protech 62-102635-81 Instructions Manual

Brand: protech

Model: 62-102635-81

Category: Motorcycle Accessories

Type: Instructions Manual

92-26177-555-01

Page 1 of 6

-GPK, -GLK, -GPQ, -GLQ (TWO-STAGE, 80+ GAS FURNACES WITH ECM MOTORS): INSTRUCTIONS

FOR REPLACING THE INTEGRATED FURNACE CONTROL (IFC).

Use this replacement control kit (62-102635-81) to replace the following controls on -GPK, -GLK, -GPQ,

and -GLQ models:

Controls

Vendor (UT Electronic Controls)

62-24320-01 1095-100

62-24320-02 1095-101

Parts Supplied with this Kit:

1. Furnace Control (IFC) (62-102635-01)

2. Green Ground Wire Spear Connector Assembly (AS-50208-31-CY)

3. These Instructions (92-26177-555)

4. Replacement Wire Diagram Label (90-24314-04)

Necessary Tools:

¼” Nut Driver

Multi-Meter

CONTROL BOARD REPLACEMENT INSTRUCTIONS:

1. Remove power by turning off the main power disconnect or opening (turning off) the breaker controlling

the circuit (see warnings above). Always verify that there is no voltage at the furnace by using a meter

or a test light before starting work.

2. Turn off the gas supply to the furnace at the gas stop outside the furnace jacket.

3. Remove the furnace access doors. Always verify that there is no voltage at the furnace by using a

meter or a test light before starting work.

4. Remove (and identify for rewiring later

) all other wires and wire assemblies (inducer control, power,

etc.) from both control boards. (Note position of thermostat wires before removing.) Disconnect

any connected accessories such as humidifiers and electronic air cleaners from both control boards.

THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED, LICENSED SERVICE

PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT AND OPERATION OF THIS UNIT. READ

THESE INSTRUCTIONS THOROUGHLY BEFORE ATTEMPTING ANY MAINTENANCE OR OPERATION.

FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN IMPROPER INSTALLATION,

ADJUSTMENT, SERVICE OR MAINTENANCE RESULTING IN FIRE, ELECTRICAL SHOCK, CARBON

MONOXIDE POISONING, EXPLOSION, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

FOR CANADIAN INSTALLATIONS, THE CONVERSION SHALL BE CARRIED OUT BY A

MANUFACTURER’S AUTHORIZED REPRESENTATIVE, IN ACCORDANCE WITH REQUIREMENTS OF

THE MANUFACTURER, PROVINCIAL OR TERRITORIAL AUTHORITIES HAVING JURISDICTION AND

IN ACCORDANCE WITH THE REQUIREMENTS OF THE CAN/CGA-B149.1 or CAN/CGA-B149.2

INSTALLATION CODES.

WARNING

DISCONNECT THE MAIN ELECTRICAL POWER TO THE UNIT BEFORE

ATTEMPTING ANY MAINTENANCE. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK

RESULTING IN SEVERE PERSONAL INJURY OR DEATH.

WARNING

SHUT OFF THE GAS SUPPLY AT A MANUAL VALVE IN THE SUPPLY PIPING TO THE UNIT

BEFORE ATTEMPTING MAINTENANCE. FAILURE TO DO SO CAN CAUSE FIRE OR AN EXPLOSION

RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

WARNING

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5. Remove the grounding screw securing the main furnace control board (IFC) to the mounting plate.

Note: This screw will not

be used with the replacement control board (IFC). Instead, a ground wire (to

be installed in a later step) takes the place of this screw.

6. Before removing control boards, note dip switch positions to be transferred to the replacement control

(IFC). Replacement should match the old control. Some particularly critical functions (such as cooling

airflow) must be transferred to the replacement by duplicating the dipswitch selections. (See furnace

installation instructions for details and dipswitch assignments). Further, some dipswitch selections have

been replaced in the new control with jumpers. The jumpers are intuitive and clearly labeled. (Note:

When using a two-stage thermostat with 2 heat speeds, the jumper at J5 should be set to the “None”

position (factory default). When using a single-stage thermostat with 1 heat output, and expecting the

timed staging feature, the jumper at J5 must be set to either 5 (five minutes) or 12 (twelve minutes)

according to the customer’s preference. The five or twelve minutes refers to the amount of time the

furnace remains in low heat before automatically switching to high-fire heat.) See Appendix A at the

end of these instructions for additional information regarding dip switches.

7. Remove existing control board by squeezing the locking tabs of the white mounting feet so that the

control can be pulled free from the mounting feet.

8. Insert green wire spear connector assembly (AS-50208-31-CY) into position #9 of the 12 pin Mate-N-

Lok style connector which plugs into the main furnace control board (IFC) at position P-1. The pin end

snaps directly into position #9 (See Figure 1). Position #9 is the only open position on the plug with no

wire inserted into it. Route the opposite end (with eyelet) of this green wire to the green grounding lug

in the junction box as indicated

9. Remove the main power junction box cover.

10. Remove the cover of the junction box and remove the grommet from the back side of the main junction

box (see Figure 2).

FIGURE 1: INSERT THE GREEN WIRE SUPPLIED WITH THE REPLACEMENT CONTROL INTO

POSITION #9 OF THE 12-PIN MATE-N-LOK STYLE CONNECTOR.

92-26177-555-01

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11. Run the green wire through the hole in the back of the junction box where the grommet was.

12. Reinstall the grommet.

13. Attach the other end of the green wire assembly to the grounding screw inside the junction box using

the eyelet (see Figure 3). Make sure that the system ground wire (which exits the furnace) is also still

attached to the ground screw. Also, it is critical that the ground wire exiting the furnace is attached to a

proper earth ground. Replace the cover of the junction box.

