Regal-Beloit GE ECM 2.3 User manual

© 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

© 2006 GE ECM by Regal-Beloit Indoor Blower Motors v 0.2
Table of Contents
Premium ECM Indoor Blower Motors 1 - 72
Then and Now – The History of the GE ECM™ 1
Residential Blower Motor Applications 2
ECM vs. PSC 3
Constant Airflow 4 - 5
PSC Motor Operation 6
Premium ECM Motor Operation 7 - 9
Comfort 10
Efficiency 11
ECM Myths and the Air Distribution System 12
The ECM Technology (overview) 13 - 14
Premium ECM Motor Construction 15 - 16
Rotor Position Sensing 17
The 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 (Direct Serial Interface) 37 - 38
Servicing the Premium ECM Motor 39 - 72
Service Basics 40 - 43
If the Motor is Operating 43 - 49
If the Motor is not Operating 50 - 54
Checking the Motor Control and Motor module 55 - 60
Replacing the ECM Modules 61 - 70
Premium ECM Motor Failure Footnotes 71 - 72
Standard ECM Indoor Blower Motor 73 - 91
X13 Standard ECM Features 74
X13 vs. PSC 74 - 75
X13 Connections and Communication 76 - 81
Servicing the X13 82 - 88
Replacing the X13 89 - 91

© 2006 GE ECM by Regal-Beloit - 1 - Indoor Blower Motors v0.2
Premium ECM Indoor Blower Motors
Then and Now – The History of the GE ECM™
1987 ECM 1.0 Hardware Programmable
1992 ECM 2.0 Complete Motor and Control Design
oTorque Calibrated machine
oRefined airflow regulation algorithm
“motor is the airflow sensor”
oLate point product identification – software
programmable, program could be changed
oOften called the ICM-2
(Integrated Control Module)
oNo Longer in Production
1998 ECM 2.3 Response to Reliability Improvement
This is the current production blower motor for most
OEM’s using variable speed.
oControl Electronics and packaging redesign
oElectronics encapsulated for moisture resistance
oNew motor controller “ASIC”
oImproved performance and features
oSometimes called the ICM-2+
(Integrated Control Module)
oCurrently in Production
2002 ECM 2.5 Digital Serial Communication
oEnables plug & play HVAC systems
oFewer replacement part numbers
oMore accurate operation and fault reporting
oCurrently in Production
Once the program was installed in the motor control it
could not be changed.
oBasic constant airflow Algorithm
oOften Called the ICM-1
(Integrated Control Module)
oNo Longer in Production

© 2006 GE ECM by Regal-Beloit - 2 - Indoor Blower Motors v0.2
Residential Blower Motor Applications
Premium ECM Models 2.3/2.5
-120/240vac & 277vac power 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 they can be and are used in single stage systems as well.
Two-Stage Furnace Geothermal Heat Pump
Air Handlers/Fan Coils Package Systems
Proven.

© 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

© 2006 GE ECM by Regal-Beloit - 4 - Indoor Blower Motors v0.2
Constant Airflow
Airflow is one of the most important factors in an HVAC system. Proper airflow is
required to maintain capacity, efficiency and comfort.
-Decreased airflow leads to decreased heat transfer, which reduces the
capacity of the system.
-The system now has to run longer to provide the same amount of heating or
cooling to the home. This reduces the efficiency of the system as longer run
time uses more energy.
Incorrect airflow 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 on today’s thinner wall metals.
-Flooding can lead to compressor failure.
-Frozen evaporators can cause water damage to critical electronic controls
including the motor when they thaw.
Continuous airflow (constant fan operation) is being utilized more often with the
increased focus on Indoor Air Quality (IAQ).
This is where the ECM motor excels. Not only does it maintain constant airflow, but it
also uses less energy in doing so. The energy savings is even larger when
continuous fan is utilized.

