Emerson Industrial Automation
Installation and
Maintenance Manual
For IntelliGear Plus™
MD and BW1
Variable Speed Drives
c
®
7120 New Buffington Road
Florence, KY 41042
Application Engineering: 800 626 2093
www.emerson-ept.com
ce
us
UL Listed
E211799
Ind. Cont EQ. 54 DN
UL is believed to be a registered trade name and/or trademark of Underwriters
Laboratories, Inc. and is NOT owned or controlled by Emerson Power Transmission.
Emerson Power Transmission Corporation cannot and does not represent or warrant
the accuracy of this information.
Emerson, Emerson Industrial Automation, Intelligear and Intelligear Plus & Design are trademarks of
Emerson Electric Co. or one of its affiliated companies.
©2004, 2008, 2012 Emerson Power Transmission Corp., All Rights Reserved.
MCIM12260E• 9708E • Printed in USA
FORM
9708E
November 2012
IntelliGear Plus™ Variable Speed MD Gearmotors
Thank you for choosing an IntelliGear Plus Gearmotor.
General Safety Instructions
•
Read and follow all instructions carefully.
•
Disconnect and lock-out power before installation and maintenance. Working on or
near energized equipment can result in severe injury or death.
•
Disconnect power at least 2 minutes prior to servicing to allow capacitors to discharge.
Handling wires sooner than this could result in electric shock, severe injury, or death.
•
Do not operate equipment without guards in place. Exposed equipment can result in
severe injury or death.
•
Any eyebolts that have been supplied with the gearmotor are designed for lifting only
these components. Lifting additional weight attached to these components may break
the eyebolt and result in personal injury or death, and product damage.
•
All electrical work should be performed by qualified personnel and compliant with local
and national electrical codes.
•
Periodic inspections should be performed. Failure to perform proper maintenance can
result in premature product failure and personal injury.
•
IntelliGear Plus contains parts sensitive to static electricity. Care should be taken to
discharge static prior to handling these components to avoid damage to them.
Contact Emerson Power Transmission for recommendations for units running at slow
speeds or unusual conditions.
•
2
IntelliGear Plus™ Variable Speed MD Gearmotors
Contents
1
General Information................................................................................................................................. 4
1.1 General operating principle........................................................................................................................ 4
1.2 Product name............................................................................................................................................. 4
1.3 Environmental characteristics.................................................................................................................... 4
1.4 Radio-frequency interference..................................................................................................................... 5
1.4.1General...................................................................................................................................................... 5
1.4.2 Standards (Emissions)............................................................................................................................... 5
1.4.3 Standards (Immunity)................................................................................................................................. 5
1.5 Description of cables and protection devices (Customer Supplied)........................................................... 5
1.6 UL conformity............................................................................................................................................. 5
1.6.1 Specified mains supply.............................................................................................................................. 5
1.6.2Cables........................................................................................................................................................ 5
1.6.3Fuses......................................................................................................................................................... 5
1.8Dimensions................................................................................................................................................ 6
2Installation................................................................................................................................................ 7
2.1General...................................................................................................................................................... 7
3Connections............................................................................................................................................. 7
3.1 Control Terminal Blocks............................................................................................................................. 7
3.2 Power terminal blocks................................................................................................................................ 7
3.2.1 Terminal block for power supply PB1 ( marked L & N ).............................................................................. 7
3.3 Wiring diagram based on standard configuration...................................................................................... 8
3.4 Terminal Block Assignments and MD Functionality................................................................................... 9
4Commissioning........................................................................................................................................ 9
5
Operator Pad.......................................................................................................................................... 10
5.1 Troubleshooting Guide............................................................................................................................. 11
5.2 Additional Troubleshooting....................................................................................................................... 11
5.3 Field Modifications of Parameters............................................................................................................ 12
6
Gear Lubrication.................................................................................................................................... 13
7
Gear Parts List....................................................................................................................................... 14
8
Motor Parts List...................................................................................................................................... 15
3
IntelliGear Plus™ Variable Speed MD Gearmotors
General Information
1 - General Information
1.1 - General operating principle
The IntelliGear Plus is a combination of a 3-phase induction motor and an integrated open loop vector variable speed
drive. The motor can be combined with many gear types from Emerson Power Transmission’s range.
