Honeywell SV9540, SV9640 Installation Manual
SV9540; SV9640
SmartValve™ System Controls
APPLICATION
The SV9540; SV9640 SmartValve™ System Controls combine gas flow control and electronic intermittent pilot sequencing functions into a single unit. The low voltage igniter, flame sensor and pilot burner are supplied by the Q3450 or Q3480 Pilot Hardware. Provides all gas ignition safety functions by controlling gas flow, ignition source, and a 120 Vac or 240 Vac combustion air blower. The control also monitors the appliance airflow proving switch and limit string to assure proper appliance operation. Provides prepurge, postpurge, timed trial for pilot igniton, with 100 percent shutoff and continuous retry. Diagnostic LED indicates system status.
This control communicates directly with the ST9160 Electronic Fan Timer (EFT) in typical forced warm air furnace applications. It also interfaces with the 208907 Terminal Board, providing compatibility with power stealing thermostats. Or, it directly interfaces with the appropriate power supplies and a system thermostat for additional appliance applications. When controlled directly by a thermostat, the control does not provide a postpurge function, as power to the control is removed when the thermostat call for heat ends.
The SV9540; SV9640 system is suitable for a wide range of fan assisted combustion gas-fired appliances including furnaces, rooftop furnaces, boilers, unit heaters, infrared heaters, water heaters and commercial cooking appliances. The specific application of the SmartValve System is the responsibility of the appliance manufacturer. See Table 1 for temperature ranges and regulator types.
SPECIFICATIONS
CAUTION
The SV9540; SV9640 provide direct replacement only. Use the Y8610 to convert standing pilot systems to electronic ignition systems.
Table 1. Model Number Suffix Letter Designation.
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Model No. |
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Suffix |
Ambient |
Pressure |
Letter |
Temperature Range |
Regulator Type |
H |
0°F to 175°F |
Slow-opening |
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(-18°C to +79°C) |
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M |
-40°F to +175°F |
Standard |
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(-40°C to +79°C) |
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P |
-40°F to +175°F |
Step-opening |
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(-40°C to +79°C) |
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INSTALLATION INSTRUCTIONS
Body Pattern:
SV9540: Straight through with 1/2 in. inlet and 1/2 in. outlet; or 1/2 in. NPT inlet and 1/2 in. inverted flare outlet.
SV9640: Straight through with 1/2 in. inlet and 1/2 in. outlet, 1/2 in. inlet and 3/4 in. outlet, or 3/4 in. inlet and 3/4 in. outlet.
Electrical Ratings:
System Transformer:
SV9540: 40 VA minimum NEMA rated.
SV9640: 40 VA minimum NEMA rated.
NOTE: Larger system transformer may be
required for specific applications.
Voltage and Frequency:
24 Vac, 60 Hz; 50 Hz models available.
Output Ratings:
Igniter Load: 1.5A maximum.
Induced Draft Motor Load: 2.5A Full Load, 10A
Locked Rotor at 120 Vac; 1.75A Full Load, 5A
Locked Rotor at 240 Vac.
Current at 24 Vac:
24V Thermostat: See Table 2.
Table 2. Thermostat Current (Run Mode); with control connected directly to thermostat.
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Model |
24 Vac, 60 Hz |
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SV9540 |
0.25A |
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SV9640 |
0.25A |
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Prepurge Time (Factory-set):
3, 15, 30 or 45 seconds, depending on model.
Trial for Ignition:
90 seconds.
Postpurge Time (Factory-set):
5 seconds; this is not available when the SmartValve System Control is connected directly to the thermostat.
Retry Delay:
5 minutes.
Flame Failure Response Time:
1.6 seconds maximum at 2 A.
Capacity:
See Table 3.
Conversion:
Use conversion factors in Table 4 to convert capacities for other gases.
