Regal genteq ECM User manual

ECM SERVICE GUIDE
ECM SERVICE GUIDE

Working on the motor with power connected may result
in electrical shock or other conditions that may cause
personal injury, death or property damage.
On models 2.0 / 2.3 / 2.5 / Eon® / X13® / 3.0 / Endura®Pro
always disconnect the power from the HVAC system
and wait at least 5 minutes before opening the motor,
i.e. removing the two bolts from the motor control (end
bell) and disconnecting the 3-pin plug to the motor. This
is to allow the capacitors to dissipate for safety.
Always disconnect the power from the HVAC system
before removing or replacing connectors, servicing
the motor, removing the high voltage plug, and before
reconnecting.
Disconnect AC power from the system and make sure
the blower wheel or fan blade has come to a complete
stop before servicing the motor.
Do not operate motor without blower wheel or fan blade
attached. Such operation will cause the motor speed to
oscillate up and down.
You must have the correct replacement module
and/or motor from the manufacturer that is a direct
replacement for the failed module and/or motor.
USING THE WRONG MODULE and/or motor VOIDS
ALL PRODUCT WARRANTIES AND MAY PRODUCE
UNEXPECTED RESULTS.
Genteq does not condone the repair of any individual
components in the motor control or motor of their
ECM products. This practice is unsafe and may cause
personal injury, death, or property damage.
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING

TABLE OF CONTENTS
Using the ECM Service Guide
Motor Diagnostics &Replacement
ECM SERVICE GUIDE
About the Company
Start Here:
Using the ECM Service Guide
HVAC SystemTroubleshooting Basics
Tech Tips
Motor Identification Chart
1
3
4
6
7
Variable Speed Motors
Premium ECM Motor Diagnostics
X13®& Endura®Pro Motors
Standard ECM Motor Diagnostics
Evergreen®Replacement Motors or Retrofit
Retrofit Motor Diagnostics
Outdoor Motors
Motor Identification Chart
Final Checks
10
26
37
50
53

1
Introduction
The ECM Service Guide provided by Genteq
is a troubleshooting tool like no other. It covers
over 20 years worth of OEM (Original Equipment
Manufacturer) and aftermarket residential HVAC ECM
motors including the Variable Speed indoor blower
motor models 2.0, 2.3, Eon
®
, and 3.0, Constant
torque Evergreen
®
indoor blower motor model X13
®
&
Endura
®
Pro, Constant Speed outdoor fan motor model
142 and 142R, and the Constant Torque Evergreen
®
indoor blower motor. Genteq
®
motors have been used
almost exclusively in OEM equipment including fossil
fuel furnaces, electric air handlers, geothermal and
package systems. Regardless of the manufacturer
of the appliance, this guide will help troubleshoot the
Genteq ECM motor driving it. It is our hope that this
guide will provide a simple and accurate process for
troubleshooting all of our motors.
About the Company
In 1987 General Electric introduced ECM technology
to the residential HVAC industry. This technology is
predominantly used in variable speed indoor blower
motors, constant speed induced draft motors and
condensing fan motors.These innovative motors
changed the industry by providing unmatched
efficiency as well as comfort options not possible with
PSC induction motors.
In 2004 the Regal Beloit Corporation acquired General
Electric’s Commercial and HVACR Motors and
Capacitors businesses with the right to use the GE
brand through 2009. These divisions were named GE
ECM by Regal Beloit, GE Commercial Motors by Regal
Beloit and GE Capacitors by Regal Beloit.
In 2009, Regal Beloit announced the rebranding of
those GE branded businesses under the name Genteq,
for markets that include residential and commercial

