Operating Instructions
Contents
1. HK42FZ051 OR HK42FZ052 CON T STEP ACTION YES NO GOTO 32 Turn power on and depress the door switch Use a piece of tape to hold switch 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 Do you have 120 volts between BLACK and WHITE power leads at blower motor 34 BLWM 36 35 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 c2. 3 HK42FZ044 HK42FZ050 HK42FZ051 and HK42FZ052 SECTION A VARIABLE SPEED FURNACE CONTROL BOARDS HK42FZ003 OR HK42FZ012 STEP ACTION YES NO GOTO 1 Turn power off remove blower access panel and disconnect R thermostat lead 2 2 ae Hi 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 R thermostat lead to the furnace control board 6 Replace blower access panel and turn power on Wait a few seconds then reset 7 thermostat Observe operation of the furnace through 1 heating cycle 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 12 on the furnace control board 14 16 You have an open wire or bad terminal on either
3. 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 Do you have 120 volts between BLACK and WHITE power leads at blower motor 34 MTR2 36 35 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
4. KGASD0301FMS ECM MOTOR SIMULATOR Operating Instructions NOTE Read the entire instruction manual before using the ECM motor simulator SAFETY CONSIDERATIONS 4 WARNING 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 Ha
5. 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 GOTO 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 GOTO 1 Turn power off remove blower access panel and disconnect User Interface ABCD 2 Connector if used or the R thermostat lead if used 2 au Si 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 stat lead if used to the furnace control board 6 Replace blower access panel and turn power on Wait a few seconds then reset 7 thermostat Observe operation of the furnace through 1 heating cycle Go to the START HERE sect
6. damage If 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 PL11 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 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 step 40 Always in 17 spect 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 SECTION B VARIABLE SPEED FURNACE CONTROL BOARDS HK42FZ022 HK42FZ024 HK42FZ026 HK42FZ031 HK42FZ035 HK42FZ043 HK42FZ044 HK42FZ050
7. ion in the main troubleshooting guide TS GUIDE Does Status Code 42 flash 8 Note If 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 IDM 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 IDM 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 IDM 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 IDM 16 Fix problem 17 Go to the CLEANUP AND START UP INSTRUCTIONS section in the main 17 troubleshooting guide TS GUIDE 18 Disconnect PL11 from the inducer motor IDM and plug into the ECM motor simulat 19 or 19 Repeat COMPONENT TEST by turning setup switch SW1 6 OFF and then back 21 20 ON Does Status Code 42 flash Replace the inducer motor or the inducer motor assembly Inspect electronics por 20 tion of failed motor for water
8. n of pins 47 Did the motor pass the resistance check 48 50 48 Does blower wheel turn freely with blower control module removed 49 50 49 Replace blower control module Inspect failed blower control module for water 17 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 50 trol module for water damage If present find source of water and fix Check A 17 coil and or humidifier Copyright 2012 CAC BDP 7310 W Morris St Indianapolis IN 46231 Printed in U S A Edition Date 02 12 Catalog No IIKKGASD0301FMS003 Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations Replaces IIKKGASD0301FMS002 4
9. onnectors 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 ACTION YES NO GO TO 40 Remove tape from door switch and turn power off at main disconnect 41 Disconnect both multi pin connectors from blower control module attached to the 41 blower motor Be sure to depress release latches on connectors or they may get 42 damaged 42 Remove control box assembly from blower shelf and position out of the way 43 43 Remove blower assembly from furnace 44 Remove two in hex head bolts from blower control module attached to blower iii motor ae Carefully lift blower control module off blower motor Depress latch on internal con 45 nector to disconnect blower control module from motor portion of blower motor 46 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 46 painted motor end plate is greater than 100k ohms Then verify motor windings are 47 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 combinatio
10. 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 MTR1 16 Fix problem 17 Go to the CLEANUP AND START UP INSTRUCTIONS section in the main u troubleshooting guide TSGUIDE 18 a PL7 from the inducer motor MTR1 and plug into the ECM motor simu 19 ator 19 Repeat COMPONENT TEST by turning setup switch SW1 6 OFF and then back 21 20 ON Does Status Code 42 flash 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 If 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
11. 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 A WARNING 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 e 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 HK42FZ04
12. ve a fire extinguisher available during start up adjustment procedures and service calls Recognize safety information This is the safety alert symbol 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
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