Icm controls Icm2915 General instructions

Installation, Operation & Application Guide

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products – plus wiring diagrams, troubleshooting tips and more,

visit us at www.icmcontrols.com

ICM2915

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

• 2-stage low heat and high heat

FEATURES

The ICM2915 is a form, t, and functional replacements for the boards shown in the cross-reference

section of this guide. The control boards are designed as automated gas ignition controls which monitor

the ignition sequence including the inducer, pressure switch, spark ignition, gas valve, ame sense, and

circulating blower while maintaining full safety circuit monitoring including the high limit switch, roll out

switch and auxiliary limit switch circuits. Onboard diagnostics will indicate when a fault condition exists.

In addition, the ICM2915 offers 2-stage low heat and high heat function for better efciency.

INTRODUCTION

• Line voltage: 230 VAC

• Line frequency: 50/60 Hz

• Control voltage: 18-30 VAC

• Circulating blower: 4 FLA @ 277 VAC

• Hi-efciencyblower:10mA @ 24 VAC

• Inducer blower: 0.7 FLA, 1.5 LRA @ 24 VAC

• Combined gas valve load: 1.5A @ 24 VAC

• Minimumamesignalthreshold:0.75 uA

SPECIFICATIONS

TRANE P/N #: D674713P01

REPLACES

Single stage operation

Upon a thermostat call for W1, the single stage heat mode is initiated. The control will verify the initial

state of the pressure switch and other safeties then engage the draft inducer. The control then veri-

es the closure of the pressure switch and enters a 20-second pre-purge (15 seconds on high speed

followed by 5 seconds on low speed). After the inducer pre-purge completes, the control energizes the

rst stage of the gas valve and initiates spark which ignites the ame. Once the ame is detected and

veried, a 45 second delay for the indoor blower is initiated. Following the delay, the indoor blower is

energized at low speed. When the W1 call from the thermostat is satised, the gas valve de-energizes,

ame sense is lost, and the control starts a 5 second draft inducer post-purge along with a eld selected

60 or 90 second indoor blower post-purge delay. After their delay times expire, the inducer and indoor

blowers will be de-energized.

Second stage operation

When a call for second stage heat (W2) occurs during a rst stage heat call (W1), the control changes

the draft inducer speed from low to high speed. Also, the control will switch the rst stage gas heat to

the second stage gas heat. Once the call for second stage heat (W2) is satised, the draft inducer is

switched from high speed to low speed, the gas valve is switched from second stage to rst stage, and

the indoor blower speed will switch from high to low within 30s.

First stage and second stage called together at the same time

The control initially processes the call as a single stage heat call. Once ame is established, the control

begins to process a second stage heat call operation after 10 minutes.

Note: A call for W2 without a call for W1 will not be recognized.

Cooling mode

Upon a thermostat call for cooling (Y) energized or (Y&G) energized, the control energizes the indoor

blower on high speed. When the thermostat is satised, the control executes a eld selectable 0 or 45

second indoor blower post purge off-delay. When the off-delay ends, the Indoor blower is turned off.

Continuous fan mode

Upon a singular (G) input which indicates a call for continuous indoor blower operation, the control will

energize the indoor blower at the low heat speed.

OPERATION

Use caution when installing and servicing the furnace to avoid and control electrostatic

discharge; ESD can impact electronic components. These precautions must be 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.

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.

2. To ground yourself, touch your hand and 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 electricity as you

shufe 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 the used and

new controls in separate; containers before touching ungrounded objects.

6. ESD damage can also be prevented by using an ESD service kit.

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

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

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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

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) 3 times in one heat call

• Flame lost after successful ignition 4 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

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).

