impac 100 Operating & Installation Manual
Contents
1. O O oo oo oo Q De 2 oo oo oo R K o UA ILE SES OC Ou NO F R MR eS BARS ABB ON 9 ALLEN BRADLEY sh Sh oo oo oo oo oo oo o 0 O o El 9 00000000000 553 AAAA SSS Es e S S AEA 5 D D gt a Es fis Lles SIS no c000000000000000002 ja ojo ojo o DAD NIE oo ofofofofofojo olojolololo oi0j00010 00020100000 0090 OOo o BERGA RE lo i lee e EEE 9 9 Figure 5 Sample 3 Phase Control Panel Layout All Customer vviring is made to the Terminal Bloch located at the bottom of the Controller The VFD impac 100 is shipped with reversing switch disabled DMC PD0597 impac 100 Operating amp Installation Manual Variable Speed AC Motors Three Phase ORANGE 230VAC 60Hz PINK BUL160 VED XNUTE FUL FUe FU3 10AMP FOR 711 3211 711 3231 1SAMP FOR 11 38120 7 3232 XXNOTE NOT CONNECTED ON S11 9211 71t 3212 LT BLUE COM MOTOR RUNNING G MR sits BLK POWER UN Y DK BLUE F VIOLET PARE EYE 2 VI vel PE1 PERI REMOTE RUN PUSH BUTTON REMOTE RUN CONTACT FORWARD CONTROL REVERSE CONTROL MOTOR RUNNING CONTACT MR2. 100 Conveyor Controller and impac Accessory Kits the user should use the following steps 1 Remove power to the impac Conveyor Controller Before installing and wiring any accessory kits Remove power to the impac controller by unplugging the impac controller from the power source 2 Select Desired Control Application from the Dorner impac 100 Application Guide Included with the impac 100 Application Guide are a list of conveyor control application examples that detail the following for many different conveyor control applications e A description of the conveyor application control requirements e An illustration of the conveyor with the impac 100 controller and impac accessory kits mounted e A list of hardware required to implement the control application described DMC PD0597 impac 100 Operating amp Installation Manual Variable Speed AC Motors Three Phase e A description of the conveyor operation Detailed conveyor control setup instructions e Illustration that shows how all accessory devices are connected to the impac 100 controller Based on review of the Dorner impac 100 Application Guide select the application example that meets the needs of the end user application If required make any final adjustments to the application accessory kit control connections needed by your particular application 3 Install all required impac accessory kits Install all accessory kits required for the application The select
3. 800 397 8664 USA TEL 02401 80 52 90 discontinue products without notice All products and FAX 1 800 369 2440 USA FAX 02401 80 52 93 services are covered in accordance with our standard Outside the USA warranty All rights reserved Dorner Mfg Corp 1997 TEL 1 414 367 7600 FAX 1 414 367 5827 851 128 Rev E Printed in U S A DMC PD0597
4. FORWARD STOP REVERSE switch to FORWARD the Motor RUNNING indicator light on the front on the controller should illuminate Slowly advance the main speed potentiometer until you reach the desired speed The motor should run and the conveyor belt will move If the motor runs opposite of the direction expected the motor leads on the terminals at the bottom the the Controller which are marked T1 and T2 will have to be reversed Disconnect power at power source before opening the door of the impac 100 Conveyo Controller and attempting to make any electri cal connections Connections to the powe source should always be the very last connec tions made WARNING Once the power has been removed open the impac Conveyor Controller door and reverse the armature leads at the terminals at the bottom of the controller labelled T1 and T2
5. Figure 3 or steel support stand leg Figure 4 using the hardware provided Figure 1 Drop in T bar Installation Detail Mounting in Conveyor T slot a Insert the two Single Drop in T bars into conveyor T slot by rolling each one into position Figure 1 b Select the desired location and attach the impac 100 enclosure in the same way it was packaged when shipped to the conveyor T slot in the manner shown in Figure 2 using the two 2 M6 x 8 mm Button Head Cap Screws through the clearance hole in each Mounting Bar Tighten the Screws with a 4 mm Hex Key Wrench 1 M6 x 8 mm Button Head Cap Screws 2 each 2 Single Drop in T bars 2 each 3 Mounting