Motive NEO-WiFi Series User manual

NEO-WiFi
technical manual

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NEO-WiFi
tutorial
https://www.youtube.com/watch?v=hUXJ47P_Qxo&feature=youtu.be

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CONTENTS:
1. INTRODUCTION
2. WORKING CONDITONS
3. MOTORS THAT CAN BE CONNECTED
4. MECHANICAL ASSEMBLY
4a. motor assembly
4b. keypad assembly
5. ELECTRICAL ASSEMBLY
5a. warnings
5b. electrical connection of NEO-WiFi to the motor
5c. electrical connection of WiFi to the line
5d. the 87Hz technique
5e. connection of external devices
6. PROGRAMMING
6a. first installation with adjustment of the Keypad-Inverter communication
6b. keypad buttons
6c. keypad leds
6d. functions menu
6e. advanced functions menu
6f. use
6g. alarms
6h. MODBUS
7. WARNINGS AND RISKS
8. DECLARATION OF CONFORMITY
9. EVENT ANALYSIS

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1. INTRODUCTION
The purpose of an integrated motor-inverter is to save time and reduce costs in supplementary material
(wires and racks mainly), study, installation, programming and testing
of the motor + inverter system, as well as the dangers due to errors
associated with these operations. However, before NEO-WiFi, there
were factors that limited the availability of motor-inverters: the
degree of protection that was needed (motors can be installed out in
the open, while inverters could not) and the fact that the motor-
inverter, and therefore its keypad, remain removed from whoever is
commanding it (imagine, for example, a ventilator that is on a roof).
Motive has solved both problems with NEO-WiFi, patented, easy to use, IP65 (Ill. 2), with removable
control panel, remotable wireless, powered by
induction (Ill. 1) when placed in its housing on the
motor or by lithium rechargeable batteries (Ill.14).
While possessing the most advanced features of the
other inverters, NEO-WiFi, thanks to its innovative
solutions, is designed as a competitive and user-
friendly turnkey integrated system, with all parts,
motor, inverter and control designed for outdoor use,
and with standard remote control. The manufacturers
of pumps, fans, and other machines can thus offer a
finished “plug-in” product, without delegating risky and
costly installations to their customers. Their customers
need only to insert the plug, wherever it is installed, and decide if they want to bring the keypad with
them.
This manual is intended to provide all the necessary information for connecting, programming and using
NEO-WiFi Three-phase inverter for industrial use. NEO-WiFi is specifically designed for operating
industrial motors, with the goal of guaranteeing perfect speed control, significant energy savings and a
greater use of inverters.
Ill. 1

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examples:
Adjusting the flow/pressure/force of a pump, a hydraulic power unit, an oil-hydraulic actuator, a compressor, an
extraction fan, a ventilator, etc is normally done through shutters or valves. If we have a choke device of this kind, it
means we have chosen not to use a variable speed drive (inverter). In this case, the disadvantages are numerous:
inability to program ramping up or stopping; nor to synchronize multiple devices; fewer opportunities for interaction with
other machines and controls (such as a pressure transducer), less access to controls, more noise, greater peak currents;
shorter life of the motor and of the mechanical parts of the system; and above all the absence of energy savings. It is like
controlling the speed of a car just by using the brake.
An inverter also simplifies the installation because a system with direct or star-delta type starting often involves the use of
suitably oversized power contactors to counter the high electric arcing caused by the overcurrent normally associated
with these starting systems. In addition, protection systems for the motor via circuit breakers should always be provided.
So: shutter/valve + cabinet + knife switch + motor control relay + motor overload protection automatic switch could be
saved with a variable speed drive. Let’s add that in certain applications, just the cost of the choke (think for example of
the proportional valve of a hydraulic power unit) exceeds that of an inverter.
So why not just use inverters? Essentially for the ease of assembly (assumed) with respect to an electronic device to be
wired up and programmed, the reduced size, the degree of protection from dust and liquids and the ease of use, the
difficulty of integrating in the system the inverter with its cabinet, the accessibility of the controls. Sometimes also the cost
of the inverter can be considerable, especially when it is added to that of a cabinet and cables.
With NEO-WiFi these reasons are no longer valid. There remain only the advantages of the inverter. In fact:
NEO-WiFi is a motor-inverter and as such cancels the need for cables and cabinets, the study, the installation,
the wiring, and the testing of the motor+inverter system, as well as the risks associated with possible errors.
Not requiring cables and cabinets, and being an integral part of the motor, it does not take up space
Programming is easier than using the TV remote control
The keypad of the NEO-WiFi is removable, can operate remotely over wireless and can be placed up to 20
meters away. No wiring, no cables. It does not need wiring because it is supplied by induction when placed in its
housing on the motor or in the "BLOCK" device, or fed by rechargeable lithium batteries. Imagine for instance
the advantage of installing a ceiling fan with this drive and controlling it from wherever you want without any
installation cost
Even a child knows how to use a device with a red button, a green one, a left-zero-right switch and a control
knob
NEO-WiFi is IP65. Its keypad is IP67

