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