Aircore EC Installation, Operation & Maintenance Manual

1. About the manual

a. Warnings, cautions and notes

Warnings, cautions and notes are throughout the manual to alert
the technician of potential hazard or process information. Below is
an explanation of the use.
Warnings: are safety related. Serious injury, death and
equipment damage can result if the instructions in the
warning are not followed.
Cautions: apply to conditions that can cause equipment
damage. If instructions in the Caution are not followed,
motor and associated equipment damage may occur.
Notes: The text of the note is Italicized. Notes add information
that can aid in the completion of a process or step.

2. Motor technology

a. Motor overview

Infinitum has developed a new generation of electric motors
with unparalleled efficiency and durability. We’ve reinvented
axial air-core motors using lightweight materials and a modular
design that generates the same power with less weight than a
legacy motor. These motors include on optimized VFD (Variable
Frequency Drive) for maximum performance and efficiency at a
wide operating range. Infinitum has an established ecosystem of
configuration software as well as optional IoT connectivity for realtime monitoring and analytics. These motors are manufactured at
a fraction of the carbon footprint created by conventional motors.
It is designed with future generations in mind taking the entire
lifecycle into account creating a huge leap in sustainability.

i. Aircore EC motor technology

The introduction of the Aircore EC motor surpasses motors
utilizing standard technology and construction. Like all motors, Infinitum machines have a stator, the stationary part and a rotor.
The rotating component Aircore EC motors have two rotors. In
traditional motors the stator is located in the body of the motor
and is usually made of iron cores with copper windings. This iron
and copper adds to the overall weight of the motor. Additionally,
the insulation on these coil windings degrades with heat and time
requiring maintenance or eventual replacement of the motor.

ii. Infinitum Aircore EC stator

The Aircore EC stator is a Printed Circuit Board (PCB) rather than
utilizing a heavy iron core and with copper windings. The Infinitum
motor is designed utilizing a PCB stator sandwiched between two
rotors (Figure 1). Permanent magnets are attached to the surface
of the two rotors. Since there is no iron in the magnetic path, the
motors can be classified as an air-core design.

iii. Aircore EC motor components

The PCB stator design allows for a smaller motor that weighs
significantly less than a conventional motor. Key components are
identified by the drawing in Figure 2

3. Receiving inspection

Review and complete all appropriate sections prior to motor
installation. The motor is shipped in a robust container. The
container and motor can be moved by using a dolly, pallet jack or
fork truck (Figure 3).

a. Packing inspection

Inspect the motor packing for damages during shipping. If the
package is damaged, remove the packing and inspect the motor
for damage. Motor damage from shipping must be reported to
shipper

b. Remove motor from container

Warning: The motor is provided with threaded holes for a
lifting lug. Lifting lugs may or may not be shipped with the
motor. (Figure 4). The lugs are intended to lift the motor
assembly only. Attaching the component it drives will
exceed the design weight limits. To reduce the possibility
of personal injury or death and equipment lift the motor
only, make sure the lugs are completely threaded into the
motor, and ensure they do not rotate out during lifting.
Lifting eye-bolts are M10x1.5t thread, 20mm shank or 1/2”-13
thread, 1 1/2” shank length, depending on motor. Consult the
appropriate drawing for that motor to be sure.
Warning: To reduce the possibility of personal injury and
equipment damage, only use a lifting device and straps
that are rated for the motor weight. Do not lift the motor
without mechanical assistance. Always inspect straps for
damages and weight certification prior to use

Remove top of the packing crate and install the supplied lifting
lugs (Figure 3). Make sure the lugs are threaded completely into
the motor housing. Use an approved lifting device and sling to
remove the motor from the packing crate.

i. Motor bearings
The bearings (Figure 5) used in this motor are lubricated and
sealed at the factory. The motor does not require bearing
lubrication in the field or during storage.

ii. Scheduled output shaft rotation

Warning: The rotor in this motor incorporates a Permanent
Magnet (PM) design. When the rotor is rotated a
voltage is produced in the stator even when the motor is
disconnected from a power source. Do not open electrical
compartments or touch unprotected terminals while the
rotor is turning. Disconnect motor supply power and allow
one minute for capacitors to discharge before servicing or
replacing. Failure to comply with rotor safety procedures
can cause serious injury or death and equipment damage.

It is recommended the rotor (output shaft) be rotated five to ten
times per every quarter (three months). This distributes grease
in the bearings and reduces the chance of corrosion formation
on bearing rolling elements and raceways. Bearing seals can add
some resistance to turning the rotor.

