Oil Furnace Shorty ECM Motor
Contents
1. DEHUM W2 C R W Y G 0G sw LH OFF A e oO Tn 2 IX E m m T Ex 1 55 en nm r ie CI Jort E pice so n Sw2 Figure 2 BOARD LAYOUT WITH SWITCHES All installations and services must be performed by qualified service personnel C Inputs Power supplies Line voltage is applied between the S1 and NI quick connect terminals 24 VAC Class II Transformer secondary voltage supplied to X and C Limit Switch The 120VAC limit switch is connected to pins P2 1 amp 9 Refer to the Heat Mode section for the control operation Thermostat call for heat W 24 VAC thermostat input A call for heat is recognized when the thermostat connects W to R This input has an indicator LED that will light when the control receives a call for heat Refer to the Heat Mode section for the control operation Thermostat call for cool Y 24 VAC thermostat input A call for cooling is recognized when the thermostat connects Y to R This input has an indicator LED that will light when the control receives a call for cooling Refer to the Cool Mode section for the control operation Thermostat call for dehumidification DEHUM 24 VAC thermostat input A call for dehumidification 1s recognized when the humidistat connects D2. Motor oscillates up amp down while being tested off e tis normal for motor to oscillate with no load on of blower shaft Motor starts but runs erratically e Varies up and down or intermittent e Check line voltage for variation or sag e Check low voltage connections G PWM W R C at motor unseated pins in motor harness connectors e Check Bk for erratic CFM command in variable speed applications e Check out system controls T stat e Perform Moisture Check e Hunts or puffs at high CFM speed e Does removing panel or filter reduce puffing Reduce restriction Reduce max airflow e Stays at low CFM despite system call for cool or e Checklow voltage T stat wires and connections heat CFM All installations and services must be performed by qualified service personnel Verify fan is not in delay mode wait until delay complete R missing not connected at motor e Stays at high CFM R missing not connected at motor Is fan in delay mode wait until delay time complete e Blower won t shut off Current leakage from controls into G Y or W Excessive noise Determine if it s air noise cabinet duct or motor noise interview customer if necessary e Noisy blower or cabinet Check for loose blower housing panels etc High static creating high blower speed gt Check for air whistling thru seams in ducts cabinets or p
3. removed the cooling blower off time will be executed prior to the control switching into a heating mode In the case where the control is in a heating mode with both Y and W inputs energized and then the W input is removed the heating blower off time will be executed prior to the control switching into a cooling mode In the case where a call for fan G already exists and either a W or a Y call is initiated the blower speed will switch to the respective W or a Y speed following the blower on delay for that call Six dip switches select Speed values for heat cool fan and dehumidification blower speeds see the CFM Tables Blower On and Off Delays Four Heat blower on and four blower off delays are selected by two dip switches for each function Refer to Table 1 for specific delay values Speed Selection values Three dip switches select 8 cooling speeds Dependant fan and dehumidification speeds are selected by the same switches their tabular values are enacted when their function is called Three additional dip switches select 8 heating speeds which are enacted when heat is called This allows independent selection of heating and cooling capacity parameters See the CFM Tables for speeds All installations and services must be performed by qualified service personnel F CFM TABLES The following tables contain blower speed settings and their respective air flowrates for the ECM blower motor To c
