Titus G3 PWM BOARD Manuel utilisateur

G3 PWM BOARD

The Titus “Generation 3 PWM” (G3 PWM) board provides a pulse-width modulated (PWM) signal to the EC motor to control fan speed. The

board is factory programmed to control the motor in either Three Speed (adjustable) mode or Proportional Control using a remote 2 – 10

V DC input signal. In Proportional Control mode, a 2 – 10 V DC signal will control EC motor speed between factory set minimum (Min) and

maximum (Max) values. For either control mode, fan on/off control is enabled via the ‘G’ signal.

PWM BOARD STATUS LED

The G3 PWM Status LED (refer to Figure 1) indicates the status of the G3 PWM board. See Table 1, below.

TABLE 1 - G3 STATUS LED DEFINITION

Flash Mode Indicates

Yes Run Normal

Yes Program Timed Out

Always On Run Error

Always On Program Program Mode

Always Off Any Fault

Tools Needed:

• Digital multimeter capable of measuring 30 volts AC/DC and duty cycle

• Insulated 1/8” flat bladed screwdriver

• Mini Hook Test Clips for multimeter (optional)

Fan Coil EC Motor Control

G3 PWM Status Descriptions

Normal - (Run mode) - If configuration switch 1 is in Run Mode (OFF) the LED will flash to indicate Normal status.

Timed Out - (Program Mode) - The PWM board has a time out function in Program Mode. If the PWM board has timed out in Program

Mode, the LED will flash. Time Out may be cleared by pushing the Reset Button.

Error - (Run Mode) - If configuration switch 1 is in Run mode (OFF) and the LED is always ON, there is a system error. Verify all connections

and proper input voltage at Line and Com, then push the Reset Button. If this fails to return the board to Normal mode, replace the board.

Program Mode - If configuration switch 1 is in Program Mode (ON) the LED will be always ON to indicate that the board is in Program

Mode. See Figure 2, below.

NOTE: While in Program Mode, the fan motor will not run.

Fault - (Any mode) - If the LED remains OFF, the board either has no power or is faulted. Verify proper input voltage at Line and Com, then

push the Reset Button. If this fails to return the board to expected mode, replace the board.

BALANCING UNITS WITH EC MOTORS

ELECTRICAL SHOCK HAZARD. All power must be disconnected prior to installation and servicing this equipment. More than one source of

power may be present. Disconnect all power sources to avoid electrocution or shock injuries. Refer to lock out tag out procedures.

1. Make sure there are no obstructions in the discharge ductwork and/or at the plenum opening.

2. Locate the G3 PWM board in the control enclosure. Refer to Figure 1 for location of test points TP3 and TP1, the Configuration

Switch, Speed Adjust Potentiometer, and Reset Button.

3. Place Configuration Switch into Program Mode. Use an insulated screwdriver to flip configuration switch #1 (closest to speed

adjust potentiometer) to the ON position. See Figure 2.

4. Press Reset button. Connect a voltmeter to test points TP1 (-) and TP3 (+). Refer to Figure 1. Set voltmeter to DC volts.

NOTE: The PWM board must be in Program Mode to read voltage across TP1 and TP3.

Fan Coil EC Motor Control

5. Apply power to the unit. Verify that the status LED is Always On, indicating that the PWM board is in Program Mode. If the status

LED blinks while in Program Mode, the board has timed out. In this case, push the reset button and verify the status LED returns to

Always On.

NOTE: The PWM board times out in Program Mode after approximately 5-6 minutes and will need to be reset by pushing the reset

button. If more time is needed to verify correct airflow, perform the STORE operation (through switch 8) after adjustment to save the

adjusted fan speed.

6. Determine desired fan operating points. Refer to the Fan Calibration Curve label supplied on the side of the equipment. There are

two different styles of Fan Calibration Curve, depending on EC motor type.

