Emerson AXP1600 Power Supply User Manual
Contents
1. 18 033 gt SO EN Ave ravage gt 401 0 y 4 7347033 T34 038 o o 210 os 5 a LON aasn ton X29 5 L3 A oe TOId o 5 ais 7 Id Ee c Ave oc 7138 10 2 p IH yoy NAA o S AlddS SNIV aN 21 Z HO9 Hd 1 0 aaa 5 2 g OL 129 7 OVA OCZ 10911 9 7 T XE ae 10 ezis G SfYld NV39ITI3LNI o SHOSNS INYA ASL OL Z 8 L SNId NO 5 5 SS IM LAdNI SV ADVLIOA IWYS 1 1 SHOLOSNNOO Nid S e IntelliGear Plus Variable Speed MD Gearmotors 3 4 Terminal block assignments and MD functionality Controller Terminal Number _ Designation Characteristics 1 10V 10VDC Analog Internal Source Maximum Output Current Voltage Input Kick Start Speed Reference Current Input 4 T Output Current 5 Overload Current 24V 24VDC Logic Internal Source Current Limiting amp Overload Fault Trip Voltage Output Analog Output Proportional Voltage Range 0 to 10 VDC ADIO3 m Motor Pump RPM Load Resistor 2 kQ Minimum Short Circuit 40 mA Maximum Logic Output Voltage Range 0 to 24 VDC 7 oe Sampling2. 9 Operat r e 10 OUI GG a TE E 0T 11 Additional __ _ _ 11 Field Modifications e m 12 RAP MUG AU 13 Gear Parts LSE ais 14 Motor Parts chttcceedccxcadeunestucerescthniannschucesennesseceteactevesunvanaenseuhenesversechissavexcivandunstsatversisessrines 15 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 Po
3. 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 50081 2 as standard 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 115V Single Phase Power Supply IntelliGear 1 6 2 Cables 230V Single Phase Power Supply Input Amps Wire Gauge Fuse Size IntelliGear Input Amps Wire Gauge Fuse Size Plus Number Plus Number 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 r
4. 7 1 in 108 AWG 14 Terminal Block for Power Supply 9 NId S 2 v 2 v v 1985 ejqeo uy 40j euuoo 9 9 1685 10j2euuoo uogeuuojur I S T o j eoo eq Yn pal ddns 1 NDLO3NNDO 41415 OLNY NI Nn OL 38 LSniW 9 9 SNId HOLO3NNOO Nn3 dWnd 035070 9 1 ASN LON SI LOVINOO dOLS NNY OLNV I LOWLNOD dOLS NNY DOLNY YaWOLSND T ALON 1 NDdn SN3dDD p v2 3ALLSIS3 Yy OvAOS2 LOWLNOD TWNOIS 13385 f 5 085 Dinv 804 TIAA a 2s SNULLO3NNU2 NId 9 2166663 amp dWnd SdIMl 1358010 218 vd 1 V1ND2 lt AV IdSIT QVdA 35 7511910 171093 UN a3W4Dnisna L lt aay pov 318v2 oF o TTA MUSN3S LINYA XIADA OL 1ndin SNIVW SIHILYW 1 9 me SNULLO3NNU2 59079 NId S B esr t
5. setting using drive keypad display Reduce start stop frequency Check motor thermostat connections between IntelliGear terminals 5 amp 9 Motor thermostat trip Overtemp Install jumper if motor has no thermostat wires P1 P2 Check motor fan amp clean debris or obstruction to air flow Check for motor overload rdY EEF EEPROM Conactfadoy Olbr Overcurrent at Brake Transistor Contact factory 5 2 Additional Troubleshooting Symptom Probable Cause s Actions Required Drive not in HAND or AUTO mode Press HAND or AUTO button on Keypad Not Running No Fault Indication on Display Drive in AUTO mode but AUTO RUN contact not Close AUTO RUN contact or closed Jumper pins 5 6 on 6 pin connector cable Connect 4 20 mA signal and Verify that the signal Unit Runs Only at Low 4 20 mA signal is not present current is present pin 18201 pin Cone uH Speed in AUTO mode tuyi Verify current enters pin 1 of 6 pin connector Reverse 4 20 mA signal polarity is reversed fhe connectors ff Signal source may not be capable of producing 20 mA with the drive input impedence of 500 ohms speed reference must be able to produce at least 10 VDC at pin 1 of In AUTO Unit Does 6 pin connector cable Not Achieve Maximum Output RPM at 20 mA Maximum speed setting of operator keypad setting is Press UP ARROW on keypad until maximum speed Signal Input not set to 10096 is attained IntelliGear MAXI