© 2006 GE ECM by Regal-Beloit - 5 - Indoor Blower Motors v0.2
Once the motor is set-up, its programming takes over to maintain constant airflow.
Ok, how does it do this you ask, and why can’t a PSC motor do the same thing?
Let’s look at the following chart and see how the two motors perform when static
pressure changes in a system.
-Notice that the PSC motor actually moves less air (CFM) as the external
static pressure (from now on we will just call it pressure) 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 listed in the OEM installation guide. They provide the
same information as the above chart, but look more like this one.
External
Static
Pressure
High
Medium
Low
0.2
1625 1520 1375
0.4
1475 1410 1225
0.6
1290 1200 1100
0.8
1120 1110 1040
1
990
950
925
Air Volume
CFM per blower speed
Air Volume vs Ext SP
900
1000
1100
1200
1300
1400
1500
1600
1700
0.0 0.2 0.4 0.6 0.8 1.0
Ext Static Pressure (" H2O)
Cu Ft/min
1-ph PSC Lo 1-ph PSC Med 1-ph PSC HI
ECM

© 2006 GE ECM by Regal-Beloit - 6 - Indoor Blower Motors v0.2
PSC (Permanent Split Capacitive) Motor Operation
The PSC motor is a slave to the frequency of the supplied voltage, the poles of the
motor, and the load on the motor.
-A 6 pole motor at 60Hz has a theoretical speed of 1200 rpm, with a typical
rated speed of 1050 rpm.
-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 simply
moves less air when static pressure increases.
Demands Speeds
-1
st
stage heat - Up to 5
-2
nd
stage heat
-1
st
stage cool
-2
nd
stage cool
-Continuous fan
-De-humidification
-Emergency Heat
The PSC motor suffers from to many demands and not enough options, audible
start/stop noise, and low efficiency.
-Three stage
-Modulating

© 2006 GE ECM by Regal-Beloit - 7 - Indoor Blower Motors v0.2
Premium ECM Motor Operation
Specific airflow requirements for all demands are programmed into the motor control
and OEM control board. Motor provides airflow matched to the system and
maintains airflow within an acceptable external static pressure range.
Let’s first look at how the ECM motor is programmed to each OEM’s (Original
Equipment Manufacturer) specifications.
-In a series of tests by the OEM, (manufacturer 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 adjust the ECM torque and chamber static pressure, and measure the
resulting ECM speed and airflow.
-These values over a wide range of static pressures and airflows are used in a
GE ECM supplied development program to create a set of blower constants
that are specific to each air mover (furnace/air handler).
-“Airflow” is programmed by the OEM and is specific and unique to the motor
and air mover combination.
No other motor offers so many ways to control comfort and efficiency.

© 2006 GE ECM by Regal-Beloit - 8 - Indoor Blower Motors v0.2
So each motor knows the specific airflow the OEM is looking for over a wide range
of external static pressure, specific to each unit, for each demand (heat, cool,
continuous fan).
At the time of installation, all that is required of the installer is to set the required
CFM (Cubic Feet per Minute) for each demand to the size of the equipment the
motor is used in and/or with.
We are no longer setting speeds; we 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
CFM
1 2 3 4 5 6 7 8
A 800 0 0
B 1000 1 0
C 1200 0 1
D
1400
1 1
Dip Switch Number
Cooling Airflow Selection
2nd Stage
CFM
1 2 3 4 5 6 7 8 Rise (°F)
A 550 0 0
51
B 600 1 0
47
C 650 0 1
43
D
700
1 1
40
Heating Airflow Selection
Dip Switch Number
Temp Rise Range (30 - 60°F)
12345678
A0 0
B1 0
C0 1
D
1 1
Dip Switch Number
Climate/Delay Profile Selection
CFM
12345678
A Norm 0 0
B +10% 1 0
C -10% 0 1
D
N/A
1 1
Dip Switch Number
Trim/Adjust Airflow Selection

© 2006 GE ECM by Regal-Beloit - 9 - Indoor Blower Motors v0.2
Now for you techies out there, the “how”:
-Each motor has a set of constant CFM curves that are programmed into the
motor; they are unique for each motor/air handler system determined by the
OEM.
-For each CFM value used by the unit there is a constant airflow curve that
plots Torque vs. RPM, like the one shown below.
-Essentially the plot says to meet the CFM needs of the unit (800 CFM in this
example) the motor must turn at a specific RPM and develop a specific
torque.
-The ECM’s ability to adjust speed in increments to find a combination of
speed and torque that sits on a specific constant airflow curve allows the
same system 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. Like a PSC motor, when pressure increases, speed (RPM) increases, except
in the case of the ECM motor, torque does not change, yet. The motor knows from
its program that the new speed and existing torque is off the curve. This is where the
cool stuff happens. The motor will gradually increase torque in small increments,
checking the speed after each change. Through a series of these iterations, the
motor eventually brings the torque and speed back to the airflow curve. And voila,
you have constant airflow.
0
200
400
600
800
1000
1200
0 10 20 30 40 50 60 70 80 90 100
Normalized Motor Torque (%)
Speed (RPM)
Constant Airflow Profile (800 cfm)
A
B
C
D
E
High Static Pressure
Low Static Pressure

