User`s Manual for Bodine ABL Unfiltered SCR - Innovative-IDM
Contents
1. Figure 2 Heatsink orientation Cable Assembly The Model 3983 Cable Assembly shown in Figure 3 is designed to simplify the electrical connections to the ABL 3910C Control One end of the cable which connects to the motor is terminated with a circular type connector The other end which connects to the control has a six pin rectangular connector three individual motor phase leads with quick disconnects and an earth ground lead Earth Ground Lead J Mates to Motor Connector or Model 3982 Extension Cable To Control O MOTOR S b i L PHASE nn A LEADS To Motor WS t Commutation Sensor Connector Figure 3 Model 3983 Cable Assembly WARNING The shield common is at a dangerous potential above ground and presents a voltage hazard Contact with the shield could cause serious injury or death If a non Bodine cable is used or if a special cable is fabricated care should be taken to insulate all exposed shield to avoid serious injury The shield should only be connected to the COM terminal on the Commutation Sensor Input Connector at the control No other shield connection should be made CAUTION Only copper wire with a minimum 60 C rated insulation is recommended if Bodine cable assemblies are not used If your control is equipped with a terminal block it will accept leads up to 14 gauge 18 gauge is the smallest recom2. Figure 4 Control Circuit Board Detail Motor or Hp At full Full DIP Switch AC rms Gearmotor Speed with Speed with Levers Input Type Unfiltered Unfiltered in the On Current Control Control Position 2 6 7 MDA 6 10 oa 1 2 6 7 MDA 8 10 ABL 3910C is 1 3 6 7 MDA 1 1 4 1 2 3 6 7 MDA 1 1 2 2 4 6 7 MDA2 1 5 6 7 MDA3 Figure 5 Horsepower DIP Switch Settings and Fuse Selection Chart 13 Commutation Sensor Connections The commutation sensor leads are prewired in the Model 3983 cable assembly and terminated in a six pin connec tor Figure 3 There is a corresponding Commutation connector on the main control board Figure 4 Mate the polarized cable connector to the Commuta tion connector on the control board The connectors can only mate one way Motor Phase Connections The ABL 3910C unfiltered control utilizes quick connect terminals on the main control board Refer to Figure 4 Locate the Motor Phase Outputs labeled A B and C on the main control board Connect the phase leads as follows Brown to Motor Phase Output A e Red to Motor Phase Output B Orange to Motor Phase Output C Fuse Installation The control input and output are fused The line input fuse has been installed at the factory The control output or Motor Fuse must be selected based on the size of the motor Line Fuse The location of line fuse F1 is shown in Figure 4 It should always be repl
3. 1 Solder the three leads to the potentiometer as shown in Figure 1 Figure 6 Manual Speed 2 Mount the potentiometer in Potentiometer Interface Details the desired location 3 Connect the speed pot to the control board terminals as follows Blue to Terminal S1 Orange to Terminal S2 Yellow to Terminal S3 Manual Disable Direction of Rotation and Deceleration Mechanical switches or relays can be used to switch the control inputs Figure 7 shows a schematic representation of manual or relay switched inputs 15 NOTE The DISCOM DIRCOM DECLCOM S1 and COM terminals on the control board are all connected in common 12V 10K DISABLE 4000 Series CMOS o DISCOM 12V Manual S 4000 Series CMOS Switches DIR or Relay gt Contacts pmooM 12V 10K DECEL 4000 Series CMOS p DECLCOM 1 Signal Common Figure 7 Manual Switch and Relay Control Inputs The following chart lists the control functions relative to the state of the mechanical switches or relays 16 Closed DISABLE Stop Run DIR CW CCW DECEL Decelerate Accelerate The ABL 3910C does not include a braking module When the DISABLE switch is closed the motor will simply coast to a stop The ABL 3910C includes a Smart Reverse Circuit which prevents plug reversing when the DIRection switch is opened or closed The motor will coast to a stop before changing direction The DECEL switch controls soft stops and starts
