USER MANUAL CoMoCo-1.0-ED-4
Contents
1. USER MANUAL CoMoCo 1 0 ED 4 03 06 2014 version 1 6 CE DECLARATION OF CONFORMITY CoMoCo B V Ambachtsweg 8 5492 NJ Sint Oedenrode The Netherlands declares that this intelligent motor controller CoMoCo 1 0 ED 4 has been produced in accordance with the CE guidelines included in the standards below It must be installed according to the accompanying instructions The intelligent motor controller must not be put into operation before the installation complies with the CE guidelines EMC guideline 2004 108 EC Low voltage guideline 2006 95 EC Te RP naa A 2 EXPLANATION OF PICTOGRAMS ccscssssssssesscecscsesccssscessccsesceenees 5 3 PRECAUTIONARY 5 6 5 CIRCUIT DIAGRAM FOR CONTROLLER 7 6 WALL MOUNTING THE 8 7 DUCT MOUNTING THE CONTROLLER 8 ate Aenean 9 COMMIS SIONIN irritar 13 10 LED INDICATION csirrminassrian pl ai 14 11 TECHNICAL INFORMATION conan narra 15 12 MAINTENANCE stan ARANA AA 15 e COMOCO 1 PREFACE General This manual contains the operating and installation instructions for the intelligent motor controller CoMoCo 1 0 ED 42. Protected by heat shrink tubing to prevent supply voltage short circuiting Figure 1 Connections a COMOCO 6 WALL MOUNTING THE CONTROLLER The distance between controller and motor is max 2 5 metres It must be mounted on a smooth wall Do not mount the controller above a 242mm jaa radiator or anything similar Take care of adequate space and air flow around the controller Do not cover Cable feedthrough bottom 107mm Do not open Figure 2 Wall mounting of the controller with drilling pattern 7 DUCT MOUNTING THE CONTROLLER Optional brackets for installing the controller on a duct order number 1 Figure 3 Brackets for installation on duct CONNECTIONS General guidelines for the electric installation and safety gt gt gt gt All work in to the installation commissioning remedying breakdowns and maintenance must be implemented by qualified electro technical personnel observe EN 50110 EN1010 IEC 60364 IEC 60204 and the national safety precautions therein The mains supply must be switched off during installation and repair work The controller contains parts that are subject to high voltage when connected to the mains supply Incorrect connection of the controller could cause damage and physical injury or have fatal consequences Follow the instructions in this manual as well as the local and nationa
3. CoMoCo 1 0 ED 4 is an intelligent controller for electromotors At the heart of the control ler is the Texas Instruments C2000 Piccolo microcontroller The controller measures the electromagnetic field in the electromotor without using mechanical sensors The built in software accurately estimates where the magnetic field will be in the next microsecond It calculates the minimum and the type of energy required to realise this field and then precisely supplies it using the data obtained The result is enormous energy savings in partial load Depending on the type of electromotor and the required capacity up to 90 more energy can be saved in respect to a controller based on Triac The highest percentage of energy saving occurs when the rotational speed is low The required rotational speed is controlled by 0 10Volt or 10 OVolt signal The rotational speed is guaranteed by the controller irrespective of external influences The controller also ensures that the required rotational can be maintained with the absolute minimum of energy The controller supplies this energy in an optimal form in regard to voltage current and frequency PFC CoMoCo 1 0 ED 4 fully complies with the CE guidelines Extra EMC filters are not necessary when installing A built in PFC Power Factor Control ensures that the energy is taken evenly from the public grid and is available when required The controller performs far above the standard set by the ene
4. MOTOR CONTROL General guidelines for installing the controller The method of installing the wiring and the accompanying components is important for proper working and compliance to the applicable regulations when using the controller A number of important points for attention e Motor cable may not be extended Connect the motor directly to the controller Make sure there are as few as possible junctions in the cable i e terminals between controller and motor Strip the motor cables as short as possible and connect the shieliding to earth on 2 sides Do not put the cable between the controller and the motor in the same cable duct as the supply cables control voltage cables and signal cables e All signal cables must be as close to each other as possible and of course as far as possible from the cable between controller and motor Two sided earthing is imperative for shielding from the low frequency interference voltage Do not run signal cables and cables parallel between controller and motor keep a distance of at least a half metre and keep crossover points at an angle of 90 If the earth shield on the cable between controller and motor has to be interrupted install the earth shield with a reliable terminal EMC on a wide flat conductor A reliable EMC terminal clamps the shield as completely as possible and makes a connection with an impedance for high frequency signals that is as low as possible e Safety earth