NOTE: The Fan Calibration Curve provided with the unit represents response for a unit with typical configuration. Actual airflow may

vary slightly depending on actual system configuration.

a. Constant RPM and Constant Torque EC Motor. Refer to Figure 3a for sample label. Five curves are shown, showing factory default

airflow for Minimum, Low, Medium, High, and Maximum speeds. A table is provided which shows the expected voltage across test

points TP1 and TP3 for each speed, depending on whether the unit is set up for three speed or 2 – 10 VDC motor control.

b. Constant Airflow EC Motor. Refer to Figure 3b for sample label. Several curves are shown on the label, one for each size unit. Refer

to the 0 to 2.5 volt scale on the label and use the voltmeter to read the voltage across TP1 and TP3 to determine desired airflow

setting.

NOTE: Changing the factory setting for minimum and maximum CFMs will invalidate the range for the Fan Calibration Curve as it

will narrow the scale of the input signal.

7. Follow instructions for adjusting EC motor speed using the G3 PWM board. Separate instructions are provided for Three Speed

(adjustable) and 2 – 10 VDC Proportional motor control modes.

Fan Coil EC Motor Control

Adjusting EC Motor Speed

This section contains instructions for using the G3 PWM board to adjust the EC motor speed for balancing

purposes. There are two modes of EC motor speed control: Three Speed operation at three fixed (adjust-

able) speeds, or Proportional Control with remote 2 – 10 VDC signal.

Warning! For units with electric heat, fan speed must not be adjusted below 70 CFM/kW.

Refer to Figure 1 for location of configuration switch, speed adjust potentiometer, and reset button. These

will be used to program the EC operating mode and motor speed settings.

THREE SPEED (ADJUSTABLE) MOTOR CONTROL

High, Medium, and/or Low speed adjustment for three speed operation.

NOTE: Thermostat must be set for three speed operation

1. High Speed Setting Adjust: Set Configuration Switch to HIGH SPEED adjust (see figure A at left.)

Switches to ON-OFF-ON-OFF-OFF-OFF-OFF-OFF.

• Set switch 1 to ON (Program)

• Set switch 2 to OFF (Fixed Speed)

• Set switch 3 to ON (Hi/Max)

• Set switches 4 through 8 to OFF

• Press RESET button. (Note: RESET button only needs to be pressed once per programming session unless board

times out. Refer to Status LED.)

• Refer to voltmeter connected to TP1 and TP3. Using an insulated 1/8” flat bladed screwdriver, adjust speed poten-

tiometer to desired high speed airflow per Fan Calibration Curve on unit.

• STORE: Set switch 8 to Store (ON), wait one second, then to Set (OFF), to save the value

2. Medium speed Adjust: Set Configuration Switch to MEDIUM SPEED adjust (see figure B at left.)

Switches to ON-OFF-OFF-ON-OFF-OFF-OFF-OFF.

• Set switch 1 to ON (Program)

• Set switches 2 -3 to OFF

• Set switch 4 to ON (Med)

• Set switches 5 through 8 to OFF

• Refer to voltmeter connected to TP1 and TP3. Using an insulated 1/8” flat bladed screwdriver, adjust speed poten-

tiometer to desired high speed airflow per Fan Calibration Curve on unit.

• STORE: Set switch 8 to Store (ON), wait one second, then to Set (OFF), to save the value

3. Low Speed Adjust: Set Configuration Switch to LOW SPEED adjust (see figure C at left.)

Switches to ON-OFF-OFF-OFF-ON-OFF-OFF-OFF

• Set switch 1 to ON (Program)

• Set switches 2 -4 to OFF

• Set switch 5 to ON (Lo/Min)

• Set switches 6 through 8 to OFF

• Refer to voltmeter connected to TP1 and TP3. Using an insulated 1/8” flat bladed screwdriver, adjust speed poten-

tiometer to desired high speed airflow per Fan Calibration Curve on unit.

Fan Coil EC Motor Control

• STORE: Set switch 8 to Store (ON), wait one second, then to Set (OFF), to save the value

4. Resume Normal Three Speed Operation: Set all switches to OFF to resume normal three

speed operation. Refer to figure D at left.