®U.S. Registered |
Trademark |
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69-1059 |
Copyright © 1997 |
Honeywell Inc. • All Rights Reserved |
X-XX UL |
SV9540; SV9640 SmartValve™ SYSTEM CONTROLS
Regulation Range (Btuh); |
Natural-LP Gas Conversion Kits: |
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SV9540 with 1/2 in. NPT Outlet: |
Natural Gas to LP: |
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Natural Gas: |
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393691 Conversion Kit. |
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Minimum: 20,000. |
LP to Natural Gas: |
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Maximum: 200,000. |
394588 Conversion Kit. |
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LP Gas: |
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IMPORTANT |
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Minimum: 40,000. |
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Maximum: 200,000. |
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SV9540P; SV9640P CANNOT be field-converted |
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SV9540 with 1/2 in. Inverted Flare Outlet: |
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to LP or natural gas. |
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Natural Gas: |
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Pipe Adapters: |
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Minimum: 20,000. |
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Maximum: 180,000. |
Angle and straight adapters available for 3/8-, 1/2- and 3/ |
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LP Gas: |
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4-in. pipe. See Table 5. Flange kits include one flange with |
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Minimum: 40,000. |
attached O-ring, four mounting screws, a 9/64 in. hex |
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Maximum: 180,000. |
wrench and instructions. |
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SV9640 (3/4 in. x 3/4 in.): |
Approvals: |
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Natural Gas: |
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Minimum: 30,000. |
International Approval Services (IAS): |
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Maximum: 415,000. |
Design Certified C2030025. |
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LP Gas: |
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Minimum: 30,000. |
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Maximum: 415,000 |
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Table 3. Capacityb of SV9540; SV9640. |
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Size |
Capacity (at 1 in. |
Minimum |
Maximum |
Model |
(Inlet x Outlet) (in.) |
wc pressure dropa,c) |
Regulated Capacity |
Regulated Capacity |
SV9540 |
1/2 x 1/2 NPT |
150 ft3/hr (4.2 m3/hr) |
20 ft3/hr (0.6 m3/hr) |
200 ft3/hr (5.7 m3/hr) |
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1/2 NPT x 1/2 |
130 ft3/hr (3.7 m3/hr) |
20 ft3/hr (0.6 m3/hr) |
180 ft3/hr (5.1 m3/hr) |
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inverted flare |
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SV9640 |
1/2 x 1/2 |
240 ft3/hr (6.8 m3/hr) |
30 ft3/hr (0.8 m3/hr) |
340 ft3/hr (9.6 m3/hr) |
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1/2 x 3/4 |
270 ft3/hr (7.6 m3/hr) |
30 ft3/hr (0.8 m3/hr) |
370 ft3/hr (10.5 m3/hr) |
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3/4 x 3/4 |
300 ft3/hr (8.5 m3/hr) |
30 ft3/hr (0.8 m3/hr) |
415 ft3/hr (11.8 m3/hr) |
aCapacity based on 1000 Btu/feet3, 0.64 specific gravity natural gas at 1 in. wc pressure drop (37.3 MJ/meter3, 0.64 specific gravity natural gas at 0.25 kPa pressure drop).
bCapacity is reduced by 5 percent with the use of outlet screen.
cValves are guaranteed at only 77 percent of the rating.
Table 4. Gas Capacity Conversion Factor.
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Specific |
Multiply Listed |
Gas |
Gravity |
Capacity By |
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Manufactured |
0.60 |
0.516 |
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Mixed |
0.70 |
0.765 |
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Propane |
1.53 |
1.62 |
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Table 5. Adapter (Flange) Part Numbers.
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Part No.a,b |
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Without |
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Inlet/Outlet |
Flange |
Hex |
With Hex |
Pipe Size |
Type |
Wrench |
Wrench |
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3/8 in. NPT |
Straight |
393690-1 |
393690-11 |
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Elbow |
393690-2 |
393690-12 |
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1/2 in. NPT |
Straight |
393690-6 |
393690-16 |
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Elbow |
393690-3 |
393690-13 |
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3/4 in. NPT |
Straight |
393690-4 |
393690-14 |
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Elbow |
393690-5 |
393690-15 |
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aFlange kits include one flange, one O-ring and four mounting screws.
bDo not use flanges on control models with 3/4 in. inlet and 3/4 in. outlet. On models with 1/2 in. inlet and 3/4 in. outlet, use flanges only on the 1/2 in. inlet side.
