White Rodgers 21V51U 843 Universal Two Stage Hsi Integrated Furnace Control Kit Installation Instructions 843_37 7115C
2015-03-28
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CAUTION
WARNING
Failure to comply with the following
warnings could result in personal injury
or property damage.
21V51U-843
Integrated Two-Stage/Variable Speed Motor
Hot Surface Ignition Control Kit
PART NO. 37-7115C
Replaces 37-7115B
1102
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.
PRECAUTIONS
CONTENTS
Description .......................................................................1
Precautions ......................................................................1
Specifications ...................................................................2
Timing Table & Definitions ................................................2
Installation ........................................................................3
Mounting & Wiring
Option Switch Settings .....................................................3
Wiring ..............................................................................5
Operation .........................................................................7
Troubleshooting ................................................................7
DESCRIPTION
www.white-rodgers.com
www.emersonclimate.com
The kit Includes:
50V51-843 Ignition Control Module•
21D64-2 Ignitor Kit•
Set of Interconnect Harnesses (for Goodman)•
The 50V51-843 is a two-stage automatic gas interrupted igni-
tion control employing a microprocessor to continually monitor,
analyze, and control the proper operation of the gas burner and
inducer. The 50V51-843 provides signals for proper operation
of a variable fan speed circulator blower.
Signals interpreted during continual surveillance of the two-
stage thermostat and flame sensing element initiate automatic
ignition of the burner, sensing of the flame, and system shutoff
during normal operation.
The control incorporates system fault analysis for quick gas
flow shutoff, coupled with automatic ignition retry upon sensing
a fault correction.
Installation should be done by a qualified heating and air con-
ditioning contractor or licensed electrician.
If in doubt about whether your wiring is millivolt, line, or low volt-
age, 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.
FIRE HAZARD
-
SHOCK HAZARD
EXPLOSION HAZARD
2
21V51U-843 TIMING TABLE
(All times are in seconds, unless noted otherwise)
Event 50M51-843
Pre-purge Time The period of time intended to allow for the dissipation of any unburned
gas or residual products of combustion at the beginning of a furnace
operating cycle prior to initiating ignition
15
Igniter Warm-up Time The length of time allowed for the igniter to heat up prior to the initiation
of gas flow.
17
Trial for Ignition Period (TFI) The period of time between initiation of gas flow and the action to
shut off the gas flow in the event of failure to establish proof of the
supervised ignition source or the supervised main burner flame.
4
Ignition Activation Period (IAP) The period of time between energizing the main gas valve and
deactivation of the ignition means prior to the end of TFI
3
Retries The additional attempts within the same thermostat cycle for ignition
when the supervised main burner flame is not proven within the first
trial for ignition period.
2 times
Valve Sequence period Valve sequence period equals 4 seconds trial for ignition period x (1
initial try + 2 retries) + 12 seconds.
12
Inter-purge The period of time intended to allow for the dissipation of any unburned
gas or residual products of combustion between the failed trial for
ignition and the retry period.
60
Post-purge Time The period of time intended to allow for the dissipation of any unburned
gas or residual products of combustion at the end of a furnace burner
operating cycle. Post-purge begins at the loss of flame sense.
15
Lock-Out Time ANSI standard rated module timing. 300
Heat Delay-To-Fan-On The period of time between proof of the supervised main burner flame
and the activation of the blower motor at Heat speed.
45
Heat Delay-To-Fan-Off* The period of time between the loss of a call for heat and the
deactivation of the blower motor at Heat speed.
90/120/150/180
Cool Delay-To-Fan-On The period of time after a thermostat demand for cool before
energizing the circulator blower motor at Cool speed.
5
Cool Delay-To-Fan-Off The period of time between the loss of a call for cool and the
deactivation of the blower motor at Cool speed.
60
Automatic Reset Time After one (1) hour of internal or external lockout, the control will
automatically reset itself and go into an auto restart purge for 60
seconds.
