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SV9541, SV9641 SMARTVALVE™ SYSTEM CONTROLS

69-2012—01

16

1.

Check the system thermostat to make sure it is 

calling for heat. (Do not cycle the thermostat on 

and off at this time.)

2.

Remove the appliance burner compartment door. 

Do not interrupt power to the SV9541 or SV9641 by 

opening any electrically interlocked

panels.

3.

Observe the LED indicator on the SV9541 or 

SV9641; check and repair system as noted in 

Table 9 or 10.

Table 9. Troubleshooting with LED indicator assistance for ignition controls using

ST9160 Fan Timer or 208907 Terminal Board.

LED Status

Indicates

Check/Repair

OFF

No power to system control

1.

Line voltage input power at L1 and L2 connectors 

on ST9160 Electronic Fan Timer (EFT) or 208907 

Terminal Board.

2.

Low voltage (24V) power at 24 VAC and COM ter-

minals on ST9160 or Terminal Board.

3.

Fuse on ST9160 EFT if provided.

4.

System wiring harness is in good condition and 

securely connected at both ends.

Bright-Dim

Normal Operation

This indication shows whenever the 

system is powered, unless some 

abnormal event has occurred.

Not Applicable

2 Flashes

Airflow proving switch remains closed 

longer than 30 second after a call for 

heat begins.

Combustion air blower is not energized 

until airflow proving switch opens.

1.

Airflow proving switch stuck closed.

2.

Airflow proving switch miswired or jumpered.

3 Flashes

Airflow proving switch remains open 

longer than 30 seconds after 

combustion air blower energized.

System goes into 5 minute delay period, 

with combustion air blower off. At the 

end of the 5 minute delay, another 

ignition cycle will begin.

1.

Ignition system control switch must be in the ON 

position.

2.

Airflow proving switch operation, tubing, and wir-

ing.

3.

Obstructions or restrictions in appliance air intake 

or exhaust flue system that prevent proper com-

bustion airflow.

4 Flashes

Limit string is open.

Combustion air blower is energized. If 

control system includes ST9160 

Electronic Fan Timer, the heat speed 

circulating air fan will be energized until 

the limit string resets.

1.

Open manual reset or auto reset burner rollout 

switch.

2.

Open high temperature or auxiliary limit switch.

3.

Limit and rollout switch wiring is in good condition 

and securely connected.

5 Flashes

Flame signal sensed out of proper 

sequence.

Combustion air blower is energized. If 

control system includes ST9160 

Electronic Fan Timer, the heat speed 

circulating air fan will be energized after 

the selected heat fan on delay.

Flame at pilot burner.

6 Flashes

System Lockout

After 5-minute delay time, control 

system resets and initiates a new 

ignition sequence if the call for heat is 

still present.

1.

Gas supply off or at too low pressure to operate.

2.

Damaged or broken HSI element.

3.

Flame sense rod contaminated or in incorrect

location.

4.

Pilot burner located in incorrect position.

5.

Pilot burner leadwires are in good condition and 

properly connected.

Summary of Contents for SmartValve SV9541

Page 1: ...o the control is removed when the thermostat call for heat ends The SV9541 and SV9641 Systems are suitable for a wide range of fan assisted combustion gas fired appliances including furnaces rooftop furnaces boilers unit heaters infrared heaters water heaters and commercial cooking appliances The specific application of the SmartValve System is determined by the appliance manufacturer SmartValve S...

Page 2: ...G Fire or Explosion Hazard Can cause property damage severe injury or death Follow these warnings exactly 1 Plan the installation as outlined below 2 Plan for frequent maintenance as described in the Maintenance section Heavy demands are made on the gas controls when intermittent pilot systems are used on central heating equipment in barns greenhouses and commercial properties and on heating appli...

Page 3: ...ignition system control or pilot burner after compression fitting is tightened or gas leakage at the connection can result 4 Always install a sediment trap in the gas supply line to prevent contamination of the ignition system control CAUTION Electrical Shock or Equipment Damage Hazard Can shock individuals or short equipment circuitry 1 Disconnect power supply before installation 2 Never apply a ...