6. 2700 to 1688 gear ratio is 4 5 so 375 x 4 5 1688 ATo 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 25 Fto 125 Manufacturer 30 Cto 50 C Fuchs Sintogear 125 With Backstop 25 Fto125 F Manufacturer 30 Cto 50 C Omala RL 100 Mobil SHC 629 Shell Omala Fluids HD 150 Acceptable Mineral Oil Lubricants Ambient Range of Installation 7072 eye FandAbove 20 C to 10 C No Backstop With Backstop 50 ISO VG 68 ISO VG 100 ISO VG 150 ISO VG 220 ISO VG 150 ISO VG 320 Input Opening Primary Orient the gear head vertically and fill to gt mid point of the Primary Gear N 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
7. Emerson Industrial Automation 7120 New Buffington Road seepex com Application Engineering 800 626 2093 Installation and Maintenance Manual For IntelliGear Plus MD and BW1 Variable Speed Drives Florence KY 41042 www emerson ept com FORM 9708E November 2012 U 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 amp 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 5 EMERSON Industrial Automation IntelliGear Plus Variable Speed MD Gearmotors Thank you for choosing an IntelliGear Plus Gearmotor General Safety Instructions WARNING 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
8. Gearmotors 7 0 Gear Parts List CBN 3001 Input o ring Gearing snap ring Gearing snap ring Oil seal Output shaft ke 080 Not illustrated on diagram Typical Maintenance Items Bearings and Seals Item Description By Location Gear Bearings diis 6205 ZZ 6005 25 x 52 x 7 DL nitrile 14 IntelliGear Plus Variable Speed MD Gearmotors CbN 30 Quantity Per Unit N 6 Beain 1 cup RSS Seal T NN 18 Sud 4 m 14 40 mme 6005 2RS 47 25 7 56 8 0 Motor Parts List Descripion Qty 1 2 SelTappngScew ___ 3 Screw 9 X HBushing 12 13 Shaft Gasket 20 SelfTappingScrew 2 1 4 4 Emerson Electric or one of its affiliated companies E M E RSO N 2004 2008 2012 Emerson Power Transmission Corp All Rights Reserved Emerson Emerson Industrial Automation Intelligear and Intelligear Plus amp Design are trademarks of MCIM12260E 9708E Printed in USA
9. MUM SPEED setting has been turned drive parameter 02 to 2700 RPM using drive down keypad display 4 20 mA signal not achieving full 20 mA at maximum 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 Normal Optional Range For Parameter Description New setting New Field Setting ot Motor Minimum Speed 90 91 350 A RPM of motor 0 Motor Maximum Speed 2700 100 2699 RPM of motor os Acceleration Rate Seconds 1000 RPM 0 1 600 Seconds 1000 RPM Deceleration Rate Seconds 1000 RPM 0 1 600 Seconds 1000 RPM tt 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
10. Refresh Rate Drive Running Maximum Output Current Overload Current Logie Input Logic Input Motor Thermal Sey Fault Signal Input from Run Dry andlor High Pressure Sensor Voltage Range 9 to 33 VDC 12 ENA Drive Enable Load Impedence 8200 Drive Healthy Contact Characteristics Normally Open Single Pole Contact 14 RL2 Closed Upon Power Up Unless Rated Voltage 250 VAC Drive Tripped Current Rating Resistive Load 4A Inductive Load 2A Provides setpoint feedback function when drive is programmed for full 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 IntelliGear Plus Variable Speed MD Gearmotors 10 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 Displays operating RPM of pump Displays drive status including faults Displays parameter number and setting during drive programming setup Off button to stop motor Auto command button initiates Auto mode for operation from a 4 20 mA speed reference analog signal Set the pump s
11. e assembly Make sure that the ventilation air inlet is free of obstruction 3 Connections Connection with copper conductor only 3 1 Control Terminal Blocks e 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 e The control circuits in the drive are isolated from the power circuits by single insulation IEC 664 1 e installer must ensure that the external control circuits are isolated against any human contact e 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 Removable screws in terminal block e Tightening torque 2 62 in lbs Maximum cross section 17 AWG 3 2 Power terminal blocks 3 2 1 Terminal block for power supply PB1 marked L amp N This terminal block is used to connect the 3 phase power supply when the 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 310M amp 31M Tightening Torque
