000 -- „—e N-I 2 K two kilo-ohm two-thousand 0-2,000 FIGURE 17 ohms 200 two hundred ohms 0-200 4. Remove the two hex head bolts securing the motor Motor Module Installation control module to the motor(see figure 18). All replacement motor control modules look similar; how- ever, each module is designed for a specific motor size. It is very important to make sure that you are using the correct Remove the Hex Head Bolts replacement motor control module. USE OF THE WRONG • MOTOR CONTROL MODULE MAY RESULT IN UNEX- PECTED UNIT OPERATION. 1. Verify electrical power to unit is disconnected. 2. Connect three-wire harness from motor to control module. 3. Mount new motor control module 1 1n6 REMOVE BOTH HEX�_ ; to motor using two hex head bolts TURN HEAD BOLTS removed in figure 18.Torque bolts 11 to 22 inch pounds or 1/16th clock 9 0 3 turn as exampled to the right. 4 FIGURE 18 4. Reconnect the two harnesses to ' 6 5 5. Slide the motor control module away from the motor to the motor control module. access and disconnect the internal three wire connec- 5. The electrical connectors of the motor should be facing tor. It is not necessary to remove blower motor itself. down to form a drip loop (figure20). This will directs Set both hex head bolts aside. moisture away from the motor and its electric connec- tions on the motor. Testing the Motor(Figure19) Drip Loop If any motor fails the below tests, do not install the new con- BACK OF CONTROL trol module. The motor is defective and it also must be re- MODULE placed.The new control can fail if placed on a defective mo- 0 CONNECTOR tor. ORIENTATION 1. Using an ohmmeter check the resistance from any one BE o CLOCKNO a of the motor connector pins to the aluminum end plate lIlllo? / of the motor. This resistance should be greater than IIIIW A 100k ohms. 2. Check the resistances between each of the three mo- tor connector pins. These should all read approxim- DRIP LOOP ately the same resistance within an ohm. 3. Check to see if the blower wheel spins freely. FIGURE 20 Page 20 II-PLACEMENT AND INSTALLATION Pipe & Fittings Specifications A IMPORTANT All pipe,fittings, primer and solvent cement must conform ML196UHE exhaust and intake connections are ' with American National Standard Institute and the Ameri- made of PVC. Use PVC primer and solvent cement can Society for Testing and Materials(ANSIIASTM)stan- when using PVC vent pipe. When using ABS vent dards. The solvent shall be free flowing and contain no pipe, use transitional solvent cement to make con- nections to the PVC fittings in the unit. lumps, undissolved particles or any foreign matter that ad- versely affects the joint strength or chemical resistance of Use PVC primer and solvent cement or ABS solvent cement the cement. The cement shall show no gelation,stratifica- meeting ASTM specifications, refer to Table 9.As an alter- tion, or separation that cannot be removed by stirring. Re- nate, use all purpose cement, to bond ABS, PVC, or CPVC fer to the table 9 below for approved piping and fitting ma- pipe when using fittings and pipe made of the same materi- terials. als. Use transition solvent cement when bonding ABS to ei- ther PVC or CPVC. Low temperature solvent cement is recommended during ACAUTION cooler weather. Metal or plastic strapping may be used for Solvent cements for plastic pipe are flammable liq- vent pipe hangers. Uniformly apply a liberal coat of PVC uids and should be kept away from all sources of primer for PVC or use a clean dry cloth for ABS to clean in- ignition. Do not use excessive amounts of solvent side socket surface of fitting and male end of pipe to depth cement when making joints. Good ventilation should of fitting socket. be maintained to reduce fire hazard and to minimize Canadian Applications Only - Pipe, fittings, primer breathing of solvent vapors. Avoid contact of ce- and solvent cement used to vent (exhaust) this ap- ment with skin and eyes. pliance must be certified to ULC S636 and supplied by a TABLE 9 single manufacturer as part of an approved vent (ex- PIPING AND FITTINGS SPECIFICATIONS haust) system. In addition, the first three feet of vent Schedule 40 PVC(Pipe) D1785 pipe from the furnace flue collar must be accessible for Schedule 40 PVC(Cellular Core Pipe) F891 inspection. Schedule 40 PVC(Fittings) D2466 Schedule 40 CPVC(Pipe) F441 Schedule 40 CPVC(Fittings) F438 SDR-21 PVC or SDR-26 PVC(Pipe) D2241 SDR-21 CPVC or SDR-26 CPVC(Pipe) F442 Schedule 40 ABS Cellular Core DWV(Pipe) F628 Schedule 40 ABS(Pipe) D1527 Schedule 40 ABS(Fittings) D2468 ABS-DM(Drain Waste&Vent) D2661 (Pipe&Fittings) PVC-DWV(Drain Waste&Vent) D2665 Pipe&Fittings) PRIMER&SOLVENT CEMENT ASTM SPECIFICATION PVC&CPVC Primer F656 PVC Solvent Cement D2564 CPVC Solvent Cement F493 ABS Solvent Cement D2235 PVC/CPVC/ABS All Purpose Cement For D2564, D2235,F493 Fittings Si Pipe of the same material ABS to PVC or CPVC Transition Solvent D3138 Cement CANADA PIPE&FITTING&SOLVENT MARKING CEMENT PVC&CPVC Pipe and Fittings PVC&CPVC Solvent Cement ULCS636 ABS to PVC or CPVC Transition Cement POLYPROPYLENE VENTING SYSTEM ULC-S636 PolvProo)by Duravent ULC-S636 InnoFlue°by Centrotherm ULC-S636 Page 21 TABLE 10 OUTDOOR TERMINATION USAGE* STANDARD CONCENTRIC Flush- Wall Kit Wall Ring Kit Vent Mount 1-1/2 inch 2 inch 3 inch Input Size Pipe Kit 2 inch 3 inch 2 inch Field Dia.in. 51W11 44J40 Fabricated 71 M80 69M29 (US) 22G44(US) (US) (US) 60L46(US) 51W12 430G28(CA) 481J20S(CA) 15F74 444W92 444W92 444W93(CA) (CA) (CA) (CA) 61-1/2 3YES YES 1YES 2YES 5YES 2YES N/A N/A 2 3YES YES 1YES 1YES 5YES 2YES N/A N/A 030, 045 2-1/2 3YES YES 1YES 1YES 5YES 2YES N/A N/A 3 3YES YES 1YES 1YES 5YES 2YES N/A N/A 61-1/2 3YES YES 1YES 1YES 5YES 2YES N/A N/A 2 3YES YES 1YES 1YES 5YES 2YES N/A N/A 070 2-1/2 3YES YES 1YES 1YES 5YES 2YES N/A N/A 3 3YES YES 1YES 1YES 5YES 2YES N/A N/S 2 3YES N/A YES YES 5YES N/A YES YES 090 2-1/2 3YES N/A YES YES 5YES N/A YES YES 3 3YES N/A YES YES 5YES N/A YES YES 2 YES N/A YES YES 5YES N/A YES YES 110 2-1/2 YES N/A YES N/A 5YES N/A YES YES 3 YES N/A YES N/A 5YES N/A YES YES 135 3 YES N/A YES N/A 5YES N/A YES YES NOTE- Standard Terminations do not include any vent pipe or elbows external to the structure.Any vent pipe or elbows external to the structure must be included in total vent length calculations.See vent length tables. *Kits must be properly installed according to kit instructions. 1Requires field-provided outdoor 1-1/2"exhaust accelerator. 2Concentric kits 71M80 and 44 W92 include 1-1/2"outdoor accelerator,when used with 030, 045 and 070 input models.When using 1-1/2 inch vent pipe,transition to 2"pipe before installing concentric kit. 3Flush mount kits 51W11 and 51W12 includes 1-1/2 in.outdoor exhaust accelerator,required when used with 030, 045, 070 and 090 input models...When using 1-1/2 in.piping,the pipe must be transitioned to 2 in.pipe when used with the Flush Mount Kit. 4 Termination kits 30G28,44W92,4493 and 81J20 are certified to ULC S636 for use in Canada only 5 See table 15 for vent accelerator requirements. 62 inch to 1-1/2 inch reducer required,must be field provided. 4 - Test fit joint and mark depth of fitting on outside of pipe. Joint Cementing Procedure All cementing of joints should be done according to the 5 - Uniformly apply a liberal coat of PVC primer for PVC or use a clean dry cloth for ABS to clean inside socket specifications outlined in ASTM D 2855. surface of fitting and male end of pipe to depth of fitting socket. A DANGER NOTE - Time is critical at this stage. Do not allow DANGER OF EXPLOSION! primer to dry before applying cement. Fumes from PVC glue may ignite during system 6 - Promptly apply solvent cement to end of pipe and in- check. Allow fumes to dissipate for at least 5 minutes side socket surface of fitting. Cement should be ap- before placing unit into operation. plied lightly but uniformly to inside of socket. Take care to keep excess cement out of socket.Apply sec- 1 - Measure and cut vent pipe to desired length. and coat to end of pipe. 2 - Debur and chamfer end of pipe, removing any ridges 7 - Immediately after applying last coat of cement to pipe, or rough edges. If end is not chamfered, edge of pipe and while both inside socket surface and end of pipe may remove cement from fitting socket and result in a are wet with cement, forcefully insert end of pipe into leaking joint. socket until it bottoms out.Turn PVC pipe 1/4 turn dur- NOTE- Check the inside of vent pipe thoroughly for ing assembly(but not after pipe is fully inserted)to dis- any obstruction that may alter furnace operation. tribute cement evenly. DO NOT turn ABS or cellular 3- Clean and dry surfaces to be joined. core pipe. Page 22 NOTE-Assembly should be completed within 20 sec- - onds after last application of cement. Hammer blows CHIMNEY Alk REPLACING FURNACE THAT should not be used when inserting pipe. OR EGAs AS PART OF A COMMON check sizing VENT SYSTEM 8- After assembly,wipe excess cement from pipe at end for water - of fitting socket. A properly made joint will show a heater only ' bead around its entire perimeter.Any gaps may indi- cate an improper assembly due to insufficient sol- ■ WATER vent. HEATER FURNACE 9- Handle joints carefully until completely set. , — \ VentingPracticesOPENINGS (To Adjacent FF t / Room) m C Piping Suspension Guidelines I '' II II II II ' ' II • 1 SCHEDULE 40 [ I' a ,. PVC -5' If an ML196UHE furnace replaces a furnace which gall other pipe* -3' `— was commonly vented with another gas appliance, / a the size of the existing vent pipe for that gas ap- A u pliance must be checked. Without the heat of the I) c I original furnace flue products,the existing vent pipe See table 9 for allowable pipe. is probably oversized for the single water heater or other appliance. The vent should be checked for NOTE-Isolate piping at the point where it exits the outside wall or roof in order to prevent transmission of vibration to the structure. proper draw with the remaining appliance. FIGURE 22 Wall Thickness Guidelines 24" maximum 3/4" minimum Exhaust Piping (Figures 25 and 26) inside Wall outside Route piping to outside of structure. Continue with installa- A7 tion following instructions given in piping termination sec- tion..,, ,,. -- F-....,,....,..., 1. IMMO ."' insulation A CAUTION (if required) Do not discharge exhaust into an existing stack or stack that also serves another gas appliance. If verti- calFIGURE 21 discharge through an existing unused stack is re- quired, insert PVC pipe inside the stack until the end 6. In areas where piping penetrates joists or interior is even with the top or outlet end of the metal stack. walls, hole must be large enough to allow clearance on all sides of pipe through center of hole using a hanger. A CAUTION 7. When furnace is installed in a residence where unit is shut down for an extended period of time,such as a va- The exhaust vent pipe operates under positive pres- cation home, make provisions for draining condensate sure and must be completely sealed to prevent leak- collection trap and lines. age of combustion products into the living space. Page 23 Vent Piping Guidelines TABLE 11 MINIMUM VENT PIPE LENGTHS NOTE- Lennox has approved the use of DuraVent®and ML196UHE MIN.VENT LENGTH* Centrotherm manufactured vent pipe and terminations as MODEL r an option to PVC. When using the PolyPro®by DuraVent or 15 k.030,045,070,090, 110, 135 5 ft.plus 2 elbows or lnnoFlue®by Centrotherm venting system the vent pipe re- 1 o ft.plus 1 elbow quirements stated in the unit installation instruction-mini- Any approved termination may be added to the minimum length listed. mum & maximum vent lengths, termination clearances, Use the following steps to correctly size vent pipe diameter. etc. -apply and must be followed. Follow the instructions provided with PoyPro by DuraVent and InnoFlue by Cen- trotherm venting system for assembly or if requirements Piping Size Process are more restrictive. The PolyPro by Duravent and In- noFlue by Centrotherm venting system must also follow the uninsulated and unconditioned space criteria listed in What is the table 14. O furnace capacity? The ML196UHE 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 1 taken from indoors and flue gases are discharged outdoors. Which style termination In Direct Vent installations, combustion air is taken from out-0 being used? doors and flue gases are discharged outdoors. Intake and exhaust pipe sizing--Size pipe according to ta- Standard or concentric? bles 11 and 12. Count all elbows in side and outside the home. Table 11 lists the minimum vent pipe lengths permit- - Which needs ted. Table 12 lists the maximum pipe lengths permitted. 3 most elbows? Regardless of the diameter of pipe used,the standard roof O Intake or and wall terminations described in section Exhaust Piping exhaust? 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 15. How many elbows? In some applications which permit the use of several differ- ® Count all elbows inside ent sizes of vent pipe, a combination vent pipe may be and outside house. used. Contact Lennox' Application Department for assis- tance in sizing vent pipe in these applications. - NOTE- The exhaust collar on all models is sized to ac- O Desired pipe size? commodate 2"Schedule 40 vent pipe. In horizontal appli- cations, any transition to exhaust pipe larger than 2"must , be made in vertical runs of the pipe. Therefore a 2"elbow i must be added before the pipe is transitioned to any size 1 larger than 2". This elbow must be added to the elbow What is the altitude of count used to determine acceptable vent lengths. Con- © the furnace installation? tact the Application Department for more information concerning sizing of vent systems which include multiple pipe sizes. Find max intake or • exhaust pipe length. Exhaust Pipe I O Includes all vent pipe and If 12"Min. loll elbows inside and outside roil— —pi Ifr—Sthe house. 