Emerson BW1, BW2 User Manual

Installation and
Maintenance Manual
For IntelliGear Plus™
MD and BW1/BW2
Variable Speed Drives

Emerson Industrial Automation

7120 New Bufngton Road

Florence, KY 41042

Application Engineering: 800 626 2093

www.emerson-ept.com

F O R M

9178E

Revised

April 2012

®

c

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

ce

us

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.

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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

1.4.1 General .....................................................................................................................................................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

1.6.2 Cables .......................................................................................................................................................5

1.6.3 Fuses ........................................................................................................................................................5

1.8 Dimensions ............................................................................................................................................6-7

2 Installation ...............................................................................................................................................8

2.1 General .....................................................................................................................................................8

3 Connections ............................................................................................................................................8

3.1 Control T erminal Blocks ............................................................................................................................8

3.2 Power terminal blocks ...............................................................................................................................8

3.3 Wiring diagram based on standard configuration .....................................................................................9

3.4 Terminal Block Assignments and MD Functionality ................................................................................10

4 Commissioning .....................................................................................................................................10

5 Faults - Diagnostics ..............................................................................................................................11

5.1 Troubleshooting Guide ............................................................................................................................11

6 Gear Lubrication ...................................................................................................................................12

7 Gear Parts List ......................................................................................................................................13

8 Motor Parts List .....................................................................................................................................14

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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 230V Single Phase Power Supply

Rating Power (HP) Rating Power (HP)

310 M 050 0.50 31 M 050 0.50

32 M 075 0.75 31 M 075 0.75

Designation Description

RP1 4-20 mA follow or local Start/Stop/10 Turn Potentiometer

Designation Description

KEYPAD LCD Parameter setting console w/cable to locally reprogram to customize parameters

VMA30SOFT CD w/cable and USB to locally reprogram to customize parameters

1.3 - Environmental Characteristics

Characteristics Level - IntelliGear PLUS
Degree of protection TEFC V ersion TEFC motor and NEMA 4/12 Controller
Storage temperature -40

Transport temperature -40 oC to +70 oC

Ambient operating temperature -20

Altitude Up to 3000 feet above sea level without derating

Ambient humidity 95% non-condensing

Humidity during storage 93%, 40

Vibration

Shocks

IntelliGear PLUS Controlling Options

IntelliGear PLUS Accessories

o

C to +70 oC

o

C to +40 oC (above 40 oC requires derating 1% per oC

o

C, 4 days

Immunity Conforming to EN61000-6-2

Radiated and conducted

Conforming to EN500081-2 with internal filters

emissions

UL (USA) Conforming to UL 508 C (E211799)

CUL (CANADA)

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IntelliGear Plus™ Variable Speed MD Gearmotors

1.4 - Radio-frequency interference:

1.4.1 - General

V ariable speed drives use high-speed s witches (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

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.

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lter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

Motor 115V Single Phase Power Supply 230V Single Phase Power Supply

HP Rating

0.50 I 310M 050 5 14AWG 10 A I 31M 050 2.5 14AWG 8A

0.75 I 32M 075 8.5 14AWG 14A I 31M 075 4 14AWG 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.

IntelliGear

Plus Number

Input Amps Wire Gauge Fuse Size IntelliGear

Plus Number

Input Amps Wire Gauge Fuse Size

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