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S e r v i c e L i t e r a t u r e
ML196DFEK series units are high-efficiency gas furnaces
manufactured with Lennox DuralokPlus aluminized steel
clamshell-type heat exchangers, with a stainless steel
condensing coil. ML196DFEK units are available in heat-
ing input capacities of 44,000 to 110,000 Btuh and cooling
applications from 2 through 5 tons. Refer to Product Spec-
ifications for proper sizing.
Units are factory equipped for use with natural gas. A kit
is available for conversion to LP/Propane operation. All
ML196DFEK units are equipped with a hot surface igni-
tion system. The gas valve is redundant to assure safety
shut-off as required by C.S.A.
The heat exchanger, burners and manifold assembly can
be removed for inspection and service. The maintenance
section gives a detailed description on how this is done.
All specifications are subject to change. Procedures out-
lined in this manual are presented as a recommendation
only and do not supersede or replace local or state codes.
WARNING
This furnace is equipped with an ignition control
factory enabled for use with A2L refrigerant systems.
Disabling the refrigerant detection functionality on
A2L system is prohibited by safety codes. Refer
to furnace installation instructions for refrigerant
system setup.
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.
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . . 3
Twinning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
I-Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
II-Placement and Installation . . . . . . . . . . . . . . . . . . . . 24
III-Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
IV-Heating System Service Checks . . . . . . . . . . . . . . 45
V-Typical Operating Conditions . . . . . . . . . . . . . . . . . 49
VI-Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
VII- Low GWP Application . . . . . . . . . . . . . . .. . . . . . . . . . 53
IX-Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
UNIT INFORMATION
UNIT INFORMATION
ML196DFEK WITH R454B SERIES UNITS
. . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . 56
100164
Improper
installation,
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.
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.
Page 1
ML196DFEK
WARNING
adjustment,
CAUTION
alteration,
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Table of Contents
Related Manuals for Lennox ML196DFEK Series
Summary of Contents for Lennox ML196DFEK Series
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Page 1: Table Of Contents
S e r v i c e L i t e r a t u r e ML196DFEK WITH R454B SERIES UNITS ML196DFEK series units are high-efficiency gas furnaces manufactured with Lennox DuralokPlus aluminized steel clamshell-type heat exchangers, with a stainless steel condensing coil. -
Page 2: Specifications
S PECIFIC ATIO N S Model ML196DF ML196DF ML196DF ML196DF Heating 045XE36BK 070XE48BK 090XE48CK 110XE60CK Performance AFUE Input - Btuh 44,000 66,000 88,000 110,000 Output - Btuh 43,000 64,000 86,000 108,000 Temperature rise range - °F 30 - 60 35 - 65 50 - 80 40 - 70 Gas Manifold Pressure (in. -
Page 3: Optional Accessories
OP TIONAL A CC ES SORIES “B” Width Models “C” Width Models CABINET ACCESSORIES Downflow Combustible Flooring Base 11M60 11M61 CONDENSATE DRAIN KITS Condensate Drain Heat Cable 6 ft. 26K68 26K68 24 ft. 26K69 26K69 Crawl Space Vent Drain Kit 51W18 51W18 Canada... -
Page 4: Blower Performance Data
B LO WER DATA ML196DF045XE36BK PERFORMANCE (Less Filter) Air Volume / Watts at Various Blower Speeds External High Medium-High Medium Medium-Low Static (Black) (Brown) (Blue) (Yellow) (Red) Pressure in. w.g. Watts Watts Watts Watts Watts 0.10 1385 1230 1125 0.20 1356 1201 1089... -