4. The degree of acceleration and deceleration can be varied with the trim potentiometers on the control board See Page 22 The output shafts of gearmotors with odd number of stages Bodine type designations ending with W3 E1 or E3 will rotate in the opposite direction Electronic Control Input Connections Optional Interface Boards are available from Bodine and other manufacturers They provide electrical isolation between the input signal and the brushless DC motor control circuitry and are recommended for motion control applications requiring electronic control of motor speed rotational direction deceleration and disable Electronic Speed Control Motor speed can be controlled with a 0 to 10 VDC isolated signal with 0 1 mA current capability in lieu of the manual speed potentiometer This speed control input should be connected to terminal S2 on the control board The common side of the signal must also be isolated and connected to terminal S1 on the main control board Logic Signal Control of Disable Direction of Rotation and Deceleration Motor disable direction of rotation and deceleration can be controlled using optically isolated logic signals from a programmable controller personal computer or other electronics WARNING Never rely on logic circuitry as a means of disabling the motor or control To prevent unsuspected mechanical motion and potential injury the 115 VAC power should always be disconnected whenever
5. given setting of the TORQ potentiometer the output torque at speeds below 100 RPM will be less than at higher speeds Refer to Figure 8 RPM 100 e 1725 80 OZ IN o e e e 0 50 100 L 180 OZ IN FILTERED STALL 140 OZ IN Figure 10 Speed Torque Curve showing decreased torque at lower speeds Acceleration Adjustment Adjusting the ACCEL trim potentiometer See Figure 4 counterclockwise decreases the motor s acceleration time down to a minimum of approximately 0 2 seconds A clockwise adjustment increases the rate up to a maximum of approximately 10 seconds Deceleration Adjustment Adjusting the DECEL trim potentiometer See Figure 4 counterclockwise decreases the motor s deceleration time down to a minimum of approximately 0 2 seconds A clockwise adjustment increases the rate up to a maximum of approximately 10 seconds 22 TROUBLESHOOTING WARNING Disconnect the control from the power source before working on the control motor or driven equipment Your control should not require maintenance under normal conditions If you encounter a problem read all applicable instruction literature provided with this control and accessories and double check the wiring The charts on the following pages also provide assistance in troubleshooting those problems which usually occur during normal installation and operation If the problem persists contact your source of purchase or a Bodine Authorized
6. ha a iiini ari eiea 20 Preliminary Checks eere RD Uere eee ri EA TER S 20 Operating the Control ere ee ttt ree einen 20 Internal Adjustments rr rentem nre te ere eren 21 TROUBLESHOOTING ott fi Ai RR e PEDE soda tabevegeentos 23 WARRANTY te e eee PD eb rtu e RR o I S reed 26 FIGURES Figure 1 Quick Reference Connection Diagram sss 2 Figure 2 Heatsink Orientation esee 11 Figure 3 Model 3983 Cable Assembly sss 12 Figure 4 Control Circuit Board Detail 13 Figure 5 Horsepower DIP Switch Settings and Fuse Selection Chart 13 Figure 6 Manual Speed Potentiometer Interface Details sss 15 Figure 7 Manual Switch and Relay Control Inputs sss 16 Figure 8 Connection to Model 3984 Isolation Interface sss 18 Figure 9 Tachometer Output ssassn ennan nennen enne 18 Figure 10 Speed Torque Curve Showing Reduced Torque at Low Speeds 22 Mounting Template 1 eeeeee eese eese esten eene sten atn setae en sense sn sess en seno Centerfold 1999 Bodine Electric Company All Rights Reserved Printed in U S A GENERAL INFORMATION Congratulations And thank you for selecting a Bodine Type ABL 3900 Series Brushless DC Motor Control Your new control will provide the same excellent performance and reliability that have been a Bodine tradition since 1905 Bodine Elect
7. logic circuits or the driven equipment are serviced Exercise extreme caution when using Programmable Logic Controllers PLCs Although some may claim to have optically isolated output modules their output commons may be connected to other circuitry either within or connected to the PLC In such cases the PLC outputs should be isolated from the ABL 3900 Series control board by a relay or by an electronic isolation module to prevent damage to the PLC or the ABL 3900 Series control If a Programmable Controller with a relay output module is not available AC or DC outputs from the PLC can be used to drive separate relay coils See PLC user s manual for application information See Figure 6 to determine how to connect relay contacts to the ABL 3910C 17 Signal Isolation Using a Bodine Model 3984 Interface Module Follow the installation instructions provided with the module to isolate the input signals between the control electronics and the ABL 3900 Series Control See Figure 8 for connections Model 3984 ISO IDIR Motor anon N ABL 3910 Brushless DC Motor Control pis Figure 8 Connection to Model 3984 Isolation Interface Tachometer Output When used with the Bodine ABL 3910 Brushless DC Motor Controls the Model 3984 module provides a digital tachometer output at the ITAK terminal for monitoring motor speed The output pulse levels are low to high to low The typical pulse w
