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1. Dimensions linches except as noted STABLE Motor Slide Bases continued MTA BASE Wxxxx H I J K mm L M N 56 2 7 8 3 8 3 2 mm 7 8 5 16x1 3 8x4 Page 4 2 IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 VAUTOMATIONDIRECTE Chapter 4 Accessories REPLACEMENT ACCESSORIES o e LI e Ne Replacement brushes and spare replacement parts can be ordered at www automationdirect com REPLACEMENT DC MOTOR BRUSHES All small frame IronHorse DC motors ship with brushes installed and the brushes should be replaced as needed Minimum brush length is 6mm Brushes for 56C frame motors should be changed after every 2500 hours of use Each 56C frame motor ships with brushes installed plus one extra set of spare replacement brushes Match the replacement brush part number against the motor horsepower carefully to insure you order the correct brushes for your motor When replacing brushes pay special attention that the correct brush 1s inserted into the motor especially 1f you have multiple motor sizes at your facility Verify that the width of the brush you remove matches the width of the replacement brush DO NOT install smaller brushes into a larger motor See Chapter 3 Maintenance and Troubleshooting for brush replacement procedure w R Part Number Description Motor Type anal Motor HP Brush Materials MTP
2. gt RR REU WR 5 0 0 x 5 18 Permanent Magnet Motors a 5 18 Controlling Speed aa a a 5 18 Load Considerations 5 18 High Temperature Considerations 2 2 2 2 2 aa aa ll aa 5 19 Contamination Considerations 2 2 2 2 2 4 2 a a a 5 19 Vibration Considerations 2 2 4 4 a a 44 a a e 5 19 Altitude Considerations ara 5 19 Ambient Temperature 2 I a 5 20 TOC 2 IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 GETTING STARTED TABLE OF CONTENTS Manual Overview R5 1 2 Overview of this Publication 2 aaa aa a a a aa 1 2 Who Should Read This Manual yg 1 2 Technical Support 2 2 ha ee et 1 2 Special Symbols UU ee ue n 1 2 Receiving and Inspection E I 2 OT 4 1 2 Available Models 0 gt gt d Wn 1 3 IronHorse Motors Part Number Information a 1 3 Permanent Magnet DC Motors Features and Specifications 1 3 Reshipping 1 6 Long Term Storage 1 6 Warranty 1 6 IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 Page 1 1 Chapter 1 Getting Started VAUTOMATIONDIRECTE mM MANUAL OVERVIEW OVERVIEW OF THIS PUBLICATION The IronHorse General Purpose DC Motor User Manual describes the in
3. I i i i i M KT 15 pus iis ui pill E Air 2147 RY N iM br 154 LOL 1004 A Performance Data MTPM P50 1L18 Description No Load Rated Max Eff Max Pout Max Torque End IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 VAUTOMATIONDIRECTE Chapter 5 Reference _ _ _ 00370707 PERFORMANCE CURVES CONTINUED MTPM P75 1L18 LNH i i i i i i im AL i Hi ls 13504 35 120 1200 lem i i i e 2 i i i 105 1050 a nan i i i i F i i i X p p i i i i i rn 750 A Er SF Iya Katnr i i i amp i amp 600 i i i i x i i i 5 150 Fe NN 4 i i i i i i a i i i i Hi 300 june mn i i i TE gt 1 i i In Lot g 1 i i roer i i i i i i i i i i i i i i i i ni n q E 1 i i i gt i i 0 06 1 2 1 8 2 4 3 36424854 B Performance Data MTPM P75 1L18 Description No Load Rated Max Eff Max Pout Max Torque End IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 Page 5 5 Chapter 5 Reference VAUTOMATIONDIRECTE TF PERFORMANCE CURVES CONTINUED MTPM 001 1L18 A 0 ALI th Performance Data MTPM 001 1L18 Description No Loa
4. JU L 2 2 Motor Dimensions na LI Terminal Diagram and Wiring 2 5 Motor Mounting Zo 62 4 425 STABLE Slide Bases 4 s s 2 5 Proper Installation Conditions 2 a a a 2 6 Coupling Alignment 2 2 2 2 2 aa aa 4 e 2 6 Motor Nameplate and Starter Information 2 7 Typical IronHorse Motor Nameplate eee 2 7 Motor Control Information s s a a a a a a a a a a aa 2 7 Inspection Before Startup 2 7 Initial Startup Inspection 2 7 IronHorse General Purpose DC Motors User Manual 2nd Edition 0310412014 Page 2 1 Chapter 2 Mounting and Initial Startup VAUTOMATIONDIRECTE SAFETY INFORMATION 2 HAZARDOUS VOLIAGE BEFORE MAKING ANY CONNECTION TO THE MOTOR DISCONNECT ALL POWER TO THE MOTOR WARNING ANY ELECTRICAL OR MECHANICAL MODIFICATION TO THIS EQUIPMENT WITHOUT PRIOR N WRITTEN CONSENT OF AUTOMATIONDIRECT COM INC WILL VOID ALL WARRANTIES MAY RESULT IN A SAFETY HAZARD AND MAY VOID THE CSA ys LISTING WARNING TO AVOID PHYSICAL INJURY KEEP YOUR HANDS AND CLOTHING AWAY FROM ALL MOVING AN PARTS VVIRING NOTES PLEASE READ PRIOR TO INSTALLATION 1 During installation follow all local electrical construction and safety codes for the country in which the motor is to be installed 2 Make sure the appropriate protective devices circuit breaker or fuse
5. _ _ _ _ _ _ 00370707 PERFORMANCE CURVES CONTINUED Pi mm iy EE Mie dX dir dO 100 e e SS SE SS SK SS SH i i i i i i i i E H na PE 7 i i i i i i i i i i i 1000 00 L 77 i i i i rh Ap i trate 254 o i i i i ALH j 1n I Vy i i i an s 4 HHH AAI LAN 3 D F z i i 1 i i Pret F i 1 TM 250 i i i i i i i i i i i I 1000 ok Ont k HOUR NESH AA AAA AAA A Rao i i i Ej rJ i i i 00 50 ii SS SHTO ID i i i i i li 0 0 I LO 10 812 614 416 2 18 M N m Performance Data MTPM 002 1M18 Description No Load Rated Max Eff Max Pout Max Torque End IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 Page 5 13 Chapter 5 Reference VAUTOMATIONDIRECTE i INTRODUCTION TO PERMANENT MAGNET DC MOTORS INTRODUCTION Permanent magnet DC motors are useful in a range of applications from conveyors to pumps PMDC motors have a linear speed torque curve well suited to adjustable speed applications where the motor will operate at less than 3000 rpm Inside these motors permanent magnets replace the field windings found in
6. CONTENTS Junction Box Dimensions for 56C Frame Motors 5 2 Shipping Crate Dimensions for 56C Frame Motors 5 2 Decibel Levels for 56C Frame Motors 5 2 Performance Curves for 56C Frame Motors p 4 2 DET MTPM P33 1L18 2 a oe ow 6 de S SA 5 3 MTPM P50 1L18 aaa oa 5 4 MTPM P75 1L18 0 1 1 x x2 n 5 5 MTPM 001 1L18 kk kk nn a 5 6 MTPM 1P5 1L18 2 d a 4 X DEE 5 MTPM P33 1M18 0000000000 5 8 MTPM P50 1M18 I I aaa 5 9 MTPM P75 1M18 I aaa 5 10 MTPM 001 1M18 I aa 5 11 MIPM IP5 IMIO 2 ba 5 8 ROW GR A 9 X 4 X 8 5 2 MTPM 002 1M18 LL kn ks 5 13 Introduction to Permanent Magnet DC Motors 5 14 0000782 s s e z a 4x 5 14 Form FACTO uo AAA IAEA 5 14 Enclosure and Electrical Insulation Systems 2 2 2 2 5 15 Permanent Magn l5 s s x 6 fomm a w ah a 5 15 DU lC e gt Y ORO 9 W 9 5 16 Power Supply 2 2 2 2 2 e 5 17 DE MOLO TYPOS e gt ss E 5 18 Permanent Magnet Motors 4 5 18 Controlling Speed 4 4
7. PMDC MOTORS WE DO NOT RECOMMEND USING OTHER MANUFACTURER S BRUSHES Page 5 16 IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 VAUTOMATIONDIRECTE Chapter 5 Reference na POWER SUPPLY Ironhorse PMDC motors are designed for use with NEMA code K power supplies but can be supplied by five basic types of power sources batteries generators six step SCR three step SCR and single phase SCR These types of supplies are divided into four NEMA codes based on the quality of the output power as shown below NEMA Code Description Power Quality Use Form Factor Batteries Generators Excellent Limited 1 0 C 1 04 D 1 13 3 Phase 3 Step SCR Solid State Average Limited 1 05 K 1 Phase SCR Solid State Poor High for low hp 1 35 The most common way to provide DC voltage to a motor from an AC line 1s through the use of an electronic drive Depending on the construction a drive will provide a pulse wave form similar to the voltage from a battery These pulses are characterized by a form factor which is defined by NEMA National Electrical Manufacturers Association as a power supply code Codes are based on the quality of the power output Application concerns include drive cost operational cost efficiency reliability and output power quality NEMA POWER CODE A 3 Phase 6 Step SCR Solid State Excellent High for high hp This power supply is a pure DC power
