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Johnson Controls
Start-Up & Operation Guide | 5586996-JSG-A-0120
55
Operation
•
When flame rectification is established, the con
-
troller enters a warm-up cycle to ensure flame sta
-
bilization and to reduce condensation forming in
the heat exchanger
• After completing the warm-up cycle, the controller
enters the run cycle
• During the run cycle, the burner firing rate
and draft inducer pressure are determined
based on the heating demand sent via Mo-
dus from the unit controller
• The unit controller determines when more
or less heating capacity is needed and com-
municates this via Modbus to the modulating
gas controller
• The run cycle terminates when
• The heating demand is removed
• Any of the gas heat safeties open
• The control reaches its maximum runtime
of 6 hours. When this limit is reached, the
control terminates the run cycle and im-
mediately re-enters heating operation
when a heating demand still exists
• After terminating the run cycle, the 2-stage gas
valve closes and the modulating gas valve returns
to a set position
• The inducer is controlled to the light-off setting for
a 45-second post-purge cycle
• After completing the post-purge cycle, the control-
ler enters the off cycle. In the off cycle, all outputs
are de-energized but all safeties are still monitored
• When more heating capacity is needed, the unit
controller starts staging on other burners (2, 3, or
1B)
Table 24: Modulating Gas Heating Faults List
LED Display Diagnostic Code
Type
Description
888
1
Lockout
Board failure (also during power up)
OFF
2
Status
UP mode: burner state = OFF
Pur
3
Status
UP mode: burner state = Purge
16n
Status
UP mode: burner state = Ignition
HEA
Status
UP mode: burner state = Warm-up
run
Status
UP mode: burner state = Run
rEt
4/5
Status
UP mode: burner state = Retry
A01
4
Alert
Failed ignition attempt
A02
5
Alert
Lost flame
A03
6
Alert
Insufficient combustion air—auto-derating
A04
7
Alert
Limited low fire (due to lost flame auto adaption)
A05
8
Alert
Weak flame signal, main burner
A06
9
Alert
Reserved
A07
33
Alert
Air modulating failure (inducer isn’t modulating down)
A08
34
Alert
Air sensor null pressure check (out of tolerance)
A11
24
Alert
Failed ignition, split manifold burner, retries exhausted
A15
10
Alert
Weak flame signal, one or more split manifold staged burners
E01
11
Lockout
Failed ignition, retries exhausted
E02
12
Lockout
Primary limit failure (or open fuse)
E03
13
Lockout
Modulating valve failure
E04
14
Lockout
Air pressure sensor reading low (pressure switch failed to open or
insufficient air/blocked vent)
E05
15
Lockout
Air pressure sensor reading high (pressure switch failed to close)
E08
18
Lockout
Unexpected flame, main burner
E09
19
Lockout
No R-W enable signal during CFH
E13
23
Lockout
Open fuse
E18
22
Lockout
Unexpected flame, split manifold burner
Ed
20
Lockout
Invalid ID, plug installed
None
None
Lockout
Board not receiving 24 volts