Page 5: Blower D Ata
BLOWER D ATA ML196DF090XE48CK PERFORMANCE (Less Filter) Air Volume / Watts at Various Blower Speeds External High Medium-High Medium Medium-Low Static (Black) (Brown) (Blue) (Yellow) (Red) Pressure in. w.g. Watts Watts Watts Watts Watts 0.10 1714 1510 1378 1302 1172 0.20 1679 1469... -
Page 6: Twinning
The 24 VAC secondary of the two systems must be in Twinning phase. All thermostat connections are made to one control The control board in this furnace is equipped with a provi- only. See diagram below. sion to ”twin” (interconnect) two(2) adjacent furnaces with The twinned furnace without thermostat connections is a common plenum such that they operate as one (1) large to have the call for heat supplied by an external 24VAC... -
Page 7: Parts Arrangement
PARTS ARRANGEMENT CONTROL BOX (Includes integrated control, transformer, circuit breaker and door switch) BLOWER MOTOR (hidden) BAG ASSEMBLY (shipping location) BLOWER ACCESS PANEL COMBUSTION AIR INDUCER BLOWER DECK DuralokPlus HEAT EXCHANGER ASSEMBLY BURNER ACCESS PANEL COLD END HEADER BOX COMBUSTION AIR INDUCER PRESSURE SWITCH PRIMARY LIMIT BURNER BOX ASSEMBLY... -
Page 8: I-Unit Components
I-UNIT COMPONENTS 3. Circuit Breaker (CB8) A 24V circuit breaker is also located in the control box. The ELECTROSTATIC DISCHARGE (ESD) switch provides overcurrent protection to the transform- Precautions and Procedures er (T1). The breaker is rated at 3A at 32V. If the current CAUTION exceeds this limit the breaker will trip and all unit opera- tion will shutdown. - Page 9 Indoor Blower Operation DIP Switch Settings Electronic Ignition (FIGURE 5) The heat fan-on time of 30 seconds is not adjustable The On a call for heat the integrated control monitors the com- heat fan-off delay (amount of time that the blower oper- bustion air inducer pressure switch.
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Page 10: Electronic Ignition
On Board Links Must NOT Be Cut To Select Thermostat Wiring Connections AC ON System Options Heat / Cool FURNACE OUTDOOR T'STAT TERM. STRIP UNIT DO NOT CUT ANY ON-BOARD LINKS FIGURE 3 On Board Links Must Be Cut To Select Wiring Connections Thermostat Heat Pump Options... -
Page 11: Common Ground
TABLE 2 TABLE 3 THERMOSTAT INPUT TERMINALS LOW GWP INTERFACE HEAT LGWP1 LOW GWP SENSOR #1 INTERFACE COMMON GROUND LGWP2 LOW GWP SENSOR # 2 INTERFACE 24V AC ALARM INTERFACE TO LOW GWP LEAK AUDIBLE ALARM (DRY CONTACT) ZONE INTERFACE TO ZONING CONTROL (DRY COOL CONTACT) REVERSING VALVE (when W951 is clipped) - Page 12 TABLE 4 Integrated Diagnostic Codes/Status of Equipment Code Diagnostic Codes/Status of Equipment Action Required to Clear and Recover Indoor Blower Opetration: Continuous Fan only mode Defrost mode Idle mode (Decimal blinks at 1 Hertz -- 0.5 second ON, 0.5 second OFF). Cooling stage (1 second ON, 0.5 second OFF) 1 or 2 displayed / Pause / Repeat codes.
- Page 13 The sensor #1 is of a type not suitable for use in the application. incorrect Replace the sensor with a Lennox approved replacement part. This fault clears when a sensor suitable for the application is detected by the furnace control board, but blower will latch for a minimum of 5 minutes.
- Page 14 TABLE 4 Continued Code Diagnostic Codes/Status of Equipment Action Required to Clear and Recover E164 Low GWP Test Low GWP Test mode activates by manually engaging Low GWP test button. Normal operations resumes and code clears automatically after 1-minute E200 Hard lockout - Rollout circuit open or previously Correct cause of rollout trip, or replace flame rollout switch.
