Installation and Operating Instructions Furnace Control Tester KGACT0201 Table 1 Kit Contents DESCRIPTION PART NO. QUANTITY Furnace Control Tester KGACT0201 1 Adapter Harness 320742-301 1 Installation Instructions AG-GACT-02 1 NOTE: Read the entire instruction manual before starting the installation. INTRODUCTION This instruction covers the installation and operation of the hot surface ignition () furnace control tester Part No. KGACT0201 on gas-fired furnaces utilizing systems. SAFETY CONSIDERATIONS Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained service personnel should install or service heating equipment. Untrained personnel can perform basic maintenance functions such as cleaning coils, or cleaning and replacing filters. All other operations should be performed by trained service personnel. When working on heating equipment, observe precautions in literature, on tags, and on labels attached to the unit. Follow all safety codes. Wear safety glasses and work gloves. Have a fire extinguisher available. DESCRIPTION AND USAGE The furnace control tester is designed to assist the service technician in troubleshooting the control board sequence of operation. The furnace control tester also helps indicate system components that may be defective. A generic furnace schematic diagram is displayed on the furnace control tester face. (See Fig. 1.) Refer to schematic diagram on furnace for actual component location and function. Connection and testing procedures are affixed to the rear of the furnace control tester. (See Fig. 2.) Each light emitting diode () on the furnace control tester face indicates operating portions of furnace control circuit. (See Fig. 1.) As components in control circuit are energized, the indicating that component will light. CAUTION: As with any mechanical equipment, personal injury can result from sharp metal edges, etc.; therefore, be careful when removing parts. WARNING: The ability to properly perform service on this equipment requires certain expertise, mechanical skills, tools, and equipment. If you do not possess these, do not attempt to perform any service on this equipment other than those procedures recommended in the User s Manual. A failure to follow this warning could result in possible damage to this equipment, serious personal injury, or death. INSTALLATION AND OPERATION This Furnace Control Tester is designed to be used with 2 designs of furnace control boards. One control board design has open components and an 11-pin edge connector that furnace wire harness attaches to. The other control board design has a plastic enclosure and individual connectors for furnace wire harness to connect to. PROCEDURE 1 ATTACH FURNACE CONTROL TESTER TO OPEN COMPONENT FURNACE CONTROL BOARD 1. Turn power to the furnace off. 2. Remove 11-pin connector wire harness from furnace control board. 3. Attach furnace control tester s 11-pin connector to furnace control board. (See Fig. 3.) 4. Insert furnace wire harness s 11-pin connector into furnace control tester s connector. (See Fig. 3.) Form: AG-GACT-02 Cancels: AG-GACT-01 Printed in U.S.A. 9-93 Catalog No. 92-33GA-CT2
5. Turn power to furnace on. 6. Proceed with testing, using instructions on back of furnace control tester or Fig. 2. 7. After test is complete, reverse steps to remove furnace control tester. PROCEDURE 2 ATTACH FURNACE CONTROL TESTER TO PLASTIC ENCLOSED FURNACE CONTROL CENTER 1. Turn power to furnace off. 2. Disconnect 9-pin main wire harness connector, 3-pin inducer motor connector, and 2-pin connector from furnace control center. 3. Attach connectors, disconnected in step 2, to adapter harness supplied with kit. 4. Attach wire harness adapter 3 connectors to furnace control center. (See Fig. 4.) 5. Attach 11-pin adapter harness s connector to furnace control tester s 11-pin connector. (See Fig. 4.) 6. Turn power to furnace on. 7. Proceed with testing, using instructions on back of furnace control tester or Fig 2. 8. After test is complete, reverse steps to remove furnace control tester. 2
ILK L1 L2 GND FURNACE CONTROL TESTER L1 BLWR R EAC 1 HI/LO EAC 2 HEAT COOL COM LO MED LO MED HI HI OL START COM GRN BLWM 1 CAP 1 L2 1 ILK WHEN USED TEST IDR FU1 PR1 TRAN 115VAC 24VAC PR2 2 2 M IDM OL AUX CAP 2 R-W SWITCH R-Y OR G SWITCH HUM R W ON OFF ON OFF Y SEC 1 GVR 2/HUM R SEC 2 BLWR HI IDR LO HUM CPU GVR 1 LS ALS (WHEN USED) LGPS (WHEN USED) 2 PRS GV 3 1 FRS G FSE C PRINTED CIRCUIT BOARD FLAME SENSE OVERRIDE OFF ON FLAME SENSE OVERRIDE 320796 401 REV. B Fig. 1 Furnace Control Tester-Schematic A93445 3
