SmarTester Manual
Contents
1. Air flow Limit Intermittent problems 1 3 Preventative Maintenance e Proper Sequence of Operation Timing of Ignition Warm Up Fan Timer etc Detects intermittent problems the thermostat circuit e Detects a quick drop out of pressure switch e Can measure accuracy of a pressure switch closing with the use of a manometer On polarized equipment detects reverse polarity on the 24VAC side Detects loss of source voltage 24VAC 115VAC e Detects open circuits Detects a limit dropping out before thermostat is satisfied e Measures microAmps in the flame rectification circuit 1 4 Benefits e Hands free Quick amp easy setup Saves time e Tests multiple circuits simultaneously e No guesswork e Reduces call backs e Reduces frustration e Pinpoints the current problem and future problems with one simple test No wire stripping e Reads multiple circuits within minutes of the service call Pinpoints intermittent problems that the flashing LED on the circuit board may not pick up No more struggling with hard to read wiring diagrams and checking Single circuits Work flow continuity e Checks accuracy of a pressure switch with a partner manometer e Feel confident while working with circuit boards electronics and a large number of wires 2 0 SmarTester Components The SUPCO Smartester consists of three main components Combining them together provide2. I i al Ui Pa i 17 o e iranien Awn li l ett All hiv li A Ti mij al EI Limi al li UY E N ul kal li Ilha LILE LI PN AP ee ajii EL yj pa 0 Pd lh H Uaa m Jinny banj Ve gy eg Ea fi 5 fiee mme ili u peren fimm TRANI A Livi tia di W al tanita eel a 1 Pine hi mim ji BIEI dura hin EAIN IE al tiv iid Clean or replace flame sensor The diagnostics used in this chart illustrate some of the possible scenarios With service knowledge and experience gained through use of the SmarTester many more troublesome service problems will become
3. v T 8 me Tmi il Ek on i iE J 1 ei Ager dee ial oC ema i ipri 1 a IH ili ae M j i a Irim i i 10 Hiriy llame DE N Penjar lana pasiuni A ue UME MRE mHE A lee GME hiui awa at ye Cea oh JE Mali reser peers T HE T mpr wiry iehi an EYANI Gin EH crea eee ye Hoe ee ed Clean or replace flame sensor The diagnostics used in this chart illustrate some of the possible scenarios With service knowledge and experience gained through use of the SmartTester many more troublesome service problems will become easily diagnosed Smart Valve Flow Chart EEE TE iia miam jaga
4. e Thermostat Closed LED Lit Pressure Switch Open LED Lit Inducer LED Lit e Pressure Switch LED Off e Ignitor LED Lit e Main Valve EFT LED Lit e Burner Ignition e Ignitor LED MicroAmp Reading Present Have Fluctuations Normal Heat Cycle MicroAmp Reading Complete Kits Optional Accessories STSVK SmarTester Smart Valve Kit 150 SmarTester Interface Kit MODEL NO For Use With Honeywell For Use With White Rodgers 50A50 209 230 1 Generation SV95XX 50A50 50A55 etc Includes SmarTester WR50C Smart 50Series Diagnostic Tips Smart Card WR5042C Smart 50A 4 to 2 Smart Valve Cable WR50 Cable 50A Series Onacall for heat the Pressure Switch Open red LED will glow Soft Case WR42 Adapter Cable 50A 4 to 2 indicating an open pressure switch This is a normal function with a Instructional DVD WR42WC Adapter Cable 50 normally open pressure switch If the LED does not glow check for a w Ground Clip STMANUAL Instruction Manual SCCP soft Case Stuck closed pressure switch After motor has come up to speed the STFC ONEA ane cael LED should go out ST50K Smartester 150 SmartTester Interface Kit Watch the sequence of the LEDs and verify that each component is WR50A Series Kit Smart Valve operating If LEDs are lit but there is no flame to the main burner 1 Generation SV95XX check for correct supply gas pressure and all valves are open Includes After l
5. easily diagnosed
6. If LEDs are lit but there is no pilot or main burner check to make sure you have supply gas and all valves are open Check microAmps by watching when pilot comes on but before main burner lights for a more accurate reading If microAmps are weak clean the pilot and flame sensor for better reading Best if Flame Sensor is replaced Record microAmp reading in customer record for future reference 10 After locating the problem always re check and cycle until unit is working properly 11 Remove bypass from blower door safety switch if bypassed 4 0 White Rodgers 50A50 and related Control circuits WR50 This Smartinterface cable WR50C Smart Card used in conjunction with the SmartTester Instrument will analyze the following models and many White Rodgers 50A50 110 111 112 113 142 209 286 296 405 406 408 438 471 472 473 474 50 55 286 143 241 438 474 571 50 65 475 02 Johnson Controls G951ABD 1403 York 031 01234 000 When used with the included 4 terminal Molex to 2 terminal Molex adapters this interface cable will work with 50A50 205 206 207 285 288 295 50A55 285 Warning Using this interface cable on a control not listed could damage the equipment or Smartester or could pose a shock hazard USE ONLY WITH RECOMMENDED CONTROLS Before doing any tests always check for correct 115VAC supply voltage to equipment Incorrect supply voltage may give you a false rea