PLANNING THE INSTALLATION
WARNING
FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE, SEVERE INJURY, OR DEATH
Follow these warnings exactly:
1.Plan the installation as outlined below.
2.Plan for frequent maintenance as described in the Maintenance section.
When intermittent pilot systems are used on central heating equipment in barns, greenhouses, and commercial properties and on heating appliances such as commercial cookers, agricultural equipment, industrial heating equipment and pool heaters, heavy demands are made on the controls. Special steps may be required to prevent nuisance shutdowns and control failure due to frequent cycling, severe environmental conditions related to moisture, corrosive chemicals, dust or excessive heat. These applications require Honeywell Home and Building Control Engineering review; contact your Honeywell Sales Representative for assistance.
Review the following conditions that can apply to your specific installation and take the precautionary steps suggested.
69-1059 |
2 |
SV9540; SV9640 SmartValve™ SYSTEM CONTROLS
Frequent Cycling
This control is designed for use on appliances that typically cycle three to four times an hour only during the heating season. In year-around applications with greater cycling rates, the control can wear out more quickly. Perform a monthly checkout.
Water or Steam Cleaning
If a control gets wet, replace it. If the appliance is likely to be cleaned with water or steam, protect (cover) the control and wiring from water or steam flow. Mount the control high enough above the bottom of the cabinet so it does not get wet during normal cleaning procedures.
High Humidity or Dripping Water
Dripping water can cause the control to fail. Never install an appliance where water can drip on the control.
In addition, high ambient humidity can cause the control to corrode and fail. If the appliance is in a humid atmosphere, make sure air circulation around the control is adequate to prevent condensation. Also, regularly check out the system.
Corrosive Chemicals
Corrosive chemicals can attack the control, eventually causing a failure. If chemicals are used for routine cleaning, avoid contact with the control. Where chemicals are suspended in air, as in some industrial or agricultural applications, protect the control with an enclosure.
Dust or Grease Accumulation
Heavy accumulations of dust or grease can cause the control to malfunction. Where dust or grease can be a problem, provide covers for the control to limit contamination.
Heat
Excessively high temperatures can damage the control. Make sure the maximum ambient temperature at the control does not exceed the rating of the control. If the appliance operates at very high temperatures, use insulation, shielding, and air circulation, as necessary, to protect the control. Proper insulation or shielding should be provided by the appliance manufacturer; verify proper air circulation is maintained when the appliance is installed.
INSTALLATION
When Installing this Product…
1.Read these instructions carefully. Failure to follow them could damage the product or cause a hazardous condition.
2.Check the ratings given in the instructions and on the product to make sure the product is suitable for your application.
3.Installer must be a trained, experienced service technician.
4.After installation is complete, check out product operation as provided in these instructions.
WARNING
FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE, SEVERE INJURY OR DEATH
Follow these warnings exactly:
1.Disconnect power supply before wiring to prevent electrical shock or equipment damage.
2.To avoid dangerous accumulation of fuel gas, turn off gas supply at the appliance service valve before starting installation, and perform Gas Leak Test after completion of installation.
3.Do not bend pilot tubing at ignition system control or pilot burner after compression fitting is tightened, or gas leakage at the connection can result.
4.Always install a sediment trap in gas supply line to prevent contamination of ignition system control.
WARNING
LINE VOLTAGE
CAN CAUSE PROPERTY DAMAGE, SEVERE INJURY OR DEATH.
Never apply a jumper across or short any of the terminals in the SV9540; SV9640 wiring harness. This can damage the system transformer or the control.
Follow the appliance manufacturer instructions if available; otherwise, use these instructions as a guide.
Converting Ignition System Control from Natural Gas to LP Gas Application (or LP Gas to Natural Gas Application)
WARNING
FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE, SEVERE INJURY OR DEATH
Do NOT attempt to convert step-opening models (SV9540P/SV9542P; SV9640P/SV9642P). Always change the main and pilot burner orifices when converting from natural to LP gas or from LP to natural gas. Follow appliance manufacturer specifications and instructions carefully to assure proper appliance conversion.
Ignition system controls are factory-set for natural (and manufactured) or LP gas. Do not attempt to use an ignition system control set for natural (manufactured) gas on LP gas, or an ignition system control set for LP gas on natural (manufactured) gas.