4. via male quick connect terminal labeled EAC Humidifier The control provides a 120 VAC output for a humidifier Connections are made to a male quick connect terminal labeled EAC In this application the humidifier will operate on any blower operation Humidifier should be controlled by humidistat to prevent operation during cooling fan operation Status LED A red LED is provided to indicate any thermostat input has been recognized by the microprocessor on the control See Diagnostic Features for a function description of operation Thermostat Input LEDs Four green LEDs are placed beneath their respective thermostat connections W Y G and DEHUM and operate whenever a call is present See Diagnostic Features for a function description of operation E Operating Modes Standby Mode All outputs are off and the control is waiting for a thermostat demand The thermostat inputs and limit switch are continuously monitored The control initiates action when a thermostat call is received or limit switch opens Fan Mode A call for fan G is received from the thermostat If no other mode is calling for blower operation the control will choose a Low speed value from the position of DIP switch SW1 positions 4 through 6 as shown in the CFM Tables and operate the fan at that speed The fan mode will be operated as long as the G input is calling and neither the Heat mode nor the Cool mode is calling for blower operation When the
5. CROWN ECM OPERATION MANUAL Model CSHB60 90XE WARNING e Do NOT store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Improper installation adjustment alteration service or maintenance can cause a fire or explosion resulting in property damage personal injury or loss of life For assistance or additional information consult a qualified installer or service agency These instructions should be e read prior to installing the furnace e retained for reference by qualified service personnel e reviewed before performing any service or maintenance Crown Boiler Company 3633 I Street RATING Philadelphia Pennsylvania 19134 ama c Us Liste MO 453 ECN 4809 MA MADE IN USA All installations and services must be performed by qualified service personnel INDEX SECTION I II BLOWER CONTROLLER INFORMATION A TERMINAL DEFINITIONS amp FIELD WIRING B WIRING amp SWITCHES C INPUTS D OUTPUTS E OPERATING MODES F CFM TABLES ECM TROUBLESHOOTING A DIAGNOSTIC FEATURES B GENERAL GUIDELINES TO TROUBLESHOOTING GE ECM C TROUBLESHOOTING CHARTS BEGINNING PAGE DANPBRWNR KR enn Oo All installations and services must be performed by qualified service personnel I BLOWER CONTROLLER INFORMATION A TERMINAL DEFINITIONS amp FIELD WIRING Burner Harness Connector P1 Pin 1 Limit switch connection Pin 2 120
6. EHUM to R This input has an indicator Led that will light when the control receives a call for dehumidification Refer to the Cool Mode section for the control operation Thermostat call for fan G 24 VAC thermostat input A call for fan is recognized when the thermostat connects G to R This input has an indicator LED in that will light when the control receives a call for fan Refer to the Fan Mode section for the control operation D Outputs ECM Control The control controls a multiple speed ECM motor through the 6 pin P3 connector This connector provides connection for ECM Speed common Pin 1 Speed output Pin 2 Blower Enable Pin 4 Cool Enable Pin 5 and R output Pin 6 Oil Burner Control The control provides dedicated contacts to operate the T T input of an oil primary control Rating shall be class 2 24 VAC pilot duty 24 VAC lt 200mA Power The switched 120V AC power from the LIMIT switch passes through the board between Pins 1 amp 2 of connector P2 Compressor contactor The control provides switched 24V AC to operate a compressor contactor Rating shall be class 2 24 VAC pilot duty 24 VAC lt 200mA All installations and services must be performed by qualified service personnel EAC electronic air cleaner The control provides a 120VAC output for an electronic air Cleaner This output 1s energized whenever the fan motor is energized either low heat or cool speed Connection is made
