USER`S MANUAL - Leeson Electric Corporation
Contents
1. 6 30 160 6 TT o E L 4 40 112 ek 5 S 3 00 76 2 2 6 HII TIL 8 255 0 70 18 6 90 175 1 ALL DIMENSIONS INCHES MILLIMETERS E hs MN 445 113 Wi ool mr TTT Figure 9 175311PCM Dimensions 10 Installation 175324 Process Control Module PCM Mounting The FHP Series PCM Adder Board accepts a 0 5 VDC 0 10 VDC or 4 20 mA signal and outputs an isolated 0 5 VDC signal without requiring additional panel space mounts directly over the main AC board bottom board thus maintaining the same footprint Step by step information for mounting the PCM Adder Board to a FHP Series drive is shown on pages 12 14 Figure 10 page 11 shows a FHP Series drive with the PCM adder board installed on the unit and the parts supplied in the PCM adder kit Installation 11 MAIN AC BOARD BOTTOM BOARD PCM ADDER BOARD PARTS SUPPLIED IN THIS KIT ADDER BOARD 1 2 JUMPER 12. Q 9 jJ 0 0 6 SHOULDER 0 578 NYLON 6 32 x 1 5 16 HEADER 1 WASHER 1 SPACER 1 PHILLIPS SCREW 1 Required Tools Phillips Screwdriver Figure 10 FHP Series Drive with PCM adder board amp PCM adder kit 12 Installation Yf STER 1 USING PHILLIPS SCREWDRIVER REMOVE SCREW AND PLASTIC FROM BOTTOM BOARD AND DISCARD te 0 1 lt l MAX 0 2307 157 1 1 DO NOT REMOVE THE SHOULDER WASHER FROM THE BOTTOM BOARD STEP 2 PLACE THE JUMPER NOTCH SIDE UP ON JMP501 OF THE BOTTOM BOARD 0 00000 Installation 13 STEP 3 INSTALL TWO 2 PLASTIC STANDOFFS ONTO BOTTOM BOARD SNAP THE SHORT SIDE OF THE 6 HEADER J501 INTO J501 LOCATED ON THE BOTTOM BOARD STEP 4 dE STEP 5 5 INSERT THE SHOULDER SIDE VIEW WASHER included with the kit THROUGH THE Q Emum TOP SIDE OF THE PCM STEP 6 ADDER BOARD ATTACH THE 0 578 SPACER T
3. FOVLIOA 8 es zs is 13 za 10 2 Suid a 209 ojo esum us p 235 fea suo 02 2 ooo 10 uonisod B 2 9 ooo 1ndui eufis 01 0 lo o 20 0 0 2 Wod 20 8 0 1 1 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 for Doubler Drives 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 37 38 Operation 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 Doubler 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 23
4. U nnannn rror ea L1 Tr Figure 15 Motor Connections for Single Phase Operation Motor With Pre Wired Capacitor Installation 29 MOTOR WINDINGS NOTE Motor starter cap must be removed from the circuit Y Y This method works with WINDING most but not all motors WITHOUT CAPACITOR J 6559956 U o S Figure 16 Motor Connections for Single Phase Operation Configured for use with DIRECTION switch 30 Installation MOTOR WINDINGS J DECEL GR BOOST Ww SS ACCEL KO TQ LIMIT amp eTeTeTo e e 9 8 x gt G 00 LJ Sisisisisis Can e S4 Or x ie d p 9 d Hh og t oooooo nnnnnn TOT L3 Figure 17 Motor Connections for Three Phase Motors
5. Line starting and line stopping Contents vii Calibration 44 Calibration Procedure Setup for 60 Hz Motors 46 MAXIMUM SPEED MAX SPD 46 TORQUE LIMIT TQ EIMIT fer 47 ACCELERATION ACCEL 48 DECELERATION nega yee 48 BOOST ss dt eI OS Re Ne red 49 Calibration Procedure Conclusion 50 Application Notes 51 Independent adjustable speeds with DIR switch 51 BUNAIOG SWIGI ad ee ROTE OL eas NR ee 52 Single speed potentiometer control of multiple motors 53 Quick Reversing sev de bRePPEFER toe eto on eater 54 Troubleshooting 55 Before tro bleshooting esae See x xS VERSE a e 55 Diagnostic 57 ain ote ties ae IU ER nce lee 57 OE ne ae eee 57 256 do e td mone nema weet eke bd 58 Optional C510 Capacitor Kit p n 175325 63 Replacement Pans SQUE EN ELE d Rae 65 Tables Table 1 Line F sing Ghart sss HR emis 20 Table 2 Replacement aston
6. 4 2 y L 4 M 1 1 1 21 2 1 600 601 oe __ R Lira 96 0 ls 7 Dimensions 116571 2 S43 LINITIIN S3HONI SNOISN3WIQ TV 82 06 9 10911 0 9 gt 0 70 4 2 1006 o7 ler Srt zz 270 j sz 001 Dimensions r 4 30 109 3 80 97 Qr 0 97 25 9 3 2 00 51 mE TOTAL HEIGHT TOP OF CAP TO 5515 175319PCM 175310PCM 2 56 65 0 3 02 76 7 ALL DIMENSIONS IN INCHES MILLIMETERS Figure 8 175319PCM and 175310PCM Dimensions Dimensions 9
7. Lt L TT B 7 Sa 501 O DECEL BOOST 5 D TQ LIMIT e e o FAULT ILE AX Bo 2 noon VER POWER O ooo ee iL nu tn e E 9 L1 Figure 29 FHP Series diagnostic LED locations Problem External line fuse blows External 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 Troubleshooting 59 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 47 Increase the speed adjust potentiometer setting or voltage input signal Check connections to input Verify that connections are not open 60 Troubleshooting Problem External line fuse does not blow but the motor does not run cont Motor runs too slow or too fast at set speed Possible C
