Bryant KGASD0301FMS Operating Instructions 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.

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

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.

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 Isblower 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?