User`s Manual - Bison Gear and Engineering Corporation
Contents
1. HE c mE LING 0 0 o0 4 Orana NO Models 170 203 0002 170 203 0005 Pulse Width Modulated Adjustable Speed Drives for DC Brush Motors Copyright 2006 by Bison Gear amp Engineering All rights reserved No part of this manual may be reproduced or transmitted in any form without written permission from Bison Gear amp Engineering The information and technical data in this manual are subject to change without notice Bison Gear amp Engineering and its Divisions make no warranty of any kind with respect to this material including but not limited to the implied warranties of its merchantability and fitness for a given purpose Bison Gear amp Engineering and its Divisions assume no responsibility for any errors that may appear in this manual and make no commitment to update or to keep current the information in this manual Printed in the United States of America Safety Warnings HAZARD HEAT DRY VIBRATION This symbol denotes an important safety tip or warning Please read these instructions carefully before performing any of the procedures contained in this manual DO NOT INSTALL REMOVE OR REWIRE THIS EQUIPMENT WITH POWER APPLIED Have a qualified electrical technician install adjust and service this equipment Follow the National Electrical Code and all other applicable electrical and safety codes including the provisions of the Occupationa2. 19 Calibration Trimpot Layout 20 Approximate CURRENT LIMIT and IR COMP Settings for 120 VAC in 90 VDC out actual settings may vary 27 Approximate CURRENT LIMIT and IR COMP Settings for 120 VAC in 130 VDC out actual settings may vary 28 Approximate CURRENT LIMIT and IR COMP Settings for 240 VAC in 180 VDC out actual settings may vary 29 Approximate CURRENT LIMIT and IR COMP Settings for 240 VAC 240 VDC out actual settings may vary 30 Multiple Fixed Speeds 31 Adjustable Speeds Using Potentiometers In Series 32 Independent Adjustable Speeds 33 RUN JOG Option 1 34 RUN JOG Option 2 35 Leader Follower Application 36 Reveisirig YET E IP FRI t 37 Diagnostic LED locations 39 CE Filter Connections tecie ip 45 vi Tables Table 1 Recommended Line Fuse Sizes 6 Table 2 Inhibit Plug Part Numbers 16 Table 3 Dynamic Brake Resistor Part Numbers 19 Table 4 AC Line Filters Specifications Max Continuous HP Range Range AC Armature with 12 with 24 Line Curre
3. 46 NOTES NOTES 47 48 NOTES NOTES 49 50 NOTES Bison Warranty Policy The Company warrants to the Buyer the products sold hereunder to be free of defects in material and workmanship under normal use and service for a period of one 1 year from the date of shipment The obligation of the Company under this warranty is limited to repair or replacing at its option any part or parts which upon examination shall disclose to the reasonable satisfaction of the Company to have been defective in material or workmanship Buyer must return the products to the Company s factory shipping charges prepaid and with complete information as to alleged defects and the installation operation and service of the products Except as otherwise expressly stated herein the Company makes no representation of warranty of any kind express or implied as to merchantability fitness for a particular purpose or any other matter with respect to the products sold hereunder BISON Bison Gear amp Engineering Corp 3850 Ohio Ave St Charles IL 60174 Phone 1 800 AT BISON www bisongear com Document Number 250 0417 Revision 0 May 2006
4. ASVLIOA OWA 095 061 HOLIMS 901 aSN4 OWA OFZ SI ADVLIOA ANI 3I AINO zasna TALON Suonoeuuo Ww Lost p LOSHL 20911 ND ror AA YALAWOILNALOd isnrav lt WHO 01 11 Voltage follower Instead of using a speed adjust potentiometer the drive may be wired to follow a 0 5 VDC isolated voltage signal Figure 4 Connect the signal return to 1 Connect the signal high or to S2 Make no connection to S3 A potentiometer can be used to scale the analog input voltage 0 5VDC VOLTAGE SIGNAL C505 2 Vo THs POWER 15 R501 REF COM C501 11502 CURRENT NV LIMIT XX CURRENT LIMIT MAX SPD MIN SPD IRCOMP DECEL ACCEL N N N N N Figure 4 Voltage Follower Connections 12 Operation A Warning Dangerous voltages exist on the drive when it is powered A and up to 30 seconds after power is removed and the motor stops BE ALERT High voltages can cause serious or fatal injury For your safety use personal protective equipment PPE when operating this drive If the motor or drive does not perform as described disconnect the AC line voltage immediately Refer to the Troubleshooting section on page 38 for further assistance Before applying power Verify that no conductive mater