8. If the input voltage is 115 VAC and the desired output voltage 15 230 VAC voltage doubler mode set 115V 230V jumper as shown in Figure 13 page 25 A line fuse may be added to L2 If the input voltage is 230 VAC and the desired output voltage 15 230 VAC no voltage doubler set 115V 230V jumper as shown in Figure 14 page 26 Add a line fuse to L1 and L2 Do not use the voltage doubler feature with 230 VAC line voltage Installation 25 L L L WARNING e PUDE MU ry 230 line input when the drive is AMN o set for 115 VAC input This eae will result severe 5 e damage to the motor and drive can lead to explosion and or injury I 3 o 3 START STOP 5 SWITCH 1 9 E a 115 8 T 9 LINE INPUT E Es FUSE 0 J501 Voltage Doubler Mode Setting 115 VAC in 230 VAC out Figure 13 AC Line and Fuse Connections for Doubler FHP Series Drives Voltage Doubler Mode 26 Installation ES zit 9 502 START STOP FUSE SWITCH 38 3 gt 9 230 8 LINE INPUT E
9. FUSE o 4501 Voltage Doubler 230 VAC 230 VAC out Figure 14 AC Line and Fuse Connections for Doubler FHP Series Drives Not in Voltage Doubler Mode Installation 27 Motor connections all FHP series controls Single phase operation For single phase operation connect the motor as shown in Figure 15 page 28 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 split capacitor motor connect the motor as shown in Figure 16 page 29 The motor starter cap must be removed from the circuit Three phase operation Connect a three phase motor to terminals U V and W as shown in Figure 17 page 30 28 Installation MOTOR WINDINGS CAPACITOR This connection may be internal to the motor 2 wire 11 DIRECTION switch with leads If not you must make this set up See Figure 16 this connection yourself on Page 29 for setup using o o a DIRECTION switch 1 4 1 B rM U o o o 5 5 E meson 5 X
10. 026671 816671 2 anba S43 LINITIIN SIHONI NI SNOISNAWIG 777 0 69 18 2 189 892 19151602 SISSVHO 40 WOLLOG OL dY9 40 301 LHOI3H 1 101 815941 IAN 51212121215 T 5 e E2 E1 S1 S2 3 D Q 9 CA 1 25555 It JT JT 6 08 2 rz 960 601 06 51212 H 3 Dimensions suoisueullg 22262 pue 226571 enBi4 SYSLAWITIW SIHONI NI SNOISN3WIG 71 521 06 9 c eel 89 5 T 091 069 elero 1810 4 gt Bel 2100 B po gt rt Cas H 1 8 001 4 Dimensions 4 30 109 3 80 97 Su 3 70 94 0 97 25 2 12 5
11. USER S MANUAL Variable frequency drives for 3 phase and single phase AC motors 175318 175319 175320 175321 175310 175322 175323 175311 175318PCM 175319PCM 175321PCM 175321PCM 175310PCM 175322PCM 175323PCM 175311PCM LIMITED WARRANTY A Warranty LEESON Electric warrants that its products will be free from defects in material and workmanship for a period of one 1 year from the date of shipment thereof Within the warranty period LEESON will repair or replace such products that are returned to LEESON or to the nearest Branch Office with shipping charges prepaid At our option all return shipments are F O B LEESON or its Branch Office This warranty shall not apply to any product that has been subject to misuse negligence or accident or misapplied or repaired by unauthorized persons or improperly installed LEESON is not responsible for removal installation or any other incidental expenses incurred in shipping the product to or from the repair point B Disclaimer The provisions of Paragraph A are LEESON s sole obligation and exclude all other warranties of MERCHANTABILITY or use express or implied LEESON further disclaims any responsibility whatsoever to the customer or any other persons for injury to person or damage or loss of property of value caused by any product that has been subject to misuse negligence or accident or misapplied or modified by unauthorized persons or improperly installed C Limita
12. Warning Dangerous voltages exist on the drive when it is powered and up to 60 seconds 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 FHP series has five user adjustable trimpots Each drive is factory calibrated to its maximum current rating Re adjust the calibration trimpot settings to accommodate lower current motors See Figure 24 page 45 for FHP series trimpot location 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 45 Calibration 1no e pz anpa 135 0882 502 o oJ oo JMPSO1 INPUT RANGE 220 1000 3 4 20MA AmA zero 2 3 CURRENT OL 46 Calibration Calibration Procedure Setup for 60 Hz Motors 1 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 the DIRECTION switch to the FWD open position If no switch is installed remove the jumpe
