Bryant KGASD0301FMS User manual

Operating Instructions
NOTE: Read the entire instruction manual before using the
ECM motor simulator.
SAFETY CONSIDERATIONS
FIRE, EXPLOSION, ELECTRICAL SHOCK
HAZARD
Failure to follow this warning could result in personal
injury, death and /or property damage.
The ability to properly perform service on this equipment
requires certain expertise, mechanical skills, tools, and
equipment. 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.
HK42FZ003, HK42FZ012, HK42FZ022, HK42FZ024,
HK42FZ026, HK42FZ031, HK42FZ035, HK42FZ043,
HK42FZ044, HK42FZ050, HK42FZ051 and HK42FZ052.
NOTE: The ECM motor simulator can only be used with the
furnace component self test function. In addition, an adapter
harness is included for installations with ECM 3.0 motors.
Use the procedure outlined below several times before relying on
the condensed instructions printed on the ECM motor simulator
labels. This procedure should be inserted into the main
troubleshooting guide.
DESCRIPTION AND USAGE
The ECM motor simulator is designed to assist the service
technician in troubleshooting the variable speed gas-fired
furnaces. Use the procedure outlined below to troubleshoot with
the ECM motor simulator.
Installing and servicing heating equipment can be hazardous due
to gas and electrical components. Only trained and qualified
service personnel should install, repair, or service heating
equipment.
Untrained personnel can perform basic maintenance functions
such as cleaning coils, or cleaning and replacing filters. All other
operations should be performed by trained service personnel.
When working on heating equipment, observe precautions in
literature, on tags, and on labels attached to or shipped with the
unit, and other safety precautions that may apply.
Follow all safety codes. In the United States, follow all safety
codes including the National Fuel Gas Code (NFGC) NFPA
54/ANSI Z223.1. In Canada, refer to the National Standard of
Canada Natural Gas and Propane Installation Codes
(NSCNGPIC), CSA B149.1.
Wear safety glasses and work gloves. Have a fire extinguisher
available during start-up, adjustment procedures, and service
calls.
Recognize safety information. This is the safety-alert symbol
AX. 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,
CAUTION, and NOTE. The words DANGER, WARNING, and
CAUTION are used with the safety-alert symbol. DANGER
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 may result in minor personal
injury, or product and property damage. NOTE is used to
highlight suggestions which will result in enhanced installation,
reliability, or operation.
INTRODUCTION
This instruction covers the use of the ECM motor simulator on
variable speed gas-fired furnaces that use furnace control center
ELECTRICAL OPERATION HAZARD
Failure to follow this warning could result in damage to this
equipment, personal injury, or death.
Only trained and qualified personnel should install, repair or
service this equipment.
QUICK MOTOR TEST PROCEDURE
(WHEN USING ECM MOTOR
SIMULATOR)
In an effort to provide a method of troubleshooting a variable
speed inducer and/or variable speed blower motor by themselves
the following procedure may save you some time in the event any
of the following status codes are reason for the service call.
• Status codes 12, 32, 41, 42, or 44 on furnace control
HK42FZ003 or HK42FZ012.
• Status codes 15, 32, 41, or 42 on furnace control
HK42FZ022, HK42FZ024, HK42FZ026,
HK42FZ031, HK42FZ035, HK42FZ043,
HK42FZ044, HK42FZ050, HK42FZ051 and
HK42FZ052.
If you get any other status code, you should use the main
troubleshooting guide (not included in this kit) to isolate the
problem. Select the proper section based on the furnace control
board installed in the furnace.
SECTION A Variable Speed Furnace Control Boards
HK42FZ003 or HK42FZ012.
SECTION B - Variable Speed Furnace Control Board
HK42FZ022, HK42FZ024, HK42FZ026, HK42FZ031,
HK42FZ035, HK42FZ043, HK42FZ044, HK42FZ050,
HK42FZ051 and HK42FZ052.

SECTIONA - VARIABLESPEEDFURNACECONTROLBOARDSHK42FZ003ORHK42FZ012
STEP ACTION YES NO GO TO
1 Turn power off, remove blower access panel, and disconnect R thermostat lead. 2
2 Turn the power ON and depress the door switch. Use a piece of tape to hold it 3
closed.
