Browning IntelliGear Plus Manual

F O R M
Installation and Maintenance Manual
For IntelliGear Plus™ Variable Speed
Gearmotors and Motors
9112E
Revised
October 2015
Power Transmission Solutions
Regal Beloit America, Inc.
7120 New Bufngton Road
Florence, KY 41042
Application Engineering: 800 626 2093
www.RegalPTS.com
• Periodic inspections should be performed. Failure to perform proper maintenance
can result in premature product failure and personal injury.
• Avoid contact with capacitors until safe discharge procedures have been
completed.
• All electrical work should be performed by qualied personnel 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 parts.
• High voltage and rotating parts can cause serious or fatal injury.
®c e
c
UL Listed
E211799
Ind. Cont EQ. 54 DN
us
• Be sure shaft key is fully captive before unit is energized.
• Most units are shipped with oil. Always be sure oil lubricated units
are lled with correct oil to proper level before operating.
• Avoid extended exposure to equipment with high noise levels.

Thank you for choosing an IntelliGear Plus Gearmotor.
• Periodic inspections should be performed. Failure to
perform proper maintenance can result in premature
product failure and personal injury.
• Avoid contact with capacitors until safe discharge
procedures have been completed.
• All electrical work should be performed by qualied
personnel 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.
• 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 before unit is energized.
• Most units are shipped with oil. Always be sure oil
lubricated units are lled with correct oil to proper level
before operating.
• Avoid extended exposure to equipment with high noise
levels.
2 MCIM15100E • Form 9112E • Printed in USA

IntelliGear PlusTM 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.
Unjustied 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, qualied personnel (see
IEC 364 or CENELEC HD 384, or DIN VDE 0100 and national
specications for installation, startup and accident prevention).
In these basic safety instructions, qualied personnel means
persons competent to install, mount, startup, and operate the
product and possessing the relevant qualications.
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 veried 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, modied
by 92/31/EEC) and/or local codes are met.
IntelliGear Plus motors meet the requirements of the Low
Voltage Directive 73/23/EEC, modied 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 specied 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 specied in the technical manual must be
observed.
Safety and Operating Instructions for Electrical Actuators
(In accordance with the low voltage directive 73/23/EEC modied by 93/68/EEC).
4 - Installation
The installation and cooling of equipment must comply with
the specications 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 modication 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 specications must be
respected.
The electrical installation must comply with the relevant
specications (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 lters
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
tted with additional protection and monitoring devices as laid
down in the current relevant safety regulations: law on technical
equipment, accident prevention regulations, etc. Modications 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 xed 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

IntelliGear PlusTM Variable Speed Gearmotors and Motors
Contents
1 General Information.....................................................................................................................................................................3
1.1 General operating principle............................................................................................................................................................5
1.2 Product name ................................................................................................................................................................................5
1.3 Characteristics ..........................................................................................................................................................................6 - 7
1.4 Environmental characteristics........................................................................................................................................................7
1.5 Radio-frequency interference ........................................................................................................................................................8
1.5.1 General ..........................................................................................................................................................................................8
1.5.2 Standards (Emissions)...................................................................................................................................................................8
1.5.3 Standards (Immunity) ....................................................................................................................................................................8
1.6 Description of cables and protection devices (Customer Supplied) .........................................................................................8 - 9
1.7 UL conformity.................................................................................................................................................................................9
1.7.1 Specied mains supply ..................................................................................................................................................................9
1.7.2 Cables............................................................................................................................................................................................9
1.7.3 Fuses .............................................................................................................................................................................................9
1.8 Weights and dimensions..............................................................................................................................................................10
2 Installation..................................................................................................................................................................................11
2.1 General ........................................................................................................................................................................................11
2.2 Reversing the supports................................................................................................................................................................ 11
3 Connections ...............................................................................................................................................................................12
3.1 Wiring precautions .......................................................................................................................................................................12
3.2 Control terminal blocks .........................................................................................................................................................13 - 14
3.3 Power terminal blocks..................................................................................................................................................................15
3.4 Terminal blocks for options ..........................................................................................................................................................15
3.5 Wiring diagrams based on the standard conguration ................................................................................................................16
3.6 Power supply and control for FCR brakemotors..........................................................................................................................17
3.6.1 Power supply for the built-in sequential control 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 knob option (P3) or remote potentiometer ......................................................................................................................18
4.4.3 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 .................................................19
6.2 Control knob with integrated run/stop control option (P1)............................................................................................................19
6.3 Control knob with forward/reverse/stop control option (P2).........................................................................................................19
6.4 Speed control knob option (P3) ...................................................................................................................................................20
6.5 Internal speed control option (P4)................................................................................................................................................20
6.6 Braking resistor option (RF100 - RF200).....................................................................................................................................20
6.7 Fieldbus options...........................................................................................................................................................................20
6.8 Parameter-setting console option (Keypad LCD) ........................................................................................................................20
6.9 Programming CD (VMA30SOFT) ................................................................................................................................................20
6.10 XPress Key (PX Key)...................................................................................................................................................................20
4 MCIM15100E • Form 9112E • Printed in USA

