Regal genteq ECM Service Manual
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Regal genteq ECM Service Manual

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ECM SERVICE GUIDE
ECM SERVICE GUIDE

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Summary of Contents for Regal genteq ECM

  • Page 1 ECM SERVICE GUIDE ECM SERVICE GUIDE...
  • Page 2 WA R N I N G Genteq does not condone the repair of any individual components in the motor control or motor of their ECM products. This practice is unsafe and may cause personal injury, death, or property damage. WA R N I N G Working on the motor with power connected may result in electrical shock or other conditions that may cause personal injury, death or property damage.

  • Page 3: Table Of Contents

    ECM SERVICE GUIDE TABLE OF CONTENTS About the Company Using the ECM Service Guide Start Here: Using the ECM Service Guide HVAC System Troubleshooting Basics Tech Tips Motor Identification Chart Motor Diagnostics & Replacement Variable Speed Motors Premium ECM Motor Diagnostics &...

  • Page 4: About The Company

    Regardless of the manufacturer of the appliance, this guide will help troubleshoot the Genteq ECM motor driving it. It is our hope that this guide will provide a simple and accurate process for troubleshooting all of our motors.
  • Page 5 HVACR solutions for which this company has always been known. Even if you are not familiar with the name Regal, you are most likely familiar with one or more of the motor brands they own such as Marathon...

  • Page 6: Using The Ecm Service Guide

    Using the ECM Service Guide Read this section before using Motor Diagnostics & Replacement START HERE: Using the ECM Service Guide The purpose of this guide is to help you accurately and efficiently troubleshoot Genteq ECM-driven ® systems. For ease of troubleshooting and to avoid misdiagnosis, it is strongly recommended that each step of this guide be used in the following order: Begin with the “HVAC System Troubleshooting...

  • Page 7: Hvac System Troubleshooting Basics

    HVAC System Troubleshooting Basics Before troubleshooting the ECM motor, check these system basics if applicable: Confirm that the correct thermostat input and ONLY the correct input voltage is present at the interface or main control board on the furnace/ air handler or outdoor unit. Loose or broken low- voltage wires are also potential problem areas and can cause intermittent problems.
  • Page 8 Check all terminal/plug connections both at the furnace/air-handler or outdoor unit control board and at the motor. Always disconnect power to the system before disconnecting and reconnecting plugs. Look for: Loose plugs and/or loose pin connections in the plug. Burnt, bent or loose pins or seats. Confirm there are no limits, rollouts or safeties tripped.

  • Page 9: Tech Tips

    Tech Tips TECH TIP #1 Do not automatically assume the ECM motor has failed. Follow this guide completely before replacing TECH TIP #2 When it is necessary to disconnect the power from the HVAC system, it is always good practice to verify that voltage has been disconnected with a voltmeter.

  • Page 10: Motor Identification Chart

    Motor Identification Chart OEM Constant Torque Indoor Blower Motor Identification ECM X13 ® Sticker & Endura C L G N ® Heat sink Speed taps 1 2 3 4 5 Evergreen Aftermarket Constant Torque Indoor Blower Motor ® Evergreen CM, AH & EM have a missing wire upper plug Evergreen IM has a white or yellow voltage jumper All Evergreen Motors have a heat sink here...
  • Page 11 Motor Identification Chart OEM Variable Speed Indoor Blower Motor motor uses ® 16-pin connector Identification Sticker ECM 3.0 Heat sink & Eon 3.0 uses 4-pin connector 2.3/2.5 wires wires Identification - 6 or more Sticker wires in the 16-pin connector NOTE: Early models do not have indentification stickers.
  • Page 12 WA R N I N G Genteq does not condone the repair of any individual components in the motor control or motor of their ECM products. This practice is unsafe and may cause personal injury, death, or property damage. WA R N I N G Working on the motor with power connected may result in electrical shock or other conditions that may cause personal injury, death or property damage.

  • Page 13: Variable Speed Motors

    Variable Speed Models 2.0 / 2.3 / 2.5 / Eon / 3.0 ® Premium ECM Motors See the Motor ID Chart on page 8 if needed. Models 2.0 / 2.3 / 2.5 / Eon / 3.0 Premium ECM Motor Diagnostics TECINspect Service Tool ®...

