GE - ECM Motor Technology and Troubleshooting

1. GE - ECM Motor Technology and Troubleshooting Presented by The RLCS Engineering Product Field Support

2. Airflow If SPEED is constant, CFM changes with Static Pressure To hold CFM constant, SPEED must change with Static Pressure If we can start out with this idea in mind, then proving that the ECM motor technology is superior will be much easier. If we take a PSC motor, whose speed is fairly constant (1075rpm), and we either add or take away static pressure, the CFM that the motor will deliver will vary. But, if we take an ECM motor, whose CFM is programmed to remain constant, then we can change the RPM of the motor to keep the CFM constant. Which would you rather have?If we can start out with this idea in mind, then proving that the ECM motor technology is superior will be much easier. If we take a PSC motor, whose speed is fairly constant (1075rpm), and we either add or take away static pressure, the CFM that the motor will deliver will vary. But, if we take an ECM motor, whose CFM is programmed to remain constant, then we can change the RPM of the motor to keep the CFM constant. Which would you rather have?

6. ECM Issues - Furnaces / Fan coils Prior to potted controls: Moisture was responsible for most failures The Power Transistors were the most common failure Contaminants from the air, added to the moisture/condensation, were also a concern Now, most common failure: NO defects found Actually the most common failure is �NO FAULT FOUND�. That is why we have put this training program together. When we find a motor that has failed, the culprit is usually moisture. Water off fan coils are the biggest problem, followed by leaking A or N-coils sitting on top of furnaces. Water is rarely the cause of ECM blower failures in furnaces. Contaminants from the air , mixing with the moisture added to the problem. The solution... Actually the most common failure is �NO FAULT FOUND�. That is why we have put this training program together. When we find a motor that has failed, the culprit is usually moisture. Water off fan coils are the biggest problem, followed by leaking A or N-coils sitting on top of furnaces. Water is rarely the cause of ECM blower failures in furnaces. Contaminants from the air , mixing with the moisture added to the problem. The solution...

7. ECM 2.3 - Potted Control Produced in fan coils and Tyler products since October 1998 Produced in furnaces since September 1999 �ECM2.3! This motor is �potted� (dipped in goo) to prevent moisture from getting to the electronics. When this motor was subjected to a moisture and salt test, the bearing on the motor failed before the electronics did! This motor has been in production in our Fan Coils and Tyler Products since 10/98. Furnaces received this motor into production in September 1999. �ECM2.3! This motor is �potted� (dipped in goo) to prevent moisture from getting to the electronics. When this motor was subjected to a moisture and salt test, the bearing on the motor failed before the electronics did! This motor has been in production in our Fan Coils and Tyler Products since 10/98. Furnaces received this motor into production in September 1999.

8. Types of ECM Control Thermostatically Controlled Fan Coils / Non-condensing furnaces / Packaged Units Pulse Width Modulation (PWM) Split systems (A/C & Heat Pump) Condensing Furnaces When we talk about ECM motors, there are two ways to control them; Thermostatic Pulse Width Modulation. The Thermostatic control is most common. We will find this type of control in our Fan Coils, Non-Condensing Furnaces and our Tyler packaged Products. The Pulse Width Modulation (PWM) control is found in our Condensing Furnaces and our Split System -A/C & HP�s. We will now explain how each type of control works. When we talk about ECM motors, there are two ways to control them; Thermostatic Pulse Width Modulation. The Thermostatic control is most common. We will find this type of control in our Fan Coils, Non-Condensing Furnaces and our Tyler packaged Products. The Pulse Width Modulation (PWM) control is found in our Condensing Furnaces and our Split System -A/C & HP�s. We will now explain how each type of control works.

9. Thermostatically Control ECM logic for fan coils, non-condensing furnaces and Tyler products Uses Full, Half, Positive, Negative or No Sine wave Bases CFM on predetermined CFM curves Models programmed differently CFM is controlled by adjusting torque in response to RPM RPM is sensed by the motor�s �back EMF� Always uses the �highest CFM� of what is being called for Thermostatic Controlled motors have pre-programmed parameters. The CFM desired is selected by �pins� that will send different signals to the motor. These signals are in �HALF-WAVE� form. Voltages of �0�v, -12vDC, +12vDC and 24vAC can be read with a volt meter. Each signal prompts the motor to run a different speed. Sometimes, combinations of signals are needed to have the motor run the requested speed (call for cooling; �Y� & �G�). The motor is a �constant volume� motor, in that it will constantly monitor the �back EMF� of the motor and adjust the RPM of the motor to provide a constant, predetermined CFM. If the motor receives more than one signal (�Y�- Heat Pump and Auxiliary Heat), the motor know to to run the higher of the two CFM�s to protect the equipment. Thermostatic Controlled motors have pre-programmed parameters. The CFM desired is selected by �pins� that will send different signals to the motor. These signals are in �HALF-WAVE� form. Voltages of �0�v, -12vDC, +12vDC and 24vAC can be read with a volt meter. Each signal prompts the motor to run a different speed. Sometimes, combinations of signals are needed to have the motor run the requested speed (call for cooling; �Y� & �G�). The motor is a �constant volume� motor, in that it will constantly monitor the �back EMF� of the motor and adjust the RPM of the motor to provide a constant, predetermined CFM. If the motor receives more than one signal (�Y�- Heat Pump and Auxiliary Heat), the motor know to to run the higher of the two CFM�s to protect the equipment.

