HP 2995 User's Manual
Contents
1. Application Note On applications with high inertial loads the deceleration may automatically increase in time This will slow down the rate of speed decrease to prevent the DC bus voltage from rising to the overvoltage trip point This function is called regeneration protection It is recommended that for very high inertial loads that both the ACC and DEC B trim pots be set to a minimum of 10 seconds DEC B Boost with 50 Hz configuration When the control is set for 50 Hz motors the DEC B 50 Hz trim pot becomes Adjustable Boost Most 60 Hz BOOST motors conforming to NEMA standards can operate from a preset volts Hz curve 50 Hz motors generally differ widely in their characteristics Therefore it is necessary to have Adjustable Boost to obtain maximum motor performance Since the boost trim pot was the deceleration trim pot in the 60 Hz mode it will take on the prior setting of the DEC B trim pot In order for the 50 Hz motor to run properly the boost must be adjusted If the application does not require full torque below 10 Hz the boost trim pot can be conservatively set at 8 9 o clock position If more precise speed regulation is required due to varying load the boost can be set as follows 1 Place an AC analog RMS ammeter in series with one motor lead Generally digital or clamp on meters do not yield accurate readings 2 Run the motor unloaded at approximately 4 Hz or 120 RPM Note An unloaded motor w2. Instructions for Installation and Operation p ESETTER ADJUSTABLE SPEED DRIVE 3 PHASE AC MOTOR SPEED CONTROL E Model 2995 for 115 230 VAC power supply with NEMA 4 enclosure and line filter for CE Mark BODINE ELECTRIC QUALITY MosioN P N 074 01040 B DX QUICK REFERENCE This manual contains the basic information needed to install and operate Bodine PACESETTER 115 230V NEMA 4 series inverter model 2995 This manual does not profess to cover all details or variations in equipment nor to provide for every possible contingency associated with installation operation or maintenance No warranty of fitness for purpose is expressed or implied Should further information be desired or should particular problems arise which are not covered sufficiently for the user s purpose the matter should be referred to the Bodine Electric Company IMPORTANT Read this manual completely and carefully Pay special attention to all warnings cautions and safety rules Failure to follow the instructions could produce safety hazards that could injure personnel or damage the control motor or other equipment If you have any doubts about how to connect the control or motor refer to the detailed sections of this manual Oma Q T G 3 8 it 3 E ay ee
3. 50 Hz HO JUMPER INSTALLED 120 Hz x T a hs 3 a D O O O 50 Hz Figure 5 The different ways of setting the base frequency jumper In this mode the motor will produce full rated torque up to 60 Hz Above 60 Hz torque will linearly reduce to 50 at 120 Hz 60 OUTPUT FREQUENCY Figure 6 Graph showing reduction in motor torque at frequencies above 60 Hz AC LINE VOLTAGE SELECTOR JUMPERS There are three voltage selector jumpers that must be repositioned if the input line voltage is 230 VAC instead of 115 VAC If the control is to be operated from a 230 VAC power supply pull out the voltage selector jumpers J1 J2 and J10 from their 115V positions and reinsert them into their 230V positions See Figure 4 for the locations of the jumpers CAUTION Connecting 230 VAC to a control configured for 115 VAC will permanently damage the control AC LINE FUSE JUMPER WIRE If the control is to be operated from a two phase 230 VAC power supply where both lines are hot typically in the USA then remove the jumper wire between the spades labeled J5 and J8 AC LINE FUSES Model 2995 has a 12A fuse already installed in both the F1 and F2 fuse holders A fuse is only really necessary in F2 if a two phase 230 VAC power supply with two hot sides is used Step 5 Connect the Motor A cord should be used for the motor connection in order to properly seal the liquid