13. ACCEL 1 Set the speed adjust potentiometer to zero full CCW and wait for the motor to come to a stop or minimum speed 2 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 3 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 to maximum full CW and wait for the motor to come to maximum speed 2 Set the speed adjust potentiometer 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 Calibration 49 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 Run the motor at the lowest continuous frequency speed required 2 Monitor the motor phase current with a true RMS meter while very slowly turning the BOOST trimpot CW until the motor operates properly or 100 of the motor nameplate current is reach
14. dada SO MUERE 65 viii Illustrations Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 FHP Series Features amp Benefits 22 iv 175318 175320 amp 175321 Dimensions 2 175322 and 175323 Dimensions Rr 3 175318PCM 175320PCM and 175321PCM Dimensions 4 175322PCM and 175323PCM Dimensions 5 175319 82175310 DIMENSIONS c de Ier pent Meda Dede RES 6 175311 Dimensions erm Oris u sei ceieibe rdi gil ean 7 175319PCM and 175310PCM Dimensions 8 175311P GM Dimensions et AY Sorelle ek ted a Er EIE 9 FHP Series Drive with PCM adder board amp PCM adder kit 11 Speed Adjust Potentiometer AC Line and Fuse Connections for Single Voltage FHP Series Drives 23 AC Line and Fuse Connections for Doubler FHP Series Drives Voltage Doubler Mode 25 AC Line and Fuse Connections for Doubler FHP Series Drives Not in Voltage Doubler
15. can be configured to follow 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 Ensure that the following jumper terminals are properly set JMP501 Input Range Settings Set jumper in position 1 for 0 5 VDC signal input Set jumper in position 2 for 0 10 VDC signal input Set jumper in position 3 for 4 20 mA signal input JMP502 Input Type Jumper pins 1 amp 2 for Voltage follower mode Jumper pins 2 amp 3 for Current follower mode See Figure 22 on page 36 for jumper locations and terminal connections Installation 36 Suonoeuuoo pue suormeoo 1eduun 1 1 i H3I3AOUuN3IOd 02 isnrav 9334 10 0 WHO 40 90A 8 0 i NANI 1 7 lt ON WNOIS 1 1 i 1 1 IVNOIS 20109 03395 OL 1 25 a es zs is es 28015 j A 5 10 2 suid 16 r 2 lt lt ao
16. coast to a stop before changing direction FWD STOP REV 0 o DPDT CENTER OFF SWITCH Figure 28 FHP Quick Reversing TB501 E2 ENABLE E1 COMMON 51 52 3 55 Troubleshooting Warning Dangerous voltages exist on the drive when it is 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 56 Troubleshooting Verify that there are no 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 Leeson distributor or the factory direct by telephone at TEL 262 377 8810 or FAX 262 377 0090 Troubleshooting 57 Diagnostic LEDs LEESON FHP Series drives
17. from dirt moisture and accidental contact Provide sufficient room for access to the terminal block and calibration trimpots Mount the drive away from heat sources Operate the drive within the specified ambient operating temperature range Prevent loose connections by avoiding excessive vibration of the drive 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 Installation 17 DO NOT 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 one motor lead may destroy the drive Use 20 24 AWG wire for speed adjust potentiometer wiring Use 14 16 AWG wire for AC line L1 L2 and motor U V and W wiring 18 Installation 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 LEESON recommends shielding of all conductors If it is not practical to shield po
