Lennox ML196UH030XE36B Unit Information
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Lennox ML196UH030XE36B Unit Information

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Service Literature
ML196UHE series units are high-efficiency gas fur­
naces manufactured with Lennox DuralokPlust alumi­
nized steel clamshell-type heat exchangers, with a stainless
steel condensing coil. ML196UHE units are available in
heating input capacities of 30,000 to 135,000 Btuh and
cooling applications from 1.5 through 5 tons. Refer to Engi­
neering Handbook for proper sizing.
Units are factory equipped for use with natural gas. A kit is
available for conversion to LP/Propane operation. All
ML196UHE units are equipped with a hot surface ignition
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 outlined
in this manual are presented as a recommendation only
and do not supersede or replace local or state codes.
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 discon­
nect switch(es). Unit may have multiple
power supplies.

Table of Contents

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Corp 1911-L7
07/2020
ML196UHE SERIES UNITS
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Improper installation, adjustment, alteration, service
2
or maintenance can cause property damage, person­
3
al injury or loss of life. Installation and service must
be performed by a licensed professional HVAC in­
4
staller (or equivalent), service agency or the gas sup­
7
plier.
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42
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As with any mechanical equipment, contact with
47
sharp sheet metal edges can result in personal in­
48
jury. Take care while handling this equipment and
wear gloves and protective clothing.
51
Page 1
ML196UHE
WARNING
CAUTION
© 2020 Lennox Industries Inc.
Litho U.S.A.

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Summary of Contents for Lennox ML196UH030XE36B

  • Page 1: Table Of Contents

    Service Literature ML196UHE SERIES UNITS ML196UHE series units are high-efficiency gas fur­ naces manufactured with Lennox DuralokPlust alumi­ nized steel clamshell-type heat exchangers, with a stainless steel condensing coil. ML196UHE units are available in heating input capacities of 30,000 to 135,000 Btuh and cooling applications from 1.5 through 5 tons.

  • Page 2: Specifications

    SP ECIF ICATIONS ML196UH ML196UH ML196UH ML196UH ML196UH Model No. Heating 030XE36B 045XE36B 070XE36B 070XE48B 090XE36C Performance AFUE Input - Btuh 30,000 44,000 66,000 66,000 88,000 Output - Btuh 29,000 42,800 63,900 63,900 85,600 Temperature rise range - °F 25 - 55 35 - 65 35 - 65 30 - 60...

  • Page 3: Optional Accessories

    O P T IONA L AC C ESSORIES “B” Width Models “C” Width Models “D” Width Models CABINET ACCESSORIES Horizontal Suspension Kit - Horizontal only 51W10 51W10 51W10 Return Air Base - Upflow only 50W98 50W99 50W99 High Performance Economizer (Commercial Only) 10U53 10U53 10U53...

  • Page 4: Blower Performance Data

    B LOWER DATA ML196UH030XE36B PERFORMANCE (Less Filter) External Air Volume / Watts at Various Blower Speeds Static High Medium-High Medium Medium-Low Pressure Watts Watts Watts Watts Watts in. w.g. 0.00 1435 1170 1000 0.10 1400 1130 0.20 1360 1085 0.30...
  • Page 5 BLO WER DATA ML196UH090XE36C PERFORMANCE (Less Filter) External Air Volume / Watts at Various Blower Speeds Static High Medium-High Medium Medium-Low Pressure Watts Watts Watts Watts Watts in. w.g. 0.00 1470 1355 1195 0.10 1445 1330 1170 0.20 1430 1300 1150 0.30 1385...
  • Page 6 BLO WER DATA ML196UH110XE60C PERFORMANCE (Less Filter) Air Volume / Watts at Different Blower Speeds Single Side Return Air − Air volumes in bold (over 1800 External Bottom Return Air, Side Return Air with Return Air from cfm) require Optional Return Air Base and field fabricated Static Both Sides or Return Air from Bottom and One Side.
  • Page 7 ML196UHE PARTS IDENTIFICATION FLEXIBLE NO-HUB EXHAUST COLLAR BURNER BOX ASSEMBLY TOP CAP GAS VALVE DuralokPlus HEAT EXCHANGER ASSEMBLY COMBUSTION AIR INDUCER BURNER ACCESS PANEL BAG ASSEMBLIES (shipping location) PRIMARY LIMIT COLD END HEADER BOX BLOWER ACCESS PANEL BLOWER COMBUSTION ASSEMBLY AIR PRESSURE SWITCH CONTROL BOX...

