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TROUBLESHOOTING GE ECM
TROUBLESHOOTING ECM
Replacing ECM Control Module
Replacing ECM Control Module
To replace the control module for the GE variable-speed indoor blower
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
alike, different modules may have completely different functionality.
USING THE WRONG CONTROL MODULE VOIDS ALL PRODUCT
WARRANTIES AND MAY PRODUCE UNEXPECTED RESULTS.
USING THE WRONG CONTROL MODULE VOIDS ALL PRODUCT
WARRANTIES AND MAY PRODUCE UNEXPECTED RESULTS.
2. Begin by removing AC power from the furnace or air handler being
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.
The plugs remove easily when properly released.
4. Locate the two standard ¼" hex head bolts at the rear of the control
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 24. 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 26. 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.
DO NOT REMOVE THE TORX-HEAD SCREWS.
5. The control module is now free of mechanical attachment to the
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
the control. Carefully rotate the control to gain access to the plug at
latch holding the plug to the control and release it by squeezing the
the control end of the wires. With thumb and forefinger, reach the latch
latch tab and the opposite side of the connector plug and gently pulling
holding the plug to the control and release it by squeezing the latch tab
the plug out of the connector socket in the control. DO NOT PULL
and the opposite side of the connector plug and gently pulling the plug
ON THE WIRES. GRIP THE PLUG ONLY.
out of the connector socket in the control. DO NOT PULL ON THE
WIRES. GRIP THE PLUG ONLY.
6. The control module is now completely detached from the motor.
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 25. (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 27. (Measure to unpainted motor end plate.) If any motor
THE MOTOR IS DEFECTIVE AND MUST BE REPLACED.
lead fails this test, do not proceed to install the control module. THE
Installing the new control module will cause it to fail also.
MOTOR IS DEFECTIVE AND MUST BE REPLACED. Installing
the new control module will cause it to fail also.
7. Verify that the replacement control is correct for your
application. Refer to the manufacturer's authorized replacement list.
7. Verify that the replacement control is correct for your application.
USING THE WRONG CONTROL WILL RESULT IN
Refer to the manufacturer's authorized replacement list. USING THE
IMPROPER OR NO BLOWER OPERATION. Orient the control
WRONG CONTROL WILL RESULT IN IMPROPER OR NO
module so that the 3-wire motor plug can be inserted into the socket in
BLOWER OPERATION. Orient the control module so that the 3-wire
the control. Carefully insert the plug and press it into the socket until
motor plug can be inserted into the socket in the control. Carefully insert
it latches. A SLIGHT CLICK WILL BE HEARD WHEN
the plug and press it into the socket until it latches. A SLIGHT CLICK
PROPERLY INSERTED. Finish installing the replacement control per
WILL BE HEARD WHEN PROPERLY INSERTED. Finish installing
one of the three following paragraphs, 8a, 8b or 8c.
the replacement control per one of the three following paragraphs, 8a, 8b or 8c.
8a. 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 AN ECM
aluminum can with air vents on the back of the can) WITH AN ECM
2.3 CONTROL (control containing black potting for water protection in
2.3 CONTROL (control containing black potting for water protection
black deep-drawn steel case with no vents in the bottom of the can),
in black deep-drawn steel case with no vents in the bottom of the can),
locate the two through-bolts and plastic tab that are packed with the
locate the two through-bolts and plastic tab that are packed with the
replacement control. Insert the plastic tab into the slot at the perimeter
replacement 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 inside of the
perimeter of the can. Rotate the can so that the tab inserts into the tab
perimeter of the can. Rotate the can so that the tab inserts into the tab
locater hole in the endshield of the motor. Using the two through-bolts
locater hole in the endshield of the motor. Using the two through-bolts
provided with the replacement control, reattach the can to the motor.
provided with the replacement control, reattach the can to the motor.
THE TWO THROUGH-BOLTS PROVIDED WITH THE
THE TWO THROUGH-BOLTS PROVIDED WITH THE
REPLACEMENT ECM 2.3 CONTROL ARE SHORTER THAN
REPLACEMENT ECM 2.3 CONTROL ARE SHORTER THAN
THE BOLTS ORIGINALLY REMOVED FROM THE ECM 2.0
THE BOLTS ORIGINALLY REMOVED FROM THE ECM 2.0
CONTROL AND MUST BE USED IF SECURE ATTACHMENT
CONTROL AND MUST BE USED IF SECURE ATTACHMENT OF
OF THE CONTROL TO THE MOTOR IS TO BE ACHIEVED.
THE CONTROL TO THE MOTOR IS TO BE ACHIEVED.
DO NOT OVERTIGHTEN THE BOLTS.
DO NOT OVERTIGHTEN THE BOLTS.
Manual 2100-522B
Page
36 of 38
™
MOTORS CONT'D.
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 can be oriented in two positions 180° apart. MAKE SURE THE
CONTROL ASSURES THE CONTROL'S CABLE CONNECTORS
ORIENTATION YOU SELECT FOR REPLACING THE CONTROL
WILL BE LOCATED DOWNWARD IN THE APPLICATION SO
ASSURES THE CONTROL'S CABLE CONNECTORS WILL BE
THAT WATER CANNOT RUN DOWN THE CABLES AND INTO
LOCATED DOWNWARD IN THE APPLICATION SO THAT WATER
THE CONTROL. Simply orient the new control to the motor's endshield,
CANNOT RUN DOWN THE CABLES AND INTO THE CONTROL.
insert bolts, and tighten. DO NOT OVERTIGHTEN THE BOLTS.
Simply orient the new control to the motor's endshield, insert bolts, and
tighten. DO NOT OVERTIGHTEN THE BOLTS.
8c. IF REPLACING AN ECM 2.0 CONTROL WITH AN ECM 2.0
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
CONTROL (It is recommended that ECM 2.3 controls be used for all
through bolts identical to those removed with the original control. DO
replacements), the new control must be attached to the motor using through
NOT OVERTIGHTEN THE BOLTS.
bolts identical to those removed with the original control. DO NOT
OVERTIGHTEN THE BOLTS.
9. Reinstall the blower/motor assembly into the HVAC equipment.
Follow the manufacturer's suggested procedures.
9. Reinstall the blower/motor assembly into the HVAC equipment.
Follow the manufacturer's suggested procedures.
10. Plug the 16-pin control plug into the motor. The plug is keyed.
Make sure the connector is properly seated and latched.
10. Plug the 16-pin control plug into the motor. The plug is keyed.
Make sure the connector is properly seated and latched.
11. Plug the 5-pin power connector into the motor. Even though the
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
FAILURE OF THE CONTROL MODULE.
12. Final installation check. Make sure the motor is installed as follows:
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 26.
d. Add a drip loop to the cables so that water cannot enter the motor
by draining down the cables. Refer to Figure 28.
The installation is now complete. Reapply the AC power to the HVAC
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 26
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 27
Figure 25
Figure 4
Winding Test
Motor Connector
(3-pin)
Motor OK when
R > 100k ohm
Figure 28
Figure 26
Figure 5
Drip Loop
Connector Orientation
Back of
Control
Between 4 and 8 o'clock
Drip Loop
Manual
2100-602A
Page
39 of 41
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Troubleshooting