18. 0 VAC output for use with 230V motors The drive output current rating remains the same Refer to Page 24 for connection information Use extreme caution when connecting this feature Incorrect use of this feature may result in fire and serious injury Operation 39 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 1 Verify that no conductive material is present on the PCB 2 Verify that the correct voltage is connected to the inputs before applying power DO NOT CONNECT 230 VAC line voltage to a 115 VAC drive Applying power in this manner will damage the motor and drive 3 Set the speed adjust potentiometer to zero full CCW 4 Set the 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 5 Set the ENABLE DISABLE switch if installed to ENABLE or short the ENABLE E2 and E1 terminals on TB501 6 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 2 seconds If the POWER LED does not light check the external line fuses to ensure that they are properly installed and not blown 40 Operation 7 f you attempt to startup and the yellow TQ LED c
19. 15 Va 4 01 10 175323 230 230 1 4 01 10 175311 115 230 230 1 4 01 15 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 175320 amp 175322 115 VAC 10 50 60 Hz single phase 175318 175321 amp 175323 230 VAC 10 50 60 Hz single phase 175319 175310 amp 175311 115 230 VAC 10 50 60 Hz single phase Standard Carrier Frequency 16 KHz Output Frequency Range 0 120 Hz Adjustable Maximum Output Frequency Range 30 120 Hz Acceleration Time Range 1 12 seconds Deceleration Time Range 1 12 seconds Analog Input Voltage Range signal must be isolated 51 to 52 0 5VDC Input Impedance S1 to S2 100K ohms Vibration 0 5G max 20 50 Hz 0 1G max 50 Hz Weight 1 2 Ib Ambient Operating Temperature Range 10 40 C An isolation board option that allows for a non isolated 0 5 VDC 0 10 VDC or 4 20 mA input signal is available PCM option The option board is installed directly above the main board maintaining the same footprint and dimensions Call the factory for more information regarding the PCM option imensions 2 D SUOISUBWIG 126571
20. 4 Arr 51 52 53 D OL Zi 0 96 24 1 175318PCM 175320PCM 175321PCM TOTAL HEIGHT H TOP OF CAP TO BOTTOM OF CHASSIS 2 03 51 6 2881630 ALL DIMENSIONS 2 48 63 0 INCHES MILLIMETERS Figure 4 175318PCM 175320PCM and 175321PCM Dimensions Dimensions 4 40 3 00 72 0 70 18 112 ALL DIMENSIONS IN INCHES MILLIMETERS 1 00 25 3 68 93 5 0 12 3 EC Figure 5 175322 175323PCM Dimensions 5 Dimensions 6 SUOISUAWIG 01262 619 1 9 794 01292 099 952 61292 SISSVHO 40 WOLLOG OL dY9 30 401 1 101 SHALSWITHW SIHONI NI SNOISNAWIG TIY E2 E1 S1 S2 S3 D i ff o s de iP iEn sz 26 0 o Q pam
21. Installation 31 Speed Adjust Potentiometer Connections 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 wiper S2 is turned clockwise CW See Figure 18 below 10K OHM TT SPEED ADJUST 92 E1 cu 7 7 POTENTIOMETER 0 Y w 2 ok 28 Z se Ole cw Zire 8 Figure 18 Speed Adjust Potentiometer Connections to 501 32 Installation Voltage Follower Connections Instead of using a speed adjust potentiometer the drive may be wired to follow a 0 5 VDC isolated voltage signal Figure 19 Connect the signal input to S2 and signal common to S1 Make no connection to S3 A potentiometer can be used to scale the analog input voltage The FHP PCM adder board may be used to scale and isolate an analog input voltage see Page 35 TB501 DQ es SIGNAL COMMON 5 VDC VOLTAGE SIGNAL gt SIGNAL INPUT Figure 19 Voltage Follower connections Installation 33 Signal and Optional Switch Connections All signal and switch connections are made at TB501 Terminal block ori
22. Mode 26 Motor Connections for Single Phase Operation Motor With Pre Wired Capacitor 28 Motor Connections for Single Phase Operation Configured for use with DIRECTION switch Motor Connections for Three Phase Motors Speed Adjust Potentiometer Connections to TB501 Voltage Follower connections Enable Disable Switch connections to 501 Signal and Optional Switch Connections PCM jumper locations and terminal connections Thermal Overload Switch with Optional Enable Disable Switch 5 ur dex Ege tare pon SERPENS EXER Sacha 42 FHP Series Calibration Trimpot Layout 45 Independent Adjustable 5 51 Switch e Ie a eset emerit En Retos c Prae box 52 Single Speed Potentiometer Control of Multiple Motors 53 FUP Quick Reversing 225242476 e RA Rep ae FHP Series diagnostic LED locations 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 175318 230 230 L 1 2 3 175319 115 230 230 L 1 2 713 175320 115 115 14 2 4 7 175321 230 230 Va 2 4 7 175310 115 230 230 Vb 2 4 10 7 175322 115 1