7. Spe Box 21 2230 Landmark Place Allenwood NJ USA 732 223 6644 Fax 732 223 1617 Wwww supco com info supco com RAW p n 19204 SMAR TESTER User Manual F igam TR E i Ea Eni k AE 20 pa wee dope 1 1 Ernari Gerd The Professional s Choice Sealed Unit Parts Co inc Box 21 2230 Landmark Place Allenwood NJ USA Introduction The SmarTester is a non intrusive hand held diagnostic tool for troubleshooting electronic ignition systems of gas fired heating appliances water heaters and more monitors electronic signals of various equipment components and power supplies through its unique interface cables The SmarTester works along side the internal test circuitry of the equipment and is capable of quickly diagnosing a number of problems within multiple circuits of the equipment control system simultaneously Hard to find intermittent problems are easily solved The service technician can then make a Smart decision to repair the equipment IMPORTANT e The Smarlester is intended be used by a qualified HVAC service technician e Always use proper techniques while testing to avoid damaging the control terminals connectors or interface cable e In cases where equipment wires are to be removed for testing always label them prior t
8. ding with the SmarTester 4 1 Using the Smartester e Shut off the power to system e Slide the Smart Card Overlay WRSOC WR5042C under the integral tabs the SmarTester e Connect the WR50 Smart Interface Cable e Turn the thermostat all the way up If necessary carefully bypass blower door safety switch for TEMPORARY TESTING PURPOSES e Unplug the system Molex type connectors from the control board Connect the matching SmarTester connectors to the ignition control board Then connect the Smarlester Molex connectors to the system connectors e Turn on the main power Note Cable connections are male and female and will only connect 1 way e The Power Polarity and MicroAmp Display will come on automatically when 24VAC or 115VAC are present If the LED and display do not come on check power supply to equipment again and the SmarTester 9 volt battery Follow sequence of operation Watch for dimming of 115VAC LED or 24VAC LED this will indicate possible low voltage e Left columns of LEDs are 24VAC circuits right column LEDs are 115VAC circuits e Green LEDs indicate NORMAL operation and are lit only when power is applied e Red LEDs indicate an open circuit and potential problem 4 2 Normal Sequence of Operation No call for heat e Power LED Lit Polarity LED Lit MicroAmp Display Erratic Low All other LEDs off Call for heat e Power LED Lit Polarity LED Lit MicroAmp Display
9. event an improper connection Smart Card Overlays 3 Smart Cards Match Smart Card to corresponding board model number HWSVC WR50C WR5042C Each Smart Card supplies minimum requirements for microAmp readings and matching Interface Cable information SmarTester Setup Installation and operation of the SmarTester is unique for each control board circuitry Go to the appropriate section that corresponds to the control board being analyzed 3 0 Honeywell Smart Valve This Smartinterface cable and Smart Card used in conjunction with the Smartester Instrument will analyze the following Smartvalve models 5 9401 5 9402 5 9403 5 9500 5 9600 5 9501 5 9502 5 9503 5 9601 5 9602 Warning Using this interface cable on a control not listed could damage the equipment or SmarTester or could pose a shock hazard USE ONLY WITH RECOMMENDED CONTROLS Before doing tests always check for correct 115VAC supply voltage to equipment Incorrect supply voltage may give you a false reading with the SmarTester Using The Smartester Shut off the power to system Slide the Smart Valve Smart Card Interface Overlay HWSVC under the integral slots on the SmarTester e Connect the Smart Valve Interface cable to the SmarTester e Turn the thermostat all the way up If necessary carefully bypass blower door safety switch for TEMPORARY TESTING PURPOSES Unplug the Molex connectors from the valve Co
10. hts MicroAmp Reading Present Read Quickly Main Valve LED Lit Main Burner Ignition e ignitor LED off Normal Heat Cycle 3 3 MicroAmp Reading Model No Minimum MicroAmp Reading 5 9500 5 9600 12 ua Minimum 5 9401 5 9402 5 9403 5 9501 5 9502 5 9503 5 9601 5 9602 1 3 ua Minimum 3 4 Diagnostic Tips lf no LEDs are lit check power to system being tested and SmarTester battery lf the red LED indicating Operating Controls Open Circuit is lit this may include pressure switch thermostat vent damper rollouts limits and other controls as this system has all operating controls connected in series lf the red LED indicating Operating Controls Open Circuit is lit and the inducer motor does not start to run look for an open fuse on Board With a normally open pressure switch if the Operating Control LED does not glow check for a stuck closed pressure switch After the inducer motor has come up to speed the Operating Control LED should go out If not check for voltage using a Multimeter All Limits and Pressure Switches are connected in series e Pressure Switch If open check e Pressure Switch e Pressure Switch Tubing for blockage or leaks e Inducer Assembly Inducer Blower Wheel e Flue for blockage Limits Follow limit circuit checking each limit and connecting wiring Watch the sequence of the LEDs and verify that each component is operating