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2. WORKING CONDITONS Ill. 2
Physical quantity Symbol UOM NEO-WiFi-3kW NEO-WiFi-11kW NEO-WiFi-22kW
Inverter protection degree* IP65
Inverter supply voltage V1n V 3x 200-460
Inverter supply frequency f1n Hz 50-60
Maximum output voltage of the inverter V2V = V1n-5%
Inverter output frequency f2Hz 200% f1n [f20-100Hz if f1n50Hz]
Rated input current to the inverter I1n A 7.5 23 47
Rated output current from the inverter (to the motor) I2n A 7.0 22 45
Maximum continuous current output from the inverter I2A I2n + 5%
Maximum Starting torque / Rated torque ratio Cs/Cn Nm 150% 200% (7,5kW)
160% (11kW) 150%
Maximum Starting current (kept for 3 seconds) I2max A 150% I2
200% I2(7,5kW)
160% I2 (11kW) Max
35A
150% I2
Storage temperature Tstor °C -20..+60
Environmental operating temperature Tamb °C 0..40
Maximum relative humidity % (40°C) 50
Maximum WiFi keypad-inverter communication distance
out in the open mt 20
Tab. 1: operating conditions
Further characteristics NEO-WiFi-3kW NEO-WiFi-11kW NEO-WiFi-22kW
Motor control V/F vectorial vectorial
synchronous motors control NO optional optional
3PH power knife switch optional optional optional
Programmer with built-in clock and battery (to make it possible to plan starts and stops); NO YES YES
EMC for DOMESTIC, COMMERCIAL AND LIGHT INDUSTRIAL ENVIRONMENT (ref. EN
50081-1, para 5)
YES (since V2.01)
Class A – Cat C1 optional optional
EMC for INDUSTRIAL ENVIRONMENT (ref. EN 50081-2, para 5) YES YES
Class A – Cat C2
YES
Class A – Cat C2
Communication Protocol (from July 2014)
MODBUS
RS485, SCADA
EIA/TIA-485-A
MODBUS
RS485, SCADA
EIA/TIA-485-A
MODBUS
RS485, SCADA
EIA/TIA-485-A
internal braking resistances YES YES YES

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For different environmental conditions contact our Support Service
*The IP65 degree refers to both the inverter case and to the removable keypad, whether it is placed in the inverter case or
whether inverter and keypad are distant from each other. This is possible thanks to:
adoption of an induction powered system (Ill.1) instead of "male-female" connectors,
shapes of the cases of the 2 items
special sealing gaskets on the keypad (Ill. 3) and on the inverter case (Ill. 4)
Ill. 3
Ill. 4