60 minutes
*These times will vary depending on option switch position.
SPECIFICATIONS
25 VAC, 60 Hz (Class II transformer required)
500mA + MV
Gas Valve Relays: 1.5 amps @ 25 VAC, 60 Hz
Inducer Relays: 2.2 FLA - 3.5 LRA @120 VAC
Ignitor Relay: 4.0 amps @ 120 VAC (Resistive)
Humidifier/EAC: 120 VAC/1 Amp
Minimum current to insure flame detection: 0.3 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)
(@ 60 Hz)
Flame Establishing Time: 0.8 sec
Flame Failure Response Time: 2.0 secs
Natural, Manufactured, Mixed, Liquefied Pe-
troleum, and LP Gas Air Mixtures are all approved for use.
3
The 50V51-843 has only one serviceable part –an automotive
type fuse, which protects the low voltage transformer from dam-
age if the 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 does not
correct the condition, replace the entire 50V51 control. There
are not other user serviceable parts.
Following installation or replacement, follow appliance manu-
facturer’s recommended installation or service instructions to
insure proper operation.
INSTALLER MUST READ FOR PROPER
INSTALLATION
• Wiring harnesses are included in this package to complete
the installation of the “UNIVERSAL 50V51-843” for
Goodman applications.
• Installer must read section and set
switches for proper control operation.
• For replacing the ignitor, a UNIVERSAL 21D64-2 is included.
For proper installation, refer to the instructions included in
the 21D64-2 kit.
• IMPORTANT: The installer may have to enlarge existing igni-
tor hole to accommodate 21D64-2 larger (.394”) diameter.
MOUNTING AND WIRING
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.
Any orientation is acceptable.
Refer to the wiring diagram and wiring table when connecting
the 50V51 control to other components of the system.
UL approved, 105°C rated 18 gauge min., stranded, 2/64” thick
insulation wire is recommended for all low voltage safety circuit
connections. Refer to 50V51 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 50V51 specification sheet for recommended terminals
to mate with those on the control.
GOODMAN NOTE
TWO ADAPTER HARNESSES INCLUDED IN THIS PACKAGE
TO COMPLETE THE INSTALLATION.
INSTALLATION
OPTION SWITCH SETTINGS
MOTOR OPTIMIZATION
The motor
configuration DIP switches S3 and S4 must be set to match set-
tings of the original furnace settings for proper motor function. To
set the new board for the motor function, the DIP switches must
be set to match the settings of the board being replace.
IMPORTANT: Be sure to use proper switches for new board
settings. Switch locations on old board may not be the same
location as on the new board.
The existing board has four shunt jumper banks to set
motor function configuration. The four jumper banks are des-
ignated DELAY , COOL , HEAT , ADJ. .
Each jumper bank has four pair of pins to have jumper installed
to determine the type of voltage to the motor. These pin pairs
are A (no signal) B (positive Half-wave rectified), C (negative
Half-wave rectified), D (Full-wave unrectified).
DELAY
A
B
C
D
A
B
C
D
A
B
C
D
COOL
Jumper Banks
(Existing Board
Example Settings)
HEAT ADJ
E45 E43 E46 E44
SW4 SW3
1 2 3 4
ON
OFF
1 2 3 4
ON
OFF
Switch Position
50V51-843
(New Board)
SW4
5 6 7 8
ON
OFF
SW3
1 2 3 4
ON
OFF
Existing 50V51
or 50V61
On the new board, the motor functions must be duplicated on
DIP switched S3 and S4 per the following table.
SW4 SW3
1 2 3 4
ON
OFF
1 2 3 4
ON
OFF
Switch Position
50V51-843
(New Board
Example Settings)
ABCD
No Signal Positive
Half Wave
Negative
Half Wave
Full
Wave
Delay
S4-1 OFF ON OFF ON
S4-2 OFF OFF ON ON
Cool
S3-1 OFF ON OFF ON
S3-2 OFF OFF ON ON
Heat
S4-3 OFF ON OFF ON
S4-4 OFF ON ON ON
Adjust
S3-3 OFF ON OFF ON
S3-4 OFF OFF ON ON
4
OPTION SWITCH SETTINGS
Heat Pump Systems
DIP switch S5-1 (see table above) is set to “On” from the factory
for use with conventional (non-Heat Pump systems). For heat
pump systems move the S5-1 DIP switch to the “Off” position.
