Crown Stove CSHB60 90XE User Manual

ECM OPERATION MANUAL  
Model:  
CSHB60-90XE  
c WARNING:  
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:  
read prior to installing the furnace  
retained for reference by qualified service personnel  
reviewed before performing any service or maintenance  
Crown Boiler Company  
3633 “I” Street  
Philadelphia, Pennsylvania 19134  
MO-453  
ECN 4809-MA  
MADE IN USA  
 
All installations and services must be performed by qualified service personnel.  
I. BLOWER CONTROLLER INFORMATION  
A. TERMINAL DEFINITIONS & FIELD WIRING  
Burner Harness Connector P1  
Pin 1 –  
Pin 2 –  
Pin 3 –  
Limit switch connection.  
120 VAC Line connection.  
Burner pilot contact.  
Pin 4&5 – 120 VAC Neutral connection.  
Pin 6 – Burner pilot contact.  
Pin 7&8 – From oil primary control.  
Pin 9 – Limit Switch Input (LSI).  
Field Wiring to Burner  
Pilot (Tstat)  
Yellow Wires  
Neutral  
White  
Line  
Red  
Harness Wires  
T-T terminals  
Beckett Connections  
Riello Connections  
Carlin Connections  
White  
White  
White  
Black  
Black  
Black  
T-stat terminals  
T-T terminals  
Thermostat/Humidistat connections  
"C"  
"W"  
Common/ground  
Thermostat call for heat  
"R"  
"G"  
"Y"  
24 VAC to thermostat  
Thermostat call for fan  
Thermostat call for cool  
“DEHUM”  
Humidistat call for dehumidification  
ECM control outputs  
Pin 1 - Speed Common  
Pin 2 - Speed Output  
Pin 3 - Not used.  
Pin 4 – Blower Enable  
Pin 5 – COOL Enable  
Pin 6 – “R” Output  
Male quick connect terminals.  
"S1-3”  
120 VAC Hot  
“N1-7”  
“EAC”  
“HUM”  
"FAN"  
“X”  
120 VAC Neutral  
Electronic Air Cleaner (120 VAC) connection.  
Humidifier connection (120 VAC).  
Fan On Signal  
24VAC from transformer.  
“C”  
"CC"  
24VAC common from transformer.  
Compressor Contactor  
"CC_COM"  
Compressor Contactor Common  
1
 
All installations and services must be performed by qualified service personnel.  
B. WIRING & SWITCHES  
: TURN OFF THE ELECTRICAL POWER to the furnace before attempting to disconnect blower  
wiring.  
Figure 2: BOARD LAYOUT WITH SWITCHES  
2
 
All installations and services must be performed by qualified service personnel.  
C. Inputs  
Power supplies  
Line voltage is applied between the "S1" and "N1" 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 & 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 is recognized when the humidistat connects  
"DEHUM" 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 (< 200mA).  
Power  
The switched 120VAC power from the LIMIT switch passes through the board between Pins 1&2  
of connector P2.  
Compressor contactor  
The control provides switched 24VAC to operate a compressor contactor. Rating shall be class 2 - 24  
VAC pilot duty @ 24 VAC (< 200mA).  
3
 
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 is energized whenever the fan  
motor is energized (either low, heat or cool speed). Connection is made 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  
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.  
4
 
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 blower 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  
STATE  
BLOWER DELAY  
TIMES  
2
OFF  
OFF  
ON  
1
OFF  
ON  
4
3
ON - SEC  
OFF - MIN  
30  
60  
Factory Set  
Factory Set  
OFF  
ON  
120  
240  
ON  
OFF OFF  
OFF ON  
2
4
6
8
ON  
ON  
OFF  
ON  
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 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.  
5
 
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  
change air flowrates from that of the shipped settings, use the respective SW1 dipswitch on the furnace’s integrated  
control board (see Figure 2).  
CSHB60-90XE  
Heating Speed Set-ups  
Cooling Speed Set-ups  
Low Fire  
Med Fire  
72,000  
High Fire  
90,000  
Air Flow  
BTUH  
60,000  
Fan  
Control  
SW 1  
Switch  
Settings  
Fan  
Control  
SW 1  
Switch  
Settings  
Heating  
CFM  
Aprox. Rise Aprox. Rise Aprox. Rise  
(F0 ) (F0 ) (F0 )  
Clg. Tonage Cool  
Continous  
6-OFF  
5-OFF  
4-OFF  
3-OFF  
2-OFF  
1-OFF  
2
799  
500  
740  
75o  
68o  
63o  
57o  
80o  
6-OFF  
5-OFF  
4-ON  
3-OFF  
2-OFF  
1-ON  
2.5  
3
1017  
1210  
1404  
1622  
508  
605  
702  
799  
812  
883  
82o  
76o  
69o  
63o  
58o  
6-OFF  
5-ON  
4-OFF  
3-OFF  
2-ON  
1-OFF  
84o  
86o  
79o  
72o  
66o  
58o  
6-OFF  
5-ON  
4-ON  
Factory  
SW1  
Setting  
3-OFF  
2-ON  
1-ON  
3.5  
4
968  
Factory  
SW1  
Setting  
6-ON  
5-OFF  
4-OFF  
3-ON  
2-OFF  
1-OFF  
1054  
1153  
1267  
1424  
3-ON  
2-OFF  
1-ON  
3-ON  
2-ON  
1-OFF  
3-ON  
2-ON  
1-ON  
Recommended Heating Speed Setting  
6
 
