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`Nidec Motor Corporation
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`Comparing Motor Technologies
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`By Brian Michael
`December 14, 2009
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`Comparing Motor Technologies
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`The heating, ventilation and air conditioning (HVAC) industry currently uses a variety of motor technologies in its equipment. The type specified in
`any product design depends upon several criteria, including the product’s performance goals, positioning, cost and potential application Historically,
`the two predominant motor types have been permanent split capacitor (PSC) single-speed motors and 2,3 electronically commutated motors (ECMs)
`with variable-speed capability. Most HVAC professionals understand the key differences between these two motor types and are comfortable
`discussing the benefits of one technology over another.
`
`In 2006, Regal-Beloit (formerly known as General Electric, now known as Genteq) introduced a third motor technology to the industry. Referred to
`as its X13 motor, this new technology has significantly gained in popularity among all heating and air conditioning equipment manufacturers. What is
`this newer motor, and how does it compare to PSC single-speed and ECM variable-speed motor technologies? Why is it popular?
`
`The Genteq X13 motor is a high-efficiency motor that help manufacturers meet the 13 SEER mandate implemented by the federal government in
`2006 (hence, the branding name of X13). The motors are based on ECM technology and can contribute to the increased overall cooling efficiency of
`a complete HVAC system when used as the circulating air blower motor in a furnace, air handler or packaged unit. In fact, manufacturers of these
`types of motors may refer to them as a standard ECM motor, or as a constant torque motor.
`
`For clarification, X13 is the Genteq brand name. Several other manufacturers offer similar motors. However, for the purpose of this article, the term
`constant torque motor will be used to describe all such motors.
`
`httptflwww.achrnewscomlarliclesfl12674—corn paring—motor-lechnol ogies
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`5H 3
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`Nidec Motor Corporation
`IPR2014-01121
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`Exhibit 2020 - 5
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`Nidec Motor Corporation
`IPR2014-01121
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`Exhibit 2020 - 5
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`Comparing Motor Technologies
`
`
`
`MOTOR COMPARISONS
`
`In order to understand the benefits of constant torque motor technology, it is important to look at, understand and compare the two other motor
`technologies prevalent in the industry - PSC single-speed and ECM 2.3 variable-speed. Constant torque motor technology offers several benefits with
`respect to efficiency, operation, comfort and cost when compared to these two other motor technologies
`
`PSC single-speed motor technology has been the standard in the industry for many years and represents the highest installed base. PSC motors are
`typically positioned by most manufacturers as a standard product offering and are used in furnaces, air handlers, condensing units and packaged
`products. The popularity of the PSC motor can be attributed to its simplicity, reliability, low cost and flexibility.
`
`PSC motors, often referred to as induction motors, typically use alternating current (AC) and include two key components in their design - a stator
`(the stationary section of the motor) and a rotor (the rotating section of the motor).
`
`A magnetic field is induced in the rotor opposite in polarity of the magnetic field in the stator. Therefore, as the magnetic field rotates in the stator,
`the rotor also rotates to maintain its alignment with the stator’s magnetic field. In this operation, the rotor constantly lags behind the magnetic field in
`the stator, resulting in what is known as asynchronous (i.e,, not synchronized) operation.
`
`This operational characteristic, which also generates excessive heat, greatly contributes to the degraded operational efficiency of PSC motors (which
`are at best only 60 percent efficient), However, since there are few mechanical components, this design has proven to be very simple and reliable, and
`can be manufactured at a relatively low cost.
`
`PSC motors are considered single-speed (speed refers to the rate of rotational motion) because they do not have any internal controls that can be
`programmed to automatically vary the rotation of the motor over an operating range. For example, an equipment manufacturer may utilize a ‘/2 hp
`motor in a 3-ton drive furnace in order to deliver an average airflow of 1,200 CFM within a range of external static pressures (ESP) often found in
`assorted applications,
`PSC Motor Darwinism!
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`But what if the duct system layout in a specific application has an increased static pressure because the mechanical contractor added a very restrictive
`media filter?
