Infinitum Upgrades Aircore EC+ for Efficient Motor Control

Infinitum has introduced the Aircore EC+, an updated electronically commutated motor designed to improve efficiency, reliability, and speed control in HVAC fan and pump applications. Featuring the company's PCB stator technology, integrated active front-end electronics, hybrid ceramic bearings, and an IP65 enclosure, the compact motor reduces harmonic distortion and eliminates the need for external variable-frequency drives. The result is a smaller, more efficient solution for demanding industrial and commercial environments.

The Aircore EC+ motor and integrated drive. Image used courtesy of Infinitum

Innovative Electronically Commutated Motor Technology

Infinitum is a manufacturer of EC motors with integrated electronics for highly efficient cooling fans and pumps. Infinitum uses a PCB stator technology that promises to increase the efficiency of a standard EC electric motor. The new Aircore EC+ is Infinitum's latest product release, featuring harmonic-reducing active front-end technology, an IP65 enclosure, high-resistance grounding, and hybrid ceramic bearings. These features make the Aircore EC+ an excellent solution for HVAC cooling fans and pumps.

Electronically Commutated (EC) Motor

An EC motor combines the benefits of precise speed control from a DC motor with the widely available AC power source in a permanent magnet, brushless motor. Each EC motor has integrated electronics that function similarly to a VFD, conditioning and controlling the incoming power before it enters the motor windings. The magnetic flux and rotor are also monitored to ensure precise timing to energize specific windings. This technology produces industrial-grade electric motors with efficiency ratings up to 90%.

The Aircore EC+ mounted on a cooling fan that might be used in an industrial furnace or heat pump. Image used courtesy of Infinitum

The Aircore EC+

Built on the Aircore EC platform, the Aircore EC+ has new features that help ensure your motors run as efficiently as possible and reduce downtime. Integrated Active Front End technology reduces VFD harmonics, which are non-sinusoidal currents in the electrical system. This distortion in the output power can cause component overheating, nuisance breaker tripping, and transformer damage. Typical installations would require a filter to be installed in the circuit, which would incur additional costs.

Further, hybrid ceramic bearings are non-conductive and will not corrode. When coupled with an IP65 enclosure, these bearings enable the Aircore EC+ to operate in harsh conditions, even in outdoor environments. Electrical ground faults and standby power often result in equipment downtime. With the Aircore EC+’s high ground resistance, the motor can continue operating even during standby power.

The Aircore EC+ is offered in four different frame sizes, from 13 to 20, and supports power ratings from 1 HP all the way up to 15 HP. All sizes operate on 460, 415, or 575 volts and have speed ratings from 100 to 5040 RPM. The AFE technology is only available on the 15, 18, and 20 frame sizes, along with a finned cover.

An exploded image of the Aircore EC+, showing the pancake design that enables a compact, powerful solution. Image used courtesy of Infinitum

Compact Yet Powerful

The Aircore EC+ has the same components you might find in a typical motor, but it's a fraction of the size. Each component is flat and stacked together to create a compact motor. The stator is a PCB stator that uses 66% less copper and is 50% smaller and lighter than a typical stator. Copper coils are etched directly into the stator, greatly reducing the amount of iron in the motor and thereby reducing eddy current losses.

EC Motor Applications

Cooling fans are often seen as energy hogs because they constantly start and stop. For years, the HVAC industry has used VFD’s with internal programming to start and stop fans in a slow, controlled manner. Using an EC motor, the industry can further reduce energy consumption through precise speed control and higher overall motor efficiency. The advanced technology used in the EC motor results in a smaller footprint and less downtime, as the motor is precisely monitored and controlled for maximum efficiency.