10. FAN COIL EASY SELECT BOARD DH - Dehumidification R - 24 VAC W1 - 1st stage Elect Ht W2 - 2nd stage Elect Ht Y1 - 1st stage Compressor YY/2 - 2nd stage Compressor or single stage Compressor G - Fan O - Reversing Valve in Clg C - Common Hum - Humidifier (24VAC) AUX - Auxiliary (24VAC) EAC This is a typical control board (40FK/FK4C/FV4A) that will control the ECM motor. We will discuss how this is done later in the program. This is a typical control board (40FK/FK4C/FV4A) that will control the ECM motor. We will discuss how this is done later in the program.

11. ECM Logic Pulse Width Modulation PWM Another other way to control an ECM motor is to send a PWM signal to the motor, receive a �Feedback� signal and then adjust the PWM to control it�s RPM. Another other way to control an ECM motor is to send a PWM signal to the motor, receive a �Feedback� signal and then adjust the PWM to control it�s RPM.

12. Pulse Width Modulation (PWM) PWM is a simple way of commanding airflow (CFM), as defined from an external device (2 wire method) The variable speed circuit board supplies this signal to the motors This method is controlled by a two wire system, which is usually a control board(external device). Like in the condensing furnace, a �personality plug� is required to tell the circuit board what signals to send to the motor. This method is controlled by a two wire system, which is usually a control board(external device). Like in the condensing furnace, a �personality plug� is required to tell the circuit board what signals to send to the motor.

13. 90% ECM MOTOR TECHNOLOGY �PWM� Pulse Width Modulation (PWM) Equation determines the slope of the curve Based on duty cycle Min PWM is Minimum torque and Max PWM is Maximum TorqueMin PWM is Minimum torque and Max PWM is Maximum Torque

14. Duty Cycle The amount of �ON-TIME� per cycle PWM= A/B or PWM%= A/B% (a=b=full speed, emergency heat, sw 4 - on) The signal sent to the motor would look very similar to the �square wave� above. The torque of the motor is determined by the width at which the �A�signal is sent to the motor electronics. The wider the signal (�B� is constant) the faster the motor will run. If A=B, the motor will run at 100% torque, which would be the maximum speed regardless of static situations or when setup switch #4 - Emergency Heat is activated.The signal sent to the motor would look very similar to the �square wave� above. The torque of the motor is determined by the width at which the �A�signal is sent to the motor electronics. The wider the signal (�B� is constant) the faster the motor will run. If A=B, the motor will run at 100% torque, which would be the maximum speed regardless of static situations or when setup switch #4 - Emergency Heat is activated.

15. ECM logic for variable speed condensing gas furnaces Furnace control board sends a PWM signal to the motor Control logic is contained in the Furnace control board Airflow is determined by the model or �personality plug� on furnace board PWM can be read by an oscilloscope will be seen as a square waveform The signal could be viewed as a square-wave by an oscilloscope. Or you can use the troubleshooting guide to determine where to look for various voltages. There are a couple other methods available to help troubleshoot the ECM motor. We will discuss them in the troubleshooting section of this program.As mentioned before, the �personality plug� determines the signals needed to run the motor. The signal could be viewed as a square-wave by an oscilloscope. Or you can use the troubleshooting guide to determine where to look for various voltages. There are a couple other methods available to help troubleshoot the ECM motor. We will discuss them in the troubleshooting section of this program.As mentioned before, the �personality plug� determines the signals needed to run the motor.

