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Regal-Beloit GE ECM 2.3 Technical Manual Download Page 63

 

© 2006

 

GE ECM

 by Regal-Beloit

 

- 61 - 

Indoor Blower Motors 

v0.2

 

Replacing the Premium ECM Control Module 

 

Warning – You must have the correct replacement module. USING THE 
WRONG MODULE VOIDS ALL PRODUCT WARRANTIES AND MAY PRODUCE 
UNEXPECTED RESULTS.  
 
Warning – Disconnect AC power from the HVAC system and wait 5 minutes 
before opening the motor to avoid electrical shock from the motor’s 
capacitors.  

 

1.  Unplug the 5-pin connector and the 16-pin connector from the motor control. 
 
2.  Remove the blower assembly from the HVAC system.  

 

3.  Remove the two (2) 

hex-head screws from 
the back of the control.  

 
4.  Unplug the 3-pin 

connector from inside 
the control by 
squeezing the latch and 
gently pulling on the 
connector. 

 

5.  Ensure the motor 

module is not damaged 
by performing the two 
simple tests listed on 
page 65. 

 

 

Summary of Contents for GE ECM 2.3

Page 1: ...2006 GE ECM by Regal Beloit Indoor Blower Motors v 0 2 GE ECM by Regal Beloit ECM Indoor Blower Motors Premium Models 2 3 2 5 Standard Model X13 Technical Manual www theDealerToolbox com...

Page 2: ...e Line Voltage high voltage Power Connection 18 19 The Signal Cable low voltage Connection 20 22 Initial Set Up Modes of Operation 23 38 Thermostat Mode 23 33 PWM Pulse Width Modulation 34 36 DSI Dire...

Page 3: ...Improvement This is the current production blower motor for most OEM s using variable speed o Control Electronics and packaging redesign o Electronics encapsulated for moisture resistance o New motor...

Page 4: ...wer input on one motor Thermostat PWM or DSI control input 1 3 1 2 3 4 1 Hp options Airflow range 0 2400 CFM Premium ECM indoor blower motors are primarily found in multi stage premium systems However...

Page 5: ...2006 GE ECM by Regal Beloit 3 Indoor Blower Motors v0 2 ECM vs PSC Why is the Premium ECM motor so much better than a PSC induction motor ECM PSC...

Page 6: ...w can lead to numerous and expensive repairs Tripping limits cause the electronic controls to cycle more reducing longevity Overheated heat exchanges expand and contract more often putting more stress...

Page 7: ...essure increases By design that s all it can do The ECM motor is designed to maintain constant airflow throughout a wide range of pressures typically from 1 to 9 in wc PSC motor charts are typically l...

Page 8: ...pm However it can only run at the rated rpm to make the designed airflow if the static pressure is also at the design rating Without the ability to add power and increase the speed of the motor it sim...

Page 9: ...r of the HVAC system the motor is taught the relationship between speed torque airflow and external static pressure In these tests or airflow characterization process a development engineer will adjus...

Page 10: ...are selecting the exact CFM designed by the OEM for the demand Example of airflow tables Airflow for all demands and comfort options is easily selected and perfectly matched to the system 2nd Stage CF...

Page 11: ...stem to maintain airflow even if the pressure changes So how does the motor know when the pressure has changed This one can get complicated so let s keep it simple We will stick with the above chart L...

Page 12: ...registers and return grills where the air enters the home In the continuous fan mode and 1st stage operations of two stage equipment this noise is almost unnoticeable in most cases This will obviously...

Page 13: ...e equipment and first stage runs at a lower airflow That means the motor is going to run more as well The big savings comes at the continuous constant fan setting With constant fan being utilized more...

Page 14: ...y the manufacturer Use deep pleated low pressure drop high efficiency filters sized to the proper CFM Because of the ECM motor s reputation for constant airflow over a wide range of static pressure to...

Page 15: ...AC power to DC power The motor control also decides at what speed RPM and torque to operate the motor to obtain and maintain the desired airflow The amount of airflow desired is communicated to the m...

Page 16: ...o maintain the selected CFM profile The Microprocessor constantly monitors motor speed RPM using sensor less technology GE ECM by Regal Beloit Premium ECM Motor 3 AC Motor Controls Convert DC To 3 AC...

Page 17: ...ROM o ASIC o 3 Inverter o Rotor Position Feedback Control Power conditioning module o EMI Electro Magnetic Interference Filter o Rectifiers o Capacitor Filter Stator Permanent magnet rotor Microcomput...

Page 18: ...rough bolt construction Inslot Salient wound o Each pole is individually wound o Less wasted copper Available in a closed partial or fully vented shell Rotor Construction ECM Rotor Three Iron Ferrite...

