Supco SMARTESTER User Manual

SMARTESTER

User ManualUser Manual

User ManualUser Manual

User Manual

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Sealed Unit Parts Co., inc.

PO Box 21 • 2230 Landmark Place • Allenwood, NJ USA

SmarTester

9 VOLT BATTERY REQUIRED

(NOT INCLUDED)

REMOVE RUBBER BOOT

TO ACCESS BATTERY

COMPARTMENT.

1

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. It 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!!!!

• The SmarTester is intended to be used by a qualified HVAC service
technician.

• Always use proper techniques while testing to avoid damaging the
control terminals, connectors, or interface cable.

• In cases where equipment wires are to be removed for testing, always
label them prior to disconnection. Wiring errors can cause improper
and dangerous operation of the equipment.

• Always refer to the equipment manual provided by the manufacturer
prior to servicing any equipment.

• 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.

• Make sure all wiring connections are secured correctly and are snug.

• A 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
SmarTester, or could pose a shock hazard.

USE ONLY WITH RECOMMENDED CONTROLS!!

• Improper use of this unit could cause death, serious injury, or property
damage

• 9 volt battery required (Not Included)

Applications

The SmarTester Diagnoses the Following

Inspections and Installations

• Loss of Power (24VAC &115VAC)

• Proper Venting (Pressure Switch)

• Proper Duct Size (Cycling on Limit)

• Thermostat for Proper Cycling

• Flame Sensor (MicroAmps)

Troubleshooting (Highlights Only)

• Inducer Motor Slowdown Due to Secondary Heat Exchanger Problems
(Pressure Switch)

• Thermostat Circuit for Intermittent Problems

• Short Cycling Due to Partially Blocked Vent (Pressure Switch)

• Air flow (Limit)

• Intermittent problems

Preventative Maintenance

• Proper Sequence of Operation

• Timing of Ignition Warm-Up, Fan Timer, etc.

• Detects intermittent problems in the thermostat circuit

• Detects a quick drop-out of pressure switch

• 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 a loss of source voltage (24VAC and 115VAC)

• Detects open circuits

• Detects a limit dropping out before thermostat is satisfied

• Measures microAmps in the flame rectification circuit

2

1.1

1.2

1.3

Benefits

• Hands-free

• Quick & easy setup

• Saves time

• Tests multiple circuits simultaneously

• No guesswork

• Reduces call backs

• Reduces frustration

• Pinpoints the current problem and future problems with one simple
test

• No wire-stripping

• 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

• Checks accuracy of a pressure switch with a partner manometer

• Feel confident while working with circuit boards, electronics and a
large number of wires.

3

SmarTester Components

The SUPCO™ SmarTester consists of three main components.

Combining them together provides an analyzer specific to standardized

control board circuitry.

• The SmarTester Instrument is the same for all control boards.

• Smart Card Application Overlays.

• Smart Interface Cables.

• The SmartInterface Cables & Overlays are designed for a specific
control board technology. Currently, the SmarTester, Interface Cables
and Overlays can support the following series control boards:

• 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.

1.4

2.0

Instrument

• Each circuit that is connected to the SmarTester is supported by a

green or red LED.

• LED lights are in sequence of operation on the instrument

• Track to hold an application card in place

• Built-in, auto-on microAmp meter

• Battery operated (9V) long life LCD display

• Low battery indicator

• Plug-in port on top of meter for interface cable

• Protective boot with convenient hanging hook

Smart Interface Cables

• Each circuit in the interface cable is wired in parallel for passive

diagnostics

• Each interface cable application is wired differently for each circuit

board series. Application wiring is done in the Interface Cable.

• WR50 and HWSV interface cables are 46” long.

• WR42 and WR42WC adapter cables are 10” long.

• All connections are made with Molex® style

connectors to prevent an improper connection

Smart Card Overlays

3 Smart Cards: Match Smart Card to corresponding board

model number

Each Smart Card supplies minimum requirements for microAmp readings
and matching Interface Cable information.

2.1

2.2

2.3

WR50C WR5042CHWSVC

4

4

5

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.

Honeywell Smart Valve™

This SmartInterface cable and Smart Card used in conjunction with
the SmarTester Instrument will analyze the following Smartvalve™
models.

•SV9401 •SV9402 •SV9403 •SV9500 •SV9600

•SV9501 •SV9502 •SV9503 •SV9601 •SV9602

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
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.

• Connect the Smart Valve™ Interface cable to the SmarTester.

• 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. Connect 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.

• If transformer does not have a common side, use a clean chassis

ground.

• Turn on the main power.

3.0

3.1

Follow sequence of operation:

• 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.

•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.

Note: Cables connection are male and female and will only connect 1 way

Call for heat :

• 24VAC LED Lit

• 24VAC Polarity LED Lit

• Operating Controls LED Lit until pressure switch closes

• Gas Valve will “click“ for Pilot Gas supply

• Ignitor LED Lit

• Ignitor glows

• Pilot lights

• MicroAmp Reading Present. (Read Quickly)

• Main Valve LED Lit.

• Main Burner Ignition

• Ignitor LED off

• Normal Heat Cycle

3.3 MicroAmp Reading:

Model No. Minimum MicroAmp Reading

SV9500/SV9600 .12 ua Minimum

SV9401/SV9402/SV9403/SV9501
SV9502/SV9503/SV9601/SV9602 1.3 ua Minimum

3.4 Diagnostic Tips:

1. If no LEDs are lit, check power to system being tested and
SmarTester battery.

2. If 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.

3. If 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.

3.2 Normal Sequence of Operation:

No call for heat: (Power Applied to Equipment)

• 24VAC LED Lit

• 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.