8. Slide Bases rv rv a 42 Slide Base Selection I I a a a a a a a a a a aaa 4 2 Slide Base Dimensions 2 2 2 4 2 Replacement Accessories aaa 3 CHAPTER 5 REFERENCE Junction Box Dimensions for 56C Frame Motors 5 2 Shipping Crate Dimensions for 56C Frame Motors 5 2 Decibel Levels for 56C Frame Motors 2 2 aaa 5 2 Performance Curves for 56C Frame Motors 2 5 3 MIPMP STIG go ROW 8 4 EER RGR ERE 4 9 8 5 9 5 3 MIPM P50 1 ea ea oUm Te EG 5 4 MPP lOa errar 5 5 MTPM 001 1LI18 wow Fe Re ee ERO gi X de RR ES x 292 5 6 MIPMSIPSSIBIOG 4 sarar A 5 7 NS SS sas A 5 8 E 5 9 E AAA AA 5 10 i A A 5 11 MIPMAIP INS gt a Y 9 8 X U rr 5 12 MIPM OO2 1M IO ra sa k r 9E Wo de HG 5 3 Introduction to Permanent MagnetDCMotors 5 14 0060072 uw 5 x d 8 AAA 5 4 POI FACO 4x uw d ELA a 5 4 Enclosure and Electrical Insulation Systems 00000 5 15 Permanent Magnets 2 2 2 a a 5 15 BIUS 2 ene BR 2 9 gt 3 5 16 Power Supply s vr r rar EE asas 5 17 DC MOIOF FD c s gt
9. ces codes Vous devez tout le moins respecter toutes les sections applicables du Code national de pr vention des incendies du Code national de l lectricit et des codes de la National Electrical Manufacturer s Association NEMA Des organismes de r glementation ou des services gouvernementaux locaux peuvent galement vous aider d terminer les codes ainsi que les normes respecter pour assurer une installation et un fonctionnement s rs L omission de respecter la totalit des codes et des normes applicables peut entrainer des dommages l quipement ou causer de graves blessures au personnel Nous ne garantissons pas que les produits d crits dans cette publication conviennent votre application particuli re et nous n assumons aucune responsabilit a l gard de la conception de l installation ou du fonctionnement de votre produit Nos produits ne sont pas insensibles aux d faillances et ne sont ni con us ni fabriqu s pour l utilisation ou la revente en tant qu quipement de commande en ligne dans des environnements dangereux n cessitant une s curit absolue par exemple l exploitation d installations nucl aires les syst mes de navigation a rienne ou de communication le contr le de la circulation a rienne les quipements de survie ou les syst mes d armes pour lesquels la d faillance du produit peut provoquer la mort des blessures corporelles ou de graves dommages mat riels ou en
10. d signations Copyright 2007 2008 2009 2011 2012 2014 Automationdirect com Incorporated Tous droits r serv s Nulle partie de ce manuel ne doit tre copi e reproduite ou transmise de quelque fa on que ce soit sans le consentement pr alable crit de la soci t Automationdirect com Incorporated AutomationDirect conserve les droits exclusifs l gard de tous les renseignements contenus dans le pr sent document ISTORY H Please include the Manual Number and the Manual Issue both shown below when communicating with Technical Support regarding this publication REVISION HISTORY Manual Number IH USER DC M WO Issue Second Edition Issue Date 03 04 2014 Publication History Issue Date Description of Changes First Edition 02 2010 Original Issue 1st Ed Rev A 06 2011 Chapter 4 Added accessory brush part MTPM BRUSH 3 1st Ed Rev B 08 2012 Chapter 5 Added motor performance curves and data Second Edition 03 2014 Added new small frame PMDC motors IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 Page 1 Revision History VAUTOMATIONDIRECTE Aa Page H 2 IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 TABLE OF CONTENTS CHAPTER 1 GETTING STARTED Manual Overview Overview of this Publication 2 20 2 ee eee Who Should Read This Manual 2 2 2 2 2 4 s a a a aa Technical
11. driven gear pitch circles Incorrectly balanced drive or driven machine components Re balance drive and or driven components Motor runs rough when uncoupled Bearing damage See Bearing Problems troubleshooting table Mounting bolts are loose Re tighten and lock mounting bolts Fitted drive components coupling or pulleys affecting rotor balance Balance rotor with coupling or pulley fitted Problem Scratching rubbing or rumbling noise from bearing Possible Causes Bearing is defective Solutions Replace bearing Whistling noise from bearing Bearing has run dry Replace bearing Faulty cage Replace bearing Excessive bearing wear Bearing overloaded Check alignment belt tension gear pressure coupling thrust Reduce bearing load If needed reduce additional axial load Scoring when motor is inoperative Bearing is being subjected to vibration from outside source Isolate motor from source of vibration or keep motor turning over Scoring when motor running Current leakage Remove motor from service Repair or replace motor Bearings in the small frame PMDC motors are not user replaceable replace motor instead of bearings IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 VAUTOMATIONDIRECTE Chapter 3 Maintenance and Troubleshooting jj TR
12. fixed shunt field excitation and adjustable armature voltage have an approximately constant torque capacity over their speed range as shown below 100 ym 100 80 _ 80 2 S 60 2 60 O D e 2 se 40 2 40 gt 20 20 O 2040 60 80100 O 2040 60 80100 Speed Speed Page 5 18 IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 VAUTOMATIONDIRECTE Chapter 5 Reference HIGH TEMPERATURE CONSIDERATIONS Overload 1s only one cause of over temperature problems High ambient temperatures or improper cleaning of filters on the machine itself contribute to short service life by increasing operating temperatures This in turn causes abnormally high differential expansion stress resulting in cracks in the insulation which usually propagate through to the bare conductor opening the circuit to contamination failure In addition the commonly known effect is the more rapid degradation of the insulation materials which shrink and harden then gradually lose both strength and insulating characteristics Ambient temperatures greater than 40 C are also harmful to grease cables brushes and commutation CONTAMINATION CONSIDERATIONS Nonconducting contaminants such as factory dust and sand gradually promote over temperature by restricting cooling air circulation In addition these may erode the insulation and the varnish gradually reducing their effectiveness Conducting contaminants such as metal
13. shunt motors A wound armature and commutator brushes complete the motor Permanent magnets supply the field flux eliminating the need for external field current This design yields a smaller lighter energy efficient motor The PMDC motor s field has a high reluctance low permeability that eliminates significant armature interaction High reluctance yields a constant field permitting linear operation over the motor s entire speed torgue range In operation with a constant armature voltage as speed decreases available torque increases As armature voltage increases the linear speed torgue curves shift upwards Thus a series of parallel speed torgue curves for different armature voltages represents the speed torgue properties of a PMDC motor Speed is proportional to voltage and torque 1s proportional to current FORM FACTOR Page 5 14 The voltage used to power a PMDC motor is not a pure DC It is derived DC voltage by rectifying an AC voltage Thus the DC voltage has a ripple component related to the frequency of the AC input Form factor is the ratio of lms to 166 and indicates how close the driving voltage is to pure DC Form factor for a pure DC source such as a battery 1s 1 0 The higher the form factor is above 1 0 the more 1t deviates from pure DC The table here shows typical form factors for common voltage sources Form Factor DC Voltage Source 1 0 Battery Pure DC 1 05 Pulse Width Modulation PWM u F
