Regal IntelliGear Plus MD Manual

F O R M
Installation and Maintenance Manual
For IntelliGear Plus™ MD and BW1
Variable Speed Drives
9708E
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.
• 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.
®c e
c
UL Listed
E211799
Ind. Cont EQ. 54 DN
us

IntelliGear PlusTM Variable Speed MD Gearmotors
2 MCIM15107E • Form 9708E • Printed in USA
Thank you for choosing an IntelliGear Plus Gearmotor.
• All electrical work should be performed by qualied
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.
• 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.
• 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 Regal Power Transmission Solutions for
recommendations for units running at slow speeds or
unusual conditions.

IntelliGear PlusTM Variable Speed MD Gearmotors
MCIM15107E • Form 9708E • Printed in USA 3
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 Specied mains supply ............................................................................................................................................. 5
1.6.2 Cables....................................................................................................................................................................... 5
1.6.3 Fuses ........................................................................................................................................................................ 5
1.8 Dimensions ............................................................................................................................................................... 6
2 Installation ............................................................................................................................................................... 7
2.1 General ..................................................................................................................................................................... 7
3 Connections ............................................................................................................................................................ 7
3.1 Control Terminal Blocks ............................................................................................................................................ 7
3.2 Power terminal blocks............................................................................................................................................... 7
3.2.1 Terminal block for power supply PB1 ( marked L & N )............................................................................................. 7
3.3 Wiring diagram based on standard conguration ..................................................................................................... 8
3.4 Terminal Block Assignments and MD Functionality .................................................................................................. 9
4 Commissioning ....................................................................................................................................................... 9
5 Operator Pad ......................................................................................................................................................... 10
5.1 Troubleshooting Guide.............................................................................................................................................11
5.2 Additional Troubleshooting.......................................................................................................................................11
5.3 Field Modications of Parameters........................................................................................................................... 12
6 Gear Lubrication ................................................................................................................................................... 13
7 Gear Parts List ...................................................................................................................................................... 14
8 Motor Parts List..................................................................................................................................................... 15

IntelliGear PlusTM Variable Speed MD Gearmotors
4 MCIM15107E • Form 9708E • Printed in USA
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 Power Transmission Solutions’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, 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.
1.2 - Product name
1.3 - Environmental Characteristics
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
IntelliGear PLUS Controlling Options
Designation Description
RPD 4-20 mA follow or local Keypad (manual control)
Characteristics Level - IntelliGear PLUS
Degree of protection TEFC Version TEFC motor and NEMA 4/12 Controller
Storage temperature -40 oC to +70 oC
Transport temperature -40 oC to +70 oC
Ambient operating temperature -20 oC to +40 oC (above 40 oC requires derating 1% per oC)
Altitude Up to 3000 feet above sea level without derating
Ambient humidity 95% non-condensing
Humidity during storage 93%, 40 oC, 4 days
Vibration - Exposed product: 0.01 g2 / Hz 1 hr. in accordance with IEC 68-2-34
- Sinusoidal vibration: 2-9 Hz 3.5 ms-2 - 9-100 Hz 10 ms-2 in accordance with IEC 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
Radiated and conducted emissions Conforming to EN500081-2 with lter
UL and CUL Conforming to UL 508 C (E211799)
IntelliGear PLUS Accessories
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

IntelliGear PlusTM Variable Speed MD Gearmotors
MCIM15107E • Form 9708E • Printed in USA 5
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.
1.6 - UL conformity
1.6.1 Specied 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.
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 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.
1.4.2 - 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 IntelliGear
Plus Number Input Amps Wire Gauge Fuse Size IntelliGear Plus Number Input Amps Wire Gauge Fuse Size
0.50 I 310M 050 5 14AWG 10 A I 31M 050 2.5 14AWG 8A

IntelliGear PlusTM Variable Speed MD Gearmotors
6 MCIM15107E • Form 9708E • Printed in USA
1.8 - Dimensions
8.52
.39
.12
6.30
5.00
Ø .344 + .007 / -.002 HOLES
Ø 4.72
Ø 3.94
5.90
11.23
3.50
1.40
5.50
Ø .280 HOLES
4 @ 90º AS SHOWN
Ø 3.1500
3.1493
CATALOG NUMBER
CBN3001BSCB524.556 CCI 109
CCI NUMBER
CCI 109-G
1 Ø Voltage
Power Model No. CCI Number Gear Ratio Standard
RPM Range
115 XS9507 CCI-123G 4.5 600-19
230 XS9508 CCI-124G 4.5 600-19

