Regal Genteq Evergreen IM User manual

A Regal Brand
EVERGREEN •IM
INSTALLATION GUIDE
REG9551_Evergreen_EM_Installation_Guide_v2.indd 1 2/26/13 9:12 AM

Genteq creates 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.
1946 West Cook Road
Fort Wayne, IN 46818
1-866-503-8566
www.theDealerToolbox.com
GTQ-8004 Rev 06/11
®
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Contents
Safety Considerations ....................................................................1
Introduction ....................................................................................2
Application Guide .........................................................................3
Motor Selection ..............................................................................3
Pre-Installation Notes .....................................................................4
Installation Guide ..................................................................... 5-17
Mounting the Evergreen IM ................................................. 5-6
Electrical Connections ....................................................... 7-17
High Voltage Power ........................................................ 7-8
High Voltage Signal ...................................................... 9-12
Low Voltage Signal ..................................................... 13-14
Special Applications ........................................................15
Continuous Fan Operation ..............................................16
Final Notes .........................................................................17
Airow Tests ............................................................................. 18-22
Sequence of Operation ........................................................ 23-28
Maintenance ................................................................................28
Troubleshooting Guidelines ................................................... 29-34
Installation Worksheet...................................................................35
Contractor Hotline ....................................................... Back page
Please read the entire instruction manual
before starting the installation.
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Safety Considerations
The following denitions are used as safety considerations on the Evergreen
IM motor and in this manual. Please read and observe all
of these safety concerns.
SAFETY SYMBOLS
Installation and service of this motor should be attempted only by
trained service technicians familiar with the Evergreen instructions
and training manual.
This motor should be installed in accordance with accepted practices
and installation instructions, and in compliance with all national and local
codes.
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Warning indicates
a hazardous situation which, if not
avoided, could result in death or
serious injury.
Caution indicates
a hazardous situation which, if not
avoided, could result in minor or
moderate injury.
Always disconnect the main power from the unit being serviced before
making any wiring connections to the Evergreen IM. It is also a good
practice to conrm that the power is off with a meter.
Improper installation, adjustment, alteration, service, maintenance,
or use can cause explosion, re, electrical shock, or other conditions
which may cause personal injury, death, or property damage. Consult
a qualied installer, service agency, or your distributor or branch for
information or assistance. The qualied installer or agency must use the
supplied or recommended parts when installing or servicing this product.
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The Evergreen IM is a multi-purpose replacement indoor blower motor.
Proper wiring is critical to provide proper operation and maintain the
proper operation of all safeties built into the HVAC System.
The Evergreen IM is a multi-volt capable motor. Read all instructions and
install the proper jumper for the line voltage application before applying
power to this motor.
Use of the wires provided in this kit is recommended. Should additional
wires be needed, use equivalent size wire gauge and reated insulation.
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Introduction
The Evergreen® IM is an ECM (Electronically Commutated Motor) designed
to replace an existing PSC (Permanent Split Capacitor), direct drive, indoor
blower motor. It is constructed with more than 20 years of proven ECM
technology and reliability.
This installation/service manual enables a qualied technician to install,
service, repair and maintain the Evergreen IM motor. This manual is to
be left near the HVAC system for future reference. Due to the advanced
multi-function of this motor it is highly recommend that you read the entire
manual before beginning any job to make sure it is the correct
motor for the HVAC System it is being applied to.
This unique ECM motor will operate and connect to the HVAC systems
controls much differently than the replaced PSC motor. For proper, safe
and efcient operation please read the entire manual before attempting
any wiring connections.
When properly installed the Evergreen IM will maintain the sequence of
operation and safety operations of the HVAC System.
On page 35 of this manual is an Installation Worksheet provided to
write down all the critical information for the selection, installation
and airow testing.
Included with this motor for help with installation and wiring connections
are the following:
• 115VAC white jumper
• Optional Y-adapter
• 230VAC yellow jumper (installed on motor)
• HVAC System ID Label
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Application Guide
The Evergreen IM is designed for use on the following types of HVAC systems:
• Direct Drive, 115 or 230VAC Motor Systems
• Clock-wise (CW) or Counter Clock-wise (CCW) rotation
• Residential Split and Packaged Systems
• Air Conditioning or Heat Pump Systems
• Natural Gas, Propane and Oil Heat Furnaces
• Dual Fuel Systems
• Hot water coil and Geothermal air handlers
DO NOT use this motor on any “twinned” furnace or air handler systems.
