Lennox ML193DFEK Series Unit Information
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Lennox ML193DFEK Series Unit Information

Lennox ML193DFEK Series Unit Information

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S e r v i c e L i t e r a t u r e
ML193DFEK series units are high-efficiency gas furnaces
manufactured with Lennox DuralokPlus aluminized steel
clamshell-type heat exch angers, with a stainless steel
condensing coil. ML193DFE units are available in heating
input capacities of 44,000 to 88, 000 Btuh and cooling ap-
plications from 1.5 to 4 tons.
Refer to Engineering Handbook for proper sizing.
Units are factory equipped for use with natural gas. A kit
is available for conversion to LPG operation. All ML193D-
FE units are equipped with a hot surface ignition system.
The gas valve is redundant to assure safety shut-off as
required by C.S.A.
The heat exchanger, burners and manifold assembly can
be removed for inspection and service. The maintenance
section gives a detailed description on how this is done.
The ML193DFEK can be "twinned" with a second unit.
Two units to operate as one, in a shared duct system con-
trolled by a single thermostat.
All specifications are subject to change. Procedures out-
lined in this manual are presented as a recommendation
only and do not supersede or replace local or state codes.
WARNING
Electric shock hazard. Can cause injury
or death. Before attempting to perform
any service or maintenance, turn the
electrical power to unit OFF at disconnect
switch(es). Unit may have multiple power
supplies.

Table of Contents

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . . 3
Twinning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
I-Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
II Placement and Installation . . . . . . . . . . . . . . . . . . . . 24
III-Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
IV-Heating System Service Checks . . . . . . . . . . . . . . 44
V-Typical Operating Conditions . . . . . . . . . . . . . . . . . 48
VI-Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
VII-Low GWP Application . . . . . . . . . . . . . . . . . . . . . . . . . .51
IX-Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..55
UNIT INFORMATION
UNIT INFORMATION
ML193DFEK WITH R454B SERIES UNITS
. . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . .54
100162
Improper installation, adjustment, alteration, service
or maintenance can cause property damage,
personal injury or loss of life. Installation and service
must be performed by a licensed professional HVAC
instale (or equivalent), service agency or the gas
supplier.
This furnace is equipped with an ignition control
factory enabled for use with A2L refrigerant systems.
Disabling the refrigerant detection functionality on
A2L system is prohibited by safety codes. Refer
to furnace installation instructions for refrigerant
system setup.
As with any mechanical equipment, contact with
sharp sheet metal edges can result in personal
injury. Take care while handling this equipment and
wear gloves and protective clothing.
Page 1
ML193DFEK
WARNING
WARNING
CAUTION

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  • Page 1: Table Of Contents

    S e r v i c e L i t e r a t u r e ML193DFEK WITH R454B SERIES UNITS ML193DFEK series units are high-efficiency gas furnaces manufactured with Lennox DuralokPlus aluminized steel clamshell-type heat exch angers, with a stainless steel condensing coil.

  • Page 2: Specifications

    SP ECIF ICATIONS Model ML193DF045XE36BK ML193DF070XE36BK ML193DF090XE48CK Heating AHRI Reference No. 20556884 20556885 20556886 Performance AFUE Input - Btuh 44,000 66,000 88,000 Output - Btuh 43,000 63,000 84,000 Temperature rise range - °F 30 - 60 40 - 70 45 - 75 Gas Manifold Pressure (in.

  • Page 3: Optional Accessories

    OPT IONAL AC C ESSORIES “B” Width Models “C” Width Models CABINET ACCESSORIES Downflow Combustible Flooring Base 11M60 11M61 CONDENSATE DRAIN KITS Condensate Drain Heat Cable 6 ft. 26K68 26K68 24 ft. 26K69 26K69 Crawl Space Vent Drain Kit 51W18 51W18 Canada 15Z70...