Ignition system controls with standard or slow opening regulators (SV9540M,H; SV9640M,H) can be converted from one gas to the other with a conversion kit (ordered separately). Order part no. 393691 to convert from natural (manufactured) to LP gas; order part no. 394588 to convert from LP to natural (manufactured) gas.
IMPORTANT
Ignition system controls with step-opening regulators (SV9540P; SV9640P) CANNOT be field-converted to LP or natural gas.
3 |
69-1059 |
SV9540; SV9640 SmartValve™ SYSTEM CONTROLS
Install Adapters To Control
If adapters are being installed on the control, mount them as follows:
Flanges
1.Choose the appropriate flange for your application.
2.Remove the seal over the ignition system control inlet or outlet.
3.Make sure that the O-ring is fitted in the groove of the flange. If the O-ring is not attached or missing, do not use the flange.
4.With the O-ring facing the ignition system control, align the screw holes on the ignition system control with the holes in the flange. Insert and tighten the screws provided with the flange. See Fig. 1. Tighten the screws to 25 inch-pounds of torque to provide a gas-tight seal.
VALVE OUTLET
FLANGE 1
9/64 INCH HEX SCREWS
(4)
1 DO NOT USE FLANGES ON 3/4 IN. INLET |
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AND 3/4 IN. OUTLET MODELS, AND ON |
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THE 3/4 IN. OUTLET SIDE OF 1/2 IN. |
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INLET AND 3/4 IN. OUTLET MODELS. |
M12168 |
Fig. 1. Firmly fasten flange to valve, but do not overtighten screws.
Bushings
1.Remove the seal over the ignition system control inlet or outlet.
2.Apply a moderate amount of good quality pipe compound to the bushing, leaving two end threads bare. On an LP installation, use compound resistant to LP gas. Do not use Teflon tape.
3.Insert the bushing in the ignition system control and carefully thread the pipe into the bushing until tight.
Complete the instructions below for installing the piping, installing the control, connecting the pilot tubing and wiring. Make sure the leak test you perform on the control after completing the installation includes leak testing the adapters and screws. If you use a wrench on the valve after the flanges are installed, use the wrench only on the flange, not on the control. See Fig. 5.
Location
The SV9540; SV9640 are mounted in the appliance vestibule on the gas manifold.
IMPORTANT
These ignition system controls are shipped with protective seals over the inlet and outlet tappings. Do not remove the seals until ready to connect the piping.
Install Piping to Control
All piping must comply with local codes and ordinances or with the National Fuel Gas Code (ANSI Z223.1 NFPA No. 54), whichever applies. Tubing installation must comply with approved standards and practices.
1.Use new, properly reamed pipe free from chips. If tubing is used, make sure the ends are square, deburred and clean. All tubing bends must be smooth and without deformation.
2.Run pipe or tubing to the ignition system control. If tubing is used, obtain a tube-to-pipe coupling to connect the tubing to the ignition system control.
3.Install a sediment trap in the supply line to the ignition system control. See Fig. 2.
DROP |
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PIPED |
IGNITION |
HORIZONTAL |
GAS |
SYSTEM |
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CONTROL |
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SUPPLY |
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RISER |
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IGNITION |
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SYSTEM |
PIPED |
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CONTROL |
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GAS |
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3 IN. |
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SUPPLY |
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(76 MM) |
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MINIMUM |
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2 |
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DROP |
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HORIZONTAL |
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3 IN. |
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TUBING |
(76 MM) |
1 |
GAS |
MINIMUM |
SUPPLY |
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2 |
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IGNITION |
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SYSTEM |
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RISER |
CONTROL |
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3 IN. |
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(76 MM) |
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MINIMUM |
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2 |
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1ALL BENDS IN METALLIC TUBING SHOULD BE SMOOTH.
2CAUTION: SHUT OFF THE MAIN GAS SUPPLY BEFORE REMOVING THE END CAP TO PREVENT GAS FROM FILLING THE WORK AREA. TEST FOR GAS LEAKAGE WHEN INSTALLATION IS COMPLETE.
