Bronco VFD Series Adjustable Frequency Drives
Contents
1. BRAK N TORQUE __ L TIME 507 RESTART 06 _ JMP503 COAST BRAKE RI 6508 1 11 TB502 2502 ACCEL BOOST TORQUE LIMIT BRAKE TIME Figure 23 BVFD163 and BVFD163WD Calibration Trimpot Locations 37 ZERO SET JMP503 UV TRIP RESTART _ 1 504 X ENABLE BRAKE COAST x IL501 x 1502 POWER FAULT JMP501 INSTALL JUMPER FOR 115VAC JMP504 2 3 mA JMP505 RANGE SELECT 1 0 5VDC BRAKE CURREN BRAKE TIME INPUT SELECT 1 2 VDC ACCEL DECEL SLIP COMP BOOST TORQUE LIMIT BRAKE CURRENT BRAKE TIME Figure 24 BVFD161 Calibration Trimpot Locations 38 Calibration Procedure Setup for 60 Hz Motors 1 Set JMP501 amp JMP502 to appropriate input voltage setting 115 230VAC Refer to Figures 6 and 7 pages 6 and 7 for Jumper Locations Set the ENABLE switch to the DISABLE open position If no switch is installed remove the jumper between the E2 and E1 terminals of TB501 Set DIRECTION switch to the FWD open position If no switch is installed confirm that there is no jumper between the D and E1 terminals of TB501 Set all trimpots except TQ LIMIT and MAX fully counterclockwise CCW Set the TQ LIMIT trimpot to maximum full CW 6 S2. PUSHBUTTON RUN JOG SWITCH m TB501 motor coasts to stop j Oo 92 E2 ENABLE RUN 92 E1 COMMON s O Figure 26 RUN JOG Switch 45 Single speed potentiometer control of multiple motors Warning The combined current draw of all motors must not exceed the current rating of the drive The BVFD series of controls is capable of operating up to eight 3 phase motors simultaneously All motors must be of the same type and must control similar loads Connect each motor as shown in Figure 27 below cw 53 52 51 BVFD SERIES SPEED ADJUST DRIVE POTENTIOMETER 10K OHM Figure 27 Single Speed Potentiometer Control of Multiple Motors 46 Quick Reversing To reverse the direction of motor shaft rotation install a DPDT center off switch as shown in Figure 28 below The drive will stop the motor before reversing so there is no need to wait for the motor to coast to a stop before changing direction JMP506 must be set to brake Refer to Figures 6 and 7 pages 6 and 7 for Jumper Locations TB501 E2 ENABLE DPDT CENTER OFF SWITCH E1 COMMON FWD s OoOo 5 a A REV Lp 51 52 53 SQQ GO GS Figure 28 BVFD Quick Reversing 47 Troubleshooting Warning Dangerous voltages exist on the drive wh
3. AC DC Drives Bronco VFD Series Adjustable Frequency Drives BVFD161 BVFD163 BVFD163WD Solutions by DA N A H E R User Manual MOTION Edition 5 06 Copyright 2006 by Danaher Motion All rights reserved No part of this manual may be reproduced or transmitted in any form without written permission from Danaher Motion The information and technical data in this manual are subject to change without notice Danaher Motion 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 Danaher Motion 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 coss Printed in the United States of America Safety Warnings A Xx 4 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 Occupational Safety and Health Act OSHA when installing equipment Reduce the chance of an electrical fire
4. 27 Voltage Doubler A Warning DO NOT connect 230 VAC line input when drive is set for 115 VAC input This will result in severe damage to the motor and drive and possible explosion or severe injury The BVFD series drives are equipped with a unique voltage doubling feature for use when 230 VAC input voltage is not available This feature converts a 115 VAC input to a 230 VAC output for use with 230V motors The drive output current rating remains the same for either AC input voltage Refer to Figure 11 12 page 19 for connection information Use extreme caution when connecting this feature Incorrect use of this feature may result in fire and or serious injury NOTE The BVFD series of drives covered in this manual are meant to be used with 208 230 VAC motors only DO NOT use this series of drives with 115 VAC motors 28 Startup Warning DO NOT change jumper settings with power applied Ensure that jumper settings are compatible with the motor being controlled Before applying power verify that no conductive material is present on the printed circuit board Verify that no conductive material is present on the PCB Verify that the correct voltage is connected to the inputs before applying power DO NOT CONNECT 230 VAC line voltage to a 115 VAC configured drive Applying power in this manner will damage the motor and drive Set the speed adjust potentiometer or reference signal to ze
5. 14 Speed adjust potentiometer 15 CONMECHONG oos vepres uie SU Na Y led SORS TIE E ZEN 16 Input AC Power Connections 16 Motor connections 20 Speed Adjust Potentiometer Connections 22 Signal and Optional Switch Connections 23 Voltage or Current Follower 24 Operation 26 Voltage Doubler a rsi 352 1 m bU ih Y Eoi UII 27 SlanUpys s Tua u aes RE RIO Z 3 28 To reverse motor direction 29 Starting and stopping methods 30 To coast the motor to a stop 30 To brake the motor stop 30 Thermal protection of the motor 31 Line starting and stopping 33 Contents vii Calibration 35 Calibration Procedure Setup for 60 Hz Motors 38 MAXIMUM SPEED MAX SPD 38 MINIMUM SPEED MIN SPD 39 TORQUE LIMIT TQ LIMIT uscite tornadi esera ETT EERW 39 ACCELERATION ACCEL 40 DECELERATION DECEL 40 BOOST en A O E E 41