  • Page 4: Blower Performance Data

    BLOWER DATA ML193DF045XE36BK PERFORMANCE (Less Filter) Air Volume / Watts at Various Blower Speeds External Static High Medium-High Medium Medium-Low Pressure (Black) (Brown) (Blue) (Yellow) (Red) in. w.g. Watts Watts Watts Watts Watts 0.10 1376 1247 1101 0.20 1349 1223 1074 0.30 1324...

  • Page 5: Twinning

    The 24 VAC secondary of the two systems must be in Twinning phase. All thermostat connections are made to one control The control board in this furnace is equipped with a provi- only. See diagram below. sion to ”twin” (interconnect) two(2) adjacent furnaces with The twinned furnace without thermostat connections is a common plenum such that they operate as one (1) large to have the call for heat supplied by an external 24VAC...

  • Page 6: Parts Arrangement

    PARTS ARRANGEMENT CONTROL BOX (Includes integrated control, transformer, circuit breaker and door switch) BLOWER MOTOR (hidden) BAG ASSEMBLY (shipping location) Exhaust Intake BLOWER ACCESS PANEL COMBUSTION AIR INDUCER BLOWER DECK DuralokPlus HEAT EXCHANGER ASSEMBLY BURNER ACCESS PANEL COLD END HEADER BOX PRIMARY LIMIT BURNER BOX ASSEMBLY (includes sensor, rollout switches and ignitor)

  • Page 7: I-Unit Components

    I-UNIT COMPONENTS 3. Circuit Breaker (CB8) A 24V circuit breaker is also located in the control box. The ELECTROSTATIC DISCHARGE (ESD) switch provides overcurrent protection to the transform- Precautions and Procedures er (T1). The breaker is rated at 3A at 32V. If the current CAUTION exceeds this limit the breaker will trip and all unit opera- tion will shutdown.
  • Page 8 Indoor Blower Operation DIP Switch Settings TABLE 1 The heat fan-on time of 30 seconds is not adjustable The 1/4” QUICK CONNECT TERMINALS heat fan-off delay (amount of time that the blower oper- 120V HUM POWER FOR HUMIDIFIER (120 VAC ates after the heat demand has been satisfied) may be LINE INCOMING POWER LINE (120 VAC)
  • Page 9 On Board Links Must NOT Be Cut To Select Thermostat Wiring Connections AC ON System Options Heat / Cool FURNACE OUTDOOR T'STAT TERM. STRIP UNIT DO NOT CUT ANY ON-BOARD LINKS FIGURE 3 Wiring Connections On Board Links Must Be Cut To Select Thermostat Heat Pump Options Dual Fuel...
  • Page 10 Single Stage, Constant, Torque, Non-Communicating 107792-XX FIGURE 6 Indoor Blower Speeds 1 - When the thermostat is set to “FAN ON,” the indoor blower will run continuously on the (FAN) speed when there is no cooling or heating demand. See “Allowable Circulation Speeds” table below. 2 - When the ML193DFEK is running in the heating mode, the indoor blower will run on the heating speed (HEAT).
  • Page 11 TABLE 4 Integrated Diagnostic Codes/Status of Equipment Code Diagnostic Codes/Status of Equipment Indoor Blower Operation: Continuous Fan only mode Defrost mode Idle mode (Decimal blinks at 1 Hertz -- 0.5 second ON, 0.5 second OFF). Cooling stage (1 second ON, 0.5 second OFF) 1 or 2 displayed / Pause / Repeat codes. Dehumidification mode (1 second ON, 1 second OFF) / Pause / Repeat Codes).
  • Page 12 The sensor #1 is of a type not suitable for use in the application. incorrect Replace the sensor with a Lennox approved replacement part. This fault clears when a sensor suitable for the application is detected by the furnace control board, but blower will latch for a minimum of 5 minutes.
  • Page 13 TABLE 4 Continued Code Diagnostic Codes/Status of Equipment Action Required to Clear and Recover E164 Low GWP Test Low GWP Test mode activates by manually engaging Low GWP test button. Normal operations resumes and code clears automatically after 1-minute E200 Hard lockout - Rollout circuit open or previously Correct cause of rollout trip, or replace flame rollout switch.
  • Page 14 B-Heating Components (FIGURE 7) Combustion air inducer (B6), primary limit control (S10), SureLight ignitor, burners, flame rollout switch (S47), gas valve (GV1), combustion air prove switch (S18), and clam- shell heat exchangers are located in the heating compart- ment. The heating compartment can be accessed by re- moving the burner access panel.
  • Page 15 1. Flame Rollout Switches 4. Gas Valve (GV1) Flame rollout switches S47 are SPST N.C. high tempera- All units use an internally redundant to valve to assure turelimits located on the top left and bottom right of the safety shut-off. If the gas valve must be replaced, the front burner box plate.
  • Page 16 To Measure Flame Signal - Integrated Control: 4 - Connect (-) lead to flame sensor wire. 5 - Connect (+) lead to Terminal ”Flame Sense” on Use a digital readout meter capable of reading DC micro- integrated control. amps. See FIGURE 10 for flame signal check. 6 - Turn supply voltage on and close thermostat 1 - Set the meter to the DC amps scale.
  • Page 17 Test 1 Check ignitor circuit for correct resistance. Remove HSI/CAI 4-pin plug from control. Check ohms reading across terminals 2 and 4. Reading should be between 39 and 70 ohms. If 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.