16. 38TDA/YDA, 598W Condensing Units Uses logic in Circuit Board of outdoor unit Control Board sends a PWM signal to the motor Signal can be read with a �DC� volt meter, with motor at full speed (22�<OAT>90�) at PW1, PW2 16-20 VDC with motor connected 20-40 VDC with motor Disconnected In the 38TDA/YDA, the condenser fan motor is controlled by the control board. The sixteen pin header is configured for each unit and the thermistors in the ambient air and on the coil help determine fan speed. Troubleshooting the fan motor can be found in the split system service manual.In the 38TDA/YDA, the condenser fan motor is controlled by the control board. The sixteen pin header is configured for each unit and the thermistors in the ambient air and on the coil help determine fan speed. Troubleshooting the fan motor can be found in the split system service manual.

17. Control Board Setups The following slides discuss the various control boards: Fan coils - 40FK/FK4C/FV4A Condensing furnaces - 58MVP / 355MAV Non-condensing furnaces - 58UHV / 333BAV Small package products (SPP) - 48-50SX / 557-657A (4 and 5 ton units ONLY) The following slides discuss the various control boards: Fan coils - 40FK/FK4C/FV4A Condensing furnaces - 58MVP / 355MAV Non-condensing furnaces - 58UHV / 333BAV Small package products (SPP) - 48-50SX / 557-657A (4 and 5 ton units ONLY)

18. FAN COIL EASY SELECT BOARD DH - Dehumidification R - 24 VAC W1 - 1st stage Elect Ht W2 - 2nd stage Elect Ht Y1 - 1st stage Compressor YY/2 - 2nd stage Compressor or single stage Compressor G - Fan O - Reversing Valve in Clg C - Common Hum - Humidifier (24VAC) AUX - Auxiliary (24VAC) EAC This is the 40FK/FK4C/FV4 circuit board. To better explain the operation of the board, let�s pick an example. This is the 40FK/FK4C/FV4 circuit board. To better explain the operation of the board, let�s pick an example.

19. FK4C Fan Coil Size 002 3 ton Heat Pump 15 KW electric Heat Setup We have selected a FK4C fan coil. We have matched it with an 3 ton Heat Pump and 15Kw of electric heat. We will also use the Comfort Heat Technology in the fan coil and the Thermidistat Control�. We have selected a FK4C fan coil. We have matched it with an 3 ton Heat Pump and 15Kw of electric heat. We will also use the Comfort Heat Technology in the fan coil and the Thermidistat Control�.

20. If we look at the Product Data Sheet, we can determine the CFM�s that the fan coil will run under various conditions. When in cooling, the unit can run at 1050cfm under normal cooling and at 840cfm under a dehumidification call Continuous fan CFM will be at 525 because of the �LO� selection made. Electric Heat CFM will be at 980 because of the �LO� selection made. Remember that the higher CFM will always prevail, to protect the equipment. If we look at the Product Data Sheet, we can determine the CFM�s that the fan coil will run under various conditions. When in cooling, the unit can run at 1050cfm under normal cooling and at 840cfm under a dehumidification call Continuous fan CFM will be at 525 because of the �LO� selection made. Electric Heat CFM will be at 980 because of the �LO� selection made. Remember that the higher CFM will always prevail, to protect the equipment.

21. Easy Select Board The violet wire determines the electric heater range. Below the selection is the CFM that the motor will run. The blue wire determines the size of the condensing unit. The orange wire begins to �massage� the CFM of the system. If �Heat Pump -Comfort� is selected, the CFM in heating will be at 315 instead of the cooling CFM of 350.The violet wire determines the electric heater range. Below the selection is the CFM that the motor will run. The blue wire determines the size of the condensing unit. The orange wire begins to �massage� the CFM of the system. If �Heat Pump -Comfort� is selected, the CFM in heating will be at 315 instead of the cooling CFM of 350.

22. Easy Select Board The black wire will adjust certain CFM�s either -10% or +15%. The white wire allows adjustment of the motor�s blower on/off delays. When this function is coupled with the Thermidistat Control�, the blower off delay in cooling can be eliminated be prevent re-evaporation of the water off the coil. The yellow wire allows 50, 66, and 100% of cooling speed for continuous fan. The black wire will adjust certain CFM�s either -10% or +15%. The white wire allows adjustment of the motor�s blower on/off delays. When this function is coupled with the Thermidistat Control�, the blower off delay in cooling can be eliminated be prevent re-evaporation of the water off the coil. The yellow wire allows 50, 66, and 100% of cooling speed for continuous fan.