- Page 15 Burner Box Assembly IGNITOR BURNERS ROLLOUT SWITCHES SENSOR GAS VALVE FIGURE 7 B-Heating Components (FIGURE 7) 3. Gas Valve (GV1) Combustion air inducer (B6), primary limit control (S10), The ML196DFEK uses an internally redundant to valve to SureLight ignitor, burners, flame rollout switch (S47), gas assure safety shut-off.
- Page 16 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.
- Page 17 4. Flame Sensor To Measure Flame Signal - Integrated Control: A flame sensor is located on the left side of the burner Use a digital readout meter capable of reading DC micro- support. The sensor is mounted on the bottom burner box amps.
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Page 18: Pressure Switch
7. Combustion Air Pressure Switch (FIGURE 12) gas / air mixture is then burned at the entrance of each ML196DFEK series units are equipped with a differential clamshell. Combustion gases are then pulled through the pressure switch located on the cold end header box. The... - Page 19 Checks of pressure differential can aid in troubleshoot- TABLE 6 ing. When measuring the pressure differential, readings Altitude ft should be taken at the pressure switch. See FIGURE 13 Unit 0-4500 4501-7500 7501-10,000 and TABLE 7. Lack of differential usually indicates prob- lems in the intake or exhaust piping, but may indicate Set Point Set Point...
- Page 20 TABLE 7 Problem Corrective Action Check that the pressure switch is open without the com- Pressure switch stuck closed bustion air inducer operating. Replace if defective. Pressure switch does not close due to obstruction in vent Check for restricted vent. Remove all blockage. Check for pipe.
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Page 21: Secondary Limit Control
C- Blower Compartment BLOWER WHEEL REPLACEMENT IMPORTANT Center Blower Wheel in Blower Housing Each blower is statically and dynamically balanced as an assembly before installation in the unit. 1. Indoor Blower Motor ML196DFEK units are equipped with a constant torque ECM motor. - Page 22 Multi−Meter (set to VAC) Multi-met (set to VAC) "9A” Test 3 (if necessary) NOTE- Ignition control illustration is typical "7A” Check for 120 volts across terminals “L1” and “Neutrals” on the Turn power on to unit. Check for 120 volts integrated control.
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Page 23: Motor Test
Replacing the Motor Module Motor Test NOTE - Not all motors have field replaceable control mod- ules. Only motors that utilize a 4 pin power connector and 5 pin signal connector as shown below may have replace- able controls. Motors that use a 3 pin power connector and 6 pin signal connector do not have field replaceable control modules. -
Page 24: Ii-Placement And Installation
II-PLACEMENT AND INSTALLATION IMPORTANT Pipe & Fittings Specifications Exhaust and intake connections are made of PVC. All pipe, fittings, primer and solvent cement must conform Use PVC primer and solvent cement when using with American National Standard Institute and the Ameri- PVC vent pipe. -
Page 25: Danger Of Explosion
TABLE 10 OUTDOOR TERMINATION USAGE* STANDARD CONCENTRIC Flush Mount Wall Kit 1-1/2 inch 2 inch 3 inch Vent Pipe Input Size Field Dia. in. 2 inch 3 inch 71M80 (US) 69M29 (US) 60L46 (US) Fabricated 51W11 (US) 44W92 44W92 444W93 22G44 (US) 44J40 (US) 51W12 (CA) -
Page 26: Venting Practices
Removal of the Furnace from Common Vent Venting Practices In the event that an existing furnace is removed from a venting system commonly run with separate gas applianc- HORIZONTAL PIPING SUPPORT GUIDELINES es, the venting system is likely to be too large to properly vent the remaining attached appliances. -
Page 27: Vent Piping Guidelines
NOTE - It is acceptable to use any pipe size which fits NOTE - Lennox offers a glueless vent adapter kit 17H92 as an within the guidelines allowed in table 13. option for exhaust exiting at the furnace top cap coupling. - Page 28 TABLE 12 NOTE - Size intake and exhaust pipe length separately. Values in table are for Intake OR Exhaust, not combined total. Both Intake and Exhaust must be same pipe size. NOTE - Additional vent pipe and elbows used to terminate the vent pipe outside the structure must be included in the total vent length calcu- lation.
