5742637-YIM-D-0620
Johnson Controls Ducted Systems
63
(white and red on single stage models). If it is less than
177 volts, then check and repair the power circuit to the
draft motor. If the voltage is greater than 176 volts and
the draft motor is not turning, then disconnect power
and draft motor power leads. Measure the resistance of
the draft motor windings. If an open circuit exists in the
motor, then replace the draft motor. If the voltage is
greater than 176 volts and the motor is turning, then
check the centrifugal switch wiring between the ICB and
the draft motor. If OK, then disconnect power to the unit
and place the gas valve in the off position. Prepare to
temporarily jumper the wires connected to terminals 3
and 8 of the ICB 9 pin harness connector by
disconnecting the draft motor leads from the 9 pin
harness. Restore the power to the unit and induce a call
for heat. Jumper wires 3 and 8. If the ignition sequence
is started after 15 seconds (audible sparking of the
igniter), then replace the draft motor reconnecting the
centrifugal switch wiring per the wiring diagram. If not,
then replace the ICB, remove the jumper and reconnect
the centrifugal switch wiring per the wiring diagram.
Place the gas valve in the on position and verify proper
furnace operation.
2.
If the flash code indicates the switch is closed with the draft
(inducer) motor off (flash code 3), then disconnect the 9 pin
connector from the ICB and measure the continuity of the
centrifugal switch with a battery powered test light or an
ohm meter between terminals 3 and 8 of the harness
connector. If a closed circuit is indicated, then check the
wiring between the ICB and the draft motor. If the wiring is
not shorted together, then replace the draft motor. If an
open circuit is indicated, then reconnect the 9 pin wiring
harness to the ICB and remove power to the unit for at
least 20 seconds. Restore power to the unit. If the ICB
continues to flash a code 3, then replace the ICB.
Pilot Flame Lockout
The ICB counts the number of flame losses during the same call
for heat. If more than 16 flame losses occur within the same call
for heat, then the control temporarily locks out furnace operation
for 5 minutes (flash code 5). If the call for heat remains after the
5 minutes, then the ICB will retry the ignition sequence. The
flame losses can be due to low inlet pressure, debris around
flame sensor, plugged pilot burner, soot on the surface of the
flame sensor or misadjusted pilot pressure. Remove the power
to the unit for 20 seconds and then restore power to the unit.
Induce a call for heat and observe the pilot flame in the flame
sensor area to determine the best course of action.
1.
If the flame is strong and stable in the flame sensor area,
then verify the position of the flame sensor per the start up
procedures. If ok, then remove the flame sensor and check
the cleanliness of the electrode. If clean, then replace the
flame sensor and adjust pilot per the start up procedures. If
not clean, then clean, reinstall and adjust pilot per the start
up procedures.
2.
If the flame is weak or unstable in the flame sensor area,
then verify the gas inlet pressure. If gas inlet pressure is
above the minimum inlet pressure stated on unit data label,
then adjust the pilot pressure per the start up procedures. If
the pilot cannot be adjusted to obtain a strong and stable
flame in the flame sensor area, then remove the burner
assembly and verify the pilot burner assembly is open
internally and the holes in the burner are clean. Check the
pilot orifice size to the unit data plate and the cleanliness of
the pilot orifice. Verify that the flame sensor electrode is
clean and is adjusted properly. After cleaning or
replacement of the pilot assembly components, reinstall the
burner assembly and adjust pilot per the start up procedure.
Primary or Aux Temperature Limit
The temperature limits limit the temperature in the furnace to a
safe level. If a temperature higher than the preset limit is
achieved due to low or no air flow through the furnace, then the
temperature limits opens and the ICB closes the gas valve and
flashes code 6. The primary limit is automatic reset type while
the auxiliary limit is manual reset type. If either one opens, then
the ICB removes power to the gas valve and the UCB
energizes the indoor blower until the primary limit automatically
resets or the auxiliary limit is manually reset. Verify adequate air
flow through the furnace. If air flow is nonexistent or weak, then
troubleshoot and repair the conditioned space air circulation
system as necessary. Reset the auxiliary limit and verify proper
operation of the furnace. If airflow is normal, then verify the gas
input rate to the furnace following the start up procedures
(auxiliary limit must be reset before the furnace will operate). If
after verifying the circulating air system, the input rate to the
furnace and that the air temperature rise through the furnace is
within the rise range on the unit data plate the flash code still
exists, then set the gas valve to the off position and temporarily
apply control voltage (~24 volts) to pin 9 of the 9 pin ICB
connector. With power applied to the unit, if the ICB LED
continues to flash a code 6, then replace the ICB and return unit
to operation (you must remove the temporary voltage to pin 9
before the gas valve is turned on). If the ICB LED flashes a
heartbeat, then replace the limit that is opening, remove the
temporary voltage applied to pin 9, turn on the gas valve, restart
the furnace and verify proper operation of the furnace.
Roll-out Switch
The roll-out switch is installed to protect the furnace from
damage due to excessive heat in the burner area. There are 4
main reasons the roll-out switch will open (flash code 7) due to
excessive heat in the burner area. You must remove power to
the unit for 20 seconds to reset the ICB.
1.
A blocked flue outlet is the most common cause for the roll-
out switch to open. Check the flue outlet for debris and
clear if necessary.
2.
Loose blower wheel on draft motor. Verify that the blower
wheel is securely fastened to the draft motor shaft.
3.
Unit operating outside the air temperature rise range stated
on the unit data plate. Either the air flow through the
furnace is not sufficient or the gas input rate to the furnace
exceeds the recommended rate. Verify both conditions are
within the published ranges.
4.
Cracked heat exchanger tube(s). If a heat exchanger tube or
tubes is cracked, then the flow through the heat exchanger