3 Put setup switch SW1-6 for COMPONENT TEST in the ON position. 4
4 After the COMPONENT TEST is completed, does Status Code 11 flash? 5 8
5 Turn power off, put setup switch SW1-6 for COMPONENT TEST in the OFF posi- 6
tion, and reconnect the Rthermostat lead to the furnace control board.
Replace blower access panel and turn power on. Wait a few seconds then reset
6 thermostat. Observe operation of the furnace through 1 heating cycle. 7
7 Go to the "START HERE" section in the main troubleshooting guide. TS GUIDE
8 Does Status Code 42 flash? 9 24
9 Did inducer motor MTR1 turn on and come up to speed? 18 10
10 Does the inducer wheel rub against the inducer housing? 16 11
11 Does the inducer wheel turn freely? 12 20
Disconnect PL7 from the inducer motor MTR1 and plug into the ECM motor simu-
12 lator. Does the LED next to the inducer motor connector on the ECM motor simulat- 15 13
or turn ON?
13 Do you have 120 volts between I1 and 12on the furnace control board? 14 16
You have an open wire or bad terminal on either the BLACK or WHITE wire
14 between the furnace control board and inducer motor MTR1. Repair it or replace 16
main harness.
15 Are all pins and wire leads intact on the connectors between the furnace control 19 16
board and the inducer motor MTRI?
16 Fix problem. 17
Go to the "CLEANUP AND START-UP INSTRUCTIONS" section in the main
17 TS GUIDE
troubleshooting guide.
18 Disconnect PL7 from the inducer motor MTR1 and plug into the ECM motor simu- 19
lator.
Repeat COMPONENT TEST by turning setup switch SW1-6 OFF and then back
19 ON. Does Status Code 42 flash? 21 20
Replace the inducer motor or the inducer motor assembly. Inspect electronics por-
20 tion of failed motor for water damage. If present, find source of water and fix. 17
Check A-coil and/or humidifier.
Turn power off and disconnect PL7 from the ECM motor simulator. Do you have
21 continuity across the BROWN, YELLOW, and ORANGE wires between connectors 23 22
PL1 and PL7?
You have an open wire or bad terminal on either the BROWN, YELLOW, or
22 ORANGE wire between connectors PL1 and PL7. Repair it or replace the main 17
harness.
Replace the furnace control board. NOTE: tf replacing the furnace control board
23 still results in the same problem reinspect the wire harness terminals checked in the 17
previous step (step 21, or step 38).
24 Does Status Code 41 flash? 25 7
25 Did blower motor MTR2 turn on and come up to speed? 37 26
26 Remove tape from door switch and shut power off at main disconnect. 27
27 Does the blower wheel rub against the blower housing? 16 28
28 Does the blower wheel turn freely? 29 30
29 Is blower wheel firmly mounted on motor shaft? 31 16
Replace the entire blower motor or the blower control module attached to the
30 blower motor. If you replace the blower control module go to Section B - Step 40. 17
Always inspect failed motor for water damage. If present find source of water and
fix it. Check A-coil and/or humidifier.
31 Put setup switch SW1-6 for COMPONENT TEST in the OFF position. 32
32 Turn power on and depress the door switch. Use a piece of tape to hold switch 33
closed. Wait a few seconds for self test before proceeding to the next step.
33 Do you have 120 volts between B1 and B2 on the furnace control board? 34 16
34 Do you have 120 volts between BLACK and WHITE power leads at blower motor 36 35
MTR2?
You have an open wire or bad terminal on either the BLACK or WHITE wire
35 between the furnace control board and blower motor MTR2. Repair it or replace 16
blower harness(es).
36 Are all pins and wire leads intact on the connectors between the furnace control 37 16
board and the blower motor?
Disconnect PL13 from the blower motor MTR2 and plug into the ECM motor simu-
37 lator. Repeat COMPONENT TEST by turning setup switch SW1-6 OFF and then 38 30
back ON. Does Status Code 41 flash?
