Emerson 50A55-843 Installation Instructions

Page 1

50A55-843

Universal Integrated Furnace Control

INSTALLATION INSTRUCTIONS

Operator: Save these instructions for future use!

FAILURE TO READ AND FOLLOW ALL INSTRUCTIONS CAREFULLY BEFORE INSTALLING OR OPERATING THIS CONTROL COULD CAUSE PERSONAL INJURY AND/OR PROPERTY DAMAGE.

DESCRIPTION

The 50A55-843 is an automatic gas interrupted ignition control that employs a microprocessor to continually monitor, analyze, and control the proper operation of the gas burner, inducer, and fan.

Signals interpreted during continual surveillance of the thermostat and ﬂame sensing element initiate automatic ignition of the burner, sensing of the ﬂame, and system shut-off during normal operation.

TRANE APPLICATION - Installer MUST read page 3 “Mounting and Wiring”

PRECAUTIONS

Installation should be done by a qualiﬁed heating and air conditioning contractor or licensed electrician.

If in doubt about whether your wiring is millivolt, line, or low voltage, have it inspected by a qualiﬁed heating and air conditioning contractor or licensed electrician.

Do not exceed the speciﬁcation ratings.

All wiring must conform to local and national electrical codes and ordinances.

This control is a precision instrument, and should be handled carefully. Rough handling or distorting components could cause the control to malfunction.

Following installation or replacement, follow manufacturer’s recommended installation/service instructions to ensure proper operation.

CAUTION

Do not short out terminals on gas valve or primary control. Short or incorrect wiring may damage the thermostat.

CONTENTS

Description ...................................................................... 1

Precautions ...................................................................... 1

Speciﬁcations .................................................................. 2

Installation ....................................................................... 3

Mounting & Wiring

Operation ......................................................................... 6

Mounting Hole Template .................................................. 8

These controls incorporate system fault analysis for quick gas ﬂow shut-off, coupled with automatic ignition retry upon sensing a fault correction.

WARNING

Failure to comply with the following warnings could result in personal injury or property damage.

FIRE HAZARD

• Do not exceed the speciﬁed voltage.

• Protect the control from direct contact with water (dripping, spraying, rain, etc.).

• If the control has been in direct contact with water, replace the control.

• Label all wires before disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

• Route and secure wiring away from ﬂame.

SHOCK HAZARD

• Disconnect electric power before servicing.

• Ensure proper earth grounding of appliance.

• Ensure proper connection of line neutral and line hot wires.

EXPLOSION HAZARD

• Shut off main gas to appliance until installation is complete.

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PART NO. 37-6265001

Replaces 37-6265G

2053

Page 2

SPECIFICATIONS

ELECTRICAL RATINGS [@ 77°F (25°C)]:

Input Voltage: 25 VAC 50/60 Hz Max. Input Current @ 25 VAC: 0.45 amp

Relay Load Ratings:

Valve Relay: 1.5 amp @ 25 VAC 50/60 Hz 0.6 pf Ignitor Relay: 6.0 amp @ 120 VAC 50/60 Hz (resistive) Inducer Relay: 2.2 FLA–3.5 LRA @ 120 VAC Circulator Relay: 14.5 FLA–25.0 LRA @ 120 VAC

Flame Current Requirements:

Minimum current to insure ﬂame detection: 1 µa DC* Maximum current for non-detection: 0.1 µa DC* Maximum allowable leakage resistance: 100 M ohms

*Measured with a DC microammeter in the ﬂame probe lead

OPERATING TEMPERATURE RANGE:

-40° to 175°F (-40° to 80°C)

HUMIDITY RANGE: 5% to 93% relative humidity (non-condensing)

MOUNTING:

Surface mount multipoise

Timing Specs: (@ 60 Hz**)

maximum Flame Establishing Time: 0.8 sec Flame Failure Response Time: 2.0 sec

**At 50 Hz, all timing speciﬁcations should be increased by 20%

Gases Approved: Natural, Manufactured, Mixed, Liquiﬁed Petroleum, and LP Gas Air Mixtures are all approved for use.