23. O THE BOTTOM SIDE OF THE SHOULDER WASHER AS SHOWN 14 Installation J501 STEP 7 POSITION THE PCM ADDER BOARD OVER THE BOTTOM BOARD AS SHOWN NOTE First align the bottom holes of J501 on the PCM adder board with the 6 pin header installed on the bottom board The PCM adder board will snap into place at J501 and the two standoffs SECURE THE PCM ADDER BOARD WITH THE 6 32 x 1 5 16 PHILLIPS SCREW INSTALLATION COMPLETE Installation 15 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 mouting may require derating the drive See your LEESON 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 Six 0 19 inch 5 mm wide slots accept 8 pan head screws Fasten either the large base or narrow flange of the 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 16 Installation Protect the drive
24. ant 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 SHOCK AVOID HAZARD VIBRATION Reduce the chance of an electrical fire 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 result of a component failure LEESON 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 screwdiver for adjusting the calibration trimpots approved personal protective equipment and insulated tools if working on this drive with power applied General Information The LEESON FHP Series are solid state variable frequency AC motor drives The FHP utilizes a 115 or 230 VAC 50 60 Hz single phase input and is
25. are equipped with diagnostic LED s to assist the user in troubleshooting and monitoring equipment status while in use Refer to Figure 29 page 58 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 FAULT LED The red FAULT LED turns on when the drive output is locked out or not ENABLED and any one of the following fault conditions occur 1 Overvoltage FHP 230AC controls DC bus exceeds 400 VDC FHP 115AC controls DC bus exceeds 200 VDC 2 Undervoltage FHP 230AC controls DC bus drops below 200 VDC FHP 115AC controls DC bus drops below 100 VDC 3 Instantaneous Overcurrent Trip Inverter output current has exceeded safe levels Note The FAULT condition must be reset using the ENABLE function of the FHP opening and closing the ENABLE input 58 Troubleshooting TQ 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 47 for information on calibrating the TQ LIMIT trimpot
26. ause 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 ENABLE EN and COM terminals are properly connected Verify that motor is not jammed Increase setting if it is set too low page 47 Apply AC line voltage to L1 and L2 Connect motor to drive outputs U V and W Calibrate MAX SPD trimpot page 46 Troubleshooting 61 Problem Possible Suggested Cause Solution Motor will not reach the MAX SPD setting is Increase MAX SPD desired speed too low setting page 46 Nominal input voltage Compare motor may be too low for voltage to input motor voltage replace motor if necessary Motor is overloaded Check motor load Resize the motor or drive if necessary Motor pulsates or surges Motor bouncing in Make sure motor is under load and out of torque limit not undersized for load adjust TQ LIM setting CW page 47 Motor does not reverse Defective DIRECTION Check DIRECTION Switch connection Switch connection Reversing circuit not Check reversing working properly circuit by shorting TB501 D terminal to E1 terminal with jumper wire 62 Troubleshooting P
27. ed NOTE 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 LEESON representative for assistance 50 Calibration Calibration Procedure Conclusion 1 Set the speed adjust potentiometer to zero full CCW 2 Disable the drive by opening the ENABLE DISABLE switch or removing the jumper from TB501 E2 and E1 terminals 3 Remove power to the motor and drive Calibration is now complete 51 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 shows the connection of two independent speed adjust potentiometers that can be mounted at two separate operating stations TB501 AY FORWARD SPEED 20K OHM E1 SI ied l 20 d of FORWARD 92 D DIRECTION REVERSE L Figure 25 Independent Adjustable Speeds 52 Application Notes 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 po