Bars 2 each Figure 2 Conveyor T slot Attachment Detail Mounting to Aluminum Support Stand Leg DMC PD0597 a For an Aluminum Support Stand Leg refer to Figure 3 and detach rotate and re attach the Mounting Bars to the impac 100 enclosure in the horizontal position b Select the desired mounting location and insert the two Single Drop in T bars into Leg channel by rolling each of them into position see Figure 1 c Then attach the impac 100 enclosure to the two Single Drop in T bars using the M6 x 8 mm Button Head Cap Screws Tighten Screws with a 4 mm Hex Key Wrench 1 M6 x 8 mm Button Head Cap Screws 6 each 2 Mounting Bars 2 each 3 Single Drop in T bars 2 each Figure 3 Aluminum Leg Attachment De
6. Setup 1 Reversing on lones es um aoe eee sees 2 Acceleration amp Deceleration 5 9 Controlling the Speed with an External Reference Signal 5 10 Controlling the Direction with an External Signal Implementing Conveyor Control Applications Operating the Conveyor Controller 7 1 Starting the Controller 7 2 Stopping the Controller Troubleshooting ei tas rara vw Bind ase wate eek es CB DES add tee Replacement Parts List iti wae cia eh tee ain ete wae 2 DMC PD0597 impac 100 Operating amp Installation Manual Variable Speed AC Motors Three Phase 1 0 Safety Considerations A WARNING A Disconnect power at source before opening door of impac 100 Conveyor Controller A WARNING A Both control enclosure and motor must be securely mounted and properly grounded Failure to properly ground either device may cause injury to personnel Grounding 1 2 Fusing A WARNING A If fuses need to be replaced they must always conform to the values and ratings specified on the controls labels 1 3 Power Wiring to Controller A WARNING A The branch circuit which provides power to this control must be protected The circuit protection must be properly sized to meet the current requirements and must comply with 2 0 Introduction all applicable codes Al WARN
7. and 2 for Reliance This defines how the input wiring is configured DO NOT CHANGE THIS PARAMETER otherwise the forward stop reverse switch on the door of the impac and or any installed kits will not control the drive 7 Output Configure Allen Bradley parameter 47 Reliance parameter 12 This parameter has been set to 2 This parameter controls the motor running contact terminals MRI and MR2 and the motor RUNNING indicator light 5 8 Controller Setup 1 Reversing The VFD impac 100 is shipped with the reversing switch disabled Damage may occur to the belt of a center drive conveyor if operated in the reverse direction If a Center Drive is not being used reversing can be enabled as follows a Open the cover of the impac 100 Locate the termi nal blocks labeled RV1 and RV2 Remove one of the wires from terminal RV1 and re connect it at terminal RV2 b To disable reversing remove the jumper at terminal RV and reconnect it to terminal RV 1 2 Acceleration amp Deceleration The Variable Frequency Drive VFD has an adjustable value for the acceleration and deceleration The range is 0 1 to 600 Seconds If this time value is set too short the drive will fault To change the acceleration change drive parameter 30 to the desired time To change the deceleration change drive parameter 31 to the desired time Refer to the drive manufacturer s user manual for parameter programming in
8. defective SPEED potentiometer is shorted or defective Wiring connections are loose FORWARD STOP REVERSE switch S2 is defective Relay F or relay R defective Relay F or relay R not properly seated in mounting socket s REVERSE Enable Jumper is in the REVERSE DISABLE position Wiring connections are loose Relay MR is defective FORWARD STOP REVERSE S2 switch is in STOP position AC variable frequency drive has faulted Securely anchor all connections Move switch to STOP position Replace drive Locate circuit short or replace potentiometer Securely anchor all connections Replace defective FORWARD STOP REVERSE switch Replace defective Relay s Securely and properly seat Relay s in their socket s respective Move ENABLE position Jumper to Securely anchor all connections Replace defective Relay Move switch away from STOP position Cycle power to the impac 100 to reset drive Refer to the drive manufacturer s user manual Troubleshooting and Fault Information section chapter 6 for additional information DMC PD0597 13 851 128 Rev E impac 100 Operating amp Installation Manual Variable Speed AC Motors Three Phase 9 0 Replacement Parts List Dorner Description Part Number 1 Power Supply 831 110 2 AC Drive Model 711 3211 Model 711 3231 8
