Lennox ML193UH030XE36B Manual Download

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Page 6

ML193UHE PARTS IDENTIFICATION

FIGURE 1

TOP CAP

BURNER BOX

ASSEMBLY

DuralokPlus

HEAT EXCHANGER

ASSEMBLY

CONTROL BOX

(includes integrated ignition control, trans

former, circuit breaker and interlock switch)

COMBUSTION AIR

INDUCER

BURNER

ACCESS

PANEL

COMBUSTION

AIR PRESSURE

SWITCH

PRIMARY LIMIT

GAS VALVE

BLOWER

ASSEMBLY

FLEXIBLE NO-HUB

EXHAUST COLLAR

COLD END

HEADER BOX

BAG ASSEMBLIES

(shipping location)

BLOWER

ACCESS

PANEL

Summary of Contents for ML193UH030XE36B

Page 1: ...nits to operate as one in a shared duct system controlled by a single ther mostat All specifications are subject to change Procedures outlined 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 ...

Page 2: ... provided 1 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 Heating Performance Model No ML193UH090XE48C ML193UH110XE48C ML193UH110XE60C AHRI Reference No 20256881 20256882 20256883 1 AFUE 93 93 93 Input Btuh 88 000 110 000 110 000 Output Btuh 84 000 104 000 1...

Page 3: ...x 25 x 1 NIGHT SERVICE KIT Night Service Kit 84W48 84W48 TERMINATION KITS See Installation Instructions for specific venting information Termination Kits Direct Vent Applications Only Concentric US 2 in 71M80 69M29 3 in 60L46 Canada 2 in 44W92 44W92 3 in 44W93 Flush Mount US 2 2 1 2 or 3 in 51W11 51W11 Canada 2 2 1 2 or 3 in 51W12 51W12 Wall Close Couple US 2 in 22G44 3 in 44J40 44J40 Wall Close C...

Page 4: ...05 970 237 685 147 455 100 0 70 1210 401 1080 316 930 247 635 152 405 109 0 80 1185 412 1045 325 885 255 600 158 355 114 ML193UH030XE36B PERFORMANCE Less Filter External Static Pressure in w g Air Volume Watts at Various Blower Speeds High Medium High Medium Medium Low Low 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...

Page 5: ... 1885 715 1635 521 1485 425 1345 359 1140 271 1900 698 1635 506 1450 413 1330 351 1125 270 0 80 1855 735 1600 534 1440 426 1305 367 1085 279 1850 711 1605 520 1415 430 1285 363 1075 281 ML193UH090XE48C PERFORMANCE Less Filter External Static Pressure in w g Air Volume Watts at Various Blower Speeds High Medium High Medium Medium Low Low cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts 0 00 1710 3...

Page 6: ...ONTROL BOX includes integrated ignition control trans former circuit breaker and interlock switch COMBUSTION AIR INDUCER BURNER ACCESS PANEL COMBUSTION AIR PRESSURE SWITCH PRIMARY LIMIT GAS VALVE BLOWER ASSEMBLY FLEXIBLE NO HUB EXHAUST COLLAR COLD END HEADER BOX BAG ASSEMBLIES shipping location BLOWER ACCESS PANEL ...

Page 7: ...ion to the transformer T1 The breaker is rated at 3A at 32V If the current ex ceeds this limit the breaker will trip and all unit operation will shutdown The breaker can be manually reset by pressing the button on the face 4 Integrated Ignition Control A92 WARNING Shock hazard Disconnect power before servicing Control is not field repairable If control is inoperable simply re place entire control ...

Page 8: ...uring 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 ...

Page 9: ... on time of 30 seconds is not adjustable Heating Fan Off Time Fan off time time that the blower operates after the heat demand has been satisfied can be adjusted by moving the jumper to a different setting The unit is shipped with a fac tory fan off setting of 90 seconds For customized comfort monitor the supply air temperature once the heat demand is satisfied Note the supply air temperature at t...

Page 10: ...gure 6 ML193UHE units use an aluminized steel primary and stainless steel secondary heat exchanger assembly Heat is transferred to the air stream from all surfaces of the heat exchanger The shape of the heat exchanger en sures maximum efficiency The combustion air inducer pulls fresh air through the burn er box This air is mixed with gas in the burners The gas air mixture is then burned at the ent...

