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