Nidec RESCUE EZ16 User manual

RESCUE®EZ16™Motor
Installation and
Operation Manual
For technical assistance or questions
related to your RESCUE®EZ16™Motor
call the Technical Hotline:
1-888-540-5540
Read the entire manual prior to installation of the
RESCUE®EZ16™Motor.
Follow all instructions contained herein.
M018204450000
Rev: B

Table of Contents
Important Safety Information .......................................................................................1
Product Overview .........................................................................................................4
Features.................................................................................................................4
Specifications.........................................................................................................4
Motor Dimensions..................................................................................................5
General Information................................................................................................6
Materials Enclosed ........................................................................................6
Initial Inspection.............................................................................................6
Installing the Motor.................................................................................................7
Handling and Care.........................................................................................7
STEP 1: Turn Off Electrical Power.................................................................7
STEP 2: Locate and Verify the Connector .....................................................8
STEP 3: Remove the Blower Housing from the HVAC Equipment.................8
STEP 4: Remove the Original ECM Motor.....................................................9
STEP 5: Install the Replacement Motor.......................................................10
STEP 6: Install the Replacement Motor in the Air Handling Unit..................11
STEP 7: Reinstall the Blower Assembly in the HVAC System .....................11
STEP 8: Set Up EZI Connections................................................................11
STEP 9: Set Up EZI Communications..........................................................14
STEP 10: Connect the HVAC System Power Harness to the Motor.............16
STEP 11: Mount the EZI..............................................................................16
For PWM Inputs Only...........................................................................................17
Operating Mode Checklist....................................................................................17
Final Checks........................................................................................................18
Troubleshooting..........................................................................................................19
General................................................................................................................19
Warranty Information..................................................................................................21

1
Important Safety Information
Only trained and qualified professionals familiar with RESCUE®EZ16™motors should service the motor
and control.
Before connecting or disconnecting cables or other electrical connections, verify that the electrical power to
the system is removed. Failure to comply may cause serious damage to the motor or HVAC system or
injury to personnel.
Because of the risk of electric shock, only individuals thoroughly trained in the use of multimeters should
conduct voltage tests.
Never touch the metal contacts on the multimeter during a test.
Always check testing equipment for proper operation before use.
Installation, operation, and maintenance must be performed by qualified personnel. Familiarization with and
adherence to the National Electrical Code (NEC) and National Fire Protection Association (NFPA) standards
and to local codes are required. It is important to observe safety precautions to protect personnel from
possible injury. Personnel should be instructed for handling each of the following:
Insulate all connections carefully to prevent grounding or short circuits. Reinstall all conduit and terminal
box covers. To avoid overheating or loss of performance, voltage to the motor control unit must be within
plus or minus 10% of the nameplate voltage.
Make sure the unit is electrically grounded and that proper electrical installation wiring and controls are
used consistent with local and national electric codes. Refer to NEC Handbook and NFPA No. 70. Employ
qualified electricians.
Code requirements differ from state to state. Install equipment using qualified electricians in accordance
with the applicable codes and ordinances in your area and in accordance with NEC. All electrical
connections should be made and maintained by a qualified or licensed electrician.
Make sure there are no unusual noises or vibrations when the motor is running.
Avoid contact with energized circuits or rotating parts.
Provide proper safeguards for personnel against rotating parts.