IntelliGear PlusTM Variable Speed Gearmotors and Motors
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 Regal 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. Based on the advanced technology of the
IGBT power module, very high efciency and reduced noise levels are achieved.
1.2 - Product name
IntelliGear Plus Range
"115V Single Phase Power
Supply"
"230V Single Phase Power
Supply"
"230V Three Phase Power
Supply"
"460V Three Phase Power
Supply"
Catalog
Number Motor HP Catalog Number Motor HP Catalog Number Motor HP Catalog Number Motor HP
310 M 033 0.33 31 M 033 0.33 31 TL 033 0.33 31 T 033 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 100 131 T 100 1
32 M 150 1.5 32 TL 150 1.5 31 T 150 1.5
32 M 200 2 32 TL 200 231 T 200 2
33 TL 300 332 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./Rev./stop/speed-up/speed-down/speed display
P1 Run/Stop/Control knob mounted on enclosure
P2 For./Rev./Stop/Control knob mounted on enclosure
P3 Control knob (only) mounted on enclosure
P4 Control knob (only) mounted inside enclosure w/trim potentiometers
RRemote signal following (either 0-10 vDC or 4-20 mA)
RP Fieldbus controlled by customer's PROFIBUS DP
IntelliGear Plus Options
Part ID Description
KEYPAD LCD Parameter setting console w/cable to locally reprogram to customized parameters
PX KEY Drive parameter set-up key storage Fob
AEM904KA006 DC Braking resistors 100W
AEM904KA007 DC Braking resistors 200W
VMA30SOFT CD w/cable and USB to locally reprogram to customized parameters
MCIM15100E • Form 9112E • Printed in USA 5

IntelliGear PlusTM Variable Speed Gearmotors and Motors
1.3 - Characteristics
1.3.1 - Electrical Data
Single phase design
Three phase design
Power supply 115 V ± 10%, 50 - 60 Hz 230 V ± 10%, 50 - 60 Hz
Output voltage From input voltage down to (input voltage/speed range)
Power range 0.33, 0.50, 0.75 HP 0.33, 0.50, 0.75. 1.0, 1.5, 2.0 HP
Maximum numbers of power-ups per hour 10
Power supply 230 V ± 10%, 50 - 60 Hz 460 V ± 10%, 50 - 60 Hz
Output voltage From input voltage down to (input voltage/speed range)
Power range 0.33, 0.50, 0.75. 1.0, 1.5, 2.0, 3, 5 HP 0.33, 0.50, 0.75. 1.0, 1.5, 2.0, 3.0, 5.0, 7.5, 10 HP
Maximum numbers of power-ups per hour 100
1.3.2 - Characteristics and Functions
Characteristic IntelliGear Plus
Overload 150 % of full load setting for 60 seconds, 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
Efciency 97.5 % x motor efciency x gear efciency (if applicable)
Drive Control IntelliGear Plus
Speed Reference "• Analog reference ( 0V or 4mA = minimum speed)
(10V or 20mA = maximum speed)
- 0 to 10V with integral potentiometer on enclosure ( P1,P2 and P3)
- 0 to 10V with integral potentiometer in enclosure (P4)
- 4 to 20 mA, 20 to 4 mA, 0 to 20 mA, 20 to 0 mA or 0 to 10 VDC (R)
• Digital references
- PD Digital Keypad
- Fieldbus using Probus DP
Speed regulation - Speed regulation with encoder feedback option (only size 33)
- Regulation of a reference with integrated PI loop
6 MCIM15100E • Form 9112E • Printed in USA