`
`In order to make PSC motors more flexible for a variety of applications, they include speed taps that allow the mechanical contractor (or
`manufacturer) to manipulate the motor’s speed to ensure that the correct amount of airflow is delivered for both optimal performance and safety
`within a range of external static pressures. It should be understood that there is a limit to the amount of static pressure the motor can handle. As static
`pressure increases, a PSC motor’s performance drops off, because it cannot adjust speed or torque,
`
`As a result, higher static pressures equate to lower airflows. Although the lack of programmability may appear to be a disadvantage, it actually makes
`PSC motors more flexible or universal because they can be used for most retrofit and original equipment manufacturer (OEM) applications.
`
`Because of the motor’s design, there are some disadvantages inherent in PSC motors. For example, PSC motors are significantly less efficient than
`constant torque or ECM 2.3 motors because they consume more watts, making them more difficult for a manufacturer to apply to a high-SEER
`system design. On average, PSC motors will use approximately 552 watts in cooling mode and 515 watts in continuous fan mode. Therefore, they are
`not ideal for continuous fan operation because they run close to full speed when applied in this manner, using more energy than this function really
`requires. (As a comparison, imagine the power consumed by five 100-watt light bulbs lit all day long). This also makes them less attractive for
`continuous filtration applications. Additionally, since PSC motors are not programmable and their motor speed cannot be easily varied, it is more
`difficult to apply the motors to two-stage or advanced systems.
`
`PSC motors are also the least quiet of the three motor technologies. In addition, PSC motors do not offer customized airflow patterns, which are ofien
`critical in designs intended to manage humidity. Consistent air stratification and temperatures are also harder to obtain.
`
`Finally, products that utilize PSC motors typically do not qualify for the federal tax credit program based on the motor itself. However, if the rest of
`the system components meet performance requirements (specific SEER, BER and HSPF combinations or a minimum 95 percent AFUE) as outlined
`under the program, then the installation may be eligible for a federal tax credit.
`
`httptfiwww.achrnewscomiarticlesfl12674corn paring—motor-lechnol ogies
`
`6M 3
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`Nidec Motor Corporation
`IPR2014-01121
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`Exhibit 2020 - 6
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`Nidec Motor Corporation
`IPR2014-01121
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`Exhibit 2020 - 6
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`

`

`413012015
`1413 Molar Perlurrnanco
`
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`
`Comparing Motor Technologies
`
`PREMIUM ECM 2.3 VARIABLE-SPEED MOTOR TECHNOLOGY
`
`ECM 2.3 variable-speed motor technology can be compared to using a dimmer switch in lighting applications, meaning it is highly variable, making
`its precise performance ideal for a variety of advanced applications. Most manufacturers typically position an ECM 23 motor as a premium product
`offering and use the motors in furnaces, air handlers, condensing units and packaged products The popularity of the ECM 2.3 motor can be attributed
`to its performance, flexibility and reliability
`
`(Note: There are several other ECM motor designs on the market. Some of these models are identified as ECM 2.5 or ECM 3.0 and include additional
`features that allow for more sophisticated programming options specifically intended for equipment that utilizes communicating control systems (also
`known as four-wire systems). In any case, the information that follows generally applies to all three ECM motor types.)
`
`ECM technology is based on a direct current (DC) design that is inherently more efficient and runs cooler than alternating current PSC motor designs.
`In fact, ECM 2.3 motors are approximately 80 percent efficient compared to the 60 percent efficiency rating typical of PSC designs
`
`In a traditional DC motor, permanent magnets replace the stator, and a series of windings wrap around the rotor. When electricity is applied to the
`motor, a magnetic field is created in the windings, causing it to turn toward the magnetic field created by the stator. From there, brushes in contact
`with a commutator (i.e., an electrical switch that periodically reverses electrical current) allow the current and magnetic field to shift from winding to
`winding, forcing the rotor to continuously rotate. Unfortunately, the brushes and the commutator eventually wear out, resulting in motor failure.
