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TROUBLESHOOTING ECM ™ MOTORS CONT'D.
TROUBLESHOOTING GE ECM
Replacing ECM Control Module
To replace the control module for the GE variable-speed indoor blower
Replacing ECM Control Module
motor you need to take the following steps:
To replace the control module for the GE variable-speed indoor blower
1. You MUST have the correct replacement module. The controls are
motor you need to take the following steps:
factory programmed for specific operating modes. Even though they look
1. You MUST have the correct replacement module. The controls are
alike, different modules may have completely different functionality.
factory programmed for specific operating modes. Even though they look
USING THE WRONG CONTROL MODULE VOIDS ALL PRODUCT
alike, different modules may have completely different functionality.
WARRANTIES AND MAY PRODUCE UNEXPECTED RESULTS.
USING THE WRONG CONTROL MODULE VOIDS ALL PRODUCT
2. Begin by removing AC power from the furnace or air handler being
WARRANTIES AND MAY PRODUCE UNEXPECTED RESULTS.
serviced. DO NOT WORK ON THE MOTOR WITH AC POWER
2. Begin by removing AC power from the furnace or air handler being
APPLIED. To avoid electric shock from the motor's capacitors, disconnect
serviced. DO NOT WORK ON THE MOTOR WITH AC POWER
power and wait at least 5 minutes before opening motor.
APPLIED. To avoid electric shock from the motor's capacitors, disconnect
3. It is usually not necessary to remove the motor from the blower
power and wait at least 5 minutes before opening motor.
assembly. However, it is recommended that the whole blower assembly,
3. It is usually not necessary to remove the motor from the blower
with the motor, be removed from the furnace/air handler. (Follow the
assembly. However, it is recommended that the whole blower assembly,
manufacturer's procedures). Unplug the two cable connectors to the motor.
with the motor, be removed from the furnace/air handler. (Follow the
There are latches on each connector. DO NOT PULL ON THE WIRES.
manufacturer's procedures). Unplug the two cable connectors to the motor.
The plugs remove easily when properly released.
There are latches on each connector. DO NOT PULL ON THE WIRES.
4. Locate the two standard ¼" hex head bolts at the rear of the control
The plugs remove easily when properly released.
housing (at the back end of the control opposite the shaft end). Refer to
4. Locate the two standard ¼" hex head bolts at the rear of the control
Figure 25. Remove these two bolts from the motor and control assembly
housing (at the back end of the control opposite the shaft end). Refer to
while holding the motor in a way that will prevent the motor or control
Figure 24. Remove these two bolts from the motor and control assembly
from falling when the bolts are removed. If an ECM2.0 control is being
while holding the motor in a way that will prevent the motor or control
replaced (recognized by an aluminum casting rather that a deep-drawn
from falling when the bolts are removed. If an ECM2.0 control is being
black steel can housing the electronics), remove only the hex-head bolts.
replaced (recognized by an aluminum casting rather that a deep-drawn
DO NOT REMOVE THE TORX-HEAD SCREWS.
black steel can housing the electronics), remove only the hex-head bolts.
5. The control module is now free of mechanical attachment to the
DO NOT REMOVE THE TORX-HEAD SCREWS.
motor endshield but is still connected by a plug and three wires inside
5. The control module is now free of mechanical attachment to the
the control. Carefully rotate the control to gain access to the plug at
motor endshield but is still connected by a plug and three wires inside
the control end of the wires. With thumb and forefinger, reach the latch
the control. Carefully rotate the control to gain access to the plug at
holding the plug to the control and release it by squeezing the latch tab
the control end of the wires. With thumb and forefinger, reach the
and the opposite side of the connector plug and gently pulling the plug
latch holding the plug to the control and release it by squeezing the
out of the connector socket in the control. DO NOT PULL ON THE
latch tab and the opposite side of the connector plug and gently pulling
WIRES. GRIP THE PLUG ONLY.
the plug out of the connector socket in the control. DO NOT PULL
6. The control module is now completely detached from the motor.
ON THE WIRES. GRIP THE PLUG ONLY.
Verify with a standard ohmmeter that the resistance from each motor
6. The control module is now completely detached from the motor.
lead (in the motor plug just removed) to the motor shell is >100K ohms.
Verify with a standard ohmmeter that the resistance from each motor
Refer to Figure 26. (Measure to unpainted motor end plate.) If any
lead (in the motor plug just removed) to the motor shell is >100K ohms.
motor lead fails this test, do not proceed to install the control module.