2
HVAC equipment and electrical applications that
utilize capacitors. With this rebranding, the Genteq
®
logo took the place of GE ECM, GE Commercial
Motors and GE Capacitors logos on all branded
products, sales and marketing materials, Web sites,
communications documents, signage and other
related items.
This rebranding reflects the company’s reputation
for innovation and speaks to the future. We want to
assure customers that this rebranding is an exciting,
progressive step. Genteq continues providing
unparalleled service and developing the progressive,
innovative HVACR solutions for which this company
has always been known. Even if you are not familiar
with the name Regal, you are most likely familiar with
one or more of the motor brands they own such as
Marathon
®
, Lincoln, Leeson
®
and Fasco
®
. Regal is
a leading manufacturer of mechanical and electrical
motion control and power generation products
serving markets throughout the world. Regal is
headquartered in Beloit, Wis., and has manufacturing,
sales, and service facilities throughout the United
States, Canada, Mexico, Europe and Asia.
Genteq will continue to create innovative, premium
comfort and electrical components. Our proven
reputation for high quality, highly reliable products and
strong customer relationships make us the preferred
brand throughout the industry.
For more information on our company, Please visit our
Web site at jointhegeneration.com.
For technical information and training on our OEM
products please visit theDealerToolbox.com. For
information and training on Evergreen
®
motors
visit EvergreenDealer.com. And for information on
homeowner benefits and tax rebates please
visit genteqcomfort.com.

3
The purpose of this guide is to help you accurately
and efficiently troubleshoot Genteq
®
ECM-driven
systems. For ease of troubleshooting and to avoid
misdiagnosis, it is strongly recommended that each
step of this guide be used in the following order:
START HERE:
Using the ECM Service Guide
Read this section before using
Motor Diagnostics & Replacement
Using the ECM Service Guide
Begin with the “HVAC System Troubleshooting
Basics” section on the opposite page.
If the answer to the problem is not solved there,
read all of the Tech Tips on page 6.
After reading all of the Tech Tips, go to the “Motor
ID” section of this guide on page 7 to be sure you
use the procedures for the correct motor.
After determining which motor you are working
on from the “Motor ID” chart on page 7, go to the
section in this guide for the motor model you are
working on and follow the instructions listed there.
1.
2.
3.
4.

4
Before troubleshooting the ECM motor,
check these system basics if applicable:
HVAC System
Troubleshooting Basics
Confirm that the correct thermostat input and
ONLY the correct input voltage is present at the
interface or main control board on the furnace/
air handler or outdoor unit. Loose or broken low-
voltage wires are also potential problem areas and
can cause intermittent problems.
For the heating and/or cooling systems, use the
manufacturers guide to confirm proper demands
(heat or cool), especially on multi-stage systems.
Use the “Sequence of Operation” charts and the
“Thermostat Wiring Diagrams,” found in these
guides to confirm proper wiring and operation.
When checking low-voltage connections, always
use the C terminal on the board,never ground.
Check the setting of the jumper pins or switches
or menu selections on the manufacturer’s control
board or system interface. Do not assume they
are correct; use the manufacturer’s guide to select
the proper airflow, delays, and profiles.
Always
disconnect the main power to the unit when
making these adjustments, unless required for
interface operation.
1.
2.
3.
START HERE

5
Check all terminal/plug connections both at the
furnace/air-handler or outdoor unit control board
and at the motor.
Always disconnect power
to the system before disconnecting and
reconnecting plugs.
Look for:
Loose plugs and/or loose pin connections in
the plug.
Burnt, bent or loose pins or seats.
Confirm there are no limits, rollouts or safeties
tripped. Also check for any fault codes present
on the furnace/air-handler or outdoor unit control
boards.
If fault codes are present, follow the
manufacturer’s recommendations to resolve
the problem.
If these checks do not solve the problem, or if a
fault code reveals a motor problem, read theTech
Tips on page 6, and go to the “Motor ID” section
on page 7 to identify the motor. Then go to the
corresponding motor section in this guide for
additional diagnostics.
4.
5.
6.

