Reznor CAUA Manuale utente

Revision: CAUA-IGN-CNTRL (03-22) 178435-A

IGNITION CONTROLLER REPLACEMENT KIT INSTALLATION

FOR GAS-FIRED INDOOR HEATER

Supersedes: CP-CAUA-IGN CNTRL (04-15) PN178435R6

MODEL CAUA

Table 1. Ignition Controller Replacement Kit (PN 258251) Components

Item No. Component Description PN (Quantity)

DSI control board Heat only (

UTEC #1097-211

)

195573 (1)

Wire assembly

9-pin, P1 on wiring diagram 257666 (1)

3 5-pin, P3 on wiring diagram 257675 (1)

4 24-inch, red, with one terminal 129869 (1)

5 Template Drill 257013 (1)

6 Ignition cable 18-inch 257665 (1)

7Terminal Quick connect, 1/4-inch, red 142860 (7)

8 Spade 1350 (1)

9 Wire nut Crimp 22573 (2)

10 Tie Cable 20913 (6)

11 Label NOTICE 203058 (1)

Wiring diagram 258250

(1)

⚠ DANGER ⚠

To ensure safe and proper operation, read and follow these installation instructions. Failure to do

so could result in property damage, personal injury, and/or death.

•These instructions are for replacing an obsolete ignition controller (RAM #3MC4-06, serial number code 76 or J/C

#G822KCC-5401D, serial number code 77) with an ignition controller (see Figure 1) replacement kit (PN 258251).

•Refer to the installation manual provided with the heater for important safety information.

•Refer to the replacement parts manual at www.reznorhvac.com for serial number information. All serial number

codes apply to original equipment only.

•Ensure that all components listed in Table 1 are available before beginning installation.

Figure 1. Replacement Ignition Controller

SPARK TRANSFORMER

123

456

789

9-Pin

Harness

Plug P1

5-Pin Harness

Plug P3

WIRE TERMINALS

2CAUA-IGN-CNTRL (03-22) 178435-A

INSTALLATION

Install the ignition controller replacement kit as follows. Item numbers in parentheses refer to Table 1.

1. Turn OFF gas and electric power.

2. Remove existing ignition controller:

a. Open control compartment and locate ignition controller.

b. Disconnect wiring and existing ignition cable from controller.

c. Remove four screws that secure controller and remove controller.

3. Install replacement ignition controller:

a. Position drill template (5), with painted side facing up, over mounting holes for ignition controller removed in

step 2. Justify holes for replacement controller toward bottom of panel.

b. Mark and drill four 3/16-inch holes.

c. Position DSI control board (1) so that spark transformer is located nearest to spark electrode on burner. Snap

control board into holes.

4. Install replacement ignition cable:

a. Remove existing ignition cable from spark electrode on burner.

b. Connect one end of replacement ignition cable (6) to spark electrode on burner and other end to spark

transformer (see Figure 1) on replacement DSI control board (1).

NOTE: Refer to Table 2 for terminal cross-reference between old and new ignition controllers.

Table 2. Terminal Cross-Reference

Existing Controller Replacement Controller

ACC EAC/BLO

24 VAC HOT SEC

Ground COM

LINE VAC HOT L1

CMB BLWR IND

5. Connect wiring in accordance with replacement wiring diagram label (12, see Figure 2):

a. Connect P3 5-pin wire assembly (3) to thermostat terminal strip as shown in Figure 1.

b. Connect P1 9-pin wire assembly (2) as shown in Figure 1. As necessary, shorten wires and install replacement

terminals (8).

c. Connect existing wires to DSI control board (1) wire terminals. If terminal on line voltage wire is 3/16 inch, cut

off terminal, strip wire, and install quick connect terminal (7). Connect line voltage wire to terminal L1.

d. Connect one end of 24-inch red wire assembly (4) to rollout switch located on burner box top. Connect other

end to high limit switch wire lead using wire nut (9).

e. Install cable ties (10) as necessary for routing and for excess wire length.