5. and earthing for suppression may be combined however the earth connection for suppression must have an impedance that is as low as possible Therefore no long wires but as short as possible and a strip or board that is as wide and flat as possible Control cable Various functions of the intelligent motor controller can be adjusted via the control cable Adjustment of the rotational speed by means of a control voltage 0 10V or 10 0V Starting calibration Alarm output potential free Normally Open NO Inverting control voltage 10 OV Inverting direction of rotation An overview of the control cable wires can be found in the table below Control cable Description connection colours Control voltage 0 10V 10 OV calibration motor recognition free Alarm contact NO Figure 4 Control cable wires Red Inverting direction of rotation 10 a COMOCO IMPORTANT The controller can suffer irreparable damage if the control gt cable wires unintentionally short circuit Adjustment of rotational speed by means of external control voltage The rotational speed of the electromotor can be adjusted by means of a control voltage from external control equipment The control voltage for this controller must be connected as shown in figure 5 0 10V White External Control COMOCO Equipment Ground Green Figure 5 Adjustment by means of external voltage In most cases the e
6. gt e COMOCO 3 PRECAUTIONARY MEASURES Read the following instructions carefully before connecting or starting up the controller Breakdowns and injury could result if the instructions in this manual are not followed The manufacturer retains the right to change the specifications of the controller and its performance or the contents of this manual without giving prior notification Although the controller is protected from overload and overvoltage we recom mend the installation of an additional safety device on the supply circuit for the alarm system The connecting cables are fed through waterproof glands on account of the IP67 standard Do NOT drill extra holes in the housing because this will result in the controller no longer meeting the IP67 standard gt gt IMPORTANT Opening will be detected and the guarantee will be void 4 SCOPE OF DELIVERY The controller packaging must include the following items CoMoCo 1 0 ED 4 Manual e COMOCO 5 CIRCUIT DIAGRAM FOR CONTROLLER Controller Electromotor phase 3x230V lt 3 Earth Status Max 300 metres Ground lt Green Blue gt 10V Control voltage 0 10V 10 0 lt White Control device o a Yellow gt Calibration motor recognition Brown gt Potential free Alarm contact NO Grey gt Pink gt Inverting control voltage Red gt Inverting direction of rotation
7. l safety precautions IMPORTANT Motor is delta connected in case of a 3 phase control output voltage is 3x230V Contact with electrical parts could lead to serious physical injury or death even when the mains supply is switched off Wait for 5 minutes after the mains supply has been switched off before starting work The user or installer is responsible for correct earthing and protection in accordance with the applicable local national and international regulations The voltage supply to the controller unit must have a series fuse See the maximum voltage use in the table of technical data chapter 11 for the control unit for the correct value The earth leakage protection on the control unit amounts to more than 3 5 mA AC According to the EN61800 5 1 standard the required safety circuit must conform with one or more of the following conditions A second earth wire with the same cross section as the original earth wire connected to an extra terminal clamp Or the earth wire must have a cross section of at least 10 Cu or 16 Al along the whole connection Or a provision for the automatic interruption of the power supply in the case the earth wire being interrupted The controller could cause a direct current in the earth wire circuit breaker is used in the case of direct or indirect contact protection a circuit breaker type B must be used in the supply wire to the control unit e COMOCO INTELLIGENT
