EVERGREEN • IM INSTALLATION GUIDE A Regal Brand REG9551_Evergreen_EM_Installation_Guide_v2.
® Genteq creates innovative, premium comfort and electrical components. Our proven reputation for high quality, highly reliable products and strong customer relationships make us the preferred brand throughout the industry. 1946 West Cook Road Fort Wayne, IN 46818 1-866-503-8566 www.theDealerToolbox.com GTQ-8004 Rev 06/11 Evergreen IM manual 01-13.
® I Contents Safety Considerations .....................................................................1 Introduction .....................................................................................2 Application Guide ..........................................................................3 Motor Selection ...............................................................................3 Pre-Installation Notes ......................................................................
® I Safety Considerations The following definitions are used as safety considerations on the Evergreen IM motor and in this manual. Please read and observe all of these safety concerns. safety symbols Warning indicates a hazardous situation which, if not avoided, could result in death or serious injury. Caution indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
® I Introduction The Evergreen® IM is an ECM (Electronically Commutated Motor) designed to replace an existing PSC (Permanent Split Capacitor), direct drive, indoor blower motor. It is constructed with more than 20 years of proven ECM technology and reliability. This installation/service manual enables a qualified technician to install, service, repair and maintain the Evergreen IM motor. This manual is to be left near the HVAC system for future reference.
® I Application Guide The Evergreen IM is designed for use on the following types of HVAC systems: • Direct Drive, 115 or 230VAC Motor Systems • Clock-wise (CW) or Counter Clock-wise (CCW) rotation • Residential Split and Packaged Systems • Air Conditioning or Heat Pump Systems • Natural Gas, Propane and Oil Heat Furnaces • Dual Fuel Systems • Hot water coil and Geothermal air handlers DO NOT use this motor on any “twinned” furnace or air handler systems.
® I Pre-Installation Notes Before removing the existing motor, check off the existing speed selections, in each mode of operation, in the spaces below. If the motor is operational, also record the Total External Static Pressure (TESP) and/or the Temperature Rise (TR) in each mode of operation. This information will help select the new motor speeds.
® I Installation Guide Mounting the Evergreen IM Always disconnect the main power from the unit being serviced before making any wiring connections to the Evergreen IM. It is also a good practice to confirm that the power is off with a meter. Remove the blower section from the HVAC system. Remove the existing PSC motor from the blower section. Properly dispose of the motor and the run capacitor. The Evergreen IM motor does not require a run capacitor.
® I Mounting the Evergreen IM (cont’d) If a new motor mount is required and the legs do not line up with the original holes in the blower housing, it is required to use a bolt with either a lock washer and nut or a locking nut through the new drilled hole(s). Self tapping or sheet metal screws are not a sufficient long term installation when a new hole is drilled through the thin wall of the blower housing.
® I Electrical Connections High Voltage POWER Connections • The Evergreen IM is connected to line (High) voltage power at ALL TIMES. • Do not connect the High Voltage Power leads of the Evergreen IM motor to any relays or switched circuit board terminals. • If a door switch is present, wire after the switch so power will be disconnected when the door is removed for service or maintenance.
® I Electrical Connections High Voltage POWER Connections (CONT’D) Step 2: Cut the High Voltage POWER harness to the length needed (leave a little extra) to reach the desired line voltage connection point. Step 3: Strip the insulation back to connect bare wires or install terminals as needed. Always disconnect the main power from the unit being serviced before making any wiring connections to the Evergreen IM. It is also a good practice to confirm that the power is off with a meter.
® I Electrical Connections High Voltage SIGNAL Connections • The High Voltage SIGNAL connections communication tell the Evergreen IM when to turn on and off according to the HVAC systems original fan control or fan relay outputs. This maintains the operational integrity of the HVAC System. • These connections will also determine the output horse power (Hp) of the Evergreen IM. The output Hp of the Evergreen IM should be set to match the Hp rating of the PSC motor that was removed.
® I Electrical Connections High Voltage SIGNAL Connections (CONT’D) Step 2: Prepare the High Voltage SIGNAL (HV) connections of the Evergreen IM motor to provide the desired horse power output using the diagram below. Configure the output of the Evergreen IM to match the horse power rating of the PSC motor it is replacing. This symbol represents a wire nut - 10 - Evergreen IM manual 01-13.
® I Electrical Connections High Voltage SIGNAL Connections (CONT’D) Step 3: Identify where on the HVAC system the PSC motor speed(s) were connected. These connections could be on a main circuit board, a separate fan control circuit board, or individual fan relay or fan switch. All of the connections previously used by the PSC motor speeds except Neutral will now be connected/wired together. This will allow the Evergreen motor to receive 115VAC communication from all HVAC system demands.