© 2006 GE ECM by Regal-Beloit - 10 - Indoor Blower Motors v0.2
Comfort
Two big comfort issues, noise and stratified air, are both improved with the ECM
motor.
Noise can be a big problem, especially in smaller homes, condos, or any design
where the furnace or air hander is located near the customer or where the return run
is short. There are really two noise issues, start up, and air movement.
-Start up noise is greatly reduced by slowing bringing the motor up to speed.
This is also done on the off setting as well. Comfort (delay) profiles reduce
noise issues even more.
-Air movement can be very noisy through the supply registers and return grills
where the air enters the home. In the continuous fan mode and, 1
st
stage
operations of two stage equipment, this noise is almost unnoticeable in most
cases. This will obviously depend on the design of the duct as previously
mentioned.
Another comfort improvement is stratified air. When there is no air movement in a
room, the hotter air will rise and the cooler air will fall. By running the fan
continuously the air is always being circulated not just in one room, but throughout
the home. This can even help all of the rooms of the home stay at a more even
temperature.
You can see how running the fan continuously would be something most
homeowners would want to take advantage of, especially with the energy savings,
added comfort, and virtually unnoticeable operation of the ECM motor.

© 2006 GE ECM by Regal-Beloit - 11 - Indoor Blower Motors v0.2
Efficiency
Efficiency in simple terms of dollars and cents is big concern to consumers these
days. Products that save money on utility bills are in high demand.
The ECM motor simply costs less to operate than the PSC motor. However, the
amount of savings will vary depending on its use. The more the motor is used, the
more it saves. So depending on the market it is used in the savings will vary.
Obviously the motor is in use anytime the heating or cooling system is operating.
With two stage systems becoming the norm for comfort and efficiency, the savings
really grow. Two-stage equipment is going to run longer than single stage
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 and more for comfort and indoor air quality, this savings is the
big winner. The PSC motor can only run at its lowest speed tap/winding. The ECM
motor can be programmed to run much lower. And the power consumption drops off
dramatically, as shown here.
Depending on the programming, the continuous fan operation of the ECM motor
could actually cost less than a typical household light bulb to operate.
0
50
100
150
200
250
300
350
400
450
500
550
600
250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 1050 1100 1150 1200
Motor Speed (RPM)
Input Power (Watts)
Low Winding
High Winding
35 Watts
280 Watts
Induction
motor needs
over 130 Watts
more power
than GE ECM
Induction
ECM

© 2006 GE ECM by Regal-Beloit - 12 - Indoor Blower Motors v0.2
ECM Myths and the Air Distribution System
ECM motors can overcome poor duct construction and sizing. This is true
within reason. However, severe duct blockages, improper installation practices and
under sizing can cause airflow problems and noise issues.
ECM motors can overcome dirty filters and coils. This is also true within reason.
In fact this problem may even be worsened if the filter being used has a high
pressure drop.
Here are some air distribution system guidelines:
-Low static, high quality ducted applications will run slowly, quietly and
efficiently while delivering the correct airflow.
-High static applications will run fast, be noisy and power hungry. The ECM
may still provide the correct airflow, but at a price.
Use good duct design practices and hold static pressure to less than 1”, ideally
around .5”, or the pressure recommended by 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 too often contractors install ECM’s to overcome poor ductwork
practices. ECM’s will run quiet and with high efficiency at the manufactures
recommended external static pressure.
Even ECM Motors do have their limits:
If we didn’t put limits on the motor, it would just keep increasing power and speed,
beyond the reliable design of its components. The motor program has a built in limit,
again specific to each OEM. In extreme high static applications the motor may reach
that limit and basically “max out”. This can lead to oscillation and high power
consumption.
-ECM motors are not thermally protected
-Open returns in high ambient areas may cause permanent damage to the
motor.
-Zoning and humidifier bypass connections should be as far upstream in the
return as possible from the unit.
-ECM motors are designed to handle the maximum (or higher) return air
temperature specified by the manufacturer for their unit.