6. 20 AC e Figure 7 BVFD161 Jumper Locations Installation A Warning input power applied Failure to heed this warning 4 DO NOT install rewire or remove this control with 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 Opening any one motor lead may damage the drive Wait at least one minute after power is removed from drive before working on drive It is recommended that tape be applied to the back side of the conduit knockouts before knocking the two holes out to shield the drive from metal shavings Surface should be cleaned of all metal shavings and other metal coating material before 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 that you read and understand the Safety Warnings before attempting installation NOTE Horizontal mounting may require derating the drive See your Danaher Motion representative for more information It is recommended that the drive be oriented with the chassis vertical for best heat dissipation Horizontal mounting while acceptable may require some thermal derating Four 0 19 inch
7. Layouts C501 C502 D S3 S2 51 E1 E2 78501 nk vee Icso2 et 2501 g gt E 123 SELECT INPUT TYPE 10503 1 URRENT INPUT 2 amp 3 VOLTAGE o 1804 ENABLE POWER FAULT BRAKE TORQUE TIME LIMIT C507 uv TRIPS RESTART JMP506 s JMP503 COAST BRAKE 1503 6l R1 m 123 JMP507 gt gt RESTART 1 2 MANUAL 23 AUTO 115V lt 2307 501 o 8502 jt 1 Figure 4 BVFD163 and BVFD163WD Circuit Board Layout 4 TBS01 ZERO SET JMP503 UV TRIP RESTART 1504 XX ENABLE BRAKE coast XX POWER FAULT 0 JMP501 INSTALL JUMPER FOR 115VAC JMP504 INPUT SELECT 1 2 VDC 2 3 mA JMP505 RANGE SELECT 1 0 5VDC 2 0 10VDC 3 4 20 CURREN BRAKE TIME Figure 5 BVFD161 Circuit Board Layout 6 Jumper Locations C501 id
8. SLIP COMPENSATION 42 Calibration Procedure Conclusion 42 Application Notes 43 Independent adjustable speeds with DIR switch 43 RUN JOG ER EEUU RETE R e ds 44 Single speed potentiometer control of multiple motors 45 Quick Reversing e ens br repe ene ee repre c e n erm ni ena 46 Troubleshooting 47 Before troubleshooting 47 Diagnostic LEDS7 ix veterem iienhe Utere E ae 49 POWERLED SEM IBN 49 ENABLE LED ene Dedi qne obe eet s 49 49 TQLIMIT LED 50 Optional C510 Capacitor Kit 56 Tables Table LinecdF sing Cliart 55 ehh be ee fen oe 16 Table 2 Trip Restart Mode Chart 34 viii Illustrations Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Bronco VFD Series Features amp Benefits iv BVFD163 163WD Dimensions 2 BVED161 Dimensions zz dene ete eo 3 BVFD163 163WD Circuit Board 4 BVED461 Circuit Board layout cM TS ee ee ae
9. NOTE Run the motor at the lowest continuous frequency speed required Monitor the motor phase current with a true RMS meter while very slowly turning the BOOST trimpot CW until the motor operates properly or 10096 of the motor nameplate current is reached Use the absolute minimum amount of BOOST necessary to achieve proper motor operation Improper use of the BOOST feature may cause motor and or drive overheating and failure If proper motion operation cannot be achieved with the above procedure please contact your Danaher Motion representative 42 SLIP COMPENSATION SLIP COMP Slip compensation is used to minimize the normal speed changes occurring in an induction motor from no load to full load conditions 1 2 Using the speed adjust potentiometer or reference signal run the motor at the desired RPM under a no load condition Measure the RPM with a tachometer Without changing the speed adjust potentiometer or reference signal apply a full load to the motor and bring the motor speed back up using the SLIP COMP pot to the originally measured RPM These procedures 1 amp 2 may need to be repeated several times to reach the desired accuracy required Wide speed range accuracy of the slip compensation method depends heavily on motor slip vs frequency characteristics Calibration Procedure Conclusion 1 Set the speed adjust potentiometer or reference signal to zero full CCW Disable the
10. shock or explosion by using 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 Danaher Motion 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 General Information The SECO Bronco VFD Series are solid state variable frequency AC motor drives The Bronco VFD utilizes a 115 or 230 VAC 50 60 Hz single phase input and is factory calibrated for an output of 0 to 60 Hz They will operate any 1 5 HP or smaller 208 230 volt three phase AC induction single phase permanent split capacitor motor see page v and can be user calibrated for O through 120 Hz output Although Bronco VFD inverters can operate over their full speed range most motors will operate with constant torque over a 10 1 speed range 6 Hz to 60 Hz and constant horsepower above 60 Hz Inverter duty motors may operate satisfactorily over a 20 1 speed range Some motors can be satisfactoril
11. 120 Hz Minimum Output Frequency Range 0 30Hz Acceleration Time Range 1 12 seconds Deceleration Time Range 1 12 seconds Analog Input Voltage Range 0 5VDC 0 10VDC 4 20mA Input Impedance S1 to S2 100K ohms Braking Current 0 100 rated output Braking Time 1 12 seconds Vibration 0 56 max 20 50 Hz 0 1G max 50 Hz Weight 1 216 Ambient Operating Temperature Range 10 40 C solation is standard and allows for non isolated speed input enable and direction switch inputs to be used 2 Dimensions Forward Reverse sai Stop 8 125 8 875 9 500 F 2 500 k 5 000 0 250 W x 0 375 L SLOT 1 500 CONDUIT KNOCKOUT 0 875 2PLACES Figure 2 BVFD163 and BVFD163WD Dimensions 5 625 143 7 200 183 H 6 350 161 0 850 22 n oooooolxO x UV TRIP ENABLE xus i es m FOR Den M INPUT SELECT 388 4 2 VDC BRs01 Baa 23 IEEE la 89 SCR501 a ius pes E SLE i x f 0 188 5 LL DIMENSIONS IN INCHES MILLIMETERS Maximum Height C1 amp C2 3 30 84 Figure 3 BVFD161 Dimensions 4
