AMETEK, Inc.

Dynamic Fluid Solutions Division

100 E. Erie St.
Kent, Ohio 44240

User's Guide
4930721
INTEL2 PRODUCTS

Windjammer 5.7” 120 Volt, 240 Volt, Universal 100V-240V

Nautilair 7.6” 120 Volt, 240 Volt, Universal 100V-240V
Nautilair 8.9” 120 Volt, 240 Volt, Universal 100V-240V

Brushless Motor Drive Electronics

November 2018

Proprietary Notice

"This document has been prepared by the Dynamic Fluid Solutions Division (DFS)
of AMETEK, Inc. and is supplied on the condition that it will be used by the
customer solely for the purpose of supporting the installation, operation,
service, and maintenance of this TIP product. The Dynamic Fluid Solutions
(DFS) Division believes that the information contained in this document is
accurate and reliable, and much care has been taken in its preparation. However,
no responsibility, financial or otherwise, is accepted for any consequences
arising out of the use or miss-use of this document or product. The information
contained herein is subject to change. Revisions may be issued to advice of such
changes and/or additions. The information included in this document shall not be
duplicated by the customer nor released, disclosed, or used, in full or in part,
for any other purpose other than as stated herein, without the express written
consent of the Dynamic Fluid Solutions Division (DFS) of AMETEK, Inc."

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INTEL2 User's Guide
Introduction

The brushless drive electronics module is used to power a variety of brushless DC

motors and blower systems in the AMETEK Windjammer 5.7" (145 mm) and Nautilair
7.6” (193mm), 8.9” (226mm) families. The input power designation refers to a
nominal mid-range operating point; actual power input will depend upon the
application.

The Printed Circuit Board (PCB) electronics provides: Conversion of the AC input
to a DC bus voltage, a small signal power source for the analog and digital
components, commutation and power electronics, input command, and velocity
sensing and feedback.

When used in blower products, the PCB also supports the motor stator and Hall
Effect Rotor Position Sensors, providing a compact and reliable package.

The electronics module implements uni-directional, single quadrant speed control.

Motor speed is monitored by converting the frequency of the signals from the
Rotor Position Sensors to an analog DC voltage. This voltage is compared to the
User's Input Command. The compensated error between actual speed and commanded
speed is used to control the voltage applied to the motor windings in a manner to
minimize the speed error. The Command Input is optically isolated from the AC
source and all internal power circuits. A variety of speed control options are
available.

Protection features include over temperature and over current sensing and
shutdown. A fuse, in-rush current limiter, and MOV voltage transient protector
are connected to the AC source.

This User's Guide will provide information on the use and operation of the
electronics module and its interfaces. Actual blower performance will depend
upon the blower characteristics and the User's application.

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Precautions for Use

WARNING: THIS PRODUCT OPERATES FROM AND USES VOLTAGES THAT ARE POTENTIALLY
DANGEROUS! FAILURE TO OBSERVE APPROPRIATE SAFETY PRECAUTIONS COULD RESULT IN
SERIOUS BODILY INJURY, INCLUDING DEATH IN EXTREME CASES. We recommend that
adequate instructions and warnings by the Original Equipment Manufacturer (OEM)
include labels clearly stating the precautions necessary for this type of
equipment in the application.

WARNING: Secure blower prior to initial start to prevent sudden movement and
possible damage.

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Blower Safety Precaution

In the application of Ametek, Inc. blowers are considered as a component in your

product, you must exercise the following minimum precautions:

THE FAILURE TO OBSERVE THE FOLLOWING SAFETY PRECAUTIONS COULD RESULT IN

SERIOUS BODILY INJURY, INCLUDING DEATH IN EXTREME CASES. We recommend that
adequate instructions and warnings by the original equipment manufacturers (OEM)
include labels setting forth the precautions listed below to the end user.

The blowers must be connected to a proper and effective ground or mounted in a

manner that will guarantee electrical isolation and insulate the user and others
from electric shock. End product design should not rely solely on the primary
insulation of the motor.

Standard blowers are not designed to handle volatile or flammable materials

through the fan system unless specifically designed. Passing combustible gases or
other flammable materials through the fan system could result in leakage which
could cause a fire or explosion.

These products must not be used in an area contaminated by volatile or flammable

materials since sparking is predictable in the normal operation of the motor and
may ignite the volatile causing a dangerous explosion.