7. FM tables on page 6 LOW The LOW Blower speed selected by positions 4 5 amp 6 of SW1 CFM tables on page 6 ECM PSC Replacement In an emergency situation a defective ECM motor can be replace with a PSC motor to provide temporary circulating air flow for heating or cooling This is done by replacing the ECM motor in the motor mounting bracket with a PSC motor of similar Horsepower Wire the common lead typically white of the replacement PSC motor to the neutral common terminal on the fan control board N 1 through 7 Connect the high speed replacement PSC motor lead typically black to the EAC terminal on the fan control board The EAC contact is energized with 115V AC any time the control board is calling for fan operation whether in heating or cooling mode This replacement should be only used in emergency situations and only until a replacement ECM motor can be obtained and reinstalled 12
8. Heat and Cool modes call for blower operation their respective outputs will take over after their respective turn on time delays have expired The speed Output is present until the fan call is satisfied Cooling Mode A call for cool Y is received from the thermostat If the heat mode is not active or the anti short cycle delay is not in effect the control will energize the CC terminal After a 10 second delay ramps up to the COOL speed determined by the position of DIP switch SW1 positions 4 through 6 determine a speed as shown in CFM Tables When the call for cool is satisfied the CC terminal is de energized and the cooling off delay of 45 seconds is started Forty five seconds later the blower speed ramps toward zero and the control reverts to Standby Mode Dehumidification Operation If a call for dehumidification is received while the Cool Mode is active blower speeds will be reduced The speed value will be selected from the LOW column of the CFM Tables Anti Short Cycle Operation To prevent compressor short cycling a call for cooling will be ignored for four minutes after the termination of any cooling call The anti short cycle delay is also in effect at power up All installations and services must be performed by qualified service personnel Heat Mode When a call for heat W is received from the thermostat if the Cool mode is not already active the T T terminal is energized and the blo
9. 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 DOES BLOWER SPIN FREELY Beo HOUSING OR MOTOR SHAFT IS SPINNING FREELY REPAIR OR REPLACE AS NECESSARY YES CHECK 115V SUPPLY IS THERE 115V NO CONNECTION FUSES SUPPLIED TO MOTOR SERVICE SWITCH AND DOOR SWITCH YES DISCONNECT 16 PIN ESUERERIUNC HARNESS FROM N ee A MOTOR IS THERE 12VDC Bie OTHE NO CHECK 24VAC ACROSS PIN12 amp PIN1 s TO INTEGRATED CONTROL INTEGRATED AND PIN12 amp PIN3 CONTRO AT THE HARNESS PLUG YES DISCONNECT 16PIN HARNESS FROM INTEGRATED CONTROL NO REPLACE IS THERE 12VDC ACROSS INTEGRATED PIN 6 amp PIN 1 CONTROL YES AT THE CONROL ES CHECK HARNESS CONNECTIONS AND WIRE TURN THERMOSTAT MANUAL FAN SWITCH ON IF AVAILABLE OR JUMPER KG CHECK CONNECTIONS AND WIRES BETWEEN R amp G ON INTEGRATED CONTROL gt AT INTEGRATED CONTROL IF OK IS THERE VOLTAGE GREATER THAN REPLACE INTEGRATED CONTROL 12VDC BETWEEN PIN15 amp PIN1 YES CHECK CONNECTION ON HARNESS AND MOTOR RECONNECT HARNESS TO MOTOR IF CONNECTIONS ARE GOOD AND MOTOR STILL DOES NOT RUN REPLACE MOTOR 10 All installations and services must be performed by qualified service personnel Sequence of Operati
10. VAC Line connection Pin 3 Burner pilot contact Pin 4 amp 5 120 VAC Neutral connection Pin 6 Burner pilot contact Pin 7 amp 8 From oil primary control Pin 9 Limit Switch Input LSJ Field Wiring to Burner Pilot Tstat Neutral Line Harness Wires Yellow Wires White Red Beckett Connections T T terminals White Black Riello Connections T stat terminals White Black Carlin Connections T T terminals White Black Thermostat Humidistat connections C Common ground Ww Thermostat call for heat R 24 VAC to thermostat G Thermostat call for fan y Thermostat call for cool DEHUM Humidistat call for dehumidification ECM control outputs Pin 1 Speed Common Pin 4 Blower Enable Pin 2 Speed Output Pin 5 COOL Enable Pin 3 Not used Pin 6 R Output Male quick connect terminals SI 3 N1 7 EAC HUM FAN exa c CE CC_COM 120 VAC Hot 120 VAC Neutral Electronic Air Cleaner 120 VAC connection Humidifier connection 120 VAC Fan On Signal 24VAC from transformer 24VAC common from transformer Compressor Contactor Compressor Contactor Common All installations and services must be performed by qualified service personnel B WIRING amp SWITCHES A WARNING TURN OFF THE ELECTRICAL POWER to the furnace before attempting to disconnect blower wiring
