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1. Notes on 16 Pin Control Connection See Figure 6 Control functions G Y1 Y2 may be active at greater than 5 x control transformer voltage Do not apply 24vac to either Out pin 8 or16 High voltage on control pins will destroy motor Make sure pins are fully seated in connector and housing Verify common connection from transformer C or B to C1 C2 Pin 1 and Pin 3 Once common is verified test motor by applying 24vac R to control pins FIGURE 13 Page 10 COOL The COOL jumper is used to determine the CFM during ei ther 1 cooling or 2 heat pump operation without a call for electric heat These jumper selections are activated for cooling when Y2 and DS terminals in the CB31MV are en ergized and for heating when Y2 is energized For applications with Harmony II zone control the blow er CFM volume is determined by the Harmony II control center This speed is not adjustable With the thermostat set for Continuous Fan and without a call for heating or cooling the CB31MV will provided 5096 of the COOL CFM selected NOTE For two speed heat pumps blower will operate at 60 or 65 of COOL selection For single speed heat pumps blower will operate at 100 of COOL selection un til supplemental electric heat is demanded At that time the blower will operate at the HEAT speed selected This ar rangement provides for warmer supply air during heat pump operation only HEAT
2. Disconnect power to unit Disconnect plug J46 from P46 located on the blower control board Connect voltage source as shown above Turn on power to unit Blower should operate at low cool speed HIGH COOL SPEED 0 Y2 on 787 To Y on ignition control 12 3456 7 8 9 10 11 12 13 B 0200 Disconnect power to unit Connect voltage source as shown above Disconnect Y on ignition control AND re move connection from Y2 on TB1 in control box Connect a seperate wire between the side of the battery and BOTH Y on the igni tion control and Y2 on TB1 Turn on power to unit Blower should operate at high cool speed LOW HEAT SPEED 2 3 4 5 6 7 8 9 10 11 12 13 To W on ignition control board 9 Disconnect power to unit 10 Connect voltage source as shown above 11 Disconnect W terminal on ignition control board and connect a seperate wire between W and side of battery 12 Turn on power to unit Blower should operate at low heat speed HIGH HEAT SPEED 12 3456 7 8 9 10 11 12 13 B To W2 on TB1 13 Disconnect power to unit 14 Connect voltage source as shown above 15 Disconnect W2 on TB1 in control box and connect a seperate wire between W2
3. IS 24VAC ACROSS RAND YES PLACE JUMPER ACROSS R AND G IS BLOWER ON LOW SPEED COOLING TAP AND IS DS1 LIT YES N IS THE ACCESSORY NO RELAY PULLED IN CHECK VOLTAGE ON TB2 FROM ACC TO N ON TERMINAL YES BLOCK INSIDE CONTROL BOX SHOULD READ 120 VOLTS AC IN ADDITION TO R AND G JUMPER R AND DS YES IS BLOWER ON HIGH END OF COOLING TEST 4 spEED COOLING TAP ARE DS1 AND DS3 LIT START HERE DOES UNIT OPERATE NO NO HEATING MODE NO CHECK 1 UNIT POWER 2 INTERLOCK SWITCH 3 TRANSFORMER 4 TRANSFORMER FUSE NO 5 UNIT WIRING PRIMARY LIMIT S10 IS NC ALLOW UNIT TO COOL IF LIMIT REMAINS OPEN REPLACE LIMIT REPLACE VSP1 CHECK WIRING BETWEEN TB1 AND VSP1 REPAIR IF NECESSARY DS3 DS2 DS1 CHECK UNIT WIRING AND IF CORRECT REPLACE VSP1 CHECK UNIT WIRING FROM VSP1 TO TB2 AND IF CORRECT REPLACE VSP1 a NA DS3 DS2 DS1 CHECK UNIT WIRING AND IF CORRECT REPLACE THE VSP1 CHECK OUT ELECTRONICALLY CONTROLLED BLOWER MO YES TOR AND VSP1 Y IS 24VAC ACROSS PIN 8 AND 1 OF VSP1 gt IS 24VAC ACROSS J73 PIN 7 AND 1 NO OF VSP1 i YES IS 24VAC ACROSS J73 PIN 3 1 NO OF VSP1 y YES continued on next page Page 29 CHECK 1 UNIT POWER 2 INTERLOCK SWITCH 3 TRANSFORMER 4 TRANSFORMER FUSE 5 UNIT WIRING PRIMARY LIMIT 510 IS NC ALLOW UNIT TO COOL IF LIMIT REMAINS OPEN REPLACE
4. 6 Disconnect power to unit 7 Connect voltage source as shown above 8 Turn on power to unit Blower should operate at high speed HEATING SPEED CHECK OUT 123456 7 8 9 1011 12 13 9 Disconnect power to unit 10 Connect voltage source as shown above 11 Turn on power to unit Blower should operate at heating speed A kit is available from the Lennox parts center to use in testing the variable speed motor The kit 70J11 includes a test plug harness to facilitate ICM2 check out Follow testing procedures outlined in the instructions provided with the kit The testing procedures are different than those listed above FIGURE 25 Page 26 ICM 2 WITH VSP3 CHECK OUT 120V to the motor must not be interupted All connections for check out will be from the voltage source below battery or 24V to plug J46 after disconnectiong from blower control board CHECK OUT PROCEDURE USING BATTERY CHECK OUT PROCEDURE USING 24V SOURCE An ordinary 9 volt battery with maximum DC Unit transformer T1 with a maximum AC 30 volts 20volts is recommended A 9 volt battery will may be used in lieu of a battery If transformer T1 last for about one day of normal operation is used double check all wiring connections be fore placing unit back in operation LOW COOL SPEED 8 9 10 11 12 13 5 7 6 3 4 Ga
5. technician at the same electrostatic potential Neutralize electrostatic charge by touching hand and all tools on an unpainted unit surface such as the gas valve or blower deck before perform ing any service procedure Technical Publications Page 1 A CAUTION The IMC1 ICM2 may be energized during some service procedures Care must be taken not to wear loose clothing and to keep hands away from wheel FIGURE 1 TABLE OF CONTENTS I Introduction 1 Il Equipment Matchups 2 Ill Motor 3 IV Blowerr Motor Control 7 BDGO lecto theo eR teta 7 BD 2 2 RE Np bU RS E a 8 BOGS c xta We Vel iL 10 VSP zo Eh DURER CREE 13 2 ot etu ust ea Qt stt uai as 15 MSB32 A e RR eae Re et ens 19 Two Stage Variable Speed Control 23 V Troubleshooting 25 2001 Lennox Industries Inc Il Equipment Matchups MODEL CB21 CB21H CB21V CB21HV CB31MV CBX32MV G25MV G21V 1 to 3 GSR21V 1 to 9 G21V 4 to 8 GSR21V 10 to 15 G32V 1 3 G32V 4 G32V 5 GHR32V 1 3 GHR32V 4 GHR32V 5 G60UHV G60DFV G61MPV TABLE 1 BLOWER CONTROL BOARD BDC2 BDC3 BDC3 VSP2 1 VSP1 VSP2 1 VSP2 1 VSP3 1 Two Stage Variable Speed SureLight VSP2 1 VSP3 1 Two Stage Variable Speed SureLight Two Stage Variable Speed SureLight Two Stage Variable Speed Sur
6. The ON OFF LED may be delayed by the action of thermal heat relays in the ECB21 For example when the unit is in EM HEAT mode the ON OFF light energizes after the thermal heat relay closes and de energizes after the ther mal heat relay opens If the unit is switched from a heating demand to a 2nd stage cooling demand all three lights may be energized for a short time During this period the blower operates on heating speed When the thermal heat relay cools and opens the HEAT light de energizes and the blower switches to high speed BDC BLOWER CONTROL HILOW LED FIGURE 11 B BDC2 Blower Control Units equipped with a variable speed motor are capable of maintaining a specified CFM throughout the external static range A particular CFM can be obtained by positioning four jumpers Low High Heat and Adjust on the BDC 2 control board The Low High and Heat jumpers are labeled 1 2 3 and 4 This indicates the selected air volume CFM The ad just jumper is labeled Test and Norm The and pin set tings are used to add or subtract a percentage of the CFM se lected The Test jumper is used to operate the motor in the test mode Figure 12 shows the BDC 2 control board jumper set tings Diagnostic LEDs located on the BDC 2 control board are provided to aid in identifying the unit s mode of op eration Certain scenarios will arise depending on the jumper positions Read through the diagnostic and jumper settings
7. a COOLING DEMAND Switches 11 and 12 Heating Mode Blower Speed Switches 11 and 12 are used to select heating mode blow er motor speed The unit is shipped from the factory with the dip switches positioned for medium low 2 speed in QEF OFF door blower motor operation during the heating mode The table below provides the heating mode blower speeds that will result from different switch settings Refer to table 13 example only for corresponding cfm values TABLE 12 Heating Mode Blower Speeds Speed Swichti Switch 12_ 2 Medium Low Off On Facto 3 Medium High On Board Jumper W914 On board jumper W914 which connects terminals DS and R on the integrated control board must be cut when the furnace is installed with either the Harmony II zone control board or the CCB1 EfficiencyPlus humidity control On Board Jumper W951 On board jumper W951 which connects terminals R and O on the integrated control board must be cut when the furnace is installed in applications which include a heat pump unit and the FM21 FuelMaster control board Factory Installed Jumper Y1 to Y2 A factory installed jumper from Y 1 to Y2 terminals on the integrated control board terminal strip must be removed if two stage cooling will be used Diagnostic LEDs DS1 and DS2 Two diagnostic LEDs are located on the two stage vari able speed integrated control just to the left of the first bank of dip switches These lights flashes
8. in sequence the rotor shaft turns the blower Internal Operation Each time the controller switches a stator winding figure3 on and off it is called a pulse The length of time each pulse stays on is called the pulse width By varying the pulse width figure 4 the controller varies motor speed called pulse width modulation This allows for precise control of motor speed and allows the motor to compensate for varying load conditions as sensed by the controller In this case the con troller monitors the static workload on the motor and varies motor rpm in order to maintain constant airflow cfm The ICM1 motor is equipped with 11 incremental taps which are driven by the integral controller The controller is capable of controlling three of the 11 taps The VSP2 and VSP3 control board gives the ICM2 several options for cfm for heat or cool call Figure 18 for example shows four pin selections for High Cool speed and four pin selections for Heat speed In addition there is four pin selections for Low speed which can be used for either Heat or Cool Page 2 The motor controller is driven by a blower control board The blower control board receives its demand PWM sig nal or fixed 24 VAC or VDC signal from optional controls such as the Harmony zone control system Efficiency Plus Humidity Control CCB1 or a conventional thermostat Motor rpm is continually adjusted internally to maintain constant static pressure again