5. Connect the switch as shown in Figure 6 Close the switch between S1 and S2 to decelerate the motor from set speed Open the switch to accelerate the motor to set speed The ACCEL and DECEL trimpot settings determine the rate at which the motor accelerates and decelerates respectively 10K OHM SPEED ADJUST POTENTIOMETER DECEL TO MIN SPEED Figure 6 Run Decelerate to Minimum Speed Switch 18 Dynamic braking A Warning Wait for the motor to come to a complete stop before setting the RUN BRAKE switch to RUN This will prevent high armature currents from damaging the motor or drive Dynamic braking may be used to rapidly stop a motor see Figure 7 on page 19 For the RUN BRAKE switch use a double pole double throw switch rated for at least the maximum DC armature voltage and maximum braking current RUN BRAKE switch Install a double pole double throw switch between the INHIBIT terminals and a dynamic brake resistor as shown in Figure 7 on page 19 Set the switch to the BRAKE position to dynamically brake the motor to a stop Set the switch to the RUN position to accelerate the motor to set speed at a rate controlled by the ACCEL trimpot Dynamic brake resistor sizes Size the dynamic brake resistor according to the motor current rating refer to Table 3 on page 19 The dynamic brake resistance listed in the table is the smallest recommended resistance allowed to prevent possible demagnetization of the motor The
6. Fuse Current DC Amps Rating AC Amps 1 5 and below 3 2 6 5 3 5 8 5 0 10 Speed adjust potentiometer A Warning Be sure that the potentiometer tabs do not make contact with the potentiometer enclosure Grounding the input will cause damage to the drive Mount the speed adjust potentiometer through a 0 38 in 10 mm hole with the hardware provided Figure 2 Install the circular insulating disk between the panel and the 10K ohm speed adjust potentiometer Twist the speed adjust potentiometer wire to avoid picking up unwanted electrical noise If speed adjust potentiometer wires are longer than 18 in 457 mm use shielded cable Keep speed adjust potentiometer wires separate from power leads L1 L2 A1 A2 MOUNT THROUGH A 0 38 IN 10 MM HOLE NUT STAR WASHER SPEED ADJUST POTENTIOMETER INSULATING DISK POT TAB ASSIGNMENTS PANEL Figure 2 Speed Adjust Potentiometer 8 Connections A Warning Do not connect this equipment with power applied Failure to heed this directive may result in fire or serious injury Bison strongly recommends the installation of a master power switch in the voltage input line as shown in Figure 3 page 10 The switch contacts should be rated at a minimum of 200 of motor nameplate current and 250 volts Power fuse and motor connections Connect the power input leads an external line fuse and a DC motor to the drive s printed circuit board PCB as sho
7. lights when AC line voltage is applied to the drive CURRENT LIMIT CL FLT Red LED lights when drive output current exceeds the threshold set by the CURRENT LIMIT trimpot S j COB c CURRENT up LIMIT ew POWER gt of 1L501 C CURRENT POWER LIMIT LED LED Figure 20 Diagnostic LED locations Line fuse blows Line fuse does not blow but the motor does not run Possible Causes 1 Line fuses are the wrong size Motor cable or armature is shorted to ground Nuisance tripping caused by a combination of ambient conditions and high current spikes Reference signal or speed adjust pot is set to zero speed Reference signal or speed adjust potentiometer connections are open Suggested Solutions 1 Check that line fuses are the proper size Check motor cable and armature for shorts 3 Add a blower to cool the drive components decrease CURRENT LIMIT settings or resize motor and drive for actual load demand or check for incorrectly aligned mechanical components or jams See page 25 for information on adjusting the CURRENT LIMIT trimpot Increase reference signal or speed adjust potentiometer setting Check that the reference signal or speed adjust potentiometer connections are not open Line fuse does not blow but the motor does not run cont Motor runs too fast at maxim
