GMV9, and GCV9
GMV9 Two-Stage Variable-Speed GCV9
Heating Capacity
Model
Hi-Fire
Lo-Fire
(thousand btu/h)
(thousand btu/h)
Input
GMV90703B
GMV90904C
GMV91155D
GCV90704C
GCV90905D
Output
70 66.9
90 88.8
115 111.1
70 65.3
90 86.5
Input
Output
48
64
80
48
64
46.4
61.7
77.4
45
60.1
GMV9 Two-Stage Variable-Speed GCV9
Cooling Capacity
Model
GMV90703B
GMV90904C
GMV91155D
GCV90704C
GCV90905D
Hi-Stage Cooling
1.5 2.0 2.5 3.0
1.5 2.0 2.5 3.0 3.5 4.0
1.5 2.0 2.5 3.0 3.5 4.0 5.0
1.5 2.0 2.5 3.0 3.5 4.0
1.5 2.0 2.5 3.0 3.5 4.0 5.0
Supports a wide range of Cooling requirements
GMV9 Two-Stage Variable-Speed GCV9
VENT TERMINATION CLEARANCES
GMV9 Two-Stage Variable-Speed GCV9
STANDARD CONNECTIONS
GMV9 Two-Stage Variable-Speed GCV9
VERTICAL TERMINATIONS
(DUAL PIPE)
GMV9 Two-Stage Variable-Speed GCV9
STANDARD HORIZONTAL
TERMINATIONS
GMV9 Two-Stage Variable-Speed GCV9
ALTERNATE HORIZONTAL
VENT TERMINATIONS
GMV9 Two-Stage Variable-Speed GCV9
TERMINATIONS ABOVE
ANTICAPATED SNOW LEVEL
GMV9 Two-Stage Variable-Speed GCV9
HORIZONTAL CONNECTIONS
(RIGHT SIDE DOWN)
GMV9 Two-Stage Variable-Speed GCV9
HORIZONTAL CONNECTIONS
(LEFT SIDE DOWN)
GMV9 Two-Stage Variable-Speed GCV9
TUBE INSTALLATIONS /
GREEN HOSES
GMV9 Two-Stage Variable-Speed GCV9
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
GMV9 Two-Stage Variable-Speed GCV9
THEMOSTAT WIRING
GMV9 Two-Stage Variable-Speed GCV9
Thermostat wiring
GMV9 Two-Stage Variable-Speed GCV9
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
GMV9 Two-Stage Variable-Speed GCV9
GAS PRESSURE
ADJUSTMENTS
GMV9 Two-Stage Variable-Speed GCV9
MANIFOLD GAS PRESSURE
GMV9 Two-Stage Variable-Speed GCV9
Induced-Draft Blower
• Jackel 2-speed blower assembly
• Motor suspended on four motor mounts for vibrationfree operation
• Factory-installed rubber discharge makes venting a
snap
• Alternate flue/vent through RIGHT side with GMV9
and LEFT side for GCV9
Air flow
GMV9 Two-Stage Variable-Speed GCV9
Electronic Controls
GMV9 Two-Stage Variable-Speed GCV9
Integrated Control Board
16-pin connector
(ECM Motor)
3 amp Fuse
Green CFM LED
12-pin connector
(Diagnostics)
24V Terminal block
D-hum,W2,W1,R,G,B,Y,YLO,O
Yellow
Dehumidification LED
ICM
Microprocessor
Red Diagnostic
LED
5-pin connector
(inducer/ignitor)
Hot Connections
Neutral Connections
(Line, XFMR, EAC, HUM)
(Line, XFMR, EAC, HUM)
GMV9 Two-Stage Variable-Speed GCV9
Single-stage Thermostat?