9. number for reference There will be a return charge on all new undamaged items returned for credit where Dorner was not at fault Dorner is not responsible for return freight on such items Conveyors and conveyor accessories Standard catalog conveyors 30 MPB Series cleated and specialty belt conveyors 50 7400 amp 7600 Series conveyors non returnable items Engineered special products case by case Drives and accessories 30 Sanitary stand supports non returnable items Parts Standard stock parts 30 MPB cleated and specialty belts non returnable items Returns will not be accepted after 60 days from original invoice date The return charge covers inspection cleaning disassembly disposal and reissuing of components to inventory If a replacement is needed prior to evaluation of returned item a purchase order must be issued Credit if any is issued only after return and evaluation is complete Dorner has representatives throughout the world Contact Dorner for the name of your local representative Our Technical Sales Catalog Sales and Service Teams will gladly help with your questions on Dorner products For a copy of Dorner s Warranty contact factory distributor service center or visit our website at www dorner com TN DORNER MFG CORP DORNER 5 975 Cottonwood Ave PO Box 20 Arnold Sommerfeld Ring 2 Hartland WI 53029 0020 USA D 52499 Baesweiler USA Germany Dorner Mfg Corp reserves the right to change or TEL 1
10. 05 869 Model 711 3212 Model 711 3232 805 885 Model 711 3431 805 886 Model 711 3432 805 887 Model 711 3111 805 997 3 AC Drive Keypad All models except 711 3111 805 985 Model 711 3111 805 998 4 Fuse Holder All models except 711 3111 819 132 Model 711 3111 819 134 5 Fuse Model 711 3431 819 138 Model 711 3211 Model 711 3231 819 113 Model 711 3432 Model 711 3212 Model 711 3232 819 103 Model 711 3111 6 Relay 805 470 7 Disconnect Switch 805 881 8 Amber Pilot Light Assembly 830 133 9 Green Pilot Light Assembly 830 134 10 Forward Stop Reverse Switch 830 161 11 Speed Potentiometer 805 866 851 128 Rev E DMC PD0597 impac 100 Operating amp Installation Manual Variable Speed AC Motors Three Phase Notes DMC PD0597 15 851 128 Rev E Return Policy Returns must have prior written factory authorization or they will not be accepted Items that are returned to Dorner without authorization will not be credited nor returned to the original sender When calling for authorization please have the following information ready for the Dorner factory representative or your local distributor 1 Name and address of customer 2 Dorner part number s of Item s being returned 3 Reason for return 4 Customer s original order number used when ordering the item s 5 Dorner or distributor invoice number A representative will discuss action to be taken on the returned items and provide a Returned Goods Authorization
11. C Motors Three Phase impac 100 4 0 Product Specifications 711 3111 711 3211 711 3212 711 3231 711 3232 Input Voltage 100 120 volts A C 1 Phase 50 60 Hz 200 240 1 Phase 50 60 Hz volts A C 200 240 volts A C 3 Phase 50 60 Hz Input Line Fuse 1 15 Ampere 3 10 Ampere 3 15 Ampere 3 10 Ampere 3 15 Ampere Input Current 10 Amperes 7 Amperes 10 Amperes 7 Amperes 10 Amperes Output Voltage 230 volts A C 3 Phase 60 Hz Note Models 711 3111 711 3211 amp 711 3212 have a single phase input with a three phase output to the motor Speed Reference Standard Speed Potentiometer mounted on cover of enclosure or Optional Isolated 10 to 10 volt analog input 0 to 10 volt analog input 4 to 20 milliampere input Motor Range in hp watts 0 to 1 2 1 to 373 0 to 3 4 1 to 559 Above 3 4 to 1 560 to 746 Otol 1 to 746 Above 1to2 747 to 1500 Operating Temperature A C Line Cord 0 to 40 C to 95 Humidity Non condensing 8 Ft 2 4 m Pre wired 8 Ft 2 4 m Pre wired with 8 Ft 2 4 m Pre wired with NEMA NEMA with NEMA 5 15P Plug 6 15P Plug 15 20 Plug 5 Ft 1 5 m Pre wired NEMA L15 20 Receptacle NEMA Type 12 IP54 Continuous Hinge Weight 23 Ib 10 5 kg Dimensions 12 305 mm High x 10 254 mm Wide x 6 152 mm Deep 24 volts D C 1 1 Amperes with Over c
