Honeywell S9240F1004 User manual

INSTALLATION INSTRUCTIONS

69-2088-01

Automatic Ignition Systems

ANSI Z21.20

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

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 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.

• Controls a 120 Vac humidifier output and a 120 Vac

EAC output.

• Operates with 120 Vac single phase, 60 Hz power

supply.

• Uses a 7-segment LED display to communicate error

code and status information. A single on board button

is provided to generate the desired information

display.

• Provides field selectable DIP switches to select field

specific control operating parameters such as type of

thermostat, delay timings, and fan operating

parameters.

• Provides on-board jumpers that can be clipped to

permanently enable 2-stage cooling, heat pump

compatibility, dehumidification sequences, and define

appliance characteristics for field replacement

purposes.

• Provides Field Test Mode and Diagnostic Recall Mode

to assist the installation/service technician.

• Stores the 10 most recent error codes, which are

accessible by the service technician in Diagnostic

Recall Mode.

S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL

69-2088—01 2

SPECIFICATIONS

Electrical Ratings

Line Voltage Supply: 97-120 Vac, 58-62 Hz; single phase

(132 Vac and 62 Hz maximum)

Input Voltage: 18-24 Vac (30 Vac maximum)

Input Current: 500 mA (control only)

Current Draw: 0.5A Input Current plus valve load and

optional 24 VAC humidifier load at 24Vac

Igniter Current: 1.0A resistive at 95 Vac output

Induced Draft Blower: 33-110 Vac; 45-180 Hz; 1.1 A at

110 Vac 3-phase (full load)

Gas Valve: 1.5 A at 30 Vac; Inrush current 3.0 A at 30 Vac;

Inrush duration 16 ms

Line Voltage Humidifier: 1A resistive load maximum at

120 Vac

Electronic Air Cleaner: 1A resistive load maximum at

120 Vac

Gas Control: Honeywell VK8105R variable firing rate, 24 Vac

valve

Cooling Contactor: Any 24 Vac contactor rated at 1.0A or

less

Timings

Prepurge: 15 seconds

HSI Warm-up: 20 seconds

Trial for Ignition: 4 seconds

Ignition Stabilization Period: 10 seconds

Flame Failure Response Time: 2 seconds maximum

Gas Valve Sequence Period: 20 seconds

Postpurge: 20 seconds (15 seconds at current fire rate and 5

seconds at 40% fire rate)

Interpurge: 15 seconds

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 is

7 minutes

Third Stage ON Delay: 10 minutes - when used with a single

stage thermostat

Fan Delays:

Heat Fan ON Delay: 45 seconds

Heat Fan OFF Delay: 60, 90, 120, or 180 seconds; default

90 seconds; see Table 5 on page 8

Cool Fan ON Delay: 2 seconds plus selected Cooling Pro-

file; see Table 6 on page 9

Cool Fan OFF Delay: selected Cooling Profile; see Table 6

on page 9

Circulator Speeds:

Heat: various settings available; see Table 7 on page 10

Cool: low, medium-low, medium-high, and high speeds

available; see Table 6 on page 9

Fan - Thermostat “G”: low, medium-low, medium-high, and

high speeds available; see Table 5 on page 8

LED

The 7-segment LED communicates:

• System status

• Error codes

• Enables, via a pushbutton, alternate modes (Idle,

Diagnostic, and Field Test) of operation

Operating

Operating Temperature: -40°F to +175°F (-40°C to +79°C)

Storage Temperature: -40°F to +185°F (-40°C to +85°C)

Relative Humidity: 0% to 95% non condensing

Approvals

CSA

ANSI Z21.20

S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL

369-2088—01

INSTALLATION

When Installing This Product…

1. Read these instructions carefully. Failure to follow them

could damage the product or cause a hazardous condi-

tion.

2. Check the ratings given in these instructions to make

sure the integrated furnace control is suitable for your

application.

3. Installer must be a trained, experienced service techni-

cian.

4. After installation is complete, check out operation as

provided in these instructions.

WARNING

Fire or Explosion Hazard.

Can cause severe injury, death or property

damage.

1. The integrated furnace control can malfunction if it

gets wet, leading to accumulation of explosive gas.

— Never install where water can flood, drip or

condense on the IFC.

