GMV9 Two-Stage Variable-Speed GCV9 GMV9, and GCV9.

GMV9 Two-Stage Variable-Speed GCV9

GMV9, and GCV9GMV9, and GCV9


Heating Capacity

ModelHi-Fire

(thousand btu/h)

Lo-Fire (thousand btu/h)

Input Output Input Output

GMV90703B 70 66.9 48 46.4

GMV90904C 90 88.8 64 61.7

GMV91155D 115 111.1 80 77.4

GCV90704C 70 65.3 48 45

GCV90905D 90 86.5 64 60.1


Supports a wide range of Cooling requirements

Cooling CapacityModel Hi-Stage Cooling

GMV90703B 1.5 2.0 2.5 3.0

GMV90904C 1.5 2.0 2.5 3.0 3.5 4.0

GMV91155D 1.5 2.0 2.5 3.0 3.5 4.0 5.0

GCV90704C 1.5 2.0 2.5 3.0 3.5 4.0

GCV90905D 1.5 2.0 2.5 3.0 3.5 4.0 5.0


VENT TERMINATION CLEARANCES


STANDARD CONNECTIONS


VERTICAL TERMINATIONS(DUAL PIPE)


STANDARD HORIZONTAL TERMINATIONS


ALTERNATE HORIZONTAL VENT TERMINATIONS


TERMINATIONS ABOVE ANTICAPATED SNOW LEVEL


HORIZONTAL CONNECTIONS(RIGHT SIDE DOWN)


HORIZONTAL CONNECTIONS(LEFT SIDE DOWN)


TUBE INSTALLATIONS / GREEN HOSES


Thermostat Options

• Single-stage heating/Single-stage cooling

• Two-stage heating/Single-stage cooling

• Two-stage heating/Two-stage cooling

• Fossil fuel application (Kit required)– Three-stage heat pump thermostat required


THEMOSTAT WIRING


Thermostat wiring


Pressure Switch Check

• There are 3 Pressure Switches

• Hi and Low Fire are grouped together

• The Pressure Switch by itself is the Cover Switch

• All Pressure Switches are open Switches


GAS PRESSURE ADJUSTMENTS


MANIFOLD GAS PRESSURE


Induced-Draft Blower

• Jackel 2-speed blower assembly• Motor suspended on four motor mounts for vibration-free

operation• Factory-installed rubber discharge makes venting a snap• Alternate flue/vent through RIGHT side with GMV9 and

LEFT side for GCV9

Air flow


Electronic Controls


Neutral Connections(Line, XFMR, EAC, HUM)

12-pin connector (Diagnostics)

24V Terminal blockD-hum,W2,W1,R,G,B,Y,YLO,O

Green CFM LED

Yellow Dehumidification LED

16-pin connector (ECM Motor)

5-pin connector (inducer/ignitor)

Hot Connections(Line, XFMR, EAC, HUM)

Red Diagnostic LED

ICM

Microprocessor

3 amp Fuse

Integrated Control Board


Single-stage Thermostat?

Easily converted from 2-stage to 1-stage T-stat operation

Move this jumper to the left

Off = 5 minutes

On = 10 minutes

Then

Set dip switch #3


Accessories Supported

• Dehumidistat (Yellow LED indicator)

• 115-volt Humidifier (1 amp @ 120 volts)

• 115-volt EAC (1 amp @ 120 volts)