12"max � I of straight pipe, I U/ I-0 Horizontal Application FIGURE 24 NOTE-All horizontal runs of exhaust pipe must slope back to- ward unit.A minimum of 1/4"(6mm)drop for each 12"(305mm) A I M P O RTP N T of horizontal run is mandatory for drainage. NOTE-Exhaust pipe MUST be glued to furnace exhaust fittings. NOTE-Exhaust piping should be checked carefully to make Do not use screens or perforated metal in exhaust or sure there are no sags or low spots. intake terminations. Doing so will cause freeze-ups FIGURE 23 and may block the terminations. Page 24 TABLE 12 . Maximum Allowable Intake or Exhaust Vent Length in Feet NOTE-Size intake and exhaust pipe length separdlely. Values in table are for Intake OR Exhaust,not combined total. Both Intake and Exhaust must be same pipe size. NOTE- Additional vent pipe and elbows used to terminate the vent pipe outside the structure must be included in the total vent length calculation. Standard Termination at Elevation 0-4500 ft 1-1/2"Pipe 2"Pipe 2-1/2"Pipe 3" Pipe Number Of 90°El- Model Model Model Model bows Used 030 045 070 090 110 030 070 090 110 030 070 090 110 030 070 090 110 135 045 045 045 1 25 20 15 81 66 44 24 115 115 93 58 138 137 118 118 80 2 20 15 10 76 61 39 19 110 110 88 53 133 132 113 113 75 3 15 10 71 56 34 14 105 105 83 48 128 127 108 108 70 4 10 66 51 29 100 100 78 43 123 122 103 103 65 5 61 46 24 95 95 73 38 118 117 98 98 60 n/a n/a - 6 56 41 19 90 90 68 33 113 112 93 93 55 n/a 7 n/a 51 36 14 n/a 85 85 63 28 108 107 88 88 50 n/a 8 46 31 80 80 58 23 103 102 83 83 45 9 41 26 n/a 75 75 53 18 98 97 78 78 40 10 36 21 70 70 48 13 93 92 73 73 35 Standard Termination Elevation 4500-10,000 ft 1-1/2"Pipe 2"Pipe 2-1/2"Pipe 3"Pipe Number Of 90°El- Model Model Model Model bows Used 030 045 070 090 110 030 070 090 110 030 070 090 110 030 070 090 110 135 045 045 045 1 25 20 15 81 66 44 115 115 93 58 138 137 118 118 80 2 20 15 10 76 61 39 110 110 88 53 133 132 113 113 75 3 15 10 71 56 34 105 105 83 48 128 127 108 108 70 4 10 66 51 29 100 100 78 43 123 122 103 103 65 5 61 46 24 95 95 73 38 118 117 98 98 60 n/a n/a - n/a 6 56 41 19 90 90 68 33 113 112 93 93 55 n/a 7 n/a 51 36 14 85 85 63 28 108 107 88 88 50 1 n/a : - 8 46 31 80 80 58 23 103 102 83 83 45 9 41 26 n/a 75 75 53 18 98 97 78 78 40 10 36 21 70 70 48 13 93 92 73 73 35 Page 25 TABLE 12 Continued 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. Concentric Termination at Elevation 0-4500 ft Number Of 1-1/2"Pipe 2"Pipe 2-1/2"Pipe 3"Pipe I 90°Elbows Model Model Model Model Used 030 045 070 090 110 030 070 090 110 030 070 090 110 030 070 090 110 135 045 045 045 1 20 15 10 73 58 42 22 105 105 89 54 121 121 114 114 70 2 15 10 68 53 37 17 100 100 84 49 116 116 109 109 65 3 10 63 48 32 12 95 95 79 44 111 111 104 104 60 4 58 43 27 90 90 74 39 106 106 99 99 55 5 53 38 22 85 85 69 34 101 101 94 94 50 n/a n/a - - 6 n/a 48 33 17 80 80 64 29 96 96 89 89 45 n/a - - 7 n/a 43 28 12 n/a 75 75 59 24 91 91 84 84 40 8 38 E 23 70 70 54 19 86 86 79 79 35 9 33 1 18 n/a 65 65 49 14 81 81 74 74 30 10 28 13 60 60 44 n/a 76 76 69 69 25 Concentric Termination Elevation 4501 -10,000 ft Number Of 1-1/2 Pipe 2"Pipe 2-1/2"Pipe 3"Pipe 90°Elbows Model Model Model Model Used 030 045 070 090 110 030 070 090 110 030 070 090 110 030 070 090 110 135 045 045 045 1 20 15 10 73 58 42 105 105 89 54 121 121 114 114 70 2 15 10 68 53 37 100 100 84 49 116 116 109 109 65 3 10 63 48 32 95 95 79 44 111 111 104 104 60 4 58 43 27 90 90 74 39 106 106 99 99 55 5 53 38 22 85 85 69 34 101 101 94 94 50 n/a n/a n/a 6 n/a 48 33 17 80 80 64 29 96 96 89 89 45 n/a 7 n/a 43 28 12 75 75 59 24 91 91 84 84 40 8 38 23 70 70 54 19 86 86 79 79 35 9 33 18 n/a 65 65 49 14 81 81 74 74 30 10 28 13 60 60 44 n/a 76 76 69 69 25 Page 26 TABLE 13 Maximum Allowable Exhaust Vent Lengths With Furnace Installed in a Closet or Basement Using Ventilated Attic or Crawl Space For Intake Air in Feet NOTE- Additional vent pipe and elbows used to terminate the vent pipe outside the structure must be included in the total vent length calculation. Standard Termination at Elevation 0 - 10,000 ft 1-1/2"Pipe 2"Pipe 2-1/2"Pipe 3"Pipe Number Of 90° Model Model Model Model Elbows Used 030 045 070 090 110 030 070 090 110 030 070 090 110 030 070 090 110 135 045 045 045 1 20 15 10 71 56 34 14 100 100 78 43 118 117 98 98 60 2 15 10 66 51 29 9 95 95 73 38 113 112 93 93 55 3 10 61 46 24 4 90 90 68 33 108 107 88 88 50 4 56 41 19 85 85 63 28 103 102 83 83 45 5 51 36 14 80 80 58 23 98 97 78 78 40 n/a n/a 6 n/a 46 31 9 85 75 63 18 93 92 73 73 35 7 n/a Na 41 26 4 n/a 70 70 48 13 88 87 68 68 30 8 36 21 65 65 43 8 83 82 63 63 25 9 31 16 n/a 60 60 38 3 78 77 58 58 20 10 26 11 55 55 33 n/a 73 72 53 53 15 Page 27 TYPICAL EXHAUSTAND INTAKE PIPE CONNECTIONS IN UPFLOW DIRECT OR NON-DIRECT VENT APPLICATIONS 2" EXHAUST INTAKE EXHAUST INTAKE 2„ 2" r or 2" 2„ 3„ 3„ I I )—I) t o 1.1111 O 030/045/070 Only � 1-1/2" I TRANSITION 1 Exhaust DO NOT transition Exhaust from larger to smaller DO NOT transition Exhaust pipe in horizontal runs from smaller to larger of exhaust pipe. , , pipe in horizontal runs of exhaust pipe. *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 25 TYPICAL EXHAUST AND INTAKE PIPE CONNECTIONS IN HORIZONTAL DIRECT OR NON-DIRECT VENT APPLICATIONS (RIGHT HAND DISCHARGE SHOWN) 12"max. 45° 45° _bI 141—r MAX MAX I I 2" EXHAUST I I or 2•I I Exhaust I Ij 10) i „/i ,. DO NOT transition SIDE VIEW O — or 2" from smaller to larger pipe in horizontal runs 2„ of exhaust pipe. INTAKE 2.. Exhaust III I� fa ■►+ Va& EXHAUST *2"1 3" 030/045/070 Only I *2,. ligi DO NOT transition rit _ from larger to smaller 1-1/2" pipe in horizontal runs TRANSITION O *2"' of exhaust pipe. INTAKE *2,. ii, *2.. Exhaust —. d *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 26 Page 28 Intake Piping TYPICAL AIR INTAKE PIPE CONNECTIONS The ML196UHE furnace may be installed in either direct UPFLOW NON-DIRECT vent or non-direct vent applications. In non-direct vent VENT APPLICATIONS applications,when intake air will be drawn into the furnace INTAKE from the surrounding space,the indoor air quality must be [ DEBRIS considered and guidelines listed in Combustion, Dilution SCREEN and Ventilation Air section must be followed. (Provided) Follow the next two steps when installing the unit in Direct Vent applications, where combustion air is taken from ° O - outdoors and flue gases are discharged outdoors. The -! provided air intake screen must not be used in direct _ !ql. vent applications (outdoors). b _--� 1 - Use transition solvent cement or a sheet metal screw 08 01. to secure the intake pipe to the inlet air connector. 2 - Route piping to outside of structure. Continue with in- stallation following instructions given in general guide- lines for piping terminations and intake and exhaust piping terminations for direct vent sections. Refer to r r table 12 for pipe sizes. , 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 NOTE- Debris screen and elbow may be rotated, so that air intake screen to route the intake piping as shown in screen may be positioned to face forward or to either side. figure 27 or 28. Maintain a minimum clearance of 3" (76mm)around the air intake opening. The air intake FIGURE 27 opening (with the protective screen)should always be TYPICAL AIR INTAKE PIPE CONNECTIONS directed forward or to either side in the upflow position, HORIZONTAL NON-DIRECT VENT APPLICATIONS and either straight out or downward in the horizontal (Horizontal Right-Hand Air Discharge Application Shown) position. The air intake piping must not terminate too close to the flooring or a platform. Ensure that the intake air inlet will not be obstructed by loose insulation r -L PVC pipe or other items that may clog the debris screen. coupling •III 2 - If intake air is drawn from a ventilated attic(figure 29) - L or ventilated crawls ace (figure 30)the exhaust vent 0 - P length must not exceed those listed in table 13. If 3"di- oR ameter pipe is used, reduce to 2"diameter pipe at the termination point to accommodate the debris screen. 11 ) 3 - Use a sheet metal screw to secure the intake pipe to rI the connector, if desired. INTAKE DEBRIS SCREEN (Provided) NOTE- Debris screen may be positioned straight out (preferred) or with an elbow rotated to face down. FIGURE 28 Page 29 ACAUTION General Guidelines for Vent Terminations In Non-Direct Vent applications, combustion air is taken If this unit is being installed in an application with from indoors and the flue gases are discharged to the out- combustion air coming in from a space serviced by doors. The ML196UHE is then classified as a non-direct an exhaust fan, power exhaust fan, or other device vent, Category IV gas furnace. which may create a negative pressure in the space, take care when sizing the inlet air opening. The in- In Direct Vent applications, combustion air is taken from iet air opening must be sizes to accommodate the outdoors and the flue gases are discharged to the out- maximum volume of exhausted air as well as the doors. The ML196UHE is then classified as a direct vent, maximum volume of combustion air required for Category IV gas furnace. all gas appliances serviced by this space. In both Non-Direct Vent and Direct Vent applications, the vent termination is limited by local building codes. In the EQUIPMENT IN CONFINED SPACE absence of local codes, refer to the current National Fuel (Inlet Air from Ventilated Attic and Outlet Air to Outside) Gas Code ANSI Z223-1/NFPA 54 in U.S.A., and current _ Ventilation Louvers CSA-B149 Natural Gas and Propane Installation Codes in Roof Terminated Inlet Air Canada for details. Exhaust Pipe (Minimum r� /12 in.(305mm)Above Position termination according to location given in figure 32 \attic floor) or 33. In addition, position termination so it is free from any \ obstructions and 12" above the average snow accumula- *Intake Debris tion. Screen (Provided) At vent termination, care must be taken to maintain Furnace protective coatings over building materials (prolonged exposure to exhaust condensate can destroy protective coatings). It is recommended that the exhaust outlet not be * See table 13 for maximum vent lengths located within 6 feet (1.8m)of a condensing unit because NOTE-The inlet and outlet air openings shall each have a free area the condensate can damage thepainted coating. of at least one square inch per 4,000 Btu(645mm2 per 1.17kW)per g hour of the total input rating of all equipment in the enclosure. NOTE- See table 14 for maximum allowed exhaust pipe FIGURE 29 length without insulation in unconditioned space during winter design temperatures below 32°F(0°C). If required EQUIPMENT IN CONFINED SPACE exhaust pipe should be insulated with 1/2" (13mm) Ar- (Inlet Air from Ventilated Crawlspace and Outlet Air to Outside) ma flex or equivalent. In extreme cold climate areas, 3/4" (19mm)Armaflex or equivalent may be necessary. Insula- tion must be protected from deterioration. Armaflex with UV protection is permissable. Basements or other en- Roof Terminated Exhaust Pipe I _� closed areas that are not exposed to the outdoor ambient %.♦ temperature and are above 32 degrees F(0°C) are to be considered conditioned spaces. I , ' Inlet Air (Minimum A IMPORTANT Ventilation 12 in.(305mm) Louvers Furnac= Above crawl Do not use screens or perforated metal in exhaust (Crawl space) space floor)/ - terminations. Doing so will cause freeze-ups and p p may block the terminations. o Coupling or 3 in.to 2 in. *Intake Debris Screen Provided) A IMPORTANT Transition (Field Provided) For Canadian Installations Only: * See table 13 for maximum vent lengths In accordance to CSA International B149 installation NOTE-The inlet and outlet air openings shall each have a free area codes, the minimum allowed distance between the of at least one square inch per 4,000 Btu(645mm 2per 1.17kW)per combustion air intake inlet and the exhaust outlet of hour of the total input rating of all equipment in the enclosure. other appliances shall not be less than 12 inches FIGURE 30 (305mm). Page 30 TABLE 14 Maximum Allowable Exhaust Vent Pipe Length (in ft.)3 Without Insulation In Unconditioned Space For Winter Design Temperatures Single -Stage High Efficiency Furnace Winter Design Vent Pipe Unit Input Size 1Diameter Temperatures1 °F (°C) D a 070 090 110 135 p 030 045 PVC 2PP PVC 2PP PVC 2PP PVC 2PP PVC 2PP PVC 2PP 1-1/2 in. 25 N/A 20 N/A N/A N/A N/A N/A N/A N/A 32 to 21 2in. 18 16 31 28 50 48 30 30 N/A N/A (o to-6) 2-1/2 in. 13 N/A 24 N/A 42 N/A 56 N/A N/A N/A 3 in. 9 9 18 18 35 35 47 47 42 42 1-1/2 in. 15 N/A 20 N/A N/A N/A N/A N/A N/A N/A 20 to 1 2in 9 8 18 16 32 29 30 30 N/A N/A N/A N/A (-7 to-17) 2-1/2 in. 5 N/A 13 N/A 24 N/A 34 N/A N/A N/A 3 in. N/A N/A 8 8 19 19 26 26 23 23 1-1/2 in. 10 N/A 15 N/A N/A N/A N/A N/A N/A N/A 0 to-20 2in. 5 3 12 10 22 19 30 27 N/A N/A (-18 to-29) 2-1/2 in. N/A N/A 7 N/A 15 N/A 22 N/A N/A N/A 3 in. N/A N/A N/A N/A 10 10 16 16 13 13 1Refer to 99%Minimum Design Temperature table provided in the current edition of the ASHRAE Fundamentals Handbook. 2Poly-Propylene vent pipe(PP)by Duravent and Centrotherm. NOTE-Concentric terminations are the equivalent of 5'and should be considered when measuring pipe length. NOTE-Maximum uninsulated vent lengths listed may include the termination(vent pipe exterior to the structure)and cannot exceed 5 linear feet or the maximum allowable intake or exhaust vent length listed in table 12 or 13 which ever is less. NOTE-If insulation is required in an unconditioned space,it must be located on the pipe closest to the furnace. See figure3l. 3 Vent length in the table is equivalent length.Each elbow is equivalent to 5ft of straight pipe length and should be included in measuring total pipe length. Conditioned Space Exhaust (Pipe Insulation f Pipe Conditioned Intake Pipe Space Unconditioned Space I 1 1 1 1 1 1 I I I I I I I I I FIGURE 31 Page 31 VENT TERMINATION CLEARANCES FOR NON-DIRECT VENT INSTALLATIONS IN THE USA AND CANADA - INSIDE CORNER DETAIL —vi G k —.1 Hr-- I I Fixed Fixed ' Operable Closed , ' ,/ f F Closed + \ Operable 1— N y',:, K A ��0� F71 WHERE ID VENT TERMINAL ®AIR SUPPLY INLET SREA PERMITT DMINAL US Installationst Canadian Installations2 A= Clearance above grade,veranda, 12 inches(305mm)or 12 in.(305mm) 12 inches(305mm)or 12 in.