23. Easy Select Board Remove J1 jumper to activate dehumidify mode Remove J2 jumper to separate W1 & W2 (Intelligent Heat staging) J1 jumper allows the separation of the De-Hum signal from the �R� terminal. This will allow the control to slow the blower down 20% during certain operations. J2 allows the Electric Heat to be separated. W1 and W2 will only be activated with a call from the TSTAT or the outdoor unit (during defrost). When W1 is activated without W2, the motor will run at 75% of the W2 speed.J1 jumper allows the separation of the De-Hum signal from the �R� terminal. This will allow the control to slow the blower down 20% during certain operations. J2 allows the Electric Heat to be separated. W1 and W2 will only be activated with a call from the TSTAT or the outdoor unit (during defrost). When W1 is activated without W2, the motor will run at 75% of the W2 speed.

24. This is a wiring diagram of the FK4C/40FK/FV4A fan coil. If we look at the signals sent to the motor, we can see that the motor can run several different speeds. Troubleshooting the motor is not as bad at it would seem. We will show a detailed chart to help troubleshoot the motor and circuit board.This is a wiring diagram of the FK4C/40FK/FV4A fan coil. If we look at the signals sent to the motor, we can see that the motor can run several different speeds. Troubleshooting the motor is not as bad at it would seem. We will show a detailed chart to help troubleshoot the motor and circuit board.

25. ECM setup for Variable Speed Condensing Gas Furnace 2 Sets of three (3) field selectable dip switch banks, Model Plug, and Thermostat inputs determine airflow. Once the �personality plug� is installed, the installer must set the desired CFM for certain operations. The heating portion of the Infinity furnace is already pre-determined. We will discuss board setup in the Installation portion.Once the �personality plug� is installed, the installer must set the desired CFM for certain operations. The heating portion of the Infinity furnace is already pre-determined. We will discuss board setup in the Installation portion.

26. MVP furnace Board Setup(changes made in idle mode) The 58MVP circuit board has two different 3 switch dip switch banks to adjust blower CFM�s. The personality plug is critical in the operation of the board. Without it, the technician would need to jumper certain pins to tell the board what furnace it is trying to run. The red arrow shows the continuous fan �CF� setting. This would need to be adjusted for low speed operation of a two speed A/C or Heat pump or when more CFM is needed for Continuous Fan operation. This CFM can NEVER be higher than the A/C selection described next. The blue arrow shows where to adjust the A/C CFM. Some models are only capable of 1400CFM. Trying to adjust CFM higher than that will create a fault code and default to 1400 CFM. The green arrow show the 8 switch dip bank. Depending on what the system is, certain switches will need to be used (see description above).The 58MVP circuit board has two different 3 switch dip switch banks to adjust blower CFM�s. The personality plug is critical in the operation of the board. Without it, the technician would need to jumper certain pins to tell the board what furnace it is trying to run. The red arrow shows the continuous fan �CF� setting. This would need to be adjusted for low speed operation of a two speed A/C or Heat pump or when more CFM is needed for Continuous Fan operation. This CFM can NEVER be higher than the A/C selection described next. The blue arrow shows where to adjust the A/C CFM. Some models are only capable of 1400CFM. Trying to adjust CFM higher than that will create a fault code and default to 1400 CFM. The green arrow show the 8 switch dip bank. Depending on what the system is, certain switches will need to be used (see description above).

27. 80% Variable Speed Control Board When dealing with the non-condensing furnace, we are using the similar setup of the FV4A fan coil(Thermostatic control). The yellow wire will determine the blower cooling CFM. You have to know which furnace blower drive you have to determine which pin to select. The blue wire allows us to use 315, 350 or 400CFM/ton for cooling. The orange wire is used if we have a straight A/C or dual fuel application. The red wire allows the adjustment of the Temperature rise range to be medium, medium-hi and high. Making sure the furnace is fired correctly is important before adjusting this option. The green wire will allow 50, 65 and 100% A/C CFM in the continuous fan operation. When dealing with the non-condensing furnace, we are using the similar setup of the FV4A fan coil(Thermostatic control). The yellow wire will determine the blower cooling CFM. You have to know which furnace blower drive you have to determine which pin to select. The blue wire allows us to use 315, 350 or 400CFM/ton for cooling. The orange wire is used if we have a straight A/C or dual fuel application. The red wire allows the adjustment of the Temperature rise range to be medium, medium-hi and high. Making sure the furnace is fired correctly is important before adjusting this option. The green wire will allow 50, 65 and 100% A/C CFM in the continuous fan operation.

28. Tyler Packaged Units The Tyler Packaged products (48/50SX) also uses the Thermostatic Control type ECM motor. As you can see the adjustment are very similar to the fan coil and non-condensing furnaces.The Tyler Packaged products (48/50SX) also uses the Thermostatic Control type ECM motor. As you can see the adjustment are very similar to the fan coil and non-condensing furnaces.