11. anels gt Check for cabinet duct deformation e Hunts or puffs at high CFM speed Does removing panel or filter reduce puffing gt Reduce restriction gt Reduce max airflow Evidence of Moisture e Motor failure or malfunction has occurred and moisture is present Replace motor and perform Moisture Check e Evidence of moisture present inside air mover Perform Moisture Check DO DON T e Check out motor controls wiring and connections thoroughly before replacing motor Automatically assume the motor is bad e Orient connectors down so water can t get in gt Install drip loops Locate connectors above 7 and 4 o clock positions e Use authorized motor and control model s for replacement Replace one motor or control model with another unless an authorized replacement e Keep static pressure to a minimum gt Recommend high efficiency low static filters gt Recommend keeping filters clean gt Design ductwork for min static max comfort gt Look for and recommend ductwork improvement where necessary in replacement Use high pressure drop filters some have 2 H 0 drop Use restricted returns e Size the equipment wisely Oversize system then compensate with low airflow e Check orientation before inserting motor connectors Plug in power connector backwards Force plugs Moisture Check e Connectors are o
12. hange air flowrates from that of the shipped settings use the respective SW1 dipswitch on the furnace s integrated control board see Figure 2 Heating Speed Set ups CSHB60 90XE Fan Control Swi Switch Settings BTUH Heating CFM Low Fire 60 000 Med Fire 72 000 High Fire 90 000 Aprox Rise E Aprox Rise F Aprox Rise F 3 OFF 2 OFF 1 OFF 3 OFF 2 OFF 1 ON 3 OFF 2 ON 1 OFF Factory 5 opp SWI1 2 ON Setting 1 ON 3 ON 2 OFF 1 OFF 3 ON 2 OFF 1 ON 3 ON 2 ON 1 OFF 3 ON 2 ON 1 ON 740 75 80 812 68 82 883 63 76 84 968 Su 69 86 1054 63 02 1153 58 2s 1267 66 1424 58 Recommended Heating Speed Setting Cooling Speed Set ups Factory SWI Setting Fan Control SW1 Switch Settings Clg Tonage Cool Air Flow Continous 6 OFF 5 OFF 4 OFF 6 OFF 5 OFF 4 ON 6 OFF 5 ON 4 OFF 6 OFF 5 ON 4 ON 6 ON 5 OFF 4 OFF 799 500 2 5 1017 508 1210 605 3 5 1404 702 1622 799 All installations and services must be performed by qualified service personnel II ECM TROUBLE SHOOTING A DIAGNOSTC FEATURES The control board is equipped with 4 green Input Status LEDs and 1 red Board Status LED These are intended to provide a quick view into furnace
13. on BLOWER Off Delay Active No HEAT Yes Yes Yes Yes Mode On On Delay Ended No No No No 1 BURNER Off BURNER On 2 HEAT mode Off 3 BLOWER Off Delay Started 4 Status LED Off Yes Yes DEHUM Active On Delay Ended BLOWER LOW No 1 AIC Off z 2 COOL mode Off BLOWER COOL 3 BLOWER Off Delay Started 4 Status LED Off BLOWER LOW 1 BLOWER Off No Delay 2 Status LED Off 1 HEAT mode On 2 BLOWER HEAT 3 Status LED Flashes 1 HEAT mode On 2 Blower On Delay Started 3 Burner On 4 Status LED On continuous 1 COOL mode On 2 Blower On Delay Started 3 Condenser On 4 Status LED On continuous 1 FAN mode On 2 BLOWER LOW 3 Status LED On continuous 11 All installations and services must be performed by qualified service personnel Sequence of Operation Glossary Inputs LIMIT 120vac power from the High Limit Switch used to power the burner W Switched 24vac indicating a Heat call from the thermostat Y Switched 24vac indicating a Cool call from the thermostat G Switched 24vac indicating a call for blower operation from the thermostat DEHUM Switched 24vac indicating a call for Dehumidification from a de humidistat BLOWER Speeds HEAT The Heating Blower speed selected by positions 1 2 amp 3 of SW1 CFM tables on page 6 COOL The Cooling Blower speed selected by positions 4 5 amp 6 of SW1 C