Page 19: ...rmation the motor control knows when to change phases and what the actual rpm or speed of the motor is at any time This motor operates at synchronous speed meaning whatever frequency the phases are sh...

Page 20: ...voltage Power Connection Line voltage to this motor can be either 120vac or 240vac through the 5 pin power connector Caution with proper jumper connection The connector is keyed for proper connection...

Page 21: ...Nominal Voltage 120v Minimum Voltage 102v Maximum Voltage 138v Nominal Voltage 240v Minimum Voltage 204v Maximum Voltage 276v The motor control is connected to line voltage at all times as shown on th...

Page 22: ...lizing all or some of the pins depending on the mode of operation and the systems requirements The 2 3 motor communicates in one of two formats Thermostat Mode also used on model 2 0 motor PWM Pulse W...

Page 23: ...irflow and comfort settings is the key to proper operation comfort and efficiency Cooling Airflow Heating Airflow Trim Adjust Multipliers Climate delay Profiles Continuous Fan Humdistat Option Set up...

Page 24: ...the main control board The thermostat sends the 24vac demand heat cool continuous fan to the OEM control board The OEM control board sends the 24vac demand to the interface tap board The interface tap...

Page 25: ...rity The motor control can read these different signals and match them to a stored airflow or timing programmed into the motor per demand These functions are designed to convert one thermostat input i...

Page 26: ...elect ECM 2 0 2 3 Motor Control Interface Board 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 hea...

Page 27: ...Table 018 1 5 ton 600 CFM 024 2 ton 800 CFM 030 2 5 ton 1000 CFM 036 3 ton 1200 CFM 042 3 5 ton 1400 CFM 048 4 ton 1600 CFM 054 4 5 ton 1800 CFM 060 5 ton 2000 CFM The manufacturer s instructions cha...

Page 28: ...ment will significantly alter the systems performance Example of Airflow Table First stage heating airflow is typically a preset percentage of the selected heating airflow setting Benefits Option 1 o...

Page 29: ...t up properly Adjustments to this setting should only be made following the factory recommendations Benefits The trim setting is good for tailoring a system for specific comfort and dehumidification n...

Page 30: ...at up or cool down to eliminate unwanted hot or cold air blasts The profiles help to alleviate temperature extremes and noticeable temperature swings The desired temperature may be reached before airf...

Page 31: ...2006 GE ECM by Regal Beloit 29 Indoor Blower Motors v0 2 Climate Delay Profiles Shown here are the recommendations for cooling profiles in relationship to the humidity index map...

Page 32: ...that setting Conversely there may be a programmed amount of time once the cycle ends before the motor will come to a full stop There may even be step down levels in the off cycle depending on the pro...

Page 33: ...turn to normal when the set humidity level is satisfied Benefits Lower airflow across the cooling coil will remove more moisture by allowing it to condense on the coil and drain Lower humidity allows...

Page 34: ...idity is higher or lower than the set point The humidistat option is typically utilized in one of two ways Option 1 In this application a humidistat is used separate from the thermostat to break the s...

Page 35: ...constant airflow by responding to changes in duct pressure Another feature is the use of output information that the OEM can program for different options The most commonly used option is the CFM Dem...

Page 36: ...are used to select demand airflow delays de humidification option and continuous fan option There are no climate profiles in PWM mode The OEM can provide fixed and adjustable on and off delays A de hu...

Page 37: ...le D T 23 V Control Board Pin number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Connected to PWM common NC Connected to PWM common NC NC NC NC NC NC PWM signal NC NC NC NC Start Stop signal 9 23VDC NC Not...

Page 38: ...al duty cycle For Example 20 vdc is measure between terminals 3 and 15 value T 10 vdc is measure between terminals 3 and 10 value D The percentage of demand motor output or airflow would be 50 10 D 5...

Page 39: ...Starts Stop etc There are 2 leads for power 12VDC and 2 leads for communication 12 V 0 V 1000001 0011100 0001110 0 3 sec Command 1 12 VDC 2 GND 3 Transmit Receive 4 Transmit Receive 16 pin connector...

Page 40: ...e system and connected IAQ devices Airflow for OEM matched zoning systems can not only be tailored to the size of each zone but may be able to set itself up reducing time System to system wiring is ty...

Page 41: ...gged hard copy or download and print a free copy from our web site at www thedealertoolbox com Included in this guide are the following HVAC System Troubleshooting Basics Tech Tips Motor Identificatio...

Page 42: ...are being referenced keep this in mind When you call for technical assistance on a computer the technician on the other end of the phone is using a troubleshooting guide They could not possibly memori...