  • Page 8: I-Unit Components

    I-UNIT COMPONENTS 3. Circuit Breaker (CB8) A 24V circuit breaker is also located in the control box. The switch provides overcurrent protection to the transformer (T1). The breaker is rated at 3A at 32V. If the current ex­ ELECTROSTATIC DISCHARGE (ESD) ceeds this limit the breaker will trip and all unit operation will Precautions and Procedures shutdown.
  • Page 9 TABLE 3 1/4” QUICK CONNECT TERMINALS 120HUM Humidifier 120VAC LINE 120VAC XFMR Transformer 120VAC CIRC Indoor blower 120VAC Indoor air quality accessory 120VAC NEUTRALS Common 120VAC HUM24 Humidifier 24VAC 3/16” QUICK CONNECT TERMINALS COOL Cooling tap 24VAC HEAT Heating tap 24VAC Continuous blower 24 VAC PARK (no power) Park terminal for unused speed taps...
  • Page 10 tal of five trials for ignition (including the initial trial), the inte­ INTEGRATED CONTROL grated control goes into Watchguard-Flame Failure mode. (Automatic Hot Surface Ignition System) After a 60-minute reset period, the integrated control will begin the ignition sequence again. Fan Time Control Heating Fan On Time The fan on time of 30 seconds is not adjustable.
  • Page 11 ML196UHE Burner Box Assembly Burner Assembly Rollout Switch(s) Flame Sensor Ignitor Gas Valve Burner Box Front FIGURE 5 B-Heating Components 2. Heat Exchanger (Figure 6) ML196UHE units use an aluminized steel primary and Combustion air inducer (B6), primary limit control (S10), ig­ stainless steel secondary heat exchanger assembly.
  • Page 12 5. Flame Sensor (Figure 5) Primary Limit Location and Heat Exchanger A flame sensor is located on the left side of the burner sup­ port. The sensor is mounted on the front burner box plate and the tip protrudes into the flame envelope of the left- most burner.
  • Page 13 Measuring Flame Signal Flame Signal In Microamps Normal Drop Out  1.5  0.4 0.5 - 1.4 Flame Sensor Wire Remove sensor from integrated control and connect alligator clip (−) to flame sensor lead. Multi−Meter Intergrated Control Set Dial to DC MicroAmps Flame Sensor Terminal (−) T o Flame...
  • Page 14 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 15 7. Combustion Air Inducer (B6) Pressure Switch & Cold End Header Box All ML196UHE units use a combustion air inducer to move air through the burners and heat exchanger during heating operation. The blower uses a shaded pole 120VAC motor. The motor operates during all heating op­ eration and is controlled by integrated control A92.
  • Page 16 Measuring Pressure Differential Black Tubing (positive +) Red and Black Tubing or Red Tubing (negative -) To Cold End Header Box To Cold End Header Box Field Provided Tubing To Pressure Switch “+” High “-” 1 - Remove thermostat demand and allow unit to 4 - Operate unit and observe manometer reading.
  • Page 17 TABLE 7 Pressure Switch Troubleshooting Guide Problem Corrective Action Check that the pressure switch is open without the combustion air inducer operat­ Pressure switch stuck closed ing. Replace if defective. Pressure switch does not close due to Check for restricted vent. Remove all blockage. obstruction in vent pipe.
  • Page 18 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. ML196UHE units are equipped with a constant torque ECM motor. It has a DC motor coupled to an electronic control module both contained in the same motor housing.
  • Page 19 Multi−Meter (set to VAC) Multi−Meter (set to VAC) Test 1 Test 3 (if necessary) Turn on power to unit. Check for 120 volts across terminals Check for 120 volts across terminals “CIRC” and “Neutrals” “L” and “N” on input plug P48. If voltage is present continue on the integrated control.
  • Page 20 Replacing the Motor Module Motor Test 1. Disconnect electrical power to unit. 2. Remove unit access panel. 3. Unplug the two harnesses from the motor control mod­ ule. See figure 17. Unplug the Two Harness Connection TWO HARNESS FIGURE 19 CONNECTIONS TABLE 8 MOTOR...