- Page 29 TABLE 12 continued NOTE - Size intake and exhaust pipe length separately. Values in table are for Intake OR Exhaust, not combined total. Both Intake and Exhaust must be same pipe size. NOTE - Additional vent pipe and elbows used to terminate the vent pipe outside the structure must be included in the total vent length calcu- lation.
- Page 30 TABLE 13 Maximum Allowable Exhaust Vent Lengths With Furnace Installed in a Closet or Basement Using Ventilated Attic or Crawl Space For Intake Air in Feet NOTE - Additional vent pipe and elbows used to terminate the vent pipe outside the structure must be included in the total vent length calculation.
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Page 31: Top View
TYPICAL EXHAUST PIPE CONNECTIONS 045/070 Only 2” 1−1/2” 2” 2” 2” 2” TRANSITION 2” Exhaust Exhaust 3” DO NOT transition from larger to smaller pipe in horizontal runs of exhaust pipe. TRANSITION INTAKE EXHAUST DO NOT transition from smaller *2” to larger pipe size in horizontal TOP VIEW runs of exhaust pipe. - Page 32 Intake Piping TYPICAL AIR INTAKE PIPE CONNECTIONS NON−DIRECT VENT APPLICATIONS The ML196DFEK furnace may be installed in either direct vent or non-direct vent applications. In non-direct vent INTAKE applications, when intake air will be drawn into the furnace SCREEN from the surrounding space, the indoor air quality must be (Provided) considered.
- Page 33 In Direct Vent applications, combustion air is taken from EQUIPMENT IN CONFINED SPACE outdoors and the flue gases are discharged to the out- (Inlet Air from Ventilated Attic and Outlet Air to Outside) doors. The ML196DFEK is then classified as a direct vent, Ventilation Louvers Category IV gas furnace.
- Page 34 TABLE 14 Maximum Allowable Exhaust Vent Pipe Length (in ft.) Without Insulation In Unconditioned Space For Winter Design Temperatures Single - Stage High Efficiency Furnace Winter Design Unit Input Size Vent Pipe Diameter Temperatures °F (°C) 1-1/2 in 32 to 21 2 in (0 to -6) 2-1/2 in...
- Page 35 ‡ Permitted only if veranda, porch, deck or balcony is fully open NOTE - This figure is intended to illustrate clearance on a minimum of two sides beneath the floor. Lennox recommends requirement and does not serve as a substitute for avoiding this location if possible.
- Page 36 ‡ Permitted only if veranda, porch, deck or balcony is fully open on a minimum of locally adopted installation codes. two sides beneath the floor. Lennox recommends avoiding this location if possible. FIGURE 32 Page 36...
- Page 37 Details of Intake and Exhaust Piping Terminations for 6 - On field supplied terminations, a minimum distance Direct Vent Installations between the end of the exhaust pipe and the end of the intake pipe without a termination elbow is 8” and NOTE - In Direct Vent installations, combustion air is taken a minimum distance of 6”...
- Page 38 7 - - If intake and exhaust piping must be run up a side wall to position above snow accumulation or other obstructions, iping must be supported. At least 12” EXHAUST one bracket must be used within 6” from the top of (305mm) VENT 5-1/2”...
- Page 39 FIELD FABRICATED WALL TERMINATION NOTE − FIELD−PROVIDED REDUCER MAY BE 2” (51mm) 3” (76mm) REQUIRED TO ADAPT LARGER VENT PIPE SIZE Vent Pipe Vent Pipe TO TERMINATION A− Minimum clearance above grade or average 12” (305 mm) 12” (305 mm) snow accumulation B−...
- Page 40 (CANADA) Crawl Space and Extended Horizontal Venting FIGURE 44 Lennox provides kit 51W18 (USA) and kit 15Z70 (Cana- da) to install 2” or 3” PVC exhaust piping through the floor joists and into the the crawl space. See FIGURE 44.
