ICM Controls ICM2916 General instructions

Installation, Operation & Application Guide
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ICM2916
Gas Ignition Replacement Board
• Controls blower motors, gas valve, & spark ignitor in sequence
• Protects against short cycling
• Selectable Heat/Cool blower off-delay time
• FlashcodesfromtheonboardLEDindicatespecicproblemsforeasiertroubleshooting
• Repeatedignitionfailuresoramelosseswilldisableheatoperationforsafety
FEATURES
INTRODUCTION
• Line voltage: 240 VAC
• Line frequency: 50/60 Hz
• Control voltage: 18-30 VAC
• Hi-efciencyblower:10 mA @ 24 VAC
• Inducer blower: 0.7 FLA, 1.5 LRA @ 240 VAC
• Combined gas valve load: 1.5 A @ 24 VAC
• Minimumamesignalthreshold:0.75 uA
SPECIFICATIONS
TRANE P/N #: D674712P02
REPLACES
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.
1. Turn thermostat to the OFF position or set it to the lowest possible setting.
2. Turn OFF the electrical supply to furnace.
3. Turn OFF the gas supply to furnace.
CAUTION! Failure to turn off gas and electric supplies can result in explosion, re, death or
personal injury.
4. Remove the furnace blower and control access doors.
5. Disconnectthethermostatwiresandhumidierwires(ifequippedwithahumidier).
6. Disconnectthe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 the control and the control box for water stains.
9. Makerepairsifanysourcesofwaterleakagearefound.Besuretocheckhumidiers,evaporator
coils and vent systems in the area of the control.
REMOVE EXISTING CONTROL
1. Ground yourself. When handling the circuit board; hold it by the edges.
2. Fasten the circuit board with the retaining screws.
3. Connect all line voltage, low voltage and accessory wires.
4. Verifythesequenceofoperation.
INSTALL NEW CONTROL
On a call for heat (24 VAC on the W input), the following occurs:
• Upon a call for heat the control checks the status of the pressure switch; if the pressure switch is open,
the control will energize the draft inducer.
• Whenthecontrolveriesthepressureswitchhasclosed,thecontrolwillstarta20-secondprepurge.
• When the pre-purge time delay is over, the control will energize the gas valve and initiate spark.
• Theignitormustbede-energizedwhentheameissensedorattheconclusionofthetrialforignition
period,whichevercomesrst.
• Whenameissensed,thecontrolwillenergizethecirculatorfanwithintheON-delayperiod.
When the call for heat is terminated, the following occurs:
• The control shall de-energize the gas valve and the draft inducer within the post purge period.
• When the heat mode fan OFF delay timer expires, the control will de-energize the circulator fan.
With a call for cooling, the following occurs:
Onacallforcooling(24VaconYandG),thecirculatorfanisenergizedwithinthecoolondelayperiod.
ThecontrolwillignoreacallforYwithoutacallforG.Afterthethermostatissatised,thecompressor
is de-energized and the jumper selected cool Off delay period begins. Following the cooling Off delay
period, the circulator fan is de-energized.
OPERATION
ELECTRICAL SHOCK HAZARD! Before installing this unit, turn off power at the
main service panel by removing the fuse or switching the appropriate circuit breaker to
the OFF position. Follow all Local, State and National Electrical Codes when installing
this device.
CAUTION! 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.
> > > CAUTION < < <
FAULT CODES, STATUS LIGHTS AND TROUBLESHOOTING
Flashes Fault Condition Trouble Shooting
Solid RED Internal Control Board error Internal board failure, replace control board
Solid RED w/Solid Status LED Continuous reset Reset caused by internal board failure, replace the control board
2Lockout Thenumberofretry’sorrecycleshasexceededthelimitforthecontrol.Cleanorreplacetheamesensor,checktheigniterfor
properoperation&inputvoltage,checkthetransformer’scommonisgroundedtoearthground.
3Pressure switch or Inducer error Check for obstructed pressure switch tubing or defective pressure switch. Check for oxidation on terminals, broken wires, or
defective inducer motor . Check for proper voltage at the inducer motor input.
4Open limit switch Checkforblockedairow,blockedductwork,anddirtylter.Checkorreplacehighlimitswitchif
defective.
5False Flame Flamewassensedwhennoameispresent.Checkorreplaceamesensorandcheckthegrounds.
