Johnson Controls S1-33103010000 User manual

Johnson Controls Unitary Products 035-22285-002-B-0914
ACCESSORY KIT INSTALLATION MANUAL
IGNITION CONTROL P/N S1-33103010000
FOR MODELS: ALL SINGLE-STAGE 115VAC MODELS WITH HOT SURFACE IGNITION (HSI)
GENERAL INFORMATION
This part is a direct replacement for part numbers
S1-03109167000, S1-03101933000, S1-03101267000,
S1-03101267001, S1-03100662000, S1-03101250000,
S1-03101266000, S1-03101284000, S1-03101973000
and S1-03101972000, 265901, 265902, & 539617.
Figure 1 shows the basic board layout and Figure 2 shows the general
component and safety circuit connections (Refer to the electrical wire
diagram for the furnace being serviced for circuit connections specific to
that model).
KIT S1-33103010000 INCLUDES
1. Ignition control board P/N S1-03103010000
2. Accessory Kit Installation Manual P/N 035-22285-002
INSTALLATION
The required number of steps to remove the failed ignition control and
install the new ignition control will vary depending on the furnace model.
However the wire connections will remain the same.
Some models (certain upflow 90% models) will require that the sheet
metal control box be replaced. The existing door switch and transformer
will be re-used.
Some models (BGU Series) will require that new holes be drilled in the
existing control box and that the transformer be relocated.
Some models will need new mounting holes to be drilled in the existing
panel. Use the drill template on the last page of these instructions as a
guide.
REMOVAL OF FAILED IGNITION CONTROL
1. Turn off electrical power.
2. Remove furnace blower access panel.
3. Remove electrical box cover, if required.
4. Label all wires prior to disconnection.
5. Disconnect all wires to failed ignition control.
6. Remove screws or pegs fastening ignition control to electrical
panel.
7. Fasten hole template, included with this installation instruction, to
electrical panel and drill new mounting holes. (If required).
FIGURE 1: Furnace Control Board
PARK
PARK
HI COOL
HEAT
EAC-H
L1
XFMR
NEUTRALS
HUM
TWIN
60
90
120
180
BLOWER OFF DELAY
Y/Y2
WRGC
Y1
LO COOL
CONT FAN SPEED
LO COOL HEAT
HI COOL
FAN OFF
ADJUSTMENT
JUMPER
CONTINUOUS
FAN SPEED
JUMPER
A0233-001
LED
Disconnect electrical power to the furnace before installing this con-
trol. Failure to cut power could result in an electrical shock or equip-
ment damage.
Label all wires prior to disconnection when servicing controls. Wiring
errors can cause improper and dangerous furnace operation. Verify
proper operation after servicing.
If power is applied and 9 red flashes immediately occur, check for
correct transformer phasing. Refer to the description for the 9 RED
FLASHES of the LED indicator on page 3.
All wiring must be in accordance with both the National Electric
Code, latest edition, and all local electrical codes.
NOTICE

035-22285-002-B-0914
2Johnson Controls Unitary Products
INSTALLATION OF IGNITION CONTROL
1. Orient the control as close as possible to the orientation of the
board being replaced.
2. Align the plastic mounting feet with the mounting holes in the elec-
tric panel and press on each corner of the control board to seat the
mounting feet.
3. Figure 2 shows a typical system wiring diagram, which may vary
slightly depending on the furnace model. Use the wiring diagram
label on the furnace as your primary guide.
4. Check to see that all wire connections were made properly before
applying power.
5. Apply power and test furnace operation.
FURNACE CONTROL DIAGNOSTICS
The furnace has built-in, self-diagnostic capability. If a system problem
occurs, a blinking LED can flash red, green or amber to indicate various
conditions.
The control continuously monitors its own operation and the operation
of the system. If a failure occurs, the LED will indicate the failure code. If
the failure is internal to the control, the light will stay on continuously. In
this case, the entire control should be replaced, as the control is not
field repairable.
Flash sequence codes 1 through 11 are as follows: LED will turn “on”
for 1/4 second and “off” for 1/4 second. This pattern will be repeated the
number of times equal to the code. For example, six flashes “on” will
equal a number 6 fault code. Each separate flash code sequence will
be separated by a 2 second “off” period.
SLOW GREEN FLASH: Normal operation.
SLOW AMBER FLASH: Normal operation with call for heat.
RAPID RED FLASH: Twinning error, incorrect 24V phasing. Check
twinning wiring.
RAPID AMBER FLASH: Flame sense current is below 1.5 microamps.
Check and clean flame sensor. Check for proper gas flow. Verify that
current is greater than 1.5 microamps at flame current test pad.
4AMBER FLASHES: The control is receiving a “Y” signal from the
thermostat without a “G” signal, indicating improper thermostat wiring.
1 RED FLASH: This indicates that flame was sensed when there was
not a call for heat. The control turns on both the inducer motor and sup-
ply air blower. A gas valve that leaks or is slow closing would typically
cause this fault.
2 RED FLASHES: This indicates that the normally open pressure
switch contacts are stuck in the closed position. The control confirms
these contacts are open at the beginning of each heat cycle. This would
indicate a faulty pressure switch or miswiring.
Apply only enough pressure to seat the mounting foot or the ignition
control may be damaged. If power is applied and 9 red flashes immediately occur, check for
correct transformer phasing. Refer to the description for the 9 RED
FLASHES of the LED indicator on page 3.
FIGURE 2: Board Layout - Typical System Wiring
A0234-001