12. DIU RAE 5 BVFD163 163WD Jumper Locations 6 BVFD161 Jumper Locations 7 Figure 8 Speed Adjust Figure 9 AC Line Connections for 161 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 Figure 32 AC Line Connections for BVFD163 163WD Voltage Doubler Feature for BVFD163 163WD Voltage Doubler Feature for 161 Motor Connections Single Phase Operation pre wired cap 20 Motor Connections Single Phase 21 Motor Connections Three Phase Operation 21 Speed Adjust Potentiometer Connections to TB501 22 Signal and Optional Switch Connections 24 Jumper Settings JMP504 and 505 25 BVFD163 163WD Jumper Settings JMP506 31 BVFD161 Jumper Settings JMP506 31 Thermal Overload Switch with Optional Enable Disable Switch 32 Jumper Sett
13. Input AC Power connections Connect the AC power input to TB502 L1 and L2 as shown in Figures 9 and 10 page 17 Connect an external master stop switch Install the switch between the external AC power input as shown 17 L1 12 U V w TB502 startistop SWITCH 115 230 LINE INPUT Figure 9 Line Connections for BVFD161 u V w L1 L2 e JE ARIE 6p TB502 START STOP 5 E SWITCH 115 230 VAC LINE INPUT Figure 10 AC Line Connections for BVFD163 and BVFD163WD 18 Warning Do not connect 230 VAC line AAA input when the drive is set for 115 VAC input This will result in severe damage to the motor and can lead to explosion and or injury Connect AC Power input to L1 and L2 as shown in Figures 9 and 10 page 17 depending on the model of drive being usedbvg NOTE The BVFD series drives are equipped with a voltage doubler feature which converts a 115 VAC input to a 230 VAC output for use with 230V motors The drive output current rating remains the same for either AC input voltage Use caution when connecting this output If the input voltage is 115 VAC and the desired output voltage is 230 VAC voltage doubler mode set jumpers as shown in Figures 11 12 page 19 If the input voltage is 230 VAC and the desired output voltage is 230 VAC no voltage do
14. Jumper Pins 1 amp 2 to Brake 3 COAST Jumper Pins 2 amp 3 to Coast Figure 20 BVFD161 Jumper Settings JMP506 Thermal protection of the motor The enable input can also act as a motor thermal protection circuit for motors having a built in thermal protector These thermal protectors are operated only by motor heat and open the enable circuit when the motor reaches a temperature capable of causing damage to the motor winding 32 Normally these thermal procedures automatically close the circuit when the motor has cooled to a safe temperature In operation the drive can be disabled by opening the enable Switch or opening the thermal overload switch See Figure 21 below ENABLE DISABLE SWITCH THERMAL TB501 OVERLOAD CLOSE TO ENABLE SWITCH O O oro E2 ENABLE E1 COMMON Figure 21 Thermal Overload Switch with Optional Enable Disable Switch 33 Line starting and line stopping Warning Danaher Motion strongly recommends the installation of a master power switch in the voltage input line see Power and Fuse connections page 16 The switch contacts should be rated at a minimum of 20096 of motor nameplate current and 250 volts Line starting stopping applying and removing AC voltage input may be used by setting the drive to Automatic Restart as shown in Table 2 Automatic Restart allows the drive to run the motor when AC power is first applie
15. Shielding guidelines A Warning Under no circumstances should power and logic leads be bundled together Induced voltage can cause unpredictable behavior in any electronic device including motor controls As a general rule Danaher Motion recommends shielding of all conductors If it is not practical to shield power conductors Danaher Motion recommends shielding all logic level leads If shielding the 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 13 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 on this drive Heat sinking BVFD series drives are delivered with a heat sink chassis Ensure that there is adequate space above and below the drive for proper convection air flow A small fan may be necessary for proper cooling in restricted space applications 14 Fusing BVFD series dr
16. shown in Figure 17 above Ensure that the following jumper terminals are properly set as shown in Figure 18 page 25 25 JMP504 Input Type Jumper pins 1 amp 2 for Voltage follower or speed pot mode Jumper pins 2 amp 3 for Current follower JMP505 Input Range Settings Set jumper in position 1 for 0 5 VDC signal or speed pot input Set jumper in position 2 for 0 10 VDC signal input Set jumper in position 3 for 4 20 mA signal The 4 20 mA ZERO SET potentiometer should be used to calibrate the zero or minimum speed of the drive with 4 applied to the input For voltage inputs this pot should be set to full CCW JMP504 504 1 amp 2 for Voltage Input Toe 2 amp 3 for Current Input 2 3 JMP505 505 1 0 5 VDC INPUT 8 26 de 2 0 10 INPUT ele e 3 4 20 INPUT 123 Figure 18 Jumper Settings JMP504 JMP505 26 Operation A Warning Dangerous voltages exist on the drive when it is powered and up to 60 seconds after power is removed and the motor stops BE ALERT High voltages can cause serious or fatal injury Do not change jumper settings with power applied Ensure that jumper settings are compatible with the motor being controlled Voltage Input Warning DO NOT connect 230 VAC line input when the drive is set for 115 VAC input This will result in severe damage to the motor and drive and possible explosion and or injury