  • Page 21: Placement And Installation

    II-PLACEMENT AND INSTALLATION IMPORTANT Pipe & Fittings Specifications ML196UHE exhaust and intake connections are All pipe, fittings, primer and solvent cement must conform made of PVC. Use PVC primer and solvent cement with American National Standard Institute and the Ameri­ when using PVC vent pipe.
  • Page 22 TABLE 10 OUTDOOR TERMINATION USAGE* STANDARD CONCENTRIC Flush­ Wall Kit Wall Ring Kit Mount 1-1/2 inch 2 inch 3 inch Vent 2 inch 3 inch 2 inch Pipe Input Size Field Dia. in. 51W11 71M80 69M29 Fabricated 44J40 (US) 22G44 (US) (US) (US) 60L46 (US)
  • Page 23 NOTE - Assembly should be completed within 20 sec­ REPLACING FURNACE THAT onds after last application of cement. Hammer blows CHIMNEY WAS PART OF A COMMON OR GAS should not be used when inserting pipe. VENT VENT SYSTEM (Check sizing 8 - After assembly, wipe excess cement from pipe at end for water heater only)
  • Page 24 Vent Piping Guidelines MINIMUM VENT PIPE LENGTHS ML196UHE MIN. VENT LENGTH* ® NOTE - Lennox has approved the use of DuraVent MODEL Centrotherm manufactured vent pipe and terminations as 15 ft. or ® an option to PVC. When using the PolyPro by DuraVent or 5 ft.
  • Page 25 TABLE 12 Maximum Allowable Intake or Exhaust Vent Length in Feet 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 calculation.
  • Page 26 TABLE 12 Continued Maximum Allowable Intake or Exhaust Vent Length in Feet *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. Concentric Termination at Elevation 0 - 4500 ft 1-1/2”...
  • Page 27 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. Standard Termination at Elevation 0 - 10,000 ft 1-1/2”...
  • Page 28 TYPICAL EXHAUSTAND INTAKE PIPE CONNECTIONS IN UPFLOW DIRECT OR NON-DIRECT VENT APPLICATIONS 2” EXHAUST 2” EXHAUST INTAKE INTAKE 2” 2” 2” 2” 3” 3” 030/045/070 Only 1−1/2” TRANSITION Exhaust 2” Exhaust DO NOT transition from larger to smaller DO NOT transition Exhaust pipe in horizontal runs from smaller to larger...
  • Page 29 Intake Piping TYPICAL AIR INTAKE PIPE CONNECTIONS The ML196UHE furnace may be installed in either direct UPFLOW NON−DIRECT VENT APPLICATIONS vent or non-direct vent applications. In non-direct vent applications, when intake air will be drawn into the furnace INTAKE from the surrounding space, the indoor air quality must be DEBRIS SCREEN considered and guidelines listed in Combustion, Dilution...
  • Page 30 General Guidelines for Vent Terminations CAUTION In Non‐Direct Vent applications, combustion air is taken If this unit is being installed in an application with from indoors and the flue gases are discharged to the out­ combustion air coming in from a space serviced by doors.
