Instruction Manual for ICM CONTROLS models including: ICM292A, 62-24140-04, ICM292A DSI Gas Ignition Replacement Control Board, Ignition Replacement Control Board, Replacement Control Board, Control Board, Board
ICM Controls ICM292A DSI Gas Ignition Replacement Control Board For Rheem 62-24140-04
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DocumentDocumentINSTALLATION, OPERATION & APPLICATION GUIDE For more information on our complete range of American-made products plus wiring diagrams, troubleshooting tips and more, visit us at www.icmcontrols.com ICM292A Gas Ignition Control Board 5018419 FEATURES · Direct Spark Ignition (DSI) control board · Microprocessor-based · Controls inducer motors, air cleaner (if equipped), humidifier (if equipped), spark ignitor and the gas valve · 100% lockout safety feature · Monitors timing, trial for ignition, vent pressure switch, limit switches (main and over-temperature switches in series), flame sensing and lockout · Compatible with LP or natural gas · LED indication for status and fault codes to aid in troubleshooting · Replaces: Rheem 62-24140-04 SAFETY CONSIDERATIONS Only trained personnel should install or service heating equipment. When working with heating equipment, be sure to read and understand all precautions in the documentation, on labels, and on tags that accompany the equipment. Failure to follow all safety guidelines may result in damage to equipment, severe personal injury or death. INTRODUCTION The ICM292A DSI gas ignition control replaces the following Rheem model: 6224140-04. The ICM292A has incorporated LED diagnostics to assist in troubleshooting. Fault code information can be found in this application guide. Please keep this application guide with the furnace installation manual for future reference. SPECIFICATIONS · Line voltage: 115 VAC, 60 Hz TIMING · Control voltage: 18-30 VAC, 60 Hz · Pre-purge: 30 seconds · Power consumption: 0.3A plus gas valve current · Trial for ignition: 7 seconds @ 24 VAC · Retries: Two groups of two: 1st · Operating temperature: -40°C (-40°F) to 75°C trial, 30 seconds delay, 2nd trial. (176°F) 3 minutes delay. 3rd trial, 30 OUTPUTS · Gas valve: 3A Pilot Duty @ 24 VAC · Draft inducer motor: 3A max., 1/6HP @ 125 VAC · Cool blower speed: 16A max., 1/2HP @ 277 VAC · Heat blower speed: 14A max., 1/2HP @ 277 VAC · Fan blower speed: 12A max., 1 HP @ 125 VAC · Heat/cool single-speed: 10 A max., 1/2 HP @ seconds delay, 4th trial. Lockout. · Lockout: 1 hour · Heat blower ON delay: 20 seconds · Post-purge: 10 seconds · Heat blower OFF delay: Toggle switches SW1 and SW2 277 VAC TIME SW1 · Electronic Air Cleaner: 10 A max., 1HP @ 125 VAC 90 sec OFF · Humidifier: 11 A max., 1/6HP @ 125 VAC 120 sec OFF SW2 ON OFF LED INDICATORS · Power, green LED: PWR · Status, green LED: OK 160 sec ON OFF 180 sec ON ON · Flame status, yellow LED: FLAME OPERATION A W call from the thermostat engages the Inducer Draft motor, provided that the system safety switches (Main and Over-temperature switches in series) are closed. The Vent Pressure switch closes. After a 30 second pre-purge, gas valve and spark are engaged. The ignitor turns off after flame is sensed or at the end of the trial for ignition, whichever comes first. If flame is not sensed, the board performs a retry. When flame is sensed, previous retries are cleared. After the Heat blower On-delay, the Blower motor engages at HEAT speed. When W call is satisfied, the gas valve is turned off. The Inducer motor turns off after 10 seconds and Blower motor turns off according to Heat Blower Off-delay setting. A G call from the thermostat will engage Blower motor without delay at FAN speed. It disengages without delay when G call is removed. A Y call from the thermostat will engage Blower motor without delay at COOL speed. It disengages 45 seconds after Y call is satisfied. ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS 1. Disconnect all power to the furnace. Do not touch the control or the wiring prior to discharging your body's electrostatic charge to ground. CAUTION! Use caution when installing and servicing the furnace to avoid and control electrostatic discharge; ESD can impact electronic 2. To ground yourself, touch your hand and components. These precautions must be tools to a clean, metal (unpainted) furnace surface near the control board. 3. Service the furnace after touching the chassis. Your body will recharge with static followed to prevent electrostatic discharge from hand tools and personnel. Following the precautions will protect the control from ESD by discharging static electricity buildup to ground. electricity as you shuffle your feet or move around, and you must reground yourself. 4. Reground yourself if you touch ungrounded items. 5. Before handling a new control, reground yourself; this will protect the control. Store used and new controls in separate containers before touching ungrounded objects. 6. ESD damage can also be prevented by using an ESD service kit. REMOVE EXISTING CONTROL 1. Turn thermostat to OFF position or set it to the lowest possible setting. 