Lennox ML180DFE SERIES Installation and operation manual
Page 1
UNIT INFORMATIONUNIT INFORMATION
Service Literature
©2016 Lennox Industries, Inc.
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.
WARNING
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 installer or equivalent, service agency, or the
gas supplier.
-
CAUTION
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.
TABLE OF CONTENTS
ML180DFE
ML180DFE SERIES UNITS
SPECIFICATIONS
Gas
Heating
Performance
Model No. ML180DF045E36A ML180DF070E36A ML180DF070E36B
1 80% 80% 80%
High Static - in. w.g.
Connections
in.
Indoor
Blower
Electrical Data
Shipping Data
1
SPECIFICATIONS
Gas
Heating
Performance
Model No. ML180DF090E48B ML180DF110E60C
1 80% 80%
High Static - in. w.g.
Connections
in.
Indoor
Blower
1
Electrical Data
Shipping Data
1
OPTIONAL ACCESSORIES - ORDER SEPARATELY
“A” Width
Models
“B” Width
Models
“C” Width
Models
CABINET ACCESSORIES
Downow Combustible Flooring Base 11M59 11M60 11M61
CONTROLS
iComfort®M30 Smart Wi-Fi Thermostat 15Z69 15Z69 15Z69
Remote Outdoor Air Temperature Sensor X2658 X2658 X2658
Blower Relay Kit (for two-stage outdoor units) 85W66 85W66 85W66
Furnace Twinning Panel Y3653 Y3653 Y3653
Furnace Twinning Kit 16W72 16W72 16W72
FILTERS
1 Downow Filter Cabinet 51W06 51W07 51W08
-
NIGHT SERVICE KIT
Night Service Kit 84W47 84W47 84W47
1
BLOWER DATA
ML180DF045E36A 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
180 110 100
100
110
100
1000
180
ML180DF070E36A 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
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
1110
181
1010
ML180DF070E36B 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
1110 100
1000
1110 180
1000
ML180DF090E48B 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
180
810
1080 1000
ML180DF110E60C 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
180
1800
1100
BLOWER DATA
PARTS ARRANGEMENT
Primary Limit
(under combustion
air inducer)
Control Box
(includes integrated control,
interlock switch and transformer)
Gas Valve
Burner Box
(includes sensor, ignitor
and rollout switches)
Combustion
Air Inducer
Blower Access Panel
Heating Compartment
Access Panel
Heat Exchanger
Flue Chase
Blower Assembly
Secondary Limit
FIGURE 1
I-UNIT COMPONENTS
ELECTROSTATIC DISCHARGE (ESD)
Precautions and Procedures
CAUTION
Electrostatic discharge can aect
electronic components. Take precautions
to neutralize electrostatic charge by
touching your hand and tools to metal
prior to handling the control.
1. Control Transformer (T1)
2. Door Interlock Switch (S51)
NOTE - The door interlock switch is a safety switch. Do
not by-pass or jumper switch.
CONTROL BOX
DOOR INTERLOCK
SWITCH (S51)
INTEGRATED CONTROL
(A92)
TRANSFORMER
(T1)
CIRCUIT
BREAKER
(CB8)
FIGURE 2
3. Circuit Breaker (CB8)
-
-
4. Integrated Control (A92)
103217-03 & 107163-01
WARNING
Shock hazard.
Disconnect power before servicing. Control is not
eld repairable. If control is inoperable, simply
replace entire control.
Can cause injury or death. Unsafe operation will
result if repair is attempted.
-
-
-
-
Electronic Ignition (Figure 4)
-
-
-
-
-
-
TABLE 1
4-Pin Terminal Designation
1
TABLE 2
12-Pin Terminal Designations
1
8
10
11
TABLE 3
1/4” Quick Connect Terminals
3/16” Quick Connect Terminals
BLOWER OFF DELAY
RED LED RECALL BUTTON
IGNITION CONTROL 103217-03
FIGURE 3
Heating Blower Off
Delay Selector Switch
Diagnostic LED
Push Button
Error Recall
IGNITION CONTROL 107163-01
PARKS
WCRGY
HUM24
FS
24VCOM
COOL
HEAT
FAN
Page 8
TABLE 4
Ignition Control 103217-02
RED LED
Flash Code2Diagnostic Codes / Status of Furnace
Off No power to control or board fault detected
Heartbeat
1
Normal Operation - Idle, Continuous Fan, Cool
1Reverse Line Voltage Polarity
2Improper Earth Ground
3Burner failed to light, or lost flame during heat demand
4Low Flame Signal - check flame sensor
5Watchguard - burner failed to light, exceeded maximum number of retries or recycles.