4. Motor installation

a. Preparation

Review this entire manual prior to scheduling the motor
installation. All equipment related to systems operation must be
secured and have an active LOTO (Lock Out Tag Out) procedure
in accordance with application specific safety policies. All users of
should be notified of equipment outage.

i. Operating ambient temperature

The ambient temperature of the air supplied to the motor cooling
inlet should not exceed 40° C (104° F) or be less than -25° C (-13° F).
Power can be derated at higher temperatures by 2% per degree
C up to 50° C. Consult Infinitum for ambient temperatures not
within these requirements.

ii. Ingress protection

Infinitum motor Ingress Protection (IP) ratings are identified by
their respective nameplates. To maintain this IP rating, cable
glands or seals must be used at all wiring ports and all gaskets in
place with covers.

c. Motor Orientation

Gen4 Aircore EC motors can be used in any orientation,
horizontal, shaft up or shaft down.

d. Motor mounting and alignment

The Aircore EC motor system is supplied with an integrated VFD.
The motor and drive are the major components of the assembly.
Refer to motor datasheets for detailed dimension drawings.

i. Mounting options

Driven equipment (for example, a fan wheel) should be mounted
to the shaft using as much of the available shaft length as
possible. A shaft key-way and shaft key are provided for secure
coupling of hubs to the shaft

There are two mounting options for the motor, peripheral
mounting or C-face mounting.

ii. Peripheral mounting block

There are four mounting blocks on the surface of the motor,
spaced at 90º intervals. Each block has provisions for a lifting lug
that can be used to lift the motor, and mounting holes at the
drive end (DE) face and transverse surface.
The transverse face of the mounting block has threaded holes for
four mounting bolts. All four mounting bolts should be installed
for secure motor mounting. See the respective motor diagram for
a its mounting hole pattern in Figure 6.

iii. C-face mounting

Infinitum Aircore EC motors are not a NEMA standard frame size
but utilize a NEMA 182TC faceplate mounting configuration.
The DE face of the mounting block has threaded holes for four
bolts (M8X1.25). All bolt holes should be used for secure mounting
of the motor to equipment (Figure 7).

Caution: Use care when installing the driven equipment
onto the rotor shaft. Do not force the hub or coupling onto
the shaft since this may damage the motor bearings. If the
hub or coupling does not slide without resistance, check
alignment of the equipment with the rotor shaft.

Maintain adequate clearance between the front of the motor
body and the equipment to prevent mechanical obstruction that
may cause damage or injury.

The motor and stator assembly must be mounted on a structure
that will support the operational weight of the motor. Use
vibration dampers at motor assembly mounts to reduce motor
vibration. Align the stator output shaft centerline with the driven
component and install mounting hardware but do not tighten.
This is completed with the alignment process.

f. Minimum motor connection requirements

Warning: Always disconnect power to the motor and
practice all application specific safety procedures when
installing, troubleshooting, or repairing a motor. Always
verify power is secured with a multimeter prior to work.
Failure to disconnect power from motors can result in
serious personal injury or death and equipment damage.
Warning: The rotor in this motor incorporates a Permanent
Magnet (PM) design. When the rotor is rotated in a
disconnected motor voltage is produced. Do not touch
unprotected terminals while the rotor is turning. Disconnect
motor supply power and allow one minute for capacitors to
discharge before servicing or replacing. Failure to comply
with rotor safety procedures can cause serious injury or
death and equipment damage.
Warning: To reduce the possibility of personal injury or
death and equipment damage, always make sure wire
connections are secure and wires are in the correct location.
Caution: To prevent the possibility of motor damage, always
use terminating ferrules for all supply wires. Terminating
ferrules create a single connection point that is more secure
than stranded wire.

Wire tensile forces can affect the point of termination during
installation and motor operation. Terminal blocks with the correct
wiring installed ensure safe motor operation. Using the correct
wire gauge and amount of exposed conductor length with ferrules
installed on each wire satisfies the requirements.
Make sure the source of power to the motor has been
disconnected.
Strip wires and crimp on wire ferrules. Install each wire into the
appropriate terminal block as provided in the wiring instructions.
Verify all connections are tight and installed to specifications.
NEC 70 and NEMA MG2 standards should be followed for proper
motor power wiring. 

g. Motor control connections

Infinitum Aircore EC motors support standard industry control
methods. The following are supported:
• Analog/Digital
• Modbus RTU
• Modbus TCP
Infinitum also supplies proprietary configuration and control
software known as I-con (motor control software).

c. Compare nameplate data

• Compare data on nameplate with purchase order to verify
receipt of proper motor.
• Compare data on nameplate for desired power supply and
control equipment requirements.

d. Rotate motor output shaft

Warning: The rotor in this motor incorporates a Permanent
Magnet (PM) design. When the rotor is rotated a
voltage is produced in the stator even when the motor is
disconnected from a power source. Do not open electrical
compartments or touch unprotected terminals while the
rotor is turning. Disconnect motor supply power and allow
one minute for capacitors to discharge before servicing or
replacing. Failure to comply with rotor safety procedures
can cause serious injury or death and equipment damage.