9. speed The unit is shipped from the factory with the dip switches positioned for high speed 4 indoor blower motor operation during the cooling mode The table below pro vides the cooling mode blower speeds that will result from different switch settings Refer to table 13 example only for corresponding cfm values TABLE 9 Cooling Mode Blower Speeds Speed switch5 Switche 1 Low roc E 3 MedumHigh Of Switches 7 and 8 Blower Speed Adjustment Switches 7 and 8 are used to select blower speed adjust ment settings The unit is shipped from the factory with the dip switches positioned for NORMAL no adjustment The dip switches may be positioned to adjust the blower speed by 10 or 10 to better suit the application The table below provides blower speed adjustments that will result from different switch settings Refer to table 13 example only for corresponding cfm values TABLE 10 Blower Speed Adjustment Adjustment Switch 7 Switch 8 10 approx On of 10 approx Of On Switches 9 and 10 Cooling Mode Blower Speed Ramping Switches 9 and 10 are used to select cooling mode blower speed ramping options Blower speed ramp ing may be used to enhance dehumidification perfor mance The switches are factory set at option A which has the greatest effect on blower motor performance The table below provides the cooling mode blower speed ramping options that will
10. 1 Disconnect power to unit 2 Disconnect plug J46 from P46 lo cated on the blower control board 3 Connect voltage source as shown above 4 Turn on power to unit Blower should operate at low speed HIGH SPEED CHECK OUT 12 34 5 6 7 8 9 10 11 12 13 6 Disconnect power to unit 7 Connect voltage source as shown above 8 Turn on power to unit Blower should operate at high speed HEATING SPEED CHECK OUT 12 3456 7 8 9 10 11 12 13 9 Disconnect power to unit 10 Connect voltage source as shown above 11 Turn on power to unit Blower should operate at heating speed CHECK OUT PROCEDURE USING 24V SOURCE Unit transformer T1 with a maximum AC 30 volts may be used in lieu of a battery If transformer T1 is used double check all wiring connections be fore placing unit back in operation LOW SPEED CHECK OUT 123 45 6 78 9 1011 12 13 1 Disconnect power to unit 2 Disconnect plug J46 from P46 lo cated on the blower control board 2 3 Disconnect C and R from control board 4 Connect voltage source as shown above 5 Turn on power to unit Blower should operate at low speed HIGH SPEED CHECK OUT 12 3 45 6 7 8 9 1011 12 13 non
11. FLOW CHART in the TROUBLE SHOOTING section of this manual Diagnostic LED Lights Three diagnostic LED lights are provided on the control for troubleshooting The three lights DS1 DS2 and DS3 fig ure 17 are on off hi speed heat and high speed cool In the heating and cooling mode the on off LED DS1 is lit indicating the blower is operating on low speed heat cool tap It is lit whenever a 24VAC thermostat demand is sup plied to the control jackplug JP73 pin 2 When the hi speed heat DS2 and the on off 051 LED are both lit the blower is operating on high speed heating tap 12 17VDC from CCB1 terminal DS or 24VAC from Y2 if CCB1 is not used During dehumidification mode the CCB1 turns off the DS output and the blower operates on low speed heat cool tap When the high speed cool 053 and the on off DS1 LED are both lit the blower is operating on high speed cool tap If the unit is switched from a heating demand to a 2nd stage cooling demand all three lights DS1 DS2 and DS3 may be energized for a short time During this period blower operates on high speed heating tap VSP1 BLOWER CONTROL BOARD FRONT VIEW PARTIAL 9 6 WOO 12 OE 3 O DS2 Ds1 1 OOO DIAGNOSTIC eooGl1 wx pur ses oos NOTLIT LIT PLUG INPUTS DS3 052 D51 o UNIT OPERATING ON LOW EN SPEED ps
12. MIN OFF 52 CFM 1 2 MIN 5096 CFM 10096 CFM OFF COOLING DEMAND 9 4 PIN JUMPERED A Motor runs at 5096 for 1 2 minute B Motor then runs at 82 for approximately 7 1 2 minutes If demand has not been satisfied after 7 1 2 minutes C Motor runs at 10096 until demand is satisfied D Once demand is met motor runs at 50 for 1 2 minute then E Motor ramps down to off 7 1 2 MIN p lt 100 82 CFM CFM 1 2 MIN 50 CFM COOLING DEMAND OFF ICM2 CHECK Kit 70J11 can be used to check the ICM2 The kit is avail able at the Lennox parts center If not using the kit follow the procedure below These settings and jumper place ments will bypass the BDC3 control board and confirm cor rect ICM2 operation 60 65 of Cool speed e Disconnect power to the unit e Change delay pin setting on the BDC3 board to 1 e Remove wires from terminal strips in control box e Install jumpers between R and Y1 and R and G e Turn on power to unit Blower should operate on 60 6596 of cool speed e When check is complete disconnect power and replace delay setting to original position Cool speed e Disconnect power to unit TABLE 3 Change delay pin setting on the BDC3 board to 1 Remove wires from terminal strips in control box Install jumpers between R and Y1 and Y2 R and DS and R and Turn on power to unit Blower should operate on cool speed When check
13. The HEAT jumper is used to determine CFM during a W1 demand for electric heat operation These jumper selec tions are activated when W1 is energized with or without a Y1 demand for heat pump compressor DELAY The DELAY jumper is used to set the specific motor fan mode of operation during cooling Depending on the ap plication one of four fan options may be chosen by moving the jumper pins to the appropriate set of pins Options 1 2 3 or 4 will have an increased dehumidification effect on the system Option 1 will have the least effect and option 4 will have the greatest effect NOTE For HARMONY II and or CCB1 applications the delay jumper must be set to position 1 Page 11 DELAY OPTIONS 1 PIN JUMPERED A Motor runs at 10096 until demand is satisfied B Once demand is met motor ramps down to off A B OFF 10096 CFM OFF DEMAND 2 PIN JUMPERED A Motor runs at 82 for approximately 7 1 2 minutes If demand has not been satisfied after 7 1 2 minutes B motor runs at 100 until demand is satisfied C Once demand is met motor ramps down to off B C A 7 1 2 MIN OFF 82 CFM COOLING DEMAND 100 CFM OFF 3 PIN JUMPERED A Motor runs at 50 for 1 2 minute B Motor then runs at 82 for approximately 7 1 2 minutes If demand has not been satisfied after 7 1 2 minutes C Motor runs at 10096 until demand is satisfied D Once demand is met motor ramps down to off C D 7 1 2
14. effect 1 PIN JUMPERED A Motor runs at 100 until demand is satisfied B Once demand is met motor ramps down to off B OFF 100 CFM OFF I DEMAND 2 PIN JUMPERED A Motor runs at 82 for approximately 7 1 2 minutes B If demand has not been satisfied after 7 1 2 minutes the motor runs at 100 until demand is satisfied C Once demand is met motor ramps down to off Page 21 7 1 2 MIN OFF 8296 CFM COOLING DEMAND 10096 CFM OFF 3 PIN JUMPERED A Motor runs at 5096 for 1 2 minute B Motor then runs at 82 for approximately 7 1 2 min utes C If demand has not been satisfied after 7 1 2 minutes motor runs at 10096 until demand is satisfied D Once demand is met motor ramps down to off 03 D 7 1 2 MIN OFF 82 CFM 1 2 MIN 50 CFM 100 CFM OFF COOLING DEMAND 9 4 PIN JUMPERED A Motor runs at 5096 for 1 2 minute B Motor then runs at 82 for approximately 7 1 2 min utes C If demand has not been satisfied after 7 1 2 minutes motor runs at 10096 until demand is satisfied D Once demand is met motor runs at 50 for 1 2 min ute E Motor ramps down to off 7 1 2 MIN p lt 100 OFF 82 CFM CFM 1 2 MIN 50 CFM COOLING DEMAND COOL The cool jumper is used to set the blower speed to obtain the required CFM as outlined in the blower performance tables OFF VSP Operation Table 7 outlines the
15. indi cate the blower is operating on low speed heat When HEAT LED DS2 is lit the blower is operating in high speed heat and second stage W2 is calling Harmony Zoned Applications The blower speed is controlled by the PWM pulse width modulation signal sent from the control center of the zoning system to the termi nal strips DS terminal HI LOW LED DS1 and ON OFF LED DS3 are lit to indicate the blower is oper ating Note In Harmony II zoning ap plications HTG BLOWER jumper must be in position 2 Units With Two Stage Heating Non Zoned Applications Using a two stage thermostat with first stage W1 calling the ON OFF LED DS3 is lit to indicate the blower is operating in low speed heat When the ON OFF LED DS3 and HEAT LED DS2 are lit the blower is operating in high speed heat and second stage W2 is calling HEAT LED DS2 is lit with a call for heat from the thermostat ON OFF LED DS3 is after 110 seconds from the time a call for heat is made Harmony Zoned Application The blower speed is controlled by the PWM pulse width modulation signal sent from the control center of the zoning system to the terminal strips DS terminal H ILOW LED DS1 and ON OFF LED DS3 are lit to indicate the blower is operating Note In Harmony 1 zoning ap plications HTG BLOWER jumper must be in position 2 Units With Single speed Compressor Non Zoned Applications Y1 DS and Y1 Y2 must be jump ered tog
16. input only PIN 2 Jumper PIN 1 to PIN2 for 120VAC line input only PIN 3 Ground PIN 4 AC Line PIN 5 AC Line Precautions ICM1 and ICM2 If the unit equipped with an electronically controlled blower motor is improperly or inadequately grounded it may cause television interference commonly known as RFI or radio fre quency interference This interference is caused by internal switching frequencies of the motor controller see figure 9 TV interference may show up as small specks or lines which randomly appear on the TV screen accompanied by pops or clicks in the sound Before attempting any service make sure the indoor unit is causing the interference To check disconnect power to in door unit then check TV for continued signs of interference TV interference may be stopped by making sure the motor is solidly grounded to the cabinet metal to metal and by making sure the cabinet is solidly grounded If TV interference per sists make sure the television and all affected RF appliances are moved away from the unit Also make sure affected ap pliances are connected to a separate electrical circuit Coil Choke L13 A coil choke is used on some ICM2 motors The choke is lo cated on the blower housing and is used to supress transient current spikes ICM SWITCHING FREQUENCY The electrical pulses to the windings cycle on and off at a rate of 20 000 cycles per se
17. low heat speed HIGH HEAT SPEED 12345 6 7 8 9 1011 12 13 0000 To W2 on TB1 9 Disconnect power to unit 10 Connect voltage source as shown above 11 Disconnect W2 from TB1and connect a seperate wire between R on transformer and W2 on TB1 11 Turn on power to unit Blower should operate at low heat speed ICM 2 WITH TWO STAGE VARIABLE SPEED SURELIGHT 120V to the motor must not be interrupted All connections for check out will be from the volt age source below battery or 24V to plug J46 after disconnecting from blower control board REMOVE PLUG FROM BOARD CHECK OUT PROCEDURE USING BATTERY An ordinary 9 volt battery with maximum DC 20volts is recommended A 9 volt battery will last for about one day of normal operation 1 Disconnect power to unit 2 Disconnect plug J46 from P46 located on the blower control board 3 Connect voltage source as shown above 4 Turn on power to unit Blower should operate at low cool speed 9 10 11 12 13 1 15 16 5 Disconnect power to unit 6 Connect voltage source as shown above 7 Turn on power to unit Blower should operate at high cool speed 8 Disconnect power to unit 9 Connect voltage source as shown above 10 Turn on power to unit Blower should operate at low heat speed 11 Discon