TIMING SPECIFICATIONS

(All times are in seconds, unless noted otherwise)

50A55-843

PRE-PURGE 30

INITIAL IGNITOR WARM-UP (1st 64 attempts)

MINIMUM IGNITOR WARM-UP 5

MAXIMUM IGNITOR WARM-UP 21

IGNITION ACTIVATION PERIOD 1

TRIAL FOR IGNITION PERIOD 4

RETRIES 2 times

VALVE SEQUENCE PERIOD 12

INTERPURGE 60

POST-PURGE 15

LOCKOUT TIME 300

HEAT DELAY-TO-FAN-ON* 30, 45

HEAT DELAY-TO-FAN-OFF* 60/90/120/180

COOL DELAY-TO-FAN-ON 5

COOL DELAY-TO-FAN-OFF* 45, 90

AUTO RESET 60 minutes

HUMIDIFIER YES

ELECTRONIC AIR CLEANER YES

*These times will vary depending on option switch

position. The control is factory-set at 30 seconds heat delay-to-fan-on, 180 seconds heat delay-to-fan-off and 45 seconds cool delay-to-fan-off. See OPERATION section for further information.

Page 3

INSTALLATION

MOUNTING AND WIRING

WARNING

FIRE HAZARD

• Do not exceed the speciﬁed voltage.

• Replace existing control with exact model and dash number.

• Protect the control from direct contact with water (dripping, spraying, rain, etc.).

• Label all wires before disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

• Route and secure wiring away from ﬂame.

SHOCK HAZARD

• Disconnect electric power before servicing.

• Ensure proper earth grounding of appliance.

• Ensure proper connection of line neutral and line hot wires.

EXPLOSION HAZARD

• Shut off main gas to appliance until installation is complete.

CAUTION

Do not short out terminals on gas valve or primary control. Short or incorrect wiring may damage the thermostat.

All wiring should be installed according to local and national electrical codes and ordinances.

The control must be secured to an area that will experience a minimum of vibration and remain below the maximum ambient temperature rating of 175°F. The control is approved for minimum ambient temperatures of -40°F.

When mounting the control, any orientation is acceptable. Choose a location that will not damage, obstruct or place stress on the control’s terminations, system wiring harness or system components. After ﬁnding a suitable location, drill four (4) 1/8" holes for mounting control. To ensure proper mounting hole locations, there is a mounting hole template on page 8 of this instruction sheet. Detach the page with the template from the instruction sheet and apply it to the mounting location. When drilling the holes, take care so that the transformer, wiring harness or other system components are not damaged. Four (4) #8 sheet metal screws are provided to complete the installation.

Refer to the wiring diagram and wiring table when connecting the 50A55 control to other components of the system.

UL approved, 105°C rated 18 gauge, stranded, 2/64" thick insulation wire is recommended for all low voltage safety circuit connections. Refer to 50A55 speciﬁcation sheet for recommended terminals to mate with those on the control.

UL approved 105°C rated 16 gauge min., stranded, 4/64" thick insulation wire is recommended for all line voltage connections. Refer to 50A55 speciﬁcation sheet for recommended terminals to mate with those on the control.

After installation or replacement, follow appliance manufacturer’s recommended installation or service instructions to ensure proper operation.

The 50A55 has only one serviceable part–an automotive type fuse, which protects the low voltage transformer from damage if its output is short-circuited. If the fuse has opened up, remove whatever caused the short circuit and replace the fuse with only a 3 Amp automotive type fuse. If the fuse is not the cause of the control’s problem, replace the entire 50A55 control. There are no other user serviceable parts.

Additional jumper wires are included in this package and should be used if the original wiring does not reach the control after mounting. Refer to the furnace wiring diagram for proper connection of the wires.

