Installation and Maintenance Manual WARNING For ......Emerson Power Transmission P. O. Box 687...

Emerson Power TransmissionP. O. Box 687

Maysville, KY 41056Phone: 800-626-2093www.emerson-ept.com

F O R M9112

November 2007

® c eccccc

™

Installation andMaintenance ManualFor IntelliGear Plus™Variable SpeedGearmotors and Motors

UL is believed to be a registered trade name and/or trademark of UnderwritersLaboratories, Inc. and is NOT owned or controlled by Emerson Power Transmission.Emerson Power Transmission Corporation cannot and does not represent or warrantthe accuracy of this information.

WARNING!

High voltage and rotating parts may causeserious or fatal injury.

Turn off power to install or service.

Operate with guards in place.

Read and follow all instructions in this manual.

UL ListedE211799Ind. Cont EQ. 54 DN

ususususus

IntelliGear PlusVariable Speed Gearmotors and Motors

Disconnect all power before adjusting units.

2 © 2007 Emerson Power Transmission. All rights reserved.

Safety First

High voltage and rotating parts can cause serious or fatal injury. Safe installation, operation and maintenance mustbe performed by qualified personnel. Familiarization with and adherence to NEMA MG2, the National Electric Codeand local codes is recommended. It is important to observe safety precautions to protect personnel from possibleinjury. Personnel should be instructed to:

1. Avoid contact with energized circuits or rotating parts.

2. Disconnect all power sources before initiating any maintenance or repair.

3. Act with care in accordance with prescribed procedures in handling and liftingthis equipment.

4. Be sure unit is electrically grounded in accordance with code requirements.

5. Be sure equipment is properly enclosed to prevent access by children or otherunauthorized personnel in order to prevent possible accidents.

6. Be sure shaft key is fully captive before unit is energized.

7. Avoid contact with capacitors until safe discharge procedures have beencompleted.

8. Most units are shipped with oil. Always be sure oil lubricated units are filled withcorrect oil to proper level before operating.

9. Provide proper safeguards for personnel against rotating parts and applicationsinvolving high inertia loads which can cause overspeed.

10. Avoid extended exposure to equipment with high noise levels.

11. Be familiar with the equipment and read all instructions thoroughly beforeinstalling or working on equipment.

Thank you for choosing an IntelliGear Plus Gearmotor.

The Emerson logo is a trademark and a service mark of Emerson Electric Co.


3© 2007 Emerson Power Transmission. All rights reserved.


1 - General

Depending on their exposure after mounting, IntelliGear Plus mo-tors may contain moving parts, as well as hot surfaces, duringoperation.

Unjustified removal of protection devices, incorrect use, faultyinstallation or inappropriate operation could represent a serious riskto personnel, animals and equipment.

For further information, consult the manual.

All work relating to transportation, installation and maintenancemust be performed by experienced, qualified personnel (see IEC364 or CENELEC HD 384, or DIN VDE 0100 and nationalspecifications for installation, startup and accident prevention).

In these basic safety instructions, qualified personnel means personscompetent to install, mount, startup, and operate the product andpossessing the relevant qualifications.

2 - Use

IntelliGear Plus motors are components designed for integration ininstallations or electrical machines.

When integrated in a machine, commissioning must not take placein Europe until it has been verified that the machine conforms withdirective 89/392/EEC (Machinery Directive).

It is also necessary in Europe to comply with standard EN 60204,which stipulates in particular that electrical actuators (which includeIntelliGear Plus) cannot be regarded as circuit-breaking devicesand certainly not as isolating switches.

Commissioning can take place only if the requirements of theElectromagnetic Compatibility Directive (89/336/EEC, modified by92/31/EEC) and/or local codes are met.

IntelliGear Plus motors meet the requirements of the Low VoltageDirective 73/23/EEC, modified by 93/68/EEC. The harmonizedstandards of the DIN VDE 0160 series in connection with standardVDE 0660, part 500 and EN 60146/VDE 0558 are also applicable.

The technical characteristics and instructions concerning theconnection conditions specified on the nameplate and in thedocumentation provided must be observed without fail.

3 - Transportation, Storage

All instructions concerning transportation, storage and correcthandling must be observed.