Other Divisions of AMETEK, Inc. can supply specifically designed motors and
blowers for use in handling combustible gases or for use in hazardous duty
locations. These specially designed units should only be used in conjunction with
combustible gases, which they were specifically designed to handle. The type of
gases must be so noted on the product label and in the instructions.

The rotation of the blower is a potential source of injury and must be taken into
account in the design of your end product. You must provide the necessary
guarding or housing as required by the finished product. Do not remove guard as
severe bodily injury may occur to fingers or appendages.

Products incorporating vacuum blowers must be designed so as to prevent the

vacuum or air pressure from being concentrated in a manner that can expose the
user to injury by coming into contact with any body area, such as eyes, ears,
mouth, etc.

The blowers must not be exposed to moisture or liquid or used outdoors, except in
equipment which is specifically designed for outdoor use and meets the
appropriate regulatory agency requirements for outdoor use. Moisture or liquid
can damage the blower and defeat the electrical insulation resulting in a severe
electrical shock to the user.

Ametek blowers must not be operated above the design voltage. Over voltage
conditions can cause excessive speed of the motor and can result in severe
electrical shock and/or other traumatic injury to the operator.

Precautions must be exercised to ensure blower leads are properly routed and
connected in your equipment. Lead wires must be routed and retained to ensure
that they do not become pinched or come in contact with rotating parts during

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INTEL2 User's Guide
assembly or subsequent operations. Connections must be designed so that proper
electrical contact is established and the connections must be properly insulated.

Disassembly or repairs of AMETEK products should not be attempted. If

accomplished incorrectly, repairs can create an electrical shock and/or
operational hazard. It is recommended that repairs be made only by AMETEK and not
by others.

In the event that the motor or blower ceases to operate, power must be
disconnected before examination and/or removal from the system.

Contact AMETEK, Inc. to discuss any questionable application before selecting a

blower. In setting forth the above listed recommendations with regards to
precautionary steps that must be considered, we in no way intend to imply that if
these steps are taken a product will meet the applicable safety standards. We, at
AMETEK, are not sufficiently conversant with the specific safety hazards which
may be associated with particular products. We can only advise precautions to be
employed generally for the safe use of AMETEK products as components. For testing
specifically related to the safety of the product, we recommend that you contact
the appropriate regulatory agency as indicated by the type of product being
manufactured.

Installation

Interface:
Please refer to the Block Diagram. All electrical connections are made
through J1. Safety ground connections should be made to J1 pin 3.

Warning! Use care when making initial power connections. Application of main
power to the User Speed Command Input pins will result in destruction of the
velocity control circuit. Check all connections before applying power!

Power Input:
The 50/60 Hz AC power source is connected to J1, pins 5 and 4.

Speed Command Input (when applicable):

The Speed Command is connected to J1, pin 2 (positive) and pin 1
(negative).

Note: Application of opposite polarity voltages to input pins 1 & 2 will not
destroy the unit unless the input voltage exceeds 45VDC.

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Connector:

Refer to the outline drawing of the specific blower model for the required
connector type.

Windjammer 5.7” and 7.6”

INTERNAL Mechanical Speed Control EXTERNAL Speed Control

POST HEADER ASSEMBLY

Windjammer 5.7

Option- Status or Tach-Out

POST HEADER ASSEMBLY

Nautilair 7.6” and 8.9”

0-10V speed control PWM speed control and/or Tach out

POST HEADER ASSEMBLY

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Ambient Temperature:

Operational: -20oC to +50oC

Storage: -40oC to +85oC

High Voltage Testing:

AC input and ground:

3000 VAC RMS (50/60Hz) applied for one minute, 2 mA leakage maximum.

AC input and Isolated Speed Control Input:

3000 VAC RMS (50/60 Hz) applied for one minute between AC input and
Isolated Speed Control Input, 1 mA leakage maximum.

AC input and Isolated Status or Tach Output:

3000 VAC RMS (50/60 Hz) applied for one minute between AC input and
Isolated Speed Control Input, 1 mA leakage maximum.

Electrical Performance Characteristics

AC Input:
240VAC Models:
180 to 264 VAC RMS, 50/60Hz, single phase

120VAC Models:
90 to 132 VAC RMS, 50/60Hz, single phase

Universal Models:
90 to 264 VAC RMS, 50/60Hz, single phase

Note: Although the unit contains a lock-out feature that detects low
voltage conditions, the electronics should not be operated
continuously with the AC Input lower than 180V FOR 240V models OR 90V
for 120v / Universal models. Also, the blower performance changes
with applied line voltage.