8. INSTRUCTIONS FOR INSTALLATION AND OPERATION Type ABL Unfiltered SCR Brushless DC Motor Control Model 3910 BODINE ELECTRIC COMPANY Manual No 074 00210A IMPORTANT Read this manual completely and carefully Pay special attention to all warnings cautions and safety rules Failure to follow the instructions could produce safety hazards which could injure personnel or damage the control motor or other equipment If you have any doubts about how to connect the control or motor refer to the detailed sections of this manual QUICK REFERENCE Motor A Brown Page 14 Phase B Outputs C 115 Volts L AC Power Inputs Gs dou 60Hz y Page 19 a Red ae gommanion HA Brown BODINE ms Earth ensor ug White BLDC Ground Inputs uc Green Metar Chassis Page 14 COM Black Ground COM 7 Screw Shielded Commutation Cable DIR So DIRECTION SWITCH Yell Closed CW oon ss DIRCOM __3 Open CCW Orange Speed Pot Inputs TS TTE 2 Control DISABLE __ DISABLE SWITCH Page 15 Inputs Closed Stop Page 15 18 Blue 1 DISCOM Open Run DECEL DECEL SWITCH 10K Ohm Speed Closed Decel Potentiometer Q DECLCOM 7 Open Accel NOT INCLUDED w aBL 3910c MAX MIN ACCEL DECEL TORQ 2 2 NE TORQ Adjust motor torque limit CW increases torqu
9. Service Center and describe the problem in detail Include all the nameplate data Do not disassemble the product unless authorized by Bodine Electric Company Performing repairs not authorized by Bodine Electric Company or removing screws will void the Warranty SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION CONTROL BLOWS Control or motor Check for shorts and repair LINE FUSE connected to or shorted control and or motor as required to earth ground Shorted phase leads Correct wiring wiring incorrect Damaged control Contact Bodine or Service Components Center for assistance MOTOR WILL Open line fuse Replace fuse Refer to Figure 5 NOT START AND for proper value POWER LIGHT IS OFF Open line switch Close the line switch MOTOR WILL Motor overloaded Correct load or choose larger NOT START AND motor POWER LIGHT IS ON TORQ trim pot is out Visually check setting Figure 4 of adjustment Adjust TORQ trim pot page 21 23 SYMPTOM MOTOR WILL NOT START AND POWER LIGHT IS ON Cont MOTOR WILL NOT START AND FAULT LIGHT IS ON MOTOR WILL NOT COME UP TO SPEED 24 PROBABLE CAUSE Open motor fuse Speed potentiometer set to zero Closed DISABLE switch Closed DECEL switch Electrical noise on DISABLE and or DECEL input Damaged motor Mistake in motor commutation sensor connections Electric noise on commutation sensor inputs Damaged motor MAX trim pot set too low Speed potentiometer set t
10. aced with a fuse of the same type and rating Its rating can be determined by referring to the chart in Figure 5 Motor Fuse The location of motor fuse F2 is shown in Figure 4 The fuse rating will vary with the size of the motor used To determine the proper fuse rating locate the first four digits of your motor s type number on the motor nameplate Find the same four digits in the chart in Figure 5 to determine the fuse size The ABL 3910C is supplied without motor fuses Manual Control Input Connections Motor speed braking direction of rotation and deceleration can be controlled manually or electronically Refer to the following procedures for connecting control inputs 14 CAUTION The control board signal common is not at ground potential any external signal or equipment connected to the control must be electrically isolated from ground e g relay or optically isolated Non isolated signals will damage the control and or associated external equipment Manual Speed Control A Manual Speed Potentiometer Kit for control ling motor speed is available from Bodine Model number 43300270 The kit contains a 10K Ohm potenti ometer mounting hardware and three 24 inch long leads terminated on one end with 1 4 inch quick connects To connect the speed potentiometer proceed as follows 10K Minimum Speed Adjustment 10K Adjustment 100K bL Signal Common 51 1K 10K Signal Common
