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Welcome back to Teaching the Unteachables, where we dive into teaching and learning methodologies

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for professionals like you.

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This episode is part of episode 74 of Did You Know?

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The ESCO HVAC Show.

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Learn more about Regal-RexNord at regalrexnord.com.

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Alright everyone, thank you so much for joining us once again on Did You Know?

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The ESCO HVAC Show.

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Now we have done three different episodes, Chris, on talking about ECM motors.

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Isn't that crazy?

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Can't believe it.

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I know, we're four months in right now.

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So we've covered ECM constant torque, we've covered ECM constant airflow, we've covered

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ECM condenser motors.

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And so what we're going to wrap up today is kind of going to like a high level view, demystifying

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ECM motors in general and bringing in the ECMs really into the classroom.

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I'll also put together a fun little video we're going to share that I want to get your

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input on and find some potentially incorrect words.

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So I want you to pay real close attention to it.

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They're close, but there's better ways to explain it.

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I'm afraid.

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Oh boy, we're doing a lot of fun.

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I'm rolling up the sleeves.

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Let's go.

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Here we go.

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And everyone, as always, we truly enjoy you hanging out with us, spending your time talking

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about a changing industry.

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What do you think, Chris?

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Want to bring some clear definition to what ECMs really are?

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Let's have some fun.

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You know, as I was talking to you before the show about when I come out and do classes,

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you know, technicians don't have a lot of time out of the field.

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You're always teaching the nuts and bolts, the need to know, get out the door.

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We rarely get a chance to talk about the high level information.

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And you know, we use the wrong terminology.

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We don't really understand where this motor fits in, where that motor fits.

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Why, you know, why are there two ECMs that seem to do the same thing, but they really

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don't and all that kind of stuff.

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And we've, yeah, we've talked about them in the different shows, you know, I can't believe

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we're on the fourth show already.

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It's been too much fun.

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It's like when you go to your, you know, it's like you're headed to that ski trip and all

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of a sudden driving home, you're like, wait, what happened?

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So, so yeah, this is going to be a lot of fun.

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I don't get to teach all this information all the time.

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Some of it's going to seem a little rudimentary.

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I am going to start out with some basics just to make sure we're on the same page.

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You know, the terms of motors in the HVAC industry get confused and convoluted depending

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on where you learned them.

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You know, in the southern regions, in the northern regions, if you're a heat pump tech

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or a gas tech, you may think of motors as evaporator and condenser or indoor or outdoor.

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So I like the terms indoor blower motor and outdoor fan motor.

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And when I start a lot of classes, I start here and say, just to make sure we're on the

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same page, an indoor blower motor doesn't mean it's indoors, doesn't mean the motor's

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inside the house.

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It means that's the air that it moves.

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It moves the indoor air from the home to the appliance and back to the home.

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And it could be in a gas furnace, an air handler or a package unit, which means that the indoor

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blower motor could be inside the structure or it could be outside the structure.

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So yeah, so I just like to, you know, bring those terms in so that we're all on the same

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page again, outdoor fan motor.

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Obviously, it's the fan that moves the air across the condensing unit or evaporator coil

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if we're in the heating mode of a heat pump.

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So that could be a split system or package system as well.

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And if you've ever worked on like a through the wall unit or a P-TAC for a hotel, you

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know, that outdoor fan motor could be inside the structure.

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So just just a little clarity in terms.

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I don't know.

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You know, you and you and I are both nerds of reading schematics and manuals.

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And if you've read more than one OEM manuals, you've seen more than 10 acronyms used to

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describe these motors.

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And it's always fun trying to figure out what those three letters, what are they trying

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to imply by IDM or whatever they've used?

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So I always laugh.

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Exactly, exactly, exactly.

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So we're going to talk about HVAC direct drive fractional horsepower motors.

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And again, you know, sometimes when you're teaching the nuts and bolts, you don't teach

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these terms.

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You know, what does what does direct drive mean?

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What is fractional FHP mean?

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Fractional horsepower simply means that these motors are rated in fractions.

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Don't ask me why it includes one horse.

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I guess one over one is a fraction.

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I wonder.

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But I didn't see that until you mentioned it.

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Yeah, fractional horsepower motors includes everything one horsepower and below.

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And then direct drive simply implies the type of drive it is.

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So the whatever blade it's running, whether it's a fan blade, axial fan blade or forward

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curve fan blade, that is going to be attached directly to the shaft.

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The motor is going to be no sprocket, only a bling or a shiv in between the motor and

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what it's actually driving.

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It's going to be connected directly to that.

