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IntelliGear Plus

TM

 Variable Speed Gearmotors and Motors

1 - General

Depending on their exposure after mounting, IntelliGear

 

Plus 

motors may contain moving parts, as well as hot surfaces, during 

operation.  

Unjustified removal of protection devices, incorrect use, faulty 

installation or inappropriate operation could represent a serious 

risk to personnel, animals and equipment.  

For further information, consult the manual.  

All work relating to transportation, installation and maintenance 

must be performed by experienced, qualified personnel (see 

IEC 364 or CENELEC HD 384, or DIN VDE 0100 and national 

specifications for installation, startup and accident prevention).  

In these basic safety instructions, qualified personnel means 

persons competent to install, mount, startup, and operate the 

product and possessing the relevant qualifications.  

2 - Use

IntelliGear

 

 Plus motors are components designed for integration 

in installations or electrical machines.  

When integrated in a machine, commissioning must not take 

place in Europe until it has been verified that the machine 

conforms with directive 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 include IntelliGear Plus) cannot be regarded as circuit 

breaking devices and certainly not as isolating switches.  

Commissioning can take place only if the requirements of the 

Electromagnetic Compatibility Directive (89/336/EEC, modified 

by 92/31/EEC) and/or local codes are met.  

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.  

The technical characteristics and instructions concerning the 

connection conditions specified on the nameplate and in the 

documentation provided must be observed without fail.  

3  -  Transportation, Storage

All instructions concerning transportation, storage and correct 

handling must be observed.  

The climatic conditions specified in the technical manual must be 

observed.  

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 

the specifications in the manual supplied with the product. 

IntelliGear Plus motors must be protected against excessive 

shock or vibration. In particular, there must be no damage to 

parts and/or modification of the clearance between components 

during transportation and handling. Avoid touching the electronic 

components and contact parts.  

IntelliGear

 

 Plus motors contain parts which are sensitive to static 

electricity and may be easily damaged if handled incorrectly. 

Electrical components must not be exposed to mechanical 

damage or destruction (risks to health).  

5  -  Electrical Connection

When work is performed on IntelliGear

 

Plus motors which are 

powered up, national accident prevention specifications must be 

respected.  

The electrical installation must comply with the relevant 

specifications (for example conductor cross-sections, protection 

via fused circuit-breaker, connection of protective conductor). 

More detailed information is given in the manual.  Instructions for 

an installation which meets the requirements for electromagnetic 

compatibility, such as screening, grounding, presence of filters 

and correct insertion of cables and conductors, are given in 

the documentation supplied with the IntelliGear Plus. These 

instructions must be followed in all cases, even if the IntelliGear 

Plus carries the CE mark.  

Adherence to the limits given in the EMC legislation is the 

responsibility of the manufacturer of the installation or the 

machine.  

6  -  Operation

Installations incorporating IntelliGear Plus motors must be 

fitted with additional protection and monitoring devices as laid 

down in the current relevant safety regulations: law on technical 

equipment, accident prevention regulations, etc. Modifications to 

Intelligear Plus motors using control software are permitted.  

Active parts of the device and live power connections must not 

be touched immediately after the IntelliGear Plus is powered 

down, as the capacitors may still be charged. In view of this, the 

warnings fixed 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.  

MCIM15100E • Form 9112E • Printed in USA 

3

Summary of Contents for IntelliGear Plus

Page 1: ...l and be compliant with local and national electrical codes 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 Do not operate equipment without guards in place Exposed equipment can result in severe injury or death Avoid contact with energized circuits or rotating p...

Page 2: ...ct and lock out power before installation and maintenance Working on or near energized equipment can result in severe injury or death Avoid contact with energized circuits or rotating parts High voltage and rotating parts can cause serious or fatal injury Do not operate equipment without guards in place Exposed equipment can result in severe injury or death Be sure shaft key is fully captive befor...

Page 3: ...s 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 the specifications in the manual supplied with the product IntelliGear Plus motors must be protected against excessive shock or vibration In particular there must be no damage to parts and or modification of the clearance ...

Page 4: ...ntrol brake 17 3 6 2 Separate power supply 17 3 7 Wiring diagrams for ESFR option 17 3 7 1 Connection of the ESFR option 17 4 Commissioning 18 4 1 Starting with the power supply 18 4 1 1 Automatic starting 18 4 2 Starting with remote volt free contact 18 4 3 Starting with the local run stop control PD P1 or P2 options 18 4 4 Setting the speed 18 4 4 1 External reference R option 18 4 4 2 Control k...

Page 5: ...0 33 310 M 050 0 5 31 M 050 0 5 31 TL 050 0 5 31 T 050 0 5 32 M 075 0 75 31 M 075 0 75 31 TL 075 0 75 31 T 075 0 75 31 M 100 1 31 TL 100 1 31 T 100 1 32 M 150 1 5 32 TL 150 1 5 31 T 150 1 5 32 M 200 2 32 TL 200 2 31 T 200 2 33 TL 300 3 32 T 300 3 33 TL 500 5 32 T 500 5 33 T 750 7 5 33 T 1000 10 IntelliGear Plus Speed Controlling Options Designation Description PD Digital keypad on enclosure For Re...