8. peed of the electromotor can be adjusted using the control voltage Check the electromotor for correct rotational direction If the rotational direction differs from what is expected check the motor connection or check red wire of the control cable as described in chapter 8 IMPORTANT The whole commissioning procedure must always be gt repeated when re using the controller or replacement of the motor In that case the red LED will in fact not flash 5 times because all the motor parameters are known from the previous motor A new calibration is necessary 10 LED INDICATION LED description Indication Continuous green Flashes green Continuous red Flashes 1 x red with PFC overflow pause of 4 sec DC link precharging DC link discharging PFC flow too high Check quality of the mains voltage and motor status Overload Reduce load Clean Controller temp or controller Reduce ambient ambient temp too high temperature Flashes 4 x red with Under or overvoltage Mains voltage too low Check quality of mains pause of 4 sec or too high voltage Flashes 5 x red with Not calibrated Calibrate pause of 4 sec If there is a motor overflow alarm the controller will try to restart the motor after 15 seconds If the motor over temperature has not been remedied for example the temperature of the motor is still too high a pause of 10 minutes will follow after 3 attempts The cycle will then be repeated Flashes 3 x red with Ove
9. rgy companies In addition the PFC is dynamic In other words it switches off when the load is low to save even more energy Input output and power The input voltage is between 85 and 265Volt 50 60Hz both for 1 phase and 3 phase electromotors The output signal is suitable for a three phase 230 380V induction motor which is delta connected or a single phase induction electric motor 230V where the capacitor of the auxiliary winding is disconnected The controller can supply 1 000VA of power with static cooling and when the controller is placed in an air flow up to 1 150VA The abovementioned applies for a supply voltage of 230VAC The controller will operate at a lower voltage but will automatically reduce the maximum power that can be supplied The controller will supply a maximum of 500VA at 110VAC Extra intelligence When overloaded the controller will remain working by reducing the supplied power The controller can run the electromotor at a much lower rotational speed than is usual possible with the current available controllers Moreover up to 150 of the maximum torque is available at these low rotational speeds and at idle without damaging the motor In the event of an overload or the temperature is too high or other malfunctions the controller will continue to operate but will also produce an alarm signal via a potential free contact The cause of the alarm can be read from a flashing LED signal undernea
10. rtemperature pause of 4 sec Flashes 2 x red with Motor overlow Motor flow too high Check wiring and motor pause of 4 sec status 14 COMOCO INTELLIGENT MOTOR CONTROL 11 TECHNICAL INFORMATION Is identical for 1 phase and 3 phase electromotors Control voltage of maximum rotational speed 10 OV 1V 100 9 5V 6 10V 0 5V 6 9V 100 Input impedance control signal 25kOhm Maximum length of control cable 300 metres Alarm contact potential free 1A 24V DC 0 5A 120V Dimensions LxBxH 280 x 250 x 130mm Weight 12 MAINTENANCE It is advisable to check the controller regularly for dirt If the openings between the cooling fins are dirty clean them with a brush DISCLAIMER CoMoCo works continuously on the further development of its humidifiers We therefore reserve the right to modify the design construction and technology of the product at any time For this reason no claims can be made based on the data illustrations and description in this user manual Additional up to date information is available on www comoco nl 15 COMOCO INTELLIGENT MOTOR CONTROL P O Box 144 ma 5490 AC Sint Oedenrode The Netherlands O M occ Telephone 31 0 413 487 000 Telefax 31 0 413 473 903 INTELLIGENT MOTOR CONTROL Website WWW COMOCO nl E mail info comoco nl
11. th the controller The housing is extremely robust and completely enclosed so that the controller can also be placed in aggressive surroundings The direction of rotation of the connected electromotor can be set by the control cable Installation For proper functioning and to conform to the CE rules the controller must be installed no further than 2 5 metres from the electromotor The electronics are enclosed in an aluminium housing with a special coating suitable for aggressive surroundings The housing conforms to the IP67 standard The required cables have been pre installed to guarantee IP67 and CE Opening the controller is therefore unnecessary Opening will be detected and the guarantee will be void It is imperative for optimal working that the motor is recognised and the controller calibrated when connected This is easy to start up by briefly connecting two of the wires in the control cable to each other The procedure will then run fully automatically The electromotor must be able to move freely After a short while the controller and motor will be tuned to each other 2 EXPLANATION OF PICTOGRAMS Danger Risk of electric shock or danger if the following instructions are not observed Warning Read the following text carefully because it contains important information The working of the controller cannot be guaranteed if this is not taken into account Important Following text contains especially important information gt
