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S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL

Automation and Control Solutions

Honeywell International Inc.

Honeywell Limited-Honeywell Limitée

1985 Douglas Drive North

35 Dynamic Drive

Golden Valley, MN  55422

Toronto, Ontario  M1V 4Z9

customer.honeywell.com

® U.S. Registered Trademark
© 2007 Honeywell International Inc.
69-2088—01    M.S.  11-07 

Low pressure switch failed (stuck) Closed

224 Resume normal operation after fault removed.

Wait for 

Recovery

High pressure switch failed (stuck) Open

225 Increase inducer RPM every few seconds. If upper limit 

reached, start pressure switch calibration.

High pressure switch failed (stuck) Closed

226 Wait for it to open, then start calibration.

Low pressure switch opened in run or Trial for 

Ignition

227 Increment recycle/retry. Go to Soft Lockout if > maximum

Limit switch circuit open

250 Wait for Limit switch circuit to close. If closed in 3 minutes, 

resume operation, else enter Soft Lockout after close.

Valve relay contact failure

125

a

Soft Lockout after fault recovers.

Soft

Lockout

Inducer/pressure switch calibration failure

228 Retry after 5 minutes. If failed allowed times, go to Soft 

Lockout. Error counter cleared when exiting lockout.

Flame out of sequence while flame still 

present

241 Wait for flame loss, then go to Soft Lockout. Error counter 

cleared when exiting lockout.

Retry > maximum – last one due to no flame

270 Retry. If failed allowed times, go to Soft Lockout. Error 

counter cleared when exiting lockout.

Retry > maximum – last one due to low 

pressure switch open

271 Retry. If failed allowed times, go to Soft Lockout. Error 

counter cleared when exiting lockout.

Recycle > maximum – last one due to low 

pressure switch open

272 Retry. If failed allowed times, go to Soft Lockout. Error 

counter cleared when exiting lockout.

Recycle > maximum – last one due to flame 

lost in run mode

273 Retry. If failed allowed times, go to Soft Lockout. Error 

counter cleared when exiting lockout.

Limit switch open > 3 minutes

274 Soft Lockout. Error counter cleared when exiting lockout.

Flame out of sequence and flame is gone

275 Soft Lockout. Error counter cleared when exiting lockout.

Failed ignitor or trigger circuit

290 Soft Lockout. Error counter cleared when exiting lockout.

Available CFM below minimum firing rate

291 Soft Lockout. Error counter cleared when exiting lockout.

Circulator unable to start

292 Soft Lockout. Error counter cleared when exiting lockout.

Circulator RPM out of range (failed wheel)

293 Soft Lockout. Error counter cleared when exiting lockout.

Inducer over current

294 Soft Lockout. Send command to reset-motor. Error counter 

cleared when exiting lockout.

Rollout open or previously opened

200 Wait for rollout switch to close, then enter Hard Lockout. All 

error counters cleared after reset.

Hard 

Lockout

Furnace size select missing or mis-match with 

installed circulator motor

202 Hard Lockout. All error counters cleared after reset.

a

Recycle furnace power and perform operational check. If error repeats, there may be a permanent failure on the control board.

Table 12. LED Status Codes. (Continued)

Error/Fault Condition

Code

Error Handling 

(in addition to displaying error code)

Result

Содержание S9240F1004

Страница 1: ...Honeywell amplified gas air gas valve Controls a 3 phase 120 Vac inducer motor Fasco Model 92B1 or other with identical voltage frequency curve and blower assembly based on heat demand and other parameters Controls the Regal Beloit 3 0 ECM circulator motor and blower based on defined appliance CFM profiles and or a discharge air sensor signal Controls single stage or 2 stage cooling equipment The ...

Страница 2: ... Auto Restart Delay 60 minutes after Soft Lockout Ignition Trials Five total four retries if flame is not sensed on the first trial Ignition Recycles 4 total 3 recycles if flame lost on first trial Second Stage Recognition Delay 30 seconds only on First Call for High Fire on a Call for Heat Second Stage ON Delay 7 or 12 minutes when used with a single stage thermostat see Table 5 on page 8 default...