8. motor stops less rapidly with higher brake resistor values 19 Table 3 Dynamic Brake Resistor Part Numbers Minimum Minimum Motor Armature Dynamic Brake Dynamic Brake Current Rating Resistor Value Resistor Wattage Less than 2 ADC 1 ohm 1W 2 3 ADC 5 ohm 5W 3 5 ADC 10 ohm 10W 5 10 ADC 20 ohm 20W For motors rated 1 17 horsepower and lower a brake resistor is not necessary since the armature resistance is high enough to stop the motor without demagnetization Replace the dynamic brake with 12 gauge wire INHIBIT Figure 7 Dynamic Brake Connection 20 Calibration Each drive is factory calibrated to its maximum current rating Readjust the calibration trimpot settings to accommodate lower current motors All adjustments increase with CW rotation and decrease with CCW rotation Use a non metallic screwdriver for calibration Each trimpot is identified on the printed circuit board 11502 CURRENT LMT XX CURRENT LIMIT CURRENT LIMIT MAX MIN SPEED SPEED IR COMP DECELERATION ACCELERATION Figure 8 Calibration Trimpot Layout 21 Calibration procedure Before applying power 1 Verify that no conductive material is present on the printed circuit board 2 Setall trimpots full except CURRENT LIMIT full counterclockwise CCW 3 Set the CURRENT LIMIT trimpot full clockwise CW 4 Set the speed adjust potentiomete
9. IM COMP MOTOR LIM COMP HP 1 20 HP 1 2 VOLTS 130 VDC VOLTS 130 VDC RPM 2500 RPM 2500 AMPS 0 4 ADC AMPS 3 8 ADC MOTOR MOTOR HP 18 HP 13 VOLTS 130 VDC VOLTS 130 VDC RPM 2500 RPM 2500 AMPS 1 0 ADC AMPS 2 6 ADC MOTOR MOTOR HP 1 4 HP 14 VOLTS 130 VDC VOLTS 130 VDC RPM 2500 RPM 2500 AMPS 1 8 ADC AMPS 2 0 ADC Figure 10 Approximate CURRENT LIMIT and IR COMP Settings for 120 VAC in 130 VDC out actual settings may vary 29 170 203 0002 170 203 0005 CURR CURR MOTOR LIM MOTOR LIM HP 1 2 HP 1 VOLTS 180 VDC VOLTS 180 VDC RPM 1750 RPM 1750 AMPS 1 4 ADC AMPS 5 0 ADC MOTOR MOTOR HP 1 4 HP 3 4 VOLTS 180 VDC VOLTS 180 VDC RPM 1750 RPM 1750 AMPS 1 0ADC AMPS 3 5 ADC MOTOR MOTOR HP 1 8 HP 1 2 VOLTS 180 VDC VOLTS 180 VDC RPM 1750 RPM 1750 AMPS 0 6 ADC AMPS 2 7 ADC Figure 11 Approximate CURRENT LIMIT and IR COMP Settings for 240 VAC in 180 VDC out actual settings may vary 30 170 203 0002 170 203 0005 CURR VR CURR VR MOTOR LIM COMP MOTOR LIM COMP 1 2 HP 1 VOLTS 240 VDC VOLTS 180 VDC RPM 2500 RPM 1750 AMPS 1 9ADC AMPS 5 0 ADC MOTOR MOTOR HP 13 HP 3 4 VOLTS 240 VDC VOLTS 240 VDC RPM 2500 RPM 2500 AMPS 1 0ADC AMPS 2 7 ADC MOTOR MOTOR HP 14 HP 1 2 VOLTS 240 VDC VOLTS 240 VDC RPM 2500 RPM 2500 AMPS 0 75 ADC AMPS 2 0 ADC Figure 12 Approximate CURRENT LIMIT and IR COMP Settings for 240 VAC in 240 VDC out actual settings may vary 31 Applic
10. PEE 9 Power input x Scie See ee 9 ori perc dat ad ME oa ae 9 Voltage Follower enit eens Pot ee aE Ta VEEEd e nia 11 Operation 12 Before applying powers i 12 Startup 2 952053 13 Starting and Stopping Methods 14 Line starting and line stopping 14 Automatic restart upon power restoration 15 inhibit terminals 155 Soave were pee or RUN E UP bien 15 e e eod seo Stel e 16 Decelerating to minimum speed 17 Dynaric braking 24 4 2 steed Bhd at ied 18 RUN BRAKE switch Dynamic brake resistor sizes Calibration Calibration procedure Before applying power MINIMUM SPEED MIN SPD MAXIMUM SPEED MAX SPD ACCELERATION ACCEL i nre erp HERR DECELERATION DECEL REGULATION IR COMP ober RE re 24 Pe REE SG CURRENT LIMIT CURR LIM m RII Application Notes Multiple fixed speeds Adjustable speeds using potentio