17. 5 mm wide slots accept 8 pan head screws Fasten the heatsink chassis to the subplate Drive components are sensitive to electrostatic fields Avoid direct contact with the circuit board Hold the drive by the chassis only 10 Protect the drive from dirt moisture and accidental contact Provide sufficient room for access to the terminal block and calibration trimpots Mount the drive away from the heat sources Operate the drive within the specified ambient operating temperature range Prevent loose connections by avoiding excessive vibration of the drive 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 11 DO install rewire or remove this control with input 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 Opening any motor lead may damage the drive Wait at least one minute after power is removed from drive before working on drive Use 20 24 AWG wire for speed adjust potentiometer wiring Use 14 AWG wire for AC line L1 L2 and motor W wiring 12
18. IM setting page 39 Fix load i e straighten mounting coupling etc or replace motor and drive with motor and drive rated for higher horsepower Compare motor voltage to input voltage Replace motor if necessary 56 Optional Capacitor Kit p n 202 0108 In some applications lowering carrier frequency reduces switching losses and increases bearing life in some motors Danaher Motion provides an optional capacitor kit for lowering the carrier frequency The default carrier frequency on BVFD controls is 16kHz Using one of the capacitors supplied in the kit the carrier frequency can be lowered to a range of 12kHz to 4kHz Note Audible noise will increase when the carrier frequency is lowered To lower the carrier frequency on all BVFD controls install one of the following 2 pin capacitors on the board LABEL ON CAPACITOR FREQUENCY VALUE 3n3J 12kHz 0 0033uF 6n8 10kHz 0 0068uF 10n 8kHz 0 01uF 33n 4kHz 0 033uF See Figures 31 and 32 for Capacitor locations and installation instructions 57 Insert the 2 pins of the carrier frequency capacitor into the 2 Socket holes C503 located on board Cap Label 7 3n3 J100 i D 1 1 D D TORQUE LIMIT JMP504 T C503 INPUT SELECT 2 2 3 mA JMP505 RANGE SELECT 120 5 220 10 VDC 3 4 20 Figure 31 BVFD161 Carrier frequency capacitor location 58 Insert the 2 pins
19. JMP504 D S3 S2 51 El E2 Ls JMP505 JMP504 9 123 gl umpsos 8 123 T501 SELECT INPUT 10503 14 2 CURRENT INPUT 28 3 VOLTAGE INPUT 1504 502 SELECT RANGE 1 0 5VDC INPUT ENABLE 2 0 10 VDC INPUT 3 4 20 MA INPUT 1501 _ 1502 s Ww SLIP E TN COMP POWER FAULT BRAKE CURRENT JMP506 Y E TIME LIMIT C507 JMP503 Uv TRIP RESTART ue JMP506 gt JMP503 Ej COAST BRAKE R1 J502 1503 7650 507 JMP507 2 RESTART 1 2 MANUAL 23 115V 230V JMP501 JMP501 T TB502 Figure 6 BVFD163 and BVFD163WD Jumper Locations 123 JMP504 looo000 21 JMP503 1501 Jupsos Z uy TRIP RESTART C502 XX ENABLE BRAKE IMP JMP506 eos FAULT PEGEL aes E JMP507 1 503 e JMP501 WP INSTALL JUMPER 020 General Location FOR 115VAC e JMP504 aa INPUT SELECT as C 1 2 VDC BR501 2 3 mA JMP505 RANGE SELECT 120 5VDC 2 0 10VDC 3 4 20 IFU502 Dee se JMP502 Jelelelee C508 SCR501
20. LIMIT Figure 30 BVFD161 LED locations Problem Internal line fuse blows Internal line fuse does not blow but the motor does not run Possible Cause Line fuses are the wrong size Motor or motor cable is shorted to ground Nuisance tripping caused by a combination of ambient conditions and high current Spikes i e reversing Speed adjust potentiometer or voltage input signal is set to zero speed Speed adjust potentiometer or voltage input signal is not properly connected to drive input connections are open Suggested Solution Check that line fuses are properly sized for the motor being used Check motor cable and motor for shorts Add a blower to cool the drive components increase TQ LIMIT settings page 39 Increase the speed adjust potentiometer setting or voltage input signal Check connections to input Verify that connections are not open Problem Internal line fuse does not blow but the motor does not run cont Motor runs too slow or too fast at set speed Possible Cause Drive is tripped off or has gone into thermal overload Drive has been disabled Drive is in current limit Drive is not receiving AC voltage input Motor is not connected MAX SPD trimpot is not calibrated correctly Suggested Solution Disable then re enable the drive Ensure that E
21. NABLE EN and COM terminals are properly connected Verify that motor is not jammed Increase TQLIM setting if it is set too low page 39 Apply AC line voltage to L1 and L2 Connect motor to drive outputs U V and W Calibrate MAX SPD trimpot page 38 Problem Motor will not reach the desired speed Motor pulsates or surges under load Motor does not reverse Possible Cause MAX SPD setting is too low Nominal input voltage may be too low for motor Motor is overloaded Motor bouncing in and out of torque limit Defective DIRECTION Switch connection Reversing circuit not working properly Motor not wired correctly for reverse Suggested Solution Increase MAX SPD setting page 38 Compare motor voltage to input voltage replace motor if necessary Check motor load Resize the motor or drive if necessary Make sure motor is not undersized for load adjust TQ LIM setting CW page 39 Check DIRECTION Switch connection Check reversing circuit by shorting TB501 D terminal to E1 terminal with jumper wire Check motor wiring Review motor connections section Problem TQ is unsatisfactory at high speeds Possible Cause TQ LIMIT set too low Load may exceed rating of motor drive Nominal input voltage may be too low for motor Suggested Solution Check TQ L