12. DORNER impac Operating Installation Manual e Tu impac DORNER Variable Speed AC Motors 0 to 2 hp 1 5 kw 115 230 460 VAC 50 60 Hz Models 711 3111 711 3211 amp 711 3212 711 3231 amp 711 3232 711 3431 amp 711 3432 851 128 Rev E 851 128 Rev E 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 0 Table of Contents Safety Considerations siria i 1 1 COAC OS sensei 1 2 FUSNI sare tea a te tini a 1 3 Power Wiring to Controller INTFOGUCTION Marcus cit weeded hate EE ena cash oak Petes Product Description asportare aoe is Product Specifications ces dt set ee ae ae sk Conveyor Controller Installation 5 1 Inspecting the Controller 5 2 Mounting the Controller 5 3 Power Connections to Controller 5 4 Conveyor Controller Power up Testing 5 5 Motor Connections to Conveyor Controller 5 6 Motor and Conveyor Controller Power up Testing 5 7 Internal Adjustments 1 General ret wk aed a daa eS eA ea 2 Acceleration Time Parameter 30 3 Deceleration Time Parameter 31 4 Minimum Frequency Parameter 32 5 Motor Overload Current Parameter 42 6 Input Mode Parameter 46 5 Output Configure Parameter 47 5 8 Controller
13. ING A Read this Manual completely and carefully Pay special attention to the Warnings Pre cautions and Safety Rules listed Failure to follow the instructions could produce Safety Hazards to personnel or lead to damage of the Conveyor Controller and or the optional Accessory Kits Due to the wide variety of set ups amp applications guarding is the responsibil ity of the end user DMC PD0597 This manual contains the information needed to install operate and troubleshoot the Dorner impac 100 Conveyor Controller It is organized in a step by step fashion so that the Conveyor Controller may be safely set up in the shortest possible time 3 0 Product Description The impac 100 Conveyor Controller is a low cost Industrial Multi Purpose Application Controller that can be used to control a Conveyor motor on off operation as well as vary the speed of the motor The Conveyor Controller is user installable with control options that allow it to meet the needs of a wide range of Conveyor control applications indexing jogging accumulation variable speed automatic end stop emergency stop clutch brake merging of Conveyors linking multiple Conveyors etc The impac 100 Conveyor Controller s motor control circuit is designed to support electrical interconnections to a variety of accessory kits photo eyes E stops jog buttons foot switches E stop pull cord units process machine PLC PC dry contact interfac
14. ON and the Motor RUNNING indicator lights on the front of theimpac Conveyor Controller should illuminate 5 5 Motor Connections to Conveyor Controller Plug the motor cord into the impac 100 Conveyor Controller receptacle cord Each Conveyor Controller has a pre wired receptacle for a motor The type of receptacle is dependent on the Controller voltage If a motor was ordered along with the Controller then the motor was pre wired with a mating power plug The motor can also be hard wired to the Controller by first removing the receptacle and wiring directly to the terminals T1 T2 T3 and GND inside the Controller See the Controller panel layout Figure 5 and the schematic diagrams Figures 6 amp 7 for more information 5 6 Motor and Conveyor Controller Power up Testing A A WARNING When power is supplied to the impac 100 Con veyor Controller and the disconnect switch is turned ON the Conveyor belt will begin to move After connections are made to the impac controller move the main speed potentiometer located on the front panel of the enclosure to zero and the FORWARD STOP REVERSE switch to the STOP position see picture on cover of this 851 128 Rev E manual Plug the controller into the appropriate power source and turn the controller disconnect switch ON The Power ON indicator light on the front on the controller should illuminate Move the