4. Electrical connections for Model 2995 10 GRN YEL TR Figure 8 Connection diagram for Bodine 230V inverter duty motors BLA GRN TR BLU GRN TR RED A RED GRN TR BLE YEL TR RED YEL TR GRN YEL TR Figure 9 Connection diagram for Bodine 230 460V inverter duty motors wired for 230V operation Step 6 Connect AC Line Cord Table 3 Direction of Bodine motor driveshaft rotation viewing end of driveshaft when connected per the diagrams at the left and with control set for forward direction Direction CCW CW CW CCW CCW CCW CCW CW CCW CW CCW Bodine Motor Type CCW CW CCW CW CCW CCW CCW A cord should be used for the AC power connection in order to properly seal against water through the liquid tight fitting Connect the hot side of the line to L1 and the neutral side to L2 Connect earth ground to the terminal labeled CHASSIS GROUND Tighten the barrier terminal block screws to 6 Ib in Step 7 Close and Seal the Enclosure Close the hinged cover and tighten the four screws one at each corner Step 8 Connect to AC Power After all other connections are made and the control is closed connect the AC line cord to the AC power supply 11 OPERATION Step 9 Check System Before Starting amp WARNING Recheck all connections Do not open the cover of the inverter when the power is ON to avoid injury caused by electrical shock Do n
5. for an extended period of time and just recently stopped working then this would indicate that the control was initially installed properly but something has somehow changed Is the problem continuous or intermittent f the problem always occurs and never goes away then it would indicate something inherently wrong in the connections or a defective component On the other hand if the system operates properly most of the time and only occasionally does something wrong then this might indicate loose connections or electrical noise interference Table 4 General problem evaluation method ABNORMALITY CHECK POINT COUNTERMEASURE Reconfirm the power voltage level status indicator either Forward or Reverse Is the main speed pot damaged Examine the speed pot and correct it Motor runs but in Is wiring to the motor correct Swap any two of the three motor wires wrong direction Change direction jumper Model 2997 Change direction switch Model 2996 Motor runs but speed can t be adjusted e Reduce loading Motor runs but speed is too high preg ON Motor runs but with abnormal speed ae 17 J Figure 13 Location of LED Status Indicators inside the enclosure LED STATUS INDICATORS Models 2995 contains two LED status indicators on the printed circuit board inside the enclosure One LED is a green Power On indicator PWR that indicates the presence of the bus voltage and the operation of the main control
6. in detail and observe those paragraphs with the safety alert symbol This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible Injury or death WARNING indicates a potentially hazardous a WARNING situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous A CAUTION situation which if not avoided may result in minor or moderate injury CAUTION used without the safety alert symbol indicates a potentially hazardous CAUTION situation which if not avoided may result in property damage amp WARNING Do not touch printed circuit board PCB right after turning off power Wait until power light turns off Do not attempt to wire circuitry while power is on Do not attempt to examine components and signals on the PCB while the inverter is operating Do not attempt to disassemble or modify internal circuitry wiring or components of the inverter Inverter must be properly grounded INSTALLATION This control should only be installed by a qualified person familiar with its operation and associated hazards The National Electrical Code NEC local electrical and safety codes and when applicable the Occupational Safety and Health Act OSHA should be observed to reduce hazards to personnel and property Step 1 Examine before installation Check that
7. tight fitting The fitting will accept cord diameters between 0 17 and 0 47 diameter The length of the cord should be kept short for minimum voltage drop and only copper wire with 60 C rated insulation should be used Loosen the nut from the liquid tight fitting and insert the cord through the fitting and into the enclosure Connect the three motor power leads to U V and W on the terminal block inside the control Since the controls are capable of changing motor direction electronically it doesn t really matter which motor wires go to which terminal However if it is desired for the motor to rotate a specific direction when wired a certain way then refer to the connection diagrams for Bodine inverter duty motors in Figures 8 and 9 on the next page If the motor doesn t rotate in the desired direction as connected with reference to the forward and reverse settings of the direction switch on Model 2995 then swap any two of the three motor wires Note that these connection diagrams apply to Bodine motors only The terminal block will accept wire sizes from 18 to 14 gauge The terminal block screws should be tightened to 6 Ib in 0 678 Nm Connect the motor frame ground to CHASSIS GROUND on the terminal block When the connections are done tighten the nut on the liquid tight fitting DUEN 115 or 230 VAC Single Phase Line Earth Ground 230 VAC 3 Phase Induction Motor Figure 7