Page 11: ...d through the flame and sensing electrode The igni tion control allows the gas valve to remain open as long as flame signal is sensed NOTE The ML193UHE 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 on the integrated control Flame microamp signal is an electrical current which passes from the inte...

Page 12: ...5 0 5 1 4 0 4 Set Dial to DC MicroAmps Multi Meter To Control Sensor Terminal To Flame Terminal Flame Sensor Terminal Flame Sensor Wire Intergrated Control Remove sensor from integrated control and connect alligator clip to flame sensor lead Remove sensor from integrated control and connect alligator clip to terminal on control ...

Page 13: ... and check resistance of ignitor at the plug Reading should be between 39 and 70 ohms If the reading is correct then the problem is with the wiring between the jack plug and the control If reading is not correct the issue is the ignitor Test 3 Check ignitor for correct voltage Insert meter probes into terminals 2 and 4 use small diameter probes in order not to damage plug Check voltage during 20 s...

Page 14: ... air inducer orifice to in sure proper flow through the heat exchanger The switch is a SPST N O pressure switch electrically con nected to the integrated control The purpose of the switch is to prevent burner operation if the combustion air inducer is not moving enough air for proper combustion FIGURE 10 Pressure Switch Positive Port Negative Port Terminals On start up the switch monitors whether ...

Page 15: ...he port reads less negative pressure than the port 4 Operate unit and observe manometer reading Readings will change as heat exchanger warms a Take one reading immediately after start up b Take a second reading after unit has reached steady state approximately 5 minutes This will be the pressure differential The pressure differential should be greater than those listed in table 6 5 Remove thermost...

Page 16: ...h Check the differential pressure across the pressure switch Check for restricted inlet vent Remove all blockage Check for proper vent sizing and run length See table12 Wrong pressure switch installed in the unit or pressure switch is out of cal ibration Check that the correct pressure switch is installed in the unit Replace pressure switch if necessary Miswiring of furnace or improper con nection...

Page 17: ...s 1 and 2 and motor is not operating properly replace motor The motor is not field re pairable If replacing the indoor blower motor or blower wheel is nec essary placement is critical The blower wheel must be cen tered in the blower housing as shown in figure 12 When re placing the indoor blower motor the set screw must be aligned and tightened with the motor shaft as shown in figure 13 9 Secondar...

Page 18: ...us fan 1 2 3 4 or 5 on input plug P49 If 24 volts is not present problem may be up stream of plug P49 Proceed to test 4 Multi Meter set to VAC 12 0 12 0 24 Multi Meter set to VAC Check for 24 volts across terminals 24 COM and FAN ter minals on the integrated control If voltage is present prob lem is with the harness If voltage is not present problem may be may be with the integrated control Check ...

Page 19: ...l read approximate ly the same resistance within an ohm 3 Check to see if the blower wheel spins freely FIGURE 18 Motor Test TABLE 8 Scale Measurement range in words ohms 2 M two megohm two million ohms 0 2 000 000 200 K two hundred kilo ohm two hundred thousand ohms 0 200 000 20 K twenty kilo ohm twenty thousand ohms 0 20 000 2 K two kilo ohm two thousand ohms 0 2 000 200 two hundred ohms 0 200 M...

Page 20: ...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 DWV Drain Waste Vent Pipe Fittings D2661 PVC DWV Drain Waste Vent Pipe Fittings D2665 PRIMER SOLVENT CEMENT ASTM SPECIFICATION PVC CPVC Primer F656 PVC Solvent Cement D2564 CPVC Solvent Cement F493 ABS Solvent Cement D2235 PVC CPVC ABS...

Page 21: ...ly 5 See table 15 for vent accelerator requirements 6 Requires field provided 2 to 1 1 2 reducer Joint Cementing Procedure All cementing of joints should be done according to the specifications outlined in ASTM D 2855 NOTE A sheet metal screw may be used to secure the intake pipe to the connector if desired Use a drill or self tapping screw to make a pilot hole DANGER DANGER OF EXPLOSION Fumes fro...

Page 22: ... another gas appliance the size of the existing vent pipe for that gas ap pliance must be checked Without the heat of the original furnace flue products the existing vent pipe is probably oversized for the single water heater or other appliance The vent should be checked for proper draw with the remaining appliance FIGURE 21 REPLACING FURNACE THAT WAS PART OF A COMMON VENT SYSTEM CAUTION Do not di...