`
`So what makes ECM 23 motor designs better than their traditional DC counterparts? First, in the ECM 23 motor, the magnets and windings switch
`positions - the permanent magnet is on the rotor and the series of windings are placed around the rotor. This makes the ECM 2.3 a brushless motor,
`eliminating failures caused by worn brushes and commutators.
`
`Second, the ECM 2.3 design combines a microprocessor and an electronic control directly with the motor. These electronics precisely manage the
`commutation of the stator so that it is always synchronous (i.e., in tune) with the rotor. They also make the motor programmable. Additionally, in the
`case of a failure, either the control or the motor can be replaced without necessarily replacing the entire unit.
`
`Unlike conventional PSC motors, which are designed to operate at one speed, ECM 2.3 variable-speed motors can run over a wide range of speeds.
`This is critical because blowers need to be flexible in order to deliver the airflow required by a multitude of system designs. ECM 2.3 motor
`technology provides the ability to program and deliver constant airflow over a wide range of ESP, typically up to 1.0 inches water column.
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`This feature automatically compensates for any added pressure drop introduced to the system. For example, if a duct system layout has an increased
`static pressure due to a dirty filter, the presence of a media filter or simply because of poor design, the motor will automatically ramp up to ensure that
`the programmed amount of airflow is delivered. This is accomplished without the use of any additional components.
`
`Equipment manufacturers don’t condone poor duct design, but ECM 23 motor technology can compensate for some applications if sized incorrectly.
`However, it is important to be cautious, because increased noise levels, which are uncharacteristic of these motors, may result if the design is overly
`restrictive.
`
`Overall, ECM 2.3 motors draw the least amount of watts, which makes them the most efficient. On average, they will use approximately 413 watts in
`cooling mode and only 83 watts (less than a lOO-watt light bulb) in continuous fan mode. This combination of performance, reliability and
`programmable flexibility makes ECM 2.3 motors an ideal solution for high-SEER or multi-stage system designs. It also has the potential to increase
`overall cooling system performance by as much as one or more SEER points.
`
`Beyond programmability and efficiency, ECM 2.3 motors offer many other advantages that enhance consumer comfort. These motors are the quietest
`of the three motor types because they have the ability to ramp up and down slowly, making them ideal for applications where noise is a concern.
`
`Variable-speed motors are also the best choice for constant fan or constant filtering applications because the motor will only run at about one-third of
`its designed speed, using less power than a lOO-watt light bulb and resulting in both noise reduction and energy savings that the consumer will
`appreciate. The indoor environment will also benefit from better air stratification, ensuring more consistent and precise temperatures.
`
`In addition, ECM 2.3 motors have the ability to deliver customized airflow based on the consumer’s geographic region, making them versatile in
`humid, arid or temperate climates If dehumidification is required, variable-speed motors offer the best solution because of the wide range of speeds,
`and they are particularly effective when combined with two-stage compressors and a dehumidification control. Lastly, due to their efficiency, most
`products that utilize ECM 2.3 motors may qualify for up to $1,500 under the federal tax credit program.
`
`ECM 2.3 variable-speed motors do have a few disadvantages, including a cost premium. On average, a mechanical contractor can anticipate a 40-60
`percent cost premium for products that utilize ECM 2.3 motors.
`
`httptflwww.achrnewseomiarliclesfl12674corn paring—motor-lechnol ogies
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`7113
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`Nidec Motor Corporation
`IPR2014-01121
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`Exhibit 2020 - 7
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`Nidec Motor Corporation
`IPR2014-01121
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`Exhibit 2020 - 7
`
`

`

`413012015
`
`#910! Performance COMDDIISIM
`
`
`
`Comparing Motor Technologies
`
`STANDARD ECM CONSTANT TORQUE MOTOR TECHNOLOGY
`
`Constant torque motor technology is quickly becoming a popular motor technology. As a matter of fact, it may totally replace PSC motors in the near
`future as government actions and regulations continue to mandate increased efficiencies. Most manufacturers typically position constant torque
`motors as a mid-tier product offering and use the motors in furnaces, air handlers and packaged products The popularity of the constant torque motor
`can be attributed to its performance and cost.