14. supply such as a battery or a generator High frequency PWM power supplies will approach NEMA power code A NEMA POWER CODES C AND D This power supply 1s close to being pure and consists of six silicon controlled rectifiers SCRS connected in a three phase full wave bridge configuration NEMA POWER CODE E This power supply has average quality and consists of three controlled rectifiers SCRS connected in a three phase halfwave bridge configuration Most DC motors will require some derating when used on this type of power supply NEMA POWER CODE K This power supply has limited applications and consists of two controlled rectifiers SCRs and two diode style rectifiers connected in a single phase full wave bridge configuration A freewheeling rectifier may be used across the motor armature terminals This type of power supply 1s normally used for motors rated up to 7 1 2 HP Ironhorse MTPM series motors are rated for use with Code K DC power supplies SINGLE PHASE POWER SUPPLY CONSIDERATIONS This type of power supply is limited to motors fractional through 7 1 2hp Drive application is limited due to simplicity of power supply IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 Page 5 17 Chapter 5 Reference YAUTOMATIONDIRECTE DC MOTOR TYPES There are four kinds of DC motors commonly used in industrial applications shunt series compound wound or stabilized shunt and permanent magn
15. 1 5 Chapter 1 Getting Started VAUTOMATIONDIRECTE e RESHIPPING If an IronHorse motor needs to be reshipped from the initial shipping point the following procedures should be followed to protect the motor from damage 1 Ifthe original packaging is to be used for reshipment inspect the packaging for previous shipping damage and repackage if necessary Take care to protect the motor body fan cover and shaft 2 Itis a good idea to bolt or strap the motor to a platform that fits securely in the bottom of the shipping crate or box This helps prevent the motor from shifting during transport and thus protects the bearings from damage LONG TERM STORAGE The following preventative measures should be taken when storing IronHorse motors for a long period of time 1 Store motors in a controller temperature dry atmosphere free of excess dirt dust and airborne particles 2 Rotate the motor shaft every sixty days to prevent hardening of the bearing grease WARRANTY IronHorse 56C frame PMDC motors carry a two year warranty from the date of invoice and the small frame PMDC motors carry our standard one year warranty Page 1 6 IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 MOUNTING AND INITIAL STARTUP TABLE OF CONTENTS Safety Information 2 2 DE 1650 a s a g gt CE eee Pete ss Wiring Notes PLEASE READ PRIOR TO INSTALLATION 2 2 Applicable Codes 2 2 2 1
16. 5 18 Load Considerations JS a 4 4 4 a a a a 5 18 High Temperature Considerations 2 2 2 2 2 aa aa ll ll 5 19 Contamination Considerations 2 2 va a a aa 5 19 Vibration Considerations 2 2 av a a 4 4 a a aa 5 19 Altitude Considerations JJ a 5 19 Ambient Temperature 2 r r e 5 20 IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 Page 1 Chapter 5 Reference VAUTOMATIONDIRECTE a JUNCTION BOX DIMENSIONS FOR 56C FRAME MOTORS XC XD Length N y Width AA Conduit Hole lt HH Depth Diameter ru F Junction Box Dimensions Frame Size XD Width XC Length HH Depth AA Conduit Hole NPT 56 2 5 in 2 76 in 1 55 in 1 2 in SHIPPING CRATE DIMENSIONS FOR 56C FRAME MOTORS Nominal Shipping Crate Dimensions Frame Size Width x Depth x Height in 13 2x7 5x8 5 15 2x7 5x8 5 15 9x7 5x8 5 181x7 5x8 5 18 7x9 8x10 6 Motor and shipping weights are listed in the Motor Specifications tables in Chapter 1 Getting Started DECIBEL LEVELS FOR 56C FRAME MOTORS The decibel sound level of an IronHorse PMDC motor should be measured after initial startup after 30 days and after six months of use Decibel levels should remain fairly consistent and can be an indication of misalignment and premature bearing wear Ifthe measured decibel level for your IronHorse model exceeds the value listed below by mor
17. E O 4 EE O Performance Data MTPM P75 1M18 Description No Load Rated Max Eff Max Pout Max Torque End Page 5 10 IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 VAUTOMATIONDIRECT Chapter 5 Reference _ _ _ _ _ _n__ _ _ _ _ __ ___n _ _ _ _ __ _ _ _ _ _ _ Y PERFORMANCE CURVES CONTINUED 1 L r2 IL EFF ur W A rm te 1500 1500 Br 30007 ppm a a pp i i 1 P se 1350 7 1350 2 2700 kj inia de m UL ym 1 i i I i i i n PUL 200 6 47 2400 p p r re TN i l i af I p T Let i i i i i i i i CNE CANH I IRANI as ir mm mm m i 0 i i i i mr a 1 gii TER 1 Fal Hh HH per I i i i i i i i 1 600 00 X2 1200 la i 450 mor 4t 90 MAH RAE Dy pap i i i i 3 i 200 300 Lat id tu sd a i Ar Sa i i i i 1564 1504 Ost 300 pp i i i i 0 i 0 0 i l 0 051 2 L 2 4 3 36424354 6 M N m Performance Data MTPM 001 1M18 Description No Load Rated Max Eff Max Pout Ma
18. EMOVING THE BRUSH COVER Motor has two brushes one on each side of the motor Always replace the brushes in pairs 1 Remove the brush cover using a flathead screwdriver as shown Turn the brush cover counterclockwise to remove 2 Carefully remove the old brush and spring assembly and install the replacement 3 Reinstall the brush cover turning clockwise 4 Replace the other motor brush and spring following the same steps IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 Page 3 3 Chapter 3 Maintenance and Troubleshooting TROUBLESHOOTING To prevent serious damage faults observed when a motor first goes into service or during subsequent operation should be investigated and repaired immediately These troubleshooting tables cover most common PMDC motor problems A Page 3 4 WARNING EQUIPMENT YOUR MOTOR WAUTOMATIONDIRECT TO PREVENT SERIOUS PERSONAL INJURY AND DAMAGE TO YOUR ALWAYS DISCONNECT INPUT POWER BEFORE INSPECTING OR REPAIRING Problem Possible Causes Solutions Motor vibrates or runs noisily when coupled up but runs okay when uncoupled Defective transmission components or problem with the machine being driven Inspect transmission and drive components Check alignment Foundation has become unlevel Realign machine set Check and repair foundation level Problem with gear drive Align drive check driving and
19. Edition 03 04 2014 Page 2 5 Chapter 2 Mounting and Initial Startup VAUTOMATIONDIRECTE i PROPER INSTALLATION CONDITIONS SMALL FRAME MOTORS IronHorse small frame motors should be properly mounted to prevent premature motor and or bearing failure There are no limitations on mounting orientation that is the motor can be installed vertically horizontally upside down or at any angle Use proper diameter bolts of the highest grade material available for the application as shown on the dimension diagrams A mounted motor must operate vibration free Each motor installation should be checked for potential vibration situations 56C FRAME MOTORS Care should be taken to make sure that an IronHorse 56C frame motor is mounted at least thirty inches from a wall or structure that would prevent proper ventilation of the motor The installation area should be free of dust and smoke particles Any air contaminate could inhibit proper operation of the motor fan If an IronHorse motor is to be installed in a high altitude or in a low temperature location use the Altitude Ambient Temperature Derating chart below for proper motor sizing Altitude Meters Feet Above Sea Level 1000 1500 2000 2500 3000 3500 4000 3281 4921 6562 8202 9842 11 483 13 123 10 50 1 50 15 59 0 99 20 68 0 93 25 77 0 88 30 86 0 82 40 104 0 72 o e D 3 de S o Q S la 50 122 0 62 60 140 0 52 Examp
20. M BRUSH 1 e 0 33 1 Brushes with 180 VDC MTPM BRUSH 2 springs 180 VDC 1 5 2 hp one set of 2 MTPM BRUSH 3 90 VDC 1 5 hp Resin class Graphite MTPM BRUSH 4 IronHorse 1 4 24VDC MTPM 12 24 VDC Copper Graphite 1 10 1 6 24VDC MTPM BRUSH 5 Brushes vvith springs and MTPM BRUSH 6 Caps one set of 2 90VDC 1 8 1 7 90VDC 180VDC 1 8 1 7 Q 180VDC 90VDC 1 31 1 19 90VDC 180VDC 1 15 Q 180VDC All IronHorse DC motors ship with one set of brushes installed Carbon Graphite MTPM BRUSH 7 All IronHorse 56C frame DC motors ship with one set of brushes installed and one extra set in the box SPARE REPLACEMENT PARTS KIT FOR SMALL FRAME DC MOTORS Part Number Description For Motors MTPM DC motor spare parts kit for certain MTPM series permanent magnet DC motors as listed Includes two metal brush cap covers one terminal box one 1 8 0 125 inch shaft key and one 3 16 0 187 inch shaft key PO5 1L19 P13 1L19 P14 1L19 P17 1JK43 P25 1JK40 P25 1JK44 Pxx 1Mxx MTGA KIT 1 MTGA KIT 1 includes spare replacement parts only All parts in the kit are included with the applicable motors IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 Page 4 3 Chapter 4 Accessories VAUTOMATIONDIRECTE EMM Page 4 4 IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 REFERENCE TABLE OF