Страница 3: ...equipment damage or malfunction If the integrated furnace control must be mounted near water or moisture provide suitable waterproof enclosure Location The integrated furnace control is mounted on a panel within the circulator compartment of the furnace The location must provide Access to the field wiring terminals Operating ambient temperatures between 40 F and 175 F 40 C and 79 C Relative humidi...

Страница 4: ... screw Outdoor Sensor E4 Not used Discharge Air Sensor optional If used Discharge air sensor Straight Spade Quick Connect Flame Sense E42 Flame signal input 12 pin connector male terminals Main Harness J2 Main valve pressure switches rollout limit chassis ground and 24 Vac 6 pin connector male terminals Circulator Motor P79 Motor serial control interface and furnace size select input Table 2 Wirin...

Страница 5: ...ation disabled factory default CUT Harmony III and dehumidifying operation enabled M28148 EAC HUM HSI 3 1 1 7 4 10 6 9 3 12 15 17 16 14 18 19 L1 1 11 9 8 10 13 12 4 3 6 1 P80 1 2 3 4 5 6 7 2 NEUTRALS R C I I FLAME SENSE OUTDOOR SENSOR DISCHARGE AIR SENSOR I W914 DEHUM OR HARMONY W951 HEAT PUMP W915 2 STAGE COMPR CUT FOR OPTION SELECTION W1 W2 G Y2 Y1 DH H O DS C OUTDOOR EQUIPMENT INDOOR EQUIPMENT ...

Страница 6: ...NS 3 PHASE COMBUSTION AIR INDUCER 95V HSI FLAME ROD DISCHARGE AIR SENSOR OPTIONAL FLAME SENSE HUM EAC LINE VOLTAGE HUMIDIFIER OPTIONAL ELECTRONIC AIR CLEANER OPTIONAL REGAL BELOIT ECM 3 0 INDOOR AIR BLOWER 24 VAC MAIN VALVE LOW PRESSURE SWITCH HIGH LIMIT SWITCH ROLLOUT SWITCH HIGH PRESSURE SWITCH W951 W914 W915 24V HUMIDIFIER OPTIONAL L1 L2 1 2 P77 P79 J3 J2 E7 E4 M W1 G Y2 Y1 C R DH H L O DS W2 F...

Страница 7: ...espond to a thermostat as dictated by the SW1 selection The ON position configures the IFC for the Lennox modulating firing state sequence with 2 stage thermostat NOTE SW2 position is ignored if SW1 is ON SW3 2ND STAGE ON DELAY The On Delay timing applies to systems configured only with single stage thermostats It is the length of time operating in normal low fire mode before switching to high fir...

Страница 8: ...tat OFF Lennox modulating sequence with 2 stage thermostat ON 2nd Stage On Delay 7 minutes OFF 2nd Stage On Delay 12 minutes ON Heat Fan Off Delay 60 seconds OFF ON Heat Fan Off Delay 90 seconds OFF OFF Heat Fan Off Delay 120 seconds ON OFF Heat Fan Off Delay 180 seconds ON ON Low fan speed fan only operation OFF ON Medium low fan speed fan only operation OFF OFF Medium high fan speed fan only ope...

Страница 9: ...factory set cooling profile The fan speed ramps up and down during speed changes Fig 7 Fan cooling speed ramp up and ramp down profile factory default shown DIP SWITCH S2 M28152 COOLING PROFILE COOL SPEED 8 9 11 10 12 13 COOL SPEED ADJUSTMENT ON M28161 30 TIME SECONDS F A N S P E E D 50 82 100 30 1 1 FAN SPEED AS A PERCENT OF MAXIMUM 450 Table 6 DIP Switch S2 Settings Cooling Airflow Description I...