28. entation and terminal names are identical for all FHP series drives Use 20 24 AWG wire for speed adjust potentiometer and switch connections 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 to a stop Close the switch to accelerate to set speed at a rate controlled by the ACCEL trimpot ENABLE DISABLE SWITCH TB501 OPEN TO DISABLE T re 92 E1 COMMON s Z Figure 20 Enable Disable Switch connections to TB501 34 Installation DIRECTION D switch Connect a single pole single throw DIRECTION switch between the D and COMMON E1 terminals as shown in Figure 21 below 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 to a stop before changing direction DIRECTION SWITCH CLOSE TO REVERSE Figure 21 501 Qe 1 s Qs gt Signal and Optional Switch Connections Installation 35 Voltage or Current Follower PCM models PCM series drives
29. erated only by motor heat and open the enable circuit when the motor reaches a temperature capable of causing damage to the motor winding Normally these thermal protectors automatically close the circuit when the motor has cooled to a safe temperature In operation when the drive is disabled or when the motor overheats the thermal protector opens the circuit See Figure 23 page 42 42 Operation ENABLE DISABLE SWITCH THERMAL OVERLOAD CLOSE TO ENABLE SWITCH 501 O O odo 2 2 1 2 e e S2 j 83 Figure 23 Thermal Overload Switch with Optional Enable Disable Switch Operation 43 Line starting and line stopping A Warning LEESON strongly recommends the installation of a master power switch in the voltage input line see Power and Fuse connections page 22 The switch contacts should be rated at a minimum of 200 of motor nameplate current and 250 volts Line starting and line stopping applying and removing AC voltage input is not recommended and should be used for emergency stopping only When AC voltage input is applied to the drive the motor accelerates to the speed set by the speed adjust potentiometer When AC voltage input is removed the motor coasts to a stop To jog a motor install a normally open pushbutton switch on the ENABLE input 44 Calibration
30. factory calibrated for an output of 0 to 60 Hz They will operate any 1 HP or smaller 115 or 208 230 volt three phase AC induction single phase permanent split capacitor motor see page v and can be user calibrated for 0 through 120 Hz output Although FHP 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 satisfactorily 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 FHP 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 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 FHP uses this method of connection its fundamental design enables it to operate efficiently under these conditions The FHP series features sol
31. id state reversing with adjustable acceleration and deceleration The FHP may also interface with motor thermal protection through the enable circuit General Information FHP 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 green FAULT red TORQUE yellow ADJUSTABLE CALIBRATION TRIMPOTS LED INDICATORS DECEL ACCEL TQ LIMIT optional ACCEPTS 0 5 VDC DOUBLES THE OUTPUT ZERO SET 0 10 VDC or 4 20 mA VOLTAGE TO THE AC MOTOR NON ISOLATED SIGNAL WHEN 115 IS APPLIED on isolation board OPTIONAL ISOLATION BOARD DOUBLER VERSIONS Figure 1 FHP Series Features amp Benefits Important Information 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 LEESON 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 FHP Series drives Permanent split capacitor PSC Shaded pole AC synchronous A The following motor types MAY NOT be used Split phase Capacitor start Repulsion induction Series Universal AC DC Any m
32. nput Max Amps Fuse Drive VAC HP In Size Amps 175318 230 V 3 5 175319 115 230 Va 7 3 10 5 175320 115 V 7 10 175321 230 Vo 7 10 175310 115 230 Vo 10 7 15 10 175322 115 Vo 10 15 175323 230 1 10 15 175311 115 230 1 15 10 20 15 Installation 21 Speed adjust potentiometer A Warning Be sure that the potentiometer tabs do not make contact with the potentiometer enclosure Grounding the input will cause damage to the drive Mount the speed adjust potentiometer through a 0 38 in 10 mm hole with the hardware provided Figure 11 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 DELE I NUT STAR WASHER SPEED ADJUST POTENTIOMETER INSULATING DISK POT TAB ASSIGNMENTS PANEL Figure 11 Speed Adjust Potentiometer 22 Installation Connections A Warning DO NOT connect this equipment with power applied Failure to heed this directive may result in fire or serious injury LEESON strongly recommends the installation of a master power switch in the voltage input line The switch contacts should be rated at a minim
