Transcript
INSTALLATION INSTRUCTIONS 2940-4651/A DSI to HSI CONVERSION KIT with REMOTE FLAME SENSOR IMPORTANT NOTICE These instructions are intended for the use of qualified individuals specially trained and experienced in installation of this type of equipment and related system components. Installation and service personnel are required by some states to be licensed. Persons not qualified shall not install this equipment or interpret these instructions.
WARNING IMPROPER INSTALLATION MAY DAMAGE EQUIPMENT, CAN CREATE A SHOCK HAZARD, AND WILL VOID THE WARRANTY.
NOTE The words “Shall” or “Must” indicate a requirement which is essential to satisfactory and safe product performance. The words “Should” or “May” indicate a recommendation or advice which is not essential and not required but which may be useful or helpful.
CONVERSION PROCEDURE A. Turn off gas supply and electrical supply to furnace.
DANGER SHOCK HAZARD TO AVOID THE POSSIBILITY OF ELECTRICAL SHOCK, TURN OFF ELECTRICAL POWER SUPPLY TO FURNACE BEFORE ANY DISASSEMBLY OR MAINTENANCE WORK IS PERFORMED. B. Remove gas control valve. 1. Disconnect main gas supply piping from valve. 2. Disconnect wires from valve. 3. Remove four valve mounting screws and remove valve assembly. See Figure 1. C. Remove burner assembly. 1. Remove four burner mounting screws. See Figure 1.
APPLICATION GAS VALVE
This kit is to be used to convert 2800, 2900, or 8900 series upflow furnaces from direct spark ignition to hot surface ignition.
CONTENTS A. Hot surface ignitor B. Hot surface ignition module. C. Wiring assemblies to fit either 2800, 2900, or 8900 Series furnaces D. Ignitor bracket and necessary hardware E. Wiring diagrams F. Caution sticker G. Lighting instructions label H. Remote sensor rod I.
Sensor mounting bracket with screws
J.
Sensor wire
GAS VALVE MOUNTING SCREWS (2 each side)
Figure 1
BURNER MOUNTING SCREWS (2 each side)
2. Carefully remove burner from furnace and unplug wires from ignition electrodes. 3. Remove screw and nut from electrode bracket. Remove and discard electrode assembly. D. Install hot surface ignitor, sensor rod and sensor rod bracket. 1. Position ignitor bracket on burner tube as shown in Figure 2, with ignitor bracket band flush against flame spreader bracket.
SENSOR ROD BRACKET
SENSOR ROD IGNITOR BRACKET IGNITOR
Figure 2 2. Use #10 screw and nut supplied in kit to fix bracket in place. The bracket should be rotated so that the ignitor tip will be opposite the flame spreader bracket.
CAUTION
3. Install sensor rod and bracket on ignitor bracket as shown in Figure 2 & 3. The sensor rod should be located as shown, with the rod bent toward the burner port.
HOT SURFACE IGNITOR IS VERY FRAGILE AND SHOULD BE HANDLED WITH CARE. A CRACKED OR BROKEN IGNITOR WILL NOT FUNCTION PROPERLY AND MUST BE REPLACED.
SENSOR ROD BRACKET
SENSOR ROD
IGNITOR
IGNITOR BRACKET
4. Attach ignitor to bracket as shown in Figure 2. Make sure that the gap between the ignitor and the end of the burner tube is no less than 1/8”. If necessary, the bracket can be carefully bent so as to achieve this dimension.
Figure 3
2. Re-install gas valve assembly and secure with screws. For now, leave out the upper right hand screw. F. Wiring 1. Remove and discard DSI ignition module and spark plug wire. Save the two sheet metal screws.
5. Attach un-insulated terminal of sensor wire to the sensor rod spade terminal.
2. Using the ignition module as a template, drill two #38 (.101) holes in the vestibule to mount the ignition module in the area shown in Figure 4.
E. Re-install burner and valve assemblies. 1. Very carefully insert burner assembly into furnace and secure with four screws. Make sure that the ignitor and sensor wires extend out of the burner chute for easy access. Make sure that the sensor rod does not touch the burner chute.
Secure the ignition module using the original two mounting screws. The wire terminals of the module should be positioned toward the center of the furnace. 2
CONTROL BOX
LIMIT SWITCH HEATIN G RELAY
CONTROL BOX GAS VALVE
BLOWER RELAY
IGNITION MODULE
TRANSFORMER
Figure 4 3. Remove strain relief from lower right side of control box.
Figure 5
4. Remove and discard DSI wiring harness. 5. Connect the white ignitor wires to the terminals on the ignition module marked IGN.