29. ECM Troubleshooting

30. ECM Troubleshooting All troubleshooting information can be found in Service Manuals Fan Coil (catalog# 03FA-5A0) Mid-efficiency furnace (catalog# 535-800) Infinity furnace (catalog# 565-829) ECM Troubleshooting Guide / Tyler products (catalog# 534-897) These are the current catalog numbers for the troubleshooting guides for the ECM motors.These are the current catalog numbers for the troubleshooting guides for the ECM motors.

31. All ECM Motors Slight �cogging� or rocking is inherent to all ECM motors motor is finding its location between stator and rotor and is determining rotation �Rumbling� sound during startup and shutdown System mechanical resonance (approx 300-400rpm), three (3) permanent magnets (stators) cause the rotor to have a �rumble� during low RPM�s �Fixes� Don�t replace motor! Isolate sound: Canvas duct connectors, rubber grommets, etc. All ECM motors have inherent operating conditions that may seem troublesome to the untrained technician. As the ECM motor starts up, a slight �rocking� or �cogging� can occur. The motor may even run backwards for a brief second to find its� location. In some situations, the motor may exhibit a rumbling sound during start up or shutdown. This is because of the three permanent magnets. If the rumble goes away once the motor comes up to speed, DO NOT change the motor. You need to isolate the sound to the fan coil or furnace. The noise was only noticeable on 1 hp motors in the MVP and has been resolved for several years. An older motor may have to be replaced along with the motor arms to resolve audible noise. All ECM motors have inherent operating conditions that may seem troublesome to the untrained technician. As the ECM motor starts up, a slight �rocking� or �cogging� can occur. The motor may even run backwards for a brief second to find its� location. In some situations, the motor may exhibit a rumbling sound during start up or shutdown. This is because of the three permanent magnets. If the rumble goes away once the motor comes up to speed, DO NOT change the motor. You need to isolate the sound to the fan coil or furnace. The noise was only noticeable on 1 hp motors in the MVP and has been resolved for several years. An older motor may have to be replaced along with the motor arms to resolve audible noise.

32. Power Plugs When we begin to look at troubleshooting the motor electrically, we need to observe certain precautions. Here we show the High and Low voltage connections.When we begin to look at troubleshooting the motor electrically, we need to observe certain precautions. Here we show the High and Low voltage connections.

33. ECM Warning !!! NEVER remove or connect the 5 PIN HIGH VOLTAGE CONNECTOR of the motor, with the power ON !! - High Voltage is always present at the motor - Arcing could damage electronics. It is very important to remove power before we disconnect the High voltage power. Failure to do this could cause irreversible damage to the motor.It is very important to remove power before we disconnect the High voltage power. Failure to do this could cause irreversible damage to the motor.

34. ECM warning!!! ECM motors should NOT be tested UNLESS under LOAD Erratic motor behavior could occur without a load (static pressure)

35. High Voltage Power Connector This is the description of the High voltage wires. Notice that the 230 Volt motor will NOT have the jumper between pins 1 & 2.This is the description of the High voltage wires. Notice that the 230 Volt motor will NOT have the jumper between pins 1 & 2.

36. Troubleshooting ECM Motors Check HIGH VOLTAGE at motor Pins 4, 5 of five pin connector SHOULD ALWAYS HAVE HIGH VOLTAGE 120 Volts for furnaces 240 Volts for fan coils / Tyler products What may seem unusual to an untrained technician, is that the motor will always have High voltage at the motor. It is up to the Low voltage to control the RPM�s of the motor.What may seem unusual to an untrained technician, is that the motor will always have High voltage at the motor. It is up to the Low voltage to control the RPM�s of the motor.

37. Low Voltage Connector All the ECM motor�s low voltage connections are like the picture above. What voltages appear may be different, but the terminal will stay the same. This picture really only applys to the 80v and the fan coil. The 58MVP uses different namings for the motor control inputs.All the ECM motor�s low voltage connections are like the picture above. What voltages appear may be different, but the terminal will stay the same. This picture really only applys to the 80v and the fan coil. The 58MVP uses different namings for the motor control inputs.

38. Troubleshooting ECM Motors If we looked at the previous slide, we could see that the motor should always have voltage at pins 1 & 12. These are the �R� and �C:� of the motor, similar to the �R� and �C� of a thermostat. This does not apply to the 58MVP.If we looked at the previous slide, we could see that the motor should always have voltage at pins 1 & 12. These are the �R� and �C:� of the motor, similar to the �R� and �C� of a thermostat. This does not apply to the 58MVP.

