USER`S MANUAL 170-543-0004 - Bison Gear and Engineering
Contents
1. 12 connecti Sien ced dade eee GEES 16 Speed Adjust Potentiometer Connections 18 Signal and Optional Switch Connections 19 Voltage or Current Follower 20 Operation 22 Voltage Doubler aed eats 23 ox arith cae enh ean oe eae an dead ened Bid 24 To reverse motor direction 25 Starting and stopping methods 26 To coast the motor to a stop 26 To brake the motor to a 5 26 Thermal protection of the motor 27 Line starting and stopping 29 Calibration Calibration procedure Setup for 60 Hz Motors MAXIMUM SPEED MAX SPD MINIMUM SPEED MIN SPD TORQUE LIMIT TQ LIMIT ACCELERATION ACCEL DECELERATION DECEL BOOST 2 Voie SLIP COMPENSATION Calibration Procedure Conclusion Application Notes Independent adjustable speeds with DIR switch RUN JOG switch Single speed potentiometer control of multiple motors Quick2. ewes Troubleshooting Before troubleshooting Diagnostic LEDs POWER LED ENABLE LED FAULT LED Unconditional Warranty Tables Table 1 Line Fusing Chart TQLIMIT LED vii 31 dere See 33 Inside Back Cover 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 21 170 543 0004 Series Features 8 Benefits iv 170 543 0004 Dimensions 2 170 543 0004 Circuit Board Layout 3 170 543 0004 Jumper Locations 4 AC Line Connections for 170 543 0004 13 Voltage Doubler Feature for 170 543 0004 15 Motor Connections Single Phase Operation pre wired cap 16 Motor Connections Single Phase Operation Motor Connections Three Phase Operation Speed Adjust Potentiometer Connections to 501 Signal and Optional Switch Connections for 170 543 0004 Jumper Settings JMP504 and
3. FWD O 5 Ver a REV Lp 51 52 53 NIVNO Figure 20 170 543 0004 Quick Reversing 42 Troubleshooting Warning Dangerous voltages exist on the drive when it is 4 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 43 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 Bison distributor or the factory direct by telephone at 1 800 AT BISON 44 Diagnostic LEDs Bison 170 543 0004 is equipped with diagnostic LED s to assist the user in troubleshooting and monitoring equipment status while in use Refer to Figure 21 pag
4. 505 170 543 0004 Jumper Settings JMP506 Thermal Overload Switch with Optional Enable Disable Switch 28 Jumper Settings JMP508 gt Ieee 30 170 543 0004 Calibration Trimpot Layout 4 32 Independent Adjustable lt 38 RUN JOG SWItCH becca nee tate hee 39 Single Speed Potentiometer Control of Multiple Motors 40 170 543 0004 Quick Reversing 41 170 543 0004 Diagnostic LED location 45 Specifications 1 Phase 1 or 3 Phase Max Continuous AC Input Output Max Output Amps Drive VAC VAC Current AC In 170 543 0004 415 230 230 1 4 0 14 7 Connect only 115 VAC line input to the 115 VAC terminals Application of 230 VAC line input when set for 115 VAC will result in severe damage to the motor and drive and possible explosion and injury t Derate current by 2 per degree if the operating temperature is above 40 C Under no circumstances may the ambient temperature exceed 55 C AC Voltage Input Range 115 230 VAC 10 50 60 Hz single phase Standard Carrier Frequency 16 KHz Output Frequency Range 0 120 Hz Maximum Output Frequency Range 30 120 Hz Minimum
5. 4 page 4 for Jumper Locations Set the ENABLE switch to the DISABLE open position If no switch is installed remove the jumper between the 22 E1 terminals of TB501 Set the DIRECTION switch to the FWD open position If no switch is installed confirm that there is no jumper between the D and E1 terminals of TB501 Set all trimpots except TQ LIMIT and MAX fully counterclockwise CCW Set the TQ LIMIT trimpot to maximum full CW 6 Set the MAX trimpot to the 50 position 7 Set the speed adjust potentiometer or reference signal to zero full CCW Calibrate the trimmer pots as follows MAXIMUM SPEED MAX Rotate the speed adjust potentiometer full CW or set the reference signal to maximum Using a hand held tachometer or analog frequency meter as a reference adjust the MAX trimpot until the desired maximum speed or frequency is reached 34 MINIMUM SPEED MIN Rotate the speed adjust potentiometer CCW or set the signal reference to a minimum Adjust the MIN trimpot until the motor has stopped for zero speed setting or until desired minimum speed has been reached The MAX may need to be readjusted after calibration of the MIN TORQUE LIMIT TQ LIMIT Warning Although the TORQUE LIMIT trimpot can be set up to 150 of the drive nameplate rating continuous operation beyond the drive nameplate rating may cause damage to the motor and or drive 1 With no power applied to the drive co