11. age can cause unpredictable behavior in any electronic device including motor controls As a general rule Bison recommends shielding of all conductors If it is not practical to shield power conductors Bison recommends shielding all logic level leads If shielding logic leads is not practical the user should twist all logic leads with themselves to minimize induced noise It may be necessary to earth ground the shielded cable If noise is produced by devices other than the drive ground the shield at the drive end If noise is generated by a device on the drive ground the shield at the end away from the drive Do not ground both ends of the shield If the drive continues to pick up noise after grounding the shield it may be necessary to add AC line filtering devices or to mount the drive in a less noisy environment Logic wires from other input devices such as motion controllers and PLL velocity controllers must be separated from power lines in the same manner as the logic I O on this drive 6 Line fusing Protect all Bison drives with AC line fuses Use fast acting AC line fuses rated for 250 volts and approximately 15096 20096 of the maximum armature current Fuse only the hot side of the AC line L1 if using 115 VAC line voltage Do not add line fuses to L2 unless you use 240 VAC line voltage See Table 1 below for recommended line fuse sizes Table 1 Recommended Line Fuse Sizes Maximum Armature AC Line
12. akes to ramp to a lower speed See Specifications on page 1 for approximate deceleration times The DECELERATE setting is factory set to its minimum value full CCW Turn the DECEL trimpot CW to increase the deceleration time and CCW to decrease the deceleration time 24 REGULATION IR COMP The IR COMP setting determines the degree to which motor speed is held constant as the motor load changes It is factory set for optimum motor regulation Recalibrate the IR COMP setting when using a lower current rated motor Refer to Figures 9 12 pp 27 30 for typical IR COMP settings or recalibrate using the following procedure If the motor does not maintain set speed as the load changes gradually rotate the IR COMP trimpot CW If the motor oscillates overcompensation the IR COMP trimpot may be set too high CW Turn the IR COMP trimpot CCW to stabilize the drive 25 CURRENT LIMIT CURR LIM A Warning Although the current limit trimpot can be set to exceed the motor s maximum armature current rating Bison recommends you do not run the motor continuously beyond that rating Continuous operation beyond the maximum armature current rating may cause thermal degradation of the motor and drive The CURRENT LIMIT setting determines the maximum torque for accelerating and driving the motor CURRENT LIMIT is factory set at 12096 of maximum drive current You must recalibrate the CURRENT LIMIT setting if using a lower current rate
13. al contact Provide sufficient room for access to the terminal block and calibration trimpots Mount the drive away from heat sources Operate the drive within the specified ambient operating temperature range Prevent loose connections by avoiding excessive vibration of the drive Mount drive with its board in either a horizontal or vertical plane Six 0 19 in 5 mm wide slots in the chassis accept 8 pan head screws Fasten either the large base or the narrow flange of the chassis to the subplate The chassis must be earth grounded Use a star washer beneath the head of at least one of the mounting screws to penetrate the anodized chassis surface and to reach bare metal Wiring Warning Do not install remove or rewire this equipment with power applied Failure to heed this warning may result in fire explosion or serious injury Circuit potentials are at 115 or 230 VAC above ground To prevent the risk of injury or fatality avoid direct contact with the printed circuit board or with circuit elements Do not disconnect any of the motor leads from the drive unless power is removed or the drive is disabled Opening any one motor lead may destroy the drive Use 16 20 AWG wire for speed adjust potentiometer wiring Use 14 16 AWG wire for AC line L1 L2 and motor A1 and A2 wiring Shielding guidelines A Warning Under no circumstances should power and logic leads be bundled together Induced volt