11. but not limited to any implied warranties of merchantability and or fitness for a particular use or purpose Bodine s liability under this warranty shall be solely limited to repair or replace ment of the Bodine product within the warranty period and Bodine shall not be liable under any circumstances for any consequential incidental or indirect damages or expenses associated with the warranted products Commutator and or brush wear and its associated effects are a normal occur rence and are not covered by this warranty unless otherwise agreed to by Bodine in writing Any Bodine product which is damaged due to misuse abuse negligence or has been modified or dismantled without the knowledge or written consent of Bodine is not covered by this warranty Control Type Serial No Date of Purchase Place of Purchase 26 NOTES BODINE kf ELECTRIC COMPANY Printed in U S A Bodine Electric Company 2500 W Bradley Place Chicago Illinois 60618 U S A TEL 312 478 3515 FAX 312 478 3232 bodine electric com Quaury MofoN Manual No 074 00210A AP
12. d by the Bodine Electric Company will void the warranty Field repairs must be limited to replacing an entire printed circuit board assembly Because of the danger of introducing safety hazards do not install substitute parts or perform any unauthorized modifications to electronic PC boards components or motors To ensure continued compliance with the design specifications and safety standards the electronic control or motor should be returned to Bodine Electric Company or an Authorized Service Center for servicing WARNING To avoid injury because of unsuspected mechanical motion always disconnect the 115 VAC power to the control before performing any service procedures on the motor control or driven equipment INSTALLATION INSTRUCTIONS WARNING This control should only be installed by a qualified technician electrician or electrical maintenance person familiar with its operation and associated hazards The National Electrical Code NEC local electrical and safety codes and when applicable the Occupational Safety and Health Act OSHA should be observed to reduce hazards to personnel and property The user must provide a proper enclosure for chassis type controls Circuitry is not at ground potential Do not perform work on or near the control while it is connected to the AC line CAUTION Exposed circuit boards should be protected from electrostatic discharge The control board uses CMOS circuitry Static discharge int
13. e limit DECEL Adjust motor deceleration response time CW increases time ACCEL Adjust motor acceleration response time CW increase time MIN Adjust motor minimum speed CW increases speed MAX Adjust or scale maximum motor speed CW increases speed Page 21 22 Front View Figure 1 Quick Reference Connection Diagram TABLE OF CONTENTS QUICK REFERENCE INSTALLATION eene 2 GENERAL INFORMATION eee T AA EA etn etn sain 4 CONTROL DESCRIPTION AND FEATURES eee 5 SPECIFICATIONS niooo ton etr rt ort IU ea ra p eset eR ER EUST 6 IMPORTANT SAFETY PRECAUTIONS 1 eere en ener 6 INSTALLATION INSTRUCTIONS esee rernm nennen 10 Mounting the Control eo oe retineret eere etr aH Tn eR 10 Electrical Connectiolis irte tnter reete trn EE aa Ei 10 Cable Assembly doit ette Hit te eie hri o eatis 11 Horsepower DIP Switch Settings sse 12 Commutation Sensor Connections sssssssssseeeeeeenene 14 Motor Phase Connections ri e ettet aa trt pstoadossesbendsaensosss 14 Euse Installationi ce err rer RR re I CO CI ES IO TIR OXERRDR ees 14 Manual Control Input Connections sese 14 Electronic Control Input Connections seseeseeeeeeeeeen 17 Tachometer QUIDUE sennie ii rh t P i eir Pe e tert is 18 AC Power Connections Testaa ote t Fn eee tre d ces EUR eeu e Y ox ev 19 OPERATING INSTRUCTIONS caeeaaeo
14. eleration and deceleration time A built in Smart Reverse circuit prevents plug reversing by disabling the motor until it coasts to a stop before changing its direction A built in shutdown circuit disables the control during overvoltage under voltage or invalid commutation sensor state conditions Specific Bodine motor sizes which can be used with these controls are listed in the Chart in Figure 4 Accessory Items Model 3983 Connection Cable Assembly one end equipped with circular connector other end equipped with quick disconnects for phase leads and connector for commutator leads Length 6ft See Figure 3 Model 3982 Extension Cable extends cable between motor and control by six feet Both ends equipped with circular connectors for easy connection between Model 3983 Cable and motor Length 6ft Model 3984 Isolated Interface Module See page 18 Model 433 00270 Manual Speed Potentiometer Kit SPECIFICATIONS Input Voltage 115 VAC 10 50 60 Hz Single Phase Input Current 6 Amps rms Output Voltage s 0 to 90 VDC Ambient Temperature 0 to 50 C Maximum Control Hp Range Up to 3 8 Hp Control Speed Range Up to 30 1 Control Speed Regulation Less than 1 of rated Typical Line Voltage Compensation Negligible speed change with changes in line vo