IntelliGear PlusTM Variable Speed Gearmotors and Motors
1.3.2 - Characteristics and Functions (cont'd.)
Drive Control IntelliGear Plus
Run/Stop - With power supply
- With remote volt-free contact
- With eldbus
- With local run/stop control
Forward/Reverse - With internal connection on the terminal block
- With remote volt-free contact
- With eldbus
- With local For./Rev. controls
Stop Mode - On ramps (using volt-free contact of integrated control)
- Freewheel
- DC injection brake
- With electromechanical brake
Ramps - Ramps are adjustable from 0.1 to 600 seconds/1000 rpm
Fieldbus - PROFIBUS DP
Protection IntelliGear Plus
Power - Input/output phase loss
- Under voltage
- Overvoltage
- Overloads
- Short-circuit
- Over speed
Control - Short circuit on 0 - 10V/24V inputs or outputs
Drive reset - By switching off the IntelliGear Plus or by opening/closing the connection between the 24V
and ENA (size 31 and 32) terminals, 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 temperature -20°C to +40°C (above 40°C requires derating 1% per °C
Altitude Up to 3000 feet above sea level without derating
Ambient humidity 95% non-condensing
Humidity during storage 93%, 40°C, 4 days
Vibration - Exposed product: 0.01 g2 /Hz 1 hr. in accordance with IEC 60068-2-34
- Sinusoidal vibration: 2-9 Hz 3.5 ms-2 - 9-200 Hz 10 ms-2 in accordance with IEC 60068-2-6
Shocks Packaged product: 15 g, 6 ms, 500 times/direction in all 6 directions in accordance with
Standard IEC 600068-2-29
Immunity Conforming to EN61000-6-2
Radiated and conducted emissions Conforming to EN500081-2 with internal lters
UL and cUL Standards Conforming to UL 508 C (E211799)
MCIM15100E • Form 9112E • Printed in USA 7

IntelliGear PlusTM Variable Speed Gearmotors and Motors
1.6 - Description of cables and protection devices (Customer Supplied)
WARNING! 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.
1.5 - Radio-frequency interference:
1.5.1 - 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 efciency 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.
1.5.2 - 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 lter 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
Motor
hp
Rating
115V Single Phase Power Supply 230V Single Phase Power Supply Motor
hp
Rating
IntelliGear Plus
Number
Input
Amps
Wire
Gauge
Fuse
Size
IntelliGear Plus
Number
Input
Amps
Wire
Gauge
Fuse
Size
0.33 I 310 M 033 4 14AWG 8 A I 31 M 033 2 14AWG 8 A 0.33
0.5 I 310 M 050 5 14AWG 10 A I 31 M 050 2.5 14AWG 8 A 0.5
0.75 I 32 M 075 8.5 14AWG 14 A I 31 M 075 414AWG 8 A 0.75
1- - - - I 31 M 100 5 14AWG 12 A 1
1.5 - - - - I 32 M 150 814AWG 14 A 1.5
2- - - - I 32 M 200 10 14AWG 16 A 2
8 MCIM15100E • Form 9112E • Printed in USA

IntelliGear PlusTM Variable Speed Gearmotors and Motors
Note:
• The mains current value is a typical value which depends on the source impedance. The higher the impedance, the lower
the current.
1.7 - UL conformity
1.7.1 - Special mains supply
The drive can be incorporated in an installation with short circuit capacity of 5000 A rms maximum at a voltage 264 VAC
rms maximum for 230 V (TL) drives or 528 VAC rms maximum for 400 V (T) drives.
1.7.2 - Cables
Only class 1 copper cables 60/75° C (140/167° F) should be used.
1.7.3 - Fuses
UL conformity is adhered to if the fuses used 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.
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 314AWG 6 A I 31 T 050 214AWG 4 A 0.5
0.75 I 31 TL 075 4.1 14AWG 8 A I 31 T 075 2.5 14AWG 6 A 0.75
1 I 31 TL 100 5,3 14AWG 8 A I 31 T 100 3 14AWG 6 A 1
1.5 I 32 TL 150 6.1 14AWG 10 A I 31 T 150 4.1 14AWG 8 A 1.5
2 I 32 TL 200 8 14AWG 16 A I 31 T 200 5.3 14AWG 10 A 2
3 I 33 TL 300 12 12AWG 16 A I 32 T 300 8 14AWG 10 A 3
5 I 33 TL 500 15 12AWG 20 A I 32 T 500 914AWG 16 A 5
7.5 - - - - I 33 T 750 12 12AWG 16 A 7.5
10 - - - - I 33 T 1100 16 12AWG 20 A 10
MCIM15100E • Form 9112E • Printed in USA 9

