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

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methodologies for professionals like you. This episode is part of episode 74 of

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Did You Know? The ESCO HVAC Show. Learn more about Regal-Rexnord at

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regalrexnord.com.

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Alright so this is where we left off in the history lesson. We took a

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side off ramp to PSC motors for a little bit but we left off 1986 saying

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that back then all indoor blower motors were using PSC technology. So if we fast

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forward to 2005 and it'll become clear in a few minutes like why did he that's

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a very obscure year to jump to but it'll make sense there's always a method to

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the magnet. I need to borrow your Einstein here when I say that. So ECMs

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were introduced in 1987 that's why I chose 1986 as the starting point because

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the very next year we started ECM we started introducing ECM technology. So if

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you fast forward to 2005 which if my math is correct is about 18 years later

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we see that in the indoor blower motor market of brand new equipment that ECMs

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had gained about 15% of the market share and I don't know about any one of you

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that may or may not you know do investments or focus on investments or

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investment in manufacturing companies but that's not a good business model to

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penetrate only 15% of the industry in 18 years. But there's a very good

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reason why and I'm gonna explain that in just a minute. So 18 years later

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2005 we've got ECMs in the industry we've gone through multiple iterations in

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that time frame. Anybody's been around long enough remembers the old

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square back one and then we progressed to the one with no paint on it

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that looked kind of weird and then the 2.3 which is the name of this motor

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that went from 98 all the way to 2013. So whether it's air handler package or

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fossil fuel again only about 15% of units were using ECM. So before I tell

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you why only 15% of the industry had had switched to that technology let's take a

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little another detour and talk about what is ECM because we've we've done

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three discussions so far each one of the ECM technologies and we've drilled down

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explained the nuts and bolts of how they work the diagnostics the airflow but

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we've really never explained the technology itself the what's going on

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on the inside. So ECM of course stands for electronically commutated motor if

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you're one of those typo experts you know you don't like to type ECM or

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electronically commutated motor motor so you know it's really EC motor.

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Yeah, well and I have to say that because very recently there was an

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I think was a manufacturer may have may have been another training

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organization but they were calling all their motors EC motors and I started

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getting these phone calls I say hey are these EC motors brand new are they just

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like yours like it's an ECM you know you're on the phone you could just hear

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them turning red like I should have known that.

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I'm all good never mind but we have these other terms that also get used and

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brushless DC and permanent magnet and the thing is is these terms are a part

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of the technology of the motor so an ECM technically you know I'm gonna read this

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verbatim it's a brushless DC three-phase motor with a permanent magnet rotor the

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motor phases are sequentially energized by the electronic control powered from a

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single-phase power supply probably could have read it without staring at the

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screen but I like to get that one exactly right because it was written by

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one of my engineers and there you go I want to plagiarize properly so but we

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end up with these terms what is permanent magnet motor PMM what is BPM

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brushless permanent magnet BLDC what these all mean well basically to

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understand that you have to understand everything that's going on inside of an

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ECM because these terms are bits and pieces of the technology so in an ECM

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motor in the control so you see here I've taken the control off of the motor

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so here here's the motor I know you can still see me on the little screen there

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yeah and here's the control I know you can see it on the screen but I wanted to

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pop it up so the okay so I'm at the point where I've got AC power coming in

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I'm converting that AC power to DC power and now I have a clean DC power source

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inside my ECM control okay good to go yep that that volts DC power is gonna

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power my microprocessor just like it does in your home computer your laptop

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your phone you know any anything you're using but that DC power is also going to

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go through my frequency drive and it's gonna operate the motor so going to the

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motor and this is where this is where in many classes I'll finish this sentence

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or this phrase and I'll pause and I can see a little bit of smoke coming out of

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here yeah yeah this right so so what is actually going to the motor is it is it

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DC power or is it AC power well it on an oscilloscope but actually it would look

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like an AC sine wave it looked like a three-phase AC sine wave but if you look

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a little closer you're gonna see ripples in in the in the flat areas of that sine

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wave and what those ripples are is that is not actually a clean sine wave it is

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a PWM frequency drive that's turning the power on and off on and off so it turns

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an on and off from zero to positive voltage on and off from zero to negative

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voltage over over a proper amount of timing and it ends up looking like an

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AC sine wave and you might think well boy that would have to be going on and