14. ation Notes Multiple fixed speeds Replace the speed adjust potentiometer with series resistors having a total series resistance of 10 K ohms Figure 13 Add a single pole multi position switch with the correct number of positions for the desired number of fixed speeds TOTAL SERIES RESISTANCE 10K OHMS Figure 13 Multiple Fixed Speeds 32 Adjustable speeds using potentiometers in series Connect two speed adjust potentiometers as shown in Figure 14 to select between high speed and low speed Figure 14 Adjustable Speeds Using Potentiometers In Series 33 Independent adjustable speeds Connect two speed adjust potentiometers with a single pole multi position switch and two or more potentiometers in parallel with a total resistance of 10K ohms Figure 15 shows the connection of two independent speed adjust potentiometers that can be mounted at two separate operating stations SPEED 1 Figure 15 Independent Adjustable Speeds 34 RUN JOG switch Using a RUN JOG switch is recommended in applications where quick stopping is not needed and frequent jogging is required Use a single pole two position switch for the RUN JOG switch and a single pole normally closed momentary operated pushbutton for the JOG pushbutton RUN JOG option 1 In option 1 Figure 16 connect the RUN JOG switch and the JOG pushbutton to the INHIBIT terminals When the RUN JOG Switch is set to JOG the motor coasts to minimum sp
15. d motor Refer to Figures 9 12 pp 27 30 for typical CURRENT LIMIT settings 1 With no power applied to the drive connect a DC ammeter in series with the motor armature 2 Set the CURRENT LIMIT trimpot to full CCW 3 Carefully lock the motor armature Ensure that the motor is firmly mounted 4 Apply line power The motor should be stopped 5 Set the speed potentiometer or reference signal to maximum speed The motor should remain stopped 26 CURRENT LIMIT cont 10 Slowly rotate the CURRENT LIMIT trimpot clockwise CW until the ammeter reads 12096 of maximum motor armature current Set the speed adjust potentiometer or reference signal to zero speed Remove power from the drive Remove the lock from the motor shaft Remove the ammeter in series with the motor armature 170 203 0002 HP 1 20 VOLTS 90 VDC RPM 1750 AMPS 0 5 ADC MOTOR HP 1 8 VOLTS 90 VDC RPM 1750 AMPS 1 3ADC MOTOR HP 1 4 VOLTS 90 VDC RPM 1750 AMPS 2 5 ADC CURR LIM I R COMP 27 170 203 0005 CURR I R LIM COMP MOTOR HP 1 2 VOLTS 90 VDC RPM 1750 AMPS 5 0ADC MOTOR HP 1 3 VOLTS 90 VDC RPM 1750 AMPS 3 5 ADC MOTOR HP 1 4 VOLTS 90 VDC RPM 1750 AMPS 2 7 ADC CURR I R LIM COMP Figure 9 Approximate CURRENT LIMIT and IR COMP Settings for 120 VAC in 90 VDC out actual settings may vary 28 170 203 0002 170 203 0005 CURR VR CURR VR MOTOR L
16. eed Press the JOG pushbutton to jog the motor Return the RUN JOG switch to RUN for normal operation JOG PUSHBUTTON RUN oo 1 INHIBIT JOG Figure 16 RUN JOG Option 1 35 RUN JOG option 2 In option 2 connect the RUN JOG switch to the speed adjust potentiometer using a single pole two position switch for the RUN JOG switch and a single pole normally closed momentary operated pushbutton for the JOG pushbutton as shown in Figure 17 When the RUN JOG switch is set to JOG the motor decelerates to minimum speed Press the JOG pushbutton to jog the motor Return the RUN JOG switch to RUN for normal operation SPEED ADJUST POTENTIOMETER JOG PUSHBUTTON Figure 17 RUN JOG Option 2 36 Leader follower application In this application use a 170 993 0200 to monitor the speed of the leader motor Figure 18 The 170 993 0200 outputs a voltage proportional to the leader motor armature voltage The follower drive uses this voltage reference to set the speed of the follower motor An optional ratio potentiometer may be used to scale the 170 993 0200 output voltage Follower Drive 8 170 993 0200 1 TB502 10K Ohm optional Figure 18 Leader Follower Application 37 Reversing A dynamic brake may be used when reversing the motor direction Figure 19 Use a three pole three position switch rated for at least the maximum DC armature voltage and ma