6. Adjust Potentiometer Connections to TB501 19 Signal and Optional Switch Connections All signal and switch connections are made at TB501 Use 20 24 AWG wire for speed adjust potentiometer and switch connections NOTE The Enable Disable and Direction switch are factory installed on the 170 543 0004 drives ENABLE DISABLE switch Connect a single pole single throw ENABLE DISABLE switch between the ENABLE E2 and COMMON E1 terminals as shown Open the switch to disable the drive and coast or brake to a stop Refer to page 26 for stopping method Close the switch to accelerate to set speed ata rate controlled by the ACCEL trimpot The ENABLE input is isolated DIRECTION D switch Connect a single pole single throw DIRECTION switch between the and COMMON 1 terminals as shown Figure 11 page 20 Opening the switch will cause the motor to rotate in the forward direction closing the switch will reverse motor rotation The DIRECTION input is isolated The drive will decelerate the motor to a stop at the DECEL trimpot setting before reversing so there is no need to wait for the motor to coast or brake to a stop before changing direction For faster reversing see Application Notes page 38 20 ENABLE DISABLE TO SPEED POT SWITCH DIRECTION OR SIGNAL INPUT open to disable SWITCH 53 52 51 E2 TB501 Figure 11 Signal and Optional Switch Connections for 170 543 0004 Volta
7. Problem Internal line fuse blows Internal line fuse does not blow but the motor does not run Possible Cause Line fuses are the wrong size Motor or motor cable is shorted to ground Nuisance tripping caused by a combination of ambient conditions and high current spikes i e reversing Speed adjust potentiometer or voltage input signal is set to zero speed Speed adjust potentiometer or voltage input signal is not properly connected to drive input connections are open Suggested Solution Check that line fuses are properly sized for the motor being used Check motor cable and motor for shorts Add a blower to cool the drive components increase TQ LIMIT settings page 34 Increase the speed adjust potentiometer setting or voltage input signal Check connections to input Verify that connections are not open Problem Internal line fuse does not blow but the motor does not run cont Motor runs too slow or too fast at set speed Possible Cause Drive is tripped off or has gone into thermal overload Drive has been disabled Drive is in current limit Drive is not receiving AC voltage input Motor is not connected MAX SPD trimpot is not calibrated correctly Suggested Solution Disable then re enable the drive Ensure that ENABLE EN and COM terminals are prope
8. amp 2 may need to be repeated several times to reach the desired accuracy required Wide speed range accuracy of the slip compensation method depends heavily on motor slip vs frequency characteristics Calibration Procedure Conclusion 1 Set the speed adjust potentiometer or reference signal to zero full CCW Disable the drive by opening the ENABLE DISABLE switch or removing the jumper from TB501 E2 and E1 terminals Remove power to the motor and drive Calibration is now complete 38 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 17 below shows the connection of two independent speed adjust potentiometers that can be mounted at two separate operating stations TB501 SY 2 le FORWARD SPEED 20K OHM 2 2 SY 20K OHM SHOE FORWARD 23 D DIRECTION REVERSE O _ L Figure 17 Independent Adjustable Speeds 39 RUN JOG switch Use a single pole two position switch for the RUN JOG switch and a single pole normally open momentary operated pushbutton for the JOG pushbutton Set JMP506 to either Coast or Brake depending on how the motor should stop Connect the RUN
