Abstract: A motor control system for heating, ventilation, and air conditioning (HVAC) applications is described. The motor control system includes a thermostat and an electronically commutated motor (ECM) coupled to the thermostat. The ECM is configured to retrofit an existing non-ECM electric motor included in an HVAC application and to operate in one of a plurality of HVAC modes. The HVAC modes include at least one of a heating mode, a cooling mode, and a continuous fan mode. The HVAC mode is determined based at least partially on outputs provided by the thermostat.

Abstract: An electric motor communication system for use with a fluid moving system is provided. The electric motor communication system includes an electric motor including a wireless communication device configured to transmit and receive wireless signals, and a processing device coupled to the wireless communication device and configured to control the electric motor based at least in part on wireless signals received at the wireless communication device. The electric motor communication system further includes at least one external device configured to communicate wirelessly with the electric motor.

Abstract: A drive circuit for a permanent split capacitor (PSC) motor includes an inverter, a solid state switch, and a contactor coupled in parallel with the solid state switch. The inverter is configured to supply variable frequency current to the PSC motor over a first duration. The solid state switch is configured to supply line frequency current to the PSC motor at the expiration of the first duration. The contactor is configured to supply the line frequency current to the PSC motor over a second duration beginning when the contactor closes after expiration of the first duration.

Abstract: Controllers for controlling hybrid motor drive circuits configured to drive a motor are provided herein. A controller is configured to drive the motor using an inverter when a motor commanded frequency is not within a predetermined range of line input power frequencies, and couple line input power to an output of the inverter using a first switch device when the motor commanded frequency is within the predetermined range of line input power frequencies.

Abstract: A motor control assembly for an electric motor. The motor control assembly is configured to be coupled to the electric motor, and includes a wireless communication module, an input power connector, and an inverter module. The wireless communication module is configured to receive a wireless signal from a system controller. The input power connector is configured to receive a DC voltage from an external power supply module. The inverter module is coupled to the wireless communication module and the input power connector. The inverter module is configured to convert the DC voltage to an AC voltage to operate the electric motor according to the wireless signal.

Abstract: An electric motor communication system for use with a fluid moving system is provided. The electric motor communication system includes an electric motor including a wireless communication device configured to transmit and receive wireless signals, and a processing device coupled to the wireless communication device and configured to control the electric motor based at least in part on wireless signals received at the wireless communication device. The electric motor communication system further includes at least one external device configured to communicate wirelessly with the electric motor.

Abstract: A fluid flow system is provided. The system includes a rotation producing device, a first fluid flow device coupled to the rotation producing device and a second fluid flow device coupled to the rotation producing device and spaced from the first fluid flow device.

Abstract: Methods and systems for programming an electric motor are provided. An electric motor controller configured to be coupled to an electric motor is configured to control the electric motor to produce torque when direct current (DC) link voltage has up to 100% voltage ripple. The controller includes a first power input, a second power input, and a third power input, an energized line detection device, and a microprocessor. Each power input is configured to receive power from an alternating current (AC) power source. The energized line detection device is configured to sense which power input has received power from the AC power source and output an isolated signal. The microprocessor is coupled downstream from the energized line detection device and is configured to determine an operating profile for the electric motor based on the isolated signal.

Abstract: A dual-drive electric motor control system configured to drive a first electric motor and a second electric motor is provided. The system includes a shared front-end motor drive circuit for converting AC input voltage from an AC voltage source to a DC-link voltage. A first control system has a first inverter coupled to the shared front-end motor drive circuit, and a first switch device configured to couple the AC voltage source directly to the first electric motor. The system further includes a second control system having a second inverter coupled to the shared front-end motor drive circuit, and a second switch device configured to couple the AC voltage source directly to the second electric motor.

Abstract: A controller and methods for hybrid operation control of an electric motor in an electric motor system are provided. The controller is configured to receive a speed command for operating the electric motor, measure available voltage on an inverter configured to provide conditioned AC voltage to the electric motor, and determine a winding phase angle difference based on the received speed command and the measured available inverter voltage. The controller is also configured to adjust a phase angle difference between winding voltage commands for the switches of the inverter using the determined winding phase angle difference, and apply the winding voltage commands including the adjusted phase angle difference to the inverter switches to control the electric motor.

