SURELIGHT Corp. 0222 L7 IGNITION SYSTEM Service

TABLE 7100869, 100870SureLight BoardsFLASH CODE(X Y)STATUS / ERROR DESCRIPTIONFLASH CODE DESCRIPTIONSPulseA 1/4 second flash followed by four seconds of off time.HeartbeatConstant 1/2 second bright and 1/2 second dim cycles.X YLED flashes X times at 2Hz, remains off for two seconds, flashes Y times at 2Hz, remains off for fourseconds, then repeats.PulsePower on Standby.HeartbeatNormal operation signaled when heating demand initiated at thermostat.FLAME CODES1 2Low flame current run mode.1 3Flame sensed out of sequence flame still present.2 3Low pressure switch failed open.2 4Low pressure switch failed closed.2 5High pressure switch failed open.2 6High pressure switch failed closed.2 7Low pressure switch opened during ignition trial or heating demand.3 1Limit switch open.4 1Watchguard Exceeded maximum number of retries.4 2Watchguard Exceeded maximum number of retries or last retry was due to pressure switch opening.4 3Watchguard Exceeded maximum number of retries or last retry was due to flame failure.4 5Watchguard Limit remained open longer than three minutes.4 6Watchguard Flame sensed out of sequence; flame signal gone.4 7Ignitor circuit fault Failed ignitor or triggering circuitry.4 8Low line voltage.5 1Hard lockout Rollout circuit open or previously opened.5 2Control failed self check, internal error (control will restart if error recovers).5 3No Earth ground (control will restart if error recovers).5 4Reversed line voltage polarity (control will restart if the error recovers).5 6Low secondary (24VAC) voltage.PRESSURE SWITCH CODESLIMIT CODEWATCHGUARD CODESHARD LOCKOUT CODESError Code StorageThe ignition control stores the last ten error codes inmemory. The codes are retained in case of power loss.Error Code Review1 Short R (2) to (1). Within 1/2 second, the STATUS LEDwill stay lit continuously to indicate that the short wassensed.2 Continue to hold the short between R (2) to (1). After 5seconds, STATUS LED will go from being continuouslylit to off. This indicates that error code review is pending.3 Remove R (2) to (1) short within ten seconds of STATUS LED turning off. This activates error code review.5 After final error code is indicated, STATUS LED willflash to indicate normal operation.Clearing Error Codes1 Short R (2) to (1). Within 1/2 second, the STATUS LEDwill stay lit continuously to indicate that the short wassensed.2 Continue to hold the short between R (2) to (1). After 5seconds, STATUS LED will go from being continuouslylit to off.3 Continue to hold the short between R (2) to (1) beyondten seconds after STATUS LED has turned off. STATUS LED will turn on, indicating that error codes havebeen cleared.4 Last ten error codes will be flashed on the STATUS4 Remove R (2) to (1) short. STATUS LED will flash to inLED.dicate normal operation.Page 6