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So just clearing up some terms and then oh, sorry.

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And then the chart shows the typical horsepower ratings you're going to find on the indoor

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blower and the outdoor fan.

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This is kind of interesting because if you go back, depending on how old you are, and

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I'm old, you know, back when air conditioning with it, when it was in its infancy and gas

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furnaces were or had been around for a while, you saw quarter, fifth and third horsepower

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motors in in gas only systems where you didn't have to move the higher amount of air that's

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typically required for air conditioning unless you got one hundred and fifty thousand BTU

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furnace.

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Then of course you're going to need a larger motor.

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But today and when I say today, my career spans 30, just we'll just say 30 years.

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You know, you don't see too many quarter and fifth horsepower motors anymore in the indoor

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blower category.

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It's pretty much all third through one.

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And since the invention of ECM, which is over 30 years as well, you know, you see a lot

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more half and third half and three quarter horsepower motors than you do one and third

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because they're programmable.

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Right.

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So I can take a motor of a higher horsepower and I can make it act like a motor of a lower

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horsepower by programming.

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And I can take a three quarter horsepower motor.

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And depending on whether I need three fifty four hundred or four hundred and fifty CFM

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per ton, I can probably get five ton of airflow out of a three quarter horsepower ECM motor.

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So a little changing industry when ECM's were introduced.

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And then in the outdoor fan motor market, the opposite shift has happened.

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You know, it was very common 20 years ago to see third quarter, third quarter, fifth

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horsepower motors.

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And now, especially in your two and a half, two ton and one and a half systems, you're

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seeing the sixth, the eighth, the tenth.

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I even saw a 12th horsepower PSC motor the other day.

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Darn thing wasn't more.

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I mean, it was like an inch thick.

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It looked like it looked like a ceiling fan motor.

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So it was interesting looking.

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So so yeah, there's some of the ways the industry has changed and some of the terms that we

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use.

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So there are basically four types of motor technologies used in fractional horsepower

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HVAC.

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And those include permanent split capacitor, which the acronym is PSC.

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We will talk a little bit more about that.

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You've got constant torque ECM and then constant airflow and then constant speed, which you

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announced at the beginning of the show.

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If you haven't if you haven't caught the previous three shows, we've we've done a special on

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each one of these shows.

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So are each one of these motor groups technologies so you can watch those webcasts and learn

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all about those motors.

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But the most common application of these motors is kind of interesting.

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I often get asked, well, how do you know that a constant speed motor?

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Well, because it's in the outdoor application.

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Well, how do you know?

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It's just where the industry has landed that technology.

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They don't the industry doesn't typically apply a constant speed ECM to an indoor blower

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motor.

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Conversely, the industry doesn't typically use a constant torque programmed motor as

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an outdoor fan motor.

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So you find constant torque and constant airflow in the indoor motors and constant, excuse

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me, constant speed in the outdoor motors.

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And we're going to talk about that at the end.

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We're kind of kind of wrap back up with that.

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That has a lot to do with the the air it's moving and the type of blade it's turning.

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So whether it's a forker fan or an outdoor fan, the programming, constant torque, speed

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or airflow, some some of those programming methods work better with different types of

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blades and under different types of loads.

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So that's a little little teaser there for the end of the presentation.

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I also wanted to work in a little bit of history because I think I don't know, maybe it's just

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me.

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You know, I got I got older and I became a history nerd.

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I wasn't really a history nerd when I was a kid, but history became more human.

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I got older, you know.

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But it's it's interesting if you watch this progression and it's sort of interwoven in

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the presentation.

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It's sort of eye opening where ECM's came into the industry and how much earlier they

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were around before most people thought they were in the industry.

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So if we focus on the indoor blower motor side of the industry and we talk about new

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equipment built and we go all the way back to 1986 and there's you'll understand why

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I chose 1986.

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It's not just because I graduated that year, but we go all the way back to 1980.

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Look, giveaway there, all the way back to 1986 and in the indoor blower application

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of new equipment, the number one motor used was a PSE direct drive motor.

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Now I know there's somebody that's out there saying, oh man, there were belt drives back

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then and there were still some shaded.

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Yeah, there were some belt drives and some shaded poles.

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But the primary motor technology and HVAC equipment in 86 was a direct drive PSE motor.

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And it doesn't matter if it was a air handler, fossil fuel, package unit.

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That was the technology.

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And the reason why I like to go back that far is a couple of reasons why I like to go

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back that far.

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It helps understand the integration of ECM, but also because we did we did three webinars

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on ECM motors and we talked about PSE motors for probably a collective five minutes.