Refer to Figure 25. (Measure to unpainted motor end plate.) If any
THE MOTOR IS DEFECTIVE AND MUST BE REPLACED.
motor lead fails this test, do not proceed to install the control module.
Installing the new control module will cause it to fail also.
THE MOTOR IS DEFECTIVE AND MUST BE REPLACED.
7. Verify that the replacement control is correct for your application.
Installing the new control module will cause it to fail also.
Refer to the manufacturer's authorized replacement list. USING THE
7. Verify that the replacement control is correct for your
WRONG CONTROL WILL RESULT IN IMPROPER OR NO
application. Refer to the manufacturer's authorized replacement list.
BLOWER OPERATION. Orient the control module so that the 3-wire
USING THE WRONG CONTROL WILL RESULT IN
motor plug can be inserted into the socket in the control. Carefully insert
IMPROPER OR NO BLOWER OPERATION. Orient the control
the plug and press it into the socket until it latches. A SLIGHT CLICK
module so that the 3-wire motor plug can be inserted into the socket in
WILL BE HEARD WHEN PROPERLY INSERTED. Finish installing
the control. Carefully insert the plug and press it into the socket until
the replacement control per one of the three following paragraphs, 8a, 8b or 8c.
it latches. A SLIGHT CLICK WILL BE HEARD WHEN
8a. IF REPLACING AN ECM 2.0 CONTROL (control in cast
PROPERLY INSERTED. Finish installing the replacement control per
aluminum can with air vents on the back of the can) WITH AN ECM
one of the three following paragraphs, 8a, 8b or 8c.
2.3 CONTROL (control containing black potting for water protection
8a. IF REPLACING AN ECM 2.0 CONTROL (control in cast
in black deep-drawn steel case with no vents in the bottom of the can),
aluminum can with air vents on the back of the can) WITH AN ECM
locate the two through-bolts and plastic tab that are packed with the
2.3 CONTROL (control containing black potting for water protection in
replacement control. Insert the plastic tab into the slot at the perimeter
black deep-drawn steel case with no vents in the bottom of the can),
of the open end of the can so that the pin is located on the inside of the
locate the two through-bolts and plastic tab that are packed with the
perimeter of the can. Rotate the can so that the tab inserts into the tab
replacement control. Insert the plastic tab into the slot at the perimeter
locater hole in the endshield of the motor. Using the two through-bolts
of the open end of the can so that the pin is located on the inside of the
provided with the replacement control, reattach the can to the motor.
perimeter of the can. Rotate the can so that the tab inserts into the tab
THE TWO THROUGH-BOLTS PROVIDED WITH THE
locater hole in the endshield of the motor. Using the two through-bolts
REPLACEMENT ECM 2.3 CONTROL ARE SHORTER THAN
provided with the replacement control, reattach the can to the motor.
THE BOLTS ORIGINALLY REMOVED FROM THE ECM 2.0
THE TWO THROUGH-BOLTS PROVIDED WITH THE
CONTROL AND MUST BE USED IF SECURE ATTACHMENT OF
REPLACEMENT ECM 2.3 CONTROL ARE SHORTER THAN
THE CONTROL TO THE MOTOR IS TO BE ACHIEVED.
THE BOLTS ORIGINALLY REMOVED FROM THE ECM 2.0
DO NOT OVERTIGHTEN THE BOLTS.
CONTROL AND MUST BE USED IF SECURE ATTACHMENT
OF THE CONTROL TO THE MOTOR IS TO BE ACHIEVED.
DO NOT OVERTIGHTEN THE BOLTS.
Manual 2100-522B
Page
36 of 38
™
MOTORS CONT'D.
8b. IF REPLACING AN ECM 2.3 CONTROL WITH AN ECM 2.3
CONTROL, the plastic tab and shorter through-bolts are not needed. The
8b. IF REPLACING AN ECM 2.3 CONTROL WITH AN ECM 2.3
control can be oriented in two positions 180° apart. MAKE SURE THE
CONTROL, the plastic tab and shorter through-bolts are not needed. The
ORIENTATION YOU SELECT FOR REPLACING THE CONTROL
control can be oriented in two positions 180° apart. MAKE SURE THE
ASSURES THE CONTROL'S CABLE CONNECTORS WILL
ORIENTATION YOU SELECT FOR REPLACING THE
BE LOCATED DOWNWARD IN THE APPLICATION SO THAT
CONTROL ASSURES THE CONTROL'S CABLE CONNECTORS
WATER CANNOT RUN DOWN THE CABLES AND INTO THE
WILL BE LOCATED DOWNWARD IN THE APPLICATION SO
CONTROL. Simply orient the new control to the motor's endshield, insert
THAT WATER CANNOT RUN DOWN THE CABLES AND INTO
bolts, and tighten. DO NOT OVERTIGHTEN THE BOLTS.