Amana/Goodman application - An additional wiring harness (WR 115-0223) is included in this package. If the control being replaced has a 2-pin (inducer/ignitor) connector, this wiring harness will adapt the furnace wiring to the 4-pin connector of the replacement control.

Trane application - Jumper wire 151-2906 (provided with control) must be installed on the furnace from R01 to R02 of the 12-pin connector.

Page 4

(LINE)

NEUTRAL

TYPICAL SYSTEM WIRING DIAGRAM

NOTE

HOT

120 VAC

24 VAC

TH TR

50A55

COOL

HEAT PARK PARK

LINE

XFMR

EAC

HUM

(LINE)

24 VAC CLASS II

TRANSFORMER

CIRCULATOR

BLOWER

HUMIDIFIER

ELECTRONIC

AIR CLEANER

FLAME

SENSOR

PROBE

INDUCER

50A55-843

in other

furnace(s)

—

TWINNING

APPLICATIONS

ONLY

IND

IGN IND N IGN N

CIR N

LINE N

XFMR N

HUM N EAC N

TWIN*TWIN*

HLI

HLO

RO1

GND

RO2

MV MV

TR TH

IGNITOR

THERMOSTAT

PRESSURE SWITCH (N. O.)

HIGH LIMIT

(N. C.)

ROLLOUT

(N. C.)

COMPRESSOR

CONTACTOR

AUX. HIGH

LIMIT (N. C.)

GAS

VALVE

LEGEND

Low Voltage (24 VAC)

Line Voltage (120 VAC)

N. C. = Normally closed switch N. O. = Normally open switch

If ROLLOUT is part of the HIGH LIMIT circuit, jumper wire 151-2906 (provided with control) must be installed on the furnace from R01 to R02 of the 12-pin connector.

Page 5

50A55

TYPICAL SYSTEM WIRING TABLE

TERMINAL

TWIN*

MV (2 terminals)

RO1

RO2

HLI

HLO

GND

(unused terminal)

TERMINAL

TYPE

Terminal

block with

captive

screws

12-pin

connector

& harness

SYSTEM COMPONENT

CONNECTION

low voltage thermostat W terminal (or equivalent)

low voltage thermostat G terminal (or equivalent)

low voltage thermostat R terminal (or equivalent)

low voltage thermostat Y terminal (or equivalent)

(2nd wire from Y terminal goes to 24 VAC HOT side of

compressor contactor coil)

24 VAC COMMON side of compressor contactor coil

one wire twinning terminal

gas valve (both gas solenoids are connected in parallel)

24 VAC transformer (low voltage COMMON side)

24 VAC transformer (low voltage HIGH side)

rollout switch OUTPUT**

rollout switch INPUT**

flame sensor probe*

pressure switch INPUT

high limit INPUT

high limit OUTPUT

MUST BE RELIABLY GROUNDED TO CHASSIS

IND

IGN

IND N

IGN N

COOL

HEAT

PARK (2 terminals)

LINE

XFMR

EAC (optional)

HUM (optional)

CIR N

LINE N

XFMR N

EAC N (optional)

HUM N (optional)

* The twinning feature is available only on models with six screw terminals; one of these terminals will be designated “TWIN”. All 50A55-843 controls used in twinning applications must have the “TWIN” terminal.

†

Maximum recommended flame probe wire length is 36 inches.

** If ROLLOUT is part of the HIGH LIMIT circuit, jumper wire 151-2906 (provided with control) must be installed on the furnace from R01 to R02 of the 12-pin connector.

4-pin connector & harness

spade terminal

inducer HOT side

ignitor HOT side

inducer NEUTRAL side

ignitor NEUTRAL side

circulator blower COOL SPEED terminal

circulator blower HEAT SPEED terminal

unused circulator blower terminals

input voltage (120 VAC) HOT side

24 VAC transformer line voltage HOT side

electronic air cleaner HOT side

humidifier HOT side

circulator blower NEUTRAL terminal

input voltage (120 VAC) NEUTRAL side

24 VAC transformer line voltage NEUTRAL side

electronic air cleaner NEUTRAL side

humidifier NEUTRAL side

Page 6

OPERATION

OPTION SWITCH POSITIONS

* Factory setting

OPTION SWITCHES

The option switches on the 50A55-843 control are used to determine the length of the cool delay-to-fan-off, heat delayto-fan-on and heat delay-to-fan-off periods. The following table shows the time periods that will result from the various switch positions.