15. UP 3 GROUP 4 l OUTPUT POINTS SPARE POINTS COM 24v PE1 PE2 ES1 MR1 SP1 SP2 STANDARD l il STANDARD i H PHOTO EYE ACCESSORY KITS STANDARD PHOTO EYE PARALLEL Kir SERIES Figure 8 Simplified impac 100 Control Circuit 6 0 Implementing Conveyor Control Applications Theimpac 100 control circuit is designed to support electrical interconnections to a variety of accessory kits photo eyes E stops jog buttons foot switches E stop pull cord units process machine PLC PC dry contact interface and more The kits are connected to the impac 100 using convenient terminal point connections inside the controller This allows the user to interconnect the kits to fit specific application control needs A simplified version of the impac 100 control circuit is shown in Figure 8 Four groupings of terminal point connections have been provided for connecting all impac accessory kits 1 The first group COM 24V provides 24 volts D C power for any accessory kits that need power photo eyes illuminated pushbuttons etc 2 The next group PE1 PE2 ES1 ES2 and RR1 RR2 provide three sets of control points for wiring accessory kits into the impac 100 control circuit Each group is configured with a jumper when the impac 100 controller is shipped W
16. ac 100 Operating amp Installation Manual Variable Speed AC Motors Three Phase 8 0 Troubleshooting Refer to Figures 5 6 amp 7 for component locations PROBLEM CAUSE CORRECTION Motor will not run and Motor RUNNING indicator is ON and POWER indicator is illuminated Motor will not run and Motor RUNNING indicator is OFF POWER indicator is illuminated and Power Supply LED is ON Motor will not run and Motor RUNNING indicator is OFF POWER indicator is illuminated and Power Supply LED is OFF Motor will not run and Motor RUNNING indicator is OFF and POWER _ indicator is not illuminated Motor runs unexpectedly and Motor RUNNING indicator is ON and POWER indicator is illuminated 851 128 Rev E Open wiring connection between impac 100 amp motor Motor Cord is not connected to motor Defective motor AC variable frequency drive has faulted One or more accessory kits are not working properly and thus causing an OPEN contact One or more accessory kit jumpers at impac 100 are removed and kit Devices are not installed or incorrectly installed Power supply fuse has blown One or more accessory kits are incorrectly installed and thus shutting down the power supply No power to impac 100 or impac 100 is not plugged in Blown line fuse FU1 and or FU2 and or FU3 One or more accessory kits are incorrectly installed One or more
17. accessory kit jumpers at impac 100 is are not correctly installed Remove any power and using appropriate means check continuity and integrity of wiring Properly connect motor cord Replace motor Cycle power to the impac 100 to reset drive Check and properly install and wire accessory kits per the Setup amp Installation Guide information provided with kit Properly install and wire accessory kits per the Setup amp Installation Guide information provided with kit Replace with correct amperage and type of fuse Properly install and wire accessory kits per the Setup amp Installation Guide information provided with kit Check all related wiring and make sure impac 100 power cord is plugged in Replace with correct amperage and type of fuse and or fuses Properly install and wire accessory kits per the Setup amp Installation Guide information provided with kit install and wire appropriate jumpers per the Setup amp Installation Guide information provided with kit Properly DMC PD0597 impac 100 Operating amp Installation Manual Variable Speed AC Motors Three Phase PROBLEM CAUSE CORRECTION Motor speed will not increase when SPEED Potentiometer is increased Motor will not switch between FORWARD and REVERSE Motor RUNNING contact does not give indication Wiring connections are loose FORWARD STOP REVERSE switch is not in the STOP position AC drive is
18. acent devices e Connect the external signal V to the terminal labeled 2 e Connect the external signal V to the terminal labeled 3 The speed pot on the door of the impac controller is now disabled 5 10 Controlling the Direction with an External Signal The impac 100 control is shipped with the FWD OFF REVERSE switch located on the front of the enclosure as the only method to change the direction of the motor Some applications may require that the direction of the motor be controlled by another machine or controller To control the direction from a remote location Remove the blue jumper wires from between the terminals labeled FW1 amp FW2 and RV1 amp RV2 This will disable the selector switch on the front of the enclosure e Supply a dry contact between terminals RR amp FW2 Closing this contact will command the Forward direction Supply a dry contact between terminals RR amp RV2 Closing this contact will command the Reverse direction NOTE Close only one direction at a time If both Forward and Reverse is commanded at the same time an undeter mined direction can occur 851 128 Rev E impac 100 Operating amp Installation Manual Variable Speed AC Motors Three Phase IMPAC CONTROLLER MOTOR CONTROL GROUP 1 GROUP 2 24VDC POWER ACCESSORY INPUT POINTS GRO