21. NDED BRUSHES INCLUDING RESIN CLASS GRAPHITE CARBON GRAPHITE BRUSHES The raw material is graphite bonded with resin which is pressed and heat treated in a special process The advantage of special graphite brushes is their high contact drop and low internal resistance They also have good oxidation resistance These properties are very valuable for machines with high commutating requirements The main field of application for special graphite brushes covers machines with high commutating requirements but with relatively low brush current These include small PMDC motors Other factors also affect brush life and performance including temperature humidity altitude spring pressure control form factor size and duty cycle If spring pressure is too low excessive electrical wear may occur If it is too high excessive mechanical wear may occur The optimal spring pressure range for minimal wear 1s between the high electrical and mechanical wear regions Low humidity high temperature or high altitude environments may not have enough moisture present to form the necessary lubricating film between brush and commutator bar Special lubricant impregnated brushes can correct the problem Under light load conditions the low current draw can cause poor lubrication of the commutator Smutting of the commutator and uneven commutation often result IRONHORSE PMDC BRUSHES HAVE BEEN SPECIFICALLY MANUFACTURED FOR OPTIMAL PERFORMANCE WITH THE IRONHORSE
22. ONTINUED DIMENSIONS in mm 56C FRAME TENV DC MOTOR 0 33 TO 0 5 HP DIMENSIONS 0 19 4 76 SQ KEY 1 38 34 9 LONG 64 5 0 34SLOT 7 8 6 62 0 62 0 8 0 203 2 0 33 HP 90VDC 1800RPM 8 0 203 2 0 33 HP 180VDC 1800RPM 8 88 225 5 0 50 HP 90 00 1800RPM 8 88 225 5 0 50 HP 180VDC 1800RPM gt gt gt gt 56C FRAME TEFC DC MOTOR 0 75 TO 1 5 HP DIMENSIONS 2 06 A 52 4 1 88 0 19 4 76 sa key 47 8 1 38 34 9 LONG m a o 2 gj Rj 3 0 34 SLOT a 8 6 2 75 3 0 69 9 76 3 62 0 62 0 680 Ul A 11 45 290 8 75 HP 90VDC 1800RPM A 11 45 290 8 5 HP 180VDC 1800RPM A 12 24 311 0 1 HP 90VDC 1800RPM A 12 24 311 0 1 HP 180VDC 1800RPM A 14 39 365 5 1 5 HP 90VDC 1800RPM A 14 39 365 5 1 5 HP 180VDC 1800RPM 56C FRAME TEFC DC MOTOR 2HP DIMENSIONS 2 06 14 75 alt S ev uo s E 5 olo Old m amp 5 o 13 4X 3 8 16 TAP 2 44 2 44 62 0 62 0 0 19 4 76 SQ KEY 2 75 2 75 1 38 34 9 LONG 69 8 69 8 Page 2 4 IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 VAUTOMATIONDIRECTE Chapter 2 Mounting and Initial Startup TERMINAL DIAGRAM AND VYIRING DC motors are very easy to wire There are only two terminals one for the positive red lead and one for the negative black l
23. OUBLESHOOTING CONTINUED Problem Possible Causes Solutions Motor shaft rotates in wrong direction should rotate clockwise when facing shaft Positive and negative input power leads are Switch the input power connections reversed Break in the armature supply Check and repair connection Fuse is blown Replace fuse Controller damaged or Check starter for break in circuit and repair break incorrectly connected Motor fails to start off load Armature coils burned out or Correct short circuit This may require bringing the short circuiting motor to a repair shop Brushes not bearing down Check brush position and bearing pressure correctly Replace worn brushes Break in starter circuit Repair break Correct short circuit This may require bringing the Jerky starting Armature short circuit motor to a repair shop Commutator short circuit Check commutator and repair short circuit Short circuit in the supply Locate short circuit and repair Motor will not run under load Overloading Check current input and remedy overload Voltage drop Increase supply line cross section Decrease IR compensation Controller Check speed potentiometer wiring and signal and repair if needed Motor overspeeding and hunting while under load Check voltage and current levels and correct Overloading A B overload condition Insufficient airflow Improve co
24. Support 2 2 2 2 eee eee ca ca on Special Symbols 2 4 4 s r Receiving and Inspection Unpacking 2 2 2 2 2 2 2 a oh a Available Models IronHorse Motors Part Number Information 2 2 Permanent Magnet DC Motors Features and Specifications Reshipping Long Term Storage Warranty CHAPTER 2 MOUNTING AND INITIAL STARTUP Safety Information Danger Wiring Notes PLEASE READ PRIOR TO INSTALLATION Applicable Codes 2 2 Motor Dimensions Terminal Diagram and Wiring Motor Mounting STABLE Slide Bases a a a a a a a Proper Installation Conditions a Coupling Alignment 2 22 ae a a a a a on Motor Nameplate and Starter Information Typical IronHorse Motor Nameplate 2 2 eee ee es Motor Control Information 2 aa a a a a te Inspection Before Startup Initial Startup Inspection IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 ha tha K l O 2 rm c un ral A l l l Fr hu o O NS WBWW NHN NNNN Ny TOC 1 Table of Contents WAUTOMATIONDIRECT TF CHAPTER 3 MAINTENANCE AND TROUBLESHOOTING Routine Maintenance JI a a aa o o a a 3 2 Bearing Size Information Jc Replacing Brushes 2 aa a 33 Troubleshooting 4 JJ 4 CHAPTER 4 ACCESSORIES STABLE
25. WVAUTOMATIONDIRECT IRONHORSE General Purpose DC Motors Manual Number IH USER DC M WO BLANK PAGE Thank you for purchasing automation equipment from Automationdirect com doing business as AutomationDirect We want your new automation equipment to operate safely Anyone who installs or uses this equipment should read this publication and any other relevant publications before installing or operating the equipment To minimize the risk of potential safety problems you should follow all applicable local and national codes that regulate the installation and operation of your equipment These codes vary from area to area and usually change with time It 1s your responsibility to determine which codes should be followed and to verify that the equipment installation and operation 1s in compliance with the latest revision of these codes At a minimum you should follow all applicable sections of the National Fire Code National Electrical Code and the codes of the National Electrical Manufacturer s Association NEMA There may be local regulatory or government offices that can also help determine which codes and standards are necessary for safe installation and operation Equipment damage or serious injury to personnel can result from the failure to follow all applicable codes and standards We do not guarantee the products described in this publication are suitable for your particular application nor do we assume any responsi
26. any names may be trademarked and are the sole property of their respective owners AutomationDirect disclaims any proprietary interest in the marks and names of others Copyright 2007 2008 2009 2011 2012 2014 Automationdirect com Incorporated All Rights Reserved No part of this manual shall be copied reproduced or transmitted in any way without the prior written consent of Automationdirect com Incorporated AutomationDirect retains the exclusive rights to all information included in this document AVERTISSEMENT Nous vous remercions d avoir achet l quipement d automatisation de Automationdirect com en faisant des affaires comme AutomationDirect Nous tenons a ce que votre nouvel quipement d automatisation fonctionne en toute s curit Toute personne qui installe ou utilise cet quipement doit lire la pr sente publication et toutes les autres publications pertinentes avant de l installer ou de l utiliser Afin de r duire au minimum le risque d ventuels probl mes de s curit vous devez respecter tous les codes locaux et nationaux applicables r gissant l installation et le fonctionnement de votre quipement Ces codes diff rent d une r gion l autre et habituellement voluent au fil du temps Il vous incombe de d terminer les codes respecter et de vous assurer que l quipement l installation et le fonctionnement sont conformes aux exigences de la version la plus r cente de
