This material has been created and distributed for the purpose of education and to encourage best practices of the HVAC industry. The integrity of the.

The ECM Textbook

The ECM Textbook

Table of Contents History of ECM Constant Airflow ECM

Constant Torque ECM

Constant Speed ECM

The ECM TextbookHistory of ECM v3.0

History of ECM Technology

1987• General Electric introduces first ECM to residential

HVAC

2004• Regal Beloit purchases the ECM, PSC and Capacitor

divisions from GE with permission to brand as:

Page 1

• Public Corporation established in 1955 -• History

50s to 70s - Special Cutting Tools 80s to 90s – Mechanical Power Transmission 90s to 00s – Motors and Generators Largest Non-Captive Motor supplier globally #1 Commercial and Industrial and #1 HVAC

• Recognized Motor Brands

Regal-Beloit Corporation Background

NYSE – RBC

History of ECM Technology Page 1

History in the Making

2009• Regal Beloit introduces a new brand for all of the GE

_______ by REGAL BELOIT divisions.

History of ECM Technology Page 1

A wealth of information at your fingertips

www.GenteqMotors.com

www.GenteqComfort.com

Page 2 History of ECM Technology

New Name, same reputation for innovative, premium comfort and electrical components

Proven reputation for high quality, highly reliable products and strong customer relationships

Overview of ECM Technology

• ECM (Electronically Commutated Motor)• Brushless DC, permanent magnet rotor• More efficient than PSC (Permanent Split Capacitor)

motors• Used throughout HVACR • Programmable• Direct drive fractional horse power motors

ECM PSC

Page 3


• Mid 1900’s PSC replaces shaded pole as standard• Better starting torque and efficiency• Low cost and simple• Limited operation due to fixed motor poles, fixed supplied

frequency (60 Hz), 3-5 speeds

• Slave to airside resistance PSC

Page 3


• PSC Motor Chart• Synchronous speed = Frequency x 120 / Poles• Rated Speed = Synchronous speed minus electrical

and mechanical losses in the motor and load• Operation range = The range the motor will typically

operate at under load

Page 4


• PSC peak efficiency is 60% at design rated speed and load

• Efficiency degrades by load and speed changes• Efficiency loss of the rotor• Basic A/C motor design, rotor follows the rotating field

(magnetic effect) in the stator

PSC

Page 4


• ECM – Basic electric motor operated by a microprocessor based control

• Line voltage powers control, control operates motor from communication and programming

• Ability to control Torque, Speed or both• Increased range of operation and efficiency• More precise control than speed taps• Ability to compensate for airside restrictions

Page 5


• Old definition– ICM (Integrated Control Module)

• Current definition– ECM (Electronically Commutated Motor)

– Commutate – change or reverse the direction of an electric current (the means by which all electric motors rotate)

Page 5


• The Genteq™ motor, currently used by most residential HVAC systems is a brushless DC, three-phase motor with a permanent magnet rotor.

• Motor phases are sequentially energized by the electronic control, powered from a single-phase supply.

• Made of two components

– Motor Control (control module)

– Motor (motor control)Motor Control 3-Phase Motor

Page 5


• Motor Control and Motor as separate components

• Motor Control integrated into the motor shell

Motor Control Motor Control

Motor Motor

Page 5


• The Motor Control– Connected to single phase (1Ø) 120, 240 or 460vac 50 or

60 cycle power (Hz)

– AC power is converted to DC power to operate the electronics

– DC power is converted to a three phase (3Ø) signal to drive motor

– Microprocessor controls frequency (RPM) and torque (power) delivered to motor.

MotorControl

Permanent magnet rotor

Motor

Page 6


• The Motor Control– Microprocessor operates motor by program and

communication from HVAC system• AC or DC voltage, PWM or DSI

– Unique features by program specific to each motor

– Constant Airflow, Constant Torque, Constant Speed

– Ability to monitor and control current and frequency

– Typical operating range of 600-1200 rpm

MotorControl


Motor

Page 6


• The Motor– Three phase motor, permanent magnet rotor

• Electrical efficiency

• Brushless (Electronically Commutated)

– 80% electrically efficient across entire operating range

MotorControl


Page 6

Line voltage 120/240vac 1 Ø

Communication from Air Handler

demand (heat, cool, fan…)

The Microprocessor continuously directs the controls to adjust current (torque) and/or frequency (speed)

to maintain the designed program.

The Microprocessor constantly monitors motor speed (RPM) or torque (current).

Genteq™Premium ECM Motor

3 Ø Motor

ControlsConvert DC To

3 Ø

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 specifying the current (torque) and frequency (speed)

Microprocessor

DC Voltage

Motor Module

3 Ø


• Genteq ECM motor types

– Constant Airflow (Variable Speed) indoor blower motor• Current OEM models include Think Tank 2.3 & 3.0, out of production

models include 1.0, 2.0 and 2.5

– Constant Torque indoor blower motor• OEM model X13 and aftermarket retrofit model Evergreen

– Constant Speed• Current outdoor fan motor OEM model 142R, out of production model

142

• Current commercial refrigeration models ARKTIC/ICE 59, ARKTIC SSC, and ARKTIC/ICE 142, out of production models include 44/64 frame, 58mm, 84mm, SSC and SSC2

Page 7

Page 7


• Benefit of Technology– Electrical Efficiency

– Program more precise and controlled operation

– Wider range of operation

– Enhance consumer comfort• Dehumidification

• Constant Fan

• Soft Start/Stop

• Improved Airflow

MotorControl


Page 8

That’s All Folks!

This material has been created and distributed for the purpose of education and to encourage best practices of the HVAC industry. The integrity of the.

Documents

ecm textbook slide

genteq motor

motor phases

phase motor page

ecm textbook history

overview of ecm technology

history of ecm technology

fixed motor poles