Page 6: ...s 10 times per hour Motor Frequency Variation Ranges Standard 60 to 10 Hz 6 1 constant torque up through 3 HP 74 to 12 Hz 6 1 constant torque for 5 through 10 HP Optional 60 to 6 Hz 10 1 constant torque up through 1 5 HP 90 to 9 Hz 10 1 constant torque for 2 through 10 HP Special 120 to 2 Hz depending on thermal and mechanical limits Efficiency 97 5 x motor efficiency x gear efficiency if applicab...

Page 7: ... or SDI1 and SDI 2 size 33 thermal of motor or drive protection from locked rotor motor windings 1 4 Environmental Characteristics C Face motors Characteristics Level IntelliGear Plus Degree of protection TEFC Version TEFC motor and NEMA 4 12 Controller Washdown Version Washdown Motor and NEMA 4 12 Controller Storage temperature 40 C to 70 C Transport temperature 40 C to 70 C Ambient operating tem...

Page 8: ...eedback 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 frequencyrangeconcerned radio frequency doesnotaffect the energy distribution company 1 5 2 Standards Emission The maximum emission level is set by the generic industrial EN 50...

Page 9: ...uit symmetrical current does not exceed 5 kA 1 6 Description of cables and protection devices Customer Supplied cont d Motor hp Rating 230V Three Phase Power Supply 460V Three Phase Power Supply Motor hp Rating IntelliGear Plus Number Input Amps ire Gauge Fuse Size IntelliGear Plus Number Input Amps Wire Gauge Fuse Size 0 33 I 31 TL 033 2 5 14AWG 4 A I 31 T 033 1 5 14AWG 4 A 0 33 0 5 I 31 TL 050 3...

Page 10: ... or 31M or 31 7 74 6 45 5 91 4 35 5 61 2 25 2 95 0 62 0 55 8 53 9 791 7 32M 7 74 6 45 5 91 4 35 5 61 2 25 2 95 0 62 0 55 9 12 9 791 7 5 143T 145T 31M or 31 7 74 6 45 5 91 4 35 5 61 2 25 2 95 0 62 0 55 8 53 11 041 7 145TY 31 7 74 6 45 5 91 4 35 5 61 2 25 2 95 0 62 0 55 8 53 12 04 7 143T 145T 32 or 32M 7 74 6 45 5 91 4 35 5 61 2 25 2 95 0 62 0 55 9 12 11 041 7 5 145TY 32 or 32M 7 74 6 45 5 91 4 35 5...

Page 11: ...sually 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 4 Reverse the option and cable gland supports 5 Reconnect the printed circuit p...

Page 12: ...The shielding must be connected to control circuit common at one end only Insure that control circuit commons being connected are at the same voltage relative to earth ground Incorporate a bend where the cables enter the cable glands so that water cannot penetrate the terminal box Tighten the cable glands firmly 3 2 Control Terminal Blocks Removetheterminalblockfromit sfixedholder unplugged before...

Page 13: ...6 ms 0 10V or 4 20mA Logic input if connected to the 24 V speed reference as selected Threshholds 0 5V 1 10V by DI4 below Voltage range 0 to 24V Load 95 kΩ Input threshold 7 5V 3 3 0V Logic circuit common 0V Voltage input Full scale voltage 10 V 2 Input Impedance 95 kΩ Current input Analog or logic Current range 0 to 20 mA 5 Input 2 Input impedance 500 Ω Resolution 10 bits 4 4 ADI2 Assignment in s...

Page 14: ...V digital input Logic input External fault interlock Maximum output current 50 mA Overload current 50 mA Output current 10 mA in total 5 8 Overload current 33 150mA 31 32 50mA 24V 24V internal source Accuracy 5 11 11 Protection Current limiting and overload fault trip Logic input 2 Characteristics Logic input positive logic 8 9 DI2 Assignment in standard Threshold 0 5V 1 10V configuration Run forw...

Page 15: ...Terminal block for power supply PB1 marked L1 L2 and L3 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 supplyshouldbeattachedtotheterminalslocated on top of the filter 3 3 2 Terminal block for braking resistor PB2 marked R and R This terminal block is...

Page 16: ...iable Speed Gearmotors and Motors 3 5 Wiring Diagrams 3 5 1 Standard configuration connection diagram Note For single phase versions the power supply is connected to terminals L and N 16 MCIM15100E Form 9112E Printed in USA ...

Page 17: ...al Power Transmission Solutions 3 7 Wiring diagrams for ESFR option 3 7 1 Connection of the ESFR option 31 and 32 only Use of this option to power a second motor and brake is a special and must be specified at order entry The illustration for the wiring for the second motor in the diagram will not apply when this special feature is not specified Coil brake Full wave 208 230VAC mains supply Half wa...

Page 18: ...remote volt free contact Once it has been switched on the motor starts in accordance with the run command given by the closing of the volt free contact corresponding to the desired direction 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 or P2 options Once input power has been ...

Page 19: ...o trip Mains present Flashing green Current limiting Check that the motor is not overloaded or stalled Flashing red IGBT temperature alarm Motor overload Braking resistor option overload Check that air is able to circulate around the motor fins and IntelliGear Plus casing The motor is overloaded check the motor current using a clamp ammeter Check that the deceleration ramp is long enough for appli...

Page 20: ...ings terminal block configuration range speed and PI settings etc Descriptions of the option 1 CD in case 1 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 Plus parameters 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 ...

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