THE CONTROL. Simply orient the new control to the motor's endshield,
8c. IF REPLACING AN ECM 2.0 CONTROL WITH AN ECM 2.0
insert bolts, and tighten. DO NOT OVERTIGHTEN THE BOLTS.
CONTROL (It is recommended that ECM 2.3 controls be used for all
8c. IF REPLACING AN ECM 2.0 CONTROL WITH AN ECM 2.0
replacements), the new control must be attached to the motor using through
CONTROL (It is recommended that ECM 2.3 controls be used for all
bolts identical to those removed with the original control. DO NOT
replacements), the new control must be attached to the motor using
OVERTIGHTEN THE BOLTS.
through bolts identical to those removed with the original control. DO
9. Reinstall the blower/motor assembly into the HVAC equipment.
NOT OVERTIGHTEN THE BOLTS.
Follow the manufacturer's suggested procedures.
9. Reinstall the blower/motor assembly into the HVAC equipment.
10. Plug the 16-pin control plug into the motor. The plug is keyed.
Follow the manufacturer's suggested procedures.
Make sure the connector is properly seated and latched.
10. Plug the 16-pin control plug into the motor. The plug is keyed.
11. Plug the 5-pin power connector into the motor. Even though the
Make sure the connector is properly seated and latched.
plug is keyed, OBSERVE THE PROPER ORIENTATION. DO NOT
11. Plug the 5-pin power connector into the motor. Even though the
FORCE THE CONNECTOR. It plugs in very easily when properly
plug is keyed, OBSERVE THE PROPER ORIENTATION. DO NOT
oriented. REVERSING THIS PLUG WILL CAUSE IMMEDIATE
FORCE THE CONNECTOR. It plugs in very easily when properly
FAILURE OF THE CONTROL MODULE.
oriented. REVERSING THIS PLUG WILL CAUSE IMMEDIATE
12. Final installation check. Make sure the motor is installed as follows:
FAILURE OF THE CONTROL MODULE.
a. Unit is as far INTO the blower housing as possible.
12. Final installation check. Make sure the motor is installed as follows:
b. Belly bands are not on the control module or covering vent holes.
a. Unit is as far INTO the blower housing as possible.
c. Motor connectors should be oriented between the 4 o'clock and 8
b.Belly bands are not on the control module or covering vent holes.
o'clock positions when the blower is positioned in its final
c. Motor connectors should be oriented between the 4 o'clock and 8
location and orientation.
o'clock positions when the blower is positioned in its final
d. Add a drip loop to the cables so that water cannot enter the motor
location and orientation.
by draining down the cables. Refer to Figure 27.
d.Add a drip loop to the cables so that water cannot enter the motor
The installation is now complete. Reapply the AC power to the HVAC
by draining down the cables. Refer to Figure 26.
equipment and verify that the new motor control module is working
The installation is now complete. Reapply the AC power to the HVAC
properly. Follow the manufacturer's procedures for disposition of the old
equipment and verify that the new motor control module is working
control module.
properly. Follow the manufacturer's procedures for disposition of the old
control module.
Figure 25
Figure 24
Figure 3
Control Disassembly
Only remove
From Motor
Hex Head Bolts
Push until
Latch Seats
Over Ramp
Circuit
Board
Motor
ECM 2.0
Note:
Use the shorter
bolts and
alignment pin
supplied when
replacing an
ECM 2.0
Motor Connector
control.
(3-pin)
ECM
Control Connector
2.3/2.5
(16-pin)
Power Connector
(5-pin)
Hex-head Screws
Figure 26
Figure 25
Figure 4
Winding Test
Motor Connector
(3-pin)
Motor OK when
R > 100k ohm
Figure 27
Figure 26
Figure 5
Drip Loop
Connector Orientation
Back of
Control
Between 4 and 8 o'clock
Drip Loop
Manual
2100-601B
Page
39 of 42
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