8. armotors are covered by the standard twelve month warranty period The Bodine Electric Company will repair or replace at its option any of its products which has been found to be defective and is within the warranty period provided that the product is shipped freight prepaid with previous authorization to Bodine s plant in Chicago Illinois 60618 U S A or to the nearest Bodine Authorized Service Center At its option all return shipments are F O B Bodine s plant or Authorized Service Center Bodine is not responsible for removal installation or any other incidental expenses incurred in shipping the products to or from Bodine This warranty is in lieu of any other expressed or implied warranty including but not limited to any implied warranties of merchantability and or fitness for a particular use or purpose Bodine s liability under this warranty shall be solely limited to repair or replacement of the Bodine product within the warranty period and Bodine shall not be liable under any circumstances for any consequential incidental or indirect damages or expenses associated with the warranted products Commutator and or brush wear and its associated effects are normal occurrences and are not covered by this warranty Any Bodine product that is damaged due to misuse abuse negligence or has been modified or dismantled without the knowledge or written consent of Bodine is not covered by this warranty Proof of purchase of
9. d The MIN trim pot is used to set the minimum output frequency of the drive which sets the minimum motor speed The minimum speed is factory set to 10 Hz Readjust the trim pot as follows Rotate main speed potentiometer to the minimum speed position full counterclockwise runs at desired minimum speed MAX Maximum Speed The MAX trim pot is used to set the maximum output frequency of the drive which sets the maximum motor speed The maximum speed is factory set to full rated motor speed Readjust the trim pot as follows maximum speed position full clockwise runs at desired maximum speed ACC Acceleration The ACC trim pot sets the time it takes the motor to reach full speed from an initial zero start The trim pot is factory set to approximately 1 5 seconds Adjust the ACC trim pot as required for the application SECONDS Note When the control is set for 50 Hz operation the ACC trim pot will automatically change to adjustable acceleration and deceleration Note Rapid acceleration may cause the current limit circuit to activate This will automatically extend the acceleration time DEC B Deceleration with 60 Hz or 120 Hz configuration The DEC B trim pot sets the time it will take the SECONDS motor to reach zero speed from an initial full speed 60Hz ONLY setting The trim pot is factory set to approximately 1 5 seconds Adjust the trim pot as required for the application
10. e Box gt D O C g remas 3 L dp 115 or 230 VAC Single Phase Line Earth Ground 230 VAC 3 Phase Induction Motor FIGURE 1 Overview of installation for reference only and not be used as a replacement for the detailed instructions within this manual TABLE OF CONTENTS QUICK REFERENCE PRODUCT SPECIFICATIONS IMPORTANT SAFETY PRECAUTIONS INSTALLATION Step 1 Examine Before Installation Step 2 Choose a Suitable Location Step 3 Mount the Control CONNECTION Step 4 Preliminary Setup Step 5 Connect Motor Step 6 Install Fuse Step 7 Connect AC Line Cord Step 8 Close and Seal the Enclosure Step 9 Connect to AC Power OPERATION Step 10 Check System Before Operating Step 11 Operate Inverter Step 12 Adjust Trim Pots optional TROUBLESHOOTING DECLARATION OF CONFORMITY WARRANTY copyright 2002 Bodine Electric Company All Rights Reserved Printed in U S A PAGE PRODUCT SPECIFICATIONS ABOUT THIS PRODUCT Bodine s PACESETTER NEMA 4 series inverter is designed to provide variable speed control of standard three phase AC induction motors Adjustable linear acceleration and deceleration are provided making the drive suitable for soft start applications The output voltage is sinewave coded PWM operating at 16 kHz which provides high motor torque high efficiency and low noise The full featured drive is easy to