This will continuously output an O signal to the motor whenever
there is Y signal and run the circulator blower at a constant speed
when the pump is operating.
De-Humidification Connection
DIP switch S5-2 (see table above) is set to “On” from the factory
for systems that do not have a dehumidification terminal con-
nection from the thermostat. For systems using a thermostat
that provides a De-Humidification option move DIP switch S5-2
to “Off”.
Options
Heat Pump
S5-1
S5-1
Off Installed
On Not Installed*
De-humidifier
S5-2
S5-2
Off Installed
On Not Installed*
*Factory Settings
S5
1
2
OFF ON
HEAT PUMP AND DE-HUMIDIFICATION
Heat Fan Off Delay Timing
DIP switches S7-3 and S7-4 (see table above) configure the
number of seconds the blower will run after the call for heat
ends. Factory default is 90 seconds.
than
0 38 12 minutes Light
38 50 10 minutes Light to Average
50 62 7 minutes Average
62 75 5 minutes Average to Heavy
75 88 3 minutes Heavy Light
88 100 1 minute Heavy
S7
Options
Thermostat
Type and W2
Delay
S7-2
S7-1 S7-2
Off Off Off*
On Off 10 Minutes
Off On Auto
On On 20 Minutes
Heat Fan Off
Delay
S7-4
S7-3 S7-4
Off Off 90 Secs*
Off On 120 Secs
On Off 150 Secs
On On 180 Secs
*Factory Settings
3
4
1
2
OFF ON
THERMOSTAT TYPE AND HEAT-FAN-OFF-DELAY
Multi-stage Thermostat Set-up,
Factory Default
DIP switches S7-1 and S7-2 (see table above) are set to the
“Off” position from the factory for use with a multi-stage ther-
mostat. This allows the thermostat to control staging between
low and high fire.
Single Stage Thermostat Set-up,
Module Controls Staging
DIP switches, S7-1 and S7-2 (see table above) configure for a
single stage thermostat. Options include a 10 minute delay on
second stage, 20 minute delay on second stage or an Auto set-
ting allowing the module to calculate the time delay for second
stage based on average demand. The “Average Calculated
Duty Cycle” table shows how the module calculates staging
based on demand.
FURNACE MANUFACTURER
S2 OEM
1 2
OFF OFF Trane
OFF ON Thermo Pride/
Goodman
ON OFF Lennox
ON ON York
3
1
2
OFF ON
S2
-
Set DIP switches S2-1 and S2-2 to match the equipment using
the table above. NOTE: DIP switch S2-3 is not used.
5
The 50V51-843 has only one serviceable part –an automotive
type fuse, which protects the low voltage transformer from dam-
age if the 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 50V51-843
control. There are no other user serviceable parts.
Following installation or replacement, follow appliance manu-
facturer’s recommended installation or service instructions to
insure proper operation.
Y
W1
W2
G
R
O
B/C
DEHUM
YLO
R
G
W2
W1
Y2
Y
THERMOSTAT
50V51-843 TYPICAL SYSTEM WIRING DIAGRAM
LEGEND
HOT
NEUTRAL
120 VAC
24 VAC CLASS II
TRANSFORMER
50V51-843
24 VACTH TR
LINE
XFMR
EAC
HUM
CIRC N
HUM N
LINE N
XFMR N
EAC N
E2
HUMIDIFIER
ELECTRONIC
AIR CLEANER
CONDENSING
UNITS
FLAME
SENSOR
PROBE
2ND STAGE PRESSURE
HIGH LIMIT
AUX. HIGH
1ST STAGE PRESSURE
GAS
VALVE
HLO
HLI
FP
PS1
MVL
MVH
GND
GND
PS2
MV COM
TR
TH
INDUCER IGNITOR
IGN
IND HI
IND LO
IND N
IGN N
ROLLOUT
CIRCULATOR
CIRC.