2
All aspects of the installation must conform to the applicable requirements of the NEC, including Article
430 (Motor Circuits and Controllers), as well as all local codes.
Always disconnect electrical power at the fuse box or circuit breaker panel before handling electrical
connections or performing maintenance on this unit. Allow the motor to come to a complete stop and wait
four (4) minutes. This allows the capacitors to discharge any residual voltage for safety.
Double-check to make sure that electrical power is removed and that it cannot be turned on while you are
working on the equipment.
A poor electrical connection can overheat and cause terminal and/or terminal board failures. Examine the
wiring harness quick-connect terminals carefully for any signs of physical deterioration or loose fit to the
terminals on the motor terminal board.
If there is evidence of deterioration or loose fit, remove the quick-connect terminals from the wiring harness
and then connect the harness wires directly to the motor terminal board wiring terminals.
Care must be taken to assure connections are made to the proper terminals and adequate electrical
clearances are maintained.
The control unit on the motor contains potentially hazardous voltage.
Use only specially designed motors where explosive atmospheric hazards exist. See the National
Electrical Code (NEC) Article 500 or check with local codes for explanation of hazardous or classified
atmospheres and locations. Unless the motor is specifically marked “Electric Motor for Hazardous
Locations,” it is not suitable for use in Class I or II hazardous locations as defined by the NEC.
Wear safety glasses to inspect the equipment while it is running or while working on equipment, especially
if cover plates are removed.
The motor and control unit are assembled and calibrated as a set. Replacing either the motor or control unit
with other unsuitable parts could drastically affect performance tolerance.
To prevent permanent damage to the unit, only apply nameplate voltage.
Do not apply 240 Vac to the motor with a jumper in positions 1 and 2. Refer to the diagram on page 16.
Do not strike the motor shaft with a hammer or other tool as this may damage the bearings.
Do not operate the motor without the blower wheel attached. Without the blower wheel attached, the motor
will run continuously to a maximum speed and then stop.
Voltage symbols vary among different multimeters and may be displayed as Vac, AC, V, or a V beneath a
wavy line. Select the correct symbol and set the multimeter to the voltage closest to but higher than the
voltage you are measuring.
Read all instructions thoroughly and be familiar with the equipment before installing or working on it.

3
The RESCUE®EZ16™motor is properly packaged for shipment and storage and should be kept in a clean
and dry indoor area.
The motor should be stored indoors in a clean, dry location. Proper selection, installation, and maintenance
will assure longer life and more dependable service.
The RESCUE®EZ16 motor may is designed for direct-drive centrifugal blower applications only.
The RESCUE®EZ16 motor is designated for continuous, air-over duty, and must be mounted in the air
stream of an air moving device, such as a fan. Do not operate the motor outside of the air stream as that
may overheat and damage the motor.

4
Product Overview
The RESCUE®EZ16™provides an easy drop-in solution for systems using legacy 16-Pin controls.
The RESCUE®EZ16™motor is the solution to meet the increasing demand for electrically commutated
motors (ECM) in modern HAC and ventilation systems. With a wide range of control options, voltages, and
mechanical configurations, the motor offers the high efficiency and airflow control needed in a broad array of
air-moving applications, all backed by Nidec's extensive ECM experience and close application support.
Features
Drop-in replacement
Field adjustable
Dual voltage
Flexible control methods
24 Vac or PWM inputs
Selectable rotation and voltage
Specifications
Horsepower: 1/3, 1/2, 3/4, or 1HP
Voltage: 115 or 208-230 Vac
Speeds: 1075 / Variable Speed
Inputs: 24 Vac or PWM
Frequency: 50 / 60 Hz
Frame: NEMA®48
Enclosure: Open Air Over (OAO)
Efficiency: Up to 82%
Mounting: Belly-band
EZ16 Motor
EZ Interface (EZI)

5
Motor Dimensions
All dimensions are for reference only.
HP
Dim. A
Dim. B
Dim. C
1/3
3.41
10.48
2.06
1/2
3.66
10.73
2.06
3/4
4.04
11.10
2.06
1
4.41
11.98
2.56
Remote mounting of the EZ Interface is recommended using either double-sided tape or
screws in combination with the integrated mounting tabs on the unit.

6
General Information
Materials Enclosed
RESCUE®EZ16 Motor
EZ Interface (EZI)
RESCUE®EZ16 Motor Installation and Operation Manual
4-Pin Output Harness
Auxiliary Wire for connecting 24V power
Initial Inspection
Check the RESCUE®EZ16 motor to verify the following:
The nameplate data conforms to the specifications of the motor ordered.
The shaft spins freely by hand.
The RESCUE®EZ16 motor may look visually different than the motor it is replacing. The external
appearance is not an exact replica of the motor it is replacing. However, when properly installed, the motor
will fit in the blower housing and function according to specifications.
Note: ECM 2.5 and Less Than 6 Leads
If the nameplate on the original ECM motor reads ECM 2.5 and the number of leads on the system 16-Pin
connector harness is less than 6, the RESCUE®EZ16 is not your solution.