6Ignitor Circuit Failure - not available on this control
7Primary or Secondary Limit Open or Watchguard Mode - Limit Switch Open longer than 3 minutes
8Rollout Switch Open
9Pressure 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 1A ”Heartbeat” is indicated by a ”Slow Flash” - 1 sec on 1 sec off, repeating
Note 2Error codes are indicated by a “rapid flash” - the LED flashes X times at ½ second on ½ second off, remains off for 3
seconds then repeats.
Note3
Last 10 error codes are stored in memory including when power is shut off to the unit. - To recall, 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.
TABLE 5
Ignition Control 103217-03
1
1
8
10
11
Page 10
Ignition Control 107163-01
RED LED Flash Code Diagnostic Codes / Status of Furnace
1
Page 11
DEMAND
CAI
GAS VALVE
15
ON
OFF
38
IGNITOR
34
1
Pre -Purge Ignitor Warm-up Trial for
Ignition Post
Purge
5 SEC80
*Blower on time will be 30 seconds after flame is sensed. Blower off time will depend on “OFF TIME” Setting.
INDOOR BLOWER
Blower “On”*
Delay
ELECTRONIC IGNITION
FIGURE 4
Fan Time Control
Ignition Control 103217-03
Heating Fan On Time
Heating Fan O Time
-
-
-
Cooling Fan On Time
Cooling Fan O Time
HEAT FAN‐OFF TIME IN SECONDS
To adjust fan-off timing, reposition jumper across pins to
achieve desired setting.
NO JUMPER
60
90
120
180
60
90
120
180
60
90
120
180
60
90
120
180
60 Second
off Time
90 Second
off Time
120 Second
off Time
180 Second
off Time
FIGURE 5
Ignition Control 107163-01
-
-
180
BURNER ASSEMBLY REMOVAL
gasket
collector box
orifice plate
internal flue pipe
pressure switch
combustion air inducer
burners
manifold and gas valve retention rings
cross over
gasket
collector box
orifice plate
internal flue pipe
pressure switch
combustion air inducer
burners
manifold and gas valve
flue chase
gasket
ignitor
rollout switch
sensor
FIGURE 6
5. Flame Rollout Switches (Figure 6)
-
-
-
6. Primary Limit Control
-
®
-
7. Flame Sensor (Figure 6)
-
-
To Measure Flame Signal - Integrated Control:
-
1 -
TABLE 6
Flame Signal in Microamps
Measuring Flame Signal
(Typical Furnace and Control)
Flame
Sensor
Flame Sensor
Wire
Integrated
Control
Remove Sensor Wire from
Integrated Control and
Connect Alligator Clip (−)
to Flame Sensor Lead
Flame Sensor
Terminal
Remove Sensor Wire from
Integrated Control and
Connect Alligator Clip (+)
to Terminal on Control
(+)
DIGITAL METER
(+) To Control
Sensor
Terminal
(-) To
flame
sensor
Set dial to measure dc microamps
(+)
Red Collar
Indicates
Positive
Lead
FIGURE 7
8. Ignitor (Figure 6)
-
NOTE - The ML180UDFE(X) furnace contains electronic
components that are polarity sensitive. Make sure that the
furnace is wired correctly and is properly grounded.
Test 1
Check ignitor circuit for correct resistance.
Remove 4-pin plug from control.
Check ohms reading across terminals 2 and 4.
If value is correct (39 to 70 ohms), this is the only test
needed.If the reading on the meter is not correct,
(0 or infinity) then a second test is needed.
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
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 second ignitor warm up period.
Voltage should read 120 volts +10%. If voltage reads below
these values, check for correct supply voltage to furnace.
Integrated Control B
o
Detail
Test 1
Integrated Control Board
Detail
Integrated Control Board
Detail
FIGURE 8
9. Gas Valve (Figure 6)
-
-
10. Combustion Air Inducer (B6)
-
-
-
TABLE 7
Model C.A.I. Orice Size
11. Combustion Air Inducer Pressure Switch (S18)
-
-
-
TABLE 8
Unit
Troubleshooting
-
MULTI−METER
SET TO MEASURE OHMS
+-
or
Field Provided
Tubing To CAI Port
To Pressure Switch
Remove tubing from CAI and
insert “Tee” and additional tubing.
High
Low
FIGURE 9
12. Blower Motor
IMPORTANT
Each blower is statically and dynamically balanced
as an assembly before installation in the unit.
Input Voltage Requirements
Troubleshooting
1 -
NOTE - Figure 13 is typical ignition control illustration.