(305mm) porch,deck or balcony above average snow accumulation. above average snow accumulation. B= Clearance to window or 6 inches(152mm)for appliances<10,000 door that may be opened 4 feet(1.2 m)below or to side of opening; Btuh(3kw), 12 inches(305mm)for 1 foot(30cm)above opening appliances> 10,000 Btuh(3kw)and <100,000 Btuh(30kw),36 inches(.9m) for appliances>100,000 Btuh(30kw) C= Clearance to permanently . 12" *12" closed window D= Vertical clearance to ventilated soffit located above the terminal within a *Equal to or greater than soffit depth. *Equal to or greater than soffit depth. horizontal distance of 2 feet(610 mm) from the center line of the terminal E= Clearance to unventilated soffit •Equal to or greater than soffit depth. *Equal to or greater than soffit depth. F= Clearance to outside corner *No minimum to outside corner *No minimum to outside corner • G= Clearance to inside corner * * H= Clearance to each side of center line ex- • 3 feet(.9m)within a height 15 feet(4.5m) 3 feet(.9m)within a height 15 feet(4.5m) tended above meter/regulator assembly above the meter/regulator assembly above the meter/regulator assembly I= Clearance to service regulator •3 feet(.9m) 3 feet(.9m) vent outlet J= Clearance to non-mechanical air 6 inches(152mm)for appliances<10,000 supply inlet to building or the corn- 4 feet(1.2 m)below or to side of opening; Btuh(3kw), 12 inches(305mm)for bustion air inlet to any other ap- 1 foot(30 cm)above opening appliances> 10,000 Btuh(3kw)and pliance <100,000 Btuh(30kw), 36 inches(.9m) for appliances>100,000 Btuh(30kw) K= Clearance to mechanical air sup- 3 feet(.9m)above if within 10 feet 6 feet(1.8m) ply inlet (3m)horizontally L= Clearance above paved sidewalk or 7 feet(2.1m)t 7 feet(2.1m)t paved driveway located on public property M= Clearance under veranda, porch,deck or balcony •12 inches(305mm)$ 12 inches(305mm)$ z In accordance with the current ANSI Z223,l/NFPA 54 Natural Fuel Gas Code *For clearances not specified in ANSI Z223.1/NFPA 54 or CSA In accordance with the current CSA B149.1,Natural Gas and Propane Installation Code B149.1, clearance will be in accordance with local installation t A vent shall not terminate directly above a sidewalk or paved driveway that is codes and the requirements of the gas supplier and these instal- located between two single family dwellings and serves both dwellings. lation instructions." t 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 32 Page 32 VENT TERMINATION CLEARANCES FOR DIRECT VENT INSTALLATIONS IN THE USA AND CANADA INSIDE CORNER DETAIL G CI A H►� OO o V Fixed Fixed Operable Closed F rj Closed 1 �y 0 hib•perable A ►�B F71 AREA WHERE n VENT TERMINAL AIR SUPPLY INLET IL,LiISNO NOT TERMINAL US Installations.' Canadian Installations2 A= Clearance above grade,veranda, 12 inches(305mm)or 12 in.(305mm) 12 inches(305mm)or 12 in. (305mm) porch,deck or balcony above average snow accumulation. above average snow accumulation. B= Clearance to window or 6 inches(152mm)for appliances<10,000 6 inches(152mm)for appliances<10,000 door that may be opened Btuh(3kw),9 inches(228mm)for ap- Btuh(3kw), 12 inches(305mm)for pliances> 10,000 Btuh(3kw)and<50,000 appliances>10,000 Btuh(3kw)and Btuh(15 kw), 12 inches(305mm)for ap- <100,000 Btuh(30kw),36 inches(.9m) pliances>50,000 Btuh(15kw) for appliances>100,000 Btuh(30kw) C= Clearance to permanently *12" *12" closed window D= Vertical clearance to ventilated soffit located above the terminal within a *Equal to or greater than soffit depth *Equal to or greater than soffit depth horizontal distance of 2 feet(610mm) from the center line of the terminal E= Clearance to unventilated soffit *Equal to or greater than soffit depth *Equal to or greater than soffit depth F= Clearance to outside corner *No minimum to outside corner *No minimum to outside corner G= Clearance to inside corner * H= Clearance to each side of center line ex- 3 feet(.9m)within a height 15 feet(4.5m) 3 feet(.9m)within a height 15 feet(4.5m) tended above meter/regulator assembly above the meter/regulator assembly above the meter/regulator assembly I= Clearance to service regulator * 3 feet(.9m) 3 feet(.9m) vent outlet J= Clearance to non-mechanical air 6 inches(152mm)for appliances<10,000 6 inches(152mm)for appliances<10,000 supply inlet to building or the corn- Btuh(3kw),9 inches(228mm)for ap- Btuh(3kw), 12 inches(305mm)for bustion air inlet to any other ap- pliances> 10,000 Btuh(3kw)and<50,000 appliances>10,000 Btuh(3kw)and pliance Btuh(15 kw), 12 inches(305mm)for ap- <100,000 Btuh(30kw),36 inches(.9m) pliances>50,000 Btuh(15kw) for appliances>100,000 Btuh(30kw) K= Clearance to mechanical air sup- 3 feet(.9m)above if within 10 feet 6 feet(1.8m) ply inlet (3m)horizontally L= Clearance above paved sidewalk or *7 feet(2.1 m) 7 feet(2.1 m)t paved driveway located on public property 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 2 In accordance with the current CSA B149.1,Natural Gas and Propane Installation Code *For clearances not specified in ANSI Z223.1/NFPA 54 or CSA A vent shall not terminate directlyabove a sidewalk orpaved drivewaythat is located B149.1,clearance will be in accordance with local installation t codes and the requirements of the gas supplier and these between two single family dwellings and serves both dwellings. installation instructions." $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 33 Page 33 Details of Intake and Exhaust Piping Terminations for Exiting Exhaust and Intake Vent Direct Vent Installations (different pressure zones) 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 any vent termination is used and the flue gasses may impinge on the building ma- 1 I? 9 terial, a corrosion-resistant shield (minimum 24 inches q square) should be used to protect the wall surface. If the Exhaust Furnace i A1r Pipe (Minimmut um 12 in. optional tee is used, the protective shield is recommended. 305 MM)above The shield should be constructed using wood, plastic, grade or snow sheet metal or other suitable material. All seams, joints, accumulation cracks, etc. in the affected area should be sealed using an FIGURE 35 appropriate sealant. See figure 42. Intake and exhaust pipes may be routed either horizontally through an outside wall or vertically through the roof. In at- tic or closet installations, vertical termination through the roof is preferred. Figures 34 through 41 show typical termi- nations. Exiting Exhaust and Intake Vent 1. Intake and exhaust terminations are not required to be (different pressure zones) in the same pressure zone.You may exit the intake on one side of the structure and the exhaust on another i► side (figure 35).You may exit the exhaust out the roof Roof Terminated and the intake out the side of the structure (figure 36). Exhaust Pipe ..„,„,--A"--...„.„. 2. Intake and exhaust pipes should be placed as close together as possible at termination end (refer to illus- II trations). Maximum separation is 3" (76mm) on roof terminations and 6" (152mm) on side wall termina- tions. Inlet Air NOTE- When ventingin differentpressure zones, the Furnace (Minimum b e 305 MM)above maximum separation requirement of intake and ex- grade or snow haust pipe DOES NOT apply. accumulation 3. On roof terminations, the intake piping should termi- FIGURE 36 nate straight down using two 90° elbows (See figure 34). TABLE 15 4. Exhaust piping must terminate straight out or up as EXHAUST PIPE TERMINATION SIZE REDUCTION shown.A reducer may be required on the exhaust pip- ML196UHE Termination ing at the point where it exits the structure to improve MODEL Exhaust Pipe Size Pipe Size the velocity of exhaust away from the intake piping. *030,045 and 070 1-1/2"(38mm) See table 15. *090 2"(51mm),2-1/2" 2"(51mm) 110 (64mm),3"(76mm) 2"(51mm) 3"(76mm)MAX. 135 2"(51mm) Inches(mm) SIZE TERMINATION -g. PIPE PER TABLE 15. `ML196UHE-030, -045, -070 and-090 units with the flush 1T UNCONDITIONED mount termination must use the 1-1/2"accelerator supplied 8"(203mm)MIN , , ATTIC SPACE with the kit. 91 1/2"(13mm)FOAM NOTE- Care must be taken to avoid recirculation of ex- 12"(305mm)ABOVE I INSULATION IN AVERAGE SNOW pi/ UNCONDITIONED haust back into intake pipe. ACCUMULATION 4 I', SPACE N. 5. On field-supplied terminations for side wall exit, ex- %II. —7 haust piping may extend a maximum of 12 inches 3"(76mm)0- g .7 I (305mm) for 2" PVC and 20 inches (508mm) for 3" 2"(51mm)PVC ■ (76mm) PVC beyond the outside wall. Intake piping should be as short as possible. See figure 42. PROVIDE SUPPORT FOR INTAKE AND 6. On field-supplied terminations, a minimum distance EXHAUST LINES between the end of the exhaust pipe and the end of DIRECT VENT ROOF TERMINATION KIT the intake pipe without a termination elbow is 8"and a (15F75 or 44J41) minimum distance of 6"with a termination elbow. See FIGURE 34 figure 42. Page 34 7. If intake and exhaust piping must be run up a side wall - to position above snow accumulation or other ob- FIELD-P REDUCERMAYROVIDEDBEREQUIRED 1-1/2"(38mm)accelerator on 1M80 structions, piping must be supported. At least one TO ADAPT DIFFERENT VENT provideditsrL1 6UHE 444W92 P P 9 PP kits for ML196UHE045P24B, bracket must be used within 6"from the top of the el- PIPE SIZE TO TERMINATION 000 070P24B&070P36B • bow and then every 24" (610mm)as shown in figure OUTSIDE INTAKE 42, to prevent any movement in any direction.When WALL AIR exhaust and intake piping must be run up an outside EXHAUST VENT -. EXHAUST VENT wall,the exhaust piping must be terminated with pipe VENT sized per table 15.The intake piping maybeequipped ♦ ��=�-'EI'll I� PP 9 -r 4 ap .11 with a 90°elbow turndown. Using turndown will add 5 a 21-LIK: 12 (305mm)Mi . feet (1.5m)to the equivalent length of the pipe IAIR E CLAMP AIR above grade or (Not Furnished) average snow 8. A multiple furnace installation may use a group of up to accumulation. four terminations assembled together horizontally, as I GRADE shown in figure 40. DIRECT VENT CONCENTRIC WALL TERMINATION 71M80,69M29 or 60L46(US) 44W92 or 44W93(Canada) FIGURE 39 2"EXTENSION FOR 2" PVC PIPE1"EX EN QN FOR ' PVC PIPE --� FURNACE EXHAUST �I �, �) �� EXHAUST �(305mm) 4„ VENT : PIPE INTAKE y((- (725m"► �svz , 40m '. .Dad�L ',FURNACE --Nil". AIR INTAKE I(_ _66I P 'E (457mm) Front View 11 �1 - GLUE EXHAUST EXHAUST VENT ,;.. -� END FLUSH INTO 12"(305mm)Min. e • \ TERMINATION r grade� ' aboveor ''r average snow 11i FLAT Inches(mm) INTAKE accumulation. --�;�,I SIDE 1-1/2"ACCELERATOR Pill PI AIR (all-030, -45,-070 and-090 units) N,oaa 1 FLUSH-MOUNT SIDE WALL TERMINATION • 51W11 (US)or 51 W12(Canada) optional intake elbo Side View FIGURE 37 OPTIONAL VENT TERMINATION FOR MULTIPLE UNIT INSTALLATION OF DIRECT VENT WALL TERMINATION KIT (30G28 or 81J20) FIGURE 40 1 1/2"(38mm)accelerator provided on 71M80&44W92 ML196UHE DIRECT VENT APPLICATION EXHAUST ■ kits for ML196UHE045P24B, USING EXISTING CHIMNEY VENT M—I070P24B&070P36B AM FLASHING 3 $" STRAIGHT-CUT OR 12" (305mm) [INTAKE ANGLE-CUT IN DIRECTION (Not Furnished) (76mm203mm) OF ROOF SLOPEMinimum AIR Above Average ow �� . EXHAUST VENT AccmSaultion " 6•• \\\ (203mm-305mm) , wEVTH(ERPR)GOP .L/ INSULATION ��••• WSW SHEET METAL STRAP Minimum abov above chimney mney top ) INSSLSnIKEEET a I KE PIPE soPR Le oN SUPPORT oo OR TE (Clamp and sheet metal strap plate or average snow METAL TOP I /_ ALTERNATS E must be field installed to support • accumulation PLATE INTAKE PIPE ® ✓ Ilk the weight of the termination kit.) CLAMP -•' IIIII, wOO...I li 4 FIELD-PROVIDED pcmm- • r MIME 0 xo3mml ' I REDUCER MAY BE REQUIRED TO FORM - II- PORT of of L1 TO ADAPT LARGER VENT SEAL CHIMNEY p7 PIPE SIZE TO TERMINATION "SIZE TERMINATION = �V�i PIPE PER TABLE 15. - DIRECT VENT CONCENTRIC ROOFTOP TERMINATION 71M80,69M29 or 60L46(US) NOTE-Do not discharge exhaust gases directly into any chimney. -nt stack.If ver- 44W92 or 44W93(Canada) 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- FIGURE 38 trated.In any exterior portion of chimney,the exhaust vent must be insulated. FIGURE 41 Page 35 FIELD FABRICATED WALL TERMINATION NOTE-FIELD-PROVIDED REDUCER MAY BE REQUIRED TO ADAPT 2" (51mm) 3" (76mm) LARGER VENT PIPE SIZE Vent Pipe Vent Pipe TO TERMINATION p P A-Minimum clearance above grade or average 12"(305 mm) 12"(305 mm) �4 snow accumulation ��' `D �� D B-Maximum horizontal � l separation between 6"(152 mm) 6"(152 mm) 10> intake and exhaust l;� B� Cl -Minimum from end of 8"(203 mm) 8"(203 C1 Intake - exhaust to inlet of intake mm) CElbow . C2-Minimum from end of \ A,` STRAIGHT \ A�` exhaust to inlet of intake 6"(152 mm) 6"(152 mm) �c APPPLICATION �C D-Maximum exhaust 12"(305 mm) 20"(508 mm) pipe length E-Maximum wall support WALL distance from top of each 6"(152 mm) 6"(152 mm) SUPPORT pipe(intake/exhaust) E �D (` \D See venting table 12 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 within 6" (152 mm) Cl A yyy✓✓✓ \A� from top of each pipe (intake and exhaust) to prevent C EXTENDED C2 /' �c movement in any direction. APPLICATION ALTERNATE TERMINATIONS (TEE & FORTY-FIVE DEGREE ELBOWS ONLY) 2" (51MM) 3" (76MM) / Vent Pipe Vent Pipe ,;'- -4 DI Exhaust A-Clearance above / grade or average snow 12"(305 mm) Min. 12"(305 mm) Min. iz O �� D,/ accumulation 11.1<W0111 �C , B-Horizontal 6"(152 mm)Min. 6"(152 mm)Min. II C / i separation between 24"(610 mm) Max. 24" 610 mm) Max. Intake intake and exhaust ( O A Elbow A C-Minimum from �- end of exhaust to inlet of intake 9"(227 mm)Min. g°(227 mm)Min. 12" 305 305 D-Exhaust pipe length 6"( ) Max. 20"( ) Max. Front View of (405mm) (508mm) D Intake and Exhaust E-Wall support distance from top of each pipe 6"(152 mm)Max. 6"(152 mm)Max. ,.E _O -1' (intake/exhaust) " _ Intake Exhaust //� 12" rl't�C 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. 