Page 23: ... size larger than 2 This elbow must be added to the elbow count used to determine acceptable vent lengths Con tact the Application Department for more information concerning sizing of vent systems which include multiple pipe sizes FIGURE 22 Exhaust Pipe NOTE Exhaust pipe MUST be glued to furnace exhaust fittings NOTE All horizontal runs of exhaust pipe must slope back to ward unit A minimum of 1 4...

Page 24: ...0 045 070 090 110 030 045 070 090 110 030 045 070 090 110 030 045 070 090 110 1 20 15 n a n a 73 58 42 22 105 90 64 39 121 121 114 114 2 15 10 68 53 37 17 100 85 59 34 116 116 109 109 3 10 n a 63 48 32 12 95 80 54 29 111 111 104 104 4 n a 58 43 27 n a 90 75 49 24 106 106 99 99 5 53 38 22 85 70 44 19 101 101 94 94 6 48 33 17 80 65 39 14 96 96 89 89 7 43 28 12 75 60 34 n a 91 91 84 84 8 38 23 n a 70...

Page 25: ...rger to smaller pipe in horizontal runs of exhaust pipe Exhaust FIGURE 25 SIDE VIEW 2 2 2 or TYPICAL EXHAUST AND INTAKE PIPE CONNECTIONS IN HORIZONTAL DIRECT OR NON DIRECT VENT APPLICATIONS RIGHT HAND DISCHARGE SHOWN 3 2 45 MAX 45 MAX DO NOT transition from smaller to larger pipe in horizontal runs of exhaust pipe EXHAUST 12 max 2 2 When transitioning up in pipe size use the shortest length of 2 P...

Page 26: ...RIZONTAL NON DIRECT VENT APPLICATIONS Horizontal Right Hand Air Discharge Application Shown INTAKE DEBRIS SCREEN Provided OR NOTE Debris screen may be positioned straight out preferred or with an elbow rotated to face down coupling PVC pipe 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 out...

Page 27: ...tions combustion air is taken from outdoors and the flue gases are discharged to the out doors The ML193UHE is then classified as a direct vent Category IV gas furnace In both Non Direct Vent and Direct Vent applications the vent termination is limited by local building codes In the absence of local codes refer to the current National Fuel Gas Code ANSI Z223 1 NFPA 54 in U S A and current CSA B149...

Page 28: ...A N A N A 2 in 5 3 12 10 22 19 30 27 2 1 2 in N A N A 7 N A 15 N A 22 N A 3 in N A N A N A N A 10 10 16 16 1Refer to 99 Minimum Design Temperature table provided in the current edition of the ASHRAE Fundamentals Handbook 2 Poly 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 uni...

Page 29: ...p ply inlet Clearance above paved sidewalk or paved driveway located on public property Clearance under veranda porch deck or balcony 12 Equal to or greater than soft depth 3 feet 9m 12 3 feet 9m within a height 15 feet 4 5m above the meter regulator assembly 3 feet 9m 6 inches 152mm for appliances 10 000 Btuh 3kw 12 inches 305mm for appliances 10 000 Btuh 3kw and 100 000 Btuh 30kw 36 inches 9m fo...

Page 30: ...e above paved sidewalk or paved driveway located on public property Clearance under veranda porch deck or balcony 12 7 feet 2 1m 3 feet 9m within a height 15 feet 4 5m above the meter regulator assembly 3 feet 9m 6 inches 152mm for appliances 10 000 Btuh 3kw 9 inches 228mm for ap pliances 10 000 Btuh 3kw and 50 000 Btuh 15 kw 12 inches 305mm for ap pliances 50 000 Btuh 15kw 6 inches 152mm for appl...

Page 31: ...ferent pressure zones the maximum separation requirement of intake and ex haust pipe DOES NOT apply 3 On roof terminations the intake piping should termi nate straight down using two 90 elbows See figure 33 4 Exhaust piping must terminate straight out or up as shown A reducer may be required on the exhaust pip ing at the point where it exits the structure to improve the velocity of exhaust away fr...

Page 32: ... installed to support the weight of the termination kit FLASHING Not Furnished CLAMP FIELD PROVIDED REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION 1 1 2 38mm 12 305mm INTAKE AIR EXHAUST VENT 12 305mm Min above grade or average snow accumulation FIGURE 37 DIRECT VENT CONCENTRIC WALL TERMINATION 71M80 69M29 or 60L46 US 44W92 or 44W93 Canada INTAKE AIR INTAKE AIR INTAKE AIR OUT...

