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SV9440, SV9540, AND SV9640 SMARTVALVE™ SYSTEM CONTROLS

15

69-1227—02

Fig. 15. Sequence of operation for two-stage ignition controls with ST9162 fan timer.

THERMOSTAT CALLS FOR HEAT

HI AND LOW AIR PROVING 

SWITCHES PROVED OPEN?

COMBUSTION AIR BLOWER ON

HIGH SPEED

PILOT VALVE OPENS;  

IGNITER POWERED

PILOT LIGHTS AND FLAME IS 

SENSED DURING TRIAL 

FOR IGNITION?

CIRCULATING FAN ON AND

COMBUSTION AIR BLOWER

ON LOW SPEED, MAIN VALVE

ON LOW FIRE AFTER DELAY

MAIN VALVE OPENS ON 

HIGH; IGNITER OFF

FLAME SENSE LOST?

THERMOSTAT CALL FOR 

HEAT ENDS

FIVE-MINUTE WAIT PERIOD

WAIT FOR AIR PROVING

SWITCH TO OPEN    

FLAME SENSE LOST MORE 

THAN FIVE TIMES IN THIS 

CALL FOR HEAT OR OTHER 

ABNORMAL OPERATION?

PREPURGE

HI AIR PROVING SWITCH

PROVED CLOSED?

LOW AIR PROVING SWITCHE 

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 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

M10964D

SV9440; SV9540; SV9640 INTERMITTENT PILOT SmartValve™ 

SYSTEM CONTROL SEQUENCE OF OPERATION 

WITH ST9162A 2-STAGE ELECTRONIC FAN TIMER 

2

1

3

3

CIRCULATING AIR FAN OFF

AFTER DELAY

1

2

3

IGNITER TURNS OFF ABOUT 30 SECONDS INTO THE TRIAL FOR IGNITION IF THE 

PILOT FLAME HAS NOT LIT.  IT TURNS BACK ON FOR THE FINAL 30 SECONDS OF THE 

90 SECOND TRIAL FOR IGNITION.  THE PILOT VALVE IS ENERGIZED DURING THE ENTIRE 

TRIAL FOR IGNITION.  THIS IS NORMAL OPERATION FOR THIS GAS IGNITION SYSTEM.

IF A W2 CALL FOR HEAT IS PRESENT, CIRCULATING FAN ON HIGH HEAT SPEED, COMBUSTION 

AIR BLOWER AND MAIN VALVE REMAIN ON HIGH.

IF HIGH AIR PROVING SWITCH DOES NOT PROVE CLOSED, THE SYSTEM WILL LIGHT ON LOW 

FIRE. IF HIGH AIR PROVING SWITCH DOES NOT PROVE CLOSED IN 30 SECONDS AFTER LOW AIR 

PROVING SWITCH PROVED CLOSED, THEN CONTROL DROPS TO LOW FIRE, LOW FAN SPEED AND 

FLASHES ERROR CODE 9. AFTER 5 MINUTES, CONTROL WILL ATTEMPT TO MOVE TO HIGH FIRE.

POWER APPLIED TO APPLIANCE

Summary of Contents for SV9440

Page 1: ... these controls do not provide a postpurge function because power to the control is removed when the thermostat call for heat ends The SV9440 SV9540 and SV9640 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 ...

Page 2: ...ble 1 Natural LP Gas Conversion Kits See Table 4 Table 4 Natural LP Gas Conversion Kits Pipe Adapters Angle and straight adapters available for 3 8 1 2 and 3 4 in pipe See Table 5 Flange kits include one flange with attached O ring four mounting screws a 9 64 in hex wrench and instructions Approvals International Approval Services IAS Design Certified C2030025 Table 5 Flange Adapter Part Numbers a...

Page 3: ...ustrial or agricultural applications protect the control with an enclosure Dust or Grease Accumulation Heavy accumulations of dust or grease can cause the control to malfunction Where dust or grease can be a problem provide covers for the control to limit contamination Heat Excessively high temperatures can damage the control Make sure the maximum ambient temperature at the control does not exceed...

Page 4: ...he ignition control as follows 1 Remove the pressure regulator cap Fig 1 2 Invert the cap so that the letters appear that repre sent the gas type appropriate for the appliance NAT for natural manufactured gas LP for liquid petroleum gas 3 Replace the cap and tighten firmly Fig 1 Top view of convertible pressure regulator cap Install Adapters To Control If adapters are being installed on the contro...