  • Page 18: Pressure Switch

    7. Combustion Air Inducer (B6) Pressure Switch & Cold End Header Box Units use a combustion air inducer to move air through the burners and heat exchanger during heating operation. The blower uses a shaded pole 120VAC motor. The motor operates during all heating operation and is controlled by burner ignition control A3.
  • Page 19 Measuring Pressure Differential Red and Black Tubing or Red Tubing (negative −) Black Tubing (positive +) To Cold End Header Box To Cold End Header Box Field Provided Tubing To Pressure Switch “+” High “−” Low Operate unit and observe manometer reading. Remove thermostat demand and allow unit to cycle off.
  • Page 20 TABLE 7 Problem Corrective Action Check that the pressure switch is open without the com- Pressure switch stuck closed bustion air inducer operating. Replace if defective. Pressure switch does not close due to obstruction in vent Check for restricted vent. Remove all blockage. Check for pipe.

  • Page 21: Secondary Limit Control

    C-Blower Compartment BLOWER WHEEL REPLACEMENT IMPORTANT Center Blower Wheel in Blower Housing Each blower is statically and dynamically balanced as an assembly before installation in the unit. 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.
  • Page 22 Multi−Meter (set to V AC) Multi-met (set to VAC) "9A” Test 3 (if necessary) NOTE- Ignition control illustration is typical "7A” Check for 120 volts across terminals “L1” and “Neutrals” on the Turn power on to unit. Check for 120 volts integrated control.

  • Page 23: Motor Test

    Replacing the Motor Module Motor Test NOTE - Not all motors have field replaceable control mod- ules. Only motors that utilize a 4 pin power connector and 5 pin signal connector as shown below may have replace- able controls. Motors that use a 3 pin power connector and 6 pin signal connector do not have field replaceable control modules.

  • Page 24: Placement And Installation

    II-PLACEMENT AND INSTALLATION IMPORTANT Pipe & Fittings Specifications Exhaust and intake connections are made of PVC. All pipe, fittings, primer and solvent cement must conform Use PVC primer and solvent cement when using with American National Standard Institute and the Ameri- PVC vent pipe.
  • Page 25 TABLE 10 OUTDOOR TERMINATION USAGE* STANDARD CONCENTRIC Flush Mount Wall Kit 1-1/2 inch 2 inch 3 inch Vent Pipe Input Size 2 inch 3 inch Field Dia. in. 71M80 (US) 69M29 (US) 60L46 (US) Fabricated 51W11 (US) 22G44 (US) 44W92 44W92 444W93 44J40 (US)