IntelliGear PlusTM Variable Speed MD Gearmotors
MCIM15107E • Form 9708E • Printed in USA 7
2 - Installation
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.
3 - Connections
Connection with copper conductor only.
3.1 - Control Terminal Blocks
• Remove the terminal block from it’s xed holder
(unplugged) before making any connections, to
avoid putting pressure on the card.
CAUTION: 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.
Removable screws in terminal block:
• 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&N)
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. (See table below)
Screw terminal blocks 310M & 31M
Tightening Torque 7.1 in. lbs.
Max. cross-section AWG 14
Numbered Controller
Terminal Blocks
Terminal Block
for Power Supply

IntelliGear PlusTM Variable Speed MD Gearmotors
8 MCIM15107E • Form 9708E • Printed in USA
3.3 Wiring diagram based on standard conguration
NOTE: IF AUTO MODE RUN/STOP CONTACT IS NOT USED, 4-20mA INPUT
CONNECTOR PINS 5 & 6 MUST BE JUMPERED TO RUN IN AUTO MODE. User supplied male Turck connectors can be secured locally using the following information - 5 pin connector with 4 meter cable attached = Turck # SB5T - 4 6 pin connector with 4 meter cable attached = Turck # SB6T - 4

IntelliGear PlusTM Variable Speed MD Gearmotors
MCIM15107E • Form 9708E • Printed in USA 9
3.4 Terminal block assignments and MD functionality
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.
Controller
Terminal
Number
Designation Function Characteristics
110V +10VDC Analog Internal
Source
Accuracy ±2%
Maximum Output Current 30 mA
2 ADI1 Kick Start Speed Reference
Voltage Input
Full Scale Voltage 10 VDC ±2%
Input Impedence 95 kΩ
30V Logic & Analog Circuit Common
4 ADI2 Auto Mode Speed Reference
**
Current Input
Current Range 4-20 mA ±5%
Input Impedence 500 Ω
Resolution 10 bits
Sampling 6 ms
5
11 24V +24VDC Logic Internal Source
Output Current 30 mA
Overload Current 60 mA
Accuracy ±5%
Protection Current Limiting & Overload Fault Trip
6ADIO3 Analog Output Proportional to
Motor/Pump RPM
Voltage Output
Voltage Range 0 to 10 VDC
Load Resistor 2 kΩ Minimum
Protection Short Circuit (40 mA Maximum)
7DIO1 Logic Output 1
Drive Running
Logic Output
Voltage Range 0 to +24 VDC
Sampling/Refresh Rate 2 ms
Maximum Output Current 50 mA
Overload Current 50 mA
8 DI2 Logic Input 2
Auto Mode Run/Stop
Characteristics Logic Input (Positive Logic)
Thresholds “0”: <5 VDC “1”: >10 VDC
9 DI3 Logic Input 3
Motor Thermal Input
Voltage Range 0 to +24 VDC
Sampling/Refresh Rate 2 ms
10 DI4
Logic Input 4
Fault Signal Input from Run
Dry
and/or High Pressure Sensor
Absolute Maximum Voltage
Range 0 to +35 VDC
Load Impedence 15 kΩ
Input Threshold 7.5 V
12 ENA Drive Enable Voltage Range 9 to +33 VDC
Load Impedence 820 Ω
13
14
RL1
RL2
Drive Healthy Contact
Closed Upon Power Up
Unless Drive Tripped
Characteristics Normally Open Single Pole Contact
Rated Voltage 250 VAC
Current Rating Resistive Load: 4 A Inductive Load:
2 A
** Provides setpoint feedback function when drive is programmed for full PI mode of operation