27. ation has on the conductor itself resulting in an open circuit by conduction or cracking Commutation problems may arise because of brush bouncing Continued severe vibration fatigues metals and could cause failure 1n casting or bearings ALTITUDE CONSIDERATIONS Standard motor ratings are based on operation at any altitude up to 3300 feet 1000 meters All altitudes up to and including 3300 feet are considered to be the same as sea level High altitude derating is required because of lower air density which requires a greater amount of cooling DC motors are derated by 3 per 1000 feet above the 3300 feet In some cases a blower will be sufficient to cool the motor instead of using a larger frame motor IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 Page 5 19 Chapter 5 Reference VAUTOMATIONDIRECTE TF AMBIENT TEMPERATURE Page 5 20 Motors for use in abnormally hot places are usually designed to accommodate the higher ambient by having a lower winding temperature rise If the ambient temperature is above 50 C special consideration must also be made of the lubricant Although 1t s possible to operate in ambients above 50 C application should be referred to the manufacturer to determine what steps must be taken In general the simplest method of derating for high ambient temperatures 1s to derate the horsepower rating of the motor In this way the armature will operate at reduced current For a
28. ax Eff Max Pout Max Torque End IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 Page 5 7 Chapter 5 Reference WAUTOMATIONDIRECT mm PERFORMANCE CURVES CONTINUED Page 5 8 MTPM P33 1M18 PI IN IV XXI BU HN 150 Pl 100 7004 350 dy 300 Spor 25 di 200 AO E 20r 100 Lik Ri 0 ol Description pu m Tr Ar ni No Load Rated Max Eff Max Pout Max Torque End A Fi al n EFF rpm Ur 400M i Sii HI AMI 28004 BIN Performance Data MTPM P33 1M18 IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 VAUTOMATIONDIRECT MTPM P50 1M18 1 tae B TUO Description No Load Rated Max Eff Max Pout Max Torque End LA Chapter 5 Reference DDR PERFORMANCE CURVES CONTINUED H EFF rpa Li LE HI omm m id im rims m jr am O UR m ee TH dd mm a a mm Bn OU mu mm om e m amm m e e n Performance Data MTPM P50 1M18 IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 Page 5 9 Chapter 5 Reference VAUTOMATIONDIRECTE mm PERFORMANCE CURVES CONTINUED MTPM P75 1M18 Pi pea EF iki SSS Fm dh AA E
29. bility for your product design installation or operation Our products are not fault tolerant and are not designed manufactured or intended for use or resale as on line control equipment in hazardous environments requiring fail safe performance such as in the operation of nuclear facilities aircraft navigation or communication systems air traffic control direct life support machines or weapons systems in which the failure of the product could lead directly to death personal injury or severe physical or environmental damage High Risk Activities AutomationDirect specifically disclaims any expressed or implied warranty of fitness for High Risk Activities For additional warranty and safety information see the Terms and Conditions section of our catalog If you have any questions concerning the installation or operation of this equipment or if you need additional information please call us at 770 844 4200 This publication is based on information that was available at the time it was printed At AutomationDirect we constantly strive to improve our products and services so we reserve the right to make changes to the products and or publications at any time without notice and without any obligation This publication may also discuss features that may not be available in certain revisions of the product TRADEMARKS This publication may contain references to products produced and or offered by other companies The product and comp
30. corresponds with the part number on your order e For all 56C frame motors make sure that the shipment contains the motor with attached removable mounting foot and two spare brushes Motor Nameplate Extra set of brushes nm Mounting foot 56C motors only not available on all models Page 1 2 IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 VAUTOMATIONDIRECT Chapter 1 Getting Started AVAILABLE MODELS IRONHORSE MOTORS PART NUMBER INFORMATION MT PM 105 1 M 18 PERMANENT MAGNET DC MOTORS FEATURES AND SPECIFICATIONS SMALL FRAME PERMANENT MAGNET DC PMDC Morons IronHorse small frame PMDC motors are available from 1 31 hp to 1 4 hp All models have a TENV rolled steel frame Motors have easy access brushes L Optional Identifier CK C face cast iron motor Nominal RPM Two digits representing 100s of rpm Voltage Class multiple letters possible 115 VAC 208 230 VAC 460 VAC 12 VDC 24 VDC 90 VDC M 180 VDC Phase 1 Single phase 3 Three phase Rated Horsepower P Decimal point left of P Rated full hp FACOUW gt right of P Rated fractional hp expressed as decimal Motor type A Motor accessory C AC Motor with cast iron frame R AC Motor with rolled steel frame PM DC Permanent magnet IronHorse Motors Series Designation SMALL FRAME PMDC MOTOR SPECIFICATIONS Part Number Voltage VDC F L Current A Ove
31. d Rated Max Eff Max Pout Max Torque End Page 5 6 IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 VAUTOMATIONDIRECTE Chapter 5 Reference _ Y PERFORMANCE CURVES CONTINUED MTPM 1P5 1L18 v Fi d i H Lad mim 1 ARR ii 1 Emi i i a p I ga al I i i i i 1 T i T lg 2 i E j 1 E z i 4 i 14 F F r i ALA SAT i E E i 4 1 i 1 5 1 SHU L Ur d zo Lr 1 _ gt is MAI u i LU 1 i i i Wr ae i i I 7 I i F ESF H E i z z z E DT EDN IT ZARI l i i i i i i i i L i i i i i il a T i p ka i Ra h EM E i i j I i i si i i i i i i 1 i i i i Ea y a E i ae F I i E i i i i iM gt i t j 1 a LLM mme i i i i at Kiki mm i i i i i i Se SE WM 1 ai OO e E i 1 i i i aT 12 13 5 15 N m Performance Data MTPM 1P5 1L18 Description No Load Rated M
32. d 60 C 1409F 3 Have the insulation checked periodically by an authorized motor specialist 4 Replace the motor brushes after every 2500 hours of operation BEARING SIZE INFORMATION Drive End Bearing SKF Opposite Drive End Frame Size Type Bearing SKF Type Small Frame not user serviceable 56C 6203 6203 All IronHorse 56C frame motors use premium sealed SKF brand bearings Page 3 2 IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 VAUTOMATIONDIRECTE Chapter 3 Maintenance and Troubleshooting REPLACING BRUSHES NARNING TO PREVENT SERIOUS PERSONAL INJURY AND DAMAGE TO YOUR EQUIPMENT ALWAYS DISCONNECT INPUT POWER BEFORE REPLACING BRUSHES A spare set of brushes ship in each 56C frame PMDC motor box and the brushes should be replaced after every 2500 hours of operation Small frame PMDC motor brushes should be replaced as needed If you visually inspect the brushes the minimum acceptable length 1s 6mm See Chapter 4 Accessories for replacement brush ordering information Make sure you install the correct replacement brushes check the part numbers carefully Ensure that the replacement brushes are the same width as the brushes being removed from the motor DO NOT install smaller brushes in a larger motor There is no break in period with new brushes Replacement brush and spring assembly sets nd Pis NOTE HE BRUSHES ARE SPRING LOADED BE CAREFUL WHEN R
33. dust carborundum carbon and salt in addition to promoting over temperature also provide immediate conducting paths for shorting or grounding leakage currents wherever the electrical circuit is contacted Normal differential expansion rotational stresses and thermal expansion of trapped air in voids within the insulation system eventually open the insulated circuit at unpredictable locations Depending on the severity of the operating voltage service life may be measured in years months days or hours Oil deposits promote easy adhesion of contaminants to the internal insulated and exposed un insulated surfaces to promote early service life problems Water from splashing or condensation seriously degrades an insulation system The water alone 1s conducting Nonconducting contaminants are readily converted into leakage current conductors Intermittent or occasional wetness ultimately causes service failure because successive leakage situations gradually deposit a permanent path for continuation of the damaging shorting or grounding currents VIBRATION CONSIDERATIONS High vibration promotes service life problems by subjecting the shaft to stress which finally results in actual shorting of conductors between turns or between layers In addition the severe stress causes fissures and cracks in the conductor insulation exposing the electrical circuit to contamination failure Another important factor 1s the work hardening effect that this vibr