9 A 2 As required.Flue gas may be acidic and may adversely affect some building materials.If a side wall vent 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 recommended.The shield should be constructed using wood,sheet metal or other suitable material. All seams,joints,cracks,etc.in affected area,should be sealed using an appropriate 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 42 Page 36 Details of Exhaust Piping Terminations for Non-Direct ML196UHE NON-DIRECT VENT APPLICATION Vent Applications USING EXISTING CHIMNEY Exhaust pipes may be routed either horizontally through an SIZE TERMINATION STRAIGHT-CUT OR PIPE PER TABLE 15. ' ANGLE-CUT IN DIRECTION outside wall or vertically through the roof. In attic or closet /1 OF ROOF SLOPE installations, vertical termination through the roof is pre- t EXHAUST VENT ferred. Figures 43 through 44 show typical terminations. „z„ „, Minimum 12"(305MM) WEATHERPROOF I INSULATION 1. Exhaust piping must terminate straight out or up as above chimney top plate or average snow HOULDER OF FITTINGS shown. The termination pipe must be sized as listed in accumulation PROVIDE SUPPORT OF PIPE ON TOP PLATE table 15.The specified pipe size ensures proper ve- SHEET METAL TOP locity required to move the exhaust gases away from PLATE • the building. = n 2. On field supplied terminations for side wall exit, ex- INSULATE NM TO FORM M EXTOR haust piping may extend a maximum of 12 inches SEF � PC ERI CHIMNEY (305mm) for 2" PVC and 20 inches (508mm) for 3" = N (76mm) PVC beyond the outside wall. 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- SIZE TERMINATION Crated.In any exterior portion of chimney,the exhaust vent must be insulated. 12"(305mm) PIPE PER TABLE ABOVE AVE. 15. FIGURE 44 l SNOW ACCUMULATIO 1/2"(13mm)FOAM Condensate Piping '', INSULATION This unit is designed for either right-or left-side exit of con- , densate piping in upflow applications. In horizontal applica- tions, the condensate trap must extend below the unit. An 3"(76mm)OR UNCONDITIONED 8 service clearance is required for the condensate trap. 2"(51mm)PVC ATTIC SPACE Refer to figures 45 and 47 for condensate trap locations. PROVIDE SUPPORT Figure 53 shows trap assembly.. • FOR EXHAUST LINES 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 NON-DIRECT VENT ROOF TERMINATION KIT must slope down a minimum of 1/4"per ft. toward trap. (15F75 or 44J41) 1 - Determine which side condensate piping will exit the FIGURE 43 unit, location of trap,field-provided fittings and length of PVC pipe required to reach available drain. 3. If exhaust piping must be run up a side wall to position 2 - For furnaces with a 1/2" drain connection use a 3/8 above snow accumulation or other obstructions, pip- alien wrench and remove plug (figure 45)from the cold ing must be supported every 24 inches (610mm). end header box at the appropriate location on the side When exhaust piping must be run up an outside wall, of the unit. Install field-provided 1/2 NPT male fitting any reduction in exhaust pipe size must be done after into cold end header box. For furnaces with a 3/4" the final elbow. drain connection use a large flat head screw driver or a 1/2" drive socket extension and remove plug. Install 4. Distance between exhaust pipe terminations on multi- provided 3/4 NPT street elbow fitting into cold end pie furnaces must meet local codes. header box. Use Teflon tape or appropriate pipe dope. Page 37 NOTE-Cold end header box drain plugs are factory in- NOTE-Appropriately sized tubing and barbed fitting may - stalled. Check the unused plug for tightness to prevent be used for condensate drain. Attach to the drain on the leakage. trap using a hose clamp. See figure 46. 3 - Install the cap over the clean out opening at the base- Field Provided Drain Components of the trap. Secure with clamp. See figure 53. I _ 4- Install drain trap using appropriate PVC fittings, glue —I all joints. Glue the provided drain trap as shown in fig- ure 53. Route the condensate line to an open drain. Condensate line must maintain a 1/4"downward slope M from the furnace to the drain. Elbow i� I� ,,o CONDENSATE TRAP AND PLUG LOCATIONS ',� (Unit shown in upflow position) �—.�._ Tubing Barbed Fitting Trap ® ® (same on �� Hose Clamp right side) '*: �' , 1-1/2 in. II. i.(c,4 FIGURE 46 �I o `IG 1! a1114,k41, _.. ——17° Plug A CAUTION 1,! .inn (same on left side) Do not use copper tubing or existing copper conden- ginilli,;Yyn sate lines for drain line. lIU - o':._""1 6 - If unit will be started immediately upon completion of in- u.. - 10 stallation, prime trap per procedure outlined in Unit Start- Up section. !! 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 NOTE-In upflow applications where side return line should be routed within the conditioned space to air filter is installed on same side as the conden- avoid freezing of condensate and blockage of drain sate trap, filter rack must be installed beyond line. If this is not possible, a heat cable kit may be used condensate trap or trap must be re-located to on the condensate trap and line. Heating cable kit is available from Lennox in various lengths; 6 ft. (1.8m)- avoid interference. kit no. 26K68 and 24 ft. (7.3m) - kit no. 26K69. FIGURE 45 5- Figures 48 and 50 show the furnace and evaporator coil using a separate drain. If necessary the conden- sate line from the furnace and evaporator coil can drain together. See figures 49, 51 and 52. Upflow furnace (figure 51) - In upflow furnace applica- tions the field provided vent must be a minimum 1"to a maximum 2" length above the condensate drain outlet connection.Any length above 2" may result in a flood- ed heat exchanger if the combined primary drain line were to become restricted. Horizontal furnace (figure 52) - In horizontal furnace applications the field provided vent must be a mini- mum 4"to a maximum 5"length above the condensate drain outlet connection. Any length above 5" may re- sult in a flooded heat exchanger if the combined pri- mary drain line were to become restricted. NOTE-In horizontal applications it is recommended to install a secondary drain pan underneath the unit and trap assembly. Page 38 . CONDENSATE TRAP LOCATIONS Condensate Trap With Optional Overflow Switch (Unit shown in upflow position with remote trap) Field—Provided Vent From Evaporator Coil n (Upflow/Furnace 1"Min.to 2"Max. Horizontal Furnace 4"Min.to 5"Max.above Field ProvidedVent condensatedrain connection) Min.1"AboveCondensate _ / Drain Connection } 1"Min. ��+ 2 Max. I / ,� FurnaceCondensate O, �■ *5' max.--ol� �� Drain Connection PAC Pipe Only Optional 1� 0 of - Overflow Switch,�, O `' li n I Trap Can Be Installed a 1p p Maximum 5' From Furnace � � o iii To Drah *Piping from furnace must slope down a FIGURE 49 minimum 1/4"per ft.toward trap FIGURE 47 ML196UHE With Evaporator Coil Using A Separate Drain Evaporator drain line required. 0 00� V Trap optional. %• ,' • • 00 Field Provided Vent 0/1' (1"min.2"max.above i --- •I■r' l condensate connection) initir.. Owl Condensate Drain ConnectionII rat • FIGURE 48 Page 39 ML196UHE with Evaporatoir Coil Using a Separate Drain (Unit shown in horizontal left-hand discharge position) III Field Provided Vent Evaporator (4"min.to 5"max.above Coil4 condensate connection) • 4"min �I I.....,,, _ 5"max u) '—It 5'max. PVC Pipe Only /: _ �� V Condensate F Drain Connection I I 0% Drain Pan/ I Piping from furnace and evaporator coil must slope down a minimum 1/4"per ft.toward trap FIGURE 50 • ML196UHE with Evaporator A IMPORTANT Coil Using a Common Drain Evaporator drain line required. When combining the furnace and evaporator ,,00 %c Trap optional. coil drains together, the A/C condensate drain - ',% outlet must be vented to relieve pressure in or- ,00" der for the furnace pressure switch to operate Oo' I. properly. Field-Provided Vent .0- (1"min.to 2"Max.above r� I"'� condensate drain connection) �'7 Li Condensate Drain Connection rll y01 FIGURE 51 ML196UHE with Evaporator Coil Using a Common Drain (Unit shown in horizontal left-hand discharge position) Field-Provided Vent Evaporator (4"min.to 5"Max.above Coil condensate drain connection) .. � • 7 4"min „I I _ 5"max 5'max. I1! I PVC Pipe Only �I. ir___ , 11 I lin CondensConnectae ionDran 'ale u .' Drain Pan/ I Piping from furnace and evaporator coil must slope down a minimum 1/4"per ft.toward trap FIGURE 52 Page 40 TRAP/DRAIN ASSEMBLY USING 1/2" PVC OR 3/4" PVC Optional Condensate Drain Connection Adapter 3/4 inch slip X 1 3/4 inch mpt (not furnished) 90° Street Elbow \ 3/4 inch PVC (not furnished) JI1t1H1 Adapter 3/4 inch slip X 3/4 inch mpt(not furnished) Condensate Drain U 1 (25 mm) Min. Connection In Unit 2 (50 mm) Max. Vent i Condensate Drain Above Top Of �— 5 Feet 1_(... Connection In Unit Condensate Drain + Max mffil 90° Street Elbow Connection In Unit 0„ " I I 3/4 inch PVC I- 14. W (furnished) 90° Elbow 3/4 inch PVC (Not Furnished) To / Trap .. 1/2 inch PVC Pipe 3/4 inch PVC Pipe Optional Drain Piping From Trap (Not Furnished) (Not Furnished) C .1 Drain Assembly for 1/2 inch Drain Pipe Coupling 3/4 inch slip X slip (Not Furnished) r:1111 IIII _\1/2 inch PVC Pipe Ii (Not Furnished)IIII9Drain Trap W 90° Elbow So Assembly 1/2 inch PVC I 0 (Furnished) To (Not Furnished) i,i0 Drain — / �p Drain Assembly for 3/4 inch Drain Pipe ill Drain Trap Cl IJ Clean Out 90° Elbow — 90° Elbow I. 3/4 inch PVC I 3/4 inch PVC W (Not Furnished) W (Not Furnished) To To Coupling 3/4 inch slip X slip Drain Drain (Not Furnished) DrainTrap Assembly with 1/2 inch Piping DrainTrap Assembly with 3/4 inch Piping C1 (25 mm) Min. 2 (50 mm) Max.Above Top 1 (25 mm) Min.2 (50 mm) Max.Above Top , Of Condensate Drain Connection In Unit Of Condensate Drain Connection In Unit DrainTrap Assembly Vent Vent (Furnished) —rill f 3/4 inch ijt)1 iii Mil)) 1/2 inch �I I Condensate Drain Condensate Drain rir, (178) M ° Connection In Unit E Connection In Unit 13M '.- • p tjIJ ` lit' ili IICINI :Jli ? - To To 4f Drain To Drain J FIGURE 53 Page 41 l I III-START-UP 2 - Set the thermostat to the lowest setting. A-Preliminary and Seasonal Checks 3- Turn off all electrical power to the unit. 1- Inspect electrical wiring, both field and factory installed 4 - This furnace is equipped with an ignition device which for loose connections. Tighten as required. automatically lights the burners. Do not try to light the 2 - Check voltage at disconnect switch.Voltage must be with- burners by hand. in range listed on the nameplate. If not,consult the power 5- Remove the access panel. company and have voltage condition corrected be- 6- Move gas valve switch to OFF. See figure 54. fore starting unit. 3 - Inspect condition of condensate traps and drain as- 7 - Wait five mnutes to clear out any gas. If you then smell sembly. Disassemble and clean seasonally. gas, STOP! Immediately call your gas supplier from a B-Heating Start-Up neighbor's phone. Follow the gas supplier's instruc- tions. If you do not smell gas go to next step. BEFORE LIGHTING the unit, smell all around the fur- 8- Move gas valve switch to ON. See figure 54. 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 MANIFOLD PRESSURE floor. ADJUSTMENT SCREW (under barbed fitting) The gas valve on the ML196UHE is equipped with a gas �� MANIFOLD o PRESSURE control switch. Use only your hand to move the switch. i!rl,�;,�1/ �� 4 OUTLET Never use tools. If the the switch will not move by hand, 110 �. PORT replace the valve. Do not try to repair it. Force or attempt- i I ed repair may result in a fire or explosion. �I� �►- Placing the furnace into operation: iw•*OI ul _J ML196UHE units are equipped with a SureLight ignition INLET ��\ O �-' system. Do not attempt to manually light burners on this PRESSURE furnace. Each time the thermostat calls for heat, the PORT GAS VALVE SHOWN IN ON POSITION burners will automatically light. The ignitor does not get FIGURE 54 hot when there is no call for heat on units with SureLight- 9- Replace the access panel. ignition system. Priming Condensate Trap 10- Turn on all electrical power to to the unit. The condensate trap should be primed with water prior to 11 Set the thermostat to desired setting. start-up to ensure proper condensate drainage. Either NOTE - When unit is initially started, steps 1 through 11 pour 10 fl. oz. (300 ml) of water into the trap, or follow may need to be repeated to purge air from gas line. these steps to prime the trap: 12- If the appliance will not operate,follow the instructions 1 - Follow the lighting instructions to place the unit into op- "Turning Off Gas to Unit"and call your service techni- eration. cian or gas supplier. 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- 2 - Turn off all electrical power to the unit if service is to be mand. performed. 5 - Wait for the combustion air inducer to stop. Set the 3- Remove the access panel. thermostat to initiate a heating demand and again al- 4- Move gas valve switch to OFF. low the burners to fire for approximately 3 minutes. 6- Adjust the thermostat to deactivate the heating de- 5 - Replace the access panel. mand and again wait for the combustion air inducer to Failure To Operate stop. At this point,the trap should be primed with suffi- If the unit fails to operate, check the following: cient water to ensure proper condensate drain opera- 1 - Is the thermostat calling for heat? tion. 2- Are access panels securely in place? 3- Is the main disconnect switch closed? A WARNING 4 - Is there a blown fuse or tripped breaker? 5 - Is the filter dirty or plugged? Dirty or plugged filters will If you do not follow these instructions exactly, a fire cause the limit control to shut the unit off. or explosion may result causing property damage, 6 - Is gas turned on at the meter? personal injury or death. 