In the standard product version, the integrated drive does not require any connection other than the power supply. The
options may be used to broaden the application range of the IntelliGear Plus.
IntelliGear Plus motors meet the requirements of the Low Voltage Directive 73/23/EEC, modified by 93/68/EEC. The
harmonized standards of the DIN VDE 0160 series in connection with standard VDE 0660, part 500 and EN 60146/VDE
0558 are also applicable.
1.2 - Product name
115V Single Phase Power Supply
Rating
Power (HP)
310 M 050
0.50
IntelliGear PLUS Controlling Options
Description
4-20 mA follow or local Keypad (manual control)
Designation
RPD
Designation
KEYPAD LCD
VMA30SOFT
230V Single Phase Power Supply
Rating
Power (HP)
31 M 050
0.50
IntelliGear PLUS Accessories
Description
Parameter setting console w/cable to locally reprogram to customize parameters
CD w/cable and USB to locally reprogram to customize parameters
1.3 - Environmental Characteristics
Characteristics
Degree of protection
Storage temperature
Transport temperature
Ambient operating temperature
Altitude
Ambient humidity
Humidity during storage
Vibration
Shocks
Immunity
Radiated and conducted
emissions
UL and CUL
4
Level - IntelliGear PLUS
TEFC motor and NEMA 4/12 Controller
TEFC Version
-40 oC to +70 oC
-40 oC to +70 oC
-20 oC to +40 oC (above 40 oC requires derating 1% per oC)
Up to 3000 feet above sea level without derating
95% non-condensing
93%, 40 oC, 4 days
- Exposed product: 0.01 g2 / Hz 1 hr. in accordance with IEC 68-2-34
- Sinusoidal vibration: 2-9 Hz 3.5 ms-2 - 9-100 Hz 10 ms-2 in accordance with
IEC 68-2-6
Packaged product: 15 g, 6 ms, 500 times/direction in all 6 directions in
accordance with Standard IEC 68-2-29
Conforming to EN61000-6-2
Conforming to EN500081-2 with filter
Conforming to UL 508 C (E211799)
IntelliGear Plus™ Variable Speed MD Gearmotors
1.4 - Radio-frequency interference:
or the drive/motor cable: radiated emissions
1.4.1 - General
Variable speed drives use high-speed switches (transistors,
semi-conductors) which switch high voltages (around 660V
for 3-phase drives) at high frequencies (several kHz). This
provides better efficiency and a low level of motor noise. As
a result, they generate radio-frequency signals which may
disturb operation of other equipment or distort measurements
taken by sensors:
•due to high frequency leakage currents which escape to
ground via the stray capacity of the drive/motor cable and
that of the motor via the metal structures which support
the motor
•by conduction or feedback of R.F. signals on the power
supply cable; conducted emissions
These phenomena are of direct interest to the user. The
frequency range concerned (radio-frequency) does not affect
the energy distribution company.
1.4.2 - Standards (Emission)
The maximum emission level is set by (EN 50081-2) and
(EN 50081-1). IntelliGear Plus conforms to:
•EN 50081-2 as standard
•EN 50081-1 with filter option
1.4.3 - Standards (Immunity)
The maximum immunity level is set by (EN 50082-2) and
(EN 50082-1). IntelliGear Plus conforms to:
• EN 50082-2 and EN 50082-1 as standard
•by direct radiation near to the main supply power cable
1.5 - Description of cables and protection devices (Customer Supplied)
NOTICE: When using a circuit-breaker, it must be a motor circuit-breaker (D curve).
• Comply with the size of protection fuses. • The cable size may vary according to legislation applicable in the country, which will take precedence over the values
given in the table below without exception.
Motor
HP Rating
0.50
115V Single Phase Power Supply
IntelliGear Input Amps Wire Gauge
Plus Number
I 310M 050
5
14AWG
230V Single Phase Power Supply
Fuse Size
10 A
IntelliGear Input Amps Wire Gauge
Plus Number
I 31M 050
2.5
14AWG
Fuse Size
8A
1.6 - UL conformity
1.6.1 Specified mains supply
The drive can be incorporated in an installation with short circuit capacity of 5000 A rms maximum at voltage 264 VAC rms
maximum for 230 V (TL) drives or 528 VAC rms maximum for 400 V (T) drives.