9. be necessary for proper cooling in restricted space applications Bison recommends mounting the drive vertically 11 Fusing The 170 543 0004 includes AC power line fuses on the main PC Board Use fast acting fuses rated for 250 VAC or higher See Table 1 for recommended line fuse sizes Table 1 Line Fusing Chart 1 Phase AC AC Line Input Max Amps Fuse Drive VAC HP In Size Amps 170 543 0004 115 230 1 14 7 15 12 Connections All power input and power output connections are made to TB502 A Warning DO NOT connect this equipment with power applied Failure to heed this directive may result in fire or serious injury Bison strongly recommends the installation of a master power switch in the voltage input line The switch contacts should be rated at a minimum of 20 Amps and 250 volts Input AC Power connections Connect the AC power input to TB502 L1 and L2 as shown in Figure 5 page 13 Connect an external master stop switch Install the switch in series of the AC power input as shown 13 START STOP SWITCH 115 230 VAC LINE INPUT Figure 5 AC Line Connections for 170 543 0004 14 Warning Do not connect 230 VAC line AAA input when the drive is set for 115 VAC input This will result in severe damage to the motor and can lead to explosion and or injury Connect AC Power input to L1 and L2 as shown in Figure 5 page 13 NOTE The 170 543 0004 is equippe
10. 06 XX uso POWER UV TRIP Ng gt A 501 501 GENERAL LOCATION ee C503 R501 ors 2 5 501 Fus 7 al g 8 8 502 pie sscrs02 JMP504 504 505 RANGE SELECT 1 DC BRAKE TIME T8602 Figure 4 170 543 0004 Jumper Locations Installation A Warning 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 damage the drive Wait at least one minute after power is removed from drive before working on drive Mounting A Warning DO NOT install rewire or remove this control with input power applied Doing so may cause fire or serious injury Make sure that you read and understand the Safety Warnings before attempting installation NOTE Horizontal mounting may require derating the drive See your Bison representative for more information Itis recommended that the drive be oriented with th
11. 24 AWG wire for speed adjust potentiometer wiring Use 14 AWG wire for AC line L1 L2 and motor U V and W wiring 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 Bison recommends shielding of all conductors If it is not practical to shield power conductors Bison 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 10 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 The 170 543 0004 drive is delivered with a heat sink chassis Ensure that there is adequate space above and below the drive for proper convection air flow A small fan may
12. BISON USER S MANUAL Variable frequency drive for 3 phase and single phase AC motors 170 543 0004 Copyright 2006 by Bison Gear amp Engineering All rights reserved No part of this manual may be reproduced or transmitted in any form without written permission from Bison Gear amp Engineering The information and technical data in this manual are subject to change without notice Bison Gear amp Engineering and its Divisions make no warranty of any kind with respect to this material including but not limited to the implied warranties of its merchantability and fitness for a given purpose Bison Gear amp Engineering and its Divisions assume no responsibility for any errors that may appear in this manual and make no commitment to update to keep current the information in this manual kcosos Printed in the United States of America Safety Warnings e This symbol A denotes an important safety tip or warning Please read these instructions carefully before performing any of the procedures contained in this manual DO NOT INSTALL REMOVE OR REWIRE THIS EQUIPMENT WITH POWER APPLIED Have a qualified electrical technician install adjust and service this equipment Follow the National Electrical Code and all other applicable electrical and safety codes including the provisions of the Occupational Safety and Health Act OSHA when installing equipment Reduce the chance of an electrical fire sh
13. JOG switch and JOG pushbutton to terminal board TB501 as shown in Figure 18 below The motor stops when the RUN JOG switch is set to JOG Press the JOG pushbutton to jog the motor Return the RUN JOG switch to RUN for normal operation NORMALLY OPEN RUN JOG PUSHBUTTON RUN JOG SWITCH 501 oo Oo A E2 ENABLE RUN E1 COMMON Q Is L Figure 18 RUN JOG Switch 40 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 170 543 0004 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 19 below cw Ww 10K OHM SPEED ADJUST POTENTIOMETER Figure 19 Single Speed Potentiometer Control of Multiple Motors 41 Quick Reversing To reverse the direction of motor shaft rotation install a DPDT center off switch as shown in Figure 20 below The drive will stop the motor before reversing so there is no need to wait for the motor to coast to a stop before changing direction JMP506 must be set to brake Refer to Figure 4 page 4 for Jumper Locations 501 E2 ENABLE DPDT CENTER OFF SWITCH E1 COMMON