17. ial is present on the printed board 13 Startup To start the drive 1 Turn the speed adjust potentiometer full counterclockwise CCW If the drive is following a voltage signal set the voltage signal to 0 VDC Apply AC line voltage Slowly advance the speed adjust potentiometer clockwise CW If the drive is following a voltage signal slowly increase the voltage signal The motor slowly accelerates as the potentiometer is turned CW or the voltage signal is increased Continue until the desired speed is reached Remove AC line voltage from the drive to coast the motor to a stop 14 Starting and Stopping Methods A Warning Decelerating to minimum speed or coasting to a stop is recommended for frequent starts and stops Do not use any of these methods for emergency stopping They may not stop a drive that is malfunctioning Removing AC line power both L1 and L2 is the only acceptable method for emergency stopping For this reason Bison strongly recommends installing an emergency stop switch on both the L1 and L2 inputs see Connections on page 10 Line starting and line stopping Line starting and line stopping applying and removing AC line voltage is recommended for infrequent starting and stopping of a drive only When AC line voltage is applied to the drive the motor accelerates to the speed set by the speed adjust potentiometer When AC line voltage is removed the motor coasts
18. l Safety and Health Act OSHA when installing equipment Reduce the chance of an electrical fire shock or explosion by proper grounding over current protection thermal protection and enclosure Follow sound maintenance procedures It is possible for a drive to run at full speed as a result of a component failure Bison strongly recommends the installation of a master switch in the main power input to stop the drive in an emergency Circuit potentials are at 115 VAC or 230 VAC above earth ground Avoid direct contact with the printed circuit board or with circuit elements to prevent the risk of serious injury or fatality Use a non metallic screwdriver for adjusting the calibration trimpots Use approved personal protective equipment and insulated tools if working on this drive with power applied Contents Safety Warnings i Specifications 1 Dimensions 2 Installation 3 E IDA ARD E KO ES 3 WINGS is zer snm mete tb eleg pe b ys feed RR E a 4 Shielding guidelines 5 LING FUSING ose pe Ede eyesore ners een ee 6 Speed adjust 7 COMNBCHONG ees rubeo oed ea verdes frd etta aka A 8 Power fuse and motor connections 8 Master power switch 8 MOOR cause one PAN QOEPENRLDMERARA SG RINT OOGO EE
19. meters in series Independent adjustable speeds RUN JOG SWilch 4 355 oa whe breve lebe pt e R N JOG option Hi o aw eed SER OOS RUN JOG option 2 nose eee tie Ee REO Leader follower application Reversirig unisce tee hae ain RIQU Troubleshooting Before troubleshooting TENG BNGET ANE E a Diagnostic EEDS 2 V ARI aaa a a doa lett ana ea POWER uve dev Cm rre ee eem imer CURRENT LIMIT lt 5 RR III Certificate of Compliance 43 GE Coertification lt 43 Filters 1 ceu ope IU ERR ER UOTIS RAM Bees EON 44 Unconditional Warranty inside back cover Illus Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 trations DIMENSIONS DT 2 Speed Adjust 7 Connections casco road 40 xta e Reo Kor RR RERO RU 10 Voltage Follower Connections 11 Inhibit Terminal Location 16 Run Decelerate to Minimum Speed Switch 17 Dynamic Brake Connection
20. nt VAC VAC Model Voltage Amps DC Applied Applied 170 203 0002 120 OR 240 2 1 20 1 4 1 10 1 2 170 203 0005 120 OR 240 5 1 4 1 2 1 2 1 AC Line Voltage 120 240 VAC x 10 50 60 Hz single phase Armature Voltage Range 120 VAC input 0 130 VDC 240 VAC input 0 240 VDC Form Factor at base speed 1 05 Acceleration Deceleration Time Range no load 0 5 6 seconds Analog Input Voltage Range S1 to S2 0 5 VDC Input Impedance S1 to S2 with 5 VDC input approximately 70K ohms Speed Regulation 196 base speed or better Ambient Temp Range chassis drive 10 C 40 Vibration 0 59 max 20 50 Hz 0 1 g max gt 50 Hz Weight 170 203 0002 0 66 Ib 0 30 kg 170 203 0005 0 72 Ib 0 32 kg Signal must be isolated 2 Dimensions 3 64 92 1 75 44 ame yt lei OO 0 70 18 3 80 97 4 30 109 DIMENSION A MODEL HEIGHT 170 203 0002 2 50 62 ALL DIMENSIONS IN INCHES 170 203 0005 3 20 81 MILLIMETERS Figure 1 Dimensions Installation Mounting A Warning Do not install rewire or remove this control with input power applied Doing so may cause fire or serious injury Make sure you have read and understood the Safety Warnings before attempting installation Drive components are sensitive to electrostatic fields Avoid direct contact with the circuit board Hold drive by the chassis only the drive from moisture and accident