— Never try to use an integrated furnace control

that has been wet—replace it.

2. Liquefied petroleum (LP) gas is heavier than air

and will not naturally vent upward.

— Do not operate electric switches, lights, or

appliances until you are sure the appliance area

is free of gas.

WARNING

Electrical Shock Hazard.

Can cause severe injury, death or property

damage.

Disconnect power supply before beginning wiring or

making wiring connections to prevent electrical shock

or equipment damage.

CAUTION

Equipment Damage Hazard.

Water can cause 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 humidity below 95% non condensing.

— Protection from water, steam or corrosive chemicals that

are used to clean the appliance.

— Protection from dripping water, such as from an overfilled

humidifier or from condensation.

— Protection from dust or grease accumulation.

Mounting

The integrated furnace control is designed to snap into the

appliance mounting panel.

1. While holding the controller board with the thermostat

terminals (E7) at the bottom, insert the two left-side

hooks on the board into the holes in the mounting panel.

See Fig. 1 on page 5.

2. Press the board into the mounting panel’s right-side

holes until it snaps into place.

Wiring

Check the wiring diagrams furnished by the appliance

manufacturer, if available, for circuits differing from the

general hookup shown. Carefully follow any special

instructions affecting the general procedures outlined below.

All wiring must comply with local codes and ordinances.

See Table 1, Table 2, Table 3, and Fig. 1 beginning on page 4

for typical connections, but refer to furnace manufacturer

instructions, if available.

See Fig. 2 on page 6 for a typical wiring diagram.

S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL

69-2088—01 4

Table 1. Wiring Connections - Class 2 - Low Voltage.

Terminal Type Connection/Label

Board label

(see Fig. 1) Connects S9240F to:

12-position screw terminal block

(#5 screw)

Thermostat 1st stage heat input

W2 Thermostat 2nd stage heat input

G Thermostat continuous fan input

Y2 Thermostat 2nd stage cool input

Y1 Thermostat 1st stage cool input

C 24 Volt ground (connected to transformer and

chassis ground)

R 24 Volt hot

DH Not used

H - (optional) If used: 24V humidifier output

L Not used

O - (optional) If used: Thermostat signal to heat pump

reversing valve input

DS - (optional) If used: Thermostat Dehumidification or

Harmony Zoning input

4-position screw terminal block

(#5 screw)

Outdoor Sensor

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. Wiring Connections - Class 1 - Line Voltage.

Terminal Type Connection/Label

Board label

(see Fig. 1) Connects S9240F to:

2 pin connector (male terminals) Igniter P77 – HSI Igniter interface

3-pin connector (male terminals) CAI Connector J3 – CAI 3-phase AC power

Straight Spade Quick-connect Humidifier HUM Humidifier 120 Vac output

EAC EAC Electronic air cleaner 120 Vac output

Neutrals E36, E37,

E38, E39,

and E40

Any neutral connector can be used for:

•120 Vac Input neutral

•Transformer neutral

•Electronic air cleaner neutral

•Circulator neutral

•Humidifier neutral

S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL

569-2088—01

Fig. 1. Typical wiring connections and component locations for S9240F1004 Integrated Furnace Control

(minor components removed for clarity).

Table 3. Jumpers.

Jumper

Board label

(see Fig. 1) Action:

W915 - 2-Stage Compressor W915 UNCUT: Single stage compressor (factory default)

CUT: 2-stage compressor

W951 - Heat Pump W951 UNCUT: Compressor heating disabled (factory default)

CUT: Compressor heating enabled

W914 - Dehumidifier or Harmony III W914 UNCUT: Harmony III and dehumidifying operation disabled

(factory default)

CUT: Harmony III and dehumidifying operation enabled

M28148

EAC HUM

HSI

410

312

15 17

1614 1819

119

810 13

P80

1234567

NEUTRALS

RCI –I +

FLAME

SENSE

OUTDOOR

SENSOR

DISCHARGE

AIR SENSOR

I+

W914

DEHUM

HARMONY

W951

HEAT

PUMP

W915

2 STAGE

COMPR

CUT FOR

OPTION

SELECTION

W1 W2 G Y2 Y1 DH H O DSC

OUTDOOR

EQUIPMENT

INDOOR

EQUIPMENT

RCI –I +

I –

TEMPERATURE SENSORS – E4

LED

P79

CIRCULATOR

MOTOR

HARNESS

MAIN

HARNESS

NEUTRALS

E36, E37, E38, E39, AND E40

HUMEAC

W914

DEHUM

HARMONY

W951

HEAT

PUMP

W915

2-STAGE

COMPR

P77

HSI

ON ON

FACTORY USE ONLY.1

50029412-001 Rev. A

SIDE HOOK (X2)