7
Installing the Motor
Always disconnect electrical power at the fuse box or circuit breaker panel before handling electrical
connections or performing maintenance on this unit. Allow the motor to come to a complete stop and wait
four (4) minutes. This allows the capacitors to discharge any residual voltage for safety.
Double-check to make sure that electrical power is removed and that it cannot be turned on while you are
working on the equipment.
A poor electrical connection can overheat and cause terminal and/or terminal board failures. Examine the
wiring harness quick-connect terminals carefully for any signs of physical deterioration or loose fit to the
terminals on the motor terminal board.
Handling and Care
The motor should be stored indoors in a clean, dry location. Proper selection, installation, and maintenance will
assure longer life and more dependable service.
The RESCUE®EZ16 motor may is designed for direct-drive centrifugal blower applications only.
The RESCUE®EZ16 motor is designated for continuous, air-over duty, and must be mounted in the air
stream of an air moving device, such as a fan. Do not operate the motor outside of the air stream as that
may overheat and damage the motor.
STEP 1: Turn Off Electrical Power
These instructions provide field technicians a guide for installing a RESCUE®EZ16 motor and are intended
for a typical air handler/furnace equipment system. These instructions do not override or replace instructions
by the HVAC system manufacturer.
1. Turn OFF electric power to the HVAC unit at the disconnect or the main service panel before making any
electrical connections.
2. Make sure electrical power cannot be accidentally switched on while you are working on the equipment.

8
STEP 2: Locate and Verify the Connector
1. Disconnect the 16-Pin HVAC wiring harness from the motor.
2. Connect the 16-Pin HVAC wiring harness to the bottom of the EZI to ensure proper fit.
3. Disconnect the 16-Pin HVAC wiring harness from the EZI and set aside.
STEP 3: Remove the Blower Housing from the HVAC Equipment
1. Remove the blower housing from the air handling unit. Refer to the manufacturer’s installation manual for
blower removal instructions.

9
STEP 4: Remove the Original ECM Motor
1. Loosen the set screw on the motor shaft.
2. Remove the screw that secures the belly-band mounting bracket to the original motor and set them aside.
3. Remove the original motor from the belly-band.
4. Verify that the RESCUE®EZ16 motor provides the same horsepower and voltage rating as the original
ECM motor.

10
STEP 5: Install the Replacement Motor
1. Insert the RESCUE®EZ16 motor into the mounting bracket. The belly-band can be positioned anywhere on
the motor shell except the end bell (i.e., the control). The preferred position is at the midpoint between the
motor vents. Do not cover any of the vents with the belly-band.
The RESCUE®EZ16 motor can be installed with the mounting bracket from the original ECM motor. If a
replacement bracket is needed, contact your authorized U.S. Motors®distributor.
Placing the belly-band on the control housing can damage the motor.
Incorrect Mounting Position
Correct Mounting Position
2. When mounting the motor and control into the belly-band ensure that the Drip Slot is positioned at or near a
6 o’clock position to allow any condensation build-up to drain from the motor.
3. Secure the bracket to the motor by tightening the bracket mounting screw.
The motor must be securely fastened to minimize noise and prevent vibration. Ensure the belly-band legs
cannot be moved. For secure mounting, use high-quality bolts of the largest possible diameter.
Drip Slot
Drip Slot
at or near
6 o’clock
position

11
STEP 6: Install the Replacement Motor in the Air Handling Unit
1. Insert the motor shaft into the blower wheel, securing the motor to the blower housing.
2. Align the blower wheel so it is properly centered in the blower housing, aligning the wheel’s set screw to the
flat of the motor shaft.
3. Secure the blower wheel to the motor shaft by tightening the set screw to a torque setting of 157 in-lbs.
STEP 7: Reinstall the Blower Assembly in the HVAC System
1. Follow the manufacturer’s installation manual for blower installation instructions.
2. Connect the HVAC wiring harness to the replacement motor.
STEP 8: Set Up EZI Connections
1. Determine the number of pin used on the HVAC system Connector Harness for proper setup of the
16-Pin connections.
If the system Connector Harness is using all 16 Pins, proceed to Figure 1 to connect the system, the
motor, and the EZI.
If the system Connector Harness is using 15 Pins (Pin 12 is missing), proceed to Figure 2 to connect
the system, the motor, and the EZI.
Pin 12
is missing.