14. OAST Jumper Pins 2 amp 3 to Coast Figure 13 Jumper Settings JMP506 Thermal protection of the motor The enable input can also act as a motor thermal protection circuit for motors having a built in thermal protector These thermal protectors are operated only by motor heat and open the enable circuit when the motor reaches a temperature capable of causing damage to the motor winding 28 Normally these thermal procedures automatically close the circuit when the motor has cooled to a safe temperature In operation the drive can be disabled by opening the enable switch or opening the thermal overload switch See Figure 14 below ENABLE DISABLE SWITCH THERMAL TB501 OVERLOAD CLOSE TO ENABLE SWITCH E2 ENABLE E1 COMMON Figure 14 Thermal Overload Switch with Optional Enable Disable Switch 29 Line starting and line stopping Warning Bison strongly recommends the installation of a master power switch in the voltage input line see Power and Fuse connections page 13 The switch contacts should be rated at a minimum of 20 Amps and 250 volts Line starting line stopping applying and removing AC voltage input may be configured to operate two different ways by use of JMP503 When 503 is set to the UV TRIP position as shown in Figure 15 page 30 the drive will stop and latch off when an under voltage condition bus voltage drops below 200VDC occurs This can occur due to line sa
15. Output Frequency Range 0 30 Hz Acceleration Time Range 1 12 seconds Deceleration Time Range 1 12 seconds Analog Input Voltage Range 0 5VDC 0 10VDC 4 20mA Input Impedance S1 to S2 100K ohms Braking Current 0 100 rated output Braking Time 1 12 seconds Vibration 0 5G max 20 50 Hz 0 1G max gt 50 Hz Weight 3 0 Ib Ambient Operating Temperature Range 10 40 C Isolation is standard and allows for non isolated speed input enable and direction switch inputs to be used 2 Dimensions 0 188 7 200 183 6 350 161 ADJUSTABLE SPEED REVERSING AC MOTOR CONTROL BOTTOM PLATE 0 73 18 5 CONDUIT HOLES 2 PLACES 4 56 116 2 12 53 8 ALL DIMENSIONS IN INCHES MILLIMETERS Figure 2 170 543 0004 Dimensions Layout TB501 ZERO JMP505 SET 504 UV TRIP RESTART itso ENABLE BRAKE POWER FAULT TORQUE LIMIT JMP501 504 INPUT SELECT 1 2 BR501 2 3 mA 505 RANGE SELECT 1 0 5 VDC 2 0 10VDC 3 4 20mA BRAKE CURREN 2 TIME 1027 502 Figure 3 170 543 0004 Circuit Board Layout 4 Jumper Locations C501 JMP503 E UV TRIP RESTART _ 1 504 a ENABLE fe JMP5
16. S A 0 5 VDC 0 10 VDC or 4 20 mA NON ISOLATED SIGNAL ZERO SET VOLTAGE DOUBLER DOUBLES THE OUTPUT VOLTAGE TO THE AC MOTOR WHEN 115 IS APPLIED Figure 1 170 543 0004 Features amp Benefits Important Information A Warning Caution should be taken when operating fan cooled motors at low speeds because their fans may not move sufficient air to properly cool the motor Bison recommends inverter duty motors when the speed range is beyond 10 1 In addition to standard 3 phase induction motors the following motor types may be used with the 170 543 0004 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 motor with starting switch centrifugal or relay and or separate starting winding vi Contents Safety Warnings i General Information ii Important Information v Specifications 1 Dimensions 2 Layouts 3 Jumper Locations 4 Installation 5 Mounting a Ate 6 E E AAR E E E E EEE 8 Shielding Guidelines dials na aa seee aie aG E es Ea 9 Heat SKO D oe he oe ae 10 BUSING ces ae Oth 11 GONMGCHONS SoS A ee hae 12 Input AC Power Connections
17. ctorily 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 170 543 0004 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 Many 3 phase inverter manufacturers claim that they can run single phase motors effectively This is normally accomplished by wiring only 2 phases however this method may cause instabilities due to the lack of feedback from one of the motor connections Furthermore motor torque will be reduced considerably because the phases are 120 apart Although the 170 543 0004 uses this method of connection its fundamental design enables it to operate efficiently under these conditions The 170 543 0004 features solid state reversing with adjustable acceleration and deceleration The 170 543 0004 may also interface with motor thermal protection through the enable circuit 170 543 0004 FEATURES amp BENEFITS SOLID STATE CIRCUITRY SOLID STATE REVERSING ADJUSTABLE CARRIER FREQUENCY 4 kHz 16 kHz MULTIPLE MOTOR OPERATION THREE PHASE AND SINGLE PHASE MOTOR CONTROL LED INDICATORS ADJUSTABLE CALIBRATION 5 POWER green ENABLE red FAULT red TORQUE yellow BOOST STANDARD ISOLATION SLIP COMP ACCEPT