II Operation (all control boards)A Two Stage Operation / ThermostatSelectionElectronic IgnitionAt the beginning of each heating cycle, the SureLight control monitors the first stage and second stage combustionair inducer prove switch. The control will not begin the heating cycle if the first stage prove switch is closed(by passed). Likewise the control will not begin the secondstage heating cycle if the second stage prove switch isclosed, and will allow first stage heat only. However if thesecond stage prove switch closes during the first stage pre purge, the control WILL respond to second stage heat call.Once the first stage prove switch is determined to be open,the combustion air inducer is energized on low (first stage)heat speed. When the differential in the prove switch isgreat enough, the prove switch closes and a 15 secondpre purge begins. If the switch is not proven within 2 1/2minutes, the control goes into Watchguard PressureSwitch mode for a 5 minute re set period.After the 15 second pre purge period, the SureLight ignitorwarms up for 20 seconds after which the gas valve opensfor a 4 second trial for ignition. The ignitor energizes duringthe trial until flame is sensed. If ignition is not proved duringthe 4 second period, the control will try four more times withan inter purge and warm up time between trials of 35 seconds. After a total of five trials for ignition (including theinitial trial), the control goes into Watchguard Flame Failure mode. After a 60 minute reset period, the control willbegin the ignition sequence again.The SureLight control board has an added feature that prolongs the life of the ignitor. After a successful ignition,boards 18M3401, 46M9901, 18M9901 and 49M5901 utilizes less power to energize the ignitor on successive callsfor heat. The boards continue to ramp down the voltage tothe ignitor until it finds the lowest amount of power that willprovide a successful ignition. This amount of power is usedfor 255 cycles. On the 256th call for heat, the boards againramp down until the lowest power is determined and thecycle begins again. SureLight boards 100869 and 100870regulate 95 volts to the ignitor for consistent ignition andlong ignitor life.SureLight Boards 18M3401, 46M9901, 18M9901 &49M5901Page 7The control can be utilized in two modes: SINGLE STAGEthermostat or TWO STAGE thermostat. The thermostatselection jumper E20 must be positioned for the particularapplication. The jumper is factory set on TWO" for usewith a two stage thermostat with two stage heat. Re position jumper to SINGLE" for use with a single stagethermostat with two stage heat.While in the single stage thermostat mode (single jumpersetting), the burners will always fire on first stage heat. Thecombustion air inducer will operate on low speed and indoor blower will operate on low heat speed. After a fieldselectable 10 or 15 minute delay (dip switch 3), the unit willswitch to second stage heat. While in the two stage thermostat mode (two jumper setting) the burners will fire onfirst stage heat. The combustion air inducer will operate onlow speed and indoor blower will operate on low heatspeed. The unit will switch to second stage heat on callfrom the indoor thermostat. If there is a simultaneous callfor W1 and W2 (first and second stage heat) the unit will fireon first stage heat and switch to second stage heat after 30seconds of operation. See Sequence of Operation flowcharts in the back of this manual for more detail.SureLight Boards 100869 & 100870The control can be utilized in two modes: SINGLE STAGEthermostat or TWO STAGE thermostat. The thermostatselection is made using a dip switch (figure 2 ) and must bepositioned for the particular application. The dip switch isfactory set on TWO" for use with a two stage thermostatwith two stage heat. Re position dip switch to SINGLE" foruse with a single stage thermostat with two stage heat.While in the single stage thermostat mode (single dipswitch setting), the burners will always fire on first stageheat. The combustion air inducer will operate on low speedand indoor blower will operate on low heat speed. After a10 minute recognition period, the unit will switch to secondstage heat. While in the two stage thermostat mode (twodip switch setting) the burners will fire on first stage heat.The combustion air inducer will operate on low speed andindoor blower will operate on low heat speed. The unit willswitch to second stage heat on call from the indoor thermostat. If there is a simultaneous call for first and second stageheat, the unit will fire an first stage heat and switch to second stage heat after 30 seconds of operation. SeeSequence of Operation flow charts in the back of thismanual for more detail.

Diagnostic LED’s (DS1 and DS2)Two diagnostic LED’S are located on the two stage integrated control board. See figure 1 . These light flashescorrespond with the codes detailed in table 5.B Dip Switch SettingsSureLight Boards 18M3401 & 46M9901Dip Switches 1 and 2 Heating Fan off Delay The fan ontime of 45 seconds is not adjustable. Fan off time (time thatthe blower operates after the heat demand has been satisfied) can be adjusted by flipping the dip switches 1 and 2located on the SureLight integrated control. The unit isshipped with a factory fan off setting of 90 seconds. Fan offtime will affect comfort and is adjustable to satisfy individualapplications. For customized comfort, monitor the supplyair temperature once the heat demand is satisfied. Note thesupply air temperature at the instant the blower is de energized. Adjust the fan off delay to achieve a supply airtemperature between 90 110 at the instant the blower isde energized. (Longer delay times allow for lower air temperature, shorter delay times allow for higher airtemperature). See table 8 for dip switch settings.TABLE 8Heating Fan Off DelayDelay (Seconds)Switch 1Switch 26090120180OffOffOnOnOffOnOffOnSwitch 3 Second Stage Delay (Used with Single StageThermostat Only) This switch is used to determine thesecond stage on delay when a single stage thermostat isbeing used. The switch is factory set in the ON position,which provides a 10 minute delay before second stageheat is initiated. If the switch is toggled to the OFF position,it will provide a 15 minute delay before second stage heatis initiated. This switch is only activated when the thermostat selector jumper is positioned for SINGLE stagethermostat use.Switch 4 Cooling Fan off Delay The fan on delay timeof 2 seconds is not adjustable. Fan off time (time that theblower operates after the cool demand has been satisfied)can be adjusted by flipping dip switch 4. The unit is shippedwith a factory fan off setting of 45 seconds. Fan off time willaffect comfort and is adjustable to satisfy individual applications. See table 9 for cool fan off time settings.TABLE 9Cooling Fan Off DelayDelay (Seconds)Switch 42Off45OnPage 8On Board Jumper W915A factory installed jumper from Y1 to Y2 terminals on theintegrated control board terminal strip must be removed fortwo stage cooling. On board 18M3401 remove the jumper,on board 46M9901 clip the jumper.SureLight Board 100869Switch 1 Thermostat Selection This unit may be usedwith either a single stage or two stage thermostat. Thethermostat selection is made using a DIP switch whichmust be properly positioned for the particular application.TheDIP switch is factory positioned for use with a two stage thermostat. If a single stage thermostat is to be used,the DIP switch must be repositioned.a Select OFF" for two stage heating operation controlled by a two stage heating thermostat (factorysetting);b Select ON" for two stage heating operation controlled by a single stage heating thermostat. Thissetting provides a timed delay before second stageheat is initiated.Switch 2 Second Stage Delay (Used with Single Stage Thermostat Only) This switch is used todetermine the second stage on delay when a single stagethermostat is being used. The switch is factory set in theOFF position, which provides a 10 minute delay beforesecond stage heat is initiated. If the switch is toggled to theON position, it will provide a 15 minute delay before second stage heat is initiated. This switch is only activatedwhen the thermostat selector jumper is positioned forSINGLE stage thermostat use.Switches 3 and 4 Heating Blower Off Delay Theheating blower on delay of 45 seconds is not adjustable.The heating blower off delay (time that the blower operatesafter the heating demand has been satisfied) can be adjusted by moving switches 3 and 4 on the integrated controlboard. The unit is shipped from the factory with a heatingblower off delay of 90 seconds. The heating blower offdelay affects comfort and is adjustable to satisfy individualapplications. Adjust the blower off delay to achieve a supply air temperature between 90 and 110 F at the exactmoment that the blower is de energized. Longer off delaysettings provide lower supply air temperatures; shorter settings provide higher supply air temperatures.Table 10provides the blower off timings that will result from differentswitch settings.

