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Page 46

VI-MAINTENANCE

 WARNING

ELECTRICAL SHOCK, FIRE,

OR EXPLOSION HAZARD.

Failure to follow safety warnings exactly could 

result in dangerous operation, serious injury, death 

or property damage.

Improper servicing could result in dangerous 

operation, serious injury, death, or property damage. 

Before servicing, disconnect all electrical power to 

the furnace.

At the beginning of each heating season, system should 

be checked as follows by a qualified service technician:

Blower

Check the blower wheel for debris and clean if necessary. 

The blower motors are prelubricated for extended bearing 

life. No further lubrication is needed.

 WARNING

The blower access panel must be securely in place 

when the blower and burners are operating. Gas 

fumes, which could contain carbon monoxide, can 

be drawn into living space resulting in personal 

injury or death.

Filters

All air filters are installed external to the unit. Filters should 

be  inspected  monthly.  Clean  or  replace  the  filters  when 

necessary to ensure proper furnace operation. TABLE 22 

lists recommended filter sizes.

 WARNING

If  a  highefficiency  filter  is  being  installed  as  part 

of this system to ensure better indoor air quality, 

the  filter  must  be  properly  sized.  Highefficiency 

filters  have  a  higher  static  pressure  drop  than 

standardefficiency glass/foam filters.

If the pressure drop is too great, system capacity 

and performance may be reduced. The pressure 

drop may also cause the limit to trip more frequently 

during the winter and the indoor coil to freeze in the 

summer, resulting in an increase in the number of 

service calls.

Before  using  any  filter  with  this  system,  check  the 

specifications provided by the filter manufacturer against 

the  data  given  in  the  appropriate  Lennox  Product 

Specifications bulletin. Additional information is provided 

in Service and Application Note ACC002
(August 2000).

TABLE 22

 

Furnace Cabinet Width

Minimum Filter Size

16 x 25 x 1 (1)

17-1/2”

21”

Exhaust and air intake pipes

Check the exhaust and air intake pipes and all connec

-

tions for tightness and to make sure there is no blockage.
NOTE - After any heavy snow, ice or frozen fog event the 

furnace vent pipes may become restricted. Always check 

the vent system and remove any snow or ice that may be 

obstructing the plastic intake or exhaust pipes.

Electrical

 WARNING

Fire Hazard. Use of aluminum wire with this product 

may  result  in  a  fire,  causing  property  damage, 

severe injury or death. Use copper wire only with 

this product.

 WARNING

Failure to use properly sized wiring and circuit 

breaker may result in property damage. Size wiring 

and  circuit  breaker(s)  per  Product  Specifications 

bulletin (EHB) and unit rating plate.

1 - Check all wiring for loose connections.
2 -  Check for the correct voltage at the furnace (furnace 

operating). Correct voltage is 10%

3 -  Check  amp-draw  using  a  true  RMS  meter  on  the 

blower motor with blower access panel in place.

Furnace Nameplate__________Actual__________

Check Motor AMP Draw

(Typical set−up with upflow furnace shown)

kVAr

kWh

COM

M

V3

V1 V2

POFF

MR

EX

1

W

3

2

True RMS Meter

FIGURE 57 

Winterizing and Condensate Trap Care

1 -  Turn off power to the furnace.
2 -  Have  a  shallow  pan  ready  to  empty  condensate 

water.

3 -  Remove the clean out cap from the condensate trap 

and empty water. Inspect the trap then reinstall the 

clean out cap.

Summary of Contents for ML196DF045XE36B

Page 1: ...ctory equipped for use with natural gas A kit is available for conversion to LP Propane operation All ML196DFE units are equipped with a hot surface ignition system The gas valve is redundant to assur...

Page 2: ...pt 3 4 slip x 3 4 Mipt with field supplied PVC coupling o d 3 4 slip x 3 4 MPT 3 4 slip x 3 4 MPT 3 4 slip x 3 4 MPT 3 4 slip x 3 4 MPT Indoor Blower Wheel nom diameter x width in 10 x 8 11 1 2 x 10 1...

Page 3: ...of filter in 2 16 x 20 x 1 2 16 x 20 x 1 NIGHT SERVICE KIT Night Service Kit 84W48 84W48 TERMINATION KITS See Installation Instructions for specific venting information Direct Vent Concentric US 2 in...

Page 4: ...640 150 0 70 N A N A 1255 430 1040 315 910 255 585 160 0 80 N A N A 1215 445 990 320 865 265 525 170 ML196DF045XE36B PERFORMANCE Less Filter External Static Pressure in w g Air Volume Watts at Various...

Page 5: ...cation 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 DuralokPl...

Page 6: ...transformer T1 The breaker is rated at 3A at 32V If the current exceeds this limit the breaker will trip and all unit operation will shutdown The breaker can be manually reset by pressing the button...

Page 7: ...sor 5 Watchguard burner failed to light exceeded maximum number of retries or recycles 6 Not Used 7 Primary or Secondary Limit Open or Watchguard Mode Limit Switch Open longer than 3 minutes 8 Rollout...