COOL delay-

to-fan-off:

45 sec.*

90 sec.

HEAT delay-

to-fan-on:

30 sec.*

45 sec.

HEAT delay-

to-fan-off:

60 sec. 90 sec.

120 sec.

180 sec.*

In a typical system, a call for heat is initiated by closing the thermostat contacts. This starts the 50A55 control’s heating sequence. The inducer blower and optional humidiﬁer are energized and the ignitor is powered within one second.

This controller has an adaptive algorithm that adjusts the dura-tion of the ignitor warm-up, to extend ignitor life. Upon initial application of power, the warm-up time is 17 seconds. The ignitor on-time will then be increased or decreased depending on whether or not ﬂame is achieved. The warm-up time is limited to a maximum of 21 seconds. During the ﬁrst 64 warm-up periods following power-up, the warm-up time may not be less than 17 seconds.

Upon a call for heat, if the warm-up time has not been locked, it will be decreased by one second. This reduction of the ignitor on-time will continue until ﬂame fails to be achieved (resulting in a retry).

In the event of a retry, the warm-up time will be increased by two seconds and locked in at that duration. Once the warm-up time is locked, it remains ﬁxed until another call for heat results in a retry, in which case the warm-up time is again increased by two seconds and remains locked.

In the event of two successive retry attempts, the warm-up time will be unlocked and set to 21 seconds. If ﬂame is then achieved, the warm-up time will begin adapting again with the next call for heat. If, however, this third attempt fails to achieve ﬂame, the control will go into system lockout.

At the end of the ignitor warm-up time, both valves in the 36E manifold gas valve are opened. Flame must be detected within 4 seconds.

Set switch

#3 #4

On On Off On On Off Off Off

HEAT MODE

On Off

If ﬂame is detected, the delay-to-fan-on period begins. After the delay-to-fan-on period ends, the optional electronic air cleaner is energized and the circulator fan is energized at heat speed. When the thermostat is satisﬁed, the gas valve is de-energized. After proof of ﬂame loss, the heat delay-to-fan-off period begins and the inducer blower remains energized to purge the system for 15 seconds. When the purge is complete, the inducer blower and humidiﬁer are de-energized. After the delay-to-fan-off pe-riod ends, the circulator fan and electronic air cleaner are de-energized.

If ﬂame is not detected, both valves are de-energized, the ignitor is turned off, and the 50A55 control goes into the “retry” sequence. The “retry” sequence provides a 60-second wait following an unsuccessful ignition attempt (ﬂame not detected). After this wait, the ignition sequence is restarted with an additional 2 seconds of ignitor warm-up time. If this ignition attempt is unsuccessful, one more retry will be made before the control goes into system lockout.

If ﬂame is detected, then lost, the 50A55 control will repeat the initial ignition sequence for a total of four “recycles”. After four unsuccessful “recycle” attempts, the control will go into system lockout.

If ﬂame is established for more than 10 seconds after ignition, the 50A55 controller will clear the ignition attempt (or retry) counter. If ﬂame is lost after 10 seconds, it will restart the ignition sequence. This can occur a maximum of ﬁve times before system lockout.

During burner operation, a momentary loss of power of 50 milliseconds or longer will de-energize the main gas valve. When power is restored, the gas valve will remain de-energized and a restart of the ignition sequence will begin immediately.

A momentary loss of gas supply, ﬂame blowout, or a shorted or open condition in the ﬂame probe circuit will be sensed within

2.0 seconds. The gas valve will de-energize and the control will restart the ignition sequence. Recycles will begin and the burner will operate normally if the gas supply returns, or the fault condition is corrected, before the last ignition attempt. Otherwise, the control will go into system lockout.