12
Figure 1
A. Connect the HVAC system harness to the 16-Pin Input Connector on the bottom of the EZI.
B. Connect the 4-Pin Output Harness on the EZI to the 4-Pin Connector on the motor.
C. Connect the power harness from the HVAC system to the 5-Pin Connector on the motor.
2. Proceed to STEP 9: Set Up EZI Communications.
HVAC System 16-Pin
Harness to the
EZI Connector
EZI to the
4-Pin Connector
on the Motor
HVAC system
power harness
to the Power
Connector on
the Motor
A
B
C
(EZI)

13
Figure 2
A. Connect the HVAC system harness to the 16-Pin Input Connector on the bottom of the EZI.
B. Connect the 4-Pin Output Harness from the EZI to the 4-Pin Connector on the motor.
C. Connect the power harness from the HVAC system to the 5-Pin Connector on the motor.
D. Mandatory: The Auxiliary Wire is needed to power the EZI. Plug the crimped end of the
Auxiliary Wire into the empty Pin 12 slot on the 16-Pin harness. The schematic view of the
16-Pin harness shown above is from the back.
E. Mandatory: Connect the stripped end of the Auxiliary Wire to the R Terminal of the thermostat input
on the system control board.
2. Proceed to STEP 9: Set Up EZI Communications.
HVAC System 16-Pin
Harness to the
EZI Connector
EZI to the
4-Pin Connector
on the Motor
HVAC system
power harness
to the Power
Connector on
the Motor
A
B
C
If the 16-Pin harness from the HVAC system control board is missing a lead at Pin 12,
use the Auxiliary Wire that shipped with the motor to provide power to the EZI.
D
Mandatory:
Plug Auxiliary Wire
into Slot 12 of the
16-Pin Harness
Mandatory:
Connect Auxiliary
Wire to the
R Terminal on
the system board
E
(EZI)

14
STEP 9: Set Up EZI Communications
Ensure that the dials and switches are set to the following baseline settings for initial setup. Make sure the
HP is set to the proper nameplate rating.
Quick Setup Guide
24VAC (defaults)
PWM
Setup
EZI Boxa
Rotation
Auto-Rotation
Sensing
HP
Settingb
N/A with PWM,
HP on motor
must match
OEM HP rating
Y1 / Y2
Coolingc
N/A with PWM,
determined by
the system
PWM signal
W1 / W2
Heatingc
If Less
Than 16
Leads
Refer to Step 8:
Set Up EZI
Connections
N/A
aUse PWM if the motor does NOT start in 24VAC.
bSelect the appropriate horsepower. Not applicable
for PWM.
cSettings are functional with 24VAC applications only.
Adjust CCW or CW as needed.
For detailed setup instructions, see the next page.
AIRFLOW SETTINGS
Recommended
start position
for baseline
testing of
heating and
cooling for all
HP options
NOMINAL
MIN
MAX
Decrease
Airflow
Increase
Airflow
Match HP dial
with nameplate HP