  • Page 26: Joint Cementing Procedure

    Joint Cementing Procedure Venting Pratices All cementing of joints should be done according to the specifications outlined in ASTM D 2855. HORIZONTAL PIPING SUPPORT GUIDELINES NOTE - A sheet metal screw may be used to secure the SCHEDULE 40 intake pipe to the connector, if desired. Use a drill or self PVC - 5' tapping screw to make a pilot hole.
  • Page 27 1 - - Seal any unused openings in the common venting Vent Piping Guidelines system. NOTE - Lennox has approved the use of DuraVent ® 2 - Inspect the venting system for proper size and Centrotherm manufactured vent pipe and terminations horizontal pitch.
  • Page 28 In some applications which permit the use of several dif- most elbows? ferent sizes of vent pipe, a combination vent pipe may be Intake or exhaust? used. Contact Lennox’ Application Department for assis- tance in sizing vent pipe in these applications. How many elbows? CAUTION Count all elbows inside and outside house.
  • Page 29 TABLE 12 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. 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.

  • Page 30: Top View

    TYPICAL EXHAUST PIPE CONNECTIONS 045/070 Only 2” 1−1/2” 2” 2” 2” TRANSITION 2” 2” Exhaust Exhaust 3” DO NOT transition from larger to smaller pipe in horizontal runs TRANSITION of exhaust pipe. INTAKE EXHAUST DO NOT transition from smaller *2” to larger pipe size in horizontal TOP VIEW runs of exhaust pipe.
  • Page 31 Intake Piping CAUTION The ML193DFEK furnace may be installed in either direct If this unit is being installed in an application with vent or non-direct vent applications. In non-direct vent ap- combustion air coming in from a space serviced by plications, when intake air will be drawn into the furnace an exhaust fan, power exhaust fan, or other device from the surrounding space, the indoor air quality must be...
  • Page 32 General Guidelines for Vent Terminations NOTE - See TABLE 14 for maximum allowed exhaust pipe length without insulation in unconditioned space during In Non-Direct Vent applications, combustion air is taken winter design temperatures below 32°F (0°C). If required from indoors and the flue gases are discharged to the out- exhaust pipe should be insulated with 1/2”...
  • Page 33 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 Unit Input Size Vent Pipe Temperatures Diameter °F (°C) 1-1/2 in 32 to 21 2 in (0 to -6) 2-1/2 in...
  • Page 34 ‡ Permitted only if veranda, porch, deck or balcony is fully open NOTE - This figure is intended to illustrate clearance on a minimum of two sides beneath the floor. Lennox recommends requirement and does not serve as a substitute for avoiding this location if possible.
  • Page 35 ‡ Permitted only if veranda, porch, deck or balcony is fully open on a minimum of locally adopted installation codes. two sides beneath the floor. Lennox recommends avoiding this location if possible. FIGURE 32 Page 35...
  • Page 36 Details of Intake and Exhaust Piping Terminations for NOTE - Care must be taken to avoid recirculation of Direct Vent Installations exhaust back into intake pipe. 6 - On field supplied terminations, a minimum distance NOTE - In Direct Vent installations, combustion air is taken between the end of the exhaust pipe and the end of from outdoors and flue gases are discharged to outdoors.
  • Page 37 7 - - If intake and exhaust piping must be run up a side wall to position above snow accumulation or other obstructions, iping must be supported. At least 12” EXHAUST one bracket must be used within 6” from the top of (305mm) VENT 5-1/2”...
  • Page 38 FIELD FABRICATED WALL TERMINATION NOTE − FIELD−PROVIDED REDUCER MAY BE 2” (51mm) 3” (76mm) REQUIRED TO ADAPT Vent Pipe Vent Pipe LARGER VENT PIPE SIZE TO TERMINATION A− Minimum clearance above grade or average 12” (305 mm) 12” (305 mm) snow accumulation B−...
  • Page 39 2 - On field supplied terminations for side wall exit, DIRECT VENT APPLICATION exhaust piping may extend a maximum of 12 inches USING EXISTING CHIMNEY STRAIGHT-CUT OR (305mm) for 2” PVC and 20 inches (508mm) for 3” ANGLE-CUT IN DIRECTION OF ROOF SLOPE * (76mm) PVC beyond the outside wall.

