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Honeywell S9240F1004 Installation Instructions Manual

Modulating hot surface ignition integrated furnace control
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S9240F1004 Modulating Hot Surface
Ignition Integrated Furnace Control
APPLICATION
The S9240F1004 Integrated Furnace Control (IFC) is
designed specifically to work with a Lennox G71MPP variable
firing rate, high efficiency furnace. It provides gas ignition,
safety shutoff, and variable speed fan control with multi-firing
rate gas heating and up to 2-stage electric cooling
applications.
FEATURES
The S9240F1004 provides the following features:
• Monitors a single stage or 2-stage conventional low
voltage thermostat for requests for heat, cool, or fan.
• Monitors an input provided for connection to a
thermostat with a dehumidification output or Harmony
III Zone Control.
• Provides three stage furnace input rate control when
operating with a conventional single stage thermostat.
• Provides 2-stage or modulating furnace input rate
control based on field selected option when operating
with a conventional 2-stage thermostat.
• Manages ignition of a main burner flame up to 400,000
BTU per hour using a 95 V hot surface igniter.
• Monitors the appliance pressure, limit, and rollout
switches and generate control actions as
programmed.
• Controls the 24 Vac Honeywell amplified gas/air gas
valve.
• Controls a 3-phase 120 Vac inducer motor (Fasco
• Controls the Regal Beloit 3.0 ECM circulator motor and
• Controls single stage or 2-stage cooling equipment.
• Controls a 120 Vac humidifier output and a 120 Vac
• Operates with 120 Vac single phase, 60 Hz power
• Uses a 7-segment LED display to communicate error
• Provides field selectable DIP switches to select field
• Provides on-board jumpers that can be clipped to
• Provides Field Test Mode and Diagnostic Recall Mode
• Stores the 10 most recent error codes, which are
Automatic Ignition Systems
®
ANSI Z21.20
INSTALLATION INSTRUCTIONS
Model 92B1 or other with identical voltage/frequency
curve) and blower assembly based on heat demand
and other parameters.
blower based on defined appliance CFM profiles
and/or a discharge air sensor signal.
The outdoor unit is controlled directly by the 24 Vac
conventional thermostat inputs. The IFC manages the
circulator speed based on cool demand and other
parameters.
EAC output.
supply.
code and status information. A single on board button
is provided to generate the desired information
display.
specific control operating parameters such as type of
thermostat, delay timings, and fan operating
parameters.
permanently enable 2-stage cooling, heat pump
compatibility, dehumidification sequences, and define
appliance characteristics for field replacement
purposes.
to assist the installation/service technician.
accessible by the service technician in Diagnostic
Recall Mode.
69-2088-01

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  Summary of Contents for Honeywell S9240F1004

  • Page 1 • Controls the 24 Vac Honeywell amplified gas/air gas • Provides Field Test Mode and Diagnostic Recall Mode valve. to assist the installation/service technician. • Stores the 10 most recent error codes, which are accessible by the service technician in Diagnostic Recall Mode.
  • Page 2: Specifications

    S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL SPECIFICATIONS Second Stage ON Delay: 7 or 12 minutes - when used with a single stage thermostat (see Table 5 on page 8); default is 7 minutes Electrical Ratings Third Stage ON Delay: 10 minutes - when used with a single stage thermostat Line Voltage Supply: 97-120 Vac, 58-62 Hz;...
  • Page 3: Installation

    S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL INSTALLATION CAUTION Equipment Damage Hazard. When Installing This Product… Water can cause equipment damage or 1. Read these instructions carefully. Failure to follow them malfunction. could damage the product or cause a hazardous condi- If the integrated furnace control must be mounted near tion.
  • Page 4 S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL Table 1. Wiring Connections - Class 2 - Low Voltage. Board label Terminal Type Connection/Label (see Fig. 1) Connects S9240F to: 12-position screw terminal block Thermostat 1st stage heat input (#5 screw)
  • Page 5 DEHUM HEAT 2-STAGE MAIN CIRCULATOR E36, E37, E38, E39, AND E40 HARNESS MOTOR PUMP COMPR HARMONY HARNESS FACTORY USE ONLY. M28148 Fig. 1. Typical wiring connections and component locations for S9240F1004 Integrated Furnace Control (minor components removed for clarity). 69-2088—01...
  • Page 6 W914 AIR CLEANER (OPTIONAL) FURNACE SIZE IDENTIFIER HIGH REGAL PRESSURE BELOIT SWITCH MAIN ECM 3.0 VALVE INDOOR AIR BLOWER ROLLOUT HIGH SWITCH LIMIT PRESSURE SWITCH SWITCH 24 VAC M28147 Fig. 2. Typical wiring diagram for S9240F1004 Integrated Furnace Control. 69-2088—01...
  • Page 7: Settings And Adjustments

    S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL SETTINGS AND ADJUSTMENTS DIP Switch S1 Settings Five parameters may be set with this 7-position DIP switch. Refer to Fig. 4 for location of DIP switch S1. Jumpers The default factory settings (all OFF) are shown in Fig. 5 and Three jumpers are located on the S9240 board.
  • Page 8 S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL Table 5. DIP Switch S1 Settings - Defaults in Bold. Individual Switches Description 2-Stage Thermostat: 2nd and 3rd stage On Delay disabled Single Stage Thermostat: 2nd and 3rd stage On Delay enabled...
  • Page 9 S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL DIP Switch S2 Settings – Cooling Airflow SW8-9: COOLING FAN SPEED The fan speed during cooling is factory-set to High. DIP Switch S2 is used to adjust the cooling speed and profile.
  • Page 10 S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL DIP Switch S3 Settings – Heating Airflow DIP SWITCH S3 DIP Switch S3 is used to adjust the heating airflow (CFM). Refer to Fig. 4 on page 7 for location of DIP switch S3.
  • Page 11: Check Normal Operation