FURNACE CONTROL TESTER NOTE: If furnace control contains a status, check for flashing light on furnace control and note status code. If is not flashing, refer to instructions on control cover or diagnostic label on furnace door, and initiate Recall of previous status codes before turning power off or opening furnace door/access panel. CONNECTION TO FURNACE 1. Turn off power and gas to furnace. 2. Remove door(s). 3. Separate the factory connector(s) from control board and tester plug(s). 4. Set room thermostat to auto fan and system off. 5. Close blower door switch if open. TEST PROCEDURE 1. Restore gas an power to furnace. 5 and 10 should be lit. If not, check disconnect, fuse, interlock switch (ILK), fuse (FU1) and switches (LOT, LS, ALS and FRS if applicable). 2. Initial furnaces control component test. Refer to instructions on control cover. Observe s on tester. If furnace control is in a plastic box, check for flashing light code on control before component test occurs. 3. Turn tester's R W switch ON (up). 4 and 11 should be lit followed immediately by 6 as soon as the inducer comes up to speed and pressure switch (PRS) makes. If 11 fails to light, check edge connector(s). If 11 lights but 4 fails to light: replace control board. If 6 does not light, check switch (PRS, ALS and DSS if applicable), inducer motor operation and vent sizing. 4. After 15 seconds of inducer operation with 6 on, 3 will light indicating power to the hot surface ignitor (), if not replace control board. 5. After warm up (15 or 45 seconds) 8 will light indicating power to the gas valve. 3 will go off 5 seconds after 8 is energized. If does not glow, check ignitor or wire connections. 6. Main burners will light, and 40 or 60 seconds later the main blower will come on. NOTE: If gas is not supplied to furnace or flame/main burner simulation is desired, refer to FLAME SENSE OVERRIDE instructions below. 7. Turn tester's switch R W, OFF (down). 11 (W), 6 (PRS, ALS, DDS), and 8 (MGV) will go off immediately. 4 (IDM) will continue to operate for 5 or 15 seconds (post purge), the main blower will continue to operate for 90, 135, 180, or 225 seconds. FLAME SENSE OVERRIDE The use of this feature of the tester can produce the flow of! CAUTION unignited gas from the main burners. 1. Repeat steps 1 through 5 of TEST PROCEDURE above. After 8 lights, indicating the gas valve is energized, push the FLAME SENSE OVERRIDE switch to the right (within 2 seconds) and hold. The switch must be held to the right until flame simulation is no longer desired. If the FLAME SENSE OVERRIDE switch is energized prior to the gas valve 8 being lit, the microprocessor will start the inducer motor 4 immediately. If inducer motor does not start immediately, check inducer operation. If gas valve 8 goes off after the FLAME SENSE OVERRIDE switch is energized, replace control board. 2. Sequence of operation should continue as outlined in TEST PROCEDURE 6 & 7 above, after FLAME SENSE OVERRIDE switch is energized. COOLING Y OR CONTINUOUS G FAN 1. Remove thermostat connection to Y terminal on furnace control board. Failure to remove Y connection may allow feedback! CAUTION through the thermostat and energize the condensing equipment. 2. Attach the tester's lead, with the alligator clip, to either the Y (high speed fan for cooling) or G (low speed continuous fan) terminal on the control board. The R Y or G switch will allow control of the respective operation from the tester. REMOVAL OF TESTER Reverse steps 1 through 5 of the Connection instructions. 318072-401 REV. D A93444 Fig. 2 Furnace Control Tester Instruction Label A93444 4
CONTROL TESTER FURNACE TESTER FROM 11 PIN FURNACE WIRE HARNESS CONTROL TESTER 11 PIN TO 11 PIN FURNACE CONTROL BOARD EDGE Fig. 3 Furnace Control Tester Attachment to Open Component Furnace Control Board A93442 CONTROL TESTER INDUCER FURNACE MAIN CONTROL TESTER 11 PIN FURNACE TESTER FROM FURNACE WIRE HARNESS S ADAPTER HARNESS 11 PIN TO FURNACE CONTROL BOARD S INDUCER FURNACE MAIN HARNESS Fig. 4 Control TesterSI Furnace Control Tester Attachment to Plastic Enclosed Furnace Control Center A93443 5
BLOWER OFF DELAY ADJUSTMENT SWITCH TEST/TWIN G R Y W Com 24V HUM 24V THERMOSTAT TERMINALS HUMIDIFIER TERMINAL (24-VAC 0.5 AMP MAX) OPERATION & DIAGNOSTIC LIGHT HARNESS SEC-1 3-AMP FUSE COOL HEAT 24V TRANSFORMER SEC-2 SPARE 1 BLOWER SPEED SELECTION TERMINALS SPARE 2 EAC 1 (BLACK) 115-VAC (L1) POWER SUPPLY HOT SURFACE IGNITOR 115-VAC (L2) NEUTRAL CONNECTION INDUCER MOTOR Fig. 5 Plastic Enclosed Control Center EAC-ELECTRONIC AIR CLEANER TERMINALS (115-VAC 1 AMP MAX) EAC 2 (WHITE) A93052 1993 RESCO P.O. Box 1667, Indianapolis, IN 46206 15075c 6 Book/Tab:1/6a, 4/8a Catalog No. 92-33GA-CT2