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The ECM Textbook
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The ECM Textbook
Table of Contents History of ECM Constant Airflow ECM
Constant Torque ECM
Constant Speed ECM
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The ECM TextbookHistory of ECM v3.0
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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:
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• 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
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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
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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
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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
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Overview of ECM Technology
• 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
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Overview of ECM Technology
• 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
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Overview of ECM Technology
• 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
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Overview of ECM Technology
• 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
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Overview of ECM Technology
• 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)
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Overview of ECM Technology
• 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
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Overview of ECM Technology
• Motor Control and Motor as separate components
• Motor Control integrated into the motor shell
Motor Control Motor Control
Motor Motor
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Overview of ECM Technology
• 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
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Overview of ECM Technology
• 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
Permanent magnet rotor
Motor
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Overview of ECM Technology
• The Motor– Three phase motor, permanent magnet rotor
• Electrical efficiency
• Brushless (Electronically Commutated)
– 80% electrically efficient across entire operating range
MotorControl
Permanent magnet rotor
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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
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Overview of ECM Technology
• 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
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Overview of ECM Technology
• 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
Permanent magnet rotor
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That’s All Folks!