• 24-volt Humidifier


CFM LIGHT

Green Light On The Bottom Right Side Of The Board

1 Blink For Every 100 CFM


Start-Up Procedure1 Connect 115 power, proper grounding and polarity

2 Continuous flash indicates reverse polarity

7 Adjust blower speed using ICM dip switches

3 Follow I&O procedure for natural or LP gas

4 Refer to Spec Sheet for correct cfm/temp rise

5 Determine correct system cooling cfm

6 Green cfm LED flashes once per 100 cfm

9 Verify new cfm with green LED

10 Select cooling speed with dips 1,2,3, & 4

11 Select desired ramp profile with dip 5 & 6

12 Select heating speed with dip 7 & 8

8 Turn off power for 10 sec after each adjustment


Adjusting the Proper CFM Setting

CFMTemp Rise

CFMTemp Rise

LowStage

HighStage

- 558 0 804 0 --- 351 540

Norm 620 0 893 0 1.5 390 600+ 682 0 982 0 --- 429 660

- 639 0 920 0 --- 468 720

Norm 710 0 1022 0 2.0 520 800+ 781 0 1125 0 --- 572 880

- 720 0 1037 0 --- 585 900

Norm 800 0 1152 0 2.5 650 1000+ 880 0 1267 0 --- 715 1100

- 801 0 1153 0 --- 702 1080

Norm 890 0 1282 0 3.0 780 1200+ 979 0 1410 0 --- 858 1320

GMNTE060-3HEATING COOLING / HP

Low Stage High Stage Tonsof AC

CFM

BL

OW

ER

SP

EE

D T

AP A

B

C

D


Select Cooling Speed

Cool Tap Adjust TapSW1 SW2 Tap SW3 SW4 Adjust

Off Off A Off Off Norm

On Off B On Off Pos

Off On C Off On Neg

On On D On On TestFind proper cooling tap in PDB based on ~400 cfm/ton


Select Auto-Comfort Profile

ProfileSW5 SW6 Tap

Off Off A

On Off B

Off On C

On On DSelect Profile D for Auto-Comfort Mode


Select Heating Speed

Heat TapSW7 SW8 Tap

Off Off A

On Off B

Off On C

On On DSelect slowest heating speed possible while maintaining temp rise for minimum energy usage


Select Heat-Off Delay

Heat-Off Delays

SW1 SW2 Sec.

On On 60

Off On 90

On Off 120

Off Off 150


SEQUENCE OF OPERATIONS COOLING

1. RY&G Are Energized (Hi-Cooling) Call for Cooling

2. Condenser Turns On and the Blower Ramps Up to Cooling Speed, EAC Terminal are Now Energized

3. System Runs Till T-Stat is Satisfied

4. Outdoor Unit Turns Off and Blower Continues for 45 Seconds, Blower is Ramped Down and EAC Terminals are Turned Off

5. In Constant Fan Mode, Fan Continues at 56% of Cooling Speed


SEQUENCE OF OPERATIONHeating

1. R & W1 (Low Fire) Call For Heat

2. Inducer Draft Motor Starts Pre-Purge on Hi Fire (10 seconds), Humidifer Terminals are energize

3. Inducer Draft Motor drops to Lo, Low Fire Pressure Switch Closes

4. Igniter warms up 5 Min. to 9 Seconds opens on Max.

5. Gas Valve opens on Low Fire ,…… Flame Sensor Detects Flame

6. If Call for Hi-Heat , Inducer Draft Motor and Gas Valve Jumps up to Hi-Fire

7. Blower Delay Starts Blower To Ramp Up for 30 Seconds


SEQUENCE OF OPERATIONSHeating

8. EAC Terminal Energized Unit is Now Heating

9. If T-Stat Call for Low Fire, Inducer Draft Motor and Gas Valve Jump to Low Fire till T-Stat is Satisfied

10. Call for Heat Has Been Satisfied, Gas Valve Shuts Off and Inducer Draft Motor Does a Pre-Purge (15 Seconds)

11. Selected Heat-Off Delay 90, 120,150, 180 Seconds and Then the Blower Ramps Down


TroubleshootingFlash Pattern Status Indication

LED Off/Operation No 115 volt or 24 volt PowerLED Off/No Operation No 115 volt or 24 volt PowerLED On Normal Operation1 Flash Lockout due to excessive retries2 Flashes Pressure Switch stuck closed3 Flashes Pressure Switch stuck open4 Flashes Primary or Auxilliary high-limit5 Flashes Flame sense without call for heat6 Flashes Open rollout7 Flashes Low flame signal8 Flashes Check igniter or improper grounding9 Flashes Hi Stage Pressure Switch openContinuous Flash Reversed polarity of 115 vac


