ECM OPERATION MANUAL
FOR USE WITH MODELS:
CHX1-75N
CHX1-100N
CHX1-125N
CDX1-75N
CDX1-100N
CDX1-125N
: IF YOU DO NOT FOLLOW THE SAFETY PRECAUTIONS BELOW AND IN THIS MANUAL, A
FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF
LIFE.
DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF
THIS OR ANY OTHER APPLIANCE.
WHAT TO DO IF YOU SMELL GAS:
•
•
•
•
DO NOT TRY TO LIGHT ANY APPLIANCE.
DO NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY PHONE IN YOUR BUILDING.
LEAVE THE BUILDING IMMEDIATELY.
IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S PHONE. FOLLOW THE GAS
SUPPLIER’S INSTRUCTIONS.
•
IF YOU CANNOT REACH YOUR GAS SUPPLIER; CALL THE FIRE DEPARTMENT.
INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER, SERVICE AGENCY OR
THE GAS SUPPLIER. (REFERRED TO IN THESE INSTRUCTIONS AS
CONTRACTOR).
A
QUALIFIED HEATING
PLEASE READ THESE INSTRUCTIONS PRIOR TO INSTALLATION, INITIAL FIRING, AND BEFORE
PERFORMING ANY SERVICE OR MAINTENANCE. THESE INSTRUCTIONS MUST BE LEFT WITH THE
HOMEOWNER AND SHOULD BE RETAINED FOR FUTURE REFERENCE BY QUALIFIED SERVICE
PERSONNEL.
THERMO PRODUCTS, LLC.
BOX 217
NORTH JUDSON, IN 46366
PHONE: (574) 896-2133
MADE IN USA
MG-1018
ECN4547-MA
All installations and services must be performed by qualified service personnel.
I. FURNACE SPECIFICATIONS (SHIPPED SETTINGS)
CHX1 SERIES
MODEL NO.
CHX1-75
CHX1-100
CHX1-125
HEAT INPUT RATE IN BTU/HR
(High fire/ Low fire)
HEATING CAPACITY IN BTU/HR
(High fire/ Low fire)
75,000 / 52,000
70,875 / 49,612
100,000 / 70,000
94,500 / 66,150
125,000 / 87,500
117,500 / 82,250
HEIGHT OF CASING
WIDTH OF CASING
DEPTH OF CASING
WARM AIR OUTLET
RETURN AIR INLET
44-1/4”
17”
27-1/2”
15 x 18
25 x 16
44-1/4”
21”
27-1/2”
19 x 18
25 x 16
44-1/4”
24”
27-1/2”
22 x 18
25 x 16
DIA. OF FLUE
DIA. OF COMBUSTION
AIR INTAKE
2”
2”
3”
3”
3”
3”
FLOWRATE from .2” & .5” w.c.
EXTERNAL STATIC PRESSURE
@COOLING TAP A (CFM)
@COOLING TAP B (CFM)
@COOLING TAP C (CFM)
@COOLING TAP D (CFM)
COOLING
COOLING
COOLING
1000
800
1200
1400
1200
1000
1400
1600
1400
1200
1600
2000
HEATING
931 / 760
HEATING
1243 / 1015
HEATING
1556 / 1270
@HEATING TAP A
(CFM @High fire/Low fire)
TEMPERATURE RISE (°F)
BLOWER MOTOR HP
70 / 60
.5
70 / 60
.75
70 / 60
1
POWER CHOKES
LARGEST RECOMMENDED
AIR CONDITIONER
SIZE OF FILTERS
NOTES:
-
2.65 Mh
4 Ton
2.1 Mh
5 Ton
3.5 Ton
24-3/4” x 15-3/4” 24-3/4” x 15-3/4” 24-3/4” x 19-3/4”
1. Heating capacity based on annual fuel utilization efficiency rated by manufacturer.
2. On all outlet and inlet dimensions, the first dimension is width.
3. To permit largest recommended air conditioning (at .5 static pressure), selection of the highest motor speed is
required.
4. Electrical characteristics at 115 volts, 60 Hz., 1 phase (less than 15 amps, for all models).
5. All specifications are subject to change without notice.
1
All installations and services must be performed by qualified service personnel.
CDX1 SERIES
MODEL NO.
CDX1-75
CDX1-100
CDX1-125
HEATING INPUT RATE IN BTU/HR
(High fire / Low fire)
HEATING CAPACITY IN BTU/HR
(High fire / Low fire)
75,000 / 56,250
69,750 / 52,312
100,000 / 75,000 125,000 / 93,750
93,000 / 69,750
116,250 / 87,187
HEIGHT OF CASING
WIDTH OF CASING
DEPTH OF CASING
WARM AIR OUTLET
RETURN AIR INLET
46-1/4”
17”
27-1/2”
15 x 18
15 x 22
46-1/4”
21”
27-1/2”
19 x 18
19 x 22
46-1/4”
24”
27-1/2”
22 x 18
22 x 22
DIA. OF FLUE
DIA. OF COMBUSTION
AIR INTAKE
2”
2”
3”
3”
3”
3”
FLOWRATE from .2” & .5” w.c.