Page 8: ...es into Watchguard Flame Failure mode After a 60 minute reset period the integrat ed control will begin the ignition sequence again Fan Time Control Ignition Control 103217 03 Heating Fan On Time The...

Page 9: ...rtbeat is indicated by 1s on 1s off It is used for idle continuous fan and cool modes Note 2 Error codes are indicated by a rapid flash the LED flashes X times at second on second off remains off for...

Page 10: ...See table 4 flash code 8 for troubleshooting 2 Heat Exchanger FIGURE 7 ML196DFE units use an aluminized steel primary and stainless steel secondary heat exchanger assembly Heat is transferred to the a...

Page 11: ...nd sensing electrode The ignition control allows the gas valve to remain open as long as flame signal is sensed NOTE The ML196DFE is polarity sensitive Make sure that the furnace is wired correctly an...

Page 12: ...s Multi Meter To Control Sensor T erminal T o Flame Terminal Remove Sensor Wire from Intergrated Control and Connect Alligator Clip to Terminal on Control Flame Sensor Terminal Flame Sensor Wire Remov...

Page 13: ...rect 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...

Page 14: ...er flow through the heat exchanger The switch is a SPST N O prove switch electrically con nected to the integrated control The purpose of the switch is to prevent burner operation if the combustion ai...

Page 15: ...d 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 se...

Page 16: ...tial pressure across the pressure switch Check for restricted inlet vent Remove all block age Check for proper vent sizing and run length See table 13 Wrong pressure switch installed in the unit or pr...

Page 17: ...s present in tests 1 and 2 and motor is not operating properly replace motor The motor is not field repairable If replacing the indoor blower motor or blower wheel is necessary placement is critical T...

Page 18: ...peed 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 12 0 12 0 24 Multi Meter set to...

Page 19: ...imately the same resistance within an ohm 13 Check to see if the blower wheel spins freely Motor Test FIGURE 19 TABLE 9 Scale Measurement range in words ohms 2 M two megohm two million ohms 0 2 000 00...

Page 20: ...VENTING SYSTEM PolyPro by Duravent InnoFlue by Centrotherm UL 1738 CERTIFIED GAS VENTING SYSTEM IPEX System1738 Schedule 40 PVC Pipes and Fittings UL1738 IPEX System1738 PVC FGV Cement Primer IMPORTA...

Page 21: ...g to the specifications outlined in ASTM D 2855 NOTE A sheet metal screw may be used to secure the intake pipe to the connector if desired Use a drill or self tapping screw to make a pilot hole DANGER...

Page 22: ...ng requirements section WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result...

Page 23: ...TABLE 12 minimum and TABLE 13 maximum Count all elbows inside and outside the home NOTE Lennox offers a glueless vent adapter kit 17H92 as an option for exhaust exiting at the furnace top cap coupling...

Page 24: ...127 108 108 2 10 10 56 41 19 95 75 38 122 122 103 103 3 n a n a 51 36 14 90 70 33 117 117 98 98 4 46 31 n a 85 65 28 112 112 93 93 5 41 26 80 60 23 107 107 88 88 6 36 21 75 55 18 102 102 83 83 7 31 16...

Page 25: ...a 90 70 39 n a 111 111 104 104 2 n a n a 48 33 17 85 65 34 106 106 99 99 3 43 28 12 80 60 29 101 101 94 94 4 38 23 n a 75 55 24 96 96 89 89 5 33 18 70 50 19 91 91 84 84 6 28 13 65 45 14 86 86 79 79 7...

Page 26: ...7 88 88 2 N A N A 46 31 9 80 60 23 102 102 83 83 3 41 26 n a 75 55 18 97 97 78 78 4 36 21 70 50 13 92 92 73 73 5 31 16 65 45 8 87 87 68 68 6 26 11 60 40 n a 82 82 63 63 7 21 n a 55 35 77 77 58 58 8 16...

Page 27: ...pipe and intake pipe must be the same diameter 2 TRANSITION 2 1 1 2 045 070 Only DO NOT transition from larger to smaller pipe in horizontal runs of exhaust pipe Exhaust Exhaust FIGURE 24 TYPICAL INTA...

Page 28: ...eld provided materials and the factory provided air intake screen to route the intake piping as shown in FIGURE 26 Maintain a minimum clearance of 3 76mm around the air intake opening The air intake o...

Page 29: ...ted by local building codes In the absence of local codes refer to the current National Fuel Gas Code ANSI Z223 1 NFPA 54 in U S A and current CSA B149 Natural Gas and Propane Installation Codes in Ca...

Page 30: ...2 2 10 10 7 7 1 Refer to 99 Minimum Design Temperature table provided in the current edition of the ASHRAE Fundamentals Handbook 2 Poly Propylene vent pipe PP by Duravent and Centrotherm NOTE Concentr...

Page 31: ...public property Clearance under veranda porch deck or balcony 12 Equal to or greater than soffit depth 3 feet 9m 12 3 feet 9m within a height 15 feet 4 5m above the meter regulator assembly 3 feet 9m...