    S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL CHECKOUT NOTE: The calibration process takes 60 to 120 seconds to complete successfully. The LED flashes “C A L” during a the calibration cycle. Check out the integrated furnace control system: — At initial installation of the IFC.
  • Page 12: Normal Heat Mode - Conventional 2-Stage Thermostat (Standard 2-Stage Operation Selected)

    S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL Call for Stage 2 Heat — The IFC verifies the limit and rollout switch circuits are closed. A call for 2nd stage heat is signaled by the thermostat — The IFC verifies the low and high pressure switch simultaneously closing the contacts R, W1, and W2.
  • Page 13: Normal Heat Mode - Conventional Single Stage Thermostat

    S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL Normal Heat Mode - Conventional Single — The circulator starts according to one of the selectable ramping profiles. Stage Thermostat When the cool request is satisfied, the circulator de-energizes Refer to Fig. 12 on page 22 for the operating sequence per one of the selectable ramping profiles.
  • Page 14: Ignition Retry

    S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL Ignition Retry Limit Switch Circuit Operation (during heat cycle) When flame is not sensed during the Trial for Ignition or is lost less than 10 seconds after exiting Trial for Ignition: — The gas valve is de-energized.
  • Page 15: Humidity Control

    S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL Humidity Control • This process repeats until the calibration routine is successful or the call for heat ends. Humidity control is available via line voltage or low voltage — If the low pressure switch opens for less than two operation.
  • Page 16: Error Conditions

    S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL Error Conditions If the sensed flame goes away before the Flame Debounce Period, the ignition sequence proceeds as normal. If however, The following section lists the IFC operating sequence for the the sensed flame lasts longer than the Flame Debounce stated error conditions.
  • Page 17: Standby Mode

    S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL — If the HSI triggering circuitry is sensed as shorted mum for the duration of the heat cycle, and while waiting for the low pressure switch to close or flashes the appropriate LED error code.
  • Page 18: Check Safety Shutoff Operation

    S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL Check Safety Shutoff Operation Operating Sequences 1. Shut off the gas supply at the manual gas valve ahead Figures 9 through 14 beginning on page 19 describe the of the appliance. various operating cycles (Light Off, Heat, Run, Cool, and Fan) 2.
  • Page 19 S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL 1. Light Off and Call for 1st Stage Heat (2-Stage Thermostat) Safety Check Verify There Is No Main Burner Flame Circulator OFF After Heat Fan OFF Delay (Low Heat Speed) Limit Limit...
  • Page 20 S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL 2. Call for 2nd Stage Heat (2-Stage Thermostat) 2 Stage Thermostat 1st Call for High Fire? 2nd Stage Recognition Delay (30 Seconds) Inducer ON (High Fire Speed) High Increase Pressure Switch Error Code...
  • Page 21 S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL 3. Call for Heat Satisfied RUN MODE (2-STAGE THERMOSTAT): RUN MODE (SINGLE STAGE THERMOSTAT): 1ST OR 2ND STAGE CALL FOR HEAT. ALL INPUTS MONITORED (LIMIT, PRESSURE, ALL INPUTS MONITORED (LIMIT, PRESSURE, CALL FOR HEAT/COOL, FLAME LEVEL).
  • Page 22 S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL 4. Light Off and Call for Heat (Single Stage Thermostat) Safety Check Verify There Is No Main Burner Flame Circulator OFF After Heat Fan OFF Delay (Low Heat Speed) Limit Limit De-Energize...
  • Page 23 S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL 5. Call for Cooling 1st Stage Cooling Request Received Energize 1st Stage Cooling Contactor (Compressor & Fan) Circulator ON After 2 Second Delay Energize Circulator (Per Ramping Profile) 1st Stage 2nd Stage...
  • Page 24 S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL 6. Call for Fan Call for Fan Circulator ON (Speed Determined by Dip Switch settings) Request Maintain Circulator at for Cooling Go to Call for Cooling set speed Received? Go to Call for Heat - 2 Stage Thermostat...
  • Page 25: Troubleshooting

    S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL TROUBLESHOOTING Pushbutton The pushbutton enables alternate modes of operation such as Field Test Mode and Diagnostic Recall mode. A simple, WARNING common use pattern is applied to maintain consistency. Fire, Explosion, or Electrical Shock Hazard.
  • Page 26 S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL Field Test Mode No safety control or other safety related parameters are bypassed during Field Test Mode. In Field Test Mode you can: • Initiate furnace light-off sequence and move to and hold Normal routines (like changing CAI speed if the high pressure low firing rate by applying a W1 signal.
  • Page 27: Led Error Codes

    S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL Compressor Heating/Cooling Display – System Status Table 11. Compressor Heating/Cooling LED Display. Display Example Description (LED display in bold) Heating Stage: Shows what stage of furnace heating is currently operating. Shown only while heating is Pause active and unit is set up to work as staged equipment (not modulating).
  • Page 28: Error Handling

    S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL Table 12. LED Status Codes. (Continued) Error Handling Error/Fault Condition Code (in addition to displaying error code) Result Low pressure switch failed (stuck) Closed 224 Resume normal operation after fault removed. High pressure switch failed (stuck) Open 225 Increase inducer RPM every few seconds.