Page 43: ...fic settings required on the OEM board A quick look at the picture below will remind us of just how many system to system options there are including IAQ devices After the system wiring and set up are...

Page 44: ...o continue to run at the continuous fan airflow When checking low voltage always use the C terminal on the board never ground Some manufacturers may use a different letter to represent common other th...

Page 45: ...he proper airflow after any delays or profiles have ended then the problem may be restrictions in the air side of the HVAC system not the motor Check and clean or make the necessary adjustments as nee...

Page 46: ...we know that the wheel speed increases when pressure increases Checking the External Static Pressure ESP of the system should be done at the time of installation and is also a valuable troubleshootin...

Page 47: ...n wc However this recommendation may be different on air handlers and package systems Always follow the OEM s specification This information should be listed on the equipment data plate or in the fact...

Page 48: ...the return reading is taken in the return cabinet and the supply reading is taken in the cabinet after the blower If the filter is mounted directly on the cabinet and there is no access to the evapor...

Page 49: ...If this is the case the ESP reading would be taken at the return and supply connections depending on where the filter is and if it is also included in the rating Filters are also a common airflow rest...

Page 50: ...urer supplied and or recommended Follow the filter manufacturers guidelines and try to keep the filters pressure drop to less than 0 2 in wc unless the ductwork resistance is low enough to keep the ES...

Page 51: ...ng Contractors National Association standards Filters may need to be re sized if changed from what the manufacturer supplied and or recommended The Cost Factor Remember that good duct static will move...

Page 52: ...voltage inputs There is improper or no communication to the motor controller low voltage inputs This problem could be in the interface board or the low voltage connector The motor controller has faile...

Page 53: ...motor is not doing useful work is at rest Do not trust the blower door switch for power disconnection To avoid frequent arching of the door switch contacts use the main disconnect on any system with...

Page 54: ...ion requires the red jumper and the 240vac application must have this jumper removed The jumper may not always be red Standard meter leads test pins are typically larger than the terminals or sockets...

Page 55: ...hown 120vac AC Volts Com V 120vac AC Volts Com V 240vac AC Volts Com V 120vac AC Volts Com V 120vac AC Volts Com V Meter connected between Terminal 5 and 4 Meter connected between Terminal 5 and 3 Met...

Page 56: ...the motor may actually run but future damage and or operation problems could result o On the 240vac application the motor will be permanently damaged with high voltage on the voltage doubler circuit...

Page 57: ...unication to the motor controller telling it to run TECMate XL TECMate PRO 4 button 1 button 4 button w three position G switch Indoor Blower Motors TECMate XL TECMate PRO GE ECM Troubleshooter All ma...

Page 58: ...ove the 16 pin connector from the motor and connect the 16 pin connector from the TECMate to the motor Do not disconnect the 5 pin AC power connector from the motor However removing the 5 pin connecto...

Page 59: ...res are connected to 120vac or 240vac permanent damage may be done to the motor and the TECMate 4 Make sure the switch s on the TECMate are in the off position 5 Reconnect the AC power to the system T...

Page 60: ...uminate 6 Place the correct switches in the ON position and observe the motor for 15 seconds Refer to the table on the back of the TECMate XL for switch selections of the various test mode settings Ta...

Page 61: ...Place the switch in the ON position and the LED light on the switch should illuminate when connected properly to 24vac Observe the motor for 15 seconds Refer to the Table on the back of the TECMate PR...

Page 62: ...nd completely The next logical step is to check the low voltage communication on the 16 pin connector Whether the OEM is using Thermostat Mode or PWM this troubleshooting is going to require their flo...

Page 63: ...wait 5 minutes before opening the motor to avoid electrical shock from the motor s capacitors 1 Unplug the 5 pin connector and the 16 pin connector from the motor control 2 Remove the blower assembly...

Page 64: ...g the 16 pin connector and the 5 pin connector from the motor control Step 2 Remove the blower assembly from the HVAC system Step 4 Unplug the 3 pin connector from inside the control by squeezing the...

Page 65: ...hms on any one or more leads then replace the motor module with the equivalent If the motor module passes the resistance is greater than 100k ohms then perform Test B Tech Tip Analog or digital ohm me...

Page 66: ...or Fail next to each meter and under the motor number OL Ohms Com O Open Ohms Com O OL Ohms Com O Lead 1 to Ground Pass or Fail Motor 1 Pass or Fail Lead 2 to Ground Pass or Fail Lead 3 to Ground Pas...

Page 67: ...ould be less than 20 ohms Each lead to lead resistance should be the same within 10 If the measured resistance is outside either of these ranges then the motor module needs to be replaced with an equi...