If the control has gone into system lockout, it may be possible to reset the control by a momentary power interruption of one second or longer. Refer to SYSTEM LOCKOUT FEATURES.

COOL MODE

In a typical system, a call for cool is initiated by closing the thermostat contacts. This energizes the 50A55 control and the compressor. The cool delay-to-fan-on period begins. After the delay period ends, the optional electronic air cleaner is energized, and the circulator fan is energized at cool speed. After the thermostat is satisﬁed, the compressor is de-energized and the cool mode delay-to-fan-off period begins. After the delay-tofan-off period ends, the circulator fan and electronic air cleaner (optional) are de-energized.

MANUAL FAN ON MODE

If the thermostat fan switch is moved to the ON position, the circulator fan (cool speed) and optional electronic air cleaner are energized. When the fan switch is returned to the AUTO position, the circulator fan and electronic air cleaner (optional) are de-energized.

Page 7

TROUBLESHOOTING

TWINNING INTERFACE

If the control has six screw terminals, one of which is designated TWIN, the control is equipped with a single wire twinning interface. If twinning is used, either control will process a call for heat, cool or fan as described above. However, after the heat-, cool-, or fan-on delay time expires, both units will energize the circulator blowers at the same time. Likewise, after the heat-, cool-, or fanoff delay time expires, both units will de-energize the circulator blowers at the same time. This allows for proper air ﬂow to be obtained. To assure proper control operation, both controls must share a common transformer ground (TR).

To enable twinning, do the following.

1. Power supplied to both furnaces must be from the same phase of the incoming 120 VAC power.

2. Connect the TWIN screw terminals on the 50A55-843 of the furnaces to be twinned to each other using a single wire

(14-22 AWG.).

SYSTEM LOCKOUT AND DIAGNOSTIC FEATURES

SYSTEM LOCKOUT FEATURES

When system lockout occurs, the gas valve is de-energized, the circulator blower is energized at heat speed, and, if ﬂame is sensed, the inducer blower is energized. The diagnostic indica-tor light will ﬂash or glow continuously to indicate system status. (System lockout will never override the precautionary

features.)

To reset the control after system lockout, do one of the

following:

1. Interrupt the call for heat or cool at the thermostat for at least one second but less than 20 seconds (if ﬂame is sensed with the gas valve de-energized, interrupting the call for heat at the thermostat will not reset the control).

2. Interrupt the 24 VAC power at the control for at least one second. You may also need to reset the ﬂame rollout sensor switch.

3. After one hour in lockout, the control will automatically reset itself.

DIAGNOSTIC FEATURES

The 50A55-843 control continuously monitors its own operation and the operation of the system. If a failure occurs, the LED will indicate a failure code as shown below. 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.

If the sensed failure is in the system (external to the control), the LED will ﬂash in the following ﬂash-pause sequences to indicate failure status (each ﬂash will last approximately 0.25 seconds, and each pause will last approximately 2 seconds).

1 ﬂash, then pause System lockout 2 ﬂashes, then pause Pressure switch stuck closed 3 ﬂashes, then pause Pressure switch stuck open 4 ﬂashes, then pause Open limit switch 5 ﬂashes, then pause Open rollout switch 6 ﬂashes, then pause 115 Volt AC power reversed/Im proper ground 7 ﬂashes, then pause Low ﬂame sense signal Continuous ﬂashing Flame has been sensed when no (no pause) ﬂame should be present (no call for heat) The LED will also ﬂash once at power-up.

Page 8

MOUNTING HOLE TEMPLATE

FOR MOUNTING HOLE LOCATIONS

Refer to page 3 of the installation instructions for proper installation.

4.172 ± .007 (2 plcs.)

6.402 ± .01 (2 plcs.)

TECHNICAL SUPPORT: 1-888-725-9797

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