2 – 10 VDC PROPORTIONAL MOTOR CONTROL

Speed range adjustment for Proportional Control operation. Minimum (Min) and maximum (Max) speeds

are programmed at the factory for optimum operation. Changing factory Min or Max speed defaults will

change the motor effective speed range and invalidate the voltage settings shown on the Fan Calibration

Curve. However, the speed range may still be adjusted as long as the Min speed remains greater than 70

CFM/kW for units with electric heat.

NOTE: Thermostat must be set for either analog or single (high) speed operation.

1. Connections. Connect or verify connection of remote analog signal and common wires to 2-10 VDC

Remote Control Input terminals (refer to Figure 1.)

2. Set Mode to 2 – 10 VDC Proportional Control: Set configuration switches to 2 – 10 ANALOG program-

ming mode (see figure E at left.) Switches to ON-ON-OFF-OFF-OFF-ON-OFF-OFF.

• Set switch 1 to ON (Program)

• Set switch 2 to ON (Analog)

• Set switches 3 – 5 to OFF

• Set switch 6 to ON (2-10 V)

• Set switches 7 and 8 to OFF

• Press RESET button. (Note: RESET button only needs to be pressed once per programming session unless board

times out. Refer to Status LED.)

• STORE: Set switch 8 to Store (ON), wait one second, then to Set (OFF), to save the value.

NOTE: If adjusting Min/Max CFM values, continue to step 3. Otherwise, skip to step 5.

3. Max Speed Adjust: Set configuration switches to HI/MAX SPEED balancing mode (see figure F at left.)

Switches to ON-ON-ON-OFF-OFF-ON-OFF-OFF.

• Set switch 1 to ON (Program)

• Set switch 2 to ON (Analog)

• Set switch 3 to ON (Hi/Max)

• Set switches 4 and 5 to OFF

• Set switch 6 to ON (2-10 V)

• Set switches 7 and 8 to OFF

• Refer to voltmeter connected to TP1 and TP3. Using an insulated 1/8” flat bladed screwdriver, adjust speed poten-

tiometer to desired Max speed airflow.

• STORE: Set switch 8 to Store (ON), wait one second, then to Set (OFF), to save the value

4. Min Speed Adjust: Set configuration switches to LO/MIN SPEED balancing mode (see figure G at left.)

Switches to ON-ON-OFF-OFF-ON-ON-OFF-OFF

• Set switch 1 to ON (Program)

• Set switch 2 to ON (Analog)

• Set switches 3 and 4 to OFF

• Set switch 5 to ON (Lo/min)

Fan Coil EC Motor Control

• Set switch 6 to ON (2-10 V)

• Set switches 7 and 8 to OFF

• Refer to voltmeter connected to TP1 and TP3. Using an insulated 1/8” flat bladed screwdriver, adjust

speed potentiometer to desired Min speed airflow.

• STORE: Set switch 8 to Store (ON), wait one second, then to Set (OFF), to save the value

5. Resume Normal 2 – 10 V DC Proportional Control: Set configuration switches to OFF-ONOFF-

OFF-OFF-ON-OFF-OFF for normal proportional speed control, as shown at left in figure H.

• Set switch 2 to ON (Analog)

• Set switch 6 to ON (2 – 10)

• Set all other switches to OFF

EC Motor Troubleshooting Guidelines

Ensure motors and blowers are clean as part of normal maintenance. No further maintenance is required for these motors. Warning! Follow

standard lock out tag out (LOTO) procedures when performing service on motor or blower.

EC MOTOR TROUBLESHOOTING GUIDELINES

Problem Possible Cause Corrective Action

Motor fails to start

No or loose enable jumper (Big Best manufactured

constant RPM motor only)

Verify enable jumper connected properly to motor

driver. Refer to “Enable Jumper” section (page 12).

No power to motor. Possible blown fuse

or open circuit breaker

Verify line voltage at motor driver. Replace fuse or

reset circuit breaker.