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NEO-WiFi EMC = Secure operation
Have you ever had a sporadic and inexplicable malfunction of electrical/ electronic
devices? For example, an automatic gate, a computer, a PLC, a circuit breaker ... If
you didn't find the fault, it was probably due to the electromagnetic compatibility of the
device (not sufficiently immune to electrical/electromagnetic interference received from
the power line or radiated in the air) or to that of other equipment that showed no
malfunction but was disturbing your device. Electromagnetic compatibility is a
requirement prescribed by law and by the need to guarantee the operation of all
electrical/electronic equipment, on the basis of which it must in practice:
limit below precise thresholds emissions of electrical and electromagnetic
interference which can affect the operation of other devices, whether the
interference is radiated through the air or conducted in the power line or in
the earth return circuits;
be immune to a series of conducted and radiated interference that may be
present in the environment in which it is intended to operate.
It is important therefore not only to protect the operation of the inverter (variable speed
drive), but also to protect all the other devices from it. Electromagnetic compatibility is therefore the result of coexistence
without reciprocal interference of devices in the same environment.
In an industrial environment, the immunity level must be higher compared to the others, but on the other hand, in a
residential, commercial or light industrial environment, it is necessary to limit potential interference emissions more than
in the industrial environment. So the regulations define these two environments:
DOMESTIC, COMMERCIAL AND LIGHT INDUSTRIAL
ENVIRONMENT
(ref. EN 50081-1, para 5)
INDUSTRIAL ENVIRONMENT
(ref. EN 50081-2, para 5)
This concerns residential, commercial and light industrial
locations, both internal and external.
Locations with a power supply from 50 to 1000V provided
direct from the public network are considered residential,
commercial or light industrial locations.
Industrial environments are characterized by the existence
of one or more of the following conditions:
presence of industrial, scientific or medical
equipment
inductive and capacitive loads are frequently
switched
currents and associated magnetic fields are high

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The part of the first definition that we have underlined contradicts a recurrent belief: in fact, not every location that is often
considered an "industrial environment" is only that for the EMC regulations. Indeed, the vast majority of companies also
fall within the definition of light industry and their facilities and equipment must therefore satisfy the legal requirements of
both environments.
Nevertheless, most of the three-phase inverters circulating on the market are declared in conformity with the regulations
which relate only to the industrial environment and, at times, they place limitations even on this.
Having said this, and wanting to talk about the EMC advantages of NEO-WiFi, we cite the two main ones:
1. maximum distance between inverter and motor
In a normal motor/inverter installation it is necessary to minimize the parasitic capacitance of the system and for
this (but not with NEO-WiFi), the cables connecting motor and inverter should be short and of shielded type, or
unshielded but inserted in a duct or metal tube connected to earth. This also because the cables connecting
motor and inverter also radiate radio waves. It is not uncommon for inverter manufacturers, in their declaration of
conformity, to specify for the sake of correctness the maximum length of the cable connecting motor and inverter
and this statement may be considered valid.
With an inverter motor this problem does not exist, because motor and inverter are a single unit. If, however, we
were unable to control the inverter motor in its position (under a conveyor belt, in the narrow space in which a
hydraulic control unit was installed, on an industrial fan attached to a ceiling, etc.), with a normal inverter motor
we would still have to have a control device connected via cable to the inverter. This problem does not exist with
NEO-WiFi, whose detachable keypad is connected to the inverter via authorized and tested radio frequencies.
2. the installation of additional anti-interference filters
To make a compatible inverter, the manufacturer will have to allow for additional costs, such as the insertion of
components, shielding and filters. To offer a price apparently more attractive, a frequent trick is to not incorporate
in the inverter everything you need and to resolve the problem by requiring you in the instruction manual to buy
anti-interference filters separately and install them. A careless
buyer may then fool themselves that they have saved, only to find
out later, on reading the manual, that if he/she wants to comply
with applicable laws and avoid problems operating the inverter or
other devices in the same environment, he/she will have to incur
additional costs for materials and installation.
Another recurrent story is installing inverters suitable only for
industrial environments, even if the company has power supplied
directly from the mains, putting at risk the operation of other
devices. This leaves the problem to the end user to understand
why an automatic gate, a computer, a PLC, a protective circuit breaker or other electronic devices in the same
environment will begin to have problems of malfunction which will not be confirmed and resolved by the suppliers
of the inverter.
NEO-WiFi was designed as a plug-and-play inverter motor, to avoid the costs of additional materials and labour to the
buyer. It had to take into account, viewing the situation seriously, the fact of having been designed for its intended
environment, without the need for additional material and installation costs.
Very unusually, therefore, in the NEO-WiFi-3 project, Motive has been careful to make it compatible not only with the
industrial environment, with high immunity, but also to keep its emissions below the most restrictive thresholds prescribed
for the home, commercial and light industrial environment, without the need to install additional external filters.
NEO-WiFi-11kW, however, because of its greater power, is the standard suitable for installation in industrial
environments but requires the installation of an optional external anti-interference filter to make it suitable for the
domestic, commercial and light industrial environment too.