Make sure all motor wire connections are properly terminated
and insulated. Turn motor rotor (output shaft) by hand. It should
should turn freely with some drag from the bearing seals.

e. Ready spare storage

Motors purchased for ready spares are not placed into service
immediately. These motors should be stored in a clean, dry
space. Avoid spaces with large temperature swings to reduce
condensation. Storage temperature is -40 to 185 °F (-40 to 85 °C).
Cover motors to prevent airborne dust and dirt particles. If
storage area location is prone to vibration, place vibration
dampers under motor base to prevent premature wear and
damage to bearings.

b. Motor location

Warning: This motor is not certified to operate in any
hazardous environments. Operating a motor in areas
contaminated with explosive gases can cause explosions
resulting in serious injury or death and equipment damage

Electric motors have guidelines for the location and operating
environment. These guidelines are listed below:
• The motor should be located in a ventilated enclosure and
should be in an area that allows air circulation.
• Air cooling inlets and outlets must not be obstructed.
• The enclosure cannot be located in an area with harmful or
explosive gasses.
• The area should be free from dust and metallic particles.
• The motor should be easily accessed for cleaning and
maintenance.
• The motors are intended for indoor applications.

e. Mounting and aligning motor

The motor may be directly mounted to equipment such as fan
wheels or may be connected through a belt or pulley system.
It may also be attached through a shaft coupling, e.g., to an
independently mounted pump, or to a torque meter in a
laboratory setting. Ensure proper alignment is maintained in all
arrangements.
Use driven equipment manufacturer’s recommendations for
aligning the motor with the fan drive or coupling. Tighten all bolts
and nuts on the motor mount.
Motor rotation must be verified after electrical connection.
Incorrect rotation can damage equipment.

h. Motor ground circuit verification

Warning: Motors must be properly grounded. Adhere to all
guidelines when installing the motor ground circuit. Failure
to ground a motor can cause personal injury, death, and
equipment damage.

It is advised to conduct resistance readings with a multimeter on
the motor ground circuit. Never apply power to a motor that does
not have a complete ground circuit.

i. Connecting motor

Each of the circuit boards and housing components has a
separate design function. Only two of the circuit boards have
user inputs. The main circuit boards and connection points are
highlighted in Figure 8.
1. Power board: Connections for three-phase supply. Rectifiers
convert AC to DC for internal use on this board.
2. Control interface module (CIM). This circuit board contains
advanced controls and communications.
3. AC Input: Ground terminal is in chassis. (Figure 10)

j. Conductor size and terminal data

k. Circuit breaker and wire sizing

Short circuit protection should be provided to protect the
input power conductors. UL and/or CSA (as required by
local regulations) approved fuses (such as class CC or class
J) or circuit breakers (UL 489) should be used and sized in
accordance with applicable regulations or Table 1.
The supply conductors should be sized based on the current
requirements of the motor. The connector minimum and
maximum wire sizes are included in Table 2.
Overload protection is required for Infinitum motors
marked as “Electronically Protected L” or “EPL”. UL and/
or CSA (as required by local regulations) approved motor
overload protectors should be used and set as required by
local regulations. Combination motor controllers, such as
UL Type E controllers, when used as intended may be used
to provide disconnect, short circuit protection, and overload
protection in the same device.
The maximum permissible short circuit current at the drive
input power terminals is 5kA.