Страница 10: ...ith factory default settings all OFF DIP SWITCH S3 M28153 14 15 17 16 18 19 LOW HEAT CFM CHANGE 7 OR 15 LOW HEAT CFM NORMAL MODIFIED LOW HEAT CFM INCREASE DECREASE HIGH HEAT CFM CHANGE 7 OR 15 HIGH HEAT CFM NORMAL MODIFIED HIGH HEAT CFM INCREASE DECREASE ON Table 7 DIP Switch S3 Settings Heating Airflow Description Individual Switches SW14 SW15a a Switch 15 is ignored if switch 14 is in the OFF po...

Страница 11: ...ior to calibration NOTE The calibration process takes 60 to 120 seconds to complete successfully The LED flashes C A L during a the calibration cycle Successful Calibration Calibration data is stored in volatile memory and is used to determine furnace operation and control parameters in heating mode The IFC will not perform additional calibrations unless required by changes in the appliance s oper...

Страница 12: ...to maintain the target discharge air temperature The IFC remains in this state until the thermostat generates a 2nd stage call for heat or the 1st stage call for heat is removed Call for Stage 2 Heat A call for 2nd stage heat is signaled by the thermostat simultaneously closing the contacts R W1 and W2 On the first call for 2nd stage heat the request is ignored until the 2nd stage recognition dela...

Страница 13: ...ing profiles When the cool request is satisfied the circulator de energizes per one of the selectable ramping profiles Two Stage Cooling The two stage cooling jumpera on the IFC must be clipped to enable two stage cooling control A call for 1st stage cooling is signaled by The shorting of R to Y1 The shorting of R to Y1 and G simultaneously A call for 2nd stage cooling is signaled by the shorting ...

Страница 14: ...a thermostat reset at which time the IFC resumes normal operation See Table 12 on page 27 for LED error code and lockout information Limit Switch Circuit Operation during heat cycle NOTE If the limit switch circuit opens in any mode other than heat it is ignored If the limit switch circuit opens during a heating cycle The gas valve immediately de energizes The inducer de energizes after the postpu...

Страница 15: ...ggering circuit to energize the igniter are continuously monitored during the Igniter Warm up and Ignition Activation periods If a problem is detected the IFC flashes an LED error code See Table 12 on page 27 for LED error code and lockout information Humidity Control Humidity control is available via line voltage or low voltage operation Line Voltage Humidifier The line voltage humidifier output ...

Страница 16: ...od the ignition sequence proceeds as normal If however the sensed flame lasts longer than the Flame Debounce Period The igniter de energizes The inducer energizes at ignition fire rate speed and the circulator energizes at mid heat speed The IFC flashes an LED error code indicating the flame is sensed out of sequence Once the sensed flame goes away the IFC proceeds to Postpurge followed by Soft Lo...

Страница 17: ...de If the motor does not exit cutback mode the IFC reduces the input rate by another step and adjusts the CFM to match This sequence continues until the motor exits cut back mode c If the IFC has reduced the input rate down to minimum 40 and the RBC 3 0 motor is still in cutback mode the IFC shuts down the furnace activates the blower off delay enters soft lockout and flashes the appropri ate LED ...

Страница 18: ... 2 Set the thermostat to call for heat System should oper ate as indicated in Fig 9 on page 19 or Fig 12 on page 22 3 Following lockout open the manual gas valve and make sure no gas is flowing to the burner Operating Sequences Figures 9 through 14 beginning on page 19 describe the various operating cycles Light Off Heat Run Cool and Fan of the S9240F1004 Integrated Furnace Control IFC ...

Страница 19: ...G H T O F F Safety Check Circulator OFF After Heat Fan OFF Delay Low Heat Speed Verify There Is No Main Burner Flame YES YES Low Pressure Switch Opens High Pressure Switch Opens YES Inducer ON at Ignition Firing Rate Speed NO Pressure Switch Calibration Pre Purge 15 Seconds YES H S I ON 20 Seconds Gas Valve Energized Ignition Trial Begins H S I ON Heat Fan On Delay Timer Started Flame Sensed Withi...