39. ECM Motor shaft turns,but not smoothly If the shaft (with blower wheel disconnected) is difficult to turn with the motor control attached: - and turns freely with the control disconnected, then the control is damaged. - and does not turn free with the control disconnected, then the motor is damaged. Verify continuity of windings (motor leads to unpainted motor end plate). They should be >100KW. What may appear to be a mechanical problem with the motor, may be an electrical problem. By verifying the above conditions, you may or may not have to continue with the electrical troubleshooting. In case it is an electrical problem, the following slides will show where to look for voltages.What may appear to be a mechanical problem with the motor, may be an electrical problem. By verifying the above conditions, you may or may not have to continue with the electrical troubleshooting. In case it is an electrical problem, the following slides will show where to look for voltages.

40. ECM Motor won�t stop running Check for good ground between motor ground transformer common lead Thermostat wiring Control Board Remove 12 pin connector, if motor stops it�s control wiring. If it continues to run, motor is bad. This is another condition to check before going too deep into troubleshooting. It is still advisable to investigate the source of the problem and not just fix the symptom.This is another condition to check before going too deep into troubleshooting. It is still advisable to investigate the source of the problem and not just fix the symptom.

41. Replacement Issues Insert Blower motor as far into cradle as possible air over motor helps keep motor cool Verify proper installation of motor to prevent water entering pin connections Drip legs, proper positioning Beware of electronic thermostats (90% furnaces) units that notch the waveforms �Power-Stealing� If you have to replace the ECM blower motor, make sure that the blower motor is in as far as possible. It is important to get as much air as possible over the end bell of the motor. The furnace motors are designed with this in mind just note the belly band position and put it into this same position when replacing the motor. The comment above is a GE statement and is related to design and should not be over-ridden in the field. Make sure that the connections to the motor are in the 6 o�clock position and that a drip leg has been made with the wires. The statement above does not apply to multi-poise furnaces so be careful. It is mostly for upflows and fancoils. Also, in a retro-fit application, make sure that the thermostat is compatible with ECM motors. Thermostats that may notch the A/C waveform, may cause problems. Or thermostats that power-steal from especially the �W� signal, can cause problems. Avoid using cheap 3rd party thermostats with Deluxe products.If you have to replace the ECM blower motor, make sure that the blower motor is in as far as possible. It is important to get as much air as possible over the end bell of the motor. The furnace motors are designed with this in mind just note the belly band position and put it into this same position when replacing the motor. The comment above is a GE statement and is related to design and should not be over-ridden in the field. Make sure that the connections to the motor are in the 6 o�clock position and that a drip leg has been made with the wires. The statement above does not apply to multi-poise furnaces so be careful. It is mostly for upflows and fancoils. Also, in a retro-fit application, make sure that the thermostat is compatible with ECM motors. Thermostats that may notch the A/C waveform, may cause problems. Or thermostats that power-steal from especially the �W� signal, can cause problems. Avoid using cheap 3rd party thermostats with Deluxe products.

43. RCD - Fan Coil Replacement Modules Here is a list of Fan Coil Replacement Modules that are available from RCD. They are very competitive in cost to a PSC motor.Here is a list of Fan Coil Replacement Modules that are available from RCD. They are very competitive in cost to a PSC motor.

44. RCD - Furnace Replacements Module Here is the list of the Furnace Replacement Modules. Here is the list of the Furnace Replacement Modules.

45. Pulse Width Modulation (PWM) Troubleshooting Troubleshooting the PWM motor is a little different because we have to make sure the motor and control board are talking to each other (remember we talked about a two wire system?). Troubleshooting the PWM motor is a little different because we have to make sure the motor and control board are talking to each other (remember we talked about a two wire system?).

46. Infinity Troubleshooting Guide Example: Inducer Motor Use Troubleshooting Guide Check voltages Line, PW and Feedback voltages One way to troubleshoot the 58MVP furnace is to use the service guide. This is a small portion of the guide, describing how to troubleshoot the ECM inducer motor. Even though we haven�t discussed the ECM inducer motor, it acts the very same way the blower motor does, except it is controlled at the correct speed based on the motor RPM when the pressure switches make. This is a very simple step-by-step approach to troubleshooting the motor. The next slide will show the wires attached to the ECM inducer. The most important thing to consider when using this guide is that, the voltages DO Not have to be exact. The most important thing is that you see a voltage change when there is to be a speed change from start to low or from low to high speed. One way to troubleshoot the 58MVP furnace is to use the service guide. This is a small portion of the guide, describing how to troubleshoot the ECM inducer motor. Even though we haven�t discussed the ECM inducer motor, it acts the very same way the blower motor does, except it is controlled at the correct speed based on the motor RPM when the pressure switches make. This is a very simple step-by-step approach to troubleshooting the motor. The next slide will show the wires attached to the ECM inducer. The most important thing to consider when using this guide is that, the voltages DO Not have to be exact. The most important thing is that you see a voltage change when there is to be a speed change from start to low or from low to high speed.