The climatic conditions specified in the technical manual must beobserved.

Safety and Operating Instructions for Electrical Actuators(In accordance with the low voltage directive 73/23/EEC modified by 93/68/EEC).

4 - Installation

The installation and cooling of equipment must comply with thespecifications in the manual supplied with the product. IntelliGearPlus motors must be protected against excessive shock or vibration.In particular, there must be no damage to parts and/or modificationof the clearance between components during transportation andhandling. Avoid touching the electronic components and contactparts.

IntelliGear Plus motors contain parts which are sensitive to staticelectricity and may be easily damaged if handled incorrectly.Electrical components must not be exposed to mechanical damageor destruction (risks to health).

5 - Electrical Connection

When work is performed on IntelliGear Plus motors which arepowered up, national accident prevention specifications must berespected.

The electrical installation must comply with the relevant specifications(for example conductor cross-sections, protection via fused circuit-breaker, connection of protective conductor). More detailedinformation is given in the manual. Instructions for an installationwhich meets the requirements for electromagnetic compatibility,such as screening, grounding, presence of filters and correctinsertion of cables and conductors, are given in the documentationsupplied with the IntelliGear Plus. These instructions must befollowed in all cases, even if the IntelliGear Plus carries the CEmark.

Adherence to the limits given in the EMC legislation is theresponsibility of the manufacturer of the installation or the machine.

6 - Operation

Installations incorporating IntelliGear Plus motors must be fittedwith additional protection and monitoring devices as laid down in thecurrent relevant safety regulations: law on technical equipment,accident prevention regulations, etc. Modifications to IntelligearPlus motors using control software are permitted.

Active parts of the device and live power connections must not betouched immediately after the IntelliGear Plus is powered down, asthe capacitors may still be charged. In view of this, the warningsfixed to IntelliGear Plus motors must be observed.

During operation, all protective covers must remain in place.

7 - Servicing and Maintenance

Refer to the manufacturer’s documentation.




Contents

1 General Information ....................................................................................................................................................................... 3

1.1 General operating principle .............................................................................................................................................................. 51.2 Product name ................................................................................................................................................................................... 51.3 Characteristics ............................................................................................................................................................................ 6 - 71.4 Environmental characteristics .......................................................................................................................................................... 71.5 Radio-frequency interference ........................................................................................................................................................... 81.5.1 General ............................................................................................................................................................................................. 81.5.2 Standards (Emissions) ..................................................................................................................................................................... 81.5.3 Standards (Immunity) ....................................................................................................................................................................... 81.6 Description of cables and protection devices (Customer Supplied) .......................................................................................... 8 - 91.7 UL conformity ................................................................................................................................................................................... 91.7.1 Specified mains supply ..................................................................................................................................................................... 91.7.2 Cables ............................................................................................................................................................................................... 91.7.3 Fuses ................................................................................................................................................................................................ 91.8 Weights and dimensions ................................................................................................................................................................ 10

2 Installation ..................................................................................................................................................................................... 11

2.1 General ........................................................................................................................................................................................... 112.2 Reversing the supports .................................................................................................................................................................. 11

3 Connections .................................................................................................................................................................................. 12

3.1 Wiring precautions .......................................................................................................................................................................... 123.2 Control terminal blocks ........................................................................................................................................................... 13 - 143.3 Power terminal blocks .................................................................................................................................................................... 153.4 Terminal blocks for options ............................................................................................................................................................ 153.5 Wiring diagrams based on the standard configuration .................................................................................................................. 163.6 Power supply and control for FCR brakemotors ............................................................................................................................ 173.6.1 Power supply for the built-in sequential control brake ................................................................................................................... 173.6.2 Separate power supply ................................................................................................................................................................... 173.7 Wiring diagrams for ESFR option .................................................................................................................................................. 173.7.1 Connection of the ESFR option ...................................................................................................................................................... 17

4 Commissioning ............................................................................................................................................................................. 18