22. RD ISOLATION SLIP COMP ACCEPTS 0 5 VDC 0 10 4 20 mA NON ISOLATED SIGNAL TQ LIMIT ZERO SET VOLTAGE DOUBLER BRAKE TIME DOUBLES THE OUTPUT VOLTAGE TO THE AC BRAKE MOTOR WHEN 115 IS APPLIED Figure 1 Bronco VFD Series Features amp Benefits Important Information A Warning Caution should be taken when operating fan cooled motors at low speeds because their fans may not move sufficient air to properly cool the motor Danaher Motion recommends inverter duty motors when the speed range is beyond 10 1 In addition to standard 3 phase induction motors the following motor types may be used with the Bronco VFD Permanent split capacitor PSC Shaded pole AC synchronous The following motor types MAY NOT be used Split phase Capacitor start Repulsion induction Series Universal AC DC Any motor with starting switch centrifugal or relay and or separate starting winding Contents Safety Warnings i General Information ii Important Information Specifications 1 Dimensions 2 Layouts 4 Jumper Locations 6 Installation 8 Mounting IRIS 9 7 ot tutte Rt Om DA dd dor 11 Shielding guidelines 12 Heat sinking rx yp utispa au a 22 bua ass 13 RUSINO unn pa ety Blind Send
23. ads If not you must make this connection yourself WINDINGS WARNING DO NOT use a direction EE switch with this setup CAPACITOR Figure 13 Single Phase Operation pre wired cap 21 Motor run must be removed from the circuit This method works with most but not all motors AUXILLIARY WINDING WITHOUT CAPACITOR MOTOR WINDINGS Figure 14 Single Phase Operation Reversing Three phase operation Connect a three phase motor to terminals U V and W as shown in Figure 15 below MOTOR WINDINGS Figure 15 Three phase Operation 22 Speed Adjust Potentiometer Connections Set JMP504 for VDC input by jumpering pins 1 amp 2 Set 505 for 0 5VDC by jumpering pin column 1 Refer to Figures 6 and 7 pages 6 and 7 for Jumper Locations Connect a speed adjust potentiometer to terminals S1 S2 and S3 Make sure the potentiometer is connected so that the motor speed will increase as the potentiometer is turned clockwise See Figure 16 below NOTE These settings and connections are factory installed on the BVFD163 163WD drives SPEED ADJUST POTENTIOMETER MISSIS SS D 53 52 51 E1 E2 Figure 16 Speed Adjust Potentiometer Connections to TB501 23 Signal and Optional Switch Connections All signal and switch connections are made at TB501 Terminal block names are identical for all BVFD series drives Use 20 24 AWG
24. d When JMP503 and JMP507 are set for Automatic Restart factory set for Manual Restart the drive will stop when an undervoltage bus drops below 200 VDC occurs This can occur due to line sag line transients or line disconnect A timer 1 5 seconds is started which allows an automatic restart if the bus voltage has returned to proper operational potential The Under Voltage Trip Table 2 setting causes the drive to stop and latch off when an under voltage condition bus voltage drops below 200 occurs This can occur due to line sag line transients or line disconnect The drive may then be restarted by cycling the ENABLE off then on or waiting until the DC bus drops to zero approximately 1 minute at which point the drive will restart upon reapplication of line power 34 Manual Restart Table 2 is similar to the Under Voltage Trip except that the only way to restart the drive is to cycle the ENABLE input Refer to Figure 6 and 7 pages 6 and 7 for Jumper Locations UV JMP503 5 Pins 1 2 or Trip Pins 2 3 or Restart 5 10 57 Manual Restart Not Recommended 5 a x o 5 Under Voltage Trip Automatic Restart o a Table 2 Trip or Restart Mode Chart JMP503 1 2 3 1 UV TRIP Y 2 RESTART MANUAL AUTO JMP507 Figure 22 Jumper Settings JMP503 JMP507 35 Calibration A Warning Dangerous voltages exist on the drive when it is 4 powered and up to 60 sec
25. drive by opening the ENABLE DISABLE switch or removing the jumper from TB501 E2 and E1 terminals Remove power to the motor and drive Calibration is now complete 43 Application Notes Independent adjustable speeds with DIR switch Replace the speed adjust potentiometer with two single pole multi position switches and two or more potentiometers in parallel with a total parallel resistance of 10K ohms Figure 25 below shows the connection of two independent speed adjust potentiometers that can be mounted at two separate operating stations TB501 pam FORWARD SPEED 20K OHM E1 s 20K OHM t L AU i Hi FORWARD 92 D DIRECTION REVERSE O L Figure 25 Independent Adjustable Speeds 44 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 open momentary operated pushbutton for the JOG pushbutton Connect the RUN JOG switch and JOG pushbutton to terminal board TB501 as shown in Figure 26 below The motor stops when the RUN JOG switch is set to JOG Press the JOG pushbutton to jog the motor Return the RUN JOG switch to RUN for normal operation NORMALLY OPEN RUN JOG