6
Tech Tips
Do not automatically assume the ECM motor has
failed.
Follow this guide completely before replacing
it.
When it is necessary to disconnect the power from
the HVAC system, it is always good practice to
verify that voltage has been disconnected with a
voltmeter.
A True- RMS meter is not needed to check high
voltage or low voltage (communication voltage) to
the motor.
Always pull on the connector and not the wires.
Most connectors are also keyed. Reconnecting a
connector the wrong way could damage the motor.
When checking any plug connector, the meter leads
are most likely larger than the terminals or socket.
Using thin leads will prevent the terminals from
being damaged by voltage checks. Thinner leads
are also available in a 90º angle as needed. Go to
thedealertoolbox.com for part numbers and ordering
information if needed.
TECH TIP #1
TECH TIP #2
TECH TIP #3
TECH TIP #4
TECH TIP #5
TECH TIPS

ECM X13
®
& Endura
®
Pro
OEM Constant Torque Indoor Blower Motor
Evergreen®Aftermarket Constant Torque Indoor Blower Motor
Identification
Sticker
Heat sink
Speed taps
All Evergreen Motors are aftermarket replacements
All Evergreen Motors are Painted Green
Evergreen CM, AH & EM have a missing
wire upper plug
All Evergreen Motors have a heat sink here
OEM Constant Speed Outdoor Fan Motor
Shaft down application
rounded end of control up
Shaft up application
remote located control
Cover plate over
open end of control
Umbilical cord from motor
shell to cover plate
ECM 142 Control
ECM 142RControl
Shaft up application
rounded end of control up
Cover plate over open
end of control
Umbilical cord from motor
shell to cover plate
ECM 142R
C L G N
1 2 3 4 5
Evergreen IM has a white or yellow voltage jumper
Motor Identification Chart
7

ECM 3.0
& Eon
ECM
2.3/2.5 2.3
6
wires
2.5
5
wires
Identification
Sticker
Heat sink
3.0 uses 4-pin
connector
Eon®motor uses
16-pin connector
Identification
Sticker 2.3 - 6 or more
wires in the
16-pin connector
2.5 - 5 or less
wires in the
16-pin connector
Painted, steel
motor control
Unpainted,
cast aluminum
motor control
Square motor
control
NOTE: Early models do not
have indentification stickers.
NOTE: ECM
1.0, 2.0,
2.3 & 2.5
motors are
no longer in
production
NOTE: See HVAC
manufacturer’s service guide
for 1.0 motor diagnostics.
ECM 2.0
ECM 1.0
OEM Variable Speed Indoor Blower Motor
Motor Identification Chart
8
MOTOR ID

9
Genteq does not condone the repair of any individual
components in the motor control or motor of their
ECM products. This practice is unsafe and may cause
personal injury, death, or property damage.
WARNING
Working on the motor with power connected may result
in electrical shock or other conditions that may cause
personal injury, death or property damage.
WARNING
On models 2.0 / 2.3 / 2.5 / Eon® / 3.0 / Endura®Pro always
disconnect the power from the HVAC system and wait at
least 5 minutes before opening the motor, i.e. removing
the two bolts from the motor control (end bell) and
disconnecting the 3-pin plug to the motor. This is to
allow the capacitors to dissipate for safety.
WARNING
Always disconnect the power from the HVAC system before
removing or replacing connectors, servicing the motor,
removing the high voltage plug, and before reconnecting.
WARNING
Disconnect AC power from the system and make sure
the blower wheel or fan blade has come to a complete
stop before servicing the motor.
WARNING
Do not operate motor without blower wheel or fan blade
attached. Such operation will cause the motor speed to
oscillate up and down.
WARNING
You must have the correct replacement module and/
or motor from the HVAC unit manufacturer that is a
direct replacement for the failed module and/or motor.
USING THE WRONG MODULE AND/OR MOTOR VOIDS
ALL PRODUCT WARRANTIES AND MAY PRODUCE
UNEXPECTED RESULTS.
WARNING
9