18. d with a voltage doubler feature which converts a 115 VAC input to a 230 VAC output for use with 230V motors The drive output current rating remains the same for either AC input voltage Use caution when connecting this output If the input voltage is 115 VAC and the desired output voltage is 230 VAC voltage doubler mode set jumpers as shown in Figure 6 page 15 If the input voltage is 230 VAC and the desired output voltage is 230 VAC no voltage doubler set jumpers as shown in Figure 6 page 15 Refer to Figure 4 page 4 for jumper locations 15 NOTE The 170 543 0004 series of drives covered in this manual are meant to be used with 208 230 VAC motors only DO NOT use this series of drives with 115 VAC motors 501 115 VAC Jumper Pins 2 for 115 VAC input Jumper Pins 1 amp 2 for 230 VAC input 2 230 VAC 0 9 Jumper Pins 1 6 2 115 VAC input Jumper Pins 2 amp 3 230 VAC input OWA SLL OWA 0 Figure 6 Voltage Doubler Feature for 170 543 0004 16 Motor connections Motor connections are made to TB502 Single phase operation For single phase operation connect the motor as shown below in Figure 7 Ensure that the prewired capacitor and its associated motor coil are connected to terminals U and 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 r
19. e chassis vertical for best heat dissipation Horizontal mounting while acceptable may require some thermal derating Four 0 19 inch 5 mm wide slots accept 8 pan head screws Fasten the heatsink chassis to the subplate Drive components are sensitive to electrostatic fields Avoid direct contact with the circuit board Hold the drive by the chassis only Protect the drive from dirt moisture and accidental contact Provide sufficient room for access to the terminal block and calibration trimpots Mount the drive away from the heat sources Operate the drive within the specified ambient operating temperature range Prevent loose connections by avoiding excessive vibration of the drive The chassis must be earth grounded Use a star washer beneath the head of at least one of the mounting screws to penetrate the anodized chassis surface and to reach bare metal 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 damage the drive Wait at least one minute after power is removed from drive before working on drive Use 20
20. e 45 for diagnostic LED locations POWER LED The green POWER LED is on when AC line voltage is applied and the control s low voltage power supply is operational ENABLE LED The red ENABLE LED turns on whenever the inverter output is enabled FAULT LED The red FAULT LED blinks on and off when the drive output is locked out or not ENABLED and any one of the following fault conditions occur 1 Overvoltage 170 543 0004 230AC controls DC bus exceeds 400 VDC 2 Undervoltage 170 543 0004 230AC controls DC bus drops below 200 VDC 3 Instantaneous Overcurrent Trip Inverter output current has exceeded safe levels 250 Note The FAULT condition must be reset using the ENABLE function of the drive opening and closing the ENABLE input 45 TORQUE 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 31 for information on calibrating the TQ LIMIT trimpot 4 a 123 AmA 501 o ZERO 505 Coy 11501 502 Jo Vy ENABLE 1501 X 1 502 POWER FAULT 1 503 TORQUE JMP501 LIMIT Figure 21 LED locations
21. everse a single phase permanent split capacitor motor connect the motor as shown in Figure 8 page 17 The motor cap must be removed from the circuit NOTE This connection may be internal to the motor 2 wire leads If not you must make this connection yourself WINDINGS WARNING PREWIRED DO use a direction RUN switch with this wetup CAPACITOR Figure 7 Single Phase Operation pre wired cap 17 NOTE Motor run cap must be removed from the circuit This method works with most but not motors AUXILLIARY WINDING WITHOUT CAPACITOR MOTOR WINDINGS Figure 8 Single Phase Operation Reversing Three phase operation Connect a three phase motor to terminals U V and W as shown in Figure 9 below MOTOR WINDINGS Figure 9 Three phase Operation 18 Speed Adjust Potentiometer Connections Set JMP504 for VDC input by jumpering pins 1 amp 2 Set 505 for 0 5 VDC by jumpering pin column 1 Refer to Figure 4 page 4 for Jumper Locations Connect a speed adjust potentiometer to terminals S1 S2 and S3 Make sure the potentiometer is connected so that the motor speed will increase as the potentiometer is turned clockwise See Figure 10 below NOTE These settings and connections are factory installed on the 170 543 0004 drive 10K OHM SPEED ADJUST POTENTIOMETER CW TB501 YQ 5 53 52 JS E2 Figure 10 Speed