© 2006 GE ECM by Regal-Beloit - 13 - Indoor Blower Motors v0.2
The ECM Technology (overview)
Models 2.3 & 2.5
The ECM motor is a brushless DC, Three-Phase (3Ø) motor with a permanent
magnet rotor. Motor phases are sequentially energized by the electronic control,
powered from a single-phase power supply. Huh? Lets break that down a little more.
-This motor can operate from an input power supply of 120vac or 240vac on
the same motor. (Caution: with the proper jumper connection).
-The motor control converts the incoming 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 motor from the OEM’s external circuit board
(tap board).
-To operate at the desired speed, the motor control converts the DC power
back to Three-Phase AC power at a specific level of power and frequency.
So what does ECM stand for? ECM stands for Electronically Commutated Motor. Ok
so what does that mean? In a DC motor, commutation or phase shifting is controlled
by the brushes. In this motor the phase shifting is controlled electronically using
sensor less position feedback.
Motor Control 3-Phase AC Motor

© 2006 GE ECM by Regal-Beloit - 14 - Indoor Blower Motors v0.2
Line voltage
120/240vac 1 Ø
Communication
from Air Handler
determined by dip
switc setting and
demand (Heat, Cool,
Fan…)
T e Microprocessor
continuously directs
t e controls to adjust
current (torque) and
frequency (speed) to
maintain t e selected
CFM profile.
T e Microprocessor
constantly monitors
motor speed (RPM)
using sensor-less
tec nology.
GE ECM by Regal-Beloit
Premium ECM Motor
3 Ø AC Motor
Controls
Convert
DC To
3 Ø AC
Power for
Microprocessor
Motor Control Module
Controls Convert
AC power to DC
Communication
selects stored
CFM profile
Microprocessor directs
controls to convert DC
back to 3 Ø AC specifying
t e current (torque) and
frequency (speed)
Microprocessor
DC Voltage
Motor Module
3 Ø AC

© 2006 GE ECM by Regal-Beloit - 15 - Indoor Blower Motors v0.2
Premium ECM Motor Construction
Motor Control Construction
-Microcomputer module
oMicrocomputer
oIsolated User Interface
oEEPROM
oASIC
o3 Ø Inverter
oRotor Position Feedback Control
-Power conditioning module
oEMI (Electro Magnetic Interference) Filter
oRectifiers
oCapacitor Filter
Stator
Permanent
magnet rotor
Microcomputer
Module
Power
Conditioning
Module
-The microcomputer module is encapsulated
with a polyurethane compound to protect
against moisture. This is done to enhance
reliability.
Motor
Control

© 2006 GE ECM by Regal-Beloit - 16 - Indoor Blower Motors v0.2
Motor Module Construction
Stator Construction
-Laminated, interlocked stator
-Steel shell, aluminum end shield, through-bolt construction
-Inslot Salient wound
oEach pole is individually wound
oLess wasted copper
-Available in a closed, partial, or fully vented shell.
Rotor Construction
ECM Rotor
-Three Iron Ferrite magnets glued on rotor sleeve
-Magnetized at GE ECM Factory
-Two Resilient Rings isolate the shaft from the rotor
-Ball Bearings (perform better at low RPM)
Resilient Ring

© 2006 GE ECM by Regal-Beloit - 17 - Indoor Blower Motors v0.2
Rotor Position Sensing
-At any given time while the motor is running, two of the three phases are
energized.
-The movement of the magnetized rotor past the third phase induces a
voltage, or back EMF (Electromotive Force), in the un-energized phase.
-The voltage in the third phase communicates the rotor’s position to the
control.
-With this information 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 shifted
at, the motor will operate at that speed.
Let’s pull it all together again.
The ECM motor is basically a 3-Phase motor operated by a motor control.
Motor Control 3-Phase AC motor
Phase 1
Phase 3
Phase 2
-Motor Torque is regulated at a given
level by an accurate control of the
current in the motor phases.
-The microcomputer control keeps torque
constant regardless of operating speed.

© 2006 GE ECM by Regal-Beloit - 18 - Indoor Blower Motors v0.2
The Line Voltage (high 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.
The 120vac input
uses a jumper
(red wire)
The 240vac input
does not use a
jumper