34. e than 10 contact AutomationDirect or a local motor service technician found at www easa com Average Decibel Levels Frame Size HP Noise Level Lw dB A 56 All 55 0 Page 5 2 IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 WAUTOMATIONDIRECT In PERFORMANCE CURVES FOR 56C FRAME MOTORS MTPM P33 1L18 Pi P2 I ivl L XXI 1 ini di Fo 600 150 ML 135 aO BOF 400 15 S Lh Description Chapter 5 Reference li Ef rpm E Ki p gt pa SS mD I i i i i 3600 i i BIH Performance Data MTPM P33 1L18 No Load Rated Max Eff Max Pout Max Torque End IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 Page 5 3 Chapter 5 Reference VAUTOMATIONDIRECTE aaaaaaaaaaaaaaaaauauaauauauauauauauauululualalaiasasssssssssst PERFORMANCE CURVES CONTINUED MTPM P50 1L18 Page 4 2 ti E 1g i Al rie ihe RR XX EH m ln cary KER O0 EMI TEE A AA AAA A gt v n i i 120014 20 HX TN m mm Sh TI ii i i i i M x Tr y 41 A j y 3 iUum um s n Eee E E 1 L 5 A i I p i i i i mm mr
35. ead If wired correctly the motor will turn clockwise when you are facing the motor shaft If the motor turns counterclockwise reverse the positive and negative leads NOTE THESE MOTORS DO NOT HAVE CONNECTORS FOR INSTALLING ENCODERS OR TACHOMETERS MOTOR MOUNTING IronHorse motors should be properly mounted to prevent premature motor and or bearing failure There are no limitations on mounting orientation that is the motor can be installed vertically horizontally upside down or at any angle When necessary use motor shims to level the motor at all mounting bolt holes Use proper diameter bolts of the highest grade material available for the application Use the chart below to select the correct size bolt for each frame size A mounted motor must operate vibration free Each motor installation should be checked for potential vibration situations Base shims should also be used when necessary for level mounting Bolt Minimum Usable Minimum Exposed Diameter Thread Length A Anchor Length B Face mounting only no mounting feet 5 16 in STABLE SLIDE BASES AutomationDirect offers STABLE slide bases for simple mounting of NEMA standard frame motors STABLE slide bases are manufactured from heavy duty steel and allow motor position adjustment when mounting any NEMA framed motor See Chapter 4 Accessories for complete details IronHorse General Purpose DC Motors User Manual 2nd
36. et Ironhorse MTPM series motors are permanent magnet DC motors PERMANENT MAGNET MOTORS Permanent magnet motors are generally used where response time 1s a factor They are built with a conventional type of armature but have permanent magnets in the field section rather than windings Permanent magnet motors are considered less expensive to operate as they require no field supply Magnet Maximum q Rated Permissible Torque Torque 150 100 a Magnet Rated Speed CONTROLLING SPEED The method of controlling the speed of a PM direct current motor is armature voltage control ARMATURE VOLTAGE CONTROL For this type of speed control the armature voltage is varied The output torque of a DC motor is proportional to the product of the main pole flux armature current and a machine constant which is a function of armature windings With armature voltage speed control the torque is dependent upon the armature current only that 1s at rated armature current the torque 1s constant A DC motor operated with armature voltage control and fixed field excitation will develop rated torque at rated armature current independent of the speed This is commonly called constant torque operation LOAD CONSIDERATIONS CONSTANT TORQUE Many industrial applications such as conveyors mixers squeeze rolls continuous processing machinery etc require nearly constant torque over their operating speed range Direct current motors operated with
37. le I hp 60 C and 2000 meters 1 0 64 1 56 hp The motor should be a 2hp motor COUPLING ALIGNMENT Correct coupling alignment is very important to the life of the motor Coupling misalignment is the major cause of motor bearing failure In belt driven applications pulleys should be installed correctly Belt tension alignment and wear should be checked at installation and at regular maintenance intervals Install motor couplings per the manufacturers instructions Whenever possible direct couple or flange mount IronHorse motors in their application Doing so can greatly extend the bearing life Page 2 6 IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 VAUTOMATIONDIRECTE Chapter 2 Mounting and Initial Startup MoTOR NAMEPLATE AND STARTER INFORMATION TYPICAL IRONHORSE MOTOR NAMEPLATE SMALL FRAME MOTOR NAMEPLATE 56C FRAME MOTOR NAMEPLATE AN 6 2N GENERAL PURPOSE 322 d 1 n A onm aa F 5 E365956 250724 DAY PMDC MOTOR CE SP IRONHORSE WWW AUTOMATIONDIRECT COM c us Automatlorbirect com Made in USA SER NO PM DC Motor HPC RPM RCE MIPM P UIR V ARM ALARM INSCL gt i l 17 74 Forn Factor 1 05 apre 5i p leo f F ENCL mc E AMB Speed 7732 3996 Amb 40 C Max mm J S FLA 14 20 122 SF 1 0 PF IRONHORSE Torque 96 BO in orz amp Eni TENV Date Code 0414 TO FEE MOTOR CONTROL INFORMATION Frame Size Number of Inte
38. mbients lower than 40 C a standard 40 C machine is normally used at rated load In the case when the ambient is maintained well below 40 C a standard ambient motor may be used at overload provided the following factors are Known 1 The ambient is known always to be low 2 Shaft stresses bearing loading and commutation are approved by the factory 3 Overload protection for the motor from an over load or stalled condition is available and used Operation of motors in ambients below 0 C results in severe duty on the machine component parts Of major concern are the lubrication system and the insulation system IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014
39. n for any unusual bearing noise in the drive end and opposite drive end of the motor Abnormal bearing noise can be an indication of a defective bearing Ironhorse PMDC motors have sealed bearings IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 Page 7 Chapter 2 Mounting and Initial Startup VAUTOMATIONDIRECTE E Page 2 8 IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 MAINTENANCE AND TROUBLESHOOTING TABLE OF CONTENTS Routine Maintenance 2 2 2 2 Bearing Size Information a a a a ga e Replacing Brushes 1 2 2 2 4 4 I I I I I I ca ca ca ca ca Troubleshooting 2 4 4 4 4 4 4 4 a 222 IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 Page 3 1 Chapter 3 Maintenance and Troubleshooting VAUTOMATIONDIRECTE ee ROUTINE MAINTENANCE A routine maintenance schedule should be developed for every IronHorse motor installation based on the individual application Motors installed m a harsh running environment should be serviced more frequently than those installed in a clean climate controlled area The following list should be used as a basis for creating the routine maintenance schedule 1 Clean the motor housing using a brush soft cloth or compressed air Remove any dirt and dust from the fan and fan cover vents 2 Frequently monitor the bearing temperature on the motor It should not excee