EXTERNAL STATIC PRESSURE
COOLING
COOLING
COOLING
@COOLING TAP A (CFM)
@COOLING TAP B (CFM)
@COOLING TAP C (CFM)
@COOLING TAP D (CFM)
1000
800
1200
1400
1200
1000
1400
1600
1400
1200
1600
2000
HEATING
1012 / 826
HEATING
1340 / 1094
HEATING
1673 / 1366
@HEATING TAP C
(CFM @ High fire / Low fire)
TEMPERATURE RISE (°F)
BLOWER MOTOR HP
65 / 60
.5
65 / 60
.75
65 / 60
1
POWER CHOKES
LARGEST RECOMMENDED
AIR CONDITIONER
SIZE OF FILTERS
NOTES:
-
2.65Mh
4 Ton
2.1Mh
5 Ton
3.5 Ton
21-3/4” x 14”(2) 21-3/4” x 14”(2) 21-3/4” x 14”(2)
1. Heating capacity based on annual fuel utilization efficiency rated by manufacturer.
2. On all outlet and inlet dimensions, the first dimension is width.
3. To permit largest recommended air conditioning (at .5 static pressure), selection of the highest motor speed is
required.
4. Electrical characteristics at 115 volts, 60 Hz., 1 phase (less than 15 amps. for all models).
5. All specifications are subject to change without notice.
2
All installations and services must be performed by qualified service personnel.
II. BLOWER INFORMATION
A. WIRING
Figure 1: BLOWER WIRING
: TURN OFF THE ELECTRICAL POWER to the furnace before attempting to disconnect blower
wiring.
3
All installations and services must be performed by qualified service personnel.
B. CFM TABLES
The following tables contain blower speed settings and their respective air flowrates for the ECM blower motor. To
change air flowrates from that of the shipped settings, use the respective S3 and S4 dipswitches on the furnace’s
integrated control board (see Figure 1).
HEATING SPEEDS
CDX1-75
CHX1-75
Dip
Dip
switch
High Fire
CFM
switch
High Fire
CFM
settings Low fire CFM Rise (oF)
Rise (oF)
settings Low fire CFM Rise (oF)
Rise (oF)
7-OFF
7-OFF
8-OFF
760
708
826
909
64
69
59
54
931
867
70
75
65
59
8-OFF
760
708
826
909
60
65
55
50
931
867
70
75
65
59
7-ON
8-OFF
7-ON
8-OFF
7-OFF
8-ON
7-OFF
8-ON
1012
1114
1012
1114
7-ON
8-ON
7-ON
8-ON
CDX1-100
CHX1-100
Dip
Dip
switch
High Fire
CFM
switch
High Fire
CFM
settings Low fire CFM Rise (oF)
Rise (oF)
settings Low fire CFM Rise (oF)
Rise (oF)
7-OFF
7-OFF
8-OFF
1015
947
64
69
60
55
1243
1160
1340
1450
70
75
65
60
8-OFF
1015
947
60
64
56
51
1243
1160
1340
1450
70
75
65
60
7-ON
8-OFF
7-ON
8-OFF
7-OFF
8-ON
7-OFF
8-ON
1094
1184
1094
1184
7-ON
8-ON
7-ON
8-ON
CDX1-125
CHX1-125
Dip
Dip
switch
High Fire
CFM
switch
High Fire
CFM
settings Low fire CFM Rise (oF)
Rise (oF)
settings Low fire CFM Rise (oF)
Rise (oF)
7-OFF
7-OFF
8-OFF
1270
1185
1366
1480
64
69
60
55
1556
1452
1673
1813
70
75
65
60
8-OFF
1270
1185
1366
1480
60
64
56
51
1556
1452
1673
1813
70
75
65
60
7-ON
8-OFF
7-ON
8-OFF
7-OFF
8-ON
7-OFF
8-ON
7-ON
8-ON
7-ON
8-ON
=FACTORY SHIPPED SETTINGS
4
All installations and services must be performed by qualified service personnel.