  • Page 14: Premium Ecm Motor Diagnostics

    Models 2.0 / 2.3 / 2.5 / Eon / 3.0 ® Premium ECM Motor Diagnostics IF THE MOTOR IS RUNNING It is normal for the motor to rock back and forth on start up. Do not replace the motor if this is the only symptom identified.
  • Page 15 If the motor does not shut off at the end of the cycle, check the delay times and wait for the delays to time out. Also, make sure that there is no call for “Continuous fan” on the “G” terminal. This motor may take a while to come to a complete stop with selected delays and the normal ramp down.
  • Page 16 IF THE MOTOR IS NOT RUNNING Check for proper high voltage and ground at the 5-pin connector at the motor. Correct any voltage issues before proceeding to the next step. These are dual voltage motors capable of operating in 120 or 240VAC systems. On 120VAC systems there should be a jumper between terminals 1 and 2 (see Figure 1).
  • Page 17 Figure 1 Models 2.0 / 2.3 / 2.5 / Eon / 3.0 ® GROUND NEUTRAL 120VAC LINE 1 120VAC SYSTEM W A R N I N G Always disconnect the power from the system before removing the high voltage plug, and before reconnecting. Models 2.0 / 2.3 / 2.5 / Eon / 3.0 Figure 2 GROUND...

  • Page 18: Tecinspect Service Tool

    TECINspect ® USAGE CHART In 2013 the TECMate Pro service tool was rebranded to TECINspect Service Tool. TECINspect Service Tool Generational Growth TECMate XL TECMate PRO TECINspect 4 Switches 1 Switch 1 Switch 16-pin connector 1st Generation 16&4 pin 16-pin connector connector harness 2nd Generation...

  • Page 19: Troubleshooting With The Tecinspect Service Tool

    Troubleshooting with the TECINspect ® Service Tool (Models 2.0 / 2.3 / Eon / 3.0 only) ® See Motor ID Chart on page 8, if needed. See the Usage Chart on the opposite page for motors applicable to the TECINspect Service Tool. The TECINspect Service Tool is capable of identifying a motor control failure versus another HVAC system controller or wiring failures.
  • Page 20 Connect the two alligator clips from the TECINspect Service Tool to a constant 24VAC ® (24VAC terminal and Common terminal) source such as the transformer low-voltage terminals or terminal strip on the manufacturer’s control board (see Figure 3 below). These connections are not polarity sensitive.
  • Page 21 If using a TECMate XL on Model 3.0, the only switch necessary to test the motor is the furthest switch to the right (labeled BK/PWM on the XL or DH on the Troubleshooter). When testing is finished, place the TECINspect ®...

  • Page 22: Ecm Control Module

    Replacing the ECM Control Module (Models 2.0 / 2.3 / 2.5 / Eon / 3.0 Only) ® Before replacing the electronic-control module, you must test the motor module to ensure it is not also damaged. Installing a new control on a failed motor will result in no operation, improper operation and/or potential failure of the new control.
  • Page 23 Figure 4 MOTOR CONNECTOR (3-PIN) Push until latch seats over ramp FROM MOTOR CIRCUIT BOARD 16-PIN & 5-PIN CONNECTORS HEX HEAD SCREWS Only remove Hex Head Bolts Motor Module Tests The Winding Test (see Figure 5) Set ohm meter to the highest possible setting and measure resistance between each of the three motor leads to the unpainted part of the end shield (or x-brace on model Eon...
  • Page 24 The Phase-to-Phase Test (see Figure 6 below) Set ohm meter to lowest possible setting and measure the motor phase to phase resistance by checking these combinations of the 3-pin motor connector with an ohm meter: Lead 1 to lead 2 Lead 1 to lead 3 Lead 2 to lead 3 For the purpose of this test, either end of the 3-pin...
  • Page 25 If the motor fails either of these tests or does not spin freely when rotated by hand, replace the motor and control module following the guidelines on page 24. Insert the 3-pin connector back into the new control module. A slight click will be heard when inserted properly.
  • Page 26 Model 3.0 - This model can only be replaced with an OEM 3.0. Reinstall the blower/motor assembly into the HVAC system by following the manufacturer’s guidelines. Plug the 16-pin or 4-pin communication connector and the 5-pin connector back into the motor. The connectors are keyed.
  • Page 27 Replacing the ECM Motor and Control Modules (Models 2.0 / 2.3 / 2.5 / Eon / 3.0) ® The most efficient way to install the motor is to have the control already attached. If the new motor and control are not already bolted together use the OEM instructions or steps 5 and 6 on page 22.
  • Page 28 WA R N I N G Genteq does not condone the repair of any individual components in the motor control or motor of their ECM products. This practice is unsafe and may cause personal injury, death, or property damage. WA R N I N G Working on the motor with power connected may result in electrical shock or other conditions that may cause personal injury, death or property damage.

