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INSTALLATION INSTRUCTIONS
APPLICATION Line voltage polarity sensing models monitor the line
voltage input connection to assure line voltage polarity is
correct. If line voltage polarity is incorrect, the LED
The TRADELINE® SV9510/SV9520 SmartValve™ diagnosis code will flash and the control will not respond to
System Controls combine gas flow control and electronic the call for heat. These models also provide added LED
direct main burner ignition sequencing functions into a diagnostic codes (“6+”) to indicate the reason the control
single unit. The ignition source is 120V hot surface igniter has moved to the lockout state. See Tables 9 and 10.
lighting the main burner flame. Two types of 120V
igniters may be used; see Table 1. Provides all gas
ignition safety functions by controlling gas flow, ignition
source, and a 120 Vac combustion air blower. The
SPECIFICATIONS
control also monitors the appliance airflow proving switch
circuit and limit string to assure proper appliance
operation. The SmartValve™ System Controls provide
prepurge, postpurge and timed trial for ignition with
CAUTION
Equipment Damage Hazard.
multiple ignition trials and auto reset from lockout. Incorrect replacement will damage
Diagnostic LED indicates system status. equipment.
The SV9510/SV9520 provides direct
The control communicates directly with the ST9160 replacement only. See Table 11 for a list of
Electronic Fan Timer (EFT) in typical forced warm air models this replaces.
furnace applications. It will also interface with the 208907
Terminal Board, providing compatibility with power Body Pattern:
stealing thermostats. Or, it directly interfaces with the SV9510/SV9520: Straight through with 1/2 in. inlet and
appropriate power supplies and a system thermostat for 1/2 in. outlet.
additional appliance applications. When controlled
directly by a thermostat, the control does not provide a Electrical Ratings:
postpurge function, as power to the control is removed System Transformer: 40 VA minimum NEMA rated.
when the thermostat call for heat ends. Voltage and Frequency:
24 Vac, 50/60 Hz.
This system is suitable for a wide range of fan-assisted
combustion, gas-fired appliances including furnaces, NOTE: 50 Hz operation increases all timings by 20%.
rooftop furnaces, boilers, unit heaters, infrared heaters,
water heaters and commercial cooking appliances. The Output Ratings:
specific application of the SmartValve System is the Igniter Load: 5A maximum at 120 Vac.
responsibility of the appliance manufacturer. See Table 2 Induced Draft Motor Load: 2.5A Full Load, 10A
for temperature ranges and regulator types. Locked Rotor at 120 Vac.
Current at 24 Vac:
24V Thermostat: 0.25A at 24 Vac, 60 Hz.
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SV9510/SV9520 SMARTVALVE™ SYSTEM CONTROLS
Ignition Retries:
3 retries; 4 trials total before lockout.
Size (Inlet and Capacity (at 1 in. wc Minimum Regulated Maximum Regulated
Model Outlet) (in.) pressure dropb,c) Capacity Capacity
SV9510/SV9520 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)
a
Capacity is reduced by 5 percent with the use of outlet screen.
b Capacity 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).
c Valves are guaranteed at only 77 percent of the rating.
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SV9510/SV9520 SMARTVALVE™ SYSTEM CONTROLS
Table 5. Adapter (Flange) Part Numbers. In addition, high ambient humidity can cause the control
to corrode and fail. If the appliance is in a humid
Part No.a,b atmosphere, make sure air circulation around the control
Inlet/Outlet Flange Without Hex With Hex is adequate to prevent condensation. Also, regularly
Pipe Size Type Wrench Wrench check out the system.
3/8 in. NPT Straight 393690-1 393690-11
Elbow 393690-2 393690-12 Corrosive Chemicals
1/2 in. NPT Straight 393690-6 393690-16 Corrosive chemicals can attack the control, eventually
causing a failure. If chemicals are used for routine
Elbow 393690-3 393690-13 cleaning, avoid contact with the control. Where chemicals
3/4 in. NPT Straight 393690-4 393690-14 are suspended in air, as in some industrial or agricultural
applications, protect the control with an enclosure.
Elbow 393690-5 393690-15
a Flange kits include one flange, one O-ring and four
mounting screws.
Dust or Grease Accumulation
b Heavy accumulations of dust or grease can cause the
Do not use flanges on control models with 3/4 in. inlet control to malfunction. Where dust or grease can be a
and 3/4 in. outlet. On models with 1/2 in. inlet and 3/4 in. problem, provide covers for the control to limit
outlet, use flanges only on the 1/2 in. inlet side. contamination.
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SV9510/SV9520 SMARTVALVE™ SYSTEM CONTROLS
WARNING
Fire or Explosion Hazard.
1 DO NOT USE FLANGES ON 3/4 IN. INLET
Can cause property damage, severe injury or AND 3/4 IN. OUTLET MODELS, AND ON
death. THE 3/4 IN. OUTLET SIDE OF 1/2 IN.
INLET AND 3/4 IN. OUTLET MODELS.