TABLE 11Heating Blower Off Delay Switch SettingsBlower Off DelaySwitch 3Switch 4(Seconds)60OffOn90OffOff120OnOff180OnOnSwitch 5 Cooling Blower Off Delay The coolingblower off delay (time that the blower operates after thecooling demand has been satisfied) can be adjusted bymoving switch 5 on the integrated control board. Theswitch is factory set in the OFF position, which provides acooling blower off delay of 45 seconds. If the switch istoggled to the ON position, it will provide a 2 second cooling blower off delayOn Board Jumper W951On board jumper W951, which connects terminals R and Oon the integrated control board, must be cut when the furnace is installed in applications which include a heat pumpunit and a thermostat which features dual fuel use. If thejumper is left intact, terminal O" will remain energized eliminating the HEAT MODE in the heat pump.On Board Jumper W915On board jumper W915, which connects terminals Y1 andY2 on the integrated control board, must be cut if two stagecooling will be used. If the jumper is not cut the outdoor unitwill operate in second stage cooling only.Variable Speed SureLight Board 18M9901 &49M5901Dip Switch SettingsSwitches 1 and 2 Blower Off Delay The blower on delayof 45 seconds is not adjustable. The blower off delay (timethat the blower operates after the heating demand hasbeen satisfied) can be adjusted by moving switches 1 and 2on the integrated control board. The unit is shipped fromthe factory with a blower off delay of 90 seconds. Theblower off delay affects comfort and is adjustable to satisfyindividual applications. Adjust the blower off delay toachieve a supply air temperature between 90 and 110 F atthe exact moment that the blower is de energized. Longeroff delay settings provide lower supply air temperatures;shorter settings provide higher supply air temperatures.The table below provides the blower off timings that will result from different switch settings.TABLE 12Blower Off Delay Switch SettingsBlower Off DelaySwitch 1Switch 2(Seconds)60OffOff90OffOn120OnOff180OnOnPage 9Switch 3 Second Stage Delay (Used with Single StageThermostat Only) This switch is used to determine thesecond stage on delay when a single stage thermostat isbeing used. The switch is factory set in the ON position,which provides a 10 minute delay before second stageheat is initiated. If the switch is toggled to the OFF position,it will provide a 15 minute delay before second stage heatis initiated. This switch is only activated when the thermostat selector jumper is positioned for SINGLE stagethermostat use.Switch 4 Not usedSwitches 5 and 6 Cooling Mode Blower SpeedSwitches 5 and 6 are used to select cooling blower motorspeed. The unit is shipped from the factory with the dipswitches positioned for high speed (4) indoor blower motoroperation during the cooling mode. Table 13 provides thecooling mode blower speeds that will result from differentswitch settings.TABLE 13Cooling Mode Blower SpeedsSpeed1 Low2 Medium Low3 Medium High4 High (Factory)Switch 5OnOffOnOffSwitch 6OnOnOffOffSwitches 7 and 8 Blower Speed Adjustment Switches7 and 8 are used to select blower speed adjustment settings. The unit is shipped from the factory with the dipswitches positioned for NORMAL (no) adjustment. The dipswitches may be positioned to adjust the blower speed by 10% or 10% to better suit the application. Table 14 provides blower speed adjustments that will result fromdifferent switch settings.TABLE 14Blower Speed AdjustmentAdjustment 10% (approx.)NORMAL (Factory) 10% (approx.)Switch 7OnOffOffSwitch 8OffOffOnSwitches 9 and 10 Cooling Mode Blower Speed Ramping Switches 9 and 10 are used to select cooling modeblower speed ramping options. Blower speed ramping maybe used to enhance dehumidification performance. Theswitches are factory set at option A which has the greatesteffect on blower motor performance. Table 15 provides thecooling mode blower speed ramping options that will resultfrom different switch settings. The cooling mode blowerspeed ramping options are detailed on Page 12.

