Emerson Industrial Automation
7120 New Buffington Road
Florence, KY 41042
Application Engineering: 800 626 2093
www.emerson-ept.com
Installation and
Maintenance Manual
For IntelliGear Plus™
MD and BW1/BW2
Variable Speed Drives
c
®
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.
MCIM12003E • 9178E • Printed in USA
FORM
9178E
Revised
April 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 breakmotor or gearmotor are designed
for lifting only these components. Lifting additional weight attached to theses
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.............................................................................................................................................6-7
2Installation................................................................................................................................................ 8
2.1General...................................................................................................................................................... 8
3Connections............................................................................................................................................. 8
3.1
3.2
3.3
3.4
Control Terminal Blocks............................................................................................................................. 8
Power terminal blocks................................................................................................................................ 8
Wiring diagram based on standard configuration...................................................................................... 9
Terminal Block Assignments and MD Functionality................................................................................. 10
4Commissioning...................................................................................................................................... 10
5
Faults - Diagnostics............................................................................................................................... 11
5.1 Troubleshooting Guide............................................................................................................................. 11
6
Gear Lubrication.................................................................................................................................... 12
7
Gear Parts List....................................................................................................................................... 13
8
Motor Parts List...................................................................................................................................... 14
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
32 M 075
0.75
IntelliGear PLUS Controlling Options
Description
4-20 mA follow or local Start/Stop/10 Turn Potentiometer
Designation
RP1
Designation
KEYPAD LCD
VMA30SOFT
230V Single Phase Power Supply
Rating
Power (HP)
31 M 050
0.50
31 M 075
0.75
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
Level - IntelliGear PLUS
TEFC motor and NEMA 4/12 Controller
-40 oC to +70 oC
-40 oC to +70 oC
o
o
-20 C to +40 C (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
TEFC Version
Shocks
Immunity
Radiated and conducted
emissions
UL (USA)
CUL (CANADA)
4
Conforming to EN61000-6-2
Conforming to EN500081-2 with internal filters
Conforming to UL 508 C (E211799)
IntelliGear Plus™ Variable Speed MD Gearmotors
1.4 - Radio-frequency interference:
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
•by direct radiation near to the main supply power cable
or the drive/motor cable: radiated 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
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
0.75
115V Single Phase Power Supply
IntelliGear Input Amps Wire Gauge
Plus Number
I 310M 050
5
14AWG
I 32M 075
8.5
14AWG
230V Single Phase Power Supply
Fuse Size
10 A
14A
IntelliGear Input Amps Wire Gauge
Plus Number
I 31M 050
2.5
14AWG
I 31M 075
4
14AWG
Fuse Size
8A
8A
1.6 - UL conformity
1.6.1 Special 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
CATALOG NUMBER
CBN3001BSCB524.556 CCI 109
5.00
8.52
Ø 3.1500
3.1493
.12
CCI NUMBER
CCI 109-G
Ø .344 + .007 / -.002 HOLES
6.30
.39
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
CATALOG NUMBER
SEEPEXBW2+TS1LS80B14
CCI NUMBER
CCI0109G
IntelliGear Plus™ Variable Speed MD Gearmotors
7
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. The positions
of the potentiometer/cable gland supports are specified
at the time of ordering. However they may be reversed if
necessary.
3 - Connections
Connection with copper conductor only.
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)
Screw terminal blocks
Tightening Torque
Max. cross-section
Frame 310M
7.1 in. lbs.
AWG 14
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.
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
8
Terminal Block
for Power Supply
User supplied male Turck connectors can be secured locally using the
following information 4 pin connector with 4 meter cable attached = Turck # SB4T - 4
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
9
IntelliGear Plus™ Variable Speed MD Gearmotors
3.4 Terminal block assignments and MD functionality
Controller
Terminal
Number
1
Designation
10V
Function
+10V analog internal source
Characteristics
Accuracy
± 2%
Maximum output current
30 mA
Voltage input
2
ADI1
Hand Mode Speed Reference Full scale voltage
10 V ± 2%
**
Input Impedance
95 kΩ
3
0V
Logic circuit common 0V
Current input
Current range
0 to 20 mA ± 5%
4
ADI2
Auto Mode Speed Reference Input impedance
500 Ω
Resolution
10 bits
Sampling
6 ms
Logic input (if connected to the +24 V
6
ADIO3
Fault Signal Input
Threshholds
“0”:<5V-”1”; >10V
From Pump Operation
Voltage range
0 to +24V
Run Dry and/or High Pressure Load
95 kΩ
Input threshold
7.5V
Characteristics
Digital output 1
7
DIO1
Alarm LED
Threshholds
“0”:<5V-”1”; >10V
Voltage range
0 to +24V
Sampling/refreshment
2 ms
5
Output current
10 mA in total
Overload current
33 = 150mA, 31/32 = 50mA
24V
+24V internal source
Accuracy
± 5%
11
Protection
Current limiting and overload
fault trip
Logic input 2
Characteristics
Logic input (positive logic)