19. acturers users manual that shipped with the impac 100 The 711 3111 uses a Reliance drive All other impac models use Allen Bradley 851 128 Rev E 8 Acceleration Time Allen Bradley parameter 30 Reliance parameter 30 This is the time it takes for the motor to ramp up to full speed from a stop This parameter has been set to 1 second the factory default value is 5 or 10 seconds Deceleration Time Allen Bradley parameter 31 Reliance parameter 31 This is the time it takes for the motor to ramp down from full speed to a stop This parameter has been set to 1 second the factory default value is 5 or 10 seconds If this value is set too short the drive may fault DMC PD0597 impac 100 Operating amp Installation Manual Variable Speed AC Motors Three Phase 4 Minimum Frequency Allen Bradley parameter 32 Reliance parameter 00 This is the lowest frequency speed that the drive will output This parameter is set for 6Hz This is 10 of full speed The factory default value is 0 Hz 5 Motor Overload Current Allen Bradley parameter 42 Reliance parameter 02 This parameter has been set to the FLA full load ampere rating of the motor that was ordered with the impac If no motor was ordered then the parameter is set to a value based on approximately 1 2 of the rating of the impac 100 ordered 6 Input Mode Start Control Allen Bradley parameter 46 Reliance parameter 10 This parameter has been set to 1 for Allen Bradley
20. d operate the application based on the information detailed in the selected application Operation amp Test description 6 File copy of the Control Application Documentation Place a copy of the Conveyor Control Application Example that was used in step 4 inside impac 100 controller 7 0 Operating the Conveyor Controller 7 1 The conveyor will be ready to run when the impac ON OFF disconnect switch is turned ON The Power ON light will be illuminated whenever power is applied to the Conveyor Controller and the ON OFF disconnect switch is turned ON If there are no impac accessory kits installed the conveyor will run If there is are any installed accessory kit s the conveyor may run depending on the ON OFF state of the accessory kits When an accessory kit or kits allow the conveyor to run the Motor RUNNING light will be ON and the motor will run Starting the Controller 7 2 Stopping the Controller The conveyor will be stopped when the impac ON OFF disconnect switch is turned OFF The Power ON light will be OFF whenever power is removed from the Conveyor Controller or the ON OFF disconnect switch is turned OFF If there are installed accessory kit s the conveyor may stop running depending on the state of the accessory kits When an accessory kit prohibits the conveyor from running the Motor RUNNING light will turn OFF and the motor will stop 851 128 Rev E imp
21. e SPARE TERMINALS ES1 RRI RR2 ERI cen OUTPUT SIGNA INPUT SIGNALS Figure 6 Schematic Diagram for impac 100 Controller Models 711 3211 amp 711 3212 Models 711 3231 amp 711 3232 DMC PD0597 7 851 128 Rev E impac 100 Operating amp Installation Manual Variable Speed AC Motors Three Phase ORANGE 115VAC 3 1PHASE 2 N eoz lt D o WHT GREY 5 5 F PINK sis YELLOW LT BLUE DK BLUE MOTOR RUNNING MR sa IX i G p 5 BLK PA POWER ON x y e DA F Van TAN 14 _ 18 R CL PHOTOEYE EYE RRI RR2 di REMOTE RUN REMOTE RUN FORWARD REVERSE MOTOR SPARE a PUSH BUTTON CONTACT CONTROL CONTROL RUNNING TERMINALS CONTACT MRI MR2 INPUT SIGNALS OUTPUT SIGNAL Figure 7 Schematic Diagram for impac 100 Controller Models 711 3111 5 7 Internal Drive Adjustments 2 1 General All of the drive parameters are set to the drive manufacturers default values except for the parameters listed below These variable frequency drive operating 3 parameters are set to typical conveyor user values A complete list of drive parameters can be found in the drive manuf
