ICM2 and 2.3 Control Module Replacement Kit
Contents
1. 1 2 HP RMOD44AE120 121 HD44AE120 121 HD44AE120 121 3 4 HP RMOD46AE120 HD46AE120 HD46AE120 1 HP RMOD52AE121 HDS52AE121 HD52AE121 CONDENSING FURNACES 1 2 HP RMOD44AE116 HD44AE116 HD44AE116 3 4 HP RMOD46AE121 HD46AE121 HD46AE121 1 HP RMOD52AE120 HD52AE120 HD52AE120 116 CONDENSING DOWNFLOW FURNACES 1 2 HP RMOD44AE117 HD44AE117 HD44AE117 1 HP RMOD52AE117 HD52AE117 HD52AE117 Table 4 LIGHT COMMERCIAL BLOWER MOTOR REPLACEMENT CONTROL MODULE PART NUMBERS 48SX 48HX 50SX 50HX048 060 557ANX 589ANW 658ANW048 060 657ANX048 657APX060 MOTOR HORSE POWER REPLACEMENT MODULE PART NUMBER CURRENT REPLACEMENT MOTOR NUMBER PREVIOUS REPLACEMENT MOTOR NUMBERS 1 HP RMOD52AE123 A98537 Fig 1 Disconnecting Control Module from Blower Motor 8 When control module is completely detached from motor verify with standard ohmmeter that the resistance from each motor lead in motor plug to unpainted motor end plate is HD52AE123 HD52AE119 greater than 100k ohms Use standard ohmmeter to verify that motor windings are not shorted or open by measuring resis tance between each combination of pins in motor plug there are three different combinations pin 1 2 pin 2 3 and pin 1 3 Resistance should be approximately equal across each com bination of any two of the three pins in plug If any motor fails these tests do not install control module The motor is defecti2. personal injury or product and property damage A WARNING Before installing or servicing unit always turn off all gas and electrical supplies to unit There may be more than one disconnect switch Turn off accessory heater power if appli cable Electrical shock can cause personal injury or death A WARNING 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 A failure to follow this warning could result in possible damage to this equipment serious personal injury or death INTRODUCTION This instruction covers installation of replacement electronic control modules on all variable speed fan coils variable speed gas furnaces and variable speed small packaged products which use an ICM2 or 2 3 motor with a round control module attached to the motor end bell If servicing an earlier vintage motor a complete motor which includes this module must be used instead of this kit See Tables 2 3 and 4 to match the product model with the replacement module kit part number Cancels New IIK 333B 60 1 10 98 Table 1 Kit Contents PART NO DESCRIPTION QUANTITY See Tables 2 3 4 Electronic Control Module 1 3 1 2 in 111A522AAP7 1 4 Hex Bolts 2 A 8794728AYP1 Plastic Locator Pin 1 HY76TB121 Wire
3. unpainted motor end plate is greater than 100k ohms Use standard ohmmeter to verify that motor windings are not shorted or open by measuring resis tance between each combination of pins in motor plug there are three different combinations pin 1 2 pin 2 3 and pin 1 3 Resistance should be approximately equal across each com bination of any two of the three pins in plug If any motor fails these tests do not install control module The motor is defective and must be replaced Installing new control module will cause it to fail also Spin wheel to be sure motor turns freely Step 4 Install New Control Module 1 Remove new controller from box and place it on a working surface with all electrical components facing up Find plastic locator pin in bag of fasteners included with kit Locate deep slot along upper edge of new control module See Fig 2 Slide plastic locator pin with pin facing away from control into slot Copyright 1998 Carrier Corporation NOTE This pin is needed on older ICM2 motors recognizable by gray control module housing On newer ICM2 3 motors with black housing this pin is not needed 2 Position new control module over motor housing assembly such that locator pin is aligned with mating hole on motor Attach connector coming from motor to new control module Be sure connector latches It will click when properly inserted Place controller on motor with plastic locator pin in mating hole on motor 3 Find
