Abstract: A system and method for replacing a sixteen-pin ECM with a non-sixteen-pin, field adjustable ECM in an HVAC or other system, and adjusting the performance of the replacement motor at the point of installation. A converter module receives programming information from an existing control board via an existing sixteen-pin harness, and converts the information to six signals. The module includes potentiometers for tuning speed/torque for first and second settings, adjusting a horsepower output of the replacement ECM, and adjusting a ramp time to increase or decrease a rate at which the speed/torque changes. The module includes switches for selecting between clockwise and counterclockwise directions for the replacement ECM, selecting between PWM and non-PWM control, and selecting between torque and speed modes. A non-sixteen-pin motor controller receives the information from the converter module via a four-wire harness, translates the information, and outputs a control signal to the replacement ECM.

Abstract: A system and method for replacing a sixteen-pin ECM with a non-sixteen-pin, field adjustable ECM in an HVAC or other system, and adjusting the performance of the replacement motor at the point of installation. A converter module receives programming information from an existing control board via an existing sixteen-pin harness, and converts the information to six signals. The module includes potentiometers for tuning speed/torque for first and second settings, adjusting a horsepower output of the replacement ECM, and adjusting a ramp time to increase or decrease a rate at which the speed/torque changes. The module includes switches for selecting between clockwise and counterclockwise directions for the replacement ECM, selecting between PWM and non-PWM control, and selecting between torque and speed modes. A non-sixteen-pin motor controller receives the information from the converter module via a four-wire harness, translates the information, and outputs a control signal to the replacement ECM.

Abstract: A tool for programming a controller of an electric motor by engaging a connection block of the motor and providing high voltage power and communicating programming signals to the controller. The tool includes a body having an interface for engaging the connection block, and internal wiring presenting tool terminals at the interface for making contact with corresponding motor terminals to allow for providing power and communicating signals between the tool and the controller. An energy-limited transformer having an isolated high impedance secondary winding provides both electrical isolation to protect against shock and low energy output to protect against arc flash. Redundant interlocks include a software interlock which allows the power to be present at the interface only during actual programming of the controller. A light ring encircling the body indicates the presence of high voltage and is visible from multiple directions.

Abstract: A tool for programming a controller of an electric motor by engaging a connection block of the motor and providing high voltage power and communicating programming signals to the controller. The tool includes a body having an interface for engaging the connection block, and internal wiring presenting tool terminals at the interface for making contact with corresponding motor terminals to allow for providing power and communicating signals between the tool and the controller. An energy-limited transformer having an isolated high impedance secondary winding provides both electrical isolation to protect against shock and low energy output to protect against arc flash. Redundant interlocks include a software interlock which allows the power to be present at the interface only during actual programming of the controller. A light ring encircling the body indicates the presence of high voltage and is visible from multiple directions.

Abstract: A method of estimating an input power of a motor comprises determining an output power of the motor; determining a speed of the motor; calculating a scaling factor as a function of the speed of the motor; and estimating the input power as a function of the scaling factor and the output power.

Abstract: A tool for programming a controller of an electric motor by engaging a connection block of the motor and providing high voltage power and communicating programming signals to the controller. The tool includes a body having an interface for engaging the connection block, and internal wiring presenting tool terminals at the interface for making contact with corresponding motor terminals to allow for providing power and communicating signals between the tool and the controller. An energy-limited transformer having an isolated high impedance secondary winding provides both electrical isolation to protect against shock and low energy output to protect against arc flash. Redundant interlocks include a software interlock which allows the power to be present at the interface only during actual programming of the controller. A light ring encircling the body indicates the presence of high voltage and is visible from multiple directions.

Abstract: A tool for programming a controller of an electric motor by engaging a connection block of the motor and providing high voltage power and communicating programming signals to the controller. The tool includes a body having an interface for engaging the connection block, and internal wiring presenting tool terminals at the interface for making contact with corresponding motor terminals to allow for providing power and communicating signals between the tool and the controller. An energy-limited transformer having an isolated high impedance secondary winding provides both electrical isolation to protect against shock and low energy output to protect against arc flash. Redundant interlocks include a software interlock which allows the power to be present at the interface only during actual programming of the controller. A light ring encircling the body indicates the presence of high voltage and is visible from multiple directions.

Abstract: A method of estimating an input power of a motor comprises determining an output power of the motor; determining a speed of the motor; calculating a scaling factor as a function of the speed of the motor; and estimating the input power as a function of the scaling factor and the output power.

Abstract: A motor programming tool is disclosed for associating with a connection block of a motor and sending signals to a programmable controller of the motor, where the connection block includes a plurality of terminals coupled to the controller. The programming tool includes a tool body with an interface generally corresponding with the connection block of the motor, wiring operable to carry the signals, and a plurality of terminal connecting assemblies to associate with the motor terminals. The programming tool includes circuitry disposed in the tool body. The circuitry is electrically connected to the wiring and includes a power transmission portion and a data transmission portion.

Abstract: A motor programming tool is disclosed for associating with a connection block of a motor and sending signals to a programmable controller of the motor, where the connection block includes a plurality of terminals coupled to the controller. The programming tool includes a tool body with an interface generally corresponding with the connection block of the motor, wiring operable to carry the signals, and a plurality of terminal connecting assemblies to associate with the motor terminals. The tool body includes a shiftable locking mechanism operable to selectively secure the tool body relative to the electrical connection block of the motor.

Abstract: A motor programming tool is disclosed for associating with a connection block of a motor and sending signals to a programmable controller of the motor, where the connection block includes a plurality of terminals coupled to the controller. The programming tool includes a tool body with an interface generally corresponding with the connection block of the motor, wiring operable to carry the signals, and a plurality of terminal connecting assemblies to associate with the motor terminals. The programming tool includes circuitry disposed in the tool body. The circuitry is electrically connected to the wiring and includes a power transmission portion and a data transmission portion.

Abstract: A motor programming tool is disclosed for associating with a connection block of a motor and sending signals to a programmable controller of the motor, where the connection block includes a plurality of terminals coupled to the controller. The programming tool includes a tool body with an interface generally corresponding with the connection block of the motor, wiring operable to carry the signals, and a plurality of terminal connecting assemblies to associate with the motor terminals. The tool body includes a shiftable locking mechanism operable to selectively secure the tool body relative to the electrical connection block of the motor.

Abstract: A motor programming tool is disclosed for associating with a connection block of a motor and sending signals to a programmable controller of the motor, where the connection block includes a plurality of terminals coupled to the controller. The programming tool includes a tool body with an interface generally corresponding with the connection block of the motor, wiring operable to carry the signals, and a plurality of terminal connecting assemblies to associate with the motor terminals. The tool body includes a shiftable locking mechanism operable to selectively secure the tool body relative to the electrical connection block of the motor.