1.6.2 Cables
Only class 1 copper cables 60/70° C (140/167° F) should be used.
1.6.3 Fuses
UL conformity is adhered to if the fuses are UL-listed, fast-blow fuses (class CC up to 30 A) with a rating as indicated in
the above table and if the short-circuit symmetrical current does not exceed 5 kA.
5
6
115
230
XS9507
XS9508
1 ØCATALOG
Voltage NUMBER
Model
No.
CBN3001BSCB524.556
CCI 109
Power
5.00
8.52
Ø 3.1500
3.1493
.12
CCI-123G
CCI-124G
CCI NUMBER
CCI Number
CCI 109-G
4.5
4.5
Gear Ratio
Ø .344 + .007 / -.002 HOLES
6.30
.39
Standard
RPM Range
600-19
600-19
Ø .280 HOLES
4 @ 90º AS SHOWN
Ø 4.72
Ø 3.94
1.40
5.50
5.90
3.50
11.23
IntelliGear Plus™ Variable Speed MD Gearmotors
1.8 - Dimensions
IntelliGear Plus™ Variable Speed MD Gearmotors
2 - Installation
After connection, ensure that the seals are firmly in place,
and that the screws and cable glands are watertight to ensure
drive protection. Clear any condensation from the drain holes
at the bottom of the motor.
2.1 - General
The IntelliGear Plus is usually fitted to the gear and mounted
to the machine with flange or foot mounting. The motor fan
cools the whole assembly. Make sure that the ventilation air
inlet is free of obstruction.
Removable screws in terminal block:
• Tightening torque = 2.62 in. lbs.
• Maximum cross section = 17 AWG
3.2
3.2.1
Power terminal blocks
Terminal block for power supply PB1
(marked L&N)
This terminal block is used to connect the 3 phase
power supply when the RFI filter is not used in an
IntelliGear Plus. Otherwise, the RFI filter output is screwed onto this connector and the power supply should be attached to the terminals located on top of the filter. (See table below)
3 - Connections
Connection with copper conductor only.
3.1 - Control Terminal Blocks
• Remove the terminal block from it’s fixed holder
(unplugged) before making any connections, to avoid
putting pressure on the card.
Screw terminal blocks
Tightening Torque
Max. cross-section
310M & 31M
7.1 in. lbs.
AWG 14
CAUTION: The IntelliGear Plus has a positive logic
configuration. Using a drive with a control system which
has a different control logic may cause unwanted starting
of the motor.
•
•
•
The control circuits in the drive are isolated from the
power circuits by single insulation (IEC 664-1).
The installer must ensure that the external control
circuits are isolated against any human contact.
If the control circuits need to be connected to circuits
conforming to SELV safety requirements, additional
insulation must be inserted to maintain the SELV
classification.
Numbered Controller
Terminal Blocks
Terminal Block
for Power Supply
7
8
User supplied male Turck connectors can be secured locally using the
following information 5 pin connector with 4 meter cable attached = Turck # SB5T - 4
6 pin connector with 4 meter cable attached = Turck # SB6T - 4
NOTE:
IF AUTO MODE RUN/STOP CONTACT IS NOT USED, 4-20mA INPUT
CONNECTOR PINS 5 & 6 MUST BE JUMPERED TO RUN IN AUTO
MODE.