21. r or input signal to zero speed 5 Set the INHIBIT switch to INHIBIT or install the jumper between the INHIBIT terminals of SO501 6 Apply line voltage to the drive The green POWER LED shall light but the motor should remain stopped 7 Set the INHIBIT switch to ENABLE or remove the jumper between the INHIBIT terminals of SO501 22 MINIMUM SPEED MIN SPD MIN SPD determines the minimum speed when the speed adjust potentiometer is turned full CCW It is factory set to zero speed To calibrate MIN SPD 1 Set the speed adjust potentiometer full CCW 2 Adjust the MIN SPD trimpot until the motor turns at the desired minimum speed MAXIMUM SPEED MAX SPD The MAX SPD setting determines the maximum motor speed when the speed adjust potentiometer is turned full CW It is factory set for maximum rated motor speed To calibrate MAX SPD 1 Set the MAX trimpot full CCW 2 Turn the speed adjust potentiometer full CW 3 Adjust the MAX SPD trimpot until the desired maximum motor speed is reached 23 ACCELERATION ACCEL The ACCELERATE setting determines the time the motor takes to ramp to a higher speed See Specifications on page 1 for approximate acceleration times The ACCELERATE setting is factory set to its minimum value full CCW Turn the ACCEL trimpot CW to increase the acceleration time and CCW to decrease the acceleration time DECELERATION DECEL The DECELERATE setting determines the time the motor t
22. t meet the following conditions wires including logic AC power and motor leads must be shielded Do not ground both ends of the shield This series motor control module must be enclosed in a solid metal enclosure The enclosure lid body and backplane must all be tied to a low impedance earth ground A VV series filter or equivalent must be wired into the AC main See Table 4 on page 44 The ground connection between the shielded cable installed line filter and metal enclosure must be wired to solid earth ground resistance less than 500 ohms not machine ground This is very important 44 Compliance allows this series to bear the CE mark The end user as described herein falls into one of two categories 1 Consumer will deploy a stand alone unit as an integral yet external portion of the machine being operated 2 The Original Equipment Manufacturer OEM will implement the product as a component of the machine being manufactured AC Line Filters In addition to EMI RFI safeguards inherent in this series design external filtering is required To meet CE approval conditions use the line filters or equivalent listed in Table 4 Connect the filter as shown in Figure 24 Table 4 AC Line Filters AC Corcom Drive Current Filter 170 203 0002 3A 6VV1 170 203 0005 7A 10VV1 45 wi DRIVE FILTER ENCLOSURE SOLID EARTH GROUND Figure 21 CE Filter Connections
23. to a stop 15 Automatic restart upon power restoration All drives automatically run to set speed when power is applied and the drive is enabled The drive will accelerate at a rate controlled by the ACCEL trimpot Refer to the Calibration section for information on adjusting this setting Inhibit terminals A Warning Inhibit is used for frequent starts and stops It must never be used as an emergency stop because it may not stop a drive that is malfunctioning Removing AC power L1 and L2 is the only acceptable method for emergency stopping Jumper the inhibit terminals to coast the motor to a stop Figure 5 Remove the jumper to accelerate the motor to set speed 16 Inhibit plug Bison offers an accessory plug harness for use with the inhibit terminals Table 2 Inhibit Plug Part Numbers Bison amp Part Number Description 170 998 0100 Inhibit plug with 36 in 91 cm wires Twist inhibit plug wires and separate them from other power carrying wires or sources of electrical noise Use shielded cable if the inhibit plug wires are longer than 18 inches 46 cm If shielded cable is used ground only one end of the shield to earth ground Do not ground both ends of the shield INHIBIT TERMINAL THOT E 1 g S 1 502 CURRENT 2 4 Figure 5 Inhibit Terminal Location 17 Decelerating to minimum speed A switch may be used to decelerate the motor to minimum speed