33. omes 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 accomodate the needed starting torque 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 D 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 rates are controlled by the ACCEL DECEL trimpot settings If quicker reversing is needed refer to applications notes section page 51 for further detail Operation 41 Starting and stopping methods To coast the motor to a stop Open the ENABLE DISABLE switch or remove the jumper between the ENABLE 22 and COMMON 1 terminals of TB501 Refer to the Application Notes section page 51 for instructions on switch installation 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 op
34. otor with starting switch centrifugal or relay and or separate starting winding Safety Warnings General Information Important Information Specifications Dimensions Installation 175324 Process Control Module PCM Mounting PAQUIN crn ad oe tad ete ni kh ete PRA ON QUON WitiDg Barc SING dotes aid td qn Pe Shielding guidelines lt 2 Sook CE Speed adjust potentiometer Connections A E PE a Power and fuse connections Motor connections all FHP series controls Speed Adjust Potentiometer Connections Voltage Follower Connections Signal and Optional Switch Connections Voltage or Current Follower PCM models Operation Voltage DOUGIO c ecient DG PX WERE EN e e paces d dou To reverse motor direction Starting and stopping methods To coast the motor to a eI rae Ex ERE Thermal protection of the motor
35. r 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 Set the speed adjust potentiometer to zero full CCW Calibrate the trimmer pots as follows MAXIMUM SPEED MAX SPD Rotate the speed adjust potentiometer full CW Using a hand held tachometer or analog frequency meter as a reference adjust the MAX trimpot until the desired speed or frequency is reached Calibration 47 TORQUE LIMIT TQ LIMIT A Warning Although the TQ 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 120 of maximum motor current 7 Set the speed adjust potentiometer or reference signal to zero speed 8 Remove power from the drive 9 Remove the lock from the motor shaft 10 Remove the ammeter in series with the motor lead 48 Calibration ACCELERATION
36. roblem 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 LIM setting page 41 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 Troubleshooting 63 Optional C510 Capacitor Kit p n 175325 In some applications lowering carrier frequency reduces switching losses and increases bearing life in some motors LEESON provides an optional capacitor kit for lowering the carrier frequency The default carrier frequency on FHP controls is 16 2 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 freqency on all FHP controls install one of the following 2 pin capacitors C510 on the bottom board LABEL ON CAPACITOR FREQUENCY VALUE 3n3J 12kHz 0 0033uF 6n8 10kHz 0 0068uF 10n 8kHz 0 01uF 33n 4kHz 0 033 See Figure 30 page 64 for C510 location and installation instructions 64 Troubleshooting Cap Label TN J100 CARRIER FREQUENCY CAPACITOR C510 Insert the 2 pins of the carrier frequency capacitor in
37. sition 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 The motor coasts to a stop 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 PUSHBUTTON SWITCH Pa TB501 motor coasts to stop 92 E2 ENABLE RUN 92 E1 COMMON Qs p Figure 26 RUN JOG Switch Application Notes 53 Single speed potentiometer control of multiple motors A Warning The combined current draw of all motors must not exceed the current rating of the drive The FHP 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 MOTOR MOTOR A B cone VFD SERIES SPEED ADJUST DRIVE POTENTIOMETER Figure 27 Single Speed Potentiometer Control of Multiple Motors 54 Application Notes Quick Reversing To reverse the direction of motor shaft rotation install a DPDT center off switch as shown below Figure 28 The drive will brake the motor before reversing so there is no need to wait for the motor to