INTER-
FACE
[5-Pin Connector]
[12-Pin Connector]
MVH
HLO
THPS2
GNDGND
MVL
FP HLITRPS1
MV
COM
IGN IND
LO
IND
N
IND
HI
IGN
N
5-Pin Connector 12-Pin Connector
WIRING
6
MVH (Pin 1) gas valve SECOND STAGE
PS2 (Pin 2) 2nd stage pressure switch INPUT
FP (Pin 3) flame sensor probe*
GND (Pin 4) MUST BE RELIABLY GROUNDED TO CHASSIS
TH (Pin 5) 24 VAC transformer (low voltage HIGH SIDE)
HLI (Pin 6) high limit INPUT
MVL (Pin 7) gas valve FIRST STAGE
MV COM (Pin 8) gas valve COMMON
TR (Pin 9) 24 VAC transformer (low voltage COMMON SIDE)
GND-2 terminals (Pin 10) MUST BE RELIABLY GROUNDED TO CHASSIS
HLO (Pin 11) high limit OUTPUT
PS1(Pin 12) 1st stage pressure switch INPUT
50V51-843
TERMINAL
TERMINAL
TYPE
SYSTEM COMPONENT
CONNECTION
24 VAC COMMON
low heat speed select OUTPUT Circulator Blower
24 VAC COMMON
Delay tap OUTPUT to circulator
Cool tap OUTPUT to circulator
“YLO” OUTPUT to circulator
adjust tap OUTPUT to circulator
24 VAC COMMON
“O” OUTPUT to circulator
Humidistat/Y-Y2 OUTPUT to Circulator Blower
Heat tap OUTPUT to circulator
24 VAC OUTPUT to circulator
“W2” OUTPUT to circulator
“Y” OUTPUT to circulator
“G”/YLo OUTPUT to Circulator Blower
green CFM indicator
16-pin
connector
& harness
50V51-843 TYPICAL SYSTEM WIRING TABLE
* maximum recommended flame probe wire length is 36 inches.
NOTE: Spade terminals are 0.25” x 0.032”
W1
W2
G
R
B/C
YLO
Y
DEHUM
O
E2-1
E2-2
E2-3
E2-4
E2-5
E2-6
E2-7
E2-8
E2-9
E2-10
E2-2
E2-12
E2-13
E2-14
E2-15
E2-16
9-screw
terminal
block
IGN ( Pin 1) ignitor HOT side
IND HI (Pin 2) inducer HIGH SPEED HOT side
IND LO (Pin 3) inducer LOW SPEED HOT side
IND N (Pin 4) inducer NEUTRAL side
IGN N (Pin 5) ignitor NEUTRAL side
spade terminal
spade terminal
spade terminal
spade terminal
spade terminal
spade terminal
spade terminal
spade terminal
spade terminal
spade terminal
circulator blower HOT terminal
input voltage (120 VAC) HOT side
24 VAC transformer line voltage HOT side
electronic air cleaner HOT side
humidifier HOT side
circulator blower NEUTRAL side
input voltage (120 VAC) NEUTRAL side
24 VAC transformer line voltage NEUTRAL side
humidifier NEUTRAL side
electronic air cleaner NEUTRAL side
CIRC
LINE
XFMR
EAC (optional)
HUM (optional)
CIRC N
LINE N
XFMR N
HUM N (optional)
EAC N (optional)
two-stage thermostat W1 terminal (or equivalent)
two-stage thermostat W2 terminal (or equivalent)
two-stage thermostat G terminal (or equivalent)
two-stage thermostat R terminal (or equivalent)
two-stage thermostat B/C terminal (or equivalent)
two-stage thermostat Y terminal (or equivalent)
two-stage thermostat Y2 terminal (or equivalent)
humidistat enable OUTPUT to circulator
H/P or cooling mode OUTPUT to circulator
MVH
HLO
THPS2
GNDGND
MVL
FP HLITRPS1
MV
COM
IGN IND
LO
IND
N
IND
HI
IGN
N
WIRING
7
TROUBLESHOOTING
SYSTEM LOCKOUT
When a system lockout occurs (1hour), the gas valve is de-
energized, the low speed inducer blower is energized for the
60 second interpurge period and the circulator is energized for
selected heat off delay if it was previously ON. The diagnostic
indicator light will flash the fault that is present (refer to
diagnostic table).