® I Electrical Connections High Voltage SIGNAL Connections (CONT’D) Step 4: Connect the selected High Voltage SIGNAL (HV) connection(s) from the motor in Step 2 to the combined fan output connections on the HVAC system in Step 3. See examples below. - - - - The dashed lines represent new field wiring added after the PSC motor wiring has been removed This symbol represents a wire nut - 12 - Evergreen IM manual 01-13.
® I Electrical Connections Low Voltage SIGNAL Connections DO NOT connect the Low Voltage SIGNAL (speed) connections to the existing PSC motor connections on the HVAC system. Any voltage above 30VAC connected to these terminals will cause permanent damage to the motor. • The Evergreen IM is unique in how it operates. Unlike a PSC motor, the Evergreen IM motor operation (speed) is selected by the low voltage communication inputs powered directly from the HVAC system thermostat lines.
® I Electrical Connections Low Voltage SIGNAL Connections (cont’d) Most HVAC systems use the same terminal designations for their thermostat demands. However there are variations. If the terminal designations in the HVAC system being connected to are different than the ones used in our diagrams, match them up to the operation of our generic listing below.
® I Electrical Connections Special Applications If the HVAC System this motor is applied to uses a separate speed for each heating and/or cooling demand including two-stage systems, this page is not needed. Systems that require the same speed for heating and/or cooling demands. For Example: • Heat Pump Systems with or without emergency electric strip heat. • Air Conditioning Systems with electric heat. • Large furnaces connected to a small air conditioning or heat pump.
® I Electrical Connections Special Applications High Efficiency Constant Fan Operation The Evergreen IM will automatically operate a fixed high efficiency low constant fan airflow without a (G) fan connection to the Low Voltage SIGNAL (speed) taps. When the HVAC System receives a 24VAC (G) command from the thermostat to the fan controls, they will send 115VAC to the High Voltage SIGNAL connection(s).
® I Electrical Connections Final Notes When finished connecting all of the Evergreen IM wires to the system, create the recommended drip loop, and assure it will not interfere with the blower wheel or other system wiring. It is ok to leave extra wire, especially the unused speeds. Tie them to the harness for future use if needed. Even though the extra speed and High Voltage SIGNAL wires will have no voltage or current on them, it is a good practice to wire nut and tape these unused leads.
® I Airflow Tests After installing the Evergreen IM motor it is important to verify that the speed tap(s) selected will provide the proper airflow in all modes of operation for maximum performance, comfort, capacity and safe operation. Before checking the airflow all filters should be cleaned or replaced. All grilles, balancing dampers and registers should also be clear and open.
® I Airflow Tests (CON’TD) Gas, Propane and Oil Heating Systems All Natural Gas, Propane, and Oil Heat Systems must be operated, tested and adjusted to confirm the Manifold Gas Pressure and Temperature Rise meet the values listed on the manufacturer’s data plate. Confirm system operation by operating the furnace (in both first and second stage on two stage furnaces) and measuring the Temperature Rise.
® I Airflow Tests (CON’TD) Measuring Temperature Rise Temperature rise should be measured as close as possible to the HVAC system in the return air inlet and in the supply out of the line of site of the heat exchanger. The diagram below shows an example of an up flow system and the recommended measuring points. Down flow (counter flow) and horizontal flow systems follow the same parameters. If access to the ductwork close to the furnace is not possible, use the closest return grille and supply register.
® I Airflow Tests (CON’TD) Air Conditioning and Heat Pump Systems These systems are designed to operate with a specified amount of airflow measured in Cubic Feet per Minute (CFM). Whenever possible use the manufacturer’s literature as the specification of recommended airflow. For two stage systems, only the manufacturer’s manual can provide the data for 1st Stage airflow requirements.
® I Airflow Tests (CON’TD) Temperature Rise Method Electric Strip Heat ONLY This method requires the operation of the electric strips and the indoor blower motor only by setting the thermostat to call for heat (W) on air conditioning systems with electric strip heat or emergency heat (W2) on heat pump systems with electric strips. Step 1. Operate only the electric strips and the indoor blower on the speed of choice for this measurement. Step 2.
® I Sequence of Operation When connected properly, the Evergreen IM will operate following the same sequence of operation as the replaced motor according to the HVAC Systems demands and delays. Line voltage (115 or 230 VAC) is connected to the High Voltage POWER connections on the motor at all times. This voltage powers the microprocessor and the controls that drive the motor.
® I Sequence of Operation (CONT’D) Basic Sequence of Operation Following the HVAC systems sequence of operation, the Evergreen IM will determine its operational speed from the 24VAC thermostat demand connected to the Low Voltage SIGNAL connections. The motor will then turn on at that speed only when the HVAC systems fan controls send 115VAC to the High Voltage SIGNAL connections.
® I Sequence of Operation (CONT’D) Motor On Command 1. HVAC System demand energizes 24VAC from thermostat connection to a Low Voltage SIGNAL (speed) tap. There is no motor operation at this point unless Step 2 occurs at the same time according the HVAC Systems fan control(s) sequence of operation. This allows the HVAC System to maintain any built in fan on delays. 2. H VAC System fan control(s) energize 115VAC to the High Voltage SIGNAL connection(s).