4. ICM2 and 2 3 Control Module Replacement Kit Installation Instructions NOTE Read the entire instruction manual before starting the installation SAFETY CONSIDERATIONS Installing and servicing of heating and air conditioning equipment can be hazardous due to gas system pressures and electrical components Only trained personnel should install or service heating and air conditioning equipment The qualified installer or agency must use factory authorized kits or accessories when modifying this product Refer to individual instructions packaged with kits or accessories when installing Follow all safety codes Wear safety glasses and work gloves Use a quenching cloth for brazing operations Have a fire extinguisher available Read these instructions thoroughly and follow all warning or cautions attached to the unit Consult local building codes and National Electrical Code NEC for special require ments Recognize safety information This is the safety alert symbol A When you see this symbol on the unit 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 hazards which could result in personal injury or death CAUTION is used to identify unsafe practices which would result in minor
5. Tie 1 Replacement control modules are factory programmed for specific products and model sizes Even though they look alike different modules will have completely different functionality I INSTALLATION FOR FAN COILS AND SMALL PACKAGED PRODUCTS Step 1 Check Equipment Compare contents of kit with Table 1 Step 2 Disconnect Line Voltage Disconnect line voltage from fan coil or small packaged unit being serviced There may be more than one disconnect switch Do not work on motor with line voltage applied NOTE Failure of replacement controller will also occur if power is applied to unit during replacement A WARNING Wait at least 5 minutes after disconnecting line voltage from equipment before opening motor to prevent electric shock which can cause personal injury or death Step 3 Disconnect Existing Control Module 1 Remove blower compartment access panel NOTE For gas packaged products unplug three wires from induced draft motor capacitor and move them aside 2 If necessary clip wire tie holding wires running from control module to motor mounting arms 3 Remove screw holding green ground wire to blower housing 4 Disconnect both multi pin connectors from control module attached to motor Be sure to depress release latches on connectors or they may be damaged 5 Remove blower housing and place it on its side with motor control module up It is not necessary to remove motor from housing Control m
6. URNACES Step 1 Check Equipment Compare contents of kit with Table 1 Step 2 Disconnect Line Voltage Turn off 115vac power to unit Do not work on motor with line voltage applied A WARNING Wait at least 5 minutes after disconnecting line voltage from equipment before opening motor to prevent electric shock which can cause personal injury or death Step 3 Disconnect Existing Control Module 1 Remove blower compartment access panel 2 Remove blower assembly from furnace as directed in unit s Service and Maintenance Instructions for Blower Motor and Wheel Maintenance 3 Disconnect both mult pin connectors from control module attached to motor Be sure to depress releasee latches on connectors or they may be damaged 4 Remove motor mounting leg bolts and rotate motor clockwise 90 degrees then reinstall leg bolts This step is necessary for proper control module plug orientation 5 Remove two 1 4 in hex head bolts from old control module and discard DO NOT REMOVE TORX HEAD SCREWS located next to 1 4 in hex head bolts 6 Carefully lift control module off motor Depress latch on connector to disconnect wire connector that attaches control module to motor Latch must be depressed to remove or connector and or motor may be damaged DO NOT PULL ON WIRES GRIP PLUG ONLY 7 When control module is completely detached from motor verify with standard ohmmeter that the resistance from each motor lead in motor plug to
7. odule unplugs according to the following instructions See Fig 1 6 Remove two 1 4 in hex head bolts from old control module and discard DO NOT REMOVE TORX HEAD SCREWS located next to 1 4 in hex head bolts 7 Carefully lift control module off motor Depress latch on connector to disconnect wire connector that attaches control module to motor Latch must be depressed to remove or connector and or motor may be damaged DO NOT PULL ON WIRES GRIP PLUG ONLY Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 1 4 4 PC 101 Catalog No 534 000 Tab 3d 6a 2e 8a Printed in U S A Form 40FK 2SI Pg 1 10 98 Replaces New Table 2 FAN COIL REPLACEMENT CONTROL MODULE PART NUMBERS FK4 FV4 40FKA PF1MNA071 NOTOR REPLACEMENT CURRENT PREVIOUS HORSE POWER MODULE REPLACEMENT REPLACEMENT PART NUMBER MOTOR NUMBER MOTOR NUMBERS RMOD44AE128 HD44AE128 HD44AE125 122 118 1 2 HP RMOD44AE129 HD44AE129 HD44AE127 124 119 RMOD44AE130 HD44AE130 HD44AE126 123 HD46AE240 242 241 3 4 HP RMOD46AE243 HD46AE243 HEAL TIA Table 3 FURNACE REPLACEMENT CONTROL MODULE PART NUMBERS 333BAV 333JAV 355MAV 58MVP 58UXV 58UAV MOTOR HORSE POWER REPLACEMENT MODULE PART NUMBER CURRENT REPLACEMENT MOTOR NUMBER PREVIOUS REPLACEMENT MOTOR NUMBERS NON CONDENSING FURNACES