8
DI2
Run/Stop
Threshold
“0”:<5V-”1”; >10V
Voltage range
0 to +24V
Logic input 3
Sampling/refreshment
2 ms
9
DI3
Absolute maximum voltage 0 to +35V
Motor Thermal Input
range
Logic input 4
Load
15 kΩ
10
DI4
Input threshold
7.5V
Hand Mode Selectior
Voltage range
9 to + 35V
12
ENA
Enable
Impedance
820 Ω
13
RL1
Drive Healthy Contact
Characteristics
NO single pole contact
14
RL2
N/C after start-up if OK
250VAC maximum contact 4 A, resistive load
2 A inductive load
current
** Performs scaling 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.
10
IntelliGear Plus™ Variable Speed MD Gearmotors
5. Faults - Diagnostics
Information relating to the status of the IntelliGear Plus is provided by an indicator lamp (see photo bottom
right) on the control and by the internal LED in 310M.
seepex Inc.
Tel +1(937)864-7150
Fax +1(937)864-7157
sales@seepex.net
CAUTION :RISK OF ELECTRIC SHOCK
DESCONECTAR EL APPARATO
Y ESPERAR AL MENOS
2 MINUTOS ANTES
DE INTERVENIR
METTRE L’APPAREIL HORS
DISCONNECT POWER
TENSION ET ATTENDRE 2
AT LEAST 2 MINUTES
MINUTES AU MOINS AVANT
BEFORE MAKING
TOUTE INTERVENTION
ADJUSTMENTS
POTENTIAL FAULT
Falla potencial / Defaut potentiel
PUMP
Bomba
Pompe
RED
ROJO
ROUGE
DRIVE & POWER
Impulsion & Potencia
Entrainement & puissance
OVER TEMP
OVER/UNDER VOLTAGE
LOW FLOW
WINDING FAILURE
Temperatura excesiva
Température élevée
Bajo flujo
Débit bas
HIGH PRESURE
Alta presión
Haute pression
Alto/Bajo Voltage
sur/sous tention
falla en el bobinado
Défaut d’enroulement
DRIVE FAILURE
Falla en el impulsor
Défaut d’uentrainement
5. 1 MD Gearmotor Troubleshooting Guide
Symptom
Probable Cause(s)
Actions Required
Not running in AUTO or HAND modeAlarm Light not lit
Power to drive is not on
HOA switch is in “OFF” position
HOA switch not in “AUTO” position
Pins “5” and “6” of the six pin Turck
connector are not “connected”
Check power supply and cord
Move switch to HAND or AUTO
Put HOA switch in “AUTO” position
4-20 mA signal is not present at drive
4-20 mA to drive installed in reverse into pins
“1” and “2” of six pin Turck connector
4-20 mA signal does not achieve full scale
Signal to drive is not reaching full 20 mA
Check incoming 4-20 mA signal
Reverse 4-20 mA connection polarity
Not running in AUTO mode Alarm light not lit
Unit runs at only Low Speed in
AUTO mode
Unit in AUTO mode will not achieve
high RPM output at 20 mA
Red LED “Alarm” light is on Unit has stopped
Potentiometer is not in “10” position
Refer to “badge” below and on top of unit
for mechanical/pump and electrical/
motor causes
• Connect Auto Mode Run/Stop contact to
pins “5”and “6” of six pin Turck connector.
• Make sure Auto Mode Run/Stop contact is
closed.
• Jumper pins “5” and “6” if Auto Mode Run/
Stop contact is not being utilized
Check incoming 4-20 mA signal
Repair signal
Turn potentiometer to “10” position
Check these causes to determine the
root cause for fault. Once cleared, unplug and re-install main power plug with
power source
11
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
-25˚ F to 125˚ F
(-30˚ C to 50˚ C)
Omala RL 100
Manufacturer
Shell
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
With Backstop
ISO VG 150
(50 ˚C+)
ISO VG 320
Input
Opening
Primary
Gear
Orient the gear head
vertically and fill to
mid-point of the Primary Gear
Diagram for
Size 30
Oil Level
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.
12
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
258
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
Quantity
1
1
1
1
4
1
1
4
1
* Not illustrated on diagram
Typical Maintenance Items - Bearings and Seals
Gear
Frame
30
Item Description By Location
Bearings
Seal (mm)
61
62
90
6205 ZZ
6005
25 x 52 x 7 DL nitrile
13
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
14
Part #
Description
Qty.
1
Fan Cover
1
2
Self Tapping Screw
3
3
Hex Nut
1
5
Retaining Snap Ring
1
6
Fan
1
7
Bracket
1
8
Screw
4
9
Bushing
4
10
Plastic Plug
4
11
Ball Bearing
1
12
Rotor Assembly (includes items 13 & 14)
1
13
Shaft
1
14
Rotor Core
1
15
Wound Stator Assembly
1
16
Gasket
1
17
Outlet Box Base
1
18
Self Tapping Screw
2
19
Outlet Box Cover
1
20
Self Tapping Screw
2
FRAME 56
Notes
15
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.
MCIM12003E • 9178E • Printed in USA
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