11. he control factory setting is 60 Hz To stop the motor momentarily turn the direction switch to the stop position To change direction of the motor turn the direction switch to the stop position wait until the motor comes to a complete stop and then turn the direction switch to either forward or reverse position To stop the motor for long periods of time turn the AC power off using the toggle switch If the motor does not start promptly and run smoothly refer to the TROUBLESHOOTING section Step 11 Adjust Trim Pots Optional These controls contain trim pots that have been factory adjusted for most applications Some applications may require readjustment of the trim pots in order to tailor the control to exact requirements amp WARNING Do not adjust trim pots with main power on if possible If adjustments are made with power on insulated adjustment tools must be used and safety glasses must be worn High voltage exists in this control Electrocution and or fire hazard can result if caution is not exercised mS 1 l 230V LoL PMASAN eb ah 2020 i A PL EA A Ahau v ws y E Ly mara CAMD NIOR PHASE OUTPUT Li L2 Figure 12 Location of trim pots inside enclosure 13 14 2 Increase setting of MIN trim pot so that motor 1 Rotate main speed potentiometer to the 2 Adjust setting of MAX trim pot so that motor MIN Minimum Spee
12. install and operate Simple trimpot adjustments eliminate the computer like programming required on other drives However for most applications no adjustments are necessary Table 1 Electrical Ratings Input Volts 115 or 230 VAC 10 Single Phase 50 60Hz Input Current 11 0 115V or 7 0 230V Amps AC Output Volts 0 230 VAC Three Phase Output Current per Phase 2 4 Amps RMS Maximum Motor HP kW 2 HP 0 37 kW Table 2 General Performance Specifications Parameter Specification Factory Setting 150 Current Overload for 2 Minutes Signal Following Input Voltage 0 5VDC J Signal Following Input Resolution Bits Minimum Speed Trimpot Range 0 40 of frequency setting 0 Output Frequency Setting SO Hz 60Hz or 120Hz 6 70 110 of frequency setting SpeedRange OT Boost Trimpot Range 50Hzonly 630 Range Speed Regulation 0 to Full Load a a 30 1 Speed Range Operating Temperature Range Oto 40 C o eee ee Stalled Motor Bus Overvoltage Trip Point _ 400 VDC 283 VAC Line Volts Bus Undervoltage Trip Point 260VDC 184 VAC Line Volts IMPORTANT SAFETY PRECAUTIONS Model 2995 has been evaluated by Underwriters Laboratories for conformance to UL standards 508 and 50 and CSA standard C22 2 No 14 and bears the UL Recognized Component mark The AC Drive is a power electronic device For safety reasons please read through this operations manual
13. ith the supplied installation instructions EN61010 1 Safety Requirements for Electrical Equipment EN61800 3 Adjustable Speed Electrical Power Drive Systems EMC Product Standard EN50081 Electromagnetic Compatibility General Emissions Standard EN50082 Elecromagnetic Compatibility Generic Immunity Standard EN55011 Radiated and Conducted Emissions EN61000 Electromagnetic Compatibility Low Voltage Supply Fluctuations and Harmonics And therefore satisfies the conditions for the following EC directives Low Voltage Directive EMC Directive 89 336 EEC making the products eligible for the CE Mark The undersigned hereby declares that the products specified above conform to the above standards Signature Tews bce Full Name Terrence J Auchstetter Position Product Manager Date August 2 2002 19 BODINE LIMITED WARRANTY The Bodine Electric Company warrants all products it manufactures to be free of defects in workmanship and materials when used under Normal Operating Conditions and when applied in accordance with nameplate specifications When Bodine motors and gearmotors have been purchased with and used only with appropriately applied Bodine controls this warranty shall be in effect for a period of twenty four months from date of purchase or thirty months from date of manufacture whichever comes first Bodine motors and gearmotors used with non Bodine controls and Bodine controls used with non Bodine motors and ge