IntelliGear Plus™ Variable Speed MD Gearmotors
3.3 Wiring diagram based on standard configuration
IntelliGear Plus™ Variable Speed MD Gearmotors
3.4 Terminal block assignments and MD functionality
Controller
Terminal
Number
Designation
1
10V
Function
+10VDC Analog Internal Source
Accuracy
Characteristics
Maximum Output Current
±2%
30 mA
Voltage Input
2
3
ADI1
0V
Kick Start Speed Reference
Full Scale Voltage
10 VDC ±2%
Input Impedence
95 kΩ
Logic & Analog Circuit Common
Current Input
4
5
11
ADI2
24V
Auto Mode Speed Reference
**
+24VDC Logic Internal Source
Current Range
4-20 mA ±5%
Input Impedence
500 Ω
Resolution
10 bits
Sampling
6 ms
Output Current
30 mA
Overload Current
60 mA
Accuracy
±5%
Protection
Current Limiting & Overload Fault Trip
Voltage Output
6
ADIO3
Analog Output Proportional to
Motor/Pump RPM
Voltage Range
0 to 10 VDC
Load Resistor
2 kΩ Minimum
Protection
Short Circuit (40 mA Maximum)
Logic Output
7
8
9
10
12
13
14
DIO1
DI2
DI3
DI4
ENA
RL1
RL2
Voltage Range
0 to +24 VDC
Sampling/Refresh Rate
2 ms
Maximum Output Current
50 mA
Overload Current
50 mA
Logic Input 2
Auto Mode Run/Stop
Characteristics
Logic Input (Positive Logic)
Thresholds
“0”: <5 VDC
Logic Input 3
Motor Thermal Input
Voltage Range
0 to +24 VDC
Sampling/Refresh Rate
2 ms
Absolute Maximum Voltage Range
0 to +35 VDC
Load Impedence
15 kΩ
Input Threshold
7.5 V
Voltage Range
9 to +33 VDC
Load Impedence
820 Ω
Characteristics
Normally Open Single Pole Contact
Rated Voltage
250 VAC
Current Rating
Resistive Load: 4 A
Logic Output 1
Drive Running
Logic Input 4
Fault Signal Input from Run Dry
and/or High Pressure Sensor
Drive Enable
Drive Healthy Contact
Closed Upon Power Up Unless
Drive Tripped
“1”: >10 VDC
Inductive Load: 2 A
** Provides setpoint feedback function when drive is programmed for full PI mode of operation
4. Commissioning
WARNING! Before switching on the IntelliGear Plus unit, check that the electrical
connections are correct, and that any moving parts are mechanically guarded.
WARNING! For the safety of personnel, the IntelliGear Plus must not be switched on
with any protective covering removed.
9
IntelliGear Plus™ Variable Speed MD Gearmotors
5. Operator Pad
Each RPD IntelliGear unit has a keypad on the controller lid equipped with operator elements for H-O-A
selection, manual control of unit, display of pump speed, faults and the ability to change some factory set
parameters.
REF.
Function
A
Displays operating RPM of pump
B
- Displays drive status including faults
- Displays parameter number and setting during drive programming/setup
C
“Hand” command button starts motor running in Hand mode
D
“Off” button to stop motor
E
“Auto” command button initiates Auto mode for operation from a 4-20 mA speed
reference analog signal
F
- Set the pump speed in Hand mode
- Set maximum pump speed in Auto mode
- Parameter selection and adjustment in drive programming/setup mode
G
“Mode” button to initiate parameter setting mode
- In parameter setting mode, opens and locks parameter settings
A
B
C
F
D
G
E
10
IntelliGear Plus™ Variable Speed MD Gearmotors
5. 1 Fault Mode Troubleshooting Guide
LED Pad Display
Blank Display
0019 - 0600
Drive Status/Fault Indication
Drive not powered
Display unplugged or failed
Numeric display shows Pump RPM, indicates motor running
rdY
Drive Ready (Enabled & Not Running)
inh
Drive Inhibited (Not Enabled)
tr01
Motor thermostat trip - Overtemp
tr02
tr03
UU
Internal brake resistor trip - Overtemp
Pump RUN DRY or HIGH PRESSURE fault trip
DC Bus Undervoltage
OU
DC Bus Overvoltage
ph.AC
Loss of a motor phase
OI.AC
Overcurrent at Drive Output
It.AC
Motor Overload (I X t)
Oht1
Overheating in Output Transistors
Oht2
Overheating in Brake Transistor
rS
SCL
EEF
OI.br
Stator Resistance Measurement Fault
Serial connection between keypad and drive broken
EEPROM fault in drive
Overcurrent at Brake Transistor
Actions Required
Check for drive input power
Check display plug connection
In AUTO mode, make sure AUTO-RUN contact is closed
between pins 5 & 6 of 6-pin connector if pump should be
running
Install jumper between IntelliGear terminals 11-12