Field Returns

• Handling Boards by Edges or Use ESD Ground Strap

• No Repeated Control Change-out

• Moisture Control in Board Area

• Return Tag Information

• Boxes or Bags for Field Returns


Understanding ECM Motors

What does ECM mean?Electrically Commutated Motor


How Does the ECM Work?

POWERCONDITIONING

AC TO DCCONVERTER

POWERINVERTER

MOTORCONTROL

AC POWER

HVAC SYSTEM CONTROL

INPUTS24VACCompressor On/Hi/LoFan OnRev ValveAux/Emerg HeatCapacity Select

Available Outputs CFM

ECMMOTOR


How Does the ECM Sense Static Pressure?

Input Power vs. RPM

0

50

100

150

200

250

300

350

400

450

500

550

250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 1050 1100 1150

RPM

Inp

ut

Po

we

r (w

att

s)

1000 RPM280 Watts

500 RPM35 Watts

P = kN^3

1/2 N = 1/8 P

1/8 X 280W = 35W


0.0

0.2

0.4

0.6

0.8

0 1 2 3 4 5 6 7

CFM/ Watt

Sys

tem

Pre

ssure

(Pr)

PSC

ECM

408W745W

Lower static pressure yields greater efficiency gain

ECM Advantages Efficiency gain


0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400

®408W ®745W

PR

ES

SU

RE

Airflow (CFM)

Over blowing the system • poor moisture removal • high power consumption• moisture in the duct work

System airflow is starved• insufficient cooling/heating• liquid refrigerant return to condenser

Set the airflow and go!

Typical profile with a PSC motor

ECM Advantages Static-independent Airflow


How Does the ECM Work?

The End Bell defines motor characteristics.

Only 3 motor sections ½, ¾, or 1 hp.

The motor is really a three phase motor with a permanent magnet rotor.

Motor Section

End Bell Assembly

Motor Connector


Service and

Installation

Basics


High Voltage5 PIN

CONNECTOR

Low Voltage16 PIN

CONNECTOR

Power Connectors• Connectors are keyed

• Don’t force in the wrong orientation

• Pull on the plug, NOT the cable

• DO NOT pull power cable out during

operation – Arching could occur


Power Connectors Continued5 Pin Power Connector

• 120 VAC uses a jumper (red wire)

• Control operates at 240 VAC

• Jumper enables voltage doubler

• Do not apply 240 VAC with jumper installed as motor and

control will fail.

• 240 VAC input does not use a JUMPER

• Pulse Width Modulation (PWM) or

• 24 VAC Thermostat Mode or

• Digital Serial Interface (DSI)

16 Pin Signal Connector

Operating Voltages Application Note


Troubleshooting ECM Motors

What is Normal?It is normal for the blower to rock back

and forth at start up. It is normal for the shaft to feel rough or

bumpy when turned. Don’t judge the motor by the RPM or

ramp up sequence.



Don’t judge the motor by the RPM or ramp up sequence.

Profile AProfile BProfile C

Fullcapacity

OffDelay

Pre-run Shortrun

Time: 0 - 15 min, 16 stepsLevel: 6 - 100% 16 steps

off

on

All slew rates are controlled



The # 1 failure of ECM motors…………… No Fault Found ! (80%)

The # 2 failure of ECM Motors …………… Moisture. (16%)

All other failures (4%).



Drip LoopElectrical Connections on Bottom

• Always make sure the motor is oriented such that the connectors are on the bottom

• Make sure the electrical connections form a drip loop to prevent any moisture from running down the harness and into the end bell assembly.

