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® Certied Yes Yes Yes Yes
Connections
in.
    
    
    
    
    
Indoor
Blower
    
    
    1
    
    
Electrical
Data
 
    
    
Shipping Data     

1󰀩


OPTIONAL ACCESSORIES
“B” Width Models “C” Width Models
CABINET ACCESSORIES
Downow 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 Downow 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
44W9244W9330G2851W1281J2015Z70


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 a󰀨ect
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)
        -
         
         

-

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