10
11
15
16
19
24
Models 2.0 / 2.3 / 2.5 / Eon / 3.0
Premium ECM Motor Diagnostics
TECINspect® Service Tool
TECINspect Usage Chart
Troubleshooting with the TECINspect Service Tool
Module Replacement
ECM Control Module
ECM Motor Module
Variable Speed
Models 2.0 / 2.3 / 2.5 / Eon®/ 3.0
Premium ECM Motors
See the Motor ID Chart on page 8 if
needed.
VARIABLE SPEED MOTORS

11
It is normal for the motor to rock back and forth
on start up. Do not replace the motor if this is
the only symptom identified.
If the system is excessively noisy, does not appear
to change speeds in response to a demand (Heat
or Cool), or is having symptoms during the cycle
such as a tripping limit or freezing coil, check the
following:
Wait for programmed delays to time out. If
delays are too long, then reset them using the
manufacturer’s charts.
Ensure the airflow settings are correct for the
installed system using the manufacturer’s charts.
Remember that the change in airflow between
continuous-fan speed and low stages of operation
may be very slight depending on the size of the
system. If the system is operating normally in
each stage, then there is no problem.
Remove the filter and check that all of the
dampers, registers, and grills are open and
free flowing. If removing the filter corrects the
problem, clean or replace with a less restrictive
filter. Also check and clean as needed the blower
wheel, secondary heat exchanger (if applicable)
and evaporator coil (if applicable).
If this does not correct the problem then:
Check the external static pressure. If it is
higher than the manufacturer’s recom-
mendations, correct the airflow restriction.
Models 2.0 / 2.3 / 2.5 / Eon®/ 3.0
Premium ECM Motor Diagnostics
IF THE MOTOR IS RUNNING
1.
2.

12
If the motor does not shut off at the end of
the cycle, check the delay times and wait for
the delays to time out. Also, make sure that
there is no call for “Continuous fan” on the “G”
terminal. This motor may take a while to come
to a complete stop with selected delays and the
normal ramp down.
If the 2.0 / 2.3 / Eon®/ 3.0 motor has proper high
voltage and ground at the 5-pin connector, go
to the “Troubleshooting with the TECINspect
®
Service Tool” section on page 16. If the 2.5
motor has proper high voltage and ground at the
5-pin connector, the equipment manufacturer’s
checks, located in their service manuals, must be
referenced. This guide cannot troubleshoot the
communication to the 2.5 motor. The TECINspect
Service Tool is not designed for use on the 2.5
motor.
Checking the high voltage on the 5-pin
connector is outlined in step 1 on page 13.
3.
4.

13
IF THE MOTOR IS NOT RUNNING
Check for proper high voltage and ground at the
5-pin connector at the motor. Correct any voltage
issues before proceeding to the next step. These
are dual voltage motors capable of operating in
120 or 240VAC systems. On 120VAC systems
there should be a jumper between terminals 1
and 2 (see Figure 1). On 240VAC systems the
jumper should be removed (see Figure 2). If a
motor is operating at 240VAC with the jumper in
place, the motor will be permanently damaged.
Input voltage within plus or minus 10% of the
nominal 120VAC or 240VAC is acceptable.
If the 2.0 / 2.3 / Eon
®
/ 3.0 motor has proper high
voltage and ground at the 5-pin connector, go
to the “Troubleshooting with the TECINspect
®
Service Tool” section on page 16. If the 2.5
motor has proper high voltage and ground at the
5-pin connector, the equipment manufacturer’s
checks, located in their service manuals, must be
referenced. This guide cannot troubleshoot the
communication to the 2.5 motor.
The TECINspect Service Tool is not designed
for use on the 2.5 motor.
If further troubleshooting identifies a failed control
module, go to “Replacing the ECM Control
Module” section on page 24 of this guide for
replacement steps.
1.
2.
3.