DO NOT use this motor to replace any existing ECM other than a direct
replacement of an Evergreen IM.
Motor Selection
Conrm the motor is applicable to the HVAC System using the Application
Guide above.
Conrm the motor being replaced is a direct drive indoor blower motor
operating at 115 or 230VAC. This is a dual voltage motor.
This motor will operate Clock-wise (CW) or Counter Clock-wise (CCW)
rotation automatically with its built-in Rotation Sensing feature. For more
information see the Sequence of Operation section on page 23.
Check off the HVAC systems existing PSC motor horse power (Hp) and
HVAC equipment size to determine the Evergreen IM sizing. Use the motor
that best matches the HVAC system sizing.
1/5 - 1/2 Hp ____
1.5 - 3 Ton ____ 1/2 Hp Evergreen IM
40 - 95k BTUH ____
1/2 - 1 Hp ____
3.5 - 5 Ton ____ 1 Hp Evergreen IM
100 - 150k BTUH ____
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Pre-Installation Notes
Before removing the existing motor, check off the existing speed selections,
in each mode of operation, in the spaces below. If the motor is operational,
also record the Total External Static Pressure (TESP) and/or the Temperature
Rise (TR) in each mode of operation. This information will help select the new
motor speeds.
Heat Pump Systems
Cooling/Heating Speed Hi___ MHi___ MLo___ Lo___ TESP____
Cooling/Heating Speed Hi___ MHi___ MLo___ Lo___ TESP____
(1st Stage)
Emer. Heat Speed Hi___ MHi___ MLo___ Lo___ TESP____ TR___
Furnace Heat Speed Hi___ MHi___ MLo___ Lo___
Furnace Heat Speed Hi___ MHi___ MLo___ Lo___
(1st Stage)
Air Conditioning and/or Gas, Propane
or Oil Heating Systems
Cooling Speed Hi___ MHi___ MLo___ Lo___ TESP____
Cooling Speed Hi___ MHi___ MLo___ Lo___ TESP____
(1st Stage)
Heating Speed Hi___ MHi___ MLo___ Lo___
Heating Speed Hi___ MHi___ MLo___ Lo___
(1st Stage)
NOTE: The HVAC Systems fan control connections, where the existing PSC
motor is connected, will be used to operate the Evergreen IM. Make note
of the terminals that the old motor connected to for heating and/or cooling
operation before removing the motor wires.
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Installation Guide
Mounting the Evergreen IM
Remove the blower section from the HVAC system. Remove the existing PSC
motor from the blower section. Properly dispose of the motor and the run
capacitor. The Evergreen IM motor does not require a run capacitor.
The frame size of the Evergreen IM motor is NEMA 48 frame. This is the
most common frame size for indoor blower motors. If the original motor
has the same frame size, the original mounting bracket should work on
the Evergreen IM. The Evergreen IM requires a belly band style mounting
bracket. The original mounting bracket can be used as long as it is belly
band style with no special bolts or bearing mounts. Torsion ex brackets
can be used on the ½ Hp motor only. They are not approved for the 1 Hp
motor due to noise and longevity.
If the mounting bracket must be replaced, selecting one with the same
mounting pattern on the blower housing will save drilling new holes in the
blower section.
The belly band must t the new motor properly. It should be tight enough to
prevent the motor from shifting on start-up and not cover any vents. On ECM
motors the belly band must not be placed over the motor control section.
NOTE: when attaching the bellyband mount, make sure it is not located in the
“Keep Out Area” area.
Always disconnect the main power from the unit being serviced before
making any wiring connections to the Evergreen IM. It is also a good
practice to conrm that the power is off with a meter.
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Mounting the Evergreen IM (CONT’D)
If a new motor mount is required and the legs do not
line up with the original holes in the blower housing, it is
required to use a bolt with either a lock washer and nut
or a locking nut through the new drilled hole(s).
Self tapping or sheet metal screws are not a sufcient
long term installation when a new hole is drilled through
the thin wall of the blower housing.
When positioning
the legs of the
bellyband on the
motor, make sure
that once the
motor is mounted
into the blower
section, the wires
come out towards
the bottom of the
motor as installed
in the air handler.
This will ensure that
a proper drip loop can be made with the signal and power lines.
The blower wheel should be centered in the blower
housing. The wheel should also not be resting up
against the motor bearing housing. If this is not possible
while centering the wheel the motor should be
adjusted in the belly band. If the blower wheel is dirty, it
should be cleaned.
The blower wheel hub locking bolt should be secured to
the motor shaft on the at portion of the shaft, after the
wheel has been centered in the blower housing.
