Two-Speed Furnace Control Replacement Kit Installation
Contents
1. 9 10 Disconnect line voltage blower EAC if equipped and transformer wires Remove retaining screws a For 80 percent furnaces remove retaining screws and remove furnace control board from bracket b For 90 percent furnaces remove two screws from blower deck that hold the control box assembly Lower control box assembly Remove retaining screw s from board and remove board from control box assembly Remove wiring harness connectors from furnace control board Inspect control and control box for evidence of water staining Correct any sources of water leakage humidifier evaporator coil vent system into the control area Step 2 Installing the New Control 1 2 3 4 Ground yourself Handle furnace control board by edges Insert tab s of board into slots of control box if required Install furnace control board retaining screw s Install wiring harness adapter Part 328156 701 to two connections of the existing furnace wiring harness See Fig 4 a The furnace harness 9 pin connector plugs into the mating 9 pin adapter harness connector b The furnace harness 12 pin connector plugs into the mating 12 pin adapter harness connector Connect the other end of the adapter harness part 328156 701 to the new furnace control board a The 12 pin connector connects to PL1 on the furnace control board See Fig 3 and 4 11 12 13 14 BLOWER OFF DELAY SELECTION CHART 92. control will lock out when flame current falls to 0 5 microamps DC Check flame current in low heat and high heat Step 3 System Operation 1 Perform any other safety checks as deemed necessary flame safety limit switch vent system etc 2 Run unit through 1 complete call for heat cycle SETUP SWITCHES TWINNING AND OR LOW HEAT ONLY AND COMPONENT TEST BLOWER OFF DELAY TERMINAL ACRDJ AIR CONDITIONING RELAY DISABLE JUMPER a SLO E Jol AA 24 V THERMOSTAT J TERMINALS Le i 8 O test F TO aml S TRANSFORMER 24 VAC 210 whe CONNECTIONS al HUMIDIFIER TERMINAL 7L 24 VAC 0 5 AMP MAX Hii PL1 LOW VOLTAGE MAIN 3 AMP FUSE se sec 3 HARNESS CONNECTOR 2 2 LED OPERATION amp 280 enmar 8 Je DIAGNOSTIC LIGHT fS S e E o q PL3 ICM CONTROL 5 La HARNESS CONNECTOR 1 1 E tah a ere fea BLWR HI HEAT gt I s i i LO HEAT P aE ee i as O 4 Za SPARE 2 EACT PRT So Q Ok SPARE 1 COOL 115 VAC L1 LINE PL2 HOT SURFACE BLOWER SPEED SPARE 2 VOLTAGE CONNECTION IGNITER amp INDUCER SELECTION TERMINALS MOTOR CONNECTOR EAC 1 TERMINAL 115 VAC 1 0 AMP MAX A02017 Fig 3 New Furnace Control Board To PL1 on new board To
3. 0 120 160 180 SEC SEC SEC SEC ELIE Fig 1 Blower Off Delay A04133 b The 3 pin connector which has 2 black wires and red wire connects to PL2 on the furnace control board See Fig 3 and 4 c The 2 white wires connect to the 115 volt Neutral spade connections located in front of PL1 on the new furnace control board See Fig 3 and 4 Connect the transformer to the new furnace control board See Fig 3 a Blue wire to SEC 2 terminal SEC 2 terminal is located adjacent to the 3 amp fuse b Red wire to SEC 1 terminal SEC 1 terminal is located adjacent to the 3 amp fuse c Black wire to PR 1 terminal PR 1 terminal is located adjacent to PL2 d White wire to one of the 115 volt Neutral spade connec tions located in front of PL1 Connect black wire from furnace auxiliary junction box to L1 on the new furnace control board L1 is located on the blower enable relay See Fig 3 Connect white wire from furnace auxiliary junction box to one of the 115 volt Neutral spade connections located in front of PL1 See Fig 3 Connect the blower motor leads to the new furnace control board See Fig 3 a Connect the white blower motor lead to the BLW connec tion within the group of 115 volt Neutral spade connec tions b Connect the blower motor high heat tap to the blower relay connection marked HI HEAT c Connect the blower motor low heat tap to the blower relay connectio
4. 12 pin connector PL1 of furnace wiring hamess LJ To PL2 on new board To 9 pin connector PL2 of furnace wiring harness To neutral connections on new board A04124 Fig 4 Wire Harness Adapter Copyright 2004 Carrier Corporation 340m4086 Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations rook 4 PC 101 Catalog No 535 80137 Printed in U S A Form 58MCA 12SI Pg 4 10 04 Replaces NEW a aj oa