18. operation of the variable speed motor in relation to specific modes of operation Some informa tion has been repeated from the previous section to pro vide an example Refer to each diagnostic LED or jumper settings section for more information ADJUST Jumper Positions L s 415 355 cfm 875 750 NORM Normal Minus 15 ADJUST Jumper Positions TABLE 6 Example Only VSP Jumper Speed Positions Low Speed 2 3 L s cfm 445 985 375 850 cfm 940 795 L s 465 400 cfm 915 Low Speed 1060 HEAT 4 2 L s cfm Lis cfm 500 1090 515 1175 430 940 445 995 COOL High Speed 3 4 L s cfm 605 1330 515 1180 L s 555 470 L s 630 555 cfm 1285 1095 High Speed NORM Normal 875 415 940 445 985 465 060 500 1070 505 1130 535 1270 600 1290 610 T Minus 15 750 355 795 375 850 400 915 430 900 425 940 445 1055 500 1120 530 TABLE 7 VSP3 1 Non Zoned Applications Using a single stage thermostat with heating the HEAT LED DS2 is lit when the thermostat calls for heat The ON OFF LED DS3 is lit after 110 sec onds 65 seconds prepurge and 45 seconds fan ON time from the time a call for heat is made This in dicates the blower is operating in high speed heat Using a single stage thermostat with W2 TIMED and W1 calling the ON OFF LED DS3 is lit to
19. result from different switch settings The cooling mode blower speed ramping options are detailed below TABLE 11 Cooling Mode Blower Speed Ramping Ramping Option Switch9 Switch 10 A Factory Box omn om Only option for CCB1 Ramping Option A Factory Selection e Motor runs at 5096 for 1 2 minute e Motor then runs at 82 for approximately 7 1 2 minutes e f demand has not been satisfied after 7 1 2 minutes motor runs at 10096 until demand is satisfied e Once demand is met motor runs at 5096 for 1 2 minute e Motor ramps down to off 50 COOLING DEMAND _ ____ 7 1 2 MIN 82 CFM 100 OFF CFM S OFF Ramping Option B e Motor runs at 5096 for 1 2 minute e Motor then runs at 8296 for approximately 7 1 2 min utes e f demand has not been satisfied after 7 1 2 minutes motor runs at 10096 until demand is satisfied e Once demand is met motor ramps down to off 7 1 2 MIN 82 CFM OFF 100 CFM OFF 1 2 MIN 50 CFM COOLING DEMAND Ramping Option C e Motor runs at 82 for approximately 7 1 2 minutes e f demand has not been satisfied after 7 1 2 minutes the motor runs at 10096 until demand is satisfied e Once demand is met motor ramps down to off 7 1 2 MIN 82 CFM COOLING DEMAND OFF 100 CFM Ramping Option D e Motor runs at 10096 until demand is satisfied e Once demand is met motor ramps down to off 100 CFM
20. seconds is not adjustable The blower off delay time that the blower operates after the heating demand has been satisfied can be adjusted by moving switches 1 and 2 on the integrated control board The unit is shipped from the factory with a blower off delay of 90 seconds The blower off delay affects comfort and is adjustable to satisfy individual applications Adjust the blower off delay to achieve a supply air temperature between 90 and 110 F at the exact moment that the blower is de energized Lon ger off delay settings provide lower supply air tempera tures shorter settings provide higher supply air temperatu res The table below provides the blower off timings that will result from different switch settings TABLE 8 Blower Off Delay Switch Settings Seconds Switch 3 Second Stage Delay Used with Single Stage Thermostat Only This switch is used to deter mine the second stage on delay when a single stage ther mostat is being used The switch is factory set in the ON position which provides a 10 minute delay before second stage heat is initiated If the switch is toggled to the OFF Page 23 position it will provide a 15 minute delay before second stage heat is initiated This switch is only activated when the thermostat selector jumper is positioned for SINGLE stage thermostat use Switch 4 Not used Switches 5 and 6 Cooling Mode Blower Speed Switches 5 and 6 are used to select cooling blower motor
21. the jumper off the pins and place it on the desired set of pins The following section outlines the different jumper selections available and conditions associated with each one Use table 3 as an example only for CFM per jumper setting See CFM tables in units Installation In structions or Unit Information if needed Refer to figure 13 for identification After the CFM for each application has been determined the jumper settings must be adjusted to maintain the CFM required Following are the descriptions of each of the jumper selections ADJUST The ADJUST pins allow the motor to run at normal speed approximately 1096 higher or approximately 1096 lower than normal speed The TEST pin is available to bypass the BDC3 control and run the motor at approximately 70 to test that the motor is operational This is beneficial primarily in troubleshooting G must be energized for motor to run BDC3 VARIABLE SPEED CONTROL SELECTIONS JP1 15 PIN PLUG BOARD TO MOTOR DIAGNOSTIC ACCESSORY RELAY CONTACTS DRIVES OPTIONAL ACCESSORY RELAY OPERATIONAL SELECTOR PINS _ p Affects both heating and cooling modes DELAY CFM RUN HEATING SPEED SELECTOR PINS COOLING SPEED SELECTOR PINS FAN DELAY SELECTOR PINS JP1 16 PIN PLUG Out Out Adjust G fan Y1 YIY2 Cool EM ht W2 Delay 24Vac R Common 2 Heat W W1 DS Pwn Speed Common 1 O Rev Valve
22. the thermostat J46 PIN 1 Heat Heat speed input signal to the ICM2 motor PIN 2 C 24 VAC common PIN 3 C 24 VAC common PIN 4 High Tap High Speed programming input PIN 5 Low Tap Low speed programming input PIN 6 On Off On off output signal to the ICM2 motor PIN 7 Adjust Tap ICM2 mode selection PIN 8 Hi Low Speed regulate input signal to the ICM2 motor PIN 9 Hi Low Speed regulate input signal to the ICM2 motor PIN 10 Ref V ICM2 reference voltage PIN 11 Heat Tap Heating blower speed programming PIN 12 C 24 VAC common PIN 13 cfm Motor speed diagnostic signal ADJUST JUMPER SETTING JP2 13 PIN PLUG BOARD TO MOTOR VOLTAGES INTO BDC 2 Voltage across J45 pins 6 to 1 is 24VAC constant as shown here Pin 1 to all other pins will be either 24VAC or OVAC off 24VAC 60Hz CY 34 volts 0 volts 34 volts If Harmony is used pin 4 will be DC VOLTAGES FROM BDC 2 TO ELECTRONICALLY CONTROLLED BLOWER MOTOR The output voltages from BDC 2 to ICM2 are not always 24AC In harmany applications high low pin 9 is DC Other outputs could be half rectified FIGURE 12 TABLE 2 Example Only LOW SPEED HIGH COOL SPEED HEAT SPEED BDC 2 JUMPER POSITION BDC 2 JUMPER POSITION BDC 2 JUMPER POSITION 1060 1150 1150 1250 1490 1600 1230 1340 1480 1600 1025 1025 1125 1325 1425 1125 1225 1325 1425 Page 9 C BDC3 Blower Con
23. wire from pin 3 of the J73 terminal on the VSP control board insulate the ends and secure to prevent shorting Page 22 G Two Stage Variable Speed SureLight This control manages ignition timing heating mode fan off delays and indoor blower speeds based on selections made using the control dip switches and jumpers The con trol includes an internal watchguard feature which auto matically resets the ignition control when it has been locked out because the burner has failed to light After one hour of continuous thermostat demand for heat the watch guard will break and remake thermostat demand to the fur nace and automatically reset the control to relight the fur nace Thermostat Selection Jumper E20 This unit may be used with either a single stage or two stage thermostat The thermostat selection jumper lo cated just below dip switches 1 through 3 must be properly positioned for the particular application The jumper is fac tory positioned for use with a two stage thermostat If a single stage thermostat is to be used the jumper must be repositioned a Select TWO for two stage heating operation con trolled by a two stage heating thermostat factory setting b Select SINGLE for two stage heating operation controlled by a single stage heating thermostat This setting provides a timed delay before second stage heat is initiated Dip Switch Settings Switches 1 and 2 Blower Off Delay The blower on delay of 45
24. 0 1130 4 L s 670 615 535 Page 24 V Troubleshooting A ICM1 Does Not Run If the motor does not run the problem could be with the elec tronically controlled blower motor or the VSP1 Check all connectors and wire terminations for good contact Figure 24 shows the electronically controlled blower motor and VSP1 checkout procedure The checkout procedure may be used to determine if either of these components must be replaced The procedure bypasses the VSP1 If the electronically con trolled blower motor does not operate properly it must be re placed If the electronically controlled blower appears to be operating properly replace the VSP1 For a detailed trouble shooting chart see VSP1 Blower Control Board Trouble shooting Flow Chart B ICM2 Does Not Run To check out the ICM2 motor and the VSP blower control board begin with the ICM blower Refer to figures 25 26 and 27 and follow the check out procedure as outlined If the blower fails any of these tests do not attempt to repair the ICM2 blower There are no field serviceable parts in this com ponent Replace the motor and repeat the check out proce dure To verify proper operation of the blower control board check the board as outlined in the troubleshooting flow charts If a power interrupt occurs during a demand cycle and the heat exchanger is still hot the blower may begin cycling on and off with the gas valve when power is restored This con dition
25. 3 D92 Dsd HEAT COOL TAP key o e UNIT OPERATING ON HIGH SPEED HEAT TAP DS3 DS2 DS1 e e UNIT OPERATING ON HIGH SPEED COOL TAP DS3 DS2 DS1 UNIT SWITCHED FROM HEATING DEMAND TO o e e 2nd STAGE COOLING UNIT OPERATES ON HIGH SPEED HEAT TAP MOMENTARILY Any other combination could indicate possible trouble with the VSP1 refer to TROUBLESHOOTING section of this manual FIGURE 17 Page 14 E VSP2 1 Blower Control A IMPORTANT If fan off time is too low residual heat in heat ex changer may cause primary limit S10 to trip result ing in frequent cycling of blower If this occurs ad just blower to longer time setting Units equipped with a variable speed motor are capable of maintaining a specified CFM throughout the external static range The VSP2 1 variable speed control board controls the blower speed and provides diagnostic LEDs The control has both a non adjustable factory preset ON fan timing delay and an adjustable OFF fan timing delay see figure 20 The VSP2 1 also senses limit trip condition and turns on the blower When excess heat is sensed in the heat exchanger the limit switch will open and interrupt the current to the gas valve while at the same time the VSP2 1 energizes the blow er on heating speed The limit automatically resets when the unit temperature returns to normal and the blower is de ener gized Diagnostic LEDs located on the VSP2 1 control board are provided to aid in identi
26. ACE JUMPER ACROSS R AND W1 WAIT 75 SEC OND FOR PREPURGE AND FAN ON DELAY 1 CHECK UNIT WIRING AND IF CORRECT REPLACE VSP3 1 IS BLOWER ON LOW SPEED AND IS ON OFF NO 2 BREAK AND REMAKE JUMPER LED DS3 LIT CFM LED DS4 LIGHT SHOULD W1 BLINK ONCE FOR EVERY 100 CFM 3 AFTER 30 35 SECOND PURGE IS 24VAC PRESENT AT GAS YES VALVE IS 24 VOLTS PRESENT AT J73 NO PIN 12 ON VSP3 BOARD REPLACE VSP3 1 YES PLACE HTG BLOWER JUMPER IN POSITION 1 R AND W1 REMAIN JUMPERED DOES BLOWER SHIFT TO HIGH SPEED AND IS HEAT LED DS2 ON DOES THE NO CHECK UNIT WIRING LED DS4 LIGHT BLINK ONCE FOR 9 IF CORRECT EVERY 100 CFM REPLACE VSP3 1 YES REMOVE JUMPERS YES AFTER THE SELECTED NO END OF TEST 4 TE DOES BLOWER REPLACE THE VSP3 1 TURN OFF Page 32