Re-install the blower section in the HVAC system and
proceed to the next page to make the electrical
connections.
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As installed in the air
handler, the motor should
be positioned with the
connectors facing down
between the 4 and 8
o-clock position, with the
wiring harness formed
into a drip loop.
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Electrical Connections
High Voltage POWER Connections
• The Evergreen IM is connected to line (High) voltage power at ALL TIMES.
• Do not connect the High Voltage Power leads of the Evergreen IM motor to
any relays or switched circuit board terminals.
• If a door switch is present, wire after the switch so power will be
disconnected when the door is removed for service or maintenance.
• If the HVAC system has multiple line voltage circuits (typically on systems
with multiple heat strips), connect the Evergreen IM to the
same circuit that powered the main/fan control board or fan relay for
the original motor.
• This motor is capable of operation from 115 or 230VAC line voltage with the
proper application of the voltage jumper.
Step 1: DO NOT CONNECT OR DISCONNECT ANY PLUGS OR JUMPERS WITH
LINE VOLTAGE POWER CONNECTED OR APPLIED TO THE HARNESS. Install
the proper voltage jumper for the system the motor will be installed in. For
230VAC applications, the yellow jumper is pre-installed in the motor. For
115VAC applications, remove the yellow jumper and install the supplied white
jumper. Then connect the 5-pin plug with the alignment n facing away from
the jumper. The n and the motor connector block are both labeled 1-5 for
proper orientation. Finally connect the 4-pin plug. This plug is keyed for proper
orientation. The larger end of the plug with the larger connector goes to L1 on
the motor. Make sure the jumper and both plugs are rmly inserted into the motor.
See the examples below.
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230VAC System
Conguration
(Yellow Jumper)
115VAC System
Conguration
(White Jumper)
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Electrical Connections
High Voltage POWER Connections (CONT’D)
Step 2: Cut the High Voltage POWER harness to the length needed (leave
a little extra) to reach the desired line voltage connection point.
Step 3: Strip the insulation back to connect bare wires or install terminals
as needed.
Step 4: Connect the Black L1 wire to Line Voltage L1 on either 115 or
230VAC systems.
Step 5: Connect the White L2/N to Neutral on 115VAC systems or Line
Voltage L2 on 230VAC systems.
Step 6: Connect the Green w/Yellow stripe ground wire that is pre-connected
to the silver control end of the motor to any cabinet ground within reach. The
blower section is an acceptable ground. Conrm that the HVAC system cabinet
is grounded.
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Always disconnect the main power from the unit being serviced before
making any wiring connections to the Evergreen IM. It is also a good
practice to conrm that the power is off with a meter.
Note: On 230VAC
systems, L1 from
the motor must be
connected to the same
line voltage supplied to
the HVAC system fan
control or fan relay.
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Electrical Connections
High Voltage SIGNAL Connections
• The High Voltage SIGNAL connections communication tell the Evergreen IM
when to turn on and off according to the HVAC systems original fan control
or fan relay outputs. This maintains the operational integrity of the HVAC
System.
• These connections will also determine the output horse power (Hp) of the
Evergreen IM. The output Hp of the Evergreen IM should be set to match
the Hp rating of the PSC motor that was removed.
• Due to the multi-purpose application of this motor it would be impossible to
provide a wiring diagram for each unique HVAC System it could be used
on. The diagrams on the following pages will cover the most common
HVAC system high voltage fan operation outputs.
• Depending on the HVAC System, there may be only one or up to four
individual fan control connections necessary. These can be identied using
the existing HVAC Systems wiring diagram or following where the replaced
motor speed(s) were connected.
Step 1: Identify the horse power (Hp) rating of the replaced PSC motor.
Use the following chart to determine which High Voltage SIGNAL (HV)
connection(s) to use.
HV1 & HV2 = 1/2 - 1/3 Hp operation
1/2 Hp Motor HV1 = 1/3 - 1/4 Hp operation
HV2 = 1/4 - 1/5 Hp operation
HV1 & HV2 = 3/4 - 1Hp operation
1 Hp Motor HV1 = 3/4 - 1/2 Hp operation
HV2 = 1/2 Hp operation
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Electrical Connections
High Voltage SIGNAL Connections (CONT’D)
Step 2: Prepare the High Voltage SIGNAL (HV) connections of the
Evergreen IM motor to provide the desired horse power output using the
diagram below. Congure the output of the Evergreen IM to match the
horse power rating of the PSC motor it is replacing.
