ICM CONTROLS ICM290A Installation Manual

Low cost,

ICM290A

Gas Ignition Control

• Universal intermittent pilot gas ignition control

• Patented circuitry for enhanced operation

• Provides ignition sequence, ﬂame monitoring and safety shutoff for single/ dual rod intermittent pilot control applications

• For gas ﬁred furnaces, boilers and other heating applications

• Switch selectable pre-purge and ignition trials with permanent lock

• Works with or without vent damper connected

• Works with both Natural and LP gas systems

replacement

ignition control

Installation, Operation & Application Guide

For more information on our complete range of American-made products – plus wiring diagrams, troubleshooting tips and more, visit us at www.icmcontrols.com

Speciﬁcations

Operating Temperature: – Minimum ambient temperature rating is -40°F (-40°C) – Maximum ambient rating when used with 2.0 A main valve is 165°F (74°C)

Status LEDs: – Green Status provides system status and error codes – Yellow Flame LED indicates ame presence and ame strength

Control Voltage: Line 24 VAC (18-30 VAC) 50/60 Hz

Flame Current: Typical

Anticipator Setting: 0.3 A plus valve load @ 24 VAC

Trial for Ignition: See Table 1 on reverse side

Prepurge: See Table 1 on reverse side

Flame Failure Response Time: 2 seconds maximum

Typical Gas Control: Honeywell models VR8204 and VR8304

Relative Humidity: 0% to 95% non condensing

Note: The ICM290A ame sensor operates off of 24 VAC directly; ame currents of less than one

micro ampere are typical.

Application

The ICM290A Universal Intermittent Pilot Gas Ignition Control Module replaces many popular ame rectication type of intermittent pilot ignition (IPI) modules, including those manufactured by Honeywell, Robertshaw, and Johnson Controls. Replaces modules that feature:

• Natural or LP gas

• With or without integral damper connector

• Non-100 percent shutoff, 100 percent shutoff/lockout, or 100 percent shutoff/continuous retry

• Pilot burners with ow rates of 1,500 Btuh or less

• Single (local sense) or dual (remote sense) rod ame sensing

• Shutoff/lockout times of 15 seconds or longer

• Prepurge congurable to 30 seconds or no prepurge

For more details on the key features included in the ICM290A control, as well as a cross reference list of controls that the ICM290A will replace, please see Table 1 and Table 2 on the back of this guide, or visit our web site at www.icmcontrols.com.

ICM290A Typical Wiring Connections

Sense Jumper Wire

Connects to REMOTE SENSE connector for single rod installations (local ame sensing)

Note: For remote ame sensing installations

(separate spark and sensor rods), clip the jumper wire as close to the circuit board as possible and remove.

P1 Connector

Connector for vent damper connection (used to control a connected damper in atmospheric appliances)

TH-W Terminal

24 VAC / Hot connector for heat call signal from thermostat

24V Terminal

Optional: 24 VAC power connection for vent damper

PV Terminal

MV/PV Terminal

MV Terminal

Main valve connection

Spark Ignitor

High voltage sparking electrode

Common terminal for gas valves

• If possible, mount the ICM290A control in the same position and using the same mounting holes as the unit you are replacing. If you need to reposition the control, mount the ICM290A using four screws and at a distance no greater than 3 ft. away from the pilot burner and in a place that allows for the most direct spark cable route.

• Connect the thermostat wire (used for a heat call) to the TH-W terminal. The heat call powers the unit.

• Connect common from the control transformer to 24V GND terminal

• Make the remaining PV, MV/PV and MV gas control connections to the appropriate terminals on the control module

• Spark cable specications

– Spark Cable Length: 36” maximum – Spark Cable Voltage Rating: >10,000 (preferably higher) – To ensure maximum spark voltage, plastic or ceramic insulators should be used to

ensure the spark cable does not come in direct contact with a metal surface

– If necessary, use the Rajah adapter to make the connection to the spark terminal on the

control module

– For added safety, both ends of the spark cable should be protected with insulated boots

• Grounding

– Make a ground connection from burner bracket mounting screw to BRN GND terminal

on the board

• Burner

– Ensure that the spark gap is close to 1/8 in.