6Notused
7External Gas valve circuit error Check the wires going to the gas valve for proper connection and ensure the gas valve is not mis-wired. Also, check for corro-
sion on gas valve terminals and clean up the gas valve ground.
8Lowamesense AmultimetercanbeusedtotestamesensebyplacingthemetersprobesonthetwotestpinsandtakingaDCvoltagereading
whiletheamesensorisinthepresenceofame.1VDC=1µAamecurrent.Weakorpooramesenseisrepresentedbya
reading of 0.7 VDC or lower.
The control will go into a 1-hour soft lockout if the following faults are detected:
• Limit switch open 4 times in one heat call
• Ignitionfailed(amenotsensed)4timesinoneheatcall
LOCK OUT CONDITION
• Flame lost after successful ignition 3 times in one heat call
• Gas valve sensed on when it should not be
• Gas valve sensed off when it should be on, 10 times in one heat call
**NOTE: Flame sensed while the gas valve is closed puts the control in lockout state, but lockout clears after the blower off delay is complete (90 seconds or 60 seconds, depending on jumper selection).

B24 VAC common
C24 VAC common
ECM Electonically commutated motor
F1 Fuse
FS Flame sensor
GND Ground
GV Gas valve
IDM Induced draft motor
K1, K2 Gas valve relays
LIM Limit switch
PRI Transformer primary
PS Pressure switch
R24 VAC
ROS Roll out switch
SEC Transformer secondary
TH Transformer 24 VAC hot
TR Transformer 24 VAC common
1. N/A
2. Gas valve
3. Pressure switch in
4. Flame sensor
5. N/A
6. Fusible link (Roll out switch)
7. Common (24 VAC), B
8. Limit switch (out)
9. Limit switch (in)
LEGEND 9-PIN CONNECTION
B24 VAC common
C24 VAC common
ECM
F1 Fuse
FS Flame sensor
GND Ground
GV Gas valve
IDM Induced draft motor
N/A
K1, K2 Gas valve relays
LIM Limit switch
PRI Transformer primary
PS Pressure switch
R24 VAC
ROS Roll out switch
SEC Transformer secondary
TH Transformer 24 VAC hot
TR Transformer 24 VAC common
1. N/A
2. Gas valve
3. Pressure switch in
4. Flame sensor
5. N/A
6. Fusible link (Roll out switch)
7. Common (24 VAC), B
8. Limit switch (out)
9. Limit switch (in)
LEGEND 9-PIN CONNECTION
B24 VAC common
C24 VAC common
ECM Electonically commutated motor
F1 Fuse
FS Flame sensor
GND Ground
GV Gas valve
IDM Induced draft motor
K1, K2 Gas valve relays
LIM Limit switch
PRI Transformer primary
PS Pressure switch
R24 VAC
ROS Roll out switch
SEC Transformer secondary
TH Transformer 24 VAC hot
TR Transformer 24 VAC common
1. N/A
2. Gas valve
3. Pressure switch in
4. Flame sensor
5. N/A
6. Fusible link (Roll out switch)
7. Common (24 VAC), B
8. Limit switch (out)
9. Limit switch (in)
LEGEND 9-PIN CONNECTION
B24 VAC common
C24 VAC common
ECM Electonically commuted motor
F1 Fuse
FS Flame sensor
GND Ground
GV Gas valve
IDM Induced draft motor
K1, K2, K3 Gas valve relays
LIM Limit switch
PRI Transformer primary
PS Pressure switch
R24 VAC
ROS Roll out switch
SEC Transformer secondary
TH Transformer 24 VAC hot
TR Transformer 24 VAC common
1. Stage two of gas valve (HI)
2. Stage one of gas valve (LO)
3. Pressure switch in
4. Flame sensor
5. N/A