FIGURE 2: REMOVE THE GROMMET FROM THE BACK SIDE OF THE JUNCTION BOX.

FIGURE 3: MAKE SURE THAT BOTH GREEN GROUND WIRES ARE INSTALLED TO THE

GROUNDING SCREW IN THE JUNCTION BOX. NOTE: WITHOUT NEW GROUND WIRE,

FURNACE WILL NOT FUNCTION AND “STATUS” LED WILL INDICATE A FAULT CODE

BY BLINKING 6 TIMES. THIS FAULT INDICATES THE GROUND WIRE IS NOT INSTALLED

OR THAT LINE (L1) AND NEUTRAL ARE REVERSED.

92-26177-555-01

Page 4 of 6

14. Install the replacement control in the same position as the original main control (IFC) and snap into

place. Be sure to duplicate the dipswitch selections of the existing controls.

Some functions

previously controlled with dipswitches (blower-off timing (P-6) and single-stage staging selection (P-7)

are controlled with jumper/pins on the replacement control. These jumpers are clearly labeled. Also,

read the notes about thermostat wiring in step 16 for some tips to avoid some potential issues.

15. Connect the wire assembly (modified above with the 12 pin Mate-N-Lok style connector) to plug P-1 on

the replacement control.

16. Reattach the secondary and common leads of the transformer and the inducer control wires to the

replacement control.

17. Reattach the thermostat control wires noting the correct sequence as indicated in step 4 above.

SOME PRECAUTIONS ABOUT THERMOSTAT WIRING FOR SYSTEMS USING A SINGLE-STAGE

THERMOSTAT AND TIMED-STAGING FEATURE:

If furnace control being replaced is connected to a single-stage thermostat and uses the timed

staging feature of the furnace to operate two-stage heat, the following steps and changes must

be made to ensure the same operation.

Instead of routing the heat call “W” from the thermostat to “W2” on the furnace control, the

replacement control requires that the heat call “W” from the thermostat be routed to “W1” on the

furnace control and that the jumper located at “P7” on the furnace control be moved to either

the five-minute (5) or twelve-minute (12) position (depending on the customer’s preference). If

the heat call “W” from the thermostat is routed to “W2” on the furnace control (as before), the

furnace will not

operate in heat.

18. Reattach neutral and line voltage (black and white) leads to the replacement control at the proper

locations (see wiring diagrams).

NOTE: BE SURE TO REATTACH ANY ACCESSORIES (HUMIDIFIER, ELECTRONIC AIR CLEANER,

ETC) THAT MAY BE PRESENT.

19. Install new wire diagram label (90-24314-04) over existing wire diagram label on door.

20. Do not replace the grounding screw through the control board. The replacement control does not need

this screw because the ground wire was installed. There is no clearance hole for it in the replacement

control (refer to steps 8 through 12)

21. Replace furnace access doors.

22. Open the gas stop valve.

23. Restore power to the furnace and actuate heat (test both stages of heat if available) and cooling calls

(test all available) using the thermostat to insure proper operation of the furnace and system.

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Appendix A – DIP Switch Settings

This addendum will help to transfer the dipswitch settings from the existing furnace control to the replacement.

BANK SW1 of Main Furnace Control (IFC) (obsolete) (62-24320-01 and 62-24320-02):

This bank of

dipswitches is replaced by jumper selections on the replacement control (62-102635-01 and 62-102635-81).

The switch #4 (“NORM” (OFF) and “ICM” (ON)) is now obsolete.

Dipswitches 1 & 2

These switches are used to select the heating and cooling speed blower off delays. The selections are noted in

the table in Figure A-1.

BLOWER OFF DELAYS (IN SECONDS)

LOW

FIRE

HIGH

FIRE

NORMAL

COOLING

(switch

#4 =

"OFF")

ECM

COOLING

(SWITCH

#4 =

"ON")

SWITCH

80 50 30 0 OFF ON

110 80 40 30 OFF OFF

150 120 60 20 ON OFF

170 140 90 50 ON ON

Figure A-1

– COOLING AND HEAT PUMP BLOWER OFF DELAYS BASED ON SELECTION OF

DIPSWITCHES 1 & 2 OF BANK SW1 OF MAIN IFC.

Dipswitch 3

This switch was used to specify a twinning system to the furnace control. It was not used with ECM furnaces

since twinning is not permitted with these models. Therefore, it has no application for those models. For

reference, on other (non-ECM) models, the “OFF” position specifies no twinning and the “ON” position specifies

twinning.

Dipswitch 4

This switch is used to specify to the older controls that the furnace used an ECM motor. The “ON” position

indicated that an ECM motor and corresponding daughter control were part of the system. The “OFF” position

specified to the furnace control that a PSC (Permanent Split-Capacitor) style motor was part of the system. The

switch was present so that a single furnace control (IFC) could be used to control both ECM and PSC style

motors. The new control is different for each style (PSC or ECM), therefore this switch is no longer necessary.

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Jumper Selections on the New (62-102635-01) and New Replacement (62-102635-81) Furnace Controls.

The illustration A-2 below explains the settings of the dipswitches on the new (62-102635-01) and replacement

(62-102635-81) furnace control for use on two-stage, 80+ gas furnaces with Permanent Split-Capacitor (PSC)

motor.

______________________________________________________________________________

Figure A-2 – ILLUSTRATION SHOWING ALL JUMPER SETTINGS FOR 62-102635-01 AND 62-102635-81

FURNACE CONTROLS.

protech 62-102635-81 Instructions Manual

Brand: protech

Model: 62-102635-81

Category: Motorcycle Accessories

Type: Instructions Manual

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protech 62-102635-81 Instructions Manual

protech 62-102635-81 Instructions Manual

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