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SV9440, SV9540, AND SV9640 SMARTVALVE™ SYSTEM CONTROLS

69-1227—02

10

Fig. 12. Typical wiring connections for two-stage application with ST9162 Electronic Fan Timer.

STARTUP AND CHECKOUT

Ignition System Control Switch 
Settings

Ignition system control switch settings are as follows:

OFF: Prevents pilot and main gas flow through the 

ignition system control.

ON: Permits gas to flow through the control body. At the 

appropriate time in the appliance operation, main gas 

can flow to the main burner. 

NOTE:

Controls are shipped with the ignition system 

control switch in the ON position. If the appli-

ance is operated with the ignition system con-

trol switch in the OFF position, the system will 

respond like the air proving switch is stuck in 

the no airflow position.

Turn on Main Burner

Follow the appliance manufacturer instructions or turn 

up the thermostat to call for heat.

Perform Gas Leak 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 II

INTERMITTENT

PILOT

ST9162

FAN BOARD

(TYPICAL)

2

6

1

5

4

3

1

2

3

4

ON

G

Y

W1

W2

C

R

COM 24 VAC

CONT

HUM

EAC

COOL

HEAT H

M1

M2

NEUTRALS

L1

XFMR 

MTR

IND HIGH

IND IN

IND LOW

HEA

T  LOW

THERMOSTAT

CONTINUOUS FAN SPEED
NEUTRAL
COOL SPEED
HEAT HIGH SPEED
HEAT LOW SPEED

INDUCER LOW

INDUCER HIGH
NEUTRAL

AIR

LO

HI

INDUCER

MAIN

BLOWER

ROLLOUT

SWITCH

PRESSURE

SWITCH

LIMIT 

SWITCH

40VA

TRANSFORMER

24 VAC

COM

LOAD

COM

NEUTRAL

NEUTRAL

SW SPST

F1

FUSE

L1

L1

L2 (NEUTRAL)

L1

INDUCER IN

INDUCER RETURN

SENSE

24 VAC HI

HSI N

2 STAGE

-

+

DATA
24 VAC
R
C

M10969D

C (MTR PIN3)

Y (MTR PIN2)

G (MTR PIN1)

W2 (MTR PIN5)

W1 (MTR PIN6)

Y2 (MTR PIN4)

1

1

GROUPED CABLE

Q3450 

IGNITER-

SENSOR

SV9440

SV9540

SV9640

C1

C2

C3

Содержание SV9440

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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