27. BLOWER CONTROL BOARD A24 A _ COOL ADJUST oo D o tesy 0 2 ooj oo oo 9 NORM 60 em G BLOWER HEAT 053 HI LOW 4 2 052 051 ee TE 150 J73 PIN 1 C 24 VAC common PIN 2 G Input signal from thermostat s fan signal PIN 3 W2 Input signal for second stage heat from the thermostat PIN 4 DS Input signal for the blower speed regulation PIN 5 Limit Input signal from the external limit PIN 6 R 24 VAC power to the thermostat PIN 7 C 24 VAC common Pin 8 C 24 VAC common PIN 9 CI Input signal from the fan limit control PIN 10 CO Output signal to the burner control PIN 11 HT Input signal from the fan limit control PIN 12 ACC 24 VAC accessory output PIN 13 24V Input 24 VAC power for the VSP2 1 PIN 14 24V Input 24 VAC power for the VSP2 1 PIN 15 V Input signal from the gas line J46 PIN 1 Not Used PIN 2 C 24 VAC common PIN 3 C 24 VAC common PIN 4 Delay Tap Delay profile programming input PIN 5 Cooling blower speed programming input PIN 6 On Off off output signal to the ICM2 motor PIN 7 Adjust Tap ICM2 mode selection PIN 8 NOT USED PIN 9 Hi Low Speed regulate input signal to the ICM2 motor with
28. CCB1 and HARMONY only PIN 10 Ref V ICM2 reference voltage PIN 11 Heat Tap Heating blower speed programming PIN 12 C 24 VAC common PIN 13 cfm Motor speed diagnostic signal VOLTAGES INTO VSP3 1 Voltage across J73 pins 13 to 1 and 6 to 1 is 24VAC as shown here Refer to unit wiring diagram poi 24VAC 60Hz 34 volts E z 5 MEME NEM NES Voltage across J73 pins 4 to 1 is approximately 15 20VDC straight voltage if CCB is used If Harmony is used a voltage of 0 25VDC should be present If CCB or Harmony is not used pin 4 to 1 voltage is 21VAC VOLTAGES FROM VSP3 1 TO ELECTRONICALLY CONTROLLED BLOWER MOTOR Voltage across J46 pins 6 to 3 and 1 to 3 is half rectified AC as shown here Refer to unit wiring diagram 24VAC Half Rectified DC Pulse Approx 60Hz LAE ES 0 volts Voltage across J46 pin 9 to 3 is approximately 15 20VDC if CCB is used If CCB or Harmony is not used pin 9 to 3 voltage is approximately 21VAC If Harmony is used a voltage of 0 25VDC should be present FIGURE 22 IMPORTANT 24 VAC half wave rectified DC pulse when measured with a meter may appear as a lower or higher voltage depending on the make of the meter Rather than attempting to measure the output voltage of A24 see VSP3 BLOWER CONTROL BOARD TROUBLESHOOTING FLOW CHART in the TROUBLESHOOTING section of this manual Diagnostic LED Lights DS3 ON OFF ON OFF DS3 i
29. D DS4 indicates the CFM the unit is operating according to the jumper settings The light flashes once for approximately every 100 CFM For example if the unit is operating at 1000 CFM CFM LED DS4 will flash 10 times If the CFM is 2050 CFM LED DS4 will flash 20 full times plus one fast or half flash At times the light may appear to flicker or glow This takes place when the control is communicating with the motor between cycles This is normal operation The appropriate speed according to application and CFM need is selected by moving jumper pins NOTE On Harmony Il zoning applications in the heating mode the highest speed obtainable is the same as the high est cooling speed selection Also the heating speed heat jumper position is only used when the primary limit has been tripped In non zoning applications refer to the section on the VSP2 1 control Jumper Settings IMPORTANT Before changing jumper setting make sure the motor has completely stopped Any jumper set ting change will not take place while the motor is running Jumper positions are factory set To change jumper positions gently pull the jumper off the pins and place it on the desired set of pins The following section outlines the different jumper selections available and conditions associated with each one Use table 4 as an example only for CFM per jumper setting See CFM tables in units Installation In structions or Unit Information if needed
30. FF LED indicates the blower is operating on low speed It is lit when 24VAC thermostat demand is supplied to the control jack plug JP45 2 The ON OFF LED and HI LOW LED both light to indicate the blower is operating on high speed Page 7 15 20VDC from CCB1 terminal DS or 24VAC from Y2 if CCB1 is not used During dehumidification mode the 1 turns off the DS output and the blower operates on low speed Diagnostic LED Lights Heating Mode The heat light is energized when 24VAC is supplied to the unit however when a cooling demand is present the light is not energized During heating mode the HEAT light is energized at all times with or without thermostat demand The HEAT light is tied electrically to J45 pin 5 Pin 5 receives 24VAC power from the indoor thermostat reversing valve output When the reversing valve output is off indicating that the unit is in heating mode the BDC HEAT light is on The ON OFF and HEAT lights are both energized when the blower is operating on heating speed During heating op eration the blower operates on HEATING speed regard less of compressor speed or electric heat operation 2nd stage thermostat demand energizes electric heat but does not change blower speed or BDC lights If outdoor tem perature drops enough to close the speed control thermo stat in the outdoor unit the compressor goes to high speed but the indoor blower speed does not change nor do the BDC lights
31. FTER THE SELECTED TIME DOES REPLACE VSP1 BLOWER TURN OFF Page 30 VSP2 1 TROUBLESHOOTING DOES UNIT OPERATE NO CHECK TES NO 1 UNIT POWER IS 24VAC ACROSS X 2 NTERLOCK SWITCH R AND C 3 TRANSFORMER COOLING MODE YES 4 LIMIT SWITCH PLACE JUMPER ACROSS R AND G IS BLOWER ON LOW SPEED AND IS ON OFF LED DS3 LIT CFM LED NO CHECK UNIT WIRING AND DS4 LIGHT SHOULD BLINK ONCE FOR FF CORRECT REPLACE EVERY 100 CFM VSP2 1 YES IS 24 VOLTS PRESENT AT NO J73 PIN 12 ON THE VSP2 gt REPLACE VSP2 1 YES IN ADDITION TO R AND G JUMPER R AND DS YEs IS BLOWER ON HIGH SPEED AND ARE 051 AND NO CHECK UNIT WIRING END OF COOLING TEST 053 LIT DOES THE CFM LED DS4 LIGHT AND IF CORRECT BLINK ONCE FOR EVERY 100 CFM REPLACE THE VSP2 1 oe UNIT OPERATE CHECK YES NO 1 UNIT POWER IS 24VAC ACROSS _________ 2 INTERLOCK SWITCH R AND C 3 TRANSFORMER YES 4 LIMIT SWITCH PLACE HTG BLOWER JUMPER IN POSITION 2 PLACE JUMPER ACROSS R AND W1 WAIT 75 SECOND FOR PREPURGE AND FAN ON DELAY HEATING MODE 1 CHECK UNIT WIRING AND IF IS BLOWER ON LOW SPEED AND IS ON OFF LED No aia AHD REMAKE JUMP 053 LIT CFM LED DS4 LIGHT SHOULD BLINK gt TO W1 ONCE FOR EVERY 100 CFM 3 AFTER 30 35 SECOND PURGE IS 24VAC PRESENT YES AT Ei VALVE NO IS 24 VOLTS PRESENT AT RE
32. ICM1 ICM2 LENNOX uwirmromarion Service Literature Corp 0125 L11 Revised 10 2003 Variable Speed Motors l Introduction This manual is meant to be a helpful guide in servicing Lennox residential split system products equipped witha variable speed motor See figure 1 V series units fea ture an electronically controlled motor manufactured by General Electric Lennox currently uses the ICM2 with past products using the ICM1 Variable speed motors consist of a control module controller and motor V motors can be used in all applications downflow upflow and horizontal The variable speed motor is controlled by an integrated blower control BDC BDC2 BDC3 VSP1 VSP2 VSP3 and the Two Stage Variable Speed Sur eLight Products currently equipped with a variable speed motor and control are CB21 CB21H CB21V CBH21V CB31MV G25MV G21V GSR21V G32V GHR32V G60UHV and G60DFV CFM tables can be found in the furnace Installation Instructions or the Unit Information service manual can be ordered if needed See table 1 for equipment matchups and litera ture ELECTROSTATIC DISCHARGE ESD Precautions and Procedures A CAUTION Electrostatic discharge can affect electronic components Take precautions during furnace installation and service to protect the furnace s electronic controls Precautions will help to avoid control exposure to electrostatic dis charge by putting the furnace the control and the
33. IN 10 CO Output signal to the ignition control PIN 11 HT Input signal from the fan limit control PIN 12 ACC 24 VAC accessory output PIN 13 24V Input 24 VAC power for the VSP2 1 PIN 14 24V Input 24 VAC power for the VSP2 1 PIN 15 V Input signal from the gas line J46 PIN 1 Heat Heat speed input signal to the ICM2 motor PIN 2 C 24 VAC common PIN 3 C 24 VAC common PIN 4 High Tap High Speed programming input PIN 5 Low Tap Low speed programming input PIN 6 On Off On off output signal to the ICM2 motor PIN 7 Adjust Tap ICM2 mode selection PIN 8 Hi Low Speed regulate input signal to the ICM2 motor PIN 9 Hi Low Speed regulate input signal to the ICM2 motor PIN 10 Ref V ICM2 reference voltage PIN 11 Heat Tap Heating blower speed programming PIN 12 C 24 VAC common PIN 13 cfm Motor speed diagnostic signal VOLTAGES INTO VSP2 Voltage across J73 pins 13 to 1 and 6 to 1 is 24VAC as shown here Refer to unit wiring diagram 24VAC 60Hz 34 volts 2 gt 0 volts aa E N TA 34 volts UN P E Voltage across J73 pins 4 to 1 is approximately 15 20VDC straight voltage if CCB is used If Harmony is used a voltage of 0 25VDC should be present If CCB or Harmony is not used pin 4 to 1 voltage is 21VAC VOLTAGES FROM VSP2 TO ELECTRONICALLY CONTROLLED BLOWER MOTOR Voltage across J46 pins 6 to 3 and 1 t
34. LIMIT REPLACE VSP1 VSP1 TROUBLESHOOTING CONT HEATING MODE CONTINUED IS 24VAC ACROSS RAND YES PLACE JUMPER ACROSS R AND W1 WAIT 75 SECONDS FOR PREPURGE AND FAN ON DELAY DS3 DS2 DS1 IS BLOWER ON LOW SPEED C AND IS DS1 LIT BREAK AND REMAKE JUMPER TO NO YES YES IS THE ACCESSORY g RELAY PULLED IN CHECK VOLTAGE ON TB2 FROM ACC TO N ON TERMINAL BLOCK INSIDE CONTROL BOX SHOULD READ 120 VOLTS AC YES IN ADDITION TO R AND W1 JUMPER HB AND W2 DOES BLOWER SHIFT uo HIGH HEAT SPEED AND ARE DS1 AND DS2 LIT l YES REMOVE HB AND W2 JUMPER IN ADDITION TO R AND W1 JUMPER R AND W2 DOES BLOWER SHIFT uo HIGH HEAT SPEED ARE DS1 AND DS2 LIT 1 YES REMOVE JUMPERS NO CHECK WIRING BETWEEN TB1 AND VSP1 REPAIR IF NECESSARY S78 IS A NC LIMIT ALLOW UNIT TO COOL IF LIMIT REMAINS OPEN REPLACE LIMIT s IS 24VAC ACROSS J73 PIN 11 AND 1 OF VSP1 YES IS 24VAC ACROSS J7NO PIN 10 AND 1 OF VSP1 REPLACE VSP1 NO YES IF UNIT DOES NOT OPERATE THE GAS VALVE OR IGNITION CONTROL ARE NOT OPERATING PROPERLY CHECK UNIT WIRING FROM VSP1 TO TB2 AND IF CORRECT REPLACE VSP1 O DS3 052 051 CHECK UNIT WIRING AND IF CORRECT REPLACE THE VSP1 DS3 DS2 DS1 CHECK UNIT WIRING AND IF CORRECT REPLACE THE VSP1 NO YES END OF TEST A