  • Page 29: X13 ® & Endura ® Pro Motors

    Model X13 & Endura ® ® Standard ECM Motor Diagnostics See the Motor ID Chart on page 7 if needed. IF THE MOTOR IS RUNNING It is normal for the motor to rock back and forth on start up. Do not replace the motor if this is the only problem identified.
  • Page 30 If the motor does not shut off at the end of the cycle, check the delay times and wait for the delays to time out. Also make sure that there is no call for “Continuous fan” on the “G” terminal. This motor may take a while to come to a complete stop with selected delays.
  • Page 31 is acceptable. Figure 8 NEUTRAL GROUND 115VAC LINE 1 C L G N 1 2 3 4 5 115VAC MOTOR 115VAC LINE 2 GROUND 115VAC LINE 1 C L G N 1 2 3 4 5 230VAC MOTOR NEUTRAL GROUND 277VAC LINE 1 C L G N...
  • Page 32 Model X13 & Endura ® ® Standard ECM Motor Communication Diagnostics The X13 & Endura Pro motors can be communicated through AC or DC low voltage. AC voltage is typically 24VAC and DC voltage can be between 9-23VDC (see Figures 9 and 10 on the next page). Start with the manufacturer’s literature to confirm proper set-up, connections and voltage.
  • Page 33 Figure 9 24 VAC C L G N AC VOLTS 1 2 3 4 5 VOLTAGE CONTROL INPUTS Figure 10 9-23 VAC C L G N DC VOLTS 1 2 3 4 5 VOLTAGE CONTROL INPUTS...
  • Page 34 Replacing the ECM Control Module (Model X13 & Endura Pro) ® ® Before replacing the electronic-control module, you must test the motor module to ensure it is not also damaged. Installing a new control on a failed motor will result in no operation, improper operation and/or potential failure of the new control.
  • Page 35 Figure 11 Push until latch MOTOR CONNECTOR seats over ramp (3-PIN) FROM MOTOR CIRCUIT BOARD 4-PIN & 5-PIN CONNECTORS HEX HEAD SCREWS Motor Module Tests The Winding Test (see Figure 12) Set ohm meter to the highest possible setting and measure resistance between each of the three motor leads to the unpainted part of the x-brace.
  • Page 36 The Phase-to-Phase Test (see Figure 13 below) Set ohm meter to lowest possible setting and measure the motor phase to phase resistance by checking these combinations of the 3-pin motor connector with an ohm meter: Lead 1 to lead 2 Lead 1 to lead 3 Lead 2 to lead 3 For the purpose of this test, either end of the 3-pin...
  • Page 37 If the motor fails either of these tests or does not spin freely when rotated by hand, replace the motor and control modules following the guidelines on page 36. NOTE: The X13 motor is no longer available. ® Its direct replacement is the Endura Pro.
  • Page 38 DRIP LOOP Figure 14 Connection Orientation Between 4 and 8 o’clock DRIP LOOP Figure 15 ECM X13 ® & Endura ® DO NOT COVER VENTS 2.75” BELLYBAND KEEP OUT AREA RECOMMENDED BELLYBAND AREA...
  • Page 39 Replacing the ECM Motor and Control Modules (Model X13 & Endura Pro) ® ® The most efficient way to install the motor is to have the control already attached. If the new motor and control are not already bolted together use the OEM instructions or steps 5 and 6 on page 34.