COOLING AND CONTINUOUS FAN SPEEDS
CDX1-75 & CHX1-75
CDX1-100 & CHX1-100
Continuous
CDX1-125 & CHX1-125
Dip Continuous
Dip
switch
setting
Continuous
fan
Dip
switch
setting
fan
CFM
switch
setting
fan
CFM
CFM
Cooling CFM
Cooling CFM
Cooling CFM
1-OFF
2-OFF
3-ON
1-OFF
2-OFF
3-ON
1-OFF
2-OFF
3-ON
4-OFF
500
500
500
400
400
400
600
600
600
700
700
700
1150
1000
850
4-OFF
600
600
600
500
500
500
700
700
700
800
800
800
1380
1200
1020
1150
1000
850
4-OFF
700
700
700
600
600
600
800
800
800
1000
1000
1000
1610
1400
1190
1380
1200
1020
1840
1600
1360
2300
2000
1700
1-OFF
2-OFF
3-OFF
4-OFF
1-OFF
2-OFF
3-OFF
4-OFF
1-OFF
2-OFF
3-OFF
4-OFF
1-OFF
2-OFF
3-OFF
4-ON
1-OFF
2-OFF
3-OFF
4-ON
1-OFF
2-OFF
3-OFF
4-ON
1-ON
2-OFF
3-ON
1-ON
2-OFF
3-ON
1-ON
2-OFF
3-ON
4-OFF
920
4-OFF
4-OFF
1-ON
1-ON
1-ON
2-OFF
3-OFF
4-OFF
2-OFF
3-OFF
4-OFF
2-OFF
3-OFF
4-OFF
800
1-ON
1-ON
1-ON
2-OFF
3-OFF
4-ON
2-OFF
3-OFF
4-ON
2-OFF
3-OFF
4-ON
680
1-OFF
2-ON
3-ON
1-OFF
2-ON
3-ON
1-OFF
2-ON
3-ON
4-OFF
1380
1200
1020
1600
1400
1190
4-OFF
1610
1400
1190
1700
1600
1360
4-OFF
1-OFF
2-ON
3-OFF
4-OFF
1-OFF
2-ON
3-OFF
4-OFF
1-OFF
2-ON
3-OFF
4-OFF
1-OFF
2-ON
3-OFF
4-ON
1-OFF
2-ON
3-OFF
4-ON
1-OFF
2-ON
3-OFF
4-ON
1-ON
2-ON
3-ON
4-OFF
1-ON
2-ON
3-ON
4-OFF
1-ON
2-ON
3-ON
4-OFF
1-ON
2-ON
3-OFF
4-OFF
1-ON
2-ON
3-OFF
4-OFF
1-ON
2-ON
3-OFF
4-OFF
1-ON
2-ON
3-OFF
4-ON
1-ON
2-ON
3-OFF
4-ON
1-ON
2-ON
3-OFF
4-ON
=FACTORY SHIPPED SETTINGS
5
All installations and services must be performed by qualified service personnel.
III.
ECM TROUBLE SHOOTING
A. GENERAL GUIDELINES TO TROUBLESHOOTING GE ECM – DRIVEN SYSTEMS
:
Disconnect power from unit before removing or replacing connectors, or servicing motor.
Wait at least 5 minutes after disconnecting power before opening motor.
SYMPTOM
Motor rocks slightly when starting
Motor won’t start
CAUSE/PROCEDURE
This is normal start-up for ECM
Check power at motor
Check low voltage (24 VAC R to C) at motor
Check low voltage connections (G,Y,W,R,C,) at
motor
•
•
•
•
•
No movement
•
Check for unseated pins in connectors on motor
harness
•
•
•
•
•
•
•
•
Test with a temporary jumper between R – G
Check motor for tight shaft
Perform motor/control replacement check
Run Moisture Check
Check for loose or compliant motor mount
Make sure blower wheel is tight on shaft
Perform motor/control replacement check
It is normal for motor to oscillate with no load on
shaft.
•
Motor rocks, but won’t start
Motor oscillates up & down while being tested off
of blower
Motor starts, but runs erratically
•
Varies up and down or intermittent
•
•
Check line voltage for variation or “sag”
Check low voltage connections (G,Y,W,R,C,) at
motor, unseated pins in motor harness connectors
Check “Bk” for erratic CFM command (in
variable speed applications)
•
•
•
•
Check-out system controls – T’stat?
Perform Moisture Check
Does removing panel or filter reduce “puffing”?
ꢀReduce restriction
•
•
“Hunts” or “puffs” at high CFM (speed)
ꢀReduce max airflow
Stays at low CFM despite system call for cool or
heat CFM
•
•
Check low voltage (T’stat) wires and connections
Verify fan is not in delay mode – wait until delay
complete
•
•
•
•
“R” missing/not connected at motor
Perform motor/control replacement check
“R” missing/not connected at motor
Is fan in delay mode? – wait until delay time
complete
Perform motor/control replacement check
Current leakage from controls into G,Y or W?
Check for Triac switched t’stat or solid state relay
Determine if it’s air noise, cabinet, duct or motor
noise – interview customer, if necessary
Check for loose blower housing, panels, etc.
High static creating high blower speed?