• Pilot ame

– Make sure it is blue, steady and envelopes 3/8 to 1/2 in. of the ame rod. If necessary

adjust pilot ame by turning the pilot adjustment screw on the gas control

• Damper

– If part of the system, plug the damper cable to P1 connector on the control module – If the plug is removed and the vent damper connector is plugged in instead, then an

internal fuse will blow on power up. The control will not operate without a vent damper or with the plug.

– Connect 24 VAC hot from the control transformer to 24V terminal on the control module

when the Damper assembly is used

Pilot valve connection

Remote Sense

Flame Sensor connector

• For single rod installations: connect the SENSE JUMPER WIRE

to this terminal connector.

• For dual rod installations: connect FLAME SENSE WIRE from

the burner/igniter to this terminal connector

GND Terminal

Burner ground

Power supply – provide disconnect means and overload protection as required.

Alternate limit controller location.

Max. cable length 3 Ft. [0.9 M].

Controls in 24V circuit (NOTE: must not be in ground leg to transformer).

P4 (Jumper)

Locks out DIP switch settings (See “Setting and Adjustments at the right”.)

24V GND Terminal

Return path to transformer

ICM290A

atmospheric burner / vent damper

Thermostat

Wiring Harness

Limit Controller

REMOTE SENSOR

Jumper Wire

Vent Damper

L1 (Hot) L2

SPARK

Pilot COM

1st

2nd

Operator

Dual Valve Combination Gas Control

Pilot Burner/ Igniter

Operator

MV/

GND

(BRN)

Main Valve

Ground

Pilot Gas Supply

24V

24V TH-W P1

GND

ICM290A Settings and Adjustments

Settings and Adjustments

DIP Switch (S1) Settings:

• Many ignition controls may be replaced with the ICM290A control. The DIP switch settings for the most popular competitive models can be found in Table 2 on the reverse side of this guide.

• The table to the right shows lockout control of DIP switch timing settings.

• WARNING: Ignition control should not be powered before setting the DIP

switches.

Prepurge and Trial for Ignition Parameters

• Table to the right displays preferred times for Prepurge (SW1) and Trial for Ignition (SW2).

S1 DIP Switch 2 S1 DIP Switch 1 P4 Jumper

Jumper Action to lock the control’s operating sequence

P4 The P4 Jumper locks in the the operating sequence selected

by the DIP switch settings. Following installation and checkout, pull the P4 jumper to lock the DIP switch settings and ensure proper system operation.

Note: For safety, the ignition control locks the DIP switch

settings after the 10th “heat call” cycle regardless of the jumper being removed.

IMPORTANT: Reinstalling the jumper once it has been removed and/or the

DIP switch settings have been locked will not reset the DIP switch settings.

Prepurge Trial For Ignition SW1 SW2

None 90 seconds OFF OFF

30 seconds 90 seconds ON OFF

None 15 seconds OFF ON

30 seconds 15 seconds ON ON

Note: The default factory settings are in bold.

DIP Switch (S1)

Factory preset as shown (OFF) for SW1 and SW2.

1 2

Wiring DiagramsMounting and Installation

Substitute board plug with damper plug in a system with a vent damper.

Jumper Wire:

For single rod applications: connect to remote sense connector. For dual rod applications: remove (clip as close to board as possible) and discard; rmly attach sensor wire from the igniter/sensor assembly to remote sense connector.

atmospheric burner / no vent damper

Pilot COM

1st

2nd

Operator

Dual Valve Combination Gas Control

Pilot Burner/ Igniter

Operator

MV/

GND

(BRN)

Main Valve

Ground

Pilot Gas Supply

ICM290A

24V

24V TH-W P1

GND

Limit Controller

REMOTE SENSOR

Jumper Wire

L1 (Hot) L2

SPARK

1st Operator

Dual Valve Combination Gas Control

Pilot Burner/ Igniter

Pilot COM

2nd Operator

power-assisted combustion

MV/

Pilot Gas Supply

Main Valve

GND

(BRN)

Ground

ICM290A

24V

24V TH-W P1

GND

Air Proving Switch

Combustion Air Blower Relay

Combustion

(Hot)

Air Blower Motor

REMOTE SENSOR

Thermostat

Limit Controller

L1 (Hot)