FOR

PANEL MOUNTING

S3 S2 S1 PUSH BUTTON E42 – FLAME SENSE J3 – CAI

S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL

69-2088—01 6

Fig. 2. Typical wiring diagram for S9240F1004 Integrated Furnace Control.

312 4

3511 6 1218472109

213

M28147

120 V / 60 HZ

AC MAINS

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)

P77

P79

FURNACE SIZE

IDENTIFIER

L2 L1

S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL

769-2088—01

SETTINGS AND ADJUSTMENTS

Jumpers

Three jumpers are located on the S9240 board. The jumpers

are all ON (uncut) from the factory. To change any jumper, first

disconnect the power, then cut the desired jumper.

Fig. 3. Jumper locations.

DIP Switches

There are three DIP switch blocks on the S9240F (see Fig. 4):

• S1 – see “DIP Switch S1 Settings”

• S2 – see “DIP Switch S2 Settings – Cooling Airflow” on

page 9.

• S3 – see “DIP Switch S3 Settings – Heating Airflow” on

page 10.

Fig. 4. DIP Switch locations (S1, S2, and S3).

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.

The default factory settings (all OFF) are shown in Fig. 5 and

indicated in Bold in Table 5 on page 8.

To change any setting, first disconnect the power, then set

SW1 through SW7 according to Table 5 on page 8.

Fig. 5. DIP Switch S1 - shown with factory default

settings; all OFF.

SW1: STAGE SELECTION

The stage selection is factory-set (OFF) to a 2-stage

thermostat with the 2nd and 3rd stage On Delays disabled.

The ON position configures the IFC for a single stage

thermostat with the 2nd and 3rd stage On Delays enabled.

NOTE: Selection of the single stage position (ON) allows

three stage operation with a single stage thermostat.

SW2: SEQUENCE

The sequence is factory-set (OFF) to respond 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 fire mode. The

timing is factory-set (OFF) to 7 minutes.

The ON position configures the 2nd stage On Delay for 12

minutes.

NOTE: SW3 position is ignored if SW1 is OFF.

SW4-5: HEAT FAN OFF DELAY

The Heat Fan Off Delay is the period between the loss of

supervised main burner flame after the call for heat has ended

and the deactivation of the blower motor at the low heat

speed. The timing is factory-set (all OFF) to 90 seconds. See

Table 5 on page 8 for other timing settings.

SW6-7: FAN SPEED – THERMOSTAT “G”

The fan speed is factory-set (all OFF) to Medium-low. See

Table 5 on page 8 for other speed settings.

Table 4. Jumper Conditions - Defaults in Bold.

Description

Jumper

W915 W951 W914

Single stage compressor Uncut

2-stage compressor Cut

Disable compressor heating Uncut

Enable compressor heating Cut

Disable Harmony III and

dehumidifying operation

Uncut

Enable Harmony III and

dehumidifying operation

Cut

M28149

W915 - 2 STAGE COMPRW914 - DEHUM/HARMONY

W951 - HEAT PUMP

M28150

S3 S1

DIP SWITCH S1

M28151

HEAT FAN OFF DELAY

2ND STAGE ON DELAY

SINGLE OR 2-STAGE THERMOSTAT

SELECTION

12 43576

FAN SPEED - THERMOSTAT “G”

CONVENTIONAL 2-STAGE OR

LENNOX MODULATING SEQUENCE

S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL

69-2088—01 8

Table 5. DIP Switch S1 Settings - Defaults in Bold.

Description

Individual Switches

SW1 SW2aSW3bSW4 SW5 SW6 SW7

2-Stage Thermostat: 2nd and 3rd stage On Delay disabled OFF

Single Stage Thermostat: 2nd and 3rd stage On Delay enabled ON

Conventional 2-stage sequence with 2-stage thermostat 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 operation) ON OFF

High fan speed (fan only operation) ON ON

aSwitch 2 is ignored if switch 1 is in the ON position.

bSwitch 3 is ignored if switch 1 is in the OFF position.