• A blower wheel loose on the motor shaft can cause the blower to vibrate, excessive noise, and may cause motor malfunction.



There are some ECM motor testers on the market today.


Analyzes the GE ECM independent of the HVAC system

Can test the basic settings: Fan-only, Heating, Cooling and Dehumidification

Will detect and isolate motor failures from HVAC system failures

Accurate and quick diagnosis means better customer satisfaction

Don’t even have to take the motor out of the blower

Buy it on www.thedealertoolbox.com.

Click on the TECMateXLTM Service Tool link under the Service Tools tab.

GE TECMateXLTM Service Tool


How to Use the GE TECMateXLTM

The table on the back of the TECMateXL shows expected results for various settings.

1. CAUTION: Disconnect AC power from the system being serviced and wait 5 minutes before opening motor.

2. Remove the 16-pin connector from the motor, and connect the 16-pin connector from the TECMateXL to the motor. Do not disconnect the 5-pin AC power connector from the motor (see Figure 1).

3. Connect the two alligator clips from the TECMateXL to a 24VAC source.

4. Place all switches on the TECMateXL in the off position.

Figure 1

24VAC

120V or 240V AC Power

TECMate

ECM Motor

GE TECMateXLTM Service Tool


5. Reconnect AC power to the system. The TECMateXL power led should illuminate when connected properly to 24VAC.

6. Place the correct switches in the ON position and observe the motor for 15 seconds. (Refer to the Table on back of the TECMateXL for switch selections of the various test mode settings).

7. If the motor starts with the TECMateXL, then the system malfunction is not caused by an ECM motor/control. Refer to the Troubleshooting Guide on page 2 for help in diagnosing the system malfunction.

8. When finished testing a mode, place all switches in the off position and wait for the motor to completely stop before testing the next switch selections. (Based on the OEM program, sometimes the motor will not shut-off immediately after a setting has been tested; this is normal.)

9. If the motor does not start with the TECMateXL, then proceed to replace the electronic control module in accordance with the instructions on page 4. Note: Before replacing the electronic control module, you must test the motor module to ensure it is not also damaged. Procedures for testing the motor module are included in “Replacing the ECM Control Module” instructions on page 4.

Note: Do not operate motor without blower wheel attached. Such operation will cause the motor to oscillate up and down.

GE TECMateXLTM Service Tool Continued


1. Perform a room-by-room load calculation using ACCA Manual J.

2. Select the proper size equipment so it delivers the expected comfort and efficiency.

3. Keep static pressure to a minimum. Design ductwork for minimum static and maximum comfort.

Follow ACCA Manual D. Look for and recommend ductwork improvements where necessary.

4. Recommend high efficiency, low pressure drop filters and recommend keeping the filters clean.

5. Select the proper cooling airflow to match the system tonnage using the identified switches or

jumpers on the system control board.

6. If needed make airflow adjustments to further optimize comfort using the trim selection on the system

control board.

7. Finally, install a humidistat or select the airflow ramp profile that best removes humidity or improves

efficiency for customized comfort.

GE provides a wide array of programming options in the ECM motor

that make it easier to optimize homeowner comfort.

Basic Steps to Ultimate Comfort

Ultimate Comfort Setup Guidelines


7. Attaching the new control module:

(a) If replacing an ECM 2.0 control with an ECM 2.3 control, insert plastic tab into perimeter of replacement control and align tab with mating hole in the end shield. Use the new shorter bolts provided to ensure a secure attachment. Orient the control to the end shield between 4 & 8 o’clock, insert bolts and tighten.

(b) If replacing an ECM 2.3 with an ECM 2.3, orient the new control to the motor’s endshield with connectors facing down, insert bolts and tighten.

8. Reinstall the blower/motor assembly into the HVAC system by following the manufacturer’s guidelines.

9. Plug the 16-pin connector and the 5-pin connector back into the motor. The connectors are keyed. Observe proper orientation.