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This symbol represents a wire nut
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Electrical Connections
High Voltage SIGNAL Connections (CONT’D)
Step 3: Identify where on the HVAC system the PSC motor speed(s) were
connected. These connections could be on a main circuit board, a separate
fan control circuit board, or individual fan relay or fan switch. All of the
connections previously used by the PSC motor speeds except Neutral will
now be connected/wired together. This will allow the Evergreen motor to
receive 115VAC communication from all HVAC system demands. NOTE: None
of these connections will be energized at the same time by the HVAC system
due to the fact that a PSC motor cannot be energized on more than one
speed at a time. These 115VAC fan outputs will now become communication
only for the Evergreen motor.
For heating or cooling only systems there should be only one connection. For
single or two stage heat and/or cool systems see the diagrams below.
Single Stage Heat Two Stage Heat Single Stage Heat Two Stage Heat
Single Stage Cool Single Stage Cool Two Stage Cool Two Stage Cool
- - - - The dashed lines represent new eld wiring added after the PSC motor wiring has
been removed
This symbol represents a wire nut
For systems that energize the heat or cool taps for constant fan, no other
wiring is needed for constant fan operation from the thermostat.
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Single Stage Heat
Single Stage Cool
w/CF (constant fan)
If the circuit board also
uses a Constant Fan tap
typically labeled (CF),
combine this tap with the
previous connections for
constant fan operation.
For systems that energize
the (CF) tap from a
thermostat (G) demand
no other wiring is needed
for constant fan operation
from the thermostat. See
the example:
NOTE: In rare cases the
(CF) tap on the circuit
board is always powered
when there is no heat
or cool demand. In
this case the customer
has no control over the
constant fan operation
from the thermostat.
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Electrical Connections
High Voltage SIGNAL Connections (CONT’D)
Step 4: Connect the selected High Voltage SIGNAL (HV) connection(s) from
the motor in Step 2 to the combined fan output connections on the HVAC
system in Step 3. See examples below.
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- - - - The dashed lines represent new eld wiring added after the PSC motor wiring has
been removed
This symbol represents a wire nut
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Electrical Connections
Low Voltage SIGNAL Connections
• The Evergreen IM is unique in how it operates. Unlike a PSC motor,
the Evergreen IM motor operation (speed) is selected by the low
voltage communication inputs powered directly from the HVAC system
thermostat lines.
• Do not remove the existing thermostat lines connected to the HVAC
system from the thermostat. The Evergreen IM is wired in parallel to these
connections. The lines from the thermostat still need to be connected to
the HVAC system for correct operation.
• NOTE: There can be more than one Low Voltage SIGNAL (speed) tap
powered on the Evergreen IM motor at the same time. Unlike PSC motors,
the Evergreen IM will operate the highest speed tap that has low voltage
communication. For more information, see the Sequence Of Operation
section on page 23.
Step 1: Cut the Low Voltage SIGNAL harness to the length needed (leave
a little extra) to reach the HVAC system thermostat connections.
Step 2: Strip the insulation back to connect bare wire or install terminals
as needed to the appropriate speed selections determined below.
Step 3: Connect the Low Voltage SIGNAL wire COMMON to the 24VAC
common (C) thermostat terminal or 24VAC common side of the transformer
on the HVAC System. Make sure that this line is not connected to the side
of the transformer connected to the thermostat 24VAC (R). If it is connected to
the (R) high side of the transformer, the motor will not operate. See the diagram
on the next page.
Step 4: Connect the desired speed(s), Low Voltage SIGNAL wire(s) to the
appropriate HVAC System thermostat connection(s). Use the same speed(s)
for the heating and/or cooling demand(s) as the replaced motor. Reference
the PRE-INSTALLATION NOTES on page 4.
See the diagram on the next page.
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DO NOT connect the Low Voltage SIGNAL (speed) connections to the
existing PSC motor connections on the HVAC system. Any voltage above
30VAC connected to these terminals will cause permanent damage to
the motor.
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Electrical Connections
Low Voltage SIGNAL Connections (CONT’D)
Most HVAC systems use the same terminal designations for their thermostat
demands. However there are variations. If the terminal designations in the
HVAC system being connected to are different than the ones used in our
diagrams, match them up to the operation of our generic listing below.