Always change the main burner orifices when M12168
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SV9510/SV9520 SMARTVALVE™ SYSTEM CONTROLS
Install Control
CAUTION 1. This ignition system control can be mounted 0 to 90
Equipment Damage Hazard. degrees in any direction, including vertically, from
Improper mounting location can damage the upright position of the ignition system control
control. switch.
Do not mount the SmartValve™ System Control 2. Mount the control so the gas flow is in the direction
where water can fall on the device. of the arrow on the bottom of the ignition system
control.
IMPORTANT 3. Thread the pipe the amount shown in Table 6 for
These ignition system controls are shipped with insertion into ignition system control or adapters. Do
protective seals over the inlet and outlet not thread pipe too far. Valve distortion or
tappings. Do not remove the seals until ready to malfunction can result if the pipe is inserted too
connect the piping. deeply.
DROP
IGNITION PIPE
PIPED
HORIZONTAL GAS SYSTEM
CONTROL
SUPPLY
THREAD PIPE THE AMOUNT APPLY A MODERATE AMOUNT OF
SHOWN IN TABLE FOR INSERTION PIPE COMPOUND ONLY TO PIPE
RISER INTO IGNITION SYSTEM CONTROL (LEAVE TWO END THREADS BARE).
M3344
IGNITION
SYSTEM
CONTROL
PIPED
3 IN. GAS Fig. 3. Use moderate amount of pipe compound.
(76 MM) SUPPLY
MINIMUM 5. Remove the seals over the ignition system control
inlet and outlet, if necessary.
6. Connect the pipe to the ignition system control inlet
DROP and outlet. Use a wrench on the square ends of the
HORIZONTAL 3 IN. ignition system control. If a flange is used, place the
TUBING (76 MM) wrench on the flange rather than on the ignition sys-
GAS MINIMUM
1 tem control. Refer to Fig. 4 and 5.
SUPPLY
IGNITER
IGNITION CONNECTOR
SYSTEM PRESSURE REGULATOR LINE VOLTAGE
RISER CONTROL ADJUSTMENT (UNDER CONNECTOR
C3
(76 MM)
MINIMUM INLET
PRESSURE
OUTLET
TAP
PRESSURE
1 ALL BENDS IN METALLIC TUBING MUST BE SMOOTH. TAP
INLET OUTLET
CAUTION
C1
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SV9510/SV9520 SMARTVALVE™ SYSTEM CONTROLS
APPLY WRENCH
TO FLANGE ONLY
APPLY WRENCH FROM TOP OR
BOTTOM OF IGNITION SYSTEM
CONTROL TO EITHER SHADED AREA
M12169
Fig. 5. Proper use of wrench on ignition system control with and without flanges.
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SV9510/SV9520 SMARTVALVE™ SYSTEM CONTROLS
L2 TO 120 VAC, 60 HZ
40 VA L1 POWER SUPPLY
2
TRANSFORMER (HOT) 1
ROLL-OUT
AUXILIARY
ELECTRONIC SWITCH
LIMIT SWITCH AIR PROVING
COMMON
4 1 ELECTRONIC HEAT
FAN TIMER
5 2
6 3 HUM HUMIDIFIER
MOTOR M2 C1
PARKING 5
6 1
TERMINALS M1 C 2
R 3
7
8 4
DATA
C3 C2
NEUTRAL 4 3
L1
4 3 2 1
COM R C W Y G 2 1 3
24 VAC FLAME ROD
SV9410/SV9420;
SV9510/SV9520; HOT
SV9610/SV9620 SURFACE
IGNITER
R W Y G
THERMOSTAT
ROLL-OUT
L2 SWITCH AUXILIARY
TO 120 VAC, 60 HZ
LIMIT SWITCH AIR PROVING
L1 POWER SUPPLY 1
(OPTIONAL) SWITCH COMBUSTION
(HOT) AIR BLOWER
LIMIT AIR
SWITCH
2
SV9410/SV9420;
40 VA SV9510/SV9520;
TRANSFORMER SV9610/SV9620
L2 XFMR L1 XFMR
208907
COMMON
P1
4 1 TERMINAL BOARD C1
LOAD
5
5 6 1
2 C 2
6 3 R
7 3
DATA 8 4
24 VAC R W C COM C2
C3
4 3
L1
4 3 2 1
2 1 3
FLAME ROD
R W
HOT
THERMOSTAT SURFACE
IGNITER
NEUTRAL
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SV9510/SV9520 SMARTVALVE™ SYSTEM CONTROLS
ROLL-OUT
SWITCH AUXILIARY AIR
LIMIT SWITCH PROVING
24V THERMOSTAT (OPTIONAL) SWITCH COMBUSTION
AIR BLOWER
LIMIT AIR
SWITCH
SV9410/SV9420;
SV9510/SV9520;
SV9610/SV9620
AQUASTAT
CONTROL 5
R C
C1
W G Y 5 1
C 6
2
1 R
TO 120 VAC, 60 HZ 7 3
3
POWER SUPPLY 1 3 8 4
DATA
L2 C3 C2
4 6 4 3
L1 L1
(HOT) 2 4 3 2 1
2 1 4
FLAME ROD
R8285D CONTROL CENTER
CIRCULATOR HOT
SURFACE
L2 IGNITER
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SV9510/SV9520 SMARTVALVE™ SYSTEM CONTROLS
AUXILIARY
LIMIT SWITCH
Perform Gas Leak Test
ROLL-OUT (OPTIONAL)
SWITCH
40 VA
AIR
PROVING
SWITCH
COMBUSTION
WARNING
LIMIT AIR BLOWER Fire or Explosion Hazard.