Page 4: ... a tube to pipe coupling to connect the tubing to the ignition system control 3 Install a sediment trap in the supply line to the ignition system control See Fig 2 Install Control 1 Mount 0 to 90 degrees in any direction including vertically from the upright position of the ignition system control switch 2 Mount so the gas flow is in the direction of the arrow on the bottom of the ignition system ...

Page 5: ...ile holding the tubing all the way in slide the fitting into place and engage the threads then turn until finger tight Tighten one more turn with a wrench but do not overtighten 5 Connect the other end of the tubing to the pilot burner according to the instructions supplied with the Q3450 Q3480 NOTE The pilot tubing provides the SmartValve System flame sense current path Make sure the connections ...

Page 6: ...T9160 or 208907 Terminal Board b 120 Vac line on the ST9162 With 240 Vac power supply there must not be more than 120 Vac potential between L1 or 120 LINE and the appliance chassis 3 Verify that the appliance chassis has reliable connection to earth ground 4 Connect control circuit to the ignition system control using the keyed connector See Fig 7 through 11 M10965A HI LO ADJUSTMENT SCREWS UNDER C...

Page 7: ...ITCH LIMIT SWITCH AUXILIARY LIMIT SWITCH OPTIONAL COMBUSTION AIR BLOWER AIR DATA NEUTRAL 1 2 ELECTRONIC AIR CLEANER CIRCULATING FAN HUMIDIFIER L2 L1 HOT TO 120 240 VAC 60 HZ POWER SUPPLY THERMOSTAT R 24 VAC R C W Y Y G G ST9160 ELECTRONIC FAN TIMER Q3450 IGNITER SENSOR L1 POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED FOR 120 VAC INSTALLATIONS CONNECT THE 120V HOT LEAD T...

Page 8: ...TALLATIONS THERE MUST BE NO MORE THAN 120 V BETWEEN L1 AND APPLIANCE CHASSIS 1 2 1 1 1 1 2 2 2 2 3 3 3 3 4 4 4 4 5 5 6 6 7 8 C1 C2 C3 40 VA TRANSFORMER L1 L2 LOAD COMMON THERMOSTAT M12172D PRESSURE SWITCH NEUTRAL HOT L2 L1 HOT TO 120 240 VAC 60 HZ POWER SUPPLY ROLLOUT SWITCH LIMIT SWITCH INDUCER BLOWER MOTOR R R W 24 VAC Q3450 IGNITER SENSOR AIR DATA SV9440 SV9540 SV9640 POWER SUPPLY PROVIDE DISCO...

Page 9: ...CENTER Q3450 IGNITER SENSOR SV9440 SV9540 SV9640 POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED CONNECT THE 120V HOT LEAD AS SHOWN DATA AND R LINES MUST BE CONNECTED TO AQUASTAT CONTROL FOR PROPER SYSTEM OPERATION IN THIS APPLICATION POSTPURGE FUNCTION IS NOT AVAILABLE AND THE LED FUNCTIONS ONLY DURING A CALL FOR HEAT 1 2 3 4 4 CIRCULATOR R C G Y W 1 3 4 6 L2 L1 HOT 1 2 ...

Page 10: ...ARNING Fire or Explosion Hazard Can cause property damage severe injury or death Perform Gas Leak Test every time work is done on a gas system IMPORTANT Do not spray soap and water solution on the SmartValve housing Do not use an excessive amount of soap and water solution to perform the gas leak test These can damage the control 1 2 3 4 3 4 2 1 2 6 1 5 4 8 3 7 2 6 9 1 5 4 8 3 7 SMART VALVE II INT...

Page 11: ...book and compare to Btuh input rating on appliance nameplate 3 IF CHECKING GAS INPUT WITH MANO METER Make sure the ignition system control is in the OFF position before removing outlet pressure tap plug to connect manometer pressure gauge Also move the ignition system control switch to the OFF position when removing the gauge and replacing the plug Before removing inlet pressure tap plug shut off ...