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off really fast and it is it's around 20 kilohertz which is 20,000 times per

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second right so I you know my analogy because I like analogies they help

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people remember things and relate so the lights in most of your rooms are

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probably you know fluorescent lights and they're running off a ballast there

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they're actually turning on and off because they're running at a certain

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frequency but you know my light doesn't that I don't this isn't you know this

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isn't the 70s this isn't a strobe light you know I'm not I'm not doing the but

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but but yet this light is actually turning on and off so quickly you can

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just looks like continuous light and so that's what's happening in an ACM motor

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I am truly sending DC power to that motor winding but that DC power is being

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pulsed on and off at proper intervals so fast it just looks like a three-phase

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sine wave going to the motor and I put these two up here and I didn't want to

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get too nerdy in here and I didn't want it I didn't want us to be here till like

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10 o'clock at night but yeah well we've already gone down the rabbit hole now

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we're going now we're going into the rabbit hole cave so if you look at this

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sine wave in the early years of ECM technology this was called sort of a

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trap drive a trap wave trapezoidal looking waveform and so technicians

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would often ask in the early years you know why does the motor kind of rock

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rock rock and then and then take off and so again if you think about this

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technology came out in Windows are sorry in 87 you know do you remember how

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powerful Windows 95 was and how it was right so so think about that era

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processor being in this motor and having the responsibility for directing the

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frequency drive to do all this work so it didn't do it very fast it had to get

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rotor positioning back from the motor to know that it was starting the motor in

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the right direction and so all this took a couple of seconds to happen so in the

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early ECM technology the motor would and then and then take off yeah but if you've

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ever paid attention to an ECM from the last 10 years or even five years they

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just seem to take off there's really no rock if they do rock it's so slight you

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have you got to you got to be like I'm gonna catch it I'm gonna catch it you

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know and it barely moves well that's because now we have what's called the

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sine wave drive and the sine wave drive creates a sine wave that actually looks

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almost exactly like a true waveform still being pulsed but now that I've got

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a more powerful microprocessor I can I can create that wave I can stitch that

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wave together more cleanly and I get less of that starting fluctuation man now

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we're getting into the nuts and bolts this is what we teach in class right

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that's the whole point of diving into what are we looking at how do we teach

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this in our class how do we make this more comfortable and so it's important

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to understand what that control is doing what our motor is doing how it's

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constructed I think this is a good time I want to introduce a another perspective

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for us to have in the classroom when we're talking about ECM motors like so

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if we take the the mod the control off from that motor Chris we're stuck with a

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three-phase motor that has a rotor inside and we have our stator on the

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outside in a three-phase position now I want you to think about this for a minute

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because I get this question fairly often are there are there ways that we can show

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the motor in in an electrical way that makes sense for technicians can we use

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it for different purposes I do this in classroom and I've resurrected one of my

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old training projects to be able to show that that three-phase motor is really an

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interesting component that we can use for other purposes now we've talked a

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lot about the construction of it and I want people to pay attention see if you

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catch the terminology that could be could be construed a little bit off but

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it's kind of right I want you to think about it yeah I need to do a little

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adapting to it but I do this together just for our educators to be able to

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put motors into a perspective that is a little bit more hands-on so are we ready

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all that beautiful green footage here we go so when we talked about the

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induction side of a motor Chris what we were truly talking about was a slightly

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different style of motor so I really need to reframe that a little bit and

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talk about the motor so let's go let's look at what induction really would look

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like so I took this motor apart and this is obviously an ECM but if this were a

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PSC motor the the rotor would would be made of aluminum bars and I would still

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basically have the same stator I'd still basically have steel with copper

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wrapped around the the laminations and so in a PSC motor this this rotor would

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have no magnetic effect when there's no power to it but when I put energy to the

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stator and I start creating a magnetic field around this stator that magnetic

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field is going to induce a magnetic effect into the rotor and that's

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actually where the term induction motors comes from that rotor doesn't have any

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magnetic effect and can't follow the rotating magnetic fields until the

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rotating magnetic fields establish themselves and do some of that magnetic

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effect into the motor it's also why the PSC motor is less efficient than the ECM

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it doesn't have near as much to do with the electronic control the electrical

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efficiency doesn't have near as much to do with the electronic control module as

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it has to do with the permanent magnet rotor on the in inside the ECM so when

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you add a permanent magnet rotor to the so this is a three-phase motor no no no