15. idth is 0 8 msec for the ABL 3910 Twelve pulses correspond to one motor revolution The ITAK output provides an unterminated open collector output A pull up resistor or another logic device is required for measuring the output See Figure 9 for assistance in interfacing the ITAK output eis Sey d ccm 3 1 User Logic Supply 1 V less than ori i ee eee Seana equal to 55V Pull Up Resistor Values for Open Call Dr i pul Up i l less than or Common Logic Supplies Output Eose d equal toy VDC R Ohms 1 es gt User Input 45V 4 7K Model 3984 emi s m 7 1 1 1 1 t i i Medel D rer L _ User Equipment _ Figure 9 Tachometer output 18 AC Power Connections Power should always be the last connection made during installation and the first item to be disconnected before servicing WARNING The control and motor must be securely and adequately connected to earth ground as indicated below Failure to ground properly may result in serious injury Power Input The ABL 3910C unfiltered control utilizes quick connect termi nals Refer to Figure 4 Locate the quick connect terminalslabeled L and N on the main control board near the line fuse Connect AC power as follows 1 Hot side of 115 VAC line to Terminal L 2 Neutral side of 115 VAC line to Terminal N 3 A green screw and cup washer are provided on the short surface of the heat sink for chassis g
16. im pot page 21 Reexamine the load parameters Turn the MIN trim pot CW until motor stops Check S1 S2 S3 connections Replace the potentiometer Note The Disable input should be used when the motor is expected to remain stopped NO SPEED ADJUSTMENT Defective speed potentiometer Open connection on speed potentiometer Replace the potentiometer Check S1 S2 S3 connections 25 BODINE LIMITED WARRANTY The Bodine Electric Company warrants all products it manufactures to be free of defects in workmanship and materials when used under Normal Operating Conditions and when applied in accordance with nameplate specifications This warranty shall be in effect for a period of twelve months from date of purchase or eighteen months from date of manufacture whichever comes first The Bodine Electric Company will repair or replace at its option any of its products which has been found to be defective and is within the warranty period provided that the product is shipped freight prepaid with previous authorization to Bodine s plant in Chicago Illinois 60618 U S A or to the nearest Bodine Authorized Service Center At its option all return shipments are F O B Bodine s plant or Authorized Service Center Bodine is not responsible for removal installation or any other incidental expenses incurred in shipping the products to or from Bodine This warranty is in lieu of any other expressed or implied warranty including
17. light procedures which present potential danger to people Cautions highlight possible danger to equip ment Both are used throughout this manual Warnings and Cautions must always be followed WARNING Dangerous voltages may be present in the electronic control and motor These voltages could cause serious injury or death Use extreme caution during handling testing and adjusting Properly guard the electronic control and motor to prevent accidental contact by all persons The chance of explosions fires or electric shocks can be reduced with thermal and over current protection proper grounding enclosure selection and good maintenance The following safety considerations are not intended to be all inclusive Specific references throughout this manual should also be consulted CAUTION These controls are designed to provide optimum performance when used with Bodine electric Company motors They should not be used with other manufacturer s motors without first contacting the Bodine Electric Company Failure to contact Bodine in advance could cause damage to the control or the motor Inspecting the Control Check the items you received against your purchase order Carefully examine the control and any optional kits or parts for shipping damage Parts errors should be reported to Bodine Shipping damage claims should be made to the freight carrier Before installation review the application to confirm that the proper moto