11. nnect 2 of the HWSVC connectors to the valve and the other 2 to the appliance harness connectors Be sure to connect clip wire to the common Side of the transformer e f transformer does not have a common side use a clean chassis ground e Turn on the main power Note Cables connection are male and female and will only connect 1 way e The Power Polarity and MicroAmp Display will come on automatically when 24VAC or 115VAC are present If the LED and display do not come on check power supply to equipment again and the SmarTester 9 volt battery Follow sequence of operation e Watch for dimming of 115VAC LED or 24VAC LED this will indicate possible low voltage Left columns of LEDs are 24VAC circuits right column LEDs are 115VAC circuits e Green LEDs indicate NORMAL operation and lit only when power is applied e Red LEDs indicate an open circuit and potential problem 3 2 Normal Sequence of Operation No call for heat Power Applied to Equipment e 24VAC LED Lit e 24VAC Polarity LED Lit Operating Controls LED Lit Note The first red LED will glow showing Operating Controls Open This is a normal function on start up for systems with a draft inducer fan All other LEDs off Call for heat e 24VAC LED Lit 24VAC Polarity LED Lit Operating Controls LED Lit until pressure switch closes e Gas Valve will click for Pilot Gas supply Ignitor LED Lit e Ignitor glows Pilot lig
12. o disconnection Wiring errors can cause improper and dangerous operation of the equipment e Always refer to the equipment manual provided by the manufacturer prior to servicing any equipment e Always make sure all power to the system being tested is off plug the interface cable into the SmarTester then make the connections on the control board e Make sure all wiring connections are secured correctly and are snug wet control board could cause bodily harm never test controls that have been wet Replace them A wet or damaged control board may create erroneous information WARNING Using the interface cable on a control board not listed in this manual or on the SUPCO website could damage the equipment or Smarlester or could pose a shock hazard USE ONLY WITH RECOMMENDED CONTROLS e Improper use of this unit could cause death serious injury or property damage 9 volt battery required Not Included Applications The SmartTester Diagnoses the Following 1 1 Inspections and Installations Loss of Power 24VAC amp 115VAC Proper Venting Pressure Switch Proper Duct Size Cycling on Limit Thermostat for Proper Cycling e Flame Sensor MicroAmps 1 2 Troubleshooting Highlights Only Inducer Motor Slowdown Due to Secondary Heat Exchanger Problems Pressure Switch e Thermostat Circuit for Intermittent Problems Short Cycling Due to Partially Blocked Vent Pressure Switch
13. ocating the problem always re check and cycle until unit 1 SmarTester HWSVC Card working properly Smart 50A Series HWSV Smart Valve Cable Smart Card 50 4 to 2 SCCP soft Case On some units the flame rollout safety is wired in series with the Cable 50 Series gas valve circuit If the gas valve LED is illuminated and the gas Adapter Cable 50 4 to 2 valve does not open check if there is a rollout in that circuit coe 50 w Clip STVIDEO Instructional DVD lf the burner goes out after short run and there no red LEDs STMANUAL Instruction Manual control board goes into retry and system re lights The equipment STFC Smarlester Flow Chart may do this several times before lockout occurs Check for loose wire in Pressure Switch circuit partial blockage in Sensing tube flue blockage or low microAmp Note Smarlester Pressure Switch LED will blink if this or any intermittent event occurs in the control circuit but only as long as the problem exists 031 Johnson Control White Rodgers boards If the SmarTester indicates Blown Fuse but there is no fuse or the fuse is not blown this indicates a shorted or bad board WR50 Flow Chart Upon Connection of Cables and Line Voltage Applied to Appliance Power LEG A wia aera v Papia rapa nhani di nnne uheri Psaila F
14. s an analyzer specific to standardized control board circuitry e The SmarTester Instrument is the same for all control boards Smart Card Application Overlays e Smart Interface Cables e The Smartinterface Cables amp Overlays are designed for a specific control board technology Currently the SmarTester Interface Cables and Overlays can support the following series control boards e Honeywell Smart Valve SV95XX Series White Rodgers 50AXX Series We continue to expand the capabilities of the SmarTester check our website http www supco com Smartester for the latest updated list 21 Instrument e Each circuit that is connected to the SmarTester is supported by a green or red LED e LED lights are in sequence of operation on the instrument e Track to hold an application card in place e Built in auto on microAmp meter e Battery operated 9V long life LCD display Low battery indicator e Plug in port on top of meter for interface cable e Protective boot with convenient hanging hook 2 2 Smart Interface Cables e Each circuit in the interface cable is wired in parallel for passive diagnostics e Each interface cable application is wired differently for each circuit board series Application wiring is done in the Interface Cable e WR50 and HWSV interface cables 46 long WR42 and WR42WC adapter cables 10 long e All connections are made with Molex style connectors to pr
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