Emerson Troubleshooting Guide: IntelliGear Plus Variable Speed Gearmotors

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IntelliGear PlusVariable Speed MD Gearmotors

5. 1 Fault Mode Troubleshooting Guide

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

 

 

Check motor thermostat connections between IntelliGear

 

 

terminals 5 & 9

tr01

Motor thermostat trip - Overtemp

(Install jumper if motor has no thermostat wires -P1/P2)

Check motor fan & clean debris or obstruction to air flow

 

 

 

 

Check for motor overload

tr02

Internal brake resistor trip - Overtemp

Contact factory

tr03

Pump RUN DRY or HIGH PRESSURE fault trip

Check for proper flow and pressure in pump

UU

DC Bus Undervoltage

Check incoming power for voltage level too low

 

 

Check incoming power for voltage level too high

OU

DC Bus Overvoltage

Check for over-running load (pressure over-driving pump)

Adjust drive parameter 04 (deceleration time) to a higher

 

 

 

 

setting using drive keypad/display

ph.AC

Loss of a motor phase

Check motor connections at IntelliGear grey terminal strip

 

 

Check motor connections at IntelliGear grey terminal strip

OI.AC

Overcurrent at Drive Output

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

 

 

Check heatsink fins for debris or obstruction to air flow

Oht1

Overheating in Output Transistors

Provide supply of cool air if ambient exceeds 40°C

 

 

Reduce torque load from pump

 

 

Adjust drive parameter 04 (deceleration time) to a higher

Oht2

Overheating in Brake Transistor

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

5.2 Additional Troubleshooting

 

Symptom

Probable Cause(s)

Actions Required

Not Running, No Fault

Drive not in HAND or AUTO mode

Press HAND or AUTO button on Keypad

Drive in AUTO mode, but AUTO-RUN contact not

Close AUTO-RUN contact or

Indication on Display

 

closed

Jumper pins 5-6 on 6-pin connector cable

 

4-20 mA signal is not present

Connect 4-20 mA signal and Verify that the signal

Unit Runs Only at Low

current is present (pins 1 & 2 of 6-pin connector)

Speed in AUTO mode

4-20 mA signal polarity is reversed

Verify current enters pin 1 of 6-pin connector Reverse

 

the connections if necessary

 

 

 

4-20 mA signal not achieving full 20 mA at maximum

Signal source may not be capable of producing 20

 

mA with the drive input impedence of 500 ohms -

In AUTO, Unit Does

speed reference

must be able to produce at least 10 VDC at pin #1 of

 

6-pin connector cable

Not Achieve Maximum

 

 

Maximum speed setting of operator keypad setting is

Press UP ARROW on keypad until maximum speed

Output RPM at 20 mA

Signal Input

not set to 100%

is attained

 

IntelliGear MAXIMUM SPEED setting has been turned

Adjust drive parameter 02 to 2700 RPM using drive

 

down

keypad/display

11

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Contents R M General Safety Instructions General Information ContentsIntelliGear Plus Controlling Options IntelliGear Plus AccessoriesEnvironmental Characteristics General Information General operating principleUL conformity Specified mains supply Radio-frequency interference 1.4.1 GeneralStandards Emission Standards ImmunityDimensions Control Terminal Blocks InstallationGeneral ConnectionsConnector Pins 5 & 6 Must be Jumpered to RUN in Auto Mode Wiring diagram based on standard configurationADI1 CommissioningFunction Operator PadAdditional Troubleshooting Fault Mode Troubleshooting GuidePAD Field Modifications Of ParametersSynthetic Gear LubricationRep Description Quantity Gear Parts List CBNDescription Qty Motor Parts List
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