NOTE: To cover all applications, connections shown in Figure 2 are for single-stage (AG1) and

two-stage (AG2) controls and for both direct and belt drive motors. Make the connections that ap-

ply to the options on the unit being serviced.

6. Adhere wiring diagram label (12, see Figure 2) on left panel inside burner compartment.

CAUA-IGN-CNTRL (03-22) 178435-A

Figure 2. Wiring Diagram Label

7. Adhere NOTICE label (11, see Figure 3) below wiring diagram label installed in step 6.

TERMINAL

STRIP

THERMOST

FAN RELAY

COIL

RELAY COIL

CONTACTOR COIL

MOTOR

FAN

RELAY CONTACTS

P3-4

P3-3

P3-2

P3-1

P3-5

FAN RELAY

COIL

8 7

RELAY COIL

CUSTOMER'S COOL

TERMINAL STRIP

THERMOSTAT

L1 L2

24V

LINE VOLT Y

PLUG PILOT OPENING

HONEYWELL TWO STAGE

REDUNDANT GAS VALV E

PILOT

HIGH

STG

LOW

STG

GAS VALVE

HONEYWELL

MV BL

ACB HEAT

ACB COOL BK

BK L2

CONTACTOR COIL

HEAT SPEED

CONTACTOR COIL

COOL SPEED

BK W

VENTER MOTOR

LED

DSI CONTROL

SW1

FAN OFF DELAY

TIME

120

160

180

OFF

S W 1

IND BK OR BL

NEUTRAL BK OR BR

(SEE NOTES)

LED

OKFLAME

NEUTRAL

LIMIT

CONTROL

P1-8

P1-3

BK OR BL

P1-2

P1-4

L1NEUTRAL

SEC

ATO OR AT C

3.0 AMP

TEST

FUSE

FLAME

ROLLOUT SWITCH

ACB HEAT

ACB COOL

WL2

COM

FLAME

ELECTRODE

FLAME

GROUND

P1-7

P1-9

PRESSURE SWITCH

P1-6

P1-5 W

SPARK GAP

SPARK

TRANSFORMER

40 VA

DOOR

SWITCH

BKBKBK

DSI BOARD

REPLACEMENT

Option AG2

Option AG1

BELT DRIVE

DIRECT DRIVE

NEUTRAL

W W L2

CAUA

WD #275047

GREEN LED

FAST FLASH

1 FLASH

2 FLASH

3 FLASH

4 FLASH

STEADY OFF

LED FLASH CODES

NORMAL OPERATION CALL FOR HEAT

IN LOCKOUT FROM FAILED IGNITIONS OR FLAME

LOSSES

P1-8 TO P1-3 JUMPER OPEN CIRCUIT

PRESSURE SWITCH IS CLOSED BEFORE VENTER IS

ENERGIZED

INTERNAL CONTROL FAULT OR NO POWER

YELLOW LED

FLAME SENSEDSTEADY ON

SLOW FLASHWEAK FLAME

UNDESIRED FLAME (VALVE OPEN & NO CALL FOR

HEAT)

FAST FLASH

PRESSURE SWITCH DOES NOT CLOSE WITHIN

30 SECONDS OF VENTER ENERGIZED

NORMAL OPERATION NO CALL FOR HEATSTEADY ON

Figure 3. NOTICE Label

8. Turn ON electric power and gas, start up heater, and check for proper operation.

NOTE: Refer to the installation manual at www.reznorhvac.com for operating sequence and

troubleshooting information.

NOTICE

BEFORE REPLACING CIRCUIT BOARD:

• Check Fuse on Circuit Board

• Check 24VAC Supply

• Check LED Flash Codes

Replacing circuit board will not correct

prob lems that are external to the board.

203058 Rev. 1

Speciﬁcations and illustrations subject to change without notice or incurring obligations.

Latest version of this manual is available at www.reznorhvac.com.

CAUA-IGN-CNTRL (03-22) 178435-A

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