IntelliGear PlusTM Variable Speed Gearmotors and Motors
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.
AW
AC
AB
O
AF
AZ
AY
AX
XK
AD
AV
Motor
Frame
IntelliGear Plus
Drive Size
Dimension (inches) Drive
Added
Weight (lb.)
0 AB AC AD AF AV AW AX AY AZ3XK
71* 31 or 31M 6.91 6.45 5.91 4.9724.81 2.25 2.95 0.62 0.55 8.53 7.6127
32M 6.91 6.45 5.91 4.9724.81 2.25 2.95 0.62 0.55 9.12 7.6127,5
56 310M or 31M or 31 7.74 6.45 5.91 4.35 5.61 2.25 2.95 0.62 0.55 8.53 9.7917
32M 7.74 6.45 5.91 4.35 5.61 2.25 2.95 0.62 0.55 9.12 9.7917,5
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 11.0417
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 11.0417,5
145TY 32 or 32M 7.74 6.45 5.91 4.35 5.61 2.25 2.95 0.62 0.55 9.12 12.04 7,5
182T, 184T 32 8.72 6.45 5.91 5.89 6.58 2.25 2.95 0.62 0.55 9.12 14.05 7,5
33 11.16 8.97 8.44 10.01 7.37 2.83 4.22 0.62 0.55 13.1 14.05 18
213T 33 11.99 8.97 8.44 11.73 8.11 2.83 4.22 0.62 0.55 13.1 16.15 18
215T 33 11.09 11.25 8.44 13.23 8.11 2.83 4.22 0.62 0.55 13.1 17.65 18
10 MCIM15100E • Form 9112E • Printed in USA

IntelliGear PlusTM Variable Speed Gearmotors and Motors
TX-10
TX-20
2 - Installation
It is the responsibility of the owner or user
to ensure that the installation, operation and maintenance
of the inverter and its options comply with legislation relating
to the safety of personnel, animals and equipment, and with
the current regulations of the country of use.
• Before carrying out any work, disconnect and lock the drive
power supply. For the single-phase range, wait two minutes
to make sure that the capacitors have discharged.
• After connection, ensure that the seals are rmly 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 tted to the gear and mounted
to the machine with ange 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 specied 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 plug connector on P2 and
replace the TX 10 screws using .5 ft.-lbs. of torque.
6. Replace the cover using TX-20 slot type screws by
applying 3 ft.-lbs. of torque.
3. Disconnect the plug connector from the P2 terminal if
an option is connected.
2.2 - Reversing the operators*
1. Undo the (2) TX 20 - slot type screws and remove the
cover.
2. Remove the control knob and cable gland support
attachment screws (TX10 - slot type screws).
* If IntelliGear Plus unit is equipped with an FCR brake,
reversing potentiometer is not permitted.
MCIM15100E • Form 9112E • Printed in USA 11

IntelliGear PlusTM Variable Speed Gearmotors and Motors
3 - Connections
The voltages on the power terminal blocks
and the cables connected to them may cause fatal electric
shocks. The drive stop function does not protect against
these high voltages.
• The drive contains capacitors which remain charged
at a fatal voltage even after the power supply has been
switched off.
• After switching off the drive, wait for two minutes so that
the internal circuits can discharge the capacitors, before
removing the protection (for the single-phase range).
• The drive power supply must be protected against
overloads 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, avoid
parallel routing of power cables and control cables.
• All remote control cables must be shielded and have
a cross-section between 24 AWG and 17 AWG. 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 rmly.
3.2 - Control Terminal Blocks
• Remove the terminal block from it’s xed holder (unplugged)
before making any connections, to avoid putting pressure
on the card.
• The IntelliGear Plus has a positive logic conguration. 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 classication.
Removeable screws in terminal block:
• Tightening torque = 2.62 in. lbs.
• Maximum cross section = 17 AWG
Bend
12 MCIM15100E • Form 9112E • Printed in USA