47. Infinity Inducer Motor Power / high voltage pins 6 & 12 PW voltage pins 2 & 10 Feedback voltage pins 2 & 1 pin 4 /ground The previous slide would have told you to look at various pins to determine if the fault lied in the circuit board or the ECM motor.The previous slide would have told you to look at various pins to determine if the fault lied in the circuit board or the ECM motor.

48. Advanced Product Monitor (APM) APM kit will help troubleshoot the furnace, including the ECM motors Requires: Laptop Software B&B RS485 Adapter Another way to look at the 58MVP furnace, is by using a laptop and certain hardware described above. If you ever have to make a second service call on a Infinity furnace, this combination will pay for itself after one callback. Another way to look at the 58MVP furnace, is by using a laptop and certain hardware described above. If you ever have to make a second service call on a Infinity furnace, this combination will pay for itself after one callback.

49. ECM Motor Simulator(for HK42FZ003 /012 Only) 1. Shut off power to the unit 2. Disconnect PL13 and plug it into the ECM Motor Simulator 3. Turn power on to unit 4. Put setup switch SW-6 to the �ON� position 5. Observe fault code displayed A third option will be a ECM Motor Simulator. By plugging this �blackbox� into the ECM motors, the fault code will tell whether the circuit board or ECM motor is at fault. This has been available on a limited basis for 1.5 years and will be available late 1999 from Finished Goods. This device has been received real well as an aid for troubleshooting.A third option will be a ECM Motor Simulator. By plugging this �blackbox� into the ECM motors, the fault code will tell whether the circuit board or ECM motor is at fault. This has been available on a limited basis for 1.5 years and will be available late 1999 from Finished Goods. This device has been received real well as an aid for troubleshooting.

50. Thermostatic ECM Troubleshooting The rest of the troubleshooting will deal with the Thermostatic Controlled motor.The rest of the troubleshooting will deal with the Thermostatic Controlled motor.

51. Troubleshooting ECM Motors For a Y/Y2 call, you would look for approximate -12vDC on pins 1 & 14. This does not apply to 58MVP. For a Y/Y2 call, you would look for approximate -12vDC on pins 1 & 14. This does not apply to 58MVP.

52. Troubleshooting ECM Motors When looking for �W� signals, W1 would be at pins 1 & 2, while W2 wpould be on pins 1 &13.When looking for �W� signals, W1 would be at pins 1 & 2, while W2 wpould be on pins 1 &13.

53. Troubleshooting ECM Motors for Fan Coils Check LOW VOLTAGE at R and C, at the control board Pins 8, 9 of twelve pin connector (SHOULD HAVE ~24VAC) The fan coil control board will have 24vAC at pins 8 & 9.The fan coil control board will have 24vAC at pins 8 & 9.

54. FAN COIL PINS @ CIRCUIT BOARD CHECK W1, Y/Y2, Y1 (USES 24VAC) AUX/HEAT KW/CFM, AC/HP SIZE, SYSTEM TYPE, AC/HP ADJUST, ON/OFF DELAY, CONTINUOUS FAN (Uses Half Wave Signals) This chart will allow us to determine if the circuit board is sending the proper signal to the ECM motor. It is VERY important to understand how the fan coil is setup (possibly Comfort Heat), because two signals or the lack there of, can change the motor speed.This chart will allow us to determine if the circuit board is sending the proper signal to the ECM motor. It is VERY important to understand how the fan coil is setup (possibly Comfort Heat), because two signals or the lack there of, can change the motor speed.

55. Newest FK4C installation instructions New instructions have more troubleshooting tables and examples Form # IM-FK4C-07 Catalog# 63FK-4C3

58. Other Contributing Factors Fan coils are a �DrawThru� design If not properly trapped, the water will hold in drain pan Water could drip on motor in downflow application Make trap IS DONE CORRECTLY!!

59. Troubleshooting ECM Motors for 80% two speed furnaces Check LOW VOLTAGE at R-C terminals, at the control board Pins 14, 9 of fourteen pin connector SHOULD ALWAYS HAVE ~24VAC The first thing to check on the non-condensing furnace is that the circuit board is supplying 24vAc on pins 9 & 14.The first thing to check on the non-condensing furnace is that the circuit board is supplying 24vAc on pins 9 & 14.