  • Page 31 TABLE 14 Maximum Allowable Exhaust Vent Pipe Length (in ft.) Without Insulation In Unconditioned Space For Winter Design Temperatures Single - Stage High Efficiency Furnace Unit Input Size Winter Design Vent Pipe Temperatures °F (°C) Diameter PP PVC PP PVC PP PVC PP PVC PP PVC...
  • Page 32 ‡ Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor. Lennox recommends avoiding this location if possible. FIGURE 32...
  • Page 33 ‡ Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor. Lennox recommends avoiding this location if possible. FIGURE 33 Page 33...
  • Page 34 Details of Intake and Exhaust Piping Terminations for Exiting Exhaust and Intake Vent Direct Vent Installations (different pressure zones) NOTE - In Direct Vent installations, combustion air is tak­ en from outdoors and flue gases are discharged to out­ doors. NOTE - Flue gas may be slightly acidic and may adversely affect some building materials.
  • Page 35 7. If intake and exhaust piping must be run up a side wall FIELD-PROVIDED to position above snow accumulation or other ob­ 1-1/2” (38mm) accelerator REDUCER MAY BE REQUIRED provided on 71M80 & 44W92 structions, piping must be supported. At least one TO ADAPT DIFFERENT VENT kits for ML196UHE045P24B, PIPE SIZE TO TERMINATION...
  • Page 36 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 37 Details of Exhaust Piping Terminations for Non‐Direct ML196UHE NON-DIRECT VENT APPLICATION Vent Applications USING EXISTING CHIMNEY Exhaust pipes may be routed either horizontally through an SIZE TERMINATION STRAIGHT-CUT OR ANGLE-CUT IN DIRECTION PIPE PER TABLE 15. outside wall or vertically through the roof. In attic or closet OF ROOF SLOPE installations, vertical termination through the roof is pre­...
  • Page 38 Heating cable kit is condensate trap or trap must be re-located to available from Lennox in various lengths; 6 ft. (1.8m) - avoid interference. kit no. 26K68 and 24 ft. (7.3m) - kit no. 26K69.
  • Page 39 CONDENSATE TRAP LOCATIONS Condensate Trap With Optional Overflow Switch (Unit shown in upflow position with remote trap) From Evaporator Coil Horizontal Furnace 4” Min. to 5” Max.above Field ProvidedVent condensatedrain connection) Min. 1” Above Condensate Drain Connection 1” Min. 2” Max. FurnaceCondensate Drain Connection *5’...
  • Page 40 ML196UHE with Evaporatoir Coil Using a Separate Drain (Unit shown in horizontal left-hand discharge position) Field Provided Vent Evaporator (4” min. to 5” max. above Coil condensate connection) 4”min 5”max 5’ max. PVC Pipe Only Condensate Drain Connection Drain Pan Piping from furnace and evaporator coil must slope down a minimum 1/4”...
  • Page 41 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.