15
1. Selecting 24VAC: Ensure the communication switch on the side of the EZI is flipped to the right for 24VAC.
2. Selecting Rotation: Specify the rotation using the CCW/CW switch.
3. Selecting HP: Turn the HP dial on the EZI to match the horsepower on the OEM motor nameplate.
Note: You can run a higher HP motor at a lower setting on the HP dial, but you cannot run a lower HP
motor at a higher setting on the HP dial. Default settings scale automatically.
4. Adjusting Airflow: Adjust the Y1/Y2 (cool) and W1/W2 (heat) inputs. Turn the dial clockwise to increase
airflow. Turn the dial counter-clockwise to decrease airflow.
Baseline Settings
These are the recommended start positions for the baseline testing of heating and cooling for all HP options.
Turn each dial to the left to decrease airflow. Turn each dial to the right to increase airflow.
Setting
1/3HP
1/2HP
3/4HP
1HP
Input
Y1/Y2
24VAC
W1/W2
24VAC
Preferred Method to Meet OEM System Performance Requirements
Temperature rise is a calculated difference between the temperatures in the supply air outlet and the return air
inlet of the HVAC system. The temperature reading should be taken inside of the return air and supply air
ducts, as close to the HVAC system as possible. If there is no access to the ductwork, then take the
measurement in a return and supply grill, closest to the HVAC system. Refer to the furnace/air handler
manufacturer’s rating plate for temperature rise specifications.
It is difficult to determine if the motor is operating on 24VAC or PWM.
Use 24VAC for the initial setup.
Switch to the PWM setting, if the motor does not start in 24VAC application.
For PWM setup, refer to the section called For PWM Inputs Only on page 17.

16
STEP 10: Connect the HVAC System Power Harness to the Motor
If the system is wired for 120 Vac, confirm that a jumper wire is installed between positions 1 and 2 . on
the Power Connector. Without a jumper wire installed the motor will not start.
Operating the motor at 240 Vac with a jumper wire installed on the Power Connector will cause
significant damage to the motor.
1. Apply electrical power to the motor.
2. Observe LED activity on the Interface to determine proper connection.
Note:
(1) The PW, RX, and TX LED lights on the EZI will blink intermittently.
(2) LED activity represents communication taking place between the motor and the EZI. There is no
correlation between LED activity and airflow or horsepower.
STEP 11: Mount the EZI
Remote mounting of the EZI is recommended.
1. Install the EZI using the double-sided tape provided or screws in combination with the integrated mounting
tabs on the top and bottom of the EZI.

17
For PWM Inputs Only
1. Flip the PWM/24VAC switch on the side of the EZI.
Note:
(1) The PWM signal is determined by the HVAC system.
(2) HP Setting: The HP setting on the EZI is not functional in PWM applications. For PWM applications, it
is important that the HP on the motor matches the HP on the OEM motor.
(3) Y1/Y2 and W1/W2 Settings: The airflow settings on the EZI are not functional in PWM applications.
(4) Rotation: In PWM Mode, the motor uses rotation sensing technology to determine rotation the first time
the motor is powered up. It runs for about 20 seconds in each direction to determine the proper
direction, then stores the data. In the event of a power loss longer than 60 seconds, rotation sensing
takes place again when power is restored.
Operating Mode Checklist
For air moving applications, all enclosure covers and panels must be in place before measuring the
amperage.
Voltage and moving parts around motors and motor driven equipment can cause serious or fatal injuries.
Turn OFF electrical power before connecting or servicing the motor.
After installation, motor operation should be tested in all system modes for the following:
Check
#
System Test
Description
1
Start-Up and
Shut-Off Delays
After the motor is powered ON, it is normal for the motor to
experience a 10-12 second delay before beginning operation and
may take 30 seconds before reaching full speed. When the motor is
turned OFF, it is normal for the motor to experience a 30 second
delay before turning OFF.
2
Unusual Noise
or Vibration
If unusual noise or vibration is detected, refer to the
Troubleshooting section on page 19.
3
Motor Amperage
Amperage reading at the highest speed setting should be within 10%
of the specification shown on the nameplate.
4
Air Flow
Verify that the correct airflow is present in all operating modes.

18
Final Checks
Check the mounting and fastening of both the motor and the control. Make sure the motor and control are
securely attached together and mounted tightly in HVAC system.
Check the wiring harness. Inspecting for shorts and detached wiring. Ensure that the wiring harness is
securely connected to the control connector.
Check the wiring harness and signal connections. Make sure both are securely connected to the control
connectors.
Check the blower motor and verify wheel rotation. Make sure it spins freely manually without effort or
assisted means in both directions.
Verify that the set screw on the blower wheel is securely tightened.
Check that the circuit breaker is ON.