12. ms maximum at voltage 264 VAC rms maximum for 230 V TL drives or 528 VAC rms maximum for 400 V T drives 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 6 00 9961100 80965 osz Sv 61 009 9821 1920 ZOS6SX __ 91 prepueis 1220 S31OH 200 2400 vv NMOHS SV 06 v 087 029 1008 00SL i 4 o G 5 Q o a E gt Lm o 3 G o 1 8 Dimensions IntelliGear Plus Variable Speed MD Gearmotors 2 Installation After connection ensure that the seals are firmly in place andthatthe screws and cable glands are watertightto 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 whol
13. 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 A CAUTION 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 NOTICE 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 1 1 1 2 1 3 1 4 1 4 1 1 4 2 1 4 3 1 5 1 6 1 61 1 6 2 1 6 3 1 8 2 1 3 1 3 2 3 2 1 3 3 3 4 5 1 5 2 5 3 IntelliGear Plus Variable Speed MD Gearmotors Contents 7 PR 4 General perating NMG _ m 4 Product vae paie puri 4 Environmental 166 E E SERM SR abel 4 Radio frequency interference ies dares dee yates s
14. peed in Hand mode Set maximum pump speed in Auto mode Parameter selection and adjustment in drive programming setup mode COOECS ANGAGEN IntelliGear Plus Variable Speed MD Gearmotors 5 1 Fault Mode Troubleshooting Guide LED Pad Display Drive Status Fault Indication Actions Required Drive not powered Check for drive input power Blank Displ Display unplugged or failed Check display plug connection 0019 0600 Numeric display shows Pump RPM indicates motor running In AUTO mode make sure AUTO RUN contact is closed Drive Ready Enabled amp Not Running between pins 5 amp 6 of 6 pin connector if pump should be running Drive Inhibited Not Enabled Install jumper between IntelliGear terminals 11 12 Internal brake resistor trip Overtemp Contact factory Pump RUN DRY or HIGH PRESSURE fault trip Check for proper flow and pressure in pump DC Bus Undervoltage Check incoming power for voltage level too low Check incoming power for voltage level too high DC Bus Overvoltage Check for over running load pressure over driving pump Adjust drive parameter 04 deceleration time to a higher setting using drive keypad display ph AC Loss of a motor phase Overcurrent at Drive Output Motor Overload I X t Overheating in Output Transistors Provide supply of cool air if ambient exceeds 40 Reduce torque load from pump Adjust drive parameter 04 deceleration time to a higher Overheating in Brake Transistor
15. te aedes ad ice Pon ic dete DERE 5 CD 5 Standards EMISSIONS Pe vc 5 Standards ee eee ee 5 Description of cables and protection devices Customer 5 5 Specitied mains fe REPE 5 cT HK 5 FUSES MM REM 5 DIMENSIONS LL IDQNE 6 7 General E EE Cuneta 7 elg HR 7 Control Terminal e 7 Pow r terminal DIOCKS e 7 Terminal block for power supply 1 marked L amp 7 Wiring diagram based on standard configuration Lucent cerro rara 8 Terminal Block Assignments and MD Functionality 9 COMMISSIONING
16. wer HP Power HP 310 M 050 31 M 050 IntelliGear PLUS Controlling Options RPD 4 20 mA follow or local Keypad manual control 1 3 Environmental Characteristics 40 C to 70 C 40 C to 70 C 20 C to 40 above 40 C requires derating 1 per C Altitude Ambient humidity 95 non condensing Humidity during storage 93 40 C 4 days Vibration Exposed product 0 01 g Hz 1 hr in accordance with IEC 68 2 34 Sinusoidal vibration 2 9 Hz 3 5 ms 9 100 Hz 10 ms in accordance with 68 2 6 Shocks Packaged product 15 g 6 ms 500 times direction in all 6 directions in accordance with Standard IEC 68 2 29 Immunity Conforming to EN61000 6 2 Conforming to 500081 2 with filter emissions UL and CUL 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 edue 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
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