13. Secondary Limit Controls
-
Center Blower Wheel
in Blower Housing
BLOWER WHEEL REPLACEMENT
FIGURE 10
Set Screw
Housing Hub
ALIGN AND TIGHTEN SET SCREW WITH
FLAT SIDE OF MOTOR SHAFT
Motor
Shaft
FIGURE 11
SECONDARY LIMIT CONTROL
Blower Assembly
Secondary Limit
FIGURE 12
1
2
3
4
5
C
L
G
N
Multi−Meter
(set to VAC)
P48
P49
120
120
Turn on power to unit. Check for 120 volts across terminals
“L” and “N” on input plug P48. If voltage is present continue
stream of plug P48 and proceed to test 3.
1
2
3
4
5
C
L
G
N
Multi−Meter
(set to VAC)
P48
P49 24
Switch thermostat to CONTINUOUS FAN MODE. Check for
24 volts across terminal “C” on inpult plug P48and speed tap
used for continuous 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)
120
120
24
Multi−Meter
(set to VAC)
lem is with the harness. If voltage is not present problem
may be may be with the integrated control
Check for 120 volts across terminals “CIRC” and “Neutrals”
on the integrated control. If voltage is present, problem is
with the harness. If voltage is not present problem may be
may be with the integrated control.
Test 1
Test 2
Test 3 (if necesssary)
Test 4 (if necessary)
FIGURE 13
Page 18
Replacing the Motor Module
1 -
TWO HARNESS
CONNECTIONS
MOTOR CONTROL MODULE
MOTOR
Unplug the Two Harness Connection
FIGURE 14
REMOVE
BOTH HEX
HEAD BOLTS
Remove the Hex Head Bolts
FIGURE 15
Testing the Motor (Figure16)
1 -
Motor Test
FIGURE 16
TABLE 9
Measurement range in
-
Motor Module Installation
-
USE OF THE
WRONG MOTOR CONTROL MODULE MAY RESULT IN
UNEXPECTED UNIT OPERATION.
1 -
CONNECTOR
ORIENTATION
BETWEEN 4 AND 8
O'CLOCK
BACK OF CONTROL
MODULE
DRIP LOOP
Drip Loop
FIGURE 17
II- PLACEMENT AND INSTALLATION
III- START-UP
A- Heating Start-Up
WARNING
Shock and burn hazard.
ML180UDFE units are equipped with a hot surface
ignition system. Do not attempt to light manually.
GAS VALVE SHOWN IN ON POSITION
MANIFOLD
PRESSURE
OUTLET
PORT
INLET
PRESSURE
PORT
MANIFOLD
PRESSURE
ADJUSTMENT
SCREW
FIGURE 18
1 - STOP!
8 -
10 -
11 -
NOTE - When unit is initially started, steps 1 through
11 may need to be repeated to purge air from gas
line.
Turning O Gas to Unit
1 -
B- Safety or Emergency Shutdown
C- Extended Period Shutdown
-
IV-HEATING SYSTEM SERVICE CHECKS
A- C.S.A. Certication
B- Gas Piping
-
-
C- Testing Gas Piping
CAUTION
If a exible gas connector is required or allowed by
the authority that has jurisdiction, black iron pipe
shall be installed at the gas valve and extend outside
the furnace cabinet.
IMPORTANT
In case emergency shutdown is required, turn o the
main shut-o valve and disconnect the main power
to unit. These controls should be properly labeled
by the installer.
WARNING
Do not exceed 600 in-lbs (50 ft-lbs) torque when
attaching the gas piping to the gas valve.
MANUAL MAIN
SHUT-OFF VALVE
WILL NOT HOLD
NORMAL TEST
PRESSURE
CAP
ISOLATE
GAS VALVE
FURNACE
1/8 NPT PLUG
FIGURE 19
D- Gas Pressure Adjustment
Gas Flow (Approximate)
TABLE 10
Unit
80
110
-110
-
-
NOTE - To obtain accurate reading, shut o all other gas
appliances connected to meter.
E- Supply and Manifold Pressure
Supply Pressure Measurement
1 -
Manifold Pressure Measurement
1 -
NOTE - Shut unit o and remove manometer as
soon as an accurate reading has been obtained.
Take care to remove barbed tting and replace
threaded plug.
F- Proper Combustion
-
-
The maximum car-
bon monoxide reading should not exceed 100 ppm.
TABLE 11
ML180DFE Unit % Nat % LP
-110
G- High Altitude
-
IMPORTANT
For safety, shut unit o and remove manometer as
soon as an accurate reading has been obtained.
Take care to replace pressure tap plug
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