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Page 41: Condensate Piping
4 - Install drain trap using appropriate PVC fittings, glue and line. Heat cable kit is available from Lennox in various all joints. Glue the provided drain trap as shown in lengths;... - Page 42 IMPORTANT Furnace with Evaporator Coil Using a Separate Drain When combining the furnace and evaporator coil drains together, the A/C condensate drain outlet must be vented to relieve pressure in order for the Field Provided Vent furnace pressure switch to operate properly. 1”...
- Page 43 TRAP / DRAIN ASSEMBLY USING 1/2” PVC OR 3/4” PVC Optional Condensate Drain Connection Adapter 3/4 inch slip X 3/4 inch mpt (not furnished) 90° Street Elbow 3/4 inch PVC (not furnished) Adapter 3/4 inch slip X 3/4 inch mpt (not furnished) Condensate Drain Connection In Unit 1 (25 mm) Min.
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Page 44: Iii-Start-Up
III-START-UP 2 - Set the thermostat to the lowest setting. 3 - Turn off all electrical power to the unit. A-Preliminary and Seasonal Checks 4 - This furnace is equipped with an ignition device 1 - Inspect electrical wiring, both field and factory which automatically lights the burners. -
Page 45: Iv-Heating System Service Checks
IV-HEATING SYSTEM SERVICE CHECKS Use of a specialty Gas Leak Detector is strongly recom- mended. It is available through Lennox under part number A-C.S.A. Certification 31B2001. See Corp. 8411-L10, for further details. All units are C.S.A. design certified without modifications. -
Page 46: Measuring Device
Negative Barbed Fitting (remove for manifold adjustment) (−) 2” Long Square Tubing (remove for manifold adjustment) Manifold Pressure Outlet Gas Valve Regulator Vent Hose (to burner box) Barbed Fitting 10” Long Square Tubing Measuring Device FIGURE 54 TABLE 16 Manifold and Supply Line Pressure 0-10,000ft. Manifold Pressure in. - Page 47 F- Proper Gas Flow (Approximate) TABLE 18 ML196K Unit % Nat % LP TABLE 17 -045 GAS METER CLOCKING CHART -070 Seconds For One Revolution 7.5 - 8.5 8.6 - 9.6 -090 ML196K Natuarl LP/Propane Unit -110 1 cu ft 2 cu ft 1 cu ft 2 cu ft...
- Page 48 I- Proper Ground and Voltage 2 - In addition, measure the AC voltage from Line Hot to Line Neutral (spade terminals) on the integrated WARNING control. See FIGURE 55. This voltage should be in the range of 97 to 132 Vac. Electric Shock Hazard.
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Page 49: V-Typical Operating Characteristics
V-TYPICAL OPERATING CHARACTERISTICS C-External Static Pressure 1 - Tap locations shown in FIGURE 57. A-Blower Operation and Adjustment1 2 - Punch a 1/4” diameter hole in supply and return NOTE- The following is a generalized procedure and does air plenums. Insert manometer hose flush with not apply to all thermostat controls. -
Page 50: Vi-Maintenance
Before using any filter with this system, check the specifications provided by the filter manufacturer FIGURE 58 against the data given in the appropriate Lennox Winterizing and Condensate Trap Care Product Specifications bulletin. - Page 51 Condensate Hose Screen (FIGURE 59) 12 - Disconnect the plug from the combustion air inducer. Remove two screws which secure combustion air Check the condensate hose screen for blockage and inducer to collector box. Remove combustion air clean if necessary. inducer assembly.
- Page 52 28 - Reinstall exhaust and air intake pipe seal plate. Cleaning the Burner Assembly (if needed) Reinstall exhaust and air intake pipes and tighten 1 - Turn off electrical and gas power supplies to furnace. clamps on pipe seal plate. Remove upper and lower furnace access panels.