S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL

969-2088—01

DIP Switch S2 Settings – Cooling Airflow

DIP Switch S2 is used to adjust the cooling speed and profile.

Refer to Fig. 4 on page 7 for location of DIP switch S2.

The default factory settings (all OFF) are shown in Fig. 6 and

indicated in Bold in Table 6.

To change any setting, first disconnect the power, then set

SW8 through SW13 according to Table 6.

Fig. 6. DIP Switch S2 - shown with factory default

settings; all OFF.

SW8-9: COOLING FAN SPEED

The fan speed during cooling is factory-set to High.

SW10-11: COOLING FAN SPEED ADJUSTMENT (CFM)

The fan CFM during cooling is factory-set to normal (Base

Tap).

SW12-13: COOLING PROFILE

The fan profile during cooling is factory-set to 30 seconds at

50%, 7.5 minutes at 82%, run at 100%, and with a 30 second

Off delay at 50%. Fig. 7 illustrates the 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

89 1110 12 13

COOL SPEED ADJUSTMENT

M28161

TIME (SECONDS)

50%

82%

100%

1FAN SPEED AS A PERCENT OF MAXIMUM.

450

Table 6. DIP Switch S2 Settings – Cooling Airflow.

Description

Individual Switches

SW8 SW9 SW10 SW11 SW12 SW13

High Cool Speed (circulator) OFF OFF

Medium-low Cool Speed (circulator) OFF ON

Medium-high Cool Speed (circulator) ON OFF

Low Cool Speed (circulator) ON ON

Normal CFM - Base tap OFF OFF

Decrease Cool speed CFM by 10% OFF ON

Increase Cool speed CFM 10% ON OFF

ECM Test Mode (motor slew rates disabled) ON ON

Cooling Profile -

On: 30 seconds at 50%, 7.5 minutes at 82%, then run at 100%

Off: 30 second Off Delay at 50%

OFF OFF

Cooling Profile -

On: No On Delay (run at 100%)

Off: 60 second Off Delay at 100%

OFF ON

Cooling Profile -

On: 7.5 minutes at 82%, then run at 100%

Off: no Off Delay

ON OFF

Cooling Profile - no On or Off Delays ON ON

S9240F1004 MODULATING HOT SURFACE IGNITION INTEGRATED FURNACE CONTROL

69-2088—01 10

DIP Switch S3 Settings – Heating Airflow

DIP Switch S3 is used to adjust the heating airflow (CFM).

Refer to Fig. 4 on page 7 for location of DIP switch S3.

The LOW heat CFM setting adjusts the heating CFM that

corresponds to the lowest firing rate of the appliance. The

HIGH heat CFM setting adjusts the heating CFM that

corresponds to the highest firing rate of the appliance. The

CFMs between these two points are interpolated linearly.

The default factory settings (all OFF) are shown in Fig. 8 and

indicated in Bold in Table 7.

To change any setting, first disconnect the power, then set

SW14 through SW19 according to Table 7.

Fig. 8. DIP Switch S3 - shown with factory

default settings; all OFF.

DIP SWITCH S3

M28153

14 15 1716 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)

Table 7. DIP Switch S3 Settings – Heating Airflow.

Description

Individual Switches

SW14 SW15a

aSwitch 15 is ignored if switch 14 is in the OFF position.

SW16b

bSwitch 16 is ignored if switch 14 is in the OFF position.

SW17 SW18c

cSwitch 18 is ignored if switch 17 is in the OFF position.

SW19d

dSwitch 19 is ignored if switch 17 is in the OFF position.

Normal Low Heat CFM OFF

Modified Low Heat CFM ON

Increase Low Heat CFM OFF

Decrease Low Heat CFM ON

Change Low Heat CFM by 7% OFF

Change Low Heat CFM by 15% ON

Normal High Heat CFM OFF

Modified High Heat CFM ON

Increase High Heat CFM OFF

Decrease High Heat CFM ON

Change High Heat CFM by 7% OFF

Change High Heat CFM by 15% ON

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