4.1 Starting with the power supply ....................................................................................................................................................... 184.1.1 Automatic starting ........................................................................................................................................................................... 184.2 Starting with remote volt-free contact ............................................................................................................................................ 184.3 Starting with the local run/stop control (PD, P1 or P2 options) ..................................................................................................... 184.4 Setting the speed ............................................................................................................................................................................ 184.4.1 External reference (R option) ......................................................................................................................................................... 184.4.2 Control knob option (P3) or remote potentiometer ........................................................................................................................ 184.4.3 Internal speed control option (P4 option) ....................................................................................................................................... 18

5 Faults - Diagnostics ..................................................................................................................................................................... 19

6 Operating Extensions .................................................................................................................................................................. 19

6.1 Digital keypad on enclosure with for./rev./stop./speedup and down/speed display/fault display ................................................. 196.2 Control knob with integrated run/stop control option (P1) ............................................................................................................. 196.3 Control knob with forward/reverse/stop control option (P2) .......................................................................................................... 196.4 Speed control knob option (P3) ...................................................................................................................................................... 206.5 Internal speed control option (P4) .................................................................................................................................................. 206.6 Braking resistor option (RF100 - RF200) ....................................................................................................................................... 206.7 Fieldbus options ............................................................................................................................................................................. 206.8 Parameter-setting console option (Keypad LCD) .......................................................................................................................... 206.9 Programming CD (VMA30SOFT) .................................................................................................................................................. 206.10 XPress Key (PX Key) ..................................................................................................................................................................... 20




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 speeddrive. 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. Theoptions may be used to broaden the application range of the IntelliGear Plus. Based on the advanced technology of theIGBT power module, very high efficiency and reduced noise levels are achieved.

1.2 - Product name

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1.3 - Characteristics

1.3.1 - Electrical Data

1.3.2 - Characteristics and Functions

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1.3.2 - Characteristics and Functions (cont'd.)

* C-Face motors

1.4 - Environmental Characteristics




1.6 - Description of cables and protection devices (Customer Supplied)

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.• These tables should never be used in place of current standards.

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05.0 050M013I 5 GWA41 A01 050M13I 5.2 GWA41 A8 05.0

57.0 570M23I 5.8 GWA41 A41 570M13I 4 GWA41 A8 57.0

1 - - - - 001M13I 5 GWA41 A21 1

5.1 - - - - 051M23I 8 GWA41 A41 5.1

2 - - - - 002M23I 01 GWA41 A61 2

1.5 - Radio-frequency interference:1.5.1 - GeneralVariable speed drives use high-speed switches (transistors,semi-conductors) which switch high voltages (around 660Vfor 3-phase drives) at high frequencies (several kHz). Thisprovides better efficiency and a low level of motor noise. Asa result, they generate radio-frequency signals which maydisturb operation of other equipment or distort measurementstaken by sensors:• due to high frequency leakage currents which escape toground via the stray capacity of the drive/motor cable and thatof the motor via the metal structures which support the motor• by conduction or feedback of R.F. signals on the powersupply cable; conducted emissions• by direct radiation near to the main supply power cable orthe drive/motor cable: radiated emissionsThese phenomena are of direct interest to the user. Thefrequency range concerned (radio-frequency) does not affectthe energy distribution company.

1.5.2 - Standards (Emission)The maximum emission level is set by the generic industrial(EN 50081-2) and domestic (EN 50081-1) standards.IntelliGear Plus conforms to the following standards:• EN 50081-2 as standard• EN 50081-1 with filter option

1.5.3 - Standards (Immunity)The maximum immunity level is set by the generic industrial(EN 50082-2) and domestic (EN 50082-1) standards.IntelliGear Plus conforms to the following standards:• EN 50082-2 and EN 50082-1 as standard




Note:• The mains current value is a typical value which depends on the source impedance. The higher the impedance, the lowerthe current.

1.7 - UL conformity1.7.1 - Special mains supplyThe drive can be incorporated in an installation with short circuit capacity of 5000 A rms maximum at a voltage 264 VACrms maximum for 230 V (TL) drives or 528 VAC rms maximum for 400 V (T) drives.

1.7.2 - CablesOnly class 1 copper cables 60/75° C (140/167° F) should be used.

1.7.3 - FusesUL conformity is adhered to if the fuses used are UL-listed, fast-blow fuses (class CC up to 30 A) with a rating asindicated in the above table and if the short-circuit symmetrical current does not exceed 5 kA.