40. nts Refer to the technical data on the motor nameplate for electrical and performance data IronHorse 56C frame PMDC motors are CE compliant Page 2 2 IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 VAUTOMATIONDIRECTE Chapter 2 Mounting and Initial Startup MOTOR DIMENSIONS DIMENSIONS in mm SMALL FRAME TENV DC MOTORS WITH 0 3125 INCH SHAFT DIAMETER DIMENSIONS 18 00 457 2 OUT 1 54 39 0 OF YOKE 16 AWG RED amp BLACK BEARING COVER PLATE 4X 48 32 UNC 2B THRU ON A 6 2 445 B C PER CAST LOCATION 4X 48 32 UNC 2B X 0 38 MIN 6 019 X 82 X 82 0 19 6 PO3 1L18 P10 1JK34 4 44 112 8 4 19 106 4 P04 1L17 P13 1JK42 4 94 125 5 4 69 119 1 SMALL FRAME TENV DC MOTORS WITH 0 50 INCH SHAFT DIAMETER DIMENSIONS 6 00 152 4 OUT OF YOKE 16 AWG RED amp BLACK L1 61 00 625 4 KNOCKOUT ia 39 1 FULL FLAT 0 13 X 1 00 SQUARE KEY 92 02 0 47 651 4 124 1 ES 11 9 20 50 612 7 SHAFT BEARING COVER 4X 1 4 20 UNC 2B X PLATE 0 50 FULL THD 4X 1 4 20 UNC 2B THRU P05 1L19 PO7 1M24 P17 JK43 4 92 125 0 4 56 115 8 P13 1L19 P13 1M19 P25 1JK40 6 92 175 8 6 46 164 1 P14 1L19 P14 1M18 P25 1JK44 7 92 201 2 7 46 189 5 IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 Page 2 3 Chapter 2 Mounting and Initial Startup VAUTOMATIONDIRECTE MOTOR DIMENSIONS C
41. odds 5 2 28 32 30 MTPM 1P5 1M18 1 1 2 1 1 35 70 31 MTPM 002 1M18 2 9 8 61 95 65 Note Please review the AutomationDirect Terms amp Conditions for warranty and service on this product ROLLED STEEL 56C FRAME PMDC PERFORMANCE DATA Ball Bearings DE ODE Armature Voltage VDC Armature Resistance O DC Power Form Factor Ambient Temp C F Insulation Class Mounting Wire Housing Constant Torque Speed Range Overall Speed Base Type Paint Color Efficiency MTPM P33 1L18 1 3 MTPM P50 1L18 1 2 MTPM P75 1L18 3 4 0 36 MTPM 001 1L18 1 0 67 MTPM 1P5 1L18 1 1 2 1 45 MTPM P33 1M18 1 3 7 6 MTPM P50 1M18 1 2 5 25 MTPM P75 1M18 3 4 3 23 MTPM 001 1M18 1 2 63 MTPM 1P5 1M18 1 1 2 1 45 MTPM 002 1M18 2 1 45 Wee Ww 00 U Top Mounted Junction Box 90 1800 RPM 0 2000 RPM Rigid Removable For performance curves and additional data refer to Chapter 5 Reference See the discussion of Form Factor in the following section of this chapter Page 1 4 IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 VAUTOMATIONDIRECTE Chapter 1 Getting Started PERMANENT MAGNET DC MOTORS FEATURES AND SPECIFICATIONS CONTINUED FORM FACTOR The voltage normally used to p
42. oling conditions Motor overheating Cooling air temperature too high If TEFC model inspect the fan for damage Check windings and soldered connections Repair Armature winding short circuit la coils or windings IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 Page 3 5 Chapter 3 Maintenance and Troubleshooting VAUTOMATIONDIRECTE E Page 3 6 IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 CHAPTER ACCESSORIES TABLE OF CONTENTS STABLE Slide Bases Fy 42 Slide Base Selection aa a aa a a a a a a aaa 4 2 Slide Base Dimensions 2 2 I 4 2 Replacement Accessories 4 4 ns 3 IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 Page 4 1 Chapter 4 Accessories VAUTOMATIONDIRECTE STABLE SLIDE BASES AutomationDirect offers STABLE motor slide bases for mounting NEMA motor frame sizes from 56 to 449 These heavy duty steel bases are primed with an oven baked primer ready for painting The motor mounting bolts are welded to the exact motor foot pattern to prevent the bolts from spinning The motor position 1s adjustable along the long axis SLIDE BASE SELECTION Motor Slide Bases Part Number Fits Frame Type Shipping Weight Ib IronHorse Model MTPM xxx 1L18 MTA BASE W56 56 MTPM xxx 1M18 SLIDE BASE DIMENSIONS
43. ower a permanent magnet PM DC motor 1s not pure DC It is derived by rectifying a supplied AC voltage The resulting DC voltage has a ripple that 1s related to the frequency of the AC input as shown in the example below Current Fluctuations Cause Ripple Current Full Wave Rectification N ya ja a Single Phase AC Rectifier Circuit Rectified DC Form factor 1s the ratio of Lns to Idc and indicates how close the driving voltage is to pure DC The form factor for a DC battery is 1 0 The higher the form factor is above 1 0 the more it deviates from pure DC The Form Factor Table shows examples of commonly used voltages Form factor should not exceed 1 35 for continuous operation Half wave rectification is not recommended as it increases form factor Operating Ironhorse PMDC motors with DC voltages with form factors higher than 1 35 can result in premature brush failure and excessive motor heating DC voltage source Battery pure DC Pulse width modulation PWM Full wave rectification single phase Half wave rectification single phase All DC input IronHorse GSD series DC drives are 1 05 IronHorse AC input GSD5 DC drive is 1 05 Single phase full wave rectification is the most common form of DC drive in 0 33 2 hp range All AC input IronHorse GSD series DC drives are 1 35 or better Not Recommended IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 Page
44. rhung Load Ib Wiring Type Motor Weight MTPM P10 1JK43 12 24 4 83 MTPM P13 1JK42 12 24 5 39 85 flying leads MTPM P17 1JK43 12 24 7 54 MTPM P25 1JK40 12 24 14 3 12 2 MTPM P25 1JK44 12 24 18 1 11 9 junction box MTPM P03 1L18 MTPM P04 1L17 MTPM P05 1L19 MTPM P13 1L19 MTPM P14 1L19 0 39 0 46 0 68 1 4 1 61 MTPM P07 1M24 MTPM P13 1M19 MTPM P14 1M18 0 42 0 73 0 83 IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 junction box Page 1 3 Chapter 1 Getting Started WAUTOMATIONDIRECT ROLLED STEEL 56C FRAME PERMANENT MAGNET DC PMDC MOTORS IronHorse 56C frame PMDC motors are available from 1 3 hp to 2hp All models have a TEFC or TENV rolled steel frame cast aluminum end bell and removable mounting bases Motors have easy access brushes ROLLED STEEL 56C FRAME PMDC MOTOR SPECIFICATIONS Armature Service Motor Approx Ship Part Number HP VE Housing PR Weight Weight 7 Ib Ib MTPM P33 1L18 1 3 3 5 17 70 19 MTPM P50 1L18 1 2 5 2 20 74 22 MTPM P75 1L18 3 4 7 8 25 30 27 MTPM 001 1L18 1 10 4 28 36 30 MTPM 1P5 1L18 1 1 2 15 4 34 97 37 MTPM P33 1M18 1 3 1 75 17 60 19 MTPM P50 1M18 1 2 2 6 20 74 22 MTPM P75 1M18 3 4 3 9 25 58 27 MTPM 001 1M18 1
45. rnal Internal oe DC Motor Internal Leads Lead Size Lead Length 9 Type Small Frame 2 16 AVVG 6in vvith junction box 18 vvithout junction box 12 24 90 180 VDC Permanent Magnet 56C 10 2 16 AWG 6 in 90 180 VDC INSPECTION BEFORE STARTUP 1 2 3 4 5 Turn the shaft by hand and make sure the shaft turns freely Listen for any unusual noises and feel for any interruption in the shaft as it turns Perform a final check on the installation of all parts in the assembly Check the motor mounting bolts coupling belt drive C face mount alignment etc Verify all electrical connections for the motor and drive Make sure all terminal screws are tightened properly Make sure that all electrical components used in the installation are rated for the locked rotor amperage Make sure the motor is properly grounded Use the grounding lug provided in the motor terminal box INITIAL STARTUP INSPECTION 1 2 3 At initial startup monitor the start up voltage and the running voltage of the motor The full load voltage should never exceed the line voltage on the motor nameplate multiplied by the service factor of the motor Example 180 VDC x 1 00 180 VDC Check the full load running amperage of the motor The full load running amperage should not be more than the amount indicated on the motor nameplate Listen for any unusual noises at motor start up and in the first hour of operation Liste
46. ron Their characteristics include high energy and low susceptibility to demagnetization however the cost of these materials remains high IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 Page 5 15 Chapter 5 Reference VAUTOMATIONDIRECTE XO BRUSHES PMDC motors use a mechanical commutator to switch current to the armature winding Commutator bars connect to the armature windings Spring loaded brushes make mechanical contact with the commutator bars carrying the current to the armature The armature commutator and the brushes act as a rotary switch for energizing the windings The ideal brush offers low voltage loss negligible dust formation no arcing little commutator wear and generates little noise Commonly used brush materials include carbon and carbon graphite graphite electro graphitic and metal graphite The following table compares these brush materials Material Type Voltage Drop Current Capacity Limitations of Use Carbon Carbon Graphite High Low High Voltage Low Speed Fractional hp Only Natural Graphite Medium Medium Medium Speed High Voltage Electro Graphitic Medium High Medium to High Speed High Voltage Copper Graphite Low Low Low Voltage Low Speeds Silver Graphite Very Low Very Low Very Low Voltage Low Speeds PMDC motors use resin class graphite brushes which puts them in the category of carbon graphite brushes RESIN BO