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3. MOTORS THAT CAN BE CONNECTED
Tab. RP: Power range of motors that can be connected (at 400Vac*)
motor-kW 0,25 0,37 0,55 0,55 0,75 1,1 1,1
1,5 1,9 2,2 3 4 5 5,5 7,5 9,2 11 15 18,5 22
NEO-WiFi-3 SV
NEO-WiFi-11 SV SV+F
NEO-WiFi-22
SV= applicable power only with forced ventilation (chap. 4a) . F= needed also 2 internal fans (chap. 4a)
*inverters should not be divided by power kW (they are classified by power only for practicality and by habit), but by steady current
output A. Current A is inversely proportional to voltage V.
The power that can be applied is dependent not only on the electronic characteristics of NEO-WiFi, but also
on the dissipative capacity of its case. It is therefore not allowable to use the electronic board in cases that
are different from the original one by removing the electronic board and mounting it in another case. This
transferral would also compromise its electrical insulation and safety of the device with resulting
inapplicability of the warranty
Tab. RD: Size range of IEC motors that can be connected
Motor- IEC type 71 80 90 100 112 132
160 180
NEO-WiFi-3 X X X X X X X * X *X *X *X
NEO-WiFi-11 X X X X X X
NEO-WiFi-22
*. after removing the plastic knockout as shown in chap.4
X. required mechanical adapter, chapter 4
Why connect motors size 112 and 132 to a NEO-WiFi-3kW or motors size
160 to a NEO-WiFi-11kW? Because motors with more than 4 poles can be
of a greater size (for example, 112M-6 2.2kW, 132S-6 3kW, 132S-8 2.2
kW and 132M-8 3kW).
It is important that the motor is suitable to be powered by an inverter. A fundamental requirement is that it
has reinforced insulation between the phase windings. Others, are the limited current absorption and low
temperature rise. The Delphi series of motive motors, as a standard feature, can be powered by an inverter.

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4. MECHANICAL ASSEMBLY
Dimensions o NEO-WiFi-3kW and keypad

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Dimensions NEO-WiFi-11kW

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Dimensions NEO-WiFi-22kW

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Dimensions NEO-WiFi + motor
NEO-WiFi-3 NEO-WiFi-11 NEO-WiFi-22
motor IEC AD1 AD2 L AD1 AD2 L AD1 AD2 L
71 195 208 278  
80 211 224 288  
90S 215 228 = 242 431  
90L 196 209 = 242 431  
100L 210 223 = 251 438  
112 233 246 = 261 447  
132S 252 265 = 274 475  
132M 252 265 = 274 =  
160M 342 = 318 632
160L 318 =
180M 335 =
180L 335 =

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4a. Motor assembly
The mechanical fastening with slots (Ill. 5) allows the NEO-WiFi case to be fixed onto a wide range of Delphi series motive motors
from size 71 to size 160 (Table. RD)
Ill.5
The plastic knockouts allow the NEO-WiFi-3kW to broaden its field of use to engines with greater sizes (Table RD), as shown in
the following image

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Plastic knockout removal procedure
Be careful not to disperse metal or wire ends inside the housing of the inverter, that can create dangerous short-circuits.

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For the connection between NEO-WiFi-3kw and the motors marked with X in the “Tab. RD”, specific mechanical adapters are
needed. See the following images.
NEO-WiFi-3
71-80-90S: 112-132:

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NEO-WiFi-11
160M*100L 90S/90L

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*NEO-WiFi-11 + 160M