8. og No 534 000 Tab 3d 6a 2e 8a Printed in U S A Form 40FK 2SI Pg 4 10 98 Replaces New
9. r assembly check installation to see if some application fault has caused motor to fail Is there any evidence of water damage to failed control module corrosion on inside or outside of casing If yes check that equipment is properly leveled and drains are unplugged with functioning P traps as required Verify the correct motor mounting orientation and a suitable drip loop in the cables See Fig 3 5 Slide blower housing back into fan coil small packaged unit and remount it DRIP LOOP 6 Reconnect both multi pin connectors to control module being careful to insert connector in correct orientation connectors A98560 are keyed to install only one way Reconnect ground wire if Fig 3 Drip Loop Configuration used to housing as originally connected A CAUTION INSTALLING CONNECTORS INCORRECTLY WILL RE SULT IN IMMEDIATE FAILURE OF CONTROL MOD ULE 2 Determine that blower housing is correctly secured to blower shelf 7 Secure wires from control module to motor mounting arm with wire tie See Fig 3 Step 6 Replace Fan Coil Air Handler Blower 8 Reconnect any other wiring connections which apply Compartment Access Panel Step 5 Make Final Installation Check Step 7 Reconnect Line Voltage to Unit 1 Is motor control secured to motor Is there appropriate drip Reconnect line voltage to unit and verify that new motor control loop in motor cables module is working properly ll INSTALLATION FOR GAS F
10. two 3 1 2 in bolts supplied and slip them into two holes on back of new controller Use 1 4 in hex head driver to bolt new control module to back of blower motor See Fig 2 Tighten bolts 1 4 turn past finger tight Do not over tighten 4 Slide blower housing back into furnace and remount it 5 Reconnect both multi pin connectors to control module being careful to insert connector in correct orientation connectors are keyed to install only one way 4 CAUTION INSTALLING CONNECTORS INCORRECTLY WILL RE SULT IN IMMEDIATE FAILURE OF CONTROL MOD ULE Step 5 Reconnect Furnace Piping and Wiring Reinstall vent piping condensate trap condensate tubes and any wiring connections which apply See unit s Service and Mainte nance Instructions for Blower Motor and Wheel Maintenance Step 6 Make Final Installation Check 1 Is motor control secured to motor Is there appropriate drip loop in motor cables 2 Determine that blower housing is correctly secured to blower shelf 3 Determine that all venting and condensate connections are made Step 7 Replace Furnace Blower Compartment Access Panel Step 8 Reconnect Line Voltage Turn 115vac power to unit back on and verify that new motor control module is working properly 333b601 Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 1 4 4 PC 101 Catal
11. ve and must be replaced Installing new control module will cause it to fail also Spin wheel to be sure motor turns freely Step 4 Install New Control Module 1 Remove new controller from box and place it on a working surface with all electrical components facing up Find plastic locator pin in bag of fasteners included with kit Locate deep slot along upper edge of new control module See Fig 2 Slide plastic locator pin with pin facing away from control into slot NOTE This pin is needed on older ICM2 motors recognizable by gray control module housing On newer ICM2 3 motors with the black housing this pin is not needed 2 Position new control module over motor housing assembly such that locator pin is aligned with mating hole on motor Attach connector coming from motor to new control module MULTI PIN CONNECTOR ELECTRONIC ym CONTROL MODULE PIN INDOOR Lowen HEX HEAD MOTOR A98517 Fig 2 Orientation of ICM2 3 to Blower Motor Blower housing not shown Be sure connector latches It will click when properly inserted Place controller on motor with plastic locator pin in mating hole on motor 3 Find two 3 1 2 in bolts supplied and slip them into two holes on back of new controller Use 1 4 in hex head driver to bolt new control module to back of blower motor See Fig 2 Tighten bolts 1 4 turn past finger tight Do not over tighten 4 Before replacing blower moto
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