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qualms about that question is and this is maybe a this is a question of maybe

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you know engineers and technicians deeper than me is it an induction ECM

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motor than an AC ECM motor is it easy our well three-phase motor is it a you

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know induction AC or DC three-phase motor well I've got a permanent magnet

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rotor in the middle okay so I don't need to induce a magnetic effect from the

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stator into the rotor to generate that magnetic magnetic effect it's already

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there so it really is somewhat improper to call it an induction motor but if

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you're teaching this to a technician who's not an engineer and just needs the

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concept of oh that's just a basic three-phase motor then calling it a

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three-phase induction motor helps them understand oh it's something it's gonna

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have three windings those three windings if they're working properly should all

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them out with the same ohms I reverse any two phases the motor will change

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direction so I think it's okay at a high level well when I'm teaching

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contractors and technicians yeah it's a three-phase it's a three-phase AC

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induction motor because they're gonna get that impression of how they would

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diagnose it and that's perfectly fine at the technical level it's really just a

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three-phase DC motor or to what was used earlier three-phase brushless DC motor

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so and when I bring that up I'm sorry the kid in me always wants to go back to

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my Tyco race car sets right little Tyco cars those little those little

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rotors were little magnets and you know if you when you when the car was

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completely destroyed you'd tear it apart and you'd throw the magnet at things see

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what it would stick to absolutely and then when the car would slow down you'd

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go to this you'd go to the hobby store and you buy new brushes and what did the

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brushes do the brushes flipped the polarity so that the magnetic field kept

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going back and forth and made the rotor go around so that's where these terms

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come from brushless DC is it a DC motor well technically yes because the power

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being sent to the motor is DC it it's not a C but it looks like a C to the

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motor and we generate the same alternating current in the winding that

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causes the rotor to follow we just don't need to induce that current into the

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rotor to create the magnetic effect so a couple of things happen from that

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permanent magnet rotor we get not only better efficiency but we also get a

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smaller stators and you look at the size this I probably should have a measuring

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stick out but from here to here from from a vent to vent that's about an inch

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and a half that is the stator stack of a half horsepower ECM motor if that was a

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PSC motor that stator stack would be easily an inch longer so how is an ECM

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stator that's shorter less copper able to still create a half horsepower of

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torque it's because in a PSC motor I'm wasting a certain amount of energy

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magnetizing that rotor so I need that bigger stator to create the same my

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torque with the permanent magnet rotor I've already got all that energy that I

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would have had to induce I've already got all that energy in the magnet I don't

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have to use that energy in the mat to create the magnetic effect therefore my

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stator becomes even more powerful in a smaller size so a couple of things

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happen from the permanent magnet we get the better we get better efficiency and

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we also get a smaller profile of the stator stack of the motor one more point

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of discussion before we leave this this particular rabbit hole I think I feel

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like there's more to come on the on the left you see what the early rotors looked

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like in ECM motors and they were using what was called iron ferrite so it's

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roughly a quarter inch thick I believe this one is an iron ferrite yep I'll

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hold that one up to the camera if you want to see it so it's about a quarter

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of an inch thick and you can see it's it's actually in this one's actually in

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three segments you can kind of see it there this the segment goes from from

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here to here and then the next segment goes to here you can kind of see that

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little dimple there and then comes around to here so so three individual

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pieces of iron ferrite but as technology progressed we started using neodymium

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and neodymium I'm gonna throw a number out it's probably not right but I'm gonna

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use it you know it's 10% 20% 30% stronger than iron ferrite so what happens is I

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end up with a much smaller magnet which means my my my rotor profile changes

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because that neodymium is actually stronger than iron ferrite you may you

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may have noticed in the last five to ten years ECM motors the stator stack has

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have even gotten smaller and the reason they've gotten smaller is again because

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the rotor has the rotor field has has been made stronger with the neodymium

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magnets so that's just a little bit more information about the rotor that won't

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help you diagnose the motor or set your airflow or sense but it's it's a lot of

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fun when you know how the toaster works without having to take the whole thing

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apart so we're gonna apply that to the constant airflow motor that was the

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technology that was introduced back in 1987 constant airflow we we left off at

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2005 about 15% of the industry had started using constant airflow motors but

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over 18 years well it's a long time you'd think that it would have had more

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of an impact on the industry but it makes a lot of sense when you understand