18. ltage Acceleration Time Range 0 2 to 10 seconds 0 to full speed Dimensions eese in 5 5W x 80D x 1 8H cm 14 0 W x 20 4 Dx 4 6 H Net Weight nete 2 0 Ibs 0 81 kg IMPORTANT SAFETY PRECAUTIONS The following safety precautions must be observed during all phases of installa tion operation service and repair of this motor control product Failure to comply with these precautions or with specific warnings elsewhere in this manual violates safety standards of design manufacture and intended use of the products Bodine Electric Company assumes no liability for the customer s failure to comply with safety requirements and practices The use of electric motors and generators like that of all utilization of concen trated power is potentially hazardous The degree of hazard can be greatly reduced by proper design selection installation and use but all hazards cannot be completely eliminated The reduction of hazards is a joint responsibility between the user the manufacturer of the driven or driving equipment and the manufacturer of the control or motor The user should refer to Publication No ANSI C5 1 NEMA MG 2 Safety Standard for Construction and Guide for Selection Installation and Use of Electric Motors and Generators Available from National Electrical Manufacturers Association 2101 L Street N W Washington D C 20037 U S A Warnings such as the example below high
19. mended size Horsepower DIP Switch Settings Figure 4 shows a Horsepower Select switch on the main control board which contains eight switch levers numbered 1 through 8 The chart in Figure 5 shows the proper DIP switch settings for various Bodine motor types Determine the first four digits of the motor s type number from the nameplate Find the same four digits in the chart in Figure 5 to determine the proper settings of the DIP switches An insulated alignment tool should be used to adjust the switch settings 12 HORSEPOWER SELECT SWITCH MOTOR FUSE MOTOR PHASE OUTPUTS NEUTRAL peared sp Ka 8 9 p i EN E MOTOR PHASE OUTPUTS 9 be Seep ee Te m mt C aL n Ed n m U T Anh E Ei H H E a o x COMMUTATION H NE ae arr SENSOR INPUTS EE EE AUT Q on T CONTROL _ SPEED POT INPUTS zi LADEN POWER Sci SIDE Serer scone s ELECTRIC E CCRLE L ff NX 2 MAX SPEED ADJUST CW INCREASE TORQUE ADJUST CW INCREASE MIN SPEED ADJUST DECELERATION TIME CW INCREASE ACCELERATION CW INCREASE TIME CW INCREASE
20. nts Circuit components are not at ground potential and accidental short circuiting and shock hazard may occur with conducting tools Adjustment should be made only by qualified service personnel Minimum and Maximum Speed The MIN and MAX trim potentiometers have been factory calibrated The lowest MIN trim potentiometer setting fully counterclockwise corresponds to 0 RPM and the highest MIN setting fully clockwise corresponds to approximately 30 of rated speed The lowest MAX trim potentiometer setting fully counterclockwise corre sponds to 60 of rated speed and the highest MAX trim potentiometer setting fully clockwise corresponds to approximately 120 of rated speed Refer to Figure 4 for trim potentiometer location and settings Adjustment of the MIN and MAX trim potentiometers may have to be repeated several times to arrive at the desired speeds NOTE Increasing the MIN potentiometer setting will increase the maximum speed beyond nameplate speed The MAX trim potentiometer will need to be readjusted 21 Torque Current Limiting Adjustment The TORQ trim potentiometer Figure 4 has been calibrated so that the motor will never see more than 200 to 250 of its rated current input if the DIP switches are set properly The motor s torque output can be reduced to zero or stall torque Turn the TORQ trim potentiometer counterclockwise to decrease the torque and clockwise to increase the torque NOTE For a
21. o low Motor overloaded TORQ trim pot is out of adjustment Wrong horsepower setting Damaged component on the control board CORRECTIVE ACTION Replace fuse Refer to Figure 5 for proper values Increase speed potentiometer setting Open DISABLE switch and restart Open the DECEL switch Use shielded cable Repair or replace motor Correct wiring Use shielded cable Repair or replace motor Adjust trim pot page 20 Increase speed potentiometer setting Reexamine the load parameters Visually check setting Figure 4 Adjust TORQ trim pot page 21 Check DIP switch setting page 13 Contact Bodine or Service Center for assistance SYMPTOM MOTOR SPEED IS UNSTABLE OR PULSATES MOTOR WILL NOT MAINTAIN SPEED UNDER LOAD MOTOR WILL NOT MAINTAIN SPEED UNDER LOAD Cont MOTOR WILL NOT STOP WITH SPEED POT ADJUSTED AT ZERO PROBABLE CAUSE Wrong horsepower setting Motor and load not correctly aligned Damaged motor Speed potentiometer set too low Wrong horsepower setting TORQ trim pot is out of adjustment Motor overloaded MIN trim potentiometer is set too high Open connection on speed potentiometer Defective speed potentiometer CORRECTIVE ACTION Check DIP switch setting page 13 Perform alignment Repair or replace motor Increase speed potentiometer setting Check DIP switch setting page 13 Visually check setting Figure 4 Adjust TORQ tr