22. e and more Each kit includes brackets for mounting the unit to a Dorner 2100 3100 LPZ conveyor cabling to wire the unit to an impac 100 Conveyor Controller and instructions for mounting wiring operating the unit The kits are connected to the impac 100 Conveyor Controller using convenient terminal point connections inside the Controller This allows the user to configure the kits to fit specific application needs and to re configure the kits to perform new functions The impac 100 Conveyor Controller comes with mounting hardware to allow mounting to a Dorner 2100 3100 or LPZ Conveyor side rail or Conveyor stand The unit is housed in an NEMA 12 IP54 enclosure with Power ON and Motor RUNNING LED s a locking ON OFF switch a 24 volts D C power supply adjustable motor overloads with manual reset and pre wired motor and AC line cords Overall Conveyor system reliability is enhanced by the impac 100 design features Components meet applicable ANSI NEC EC machine safety standards Local on off control and built in motor amp circuit overload protection enhance operator and application safety Low voltage 24 volts D C control circuits reduce installation and maintenance time as well as increase safety A complete Conveyor Controller wiring schematic and troubleshooting guide are attached to the inside of the Conveyor Controller cover 851 128 Rev E impac 100 Operating amp Installation Manual Variable Speed A
23. ed Application Example in the Dorner impac 100 Application Guide will show the general area of were the kits are to be located on the conveyor Follow the impac Accessory kit Setup amp Installation Guide for mounting and cable routing details WARNING Disconnect power at power source before opening the door of the impac 100 Conveyor Controller and attempting to make any electri cal connections Connections to the power source should always be the very last connec tions made Each impac accessory kit includes Setup amp Installation Guide brackets for mounting cabling to wire the unit to an impac 100 controller and instructions for mounting wiring operating the unit There are two 1 2 NPT knockouts available for accessory kit installation at the bottom on the controller Remove the rubber seal and install the accessory kit cable using the cord grip provided with the kit The only wiring that is required will be at the accessory terminal block inside the controller A 1 8 3 mm flat blade screwdriver is shipped with the controller for wiring to the terminal block DMC PD0597 11 4 Connect the impac accessory kits to the impac 100 Conveyor Controller From the selected Application Example in the Dorner impac 100 Application Guide Connect the impac accessory kit cables to the impac controller terminal block as detailed in the application Setup description 5 Verify proper conveyor operation Test an
24. hen an accessory kit is to be installed the jumper is removed and the kit connected Each set of control points represents a series connection to the impac 100 control circuit When accessory kits are wired in series it means that all connected accessories must be on for the conveyor to run For example if an accessory kit is wired to PE1 PE2 and another accessory kit is wired to ES1 ES2 then both accessories must be on for the conveyor to run The impac 100 controller also supports wiring impac accessory kits in parallel When an accessory kit is wired in parallel it means if either accessory kit is on 851 128 Rev E then run the conveyor Accessories connected in parallel are connected to the same impac 100 terminal points For example if two accessory kits are wired to PE1 PE2 then when either kit is on the conveyor will run Any number of impac accessories can be configured in any of the above series and parallel combinations 3 The third group of terminals MR1 MR2 provide an output contact dry contact that is closed when the conveyor is running This can be used to link multiple conveyor operations together or to provide status back to a host controller 4 The last group of terminals SP1 SP2 are two spare terminal points that the user can use for extra termination points for accessory kit wiring To select configure and implement a conveyor control application using the impac