47. s are connected between the power source and motor controller 3 Make sure that the leads are connected correctly and the motor is properly grounded Ground resistance should not exceed 0 10 4 Use ground leads that comply with AWG MCM standards and keep them as short as possible 5 Make sure that the power source is capable of supplying the correct voltage and required current to the motor 6 Do not attach or remove wiring when power is applied to the motor APPLICABLE CODES SMALL FRAME MOTORS All IronHorse small frame PMDC motors are UL recognized E365956 and CSA approved Therefore they comply with the requirements of the National Electrical Code NEC and the Canadian Electrical Code CEC Installations intended to meet the UL or CSA requirements must follow the instructions provided in the Wiring Notes as a minimum standard Follow all local codes that exceed UL or CSA requirements Refer to the technical data on the motor nameplate for electrical and performance data IronHorse small frame PMDC motors are RoHS compliant 56C FRAME MOTORS All IronHorse 56C frame PMDC motors are CSAys listed and therefore comply with the requirements of the National Electrical Code NEC and the Canadian Electrical Code CEC Installations intended to meet the CSA ys requirements must follow the instructions provided in the Wiring Notes as a minimum standard Follow all local codes that exceed CSAys requireme
48. stallation maintenance and use of all IronHorse General Purpose DC Motors WHO SHOULD READ THIS MANUAL This manual contains important information for those who will install maintain use and or resell any of the IronHorse motors TECHNICAL SUPPORT By Telephone 770 844 4200 Mon Fri 9 00 a m 6 00 p m E T On the Web support automationdirect com Our technical support group 1s glad to work with you in answering your questions If you cannot find the solution to your particular application or 1f for any reason you need additional technical assistance please call technical support at 770 844 4200 We are available weekdays from 9 00 a m to 6 00 p m Eastern Time We also encourage you to visit our web site where you can find technical and non technical information about our products and our company Visit us at www automationdirect com SPECIAL SYMBOLS WHEN YOU SEE THE NOTEPAD ICON IN THE LEFT HAND MARGIN THE PARAGRAPH TO ITS IMMEDIATE RIGHT WILL BE A SPECIAL NOTE WHEN YOU SEE THE EXCLAMATION MARK ICON IN THE LEFT HAND MARGIN THE PARAGRAPH A TO ITS IMMEDIATE RIGHT WILL BE A WARNING THIS INFORMATION COULD PREVENT INJURY LOSS OF PROPERTY OR EVEN DEATH IN EXTREME CASES RECEIVING AND INSPECTION UNPACKING After receiving an IronHorse motor please check for the following e Open the motor packaging and inspect for damage during shipment e Make sure the part number indicated on the motor nameplate
49. tions for PMDC motor selection include proper choice of enclosure and electrical insulation system If safety factors dictate a totally enclosed motor 1t may be non ventilated TENV or fan cooled TEFC Electrical insulation systems as shown 1s the following table are tested for 20 000 hours at a rated temperature without degradation as recognized by UL CSA BSI and VDE Subtract ambient temperatures usually 25 C or 40 C to determine allowable rise Class A 105 degrees C Class B Class F 130 degrees C 155 degrees C Class H PERMANENT MAGNETS 180 degrees C A number of magnetic materials are available for permanent magnets These include ceramic oriented ferrites rare earth permanent magnets and Alnico The following table compares common magnet materials Tvpe Cost Demagnetizing Resistance Energy Product Ceramic Oriented Ferrites Low Medium Low Samarium Cobalt High High High Neodymium Iron Boron High High High Ironhorse PMDC motors contain ceramic oriented ferrite magnets Ceramic oriented ferrites typically made with barium or strontium have become the material of choice in most PM motors replacing Alnico because of their greater resistance to demagnetization and low cost Rare earth magnets may allow a downsized PM motor or boost its power rating They include samariumcobalt and neodymium iron bo
50. ull Wave Rectification Single Phase FLOR Half Wave Rectification Single Phase All DC input IronHorse GSD series DC drives are 1 05 IronHorse AC input GSD5 DC drive is 1 05 Single phase full wave rectification is the most common form of DC drive in 0 33 2 hp range All IronHorse GSD series DC drives are 1 35 or better Not Recommended For Ironhorse PMDC motors 1t 1s recommended that form factor not exceed 1 4 for continuous operation Half wave rectification 1s not recommended because it increases the form factor Driving a Ironhorse PMDC motor with a higher form factor control than intended can cause premature brush failure and excessive internal heating PMDC motors can generate high momentary starting and acceleration torques typically 10 to 12 times full rated torque Thus they suit applications requiring high starting torques or momentary bursts of power However they are not intended for continuous operation at these higher levels of torque This can cause overheating which can result in non reversible demagnetization of the field magnets Torque current limiting in the drive limits stall conditions and current draw particularly during high torque demand and protects against detrimental overload IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 VAUTOMATIONDIRECT Chapter 5 Reference ENCLOSURE AND ELECTRICAL INSULATION SYSTEMS Other considera
51. vironnementaux activit s a risque lev La soci t AutomationDirect nie toute garantie expresse ou implicite d aptitude l emploi en ce qui a trait aux activit s risque lev Pour des renseignements additionnels touchant la garantie et la s curit veuillez consulter la section Modalit s et conditions de notre documentation Si vous avez des questions au sujet de l installation ou du fonctionnement de cet quipement ou encore si vous avez besoin de renseignements suppl mentaires n h sitez pas nous t l phoner au 770 844 4200 Cette publication s appuie sur l information qui tait disponible au moment de l impression la soci t AutomationDirect nous nous effor ons constamment d am liorer nos produits et services C est pourquoi nous nous r servons le droit d apporter des modifications aux produits ou aux publications en tout temps sans pr avis ni quelque obligation que ce soit La pr sente publication peut aussi porter sur des caract ristiques susceptibles de ne pas tre offertes dans certaines versions r vis es du produit MARQUES DE COMMERCE La pr sente publication peut contenir des r f rences des produits fabriqu s ou offerts par d autres entreprises Les d signations des produits et des entreprises peuvent tre des marques de commerce et appartiennent exclusivement leurs propri taires respectifs AutomationDirect nie tout int r t dans les autres marques et
52. x Torque End IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 Page 5 11 Chapter 5 Reference WAUTOMATIONDIRECT mm PERFORMANCE CURVES CONTINUED MTPM 1P5 1M18 PI nn i i i pg hl AOT DU TOC WN ynn mem A AAA ymru a i i i i i en KRIM Ul E o fom AA a FE FR Em mm m i i i i i i 1 i OM AMOR 3 1 g1 sales um m mg mie i i i i I I i i 2800 5i 2800 er H NG seer i j i i I i i i i i PL i i i i i i ES 2400 300 ziuu Ll CS So pira Y AI TEE yn aleta cbr chine de i Fa i i i bog i i i as i d MH XI AM SUKI DU m baie um rrr NEW rmt UTC Wr i i i j i i i i i i i 1 iF i j i me i i pat i i i i i Lo 2X j h de ado mm emm i i i j i i i i i i i i i i i i Chi n PT LA BRI Uk x EU 2 3 A 1 i i i i i i i i i i i 400 W ALL EE A Er od i i I i i i i i i i i i i i i Y 1 2 59 416 2 18 M M m Performance Data MTPM 1P5 1M18 Description No Load Rated Max Eff Max Pout Max Torque End Page 5 12 IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 VAUTOMATIONDIRECT Chapter 5 Reference _ _

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