PWM configuration switch in program

mode

Configuration switch 1 must be in Run mode (page

2, figure 2). Refer also to PWM board status LEDs

(page 1).

PWM board faulted

Refer to PWM board status LEDs (page 1). Verify

voltage input, wiring and connections. Push reset

button. Replace PWM board if fault returns.

No control signal (constant RPM)

Constant RPM EC motors will not rotate if they

lose PWM signal while enabled.

Verify PWM signal at motor connector by connect-

ing a multimeter set for “duty cycle” between pins

1P1 and 1C (or between pins 2P1 and 2C). The duty

cycle represents the on-time percentage signal sent

to the motor (this number will vary between the

minimum and maximum duty cycle set by the facto-

ry). See Figure 1 for PWM board connections (page

1). Refer also to PWM board status LEDs (page 1) to

verify board is in normal operating mode.

Improper wiring connections

Verify wiring. If Fan Coil Relay board present, verify

all jumpers installed. Refer to Fan Coil Relay Board

Troubleshooting Guide.

EC motor wiring harness improperly seated Unplug harness and re-install, making sure plugs

are fully seated.

EC motor wiring harness(es) open or intermittent Replace harness(es). See section on checking wire

harnesses (page 9).

Blower jammed Clear blockage. Verify blower rotates freely with

motor disconnected.

No 24 VAC power Refer to Fan Coil Relay Board Troubleshooting

Guide

Fan Coil EC Motor Control

EC MOTOR TROUBLESHOOTING GUIDELINES

Problem Possible Cause Corrective Action

Motor fails to start

Float switch tripped Verify float switch (if present) is made.

Motor seized Verify motor rotates freely by hand with blower

disconnected. If not, replace motor.

Damaged motor cable Cable is integral to motor, replace motor

Motor surges

Fan speed adjustment outside operating

range

Refer to Fan Calibration curve on unit. Adjust

speed on PWM Controller to value that will allow

motor to start. See instructions for Adjusting EC

Motor Speed (pages 4-5).

Blower Set Screw loose Tighten Screw onto motor shaft.

ESP (external static pressure) too high

Verify dampers, if present, are not closed. Verify

there are no obstructions in the discharge ductwork

and/or at the plenum opening. Verify filter is not

dirty and does not obstruct airflow.

Poor performance

Lack of required external static pressure Add required external static pressure

Speed adjustment outside fan operating

range

Refer to Fan Calibration curve on unit. Adjust

speed on PWM Controller to value that will allow

motor to start. See instructions for Adjusting EC

Motor Speed (pages 4-5).

Erratic speed command (in Proportional

Control mode)

Verify 2-10V analog signal at Remote Control

Input terminals.

Damaged or blocked blower Verify blower rotates freely. Clear blockage

Motor starts but stops

Voltage or ground loss at motor driver

Verify proper voltage and ground at motor driver

power terminals. Refer to Motor Driver

Connections for the EC motor.

Motor overloaded - blower binding Clear blockage. Verify blower rotates freely with

motor disconnected.

Motor overloaded

Use amp meter to verify motor amps. Verify motor

rotates freely with power disconnected. If not,

replace motor

Open ductwork for concealed units Verify ducts sealed properly

Motor overheated due to lack of airflow

Verify dampers, if present, are not closed. Verify

there are no obstructions in the discharge ductwork

and/or at the plenum opening. Verify filter is not

dirty and does not obstruct airflow

PWM board error or faulted

Refer to PWM board status LEDs (page 1). Verify

all connections. Push reset button. Replace board if

fault returns

Motor driver failure Replace motor (Constant airflow or constant torque

motors.) Replace driver (Constant RPM motor.)

Damaged motor cable Cable is integral to motor, replace motor

Fan Coil EC Motor Control

EC MOTOR TROUBLESHOOTING GUIDELINES

Problem Possible Cause Corrective Action

Motor speed cannot be adjusted

PWM board error or faulted

Refer to PWM board status LEDs (page 1). Verify

all connections. Push reset button. Replace board if

fault returns

Improper wiring connections Verify wiring. If Fan Coil Relay board present,

verify all jumpers installed.