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Page 53: Vii- Low Gwp Application
TABLE 22 WARNING DIP Switch Settings Configuration Switch 1 Switch 2 For use with Lennox approved evaporator coil and LGWP One (1) sensor, connected to SEN- sensors only. Use original manufacturer recommended SOR 1 plug (enable) (disable) LGWP sensors if using non Lennox approved evaporator Two (2) sensors, connected to SEN- coil. - Page 54 FURNACE CONTROL BOARD LOW GWP MODES OF FURNACE OPERATION CONTROL 7 SEGMENT The modes of operation for the furnace control board are SENSOR #2 Initializing, Normal, Leak Detected, and Fault. THROUGH SECOND SENSOR GROMMET THROUGH LEFT SIDE Initializing GROMMET The furnace control board is establishing connection with the refrigerant detection sensor and is completing an ini- CABLE TO SENSOR #1...
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Page 55: Start-Up Procedure
LGWP Test Button - Additional Functions NOTE - Early-generation digital and programmable ther- mostats may not retain the operation mode and tempera- TABLE 24 lists the additional functions of the Test Button ture setpoints after a power outage. while the furnace control board is functioning within the The following scenarios are likely to occur when home states of Initializing, Monitoring, Leak Detection, Servicing occupants are not available to adjust the thermostat set-... -
Page 56: Viii-Wiring And Sequence Of Operation
VIII-WIRING DIAGRAM AND SEQUENCE OF OPERATION 1- - Line voltage is applied to L1 and N. the T1 low voltage transformer is energized, and line voltage is applied to B3 indoor blower. 2 - S47 rollout switch(es) must be closed in order for 24V from transformer to be output on integrated control ”R” to power thermostat. 3 - When there is a call for heat, W1 of the thermostat energizes W of the furnace control with 24VAC. -
Page 57: Heating Sequence Of Operation
IX - Troubleshooting HEATING SEQUENCE OF OPERATION ABNORMAL HEATING MODE NORMAL HEATING MODE POWER ON GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER DELAY OFF. CONTROL SELF-CHECK OKAY? (RESET CONTROL BY TURNING MAIN POWER OFF.) SEVEN SEGEMENT LED FLASHES E111 IS POLARITY CORRECT? - POLARITY REVERSED. - Page 58 HEATING SEQUENCE CONTINUED 15 SECOND COMBUSTION AIR INDUCER PREPURGE INITIATED BY CLOSED PRESSURE SWITCH. SEVEN SEGEMENT LED E110 LOW LINE VOLTAGE. ONCE VOLTAGE IS ABOVE IGNITOR WARM UP -- 20 SECONDS. IS VOLTAGE ABOVE 70 VOLTS? 75 VOLTS, HEATING SEQUENCE RESTARTS. 4 SECOND TRIAL FOR IGNITION.
- Page 59 COOLING SEQUENCE OF OPERATION POWER ON IGNITION CONTROL MAIN POWER ON. GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER OFF WITH NORMAL DELAY. CONTROL SELF DIAGNOSTIC CHECK. SIGNAL CIRCUIT BOARD FAILURE AT LED. IS CONTROL OPERATING NORMALLY? INTERRUPT MAIN POWER TO RESET CONTROL. SEVEN SEGEMENT LED FLASHES E117 IMPROPER GROUND IS THERE A PROPER GROUND? CONTROL WILL CONTINUE TO CALL FOR COOLING...
- Page 60 CONTINUOUS FAN SEQUENCE OF OPERATION MANUAL FAN SELECTION MADE AT THERMOSTAT. CONTROL (G) ENERGIZES SYSTEM FAN AT FAN SPEED. EAC TERMINAL IS ENERGIZED. THERMOSTAT CALLS FOR HEAT (W). SYSTEM FAN CONTINUES FAN SPEED WITHOUT THERMOSTAT CALLS FOR COOLING. INTERRUPTION. EAC TERMINAL REMAIN ON. HUM TERMINAL IS ENERGIZED WITH COMBUSTION SYSTEM FAN SWITCHED TO COOL SPEED.
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