6. Fusible link (Roll out switch)
7. Common (24 VAC), B
8. Limit switch (out)
9. Limit switch (in)
LEGEND 9-PIN CONNECTION
Blower
ICM2914
MADE IN THE USA
LED2
FAULT
LED1
STATUS
HEAT
COOL
90 60
045
BLOWER RELAY
Inducer
PARK
B GWYR
E_GND
GWYRC
Thermostat
PRI
460 VAC
SEC
24 VAC
Earth
Ground
ECM
ECM
L1 L2
K4
K3
24 VAC
Load
Load
IN
IN
Spark
Electrode
Earth Ground
Earth Ground
WIRING DIAGRAM
FLAME CURRENT
1VDC = 1uA
TR
TH
F1
Blower
BLOWER
ICM2913
MADE IN THE USA
LED2
FAULT
LED1
STATUS
HEAT
COOL
90 60
045
BLOWER RELAY
Inducer
PARK
B
C
Load
Load
IN
IN
Earth Ground
B GWYR
E_GND
GWYRC
Thermostat
IDM
PRI
230 VAC
SEC
24 VAC
Earth
Ground
L1 L2
Spark
Electrode
Earth Ground
WIRING DIAGRAM
FLAME CURRENT
1VDC = 1uA
TR
TH
F1
Earth
Ground
Blower
ICM2916
MADE IN THE USA
LED2
FAULT
LED1
STATUS
HEAT
COOL
90 60
045
BLOWER RELAY
Inducer
PARK
B GWYR
E_GND
GWYRC
Thermostat
PRI
230 VAC
SEC
24 VAC
TR
TH
ECM
L1 L2
K4
K3
24 VAC
Line
VAC
IDM
Earth Ground
Spark
Electrode
Earth Ground
WIRING DIAGRAM
FLAME CURRENT
1VDC = 1uA
F1
WIRING DIAGRAM
ICM2915
LED1
STATUS
Thermostat
Earth
Ground
Spark
Electrode
F1
G
W2
W1
R
C
Y
W1
R
B
W2
G
Y
HEAT
COOL
9060
0 45
L2_BLO HIGH LOW L2_IND IND_HI
IND_LO
NC
NO
COM
NC
NO
COM
NC
NO
COM
NC
NO
NC
NO
COM
NC
NO
COM
NC
NO
COM
SEC
24 VAC
PRI
230 VAC
CR
L2L1
ECM Controller
R
B
IDM
Earth
Ground
PS ROS LIM
GV
PS RO FS
K2 K1
(C) (R)
PRI
460 VAC
SEC
24 VAC
Earth
Ground
Earth
Ground
B GWYR
E_GND
GWYRC
Thermostat
TR
TH
Chassis
Ground
Flame
Sensor
CONNECTION DIAGRAM
LIM (OUT) LIM (IN)
PS ROS LIM
Flame
Sensor
GV
PS RO LIM (OUT) FS
K2 K1
(C) (R)
PRI
230 VAC
SEC
24 VAC
Earth
Ground
Earth
Ground
B GWYR
E_GND
GWYRC
Thermostat
TR
TH
Chassis
Ground
CONNECTION DIAGRAM
LIM (IN)
PS ROS LIM
GV
PS RO FS
K2 K1
(C) (R)
PRI
230 VAC
SEC
24 VAC
Earth
Ground
Earth
Ground
B GWYR
E_GND
GWYRC
Thermostat
TR
TH
Chassis
Ground
Flame
Sensor
CONNECTION DIAGRAM
LIM (OUT) LIM (IN)
CONNECTION DIAGRAM
(C) (R)
PRI
230 VAC
SEC
24 VAC
Earth
Ground
TR
TH
Chassis
Ground
B G
W1 W2
R
Y
G
W2
WRC
Thermostat
Y
PS ROS LIM
GV
PS (IN)HILO ROS FS
K3
K1
Flame
Sensor
LIM (OUT) LIM (IN)
K2
B (COM)
Weak or intermittent spark Make sure the furnace frame is grounded to earth ground. Ensure the common of the 24 VAC 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forbadordirtyamesensor
• Check thermostat
• Checkforproperamesensesignalatamesensetestpins
• Check for proper earth ground on furnace.
• 4amelossesinasingleheatcallwillputthecontrolintoaone-hourlockout.
Noame/Ignitionfailure • Check the thermostat
• Check the pressure switch
• Check gas valve operation
• Check for good spark & check for good earth ground
Flameoutofsequence Flameoutofsequencerepresentsascenariowhereameissensedwhilethegasvalveisclosed.Thecontrolgoesintoalockoutstatewhenameisout
ofsequenceandtheindicatorLEDblinkstheappropriatecode(see“lockout”section).
• Checkandreplaceamesensor
Furnace does not ignite and main blower runs
continuously
Checkthehightemperaturelimitswitchforopencircuit.Checkallsafeties.Cleanorreplaceairlter.Checkductworkandreturnairductsforblockages.