35. ONTROL PWM signal if Harmony is used N 12 24VAC INPUT FROM FAN LIMIT CONTROL J73 Inputs Wires from J46 connect directly to indoor blower jack J49 Volt age on pins 2 and 3 are half rectified AC DC pulse Measured volt age will vary depending on the type of meter used VOLTAGES INTO VSP1 Voltage across J73 pins 8 to 1 and 3 to 1 is 24VAC as shown here Refer to unit wiring diagram cepe 24VAC 60Hz 34 volts 0 volts 34 volts Voltage across J73 pins 4 to 1 is approximately 12 17VDC straight voltage if CCB is used A PWM signal if Harmony is used If CCB or Harmony is not used pin 4 to 1 voltage is 21VAC VOLTAGES FROM VSP1 TO ELECTRONICALLY CONTROLLED BLOWER MOTOR Voltage across J46 pins 2 to 1 and 3 to 1 is half rectified AC as shown here Refer to unit wiring diagram 24VAC Half Rectified DC Pulse Approx 34 volts EN LN N ZEN T 0 volts Voltage across J46 pins 4 to 1 is approximately 12 17 VDC if CCB is used If CCB or Har mony is not used pin 4 to 1 voltage is approximately 21VAC A PWM signal if Harmony is used FIGURE 16 IMPORTANT 24 VAC half wave rectified DC pulse when mea sured with a meter may appear as a lower or high er voltage depending on the make of the meter Rather than attempting to measure the output voltage of the blower control see TROUBLE SHOOTING
36. PLACE VSP2 1 J73 PIN 12 ON THE VSP2 YES PLACE HTG BLOWER JUMPER IN POSITION 1 R AND W1 REMAIN JUMPERED DOES BLOWER SHIFT TO HEAT SPEED AND IS HEAT LED DS2 ON DOES NO CHECK UNIT WIRING THE CFM LED DS4 LIGHT BLINK AND IF CORRECT ONCE FOR EVERY 100 CFM REPLACE VSP2 1 YES REMOVE JUMPERS i YES AFTER THE SELECTED NO END OF TEST 24 TIME DOES BLOWER TURN OFF REPLACE THE VSP2 1 Page 31 VSP3 1 TROUBLESHOOTING DOES UNIT OPERATE NO CHECK NO 1 UNIT POWER IS 24VAC ACROSS amp 2 JNTERLOCK SWITCH R AND C 3 TRANSFORMER COOLING MODE YES 4 LIMIT SWITCH PLACE JUMPER ACROSS R G AND Y1 IS BLOWER ON LOW SPEED AND IS ON OFF LED DS3 AND HILOW LED DS1 LIT NO CHECK UNIT WIRING AND IF CFM LED DS4 LIGHT SHOULD BLINK ONCE FOR EVERY 100 CORRECT REPLACE VSP3 1 YES IS 24 VOLTS PRESENT AT J73 NO PIN 12 ON VSP3 BOARD REPLACE VSP3 1 YES IN ADDITION TO R G AND Y1 JUMPER R AND Y2 NO END OF COOLING Teesra e IS BLOWER ON HIGH SPEED AND 051 AND ____ CHECK UNIT WIRING DS3 LIT DOES THE CFM LED DS4 LIGHT BLINK AND IF CORRECT ONCE FOR EVERY 100 CFM REPLACE THE VSP3 1 DOES UNIT OPERATE CHECK NO 1 UNIT POWER IS 24VAC ACROSS 2JNTERLOCK SWITCH 2 3 TRANSFORMER HEATING MODE YES 4 LIMIT SWITCH PLACE HTG BLOWER JUMPER IN POSITION 2 PL
37. RM DS or 24VAC FROM TSTAT TERMINAL Y2 IF CCB IS NOT USED N5 24VAC INPUT FROM TSTAT REVERSING VALVE OUTPUT TERM O N 6 24VAC POWER Outputs J46 DIAGNOSTIC LED S Nd N 2 24VAC 1 2 rectified ON OFF N 3 24VAC 1 2 rectified HEAT N 4 12 17VDC Hi Low or 21VAC if CCB is not used Wires from J46 connect directly to indoor blower B3 jack J49 Voltage on pins 2 and 3 are half rectified AC DC pulse Measured voltage will vary depending on the type of meter used VOLTAGES INTO BDC J45 Voltage across J45 pins 6 to 1 5 to 1 3 to 1 and 2 to 1 is 24VAC as shown here Refer to unit wiring diagram 24VAC Poe rm 60Hz 34 volts a 0 volts 34 volts Voltage across J45 pins 4 to 1 is approximately 15 20VDC straight voltage if CCB is used If CCB is not used pin 4 to 1 voltage is 24VAC as shown above VOLTAGES FROM BDC TO ICM1 J46 Voltage across J46 pins 2 to 1 and 3 to 1 is half rectified AC as shown here Refer to unit wiring diagram 24VAC Half Rectified DC Pulse Approx 60Hz 30 volts UN a E ae i 0 volts Voltage across J46 pins 4 to 1 is approximately 12 17VDC if CCB is used If CCB is not used pin 4 to 1 voltage is approximately 21VAC FIGURE 10 Diagnostic LED Lights Cooling Mode Three diagnostic LED lights are provided on the control for troubleshooting The three lights figure 11 are ON OFF HI LOW and HEAT In cooling mode the ON O
38. Refer to figure 18 for identification a ADJUST The ADJUST pins allow the motor to run at normal speed approximately 1096 higher or approximately 1096 lower than normal speed The TEST pin is available to bypass the VSP2 1 control and run the motor at approximately 7096 to test that the mo tor is operational This is beneficial primarily in trouble shooting G must be energized for motor to run b HEATING BLOWER Place the HEATING BLOWER jumper across the first and second pins for single stage heating operation position 1 For two stage operation place the jumper across the second and third pins position 2 The position of the jumper determines which set of speed jumpers is activated When the HEATING BLOWER jump er is across the first and second pins the HEAT jumper selections are activated when W1 is energized If the jumper is across the second and third pins the LOW jumper selections are activated when W1 is energized HEAT jumper selections are activated when W2 is ener gized NOTE In Harmony ll zoning applications HEATING BLOWER jumper must be in position 2 c HEAT The HEAT jumper is used to set the blower speed to obtain the required CFM for HEAT SPEED If a lower heating speed is required the LOW jumper may be used to set the heating speed This is done by first plac ing the LOW jumper in the desired CFM position and then placing the HTG BLOWER jumper across the second and third pins regardles
39. WER jumper must be in position 2 TABLE 5 VSP2 1 OPERATION HEATING MODE COOLING MODE UNITS WITH TWO STAGE HEATING NON ZONED APPLICATIONS Using a two stage thermostat with first stage W1 calling the ON OFF LED DS3 is lit to indicate the blower is operating in low speed When the ON OFF LED DS3 and HEAT LED DS2 are lit the blower is operating in heating speed and sec ond stage W2 heating is calling HEAT LED DS2 is lit with a call for heat from the thermostat ON OFF LED DS3 is lit after 110 seconds from the time a call for heat is made HARMONY ZONED APPLICATIONS The blower speed is controlled by the PWM pulse width modulation signal sent from the control center of the zon ing system to the terminal strip s DS terminal H LOW LED DS1 and ON OFF LED DS3 lit to indicate the blower is operating NOTE In Harmony II zoning applica tions HTG BLOWER jumper must be in position 2 NON ZONED APPLICATIONS The terminals DS and Y must be jumpered together With a call for cooling terminals G Y and DS on the unit control board are energized from the thermostat HIILOW LED DS1 and ON OFF LED DS3 are lit to indi cate the blower is operating on high speed NOTE Y and DS are factory jump ered for single stage cooling non zoned NOTE For low speed during single stage cooling remove jumper from Y and Ds HARMONY ZONED APPLICATIONS The blower speed is controlled by the PWM puls
40. and side of battery 16 Turn on power to unit Blower should operate at high heat speed J46 LOW COOL SPEED 12345678 9 1011 12 13 To Y on ignition control 1 Disconnect power to unit 2 Disconnect plug J46 from P46 located on the blower control board 3 Disconnect C and R from ignition control board 4 Disconnect Y from ignition control and con nect a seperate wire between R on the transfomer and Y on the ignition control 5 Connect voltage source as shown above 6 Turn on power to unit Blower should operate at low cool speed HIGH COOL SPEED 12345 6 7 8 9 1011 12 13 Lt To Y2 on TB1 Disconnect power to unit Connect voltage source as shown above Disconnect Y2 on TB1 in control box and connect a seperate wire between R on transformer and Y2 on TB1 10 Turn on power to unit Blower should oper ate at high cool speed LOW HEAT SPEED 123456 78 9 1011 12 13 FIGURE 26 To W on on ignition control 9 Disconnect power to unit 10 Connect voltage source as shown above 11 Disconnect W from ignition control and connect a seperate wire between on transformer and W on the ignition control 11 Turn on power to unit Blower should operate at
41. blower If this occurs adjust blower to longer time setting Table 5 outlines the operation of the variable speed motor in relation to specific modes of operation Some informa tion has been repeated from the previous section to pro vide an example Refer to each diagnostic LED or jumper settings section for more information TABLE 4 Example Only ADJUST LOW SPEED JUMPER PME HIGH COOL SPEED HEAT SPEED sm se mm ses ne sa xm neo n6 Page 17 UNITS WITH SINGLE STAGE HEATING NON ZONED APPLICATIONS Using a single stage thermostat with one stage heating the HEAT LED DS2 is lit when the thermostat calls for heat The ON OFF LED DS3 is lit af ter 110 seconds 65 seconds pre purge and 45 seconds fan ON time from the time a call for heat is made This indicates the blower is operating in heating speed Using a single stage thermostat with W2 TIMED and W1 calling the ON OFF LED DS3 is lit to indicate the blower is operating on low speed When the HEAT LED DS2 is lit the blower is operating in heating speed and second stage W2 heating is calling HARMONY ZONED APPLICATIONS The blower speed is controlled by the PWM pulse width modulation signal sent from the control center of the zoning system to the terminal strip s DS terminal HI LOW LED DS1 and ON OFF LED DS3 are lit to indicate the blower is operating NOTE In Harmony II zoning applica tions HTG BLO
42. cond 20Khz this is called the switching frequen cy The effective d c voltage can be varied by changing the pulse width The switching frequency is necessary in order to vary the speed of the motor If the motor is not securely grounded to the cabinet and if the cabinet is not securely grounded the switching frequency may cause television interference OUTPUT FROM CONTROLLER TO MOTOR WINDINGS One Pulse 325VDC ovais N INSSI E PULSE ON ELECTRICAL CI PULSE OFF PULSE 325VDC N WINDING OFF x O volts Switching Frequency OKhz FIGURE 9 Page 6 IV Blower Motor Control A BDC Blower Control Blower drive control A15 located in the unit control box provides an interface between the analog 24VAC indoor thermostat signal and the direct current digital signal to the blower motor The control is responsible for energizing the blower motor in response to thermostat demand and for converting thermostat demand from 24VAC to 24VAC half wave rectified half rectified see figure 19 The ECM mo tor controller inside the blower motor is responsible for selecting the blower speed BLOWER DRIVE CONTROL BDC J45 N1 24VAC COMMON N2 24VAC INPUT FROM TSTAT TERM G N3 24VAC INPUT FROM BLOWER RELAY N4 15 20VDC INPUT FROM HUMIDITY CNTRL TE
43. correspond with diag nostic codes detailed in the units Installation Instructions or Unit Information Status LEDs HEAT HI LO ON OFF and CFM The integrated control includes four LEDs which indicate operating status The green ON OFF LED is lit any time the blower is operating The green CFM LED indicates the blower motor speed Count the number of blinks between the two second pauses to determine the CFM Each blink represents approximately 100 CFM The yellow HI LO LED is lit when the W914 DS to R jumper has not been clipped for CCB1 or Harmony operation The yellow HEAT LED is lit when the indoor blower is operating at the HEATING speed TABLE 13 ADJUST Switch Positions Plus NORM Normal Minus ADJUST St Stage HEAT Speed Switch 1 2 3 4 1 2 3 Plus 840 395 965 455 1195 565 1235 585 700 330 765 360 385 885 420 NORM Normal 765 360 865 410 1055 495 1105 520 660 310 715 335 750 355 800 380 Minus 700 330 785 370 955 450 985 465 595 280 665 315 695 330 730 345 2nd Stage HEAT Speed 1 2 3 Lis cfm Lis cfm 430 1055 495 1305 390 940 445 1165 350 845 400 1030 Lis 615 550 485 cfm 910 830 745 4 cfm Lis 1350 635 1215 575 1070 505 cfm 1045 945 850 1 Lis 495 445 400 2nd Stage COOL Speed 2 3 L s cfm 580 1315 520 1190 460 1035 L s 620 560 485 cfm 1230 1100 975 cfm 1420 130