Jumper Wire

SPARK

Jumper wire clipped close to board

Sensor wire from ingiter sensor

Two Rod

Remote

Sense

Package Contents

The following is included in the package with the ICM290A control:

• Easy-to-use instructions

• Accessories required to adapt the existing spark cable (Rajah adapter) to the spark terminal on the control module

• Fault code LED label to afx to the appliance

The ICM290A control also features the following:

• High voltage spark, pilot burner ignition control

• Flame rectication circuit for monitoring ame presence

• Monitoring of 24 VAC, pilot, and main gas valve

• Two status LEDs to aid in operation and troubleshooting

• Vent Damper connection

Trial for Pilot Ignition

1. When the thermostat initiates a call for heat, the spark source and the pilot valve relay become energized.

2. The pilot valve opens; gas ows to the pilot burner for the ignition trial time.

3. The control module initiates a spark and attempts to light the pilot ame.

4. A ame rectication circuit checks for the presence of the pilot ame.

5. Upon ame detection, the spark source is shut off and the main valve relay is energized.

Operation

Main Burner Operation

1. The main valve opens, allowing gas to ow to the main burner. Here, the pilot ame ignites the gas.

Note: A short delay occurs when main valve opens in order

to allow the pilot ame to stabilize as the main gas lights.

2. With the system in run mode, the ame rectication circuit will continuously monitor for the presence of the pilot ame.

3. In the event of pilot ame loss, the ICM290A will shut off both the pilot valve relay and the main valve relay for 100% gas shutoff.

Failed Trial for Pilot Ignition

1. The ICM290A is designed to operate with multiple trials for ignition (TFI).

2. When no pilot ames is sensed during the TFI period, the ignition control shuts off the spark and pilot gas (100% shutoff).

3. The control will enter a ve-minute lockout period before the next TFI cycle will begin.

Note: Continuous TFI attempts will be made until a ame is

sensed or the call for heat is satised.

While NOT recommended, the ve-minute lockout period can

be bypassed by manually ending the call for heat or removing and restoring system power.

Flame and Status LED Locations

The ICM290A has two LEDs; one for ame sensing (Yellow) and one for system status (Green). Refer to the Flame Code charts on the reverse side of this application for more details.

Flame LED Status LED

Yellow and Green LED Status Codes

Yellow LED Flame Strength Codes

Yellow LED

Flash Code* Indicates Recommended Service Action

Steady (1/2sec) Flame signal OK N/A

2 • Flame signal is weak

• May also show for few seconds on pilot ame lightoff

1 • Flame signal is marginal

• May also show for few seconds on pilot ame

Routine maintenance is recommended to prolong system work without service-clean the ame rod, ensure steady pilot ame and enveloping the ame rod

Maintenance is recommended to avoid service in a near future-clean the ame rod, ensure steady pilot ame and enveloping the ame rod, ensure good burner ground connection and ame sense wiring

lightoff

OFF Flame signal is below threshold Check for burner ground connection and ame sense wiring, clean the ame rod, ensure steady pilot ame

and enveloping the ame rod

* Flash Code Key:

– Steady: Constant ½ second bright. – LED ashes “X” times, followed by two seconds off before sequence repeats.

Green LED Flame Codes

Green LED ash

Code (X+Y) Indication Recommended Service

OFF No call for heat from the thermostat N/A

Steady (1/2 sec) Heat call, normal operation N/A

2 Flame wasn’t sensed during trial for ignition-unit in ve

minute retry period

3 Flame out during run mode Ensure steady pilot ame enveloping the ame rod. Check burner ground to unit GND connection.

4 Flame out of sequence • Replace gas valve if pilot ame is present

5 Damper related error:

- Required but not present

- Failed to open within a minute

- Failed to close within a minute

7 Flame rod grounded or leakage to ground Check ame sense lead wire for isolation from ground. Check ame rod ceramic body for damages

8 Low control voltage (below 19Vac) Check transformer voltage when fully loaded. Ensure 24 VAC between TH-W and GND when pilot

6+2 Flame wasn’t sensed for three consecutive trials for ignition

on the same call for heat- unit in ve minute retry period

6+3 Flame out during run mode six times on a same call for heat Same as for 3 above

6+4 Flame out of sequence for longer than 10 seconds Same as for 4 above

Constant ON Error not listed above detected during self-test diagnostic

check

* Flash Code Key: – Steady: Constant ½ second bright. – Single Flash Code: LED ashes “X” times followed by two seconds off, before sequence repeats. – X + Y Flash Code: LED ashes “X” times followed by two seconds off, then ashes “Y” times followed by three seconds off, before the sequence repeats.