System Reset
Remove 24 VAC power to the control for twenty (20) seconds
or longer to reset the control.
Thermostat Reset
Remove the call for heat from the thermostat for a period of
between (1) second and less 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.
Auto Restart
After one (1) hour of internal or external lockout, the control
will automatically reset itself and go into an auto restart purge
for 15 seconds.
DIAGNOSTIC FEATURES
The control continuously monitors its own operation and the
operation of the system. If a failure occurs the diagnostic
indicator LED (DSI) will flash a “RED” failure code.
If the LED
is continuously OFF, there may be no power to the control
or a failure within the control. If the sensed failure is in the
system (external to the control), the LED will flash RED in
the sequence listed in the Diagnostic Table. The LED will also
indicate “System Status” as per the Amber and Green LED
signatures listed in the Diagnostic Table. The LED will flash one
RED flash at power up.
CFM INDICATOR
The LED (DS2) CFM flashes when the blower motor is running.
The flashing indicates the motor CFM (cubic feet per minute)
air flow designated by the furnace manufacturer. Consult the
furnace manufacturer for flash code detail.
FAULT CODE RETRIEVAL
To retrieve fault codes, push and release the “LAST ERROR”
button for more than 1/5 second and less than 5 seconds.
(Control will indicate this period by solid GREEN for 1/5 secs.
to 5 secs.). The LED will flash up to five stored fault codes,
beginning with the most recent. If there are no fault codes in
memory, the LED will flash two green flashes. The control will
flash the most recent error first and the oldest error last (last in
first out). There shall be 2 seconds between codes. Solid LED
error codes will not be displayed.
NOTE
When the thermostat calls for heat the module verifies the
pressure switches are open and energizes the inducer (high
speed) and optional humidifier contacts. When the low pressure
switch contacts close a 15 second pre-purge begins. After 15
seconds the inducer switches to low speed and the 120 VAC
ignitor is energized. The ignitor warms up for 17 seconds and
the gas valve is energized on low fire. Flame must be detected
within 4 seconds. If flame is detected, a 45 second heat,
fan on time delay begins. This allows the heat exchanger to
warm up before energizing the circulator on low speed and
(optional) Electronic Air Cleaner contact. When the thermostat
(or module) initiates second stage the inducer is energized at
high speed.
This closes the second stage inducer pressure switch then
energizes the second stage on the gas valve and then the high
heat circulator speed.
When the thermostat satisfies for second stage, the control
will switch high speed inducer and high fire gas valve to low
speed inducer and low fire gas valve. After the 30 second high
heat fan delay the circulator will drop to low speed. When the
thermostat satisfies for first stage the gas valve de-energizes
and the inducer will run low speed for a 15 second post-purge.
The circulator runs until the heat off delay ends.
Note: If the module is configured for a single stage thermostat
and running on second stage when the call for heat ends, the
circulator will drop to low speed after 30 seconds and continue
until the heat off delay ends.
COOL MODE
In a typical system, a call for cool is initiated by closing Y
and G. This energizes the compressor and the electronic air
cleaner (optional). The electronic air cleaner and the G and (Y
or outputs to the Circulator motor will energize after the 5
second cool on delay period. After the thermostat is satisfied,
the compressor is de-energized and the control starts a 60
second cool circulator speed off delay. After 60 seconds the
circulator is de-energized.