44. e width modulation signal sent from the control center of the zoning system to the terminal strip s DS terminal HIILOW LED DS1 and ON OFF LED DS3 are lit to indicate the blower is operating UNITS WITH TWO SPEED COMPRESSOR NON ZONED APPLICATIONS The ON OFF LED DS3 is lit to indicate the blower is operating in first stage cooling This LED is energized on when a 24VAC thermostat demand is supplied to the control terminal G on the control board terminal strip In second stage the ON OFF LED DS3 and HI LOW LED DS1 are lit to indicate the blower is operating on high speed 24VAC is supplied to the unit terminal strip Y2 from Y2 on the thermostat NOTE Jumper must be moved from Y1 to Y2 In two speed non zoned ap plications HARMONY ZONED APPLICATIONS The blower speed is controlled by the PWM pulse width modulation signal sent from the control center of the zon ing system to the terminal strip s DS terminal H LOW LED DS1 and ON OFF LED DS3 are lit to indicate the blower is operating NOTE For zone applications with Harmony remove the wire from the pin 3 of the J73 terminal on the VSP control board insulate the end and secure it to prevent from shorting Page 18 F VSP3 1 Blower Control Board A24 Units equipped with a variable speed motor are capable of maintaining a specified CFM throughout the external static range The VSP3 1 variable speed control board controls the blower speed and provid
45. eLight Two Stage Variable Speed SureLight UNIT INFORMATION Corp 9020 L8 Corp 9433 L11 Corp 9618 L9 Corp 0206 L3 Corp 9505 L2 Corp 9815 L9 Corp 9815 L9 Corp 9816 L10 Corp 9816 L10 Corp 9816 L10 Corp 0001 L2 Corp 0001 L2 Corp 0001 L2 Corp 0124 L11 Corp 0211 L3 Corp 0310 L7 Motor The ICM2 and ICM1 motor is a three phase electronically controlled d c brushless motor controller converts single phase a c to three phase d c with a permanent magnet type rotor Because this motor has a permanent magnet rotor it does not need brushes like conventional D C motors The motors consist of a control module and motor figure 2 The 2 control module can be replaced separately from the mo tor if necessary However if the motor fails the motor module assembly must be replaced Internal components are shown in figure3 The stator windings are split into three poles which are electrically connected to the controller This arrangement allows motor windings to be turned on and off in sequence by the controller The controller is primarily an a c to d c converter Con verted d c poweris used to drive the motor The control ler contains a microprocessor which monitors varying conditions inside the motor such as motor workload The controller uses sensing devices to know what position the rotor is in at any given time By sensing the position of the rotor and then switching the motor windings on and off
46. es diagnostic LEDs The control has both a non adjustable factory preset ON fan timing delay and an adjustable OFF fan timing delay see fig ure 23 The VSP3 1 also senses limit trip condition and turns on the blower When excess heat is sensed in the heat exchanger the limit switch will open and interrupt the current to the gas valve while at the same time the VSP3 1 energizes the blow er on heating speed The limit automatically resets when the unit temperature returns to normal and the blower is de ener gized Diagnostic LEDs located on the VSP3 1 control board are provided to aid in identifying the units mode of operation Cer tain scenarios will arise depending on the jumper positions Refer to figure 21 for identification VSP3 1 VARIABLE SPEED CONTROL BOARD SELECTIONS O DELAY PROFILE cook SELECTOR PINS ADJUST JP46 13 PIN PLUG BOARD TO MOTOR COOLING ONLY HEATING SPEED SELECTOR PINS COOL SPEED SELECTOR PINS COOLING HEATING and CONTINUOUS FAN HEATING STAGE JUMPER SELECTOR PINS JP73 15 PIN PLUG BOARD TO VARIOUS DS3 HI LOW DS1 OPERATIONAL SELECTOR PINS Affects both heating and cooling modes DIAGNOSTIC DS LEDS POINTS IN FURNACE FAN OFF Page 19 TIMING PINS VSP3 1
47. essory terminal The terminal is wired directly to terminal block TB2 and powers the accessory connection on the terminal block The termi nal is energized when the blower is running It can be used for any desired accessory equipment such as an electronic air cleaner or humidifier VSP1 provides an interface between the 24VAC indoor thermostat signal and the direct current digital signal to the blower motor The control is responsible for energizing the blower motor in response to thermostat demand and for converting thermostat demand from 24VAC to 24VAC half rectified DC pulse see figure 16 The motor controller in side the blower motor is responsible for regulating blower speed to maintain the desired CFM VSP1 BLOWER CONTROL BOARD J73 1 24VAC COMMON PIN2 24VAC INPUT FROM TSTAT TERM G PIN3 24VAC POWER TO 1 TSTAT PIN4 12 17VDC INPUT FROM HUMIDITY CNTRL TERM DS or 24VAC FROM TSTAT TERMINAL Y2 IF CCB J46 OR HARMONY IS NOT Outputs USED PWM SIGNAL oe FROM HARMONY 051 N5 OUTPUT SIGNAL ps2 CONFIRMING HEATING ce BLOWER SIGNAL N6 24VAC INPUT FROM gt TSTAT TERM W2 N7 24VAC INPUT SIGNAL FROM EXTERNAL LIMIT 8 24VAC POWER FOR VSP1 9 24VAC INPUT FROM GAS J46 VALVE Common N 10 24VAC OUTPUT FROM 24VAC 1 2 rectified ON OFF VSP1 TO IGNITION 24VAC 1 2 rectified HEAT CONTROL A3 12 17VDC Hi Low if CCB1 is used N 11 24VAC INPUT FROM 21VAC if CCB or Harmony is not used FAN LIMIT C
48. ether With a call for cool ing G Y1 Y2 and DS on the unit control board are energized from the thermostat HI LOW LED DS1 and ON OFF LED DS3 are lit to in dicate a call for cooling Note Y1 to DS and Y1 to Y2 are factory jumpered for single stage cooling non zoned applications Harmony Zoned Application The blower speed is controlled by the PWM pulse width modulation signal sent from the control center of the zoning system to the termi nal strips DS terminal HI LOW LED DS1 and ON OFF LED DS3 are lit to indicate the blower is oper ating Units With Two speed Compressor Non Zoned Applications Y1 DS must be jumpered together With a call for single stage cooling G Y1 and DS on the unit control board are energized from the Ther mostat With a call for second stage cooling G Y1 Y2 and DS on the unit control board are energized from the thermostat In both cases HI LOW LED DS1 and ON OFF LED DS3 are lit to indicate a call for cooling Note Jumper Y1 Y2 must be re moved for units with two speed compressor Harmony Zoned Application The blower speed is controlled by the PWM pulse width modulation signal sent from the control center of the zoning system to the terminal strip s DS terminal HI LOW LED DS1 and ON OFF LED DS3 are lit to indicate the blower is operating NOTE For zone applications with Harmony remove the wire from pin 2 and pin 13 of the J49 terminal at the motor and the
49. f the pulses to the windings is 20KHz DO NOT ATTEMPT TO MEASURE THESE VOLTAGES LOW SPEED HEAT COOL One output from controller to motor windings E E One revolution SS ESSI ES WINDING 1 E SN Mes SM HIGH SPEED HEAT output from controller to motor windings SS One revolution gt 325VDC ovas SOIT TUTTI 325VDC O volts SISSIN NN WN SVN SATIS HIGH SPEED COOL output from controller to motor windings One revolution gt 325VDC o vois SSMS IRS SESS WINDING 1 T NOOO MMMM SN WINDING 3 FIGURE 4 Page 4 A External Operation ICM1 Figure 5 shows the two quick connect jacks J48 and J49 which connect the motor to the unit Jack J48 is the power plug and jack J49 connects the unit controls to the motor The power plug must be removed to gain access to the in cremental speed taps Line voltage must be applied to J48 pin 1 in order for the motor to operate When control voltage is applied to J49 pin 1 low speed cooling the motor is energized on the low speed heat cool tap When voltage is applied to J49 pin 2 in addition to pin1 high speed cooling the blower is energized on the high speed cooling tap When voltage is applied to J49 pin 5 heating demand the blower is energized on the low speed heat cool tap The motor assigns priority to J49 pin 5 so that if a call for cooling and a call for heating are con current heating call overrides and the bl
50. fan off timings gently disconnect jumper and reposition it across pins corresponding with new timing see figure 15 The fan off timing is factory set at 270 seconds VSP1 BLOWER CONTROL BOARD FRONT VIEW J46 129 6 OUTPUT O cies 1 PLUG T DS3 DS2 DS1 GGGQGl3O X99 Gocc 1 DIAGNOSTI LEDS Oa ae VSP1 CONTROL PLUG 0 0 0 Qi 120V 00 ii 0000000 ACCESSORY TERMINAL N gt UT L1 D L1 LINE VOLTAGE FAN OFF TIMING PINS FIGURE 14 Page 13 IMPORTANT If fan off time is too low residual heat in heat ex changer may cause primary limit 10 to trip result ing in frequent cycling of blower If this occurs ad just blower to longer time setting FAN OFF TIME ADJUSTMENT TIMING JUMPERS i To adjust fan off timings Remove jumper from VSP1 and se lect one of the other pin combina tions to achieve the desired time 210 Leave jumper off to achieve 330 second fan off timing TIMING PINS seconds Fan off timing is factory set at 270 seconds DANGER Shock Hazard VSP1 fan control is connected to line voltage Discon nect power to unit before changing pin timings Can cause personal injury or control damage The VSP1 includes a 120 VAC acc
51. fying the units mode of operation Cer tain scenarios will arise depending on the jumper positions VSP2 1 BLOWER CONTROL BOARD JP2 13 PIN PLUG BOARD TO MOTOR 1 ADJUST HEAT 1 B test P 2 n a 3 QO Oo 4 tj 79 NORM EA SELECTOR PINS HEATING STAGE HEAT 053 054 SELECTOR PIN HTG Q Q Q Q BLOWER DS2 ON OFF 057 moa DIAGNOSTIC DS LEDS 1 FAN OFF TIMING PINS 210 ee 150 JP1 15 PIN BOARD TO FURNACE 3j FIGURE 18 Page 15 VSP2 1 BLOWER CONTROL BOARD _ LOW ADJUST oo o o TEST ooj oo ecoa ea es oo HTG BLOWER HEAT 053 H LOW DS4 coo OF Q 4 2 DS2 ON OFF DS1 CFM 210 CC 150 J73 PIN 1 C 24 VAC common PIN 2 G Input signal from thermostat s fan signal PIN 3 W2 Input signal for second stage heat from the thermostat PIN 4 DS Input signal for the blower speed regulation PIN 5 Limit Input signal from the external limit PIN 6 R 24 VAC power to the thermostat PIN 7 C 24 VAC common Pin 8 C 24 VAC common PIN 9 CI Input signal from the fan limit control P
52. gized on the high speed heating tap When voltage is applied to J49 pin 10 in addition to pin 3 and 15 second stage cooling the blower is energized on the high speed cooling tap The mo tor assigns priority to J49 pin 2 so that if a call for cooling and a call for heating are concurrent heating call overrides and the blower operates on high speed heating tap ICM2 with VSP3 or TwoStage Variable Speed Control The ICM2 operates slightly different than stated above when matched with the VSP3 or the Two Stage Variable Speed control board When control voltage is applied to J49 pin 3 and 15 the motor is energized on continuous fan When voltage is applied to J49 pin 2 in addition to pin 3 and 15 first stage heating the blower is energized on the low speed heating tap When voltage is applied to J49 pin 13 in addition to pin 3 and 15 second stage heating the blower is energized on the high speed heating tap The motor as signs priority to J49 pin 2 so that if a call for cooling and a call for heating are concurrent heating call overrides and the blower operates on high speed heating tap BLOWER HARNESS CONNECTORS POWER CONTROL CONNECTOR J48 CONNECTOR J49 J49 4 PIN1 C1 T99ootb SEE Ne co YORE EID PIN 4 Delay PIN 5 Cool PIN 6 Y1 PIN 7 Adjust PIN 8 Out PIN 9 0 PIN 10 BK PWM PIN 11 Heat PIN 12 R PIN 13 W2 PIN 14 Y Y2 15 6 J48 PIN 16 Out PIN 1 Jumper PIN 1 to PIN2 for 120VAC line