Air Conditioning Systems with or without Electric Strip Heat
Y —— Call for cooling on single stage systems
Y1—— Call for rst stage cooling on two stage systems
Y2—— Call for second stage cooling on two stage systems
W —— Call for heating (electric strips)
Heat Pump Systems with or without Electric Strip Heat
Y——— Call for heating and cooling (operates the outdoor
unit contactor)
W2—— Call for Emergency Heat
Gas, Propane or Oil Heat Systems
W——— Call for heating on single stage systems
W1—— Call for rst stage heating on two stage systems
W2—— Call for second stage heating on two stage systems
The (G) continuous fan connection from the thermostat is not required on
the Evergreen IM for continuous fan operation. A special high efciency fan
speed will be energized automatically if constant fan is energized from the
thermostat through the High Voltage SIGNAL connection(s). If continuous fan
operation is desired at a higher airow, see the Special Applications section
on page 16.
See the next page for any SPECIAL APPLICATIONS and/or continue with the
FINAL ELECTRICAL CONNECTION NOTES on page 17.
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Electrical Connections
Special Applications
If the HVAC System this motor is applied to uses a separate speed for
each heating and/or cooling demand including two-stage systems, this
page is not needed.
Systems that require the same speed for heating and/or cooling demands.
For Example:
• Heat Pump Systems with or without emergency electric strip heat.
• Air Conditioning Systems with electric heat.
• Large furnaces connected to a small air conditioning or heat pump.
• Systems with multiple stages and overlapping airow requirements.
To allow the motor to operate at the same speed from two different
thermostat demands, the special Y-adapter included in the box must be
used. DO NOT attempt to use any other method to wire two thermostat lines
to the same speed. The Y-adapter is specially designed for this application
to prevent voltage feedback, and the operation of multiple demands at the
same time.
Only the MED-HI and LOW speeds can be used with the Y-adapter. If HI
or MED-LOW is found to be the required airow for two system demands
another speed will have to be used for one of the demands, or the Evergreen
IM should not be applied to that system. In most cases the speeds of the
Evergreen IM are close enough in airow range to select another speed for
one of the demands.
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Electrical Connections
Special Applications
High Efciency Constant Fan Operation
The Evergreen IM will automatically operate a xed high efciency low
constant fan airow without a (G) fan connection to the Low Voltage
SIGNAL (speed) taps. When the HVAC System receives a 24VAC (G)
command from the thermostat to the fan controls, they will send 115VAC
to the High Voltage SIGNAL connection(s). If the motor receives voltage on
the High Voltage SIGNAL connection(s) with no voltage on the Low Voltage
SIGNAL connections, the motor will operate at the special high efciency
low constant fan airow automatically. See the Sequence of Operation
section on page 28 for more information.
Increasing Constant Fan Airow
If more airow is desired during constant fan operation there are two options.
Option 1: Connect any of the Low Voltage SIGNAL (speed) taps on the
motor not being used by a heating or cooling demand to the 24VAC
constant fan (G) thermostat demand.
Option 2: If the speed desired for constant fan is currently being used by
a heating or cooling demand, use the special Y-adapter to connect any
24VAC thermostat demand and the 24VAC constant fan (G) thermostat
demand to the same motor speed. Only the MED-HI and LOW speeds can
be used with the Y-adapter. If HI or MED-LOW is currently being used by a
heating or cooling thermostat demand, another speed will have to be used
for the 24VAC constant fan (G) thermostat demand.
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Electrical Connections
Final Notes
When nished connecting all of the Evergreen IM wires to the system, create
the recommended drip loop, and assure it will not interfere with the blower
wheel or other system wiring.
It is ok to leave extra wire, especially the unused speeds. Tie them to the
harness for future use if needed. Even though the extra speed and High
Voltage SIGNAL wires will have no voltage or current on them, it is a good
practice to wire nut and tape these unused leads.
INSTALL THE SYSTEM ID LABEL on the HVAC system near the existing wiring
diagram and enter the Evergreen IM data. Record the Horse Power (Hp) of
the motor and the Date of Installation for future reference if needed. The
motors Hp rating can be found on the label located on the box.
ALWAYS verify the HVAC System operation in all demand modes applicable,
heating, cooling and continuous fan.
Note: On 230VAC systems, if the motor does not run after all High and Low
Voltage connections have been completed, reverse the High Voltage Power
L1 and L2 connection from the motor.
ALWAYS verify the airow in all demand modes by following the instructions in
the next section on “Airow Tests”.
Genteq is committed to helping with any special wiring or application
questions. We have provided more example wiring diagrams if needed
on our website at www.theDealerToolbox.com. If immediate assistance is
required you may contact technical support on the Evergreen Contractor
Hotline at 1-866-503-8566.
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