7 - Is the manual main shut-off valve open? Gas Valve Operation (Figure 54) 8 - Is the internal manual shut-off valve open? 1 - STOP! Read the safety information at the beginning of 9 - Is the unit ignition system in lockout?If the unit locks out this section. again, inspect the unit for blockages. Page 42 IV-HEATING SYSTEM SERVICE CHECKS D-Testing Gas Supply Pressure A-C.S.A. Certification Gas Flow (Approximate) - All units are C.S.A. design certified without modifications. TABLE 16 - Refer to the ML196UHE Operation and Installation Instruc- tion Manual Information. GAS METER CLOCKING CHART B-Gas Piping Seconds for One Revolution ML196 Natural LP Unit 1 cuft 2cuft 1 cuft 2cuft ACAUTION Dial Dial Dial DIAL If a flexible gas connector is required or allowed by -030 120 240 300 600 the authority that has jurisdiction, black iron pipe -045 80 160 200 400 shall be installed at the gas valve and extend outside -070 55 110 136 272 the furnace cabinet. The flexible connector can then -090 41 82 102 204 be added between the black iron pipe and the gas -110 33 66 82 164 supply line. -135 27 54 68 136 Natural-1000 btu/cu ft LP-2500 btu/cu ft A WARNING Do not over torque (800 in-Ibs) or under torque (350 Furnace should operate at least 5 minutes before check in-Ibs) when attaching the gas piping to the gas ing gas flow. Determine time in seconds for two revolu- valve. tions of gas through the meter. (Two revolutions assures a Gas supply piping should not allow more than 0.5" W.C. more accurate time.) Divide by two and compare to time drop in pressure between gas meter and unit. Supply gas in table 16. If manifold pressure matches table NO TAG pipe must not be smaller than unit gas connection. and rate is incorrect,check gas orifices for proper size and Compounds used on gas piping threaded joints should be restriction. Remove temporary gas meter if installed. resistant to action of liquefied petroleum gases. NOTE- To obtain accurate reading, shut off all other gas C-Testing Gas Piping appliances connected to meter. A IMPORTANT Supply Pressure Measurement When testing supply gas pressure, use the 1/8" N.P.T. In case emergency shutdown is required, turn off plugged tap located on the gas valve to facilitate test gauge the main shut-off valve and disconnect the main connection. See figure 7. Check gas line pressure with unit power to unit. These controls should be properly firing at maximum rate. Low pressure may result in erratic labeled by the installer. operation or underfire. High pressure can result in perma- When pressure testing gas lines, the gas valve must be dis- nent damage to gas valve or overfire. connected and isolated. Gas valves can be damaged if On multiple unit installations, each unit should be checked subjected to more than 0.5 psig (14"W.C.). See figure 55. separately, with and without other units operating. Supply MANUAL MAIN SHUT-OFF CAP pressure must fall within range listed in table 18. VALVE WILL NOT HOLD FURNACE NORMAL TEST PRESSURE ■ Manifold Pressure Measurement ISOLATE Follow the steps below and use figure 56 as a reference.Gas 1/8"N.P.T.PLUGGED TAP — GAS VALVE 7manifold Kit 10L34 provides additional components if need- r �I�. ■I r II= b ed. 1 - Connect the test gauge positive side "+" to manifold FIGURE 55 pressure tap on gas valve. When checking piping connections for gas leaks, use pre- 2 - Tee into the gas valve regulator vent hose and connect ferred means. Kitchen detergents can cause harmful corro- to test gauge negative "='. sion on various metals used in gas piping. Use of a specialty 3 - Start unit and let run for 5 minutes to allow for steady Gas Leak Detector is strongly recommended. It is available state conditions. through Lennox under part number 31B2001. See Corp. 4 - After allowing unit to stabilize for 5 minutes, record 8411-L10, for further details. manifold pressure and compare to value given in table A WARNING 18. 5- Shut unit off and remove manometer as soon as an ac- Do not use matches, candles, flame or any other curate reading has been obtained. Take care to re- source of ignition to check for gas leaks. move barbed fitting and replace threaded plug. 6 - Start unit and perform leak check. Seal leaks if found. Page 43 MANIFOLD PRESSURE CHECK SET UP Negative Barbed Fitting (remove for manifold adjustment) 2" Long Square Tubing (+) (remove for manifold adjustment) J 4. _A �J o', Manifold Pressure Outlet Gas Valve Regulator iirli ' ' , l •7h�Vent Hose �: (to burner box) �k r illimok �� .`J �� Tee J 2` Barbed Fitting - , 10" Long 44j4 Square 0 Tubing Nici Measuring Device Gt CI li I ❑lelll_l /i FIGURE 56 E-Proper Combustion F-High Altitude Furnace should operate minimum 15 minutes with correct NOTE- In Canada, certification for installations at eleva- manifold pressure and gas flow rate before checking corn- tions over 4500 feet(1372 m)is the jurisdiction of local au- bustion. Take combustion sample beyond the flue outlet thorities. and compare to the tables below. Some units installed at altitude of 4501 - 10,000 feet(1373 to 3048 m) may require a pressure switch change which can be ordered separately and a manifold de-rate. See ta- ble 18 for manifold pressures at all altitudes. Table 19 lists TABLE 17 conversion kit and pressure switch requirements at varying Unit COZ%For Nat CO2% For LP altitudes. All 7.5-8.5 8.2 -9.5 The combustion air pressure switch is factory-set and re- The maximum carbon monoxide reading should not exceed 100 ppm. quires no adjustment. TABLE 18 Manifold and Supply Line Pressure 0-10,000ft. Manifold Pressure in.wg. Supply Line ML196 — Pressure Unit Gas 4501-5500 5501-6500 in.w.g. 0-4500 ft. ft. ft 6501 -7500ft. 7501 - 10000ft. 0-10000 ft. All Natural 3.5 3.3 3.2 3.1 3.5 4.5 13.0 Sizes LP/propane 10.0 9.4 9.1 8.9 10.0 11.0 13.0 NOTE-A natural to L.P.propane gas changeover kit is necessary to convert this unit.Refer to the changeover kit installation instruction for the conversion procedure. Page 44 TABLE 19 - LP/Propane Conversion Kit and Pressure Switch Requirements at Varying Altitudes Natural to High Altitude High Altitude ML196 LP/Propane Natural Burner LP/Propane Burner High Altitude Pressure Switch Orifice Kit Orifice Kit Unit 0-7500 ft 7501 -10,000 ft 7501 -10,000 ft 4501 -7500 ft 7501 -10,000 ft (0-2286m) (2286-3038m) (2286-3038m) (1373-2286m) (2286-3048m) -030 17H63 14C90 17H66 No Change 11U65 -045 No Change 11U65 -070 17V95 11U67 -090 *11K49 73W37 *11K44 11U70 11.U64 -110 11U71 11U64 -135 11U71 11U68 Pressure switch is factory set. No adjustment necessary.All models use the factory-installed pressure switch from 0-4500 feet(0-1370 m). Page 45 G- Proper Ground and Voltage 2 - In addition, measure the AC voltage from Line Hot to - Line Neutral (spade terminals)on the integrated con- - A WARNING trol. See figure 57.This voltage should be in the range Electric Shock Hazard. Can cause of 97 to 132 Vac • injury or death. Unit must be properly TABLE 20 lir grounded in accordance with national Measurement VAC and local codes. Furnace Status Expected Maximum A poorly grounded furnace can contribute to premature ig- Power On Furnace Idle 0.3 2 nitor failure. Use the following procedure to check for CAI / Ignitor Energized 0.75 5 ground and voltage to the integrated control. Indoor Blower Energized Less than 2 10 1 - Measure the AC voltage between Line Neutral (spade terminals) and "C" terminal (low voltage terminal block)on the integrated control. See figure 57.A wide variation in the voltage between Line Neutral and "C" as a function of load indicates a poor or partial ground. Compare the readings to the table below. If the read- ings exceed the maximum shown in table 1, make re- pairs before operating the furnace. CHECK VOLTAGE BETWEEN LINE NEUTRAL CHECK VOLTAGE BETWEEN LINE HOT AND LOW VOLTAGE "C" TERMINAL AND LINE NEUTRAL 00 �s140e41 10 00 -1t 4g440 ®000 I 0 0000 ig @0 P kO d o oS ` 0 o., 0 08 !'L 0 of o o — 0 �i ' 4-60 00 11 li=,8 t , 8 8 84 8 I 1® � ��8�► 8 I 0 8 o C o ©O©a DOCK) ©oo 0 0 - iscxxi0 (ODTO . o _ p� o op O — o O O =, o8 O 0 � , 1 08 O 0 00_ _ _ o 00 CD 0 0 �0 ® 0 ®10 ® O � cp p000loo Redo -o.II W R iS Y 0 Red0ED a R 0 WCRGY 0 FIGURE 57 Page 46 V-TYPICAL OPERATING CHARACTERISTICS C-External Static Pressure 1 - Tap locations shown in figure 59. A-Blower Operation and Adjustment) 2- Punch a 1/4" diameter hole in supply and return air NOTE- The following is a generalized procedure and plenums. Insert manometer hose flush with inside does not apply to all thermostat controls. edge of hole or insulation. Seal around the hose with permagum. Connect the zero end of the manometer to 1 - Blower operation is dependent on thermostat control the discharge (supply)side of the system. On ducted system. systems, connect the other end of manometer to the return duct as above. 2 - Generally, blower operation is set at thermostat sub- 3- With only the blower motor running and the evaporator base fan switch.With fan switch in ON position, blower coil dry, observe the manometer reading.Adjust blow- operates continuously.With fan switch in AUTO position, er motor speed to deliver the air desired according to blower cycles with demand or runs continuously while the job requirements. For heating speed external static heating or cooling circuit cycles. pressure drop must not be more than 0.5" W.C. For 3 - Depending on the type of indoor thermostat, blower cooling speed external static pressure drop must not and entire unit will be off when the system switch is in be more than 0.8" W.C. OFF position. 4 - Seal the hole when the check is complete. B-Temperature Rise (Figure 58) EXTERNAL STATIC PRESSURE Temperature rise for ML196UHE units depends on unit in- Supply Duct Static put, blower speed, blower horsepower and static pressure Return Duct Static+ as marked on the unit rating plate. The blower speed must Total Duct Static = be set for unit operation within the range of "TEMP. RISE (dry coil) °F" listed on the unit rating plate. TEMPERATURE RISE ��'• Supply Duct Temperature I Return Duct Temperature- Temperature Rise = su.-i Air AireHigh"+^ Duct Static Rp4 — am irmmarLow''. I . or SUPPLY � •. AIR I + _ Th7.11 Return Air FIGURE 60 4 Temperatures D-Blower Speed Taps P' Blower speed tap changes are made on the integrated con- RETURN AIR trol. See figure 3 or 57. The heating tap is connected to the "HEAT" terminal and the cooling tap is connected to the "COOL"terminal. On all units the continuous blower tap is connected to the"FAN"terminal. Unused taps must be se- FIGURE 58 cured on two dummy terminals labeled "PARK. To change out existing speed tap, turn off power and switch out speed tap with tap connected to"PARK". See blower speed tap ta- ble on unit diagram for motor tap colors for each speed. Page 47 VI-MAINTENANCE TABLE 21 Furnace Filter Size Cabinet Width Side Return Bottom Return A WARN I N G 17-1/2" 16X25X1 (1) 16X25X1 (1) ELECTRICAL SHOCK, FIRE, 21" 16 X 25 X 1 (1) 20 X 25 X 1 (1) OR EXPLOSION HAZARD. 24-1/2" 16 X 25 X 1 (2) 24 X 25 X 1 (1) Failure to follow safety warnings exactly could result Exhaust and air intake pipes in dangerous operation, serious injury, death or Check the exhaust and air intake pipes and all connections property damage. for tightness and to make sure there is no blockage. Improper servicing could result in dangerous opera- tion, serious injury, death, or property damage. NOTE-After any heavy snow, ice or frozen fog event the Before servicing, disconnect all electrical power to furnace vent pipes may become restricted. Always check furnace. the vent system and remove any snow or ice that may be When servicing controls, label all wires prior to dis- obstructing the plastic intake or exhaust pipes. connecting. Take care to reconnect wires correctly. Electrical Verify proper operation after servicing. At the beginning of each heating season, system should be A WARN I N G checked as follows by a qualified service technician: Fire Hazard. Use of aluminum wire with this Blower product may result in a fire, causing property dam- Check the blower wheel for debris and clean if necessary. age, severe injury or death. Use copper wire only The blower motors are prelubricated for extended bearing with this product. life. No further lubrication is needed. ACAUTION Failure to use properly sized wiring and circuit AWARNINGbreaker may result in property damage. Size wiring and circuit breaker(s) per Product Specifications The blower access panel must be securely in place bulletin (EHB) and unit rating plate. when the blower and burners are operating. Gas fumes, which could contain carbon monoxide, can 1 - Check all wiring for loose connections. be drawn into living space resulting in personal inju- 2 - Check for the correct voltage at the furnace (furnace ry or death. operating). Correct voltage is 120VAC ± 10% Filters 3 - Check amp-draw using a true RMS meter on the blow- er motor with blower access panel in place. See figure All air filters are installed external to the unit. Filters should 61 be inspected monthly. Clean or replace the filters when Unit Nameplate Actual necessary to ensure proper furnace operation. Table 21 lists recommended filter sizes. Check Motor Amp Draw A IMPORTANT If a high-efficiency filter is being installed as part of "ILL O -A this system to ensure better indoor air quality, the fil- ter must be properly sized. High-efficiency filters •� have a higher static pressure drop than standard-ef- ficiency eI glass/foam filters. If the pressure drop is too great, system capacity and performance may be re- )j_e� � N� duced. The pressure drop may also cause the limit to !=`4 trip more frequently during the winter and the indoor tri coil to freeze in the summer, resulting in an increase 0 in the number of service calls. True RMS Meter Before using any filter with this system, check the specifications provided by the filter manufacturer against the data given in the appropriate Lennox Product Specifications bulletin. Additional informa- tion is provided in Service and Application Note ACC-00-2 (August 2000). FIGURE 61 Page 48 Winterizing and Condensate Trap Care 12- Mark and disconnect all combustion air pressure tub- - 1 - Turn off power to the furnace. ing from cold end header collector box. 2 - Have a shallow pan ready to empty condensate water. 13 - Mark and remove wires from pressure switch assem- 3 - Remove the clean out cap from the condensate trap bly. Remove the assembly. Keep tubing attached to and empty water. Inspect the trap then reinstall the pressure switches. clean out cap. 14 - Disconnect the plug from the combustion air inducer. Remove two screws which secure combustion air in- Condensate Hose Screens (Figure 62) ducer to collector box. Remove combustion air induc- Check the condensate hose screens for blockage and er assembly. Remove ground wire from vest panel. clean if necessary. 