Remove the heat call and check the following: burner gas supply, spark wiring, ame sense wiring, and burner ground to unit GND connection. Clean the ame rod. Initiate a call for heat and ensure a steady pilot ame enveloping the ame rod

Clean the ame rod.

• Recycle call for heat. Replace the unit if pilot ame is not present and unit senses ame

• Check 24 VAC connection to 24V on the unit and damper connection

• Remove the heat call, pause for a minute, and apply the heat call. If problem persists replace the damper

or cracks

and main valve are closed

Same as for 2 above

Control can be RESET by initiating a “Heat Call”. If problem persists, control should be replaced.

Table 1 – ICM290A Universal Intermittent Pilot Gas Ignition Controls

Igniter-Sensor Type

Combination (single rod; local ame sensing), or Separate (dual rod; remote ame sensing).

Valve Current

Rating @

24 VAC

1.0 A Pilot, and,

2.0 A Main

Prepurge

Timing

None or 30 seconds (eld selectable)

Trial for Pilot

Ignition

15 or 90 seconds (eld selectable)

Ignition

Sequence

Type

Ignition Sequence (after prepurge if

prepurge is selected) Integral Damper Connector

Retry Spark / pilot gas ON until lightoff or trial for

ignition (TFI) ends:

• Pilot gas and spark OFF (100% shutoff) if pilot fails to light; unit enters ve minute lockout before a new TFI is initiated. This sequence continues until lightoff, or heat call ends.

• Trial for ignition restarts immediately if established ame is lost.

Included for use as needed:

• If initially installed with damper attached, unit must always have a vent damper connected.

Table 2 – ICM290A Replaces the follow controls:

Camsat

Vendor / Model

IPI-24-00

Fenwall

Vendor / Model

05-203025-005, 05-203026-005

Honeywell

Vendor / Model

S86A1001, S86A1019, S86A1027, S86A1035, S86B1009, S86B1017, S86B1025, S86C1007, S86C1015 S86C1023 S86C1031, S86C1049, S86C1056, S86D1005 S86D1013

S86D1021, S86E1002, S86E1010, S86E1028, S86E1036, S86E1044, S86E1051, S86E1069, S86E1077, S86E1101, S86E1119, S86E1127, S86F1000, S86F1018, S86F1026, S86F1042, S86F1059, S86F1067, S86F1075, S86F1083, S86F1091, S86G1008, S86G1016

S86G1024 S86G1032, S86G1057, S86G1073, S86H1006 S86H1014 S86H1022, S86H1048, S86H1055 S86H1063 S86H1089, S86H1097, S86H1105 S86H1113 S86H1121 S86H1139 S86H1147, S90A1005, S90B1003, S90B1011 S860C1000, S860D1009 S860D1017 S8600A1001, S8600B1009 S8600B1025, S8600B3005 S8600B3013, S8600C1015, S8600C3003, S8600F1000, S8600F1034, S8600F1042, S8600H1006 S8600H1014 S8600H1022, S8600H1048, S8600H1055 S8600H1063 S8600H1071, S8600H1089, S8600H1097, S8600H1105, S8600H3002 S8600H3010

S8600M1005, S8600M1013, S8600M1021, S8600M2003, S8600M3001, S8600M4009, S8610A1009, S8610B1007, S8610B1015

S8610B1023, S8610B3003 S8610C1005, S8610C1013, S8610C3001, S8610F1008, S8610F1016, S8610F1024, S8610F1032 S8610H1004 S8610H1012 S8610H1020 S8610H1038, S8610H1046, S8610H1053 S8610H1061 S8610H1079, S8610H1095, S8610H3000 S8610H3018 S8610H3026, S8610M1003 S8610M1011 S8610M1029, S8610M3009 S8610M3017 ICM2901003, ICM2901011 S8620C1003, S8620C1011 S8620H1002 S8620H1010 S8620H1028 S8660D1002 S8660D1010 S8660J1008, S8660J1016, S8660J1024, S8660K1006, S8660K1014, S8660K1022, S8670D1000, S8670D1018 S8670D1026, S8670D3006 S8670D3014, S8670E1007, S8670E3003 S8670J3002 S8670J3010, S8670K3000 S8680J1004