TRANSFORMER AIR
SWITCH
L1 L2 Can cause property damage, severe injury or
SV9410/SV9420; death.
SV9510/SV9520; Check for gas leaks with soap and water solution
SV9610/SV9620
6
any time work is done on a gas system.
COMMON
C1
CAUTION
LOAD
5
6 1
C 2
R Equipment Damage Hazard.
7 3
4
8 4 Liquid can damage the SmartValve™ Control.
DATA
C3 C2 Do not spray soap and water solution on the
5 4 3 SmartValve™ housing. Do not use an excessive
4 3 2 1 amount of soap and water solution to perform the
R W 2 1
3 gas leak test. These can damage the control.
THERMOSTAT FLAME ROD
TO 1
HOT
SURFACE Gas Leak Test
IGNITER
120 VAC, 60 HZ 1. Paint pipe connections upstream of the ignition sys-
POWER SUPPLY tem control with rich soap and water solution. Bub-
L2 bles indicate a gas leak.
L1 2. If a leak is detected, tighten the pipe connections.
NEUTRAL
(HOT)
2 3. Stand clear of the main burner while lighting to
HOT prevent injury caused from hidden leaks that could
cause flashback in the appliance vestibule. Light
1 POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED. the main burner.
4. With the main burner in operation, paint the pipe
CONNECT 120V (HOT) LEAD AS SHOWN.
2 joints (including adapters) and the control inlet and
3 APPLIANCE CHASSIS MUST HAVE RELIABLE CONNECTION TO outlet with rich soap and water solution.
EARTH GROUND. 5. If another leak is detected, tighten the adapter
4 DATA AND R LINES MUST BE CONNECTED TO W ON THERMOSTAT screws, joints, and pipe connections.
FOR PROPER SYSTEM OPERATION. 6. Replace the part if a leak cannot be stopped.
5 THERMOSTAT MUST HAVE ZERO OFF-STATE CURRENT DRAW.
MECHANICAL SWITCH THERMOSTATS RECOMMENDED. TRIAC
SWITCH THERMOSTATS OR POWER-STEALING THERMOSTATS Check and Adjust Gas Input and Burner
Ignition
ARE NOT RECOMMENDED.
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SV9510/SV9520 SMARTVALVE™ SYSTEM CONTROLS
LP, at the tank. Also shut off gas supply before 4. If the desired outlet pressure or flow rate cannot be
disconnecting manometer and replacing plug. Repeat achieved by adjusting the ignition system control,
Gas Leak Test at plug with main burner operating. check the ignition system control inlet pressure
using a manometer at the ignition system control
NOTE: Check the inlet pressure before adjusting the inlet pressure tap. If the inlet pressure is in the
pressure regulator. nominal range (see Tables 8A and 8B), replace the
ignition system control. Otherwise, take the
1. Check the full rate manifold pressure listed on the necessary steps to provide proper gas pressure to
appliance nameplate. Ignition system control full the control.
rate outlet pressure should match this rating.
2. With main burner operating, check the ignition NOTE: If the burner firing rate is above the capacity (at 1
system control flow rate using the meter clocking in. wc pressure drop) of the control (see Table 3
method or check pressure using a manometer for capacities), it may not be possible to deliver
connected to the outlet pressure tap on the ignition the desired outlet pressure. This is an application
system control. See Fig. 4. issue, not a control failure. Take whatever steps
3. If necessary, adjust the pressure regulator to match are required to correct the situation.
the appliance rating. See Tables 7 and 8 for factory-
set nominal outlet pressure and adjustment range. 5. STEP-OPENING PRESSURE REGULATORS
a. Remove the pressure regulator adjustment cap ONLY. Carefully check the burner lightoff at step
screw. pressure. Make sure the burner lights smoothly and
b. Using a screwdriver, turn the inner adjustment without flashback to the orifice. Make sure all ports
screw clockwise to increase or remain lit. Cycle the burner several times, allowing
counterclockwise to decrease the gas at least 60 seconds between cycles for the
pressure to the burner. regulator to resume the step function. Repeat after
c. Always replace the cap screw and tighten firmly allowing the burner to cool. Readjust the full rate
to prevent gas leakage. outlet pressure, if necessary, to improve lightoff
characteristics.
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SV9510/SV9520 SMARTVALVE™ SYSTEM CONTROLS
.
SV9510/SV9520 DIRECT HOT SURFACE IGNITION SmartValve™ SYSTEM CONTROL
SEQUENCE OF OPERATION WITH ST9160 ELECTRONIC FAN TIMER OR 208907 TERMINAL BOARD
PREPURGE
YES
FLAME SENSE LOST? MAIN VALVE CLOSES
NO
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