60. 80% 2 SPEED FURNACE PINS AT EASY SELECT CIRCUIT BOARD Check W1, W2, Y/Y2, Y1 (Uses 24VAC) AUX/HEAT KW/CFM, AC/HP SIZE, SYSTEM TYPE, AC/HP ADJUST, ON/OFF DELAY, CONTINUOUS FAN (Uses Half Wave Signals) Next, use the chart above to determine if the circuit board is supplying the proper voltage to the motor. Next, use the chart above to determine if the circuit board is supplying the proper voltage to the motor.

61. Troubleshooting ECM Motors for Tyler Products CHECK LOW VOLTAGE R-C AT THE CONTROL BOARD PINS PL2-5, PL2-3 OF 7 PIN CONNECTOR SHOULD ALWAYS HAVE ~24VAC Tyler Packaged Products are the same as the last two scenarios. Tyler Packaged Products are the same as the last two scenarios.

62. TYLER PRODUCT PINS AT CIRCUIT BOARD CHECK W1, G, Y/Y2, Y1 (USES 24VAC) AUX/HEAT KW/CFM, AC/HP SIZE, SYSTEM TYPE, AC/HP ADJUST, ON/OFF DELAY, CONTINUOUS FAN (Uses Half Wave Signals) Then use the chart to see if voltage is being supplied or not.Then use the chart to see if voltage is being supplied or not.

63. Proper Ductwork Installation Check existing ductwork static pressure Determine existing equipment CFM Use Product Data Sheet to determine that new equipment will work with existing ductwork or if it will require ductwork modifications See following examples Trying to determine if an ECM product is �do-able� in an existing ductwork situation is simple enough, if you get the following numbers; Take a magnehelic or some type of device that will measure the external static of the furnace or fan coil. Next, determine the CFM of the current unit, one method is by using the �Temperature Rise� method. Next, take the two values and apply them to the Product Data sheet.Trying to determine if an ECM product is �do-able� in an existing ductwork situation is simple enough, if you get the following numbers; Take a magnehelic or some type of device that will measure the external static of the furnace or fan coil. Next, determine the CFM of the current unit, one method is by using the �Temperature Rise� method. Next, take the two values and apply them to the Product Data sheet.

64. Condensing Furnace Fan Performance ECM Motor�s RPM range is 250-1300rpm Outside of this range, a Status Code 44 will occur High fire will default to 1200rpm cooling- last valid PWM This example shows a 58MVP080-14 furnace fan performance curve. If we had an old system that came up with a external static of .4 @ 1100cfm, a Infinity furnace would work. If we needed 3.5 tons of cooling, we would get approximately 1350ccfmThis example shows a 58MVP080-14 furnace fan performance curve. If we had an old system that came up with a external static of .4 @ 1100cfm, a Infinity furnace would work. If we needed 3.5 tons of cooling, we would get approximately 1350ccfm

65. Fan Coil Fan Performance Performance capable of 0.9� w.c. in some applications Torque�cad-back� will limit RPM Oscillation can occur during high static Nominal 350cfm/ton Airflow can be adjusted + 15% or -10% Fan coil CFM performance is shown here... Fan coil CFM performance is shown here...

66. Additional Fan Coil Consideration Return and Supply static must be in �white area� to prevent condensate removal from drain pan When dealing with fan coils, additional considerations need to looked at. If the return static is too high, then water may be pulled out of the drain pan.Once again, this is why it is important to check external static pressures, whenever possible.When dealing with fan coils, additional considerations need to looked at. If the return static is too high, then water may be pulled out of the drain pan.Once again, this is why it is important to check external static pressures, whenever possible.

67. Other things to consider An ECM motor will out-perform a PSC motor in high static situations Condensing furnace will display a fault code (above 1300rpm�s) but still provide more CFM than standard PSC motor at comparable external static pressure Thermostatically Controlled motors will provide desired CFM in high static situations If you have ever put in an ECM motor and have had it fault due to high static situation, remember this; 1) The furnace is just trying to tell you that the external static needs to be addressed, but it still outperform a PSC motor. 2) In fan coil situations where the air noise is unacceptable, more than likely, this is the first time that the correct amount of air has ever moved through the ductwork. Corrections to the ductwork or external static pressure will quiet the air noise and/or eliminate any fault codes.If you have ever put in an ECM motor and have had it fault due to high static situation, remember this; 1) The furnace is just trying to tell you that the external static needs to be addressed, but it still outperform a PSC motor. 2) In fan coil situations where the air noise is unacceptable, more than likely, this is the first time that the correct amount of air has ever moved through the ductwork. Corrections to the ductwork or external static pressure will quiet the air noise and/or eliminate any fault codes.