22. o the control board must be avoided to prevent component damage Mounting the Control The mounting template provided in the center of this manual can be used to position and mark the location of mounting holes on the surface where the control is to be located The control should be mounted vertically using the slots on either the narrow or wide surfaces of the heatsink This arrangement provides optimum air flow around the control Refer to Figure 2 Electrical connections Read the following instructions as well as all of the applicable safety recommen dations before making any electrical connections between the control motor or motion control electronics WARNING The 115 VAC power line to the control should be the very last connection made Disconnect the power line before making any other electrical connections 10 HETEN iN f s O B arose Oo k WH ld PEE 2 N O Oo li Ee gaa z vU A Qi Of MLS N A anz oro m s fe o DoQoQo
23. ons Manual Control Input Connections 2 Connect the 115 VAC power line to the external power source Then turn on the 115 VAC input power to the control 3 Open the Disable switch if used 4 Turn speed potentiometer knob until motor rotates Then adjust the potenti ometer to achieve the desired speed If you wish to reduce the torque level refer to Internal Adjustments below 5 If the motor does not operate first observe if the green POWER light and red 20 FAULT light are on refer to Figure 4 for location Then disconnect the AC power to the control and check all connections and fuses If a fuse is blown and the motor is not locked stalled or overloaded do not replace the fuse The control may be damaged Refer to Troubleshooting and follow instruc tions If the motor is overloaded reduce the load and replace blown fuses with those of the proper type and rating as specified in Figure 5 Internal Adjustments Your control has been factory adjusted for the following settings Minimum speed 0 RPM Maximum speed 1725 RPM Acceleration 2 seconds Deceleration 2 seconds Torque 200 of rated based on proper DIP switch settings Refer to Figure 4 for the trim potentiometer locations and approximate initial settings If you need to readjust the control for your specific applications proceed as follows WARNING Use a non metallic or insulated adjustment tool such as a television alignment tool for internal adjustme
24. r and control have been selected This should be done after reading this manual and all applicable safety standards If in doubt contact your Bodine representative or the home office if there is no representative in your area Although Bodine Electric Company assists its customers in selecting motors and controls for specific applications determination of fitness for purpose or use is solely the customer s responsibility Normal Operating Conditions Unless otherwise agreed to by Bodine all control nameplate ratings are based on the following normal operating conditions Consult Bodine Electric Company if variations beyond these limits are anticipated 1 Duty Cycle 8 hours day 5 days week without frequent reversals or starts and stops 2 Maximum Ambient Temperature 50 C 122 F for chassis controls 40 C 104 F for all encased controls 3 Voltage Within 10 of nameplate rating 4 Frequency Within 5 of nameplate rating 5 Combined Variation of Voltage and Frequency Within a total of 10 providing frequency variation does not exceed 5 Grounding Both electronic controls and motors must be securely mounted and adequately grounded Failure to ground properly may cause serious injury to personnel Fusing Both the control input and output are fused When fuses are replaced they must always conform to the values and ratings specified on the control s nameplate or in the fuse chart located in Figure 5 Live Circui
25. ric Company takes pride in the quality of its products and in satisfying its custom ers Every effort has been made to provide you with a product free of defects in design workmanship and materials In order for us to maintain our tradition of quality please report any cases of unsatisfactory service or products to Bodine Electric Company promptly About This Manual This manual contains the basic information needed to install and operate a Bodine Model ABL 3910C Brushless DC Motor Control It is organized in a systematic step by step fashion so that the system may be set up safely in the shortest possible time It does not profess to cover all details or variations in equipment nor to provide for every possible contingency associated with installation operation or maintenance and no warranty of fitness for purpose is expressed or implied Should further information be desired or should particular problems arise which are not covered sufficiently for the user s purpose the matter should be referred to the Bodine Electric Company The issuance of this manual does not confer to the recipient any license to manufacture under any patents owned or controlled by the Bodine Electric Company Safety Standards Bodine products are designed and manufactured to comply to applicable safety standards and in particular to those issued by ANSI American National Stan dards Institute NEMA National Electrical Manufacturers Association U L Unde