Check motor thermostat connections between IntelliGear
terminals 5 & 9
(Install jumper if motor has no thermostat wires -P1/P2)
Check motor fan & clean debris or obstruction to air flow
Check for motor overload
Contact factory
Check for proper flow and pressure in pump
Check incoming power for voltage level too low
Check incoming power for voltage level too high
Check for over-running load (pressure over-driving pump)
Adjust drive parameter 04 (deceleration time) to a higher
setting using drive keypad/display
Check motor connections at IntelliGear grey terminal strip
Check motor connections at IntelliGear grey terminal strip
Check for ground fault or line-line fault in motor wiring
Check for moisture or insulation damage in motor windings
Check for excessive torque load at pump
Check heatsink fins for debris or obstruction to air flow
Provide supply of cool air if ambient exceeds 40°C
Reduce torque load from pump
Adjust drive parameter 04 (deceleration time) to a higher
setting using drive keypad/display
Reduce start/stop frequency
Check motor connections at IntelliGear grey terminal strip
Check display plug connection
Contact factory
Contact factory
5.2 Additional Troubleshooting
Symptom
Probable Cause(s)
Drive not in HAND or AUTO mode
Not Running, No Fault
Indication on Display Drive in AUTO mode, but AUTO-RUN contact not
closed
Unit Runs Only at Low
Speed in AUTO mode
Actions Required
Press HAND or AUTO button on Keypad
Close AUTO-RUN contact or
Jumper pins 5-6 on 6-pin connector cable
4-20 mA signal is not present
Connect 4-20 mA signal and Verify that the signal
current is present (pins 1 & 2 of 6-pin connector)
4-20 mA signal polarity is reversed
Verify current enters pin 1 of 6-pin connector Reverse
the connections if necessary
4-20 mA signal not achieving full 20 mA at maximum
speed reference
Signal source may not be capable of producing 20
mA with the drive input impedence of 500 ohms must be able to produce at least 10 VDC at pin #1 of
6-pin connector cable
In AUTO, Unit Does
Not Achieve Maximum
Output RPM at 20 mA Maximum speed setting of operator keypad setting is
Signal Input
not set to 100%
Press UP ARROW on keypad until maximum speed
is attained
IntelliGear MAXIMUM SPEED setting has been turned Adjust drive parameter 02 to 2700 RPM using drive
down
keypad/display
11
IntelliGear Plus™ Variable Speed MD Gearmotors
5.3 Field Modifications Of Parameters
The new IVD controller with keypad allows some factory set parameters to be adjusted in the field. The table below
provides the factory settings for each parameter and then optional ranges for selection of a new setting. Follow the
steps detailed below, using the keypad “M” key and UP and DOWN arrows to achieve customized settings for your IVD
gearmotor.
Step 1 - Power up the controller to “Ready” mode
Step 2 - Press “M” key
Step 3 - Use UP or DOWN arrow to go to parameter number to be changed
Step 4 - Press “M” key
Step 5 - USE UP or DOWN arrow to change the actual parameter setting
Step 6 - Press the “M” key to save the new parameter value
PAD
Parameter #
Parameter Description
Normal
Value
Optional Range For
New setting
Units
01
Motor Minimum Speed
90
91-350 Δ
RPM (of motor) ‡‡
02
Motor Maximum Speed
2700
100 - 2699
RPM (of motor) ‡‡
03
Acceleration Rate - Seconds/1000 RPM
1.0
0.1-600
Seconds/1000 RPM
04
Deceleration Rate - Seconds/1000 RPM
5.0
0.1-600
Seconds/1000 RPM
New Field Setting
‡‡ To determine new setting for this parameter, multiply pump RPM desired by gear ratio shown on gear nameplate.
example - Desire max. pump RPM of 375 requires change to parameter #2 from “2700” to
“1688” ( gear ratio is 4.5, so 375 x 4.5 = 1688 ) Δ To achieve “0” speed at minimum mA input, change setting for parameter #1 to “0”
12
IntelliGear Plus™ Variable Speed MD Gearmotors
6 - Gear Lubrication
Series 3000 CbN gearing is shipped with one of the following synthetic lubricants per the table below. The gear reducer
has been filled to accommodate any mounting position. In the case of synthetic oil, the lubricant does not require
changing, but it is recommended that proper oil level be checked periodically.