`
`Constant torque motors are high-efficiency, brushless DC motors that are based on the same ECM technology described in ECM 2.3 variable-speed
`motors. They are controlled by 24-Volt signals and were designed so that OEMs can program them, using a programming tool at the factory, for use
`in a variety of high-efficiency applications without modifying or increasing the size of existing product designs. The programming is not as flexible
`as a premium ECM 23 motor (for example, it does not allow for wider speed ranges, climate-based airflow performance profiles or constant airflow
`algorithms). Although constant torque motors utilize ECM technology, they are not variable-speed motors, as many people have considered or
`defined them. This is probably one of the biggest misconceptions regarding constant torque technology.
`
`For comparison’s sake, constant torque motors are basically upgraded, next-generation PSC motors. What differentiates constant torque motors from
`PSC motors is their ability to deliver constant torque (i.e., rotational force or power output down a shaft). In other words, if the ESP changes, then the
`motor program will maintain the amount of torque for which it was programmed (this is not the same as constant airflow).
`
`Even though constant torque motors can maintain torque, if the external static pressure increases, airflow will decrease similar to a PSC motor.
`However, the decrease is not as drastic, since the torque is being maintained. At the other extreme, an ECM 23 motor has the ability, via
`programming, to increase torque in order to maintain constant airflow in response to changes in ESP.
`
`When compared to similarly sized PSC motors, constant torque motors reduce power consumption, using approximately 413 watts in cooling mode
`and only 200 watts in continuous fan mode - compared to 552 watts and 515 watts, respectively, for PSC models. These savings make the overall
`efficiency of a constant torque motor similar to that of an ECM 2.3 variable-speed motor, which is approximately 80 percent.
`
`Constant torque motors are programmed by the OEM at the factory. But what do they actually program? Constant torque motors are designed to
`deliver constant torque (not speed). But the same amount of torque may not be required for all functions or all applications. So, equipment
`manufacturers determine the level of torque needed for each product application. Once determined, they program each of the motor’s speed taps
`(typically up to five taps) to produce the desired airflow for heating, cooling or continuous fan operation, depending upon which tap is used.
`
`The manufacturer has the flexibility to specify either a percentage of the maximum torque or the actual torque value in their motor programs. For
`example, tap 1 = 100 percent torque, tap 2 = 85 percent torque, tap 3 = 65 percent torque, tap 4 = 50 percent torque and tap 5 = 25 percent torque.
`
`Many manufacturers will only program the taps needed for the specific equipment design, meaning some taps may not be active. The manufacturer
`also programs any off-delays needed at each tap. On-delays cannot be programmed. However, the manufacturer can accomplish on-delays with
`external control boards (i.e., an integrated furnace control board or a fan control board).
`
`So how does the mechanical contractor use these taps? Let’s assume that we have applied a 4-ton drive (1,600 CFM nominal) gas furnace to a duct
`system. In order to make certain that the furnace is operating at the correct ATR, which ensures proper and safe heating operation as well as heat
`exchanger longevity, the motor speed typically must be adjusted. The technician will usually do this by re-assigning the heating speed tap from one
`designated speed to another (often labeled as low, medium low, medium, medium high or high).
`
`Now let’s assume that the consumer has a fairly restrictive media filter installed at a later date. The technician most likely had to manipulate the
`motor speed once again in order to ensure correct operation.
`
`This manipulation interface is familiar to all mechanical contractors, which is important because the reality is that changing tap connections on
`constant torque motors does not actually change the speed of the motor. Instead, it changes the programmed torque levels of the motor (most
`technicians understand adjusting speed and not torque). The manufacturer will most often not provide the actual torque values, but instead will
`indicate, via a chart, which of the five taps are to be selected for proper heating, cooling or continuous fan airflow.
`
`Constant torque motors offer several consumer benefits. With increased SEER ratings in cooling mode, homeowners will appreciate lower utility
`bills. Since these motors utilize ECM technology, they are also slightly quieter than a traditional PSC motor and will contribute to the emotional
`comfort factor.