MANUAL FAN ON MODE
If the thermostat fan switch is moved to the “ON” position, the
electronic air cleaner (optional) and the G circulator output to
the circulator motor will be energized. When the fan switch is
returned to the AUTO position, the G circulator output and the
electronic air cleaner are de-energized.
OPERATION
Green
LED
LED
1 Flame sensed when no flame should
be present
Verify the gas valve is operating and shutting down properly. Flame
in burner assemble should extinguish promptly at the end of the
cycle. Check orifices and gas pressure.
2 Pressure switch stuck closed/ inducer
error
Pressure switch stuck closed. Check switch function, verify inducer
is turning off.
3 1st-stage pressure switch stuck open/
inducer error
Check pressure switch function and tubing. Verify inducer is turning
on the pulling sufficient vacuum to engage switch.
4 Open limit switch Verify continuity through rollout switch circuit.
5 Open rollout/open fuse detect Verify continuity through rollout switch circuit, check fuse.
6 1st-stage pressure switch cycle
lockout
If the first stage pressure switch cycles 5 times (open, closed)
during one call for heat from the thermostat the control will lockout.
Check pressure switch for fluttering, inconsistent closure or poor
vacuum pressure.
7 External lockout (retries exceeded) Failure to sense flame is often caused by carbon deposits on the
flame sensor, a disconnected or shorted flame sensor lead or a
poorly grounded furnace. Carbon deposits can be cleaned with
emery cloth. Verify sensor is not contacting the burner and is located
in a good position to sense flame. Check sensor lead for shorting
and verify furnace is grounded properly.
8 External lockout (ignition recycles
exceeded where flame is established
and then lost)
Check items for exceeded retries listed above and verify valve is not
dropping out allowing flame to be established and then lost.
9 Grounding or Reversed polarity Verify the control and furnace are properly grounded. Check and
reverse polarity (primary) if incorrect.
10 Module gas valve contacts energized
with no call for heat
Verify valve is not receiving voltage from a short. If a valve wiring is
correct and condition persists, replace module.
11 Limit switch open – possible blower
failure overheating limit
Possible blower failure, restricted air flow through appliance or
duct work. Verify continuity through limit switch circuit and correct
overheating cause.
12 Module Ignitor contact failure Fault code indicates the module ignitor contacts are not functioning
properly. Replace module.
Solid Module - internal fault condition Module contacts for gas valve not operating or processor fault.
Reset control. if condition persists replace module.
3 double 2nd-stage Pressure Switch Stuck
Open/Inducer Error
Check pressure switch function and tubing. Verify inducer is turning
on and pulling sufficient vacuum to engage switch.
1 Normal Operation with call for first
stage heat
Normal operation - first stage
2 Normal Operation with call for second
stage heat
Normal operation - first stage
3 W2 present with no W1 Second stage call for heat on thermostat circuit with no call for first
stage. Verify DIP switches are set for two stage thermostat and
check thermostat first stage circuit. Configured for a multi-stage
thermostat the Module will not initiate heating unless first stage call
from thermostat is received.
4 Y present with no G call Module will allow cooling to operate with only a "Y signal from
the thermostat but will also trigger this code. Verify thermostat is
energizing both "Y" and "G" on call for cool. Check "G" terminal
connections.
Rapid Low flame sense current Low flame sense current is often caused by carbon deposits on
the flame sensor, a poorly grounded furnace or a mis-aligned
flame sense probe. Carbon deposits can be cleaned with emery
cloth. Check for improve furnace and module ground. Verify sensor
is located in or very near flame as specified by the appliance
manufacturer.
1 Standby or Call for Cool Normal operation. Waiting for call from thermostat or receiving
thermostat call for cool.
White-Rodgers is a division
of Emerson Electric Co.
The Emerson logo is a
trademark and service mark
of Emerson Electric Co.