LOCKOUT

FAULT CODE TABLE

# of Flashes Error

Steady OFF No power or board failure

Steady ON Normal operation with no thermostat call

Slow ash rate Normal operation with a heat call

2System lockout

3Pressure switch fault

4High temperature limit switch open

5Flame sensed without gas valve open or ame sensed without W call

6Flame roll out switch open

7Thermostat miswired (W1 & W2 reversed)

8Low ame sense signal

NOTE: At power up, the control will ash the last 4 faults stored in memory within the last 14 days

Function Time Units

Heat “ON” delay 45 Sec

Cool “ON” delay 1Sec

Flame recognition time 0.8 Sec

Flame establishing period 7Sec

Flame failure response time (before 10

seconds after trial for ignition period)

2Sec

Flame failure response time (otherwise) 0.8 Sec

Recycle time 20 Sec

Lockout time 300 Sec

Pre–purge time 20 Sec

Retry Time 60 Sec

Post–purge time 5Sec

Auto-restart purge time 5Sec

Trial for ignition period 7Sec

Interpurge time 60 Sec

Auto restart time 60 Min

Retry 2Each

Recycle Attempts 4Each

Heat fan OFF delay 60 or 90 sec., eld selectable, default will be 90 sec.

Cool fan OFF delay 0 or 45 sec., eld selectable, 45 sec. will be default for HEM,

45 sec. will be default for PSC.

Timing: (@ 25 VAC, 60 Hz, 25ºC unless noted)

Slow Flash: Normal operation with call for heat

Steady Flash: Normal operation without a call for heat

STATUS LED

When powering on, the control shall ash the last four error codes that have occurred in the last 14

days. The control will ash the newest error rst and oldest error last. The fault memory can be

manually erased by powering on with a G call in place and toggling W 3 times

Fault code Retrieval & Clearing

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LIAF315

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

L1 L2

24 VAC

Load

Spark

Electrode

Earth Ground

WIRING DIAGRAM

FLAME CURRENT

1VDC = 1uA

Blower

BLOWER

ICM2913

MADE IN THE USA

LED2

FAULT

LED1

STATUS

HEAT

COOL

90 60

045

BLOWER RELAY

Inducer

PARK

Load

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

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

ECM

L1 L2

24 VAC

Line

VAC

IDM

Earth Ground

Spark

Electrode

Earth Ground

WIRING DIAGRAM

FLAME CURRENT

1VDC = 1uA

WIRING DIAGRAM

ICM2915

LED1

STATUS

Thermostat

Earth

Ground

Spark

Electrode

HEAT

COOL

9060

0 45

L2_BLO HIGH LOW L2_IND IND_HI

IND_LO

COM

SEC

24 VAC

PRI

230 VAC

L2L1

ECM Controller

IDM

Earth

Ground

PS ROS LIM

PS RO FS

K2 K1

PRI

460 VAC

SEC

24 VAC

Earth

Ground

Earth

Ground

B GWYR

E_GND

GWYRC

Thermostat

Chassis

Ground

Flame

Sensor

CONNECTION DIAGRAM

LIM (OUT) LIM (IN)

PS ROS LIM

Flame

Sensor

PS RO LIM (OUT) FS

K2 K1

PRI

230 VAC

SEC

24 VAC

Earth

Ground

Earth

Ground

B GWYR

E_GND

GWYRC

Thermostat

Chassis

Ground

CONNECTION DIAGRAM

LIM (IN)

PS ROS LIM

PS RO FS

K2 K1

PRI

230 VAC

SEC

24 VAC

Earth

Ground

Earth

Ground

B GWYR

E_GND

GWYRC

Thermostat

Chassis

Ground

Flame

Sensor

CONNECTION DIAGRAM

LIM (OUT) LIM (IN)

CONNECTION DIAGRAM

PRI

230 VAC

SEC

24 VAC

Earth

Ground

Chassis

Ground

B G

W1 W2

WRC

Thermostat

PS ROS LIM

PS (IN)HILO ROS FS

Flame

Sensor

LIM (OUT) LIM (IN)

B (COM)

Thermostat interference There are some thermostats which can interfere with the way the ICM furnace boards sense the call for heat. If you are having any issues with establishing

ame, the rst step would be to remove all the thermostat wires from the board and temporarily jump R – W to test. If the furnace cycle completes, remove

the jumper, and replace the existing thermostat with a battery-operated thermostat or a hardwired thermostat which uses a R & C connection.

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 (bypass for testing)

• 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 If the ame is not established and proven during the initial sequence, there will be two more successive attempts allowed each having a sixty second

inducer purge between attempts. After three successive attempts if the ame is still not proven, there will be a 1 hour lock out before the system will try for

ignition again.

• Check the thermostat (bypass for testing)

• 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.

TROUBLESHOOTING

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