Page 5: ... ignition system control If a flange is used place the wrench on the flange rather than on the ignition system control Refer to Fig 5 Connect Pilot Gas Tubing 1 Cut tubing to the desired length and bend as nec essary for routing to the pilot burner Do not make sharp bends or deform the tubing Do not bend the tubing at the ignition system control after the com pression nut is tightened because this...

Page 6: ...liance manufacturer follow the appliance manufacturer instructions All wiring must comply with applicable electrical codes and ordinances Fig 5 Proper use of wrench on ignition system control with and without flanges Fig 6 Top view of ignition system control APPLY WRENCH FROM TOP OR BOTTOM OF IGNITION SYSTEM CONTROL TO EITHER SHADED AREA WHEN FLANGE IS NOT USED APPLY WRENCH TO FLANGE ONLY WHEN FLA...

Page 7: ...n system con trol using the keyed connector See Fig 8 through Fig 12 Fig 8 Typical wiring connections in fan assisted warm air furnace with ST9160 Electronic Fan Timer IGNITION SYSTEM CONTROL TIGHTEN NUT ONE TURN BEYOND FINGER TIGHT FITTING BREAKS OFF AND CLINCHES TUBING AS NUT IS TIGHTENED TO PILOT BURNER M3346A C1 P1 C2 C3 40 VA TRANSFORMER CONT EAC HEAT HUM M2 MOTOR PARKING TERMINALS M1 L1 NEUT...

Page 8: ...AC INSTALLATIONS 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...

Page 9: ...NTROL 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 HO...

Page 10: ...Test WARNING 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 con trol 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...

Page 11: ...or deduct their consumption from the meter reading Convert flow rate to Btuh as described in form 70 2602 Gas Controls Handbook and compare to Btuh input rating on appliance nameplate 3 IF CHECKING GAS INPUT WITH MANOMETER 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 s...

Page 12: ...nt adjustment of high and low pressure settings The following sequence details adjusting the high pressure first and then adjusting the low pressure 1 Set thermostat ten degrees above room tempera ture 2 Carefully check the main burner lightoff Make sure that the main burner lights smoothly and that all ports remain lit 3 Check the full rate high manifold pressure listed on the appliance nameplate...

Page 13: ...e 20 000 times annually should be 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 m...

Page 14: ...AIR PROVING SWITCH PROVED OPEN COMBUSTION AIR BLOWER ON PILOT VALVE OPENS IGNITER POWERED PILOT LIGHTS AND FLAME IS SENSED DURING TRIAL FOR IGNITION CIRCULATING AIR FAN ON AFTER DELAY MAIN VALVE OPENS IGNITER OFF FLAME SENSE LOST THERMOSTAT CALL FOR HEAT ENDS FIVE MINUTE WAIT PERIOD WAIT FOR AIR PROVING SWITCH TO OPEN FLAME SENSE LOST MORE THAN FIVE TIMES IN THIS CALL FOR HEAT OR OTHER ABNORMAL OP...

Page 15: ...F 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 M10964D SV9440 SV9540 SV9640 INTERMITTENT PILOT SmartValve SYSTEM CONTROL SEQUENCE OF OPERATION WITH ST9162A 2 STAGE ELECTRONIC FAN TIMER 2 1 3 3 CIRCULATING AIR FAN OFF AFTER DELAY 1 2 3 IGNITER TURNS OFF ABO...

Page 16: ...r 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 jum pered 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 anothe...

Page 17: ... energized The heat speed circulating blower is energized after the heat on fan delay 1 Open manual reset or auto reset burner roll out 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 blower is ener...

Page 18: ...in Table 11 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 SV9540 Combustion air blower does not energize...

Page 19: ...before thermostat call for heat ends 4 flash code comes on 1 Open manual reset or auto reset burner roll out switch 2 Open high temperature or auxiliary limit switch 3 Limit and rollout switch string wiring is in good condition and securely connected Main burner goes out before thermostat call for heat ends 4 flash code does not come on 1 Intermittent wiring connection between SV9440 SV9540 or SV9...

Page 20: ...e information below describes a typical igni tion 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 temp...

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