AC-Inrush Current:

With the blower connected to AC Power Line, there will be a high

Inrush Current for approx. 50ms until the internal capacitors are
charged. The inrush current is limited by a NTC-Thermistor.

Stand By Power Consumption:

240VAC 50/60 Hz version 50mA typical

120VAC 50/60 Hz version 65mA typical
100-264VAC 50/60 Hz version 65mA typical (120VAC)

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Isolated Speed Control Input:

0..10V Analog Signal Input

Voltage Range: 0 to +10 VDC nominal,

Absolute maximum of 45 VDC

PWM Digital Pulse Input:

PWM Frequency Input range: 400 Hz to 10 KHz

Duty Cycle 0..100%
0 to +10 Volt pulse nominal,
0 to +45 Volt absolute maximum

(It is possible to provide a 10VDC, 12mA source to pin 2 and pulse the ground
(sink) at pin 1.)

0..20mA Speed Control Current Input:

Current Range: 0 to 20mA

Absolute maximum 44mA (22V, 500Ω)

Speed Control Drift with Temperature:

Analog Mode: Typ. ±4% from nominal speed at +23oC

PWM or
Mechanical Mode: Typ. ±4% from nominal speed at +23oC

Operation

Prior to initial application of power, check all connections and grounds.

Speed Control:

Various speed control modes are available. The control electronics has a
built in 25 turn potentiometer that may be used to directly control speed
or to adjust motor speed in response to the signals on the Speed Command
Input.

Mechanical Direct Speed Control:

In this mode, no input is required at the Speed Command Input; J1 pins 1

and 2 must be left open. The internal potentiometer is connected to the
drive electronics and may be used to directly control motor speed over the
design range.

Potentiometer Fully Clockwise: Motor RPM Maximum

Potentiometer Fully Counter-Clockwise: Motor RPM Minimum

Analog Speed Control:

In this mode, an analog signal between 0 to 10 VDC is used to control motor

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speed. The internal potentiometer is wired to provide scaling of the input
voltage. The analog voltage is applied between J1 pin 2(+) and pin 1(-).
The analog input is used both for powering the velocity error amplifier and
providing the speed command, therefore , a minimum voltage must be present
at J1 pin 2 (+) and pin 1 (-) for proper operation. This minimum voltage
threshold ensures that the controller will be "OFF" for voltages under 1.0
volts. The command scaling potentiometer is wired such that fully
clockwise provides maximum command gain. With the potentiometer fully
clockwise:

J1-1,2 10 Volts: Maximum RPM

J1-1,2 <1 Volt: Motor Off

Digital PWM Speed Control:

In this mode, the internal potentiometer must be set fully clockwise. The
User then supplies a Pulse Width Modulated (PWM) signal switching between
15 and 45 volts to the Speed Command Input, J1 pin 2(+) and pin 1(-). The
PWM signal must have a base frequency between 400 Hz to 10 KHz. The motor
may rotate slowly at any duty cycle greater than 10%. The Velocity Error
amplifier and Filter and Compensation circuits (see the Block Diagram) will
convert the pulse width duty cycle to a DC voltage for use by the
Commutation and Control circuits.

J1-1,2 100% Duty Cycle: Maximum RPM

J1-1,2 <10% Duty Cycle: Motor Off

Speed Input Functions

In the Analog and Digital Modes the motor will not begin to rotate until a
threshold voltage or threshold duty cycle is reached. In the Analog mode, this
threshold voltage will also depend upon the setting of the potentiometer. This

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feature allows the Speed Command Input to also be used as a logical "ON/OFF"
signal.

AMETEK may pre-set the internal gain potentiometer for specific user applications
during final factory test.

With the Speed Command Input voltage or duty cycle set to minimum, or, in Direct
Mode, with the internal potentiometer set fully clockwise, apply AC appropriate
to the unit. Increase the Speed Command Input voltage or duty cycle until
rotation begins. In the Direct Mode, the motor will begin to rotate slowly;
adjust the potentiometer to obtain the desired speed, pressure, or flow.