Remove tape from door switch and turn power off at main disconnect. Disconnect
38 PL13 from the ECM motor simulator. Do you have continuity across the BLUE, 23 39
YELLOW, VIOLET, ORANGE, and RED wires between connectors PL3 and PL13?

SECTION A - VARIABLE SPEED FURNACE CONTROL BOARDS HK42FZ003 OR HK42FZ012 (CON'T)
STEP ACTION YES NO GO TO
You have an open wire or bad terminal on either the BLUE, YELLOW, VIOLET,
39 ORANGE, or RED wire between connectors PL3 and PL13. Repair it or replace 17
blower harness(es).
SECTION B - VARIABLE SPEED FURNACE CONTROL BOARDS HK42FZ022, HK42FZ024 HK42FZ026,
HK42FZ031, HK42FZ035, HK42FZ043, HK42FZ044, HK42FZ050, HK42FZ051, OR HK42FZ052
STEP ACTION YES NO GO TO
1 Turn power off, remove blower access panel, and disconnect User Interface ABCD 2
Connector (if used) or the Rthermostat lead (if used).
2 Turn the power on and depress the door switch. Use a piece of tape to hold it 3
closed.
3 Put setup switch SW1-6 for COMPONENT TEST in the ON position. 4
4 After the COMPONENT TEST is completed, does Status Code 11 flash? 5 8
Turn power off, put setup switch SW1-6 for COMPONENT TEST in the OFF posi-
5 tion, and reconnect the User Interface ABCD Connector (if used) or the R thermo- 6
star lead (if used) to the furnace control board.
Replace blower access panel and turn power on. Wait a few seconds then reset
6 thermostat. Observe operation of the furnace through 1 heating cycle. 7
7 Go to the "START HERE" section in the main troubleshooting guide. TS GUIDE
Does Status Code 42 flash?
8 Note: [f you get this status code on a furnace that does not have a variable speed 9 24
inducer motor then the model plug is incorrect. Reference the model plug chart on
the wiring schematic for the correct part number.
9 Did inducer motor [DM turn on and come up to speed? 18 10
10 Does the inducer wheel rub against the inducer housing? 16 11
11 Does the inducer wheel turn freely? 12 20
Disconnect PL11 from the inducer motor [DM and plug into the ECM motor simulat-
12 or. Does the LED next to the inducer motor connector on the ECM motor simulator 15 13
turn ON?
13 Do you have 120 volts between PL2-4 and L2 on the furnace control board? 14 16
You have an open wire or bad terminal on either the BLACK or WHITE wire
14 between the furnace control board and inducer motor [DM. Repair it or replace 16
main harness.
15 Are all pins and wire leads intact on the connectors between the furnace control 19 16
board and the inducer motor [DM?
16 Fix problem. 17
Go to the "CLEANUP AND START-UP INSTRUCTIONS" section in the main
17 TS GUIDE
troubleshooting guide.
18 Disconnect PL11 from the inducer motor [DM and plug into the ECM motor simulat- 19
or.
Repeat COMPONENT TEST by turning setup switch SW1-6 OFF and then back
19 ON. Does Status Code 42 flash? 21 20
Replace the inducer motor or the inducer motor assembly. Inspect electronics por-
20 tion of failed motor for water damage. [f present, find source of water and fix. 17
Check A-coil and/or humidifier.
Turn power off and disconnect PL11 from the ECM motor simulator. Do you have
21 continuity across the BROWN, YELLOW, and ORANGE wires between connectors 23 22
PL1 and PLll?
You have an open wire or bad terminal on either the BROWN,
22 YELLOW, or ORANGE wire between connectors PL1 and 17
PL11. Repair it or replace the main harness.
Replace the furnace control board. NOTE: If replacing the furnace control board
23 still results in the same problem, reinspect the wire harness terminals checked in 17
the previous step (step 21, or step 38).