26. en it is 7 powered and up to 60 seconds after power is removed and the motor stops When possible disconnect the voltage input from the drive while troubleshooting BE ALERT High voltages can cause serious or fatal injury Before troubleshooting Perform the following steps before starting any procedure in this section Disconnect AC voltage input from the drive Wait 60 seconds for power to discharge The green POWER LED will blink while power is discharging Check the drive closely for damaged components Check that no wire chips or other foreign material has become lodged on the printed circuit board Verify that every connection is correct and in good condition 48 Verify that there short circuits or grounded connections Check that the drive s rated phase current and RMS voltage are consistent with the motor ratings For additional assistance contact your local Danaher Motion distributor or the factory direct by telephone at 1 540 633 3400 49 Diagnostic LEDs SECO BVFD Series drives are equipped with diagnostic LED s to assist the user in troubleshooting and monitoring equipment status while in use Refer to Figures 29 and 30 page 50 and 51 for diagnostic LED locations POWER LED The green POWER LED is on when AC line voltage is applied and the control s low voltage power supply is operational ENABLE LED The red ENABLE LED turns on whenever the inverter output is
27. enabled FAULT LED The red FAULT LED blinks on and off when the drive output is locked out or not ENABLED and any one of the following fault conditions occur 1 Overvoltage BVFD 230AC controls DC bus exceeds 400 VDC 2 Undervoltage BVFD 230 controls DC bus drops below 200 VDC 3 Instantaneous Overcurrent Trip Inverter output current has exceeded safe levels 250 Note The FAULT condition must be reset using the ENABLE function of the BVFD opening and closing the ENABLE input TORQUE LIMIT LED The yellow TQ LIMIT LED is on when the drive output current exceeds the threshold set by the TQ LIMIT trimpot When the TQ LIMIT LED turns on shut down the motor and drive by disabling or removing power Check the motor to make sure it is not jammed or overloaded The TQ LIMIT trimpot may need to be recalibrated See the Calibration section page 35 for information on calibrating the TQ LIMIT trimpot C501 C502 D S3 S2 51 E 2 TB501 p 1 502 4501 T501 i MAX x JE ENABLE RE POWER FAULT 1503 x Figure 29 BVFD163 and BVFD163WD LED locations 51 1000000 123 4mA TB501 ojo o 0 ZERO JMP505 SET 1L501 E C502 11504 ENABLE Ww Ww POWER FAULT 1503 JMP501
28. et the MAX trimpot to the 5096 position Set the speed adjust potentiometer or reference signal to zero full CCW Calibrate the trimmer pots as follows JMP502 is not present on BVFD163 163WD models MAXIMUM SPEED MAX SPD Rotate the speed adjust potentiometer full CW or set the reference signal to MAX Using a hand held tachometer or analog frequency meter as a reference adjust the MAX trimpot until the desired maximum speed or frequency is reached 39 MINIMUM SPEED MIN Rotate the speed adjust potentiometer CCW or set the signal reference to a minimum Adjust the MIN trimpot until the motor has stopped for zero speed setting or until desired minimum speed has been reached TORQUE LIMIT TQ LIMIT Warning Although the TORQUE LIMIT trimpot can be set up to 150 of the drive nameplate rating continuous operation beyond the drive nameplate rating may cause damage to the motor and or drive 1 With no power applied to the drive connect a true RMS ammeter in series with one of the motor leads 2 Set the TQ LIMIT trimpot to full CCW 3 Carefully lock the motor shaft Ensure that the motor is firmly mounted 4 Apply line power The motor should be stopped 5 Set the speed adjust potentiometer or reference signal to maximum speed The motor should remain stopped 6 Slowly rotate the TQ LIMIT trimpot clockwise CW until the ammeter reads 12096 of maximum motor current 40 10 Set
29. ings JMP503 JMP507 BVFD163 163WD Calibration Trimpot Layout BVFD161 Calibration Trimpot Layout Independent Adjustable RUN JOG SwitCh vierte cca ert re em P a Y east Single Speed Potentiometer Control of Multiple Motors QUICK Reversing x dene peer RAE AES orc s oA BVFD163 163WD Diagnostic LED location BVFD161 Diagnostic LED location BVFD161 Carrier frequency capacitor location BVFD163 163WD Carrier frequency capacitor location Specifications 1 Phase 1 or 3 Phase Max Continuous AC Input Output Max Output Amps Drive VAC VAC HP Current AC In BVFD163 415 230 230 1 4 0 1477 BVFD163WD 115 230 230 1 4 0 1477 BVFD161 115 230 230 1 5 0 20 10 Connect only 115 VAC line input to the 115 VAC terminals Application of 230 VAC line input when set for 115 VAC will result in severe damage to the motor and drive and possible explosion and injury T Derate current by 2 per degree if the operating temperature is above 40 C Under no circumstances may the ambient temperature exceed 55 C AC Voltage Input Range 115 230 VAC x 1096 50 60 Hz single phase Standard Carrier Frequency 16 KHz Output Frequency Range 0 120 Hz Maximum Output Frequency Range 30
30. ives include AC power line fuses on the main PC Board Use fast acting fuses rated for 250 VAC or higher See Table 1 for recommended line fuse sizes Table 1 Line Fusing Chart 1 Phase AC AC Line Input Max Amps Fuse Drive VAC HP In Size Amps BVFD163 163WD 115 230 1 14 7 15 BVFD161 115 230 1 20 10 20 15 Speed adjust potentiometer BVFD161 Only Mount the speed adjust potentiometer through a 0 38 in 10 mm hole with the hardware provided Figure 8 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 U V W MOUNT THROUGH A 0 38 IN 10 MM HOLE STAR WASHER SPEED ADJUST POTENTIOMETER POT TAB ASSIGNMENTS NUT INSULATING DISK PANEL Figure 8 Speed Adjust Potentiometer 16 Connections All power input and power output connections are made to TB502 A Warning DO connect this equipment with power applied Failure to heed this directive may result in fire or serious injury Danaher Motion strongly recommends the installation of a master power switch in the voltage input line The Switch contacts should be rated at a minimum of 20096 of motor nameplate current and 250 volts