Table 1: Breakers and fuses (3-phase 480V AC (+/- 10%) – 3-phase 460V output)

Table 2: Terminal connection data

l. Control connections 

Remove the VFD cover for access to Analog/Digital and
Modbus connections.
1. Relay (1) – NO/NC (COM must be used)
• Max voltage: 125 VAC / 30 VDC
• Max current NO: 10A VAC, 5 A VDC
NC: 3A VAC or VDC
2. Digital input (4) – DIN1, DIN2, DIN3 & DIN4
Warning: (Do not exceed +24V on this input)
3. Digital output (2) – DO1 & DO2.
• Open drain output
• Maximum switching voltage 40 VDC
• Maximum switching current 350 mA
4. Auxiliary Voltage (1) +24v (GND must be used)
5. Analog output (1) – A_OUT (GND must be used)
6. Analog input (1) – A_IN (GND must be used)
Warning: (Do not exceed 0-10V @ 100 mA on this input)
7. EIA-485 interface (1) – 485_P & 485_N
Note: Use wirenut to connect shield wires. Do not tie to GND.
8. Modbus termination switch. (Default is Off)
9. RJ45 for I-con (motor control software) connection
Terminals on the interface board (Figure 9) feature pushbutton spring clips. The push-button on each terminal must be
depressed while inserting the wire. Releasing the push-button
clips the wire into place.

m. Analog control wire guidelines.

To control the unit using Analog control please utilize the wiring
guidelines on the CIM board (Figure 9).

Caution: DIN1-DIN4 are limited to +24VDC input. AI1 is
rated 0-10V @ 100mA max. Exceeding these voltages
will permanently damage the communication board.
terminals.

p. Check motor rotation

Note: If the motor has been tested and the technician has
verified motor rotation prior to installation, the facility can elect
not to perform this test because of redundancy

Prerequisites: The motor has been installed, aligned and
electrically connected. The fan belt is removed, or coupling is
disconnected. The motor must be briefly energized to check for
proper rotation.
Steps are outlined below:
1. Review all installation instructions and all warnings prior to
testing the motor.
2. Connect AC power
3. Follow all safety precautions and energize the motor briefly to
determine rotation. If the motor rotates opposite of intended
direction, switch the direction command utilizing I-con
software tool.
4. Disconnect AC power.

q. Connect motor to driven equipment

Warning: Always disconnect power and practice all safety
procedures when installing, troubleshooting, or repairing
a motor. Always verify power is secured with a multimeter
prior to work. Failure to adhere follow industry standard
safety practices can result in serious personal injury or death
and equipment damage.

Prerequisite: Motor rotation has been verified. The final series of
steps will place the load on the motor and test system operation.
Steps outlined below:
1. Disconnect power from the motor
2. Attach driven equipment confirming alignment
3. Install all safety covers and connect power
4. Start the system and verify the motor operates properly.

r. Default and user programmable settings

Infinitum EC Aircore motors are shipped with factory default
settings for maximum speed, control methods and other values.
To change your motor’s settings, download the I-con software.

n. Modbus RTU wiring guidelines

To control the motor with Modbus RTU please utilize the wiring
guidelines to connect to the Communication I/O (Figure 9).
• The last unit on a daisy-chain configuration should have the
Modbus Termination DIP switch “ON”.
• All other units must have the DIP switch in the “OFF” position.
• Modbus RTU operation requires changes to the motor
configuration parameters. 

o. AC main input connections 

The AC main inputs (Figure 10) are on the power board.
The supply voltage connections are:
1. Supply voltage phase A
2. Supply voltage phase B
3. Supply voltage phase C
The AC input terminals feature spring clips. The orange tab must
be raised to insert the wire. Closing the orange tab secures the wire into place. The grounding post is located off the power board on the chassis itself.

The motor is intended for connection to a solidly grounded
wye supply. Connection to ungrounded, high impedance, or
corner grounded systems may result in damage to the motor.

5. Motor maintenance

a. Maintenance tasks

This motor requires inspections and tasks be completed on a
Quarterly (3 months) basis or 500 hours whichever occurs first.
Maintaining this motor requires completion of both inspection
and tasks. Review above warnings. The basic tasks are outlined
below:
1. Disconnect motor line power and all associated operating
equipment and allow one minute for motor capacitors to
discharge.
2. Examine driven equipment for looseness or damage.
3. Inspect the motor output shaft for damages. Replace
damaged components and tighten any loose set screws.
4. Make sure the cooling fins and area around the motor are free
from dust and debris.
5. Make sure the mounting bolts and hardware are tight and
secure.
6. If used, check rubber vibration isolators for cracks and damage.
7. Make sure all wire connections are tight.
8. Inspect internal wires for signs of heat damage.
Any damages noted must be repaired before placing the motor
into service.

b. Mechanical

Problems with alignment can cause bearing wear. Lack of
maintenance, improper installation, and loose mounting bolts can
cause premature bearing wear and motor overloads.

6. Motor drive parameters and data types

The Aircore EC motor parameters can be found here.