® I Sequence of Operation (CONT’D) Multiple Demand Time Line If multiple 24VAC thermostat demands are energized at the same time to the Low Voltage SIGNAL (speed) tap selections on the motor, it is designed to operate at the highest value tap selection and ignore the communication voltage on the lower value tap(s). Value equals the Low Voltage SIGNAL (speed) taps where high speed is the highest value and low speed is the lowest value.
® I Sequence of Operation (CONT’D) Demand Changes During HVAC System Operation If there is an HVAC System demand change while the motor is operating, the motor will ramp, up or down, to the new speed of highest value. Value equals the Low Voltage SIGNAL (speed) taps where high speed is the highest value and low speed is the lowest value. Examples: Two stage systems changing from one stage to another. Dual Fuel system changing from heat pump to fossil fuel heating.
® I Sequence of Operation (CONT’D) High Efficiency Constant Fan Operation If the 24VAC thermostat constant fan (G) is not connected to a Low Voltage SIGNAL (speed) tap, and the thermostat is set to Fan On, the motor will operate at a fixed high efficiency constant fan speed. This special speed was designed for decreased electrical usage and reduced system noise.
® I Troubleshooting Guidelines Symptom Potential Problem Solution The motor does not run. The wrong Line Voltage jumper is installed. For 230VAC systems the yellow jumper should be installed. For 115VAC systems the white jumper should be installed. NOTE: If the motor was powered with 230VAC while the white jumper was installed, the motor may be permanently damaged and need to be replaced. Continue troubleshooting here after proper jumper is installed.
® I Troubleshooting Guidelines (CONT’D) See pages 7-8 for complete wiring instructions on the High Voltage POWER connections. See pages 9-12 for complete wiring instructions on the High Voltage SIGNAL connections See pages 13-14 for complete wiring instructions on the Low Voltage SIGNAL connections.
® I Troubleshooting Guidelines (CONT’D From Pg 29) Symptom Potential Problem Solution The motor is running but there is not enough airflow causing any of the following: The proper Line Voltage jumper is not installed. For 230VAC systems the yellow jumper should be installed. For 115VAC systems the white jumper should be installed. NOTE: If the motor was powered with 115VAC while the yellow jumper was installed, the motor will run but at a reduced airflow than expected.
® I Troubleshooting Guidelines (CONT’D) Symptom Potential Problem Solution The motor is running but there is not enough airflow causing any of the following: The motor is running the wrong direction. Go to page 34 “The motor is operating in the wrong direction”. The wrong motor was selected. This motor is designed to replace multiple motors based on horse power and system sizing. If the sizing of the motor is in question, please see page 30 “Selecting the Correct Replacement Motor”.
® I Troubleshooting Guidelines (CONT’D) Symptom Potential Problem Solution The motor is running with no demand from the HVAC System. There is a constant fan call from the thermostat. The Evergreen IM is designed to operate a special constant fan speed if there is power on the High Voltage POWER connections and the High Voltage SIGNAL connections with no power on the Low Voltage SIGNAL (speed) connections.
® I Troubleshooting Guidelines (CONT’D) Symptom Potential Problem Solution The motor is operating in the wrong direction. The rotation sensing feature needs to be reset. 1. Disconnect the main power to the HVAC system. 2. Disconnect the High Voltage SIGNAL connection(s) from the motor to the HVAC system. 3. Reconnect the main power to the HVAC system. Confirm there is proper voltage to the High Voltage POWER connections on the motor. 4.
® I Installation Worksheet Evergreen IM Selection Data Check off the HVAC systems existing PSC motor horse power (Hp) and HVAC equipment size to determine the Evergreen IM sizing. Use the motor that best matches the HVAC System sizing. 1/5 - 1/2 Hp —— 1.5 - 3 Ton —— 40 - 95k Btuh —— 1/2 - 1 Hp —— 3.
® I Notes CFM = BTUH CFM = Velocity x Area TD x 1.08 BTUH = Output BTU per hour CFM = Cubic Feet per Minute TD = Temperature Difference, Temperature Rise & ∆T Velocity Area Square Feet Square Inches = Feet per Minute (FPM) = Square Feet = Square Inches divided by 144 = Height x Width - 36 - Evergreen IM manual 01-13.
Need Additional Help? Contractor Hotline: 1.866.503.8566 www.theDealerToolbox.com ® A Regal Brand 1946 West Cook Road Fort Wayne, IN 46818 1-866-503-8566 theDealerToolbox.com © 2012 Regal-Beloit Corporation Part #GTQ-8004 Rev 06/11 7466X/01-13/2.5K/BH/CP Evergreen IM manual 01-13.