53. is complete disconnect power and replace delay setting to original position Heat Speed Disconnect power to the unit Change delay pin setting on the BDC3 board to 1 Remove wires from terminal strips in control box Install jumper between R and W1 Turn on power to unit Blower should operate on heat speed When check is complete disconnect power and replace delay setting to original position Example Only ADJUST Jumper Setting Page 12 D VSP1 Blower Control The VSP1 a printed circuit board located in the control box serves four primary functions 1 Controls blower timings during heating to accommo date the required initial heat up and cool down times of the heat exchanger 2 Senses limit trip condition and turns on the blower 3 Controls the accessory relay 4 Interfaces the 24VAC thermostat with the blower When operating in heating mode VSP1 controls the blower and monitors limit and gas valve operation The VSP1 con trols the fan on and fan off timings Fan on timings are pre set and non adjustable Fan off timings are adjustable Fan on timing is the amount of time the unit operates before the blower is started This period allows for heat exchanger warm up The fan on timing is pre set at 45 seconds and is not adjustable Fan Off timings time that blower operates after heating demand has been satisfied are determined by the ar rangement of a jumper on the VSP1 board To adjust
54. may continue until the demand is satisfied It is recom mended that the lower setting of the modulation control marked FAN OFF be reduced by 10 F to 20 F if this prob lem should occur This condition will not occur in zoned ap plications C ICM2 Control Module Replacment The ICM2 consists of a control module and motor Both are manufatcured by General Electric GE The motor and module should be considered two seperate peices of equipment assembled to make one piece of equipment If after following the troubleshooting procedures outlined in section V and it is determined the problem exist with the control module alone then replace the module ONLY The ICM1 module cannot be replaced The ICM1 must be re place with the later GE ICM2 All replacement control mod ules look alike however each module is factory pro grammed to be used for a specific motor It is very impor tant to make sure that you are using the correct replace ment module USE OF THE WRONG MODULE MAY RE SULT IN UNEXPECTED UNIT OPERATION Call Lennox Repair Parts Dallas Page 25 ICM1 CHECK OUT POWER CONNECTOR J48 SPEED TAPS CONTROL CONNECTOR J49 LADD rH T WARNING DISCONNECT P49 FROM J49 BEFORE BEGIN NING THIS CHECKOUT FAILURE TO DISCONNECT P49 WILL DAMAGE VSP1 NOTE Any A C voltage source less than 30 volts or any D C voltage source less than 20 v
55. n troubleshooting G must be energized for motor to run B HEAT The HEAT jumper is used to set the blower speed to obtain the required CFM for HEAT SPEED C HIGH The HIGH jumper is used to determine the CFM during cool ing speed These jumper selections are activated when G and DS terminals are energized D LOW The LOW jumper is used to determine CFM during low speed cooling These jumper selections are activated only when G is energized Page 8 BDC 2 VARIABLE SPEED CONTROL BOARD SELECTIONS ACCESSORY RELAY CONTACTS DRIVES OPTIONAL ACCESSORY RELAY c 24VAC 1 DIAGNOSTIC DS LEDS ADJUST AMP DS3 ON OFF EAT HEATING SPEED SELECTOR PINS LOW SPEED SELECTOR PINS COOLING AND CONTINUOUS FAN O DIAGNOSTIC DS LEDS HIGH SPEED SELECTOR PINS HI LOW COOLING ONLY JP1 6 PIN PLUG oo NORM Oj oj Bj D D D BOARD TO VARIOUS POINTS IN THE UNIT OPERATIONAL SELECTOR PINS Affects both heating and cooling modes JPI J45 JP2 J46 1 PIN DESIGNATIONS J45 PIN 1 C 24 VAC common PIN 2 G Input signal from thermostat s fan signal PIN 3 HEAT BLOWER RELAY Input signal PIN 4 DS Input signal for the blower speed regulation PIN 5 0 Input signal from the reversing valve PIN 6 R 24 VAC power to
56. ndicates there is a demand for the blower motor to run When the ON OFF LED DS3 is lit a demand is being sent to the motor In heating mode only there is a 45 second fan ON delay in energizing ON OFF LED DS3 Light will not go off until adjustable fan OFF delay has expired If ON OFF LED DS3 is on and both HIGH LOW LED DS1 amp HEAT LED DS2 are off the motor will operate in low speed heating DS2 HEAT If HEAT LED DS2 is on the blower is running in second stage heat speed according to the HEAT jumper setting In heating mode only there is a 45 second delay in energiz ing HEAT LED DS2 Light will not go off until adjustable fan OFF delay has expired 051 HI LOW HIGH LOW LED DS1 indicates the blower is operating in the cooling mode DS4 CFM CFM LED DS4 indicates the CFM the blower is providing according to the jumper settings FAN OFF TIME ADJUSTMENT To adjust fan off timings Remove jumper from VSP3 1 and select one of the other pin combina tions to achieve the desired time 210 Leave jumper off to achieve 330 second fan off timing TIMING PINS seconds Fan off timing is factory set at 270 seconds FIGURE 23 Page 20 Jumper Settings IMPORTANT Before changing jumper setting make sure the motor has completely stopped Any jumper set ting change will not take place while the motor is running To change jumper positions gently pull the jumper off the pins and place it on the de
57. nect power to unit 12 Connect voltage source as shown above 13 Turn on power to unit Blower should operate at high heat speed CHECK OUT PROCEDURE USING 24V SOURCE Unit transformer T1 with a maximum AC 30 volts may be used in lieu of a battery If transformer T1 is used double check all wiring connections be fore placing unit back in operation Disconnect power to unit Disconnect plug J46 from P46 located on the blower control board Connect voltage source as shown above Turn on power to unit Blower should operate at low cool speed 5 Disconnect power to unit 6 Connect voltage source as shown above 7 Turn on power to unit Blower should operate at high cool speed 8 Disconnect power to unit 9 Connect voltage source as shown above 10 Turn on power to unit Blower should operate at low heat speed 11 Disconnect power to unit 12 Connect voltage source as shown above 13 Turn on power to unit Blower should operate at high heat speed VSP1 TROUBLESHOOTING TORE HERE DOES UNIT OPERATE NO COOLING s CHECK OUT ELECTRONICALLY CONTROLLED BLOWER MOTOR AND VSP1 IS 24VAC ACROSS J73 PIN 8 AND 1 OF VSP1 Disconnect thermostat wire to DS terminal on TB2 before performing any test on cooling mode YES IS 24VAC ACROSS J73 PIN7 AND1 NO OF VSP1 YES IS 24VAC ACROSS J73 PIN 3 AND 1 OF VSP1
58. o 3 is half rectified AC as shown here Refer to unit wiring diagram 24VAC Half Rectified DC Pulse 60Hz Approx 34 volts AON EN E Z a ZN E 0 volts Voltage across J46 pins 8 and 9 to 3 is approximately 15 20VDC if CCB is used If CCB or Harmony is not used pins 8 and 9 to 3 voltage is approximately 21VAC If Harmony is used a voltage of 0 25VDC should be present FIGURE 19 Diagnostic LED Lights DS3 ON OFF ON OFF DS3 indicates there is a demand for the blower motor to run When the ON OFF LED DS3 is lit a demand is being sent to the motor In heating mode only there is a 45 second fan ON delay in energizing ON OFF LED DS3 The light will not go off until adjustable fan OFF delay has expired If ON OFF LED DS3 is on and both HIGH LOW LED DS1 amp HEAT LED DS2 are off the motor will operate in low speed DS2 HEAT If HEAT LED DS2 is on the blower is running in the heat speed according to the HEAT jumper setting In heating mode only there is a 45 second delay in energizing HEAT LED DS2 Light will not go off until adjustable fan OFF delay has expired DS1 HI LOW HIGH LOW LED DS1 indicates whether the blower is op erating in high or low speed When the light is off the blow er is running in low speed according to the LOW jumper setting When HIGH LOW LED DS1 is on the blower is operating in high speed according to the HIGH jumper setting DS4 CFM CFM LE
59. olts may be used to check out the motor An ordinary 9 volt battery is recommended Unit transformer T1 secondary may be used in lieu of a battery A 9 volt battery will last for about one day of normal operation If transformer T1 is used double check all wiring connections before placing unit back in operation CHECKOUT PROCEDURE 1 Disconnect power to unit 2 Disconnect P49 from J49 3 Connect voltage source as shown below 4 Turn on power to unit Blower should operate on low speed heat cool tap LOW SPEED CHECKOUT 5 Disconnect power to unit 6 Connect voltage source as shown below 7 Turn on power to unit Blower should operate on high speed cool tap HIGH SPEED COOL CHECKOUT 8 Disconnect power to unit 9 Connect voltage source as shown below 10 Turn on power to unit Blower should operate at high speed heat tap HIGH SPEED HEATING CHECKOUT Ic FIGURE 24 ICM2 WITH VSP2 OR BDC 2 120V to the motor must not be interupted All connections for check out will be from the voltage source below battery or 24V to plug J46 after disconnectiong from blower control board 0000000000000 CHECK OUT PROCEDURE USING BATTERY An ordinary 9 volt battery with maximum DC 20volts is recommended A 9 volt battery will last for about one day of normal operation LOW SPEED CHECK OUT 12345678 9 10 11 12 13 OG B gut
60. ower operates on high speed heating tap BLOWER HARNESS CONNECTORS POWER INCREMENTAL CONTROL CONNECTOR J48 SPEED TAPS CONNECTOR J49 UO OC DO i PIN 1 24VAC Half Rectified or PWM Input From J46 2 ON OFF PIN2 From J46 4 HI LOW 12 17VDC Straight Voltage With CCB1 21VAC Without CCB1 PWM with Harmony PIN 3 Not Used PIN 4 Control Common From J46 1 PIN 5 24VAC Half Rectified HEAT PIN6 Not Used J48 PIN 1 L1Line voltage PIN2 L2 not used 230 Volt units line voltage PIN3 Neutral 115 volt units PIN 4 Ground Motor to Cabinet NOTE Electronically switched voltage cannot be accurately measured with conventional meters Do not attempt to measure this voltage Follow diagnostic procedures outlined in this manual to determine if motor and VSP1 are operating properly FIGURE 5 A DANGER Disconnect power from unit and wait at least five minutes to allow capacitors to discharge before at tempting to adjust motor speed tap settings Failure to wait may cause personal injury or death Page 5 Blower Speed Taps Use the following procedure to change blower speed selection for high low or heat speed selection 1 Disconnect line voltage from unit 2 Wait 5 minutes 3 Disconnect AC power plug P48 from motor controller See figure 5 4 Slide tap cover toward AC power plug See figure 6 5 Remove the ap