2. Turn OFF electrical supply to furnace. 3. Turn OFF gas supply to furnace. CAUTION! To service control, and prior to disconnection, label all wires. Failure to do so may result in wiring errors that can cause dangerous operation. CAUTION: Failure to turn off gas and electric supplies can result in explosion, fire, death, or personal injury. 4. Remove furnace blower and control access doors. 5. Disconnect thermostat wires and humidifier wires (if equipped with a humidifier). 6. Disconnect line voltage, blower, electronic air cleaner wires (if equipped), and transformer wires. 7. Remove screws and any other fasteners, and the old circuit board. 8. Examine control and control box to check for water stains. 9. Make repairs if any sources of water leakage are found. Be sure to check humidifiers, evaporator coils, and vent systems in the area of the control. INSTALL NEW CONTROL 1. Ground yourself. When handling circuit board, hold it by the edges. 2. Fasten circuit board with retaining screws. 3. Connect all line voltage, low voltage, and accessory wires. 4. Verify the sequence of operation. LED FAULT CODES LEDS OK (GREEN) FLAME (YELLOW) Flashes ON 1 Flash 2 Flashes 3 Flashes 4 Flashes 5 Flashes 6 Flashes 7 Flashes Rapid Blink OFF Rapid Blink OFF ON Fault Condition Normal operation Ignition lockout (4 failed trials/5 flame losses) Pressure switch stuck open Limit switch open Pressure switch stuck closed Twin fault Brownout voltage Hot and neutral reversed or no ground Flame out of sequence Gas valve relay short Flame out of sequence No flame Flame present LOCKOUT The control will enter a 1-hour lockout if: 1. The Gas Valve is sensed on when it should not be. 2. Flame is sensed out of sequence. 3. Flame is not sensed during 4 consecutive trials for ignition. 4. Flame is lost after successful ignition 5 times in one W call. Note: All lockout types can be cleared by cycling power to the board. Ignition lockouts can also be cleared by cycling the W call. M1 M2 H/C WIRING DIAGRAM Note: Park un-used motor speeds on M1 & M2 terminals Twin Function Twinning functionality allows for simultaneous operation of two furnaces that are: installed side-by-side, connected by a common duct system, supplied main power by the same source, and controlled by a common thermostat. Twinning can be accomplished with two "ICM292A" integrated control boards by implementing the following procedure: 1. Ensure that both furnace control boards have the same part number. 2. Put the transformers of each furnace in-phase by wiring the commons of both transformers together and then connecting the commons to earth ground. TWIN Terminal of 2nd Board (if applicable) LED1 PWR LED2 OK LED3 FLAME TIME SW1 SW2 90 OFF ON 120 OFF OFF 160 ON OFF 180 ON ON ON HEAT BLOWER OFF 12 DELAY K4 K3 K2 K5 K6 K1 1 Thermostat C RWG Y C R W G YT WIN 3. Use a wire to connect the "TWIN" terminals of the two furnace control boards. Note: The "OK" LED will blink five times during a W call if twinning is not set up properly. 2 ICM292A 147 258 369 XRMR-PRI HUM EAC COOL HEAT FAN NEUTRALS Blower Motor M-LO LO NEUTRAL HI 3 AMP SEC COM LEGEND R C COM 24 VAC 24 VAC Common Transformer secondary common EAC Electronic air cleaner motor FS Flame sensor GV Gas valve H/C Single-speed heat/cool HI HUM IDM Blower high speed Humidifier motor Induced draft motor K5, K6 Gas valve relays LIM Limit switch LO Blower low speed LSI Limit switch in LSO M-LO PRI PS PSI PSO SEC XFMRPRI Limit switch out Blower medium-low speed Transformer primary Pressure switch Pressure switch in Pressure switch out Transformer Secondary 24 VAC Transformer Primary 120 VAC 9-PIN CONNECTION 147 258 369 1. N/A 2. 24 VAC common 3. Limit switch In 4. Gas valve 5. Pressure switch out 6. Pressure switch in 7. Flame sensor 8. Limit switch out 9. 24 VAC common SEC 24 VAC IDM PRI L1 120 VAC L2 Earth Chassis Ground Ground Spark Electrode Earth Ground TROUBLESHOOTING TIPS Weak or intermittent spark: Make sure the furnace frame is grounded to earth ground. Ensure that the 24 VAC common is grounded to Earth ground. Check or replace the spark igniter. Check the primary and secondary voltage of the transformer for proper voltage. Flame Loss: Check, clean, or replace the flame sensor. Check pressure switch. No flame/Ignition failure: Ensure that the 24 VAC common is grounded to Earth ground. Check, clean, or replace the flame sensor. Check or replace the spark igniter. Flame out of sequence: Flame out of sequence represents a scenario where flame is sensed while the gas valve is closed. The control enters lockout. No ignition, main blower runs continuously: Check the high temperature limit switch for open circuit. Check all safeties. Clean or replace air filter. Check duct work and return air ducts for blockages. CONNECTION DIAGRAM K5 K6 FS 7 Flame Sensor LSI LSO PSI PSO 3 8 6 5 4 2 LIM PS GV Thermostat C R WG Y C R W G YT WIN 7313 William Barry Blvd., North Syracuse, NY 13212 www.icmcontrols.com 800.365.5525 LIAF294-4