22. g line transients or line disconnect The drive may then be restarted by cycling the ENABLE off then on or waiting until the DC bus drops to zero approximately 1 minute at which point the drive will restart upon reapplication of line power Refer to Figure 4 page 4 for Jumper Locations 30 When 503 is set to the RESTART position as shown in Figure 15 below factory set to UV trip the drive will stop when an under voltage condition bus voltage drops below 200 VDC occurs This can occur due to line sag line transients or line disconnect There is a 1 5 second restart delay after the bus voltage returns to normal Refer to Figure 4 page 4 for Jumper Locations JMP503 on bottom board 5 Pins 1 amp 2 to Trip Pins 2 amp 3 to Restart a UV TRI P UV TRIP Drive has a low voltage fault amp must be manually re enabled or the bus voltage must RESTART go to zero and then return to operation potential to restart RESTART Drive has a low voltage fault amp will momentarily stop then auto restart when input voltage returns to minimum level Figure 15 Jumper Settings JMP503 31 Calibration 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
23. ge or Current Follower Drives can be configured to follow an isolated or a grounded non isolated voltage or current signal To configure the drive to follow a voltage or current signal connect the signal leads to the 51 and 52 terminals on TB501 as shown in Figure 11 above Ensure that the following jumper terminals are properly set as shown in Figure 12 page 21 21 JMP504 Input Type Jumper pins 1 amp 2 for Voltage follower or speed pot mode Jumper pins 2 amp 3 for Current follower JMP505 Input Range Settings Set jumper in position 1 for 0 5 VDC signal or speed pot input Set jumper in position 2 for 0 10 VDC signal Set jumper in position 3 for 4 20 mA signal The 4 20 mA ZERO SET potentiometer should be used to calibrate the zero or minimum speed of the drive with 4mA applied to the input For voltage inputs this pot should be set to full CCW JMP504 JMP504 1 amp 2 for Voltage Input 22 2 8 3 for Current Input 42 3 505 505 1 0 5 VDC INPUT 2 0 10VDC INPUT elo 3 4 20 INPUT 123 Figure 12 Jumper Settings JMP504 and JMP505 22 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 w
24. ith the motor being controlled Voltage Input Warning DO NOT connect 230 VAC line input when the drive is set for 115 VAC input This will result in severe damage to the motor and drive and possible explosion and or injury 23 Voltage Doubler A Warning DO NOT connect 230 VAC line input when drive is set for 115 VAC input This will result in severe damage to the motor and drive and possible explosion or severe injury The 170 543 0004 drive is equipped with a unique voltage doubling feature for use when 230 VAC input voltage is not available This feature converts a 115 VAC input to a 230 VAC output for use with 230V motors The drive output current rating remains the same for either AC input voltage Refer to Figure 6 page 15 for connection information Use extreme caution when connecting this feature Incorrect use of this feature may result in fire and or serious injury NOTE The 170 543 0004 is meant to be used with 208 230 VAC motors only DO NOT use this drive with 115 VAC motors 24 Startup Warning DO NOT change jumper settings with power applied Ensure that jumper settings are compatible with the motor being controlled Before applying power verify that no conductive material is present on the printed circuit board Verify that no conductive material is present on the PCB Verify that the correct voltage is connected to the inputs before applying power DO NOT CONNECT 230 VAC