15. Re-install the strain relief in the hole in the control box.
6. Connect the sensor rod wire to the terminal on the ignition module marked FS/S2.
G. Reconnect gas piping to furnace. Thoroughly check gas piping for leaks.
7. Connect the black wire from the kit to the ignition module terminal marked L1/120. 8. Connect the white wire from the kit to the ignition module terminal marked L2/NEU.
CAUTION
9. Connect one end of the brown wire from the kit to the ignition module terminal marked VALVE and the other end to the black wire removed earlier from the gas valve. Then attach both to one of the gas valve terminals.
NEVER USE AN OPEN FLAME TO CHECK FOR LEAKS. FIRE OR EXPLOSION COULD OCCUR. SINCE SOME LEAK SOLUTIONS INCLUDING SOAP AND WATER MAY CAUSE CORROSION OR STRESS CRACKING, THE PIPING MUST BE RINSED WITH WATER AFTER TESTING UNLESS IT HAS BEEN DETERMINED THAT THE LEAK SOLUTION IS NONCORROSIVE.
10. Connect one end of the gray wire from the kit to the ignition module terminal marked GND and the other end to the gray wires removed from the gas valve earlier. Then attach them to the other gas valve terminal. Connect the ring terminal in this wire assembly under the upper right hand valve mounting screw shown in Figure 1.
H. Attach new labels. 1. Attach the appropriate wiring diagram over the old diagram on the control box cover. The wiring diagram lists the models covered near the bottom right corner.
11. Attach one end of the red wire in the kit to the terminal on the ignition module marked TH. For 2800 or 8900 Series furnaces, attach the other end to limit switch connection above burner. See Figure 4. For 2900 Series furnaces, connect the other end to pressure switch terminal.
2. Attach the red and white lighting instructions label on the back of the upper door panel between the two sets of louvers.
12. Insert the black and white wires from the ignition module through the hole in the lower right side of the control box.
3. Attach the white caution label on the furnace vestibule near the burner area.
13. Unplug the white wires from the transformer, connect the white wire from the ignition module to these wires and plug them all back into the transformer.
I.
Inspect furnace and cycle to check for proper operation. The proper sequence of operation is as follows: 1. Upon a call for heat, the thermostat energizes the heating relay.
14. Attach black wire from harness through hole in side of control box to the existing black wire on contact #1 of heating relay. The heating relay is the top relay, with the clear plastic cover. See Figure 5.
2. When the heating relay closes, a circuit is made starting the vent blower. 3
3. As the vent blower increases in speed, a circuit is made through the centrifugal switch in 2800 and 8900 Series furnaces and through the pressure switch in 2900 Series furnaces, through the limit switch and to the ignition module.
nace tries for ignition but the burner does not stay lit, turn power off and reverse the white and black wires to “L1/120” and “L2/NEU” on the ignition module. If the burner still does not stay lit, check for proper grounding of the furnace. It may be necessary to run a ground wire from the furnace to an earth ground source such as a water pipe.
4. During the next 40 to 50 seconds, the vent blower will bring fresh air into the heat exchanger and the ignitor will begin to glow. At the end of this period, the ignition module will open the gas valve and energize a safety lock-out circuit.
8. The lapsed time from the moment the room thermostat closes to when the burner lights may be 50-60 seconds. This delay is caused by: (1) the time required for the vent blower to come to full speed, (2) the 40 to 50 seconds required for the ignitor to heat up, and (3) the time required for the vent blower to bring fresh air into the heat exchanger.
5. When the burner lights, the sensor rod then acts as a flame probe which checks for the presence of a flame. As long as flame is present, the system will monitor it and hold the gas valve open. 6. If the burner fails to light within 6-8 seconds after the gas valve opens, the ignition module will pause for a few seconds and then try again for ignition. If the burner fails to light after three tries, the ignition module will lock off the gas valve and the ignitor. The system will remain in lock-out mode until the room thermostat is set below room temperature. The lock-out circuit will then be released and setting the thermostat to above room temperature will cause the system to try for ignition again.
9. A short while after the burner has lighted, the fan switch will close and the furnace air circulation blower will run. 10. When room thermostat is satisfied the circuit to the heating relay is broken and the relay contacts return to the normally open position. The circuit to the vent blower and the ignition module is broken and the burner is extinguished. Then as heat is drawn from the heat exchanger and the air temperature is reduced to below the fan switch setting, the fan switch will open which stops the furnace air circulation blower.
7. The Robertshaw ignition module requires proper grounding of the furnace and proper polarity of the 120 volt electrical supply to the furnace. If the fur-
Evcon Industries, Inc. 1952-051/D (7/94) P.I.
3110 North Mead P.O. Box 19014 Wichita, KS 67204-9014
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LITHO IN U.S.A.