31. lication 2006 Danaher Motion Solutions by 5 DANAHER AC DC Drives MOTION
32. of the carrier frequency capacitor into the 2 socket holes C507 located on board Ww Label TUM ENABLE C x 3n3 J100 N x POWER FAULT 9 9 o o C507 Figure 32 BVFD163 and BVFD163WD Carrier frequency capacitor location Sales and Service Danaher Motion products are available world wide through an extensive authorized distributor network These distributors offere literature technical assistance and wide range of models off the shelf for fastest possible delivery Danaher Motion sales engineers are conveniently located to provide prompt attention to customers needs Call the office listed for ordering and application information or for the address of the closest authorized distributor Danaher Motion 203A W Rock Rd Radford VA 24141 Website www danahermotion com Email DMAC gdanahermotion com Phone 540 633 3400 Fax 540 639 4162 DANAHER MOTION is a registered trademark of Danaher Corporation Danaher Motion makes every attempt to ensure accuracy and reliability of the specifications in this publication Specifications are subject to change without notice Danaher Motion provides this information AS IS and disclaims all warranties express or implied including but not limited to implied warranties of merchantability and fitness for a particular purpose It is the responsibility of the product user to determine the suitability of this product for a specific app
33. onds after power is removed and the motor stops When possible disconnect the voltage input from the drive before adjusting the trimpots If the trimpots must be adjusted with power applied use insulated tools and the appropriate personal protection equipment BE ALERT High voltages can cause serious or fatal injury The BVFD series has ten user adjustable trimpots Each drive is factory calibrated to its maximum horsepower rating Re adjust the calibration trimpot settings to accommodate lower horsepower motors See Figures 23 and 24 pages 36 and 37 for BVFD series trimpot locations All adjustments increase with clockwise CW rotation and decrease with counter clockwise CCW rotation Use a non metallic screwdriver for calibration Each trimpot is identified on the printed circuit board 36 DECEL SLIP COMP BRAKE CURRENT C501 ZERO SET 6502 2090 T501 D S3 52 m E2 2501 JMPS05 1 ICs02 12503 JMPS01 SELECT INPUT TYPE 1 amp 2 CURRENT 2 amp 3 VOLTAGE INPUT 1 504 e 49502 SSLSCT RANGS 0504 AA 1 ENABLE 2 E 1502 de POWER sO BRAKE FAULT CURRENT 2503 123 JMP507 oe gt RESTART 12 MANUAL 23 nsv lt gt 2307 501
34. ro full CCW Setthe DIRECTION switch if installed to the desired direction If no switch is installed add or remove a jumper across the D and E1 terminals as required Set the ENABLE DISABLE switch if installed to ENABLE or short the ENABLE E2 and E1 terminals on TB501 Apply 115 or 230 VAC 50 60 Hz single phase power to the drive The green POWER LED will come on after an initial delay of 1 2 seconds If the POWER LED does not light check the line fuses to ensure that they are properly installed and not open 29 7 If you attempt to startup and the yellow LED comes on the control has entered torque limit mode To avoid this occurrence you may a increase the torque limit setting or b lengthen the acceleration time enough to accommodate the starting torque needed by adjusting the ACCEL trimpot Do not set the torque limit setting above 150 of the motor s nameplate current rating To reverse motor direction To reverse the direction of motor shaft rotation while the motor is running set the DIRECTION switch to the opposite position If no DIRECTION switch is installed open or short the DIR and E1 terminals on TB501 as required When a new direction is selected there is no need to open the enable input The control will automatically decelerate the motor to zero speed reverse direction and then accelerate the motor back to the set speed Acceleration and deceleration ra
35. tes are controlled by the ACCEL DECEL trimpot settings If quicker reversing is needed refer to applications notes section page 43 for further detail NOTE DO NOT use the DIRECTION switch if there is a capacitor in the motor windings 30 Starting and stopping methods factory set to COAST position To coast the motor to a stop Insure that JMP506 is set to the COAST position as shown in Figures 19 and 20 page 31 Refer to Figure 6 and 7 page 6 and 7 for Jumper Locations To coast the motor to a stop open the ENABLE DISABLE switch or remove the jumper between ENABLE E2 and COMMON E1 terminals of TB501 Refer to page 23 for instructions on Switch installation To brake the motor to a stop Insure that JMP506 is set to the BRAKE position as shown in Figures 19 and 20 page 31 Refer to Figure 6 and 7 page 6 and 7 for Jumper Locations Confirm BRAKE CURRENT and BRAKE TIME potentiometers are calibrated to a desired value BREAK CURRENT is adjustable from 0 100 of rated output current BRAKE TIME is adjustable from 1 12 seconds To brake the motor open the ENABLE DISABLE switch or remove the jumper between ENABLE E2 and COMMON E1 terminals of TB501 Refer to page 23 for instructions on switch installation 31 1 2 3 JMP506 on top board YY Jumper Pins 1 amp 2 to Coast Jumper Pins 2 amp 3 to Brake COAST BRAKE Figure 19 BVFD163 and BVFD163WD Jumper Settings JMP506 1 JMP506 on top board 2 BRAKE