  • Page 40: Evergreen ® Replacement Motors Or Retrofit

    Evergreen ® Indoor Blower Motor Diagnostics See the Motor ID Chart on page 7 if needed. Introduction: Evergreen ECM is designed as an aftermarket replacement of existing PSC (Permanent Split Capacitor), direct drive, indoor blower motors for the purpose of increasing efficiency and comfort. For more information on this motor please visit www.
  • Page 41 Evergreen • IM Diagnostics ® Note: Please read the introduction on page 37 before using these diagnostics W A R N I N G ALWAYS DISCONNECT MAIN HVAC SYSTEM POWER BEFORE DIS-CONNECTING OR RE-CONNECTING ANY WIRES OR CONNECTORS TO THE EVERGREEN MOTOR. IMPORTANT NOTE: There must be proper voltage at the High Voltage POWER and High Voltage SIGNAL connections...
  • Page 42 IF THE MOTOR IS NOT RUNNING (continued) Confirm proper system line voltage is connected. Measure the voltage at the High Voltage POWER connections L1 (black) and L2 (white). On 115VAC systems, Neutral should be connected to L2. The power connected to these taps should be continuous un-switched line voltage.
  • Page 43 IF THE MOTOR IS NOT RUNNING (continued) Final Diagnosis – If there is a 115VAC demand on one or more of the High Voltage SIGNAL connections, the correct Line Voltage Jumper is installed, there is proper voltage on the High Voltage POWER connections and the motor is not operating, replace the motor.
  • Page 44 IF THE MOTOR IS RUNNING If the motor is running but there is an airflow issue causing improper performance, undesired comfort or HVAC System failure, check the following: Confirm the proper HVAC System 24VAC thermostat demand is connected to a Low Voltage SIGNAL (speed) tap.
  • Page 45 IF THE MOTOR IS RUNNING (continued) To achieve the proper horse power (Hp) the High Voltage SIGNAL connections must be connected to the HVAC Systems fan controls according to the diagrams on page 43. When the motor was installed it should have been configured to match the Hp of the replaced motor.
  • Page 46 IF THE MOTOR IS RUNNING (continued) The High Voltage SIGNAL connections are connected together with all the 115VAC fan outputs from the HVAC Systems controls to communicate to the motor when to turn on and at what horse power to operate at.
  • Page 47 IF THE MOTOR IS RUNNING (continued) Airflow restrictions can be caused by any one or more of the following: • Dirty filters • Dirty blower wheel, secondary heat exchanger and/or evaporator • Too many registers, grilles and/or balancing dampers are closed. •...
  • Page 48 Evergreen • AH Diagnostics ® Note: Please read the introduction on page 37 before using these diagnostics WA R N I N G ALWAYS DISCONNECT MAIN HVAC SYSTEM POWER BEFORE DIS-CONNECTING OR RE-CONNECTING ANY WIRES OR CONNECTORS TO THE EVERGREEN MOTOR. IMPORTANT NOTE: There must be proper voltage at the High Voltage POWER and the Low Voltage (Speed Tap)
  • Page 49 IF THE MOTOR IS NOT RUNNING Step 1. Confirm 208-240 VAC between the two black leads of the motor. BL K GR N w / Y EL G round 2 0 8 - 2 4 0 V A C BL K If there is not proper voltage at these leads, correct the problem before the motor.
  • Page 50 Symptom: IF THE MOTOR IS RUNNING If the motor is running but there is an airflow issue causing improper performance, undesired comfort or HVAC System failure, check the following: Step 1. Check all of the airside components such as registers, diffusers, grilles, filters, blower wheel, and indoor coil for dirt or other restrictions.
  • Page 51 IF THE MOTOR IS RUNNING (continued) If the LOW speed is too much airflow or HIGH speed is not enough airflow, check the motor sizing using the selection chart on page 45. Install the correct size motor if needed and repeat step 2. (See note below first) If this does not correct the problem go to Step 3.
  • Page 52 WA R N I N G Genteq does not condone the repair of any individual components in the motor control or motor of their ECM products. This practice is unsafe and may cause personal injury, death, or property damage. WA R N I N G Working on the motor with power connected may result in electrical shock or other conditions that may cause personal injury, death or property damage.

  • Page 53: Outdoor Motors

    Models 142 and 142R ECM Outdoor Fan Motor Diagnostics See the Motor ID chart on page 7 if needed. IF THE MOTOR IS RUNNING It is normal for the motor to rock back and forth on start up. Do not replace the motor if this is the only symptom identified.
  • Page 54 IF THE MOTOR IS NOT RUNNING This motor uses a 5 or 6 wire harness with wire colors specified by the OEM. Therefore the OEM schematic for the particular unit you are working on will be necessary to identify motor connections on the system controls.
  • Page 55 L1 (115VAC) L2 (115VAC) Ground 24VAC Communicated Single Speed Models CONTROL 142 & 142 Speed Tap (24VAC) Common (24VAC) L1 (115VAC) L2 (115VAC) Ground 24VAC Communicated Multi-Speed Models CONTROL 142 & 142 Speed Tap(24VAC) Speed Tap(24VAC) Common (24VAC) L1 (115VAC) L2 (115VAC) Ground PWM Communicated...

  • Page 56: Final Checks

    Indoor Motor Final Installation Checks Check all wiring and connections, especially those removed while servicing. Ensure the system is set up as follows: Clear all condensate drain and traps. Check and plug leaks in return ducts and equipment cabinet. Verify that the system is running quietly and smoothly, producing proper air flow in all modes (heating, cooling, and continuous fan) and all stages (if applicable).
  • Page 57 Outdoor Motor Final Installation Checks Before energizing the HVAC system, confirm the fan blade is free of all obstructions, including the system shroud and compressor. Check all wiring and connections, especially those removed while servicing. Verify the system is running quietly and smoothing in all modes and stages if applicable.
  • Page 58 Any technical advice or reviews furnished by Regal Beloit America, Inc. or its affiliates (“Regal”) with respect to the use of products and components is given in good faith and without charge. However, Regal assumes no obligation or liability for the advice given, or results obtained, all such advice and reviews being given and accepted are at the customer’s risk.

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