12. tor phases of the regulator indicate is described at page 12 Motor Cable Connection 3 phase In the event that the main winding and auxiliary winding are unknown these are determined by measuring the resistance of the winding using a multimeter The resistance of the main winding is always lower than the auxiliary winding if present if presen Ds gt 5 s gt SLO Figure 9 Connection diagram 1 phase 9 COMMISSIONING Step 1 Ensure that the electromotor and control cable are connected in accordance with the instructions before supplying mains voltage to the controller The LED indication on the controller will start to flash as soon as the mains voltage is supplied because the Calibration procedure motor recognition has not yet been performed The LED indication will flash 5 times with pauses of 4 seconds 13 e COMOCO Step 2 The Calibration can now be started by connecting the green ground and the yellow calibration wires in the control cable together for 3 seconds Make sure that the electromotor can rotate freely The LED indication will flash green afterwards and the electromotor will make a number of rotations The calibration is complete as soon as the LED indication lights up green continuously For 3 phase this is approximately 2 minutes and for 1 phase this is approximately 5 minutes Step 3 The controller is now ready for use and the rotational s
13. voltage by the supply cable It is advisable to connect the motor and control cable prior to connecting the supply cable An overview of the connections of the supply cable can be found in the table below Supply cable Description connection colours Phase O Rul B cable wires Motor cable connection 3 phase The motor cable connects the electromotor to the controller The wires in this cable are numbered and correspond to the three motor phases shown in figure 8 The direction of rotation must be checked if the motor connections U V W are not known Any 2 phases must be swapped if it does not rotate in the required direction An overview of the connections of the motor cable can be found in the table below MotorphaseU Yellow green Earth Shielding Earth Figure Motor cable wires Earth connection Shielding Phase connection Figure 8 Connections 3 phase 12 Motor cable connection 1 phase A single phase electric motor can be connected according to the following connection diagram on the drive A standard single phase electric motor uses a so called capacitor which is redundant in case of connection to the controller Short circuit the capacitor or remove it to prevent any loose wires The released connection of the capacitor should be connected to the auxiliary winding to be to motor phase 2 indicate the drive as in Figure 9 A complete overview of the mo
14. xternal control equipment will supply a control voltage of 0 10V at the minimum and maximum rotational speed percentage respectively The controller will work inverted if this control voltage amounts to 10 0 in the same situation If the control voltage cannot be inverted via the external control equipment it will be necessary to adjust this inversion on the controller This inversion can be adjusted by connecting the pink wire inverting control voltage and the green wire ground of the control cable to each other Adjustment of the rotational speed by means of variable resistance potentiometer The rotational speed of the electromotor can be adjusted by means of a variable resistance which must be connected according to figure 6 The variable resistance value must be 10kOhm linear 10V Blue 0 10V White Ground Green Figure 6 Adjustment by means of variable resistance Set direction of rotation The direction of rotation can be adjusted by connecting the red wire invert the direction of rotation and green wire ground of the control cable to each other IMPORTANT The 10V wire may only be used to create a control voltage Sy by means of a variable resistance potentiometer as shown in figure 6 Protected ex factory in heat shrink tubing to prevent the supply voltage from short circuiting 11 INTELLIGENT MOTOR CONTROL Supply cable connection The controller is supplied with mains
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