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57.0 570LT13I 1.4 GWA41 A8 570T13I 5.2 GWA41 A6 57.0

1 001LT13I 3.5 GWA41 A8 001T13I 3 GWA41 A6 1

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2 002LT23I 8 GWA41 A61 002T13I 3.5 GWA41 A01 2

3 003LT33I 21 GWA21 A61 003T23I 8 GWA41 A01 3

5 005LT33I 51 GWA21 A02 005T23I 9 GWA41 A61 5

5.7 - - - - 057T33I 21 GWA21 A61 5.7

01 - - - - 0011T33I 61 GWA21 A02 01

1.6 - Description of cables and protection devices (Customer Supplied) cont'd.




1.8 - Weights and dimensions - Gearmotors

1 There will be an additional .58 inches added for select small combined gearmotors.2 For less than .75 hp, reduce by .32 inches.3 Does not include mounting of brake resistor.

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YT541 13 47.7 54.6 19.5 53.4 16.5 52.2 59.2 26.0 55.0 35.8 40.21 7

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33 61.11 79.8 44.8 10.01 73.7 38.2 22.4 26.0 55.0 01.31 50.41 81

T312 33 99.11 79.8 44.8 37.11 11.8 38.2 22.4 26.0 55.0 01.31 51.61 81

T512 33 90.11 52.11 44.8 32.31 11.8 38.2 22.4 26.0 55.0 01.31 56.71 81

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TX-10

TX-20

2 - Installation

It is the responsibility of the owner or user toensure that the installation, operation and maintenance ofthe inverter and its options comply with legislation relating tothe safety of personnel, animals and equipment, and with thecurrent regulations of the country of use.• Before carrying out any work, disconnect and lock thedrive power supply. For the single-phase range, wait twominutes to make sure that the capacitors have discharged.• After connection, ensure that the seals are firmly in place,and that the screws and cable glands are watertight toensure drive protection. Clear any condensation from thedrain holes at the bottom of the motor.2.1 - General

The IntelliGear Plus is usually fitted to the gear and mountedto the machine with flange or foot mounting.The motor fan cools the whole assembly. Make sure that theventilation air inlet is free of obstruction.The positions of the potentiometer/cable gland supports arespecified at the time of ordering. However they may bereversed if necessary.

4.Reverse the option and cable gland supports.5.Reconnect the printed circuit plug connector on P2 andreplace the TX 10 screws using .5 ft.-lbs. of torque.6.Replace the cover using TX-20 slot type screws byapplying 3 ft.-lbs. of torque.

3.Disconnect the plug connector from the P2 terminal ifan option is connected.

2.2 - Reversing the operators*1.Undo the (2) TX 20 - slot type screws and remove thecover.2.Remove the control knob and cable gland supportattachment screws (TX10 - slot type screws).

* If IntelliGear Plus unit is equipped with an FCR brake,reversing potentiometer is not permitted.




3 - Connections

The voltages on the power terminal blocksand the cables connected to them may cause fatal electricshocks. The drive stop function does not protect againstthese high voltages.• The drive contains capacitors which remain charged ata fatal voltage even after the power supply has beenswitched off.• After switching off the drive, wait for two minutes so thatthe internal circuits can discharge the capacitors, beforeremoving the protection (for the single-phase range).• The drive power supply must be protected againstoverloads and short-circuits.• It is vital to respect the rating of protection devices.• Connection with copper conductor only.

3.1 - Wiring precautions• When the IntelliGear Plus is controlled remotely, avoidparallel routing of power cables and control cables.• All remote control cables must be shielded and have across-section between 24 AWG and 17 AWG. Theshielding must be connected to control circuit common atone end only.• Insure that control circuit commons being connected areat the same voltage relative to earth ground.• Incorporate a bend where the cables enter the cableglands so that water cannot penetrate the terminal box.• Tighten the cable glands firmly.

3.2 - Control Terminal Blocks• Remove the terminal block from it’s fixed holder (unplugged)before making any connections, to avoid putting pressure onthe card.• The IntelliGear Plus has a positive logic configuration.Using a drive with a control system which has a differentcontrol logic may cause unwanted starting of the motor.• The control circuits in the drive are isolated from the powercircuits by single insulation (IEC 664-1).The installer must ensure that the external control circuits areisolated against any human contact.• If the control circuits need to be connected to circuitsconforming to SELV safety requirements, additional insulationmust be inserted to maintain the SELV classification.