14. performance without requiring a voltmeter The green Input Status LEDs are driven by the Y W G and DEHUM inputs and are located directly below those inputs They will light to indicate the presence of these signals The red Board Status LED has two functions It will light when the board recognizes a valid input signal and will stay lit until all valid signals are removed This 1s intended to show that the board is functioning and able to respond to input signals It will flash rapidly while120VAC is missing from the LIMIT switch This is intended to give a quick visual indication of the High LIMIT switch B GENERAL GUIDELINES TO TROUBLESHOOTING GE ECM DRIVEN SYSTEMS A CAUTION Disconnect power from unit before removing or replacing connectors or servicing motor Wait at least 2 minutes after disconnecting power before opening motor SYMPTOM CAUSE PROCEDURE Motor rocks slightly when starting e This is normal start up for ECM Motor won t start e Check power at motor e No movement e Check low voltage 24 VAC R to C at motor e Check low voltage connections G PWM W R C at motor e Check for unseated pins in connectors on motor harness e Test with a temporary jumper between R G e Check motor for tight shaft e Run Moisture Check e Motor rocks but won t start e Check for loose or compliant motor mount e Make sure blower wheel is tight on shaft e Perform motor control replacement check
15. rientated down or as recommended by equipment manufacturer Is condensate drain plugged Check for undercharged condition Arrange harnesses with drip loop under motor Check for low airflow too much latent capacity All installations and services must be performed by qualified service personnel e 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 CONTROL CONNECTOR PWB HEADER AMP 770974 1 N DESCRIPTION A i ZE TA SUGGESTED MATING CONNECTOR HOUSING AMP 770583 1 SONTACT AMP 770404 1 POWER CONNECTOR PWB HE ADER SMP 1 350840 0 DESCRIPTION JUMPER FIN 1 TO PIN 2 FOR 2 20vAC LINE INPUT ONLY CHASSIS GROUND AC LINE Ss SSP ES Hi ouem CONTACT AMP 350837 1 WARNING APPLYING 240VAC LINE INPUT WITH PIN 1 TO PIN 2 JUMPER IN PLACE WILL PERMANENTLY DAMAGE UNIT bb p Figure 3 ECM PIN CONNECTORS Troubleshooting table above and Figure 2 adapted from GE Industrial Systems publication GED 7161C Troubleshooting GE ECM Driven Systems C TROUBLESHOOTING CHARTS All installations and services must be performed by qualified service personnel 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
16. wer on delay is started The on off pattern of DIP switch SW2 positions 1 and 2 select one of four blower on delay values see Table 1 When the delay time has elapsed a speed value is read from DIP switch SW1 positions 1 through 3 see the CFM Tables and the blower is ramped up to that speed The control remains in steady heat mode until the thermostat is satisfied When the call for heat signal is removed the T T terminal is de energized and the blower off delay is started The on off pattern of DIP switch SW2 positions 3 and 4 select one of four blower off delay values see Table 1 When the delay time has elapsed the blower is ramped toward zero Table 1 ON and OFF Blower Delay Time Switch Settings DIP SWITCH 2 SECTION BLOWER DELAY STATE TIMES 2 1 4 3 ON SEC OFF MIN OFF OFF 30 OFF ON 60 Factory Set ON OFF 120 ON ON 240 OFF OFF 2 OFF ON 4 Factory Set ON OFF 6 ON ON 8 Motor Blower Speed Three blower speed outputs are provided A G call for fan will provide the Low speed only A W heat call will provide the Heat speed only A Y cooling call will provide the Cool speed only In the case of thermostat calls for Y and W together blower speed selection will be determined by the input that was first initiated In the case where the control is in a cooling mode with both Y and W inputs energized and then the Y input is
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