  • Page 40: Condensate Piping

    If this is not possi- ble, a heat cable kit may be used on the condensate trap and line. Heat cable kit is available from Lennox in various lengths; 6 ft. (1.8m) - kit no. 26K68 and 24 ft. (7.3m) - kit FIGURE 44 no.
  • Page 41 IMPORTANT Condensate Trap With Optional Overflow Switch From Evaporator Coil When combining the furnace and evaporator coil drains together, the A/C condensate drain outlet HorizontalFurnace4” Min. to 5” Max.above condensatedrain connection) must be vented to relieve pressure in order for the furnace pressure switch to operate properly.
  • Page 42 TRAP / DRAIN ASSEMBLY USING 1/2” PVC OR 3/4” PVC Optional Condensate Drain Connection Adapter 3/4 inch slip X 3/4 inch mpt (not furnished) 90° Street Elbow 3/4 inch PVC (not furnished) Adapter 3/4 inch slip X 3/4 inch mpt (not furnished) Condensate Drain Connection In Unit 1 (25 mm) Min.

  • Page 43: Iii-Start-Up

    III-START-UP 2 - Set the thermostat to the lowest setting. 3 - Turn off all electrical power to the unit. A-Preliminary and Seasonal Checks 4 - This furnace is equipped with an ignition device 1 - Inspect electrical wiring, both field and factory which automatically lights the burners.

  • Page 44: Iv-Heating System Service Checks

    Use of a specialty Gas Leak Detector is strongly recom- All units are C.S.A. design certified without modifications. mended. It is available through Lennox under part number Refer to the ML193DFEK Operation and Installation In- 31B2001. See Corp. 8411-L10, for further details.

  • Page 45: Measuring Device

    Negative Barbed Fitting (remove for manifold adjustment) (−) 2” Long Square Tubing (remove for manifold adjustment) Manifold Pressure Outlet Gas Valve Regulator Vent Hose (to burner box) Barbed Fitting 10” Long Square Tubing Measuring Device FIGURE 53 Page 45...
  • Page 46 F- Proper Gas Flow (Approximate) G- Proper Combustion Furnace should operate at least 15 minutes with correct TABLE 16 manifold pressure and gas flow rate before checking com- GAS METER CLOCKING CHART bustions. Take sample beyond the flue outlet and compare to TABLE 17.
  • Page 47 I- Proper Ground and Voltage 2 - In addition, measure the AC voltage from Line Hot to Line Neutral (spade terminals) on the integrated A poorly grounded furnace can contribute to premature control. See FIGURE 54. This voltage should be in ignitor failure.

  • Page 48: V-Typical Operating Characteristics

    V-TYPICAL OPERATING CHARACTERISTICS C-External Static Pressure 1 - Tap locations shown in FIGURE 56. A-Blower Operation and Adjustment1 2 - Punch a 1/4” diameter hole in supply and return NOTE- The following is a generalized procedure and does air plenums. Insert manometer hose flush with inside edge of hole or insulation.

  • Page 49: Vi-Maintenance

    1 - Turn off power to the unit. specifications provided by the filter manufacturer against 2 - Remove hose from cold end header box. Twist and the data given in the appropriate Lennox Product pull screen to remove. Specifications bulletin. Additional information is provided 3 - Inspect screen and rinse with tap water if needed.
  • Page 50 16 - Remove screws along vestibule sides and bottom Condensate Hose Screen which secure vestibule panel and heat exchanger assembly to cabinet. Remove two screws from blower rail which secure bottom heat exchanger flange. Remove heat exchanger from furnace cabinet. 17 - Back wash heat exchanger with soapy water solution or steam.