IntelliGear PlusTM Variable Speed Gearmotors and Motors
3.2 - Control Terminal Blocks (Continued)
Terminal Number
Designation Function Characteristics
IntelliGear Frame
31 or 32 33
1 1 10V +10V analog internal source Accuracy ± 2%
Maximum output current 30 mA
Voltage input
Full scale voltage 10 V ± 2%
Analog or logic Input Impedance 95 kΩ
Input 1 Current input
2 2 ADI1 Current range 0 to 20 mA ± 5%
Assignment in standard Input impedance 500 Ω
conguration: Resolution 10 bits
Sampling 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 standard Sampling 6 ms
conguration: Logic input (if connected to the +24 V
Threshholds “0”:<5V-”1”; >10V
Input PTC Voltage range 0 to +24V
Load 95 kΩ
Input threshold 7.5V
Input (PTC)
Trip ≥ 3300 Ω
Voltage range < 1800 Ω
N/A 5 0V Logic circuit common 0V
MCIM15100E • Form 9112E • Printed in USA 13

IntelliGear PlusTM Variable Speed Gearmotors and Motors
3.2 - Control Terminal Blocks (cont'd.)
Terminal Number
Designation Function Characteristics
IntelliGear Frame
31 or 32 33
Characteristics Analog voltage (common
Mode) or uni-directional
Voltage input
Full scale voltage 10 V ± 2%
Input impedance 95 kΩ
Current input
Current range 0 to 20 mA ± 5%
Analog or logic input or Input impedance 500 Ω
analog output 3 Resolution 10 bits
Sampling 6 ms
6 6 ADIO3 Assignment in standard Logic input (if connected to the +24 V
conguration: Threshholds “0”:<5V-”1”; >10V
Voltage range 0 to +24V
analog output Load 95 kΩ
(LED control option for frame Input threshold 7.5V
33 and speed feedback for Voltage output
frames 31 and 32) Voltage range 0 to 10V
Load resistance (min.) 2 kΩ
Protection Short-circuit (40mA max.)
Current output (Frame 33 ONLY)
Current range 0 to 20 mA + 5%
Maximum voltage 10 V
Load resistance 500 Ω
Characteristics Digital input or output 1
Threshholds “0”:<5V-”1”; >10V
Voltage range 0 to +24V
Digital input or output 1 Sampling/refreshment 2 ms
Digital input
Assignment in standard Absolute maximum voltage 0 to +35V
7 7 DIO1 conguration: Load 15 kΩ
Input threshold 7.5V
digital input Logic input
External fault interlock Maximum output current 50 mA
Overload current 50 mA
Output current 10 mA in total
58Overload 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
conguration: Run forward Voltage range 0 to +24V
Logic input 3 Sampling/refreshment 2 ms
9 10 DI3 Assignment in standard Absolute maximum voltage 0 to +35V
conguration: Run reverse range
Logic input 4
10 12 DI4 Assignment in standard Load 15 kΩ
Conguration: Selection of
0-10 VDC or 4-20 mA analog ref.
for ADI1 (4-20mA is selected by Input threshold 7.5V
a +24V Input)
Characteristics Logic input (positive logic)
N/A 13 SDI1 +24V dedicated to safety input Thresholds “0”:<5V-”1”; >18V
Voltage range 9 to + 35V
12 14 SDI2/ENA Safety/unlocking input Impedance 820 Ω
33: NO-NC single pole
13 15 COM/RL1 Characteristics changeover contact
N/A 16 RL1C Fault relay output 31/32: NO single pole contact
14 17 RL1O/RL2 250VAC maximum contact -4 A, resistive load
current -2 A inductive load
Characteristics NO single-pole changeover
N/A 18 SDO1 Safety contact contacts
19 250VAC maximum contact -4 A, resistive load
N/A N/A SDO2 current -2 A inductive load
14 MCIM15100E • Form 9112E • Printed in USA