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Yeah, not a whole lot about it.

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I mean, it was not a whole lot about it, but yet there's still the largest volume of motors

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used in residential HVAC today.

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And in tech support, I'm reminded every day how much how many contractors have have not

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been taught as much about PSE motors as they have about ECM motor.

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So it's just going to take a little bit of time here.

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Go back and talk about the PSE motors.

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PSE again stands for permanent split capacitor.

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It's an induction motor that uses an externally connected run capacitor to help with its starting

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and provides additional efficiency.

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You can identify it a couple of ways.

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You can physically see it, follow the wires out and hey, what's that silver thing?

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That's the cap.

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And that's oh, that's a PSE motor.

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Or you can look at the schematic on the motor.

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You got a little pictorial there showing you the cap.

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And you can see in the ratings where you've got the microfarad and voltage ratings of

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that capacitor.

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You can't I'm sorry every time PSE motors come up, I always have to say if you're ever

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replacing a cap, make sure you replace it with the rating on the motor, not with the

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rating of the cap that was there before.

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Always check the always check the rating on the motor.

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Sorry, little little plug for proper.

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This is all educators know how to relay this to the classroom.

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This is all stuff that could be potentially missed.

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Yes.

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So if we switch to the outdoor fan motor again, just talking about I know we're in the indoor

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blower motor category in our in our history lesson, but we're in PSE.

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So we'll talk about the outdoor fan motor PSE as well.

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Again you can see the run capacitor out here.

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Most commonly in the outdoor unit, it's a dual run capacitor.

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So you've got a single common terminal with an F terminal for the fan motor and an H terminal

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for the compressor.

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I know H doesn't go with compressor, but it does if you know.

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Yeah, hermetic.

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There you go.

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And then you can identify it by the diagram on the side of the motor as well.

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And again, the rating on the motor.

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So PSE motors commonly built in two sizes, either six pole or eight pole.

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And that's important because the blower wheels and fan blades that were used when PSE motors

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were king and again, they were king up until just a couple of years ago.

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Fan blade and indoor blower wheel for PSE motors had to be to 825 RPM because those

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were your high speed RPM values of six pole and eight pole motors.

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And with PSE technology, we're not going to drill all the way down to the amount of poles

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times the frequency divided by two.

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But the poles and the frequency determine the RPM.

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If you want a motor with a significantly different RPM, such as going from 1075 to 825, you have

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to get a completely different motor.

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You can't run a 1075 motor down at 800 RPM.

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You can, but it would be horribly inefficient and creating a lot of heat and probably wouldn't

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last that long.

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So that information will be very valuable when we progress into ECMs and understand

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the value of ECMs being programmable.

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But yet the fact that ECMs were used with the same blower wheels and fan blades that

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used to be used on the PSE motors and why they still operate around those typical 1075

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and 825 RPMs.

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Because the wheels didn't change, but the motor technology, the wheels and fan blades

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didn't change, but the motor technology did.

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So you've got indoor blower motors, typically multi-speed.

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They're multi-speed because quite often you've got a airflow requirement for the fossil fuel

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appliance that is different from the airflow requirement for the outdoor unit, whether

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it be AC or heat pump.

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And then you've got the outdoor fan motor, which is typically one speed because it's

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engineered by the manufacturer to run at the one speed necessary.

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Again, we're in 1986.

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We're talking about single stage equipment.

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Very good.

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Good.

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Good catch there.

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So, you know, one speed it's been engineered to operate at the one speed that maximizes

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the condenser TD across that coil.

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And that's what it does its whole life.

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So very simple motors.

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The average efficiency of a PSE motor is around 60 to 70%.

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They often get a bum rap.

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They often get, they often, oh, there are 60% efficient motors.

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Outdoor fan PSE motors can get up as high as 70% because they are optimized to run at

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the most energy efficient RPM range of a given motor with a different load in a given system.

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So when you, when you pick the RPM point on the, on the performance curve that is the

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most efficient and you design your blower blade around that, then you can get quite

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a bit of efficiency out of a PSE motor.

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But when you're using multi-speed motors, the challenge with multi-speed motors is when

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you blow a PSE motor, any induction motor down below its synchronous speed.

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So I said we wouldn't dig too far, but a six pole motor synchronous speed would be 1200.

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So any speed below that is moving away from its synchronous speed.

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The further you move away from synchronous speed by going to medium or low speed, the

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more inefficient the motor gets, the more heat it creates because the less mechanical

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energy it's creating.

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So multi-speed motors have these extra windings.