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that constant airflow motors are only used in premium tier systems so you know

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two-stage heat two-stage cool systems started in the late 80s same time these

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motors were introduced and so this motor the constant airflow premium level motor

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was only used in premium level systems so if you think about that pie chart

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again 85% still PSC 15% premium level ECM that kind of agrees with the way most

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contractors sell equipment right about 15% depending on the market your region

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you're in 15% is your premium level systems and the other 85% is probably a

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mix of your mid-tier and your builders grade level equipment and when I'm in

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front of most contractors again it's pretty much you know how other than the

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the rare contractor that sells a lot of premium or no premium that's it pretty

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much washes out with the industry so it makes sense why that motor you know it's

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kind of like we kind of launched I like to use again I like to use goofy

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analogies count we kind of launched like Tesla right we came out with our

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$80,000 car first and then later came out with the affordable $35,000 option B

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option B for the masses right exactly then and I don't think I've mentioned

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this yet so ECM motors as a whole and they can be a little higher a little

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lower as a whole and ECM motors around indoor blower motor outdoor fan motor

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48 frame one horsepower below I don't want anybody like yeah I know my motors

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89 so they're roughly 80% efficient they can be as much as 85 and they may be

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they may fall a little bit below 80% depending on where they're operating but

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they're about 80% efficient if you remember I said that PSC motors are

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between 60 and 70 depending on where they're operating if they're operating

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at lower speeds they could be operating as low as 50 or 40 percent efficient so

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we're anywhere from 10 to 50 percent more efficient than the PSC motor

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depending on where we're operating it and again keep in mind this motor was

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primarily applied to premium level two-stage systems so it's going to

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spend a lot of time operating at the lower speeds because two-stage systems

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spend a lot of time operating in their first stage capacity yep and then you

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know we talked about this in in episode one you know these are communicative

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motors if you want to know more about that go back to episode one and then you

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can get all that information we're we're in high-level mode here so we're not

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we're not drilling we're not drilling down there these motors again often

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referred to as variable speed and they have they're made in two very common

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styles and I say to we make them we gen tech the formally branded GE motors

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make them in two styles one with a five pin line voltage and the 16 pin

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communication and one with the five pin line voltage and the four pin

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communication one of our one of our largest competitors makes the motor

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similar to the five pin four pin and then some of our other competitors make

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either different size pins or they use just all wires but almost all of them

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are using either PWM or serial communication so and the only reason I

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say that as you go back and watch episode one you're not really you're not

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going to just learn about gen tech motors you're going to learn technology

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that will apply to multiple brands of motor technologies indeed so here's

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where it gets really interesting besides the electrical efficiency and this and

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this weird thing called the permanent magnet rotor these motors by by program

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can have an operating range of 300 to 1500 rpm that's pretty crazy so that's

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like going from an eight-pole motor or even a I don't if there is such a thing

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as a 1012 yeah there's 12 pole motor all the way up to a six pole motor all in

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one motor and the manufacturer of the appliance doesn't have to buy ten

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different motors they can program that motor as it's coming down the line you

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know in this system I need between 600 and 800 rpms for my two-stage system and

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the next system I need between 800 and a thousand in my next right they can they

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can program that motor for multiple systems without having to buy individual

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skew ratings for each each you know wired and wound motor highly sought after

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for those premium level system very versatile for the manufacturer also

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opened up the manufacturer to create airflow points that they're just were

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not possible with psc motors I don't know if we talked about it in any of our

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episodes but you know the Merv rating has has come up after cove it Merv 13

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running your fan continuously and running your fan continuously is very

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valuable for many reasons but if you've got a psc motor it's gonna cost you

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quite a bit of money in an ECM I'm I'm actually running 50% or more efficient

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than a psc motor when I'm running at 600 or less rpms and any and this ECM for

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example is gonna run 600 or less rpms still around 80% efficient Wow so that's

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that's pretty huge when it came to IAQ yeah indeed

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we have some fun all right everyone I know it's been a long evening I'm so

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grateful that you hung out with us all of these presentations are available

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for you on YouTube you can go into our e-learning network at the HVACR

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learning network and you can actually get credit for these courses if you're

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looking for that for continuing education so check that out we'll see you

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all at the conference everyone have a wonderful evening and we will see you

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next week on did you know the Esco HVAC show what a great time