IntelliGear PlusTM Variable Speed MD Gearmotors
10 MCIM15107E • Form 9708E • Printed in USA
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.
A
F
G
B
C
D
E
REF. Function
ADisplays operating RPM of pump
B- Displays drive status including faults
- Displays parameter number and setting during drive programming/setup
C“Hand” command button starts motor running in Hand mode
D“Off” button to stop motor
E“Auto” command button initiates Auto mode for operation from a 4-20 mA speed reference
analog signal
F
- Set the pump speed in Hand mode
- Set maximum pump speed in Auto mode
- Parameter selection and adjustment in drive programming/setup mode
G“Mode” button to initiate parameter setting mode
- In parameter setting mode, opens and locks parameter settings

IntelliGear PlusTM Variable Speed MD Gearmotors
MCIM15107E • Form 9708E • Printed in USA 11
5. 1 Fault Mode Troubleshooting Guide
5.2 Additional Troubleshooting
LED Pad Display Drive Status/Fault Indication Actions Required
Blank Display Drive not powered Check for drive input power
Display unplugged or failed Check display plug connection
0019 - 0600 Numeric display shows Pump RPM, indicates motor running
rdY Drive Ready (Enabled & Not Running)
In AUTO mode, make sure AUTO-RUN contact is closed
between pins 5 & 6 of 6-pin connector if pump should be
running
inh Drive Inhibited (Not Enabled) Install jumper between IntelliGear terminals 11-12
tr01 Motor thermostat trip - Overtemp
Check motor thermostat connections between IntelliGear
terminals 5 & 9
(Install jumper if motor has no thermostat wires -P1/P2)
Check motor fan & clean debris or obstruction to air ow
Check for motor overload
tr02 Internal brake resistor trip - Overtemp Contact factory
tr03 Pump RUN DRY or HIGH PRESSURE fault trip Check for proper ow and pressure in pump
UU DC Bus Undervoltage Check incoming power for voltage level too low
OU DC Bus Overvoltage
Check incoming power for voltage level too high
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 Check motor connections at IntelliGear grey terminal strip
OI.AC Overcurrent at Drive Output
Check motor connections at IntelliGear grey terminal strip
Check for ground fault or line-line fault in motor wiring
Check for moisture or insulation damage in motor windings
It.AC Motor Overload (I X t) Check for excessive torque load at pump
Oht1 Overheating in Output Transistors
Check heatsink ns for debris or obstruction to air ow
Provide supply of cool air if ambient exceeds 40°C
Reduce torque load from pump
Oht2 Overheating in Brake Transistor
Adjust drive parameter 04 (deceleration time) to a higher
setting using drive keypad/display
Reduce start/stop frequency
rS Stator Resistance Measurement Fault Check motor connections at IntelliGear grey terminal strip
SCL Serial connection between keypad and drive broken Check display plug connection
EEF EEPROM fault in drive Contact factory
OI.br Overcurrent at Brake Transistor Contact factory
Symptom Probable Cause(s) Actions Required
Not Running, No Fault
Indication on Display
Drive not in HAND or AUTO mode Press HAND or AUTO button on Keypad
Drive in AUTO mode, but AUTO-RUN contact not closed Close AUTO-RUN contact or
Jumper pins 5-6 on 6-pin connector cable
Unit Runs Only at Low
Speed in AUTO mode
4-20 mA signal is not present Connect 4-20 mA signal and Verify that the signal current
is present (pins 1 & 2 of 6-pin connector)
4-20 mA signal polarity is reversed Verify current enters pin 1 of 6-pin connector Reverse the
connections if necessary
In AUTO, Unit Does Not
Achieve Maximum Output
RPM at 20 mA Signal
Input
4-20 mA signal not achieving full 20 mA at maximum speed
reference
Signal source may not be capable of producing 20 mA with
the drive input impedence of 500 ohms - must be able to
produce at least 10 VDC at pin #1 of 6-pin connector cable
Maximum speed setting of operator keypad setting is not set
to 100%
Press UP ARROW on keypad until maximum speed is
attained
IntelliGear MAXIMUM SPEED setting has been turned down Adjust drive parameter 02 to 2700 RPM using drive
keypad/display

