Lennox ML196DFE Installation and operation manual
Page 1
UNIT INFORMATIONUNIT INFORMATION
Service Literature
©2016 Lennox Industries, Inc.
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.
-
-
-
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.
ML196DFE
ML196DFE SERIES UNITS
SPECIFICATIONS
Gas
Heating
Performance
Model No. ML196DF045XE36B ML196DF070XE48B ML196DF090XE48C ML196DF110XE60C
1 96% 96% 96% 96%
Energy Star® Certied Yes Yes Yes Yes
Connections
in.
Indoor
Blower
1
Electrical
Data
Shipping Data
1
OPTIONAL ACCESSORIES
“B” Width Models “C” Width Models
CABINET ACCESSORIES
Downow Combustible Flooring Base 11M60 11M61
CONDENSATE DRAIN KITS
Condensate Drain Heat Cable 26K68 26K68
26K69 26K69
Crawl Space Vent Drain Kit 51W18 51W18
15Z70 15Z70
CONTROLS
M30 Smart Wi-Fi Thermostat 15Z69 15Z69
Remote Outdoor Temperature Sensor X2658 X2658
Furnace Twinning Panel Y3653 Y3653
Furnace Twinning Kit 16W72 16W72
Blower Relay Kit (for two-stage outdoor units) 85W66 85W66
DOWNFLOW FILTER KITS
1 Downow Filter Cabinet 51W07 51W08
-
NIGHT SERVICE KIT
Night Service Kit 84W48 84W48
TERMINATION KITS
Direct Vent 71M80 69M29
- - - 60L46
44W92 44W92
- - - 44W93
51W11 51W11
51W12 51W12
22G44 - - -
44J40 44J40
30G28 - - -
81J20 81J20
15F75 15F75
44J41 44J41
VENTING
Flue Coupling 17H92 17H92
1
44W9244W9330G2851W1281J2015Z70
ML196DF090XE48C 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
ML196DF070XE48B 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
ML196DF045XE36B 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
BLOWER DATA
ML196DF110XE60C 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
669
686
CONTROL BOX
(Includes integrated control,
transformer, circuit breaker and door switch)
BAG ASSEMBLY
(shipping location)
BLOWER MOTOR
(hidden)
BURNER
ACCESS
PANEL
COMBUSTION
AIR INDUCER
BURNER BOX ASSEMBLY
(includes sensor, rollout switches and ignitor) GAS VALVE
BLOWER DECK
COLD END HEADER BOX
PRIMARY LIMIT
DuralokPlusTM
HEAT EXCHANGER
ASSEMBLY
COMBUSTION AIR INDUCER
PRESSURE SWITCH
PARTS ARRANGEMENT
BLOWER
ACCESS
PANEL
FIGURE 1
Page 6
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.
-
A-Control Box Components (FIGURE 2)
DOOR INTERLOCK
SWITCH (S51)
INTEGRATED IGNITION
CONTROL
(A92)
TRANSFORMER
(T1)
Control Box
CIRCUIT
BREAKER
(CB8)
FIGURE 2
1. Transformer (T1)
2. Door Interlock Switch (S51)
3. Circuit Breaker (CB8)
4. Integrated Ignition 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.
-
-
-
TABLE 1
4-Pin Terminal Designation
PIN #
1
TABLE 2
12-Pin Terminal Designations
PIN #
1
6
8
9
11
TABLE 3
1/4” Quick Connect Terminals
LINE
3/16” Quick Connect Terminals
TABLE 4
Ignition Control 103217-03
1
1
6
8
9
11
Page 8
BLOWER OFF DELAY
RED LED RECALL BUTTON
IGNITION CONTROL 103217-03
FIGURE 3
Electronic Ignition
-
-
-
-
-
-
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 4
Page 9
TABLE 5
Ignition Control 107163-01
RED LED Flash Code Diagnostic Codes / Status of Furnace
On
1
minutes
IGNITION CONTROL 107163-01
Push Button
Error Recall
Diagnostic LED Heating Blower Off
Delay Selector Switch
FANHEATCOOL24VCOM
PARKS
HUM24
FIGURE 5
Ignition Control 107163-01
-
-
OFF ON
OFF OFF
ON OFF
ON ON
Burner Box Assembly
Gas Valve
Burner Box Front
Rollout Switch(s)
Flame Sensor
Ignitor
Burner Assembly
FIGURE 6
B-Heating Components
-
-
-
1. Flame Rollout Switches (FIGURE 6)
-
-
-
-
2. Heat Exchanger (FIGURE 7)
3. Primary Limit Control (FIGURE 7)
-
-
Page 11
Primary Limit Location and Heat Exchanger
Install limit face down
FIGURE 7
4. Gas Valve (GV1)
-
GAS VALVE SHOWN IN ON POSITION
MANIFOLD
PRESSURE
OUTLET
PORT
INLET
PRESSURE
PORT
MANIFOLD PRESSURE
ADJUSTMENT SCREW
(under barbed fitting)
FIGURE 8
5. Flame Sensor (FIGURE 6)
-
NOTE - The ML196DFE is polarity sensitive. Make sure
that the furnace is wired correctly and is properly ground-
ed.