M3343A
Fig. 2. Sediment trap installation.
Install Control
1.This ignition system control can be mounted 0 to 90 degrees in any direction, including vertically, from the upright position of the ignition system control switch.
2.Mount the control so the gas flow is in the direction of the arrow on the bottom of the ignition system control.
3.Thread the pipe the amount shown in Table 6 for insertion into ignition system control or adapters. Do not thread pipe too far. Valve distortion or malfunction can result if the pipe is inserted too deeply.
Table 6. NPT Pipe Thread Length (in.).
Pipe |
Thread Pipe |
Maximum Depth Pipe can |
Size |
this Amount |
be Inserted into Control |
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3/8 |
9/16 |
3/8 |
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1/2 |
3/4 |
1/2 |
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3/4 |
13/16 |
3/4 |
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69-1059 |
4 |
SV9540; SV9640 SmartValve™ SYSTEM CONTROLS
4.Apply a moderate amount of good quality pipe compound (do not use Teflon tape) only to the pipe, leaving two end threads bare. On LP installations, use a compound resistant to LP gas. See Fig. 3.
TWO |
IGNITION |
IMPERFECT |
SYSTEM |
THREADS |
CONTROL |
PIPE |
THREAD PIPE THE AMOUNT |
APPLY A MODERATE AMOUNT OF |
SHOWN IN TABLE FOR INSERTION |
PIPE COMPOUND ONLY TO PIPE |
INTO IGNITION SYSTEM CONTROL |
(LEAVE TWO END THREADS BARE). |
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M3344 |
Fig. 3. Use moderate amount of pipe compound.
5.Remove the seals over the ignition system control inlet and outlet, if necessary.
6.Connect the pipe to the ignition system control inlet and outlet. Use a wrench on the square ends of the ignition system control. If a flange is used, place the
WHEN FLANGE IS NOT USED
APPLY WRENCH FROM TOP OR
BOTTOM OF IGNITION SYSTEM
CONTROL TO EITHER SHADED AREA
wrench on the flange rather than on the ignition system control. Refer to Fig. 4 and 5.
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IGNITER |
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CONNECTOR |
LINE VOLTAGE |
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PRESSURE REGULATOR |
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CONNECTOR |
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ADJUSTMENT (UNDER |
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C2 |
C3 |
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CAP SCREW) |
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INLET |
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PRESSURE |
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OUTLET |
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TAP |
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PRESSURE |
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TAP |
INLET |
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C1 |
OUTLET |
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OFF ON |
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IGNITION SYSTEM |
CONTROLS |
PILOT |
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CONTROL SWITCH |
CONNECTOR |
OUTLET M15045 |
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Fig. 4. Top view of ignition system control.
WHEN FLANGE IS USED
APPLY WRENCH
TO FLANGE ONLY
M12169
Fig. 5. Proper use of wrench on ignition system control with and without flanges.
Connect Pilot Gas Tubing
1.Cut tubing to the desired length and bend as necessary for routing to the pilot burner. Do not make sharp bends or deform the tubing. Do not bend the tubing at the ignition system control after the compression nut is tightened, because this can result in gas leakage at the connection.
2.Square off and remove burrs from the end of the tubing.
3.Unscrew the brass compression fitting from the pilot outlet (Fig. 4). Slip the fitting over the tubing and slide out of the way. See Fig. 6
4.Push the tubing into the pilot gas tapping on the outlet end of the control until it bottoms. While holding the tubing all the way in, slide the fitting into place and engage the threads—turn until finger tight. Then tighten one more turn with a wrench. Do not overtighten.
5.Connect the other end of the tubing to the pilot burner according to the instructions supplied with Q3450/Q3480.
NOTE: The pilot tubing provides the SmartValve System flame sense current path. Make sure the connections are clean and tight for proper operation.
IGNITION SYSTEM CONTROL
TIGHTEN NUT ONE TURN
BEYOND FINGER TIGHT TO PILOT
BURNER
FITTING BREAKS OFF AND CLINCHES |
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TUBING AS NUT IS TIGHTENED |
M3346 |
Fig. 6. Always use new compression fitting.
5 |
69-1059 |
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