IntelliGear PlusTM Variable Speed Gearmotors and Motors
3.4 Terminal blocks for options
3.4.1 RS485 type serial link connector
This is an RJ 45 connector and is used to connect
the PX LCD console or a PC in order to use the
VMA30SOFT PC programming software.
For the 31 or 32, it is also used to connect a
eldbus or the PD digital pad option.
3.4.2 Description of Slot 1 (Frame 33 only)
This slot is used to connect an encoder feedback
module when closed loop mode is selected
3.4.3 Description of Slot 2 (Frame 33 only)
This slot is used to connect a Probus DP eldbus
option module
3.4.4 P2 connector (Frames 31 and 32 only)
This is used to connect one of the following option
at a time ( P1 , P2, P3, or ESFR brake control).
When the ESFR option for FCR braking is
required with one of the speed control
options noted above, refer to Application
Engineering due to limitations on the
location that the speed control option can
be mounted.
Frame 31/32
RS485
PB1
and
PB2
3.3 Power terminal blocks
3.3.1 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 lter is not used in an
IntelliGear Plus. Otherwise, the RFI lter output
is screwed onto this connector and the power
supply should be attached to the terminals located
on top of the lter.
3.3.2 Terminal block for braking resistor PB2
(marked R+ and R-)
This terminal block is used to connect a braking
resistor when this option is required. The resistor
is mounted outside and/or on the rear of the heat
sink of the IntelliGear Plus.
Note: For frames 31 and 32, PB1 and PB2 are both
located on the same terminal block.
The terminal block on the 31 and 32 has a terminal
marked FI connected to the R- terminal which enables
use of the internal braking resistor. The jumper must
be removed when an external braking resistor is
connected or if the inertia is compatible with the rated
deceleration ramp.
RS485
PB2
PB1 Frame 33
Screw terminal block 31 and 32 33
Tightening torque 7.1 in. lbs. 15.9 in. lbs.
Max. cross-section AWG 14 AWG 8
Screw terminal block 31 and 32 33
Tightening torque 7.1 in. lbs. 15.9 in. lbs.
Max. cross-section AWG 14 AWG 8
MCIM15100E • Form 9112E • Printed in USA 15

IntelliGear PlusTM Variable Speed Gearmotors and Motors
3.5 Wiring Diagrams
3.5.1 Standardcongurationconnectiondiagram
Note: For single-phase versions, the power supply is connected to terminals L and N.
16 MCIM15100E • Form 9112E • Printed in USA

IntelliGear PlusTM Variable Speed Gearmotors and Motors
3.6 Power supply and control for FCR brake motors
3.6.1 Power supply for the built-in sequential control
brake
ESFR option (31 and 32 only)
- the brake is supplied via the rectier and a solid
state relay xed on the ESFR connection card.
This connection is made at the factory.
- The rectier is supplied by two mains phases.
- The brake is controlled according to the sequence
which can be adjusted using the IntelliGear Plus
parameters.
3.6.2 Separate power supply
The brake is supplied and controlled by an external
source not supplied by Regal 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 specied at order
entry. The illustration for the wiring for the second
motor in the diagram will not apply when this special
feature is not specied.
Coil
brake
Full-wave
(208-230VAC
mains supply)
Half-wave
(380 - 460VAC
mains supply)
Power supply to 2nd brake
(mains voltage output)
Power supply to 2nd brake
(mains voltage output)
*Note:With single
phase drive,
connect
power supply
between L and N.
Flex-trip to connector
for options
CG
L1
L3
ESFR
CG
230/460V
mains supply*
L1
F1 U
V
W
F2
L2 L3
Brake
S06
U
W
V
180VDC
400/460V mains supply
230V mains supply
ESFR Card
MCIM15100E • Form 9112E • Printed in USA 17