Page 33: ... 227 mm Min 12 305 mm Min 16 405 mm Max 6 152 mm Max 6 152 mm Min 24 610 mm Max 9 227 mm Min 12 305 mm Min 20 508 mm Max 6 152 mm Max Intake Elbow WALL SUPPORT B A D E B D E A ALTERNATE TERMINATIONS TEE FORTY FIVE DEGREE ELBOWS ONLY D C 12 1 2 E B A 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 t...

Page 34: ...r 44J41 UNCONDITIONED ATTIC SPACE 3 76mm OR 2 51mm PVC PROVIDE SUPPORT FOR EXHAUST LINES 12 305mm ABOVE AVE SNOW ACCUMULATION 3 If exhaust piping must be run up a side wall to position above snow accumulation or other obstructions pip ing must be supported every 24 inches 610mm When exhaust piping must be run up an outside wall any reduction in exhaust pipe size must be done after the final elbow ...

Page 35: ...ate line from the furnace and evaporator coil can drain together See figures 48 50 and 51 Upflow furnace figure 50 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 fig...

Page 36: ...minimum of 1 4 per ft toward trap FIGURE 47 ML193UHE With Evaporator Coil Using A Separate Drain Condensate DrainConnection Field Provided Vent 1 min 2 max above condensate connection Evaporator drain line required Trap at coil is optional FIGURE 48 Horizontal Furnace4 Min to 5 Max above condensate drain connection Furnace Condensate DrainConnection From Evaporator Coil Optional Condensate Trap Wi...

Page 37: ...ndensate drain connection Condensate DrainConnection Evaporator drain line required Trap at coil is optional IMPORTANT When combining the furnace and evaporator coil drains together the A C condensate drain outlet must be vented to relieve pressure in or der for the furnace pressure switch to operate properly FIGURE 51 ML193UHE with Evaporator Coil Using a Common Drain Unit shown in horizontal lef...

Page 38: ...Drain Connection In Unit Condensate Drain Connection In Unit Vent To Drain Condensate Drain Connection In Unit Optional Condensate Drain Connection OptionalDrainPipingFromTrap DrainTrapAssembly Furnished DrainTrap Assembly with 1 2 inch Piping DrainTrap Assembly with 3 4 inch Piping 1 2 inch 3 4 inch 1 25 mm Min 2 50 mm Max Above Top Of Condensate Drain Connection In Unit 1 25 mm Min 2 50 mm Max A...

Page 39: ...oint the trap should be primed with suffi cient water to ensure proper condensate drain opera tion WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or death Gas Valve Operation Figure 53 1 STOP Read the safety information at the beginning of this section 2 Set the thermostat to the lowest setting 3 Turn off all electrica...

Page 40: ... Pressure Gas Flow Approximate TABLE 16 GAS METER CLOCKING CHART ML193 Unit Seconds for One Revolution Natural LP 1 cu ft Dial 2 cu ft Dial 1 cu ft Dial 2 cu ft DIAL 030 120 240 300 600 045 80 160 200 400 070 55 110 136 272 090 41 82 102 204 110 33 66 82 164 Natural 1000 btu cu ft LP 2500 btu cu ft Furnace should operate at least 5 minutes before check ing gas flow Determine time in seconds for tw...

Page 41: ...ve Regulator Vent Hose to burner box 2 Long Square Tubing remove for manifold adjustment Tee 10 Long Square Tubing Measuring Device Barbed Fitting Manifold Pressure Outlet Negative Barbed Fitting remove for manifold adjustment ...

Page 42: ...t this unit Refer to the changeover kit in stallation instruction for the conversion procedure TABLE 18 Manifold and Supply Line Pressure 0 10 000ft ML193E Unit Gas Manifold Pressure in wg Supply Line Pressure in w g 0 10000 ft 0 4500 ft 4501 5500 ft 5501 6500 ft 6501 7500ft 7501 10000ft All Sizes Natural 3 5 3 3 3 2 3 1 3 5 4 5 13 0 LP propane 10 0 9 4 9 1 8 9 10 0 11 0 13 0 NOTE A natural to L P...

Page 43: ... 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 2 In addition measure the AC voltage from Line Hot to Line Neutral spade terminals on the integrated con trol See figure 56 This voltage should be in the range of 97 to 132 Vac TA...