Set dip switch #3
Off = 5 minutes
On = 10 minutes
Then
Move this jumper
to the left
Easily converted from 2-stage to 1-stage T-stat operation
GMV9 Two-Stage Variable-Speed GCV9
Accessories Supported
•
•
•
•
Dehumidistat (Yellow LED indicator)
115-volt Humidifier (1 amp @ 120 volts)
115-volt EAC (1 amp @ 120 volts)
24-volt Humidifier
GMV9 Two-Stage Variable-Speed GCV9
CFM LIGHT
Green Light On The Bottom Right Side
Of The Board
1 Blink For Every 100 CFM
GMV9 Two-Stage Variable-Speed GCV9
Start-Up Procedure
1 Connect
115
power, proper
grounding and
polarity
2
3 Follow
I&O
procedure for
natural or LP
gas
4 Refer
5 Determine
6
7 Adjust
8 Turn
Continuous
flash indicates
reverse
polarity
correct
system
cooling cfm
Green cfm
LED flashes
once per 100
cfm
9 Verify
10
new
cfm with
green LED
Select
cooling speed
with dips
1,2,3, & 4
to
Spec Sheet
for correct
cfm/temp rise
blower speed
using ICM dip
switches
off
power for 10
sec after each
adjustment
11 Select
12 Select
desired ramp
profile with dip
5&6
heating speed
with dip 7 & 8
GMV9 Two-Stage Variable-Speed GCV9
Adjusting the Proper CFM Setting
GMNTE060-3
HEATING
BLOWER SPEED TAP
Low Stage
A
B
C
D
COOLING / HP
High Stage
CFM
Temp
Rise
CFM
Temp
Rise
-
558
0
804
0
Norm
+
620
682
0
0
893
982
-
639
0
Norm
+
710
781
-
Tons
of AC
CFM
Low
Stage
High
Stage
---
351
540
0
0
1.5
---
390
429
600
660
920
0
---
468
720
0
0
1022
1125
0
0
2.0
---
520
572
800
880
720
0
1037
0
---
585
900
Norm
+
800
880
0
0
1152
1267
0
0
2.5
---
650
715
1000
1100
-
801
0
1153
0
---
702
1080
Norm
+
890
979
0
0
1282
1410
0
0
3.0
---
780
858
1200
1320
GMV9 Two-Stage Variable-Speed GCV9
Select Cooling Speed
Cool Tap
Find proper cooling tap in
PDB based on ~400 cfm/ton
Adjust Tap
SW1
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
Test
GMV9 Two-Stage Variable-Speed GCV9
Select Auto-Comfort Profile
Profile
Select Profile D for
Auto-Comfort Mode
SW5
SW6
Tap
Off
Off
A
On
Off
B
Off
On
C
On
On
D
GMV9 Two-Stage Variable-Speed GCV9
Select Heating Speed
Heat Tap
Select slowest heating speed possible
while maintaining temp rise for
minimum energy usage
SW7
SW8
Tap
Off
Off
A
On
Off
B
Off
On
C
On
On
D
GMV9 Two-Stage Variable-Speed GCV9
Select Heat-Off Delay
Heat-Off Delays
SW1 SW2 Sec.
On
On
60
Off
On
90
On
Off
120
Off
Off
150
GMV9 Two-Stage Variable-Speed GCV9
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
GMV9 Two-Stage Variable-Speed GCV9
SEQUENCE OF OPERATION
Heating
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
GMV9 Two-Stage Variable-Speed GCV9
SEQUENCE OF OPERATIONS
Heating
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
GMV9 Two-Stage Variable-Speed GCV9
Troubleshooting
Flash Pattern
LED Off/Operation
LED Off/No Operation
LED On
1 Flash
2 Flashes
3 Flashes
4 Flashes
5 Flashes
6 Flashes
7 Flashes
8 Flashes
9 Flashes
Continuous Flash
Status Indication
No 115 volt or 24 volt Power
No 115 volt or 24 volt Power
Normal Operation
Lockout due to excessive retries
Pressure Switch stuck closed
Pressure Switch stuck open
Primary or Auxilliary high-limit
Flame sense without call for heat
Open rollout
Low flame signal
Check igniter or improper grounding
Hi Stage Pressure Switch open
Reversed polarity of 115 vac
GMV9 Two-Stage Variable-Speed GCV9
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
GMV9 Two-Stage Variable-Speed GCV9
Understanding ECM Motors
What does ECM mean?
Electrically Commutated Motor
GMV9 Two-Stage Variable-Speed GCV9
How Does the ECM Work?
AC POWER
POWER
CONDITIONING
AC TO DC
CONVERTER
POWER
INVERTER
ECM
MOTOR
HVAC SYSTEM CONTROL
INPUTS
24VAC
Compressor
On/Hi/Lo
Fan On
Rev Valve
Aux/Emerg Heat
Capacity Select
MOTOR
CONTROL
Available Outputs
CFM
GMV9 Two-Stage Variable-Speed GCV9
How Does the ECM Sense
Static Pressure?
Input Power vs. RPM
550
500
Input Power (watts)
450
400
P = kN^3
350
1/2 N = 1/8 P
300
1/8 X 280W = 35W
1000 RPM
280 Watts
250
200
500 RPM
35 Watts
150
100
50
0
250
300
350
400
450
500
550
600
650
700
750
800
850
900
950 1000 1050 1100 1150
RPM
GMV9 Two-Stage Variable-Speed GCV9
ECM Advantages
 Efficiency gain
System Pressure (Pr)
0.8
PSC
ECM
0.6
0.4
408W
745W
0.2
0.0
0
1
2
3
4
5
6
7
CFM/ Watt
Lower static pressure yields greater efficiency gain
GMV9 Two-Stage Variable-Speed GCV9
ECM Advantages
 Static-independent Airflow
Set the airflow and go!