Страница 20: ... Delay 30 Seconds YES Inducer ON High Fire Speed Increase Inducer Speed if Not at Maximum High Pressure Switch Closes Within 10 Seconds NO Error Code Flashes NO YES Wait 5 Minutes 3A 2 Adjust Circulator To Appropriate Speed SYSTEM WILL ALWAYS LIGHT ON LOW FIRE EVEN IF 2ND STAGE CALL FOR HEAT IS IN PLACE SPECIAL LENNOX MODULATING MODE HAS NOT BEEN SELECTED IF THE HIGH PRESSURE SWITCH DOES NOT CLOSE...

Страница 21: ...EAT COOL FLAME LEVEL 3 Call for Heat Satisfied 2nd Stage Call for Heat satisfied NO Inducer speed switched to Mid speed Adjust Circulator to appropriate speed 1st Stage Call for Heat satisfied Gas valve De Energized Inducer OFF after 20 second Post Purge Circulator OFF after OFF Delay YES M28156 NO Wait for Call 2 Stage Thermostat Wait for Call Single Stage Thermostat 1 4 3A 3B RUN MODE SINGLE STA...

Страница 22: ... After Heat Fan OFF Delay Low Heat Speed Verify There Is No Main Burner Flame YES YES Low Pressure Switch Opens High Pressure Switch Opens YES Inducer ON at Ignition Firing Rate Speed NO Pre Purge 15 Seconds YES H S I ON 20 Seconds Gas Valve Energized Ignition Trial Begins H S I ON Heat Fan On Delay Timer Started Flame Sensed Within 4 seconds H S I OFF Gas Valve De energized H S I OFF Interpurge 1...

Страница 23: ...ng Contactor Compressor Fan 1st Stage Cooling Request Still Active De Energize 2nd Stage Cooling Contactor Compressor Fan Energize and Maintain Circulator at Low Cooling mode Energize Circulator High Cooling mode Maintain Circulator High Cooling mode M28158 De energize Circulator Per Ramping Profile NO NO YES NO 5 2ND STAGE COOLING OPERATION REQUIRES A 2 STAGE THERMOSTAT A 2 STAGE COOLING SYSTEM A...

Страница 24: ...Received Request for Cooling Received NO YES Call for Fan Removed YES NO Maintain Circulator at set speed Maintain Circulator at set speed YES Maintain Circulator at set speed Go to Call for Cooling M28159 Go to Call for Heat 2 Stage Thermostat Go to Call for Heat Single Stage Thermostat 6 1 4 5 OR CIRCULATOR LOW COOLING MODE AND HIGH COOLING MODE HAVE SPECIFIC ON OFF AND SPEED RAMPING PROFILES TH...

Страница 25: ...er to Table 10 12 beginning on page 26 Pushbutton The pushbutton enables alternate modes of operation such as Field Test Mode and Diagnostic Recall mode A simple common use pattern is applied to maintain consistency By pressing and holding the pushbutton The LED cycles through three menu options Idle Diagnostic Recall Field Test Every 5 seconds a new menu item displays If the button is released wh...

Страница 26: ... display in idle mode Pressure switch proving states purge states HSI warm up TFI etc All transitional ignition states H Heating stage Shows what stage of furnace heating is currently operating Shown only while heating is active and unit is set up to work as staged equipment not modulating The display example in this table shows the LED display when the 1st stage heat is active H 1 Pause Display C...

Страница 27: ...e unit is providing dehumidification instead of straight cooling D Pause Display CFM Repeat Cooling Stage Shows what stage of cooling is currently operating The display example in this table shows the LED display when the 2nd stage cooling is active C 2 Pause Display CFM Repeat Defrost Mode Shown only while in an active defrost simultaneous Y W and O D F Pause Display CFM Repeat Table 12 LED Statu...

Страница 28: ...ut Retry maximum last one due to low pressure switch open 271 Retry If failed allowed times go to Soft Lockout Error counter cleared when exiting lockout Recycle maximum last one due to low pressure switch open 272 Retry If failed allowed times go to Soft Lockout Error counter cleared when exiting lockout Recycle maximum last one due to flame lost in run mode 273 Retry If failed allowed times go t...

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