  • Page 51: Vii-Low Gwp Application

    15 - Replace heating compartment access panel. VII- Low GWP Application FIGURE 59 WARNING TABLE 22 For use with Lennox approved evaporator coil and LGWP DIP Switch Settings sensors only. Use original manufacturer recommended Configuration Switch 1 Switch 2...
  • Page 52 Each DIP switch corresponds to a sensor position (i.e., NOTE - The HVAC system may not maintain a cooling or heating setpoint if a significant leak exists. Any refrigerant DIP switch 1 to sensor 1; DIP switch 2 to sensor 2). The leaks that remain unaddressed for an extended time may default factory switch positions are set to OFF (ENABLED) cause the HVAC system to shut down on a low refrigerant...

  • Page 53: Start-Up Procedure

    LGWP Test Button - Additional Functions START UP PROCEDURE The furnace control board is equipped with a LGWP Test/ TABLE 24 lists the additional functions of the Test Button Reset button, see Test Button Functionality. After the fur- while the furnace control board is functioning within the nace control board has been mounted and wired, restore states of Initializing, Monitoring, Leak Detection, Servicing power to the HVAC system.

  • Page 54: Viii-Wiring And Sequence Of Operation

    VIII- Wiring and Sequence of Operation OUTDOOR BLOWER SPEED CHART (ML193DF) UNIT FACTORY CONNECTED SPEED TAPS UNIT COOL HEAT PARK PARK 045XE36BK BLACK YELLOW BROWN BLUE POWER 070XE36BK BROWN YELLOW BLACK BLUE CHOKE YELLOW 090XE48CK BLACK BLUE BROWN INDOOR BLOWER MOTOR BLOWER SPEED SELECTION SPEED TAPS BLUE...

  • Page 55: Heating Sequence Of Operation

    IX - Troubleshooting HEATING SEQUENCE OF OPERATION ABNORMAL HEATING MODE NORMAL HEATING MODE POWER ON GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER DELAY OFF. CONTROL SELF-CHECK OKAY? (RESET CONTROL BY TURNING MAIN POWER OFF.) SEVEN SEGEMENT LED FLASHES E111 IS POLARITY CORRECT? - POLARITY REVERSED.
  • Page 56 HEATING SEQUENCE CONTINUED 15 SECOND COMBUSTION AIR INDUCER PREPURGE INITIATED BY CLOSED PRESSURE SWITCH. SEVEN SEGEMENT LED E110 LOW LINE VOLTAGE. ONCE VOLTAGE IS ABOVE IGNITOR WARM UP -- 20 SECONDS. IS VOLTAGE ABOVE 70 VOLTS? 75 VOLTS, HEATING SEQUENCE RESTARTS. 4 SECOND TRIAL FOR IGNITION.
  • Page 57 COOLING SEQUENCE OF OPERATION POWER ON IGNITION CONTROL MAIN POWER ON. GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER OFF WITH NORMAL DELAY. CONTROL SELF DIAGNOSTIC CHECK. SIGNAL CIRCUIT BOARD FAILURE AT LED. IS CONTROL OPERATING NORMALLY? INTERRUPT MAIN POWER TO RESET CONTROL. SEVEN SEGEMENT LED FLASHES E117 IMPROPER GROUND IS THERE A PROPER GROUND? CONTROL WILL CONTINUE TO CALL FOR COOLING...
  • Page 58 CONTINUOUS FAN SEQUENCE OF OPERATION MANUAL FAN SELECTION MADE AT THERMOSTAT. CONTROL (G) ENERGIZES SYSTEM FAN AT FAN SPEED. EAC TERMINAL IS ENERGIZED. THERMOSTAT CALLS FOR HEAT (W). SYSTEM FAN CONTINUES FAN SPEED WITHOUT THERMOSTAT CALLS FOR COOLING. INTERRUPTION. EAC TERMINAL REMAIN ON. HUM TERMINAL IS ENERGIZED WITH COMBUSTION SYSTEM FAN SWITCHED TO COOL SPEED.

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