0.8
PRESSURE
0.7
System airflow is starved
0.6• insufficient cooling/heating
• liquid refrigerant return
0.5 to condenser
Over blowing the system
• poor moisture removal
• high power consumption
• moisture in the duct work
0.4
Typical profile with a PSC motor
0.3
0.2
408W ®
745W ®
0.1
0
1300
1400
1500
1600
1700
1800
1900
2000
2100
2200
2300
2400
Airflow (CFM)
GMV9 Two-Stage Variable-Speed GCV9
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 Connector
Motor Section
End Bell Assembly
GMV9 Two-Stage Variable-Speed GCV9
Service and
Installation
Basics
GMV9 Two-Stage Variable-Speed GCV9
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
Low Voltage
High Voltage
16 PIN
CONNECTOR
5 PIN
CONNECTOR
GMV9 Two-Stage Variable-Speed GCV9
Power Connectors Continued
5 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
16 Pin Signal Connector
• Pulse Width Modulation (PWM) or
• 24 VAC Thermostat Mode or
• Digital Serial Interface (DSI)
Operating Voltages Application Note
GMV9 Two-Stage Variable-Speed GCV9
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.
GMV9 Two-Stage Variable-Speed GCV9
Troubleshooting ECM Motors
Don’t judge the motor by the RPM or
ramp up sequence.
off
All slew rates are controlled
Profile A
Profile B
Profile C
on
Pre-run
Short
run
Full
capacity
Off
Delay
Time: 0 - 15 min, 16 steps
Level: 6 - 100% 16 steps
GMV9 Two-Stage Variable-Speed GCV9
Troubleshooting ECM Motors
The # 1 failure of ECM
motors…………… No Fault Found !
(80%)
The # 2 failure of ECM Motors
…………… Moisture. (16%)
All other failures (4%).
GMV9 Two-Stage Variable-Speed GCV9
Troubleshooting ECM Motors
• 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.
Drip Loop
Electrical Connections on Bottom
GMV9 Two-Stage Variable-Speed GCV9
Troubleshooting ECM Motors
There are some ECM
motor testers on the
market today.
GMV9 Two-Stage Variable-Speed GCV9
GE TECMateXLTM Service Tool
 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.
GMV9 Two-Stage Variable-Speed GCV9
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
TECMate
120V or
240V AC
Power
ECM Motor
GMV9 Two-Stage Variable-Speed GCV9
GE TECMateXLTM Service Tool Continued
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 shutoff 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.
GMV9 Two-Stage Variable-Speed GCV9
Ultimate Comfort Setup Guidelines
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
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.
GMV9 Two-Stage Variable-Speed GCV9
Replacing the ECM Control Module Continued
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).
Final installation check. Ensure the system is setup as follows:
11.
(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.
Line Transient Voltage Protection Application Note
GMV9 Two-Stage Variable-Speed GCV9
Troubleshooting ECM Motors
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.
GMV9 Two-Stage Variable-Speed GCV9
Troubleshooting ECM Motors
 Rule # 4 - ECM motors, like any motor must
have a power supply. Check the incoming
power supply.
Inductor
5
4
3
2
1
AC Line
AC Line
I
}V
Gnd
} Pin 1 & 2 must be connected together for 120Vac input applications
Power Connector
(viewed from plug end)
Inductor is used on ¾ & 1 hp – 120 VAC applications only.
GMV9 Two-Stage Variable-Speed GCV9
TSTAT Connections
Pin number
9
10
111
21
31
41
51
6
Control
(male)
1
2
3
4
5
6
7
8
Connector
(female)
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 +
GMV9 Two-Stage Variable-Speed GCV9
Troubleshooting ECM Motors
 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.
Out
Adjust +/-
8
7
16
15
Out +
G(fan)
Y1
Cool
6
5
14
13
Y /Y2
EM Ht/W2
Delay
Common 2
W /W1
4
3
2
12
11
10
24VAC (R)
Common 1
1
9
Heat
BK/PWM (Speed)
(Rev Valve)
Control Connector Cable Half
(viewed from connector end)
GMV9 Two-Stage Variable-Speed GCV9
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.
Out
Adjust +/-
8
7
16
15
Out +
G(fan)
Y1
Cool
6
5
14
13
Y /Y2
EM Ht/W2
Delay
Common 2
W /W1
4
3
2
12
11
10
24VAC (R)
Common 1
1
9
Heat
BK/PWM (Speed)
(Rev Valve)
Control Connector Cable Half
(viewed from connector end)
GMV9 Two-Stage Variable-Speed GCV9
Troubleshooting ECM Motors
 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.
Out
Adjust +/-
8
7
16
15
Out +
G(fan)
Y1
Cool
6
5
14
13
Y /Y2
EM Ht/W2
Delay
Common 2
W /W1
4
3
2
12
11
10
24VAC (R)
Common 1
1
9
Heat
BK/PWM (Speed)
(Rev Valve)
Control Connector Cable Half
(viewed from connector end)
GMV9 Two-Stage Variable-Speed GCV9
Troubleshooting ECM Motors
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
GMV9 Two-Stage Variable-Speed GCV9
any questions?
Thank you!
GMV9 Two-Stage Variable-Speed GCV9