25. line voltage to a 115 VAC configured drive Applying power in this manner will damage the motor and drive Set the speed adjust potentiometer or reference signal to zero full CCW 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 Set the ENABLE DISABLE switch if installed to ENABLE or short the ENABLE E2 and E1 terminals on TB501 Apply 115 or 230 VAC 50 60 Hz single phase power to the drive The green POWER LED will come on after an initial delay of 1 2 seconds If the POWER LED does not light check the line fuses to ensure that they are properly installed and not open 25 7 If you attempt to startup and the yellow TQ LED comes on the control has entered torque limit mode To avoid this occurrence you may a increase the torque limit setting or b lengthen the acceleration time enough to accommodate the starting torque needed by adjusting the ACCEL trimpot Do not set the torque limit setting above 150 of the motor s nameplate current rating To reverse motor direction To reverse the direction of motor shaft rotation while the motor is running set the DIRECTION switch to the opposite position If no DIRECTION switch is installed open or short the DIR and E1 terminals on TB501 as required When a new direction is selected there is no need to open the enable inpu
26. nnect 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 ammeter reads 120 of maximum motor current 35 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 ACCELERATION ACCEL 1 Set the speed adjust potentiometer or reference signal to zero 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 or reference signal to maximum full CW and wait for the motor to reach maximum speed 36 2 Set the speed adjust potentiometer or reference signal to minimum speed full CCW and note the time the motor takes to decelerate to minimum
27. ock or explosion by using proper grounding over current protection thermal protection and enclosure Follow sound maintenance procedures It is possible for a drive to run at full speed as a result of a A component failure Bison strongly recommends the installation of a master switch in the main power input to stop the drive in an emergency Circuit potentials are at 115 VAC or 230 VAC above earth ground Avoid direct contact with the printed circuit board or with circuit elements to prevent the risk of serious injury or fatality Use a non metallic screwdriver for adjusting the calibration trimpots Use approved personal protective equipment and insulated tools if working on this drive with power applied General Information The Bison Variable Frequency Drive Series are solid state variable frequency AC motor drives The 170 543 0004 utilizes a 115 or 230 VAC 50 60 Hz single phase input and is factory calibrated for an output of 0 to 60 Hz They will operate any 1 HP or smaller 208 230 volt three phase AC induction single phase permanent split capacitor motor see page v and can be user calibrated for 0 through 120 Hz output Although 170 543 0004 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 satisfa
28. rly connected Verify that motor is not jammed Increase TQ LIM setting if it is set too low page 34 Apply AC line voltage to L1 and 2 Connect motor to drive outputs U V and W Calibrate MAX SPD trimpot page 33 Problem Motor will not reach the desired speed Motor pulsates or surges under load Motor does not reverse Possible Cause MAX SPD setting is too low Nominal input voltage may be too low for motor Motor is overloaded Motor bouncing in and out of torque limit Defective DIRECTION switch connection Reversing circuit not working properly Motor not wired correctly for reverse Suggested Solution Increase MAX SPD setting page 33 Compare motor voltage to input voltage replace motor if necessary Check motor load Resize the motor or drive if necessary Make sure motor is not undersized for load adjust TQ LIM setting CW page 34 Check DIRECTION switch connection Check reversing circuit by shorting TB501 D terminal to E1 terminal with jumper wire Check motor wiring Review motor connections section Problem TQ is unsatisfactory at high speeds Possible Cause TQ LIMIT set too low Load may exceed rating of motor drive Nominal input voltage may be too low for motor Suggested Solution 1 Check TQ LIM setting page 34 Fi