10. Be certain to form a drip-loop so that water cannot enter the motor by draining down the cables (see Figure 5).

11. Final installation check. Ensure the system is setup as follows:

(a) Verify the condensate drain is not plugged or clogged.

(b) Reconnect the AC power to the HVAC system and verify that the new motor control module is working properly.

(c) Check and plug leaks in return ducts and equipment cabinet.

(d) The system should run quietly and smoothly.

Note: If this is a repeat failure, then it is important that you check the following:

Any evidence of moisture requires correcting the issue.

Replacing the ECM Control Module Continued

Line Transient Voltage Protection Application Note



How do we troubleshoot ECM motors? Rule # 1 – If the motor is running at all. The problem

is not in the motor. Rule # 2 – If the motor is running at the wrong

RPM/CFM, the most likely cause is the installation or controls sending signals to the ECM motor.

Rule # 3 – What is the most common failure mode? Water. Look for signs of moisture damage and correct before replacing end bell.



Rule # 4 - ECM motors, like any motor must have a power supply. Check the incoming power supply.

AC Line

Gnd

Pin 1 & 2 must be connected together for 120Vac

input applications

}

Power Connector(viewed from plug end)

54321

InductorAC Line

} V

I

Inductor is used on ¾ & 1 hp – 120 VAC applications only.


TSTAT Connections

12345678

9 10111213141516

Pin number

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Common C1 W/W1 Common C2 Delay tap select Cool tap Select Y1 Adjust tap select Output - Return valve (heat pump only) Humidistat (BK) Heat tap select 24 VAC (R) 2nd stage heat (EM/W2) 2nd stage cool (Y/Y2) Fan (G) Output +

Control (male)

Connector (female)



Rule # 5 - ECM motors, like any motor must have a signal or switch to turn it on, or tell it to run.

Controls should be checked with a true RMS meter or analog meter.

Controls will activate at ½ nominal voltage and 12 milliamps.

Control Connector Cable Half(viewed from connector end)

8

5

4

3

2

1

6

716

13

12

11

10

9

14

15Out

Cool

Delay

Common 2

W /W1

Common 1

Y1

Adjust +/-Out +

EM Ht/W2

24VAC (R)

Heat

BK/PWM (Speed)

(Rev Valve)

Y /Y2

G(fan)


Troubleshooting ECM Motors Check power to control.

Pins 1 to 12 and 3 to 12. You must have 24 VAC.

Set thermostat to demand for cooling. Check for 24 VAC at pins 1 to 6 and 3 to 6.

If you don’t record voltage as noted, repeat test at control or interface board.


8

5

4

3

2

1

6

716

13

12

11

10

9

14

15Out

Cool

Delay

Common 2

W /W1

Common 1

Y1

Adjust +/-Out +

EM Ht/W2

24VAC (R)

Heat

BK/PWM (Speed)

(Rev Valve)

Y /Y2

G(fan)



If control is defective, remove end bell and inspect for moisture before replacing control board.

Do not apply power to pins 8 or 16.

Do not apply line voltage to control connections.


8

5

4

3

2

1

6

716

13

12

11

10

9

14

15Out

Cool

Delay

Common 2

W /W1

Common 1

Y1

Adjust +/-Out +

EM Ht/W2

24VAC (R)

Heat

BK/PWM (Speed)

(Rev Valve)

Y /Y2

G(fan)



1.Disconnect all power to unit.

2.Disconnect 5 pin and 16 connectors from end bell.

3.Remove end bell assembly (2 Screws.

4.Disconnect 3 pin motor connector.

5.Using Ohmmeter, check for continuity in windings.

6.Using Ohmmeter, check for short to ground.

Motor Connector


Thank you!

any questions?

GMV9 Two-Stage Variable-Speed GCV9 GMV9, and GCV9.

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Transcript of GMV9 Two-Stage Variable-Speed GCV9 GMV9, and GCV9.