HSC

Vendor / Model

1003-3, 1003-300

SW1 SW2

OFF OFF

SW1 SW2

OFF OFF

SW1 SW2

OFF OFF OFF ON OFF OFF OFF ON

OFF OFF

OFF ON OFF OFF OFF ON OFF OFF OFF ON OFF OFF OFF ON OFF OFF OFF ON OFF OFF

ON OFF

ON ON OFF OFF OFF ON OFF OFF OFF ON OFF OFF OFF ON OFF OFF OFF ON

OFF OFF

OFF ON OFF OFF OFF ON OFF OFF OFF ON OFF OFF OFF ON OFF OFF OFF ON OFF OFF OFF ON OFF OFF OFF ON OFF OFF OFF ON OFF OFF OFF ON OFF OFF

ON OFF

ON ON

ON OFF

ON ON

ON OFF

ON ON

ON OFF

ON ON

SW1 SW2

OFF OFF

Vendor / Model

Johnson Controls

CSA35A-617R, CSA35A-618R, CSA42A-600R, CSA42A-601R, CSA42A-602R, CSA42A-603R, CSA42A-604R, CSA43A-600R, CSA44A-600R, CSA45A-601R, CSA45A-602R, CSA46A-600R, CSA48A-600R, CSA49A-600R, CSA49A-605R, CSA51A-601R, CSA52A-600R

G60AAA-1, G60AAG-1, G60AAG-2, G60AAG-3, G60AAG-4, G60AAG-5, G60AAG-6, G60AAG-7, G60CAA-1, G60CAA-3, G60CAG-1, G60CAG-2, G60CAG-3, G60CAG-4, G60CAG-5, G60CAG-6, G60CAG-7, G60CAG-8, G60CAG-9, G60CBA-1, G60CBA-2, G60CBA-3, G60CBG-1, G60CBG-2, G60CBG-3, G60CBG-4, G60CBG-5, G60CBG-6, G60CBG-7, G60CBG-8, G60CBG-9, G60CBG-10, G60CBG-11, G60CBG-12, G60CBG-13, G60CBG-14, G60CBG-15, G60CBG-16, G60CBG-17, G60CCA-1, G60CCG-1, G60CPG-1, G60DBG-1, G60DCG-1, G60DCG-2, G60DCG-3, G60DCG-4, G60PAG-1, G60PAG-2, G60PAG-3, G60PAG-4, G60PAG-5, G60PAG-6, G60PAJ-1, G60PAK-1, G60PAK-2, G60PFH-1, G60PFH-2, G60PFL-1, G60PFQ-1, G60PVL-1, G60QAG-1, G60QAG-2, G60QAG-3,

G60QAG-4, G60QAK-1, G60QBG-1, G60QBG-2, G60QBG-3, G60QBG-4, G60QBG-5, G60QBG-6, G60QBG-7, G60QBG-8, G60QBG-9, G60QBH-1, G60QBK-1, G60QBK-2, G60QBK-3, G60QBL-1, G60QBL-2, G60QCG-1, G60QCJ-1, G60QCL-1, G60QDG-1, G60QFL-1, G60QGH-1, G60QHL-1, G60QHL-2, G60QJL-1, G60QLG-1, G60QLK-1, G60QPL-1, G60QRH-1, G60QRH-2, G60QRH-3, G60QRL-1, G60QRL-2, G60QRL-3, G60QSL-1, G60QTH-1, G60QTL-1, G60RAG-1, G60RAK-1, G60RBG-1, G60RBG-2, G60RBG-3, G60RBK-1, G60RBK-2, G60RCG-1, G60RCG-2, G60RCJ-1, G60RDG-1, G60RDK-1, G60RGL-1, G60RHL-1, G60RHP-1, G60RPL-1, G60RSL-1, G60TTL-1, G60ZAG-1, G60ZAG-2