5. 24V VQYVYVCYS W2 Com WIW1Y Y2 R E ct PL4 S ICM CONTROL CONNECTION wI ETUP SWITCHES EAT STAGING AND LOWER OFF DELAY A95360 Fig 2 Old Furnace Control Board Variable Speed Systems For variable speed systems also wire the new control board as follows 1 The variable speed motor harness 6 pin connector that plugged into PL4 on the old style furnace control board plugs into PL3 on the new style furnace control board See Fig 2 and 3 The green wire from the variable speed motor labeled DE HUM connects to G on the furnace control if it was previously connected to G on the old style furnace control board a If so you will have to cut the inch spade terminal off and strip the wire to do this If not the green wire labeled DEHUM is probably spliced to a thermostat wire that is connected to the DHUM terminal of the Thermidistat Leave it hooked up this way and DO NOT connect it to the DHUM terminal on the new furnace control board 3 The 2 white wires previously connected to the 1 4 inch HUM spade terminal of the old furnace control board need to be connected to the 4 inch HUM spade terminal on the new furnace control board See Fig 2 and 3 SYSTEM CHECK OUT Step 1 Component Self Test 1 To initiate component test sequence ensure thermostat is turned OFF or thermostat wires are disconnected Turn power on and manually close blower door
6. Two Speed Furnace Control Replacement Kit Cancels NEW IIK 340M 40 86 10 04 Installation Instructions Part No 325879 751 NOTE Read the entire instruction manual before starting the installation SAFETY CONSIDERATIONS Installing and servicing of heating equipment can be hazardous due to gas and electrical components Only trained personnel should install or service heating equipment Untrained personnel can perform basic maintenance functions such as cleaning and replacing filters All other operations should be performed by trained service personnel When working on heating equipment observe precautions in the 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 Recognize safety information This is the safety alert symbol A When you see this symbol on the furnace and in instructions or manuals be alert to the potential for personal injury Understand the signal words DANGER WARNING and CAU TION These words are used with the safety alert symbol DAN GER identifies the most serious hazards which will result in severe personal injury or death WARNING signifies a hazard which could result in personal injury or death CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage NOTE is used to highlight suggestions which will result in enhanced installation reli
7. ability or operation A WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in possible damage to this equipment serious personal injury or death The ability to properly perform service on this equipment requires certain expertise mechanical skills tools and equip ment 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 INTRODUCTION This kit is a direct replacement for circuit boards Part No HK42FZ005 HK42FZ010 and HK42FZ015 Changes to the operation of this control include 1 The blower off delay selections are 90 120 150 and 180 seconds 2 A DHUM connection has been added to the thermostat terminal block When connected to a thermidistat and when there is a call to dehumidify the cooling airflow will be reduced to high heat airflow When jumpered to Y Y2 it will reduce the 90 second blower off delay in the cooling mode to 5 seconds 3 All 115 volt neutrals are grouped together in one location of board See Fig 3 4 Humidifier connection is removed from thermostat terminal block It is now a inch spade terminal next to the thermostat terminal block See Fig 3 KIT CONTAINS PART NUMBER Control board HK42FZ017 Wire harness adapter 328156 701 Kit Wiring diagram 328155 101 Rev A TWINNING The control board in this kit CAN also be twinn
8. ed with any of following circuit boards Part No HK42FZ005 HK42FZ010 and HK42FZ015 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS A CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may damage furnace compo nents Electrostatic discharge can affect electronic components Take precautions during furnace installation and servicing to protect the furnace electronic control Precautions will pre vent electrostatic discharges from personnel and hand tools which are held during the procedure These precautions will help to avoid exposing the control to electrostatic discharge by discharging static electricity build up to ground 1 Disconnect all power to the furnace DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CON TROL PRIOR TO DISCHARGING YOUR BODY S ELEC TROSTATIC CHARGE TO GROUND 2 Ground yourself by touching your hand and tools to clean unpainted metal surface of furnace close to control 3 After touching chassis you may proceed to service the furnace You will recharge your body with static electricity by moving about or shuffling your feet Reground yourself 4 If you touch ungrounded objects recharge your body with static electricity reground yourself Use this procedure for installed and uninstalled ungrounded furnaces 5 Ground yourself again before handling a new control to protect control from damage If control is to be installed in furnace follow items 1 through 5 again before insta
