Thermo Products MG-1018 Burner User Manual
Contents
1. 826 1340 1094 1673 1366 TEMPERATURE RISE F 65 60 65 60 65 60 BLOWER MOTOR HP 5 75 1 POWER CHOKES 2 65Mh 2 1Mh LARGEST RECOMMENDED AIR CONDITIONER 3 5 Ton 4 Ton 5 Ton SIZE OF FILTERS 21 3 4 x 14 2 21 3 4 x 14 2 21 3 4 x 14 2 NOTES 1 Heating capacity based on annual fuel utilization efficiency rated by manufacturer 2 Onall 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 Nn All specifications are subject to change without notice All installations and services must be performed by qualified service personnel II BLOWER INFORMATION A WIRING DX1 125 SER WILL DIFFER SLIG O i CHOKE Si RED LEADS TO RIES ONLY AUX LIMIT E CNIR e 2d f OTOR CONIROLLER IS MOUNTED ON CONTROL PANEL CONTROI THERMOSTAT NTEGRATED CONTRO Re S CHX1 SERIES FACTORY SETTINGS WILL DIFFER i REFER TO TABLE BELOW 4 feat ALTERNATE DIP 2 J H SETTINGS Wa oo ea B Figure 1 BLOWER WIRING A WARNING TURN OFF THE ELECTRICAL POWER to the furnace2. 4 NOTES 1 Heating capacity based on annual fuel utilization efficiency rated by manufacturer 2 Onalloutlet 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 All specifications are subject to change without notice A 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 75 000 56 250 100 000 75 000 125 000 93 750 HEATING CAPACITY IN BTU HR High fire Low fire 69 750 52 312 93 000 69 750 116 250 87 187 HEIGHT OF CASING 46 1 4 46 1 4 46 1 4 WIDTH OF CASING 17 21 24 DEPTH OF CASING 27 1 2 27 1 2 27 1 2 WARM AIR OUTLET 15x18 19x 18 22x18 RETURN AIR INLET 15x22 19x22 22x22 DIA OF FLUE 27 3 3 DIA OF COMBUSTION 2 3 3 AIR INTAKE FLOWRATE from 2 amp 5 w c EXTERNAL STATIC PRESSURE COOLING COOLING COOLING COOLING TAP A CFM 1000 1200 1400 COOLING TAP B CFM 800 1000 1200 COOLING TAP C CFM 1200 1400 1600 COOLING TAP D CFM 1400 1600 2000 HEATING HEATING HEATING HEATING TAP C CFM High fire Low fire 1012
3. before attempting to disconnect blower wiring 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 Dip Dip Switch High Fire switch High Fire settings Low fire CFM Rise F CFM Rise F settings Low fire CFM Rise F CFM Rise F fats 1012 Dip Dip switch High Fire switch settings Low fire CFM Rise F CFM Rise F i 7 OFF 7 ON pore or m me 5 7 OFF pow woe m mo os 7 ON pon ns s uo ol Dip Dip switch High Fire switch settings Low fire CFM Rise F CFM Rise F i 7 OFF 7 ON pore one m e ms 7 OFF pon x e ir os 7 ON pon wo sm w o _ FACTORY SHIPPED SETTINGS All installations and services must be performed by qualified service personnel COOLING AND CONTINUOUS FAN SPEEDS Continuous i Continuous i Continuous fan i fan i fan CFM i i CFM i i CFM FACTORY SHIPPED SETTINGS All installations and services must be performed by qualified service personnel III ECM TROUBLE SHOOTING A GENERAL GUIDELINES TO TROUBLESHOOTING GE ECM DRIVEN SYSTEMS ACAUTION Disconnect power from unit before removing or rep
4. water can t get in gt Install drip loops Locate connectors above 7 and 4 o clock positions Use authorized motor and control model s for replacement Replace one motor or control model with another unless an authorized replacement 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 1 2 H2O drop Use restricted returns 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 drain plugged Check for low airflow too much latent capacity Check for undercharged condition Check and plug leaks in return ducts cabinet Comfort Check Check proper airflow settings Low static pressure for lowest noise Set low continuous fan CFM T stat in bad location All installations and services must be performed by qualified service personnel CONTROL CONNECTOR 44 PWB HEADER HMP 770974 1 N CRIPTION Per a Ped EAE SIE c ry
5. ION A WIRING B CFM TABLES III ECM TROUBLESHOOTING A GENERAL GUIDELINES TO TROUBLESHOOTING GE ECM B TROUBLESHOOTING CHARTS BEGINNING PAGE 1 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 75 000 52 000 100 000 70 000 125 000 87 500 HEATING CAPACITY IN BTU HR High fire Low fire 70 875 49 612 94 500 66 150 117 500 82 250 HEIGHT OF CASING 44 1 4 44 1 4 44 1 4 WIDTH OF CASING 17 217 24 DEPTH OF CASING 27 1 2 27 1 2 27 1 2 WARM AIR OUTLET 15x18 19x18 22x18 RETURN AIR INLET 25x16 25x16 25x16 DIA OF FLUE 2 3 3 DIA OF COMBUSTION 2 3 3 AIR INTAKE FLOWRATE from 2 amp 5 w c EXTERNAL STATIC PRESSURE COOLING COOLING COOLING COOLING TAP A CFM 1000 1200 1400 COOLING TAP B CFM 800 1000 1200 COOLING TAP C CFM 1200 1400 1600 COOLING TAP D CFM 1400 1600 2000 HEATING HEATING HEATING HEATING TAP A CFM High fire Low fire 931 760 1243 1015 1556 1270 TEMPERATURE RISE F 70 60 70 60 70 60 BLOWER MOTOR HP 5 75 1 POWER CHOKES 2 65 Mh 2 1 Mh LARGEST RECOMMENDED AIR CONDITIONER 3 5 Ton 4 Ton 5 Ton SIZE OF FILTERS 24 3 4 x 15 3 4 24 3 4 x 15 3 4 24 3 4 x 19 3