15- Disconnect the condensate drain line. 1 - Turn off power to the unit. 16- Remove cold end header box. 2 - Remove hoses from cold end header box. Twist and 17 - Remove electrical junction box from the side of the fur- pull screens to remove. nace. 3 - Inspect screens and rinse with tap water if needed. 18- Mark and disconnect any remaining wiring to heating 4 - Reinstall screens, reconnect hoses and turn on power compartment components. Disengage strain relief to unit. bushing and pull wiring and bushing through the hole in Condensate Hose Screens the blower deck. -�J 19 - Remove the primary limit from the vestibule panel. 20 - Remove two screws from the front cabinet flange at the blower deck. Spread cabinet sides slightly to allow clearance for removal of heat exchanger. �rf� _vim 21 - Remove screws along vestibule sides and bottom 1Ir '� Hose which secure vestibule panel and heat exchanger as- Hose ��I sembly to cabinet. Remove two screws from blower ' ' _vet.- rail which secure bottom heat exchanger flange. Re- FIGURE 62 move heat exchanger from furnace cabinet. Cleaning Heat Exchanger 22 - Back wash heat exchanger with soapy water solution If cleaning the heat exchanger becomes necessary, follow or steam. If steam is used it must be below 275°F the below procedures and refer to figure 1 when disassem- (135°C) . bling unit. Use papers or protective covering in front of fur- 23 -Thoroughly rinse and drain the heat exchanger. Soap nace while removing heat exchanger assembly. solutions can be corrosive. Take care to rinse entire 1 - Turn off electrical and gas supplies to the furnace. assembly. 2 - Remove the furnace access panels. 24 - Reinstall heat exchanger into cabinet making sure that 3- Disconnect the 2 wires from the gas valve. the clamshells of the heat exchanger assembly is en- 4- Remove gas supply line connected to gas valve. Re- gaged properly into the support bracket on the blower move the burner box cover(if equipped)and remove deck. Remove the indoor blower to view this area gas valve/manifold assembly. through the blower opening. 5 - Remove sensor wire from sensor. Disconnect 2-pin 25 - Re-secure the supporting screws along the vestibule plug from the ignitor. sides and bottom to the cabinet. 6 Disconnect wires from flame roll-out switches. 26 - Reinstall cabinet screws on front flange at blower 7 - Disconnect combustion air intake pipe. It may be nec- deck. essary to cut the existing pipe to remove burner box 27 - Reinstall the primary limit on the vestibule panel. assembly. 28 - Route heating component wiring through hole in blow- 8- Remove four burner box screws at the vestibule panel er deck and reinsert strain relief bushing. and remove burner box. Set burner box assembly 29 - Reinstall electrical junction box. aside. 30 - Reinstall the cold end header box. NOTE-If necessary, clean burners at this time. Follow 31 - Reinstall the combustion air inducer. Reconnect the procedures outlined in Burner Cleaning section. plug to the wire harness. 9- Loosen the clamps to the flexible exhaust coupling. 32 - Reinstall pressure switches and reconnect pressure 10 - Disconnect condensate drain line from the cold end switch wiring. header box. 33- Carefully connect combustion air pressure switch 11 - Disconnect condensate drain tubing from flue collar. tubing from pressure switches to proper ports on Remove screws that secures the flue collar into place. cold end header collector box. Remove flue collar. It may be necessary to cut the exit- 34- Reconnect condensate drain line to the cold end ing exhaust pipe for removal of the fitting. header box. Page 49 35- Use securing screws to reinstall flue collar to the top Cleaning the Burner Assembly (if needed) - cap on the furnace. Reconnect exhaust piping and ex- 1 - Turn off electrical and gas power supplies to furnace. haust drain tubing. Remove upper and lower furnace access panels. 36 - Replace flexible exhaust adapter on combustion air in- 2 - Disconnect the wires from the gas valve. ' ducer and flue collar. Secure using two existing hose 3- Remove the burner box cover(if equipped). clamps. 4- Disconnect the gas supply line from the gas valve. Re- 37- Reinstall burner box assembly in vestibule area. Se- move gas valve/manifold assembly. cure burner box assembly to vestibule panel using 5 - Mark and disconnect sensor wire from the sensor. Dis- four existing screws. Make sure burners line up in connect wires from flame rollout switches. center of burner ports 38 - Reconnect flame roll out switch wires. 6 - Disconnect combustion air intake pipe. It may be nec- 39- Reconnect sensor wire and reconnect 2-pin plug from essary to cut the existing pipe to remove burner box assembly. ignitor. a sem- 40- Reinstall gas valve manifold assembly. Reconnect 7 - Remove four screws which secure burner box gas supply line to gas valve. bly to vest panel. Remove burner box from thea unit. unit. 41 - Reconnect the combustion air intake pipe. 8 - Use the soft brush attachment on a vacuum cleaner to 42 Reinstall burner box cover. gently clean the face of the burners. Visually inspect the inside of the burners and crossovers for any block- 43 - Reconnect wires to gas valve. age caused by foreign matter. Remove any blockage. 44 - Replace the blower compartment access panel. 9- Reinstall the burner box assembly using the existing 45- Reconnect gas supply piping. Turn on power and gas four screws. Make sure that the burners line up in the supply to unit. center of the burner ports. 46- Follow lighting instructions on unit nameplate to light 10- Reconnect the sensor wire and reconnect the 2-pin and operate furnace for 5 minutes to ensure the fur- plug to the ignitor wiring harness. Reconnect wires to nace is operating properly. flame rollout switches. 47- Check all piping connections, factory and field,for gas 11 - Reinstall the gas valve manifold assembly. Reconnect leaks. Use a leak detecting solution or other preferred the gas supply line to the gas valve. Reinstall the burn- means. er box cover. 48- Replace heating compartment access panel. 12 - Reconnect wires to gas valve. 13- Replace the blower compartment access panel. ACAUTION 14- Refer to instruction on verifying gas and electrical con- Some soaps used for leak detection are corrosive to nections when re-establishing supplies. certain metals. Carefully rinse piping thoroughly af- 15- Follow lighting instructions to light and operate fur- ter leak test has been completed. Do not use nace for 5 minutes to ensure that heat exchanger is matches, candles, flame or other sources of ignition clean and dry and that furnace is operating properly. to check for gas leaks. 16 - Replace heating compartment access panel. Page 50 r VII-WIRING DIAGRAM AND SEQUENCE OF OPERATION BLOWER SPEED CHART - FACTORY CONNECTED SPEED TAPS BURNERS UNIT COOL HEAT FAN PARK 030)4E24B 045XE24B ' BLACK YELLOW RED BROW,BLUE • LAME ROLLO❑0rl'SE R 0 IGNITER 0 OUAE ROLLOUT p OXE 6B BLACK BLACK '. YELLOW RED BROWN,BLUE YELLOW RED BROWN BLUE AIDE 090XE48C BLACK YELLOW RED BROWN,ELUE PITS II ® 110XESOC BLOWER SPEED SELECTION COMBUSTION SIB HI mN LD AIR INDUCER I. COMBUSTION AIR G PROVING SWITCH SPEED TAPS I BLACK BROWN BLUE YELLOW RED T I mum PB4 °N 1 PB4 GVI DFF • 0 to �• FAn r33KW9i•P5ITT''T:i-107A4-E-LPAMO N GAS VALVE EJIZEI r'rnanE1pND`•].*1 KVItWIGI1.18 LI (( 1 ' SI® E11:•PPSN1418VM STTU*BNOICD. ® +I !150 FLXIII4 illaKel:YONT.,1114L tj II sio f�/ Low GAS NUM ICSNRi41,1,A.19SI'L:1BILJttil m 3 i PRIMARYG PRESSURE •M ET.1 PELNAJ!t„JILIV11N4:NK:N11R:� O LIMIT SWITCH MA I Pateran r NOTE. S51 O ,O itlit 6 IF ANY WIRE IN THIS APPLIANCE IS REPLACED,IT DOOR MUST BE REPLACED WITH WIRE OF LIKE SIZE. INTERLOCK A92 RATING,INSULATION THICKNESS AND TERMINATION. CBS INTEGRATED CONTROL CIRCUIT A 'R'REQUIRED ON SOME OUTDOOR UNITS ,�BREAKER J58 re 0 0 11/ S1 �� HI000 e PARK TERMINALS ARE UNPOWERED TERMINALS.ALL ROOM THERMOSTAT TI ®0 0 0 PARrc IERMINAL Co'eIo MOTOR LEADS MUST BE WIRED TOE 'oZoo TRANSFORMER DWGNOSTIC PUSH BUTTON DO NOT USE RED(LOW SPEED)MOTOR LEAD FOR HEATING SPEED RESULTING TEMPERATURE RISE ® I W C G OlI WILL BE OUTSIDE OF RISE RANGE. II 1 L I A LI3 POWER CHOKE USED ON}AND t HP ONLY ROOM THERMOSTAT LL e 5145 IS USED WITH HONEYWELL GAS • VALVE WHEN APPLIED IN LP GAS UNITS P49 ®USE COPPER CONDUCTORS ONLY. • AU°•ON OUTDOOR — — — — JI P41 llAJl UNIT r J/� — 10.14) R • I ,— L13 (gy INDOOR THERMMO65 PSTAT HENAT ANTICIPATION VA SETTINGS • EA FAN POWER BLOWER MOTOR 50 AMP WHITE-RODGERS VALVE LVE 0 00 0 L • �A CHOKE ADD INTEGRATED CONTROL LINE VOLTAGE FIELD INSTALLED 3 CLASS VOLTAGE FIELD WIRING TH • '• © o O 0 DENOTES OPTIONAL COMPONENTS o� K1• • KB • • • A92 m I • KB • ® BLACK n LI •'• I 'K3 'K4 I .C� �akI glut ¢ ¢ u ys LINE 'jz� 5 1 JI T my 1 EQUIPMENT I Wy SEE BLOWER SPEED CHART GROUND 81 l"E I Kz s LL I m a ® rc m m 1 t45 '� 1 GN,YLW L zvi u - r m 1 J N9 m m ® O 1 JI56 /2\ Lj n /N/\./‘"P49 (1) (2) m ^ P158 ^ Ii ' TI WHTIBLK C B3 7 S47 GVI 1 - u m INDOOR W g m �� ®L((/\] BLOWER BWNWIVEL y J84`/ J1 9 1 o ,Oii ®13^PIOWER "MN MOTOR GRESTEIPE N/YELLOW W SIG a SIB gy4 CHOKE �L�ENIYELLO COMBUSTION Ca MR INDUCER mg O BURNERA SY GROUND 8 MOTOR 184 2 J159 i 124V A92 INTEGRATED 0 O 0 P&„......,2 2 TR COM CONTROL W 2 P159 ff J 3 P.5 HEATING UNITS-GAS P156 J1s8 4 A92 ML196UH03OXE24B ML196UH095XE48C rML196UH045XE24B ML196UH115XE60C ® WHITE I IZD v NEUTRALS ML 196UH045XE36B N I I I I ML196UH070XE36B ewer* WARNING- ELECTRIC SHOCK HAIARD,CAN CAUSE INJURY WI• • Form No. OR DEATH UNIT MUST BE GROUNDED IN ACCORDANCE EP WITH NATIONAL AND LOCAL CODES. 538048-01 p zo„ Dmo Msn. 1 - Line voltage is applied to L1 and N. the T1 low voltage transformer is energized,and line voltage is applied to B3 indoor blower. 2- S47 rollout switch(es)must be closed in order for 24V from transformer to be output on integrated control"R"to power thermostat. 3- When there is a call for heat,W1 of the thermostat energizes W of the furnace control with 24VAC. 4- A92 integrated control runs a self-check.S10 primary limit and S21 secondary limit contacts are found to be closed.Call for heat can continue. 5- A92 integrated control energizes B6 combustion air inducer.S18 combustion air pressure switch closes.Once S18 closes,a 15-second pre-purge follows. 6- A92 integrated control energizes R33 ignitor.A 20-second warm-up period begins. 7- GV1 gas valve opens for a 4-second trial for ignition 8- Flame is sensed,gas valve remains open for the heat call. 9- After 30-second delay(from flame sensed),A92 integrated control applies 24VAC to Heat speed of B3 indoor blower. 10- When heat demand is satisfied,W1 of the indoor thermostat de-energizes W of A92integrated control which de-energizes GV1 gas valve. B6 combustion air inducer continues a 5-second post-purge period,and B3 indoor blower completes a selected OFF time delay. Page 51 I • BLOWER SPEED CHART FACTORY CON FCTFD SPEED TAPS • I--I BURNERS UNIT COOL HEAT FAN PARK • ®0 L O O O O 547 045XE3BB BLACK YELLOW RED BRDWN.BLUE 0A5%E36B BLACK YELLOW RED BROWN.BLUE �R 070%E78B BLACK BLUE RED BROWNYELLOW =LAME ROLLOUT FUME IGNITER RDJ PLANE ROLLOJT 070%EIBB BLACK BLUE RED BROWN YELLOW SWITCH SENSOR SWITCH t\090%E3BC BLACK BROWN RED BLUE,YELLOW MB�9 B /I1\0S0%E40C BLACK YELLOW RED BROWN,SLUE 090%ESOC BLACK BLUE RED BROWN YELLOW COMBUSTION C�BUBTO A 110XE80C BLACK BLUE RED BROWN YELLOW AIR INDUCER CI PROVING SWITCH /N,135%E8OD BLACK Ell UE RED BROWN YELLOW t = V• HI • BLOWER SPEED SELECTION LO JB0 Ox 44" GVI OFF A • SPEED TAPSI BUGN BROWN BLUE YELLOW RED = 0 `•, - ry- GAS VALVE Lrff;[[[+777 111FR•1910!•INS'.TiIFPOi:Ii:••i-I LI w • • st® SURFEIVNI G1434IDJI•tlUtatEU:•1L1: AN, 5i4 510 l• LOW GAS U(UM :IN:9413EN ZSS11:121MN3:- 5 i PRMARY PRESSURE MBA LV1•L'TORLASTgNPIPOIl'•BLUIfFi� IS LIMIT SWITCH 'mama Frt•:8]tI51fB•1R•130RM:Bri7_ IBLIMSIFfTH71199EI33 S&. 551M TE- vQ QI JiS IF WIRE IN TAD APPLIANCE D REPLACEUIT IOOR INTERLOCK A MUST BE REPLACED WITH WERE OF LIKE SIZE, CBS INTEGRATED CONTROL RATINGINSUUTKN THICKNESS WHO TERMINATION CiiCUR 9 ®OOC Q R REQUIRED CN SOME OUTDOOR UNITS ,1 OO5 O © PARK MOTOR ARE UW51DB WIRED ALS.ALL St UNUSED MINARIFOD3 MST BE WIREDTOA ROOM THERMOSTAT T1 CO T 4 I RAW D NOT R. [o @Ioii0/©] PUSH Blfl'TON ® DO NOT USE RED(LOW SPEED)MOTOR LEAD FOR L - - ®11123 � G I I HEATING SPEED RESULTING TEMPERATURE RISELY WILL BE OUTSIDE OF RISE RANGE. SI m LID POWER CHOKE USED ON;AND I HP ON ROOM THERMOSTAT L I W G 8 8145 IS USED WITH HONEYWELL GAS • I__ - - - I VALVE WHEN APPLIED IN LP GAS UNITS AUTO•ON PH9 ®USE COPPERCONICTORS ONLY. • • CUTDOOR P4 UNIT 17.- -____, I• LID B3 THERMOSTAT HEIryAAETV AWV•RE{]LMLAPATKW SETTINGS ,�•T.� _�... FAH P°W® BLOWER MOTOR riAA@ Y�WIITEAODG!SYVALVE O NP 0 O O NEN Q is C_�CHOKE A92 INTEGRATED CONTROL LINE VOLTAGE FIELD INSTALLED 3 © © Q O - - -CLASS II VOLTAGE FIELD WIRING TN • DENOTES OPTIONAL COMPONENTS 2 S K/• • KS 33'I 201. KB x.I A9 m Li BUCK u' I . • I :C pV VI=1 p11 2 2 � 2 1 LINE K3 K4F 5 1 1 7� 1� 1 EQUIPMENT w SEE BLOWER SPEED CHART /•, GROUND I Dw ® 8 ; 3 3 m 3 w ..414, Rv '�D` L K2 x y� ryU' c i m a m E ®,46 1(:NlyLw ulU �p L6 gg 1 AAA),a s J4a J,56 II ;d AM/I P49 ) I2, PISS L3 -y WNOIOIC B3 (7 847 GV1 1 I `T C fie TI ® INDOOR _ i'0 Jpm B4 PIMI Sivl/ pi] I R liHOKE r MOTORBLOwR GREEN/YELLOW__STRIP SIB a 610 COMBUSTION � BURNER 0.55y�GFRWNDED AIRINDUCER MOTOR .184 2 124V AB2 INTEGRATEDU0F84/� PI59 CON CONTROL t7 B J FIFE 2' I HEATING UNITS-GASSIT ° - ADO r MMMLLL996UUUHHH004073500XXXEEE333666BB MMMLLL11969966UUUHHH0019900OXXXEEE60C6OC48C ® WHITE I 120 V NEUTRALS ML196UH07OXE48B ML196UH135XE60D N I I I I ML196UH09OXE36C WARNING I '4-"" ELECTRICDEAT IIDCA""IBE GROUNDED IN ACC' Form No. OR NIT HOCK HATBE CANCAUDMNYIgiOANf:E Q WITH NATIONAL AND LOGY CODES. `1MEM 538048-02 0 0 2011 LA.LEA. 1 - Line voltage is applied to L1 and N. the T1 low voltage transformer is energized,and line voltage is applied to B3 indoor blower. 2- S47 rollout switch(es)must be closed in order for 24V from transformer to be output on integrated control"R"to power thermostat. 