Page 32: ...anda porch deck or balcony 12 7 feet 2 1m 3 feet 9m within a height 15 feet 4 5m above the meter regulator assembly 3 feet 9m 6 inches 152mm for appliances 10 000 pliances 10 000 Btuh 3kw and 50 000 p...

Page 33: ...irement of intake and exhaust pipe DOES NOT apply 3 On roof terminations the intake piping should terminate straight down using two 90 elbows See FIGURE 32 4 Exhaust piping must terminate straight out...

Page 34: ...ATION 71M80 69M29 or 60L46 US 44W92 or 44W93 Canada INTAKE AIR EXHAUST AIR INTAKE AIR INTAKE AIR EXHAUST AIR OUTSIDE WALL GRADE CLAMP Not Furnished FIELD PROVIDED REDUCER MAY BE REQUIRED TO ADAPT DIFF...

Page 35: ...ective shield is recommended The shield should be constructed using wood sheet metal or other suitable material All seams joints cracks etc in affected area should be sealed using an appropriate seala...

Page 36: ...Distance between exhaust pipe terminations on multiple furnaces must meet local codes NON DIRECT VENT ROOF TERMINATION KIT 15F75 or 44J41 UNCONDITIONED ATTIC SPACE 3 76mm OR 2 51mm PVC PROVIDE SUPPOR...

Page 37: ...n 5 FIGURE 47 shows the furnace and evaporator coil using a separate drain If necessary the condensate line from the furnace and evaporator coil can drain together See FIGURE 48 The field provided ven...

Page 38: ...ve condensate drain Evaporator Drain Line vent required Condensate Drain Connection FIGURE 48 IMPORTANT When combining the furnace and evaporator coil drains together the A C condensate drain outlet m...

Page 39: ...ction In Unit Condensate Drain Connection In Unit Vent To Drain Condensate Drain Connection In Unit Optional Condensate Drain Connection OptionalDrainPipingFromTrap DrainTrapAssembly Furnished DrainTr...

Page 40: ...he trap should be primed with sufficien water to ensure proper condensate drain operation WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage...

Page 41: ...m mended It is available through Lennox under part number 31B2001 See Corp 8411 L10 for further details WARNING Do not use matches candles flame or any other source of ignition to check for gas leaks...

Page 42: ...TABLE 17 Manifold and Supply Line Pressure 0 10 000ft ML196 Unit Gas Manifold Pressure in wg Supply Line Pressure in w g 0 10000 ft 0 4500 ft 4501 5500 ft 5501 6500 ft 6501 7500 ft 7501 10 000 ft All...

Page 43: ...stallations at eleva tions over 4500 feet 1372 m is the jurisdiction of local authorities ML196DFE 1 2 and 3 units require no manifold pres sure adjustments for operation at altitudes up to 10 000 fee...

Page 44: ...a function of load indicates a poor or partial ground Compare the readings to the table below If the readings exceed the maximum shown in TABLE 21 make repairs before operating the furnace 2 In addit...

Page 45: ...return air plenums Insert manometer hose flush with inside edge of hole or insulation Seal around the hose with permagum Connect the zero end of the manometer to the discharge supply side of the syste...

Page 46: ...he number of service calls Before using any filter with this system check the specifications provided by the filter manufacturer against the data given in the appropriate Lennox Product Specifications...

Page 47: ...e two screws which secure combustion air inducer to collector box Remove combustion air inducer assembly Remove ground wire from vest panel 13 Remove electrical junction box from the side of the furna...

Page 48: ...er sources of ignition to check for gas leaks Cleaning the Burner Assembly if needed 1 Turn off electrical and gas power supplies to furnace Remove upper and lower furnace access panels 2 Disconnect t...

Page 49: ...or heat can continue 5 A92 integrated control energizes B6 combustion air inducer S18 combustion air pressure switch closes Once S18 closes a 15 second pre purge follows 6 A92 integrated control energ...

Page 50: ...ALVE ENERGIZED GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER ON HEATING SPEED LED FLASHES CODE 11 PRESSURE SWITCH CLOSED GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF WITH DELAY S...

Page 51: ...RESET IGNITION SEQUENCE FOUR TIMES FLAME SIGNAL 1 5 MICROAMPS OR GREATER YES YES YES ROLLOUT SWITCH CLOSED LED FLASHES CODE 8 ROLLOT SWITCH OPEN GAS VALVE POWER OFF COMBUSTION AIR INDUCER POWER ON IND...

Page 52: ...ITCH CLOSED LED SLOW FLASH RATE REMAINS UNCHANGED THROUGHOUT COOLING CYCLE THERMOSTAT CALLS FOR COOLING COMPRESSOR CONTACTOR AND SYSTEM FAN ENERGIZED WITH 2 SECOND DELAY COOLING SPEED EAC TERM ENERGIZ...

Page 53: ...AN SWITCHED TO COOL SPEED EAC TERM REMAINS ON THERMOSTAT OPENS MANUAL FAN SELECTION MADE AT THERMOSTAT CONTROL G ENERGIZES SYSTEM FAN AT FAN SPEED EAC TERM ENERGIZED NO YES YES NO SYSTEM FAN SWITCHES...

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