Synthetic
No Backstop
Manufacturer
Fuchs®
Mobil®
Shell®
With Backstop
-25˚ F to 125˚ F
(-30˚ C to 50˚ C)
Sintogear® 125
SHC 629
Omala® Fluids HD 150
Manufacturer
Shell
-25˚ F to 125˚ F
(-30˚ C to 50˚ C)
Omala RL 100
Acceptable Mineral Oil Lubricants
Ambient Range of Installation
-4˚ F to 14˚ F
ISO VG 68
122˚F and Above
14˚F to 122˚F (-10˚C to 50˚C)
(-20˚C to 10˚C)
ISO VG 100
No Backstop
ISO VG 150
ISO VG 220
Primary
Gear
With Backstop
ISO VG 150
(50 ˚C+)
ISO VG 320
Input
Opening
Orient the gear head
vertically and fill to
mid-point of the
Primary Gear
Fuchs is a registered trademark of Fuchs Petrolub; Shell is a registered
trademark of Shell Petroleum Incorporated. Omala is a registered
trademark of Shell Trademark Management.
Diagram for
Size 30
Oil Level
13
IntelliGear Plus™ Variable Speed MD Gearmotors
7.0 - Gear Parts List
CBN 3001
284
077
090
130
031
080
282
001
255
097
052
042
062
061
009
187
128
256
257
Rep
001
009
031
042
052
061
062
077
080
Description
Housing
Output flang ring
Output shaft
Pinion
Gear
Bearing front
Bearing back
Output shaft key
Gear Key
Quantity
1
1
1
1
1
1
1
1
1
Rep
090
097
127
130
175
185
186
187
282
Description
Oil seal
Input o-ring
Gearing snap ring*
Gearing snap ring
Input bracket screw
Washer for gear*
Screw washer*
Bolt
Nameplate
* Not illustrated on diagram
Typical Maintenance Items - Bearings and Seals
Gear
Frame
30
14
Item Description By Location
Bearings
Seal (mm)
61
62
90
6205 ZZ
6005
25 x 52 x 7 DL nitrile
Quantity
1
1
1
1
4
1
1
4
1
258
IntelliGear Plus™ Variable Speed MD Gearmotors
CbN 30 (Quantity Per Unit)
1
254
4
Rep
Description
Quantity
11
1
Motor adapter
1
5
2
Input shaft
1
3
Pinion
1
4
Internal snap ring
1
6
Bearing
1
8
External snap ring
1
9
Seal
1
10
Pinion pin
1
183
Stud
4
184
Nut
4
Gear
Frame
Bearing
Seal (mm)
6
9
30
6005 2RS
47 x 25 x 7
9
6
8
10
2
3
183
7
184
FRAME 56
8.0 Motor Parts List
Part #
Description
1
Fan Cover
2
Self Tapping Screw
3
Hex Nut
5
Retaining Snap Ring
6
Fan
7
Bracket
8
Screw
9
Bushing
10
Plastic Plug
11
Ball Bearing
12
Rotor Assembly (includes items 13 & 14)
13
Shaft
14
Rotor Core
15
Wound Stator Assembly
16
Gasket
17
Outlet Box Base
18
Self Tapping Screw
19
Outlet Box Cover
20
Self Tapping Screw
Emerson, Emerson Industrial Automation, Intelligear and Intelligear Plus & Design are trademarks of
Emerson Electric Co. or one of its affiliated companies.
©2004, 2008, 2012 Emerson Power Transmission Corp., All Rights Reserved.
MCIM12260E• 9708E • Printed in USA
Qty.
1
3
1
1
1
1
4
4
4
1
1
1
1
1
1
1
2
1
2
15
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