24 Does Status Code 41 flash? 25 7
25 Did blower motor BLWM turn on and come up to speed? 37 26
26 Remove tape from door switch and shut power off at main disconnect. 27
27 Does the blower wheel rub against the blower housing? 16 28
28 Does the blower wheel turn freely? 29 30
29 [s blower wheel firmly mounted on motor shaft? 31 16
Replace the entire blower motor or the blower control module attached to the
blower motor. [f you replace the blower control module go to step 40. Always in-
30 spect failed motor for water damage. [f present find source of water and fix it. 17
Check A-coil and/or humidifier.
31 Put setup switch SW1-6 for COMPONENT TEST in the OFF position. 32

SECTION B - VARIABLE SPEED FURNACE CONTROL BOARDS HK42FZ022, HK42FZ024 HK42FZ026,
HK42FZ031, HK42FZ035, HK42FZ043, HK42FZ044, HK42FZ050, HK42FZ051, OR HK42FZ052 (CON'T)
STEP ACTION YES NO GO TO
Turn power on and depress the door switch. Use a piece of tape to hold switch
32 closed. Put setup switch SW1-6 for COMPONENT TEST in the OFF position. Wait 33
a few seconds for self test before proceeding to the next step.
33 Do you have 120 volts between L1 and L2 on the furnace control board? 34 16
34 Do you have 120 volts between BLACK and WHITE power leads at blower motor 36 35
BLWM?
You have an open wire or bad terminal on either the BLACK or WHITE wire
35 between the furnace control board and blower motor BLWM. Repair it or replace 16
blower harness(es).
36 Are all pins and wire leads intact on the connectors between the furnace control 37 16
board and the blower motor?
Disconnect PL13 from the blower motor BLWM and plug into the ECM motor simu-
37 lator. Use the adapter harness for installations with ECM 3.0 blower motors. Repeat 38 30
COMPONENT TEST by turning setup switch SW1-6 OFF and then back ON. Does
Status Code 41 flash?
Remove tape from door switch and turn power off at main dis-
38 connect. Disconnect PL13 from the ECM motor simulator or adapter harness (if 23 39
used). Do you have continuity across the BLUE, YELLOW, GREEN, and RED wires
between connectors PL3 and PL13?
You have an open wire or bad terminal on either the BLUE,
39 YELLOW, GREEN, or RED wire between connectors PL3 and 17
PL13. Repair it or replace blower harness.
ELECTRICAL OPERATION HAZARD
Failure to follow this warning could result in personal
injury or death.
Wait at least five minutes after disconnecting line voltage
from equipment before opening blower motor to prevent
electric shock.
STEP GO TO
40 41
41 42
42 43
43 44
44 45
45 46
46
YES NO
48 50
49 50
ACTION
Remove tape from door switch and turn power off at main disconnect.
Disconnect both multi-pin connectors from blower control module attached to the
blower motor. Be sure to depress release latches on connectors or they may get
damaged.
Remove control box assembly from blower shelf and position out of the way.
Remove blower assembly from furnace.
Remove two ¼-in. hex head bolts from blower control module attached to blower
motor.
Carefully lift blower control module off blower motor. Depress latch on internal con-
nector to disconnect blower control module from motor portion of blower motor.
DO NOT PULL ON WIRES. GRIP PLUG ONLY.
When blower control module is completely detached from blower motor, verify with
standard ohmmeter that the resistance from each motor lead in motor plug to un-
painted motor end plate is greater than lOOk ohms. Then verify motor windings are
not shorted or open by measuring resistance 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 combination of pins.
Did the motor pass the resistance check?
Does blower wheel turn freely with blower control module removed?
Replace blower control module. Inspect failed blower control module for water
damage. If present, find source of water and fix. Check A-coil and/or humidifier.
Replace entire blower motor including blower control module. Inspect blower con-
trol module for water damage. If present, find source of water and fix. Check A-
coil and/or humidifier.
47
47
48
49 17
50 17
Copyright 2012 CAC /BDP • 7310 W. Morris St. • Indianapolis, IN 46231 Printed in U.S.A. Edition Date: 02/12 Catalo_l No: IIKKGASD0301FMSO03
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Manufacturer reserve8 the right to change, at any time, specification8 and design8 without notice and without obligations. Replaces: IIKKGASD030IFMS002
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