3- When there is a call for heat,W1 of the thermostat energizes W of the furnace control with 24VAC. 4- A92 integrated control runs a self-check.S10 primary limit and S21 secondary limit contacts are found to be closed.Call for heat can continue. 5- A92 integrated control energizes B6 combustion air inducer.S18 combustion air pressure switch closes.Once S18 closes,a 15-second pre-purge follows. 6- A92 integrated control energizes R33 ignitor.A 20-second warm-up period begins. 7- GV1 gas valve opens for a 4-second trial for ignition 8- Flame is sensed,gas valve remains open for the heat call. 9- After 30-second delay(from flame sensed),A92 integrated control applies 24VAC to Heat speed of B3 indoor blower. 10- When heat demand is satisfied,W1 of the indoor thermostat de-energizes W of A92integrated control which de-energizes GV1 gas valve. B6 combustion air inducer continues a 5-second post-purge period,and B3 indoor blower completes a selected OFF time delay. Page 52 Troubleshooting: Heating Sequence of Operation HEATING SEQUENCE OF OPERATION NORMAL HEATING MODE ABNORMAL HEATING MODE POWER ON GAS VALVE OFF.COMBUSTION AIR INDUCER OFF. CONTROL SELF-CHECK OKAY? NO ► INDOOR BLOWER DELAY OFF. LED SLOW FLASH (RESET CONTROL BY TURNING MAIN POWER OFF.) YES , NO PP IS POLARITY CORRECT? LED FLASHES CODE 1 - POLARITY REVERSED. YES • NO IS THERE A PROPER GROUND? LED FLASHES CODE 2- IMPROPER GROUND. YES V NO LED FLASHES CODE 13-LOW LINE VOLTAGE. IS VOLTAGE IP CONTROL WILL NOT RESPOND TO A CALL FOR ABOVE 70 VOLTS? 41 HEATING UNTIL VOLTAGE RISES ABOVE 75 VOLTS. YES LED FLASHES CODE 8- ROLLOUT SWITCH OPEN. NO GAS VALVE OFF.COMBUSTION AIR INDUCER ON. ►I ROLLOUT SWITCH CLOSED? INDOOR BLOWER ON. SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES YES AND POWER IS RESET OR T'STAT IS INTERRUPTED FOR MINIMUM OF 1 SECOND. V NO LED FLASHES CODE 12-FLAME SENSED BURNER OFF? , WITHOUT GAS VALVE ENERGIZED. GAS VALVE OFF.COMBUSTION AIR INDUCER ON. INDOOR BLOWER ON HEATING SPEED. YES NO NORMAL OPERATION: 41 LED SLOW FLASH YES II THERMOSTAT CALLS FOR HEAT: A p. LED FLASHES CODE 7-PRIMARY LED SLOW FLASH LMIT OPEN.COMBUSTION AIR INDUCER OFF.I NDOOR BLOWER ON YES NO PRIMARY LIMIT SWITCH.CLOSED? LED FLASHES CODE 11-PRESSURE YES + SWITCH CLOSED. GAS VALVE OFF COMBUSTION AIR IS COMBUSTION AIR NO ► INDUCER OFF.INDOOR BLOWER PRESSURE SWITCH OPEN? OFF WITH DELAY. YES + (Sequence holds until pressure switch opens or thermostat resets control.) IS COMBUSTION AIR INDUCER ENERGIZED? I � YES + LED FLASHES CODE 9-PRESSURE SWITCH FAILED YES HAS COMBUSTION AIR PRESSURE TO CLOSE OR OPENED DURING HEAT DEMAND. SWITCH CLOSED IN 2.5 MINUTES? PRESSURE SWITCH IS IN WATCHGUARD MODE.GAS - YES VALVE OFF.COMBUSTION AIR INDUCER OFF. INDOOR BLOWER OFF WITH DELAY.IS 5-MINUTE RESET PERIOD COMPLETE? CONTINUED NEXT PAGE Page 53 Troubleshooting: Heating Sequence of Operation (Continued) _ HEATING SEQUENCE CONTINUED - NORMAL HEATING MODE ABNORMAL HEATING MODE 15-SECOND COMBUSTION AIR INDUCER PREPURGF. INITIATED BY CLOSED PRESSURE SWITCH. YES 4, LED FLASHES CODE 13- NO O LOW LINE VOLTAGE. ri IGNITOR WARM-UP--20 SECONDS. IS VOLTAGE ABOVE 70 VOLTS? ONCE VOLTAGE IS ABOVE 75 VOLTS, HEATING YES + YES SEQUENCE RESTARTS. 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. YES - NO HASHAS CONTROL FAILED TO SENSE FLAME FOR NO W. FIVE CONSECUTIVE TRIES DURING A SINGLE FLAME STABILIZATION PERIOD. HEAT DEMAND? 4SECONDS + FLAME RECTIFICATION CURRENT LED SIGNAL WATCHGUARD FAILURE CODE YES 10. CHECK.CAN FLAME BE PROVEN WITHIN — WATCHGUARD MODE. GAS VALVE OFF. 4 SECONDS AFTER GAS VALVE OPENS? COMBUSTION AIR INDUCER OFF. 4 (0.5 microamps) INDOOR BLOWER OFF WITH DELAY YES ♦ IS 60-MINUTE RESET PERIOD COMPLETE? _ NO YES `► FLAME PRESENT? r HAS CONTROL RESET IGNITION NO SEQUENCE FOUR TIMES? 0 YES P. YES LED FLASHES CODE ✓ NO LED FLASHES CODE 4- LOW 7- PRIMARY LIMIT FLAME SIGNAL 1.5 MICROAMPS OR GREATER? L ' FLAME SIGNAL. OPEN.GAS VALVE, (Does not affect operation of control) COMB.AIR INDUCER YES + AND INDOOR BLOW- INDOOR BLOWER ON ER OFF.LEDs SIGNAL AFTER 30-SECOND DELAY LIMIT SWITCH OPEN LED FLASHES CODE 7-PRIMARY LIMIT OPEN UNTIL MAIN YES j GAS VALVE DE-ENERGIZED. POWER IS NO COMBUSTION AIR INDUCER DE-ENERGIZED. INTERRUPTED OR PRIMARY LIMIT SWITCH CLOSED? —► INDOOR BLOWER ON UNTIL SWITCH CLOSES. TSTAT IS CYCLED LIMIT SWITCH CLOSED? OFF/ON FOR 1 SEC. MINIMUM. 60-MINUTE YES WATCHGUARD PE- HAS PRIMARY LIMIT RESET YES RIOD STARTS AT TIME LIMIT CLOSES. YES TIME EXCEEDED 3 MINUTES? IS 60-MIN. PERIOD COMPLETE? NO i • NO ROLLOUT SWITCH CLOSED? 10- LED FLASHES CODE 8-ROLLOUT SWITCH OPEN. 4 GAS VALVE POWER OFF. COMBUSTION AIR INDUCER POWER YES ON.INDOOR BLOWER ON SEQUENCE HOLDS UNTIL ROLLOUT . SWITCH IS RESET AND MAIN POWER IS INTERRUPTED OR COMBUSTION AIR PRESSURE NO THERMOSTAT IS CYCLED OFF/ON FOR 1 SEC.MINIMUM. .411 SWITCH CLOSED? — YES 4, HAS PRESSURE SWITCH OPENED 5 LED FLASHES THERMOSTAT DEMAND SATISFIED. I TIMES IN SAME HEAT DEMAND YES CODE 10 —1" 1 HR PRESSURE YES + NO + SWITCH I LED SLOW FLASH. J GAS VALVE DE-ENERGIZED. WATCHGUARD COMBUSTION AIR INDUCER ON. MODE YES j INDOOR BLOWER OFF WITH DELAY YES COMB.AIR INDUCER CONTINUES 5-SECOND HAS CAI SWITCH CLOSED IN 2.5 MINUTES? 11, POST PURGE AFTER TSTAT DEMAND IS SATISFIED. INDOOR AIR BLOWER COMPLETES SELECTED"OFF' NO . DELAY BEFORE SHUTTING OFF. 5-MINUTE PRESSURE SWITCH WATCHGUARD MODE. Page 54 Troubleshooting: Cooling Sequence of Operation COOLING SEQUENCE OF OPERATION NORMAL COOLING MODE ABNORMAL COOLING MODE POWER ON IGNITION CONTROL MAIN POWER ON. LED FLASHES STEADY- CIRCUIT BOARD FAILURE CONTROL SELF DIAGNOSTIC CHECK. NO GAS VALVE OFF.COMBUSTION AIR INDUCER OFF. IS CONTROL OPERATING NORMALLY? INDOOR BLOWER OFF WITH NORMAL DELAY. INTERRUPT MAIN POWER TO RESET CONTROL. YES NO LED FLASHES CODE 2 IMPROPER GROUND IS THERE A PRO• PER GROUND? CONTROL WILL CONTINUE TO CALL FOR COOLING YES IN THIS CONDITION. NO LED FLASHES CODE 1 POLARITY REVERSED IS POLARITY CORRECT? • CONTROL WILL CONTINUE TO CALL FOR COOLING IN THIS CONDITION. YES ✓ NO IS VOLTAGE ► LED FLASHES CODE 13 LOW VOLTAGE.CONTROL ABOVE 70 VOLTS? • WILL CONTINUE TO CALL FOR COOLING IN THIS CONDITION. YES ✓ NO LED FLASHES CODE 8 ROLLOUT SWITCH OPEN.GAS ROLLOUT SWITCH MONITORED CONTINUOUSLY. ► VALVE OFF.COMBUSTION AIR INDUCER ON. INDOOR IS ROLLOUT SWITCH CLOSED? • BLOWER ON.SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES AND MAIN POWER IS INTERRUPTED OR THERMOSTAT IS CYCLED OFF/ON FOR 1 SEC.MINIMUM. YESI LED:SLOW FLASH RATE REMAINS UNCHANGED] THROUGHOUT CCOOLING CYCLE. THERMOSTAT CALLS FOR COOLING. COMPRESSOR CONTACTOR AND SYSTEM FAN ENERGIZED WITH 2-SECOND DELAY (COOLING SPEED) THERMOSTAT OPENS. COMPRESSOR OFF. SYSTEM FAN AND EAC TERM.OFF WITH 45-SECOND DELAY. Page 55 Troubleshooting: Continuous Fan I Accessories Sequence of Operation CONTINUOUS FAN /ACCESSORIES SEQUENCE OF OPERATION LED:SLOW FLASH RATE REMAINS UNCHANGED THROUGHOUT SEQUENCE. + MANUAL FAN SELECTION MADE AT THERMOSTAT. CONTROL(G)ENERGIZES SYSTEM FAN AT FAN SPEED.EAC TERMINAL IS ENERGIZED. + THERMOSTAT CALLS FOR HEAT(W. ' NO YES THERMOSTAT CALLS FOR COOLING. I-► SYSTEM FAN CONTINUES FAN SPEED WITHOUT + YES NO INTERRUPTION.EAC TERMINAL REMAIN ON. HUM TERMINALS ARE ENERGIZED WITH SYSTEM FAN SWITCHED TO COOL SPEED. COMBUSTION AIR BLOWER. EAC TERM. REMAINS ON. THERMOSTAT OPENS. I SYSTEM FAN SWITCHES TO HEAT SPEAD AFTER 30 SECOND DELAY.EAC AND HUM TERMINALS REMAIN ON. LMANUAL FAN SELECTION MADE AT THERMOSTAT. THERMOSTAT OPENS. CONTROL(G)ENERGIZES SYSTEM FAN AT FAN SPEED. EAC TERM. ENERGIZED. + HUM.TERMINALS OFF AFTER POST PURGE BY COMBUSTION AIR INDUCER.SYTEM FAN SWITCHES TO FAN SPEED AFTER BLOWER OFF DELAY.EAC CONTINUES WITHOUT INTERUPTION. Page 56 f AIR CONDITIONERS LENNO0 13ACXN MERIT® Series R-410A - 60 Hz RESIDENTIAL RECEIVED Bulletin No.210831 June 2020 PRODUCT SPECIFICATIONS APR 1 8 2022 Supersedes May zolo CITY OF TIGARD BUILDING DIVISION - ��- MERIT® � � � � �� - - - SERIES __-- � � � � - - � � ��,. � � � � � � � � ` - � � - -5 1. �_ � �_' �-- � � � � � -_ � � � - -' -' - N. N.N � �`. i i r SEER up to 15.50 1.5 to 5 Tons Cooling Capacity - 17,500 to 59,000 Btuh MODEL NUMBER IDENTIFICATION 13ACXN024 - 230 - 17 Nominal SEER `---Minor Revision Number Unit Type• Voltage AC=Air Conditioner 230=208/230V-1 phase-60hz Refrigerant X=R-410A -Nominal Cooling Capacity 018=1.5tons 024=2 tons Regional Standards• 030=2.5 tons N=North Region 036=3 tons 042=3.5 tons 048=4 tons 060=5 tons FEATURES HIGHLIGHTS \NON 1 © I; 4I 1. Condenser Fan \NN\� t 2. Copper Tube/Enhanced Fin Coil \N\ � '. . 3. Scroll Compressor \'� '41 `' 4. Heavy Gauge Steel Cabinet \'�� ,•'I ' 5. Refrigerant Line Access \�\\ N V .—1. l =� CONTENTS Approvals And Warranty 3 Contents 2 Controls-Order Separately 7 Dimensions-Unit 8 Electrical Data 7 Features 3 Field Wiring 9 Installation Clearance 9 Model Number Identification 1 Optional Accessories-Order Separately 7 Sound Data 9 Specifications 7 TXV/Orifice Usage 10 '11nrYN-'1 41,S Tnn Air rnnai•innar I Donn 9 APPROVALS AND WARRANTY APPROVALS • AHRI Standard 210/240 certified • AHRI Certified system match-ups and expanded ratings,visit www.LennoxPros.com • Sound rated to AHRI Standard 270-2008 test conditions • Tested in the Lennox Research Laboratory environmental test room • Rated according to U.S. Department of Energy(DOE)test procedures • Region specific models meet the minimum efficiency requirements for U.S DOE Federal Regional Standards in that area. • Unit and components ETL, NEC and CEC bonded for grounding to meet safety standards for servicing • ETL certified (U.S. and Canada) • ISO 9001 Registered Manufacturing Quality System WARRANTY • Compressor: • Limited five years in residential installations • Limited five years in non-residential installations • All other covered components: • Limited fve years in residential installations • Limited one year in non-residential installations NOTE-Refer to Lennox Equipment Limited Warranty certificate included with unit for specific details. FEATURES APPLICATIONS ®Copper Tube/Enhanced Fin Coil • 1.5 through 5 tons • Lennox designed and fabricated coil • Single phase power supply • Ripple-edged aluminum fins • Sound levels as low as 76 dBA • Copper tube construction • Vertical air discharge • Lanced fins for maximum fin surface exposure "`; • Applicable to indoor air handlers or gas furnaces with • Fin collars grip tubing for maximum contact area indoor add-on coils • Flared shoulder tubing connections • Shipped completely factory assembled, piped and wired • Silver soldering construction NOTE- Installer must set outdoor unit,connect refrigerant • Coil is factory tested under high pressure lines and make electrical connections to complete • Steel louvered panels provide complete coil protection job. • Panels can be completely removed for servicing Y REFRIGERATION SYSTEM High Capacity Liquid Line Drier 9 P Y q R-410A Refrigerant • Furnished with unit for field installation • Non chlorine,ozone friendly • Drier traps moisture or dirt • Unit is factory pre-charged • 100%molecular-sieve,bead type, bi-flow drier NOTE-Total system refrigerant charge is dependant on outdoor unit size, indoor unit size and refrigerant High Pressure Switch line length. • Shuts off unit if abnormal operating conditions cause the discharge pressure to rise above setting NOTE-Refer to the unit-mounted charging sticker to • Automatic reset determine correct amount of charge required. 0 Outdoor Coil Fan • Direct drive fan • Vertical air discharge • Louvered steel top fan guard • Totally enclosed fan motor • Ball bearings • Inherently protected 1 RArvA1-1 S fn S'inn Air rnnrlifinnnr /D nn 1 FEATURES REFRIGERATION SYSTEM (continued) COMPRESSOR Refrigerant Flow Control 0 Scroll Compressor • Units applicable to expansion valve systems or RFC • High efficiency with uniform R', systems when matched with specific indoor coils suction flow , ` tf `, RFCIV: • Constant discharge flow, high �- `' ` ' ` " • Accurately meters refrigerant in system volumetric efficiency and quiet �� " ` • Refrigerant control operation g RFCIV METERING SYSTEM .' is accomplished RFCIV Low gas pulses during i O IFICE BODY zy jii by exact sizing of �(on coil) "BULLET" compression reduces operational refrigerant metering �o ORIFICE sound levels • orifice (4... • Compressor motor is internally or' LIQUID protected from excessive current ! �" • The principle 0-RING LINE and temperature involves matching ^ +'z\ indoor coil with 0 1 LIQUID / • Muffler in discharge line reduces - ' proper bore size of ` or LINE SCREEN operating sound levels orifice in metering — SEAL • Compressor is installed in the unit on resilient rubber device ,I,— NUT SWEAT CONNECTION mounts for vibration free operation ' • Equalizes pressure shortly after compressor stops, unit starts unloaded, Scroll Compressor Operation eliminating need for additional controls • Two involute spiral scrolls matched together generate a series of crescent-shaped gas pockets between them Optional Accessories • During compression,one scroll remains stationary while Expansion Valve Kits the other scroll orbits around it • Field installed on certain indoor units • Gas is drawn into the outer pocket,the pocket is sealed • See TXV Usage Table as the scroll rotates • Chatleff-style fittings • As the spiral movement continues,gas pockets are pushed to the center of the scrolls. Volume between the Freezestat pockets is simultaneously reduced • Senses suction line temperature • When the pocket reaches the center,gas is now at high • Cycles compressor off when suction line temperature pressure and is forced out of a port located in the center falls below it's setpoint of the fixed scrolls • Opens at 29°F and closes at 58°F • During compression,several pockets are compressed • Installs on or near the discharge line of the evaporator or simultaneously resulting in a smooth continuous on the suction line compression cycle Loss of Charge Switch Kit • Continuous flank contact, maintained by centrifugal force, minimizes gas leakage and maximizes efficiency • Protects the compressor from damage due low refrigerant charge conditions • Compressor is tolerant to the effects of slugging and contaminants. If this occurs,scrolls