035-22285-002-B-0914
Johnson Controls Unitary Products 3
3 RED FLASHES: This indicates the normally open pressure switch
contact did not close after the inducer was energized. This could be
caused by a number of problems: faulty inducer, blocked vent pipe, bro-
ken pressure switch hose or faulty pressure switch.
DO NOT assume a pressure switch is faulty. Connect a manometer
using a tee fitting to verify vent pressure.
4 RED FLASHES: This indicates that a primary or auxiliary limit switch
has opened its normally closed contacts. The control operates the sup-
ply air blower and inducer. This condition may be caused by: dirty filter,
improperly sized duct system, incorrect blower speed setting, incorrect
firing rate or faulty blower motor. Also, this fault code could be caused
by a blown fuse located on the control board.
5 RED FLASHES: This fault is indicated if the normally closed contacts
in the rollout switch opens. The rollout control is manually reset.
If the contacts have opened, check for proper combustion air, proper
inducer operation, and primary heat exchanger failure or burner prob-
lem. Be sure to reset the switch and cycle power (24 VAC) to the control
after correcting the failure condition. Check for a blown fuse located on
the control board which can cause this fault code.
6 RED FLASHES: This indicates that after the unit was operating, the
pressure switch opened 4 times during the call for heat. If the main
blower is in a “Delay on” mode, it completes the delay period, and any
subsequent delay off period. The furnace locks out for one hour and
then restart.
7 RED FLASHES: This fault code indicates that the flame could not be
established. This no-light condition occurred 3 times (2 retries) during
the call for heat before locking out. Low gas pressure, faulty gas valve,
dirty or faulty flame sensor, faulty hot surface ignitor or burner problem
may cause this. The furnace locks out for one hour and then restart.
8 RED FLASHES: This fault is indicated if the flame is lost 5 times (4
recycles) during the heating cycle. This could be caused by low gas
pressure, dirty or faulty flame sensor or faulty gas valve. The furnace
locks out for one hour and then restart.
9 RED FLASHES: Indicates reversed line voltage polarity or grounding
problem, or incorrect 24V phasing. The 24V phasing can be checked by
measuring the 120V line to the 24V “R” terminal. Line voltage minus
secondary voltage should be indicated. If line voltage plus secondary
voltage is indicated, low voltage is out of phase with line voltage. The
24V secondary voltage at the transformer connections must be
reversed. Both heating and cooling operations are affected.
Check polarity at furnace and branch. Check furnace grounding. Check
that flame probe is not shorted to chassis.
10 RED FLASHES: Indicates flame sensed with no call for heat.
Check gas valve, gas valve wiring, and proper grounding.
11 RED FLASHES: This indicates that a primary or auxiliary limit switch
has opened its normally-closed contacts and has remained open for
more than five minutes. This condition is usually caused by a failed
blower motor or blower wheel. Cycle power (24 VAC) to the control to
reset the hard lockout condition after correcting the failure condition.
12 RED FLASHES: This code indicates an open igniter circuit, which
could be a disconnected or loose wire or a cracked or broken igniter.
STEADY ON RED: Control failure. Replace control board.
60-MINUTE AUTOMATIC RESET FROM LOCKOUT: This control
includes a “watchdog” type circuit that resets from a lockout condition
after 60 minutes. The operational faults 6, 7, and 8 also reset. This pro-
vides protection to an unoccupied structure if a temporary condition
exists causing a furnace malfunction. An example would be a low
incoming gas supply pressure preventing unit operation. When the gas
pressure is restored, at some point the “watchdog” would restart the
unit and provide heat for the structure. If a flame is detected, the control
flashes the LED for 1/8 of a second and then enters a flame stabiliza-
tion period.
DIAGNOSTIC FAULT CODE STORAGE AND
RETRIEVAL
The control in this furnace is equipped with memory that will store up to
five error codes to allow a service technician to diagnose problems
more easily. This memory will be retained even if power to the furnace
is lost.
This feature should only be used by a qualified service technician.
The control stores up to five separate error codes. If more than five
error codes have occurred since the last reset, only the five most recent
error codes are retained. The furnace control board has a button,
labeled “LAST ERROR” that is used to retrieve error codes. This func-
tion only works if there are no active thermostat signals. A call for heat-
ing, cooling or continuous fan must be terminated before attempting to
retrieve error codes.
To retrieve the error codes, push the LAST ERROR button. The LED on
the control board then flashes the error codes that are in memory, start-
ing with the most recent. There is a two-second pause between each of
the error flash codes. After the error codes have all been displayed, the
LED resumes the normal slow green flash after a five second pause. To
repeat the series of error codes, push the button again. If there are no
error codes in memory, the LED flashes two green flashes. To clear the
memory, push the LAST ERROR button and hold it for more than five
seconds. The LED flash three green flashes when the memory has
been cleared, and then the LED resumes the normal slow green flash
after a five-second pause.
IGNITION CONTROL
Normal flame sense current is approximately
3.7 microamps DC (µa)
Low flame signal warning starts at 1.5 microamps.
Low flame signal control lockout point is
0.1 microamp DC (µa)

Subject to change without notice. Published in U.S.A. 035-22285-002-B-0914
Copyright © 2014 by Johnson Controls, Inc. All rights reserved. Supersedes: 035-22285-002-A-0912
York International Corp.
5005 York Drive
Norman, OK 73069
FIGURE 3: Hole Template
A0235-001