Page 12: ...sing the meter clocking method or check pressure using a manometer connected to the outlet pressure tap on the ignition system control 9 If necessary adjust the low pressure regulator to match the appliance rating See Table 7 and 8 for factory set nominal outlet pressure and adjustment range a Remove the pressure regulator adjustment cap Fig 5 b Using a screwdriver turn the inner adjustment screw ...

Page 13: ...checked monthly Intermittent use Appliances that are used seasonally should be checked before shutdown and again before the next use Consequence of unexpected shutdown Where the cost of an unexpected shutdown would be high the system should be checked more often Dusty wet or corrosive environments Since these environments can cause the gas control to deteriorate more rapidly the system should be c...

Page 14: ...ALL FOR HEAT OR OTHER ABNORMAL OPERATION PREPURGE AIR PROVING SWITCH PROVED CLOSED WITHIN 30 SECONDS COMBUSTION AIR BLOWER OFF PILOT VALVE CLOSES PILOT IGNITER OFF COMBUSTION AIR BLOWER OFF AFTER POST PURGE PILOT AND MAIN VALVES CLOSE COMBUSTION AIR BLOWER OFF AFTER POSTPURGE CIRCULATING AIR FAN OFF AFTER DELAY WAIT FOR NEXT CALL FOR HEAT THREE SECOND FLAME FAILURE RECYCLE DELAY NO YES YES YES NO ...

Page 15: ...D WITHIN 30 SECONDS COMBUSTION AIR BLOWER OFF PILOT VALVE CLOSES PILOT IGNITER OFF COMBUSTION AIR BLOWER OFF AFTER POST PURGE PILOT AND MAIN VALVES CLOSE COMBUSTION AIR BLOWER OFF AFTER POST PURGE CIRCULATING AIR FAN OFF AFTER DELAY WAIT FOR NEXT CALL FOR HEAT THREE SECOND FLAME FAILURE RECYCLE DELAY NO YES YES YES YES NO NO PILOT AND MAIN VALVES CLOSE YES NO YES NO M23476 SV9541 SV9641 INTERMITTE...

Page 16: ...s Airflow proving switch remains open longer than 30 seconds after combustion air blower energized System goes into 5 minute delay period with combustion air blower off At the end of the 5 minute delay another ignition cycle will begin 1 Ignition system control switch must be in the ON position 2 Airflow proving switch operation tubing and wir ing 3 Obstructions or restrictions in appliance air in...

Page 17: ...r blower is energized The heat speed circulating blower is energized after the heat on fan delay 1 Open manual reset or auto reset burner rollout switch 2 Open high temperature or auxiliary limit switch 3 Limit and rollout switch wiring is in good condition and securely connected 5 Flashes Flame signal sensed out of proper sequence Combustion air blower is energized The heat speed circulating blow...

Page 18: ...Table 11 Troubleshooting without LED indicator assistance for ignition controls using an ST9160 Fan Timer or 208907 Terminal Board If And Check Repair Combustion air blower does not energize 2 flash code does not come on 30 seconds after call for heat starts 1 Combustion air blower wiring 2 Combustion air blower 3 Wiring between ST9160 and SV9541 Combustion air blower does not energize 2 flash cod...

Page 19: ...nds 4 flash code does not come on 1 Intermittent wiring connection between SV9541 or SV9641 and pilot burner 2 Combustion air blower moving pilot flame away from pilot burner flame rod 3 Airflow proving switch has opened 4 Flame sense rod ceramic or leadwire overheated 5 Gas flow supply reduced or interrupted 5 flash code comes on Flame at pilot burner 6 flash code comes on After 5 minute delay ti...

Page 20: ...tion below describes a typical ignition system control application but the specific controls used and the procedures outlined in your appliance manufacturer s instructions can differ requiring special instructions STOP Read the Warnings Above Before Proceeding The pilot flame is lit automatically If the appliance does not turn on when the thermostat is set several degrees above room temperature fo...

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