  • Page 42: 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 which 1 - Inspect electrical wiring, both field and factory installed for loose connections.

  • Page 43: Iv-Heating System Service Checks

    3 - Start unit and let run for 5 minutes to allow for steady Gas Leak Detector is strongly recommended. It is available state conditions. through Lennox under part number 31B2001. See Corp. 4 - After allowing unit to stabilize for 5 minutes, record 8411-L10, for further details.
  • Page 44 MANIFOLD PRESSURE CHECK SET UP 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 56 E-Proper Combustion F-High Altitude...
  • Page 45 TABLE 19 LP/Propane Conversion Kit and Pressure Switch Requirements at Varying Altitudes High Altitude High Altitude Natural to Natural Burner LP/Propane Burner High Altitude Pressure Switch LP/Propane ML196 Orifice Kit Orifice Kit Unit 0 - 7500 ft 7501 - 10,000 ft 7501 - 10,000 ft 4501 - 7500 ft 7501 -10,000 ft...
  • Page 46 G- Proper Ground and Voltage 2 - In addition, measure the AC voltage from Line Hot to Line Neutral (spade terminals) on the integrated con­ WARNING trol. See figure 57. This voltage should be in the range of 97 to 132 Vac Electric Shock Hazard.

  • Page 47: V-Typical Operating Conditions

    V-TYPICAL OPERATING CHARACTERISTICS C-External Static Pressure 1 - Tap locations shown in figure 59. A-Blower Operation and Adjustment1 2 - Punch a 1/4” diameter hole in supply and return air NOTE- The following is a generalized procedure and plenums. Insert manometer hose flush with inside edge of hole or insulation.

  • Page 48: Vi-Maintenance

    True RMS Meter 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 informa­ tion is provided in Service and Application Note FIGURE 61 ACC­00­2 (August 2000).
  • Page 49 Winterizing and Condensate Trap Care 12 - Mark and disconnect all combustion air pressure tub­ 1 - Turn off power to the furnace. ing from cold end header collector box. 13 - Mark and remove wires from pressure switch assem­ 2 - Have a shallow pan ready to empty condensate water.
  • Page 50 35 - Use securing screws to reinstall flue collar to the top Cleaning the Burner Assembly (if needed) cap on the furnace. Reconnect exhaust piping and ex­ 1 - Turn off electrical and gas power supplies to furnace. haust drain tubing. Remove upper and lower furnace access panels.

  • Page 51: Vii-Sequence Of Operation And Flow Charts

    VII-WIRING DIAGRAM AND SEQUENCE OF OPERATION Line voltage is applied to L1 and N. the T1 low voltage transformer is energized, and line voltage is applied to B3 indoor blower. S47 rollout switch(es) must be closed in order for 24V from transformer to be output on integrated control ”R” to power thermostat. When there is a call for heat, W1 of the thermostat energizes W of the furnace control with 24VAC.
  • Page 52 Line voltage is applied to L1 and N. the T1 low voltage transformer is energized, and line voltage is applied to B3 indoor blower. S47 rollout switch(es) must be closed in order for 24V from transformer to be output on integrated control ”R” to power thermostat. When there is a call for heat, W1 of the thermostat energizes W of the furnace control with 24VAC.
  • Page 53 Troubleshooting: Heating Sequence of Operation 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? LED SLOW FLASH (RESET CONTROL BY TURNING MAIN POWER OFF.) LED FLASHES CODE 1 - POLARITY IS POLARITY CORRECT? REVERSED.
  • Page 54 Troubleshooting: Heating Sequence of Operation (Continued) HEATING SEQUENCE CONTINUED NORMAL HEATING MODE ABNORMAL HEATING MODE 15‐SECOND COMBUSTION AIR INDUCER PREPURGE INITIATED BY CLOSED PRESSURE SWITCH. LED FLASHES CODE 13 - LOW LINE VOLTAGE. ONCE VOLTAGE IS ABOVE IGNITOR WARM‐UP -- 20 SECONDS. IS VOLTAGE ABOVE 70 VOLTS? 75 VOLTS, HEATING SEQUENCE RESTARTS.
  • Page 55 Troubleshooting: Cooling Sequence of Operation COOLING SEQUENCE OF OPERATION NORMAL COOLING MODE ABNORMAL COOLING MODE POWER ON IGNITION CONTROL MAIN POWER ON. LED FLASHES STEADY - CIRCUIT BOARD FAILURE CONTROL SELF DIAGNOSTIC CHECK. GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. IS CONTROL OPERATING NORMALLY? INDOOR BLOWER OFF WITH NORMAL DELAY.
  • Page 56 Troubleshooting: Continuous Fan / Accessories Sequence of Operation CONTINUOUS FAN / ACCESSORIES SEQUENCE OF OPERATION LED: SLOW FLASH RATE REMAINS UNCHANGED THROUGHOUT SEQUENCE. MANUAL FAN SELECTION MADE AT THERMOSTAT. CONTROL (G) ENERGIZES SYSTEM FAN AT FAN SPEED. EAC TERMINAL IS ENERGIZED. THERMOSTAT CALLS FOR HEAT (W).

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