TABLE 15Cooling Mode Blower Speed RampingRamping OptionSwitch 9Switch 10A (Factory)OffOffBOnOffCOffOnD*OnOn*Only option for DehumidificaionSwitches 11 and 12 Heating Mode Blower SpeedSwitches 11 and 12 are used to select heating mode blowermotor speed. The unit is shipped from the factory with thedip switches positioned for medium low (2) speed indoorblower motor operation during the heating mode. Table 16provides the heating mode blower speeds that will resultfrom different switch settings.TABLE 16Heating Mode Blower SpeedsSpeedSwitch 11Switch 121 LowOnOn2 Medium LowOffOn(Factory)3 Medium HighOnOff4 HighOffOffPage 10On Board Jumper W914On board jumper W914, which connects terminals DS andR on the integrated control board, must be cut when the furnace is installed with either the Harmony II zone controlboard or a humidity control. Refer to furnace Installation Instructions for more detail.On Board Jumper W915A factory installed jumper from Y1 to Y2 terminals on theintegrated control board terminal strip must be removed fortwo stage cooling. On board 18M9901 remove the jumper,on board 49M5901 clip the jumper.On Board Jumper W951On board jumper W951, which connects terminals R and Oon the integrated control board, must be cut when the furnace is installed in applications which include a heat pumpunit and the FM21 FuelMaster control board.Diagnostic LEDs (DS1 and DS2)Two diagnostic LEDs are located on the two stage, variable speed integrated control just to the left of the first bankof dip switches. These lights’ flashes correspond with diagnostic codes detailed in table 5.

Status LEDs (HEAT, HI/LO, ON/OFF and CFM)The integrated control includes four LEDs which indicateoperating status. The green ON/OFF LED is lit any time theblower is operating. The green CFM LED indicates theblower motor speed. Count the number of blinks betweenthe two second pauses to determine the CFM. Each blinkrepresents approximately 100 CFM. The yellow HI/LO LEDis lit when the W914 (DS to R) jumper has not been clippedfor CCB1 or Harmony operation. The yellow HEAT LED islit when the indoor blower is operating at the HEATINGspeed.Variable Speed SureLight Board 100870Heating Operation DIP Switch SettingsSwitch 1 Thermostat Selection This unit may be usedwith either a single stage or two stage thermostat. Thethermostat selection is made using a DIP switch whichmust be properly positioned for the particular application.TheDIP switch is factory positioned for use with a two stage thermostat. If a single stage thermostat is to be used,the DIP switch must be repositioned.a Select OFF" for two stage heating operation controlled by a two stage heating thermostat (factorysetting);b Select ON" for two stage heating operation controlled by a single stage heating thermostat. Thissetting provides a timed delay before second stageheat is initiated.Switch 2 Second Stage Delay (Used with Single Stage Thermostat Only) This switch is used todetermine the second stage on delay when a single stagethermostat is being used. The switch is factory set in theOFF position, whic

Lennox control board and hot surface ignitor. Both type control boards are similar except the two stage variable speed board controls an ICM2 indoor blower motor. Boards and ignitor work in combination to ensure furnace ignition and ignitor durability. Boards control all major fur-nace operations. Tables 1 through 4 show jack plug terminal .