separate,allowing • SPST, normally-closed switch liquid or contaminants to be worked toward the center • Automatic reset switch and discharged • Mounted on liquid line Optional Accessories Refrigerant Line Kits Compressor Crankcase Heater • Refrigerant lines are shipped refrigeration clean • Protects against refrigerant migration that can occur • Lines are cleaned,dried, pressurized and sealed at during low ambient operation factory Compressor Sound Cover • Suction line fully insulated • Reinforced vinyl compressor cover • Lines are stubbed at both ends • 1-1/2 inch thick batt fiberglass insulation • All open edges are sealed with a one-inch wide hook and loop fastening tape 11Af`YnI-1 S 1..S Tnn Air rnndifinnnr l Dann A FEATURES CONTROLS Thermostat Optional Accessories • Thermostat is not furnished with unit • See Lennox Price Book for selection iComfort®M30 Smart Wi-Fi Thermostat • Wi-Fi-enabled,electronic 7-day, universal, multi-stage, Compressor Hard Start Kit programmable,touchscreen • Single-phase units are equipped with a PSC compressor thermostat motor • 4 Heat/2 Cool = • This type of motor normally doesn't need a potential • Auto-changeover •0 73° relay and start capacitor Dual fuel control with 75 79° • For conditions such as low voltage kit may be required • optional outdoor sensor to increase the compressor starting torque • Controls dehumidification 1HW1117 Compressor Low Ambient Cut-Off Switch during cooling mode and • Non-adjustable switch (low ambient cut-out) prevents humidification during compressor operation when outdoor temperature is heating mode below 35°F • Offers enhanced capabilities including humidification/ Compressor Time-Off Control dehumidification/dewpoint measurement and control, • Kit prevents compressor short-cycling and allows time Humiditrol®control,and equipment maintenance for suction and discharge pressure to equalize reminders • Permits compressor start-up in an unloaded condition • Easy to read 4.3 in. color touchscreen (measured • Automatic reset with 5 minute delay between diagonally) compressor shut-off and start-up • LCD display with backlight shows the current and set temperature,time, inside relative humidity,system Indoor Blower Off Delay Relay status (operating mode and schedules) and outside • Delays the indoor blower-off time during the cooling temperature(optional outdoor sensor required) cycle • Smooth Setback Recovery starts system early to Low Ambient Kit achieve setpoint at start of program period • Air conditioners can operate down to 45°F outdoor air • Compressor short-cycle protection (5 minutes) temperature without additional controls • Up to four separate schedules are available plus • Allows unit to operate properly down to 30°F Schedule IQ"' NOTE-Crankcase heater and freezestat should be • One-Touch Away Mode-A quick and easy way to set the installed on compressors equipped with a low cooling and heating setpoints while away ambient kit. • Smart Away"'-Uses geo-fencing technology NOTE-A compressor lock-out thermostat should be to determine when the homeowner is within a added to terminate compressor operation below predetermined distance from the home to operate the recommended operation conditions. system when leaving,away and arriving • Wi-Fi remote monitoring and adjustment through a home wireless network for desktop PCs, laptops and apps for smartphones or tablets • Smart home automation compatible with Amazon Alexa®,Google Assistant and IFTTT NOTE-See the iComfort® M30 Smart Wi-Fi Thermostat Product Specifications bulletin in the Controls section for more information. Remote Outdoor Temperature Sensor • Used with the iComfort®M30 Smart Thermostat • Allows thermostat to display outdoor temperature NOTE-Sensor is required for the Enhanced Dehumidification Accessory(EDA). 1 ZACV AI_I S rn S Tnn A i./`nn.li•innn. /Da..n S FEATURES CABINET O• Heavy-gauge steel construction • Five station metal wash process • Louvered heavy gauge steel panels surround unit on all four sides to prevent damage to the coil • Powder paint finish provides superior rust and corrosion protection • Control box is conveniently located with all controls factory wired • Corner patch plate allows access to compressor components • Drainage holes are provided in base section for moisture removal PermaGuard'" Unit Base • Durable zinc-coated base section resists rust and corrosion Refrigerant Line Connections, Electrical Inlets,Service Valves • Sweat connection suction and liquid lines • Located on corner of unit cabinet • Fully serviceable brass service valves • Suction valve can be fully shut off,while liquid valve may be front seated to manage refrigerant charge while servicing system • Refrigerant line connections and field wiring inlets are located in one central area of cabinet for easy access • See dimension drawing Optional Accessories Unit Stand-Off Kit • Black high density polyethylene feet • Raises unit off mounting surface • Four feet furnished per order number 1 QnfVAI_'1 C♦n C T...,n:.!`n..d:Tinnu• /Donn 6 SPECIFICATIONS General Model No. Northern Region 13ACXN018 13ACXN024 13ACXN030 13ACXN03613ACXN042 13ACXN048 13ACXN060 Data Nominal Tonnage 1.5 2 2.5 3 3.5 4 5 Connections Liquid line o.d. -in. 3/8 3/8 3/8 3/8 3/8 3/8 3/8 (sweat) Suction line o.d. - in. 5/8 5/8 3/4 3/4 3/4 7/8 7/8 'Refrigerant(R-410A)furnished 4 lbs. 1 oz. 3 lbs. 14 oz. 5 lbs.2 oz. 5 lbs.4 oz. 6 lbs.8 oz. 7 lbs. 12 oz. 9 lbs.0 oz. RFCIV Metering Orifice Size Furnished 0.051 0.057 0.065 0.072 0.076 0.082 0.090 Outdoor Net face area Outer coil 11.33 11.33 13.22 13.22 16.33 18.67 16.33 Coil sq.ft. Inner coil --- --- --- --- --- --- 15.71 Tube diameter-in. 5/16 5/16 5/16 5/16 5/16 5/16 5/16 Number of rows 1 1 1 1 1 1 2 Fins per inch 26 26 26 26 26 26 22 Outdoor Diameter-in. 18 18 18 18 22 22 22 Fan Number of blades 3 3 4 4 4 4 4 Motor hp 1/10 1/10 1/5 1/5 1/4 1/4 1/4 Cfm 2350 2350 2400 2400 3500 3670 3600 Rpm 1010 1010 1090 1090 825 835 830 Watts 165 165 185 185 300 295 285 Shipping Data-lbs. 1 package 138 138 144 151 188 195 218 ELECTRICAL DATA Line voltage data-60 hz-1 ph 208/230V 208/230V 208/230V 208/230V 208/230V 208/230V 208/230V 2 Maximum overcurrent protection(amps) 20 25 25 35 45 50 60 3 Minimum circuit ampacity 12.4 14.7 17.1 22.0 28.1 31.9 34.6 Compressor Rated load amps 9.4 11.2 12.8 16.7 21.2 24.2 26.3 Locked rotor amps 56.6 60.8 64 70 90 100 125 Power factor 0.98 0.98 0.98 0.99 0.99 0.99 0.99 Condenser Full load amps 0.7 0.7 1.1 1.1 1.7 1.7 1.7 Fan Motor Locked rotor amps 1.3 1.3 2.0 2.0 3.2 3.2 3.2 CONTROLS - ORDER SEPARATELY iComfort®M30 Smart Wi-Fi 15Z69 Thermostat Remote Outdoor Temperature X2658 • Sensor OPTIONAL ACCESSORIES - ORDER SEPARATELY Compressor Crankcase Heater 93M04 • • 93M05 • Compressor Copeland 10J42 • • • • Hard Start Kit LG 88M91 • Compressor Low Ambient 45F08 • • • • • Cut-Off Switch Compressor Sound Cover 18J42 • Compressor Time-Off Control 47J27 • • Freezestat 3/8 in.tubing 93G35 • • • • 5/8 in.tubing 50A93 • • Indoor Blower Off Delay Relay 58M81 • • • • • Loss of Charge Switch Kit 84M23 • • 4 Low Ambient Kit(Fan Cycling) 34M72 • • Refrigerant L15-26-20, L15-26-25, • • Line Sets L15-26-35, L15-26-50 L15-41-20, L15-41-30, • L15-41-40, L15-41-50 L15-65-30, L15-65-40, • • L15-65-50 Unit Stand-Off Kit 94J45 • • NOTE-Extremes of operating range are plus 10%and minus 5%of line voltage. 'Refrigerant charge sufficient for 15 ft.length of refrigerant lines.For longer line set requirements see the Installation Instructions for information about line set length and additional refrigerant charge required. 2 HACR type circuit breaker or fuse. 'Refer to National or Canadian Electrical Code manual to determine wire,fuse and disconnect size requirements. "Crankcase Heater and Freezestat are recommended with Low Ambient Kit. •,ArVM-1 is•a a lit.*Air randi•innar i Dana 7 DIMENSIONS - UNIT n 4-3/8+ 43/8 INLET J L AIR (111) (111) v 4-3/8 ' ' ' ' 43/8 (111) n i- � (111) r � 0 ) l� / OPTIONAL UNIT /� \ INLET INLET STAND-OFF KIT(4) CeMPRES4R - <11 (Field Installed) AIR 1745,---------,____ COIL DRAIN OUTLETS' _ (Around perimeter of base) + ,� i `SUCTION LINE &3/8 \ ° ) ;,t 43/8 vvvvvv CONNECTION (162) I 1/// (111) INLET 4 AIR LIQUID LINE f t CONNECTION 6-3/81 i. c/) TOP VIEW TOP VIEW BASE SECTION r" A 11 A OUTDOOR *DISCHARGE AIR 1 . COIL FAN — „— -_ ly � s _ I •r \ mem _= = COMPRESSOR C B C SUCTION AND LIQUID LINE C - - CONNECTION\ i ' ELECTRICAL �' 11 =a INLETS .. �� 2-3/4(70) ■ ■. 2`(51) /.■ III 3/4(19) T OPTIONAL UNIT SIDE VIEW SIDE VIEW STANDOFF KIT(4) (FIELD INSTALLED) • A B C Model inches mm inches mm inches mm 13ACXN018 24-1/4 616 25-1/4 641 24-1/4 616 13ACXN024 24-1/4 616 25-1/4 641 24-1/4 616 13ACXN030 24-1/4 616 29-1/4 743 28-1/2 724 13ACXN036 24-1/4 616 29-1/4 743 28-1/2 724 13ACXN042 28-1/4 718 29-1/4 743 28-1/2 724 13ACXN048 28-1/4 718 33-1/4 845 32-1/2 826 13ACXN060 28-1/4 718 29-1/4 743 28-1/2 724 19ACYN-1 s♦n s ran Air rnnajtjnnn. /Unn 9 SOUND DATA Octave Band Sound Power Levels dBA, re 10-12 Watts 'Sound z Estimated Sound Pressure Level at ' Unit Center Frequency-HZ Rating Distance From Unit(dBA at distance in ft.) Model Number 125 250 500 1000 2000 4000 8000 (dBA) 3 5 10 15 50 018 53 60 64.5 68.5 67 61.5 54.5 76 69 64 58 55 44 024 51.5 62 64.5 68.5 67 60.5 53.5 76 69 64 58 55 44 030 52.5 62 67.5 69 67 61.5 54.5 76 69 64 58 55 44 036 52.5 61 67 69 67 61.5 52.5 76 69 64 58 55 44 042 58 68 73.5 75.5 74 69.5 62.5 79 72 67 61 58 47 048 57.5 67 73 74.5 71 64 58.5 79 72 67 61 58 47 060 57 63 69.5 71.5 71 65.5 60.5 79 72 67 61 58 47 NOTE-the octave sound power data does not include tonal correction. 'Tested according to AHRI Standard 270-2008 test conditions. 2 Estimated sound pressure level at distance based on AHRI Standard 275-2010 method for equipment located on the ground,roof,or on side of building wall with no adjacent reflective surface within 9.8 feet.Sound pressure levels will increase based on changes to assumptions.For other applications,refer to AHRI Standard 275. FIELD WIRING INSTALLATIO(---N CLEARANCE 4 DISCONNECT I DISCONNECT I SWITCH THERMOSTAT SWITCH See NOTES I_(By Other I (Required) I I_(By Others) I 1 I 0 � T 1 fSee� �` 'fSee� O NOTES �!j��llll`�� NOTES LENNOX / LENNOX AIR HEATING UNIT CONDITIONER OR AIR HANDLER CONTROL UNIT See NOTES BOX i A -Two Wire Power NOTES: B -Two Wire Power(See Electrical Data) C -Two Wire Low Voltage(18 ga. minimum) Service clearance of 30 in.(762 mm)must be maintained on one of the sides adjacent to the control box. D -Four Wire Low Voltage (Electra-Mechanical) 18 ga. Clearance to one of the other three sides must be 36 in. (914 minimum. mm) Five Wire Low Voltage(Electronic) 18 ga. minimum Clearance to one of the remaining two sides may be 12 in. (305 mm)and the final side may be 6 in. (152 mm). NOTE-Field Wiring Not Furnished A clearance of 24 in. must be maintained between two units. All wiring must conform to NEC or CEC and local electrical codes. 48 in. (1219 mm)clearance required on top of unit. 19Ar`VN_1 C to C Tnn Air r`nn.Uiinne. /Donn 0 . TXV/ORIFICE USAGE TXV SUBSTITUTION Use this table for C35, CH23, CH35 and CR33 Field A general guide for replacing the factory installed TXV if the Installed TXV/Orifice Match-Ups indoor unit(coiVair handler) is larger than the outdoor unit. Outdoor Refrigerant Metering Orifice Thermal Outdoor Unit Indoor Unit TXV TXV Unit (RFC) Expansion Furnished Replacement Order No. Orifice Size Valve (TXV) Size Tons Size Tons i 024 2 38 3.5 12J19 12J18 018 10W92 0.050 12J18 024 2 42 3.5 12J20 12J18 024 97M75 0.057 12J18 024 2 48 4 12J20 12J18 030 10W99 0.065 12J18 024 2 49 4 12J20 12J18 036 10W85 0.072 12J19 030 2.5 38 3.5 12J19 12J18 042 97M78 0.076 12J20 048 97M79 0.082 12J20 030 2.5 42 3.5 12J20 12J18 060 10M13 0.090 12J20 030 2.5 43 3.5 12J20 12J18 CX35 and CHX35 coils and all Lennox air handlers are shipped with a factory 030 2.5 44/48 4 12J20 12J18 installed TXV.In most cases,no change out of the valve is needed. If a change out is required it will be listed in the"TXV SUBSTITUTIONS"table 030 2.5 48 4 12J20 12J18 by size.The correct TXV must be ordered separately and field installed. 030 2.5 50/60 4 12J20 12J18 C35 and CH35 coils-Use the RFC orifice shipped with the outdoor unit or replace the factory installed RFC orifice with the expansion valve listed. TXV Ranges: CR33 and CH23 coils-Use the RFC orifice shipped with the outdoor unit or 12J18- 1.5 to 2.5 ton systems-Use on 2.5 ton and lower use the expansion valve listed. systems. 12J19-3 ton systems- Use down to 2 ton systems. 12J20-3.5 to 5 ton systems-Use down to 3 ton systems. AHRI STANDARD 210/240 Cooling or heating capacities are net values, including the effects of blower motor heat,and do not include supplementary heat. Power input is the total power input to the compressor(s)and fan(s),plus any controls and other items required as part of the system for normal operation. Units which do not have an indoor air-circulating blower furnished as part of the model, i.e., split system with indoor coil only, is established by subtracting from the total cooling capacity 1250 Btu/h per 1,000 cfm,and by adding the same amount to the heating capacity.Total power input for both heating and cooling is increased by 365 W per 1,000 cfm of indoor air circulated. 11ArvAl-1 4 to S Tnn Air rnnrnlinnn. /o.,nn 1n • • REVISIONS Sections Description of Change Approvals and Warranty Corrected compressor warranty. �.lii CERTIFIED,M • www.ahri di re ctu ry.c rg 4 •111?I44I crn Unitary Small AC AHRI Standard 210/240 �s�nraTr�n�,a,P�na��a�n�e��na�n�n��esrs�e�n V'MfMHER COMPANY C US riman,.ne anx� C/STEO Intertek Visit us at www.lennox.com LENNOX) For the latest technical information,www.Lennoxeros.com Contact us at 1-800-4-LENNOX NOTE-Due to Lennox'ongoing commitment to quality,Specifications,Ratings and Dimensions subject to change without notice and without incurring liability. Improper installation,adjustment,alteration,service or maintenance can cause property damage or personal injury. Installation and service must be performed by a qualified installer and servicing agency. ©2020 Lennox Industries,Inc.