6. PLY ACROSS PIN12 amp PIN1 TO INTEGRATED CONTROL INTEGRATED AND PIN12 amp PIN3 CONTROL AT THE HARNESS PLUG i YES YES Y DISCONNECT 16PIN HARNESS FROM INTEGRATED CONTROL IS THERE 24V ACROSS PIN12 amp PIN1 AND PIN12 amp PINS AT THE CONROL NO YES CHECK HARNESS CONNECTIONS AND WIRE TURN THERMOSTAT MANUAL FAN SWITCH ON IF AVAILABLE OR JUMPER BETWEEN R amp G ON INTEGRATED CONTROL IS THERE VOLTAGE GREATER THAN 12V BETWEEN PIN15 amp PIN1 gt INTEGRATED REPLACE CONTROL NO CHECK CONNECTIONS AND WIRES m AT INTEGRATED CONTROL IF OK REPLACE INTEGRATED CONTROL YES CHECK CONNECTION ON HARNESS AND MOTOR RECONNECT HARNESS TO MOTOR IF CONNECTIONS ARE GOOD AND MOTOR STILL DOES NOT RUN REPLACE MOTOR
7. Thermo Pride cU ECM OPERATION MANUAL FOR USE WITH MODELS CHX1 75N CDX1 75N CHX1 100N CDX1 100N CHX1 125N CDX1 125N WARNING 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 e 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 SETTINGS II BLOWER INFORMAT
8. e M Ij DUST Ke PM EM WZ Y G I 5 SUGGESTED MATING CONHECTOR HOWSING AMP 770583 1 SONTACT AMP 770904 1 POWER CONNECTOR PWE HEADER AMP 1 350840 0 JUMPER FIN 1 TO PIN 2 FOR 12040 LINE INPUT QNZY CHASSIS GROUND AC LINE LIT rna e S a Ap CONTACT AMP 350537 1 WARNING APPLYING 240VAC LINE INPUT WITH PIN 1 TO PIN 2 JUMPER IN PLACE WILL PERMANENTLY DAMAGE UNIT fa A fifo ie lg Figure 2 ECM PIN CONNECTORS Troubleshooting table above and Figure 2 adapted from GE Industrial Systems publication GED 7161C Troubleshooting GE ECM Driven Systems All installations and services must be performed by qualified service personnel B TROUBLESHOOTING CHARTS THIS GUIDE SHOULD BE USED IN THE CASE OF A STOPPED OR MANFUNCTIONED ECM BLOWER MOTOR THE FOLLOWING SHOULD HELP ESTABLISH THE TYPE OF MALFUNCTION OR DEVIATION FROM THE NORMAL BLOWER OPERATION TO USE THIS DIAGRAM YOU JUST NEED TO FOLLOW THE INSTRUCTIONS IN THE BOXES DOES BLOWER SPIN FREELY NO x CONFIRM IF EITHER BLOWER WHEEL IS RUBBING AGAINST HOUSING OR MOTOR SHAFT IS SPINNING FREELY REPAIR OR REPLACE AS NECESSARY YES CHECK 115V SUPPLY IS THERE 115V NO gt CONNECTION FUSES SUPPLIED TO MOTOR SERVICE SWITCH AND DOOR SWITGH YES DISCONNECT 16 PIN IS THERE 24V HARNESS FROM ACROSS R amp MOTOR IS THERE 24V B C ON THE NO CHECK 24V SUP
9. lacing connectors or servicing motor Wait at least 5 minutes after disconnecting power before opening motor SYMPTOM CAUSE PROCEDURE Motor rocks slightly when starting This is normal start up for ECM Motor won t start No movement 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 Motor rocks but won t start Check for loose or compliant motor mount Make sure blower wheel is tight on shaft Perform motor control replacement check Motor oscillates up amp down while being tested off of blower It is normal for motor to oscillate with no load on shaft Motor starts but runs erratically Varies up and down or intermittent Check line voltage for variation or sag Check low voltage connections G Y W R C at motor unseated pins in motor harness connectors Check Bk for erratic CFM command in variable speed applications Check out system controls T stat Perform Moisture Check Hunts or puffs at high CFM speed Does removing panel or filter reduce puffing gt Reduce restriction gt Reduce max airflow Stays at low CFM despite system call for cool or heat CFM Check low voltage T sta
10. t 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 Stays at high CFM R missing not connected at motor Is fan in delay mode wait until delay time complete Perform motor control replacement check Blower won t shut off Current leakage from controls into G Y or W Check for Triac switched t stat or solid state relay Excessive noise Determine if it s air noise cabinet duct or motor noise interview customer if necessary 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 panels gt Check for cabinet duct deformation 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 gt Reduce restriction gt Reduce max airflow Evidence of Moisture Motor failure or malfunction has occurred and moisture is present Replace motor and perform Moisture Check Evidence of moisture present inside air mover Perform Moisture Check DO DON T Check out motor controls wiring and connections thoroughly before replacing motor Automatically assume the motor is bad Orient connectors down so
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