14. ith excessive boost will draw more current than a partially loaded motor 3 Turn up boost until the ammeter reaches the nameplate rating 4 Using the main speed potentiometer slowly adjust motor speed over a 0 15 Hz 0 450 RPM range If motor current exceeds nameplate rating lower boost setting CAUTION To avoid motor winding overheating and failure do not over boost motor 15 CL Current Limit with I t Shutdown The CL trim pot is used to set the maximum motor current that occurs in a stalled condition The CL trim pot is factory set to approximately 160 of full control rating 3 8 amps The CL trim pot can be readjusted as required The current limit also contains an It trip function The control will trip according to a predetermined current versus time function The trip curve is directly related to the CL set point and can be changed with the CL trim pot The current limit with Ift shutdown is designed to provide motor overload protection Readjust the CL trim pot so that it is set to 160 of full rated motor current as follows 1 Connect an AC ammeter in series with one motor phase 2 Lock motor shaft and quickly adjust desired locked rotor motor current using CL trim pot Note This adjustment must be made within 60 seconds or l t trip will occur Example A HP motor has a full load current of 1 8 amps Set the CL trim pot to 1 8 X 160 2 9 amps Percent of CL Trip Time Control Rating Motor C
15. logic power supply The other LED is a tricolor lamp ST that indicates a fault or abnormal condition The information provided can be used to diagnose an installation problem such as incorrect input voltage overload condition and control circuit miswiring It also provides a normal signal that informs the user that all control and microprocessor operating parameters are proper The meaning of the different colors and flash frequencies are explained in Table 5 TABLE 5 Interpretation of ST indicator LED OPERATING LED LED FLASH CORRECTIVE CONDITION COLOR FREQUENCY ACTION Motor Running Normally Motor Running but in RED STEADY NO FLASH LED will return to slow flashing green Current Limit Trip Short Circuit supply voltage is corrected Control Under Voltage supply voltage is corrected Motor Stopped due to RED YELLOW SLOW FLASH Motor will restart automatically if Control Over Voltage supply voltage is corrected Normal Stop Condition YELLOW STEADY NO FLASH FLASH DEFINITIONS Slow Flash 1 second on 1 second off Quick Flash 25 second on 25 second off 18 DECLARATION OF CONFORMITY We the Bodine Electric Company 2500 W Bradley Place Chicago Illinois U S A phone 773 478 3515 fax 773 478 3232 declare under our sole responsibility that the following products Type HPP 5337E4 AC Motor Speed Control Model number 2995 Are in conformity with the following standards when installed in accordance w
16. motor or gearmotor and matching control as a system must be provided with any claim ERNE Bodine Electric Company 2500 W Bradley Place Chicago Illinois 60618 U S A CHIC U S A i j i J P N 074 01040 B DX
17. oles with their centers located as shown in Figure 3 If 10 screws are to be used for mounting then use a 6 204 clearance drill If 10 32 machine screws are to be used for mounting then use a 20 161 tap drill After the mounting surface has been prepared mount the control with screws through the four mounting brackets already attached to back of control enclosure Figure 3 Mounting Dimensions CONNECTION The PCB inside the inverter enclosure is vulnerable to static electrical charges Avoid contact with the PCB Choose an appropriate power source with correct voltage settings for the specification of the AC inverter Do not use a separate device between control and motor to switch motor ON or OFF during operation Step 4 Preliminary Setup Fuse Voltage Select Jumper J10 Base Frequency Jumper Voltage Select Jumpers J1 amp J2 Figure 4 Inside of control showing location of jumpers and fuses BASE FREQUENCY JUMPER Model 2995 is factory set to operate 60 Hz and 50 60 Hz motors For 50 Hz motors remove jumper J1 on the lower printed circuit board When the control is set for 50 Hz operation the DECEL B trimpot will automatically change to adjustable boost The control can also operate 60 Hz and 50 60 Hz motors not 50 Hz motors in an over speed mode by moving the jumper to the 120 Hz position S060 Hz AND 60 Hz FACTOR Y SETTING 60 120 om c 50 Hz