`
`Additionally, products that use constant torque motors can contribute to a slight improvement in dehumidification. Lastly, because of their efficiency,
`some products that utilize constant torque motor technology may qualify for up to $1,500 under the federal tax credit program. (Check with the
`equipment manufacturer for confirmation.)
`
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`httptflwww.achrnewsmomlarliclesfl12674corn paring—motor-lechnol ogies
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`81'13
`
`Nidec Motor Corporation
`IPR2014-01121
`
`Exhibit 2020 - 8
`
`Nidec Motor Corporation
`IPR2014-01121
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`Exhibit 2020 - 8
`
`

`

`4l30l2015
`
`Comparing Motor Technologies
`
`KEY HIGHLIGHTS OF THE CONSTANT TORQUE MOTOR
`
`Now that there is an understanding of the three main motor technologies used in the industry, contractors should realize the importance and benefit of
`including equipment in their product offering that features constant torque motor technology and be prepared to discuss them with their customers,
`
`' Product Positioning. Independent research confirms that consumers prefer choices and often migrate to the middle option when presented with a
`“good, better, best” scenario. Products with constant torque motor technology are typically positioned as mid-tier product offerings - they are the
`“better” in a good, better, best proposal. It is doubtful that the price point to upgrade to a product with constant torque motor technology will be hard
`to defend
`
`' Reduced Utility Bills. Many consumers are interested in lowering their energy costs, especially in the current economic climate When applied as a
`complete system, constant torque motors can increase the overall cooling efficiency by as much as one or more SEER points. Depending on the
`consumer’s lifestyle, the size of their home and the region where they live, this can equate to several hundred dollars in energy savings per year.
`
`0 Federal Tax Credits. Furnace products that utilize constant torque motor technology may qualify for up to $1,500 in tax credits under the current
`federal program due to the motor’s contribution to efficiency. (Check with the furnace equipment manufacturer to determine eligibility.) If eligible,
`the constant torque motor would be defined as an advanced air circulating fan, meaning that the motor itself has an annual electricity usage of no
`more than 2 percent of the total annual energy used by the furnace, as determined by Department of Energy (DOE) test procedures,
`
`It should be noted that this criteria, including the tax credit itself, does not apply to air handlers with constant torque motors because the benefit of the
`advanced main air circulating fan has already been accounted for in the overall energy efficiency ratings of the outdoor products.
`
`' Sustainability. One of the hottest buzzwords today is sustainability. All contractors and service technicians should be aware of what the term means
`and how sustainability relates to the equipment they sell and service, The Environmental Protection Agency (EPA) Website defines sustainability as
`“meeting the needs of the present without compromising the ability of future generations to meet their own needs.”
`
`Sustainability certainly applies to the HVACR industry. In the case of products with constant torque motor technology, sustainability can be
`associated with reduced energy use and less environmental pollution, And, depending on the equipment manufacturer, the sustainability conversation
`may include green or recycled packaging and reduced noise levels.
`
`Constant torque technology is rapidly gaining popularity among OEMs in the industry and among consumers interested in improving the efficiency of
`their home comfort systems. By understanding the advantages this new motor technology offers, contractors can create a unique, professional selling
`proposition that will set them apart from their competition, contribute to higher profit margins and address consumer demands for efficiency,
`reliability and comfort.
`
`Sources: Technical information about the three motor technologies was primarily obtainedfrom Regal-Beloit (General Electric) documentation. For
`additional details, please visit www.thedealertoolbox.com and www.regalbeloit. com).
`
`Publication date: 12/14/2009
`
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`9M 3
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`Nidec Motor Corporation
`IPR2014-01121
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`Exhibit 2020 - 9
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`Nidec Motor Corporation
`IPR2014-01121
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`Exhibit 2020 - 9
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`Nidec Motor Corporation
`IPR2014-01121
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`Exhibit 2020 - 10
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`IPR2014-01121
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