61. propriate speed connector and place it on the proper tap See figure7 6 When all connections are made to proper taps close tap cover and reconnect AC power plug to motor controller and reconnect line voltage to unit If any of the tap wires are left disconnected the motor re verts to default speed taps If the black or red wires are left off the motor defaults to tap 11 If the white wire is left off the motor defaults to tap 5 BLOWER MOTOR CONNECTOR LOCATIONS o Ook BLOWER MOTOR CONTROLLER SPEED COVER slides to left after power plug is removed AC POWER L e7 CONTROL INLET PLUG Z INTERFACE PLUG FIGURE 6 BLOWER SPEED TAPS LOW SPEED HEAT COOL WHITE CONNECTOR HIGH SPEED HEAT RED CONNECTOR HIGH SPEED COOL BLACK CONNECTOR FIGURE 7 B External Operation ICM2 Figure 8 shows the two quick connect jacks J48 and J49 which connect the motor to the unit Jack J48 is the power plug and jack J49 connects the unit controls to the motor Line voltage must be applied to J48 pin 5 in order for the motor to operate When using 120VAC pins 1 and 2 must be jumpered When control voltage is applied to J49 pin 3 and 15 single stage heating and cooling the motor is en ergized on the low speed heat cool tap When voltage is applied to J49 pin 2 in addition to pin 3 and 15 second stage heating the blower is ener
62. rom unit and wait at least five minutes to allow capacitors to discharge before at tempting adjust motor speed tap settings Failure to wait may cause personal injury or death Page 3 Motor Start Up At start up the motor gently rocks back and forth for a moment This is normal During this time the electronic controller is determining the exact position of the rotor Once the motor begins turning the controller slowly eases the motor up to speed this is called soft start The motor may take as long as 10 15 seconds to reach full speed If the motor does not reach 200rpm within 13 seconds the motor shuts down Then the motor will im mediately attempt a restart The shutdown feature pro vides protection in case of a frozen bearing or blocked blower wheel The motor may attempt to start eight times If the motor does not start after the eighth try the controller locks out Reset controller by momentarily turning off power to unit BLOWER MOTOR SPEED TAPS under cover slides open after power plug is removed BLOWER MOTOR COMPONENTS STATOR STATOR WINDINGS WINDINGS FIGURE 3 MOTOR SPEED CONTROL WITH D C PULSE WIDTH MODULATION Motor speed is determined by the size of the electrical pulse sent to the motor windings The longer the pulse the faster the motor OUTPUT FROM CONTROLLER TO MOTOR WINDINGS WINDINGS TURNED OFF WINDINGS TURNED ON BS ON PULSE L OFF PULSE IN The frequency o
63. s of the actual stage Doing so will ac tivate the low speed jumper setting when W1 is energized Page 16 d HIGH The HIGH jumper is used to determine the CFM during cooling speed These jumper selections are activated when G and DS terminals are energized e LOW The LOW jumper is used to determine CFM during low speed cooling These jumper selections are activated when G is energized The LOW jumper may also be used for low speed heating f FAN OFF Fan OFF timings time that the blower operates after the heat demand has been satisfied are determined by the ar rangement of a jumper on the VSP2 1 board See figure20 To adjust fan OFF timings gently disconnect the jumper and reposition it across pins corresponding with the new timing Fan OFF time is factory set at 270 seconds Fan ON time is factory set at 45 seconds and is not adjust able A WARNING sure to disconnect power before changing fan OFF timings FAN OFF TIME ADJUSTMENT TIMING To adjust fan off timings JUMPER Remove jumper from VSP2 1 and select one of the other pin combina tions to achieve the desired time Leave jumper off to achieve 330 second fan off timing TIMING PINS seconds 3 77 210 Fan off timing is factory set at 270 seconds FIGURE 20 NOTE TIf fan OFF time is too low residual heat in heat exchanger may cause primary limit S10 to trip resulting in frequent cycling of
64. sections before adjusting blower speed Refer to figure 12 for identification Diagnostic LEDs 053 ON OFF ON OFF DS3 indicates there is a demand for the blower motor to run When the ON OFF LED DS3 is lit a demand is being sent to the motor If ON OFF LED DS3 is on and both HIGH LOW LED DS1 amp HEAT LED DS2 are off the motor will operate in low speed B 052 HEAT If HEAT LED DS2 is on the blower is running in the heat speed according to the HEAT jumper setting If the HEAT LED DS2 is on at the same time as the HIGH LOW LED DS1 the blower is running in heat speed according to the HEAT jumper setting C D81 HILOW HIGH LOW LED DS1 indicates whether the blower is oper ating in high or low speed When the light is off the blower is running in low or heat speed according to the LOW or HEAT jumper setting When HIGH LOW LED DS1 is and the HEAT LED DS2 is off the blower is operating in high speed according to the HIGH jumper setting D DS4 CFM CFM LED DSA indicates the CFM the unit is operating ac cording to the jumper settings The light flashes once for approximately every 100 CFM For example if the unit is op erating at 1000 CFM CFM LED DS4 will flash 10 times If the CFM is 1150 CFM LED DS4 will flash 11 full times plus one fast or half flash At times the light may appear to flicker or glow This takes place when the control is communicating with the motor be tween c
65. sired set of pins The following section outlines the different jumper selections available and condi tions associated with each one Use table 6 as an example only for CFM per jumper setting See CFM tables in units Installation Instructions or Unit Information manual if needed Refer to figure 21 for identification ADJUST The ADJUST pins allow the motor to run at normal speed or approximately 15 lower than normal speed The TEST pin is available to bypass the VSP3 1 control and run the motor at approximately 70 to test that the motor is operational This is beneficial primarily in troubleshooting G must be energized for motor to run HTG BLOWER Place the HTG BLOWER jumper across the second and third pins position 2 NOTE In Harmony Il zoning applications HTG BLOWER jumper must be in position 2 HEAT The HEAT jumper is used to set the blower speed to obtain the required CFM as outlined in HEAT SPEED section of the blower performance tables The HEAT jumper selec tions are activated with a call for first stage heating W1 and second stage heating W2 DELAY The DELAY jumper is used to set the specific motor fan mode of operation during cooling Depending on the ap plication one of four fan options may be chosen by moving the jumper to the appropriate set of pins Options 1 2 3 or 4 will have an increased dehumidifica tion effect on the system Option 1 will have the least effect and option 4 will have the greatest
66. st the blower wheel The controller monitors the static work load on the motor and motor amp draw to determine the amount of rpm adjust ment Blower rpm may be adjusted any amount in order to maintain a constant cfm The amount of adjustment is de termined by the incremental taps which are used and the amount of motor loading sensed internally Since the blow er constantly adjusts rpm to maintain a specified cfm mo tor rpm is not rated Hence the terms blower speed and speed tap in this manual refer to blower cfm regardless of motor rpm When Harmony is used speed taps are overridden and a PWM signal generated by the Harmony controller continuous ly varies motor speed based upon zone demands Initial Power Up When line voltage is applied to the motor there will be a large inrush of power lasting less than 1 4 second This in rush charges a bank of DC filter capacitors inside the con troller If the disconnect switch is bounced when the dis connect is closed the disconnect contacts may become welded Try not to bounce the disconnect switch when ap plying power to the unit The DC filter capacitors inside the controller are connected electrically to the speed tap wires The capacitors take approximately 5 minutes to discharge when the discon nect is opened For this reason it is necessary to wait at least 5 minutes after turning off power to the unit before at tempting to change speed taps A DANGER Disconnect power f
67. trol Units equipped with a variable speed motor are capable of maintaining a specified CFM throughout the external static range The BDC3 variable speed control board controls the blower speed and provides diagnostic LEDs CFM can be obtained by positioning jumpers COOL HEAT and ADJUST on the BDC3 board The jumpers are labeled 1 2 3 and 4 Each enables a different air volume Diagnostic LEDs are provided as an aid in identifying the unit s mode of operation The LEDs are labeled RUN and CFM See figure 13 BLOWER SPEED ADJUSTMENTS Diagnostic LEDs RUN RUN indicates there is a demand for the blower motor to run CFM CFM LED indicates the CFM the unit is operating according to the jumper settings The light flashes once for approximately every 100 CFM For example if the unit is operating at 1000 CFM CFM LED will flash 10 times If the CFM is 1150 CFM LED will flash 11 full times plus one fast or half flash At times the light may appear to flicker or glow This takes place when the control is communicating with the motor between cycles This is normal operation The appropriate speed according to application and CFM need is selected by moving jumper pins Jumper Settings IMPORTANT Before changing jumper setting make sure the motor has completely stopped Any jumper set ting change will not take place while the motor is running Jumper settings are factory set To change jumper positions gently pull
68. ycles This is normal operation The appropriate speed according to application and CFM need is selected by moving jumper pins Jumper Settings IMPORTANT Before changing jumper setting make sure the motor has completely stopped Any jumper set ting change will not take place while the motor is running Jumper settings are factory set To change jumper posi tions gently pull the jumper off the pins and place it on the desired set of pins The following section outlines the different jumper selections available and conditions as sociated with each one Use table 2 as an example only for CFM per jumper setting See CFM tables in units Instal lation Instructions or Unit Information if needed Refer to figure 12 for identification After the CFM for each application has been determined the jumper settings must be adjusted to reflect the that value Use the tables in Installation Instructions to determine which row of CFM volumes most closely matches the desired CFM Once a specific row has been chosen NORMAL or CFM volumes from other rows cannot be used Below are the descriptions of each of the jumper selections A ADJUST The ADJUST pins allow the motor to run at normal speed approximately 10 higher or approximately 10 lower than normal speed The TEST pin is available to bypass the BDC 2 control and run the motor at approximately 70 to test that the motor is operational This is beneficial primarily i
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