-
To Measure Flame Signal - Integrated Control:
-
6. Ignitor (FIGURE 6)
Measuring Flame Signal
Flame Signal In Microamps
Normal Low Drop Out
1.50.5 - 1.40.4
(+)
Set Dial to DC MicroAmps
(+)
Multi−Meter
(+) To Control
Sensor Terminal
(−) To Flame
Terminal
Remove Sensor Wire from
Intergrated Control and
Connect Alligator Clip (+)
to Terminal on Control
Flame Sensor
Terminal
Flame Sensor
Wire
Remove Sensor Wire from
Intergrated Control and
Connect Alligator Clip (−)
to Frame Sensor Lead
Intergrated
Control
FIGURE 9
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.
Integrated Control Detail
Integrated Control Detail
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 Detail
Test 1
Check ignitor circuit for correct resistance.
Remove 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.
FIGURE 10
7. Combustion Air Inducer (B6) & Cold End Header
Box
-
-
-
-
TABLE 6
ML196DFE Unit
8. Combustion Air Pressure Switch (FIGURE 11)
-
Pressure Switch
24VAC
TERMINALS
BRACKET
TAP
TAP
FIGURE 11
-
-
-
-
-
TABLE 7
ML196DFE
Unit
*Set point is factory set and non-adjustable
Measuring Pressure Differential
1 -Remove thermostat demand and allow unit to
cycle off.
2 -Install a tee in the negative (-) line (red and black tubing
or red tubing) and a tee in the positive (+) line (black
tubing) running from the pressure switch to the cold
end header box.
3 - Install a manometer with hose from the negative (-)
side of the manometer to the tee installed in the
negative (-) line and with hose from the positive (+)
side of the manometer to the tee in the positive (+)
line.
NOTE - Both sides of the cold end header box are
negative. How
sure 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 7.
5 -Remove thermostat demand and allow to cycle off.
6 -Remove manometer and tee's. Reinstall combustion
air sensing hoses to the pressure switch.
To Cold End Header Box
Field Provided Tubing
To Pressure Switch
To Cold End Header Box
Black Tubing
(positive +)
Red and Black Tubing
or Red Tubing
(negative -)
“+”
High
“-”
Low
FIGURE 12
Page 16
TABLE 8
Problem Corrective Action
-
-
-
-
C- Blower Compartment
IMPORTANT
Each blower is statically and dynamically balanced
as an assembly before installation in the unit.
Input Voltage Requirements
Troubleshooting
NOTE - FIGURE 16 is typical ignition control
illustration.
9. Secondary Limit Controls
-
Center Blower Wheel
in Blower Housing
BLOWER WHEEL REPLACEMENT
FIGURE 13
Set Screw
Housing Hub
ALIGN AND TIGHTEN SET SCREW WITH
FLAT SIDE OF MOTOR SHAFT
Motor
Shaft
FIGURE 14
SECONDARY LIMIT CONTROL
Blower Assembly
Secondary Limit
FIGURE 15
Page 18
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 16
Page 19
Replacing the Motor Module
TWO HARNESS
CONNECTIONS
MOTOR CONTROL MODULE
MOTOR
Unplug the Two Harness Connection
FIGURE 17
REMOVE BOTH HEX
HEAD BOLTS
Remove the Hex Head Bolts
FIGURE 18
Testing the Motor (FIGURE 19)
Motor Test
FIGURE 19
TABLE 9
Measurement range in
-
Motor Module Installation
-
USE OF THE
WRONG MOTOR CONTROL MODULE MAY RESULT IN
UNEXPECTED UNIT OPERATION.
CONNECTOR
ORIENTATION
BETWEEN 4 AND 8
O'CLOCK
BACK OF CONTROL
MODULE
DRIP LOOP
Drip Loop
FIGURE 20
II-PLACEMENT AND INSTALLATION
Pipe & Fittings Specications
-
-
-
-
-
TABLE 10
PIPING AND FITTINGS SPECIFICATIONS
F891
PRIMER & SOLVENT CEMENT ASTM
SPECIFICATION
CANADA PIPE & FITTING & SOLVENT
CEMENT MARKING
POLYPROPYLENE VENTING SYSTEM
UL 1738 CERTIFIED GAS VENTING SYSTEM
Primer
IMPORTANT
Exhaust and intake connections are made of PVC.
Use PVC primer and solvent cement when using
PVC vent pipe. When using ABS vent pipe, use
transitional solvent cement to make connections to
the PVC ttings in the unit.
CAUTION
Solvent cements for plastic pipe are ammable
liquids and should be kept away from all sources of
ignition. Do not use excessive amounts of solvent
cement when making joints. Good ventilation
should be maintained to reduce re hazard and to
minimize breathing of solvent vapors. Avoid contact
of cement with skin and eyes.
-
Canadian Applications Only - Pipe, ttings, primer and
solvent cement used to vent (exhaust) this appliance must
be certied to ULC S636 and supplied by a single manu-
facturer as part of an approved vent (exhaust) system. In
addition, the rst three feet of vent pipe from the furnace
ue collar must be accessible for inspection.
This manual suits for next models
4
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