Thermo Products Burner MG 1018 User Manual

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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