Removeable screws in terminal block:• Tightening torque = 2.62 in. lbs.• Maximum cross section = 17 AWG

Bend




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3.2 - Control Terminal Blocks (Continued)




3.2 - Control Terminal Blocks (cont'd.)

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3.3 Power terminal blocks3.3.1 Terminal block for power supply PB1

(marked L1, L2, and L3)This terminal block is used to connect the 3 phasepower supply when the RFI filter is not used in anIntelliGear Plus. Otherwise, the RFI filter outputis screwed onto this connector and the powersupply should be attached to the terminals locatedon top of the filter.

3.3.2 Terminal block for braking resistor PB2(marked R+ and R-)This terminal block is used to connect a brakingresistor when this option is required. The resistoris mounted outside and/or on the rear of the heatsink of the IntelliGear Plus.

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Note: For frames 31 and 32, PB1 and PB2 are bothlocated on the same terminal block.The terminal block on the 31 and 32 has a terminalmarked FI connected to the R- terminal which enablesuse of the internal braking resistor. The jumper mustbe removed when an external braking resistor isconnected or if the inertia is compatible with the rateddeceleration ramp.

3.4 Terminal blocks for options3.4.1 RS485 type serial link connector

This is an RJ 45 connector and is used to connectthe PX LCD console or a PC in order to use theVMA30SOFT PC programming software.For the 31 or 32, it is also used to connect afieldbus or the PD digital pad option.

3.4.2 Description of Slot 1 (Frame 33 only)This slot is used to connect an encoder feedbackmodule when closed loop mode is selected

3.4.3 Description of Slot 2 (Frame 33 only)This slot is used to connect a Profibus DP fieldbusoption module

3.4.4 P2 connector (Frames 31 and 32 only)This is used to connect one of the following optionat a time ( P1 , P2, P3, or ESFR brake control).When the ESFR option for FCR braking is requiredwith one of the speed control options noted above,refer to Application Engineering due to limitationson the location that the speed control option canbe mounted.

RS485

PB2

PB1 Frame 33

Frame 31/32

RS485

PB1andPB2




3.5 Wiring Diagrams3.5.1 Standard configuration connection diagram

Note: For single-phase versions, the power supply is connected to terminals L and N.




3.6 Power supply and control for FCR brake motors3.6.1 Power supply for the built-in sequential control

brakeESFR option (31 and 32 only)- the brake is supplied via the rectifier and a solid

state relay fixed on the ESFR connection card.This connection is made at the factory.

- The rectifier is supplied by two mains phases.- The brake is controlled according to the sequence

which can be adjusted using the IntelliGear Plusparameters.

3.6.2 Separate power supplyThe brake is supplied and controlled by an externalsource not supplied by Emerson Power Transmission.

3.7 Wiring diagrams for ESFR option3.7.1 Connection of the ESFR option (31 and 32 only)

Use of this option to power a second motor andbrake is a special and must be specified at orderentry. The illustration for the wiring for the secondmotor in the diagram will not apply when this specialfeature is not specified.

Coilbrake

Full-wave(208 - 230VACmains supply)

Half-wave(380 - 460VACmains supply)

Power supply to 2nd brake(mains voltage output)

Power supply to 2nd brake(mains voltage output)

*Note:With singlephase drive, connectpower supplybetween L and N.

Flex-trip to connectorfor options

CG

L1

L3

ESFR

CG

230 / 460Vmains supply*

L1

F1 UVWF2

L2 L3

Brake

S06

U

WV

180VDC

400 / 460V mains supply230V mains supply

ESFR Card




4 Commissioning

* Before switching on the IntelliGear Plusunit, check that the elctrical connectionsare correct, and that any moving partsare mechanically guarded.

* For the safety of personnel, the IntelliGearPlus must not be switched on with anyprotective covering removed.

