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