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Emerson BW1 - page 1
® ce c Installation and Maintenance Manual For IntelliGear Plus™ MD and BW1 V ariable Speed Drives UL is believ ed to be a registered trade name and/or trademark of Underwriters Laboratories, Inc. and is NO T owned or controlled by Emerson P o wer T ransmission. Emerson P ower T ransmission Corporation cannot and does not represent or warrant th ...
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Emerson BW1 - page 2
IntelliGear Plus ™ V ariab le Speed MD Gearmotors 2 General Safety Instructions Thank y ou f or choosing an IntelliGear Plus Gear motor . • Read and f ollow all instructions carefully . • Disconnect and lock-out po wer bef ore installation and maintenance. W orking on or near energized equipment can result in se v ere injur y or death. ...
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Emerson BW1 - page 3
IntelliGear Plus ™ V ariable Speed MD Gearmotors 3 Contents 1 General Information ................................................................................................................................ 4 1.1 General operating principle ....................................................................................................... ...
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Emerson BW1 - page 4
IntelliGear Plus ™ V ariable Speed MD Gearmotors 4 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 v ector v ariable speed drive. The motor can be combined with man y gear types from Emerson P o wer T ransmission’ s range ...
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Emerson BW1 - page 5
IntelliGear Plus ™ V ariable Speed MD Gearmotors 5 1.5 - Description of cables and pr otection devices (Customer Supplied) NO TICE: When using a circuit-break er , it must be a motor circuit-break er (D cur ve). • Complywiththesizeofprotectionfuses . • Thecablesiz emayv ar yaccordingtolegisl ...
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Emerson BW1 - page 6
IntelliGear Plus ™ V ariable Speed MD Gearmotors 6 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 CA TA LOG NUMBER CBN3001BSCB524.556 CCI 109 CCI NUMBER CCI 109-G 1 Ø V oltage Po w e r Model No. CCI Number Gear Ratio Standard RPM Ran ...
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Emerson BW1 - page 7
IntelliGear Plus ™ V ariable Speed MD Gearmotors 7 2 - Installation After connection, ensure that the seals are firmly in place, and that the screws and cab le glands are water tight to ensure drive protection. Clear any condensation from the drain holes at the bottom of the motor . 2.1 - General The I ntelliGear Plus is usually fitted to the g ...
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Emerson BW1 - page 8
IntelliGear Plus ™ V ariable Speed MD Gearmotors 8 3.3 Wiring diagram based on standar d configuration NOTE: IF AUTO MODE RUN/STOP CONT AC T IS NO T USED, 4-20m A INPUT CONNECTOR PINS 5 & 6 MUST BE JUMPERED TO RUN IN AU TO MODE. User supplied male Tu rck connectors can be secured locally using the following information - 5 pin connector with ...
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Emerson BW1 - page 9
IntelliGear Plus ™ V ariable Speed MD Gearmotors 9 3.4 T erminal block assignments and MD functionality 4. Commissioning W ARNING! Before s witching on the IntelliGear Plus unit, check that the electrical connections are correct, and that any mo ving par ts are mechanically guarded. W ARNING! For the saf ety of personnel, the IntelliGear Plus mus ...
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Emerson BW1 - page 10
IntelliGear Plus ™ V ariable Speed MD Gearmotors 10 5. Operator Pad Each RPD IntelliGear unit has a ke ypad on the controller lid equipped with operator elements for H-O-A selection, manual control of unit, displa y of pump speed, faults and the ability to change some f actor y set parameters . A F G B C D E REF . Function A Displa ys operating R ...
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Emerson BW1 - page 11
IntelliGear Plus ™ V ariable Speed MD Gearmotors 11 5. 1 Fault Mode T roubleshooting Guide 5.2 Additional T roubleshooting 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, ...
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Emerson BW1 - page 12
IntelliGear Plus ™ V ariable Speed MD Gearmotors 12 5.3 Field Modifications Of P arameters The new IVD controller with k eypad allows some f actor y set parameters to be adjusted in the field. The table belo w provides the f actor y settings for each par ameter and then optional ranges f or selection of a new setting. F ollow the steps detailed ...
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Emerson BW1 - page 13
IntelliGear Plus ™ V ariable Speed MD Gearmotors 13 6 - Gear Lubrication Series 3000 CbN gear ing is shipped with one of the f ollowing synthetic lubricants per the table belo w . 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 tha ...
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Emerson BW1 - page 14
IntelliGear Plus ™ V ariable Speed MD Gearmotors 14 T ypical Maintenance Items - Bearings and Seals Rep Description Quantity 001 Housing 1 009 Output flang r ing 1 031 Output shaft 1 042 Pinion 1 052 Gear 1 061 Bear ing front 1 062 Bearing back 1 077 Output shaft k ey 1 080 Gear K ey 1 Rep Description Quantity 090 Oil seal 1 097 Input o-ring 1 1 ...
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Emerson BW1 - page 15
IntelliGear Plus ™ V ariable Speed MD Gearmotors 15 3 2 1 5 6 4 9 8 10 11 183 184 254 7 CbN 30 (Quantity P er Unit) FRAME 56 P art # Description Qty . 1 F an Cov er 1 2 Self T apping Screw 3 3 He x Nut 1 5 Retaining Snap Ring 1 6 Fa n 1 7 Brac ket 1 8 Screw 4 9 Bushing 4 10 Plastic Plug 4 11 Ball Bearing 1 12 Rotor Assembly (includes items 13 &am ...
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