38. tions of Liability In the event of any claim or breach of any of LEESON s obligations whether expressed or implied and particularly of any claim of a breach of warranty claimed in Paragraph A or of any other warranties express or implied or claim of liability that might despite Paragraph B be decided against us by any lawful authority LEESON shall under no circumstances be liable for any consequential damages losses or expense arising in connection with the use of or inability to use LEESON s product for any purpose whatsoever An adjustment made to the warranty does not void the warranty nor does it imply an extension of the original one 1 year warranty period Product serviced and or parts replaced by a no charge basis during the warranty period carry the unexpired portion of the original warranty only If for any reason any of the forgoing provisions shall be ineffective LEESON s liability for damages arising out of its manufacture or sale if equipment or use thereof whether such liability is based on warranty contract negligence strict liability in tort or otherwise shall not in any event exceed the full purchase of such equipment Any action against LEESON based upon any liability or obligation arising hereunder or under any law applicable to the sale of equipment or the use thereof must be commenced within one year after the cause of such action arises 5 Safety Warnings e This symbol A denotes an import
39. to the 2 socket holes C510 located on bottom board JMP501 DECEL 5 KO LIMIT FAULT D POWER Figure 30 Carrier frequency capacitor location em Cc Troubleshooting 65 Replacement parts are available from LEESON Electric and its distributors for this drive series Table 2 Replacement Parts Potentiometer Kit 175325 Capacitor Kit 175324 PCM Kit 10K ohm 5W Potentiometer 12 2 Capacitor 10 kHz Capacitor 8 kHz Capacitor 4 kHz Capacitor PCM Adder Board 1 PCB Standoffs 2 Jumper 1 6 Pin Header 1 Shoulder Washer 1 0 578 Nylon Spacer 1 6 32 x 1 15 16 Phillips Screw 1 DISCLAIMER The information and technical data in this manual are subject to change without notice LEESON Electric makes no warranty of any kind with regard to this material including but not limited to the implied warranties of merchantability and fitness for a particular purpose LEESON Electric assumes no responsibility for any errors that may appear in this manual and makes no commitment to update or to keep current the information in this manual 2100 Washington Street Grafton WI 53024 0241 U S A TEL 262 377 8810 FAX 262 377 9025 Document number 250 0356 Revision 2 Printed in the U S A September 2004
40. um of 200 of motor nameplate current and 250 volts Power and fuse connections Single Voltage FHP Series Drives 175318 175320 175321 175322 175323 Connect the AC power input to L1 and L2 as shown in Figure 12 page 23 Connect an external fuse between the drive and master stop switch Install the switch between the external fuse and AC power input as shown Installation 23 IMIT AULT dee s START STOP C uuuu FUSE SWITCH 25 z 79 Bo 115 230 E FUSE LINE INPUT L1 0 Do not add fuse to L2 unless line voltage is 230 VAC Figure 12 AC Line and Fuse Connections for Single Voltage FHP Series Drives 24 Installation Doubler FHP Series Drives 175319 175310 175311 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 can lead to explosion and or injury Check jumper settings before connecting AC power input Connect AC power input to L1 and L2 as shown in Figure 13 and 14 pages 25 amp 26 depending on your power needs NOTE Doubler drives are equipped with a voltage doubling 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 Use caution when connecting this output
41. wer conductors LEESON 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 Installation 19 If the drive continues to pick up noise after grounding the shield it may be necessary to add AC line filtering devices or to mount the drive in a less noisy environment Logic wires from other input devices such as motion controllers and PLL velocity controllers must be separated from power lines in the same manner as the logic I O on this drive Heat sinking LEESON 1 HP FHP drives 175322 175323 amp 175311 drives are delivered with a factory installed heat sink All other FHP series drives have sufficient heat sinking in their basic configurations No additional heat sinking is necessary 20 Installation Fusing FHP series drives require external AC power line fuses Connect the external line fuse s in series with the AC voltage input See Connections on page 22 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 I
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