9. lling control Put all used AND new controls into containers before touching ungrounded objects 6 An ESD service kit available from commercial sources may also be used to prevent ESD damage Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 4 PC 101 Catalog No 535 80137 Tab 6a 8a Printed in U S A Form 58MCA 12SI Pg 1 10 04 Replaces NEW St INSTALLATION ep 1 Removal of Existing Control A WARNING ELECTRICAL SHOCK AND UNIT DAMAGE HAZARD Failure to follow this warning could result in minor personal injury death or damage to furnace Label all wires prior to disconnection when servicing con trols Wiring errors can cause improper and dangerous operation Turn thermostat to OFF or set temperature to the lowest setting Turn off electrical supply to furnace 3 Turn off gas supply to furnace A WARNING ELECTRICAL SHOCK FIRE EXPLOSION HAZARD Failure to follow this warning could result in property damage or minor personal injury death Turn off gas and electrical supply before servicing this furnace Removing blower door or access panel a For 80 percent furnaces remove control access and blower door b For 90 percent furnaces remove outer door assembly and remove the two screws from blower access panel and set aside 5 Disconnect thermostat and humidifier wires if equipped
10. n marked LO HEAT d Connect the blower motor cool tap to the blower relay connection marked COOL e Connect the remaining blower motor leads to SPARE 1 and SPARE 2 Connect all accessory wires 10 For 90 percent furnaces reinstall control box assembly to blower deck by installing the two screws previously removed from the blower deck Set blower off delay Blower Off Delay Dip Switches are located on the top center portion of board See Fig 3 It is factory set at 120 seconds Use Fig 1 to select a different blower off delay If you are using a two stage thermostat put setup switch 1 in the ON position Install kit wiring diagram 328155 101 in close proximity to the furnace wiring diagram Do not connect thermostat wires to control board until Start up and System Check out is complete LINE VOLTAGE CONNECTIONS PL2 HOT SURFACE IGNITOR INDUCED DRAFT MOTOR CIRCUIT CONNECTOR EAC TERMINALS 115 VAC 1 AMP MAX PARK ISOLATED TERMINAL FOR THE UNUSED PSC MOTOR WIRE BLOWER MOTOR CONNECTION 3 AMP FUSE TRANSFORMER 24 V CONNECTORS PLI GAS VALVE LOW VOLTAGE SAFETY CIRCUIT CONNECTOR TWINNING JUMPER MASTER SLAVE LIGHT EMITTING DIODE FOR STATUS CODES STATUS CODE RECALL CONNECTOR HUM HUMIDIFIER TERMINAL CONNECTION 24 V 0 5 AMP MAX 24 V THERMOSTAT TERMINALS
11. switch With a short piece of wire briefly short TEST TWIN terminal to Com 24v terminal Component test sequence is as follows a Status LED will flash previous fault or status code 11 four times then turn ON the inducer motor at high heat speed Inducer motor will run for entire component test c Hot surface igniter will be turned ON for 15 seconds then OFF d Blower motor LO HEAT speed will be turned ON for 10 seconds e Blower motor HI HEAT speed will be turned ON for 10 seconds f Blower motor COOL speed will be turned on for 10 seconds When the blower motor is turned OFF the inducer motor will be switched to low heat speed for 10 seconds Repair replace or service any component that does not work properly during the self test The gas valve and humidifier are not energized during self test 3 Turn power off 4 Release blower door switch NOTE Current status code will be stored even when blower door is removed 5 Connect thermostat wires 6 Install blower and access doors 7 Turn power back on 8 Turn on gas supply to furnace Step 2 Flame Sensor Operation Connect a DC microampmeter in series with flame sensor Initiate a call for heat After burners ignite and stabilize measure flame current Nominal flame current is between 4 0 and 6 0 microamps DC If flame current is below 4 0 microamps DC remove and clean flame sensor with fine steel wool or replace flame sensor The furnace
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