25. structions and for details on an optional braking resistor that can be added for applications that require an extremely short deceleration time 5 9 Controlling the Speed with an External Reference Signal DMC PD0597 WARNING A A Any external signal or equipment connected to the control must be electronically e g optically isolated Using signals which are not isolated can damage the drive control board and or any external equipment The impac 100 control is shipped with the speed pot on the front of the control as the only method to very the speed of the motor Some applications may require that the speed of the motor be controlled by another machine or controller A 0 to 10 Volt isolated speed signal may be used to control the speed of the motor in place of the speed potentiometer on the front of the controller A shielded cable is recommended for the external speed reference signal The shield should be grounded at the signal source end only To connect an external speed reference e Locate the terminal block near the face of the AC drive Remove the brown wire from the terminal labeled 1 Tape the end of the exposed wire to avoid shorting to adjacent devices Remove the white wire from the terminal labeled 2 Tape the end of the exposed wire to avoid shorting to adjacent devices Remove the orange wire from the terminal labeled 3 Tape the end of the exposed wire to avoid shorting to adj
26. tail Mounting to Steel Support Stand Leg a For the Steel Support Stand Leg refer to Figure 4 and detach rotate and re attach the Mounting Bars to the impac 100 enclosure in the horizontal position b Then attach the impac 100 enclosure to the M6 Spring Nuts using the M6 x 18 mm Button Head Cap Screws through the clearance hole in each Mounting Bar Tighten the Screws with a 4 mm Hex Key Wrench 1 M6 x 8 mm Button Head Cap Screws 4 each 2 Mounting Bars 2 each 3 M6 x 18 mm Button Head Cap Screws 2 each 4 M6 Spring Nuts 2 each Figure 4 Steel Leg Attachment Detail 851 128 Rev E impac 100 Operating amp Installation Manual Variable Speed AC Motors Three Phase 5 3 Power Connections to Controller Each Conveyor Controller has a pre wired plug for power The type of plug is dependent on the Controller voltage A WARNING A Disconnect power at power source before opening the door of the impac 100 Conveyor Controller and attempting to make any electri cal connections Connections to the power source should always be the very last connec tions made 5 4 Conveyor Controller Power up Testing Test the Conveyor Controller before the motor is connected and before any impac accessory kits are installed Plug the Controller into the appropriate power source and turn the Controller disconnect switch ON The Power
27. urrent and Short circuit Protection Motor Cord Enclosure Internal Power Supply Standard Features Lockable Disconnect Switch Line Fuses s Angled Terminal Block for Easy Field Connections 24 volt D C Power Supply Rated 1 1 Amperes for Field Devices Power ON and Motor RUNNING Indicator Lights Mounting Brackets and Hardware Pre wired Motor and AC Line Cords Schematic Diagram Inside of Door Four 4 1 2 NPT Knockouts with NEMA 12 Plugs Speed Potentiometer Mounted on Enclosure Door Reversing Switch Mounted on Enclosure Door NOTE For additional information refer to the following Dorner Publications e impac 100 Catalog Dorner Publication 851 151 e impac 100 Accessory Kits Setup amp Installation Guides Dorner Publication 851 108 through 851 123 e impac 100 Application Guide Dorner Publication 851 124 851 128 Rev E 4 DMC PD0597 impac 100 Operating amp Installation Manual Variable Speed AC Motors Three Phase 5 0 Conveyor Controller Installation 5 1 Carefully examine your Controller for shipping damage Check to be certain that the controller you ordered is the one you received Also check any optional accessory kits which you received Inspecting the Controller 5 2 Mounting the Controller Select the desired location and mount the impac 100 enclosure to the conveyor T slot channel Figure 2 or an aluminum support stand leg
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