Page 44: ...eturn air plenums Insert manometer hose flush with inside edge of hole or insulation Seal around the hose with permagum Connect the zero end of the manometer to the discharge supply side of the system On ducted systems connect the other end of manometer to the return duct as above 3 With only the blower motor running and the evaporator coil dry observe the manometer reading Adjust blow er motor sp...

Page 45: ... 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 TABLE 21 Furnace Cabinet Width Filter Size Side Return Bottom Return 17 1 2 16 X 25 X 1 1 16 X 25 X 1 1 21 16 X 25 X 1 1 20 X 25 X 1 1 Exhaust and air intake pipes Check the exhaust and air intake pipes an...

Page 46: ...e the primary limit from the vestibule panel 20 Remove top cap screws to allow top cap to be tilted up ward to allow clearance for removing heat exchanger 21 Remove two screws from the front cabinet flange at the blower deck Spread cabinet sides slightly to allow clearance for removal of heat exchanger 22 Remove screws along vestibule sides and bottom which secure vestibule panel and heat exchange...

Page 47: ...burner mani fold assembly 8 Remove four screws that secures burner manifold as sembly to vestibule Remove the assembly and make note not to allow ignitor plate to dislodge from the as sembly 9 Gently clean the face of the burners using the soft brush attachment on a vacuum cleaner Visually in spect the inside of the burners and crossovers for any blockage caused by foreign matter Remove any blocka...

Page 48: ...l goes into 5 minute Watchguard Pressure Switch delay Once S18 clos es a 15 second pre purge follows 4 The integrated control A92 energizes ignitor A 20 second warm up period begins 5 Gas valve opens for a 4 second trial for ignition 6 Flame is sensed gas valve remains open for the heat call 7 After 30 second delay the integrated control A92 en ergizes indoor blower B3 8 When heat demand is satisf...

Page 49: ...NERGIZED GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER ON HEATING SPEED LED FLASHES CODE 11 PRESSURE SWITCH CLOSED GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF WITH DELAY Sequence holds until pressure switch opens or thermostat resets control NO NO YES YES IS VOLTAGE ABOVE 70 VOLTS LED FLASHES CODE 13 LOW LINE VOLTAGE CONTROL WILL NOT RESPOND TO A CALL FOR HEATING UNTIL VOLTA...

Page 50: ...LETE YES 4 SECONDS YES HAS CONTROL RESET IGNITION SEQUENCE FOUR TIMES FLAME SIGNAL 1 5 MICROAMPS OR GREATER YES YES YES ROLLOUT SWITCH CLOSED LED FLASHES CODE 8 ROLLOUT SWITCH OPEN GAS VALVE POWER OFF COMBUSTION AIR INDUCER POWER ON INDOOR BLOWER ON SEQUENCE HOLDS UNTIL ROLLOUT SWITCH IS RESET AND MAIN POWER IS INTERRUPTED OR THERMOSTAT IS CYCLED OFF ON FOR 1 SEC MINIMUM YES THERMOSTAT DEMAND SATI...

Page 51: ...OUT SWITCH CLOSED LED SLOW FLASH RATE REMAINS UNCHANGED THROUGHOUT COOLING CYCLE THERMOSTAT CALLS FOR COOLING COMPRESSOR CONTACTOR AND SYSTEM FAN ENERGIZED WITH 2 SECOND DELAY COOLING SPEED COMPRESSOR OFF THERMOSTAT OPENS SYSTEM FAN AND EAC TERM OFF WITH 45 SECOND DELAY NO NO LED FLASHES CODE 8 ROLLOUT SWITCH OPEN GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER ON SEQUENCE HOLDS UNTIL ROLLOU...

Page 52: ...PENS SYSTEM FAN SWITCHED TO COOL SPEED EAC TERM REMAINS ON THERMOSTAT OPENS MANUAL FAN SELECTION MADE AT THERMOSTAT CONTROL G ENERGIZES SYSTEM FAN AT FAN SPEED EAC TERM ENERGIZED NO YES YES NO SYSTEM FAN SWITCHES TO HEAT SPEAD AFTER 30 SECOND DELAY EAC AND HUM TERMINALS REMAIN ON SYSTEM FAN CONTINUES FAN SPEED WITHOUT INTERRUPTION EAC TERMINAL REMAIN ON HUM TERMINALS ARE ENERGIZED WITH COMBUSTION ...

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