IntelliGear PlusTM Variable Speed Gearmotors and Motors
4 Commissioning
* Before switching on the IntelliGear Plus
unit, check that the elctrical connections
are correct, and that any moving parts
are mechanically guarded.
* For the safety of personnel, the IntelliGear
Plus must not be switched on with any
protective covering removed.
4.1 Starting with the power supply
This connection jumpers the run command so that the
motor or gearmotor starts as soon as input power is
switched on.
The speed is adjusted with the local control knob
(P3 or P4 options) or a remote reference (0-10V or
4-20 mA).
Power-up: the green indicator lamp is lit continuously.
The control terminals SDI1 and SDI2 (size 33) or 11
and 12 (sizes 31 and 32) are linked (unlocking).
4.1.1 Automatic starting
By connecting a jumper between control terminals 8
and 11 (sizes 31 and 32) or 8 and 9 (size 33), the
motor starts running forward. For reverse rotation
connect terminals 9 and 11 (size 31 or 32) or 8 and 10
(size 33).
4.2 Starting with 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 switched on, the motor
starts after the button corresponding to the desired
direction of rotation has been pressed for one
second.
The speed is only adjusted with the local control knob
or arrow buttons.
4.4 Setting the speed
4.1.1 External reference (R option)
Adjust the speed reference using the desired
reference 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 or
a remote 10 KΩpotentiometer.
4.4.3 Internal speed control option (P4 option)
Adjust the speed reference using an internal speed
potentiometer.
Adjust the max. speed or min. speed setting with
independent potentiometers if it is not possible to
reach the desired speed of operation.
18 MCIM15100E • Form 9112E • Printed in USA

IntelliGear PlusTM Variable Speed Gearmotors and Motors
5 Faults - Diagnostics
Information relating to the status of the IntelliGear Plus is provided by two indicator lamps located on the control options P1, P2 or P3
or 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 and
11: +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 make
it possible to control the IntelliGear Plus locally, once it is has been
powered. For a run command to be taken into account, the button must
be 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 a
stop button make it possible to control the IntelliGear Plus locally, once
it has been powered. For a run command to be taken into account, the
button must be held down for one second.
• Connected on the P2 connector
• Has two indicator lights
6 Operating Extensions
6.1 Digital Keypad on enclosure with For./Rev./Stop/
Speedup and down/Speed display/Fault Display
E
B
F
G
C
D
A
Color and state of
indicator lamp IntelliGear Plus Checks to be performed
Steady green No 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 ns 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 applications with high inertia.
Steady red
• Short-circuit of a motor winding
• Locked motor rotor
• Faulty insulation of a winding
• (I2T) overheating
• Internal fault
• Undervoltage
• Overvoltage"
• Check that no incident has occurred.
• Switch off and then on again to clear the fault.
• Check the main voltage.
• Check that the deceleration ramp is long enough for applications with high inertia.
• If the fault remains, consult Regal Application Engineering
Ref. Function
A
Display comprising 4 x 7 segment digits for indicating:
- the drive operating status
- certain operating data
- the adjustment parameters (01 to 80) and their value
BLED providing a sign for the data sign) (the lit LED corresponds to the
"-" sign
CKeys which can be used to scroll up and down through the parameters
or their value. These keys can also be used to vary the speed.
D
Key which can be used to switch from standard mode to
parameter-setting mode.
In parameter-setting mode, the parameter number and
value are displayed alternately on the display.
E F G
In keypad mode, these buttons are used for the following commands:
- Reverse (standardly disabled)
- Stop, clear fault
- Forward"
MCIM15100E • Form 9112E • Printed in USA 19

Browning, IntelliGear, Intelligear Plus are trademarks of Regal Beloit Corporation or one of its afliated companies.
UL is believed to be a registered trade name and/or trademark of Underwriters Laboratories, Inc. and is NOT owned or controlled by Regal Beloit America Inc.
©2015 Regal Beloit Corporation, All Rights Reserved. MCIM15100E • Form 9112E • Printed in USA
6.7 Fieldbus options
The interface card is xed inside the casing cover. Protocol: Pro-
bus DP.
6.6 Braking resistor option (RF100 - RF200)
For operation in four quadrants and energy dissipation, resistors are
mounted 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 conguration, ramp, speed and PI settings, etc.).
See IntelliGear Plus parameter-setting manual included.
Description of the option:
1 Keypad LCD console
1 cable (3m long)
6.9 Programming CD (VMA30SOFT)
This CD with manual provides access to the drive internal settings
(terminal block conguration, 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 graduations from 15 to 100
percent. Has two indicator lamps. It is connected on the P2 con-
nector.
6.5 Internal speed control option (P4)
The speeds are set on potentiometers, which are accessible once
the cover 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.
IntelliGear Plus Minimum
Resistance
(ohms)
RF100 RF200
Frame Input
Voltage
Power (Watts) Power (kW) Resistor
Connection
Peak Cont Peak Cont
31 / 32 230 VAC 180 ohms 700 100 700 200 Series
460 VAC 2800 100 2800 200 Series