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And so we, you know, we add resistance, more resistance, less amperage, less amperage,

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less torque.

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So, you know, we've, we've called these motors multi-speed motors forever, but technically

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they're multi-torque motors.

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As I reduce the amount of torque the motor can generate, blower wheel slows down and

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the speed changes.

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So, you know, going from the high speed to the medium speed, which is really going from

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the highest torque capability of the motor to the medium torque capability of the motor,

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I slow down in RPM.

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So we call them multi-speed motors.

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It's kind of tomato tomata.

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It means the same thing, but I use this as the setup for the next motor we're going to

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or the second motor we're going to talk, third motor we're going to talk about, which is

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constant torque motor where we're going to start to understand that ECM motors absolutely

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focus on torque and speed or just torque.

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They're not multi-speed motors at all.

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Why go back to the PSC motor and say, well, they really never were.

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They're multi-torque motors that run slower when you go to a lower torque value.

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I'm glad you represented it that way.

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Cause I actually haven't thought about that from that perspective, but a hundred percent

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it when we change a resistance, we're changing the capable torque of the motor consequently

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changes the RPMs of it.

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Yeah.

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And another thing that is kind of interesting since you gave me a pause there, you know,

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you know, when you're teaching, your brain's going a mile a minute.

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Sometimes you stop and you think of something else.

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You know, we're going to, when we get to the ECM, we're also going to understand how one

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motor can be more than one horsepower very easily by programming.

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And I don't need to build many different motors to do one thing.

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In other words, I can have one ECM that takes the place of five ratings of PSC motors because

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of a wider operational range and the fact that it's programmable.

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I can tell the motor what torque I want.

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I don't have to actually tap the winding.

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So a PSC motor, let's say, let's say on this PSC motor, what I really wanted was I wanted

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a torque that was right about here.

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Right?

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Well, I can't do that unless I'm going to, you know, do a YouTube special and open up

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a motor, break the windings open and what, and solder a wire in there.

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I can't get that torque value.

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It's been built, you know, with the windings tapped here and here.

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But with an ECM, I can program it to give me that torque value or that torque value

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or that torque value.

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So I really open up the capability of a motor when I have programming versus tapped winding.

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And a tapped winding motor, it is what it is.

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It's never going to be anything else.

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Hmm.

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Okay.

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Great way to explain it.

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I'm sure there was a lot of teachers out here going, okay, all right, this makes sense.

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This is the way you deliver my content now.

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There you go.

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That's what we're shooting for.

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The other thing that I think is kind of interesting and this, I can hear five or six people out

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there yelling, that's not right.

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You know, a PSC motor really only has a value in HVAC in forward curve fan systems and even

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in an outdoor fan system only has a valuable operating range of about two to 300 RPM below

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its rating.

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So let's say you have a 1075 RPM motor.

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It's really only good to around 850, 900 RPM, somewhere in there.

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Because once you start slowing the motor down below, and you can operate it lower than that,

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but you operate it at an extremely inefficient place where it could be running less than

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30% efficient.

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And it's going to be, because it's not generating as much mechanical energy at the shaft, it's

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going to be creating a lot of heat.

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So you're probably going to have a significantly reduced lifespan.

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So I'm not saying they can't operate below that range.

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They're just, they're valuable.

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Their long-term operational range for efficiency and longevity is two to 300 RPMs less than

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what they're rated at.

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So there again, if I want one motor to operate from say 600 RPMs all the way up to 1200 RPMs,

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can't do it in PSC technology.

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I'd need two motors in a system.

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And interestingly enough, me and another trainer at Regal Rection, we asked the engineers once,

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well, couldn't you build one?

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And just for fun, they actually did build one.

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They built a multi-pole motor, all in one motor.

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And it was half horsepower.

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So this is a half horsepower ECM.

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It was half horsepower, but it was this long.

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Because it literally had to have two sets of windings.

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And it had like 16 wires coming out of it.

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It was really and truly the family truckster.

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It was nasty looking.

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But it was...

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It had to do a replacement universal.

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Yeah, but it was truly a six and eight pole motor, all in one casing.

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Man, we have some fun.

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All right, everyone.

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I know it's been a long evening.

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I'm so grateful that you hung out with us.

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All of these presentations are available for you on YouTube.

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You can go into our e-learning network at the HVACR Learning Network, and you can actually

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get credit for these courses if you're looking for that for continuing education.

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So check that out.

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We'll see you all at the conference.

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Everyone have a wonderful evening, and we will see you next week on Did You Know?

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The Esco HVAC Show.

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Have a great time.