G65BBG-1, G65BBG-2, G65BBG-3, G65BBG-4, G65BBG-5, G65BBG-6, G65BBG-7, G65BBG-8, G65BBM-1, G65BBM-2, G65BBM-3, G65BBM-4, G65BCG-1, G65BCM-1, G65BFG-1, G65BFM, G65BKG-1, G65BKG-2, G65BKG-3, G65BKM-1, G65BKM-2, G65BKM-3, G65BLG-1, G65BLG-2, G65DBG, G65DBM-1, G65DBM-2, G65DBM-3, G65DCM-1, G65DFG, G65DFM-1, G65DKG, G65DKM, G65DKM-1, G65DLM-1, G65FBG, G65FFG, G65FKG

G66AG-1, G66AG-2, G66BG-1, G66MG-1, G66MG-2, G66NG-1

G67AG-3, G67AG-4, G67AG-7, G67AG-8, G67AG-9, G67AG-10, G67AG-11, G67BG-2, G67BG-3, G67BG-4, G67BG-5, G67MG-1, G67MG-2, G67MG-3, G67MG-4, G67NG-2, G67NG-4

G600AX-1, G600AX-2, G600AX-3, G600AY-1, G600LX-1, G600LX-2, G600LY-1, G600MX-1, G600NX-1, G600RX-1

G670AW-1, G670AW-2, G670GA-1

G770LGA-1, G770LGA-2, G770LGC-1, G770LGC-2, G770LGC-3, G770LGC-4, G770LHA-1, G770LHA-2, G770LHC-1, G770MGA-1, G770MGA-2, G770MGA-3, G770MGC-1, G770MGC-2, G770MGC-3, G770MGC-4, G770MGC-5, G770MGC-6, G770MHA-1, G770MHA-2, G770MHC-1, G770NGA-1, G770NGC-4, G770NGC-5, G770NGC-6, G770NGC-7, G770NHA-1, G770NHC-1, G770RGA-1, G770RHA-1, G770RHA-2

G775RGA-1, G775RHA-1, G775RHA-2

G779

Y79ABC-1, Y79ABC-2, Y79ABC-3, Y79ABC-4, Y79ABC-5, Y79ABC-6, Y79ABC-7, Y79ABD-1, Y79ABCD-2, Y79BBA-1, Y79BBA-2

RobertShaw

Vendor / Model

780-001, 780-002 780-003 780-845, 780-715, 780-735, 780-736, 780-737 SP715, SP715A, SP735, SP735D, SP735L USI715U

White-Rodgers

Vendor / Model

50D49-350, 50D49-360 50D49-361 50D49-401

ONE-YEAR LIMITED WARRANTY

The Seller warrants its products against defects in material or workmanship for a period of one (1) year from the date of manufacture. The liability of the Seller is limited, at its option, to repair, replace or issue a non-case credit for the purchase prices of the goods which are provided to be defective. The warranty and remedies set forth herein do not apply to any goods or parts thereof which have been subjected to misuse including any use or application in violation of the Seller’s instructions, neglect, tampering, improper storage, incorrect installation or servicing not performed by the Seller. In order to permit the Seller to properly administer the warranty, the Buyer shall: 1) Notify the Seller promptly of any claim, submitting date code information or any other pertinent data as requested by the Seller.

2) Permit the Seller to inspect and test the product claimed to be defective. Items claimed to be defective and are determined by Seller to be non-defective are subject to a $30.00 per hour inspection fee. This warranty constitutes the Seller’s sole liability hereunder and is in lieu of any other warranty expressed, implied or statutory. Unless otherwise stated in writing, Seller makes no warranty that the goods depicted or described herein are t for any particular purpose.

SW1 SW2

OFF OFF

SW1 SW2

OFF OFF

ON OFF OFF OFF OFF OFF OFF OFF

SW1 SW2

OFF OFF

ON OFF OFF OFF

7313 William Barry Blvd., North Syracuse, NY 13212

(Toll Free) 800-365-5525 (Phone) 315-233-5266 (Fax) 315-233-5276

www.icmcontrols.com

Patented:

Energy Preservation & Transfer Mechanism (#5,889,645)

Fail Safe Relay Driver (#5,917,691)

Ignition Boost (#6,222,719)

PWM relay actuator circuit (#5,930,104)

LIAF050-2

ICM CONTROLS ICM290A Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual