Lennox ML196UHE 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
instale (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.
Table of Contents
ML196UHE
ML196UHE SERIES UNITS
SPECIFICATIONS
Gas
Heating
Performance
Model No. ML196UH
030XE36B
ML196UH
045XE36B
ML196UH
070XE36B
ML196UH
070XE48B
ML196UH
090XE36C
1 96% 96% 96% 96% 96%
Energy Star® Certied Yes Yes Yes Yes Yes
Connections
in.
Indoor
Blower
Electrical Data
Shipping Data
1
SPECIFICATIONS
Gas
Heating
Performance
Model No. ML196UH
090XE48C
ML196UH
090XE60C
ML196UH
110XE60C
ML196UH
135XE60D
1 96% 96% 96% 96%
Energy Star® Certied Yes Yes Yes Yes
Connections
in.
Indoor
Blower
111
Electrical Data
Shipping Data
1
OPTIONAL ACCESSORIES
“B” Width
Models
“C” Width
Models
“D” Width
Models
CABINET ACCESSORIES
Horizontal Suspension Kit - Horizontal only 51W10 51W10 51W10
Return Air Base - Upow only 50W98 50W99 50W99
High Performance Economizer (Commercial Only) 10U53 10U53 10U53
CONDENSATE DRAIN KITS
Condensate Drain Heat Cable 26K68 26K68 26K68
26K69 26K69 26K69
Crawl Space Vent Drain Kit 51W18 51W18 51W18
15Z70 15Z70 15Z70
CONTROLS
Blower Relay Kit (for two-stage outdoor units) 85W66 85W66 85W66
M30 Smart Wi-Fi Thermostat 15Z69 15Z69 15Z69
Remote Outdoor Temperature Sensor X2658 X2658 X2658
Furnace Twinning Panel Y3653 Y3653 Y3653
Furnace Twinning Kit 16W72 16W72 16W72
FILTER KITS
1Air Filter and
Rack Kit
87L96 87L97 87L98
44J22 44J22 44J22
66K63 66K63 66K63
NIGHT SERVICE KIT
Night Service Kit 84W48 84W48 84W48
TERMINATION KITS
Direct Vent 71M80 69M29 - - -
- - - 60L46 60L46
44W92 44W92 - - -
- - - 44W93 44W93
51W11 51W11 51W11
51W12 51W12 51W12
22G44 - - - - - -
44J40 44J40 44J40
30G28 - - - - - -
81J20 81J20 81J20
15F75 15F75 - - -
44J41 44J41 44J41
VENTING
Flue Coupling 17H92 17H92 17H92
1
44W9244W9330G2851W1281J2015Z70
BLOWER DATA
ML196UH045XE36B 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
ML196UH070XE36B 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
ML196UH030XE36B 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
191
199
91 61
161 66
ML196UH070XE48B 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
619
691
ML196UH090XE48C 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
ML196UH090XE36C 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
196
91
96
ML196UH090XE60C 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
Page 6
BLOWER DATA
ML196UH110XE60C PERFORMANCE (Less Filter)
External
Static
Pressure
in. w.g.
Air Volume / Watts at Dierent Blower Speeds
Bottom Return Air, Side Return Air with Return Air from
Both Sides or Return Air from Bottom and One Side.
Single Side Return Airbold
High
Medium-
High
Medium
Medium-
Low
Low
High
Medium-
High
Medium
Medium-
Low
Low
cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts
2180 685 1910 460
2155 705 1885 480
2130 725 1855 495
2085 745 1825 510
2060 760
2030 775
1995 785
1960 795
1895 790
ML196UH135XE60D PERFORMANCE (Less Filter)
External
Static
Pressure
in. w.g.
Air Volume / Watts at Dierent Blower Speeds
Bottom Return Air, Side Return Air with Return Air from
Both Sides or Return Air from Bottom and One Side.
Single Side Return Airbold
High
Medium-
High
Medium
Medium-
Low
Low
High
Medium-
High
Medium
Medium-
Low
Low
cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts
2280 929 2100 703 1935 531
2245 941 2075 720 1910 543
2210 957 2050 745 1895 558
2200 978 2030 757 1850 569
2175 990 2015 774 1845 584
2145 989 2010 783 1820 603
2125 980 1990 809
961 2060 937 1960 819
1980 912 1925 825
PARTS IDENTIFICATION
TOP CAP
BURNER BOX
ASSEMBLY
DuralokPlusTM
HEAT EXCHANGER
ASSEMBLY
CONTROL BOX
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
FIGURE 1
I-UNIT COMPONENTS
ELECTROSTATIC DISCHARGE (ESD)
Precautions and Procedures
CAUTION
A-Control Box Components (FIGURE 2)
Control Box
Integrated Control
Door Interlock
Switch
Transformer
Circuit Breaker
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
9
11
Page 9
TABLE 3
1/4” Quick Connect Terminals
LINE
3/16” Quick Connect Terminals
TABLE 4
Ignition Control 103217-03
1
1
6
9
11
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 11
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
-
-
Blower Delay Select
ON
ON
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)
-
-
Primary Limit Location and Heat Exchanger
Install limit face down
FIGURE 7
4. Gas Valve (FIGURE 8)
-
-
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 ML196UHE is polarity sensitive. Make sure
that the furnace is wired correctly and is properly ground-
ed.
To Measure Flame Signal - Integrated Control:
-
1 -
6 -
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
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.
FIGURE 9
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.
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.
Multi−Meter
(set to ohms)
Multi−Meter
(set to ohms)
Multi−Meter
(set to VAC)
FIGURE 10
Page 16
7. Combustion Air Inducer & Cold End Header Box
-
-
-
-
If replacement
is necessary the gaskets used to seal the box to the
vestibule panel and the combustion air inducer to the
box, must also be replaced.
TABLE 6
Unit
8. Combustion Air Pressure Switch (FIGURE 11)
Pressure Switch
24VAC
TERMINALS
BRACKET
TAP
TAP
FIGURE 11
-
-
-
-
-
-
TABLE 7
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
TABLE 8
Problem Corrective Action
-
-
-
-
Page 19
C- Blower Compartment
IMPORTANT
Each blower is statically and dynamically balanced
as an assembly before installation in the unit.
Input Voltage Requirements
Troubleshooting
1 -
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
Secondary Limits
FIGURE 15
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
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