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 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 is 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  
: Disconnect power from unit before removing or replacing connectors, or servicing motor.  
Wait at least 2 minutes after disconnecting power before opening motor.  
SYMPTOM  
Motor rocks slightly when starting  
Motor won’t start  
CAUSE/PROCEDURE  
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,PWM,W,R,C,) at motor  
No movement  
Check for unseated pins in connectors on motor  
harness  
Test with a temporary jumper between R – G  
Check motor for tight shaft  
Run Moisture Check  
Check for loose or compliant motor mount  
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.  
Motor rocks, but won’t start  
Motor oscillates up & down while being tested off  
of blower  
Motor starts, but runs erratically  
Varies up and down or intermittent  
Check line voltage for variation or “sag”  
Check low voltage connections  
(G,PWM,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  
Does removing panel or filter reduce “puffing”?  
Reduce restriction  
Reduce max airflow  
Check low voltage (T’stat) wires and connections  
“Hunts” or “puffs” at high CFM (speed)  
Stays at low CFM despite system call for cool or  
heat CFM  
7
 
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  
“R” missing/not connected at motor  
Is fan in delay mode? – wait until delay time  
complete  
Stays at high CFM  
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  
Check for loose blower housing, panels, etc.  
High static creating high blower speed?  
Noisy blower or cabinet  
Check for air whistling thru seams in ducts,  
cabinets or panels  
Check for cabinet/duct deformation  
“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  
moisture is present  
Evidence of moisture present inside air mover  
Replace motor and perform Moisture Check  
Perform Moisture Check  
DO  
DON’T  
Check-out motor, controls, wiring and  
connections thoroughly before replacing motor  
Orient connectors down so water can’t get in  
Automatically assume the motor is bad.  
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”  
H2O drop!  
Install “drip loops”  
Use authorized motor and control model #’s for  
replacement  
Keep static pressure to a minimum:  
Recommend high efficiency, low static  
filters  
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  
Plug in power connector backwards  
Force plugs  
Check orientation before inserting motor  
connectors  
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  
8
 
All installations and services must be performed by qualified service personnel.  
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?  
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  
9
 
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 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  
HOUSING OR MOTOR SHAFT  
IS SPINNING FREELY, REPAIR  
OR REPLACE AS NECESSARY.  
NO  
DOES BLOWER SPIN FREELY?  
YES  
CHECK 115V SUPPLY,  
CONNECTION FUSES,  
SERVICE SWITCH AND  
DOOR SWITCH.  
IS THERE 115V  
SUPPLIED TO MOTOR?  
NO  
YES  
DISCONNECT 16 PIN  
HARNESS FROM  
MOTOR. IS THERE 12VDC  
ACROSS PIN12 & PIN1  
AND PIN12 & PIN3  
IS THERE 24VAC  
ACROSS R &  
B/C ON THE  
INTEGRATED  
CONTROL?  
NO  
NO  
CHECK 24VAC  
TO INTEGRATED CONTROL.  
AT THE HARNESS PLUG?  
YES  
DISCONNECT 16PIN  
HARNESS FROM  
INTEGRATED CONTROL.  
IS THERE 12VDC ACROSS  
NO  
REPLACE  
INTEGRATED  
CONTROL.  
PIN 6 & PIN 1  
YES  
AT THE CONROL?  
YES  
CHECK HARNESS  
CONNECTIONS  
AND WIRE.  
TURN THERMOSTAT MANUAL FAN  
SWITCH ON (IF AVAILABLE) OR JUMPER  
CHECK CONNECTIONS AND WIRES  
AT INTEGRATED CONTROL, IF OK  
REPLACE INTEGRATED CONTROL.  
NO  
BETWEEN R & G ON INTEGRATED CONTROL.  
IS THERE VOLTAGE GREATER THAN  
12VDC 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 MOTOR.  
10  
 
All installations and services must be performed by qualified service personnel.  
Yes  
Sequence of Operation  
BLOWER Off-  
Delay Active?  
No  
Yes  
Yes  
Yes  
Yes  
HEAT  
Mode On?  
On-Delay  
Ended?  
W
Active?  
LIMIT  
Active?  
No  
No  
No  
No  
1.BURNER Off  
2. HEAT mode Off  
BURNER On  
3. BLOWER Off-Delay Started  
4. Status LED Off  
Yes  
Yes  
Y
Yes  
Yes  
DEHUM  
Active?  
COOL  
Mode On?  
On-Delay  
Ended?  
BLOWER  
= LOW  
Active?  
No  
No  
No  
No  
BLOWER = COOL  
1. A/C Off  
2. COOL mode Off  
3.BLOWER Off-Delay Started  
4. Status LED Off  
Yes  
Yes  
FAN Mode  
On?  
G
BLOWER = LOW  
Active?  
No  
No  
1. BLOWER Off (No Delay)  
2. Status LED Off  
Yes  
Yes  
LIMIT  
Active?  
1. HEAT mode On  
2. BLOWER = HEAT  
3. Status LED Flashes  
No  
W Active?  
1. HEAT mode On  
2. Blower On-Delay Started  
3. Burner On  
4. Status LED On (continuous)  
No  
1. COOL mode On  
2. Blower On-Delay Started  
3. Condenser On  
Yes  
Yes  
Y Active?  
No  
4. Status LED On (continuous)  
1. FAN mode On  
2. BLOWER = LOW  
G Active?  
3. Status LED On (continuous)  
No  
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 & 3 of SW1 (CFM tables on page 6)  
COOL - The Cooling Blower speed selected by positions 4, 5 & 6 of SW1 (CFM tables on page 6)  
LOW - The LOW Blower speed selected by positions 4, 5 & 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  
115VAC 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  
 

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