GROUND
120VAC
LINE 1
120VAC
LINE 2
GROUND
NEUTRAL
120VAC
LINE 1
Figure 1 Models 2.0 / 2.3 / 2.5 / Eon®/ 3.0
120VAC SYSTEM
Figure 2
240VAC SYSTEM
Always disconnect the power from the system before
removing the high voltage plug, and before reconnecting.
Models 2.0 / 2.3 / 2.5 / Eon / 3.0
WARNING
14

TECINspect®
USAGE CHART
TECMate XL TECMate PRO TECINspect
4 Switches 1 Switch 1 Switch
16-pin connector 1st Generation
16-pin connector
2nd Generation
16-pin connector
with supplied 16-4
pin adapter
3rd Generation
16 & 4 pin
connector harness
16&4 pin
connector
harness
No change from
TECMate PRO 3rd
generation
Out of Production Out of Production Current Model
In 2013 the TECMate Pro service tool was rebranded to
TECINspect Service Tool.
TECINspect Service Tool Generational Growth
TECMate XL TECMate PRO TECINspect
Applicable Motors 2.0, 2.3, EON®, 3.0
Model 3.0
diagnostics
require a 16-4 pin
adaptor1 , 2
Model 3.0
diagnostics may
require a 16-4 pin
adaptor1
TECINspect Application Chart
These service tools will properly diagnose applicable
Genteq®indoor blower motors in all HVAC OEM
equipment.
The TECINspect service tools are not designed for use
on Genteq models 1.0, 2.5, X13® & Endura®Pro or Ever-
green®. The TECINspect service tools are not designed
for use on Genteq outdoor fan motors.
1The 16-4 pin adapter can be ordered from thedealertoolbox.com
2 The TECMate XL may not accuratly troubleshoot Carrier/Bryant* 2.0/2.3
models.
15

Troubleshooting with the TECINspect®
Service Tool (Models 2.0 / 2.3 / Eon®/ 3.0 only)
See Motor ID Chart on page 8, if needed.
See the Usage Chart on the opposite page for
motors applicable to the TECINspect Service Tool.
TheTECINspect Service Tool is capable of identifying
a motor control failure versus another HVAC system
controller or wiring failures.
Connect the TECINspect Service Tool to the
communication plug on the motor
On Models 2.0 / 2.3 / Eon remove the 5-pin
AC power connector first to make accessing
the 16-pin communication connector locking tab
easier. Remove the 16-pin connector from the
motor, and connect the 16-pin connector from the
TECINspect Service Tool to the motor.
Reconnect the 5-pin AC power connector.
On Model 3.0 remove the 4-pin connector from
the motor (do not remove the 5-pin ACpower
connector). Connect the 4-pin connector from the
TECINspect Service Tool to the motor. Use the
16-4 pin adaptor (p15) with early modelTECMate
tools.
1.
(see below).
4-pin
16-pin
4-pin
16-pin
4-pin
16-pin
Disconnect AC power from the system and make sure
the blower wheel has come to a complete stop before
servicing the motor.
Do not operate motor without blower wheel attached.
Such operation will cause the motor to oscillate up and
down.
WARNING
WARNING
16

17
ECM MOTOR
TECINspect Service Tool
24VAC
Connect the two alligator clips from the
TECINspect
®
Service Tool to a constant 24VAC
(24VAC terminal and Common terminal) source
such as the transformer low-voltage terminals or
terminal strip on the manufacturer’s control board
(see Figure 3 below).These connections are not
polarity sensitive.
Figure 3
NOTE: The high voltage
5-Pin connector must be
connected to the motor
for TECINspect tests.
Place the TECINspect Service Tool switch(es) in
the OFF position.
Reconnect the AC power to the system. The
green LED light on the TECINspect Service Tool
should be on when connected properly to 24VAC.
If the green LED light is not on, there is no power
to the TECINspect Service Tool or theTECINspect
Service Tool has failed. Do not continue until the
green LED is on by correcting low voltage issue/
connections or replacing the TECINspect Service
Tool.
Refer to the table on the back of the
TECINspect Service Tool for operation
guidelines.
Observe the motor for a minimum of
15 seconds.
If using a TECMate XL on Models 2.0 / 2.3 /
Eon®,
make sure to set the switches according to
the instructions on the back for each demand test
to eliminate misdiagnosing the problem.
2.
3.
4.