18. ot attempt to wire circuitry while power is on CAUTION Do not attempt to make or break connections between motor and inverter when the power supply is turned on or the inverter may be damaged due to a surge peak Check that motor is securely mounted Test motor unloaded first to verify proper setup Check all rotating members Be sure keys pulleys etc are securely fastened and safety guards are in place Check for proper mounting and alignment of products and verify safe loading on shafts and gears The inverter can be easily operated from a low speed to a high speed Reconfirm the operating speed range of the motor and the machinery you are controlling Speed Adjustment Dial Direction Switch Power Indicator Lamp Power Toggle Switch 12 Step 10 Operate the Inverter The PACESETTER NEMA 4 series inverter is operated using the switches and speed dial on the front panel of the control See Figure 10 for panel layout Turn the AC power ON using the toggle switch The power lamp will illuminate Turn the direction switch to either the forward or reverse position Adjust speed by turning the knob of the speed potentiometer Turning the pot fully CCW will produce the minimum output frequency as set by the MIN trim pot inside the control factory setting is 0 Hz Turning the pot fully CW will produce the maximum output frequency as set by the max speed jumper and the MAX trim pot inside t
19. the model number on the control matches the model number ordered The control model number is printed as part of the serial number on an adhesive label on the outside bottom surface of the control enclosure Carefully examine the control for shipping damage Parts errors should be reported to Bodine Shipping damage claims should be made to the freight carrier EN PfTAESETTER ADJUSTABLE SPEED DRIVE COMPANY CHICAGO 60618 U S A CE em dC As Figure 2 The model number is the first four digits of the serial number S N on the control s nameplate A CAUTION Do not connect the control to the power supply if there is any sign of damage Notify the carrier and your distributor immediately Step 2 Choose a Suitable Location The installation site directly impacts the functionality and lifespan of the control Avoid areas where surrounding air temperature exceeds 40 C direct sunlight or near heating equipment or inside a panel without a cooling fan Avoid locations where the front panel dial and switch may be bumped and accidentally turned on off or damaged Avoid environments with corrosive gas Avoid locations near radioactive matter or flammable material Avoid locations near equipment that generate electromagnetic interference soldering or power machinery Avoid mounting the control to a surface that vibrates Step 3 Mount the Control Prepare the mounting surface by drilling four h
20. urrent Setpoint Minutes Amps Phase COMP Slip Compensation The COMP trim pot is used to maintain set motor speed under varying loads The factory setting of 1 5 volts Hz amp provides excellent speed regulation for most motors The COMP trim pot can be adjusted for specific applications as required 1 Wire an AC ammeter in series with one motor H2 AMP phase 2 Run motor and set unloaded speed to approximately 50 speed Using a tachometer record unloaded speed 3 Load motor to rated motor current AC amps 4 Adjust COMP trim pot so that loaded RPM is equal to unloaded RPM 5 Motor is now compensated TROUBLESHOOTING e Do not remove the cover of the inverter when the power is ON to avoid injury caused by electrical shock This control does not require maintenance under normal conditions If you encounter a problem read all instructions provided with this control and double check the wiring If problems persist contact your source of purchase or a Bodine Authorized Service Center and describe the problem in detail Performing unauthorized repairs will void the Warranty GENERAL EVALUATION Knowing the circumstances under which the problem occurred can help to identify the root cause of the problem Has the system ever operated properly f the control was just installed and doesn t work right then it is likely that something wasn t done correctly in the installation However if the system has been working
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