24. um speed setting Motor runs too slow or too fast Motor will not reach the desired speed Possible Causes Drive is overloaded Drive is not receiving AC line voltage Motor is not connected MIN SPD and MAX SPD settings are too high MIN SPD and MAX SPD are not calibrated MAX SPD setting is too low IR COMP setting is too low Motor is overloaded Suggested Solutions Verify that the motor is not jammed Increase CURRENT LIMIT setting page 25 Apply AC line voltage to L1 and L2 Connect motor to A1 and A2 Recalibrate MIN SPD page 22 and MAX SPD page 22 Recalibrate MIN SPD page 22 and MAX SPD page 22 Increase MAX SPD setting page 22 Increase IR COMP setting page 24 Check motor load Resize the motor if necessary Possible Causes Motor pulsates or 1 IR COMP is set too surges under load high 2 Control is in current limit mode Suggested Solutions Adjust the IR COMP setting slightly CCW until the motor speed stabilizes page 24 Check that motor and drive are of sufficient horsepower and amperage You may need to replace the motor and or the drive 43 Certificate of Compliance CE Certification Bison hereby certifies that this series of drives have been approved to bear the CE mark provided the conditions of approval have been met by the end user The OEM mus
25. wn in Figure 3 page 10 Master power switch Decelerating to minimum speed or coasting to a stop may not stop a drive that is malfunctioning Removing AC line power both L1 and L2 is the only acceptable method for emergency stopping For this reason Bison strongly recommends installing an emergency stop switch on both the L1 and L2 inputs The switch contacts must be rated at a minimum of 250 volts and 200 of maximum drive current Motor Bison drives supply motor voltage from A1 and A2 terminals It is assumed throughout this manual that when A1 is positive with respect to A2 the motor will rotate clockwise CW while looking at the output shaft protruding from the front of the motor If this is opposite of the desired rotation simply reverse the wiring of A1 and A2 with each other Connect a DC motor to PCB terminals A1 and A2 as shown in Figure 3 Ensure that the motor voltage rating is consistent with the drive s output voltage Power input Connect the AC line power leads to PCB terminals L1 and L2 or to a double throw single pole master power switch recommended Line fuse Wire an external line fuse between the stop switch if installed and the L1 terminal the circuit board An additional line fuse should be installed on L2 if the input voltage is 230VAC The line fuse s should be rated at 250 volts and 150 200 of maximum motor nameplate current Refer to the line fuse chart on page 6 for fuse ratings 10
26. ximum braking current Wait for the motor to stop completely before switching it to either the forward or reverse direction See the Dynamic braking section on page 18 for sizing the dynamic brake resistor DYNAMIC BRAKE RESISTOR INHIBIT Figure 19 Reversing 38 Troubleshooting A Warning Dangerous voltages exist on the drive when it is powered and up to 30 seconds after power is removed When possible disconnect the drive while troubleshooting High voltages can cause serious or fatal injury Before troubleshooting Perform the following steps before starting any procedure in this section Disconnect AC line voltage from the drive Check the drive closely for damaged components Check that no conductive or other foreign material has become lodged on the printed circuit board Verify that every connection is correct and in good condition Verify that there no short circuits or grounded connections Check that the voltage selection switch settings match the AC line and output voltages Check that the drive s rated armature and field outputs are consistent with the motor ratings For additional assistance contact your local Bison distributor or the factory direct Phone 1 800 AT BISON 39 Diagnostic LEDs This series of drives are equipped with the following diagnostic LEDs to aid in troubleshooting or monitoring equipment status Refer to Figure 20 below POWER Green LED
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