NOTE: For initial testing, or in order to check performance, the AC voltage may
be brought up slowly using an adjustable AC voltage source or variable
transformer with the Speed Command set to Maximum RPM. Prolonged operation at low
line voltages under load is not recommended. The motor must never be allowed to
stall when running under low line conditions! Use care when starting the motor
with low line conditions!

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Detailed Operation

Refer again to the Block Diagram. Input AC power is rectified and filtered to
provide an internal DC bus voltage. In-rush current is limited using a Negative
Temperature Coefficient (NTC) device in series with the Bridge Rectifier. A pre-
regulated low voltage power source supplies the analog and digital circuits.

The User Speed Command Input may be used in the three Modes described above. In
Analog Mode, through the internal command scaling potentiometer, is compared to
the velocity feedback, amplified, and translated into a velocity error voltage
that controls the commutation circuits.

In the Direct Mode (Mechanical), the internal potentiometer directly controls the
velocity command.

The electronics module implements six-step commutation of the brushless DC motor

using Hall Effect devices to detect motor rotor position. The Hall Effect
information is used to select which transistors in the Power Output Stage are
turned ON to enable rotation in the desired direction. The Hall Effect signals
are also used to provide motor velocity feedback. Velocity scaling is determined
by the factory based on the motor winding and blower maximum speed.

The Analog, Digital, or Direct Mode velocity command voltage is amplified, and
translated across the isolation interface using an analog opto-coupler. The
velocity error is used as a current command that is compared to the Current
Feedback. The output of this amplifier controls the duty cycle of an internal
PWM Modulator. This PWM frequency is selected to ensure good bandwidth and
minimum current ripple in the stator. A single sensing resistor in the lower bus
supply line is used to measure current. The output of this resistor is used to
set the Current Limit. In Current Limit, the duty cycle of the PWM Modulator is
shortened in proportion to the over current condition.

A Negative Temperature Coefficient (NTC) resistor is mounted on the Power Output

Stage heat sink. This device will shut down the Commutation and Control logic if
the internal temperature exceeds approximately +83°C ±5°C). Over temperature is
a latched fault condition; power must be removed in order to restart the unit.
If the Over temperature condition still exists, the unit will not return to
normal operation until the heat sink temperature is less than +83oC (5°C
Hysteresis).

NOTE: Constant cycling of the blower, by switching the main power, may cause
damage to the blower if the blower will be restarted within less than 1 minute
after being stopped. If the application requires constant ON/OFF the Speed Input
should be used to start and stop the blower. If the Speed Input is used to start
and stop the blower unlimited cycles are possible.
We recommend to disconnect the blower from the line voltage only if the machine
will be switched off in general.

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Blower Operation

As mentioned, the actual performance of the blower in the User's system will
depend upon the application. The ability to control motor speed provides many
benefits:

1) Adjusting speed varies the blower output, allowing the User to "tune"
the blower to a particular application;

2) The blower may be part of an external control loop. For example, the
User may adjust motor speed to maintain constant pressure or
temperature.

Note: If the blower is part of an external control loop we recommend using the
blower as an open loop version. Open loop means the internal speed
control loop is not used and the speed is set to any value commanded by
the speed input. If the blower is operated in a closed loop version and an
external control loop is wired also, this may cause blower rpm
oscillation.

Inlet Filter

Inlet Filter should be used whenever the working air or cooling air is
polluted with dust or other air borne particles and contaminants larger
than 2 microns. The filter system should be designed for minimal pressure
drop and high efficiency. Contaminated air results in reduced operating
life of the blower.

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Error States

Following reasons will latch off the blower:

- locked rotor
- over current
- over temperature

The main power has to be switched off to restart the blower.

Following reasons will stop the blower:

- under voltage (for 240V it’s 133V ; for 120V & Universal it’s 83V)
- over voltage (for 240V & Universal it’s 267V ; (for 120V it’s 150V)

The motor will automatically restart when the voltage is again within design
limits. Take precautions to insure nothing obstructs blower rotation.

Blower status and faults:

The Intelligen electronics provides external light indication of blower as long

as main power is not switched off. The status LED is situated on the main control
board and can be observed through the cooling air discharge slots of the blower.