EC wiring harness damaged or improperly seated

Unplug harness and re-install, making sure plugs

are fully seated. See section on checking wire

harnesses, below. Replace harness if damaged.

No control signal (constant airflow and

constant torque)

Constant airflow and constant torque EC motors

will run at idle speed if they lose PWM signal while

enabled.

Verify PWM signal at motor connector by connect-

ing a multimeter set for “duty cycle” between pins

1P1 and 1C (or between pins 2P1 and 2C). The duty

cycle represents the on-time percentage signal sent

to the motor (this number will vary between the

minimum and maximum duty cycle set by the facto-

ry). See Figure 1 for PWM board connections (page

1). Refer also to PWM board status LEDs (page 1) to

verify board is in normal operating mode

ESP (external static pressure) too high

Verify dampers, if present, are not closed. Verify

there are no obstructions in the discharge ductwork

and/or at the plenum opening. Verify filter is not

dirty and does not obstruct airflow.

Motor driver failure

Replace motor (constant airflow or constant torque

motors)

Replace driver (constant RPM motors)

Motor runs in reverse, doesn’t respond to

speed adjustment Motor driver failure

Replace motor (constant airflow or constant torque

motors)

Replace driver (constant RPM motors)

Excessive motor noise

Motor mounting bolts loose Tighten motor mounting bolts.

Motor bearing Replace motor

Motor overloaded

Use amp meter to verify motor amps. Verify motor

rotates freely with power disconnected. If not,

replace motor. Verify static pressure within limits

shown on Fan Calibration Curve on unit.

Fan wheel rubbing on fan housing Align wheel in housing.

Loose fan wheel Align and tighten.

Motor runs in G3 PWM Program mode but not in

Run mode Loose pin in Fixed Speed Conn. harness

Verify that the pins in the Fixed Speed Conn.

harness (see location in Figure 1 on Page 1) are

inserted fully

Fan Coil EC Motor Control

CHECKING EC WIRE HARNESSES

Use ohmmeter to verify that motor ground wire has continuity from motor case to ground.

To check signal wire harnesses:

 Remove power from the unit. Unplug signal harness at EC driver and from motor connector at PWM board.

 Use ohmmeter to check continuity for each conductor, then reconnect harnesses to driver and to PWM board.

To check power wire harness:

•  Refer to wiring diagram.

•  Remove power from the unit. Unplug power harness at EC driver.

•  Verify green wire has continuity to ground.

•  Unplug power wires from connections in electrical enclosure. Verify continuity of wires to motor driver, then reconnect to same terminals.

Before reconnecting power to unit, verify all harnesses are connected per diagram.

Use light force when inserting meter probe into plug. Excess force will damage contacts.

Fan Coil EC Motor Control

EC MOTOR AND DRIVER

Depending on application, fan coil units can use three control types for EC motors (both single and dual shaft):

• Constant RPM

• Constant Torque

• Constant Airflow

Constant Airflow/Constant Torque EC Motors

Constant CFM / Constant Torque EC Motor Driver Connections

Note that connections marked (n/u) are not used.

Signal Connector

Pin Description

1 C1 (n/u - com)

2 W/W1 (n/u)

3C2 (PWM COM)

4 DELAY (n/u)

5 COOL (n/u)

6 Y1 (n/u)

7 ADJUST (n/u)

8OUT-(PWM FB)

9 O (n/u)

10 PWM

11 HEAT (n/u)

12 R (n/u)

13 EM/W2 (n/u)

14 Y/Y2 (n/u)

15 G (Fan Enable)

16 OUT+ (PWM FB)

Power Connector

Pin Description

1Jumper pin 1 to 2 for 120

VAC Line Input only

3Chassis Ground

4AC Line (line 1)

5AC Line (Line 2, Neutral)

Fan Coil EC Motor Control

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