29. speed 3 If the deceleration time differs from the desired time adjust the DECEL trimpot until the desired time is reached Rotating the DECEL pot CW increases the deceleration time BOOST The BOOST trimpot is used to increase motor torque at low speeds The minimum setting is sufficient for most applications and does not need to be adjusted If the motor stalls or runs erratically at very low speeds below 10 Hz the boost trimpot may need adjustment 1 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 reached 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 37 SLIP COMPENSATION SLIP COMP Slip compensation is used to minimize the normal speed changes occurring in an induction motor from no load to full load conditions 1 2 Using the speed adjust potentiometer or reference signal run the motor at the desired RPM under a no load condition Measure the RPM with a tachometer Without changing the speed adjust potentiometer or reference signal apply a full load to the motor and bring the motor speed back up using the SLIP COMP pot to the originally measured RPM These procedures 1
30. t 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 38 for further detail NOTE DO NOT use the DIRECTION switch if there is a capacitor in the motor windings 26 Starting and stopping methods factory set to COAST position To coast the motor to a stop Insure that JMP506 is set to the COAST position as shown in Figure 13 page 27 Refer to Figure 4 page 4 for Jumper Locations To coast the motor to a stop open the ENABLE DISABLE switch or remove the jumper between ENABLE 22 and COMMON E1 terminals TB501 Refer to page 19 for instructions on switch installation To brake the motor to a stop Insure that JMP506 is set to the BRAKE position as shown in Figure 13 page 27 Refer to Figure 4 page 4 for Jumper Locations Confirm BRAKE CURRENT and BRAKE TIME potentiometers are calibrated to a desired value BREAK CURRENT is adjustable from 0 100 of rated output current BRAKE TIME is adjustable from 1 12 seconds To brake the motor open the ENABLE DISABLE switch or remove the jumper between ENABLE E2 and COMMON E1 terminals of TB501 Refer to page 19 for instructions on switch installation 27 Jumper Pins 1 amp 2 to Brake BRAKE 506 on top board C
31. the appropriate personal protection equipment BE ALERT High voltages can cause serious or fatal injury The 170 543 0004 has ten user adjustable trimpots Each drive is factory calibrated to its maximum horsepower rating Re adjust the calibration trimpot settings to accommodate lower horsepower motors See Figure 16 page 32 for 170 543 0004 series trimpot locations All adjustments increase with clockwise CW rotation and decrease with counter clockwise CCW rotation Use a non metallic screwdriver for calibration Each trimpot is identified on the printed circuit board 32 ZERO SET ia JMP 504 wor O MIN 4 ii JMP 505 AS ZER O Sd Set 1 1501 503 UV TRIP 2 RESTART ACCEL BRAKE Q coast Ot O DECEL DECEL IMP 506 POWER FAULT SLIP COMP eo SLIP COMP LO BOOST ats TORQUE Q LIMIT eo om TQ LIMIT INP UT SELE CT 12 2 3 old an prs 505 BRAKE 20 a CURRENT AME BRAKE 725 CURRENT me Grae TIME 2092 Figure 16 170 543 0004 Calibration Trimpot Locations 33 Calibration Procedure Setup for 60 Hz Motors 1 Set JMP501 amp JMP502 to appropriate input voltage setting 115 230VAC Refer to Figure
32. x 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 50 NOTES NOTES 51 Bison Warranty Policy The Company warrants to the Buyer the products sold hereunder to be free of defects in material and workmanship under normal use and service for a period of one 1 year from the date of shipment The obligation of the Company under this warranty is limited to repair or replacing at its option any part or parts which upon examination shall disclose to the reasonable satisfaction of the Company to have been defective in material or workmanship Buyer must return the products to the Company s factory shipping charges prepaid and with complete information as to alleged defects and the installation operation and service of the products Except as otherwise expressly stated herein the Company makes no representation of warranty of any kind express or implied as to merchantability fitness for a particular purpose or any other matter with respect to the products sold hereunder BISON Bison Gear amp Engineering Corp 3850 Ohio Ave St Charles IL 60174 Phone 1 800 AT BISON www bisongear com Document Number 250 0421 Revision 0 May 2006
Download Pdf Manuals
Related Search