36. 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 lead ACCELERATION ACCEL 1 2 3 Set the speed adjust potentiometer or reference signal to zero and wait for the motor to come to a stop or minimum speed Set the speed adjust potentiometer or reference signal to maximum speed full CW and note the time the motor takes to accelerate to maximum speed If the acceleration time differs from the desired time adjust the ACCEL trimpot until the desired time is reached Rotating the ACCEL trimpot CW increases the acceleration time DECELERATION DECEL 1 Set the speed adjust potentiometer or reference signal to maximum full CW and wait for the motor to reach maximum speed 41 2 Set the speed adjust potentiometer or reference signal to minimum speed full CCW and note the time the motor takes to decelerate to minimum speed 3 If the deceleration time differs from the desired time adjust the DECEL trimpot until the desired time is reached Rotating the DECEL pot CW increases the deceleration time BOOST The BOOST trimpot is used to increase motor torque at low speeds The minimum setting is sufficient for most applications and does not need to be adjusted If the motor stalls or runs erratically at very low speeds below 10 Hz the boost trimpot may need adjustment 1
37. ubler set jumpers as show in Figure 11 12 page 19 Refer to Figures 6 and 7 pages 6 and 7 for jumper locations NOTE The BVFD series of drives covered in this manual are meant to be used with 208 230 VAC motors only DO NOT use this series of drives with 115 VAC motors 19 JMP501 WARNING T A Using 230 VAC input in Doubler mode will damage the drive Jumper pins1 amp 2 for 115VAC 115 115 VAC INPUT DOUBLER MODE Jumper pins 2 amp 3 for 230VAC 230 230 VAC INPUT MODE Figure 11 Voltage Doubler Feature for BVFD163 and BVFD163WD MP90 INSTALL JUMPER JMP502 FOR 115VAC Pins 1 amp 2 for 115 VAC Pins 2 amp 3 for 230 VAC 115 VAC 230 VAC JMP501 Install JMP501 for 115 VAC only Figure 12 Voltage Doubler Feature for BVFD161 20 Motor connections all BVFD series controls Motor connections are made to TB502 Single phase operation For single phase operation connect the motor as shown below in Figure 13 Ensure that the prewired capacitor and its associated motor coil are connected to terminals U and V as shown This connection may be internal if using a 2 wire motor If the motor has three leads you must make this connection yourself To reverse a single phase permanent split capacitor motor connect the motor as shown in Figure 14 page 21 The motor cap must be removed from the circuit NOTE This connection may be internal to the motor 2 wire le
38. wire for speed adjust potentiometer and switch connections NOTE The Enable Disable and Direction switch are factory installed on the BVFD163 163WD drives ENABLE DISABLE switch Connect a single pole single throw ENABLE DISABLE Switch between the ENABLE E2 and COMMON E1 terminals as shown Open the switch to disable the drive and coast or brake to a stop Refer to page 30 for stopping method Close the switch to accelerate to set speed at a rate controlled by the ACCEL trimpot DIRECTION D switch Connect a single pole single throw DIRECTION switch between the D and COMMON E1 terminals as shown in Figure 17 page 24 Opening the switch will cause the motor to rotate in the forward direction closing the switch will reverse motor rotation The drive will decelerate the motor to a stop at the DECEL trimpot setting before reversing so there is no need to wait for the motor to coast or brake to a stop before changing direction For faster reversing see Application Notes page 46 24 mU SBEEU BOT ENABLE DISABLE DIRECTION SWITCH OR SIGNAL INPUT open to disable TB501 Figure 17 Signal and Optional Switch Connections for BVFD Series Voltage or Current Follower Drives can be configured to follow an isolated or a grounded non isolated voltage or current signal To configure the drive to follow a voltage or current signal connect the signal leads to the S1 and S2 terminals on TB501 as
39. y operated at speeds as low as 50 rpm speed range 50 1 Below 50 rpm some motors may show signs of stepping or cogging and may run warmer Although the Bronco VFD will allow a minimum of 0 Hz the actual minimum frequency is dependent on motor type and load The motor may need to be derated for low frequency 30 Hz and lower operation Please consult the motor manufacturer General Information iii Many 3 phase inverter manufacturers claim that they can run single phase motors effectively This is normally accomplished by wiring only 2 phases however this method may cause instabilities due to the lack of feedback from one of the motor connections Furthermore motor torque will be reduced considerably because the phases are 120 apart Although the Bronco VFD uses this method of connection its fundamental design enables it to operate efficiently under these conditions The Bronco VFD series features solid state reversing with adjustable acceleration and deceleration The Bronco VFD may also interface with motor thermal protection through the enable circuit General Information Bronco VFD SERIES FEATURES amp BENEFITS SOLID STATE CIRCUITRY SOLID STATE REVERSING ADJUSTABLE CARRIER FREQUENCY 4 kHz 16 kHz MULTIPLE MOTOR OPERATION THREE PHASE AND SINGLE PHASE MOTOR CONTROL LED INDICATORS ADJUSTABLE CALIBRATION TRIMPOTS POWER green ENABLE red FAULT red TORQUE yellow BOOST STANDA
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