Page 68: ...cise Circle the Pass or Fail next to each meter and under the motor number Lead 1 to Lead 2 Pass or Fail Motor 2 Pass or Fail Lead 1 to Lead 3 Pass or Fail Lead 2 to Lead 3 Pass or Fail Lead 1 to Lead...

Page 69: ...control does Make sure the three wire plug will reach the motor control when it is oriented properly before tightening down the belly band The control module orientation is covered on the next page Al...

Page 70: ...ield Use the new shorter bolts provided to ensure a secure attachment Orient the control connectors to the end shield between 4 8 o clock insert the bolts and tighten If replacing an ECM 2 3 with and...

Page 71: ...ables Condensate or droplets can accumulate in the harness and may find their way into the motor Re install the blower motor assembly into the HVAC system by following the manufactures guidelines Plug...

Page 72: ...in all modes heating cooling and continuous fan and all stages if applicable Return all thermostat settings to the customer s preference Note If this is a repeat failure then it is important that you...

Page 73: ...t depending on the OEM These kits may no longer be available Check with your distributor before quoting the repair With the age of this system it may not be a bad idea to recommend replacement of the...

Page 74: ...beled as such They are the only motor with a round un painted motor Early model 2 3 2 5 motors were not labeled as such These motors can be identified as follows 2 3 motors will have 10 or mores wires...

Page 75: ...2006 GE ECM by Regal Beloit 73 Indoor Blower Motors v0 2 Standard ECM Indoor Blower Motor Proven...

Page 76: ...ronics are housed safely inside the motor shell Fully encapsulated electronics to prevent water damage Ball Bearings to support the speed range EMI Filter for surge protection and line transient issue...

Page 77: ...c pressure increases airflow will decrease similar to the PSC motor curve shown above However airflow will not decrease as poorly as a PSC motor since torque is being maintained If the static pressure...

Page 78: ...he following terminals C L G N 1 2 3 4 5 High Voltage Connections 3 16 Low Voltage Connections 1 4 L Line 1 G Ground N Neutral or Line 2 The power connected to these terminals is live whenever they sy...

Page 79: ...l torque value in the motor program These values are of no consequence to the field technician other than to understand what its capabilities are The manufacturer will simply provide a table or diagra...

Page 80: ...ns they may only program two taps and so on up to five All X13 motors will physically have 5 taps As long as the manufacturer s charts are always referenced for selecting the tap required per demand t...

Page 81: ...eloit 79 Indoor Blower Motors v0 2 Program Examples Example 1 Heat cool package system Example 2 Air handler used with a heat pump Example 3 Gas heat furnace with the ability to operate with two diffe...

Page 82: ...can be made with connectors or individual wires Connectors The high voltage connection plug contains the three 3 16 terminals for L G and N and one 1 4 terminal for C The low voltage connection plug...

Page 83: ...ugs are designed to prevent improper connection The high voltage plug has a full blank tab on the opposite end from the C terminal This prevents it from being installed on the low voltage 1 5 terminal...

Page 84: ...ed hard copy or download and print a free copy from our web site at www thedealertoolbox com Included in this guide are the following HVAC System Troubleshooting Basics Tech Tips Motor Identification...

Page 85: ...the power on to prevent arcing The ECM motor may draw as much as 150 amps peak when powered up Remember that the ECM motor uses electrical energy even if the motor is not doing useful work is at rest...

Page 86: ...ays check low control voltage between terminals 1 5 and C never ground Standard meter leads test pins are typically larger than the terminals from the plug connections or wires being checked for volta...

Page 87: ...he manufacturer s controls or circuit board when the control voltage is sent to the motor from each thermostat demand and if there are any delays Here are some examples of schematics showing the X13 m...

Page 88: ...otor with or without a demand from the thermostat o The allowable voltage variance can be as much as 10 of the nominal 115vac or 230vac required per motor 1 Line voltage 115vac or 230vac which should...

Page 89: ...from the thermostat o The allowable voltage variance can be as much as 10 of the nominal 24vac o If this voltage is present but below this range confirm that this voltage is present at the unit trans...

Page 90: ...t the low control voltage is applied to the proper tap per the thermostat demand o Correct all obvious airflow restrictions such as closed or blocked registers grilles or dampers or dirty filter blowe...

Page 91: ...it it came from There are no generic replacement motors When using a bellyband for mounting the band should not be located in the area identified in the drawing as the Keep Out Area Always make sure t...

Page 92: ...manufactures guidelines Reconnect all wires plugs to the motor confirming connection to proper terminals per demand by the manufacturers manuals Be certain to form a drip loop so that water cannot en...

Page 93: ...in all modes heating cooling and continuous fan and all stages if applicable Return all thermostat settings to the customer s preference Note If this is a repeat failure then it is important that you...

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