Abstract: An interleaved bridgeless power factor correction (PFC) converter-based motor drive system is provided. The system includes a first inductor coupled to a second inductor. The coupled first and second inductors are coupled to a first input configured to be coupled to a first line of an alternating current (AC) power supply. The system also includes a third inductor coupled to a fourth inductor. The coupled third and fourth inductors are coupled to a second input configured to be coupled to a second line of the AC power supply. The system further includes a digital active power factor correction (PFC) controller configured to cause current in at least one of the coupled first and second inductors and the coupled third and fourth inductors to be interleaved.

Abstract: An electric motor controller and methods of determining which input power line of a plurality of input power lines of a motor drive controller has been energized are provided. An electric motor controller configured to be coupled to an electric motor includes a plurality of power input lines configured to receive an alternating current (AC) input voltage from an AC power source, an energized line detection device configured to sense that a power input line has been energized by the AC power source, and configured to output an isolated signal, and a rectifier configured to convert the AC input voltage having a frequency to a direct current (DC) voltage. The controller also includes a computing device coupled downstream from the energized line detection device and configured to determine which input power line has been energized.

Abstract: A control system for a permanent split capacitor (PSC) motor is provided herein. The control system includes a motor drive circuit configured to condition AC input voltage from an AC voltage source to an output voltage for operating the PSC motor at a variable speed. The control system also includes a switch device configured to couple the AC input voltage from the AC voltage source directly to the PSC motor for operating the PSC motor at a fixed speed.

Abstract: An electric motor control system and methods of manufacture are provided. The system includes a power supply module including a printed circuit board (PCB) and a plurality of power processing components configured to convert an input voltage into an output voltage. The system also includes a motor management module including an encapsulated, heat-sharing package for housing a plurality of moisture-sensitive driver components configured to convert the output voltage from the power supply module and provide output voltages for application to windings of the electric motor.

Abstract: Hybrid motor drive circuits configured to drive a motor are provided herein. A hybrid motor drive circuit includes an inverter coupled to the motor and configured to drive the motor when a motor commanded frequency is not within a predetermined range of line input power frequencies. The hybrid motor drive circuit also includes a first switch device configured to couple line input power to an output of the inverter when the motor commanded frequency is within the predetermined range of line input power frequencies.

Abstract: A motor control system for heating, ventilation, and air conditioning (HVAC) applications is described. The motor control system includes a thermostat and an electronically commutated motor (ECM) coupled to the thermostat. The ECM is configured to retrofit an existing non-ECM electric motor included in an HVAC application and to operate in one of a plurality of HVAC modes. The HVAC modes include at least one of a heating mode, a cooling mode, and a continuous fan mode. The HVAC mode is determined based at least partially on outputs provided by the thermostat.

Abstract: Protection of an electric motor drive controller from a transient voltage is described herein. The transient voltage is provided by an alternating current (AC) power line that includes a line conductor, a neutral conductor, and a ground conductor. The transient voltage protection system includes a first stage protection device coupled to an input of a rectifier of the motor drive controller. The first stage protection device is configured to suppress the transient voltage to prevent damage to the motor drive controller. The transient voltage protection system also includes a second stage protection device coupled between the rectifier and an inverter of the motor drive controller. The second stage protection device is configured to further suppress the transient voltage to prevent damage to the inverter.

Abstract: An EMI filter is described that includes an input having first and second input terminals, and an output having first and second output terminals. A first conductive path is defined between the first input and output terminals, and a second conductive path is defined between the second input and output terminals. The EMI filter also includes a first choke device coupled across the first and second conductive paths, and a first Y capacitor including a first end and a second end opposite the first end, the first end coupled to the first conductive path downstream from the first choke device. The EMI filter further includes a second Y capacitor including a first end and a second end opposite the first end, the first end coupled to the second conductive path downstream from the first choke device, and a second choke device coupled to an inverter output.

Abstract: A motor control system for heating, ventilation, and air conditioning (HVAC) applications is described. The motor control system includes a thermostat and an electronically commutated motor (ECM) coupled to the thermostat. The ECM is configured to retrofit an existing non-ECM electric motor included in an HVAC application and to operate in one of a plurality of HVAC modes. The HVAC modes include at least one of a heating mode, a cooling mode, and a continuous fan mode. The HVAC mode is determined based at least partially on outputs provided by the thermostat.

Abstract: Hybrid motor drive circuits configured to drive a motor are provided herein. A hybrid motor drive circuit includes an inverter coupled to the motor and configured to drive the motor when a motor commanded frequency is not within a predetermined range of line input power frequencies. The hybrid motor drive circuit also includes a first switch device configured to couple line input power to an output of the inverter when the motor commanded frequency is within the predetermined range of line input power frequencies.