26. round connections OPERATING INSTRUCTIONS WARNING Explosions fires or electric shock hazards can be reduced through thermal and over current protection good maintenance proper grounding and enclosure selection Review safety considerations outlined in Safety Precautions and Installing the Control Preliminary Checks 1 Before starting the control check all fuses connections and adjustments such as horsepower DIP switch settings 2 Proper consideration should be given to all rotating members Before starting be sure keys pulleys etc are securely fastened Proper guards should be provided to prevent hazards to personnel while the equipment is rotating 3 Mechanical considerations such as proper mounting and alignment of products and safe loads on shafts and gears should be reviewed Do not depend upon gear friction to hold loads 4 The motor or gearmotor should be securely mounted because of possible reaction torque Test the motor gearmotor unloaded to be certain that proper connections have been made Operating the Conirol WARNING The 115 VAC line to the driver should be switched off before starting 1 Turn input power OFF and set the speed potentiometer to ZERO fully counterclockwise If a Disable switch is used close the switch If a Direc tion switch is used set it for the desired direction of rotation If a Decelera tion switch is used open the switch See Chart in Installation Instructi
27. rwriters Laboratories Inc and CSA Canadian Standards Association Type ABL controls recognized by U L Inc are designated by having a AM symbol in the upper right corner of their nameplates In addition products that are CSA certified are identified by a symbol If you need specific information regarding the third party approval status of Bodine products contact the nearest Bodine representative or the home office 4 CONTROL DESCRIPTION AND FEATURES The ABL 3910C Brushless DC Motor Control is a chassis style control designed to be mounted into a separate control enclosure supplied by the user The control operates from a nominal 115 VAC 50 60 Hz power source The control provides electronic commutation and phase current switching needed to operate brushless DC motors DIP switch selectable current limit settings allow the control to be used with a wide range of fractional horsepower motors and gearmotors The ABL 3910C provides a 90 Volt unfiltered DC output The control allows motor speed to be manually or electronically controlled Motor direction of rotation disabling and soft starts and stops can be controlled with manual switch inputs or by logic control Since the control s signal common is not at ground potential interface circuitry is required to isolate logic signals from the control Trim potentiometers on the control board allow additional fine tuning of minimum and maximum speed settings torque acc
28. try Open type electronics should be properly guarded or enclosed to prevent accidental human contact with live circuitry No work should be performed on or close to the control or motor while the control is connected to the AC line If an AC line switch is used it should be a Double Pole Single Throw DPST so that both sides of the AC line are disconnected Environment Open controls or controls in ventilated enclosures may emit flame during failure Bodine s totally enclosed products are not explosion proof and Bodine does not offer an explosion proof motor gearmotor or control for hazardous locations e g in an environment of flammable or explosive gas vapor or dust Bodine recommends use of only approved explosion proof products in hazardous locations Exceptions are allowed by the National Electric Code NEC but NEC and NEMA safety standards should be studied thoroughly before exercising this option Moisture increases the electrical shock hazard of electrical insulation Therefore open type or unsealed controls not specifically designed for such use should be protected from contact with liquids or moisture Ventilated Products Open ventilated products are suitable for clean dry locations where cooling air is not restricted Do not insert anything into a product s ventilation openings Servicing Emergency field repairs must be made only by authorized Bodine service representatives Repairs made by persons not authorize
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