4.1 Starting with the power supplyThis connection jumpers the run command so that themotor or gearmotor starts as soon as input power isswitched on.The speed is adjusted with the local control knob(P3 or P4 options) or a remote reference (0-10V or4-20 mA).Power-up: the green indicator lamp is lit continuously.The control terminals SDI1 and SDI2 (size 33) or 11and 12 (sizes 31 and 32) are linked (unlocking).

4.1.1 Automatic startingBy connecting a jumper between control terminals 8and 11 (sizes 31 and 32) or 8 and 9 (size 33), themotor starts running forward. For reverse rotationconnect terminals 9 and 11 (size 31 or 32) or 8 and 10(size 33).

4.2 Starting with remote volt-free contactOnce it has been switched on, the motor starts inaccordance with the run command given by the closingof the volt-free contact corresponding to the desireddirection of rotation.The speed is adjusted with the local control knob(P3 or P4 options) or a remote reference (0-10V or 4-20 mA).

4.3 Starting with the local run/stop control (PD, P1 orP2 options)Once input power has been switched on, the motorstarts after the button corresponding to the desireddirection of rotation has been pressed for one second.The speed is only adjusted with the local control knobor arrow buttons.

4.4 Setting the speed

4.1.1 External reference (R option)Adjust the speed reference using the desiredreference of either 0-10 V or 4-20 mA

4.2.2 Control knob options (P3) or remote potentiometer(supplied by customer)Adjust the speed reference using a control know ora remote 10 KΩ potentiometer.

4.4.3 Internal speed control option (P4 option)Adjust the speed reference using an internal speedpotentiometer.Adjust the max. speed or min. speed setting withindependent potentiometers if it is not possible toreach the desired speed of operation.




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5 Faults - DiagnosticsInformation relating to the status of the IntelliGear Plus is provided by two indicator lamps located on the control options P1, P2 or P3or by the internal LED in 31/32.

The fault is cleared by switching off the IntelliGear Plus or by opening/closing the connection between terminals 12: ENA and11: +24V (31/32) or SDI1 and SDI2 (33).

6.2 Control knob with integrated run/stop control option (P1)In addition to speed control, a run button and a stop button makeit possible to control the IntelliGear Plus locally, once it is has beenpowered. For a run command to be taken into account, the button mustbe held down for one second.

• It is connected on the P2 connector.• Has two indicator lights.

6.3 Control knob with forward/reverse/stop control option (P2)In addition to speed control, a forward button, a reverse button and astop button make it possible to control the IntelliGear Plus locally, onceit has been powered. For a run command to be taken into account, thebutton must be held down for one second.

• Connected on the P2 connector• Has two indicator lights

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20 © 2007 Emerson Power Transmission. All rights reserved. Printed in U.S.

6.7 Fieldbus optionsThe interface card is fixed inside the casing cover. Protocol:Profibus DP.

6.6 Braking resistor option (RF100 - RF200)For operation in four quadrants and energy dissipation, resistors aremounted directly onto the IntelliGear Plus.

6.8 Parameter-setting console option (Keypad LCD)The console option provides access to the drive internal settings(terminal block configuration, ramp, speed and PI settings, etc.).

See IntelliGear Plus parameter-setting manual included.

Description of the option:1 Keypad LCD console1 cable (3m long)

6.9 Programming CD (VMA30SOFT)This CD with manual provides access to the drive internal settings(terminal block configuration, range, speed and PI settings, etc.).Descriptions of the option:1 CD in case1 cable (3m long with USB on PC to RJ45 on IntelliGear Plus)

6.10 XPress Key (PX Key)The XPress Key option is used to save a copy of all the IntelliGear Plusparameters so that they can be duplicated very simply in another drive.

6.4 Speed control knob option (P3)The speed is set using a knob with graduations from 15 to 100percent. Has two indicator lamps. It is connected on the P2 connec-tor.

6.5 Internal speed control option (P4)

The speeds are set on potentiometers, which are accessible once thecover has been removed.- a max. spd potentiometer: calibration of the maximum speed- a min. spd potentiometer: calibration of the minimum speed- an int. spd potentiometer: speed control, which replaces control via

the control knob.There are also two indicator lights.

External resistors with greater continuous power rating can be used, provided that the minimum ohmic value is maintained.

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Installation and Maintenance Manual WARNING For ......Emerson Power Transmission P. O. Box 687...

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