• Green LEDs indicate “NORMAL” operation and are lit only when

power is applied.

• Red LEDs indicate an open circuit and potential problem..

6

4. With a normally open pressure switch, if the Operating Control LED

does not glow, check for a stuck closed pressure switch.

5. 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)

• Pressure Switch:

If open, check:

• Pressure Switch

• Pressure Switch Tubing for blockage or leaks

• Inducer Assembly/ Inducer Blower Wheel

• Flue for blockage

• Limits:

• Follow limit circuit checking each limit and connecting wiring.

7. Watch the sequence of the LEDs and verify that each component is

operating. 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.

8. 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)

9. 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 and WR50C Smart Card used in
conjunction with the SmarTester Instrument will analyze the following
models and many more*.

White-Rodgers 50A50 -110, 111, 112, 113, 142, 209, 286, 296, 405,

406, 408, 438, 471, 472, 473,474

50A55 - 286, 143, 241, 438, 474, 571
50A65 - 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! 7

8

4.1 Using the SmarTester:

• Shut off the power to system.

• Slide the Smart Card Overlay (WR50C / WR5042C) under the integral
tabs on the SmarTester.

• Connect to the WR50 Smart Interface Cable.

• Turn the thermostat all the way up. If necessary, carefully bypass
blower door safety switch for TEMPORARY TESTING PURPOSES

• Unplug the system Molex® type connectors from the control board.
Connect the matching SmarTester connectors to the ignition control
board. Then connect the SmarTester Molex® connectors to the
system connectors.

• Turn on the main power

Note: Cable connections are male and female and will only connect 1 way

•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.

4.2 Normal Sequence of Operation:

No call for heat

• Power LED Lit

• Polarity LED Lit

• MicroAmp Display (Erratic-Low)

• All other LEDs off.

Call for heat:

• Power LED Lit

• Polarity LED Lit

• MicroAmp Display

• Thermostat Closed LED Lit

• Pressure Switch Open LED Lit

• Inducer LED Lit

• Pressure Switch LED Off

• Ignitor LED Lit

• Main Valve/EFT LED Lit

• Burner Ignition

• Ignitor LED

• MicroAmp Reading Present (May Have Fluctuations)

• Normal Heat Cycle

Follow sequence of operation:

• 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.

• Green LEDs indicate “NORMAL” operation and are lit only when
power is applied.

• Red LEDs indicate an open circuit and potential problem.

Before doing any tests, always check for correct 115VAC supply voltage
to equipment. Incorrect supply voltage may give you a false reading
with the SmarTester.

9

4.3 MicroAmp Reading:

MODEL NO Minimum MicroAmp Reading

50A50 – 209/230 0.30 ma
All other 50A50 and 50A55 0.15 ma

4.4 Diagnostic Tips:

1. On a call for heat, the “Pressure Switch Open” red LED will glow
indicating an open pressure switch. This is a normal function with a
normally open pressure switch. If the LED does not glow, check for a
stuck-closed pressure switch. After motor has come up to speed the
LED should go out.

2. Watch the sequence of the LEDs and verify that each component is
operating. If LEDs are lit but there is no flame to the main burner,
check for correct supply gas pressure and all valves are open.

3. After locating the problem, always re-check and cycle until unit is
working properly.

4. On some units, the flame rollout safety is wired in series with the
gas valve circuit. If the gas valve LED is illuminated and the gas
valve does not open, check if there is a rollout in that circuit.

5. If the burner goes out after short run and there are no red LEDs,
control board goes into retry and system re-lights. The equipment
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: SmarTester Pressure Switch LED will blink if this or any

intermittent event occurs in the control circuit, but only as long as
the problem exists.

6. On 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.

Complete Kits: Optional Accessories:

STSVK SmarTester Smart Valve™ Kit SI50K SmarTester Interface Kit

For Use With Honeywell For Use With White Rodgers

1st Generation SV95XX 50A50, 50A55, etc

Includes: Includes:

ST100 SmarTester WR50C Smart Card 50Series
HWSVC Smart Card WR5042C Smart Card 50A 4 to 2
HWSV Smart Valve™ Cable WR50 Cable 50A Series
SCDM Soft Case WR42 Adapter Cable 50A 4 to 2
STVIDEO Instructional DVD WR42WC Adapter Cable 50A

w/ Ground Clip
STMANUAL Instruction Manual SCCP Soft Case
STFC SmarTester Flow Chart

ST50K SmarTester SISVK SmarTester Interface Kit/

WR50A Series Kit Smart Valve™

1

st

Generation SV95XX

Includes: Includes:

ST100 SmarTester HWSVC Smart Card
WR50C Smart Card 50A Series HWSV Smart Valve™ Cable
WR5042C Smart Card 50A 4 to 2 SCCP Soft Case
WR50 Cable 50A Series
WR42 Adapter Cable 50A 4 to 2
WR42WC Adapter Cable 50A w/Clip
SCDM Soft Case
STVIDEO Instructional DVD
STMANUAL Instruction Manual
STFC SmarTester Flow Chart

10

* 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 easily diagnosed.

WR50 Flow Chart

Upon Connection of Cables and Line

Voltage Applied to Appliance

11

Smart Valve™

Flow Chart

* 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 easily diagnosed.

12

PO Box 21 • 2230 Landmark Place • Allenwood, NJ USA

732-223-6644 • Fax [phone]

www.supco.com • [e-mail]

p/n 19204

™