•
•
Stays at high CFM
•
•
Blower won’t shut off
Excessive noise
Noisy blower or cabinet
•
•
•
•
ꢀ
Check for air whistling thru seams in ducts,
cabinets or panels
ꢀ
Check for cabinet/duct deformation
6
All installations and services must be performed by qualified service personnel.
•
“Hunts” or “puffs” at high CFM (speed)
•
Does removing panel or filter reduce “puffing”?
ꢀ
ꢀ
Reduce restriction
Reduce max airflow
Evidence of Moisture
•
Motor failure or malfunction has occurred and
moisture is present
Evidence of moisture present inside air mover
•
•
Replace motor and perform Moisture Check
•
Perform Moisture Check
DO
DON’T
•
•
•
•
Check-out motor, controls, wiring and
connections thoroughly before replacing motor
Orient connectors down so water can’t get in
•
•
•
•
•
Automatically assume the motor is bad.
Locate connectors above 7 and 4 o’clock
positions
Replace one motor or control model # with
another (unless an authorized replacement)
Use high pressure drop filters – some have ½”
H2O drop!
ꢀ
Install “drip loops”
Use authorized motor and control model #’s for
replacement
Keep static pressure to a minimum:
ꢀ
Recommend high efficiency, low static
filters
Use restricted returns
ꢀ
ꢀ
Recommend keeping filters clean
Design ductwork for min static, max
comfort
ꢀ
Look for and recommend ductwork
improvement, where necessary, in
replacement
•
•
Size the equipment wisely
•
Oversize system then compensate with low
airflow
Plug in power connector backwards
Force plugs
Check orientation before inserting motor
connectors
•
•
Moisture Check
•
•
•
•
•
•
Connectors are orientated “down” (or as recommended by equipment manufacturer)
Arrange harnesses with “drip loop” under motor
Is condensate drain plugged?
Check for low airflow (too much latent capacity)
Check for undercharged condition
Check and plug leaks in return ducts, cabinet
Comfort Check
•
•
•
•
Check proper airflow settings
Low static pressure for lowest noise
Set low continuous-fan CFM
T’stat in bad location?
7
All installations and services must be performed by qualified service personnel.
Figure 2: ECM PIN CONNECTORS
Troubleshooting table above and Figure 2 adapted from GE Industrial Systems publication GED-7161C,
“Troubleshooting GE ECM – Driven Systems”.
8
All installations and services must be performed by qualified service personnel.
B. TROUBLESHOOTING CHARTS
THIS GUIDE SHOULD BE USED IN THE CASE OF A STOPPED OR MANFUNCTIONED ECM
BLOWER MOTOR. THE FOLLOWING SHOULD HELP ESTABLISH THE TYPE OF
MALFUNCTION OR DEVIATION FROM THE NORMAL BLOWER OPERATION.
TO USE THIS DIAGRAM, YOU JUST NEED TO FOLLOW THE INSTRUCTIONS IN THE BOXES.
CONFIRM IF EITHER BLOWER
WHEEL IS RUBBING AGAINST
NO
DOES BLOWER SPIN FREELY?
YES
HOUSING OR MOTOR SHAFT
IS SPINNING FREELY, REPAIR
OR REPLACE AS NECESSARY.
CHECK 115V SUPPLY,
CONNECTION FUSES,
SERVICE SWITCH AND
DOOR SWITCH.
IS THERE 115V
SUPPLIED TO MOTOR?
NO
YES
DISCONNECT 16 PIN
HARNESS FROM
MOTOR. IS THERE 24V
ACROSS PIN12 & PIN1
AND PIN12 & PIN3
IS THERE 24V
ACROSS R &
B/C ON THE
INTEGRATED
CONTROL?
NO
NO
CHECK 24V SUPPLY
TO INTEGRATED CONTROL.
AT THE HARNESS PLUG?
YES
DISCONNECT 16PIN
HARNESS FROM
INTEGRATED CONTROL.
IS THERE 24V ACROSS
PIN12 & PIN1 AND
PIN12 & PIN3
NO
REPLACE
INTEGRATED
CONTROL.
YES
AT THE CONROL?
YES
CHECK HARNESS
CONNECTIONS
AND WIRE.
TURN THERMOSTAT MANUAL FAN
SWITCH ON (IF AVAILABLE) OR JUMPER
BETWEEN R & G ON INTEGRATED CONTROL.
IS THERE VOLTAGE GREATER THAN
12V BETWEEN PIN15 & PIN1?
CHECK CONNECTIONS AND WIRES
AT INTEGRATED CONTROL, IF OK
REPLACE INTEGRATED CONTROL.
NO
YES
CHECK CONNECTION ON HARNESS AND MOTOR,
RECONNECT HARNESS TO MOTOR, IF
CONNECTIONS ARE GOOD AND MOTOR STILL
DOES NOT RUN REPLACE MOTOR.
9
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