COOLING AIR DISCHARGE SLOTS

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Status and fault Table:

Blower status Light status Action Resume operation

Powered in standby OFF N/A N/A
condition
Running ON N/A N/A
Under voltage 1 blink Start with N/A
slowly correct voltage
Over current 2 blinks and Latched Shutdown Power cycle
pause
Stall motor 3 blinks and Latched Shutdown Power cycle
pause
Over temperature 4 blinks and Latched Shutdown Power cycle
pause
Over voltage 5 blinks and Restart with N/A
pause correct voltage

........
Note: The latched error signal will stay until the main power is disconnected.

Option:

No input signal 7 blinks and N/A N/A

pause

Option: The Failure/Fault output signal can be made available via a Solid State
Relay contact. This feature is called Status Output.

Possible Stall Motor failure causes: Defect power stage, defective halls, defect
driver circuit, improper stator phases, improper winding, locked bearing,

Possible Over Current failure causes: defect bearings, blower overload,

Possible Over Temperature failure causes: Ambient Temperature not within limits,
cooling air and working air not kept separate, not enough exchange on cooling
air, air contamination too high,

Hardware electronics protection features: Hardware Fuse – fast acting

(not accessible or replaceable)

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Troubleshooting

1) Unit Will Not Start

a) AC Power not applied;

b) Connector wired incorrect;

c) Polarity of Speed Control Input is reversed;

e) In Digital Mode, Speed Control Input duty cycle is too low or base
frequency is too low (<150 Hz);

f) Motor is stalled, blower impeller is blocked, over current condition

exists;

g) Controller internal temperature still exceeds +83oC due to operating

point, ambient temperature, or both.

h) Fuse has blown.

2) Unit Runs, but Will Not Reach Required Speed

a) Blower output capability is undersized for the application;

b) Line Voltage is outside normal range;

c) Internal pot is improperly adjusted;

d) Blower impeller or motor shaft is blocked;

e) Insufficient voltage at Speed Command Input.

3) Unit Starts, Runs Briefly and then Stops

Controller internal temperature still exceeds +83oC due to operating point,

ambient temperature, or both.

4) Blower oscillates

a) Unstable speed input command;

b) If external control loop is used and the blower was supplied in closed
loop configuration, the control loops may interfere with each other;

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Maintenance & Service

Maintenance:

The blower does not require maintenance.

In the event of a fault, please do not open the blower.

Taking out of service:

The safety instructions must be read and observed prior to taking the unit out
of service.

Disposal:

Take the blower out of service. Dismantle the drive ready for disposal and
break it up into its individual components. Sort the individual parts
according to material and forward to disposal. Adherence to the requirements
of legislation governing disposal and environmental guidelines in the country
of use must be ensured when disposing of electronic components.

Service & Support:

Should you have any questions or problems, please contact:

- Your local DFS sales outlet

- Your local DFS account manager
- Your local service center
- Our online YouTube channel

You can also visit our online web page for more information.

http://www.ametekpmc.com

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Block Diagram

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17
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Electromagnetic Compatibility:

This Ametek family of blower products complies with requirements as defined

by:

EN61000-4-2 (2009)
EN61000-4-3 (2006)+A1(2008)+A2(2010)
EN61000-4-4 (2004)+A1(2010)
EN61000-4-5 (2006)
EN61000-4-11 (2004)

These AMETEK products are capable of causing conducted electromagnetic

interference on the power mains. In applications where this is a concern,
a suitable line filter should be used in the AC mains as near as possible
to the blower AC power input.

In all cases, when performing associated leakage tests, the measurement

circuit must be faithfully reproduced as specified in the applicable agency
document.

For compliance with IEC61000-3-2 and IEC61000-3-3 line perturbation and

flicker requirements consult the factory for assistance. Solutions are
available depending on the application.

AMETEK Products also have the following ratings:

- Pollution Degree 3
- Software Class B
- Overvoltage Category III

Regulatory Agency Certification:

TÜV Rheinland Bauart Certification, qualified per EN60950.

Underwriters Laboratories Inc., qualified per UL507 ,

UL1004-1 , UL1004-3 , UL1004-7 , UL2111 , UL1998 , UL60730-1

Canadian Standards Association, qualified per C22.2 #113 ,

C22.2 #100 , C22.2 #77

The Isolated Speed Control Input is a "Safety Extra-Low Voltage

Circuit" per EN60950.

Locked Rotor test per UL507, condition 8.

REV A B C

ECN 106626 106638 106651

ISSUED BY: Guenter Morlok

APPROVED BY: Gene Bennington MARCH 2014

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