IntelliGear PlusTM Variable Speed MD Gearmotors
12 MCIM15107E • Form 9708E • Printed in USA
5.3 Field Modications Of Parameters
The new IVD controller with keypad allows some factory set parameters to be adjusted in the eld. 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
PAD
Parameter # Parameter Description Normal Value
Optional Range For
New setting Units New Field Setting
01 Motor Minimum Speed 90 91-350 Δ RPM (of motor) ‡‡
02 Motor Maximum Speed 2700 100 - 2699 RPM (of motor) ‡‡
03 Acceleration Rate - Seconds/1000
RPM 1.0 0.1-600 Seconds/1000 RPM
04 Deceleration Rate - Seconds/1000
RPM 5.0 0.1-600 Seconds/1000 RPM
‡‡ To 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 “2700” to
“1688” ( gear ratio is 4.5, so 375 x 4.5 = 1688 )
Δ To achieve “0” speed at minimum mA input, change setting for parameter #1 to “0”

IntelliGear PlusTM Variable Speed MD Gearmotors
MCIM15107E • Form 9708E • Printed in USA 13
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 lled 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.
Acceptable Mineral Oil Lubricants
Synthetic
Orient the gear head
vertically and ll to
mid-point of the
Primary Gear
Primary
Gear
Input
Opening
Diagram for
Size 30
Oil Level
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.
Ambient Range of Installation
-4˚ F to 14˚ F
(-20˚C to 10˚C)
14˚F to 122˚F (-10˚C to 50˚C) 122˚F and Above
(50 ˚C+)
No Backstop With Backstop
ISO VG 68 ISO VG 100 ISO VG 150 ISO VG 220 ISO VG 150 ISO VG 320
Manufacturer -25˚ F to 125˚ F
(-30˚ C to 50˚ C)
Fuchs®Sintogear® 125
Mobil®SHC 629
Shell®Omala® Fluids HD 150
Manufacturer -25˚ F to 125˚ F
(-30˚ C to 50˚ C)
Shell Omala RL 100
No Backstop With Backstop

IntelliGear PlusTM Variable Speed MD Gearmotors
14 MCIM15107E • Form 9708E • Printed in USA
Typical Maintenance Items - Bearings and Seals
Rep Description Quantity
001 Housing 1
009 Output ang ring 1
031 Output shaft 1
042 Pinion 1
052 Gear 1
061 Bearing front 1
062 Bearing back 1
077 Output shaft key 1
080 Gear Key 1
Rep Description Quantity
090 Oil seal 1
097 Input o-ring 1
127 Gearing snap ring* 1
130 Gearing snap ring 1
175 Input bracket screw 4
185 Washer for gear* 1
186 Screw washer* 1
187 Bolt 4
282 Nameplate 1
Gear Frame
Item Description By Location
Bearings Seal (mm)
61 62 90
30 6205 ZZ 6005 25 x 52 x 7 DL nitrile
* Not illustrated on diagram
052
097
255
001
282
284
062
080
031
077
061
130
090
009
187
257
256
258
128
042
7.0 - Gear Parts List
CBN 3001

IntelliGear PlusTM Variable Speed MD Gearmotors
MCIM15107E • Form 9708E • Printed in USA 15
32
1
5
6
4
9
8
10
11
183
184
254
7
CbN 30 (Quantity Per Unit)
FRAME 56
Part # Description Qty.
1Fan Cover 1
2Self Tapping Screw 3
3Hex Nut 1
5Retaining Snap Ring 1
6 Fan 1
7Bracket 1
8 Screw 4
9Bushing 4
10 Plastic Plug 4
11 Ball Bearing 1
12 Rotor Assembly (includes items 13 & 14) 1
13 Shaft 1
14 Rotor Core 1
15 Wound Stator Assembly 1
16 Gasket 1
17 Outlet Box Base 1
18 Self Tapping Screw 2
19 Outlet Box Cover 1
20 Self Tapping Screw 2
Rep Description Quantity
1Motor adapter 1
2Input shaft 1
3 Pinion 1
4Internal snap ring 1
6 Bearing 1
8External snap ring 1
9 Seal 1
10 Pinion pin 1
183 Stud 4
184 Nut 4
Gear
Frame
Bearing Seal (mm)
6 9
30 6005 2RS 47 x 25 x 7
8.0 Motor Parts List

IntelliGear, IntelliGear Plus & Design 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. MCIM15107E • Form 9708E • Printed in USA
Notes: