Baldor IP-65 Power Supply User Manual
Contents
1. Connection Connect the motor to U V and W terminals of Terminal Block TB1 as shown in Figure 4 on page 6 and as described in Section IIC on page 6 C Start Stop Switch The control is supplied with a prewired Start Stop Switch as described in Section IIE on page 6 which is used to start and stop the control In Manual Start Mode this switch must be used to start the control each time the AC power is lost or the control shuts down due to a fault D Jumper Settings All jumpers are factory set for most applications Be sure Jumper J3 is set to the correct motor HP See Section IIIB on page 7 E AC Line Fusing Install a fuse or circuit breaker in the AC line Fuse each conductor that is not at ground potential See Section VII on page 10 for recommended fuse size F Trimpot Settings All trimpots have been factory set as shown in Figure 2 on page 3 Trimpots may be readjusted as described in Section VIII on page 10 G Diagnostic LEDs After power has been applied observe the LEDs to verify proper con trol operation as described in Section IX on page 13 i E This product should be installed and serviced by a qualified technician electrician or elec trical maintenance person familiar with its operation and the hazards involved Proper installa tion which includes wiring mounting in proper enclosure fusing or other overcurrent protection and grounding can reduce the chance of electrical shocks f2. Figure 17 Sets the minimum speed of the motor The MIN trimpot is factory set for 0 speed For a higher minimum speed setting rotate the MIN trimpot clock wise See Figure 18 Sets the amount of time for the motor to accelerate from zero speed to max speed The ACCEL trimpot is factory set for 1 5 seconds acceleration For more rapid acceleration time rotate the ACCEL trimpot counterclockwise For longer acceleration time rotate the ACCEL trimpot clockwise See Figure 19 Note Rapid acceleration settings may cause the current limit circuit to activate which will extend the acceleration time FIGURE 17 MAX TRIMPOT RANGE 80 l as P 20 dh 100 GAK Y 110 I I Percent of Frequency Setting Shown Factory Set to 100 d v FIGURE 18 MIN TRIMPOT RANGE 30 LI 5 YN 35 E 0 1 LI I Percent of Frequency Setting Shown Factory Set to 0 PA N 40 FIGURE 19 ACCEL TRIMPOT RANGE 5 I 25 AN 125 D 1 5 0 3 20 l I Seconds ZN Shown Factory Set to 1 5 Seconds Deceleration DECEL Sets the amount of time for the motor to decelerate from max speed to zero speed The DECEL trimpot is factory set for 1 5 seconds deceleration For more rapid deceleration time rotate the DECEL trimpot coun FIGURE 20 terclockwise For longer deceleration time rotate the DECEL DECEL TRIMPOT RANGE trimpot clockwise See Figure 20 Note To provide incr
3. limits the maximum current to the Shown Factory Set to 160 motor The current limit set point is established by the setting of Jumper J3 and the setting of the CL trimpot See Figure 22 FIGURE 23 E TRIP TIME vs MOTOR CURRENT 50 10 Pt TRIP TIME minutes FACTORY CL 1 0 SETTING 160 0 1 110 120 130 140 150 160 MOTOR CURRENT NOTES 1 The CL set point is factory set to 160 of nominal motor current 2 Ft Will not trip below 120 of the CL setting 11 The CL trimpot is factory set for 160 of Jumper J3 range setting For a higher current limit setting rotate the CL trimpot clockwise For a lower current limit setting rotate the CL trimpot counterclockwise The current limit also contains E trip function The control will trip according to a predetermined current vs time function The trip curve is directly related to the CL set point and can be changed with the CL trimpot See Figure 23 on page 11 CAUTION Adjusting the CL above 160 of the motor rating may cause overheating of the motor Do not leave the motor in a locked rotor condition for more than a few sec onds since motor damage may occur G Boost BOOST Sets the amount of boost voltage to the FIGURE 24 motor Jumper J7 is factory set to the FIX position which BOOST TRIMPOT RANGE provides a predefined amount of boost voltage for 50 Hz and B 60 Hz
4. motors To adjust the amount of boost voltage to the I motor set Jumper J7 to the ADJ position The amount of ale baleen boost voltage may be adjusted by the BOOST trimpot as eN described below See Figure 24 o bs 1 Connect an analog AC ammeter in series with one of the l l Volt motor leads Shown ESO Set to 5 Volts Note Generally digital or clamp on ammeters do not yield accurate readings 2 Run the motor unloaded at approximately 4 Hz or 120 RPM Note An unloaded motor with excessive boost will draw more current than a partial ly loaded motor 3 Adjust the BOOST trimpot until the ammeter reading reaches the motor nameplate rating 4 Using the Main Speed Potentiometer slowly adjust the motor speed over a O 15 Hz 0 450 RPM range If the motor current exceeds the nameplate rating lower the boost setting WARNING TO AVOID MOTOR WINDING OVERHEATING AND FAILURE DO NOT OVERBOOST THE MOTOR TABLE 5 CONTROL MODE AND STATUS LED INDICATION Status LED Information Control Mode Flash Rate Color Sequence Illumination Duration Seconds Run Slow Flash Green 1 Sec On 1 Sec Off Stop Steady Yellow Constant Stand By Slow Flash Yellow 1 Sec On 1 Sec Off Short Circuit Slow Flash Red 1 Sec On 1 Sec Off Pt Fault Quick Flash Red 0 25 Sec On 0 25 Sec Off Overload Steady Red Constant Undervoltage Quick Flash Red Yellow 0 25 Sec Red 0 25 Sec Yellow Overvoltage Slow Flash Red Yellow 1 Sec Red 1 Sec Yellow e 0 2
5. potentiometer assembly may be removed if a watertight seal is used to cover the hole in the front cover Connect the remote main speed poten tiometer wires to P1 low side P2 wiper and P3 high side terminals as shown in Figure 5 FIGURE 6 REMOTE START STOP SWITCH CONNECTION START STOP SWITCH START y WHITE BLACK STOP y RED Remote Start Stop Switch Connections The control is FIGURE 7 START STOP supplied with a prewired Start Stop switch mounted on the front cover To operate the control from a remote Start Stop Switch type ON OFF ON SPDT remove the white black and red wires from RUN COM and STOP terminals The The switch assembly may be removed if a watertight seal is used to Connect the remote Start Stop Switch wires to RUN momentary COM com mon and STOP constant terminals as shown in Figure 6 leads may be taped and left in the control cover the hole in the front cover FUNCTION ELIMINATED JUMPER INSTALLED After applying power momentarily set the Start Stop Switch to the START position The motor will operate at the set speed of the Main Speed Potentiometer To stop the motor set the Start Stop Switch to the STOP position Note To eliminate the Start Stop function connect RUN and COM terminals with the jumper that is provided See Figure 7 on page 6 CAUTION Using a jumper to eliminate the Start Stop function wil
6. that the control be mounted vertically on a flat surface with adequate ventilation Leave enough room below the control to allow for AC line motor connections and any other wiring Although the control is designed for outdoor and wash down use care should be taken to avoid extreme hazardous locations where physical damage can occur If the control is mounted in a closed unventilated location allow enough room for proper heat dissipation If operating the control at full rating a minimum enclosure size of 12 W X 24 H X 12 D is required See Figure 3 on page 4 RECOMMENDED HIGH VOLTAGE DIELECTRIC WITHSTAND TESTING HI POT FIGURE 12 RESTART MODE SELECTION J4 Set for Manual Reset Mode J4 Set for Auto Factory Setting Reset Mese g AUTO EU AUTO E Ja MAN J4 O MAN FIGURE 13 MOTOR FREQUENCY SELECTION ZEZ J5 Set for 60 Hz Motors Factory Setting 50 Hz Motors 60 Hz FREQ J5 D 50 Hz FIGURE 14 MOTOR FREQUENCY MULTIPLIER SELECTION J6 Set for 1X Motor Frequency Factory Setting J6 Set for 2x Motor Frequency J6 E ENE E MULT Je GI FIGURE 15 BOOST MODE SELECTION J7 Set for Fixed Boost Factory Setting J7 Set for Adjustable Boost E FIX A BOOST FIX BOOST ADJ Testing agencies such as UL CSA VDE etc usually require that equipment undergo a hi pot test
7. to the defect the date purchased the task performed by the control and the problem encountered No liability is assumed for expendable items such as fuses Goods may be returned only with written notification including a BALDOR Return Authorization Number and any return shipments must be prepaid BAT DOR MOTORS AND DRIVES Baldor Electric Company P O Box 2400 Ft Smith AR 72902 2400 501 646 4711 Fax 501 648 5792 A40299 Rev A 3 2001
8. 5 Sec Red 0 25 Sec Yellow Recovered Undervoltage Quick Flash Red Yellow Off Green Off 0 5 Sec Off 1 Sec Green 0 5 Sec Off 2 1 Sec Red 1 Sec Yellow 0 5 Sec Off Recovered Overvoltage Slow Flash Red Yellow Off Green Off 1 Sec Green 0 5 Sec Off Notes 1 Only if the Forward Stop Reverse Switch is installed 2 Only if the control is in Manual Reset Mode Jumper J4 set to the MAN position IX DIAGNOSTIC LEDs The motor control is designed with LEDs mounted on the front cover to display the control s operational status A B Power On ON Indicates the presence of bus voltage Status STATUS The Status LED is a tricolor LED that provides indication of the con trol s operational status including installation problems such as incorrect input voltage overvoltage undervoltage and control miswiring It also provides a normal indication if all control and microcontroller operating parameters are proper See Table 5 on page 12 X OPTIONAL ACCESSORIES Complete instructions and connection diagrams are supplied with all accessories to facilitate installation A Forward Stop Reverse Switch ID5FSR 1 Provides motor reversing and stop func tions Mounts on the enclosure cover and is supplied with a switch seal to maintain water tight integrity Signal Isolator Run Relay ID5SI 2 Provides isolation between a non isolated signal voltage source and the drive and contains a Run R
9. BALDOR MOTORS AND DRIVES mo ADJUSTABLE SPEED DRIVE Series 5 Inverter NEMA 4X IP 65 Installation amp Operating Manual MN781B TABLE OF CONTENTS Section Page i Simplified Operating Instructions LL 1 IRSA ys VV ANMIN Game TEO 1 Es e aA BAA 2 TE E A n 5 II Setting Selectable Jumpers act ind a 7 IM Mounting INSTRUCTIONS ses a e ere eie in 8 V Recommended High Voltage Dielectric Withstand Testing Hi Pot 8 Vis ControlbOperation eres ra EEE 9 VIL AC Eine FUSinNg oreina o eee ac 10 VINE Trimpot Adjustments lt ani eaa a a ay teases 10 DE Diagnostic LEDS er er dr sce ii eer 13 X Optional ACCOSSOMES sason Ee e e a e ee egie b e ie 13 A AAA AEEKO 14 Tables Vise Electrical Rangs e eenean E E UE E E E E E eon 5 2 General Performance Specifications 0 0 0 0 ccc ee 5 3 Terminal Block Wiring Information 6 4 Fault Recovery and Resetting the Control LL 10 5 Control Mode and Status LED Indication LL 12 Figures SS E a a ee tes eee n 3 2 Enlarged View of Trimpot EAO 3 3 Mechanical Specifications gre zerre Ere Eee e ezee an eg eae ezere 4 4 ROWE COMMOCIOMNS EE AETA aes 6 5 Remote Main Speed Potentiometer Connection A 6 6 Remote Start Stop Switch Connection 0 0 2 ee 6 7 Start Stop Function Eliminated Jumper Installed o oooocooooo o o 6 8 Voltage Following Connection 7 9 Enable Gircuit Gonnectioni a erreza 7 10 AC Line Input Voltage Selectio
10. DIELECTRIC WITHSTAND TESTER HI POT TESTER 1 2 LEAKAGE HUAN d SZ ACKILOVOLTS OMA uu RETURN TEST VOLTAGE 0 o LI HV RESET N 3 P CONNECT ALL SPEED CONTROL o e ZERO MAX TERMINALS TOGETHER MAIN POWER DISCONNECTED MOTOR SPEED CONTROL AC LINE INPUT L1 MOTOR ON MOTOR WIRES L2 TERMINALS EY CONNECT HI POT TO BOTH AC LINE INPUTS SIGNAL INPUTS P1 P2 CHASSIS P3 CHASSIS f Head EEE MACHINE OR EQUIPMENT FRAME VI CONTROL OPERATION A Start Up Procedure After the control has been properly setup jumpers and trimpots set to desired positions and wiring completed the startup procedure can begin If the AC power has been properly brought to the control tte POWER LED will be illuminated green once the Power On Off Switch is set to the ON position The STATUS LED will indicate control status as described in Section IX on page 13 To start the control momentarily set the Start Stop Switch to the START position The motor will begin to accelerate to the set speed Note If the motor rotates in the incorrect direction it will be necessary to disconnect the AC line reverse any two motor leads and repeat the startup procedure B Fault Recovery The control has four fault states undervoltage overvoltage short cir cuit at the motor phase to phase and E overload protection To recover from any fault
11. EW OF TRIMPOT SETTINGS MAX MIN ACCEL DECEL COMP _CL_ BOOST FIGURE 3 MECHANICAL SPECIFICATIONS Inches mm ASYSARdY dOLS GYVMHOS ANY IWANVAVOLNV TWNOILdO HLIM NMOHS A veer 1 98 S QW SIL M3H9S ONILNNON CIONINNOIIY D i I l akoa S9 dl Xb VINAN 3 10 03IdS FTAVISNGY YOLOW OV 96 Ly Sk 656 bori auymuos GES EE 03 8 O sams GOR O vamos aoc iva LI D Y ber SE bezi _ ez 90 S HEU L6 6 L ISS TABLE 1 ELECTRICAL RATINGS AC Line Input Voltage Maximum Nominal Maximum Continuous Maximum 10 50 60 Hz AC Line Input Current Output Voltage Output Load Current Horsepower Rating Single Phase Volts AC Amps AC Volts AC RMS Amps Phase HP kW 115 16 0 230 3 6 1 0 75 208 230 10 0 230 3 6 1 0 75 TABLE 2 GENERAL PERFORMANCE SPECIFICATIONS Parameter Specification Factory Setting AC Line Input Voltage Volts AC 10 50 60 Hz 115 or 208 230 208 230 Maximum Load Capacity for 2 Minutes 150 Switching Frequency kHz 8 bedi Signal Following Non Isolated Input Input Voltage Volts DC 0 5 Signal Following Input Resolution Bits 8 Maximum Speed Trimpot MAX Range of Frequency Setting 70 110 100 Minimum Sp
12. Figure 4 on page 6 Be sure to properly fuse each AC line conductor that is not at ground potential Do not fuse neu tral or grounded conductors See Section VII on page 10 A separate AC line switch or con tactor must be wired as a disconnect so that each ungrounded conductor is opened A Power On Off Switch may be used in lieu of or in addition to the Start Stop Switch The switch can be wired for single pole or double pole operation as required To maintain the watertight integrity of the control be sure to use suitable watertight connec tors and wiring which are appropriate for the application Two 7 8 22 2mm knockout holes are provided for standard 1 2 knockout connectors not supplied for wiring A watertight plug is provided if only one knockout is required The enclosure is designed with a hinged case so that when the front cover is open all wiring stays intact To open the cover the four screws must be loosened so they are no longer engaged in the case bottom After mounting and wiring close the cover making sure that the wires do not get caught or crimped as the cover is closed Tighten all four cover screws so that the gasket is slightly compressed Do not over tighten TABLE 3 TERMINAL BLOCK WIRING INFORMATION Supply Wire Gauge AWG Cu i i i Designation Connection io mejia VEO Minimum Maximum in lbs AC Line Input AA 22 12 12 Motor UN W 22 12 12 AC Line Connection Wi
13. In order to prevent catastrophic damage to the speed control which has been installed in the equipment it is recommended that the following procedure be followed Figure 16 on page 9 shows a typical hi pot test setup Note All equipment AC line inputs must be disconnected from the AC power A Connect all equipment AC power input lines together and connect them to the H V lead of the hi pot tester Connect the RETURN lead of the hi pot tester to the frame on which the control and other auxiliary equipment are mounted B The hi pot tester must have an automatic ramp up to the test voltage and an automatic ramp down to zero voltage Note If the hi pot tester does not have automatic ramping then the hi pot output must be manually increased to the test voltage and then manually reduced to zero This pro cedure must be followed for each machine to be tested A suggested hi pot tester is Slaughter Model 2550 WARNING Instantaneously applying the hi pot voltage will cause irreversible dam age to the speed control C The hi pot test voltage should be set in accordance to the testing agency standards and the leakage current should be set as low as possible without causing nuisance trips D To eliminate motor speed control damage due to auxiliary equipment hi pot failure it is also recommended that all signal inputs be wired together and connected to the AC input lines as shown FIGURE 16 HI POT SETUP HIGH VOLTAGE
14. an be used See Figure 1 on page 3 for location of jumpers Note Disconnect the AC line before changing position of jumpers A AC Line Voltage Selection J1 and J2 Jumpers J1 and J2 are both factory set to the 230V position for 208 230 Volt AC line input For 115 Volt AC line input set both Jumpers J1 and J2 to the 115V position See Figure 10 FIGURE 10 AC LINE INPUT VOLTAGE SELECTION Control Set for 208 230 Volt AC Line Input Factory Setting Control Set for 115 Volt AC Line Input J1 Set for 208 230 Volt J2 Set for 208 230 Volt J1 Set for 115 Volt J2 Set for 115 Volt AC Line Input AC Line Input AC Line Input AC Line Input 230V 230V a O Ji O Ji 115V ZOON 115V ZOON J2 0 J2 115V 115V B Motor Horsepower Selection J3 Jumper J3 is factory set to the 1HP position for 1HP motors For motors of lower horsepower set Jumper J3 to the corresponding position for the motor being used See Figure 11 Reset Mode Selection J4 Jumper J4 is facto ry set to the MAN position for manual resetting of the control every time the AC line is applied or after a fault condition has occurred undervoltage overvoltage phase to phase short circuit and E FIGURE 11 MOTOR HORSEPOWER SELECTION J3 Set for 1 HP Motor Motor Horsepower Factory Setting 1 0 75 3 4 0 5 1 2 0 37 1 4 0 18 fault To
15. eased resolution of the ACCEL and DECEL trimpots 50 rotation covers 0 3 5 seconds 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 bus volt Seconds age from rising to the overvoltage trip point This function is Shown Factory Set to 1 5 Seconds called regeneration protection It is recommended that for very high inertial loads that both the ACCEL and DECEL FIGURE 21 trimpots should not be set to less than ten 10 seconds COMP TRIMPOT RANGE E Slip Compensation COMP Sets the amount of Volts Hz Amp to maintain set motor speed under varying 15 I loads The COMP trimpot is factory set for 1 5 Volts Hz Amp i aN The slip compensation may be adjusted by the COMP trim ih pot as described below See Figure 21 Jedi b I I 1 Wire an ammeter in series with one motor phase Volts Hz Amp 2 Run the motor and set the unloaded speed to approxi Brown Factor Set to 15 RTE mately 50 FIGURE 22 3 Load the motor to the rated motor nameplate current CL TRIMPOT RANGE Amps AC 4 Adjust the COMP trimpot so that the loaded RPM is equal b to the unloaded RPM BA EGU 160 5 The motor is now compensated to provide constant ES speed under varying loads ZEAK Y 200 F Current Limit with It Shutdown CL Sets the current GEA d EO A SO i ercent of Range Setting limit overload which
16. eed Trimpot MIN Range of Frequency Setting 0 40 0 Acceleration Trimpot ACCEL Range Seconds 0 3 20 1 5 Deceleration Trimpot DECEL Range Seconds 0 3 ZO 1 5 Slip Compensation Trimpot COMP Range Volts Hz Amp 0 3 1 5 Current Limit Trimpot CL Range Range Setting 0 200 160 Boost Trimpot BOOST Range for 50 Hz Output Frequency Volts AC 0 70 Boost Trimpot BOOST Range for 60 Hz Output Frequency Volts AC 0 35 5 Motor Horsepower Selection HP 1 4 1 2 3 4 1 1 Output Frequency Hz 0 50 0 60 0 60 Frequency Multiplier 1X 2X 12 1 Minimum Operating Frequency at Motor Hz 1 Speed Regulation 30 1 Speed Range Base Speed 2 5 Speed Range Ratio 60 1 b Operating Temperature Range C 0 45 Notes 1 Requires an isolated signal If a non isolated signal voltage is used install the ID5SI 2 Signal Isolator 2 Dependent on motor performance Il WIRING INSTRUCTIONS y WARNING Read Safety Warning on page 1 before using this control Disconnect the AC line before wiring Note To avoid erratic operation do not bundle AC line and motor wires with wires from sig nal following Start Stop Switch or any other signal wires Use shielded cables on all signal wiring over 12 30cm Shield should be Earth grounded on the control side only Wire the control in accordance with the National Electrical Code requirements and other codes that may apply to your area See Table 3 and
17. elay which can be used to turn on or off equipment or to signal a warning if the control is put into the Stop Mode or a fault has occured Auto Manual Switch ID5AMS 1 When used with the ID5SI 2 it either selects an iso lated signal from the ID5SI 2 or the Main Speed Potentiometer Mounts on the enclosure cover and is supplied with a switch seal to maintain watertight integrity 13 XI LIMITED WARRANTY For a period of 2 years from date of original purchase BALDOR will repair or replace without charge controls which our examination proves to be defective in material or workmanship This warranty is valid if the unit has not been tampered with by unauthorized persons mis used abused or improperly installed and has been used in accordance with the instructions and or ratings supplied This warranty is in lieu of any other warranty or guarantee expressed or implied BALDOR shall not be held responsible for any expense including installation and removal inconvenience or consequential damage including injury to any person caused by items of our manufacture or sale Some states do not allow the exclusion or limitation of inci dental or consequential damages so the above exclusion may not apply In any event BALDOR s total liability under all circumstances shall not exceed the full purchase price of the control Claims for purchase price refunds repairs or replacements must be referred to BALDOR with all pertinent data as
18. erminal Block to facilitate wiring of the AC line and motor adjustable trimpots MAX MIN ACCEL DECEL COMP CL BOOST and selectable jumpers line voltage motor horsepower auto or manual reset modes motor frequency frequency multiplier fixed or adjustable boost Optional accessories include a Forward Stop Reverse Switch Signal Isolator and Auto Manual Switch Quick connect terminals are provided for easy installation of all accessories STANDARD FEATURES Motor Overload Protection l t Provides motor overload protection which prevents motor burnout and eliminates nuisance trips Electronic Inrush Current Limiting Eliminates harmful inrush AC line current during startup Dual Voltage Input The control operates from 115 or 208 230 Volt 50 60 Hz single phase AC line Input Horsepower Selection The control contains a horsepower selection jumper which elimi nates the need to recalibrate the CL trimpot for different motors Short Circuit Protection Shuts down the control if a short circuit occurs at the motor phase to phase Regeneration Protection Eliminates tripping due to bus overvoltage caused by rapid deceleration of high inertial loads Slip Compensation with Boost Provides excellent load regulation over a wide speed range Start Stop Switch Provides electronic start and stop Power On Off Swiitch Disconects the AC line Ride Through Provides smooth recovery to the previous set s
19. for detailed installation and Declaration of Conformity Installation of a INTRODUCTION The Baldor ID5601 BO Adjustable Speed Drive is a variable speed control in a NEMA 4X IP 65 and watertight enclosure It is designed to operate 208 230 Volt 3 phase AC induction motors through 3 6 Amps RMS The sine wave coded Pulse Width Modulated PWM output which operates at a frequency of 8 kHz provides high motor torque high efficiency and low noise The control operates from 115 or 208 230 Volt 50 60 Hz single phase AC line input Due to its user friendly design tailoring to specific applications is easily accomplished via selectable jumpers and trimpot adjustments However for most applications no adjustments are necessary Main features include adjustable RMS Current Limit and E Motor Overload Protection In addition Adjustable Slip Compensation provides excellent load regulation over a wide speed range Electronic Inrush Current Limiting eliminates harmful AC line inrush current and Adjustable Linear Acceleration and Deceleration make the drive suitable for soft start appli cations Additional features include holding torque at zero speed and ride through which pro vides a smooth recovery to the previous set speed during a momentary power loss Standard front panel features include diagnostic LEDs for power on and control status a Start Stop Switch Power On Off Switch and a Main Speed Potentiometer Other features include a Barrier T
20. ires or explosion in this product or products used with this product such as electric motors switches coils solenoids and or relays Eye protection must be worn and insulated adjustment tools must be used when work ing with control under power This product is constructed of materials plastics metals carbon silicon etc which may be a potential hazard Proper shielding grounding and filtering of this product can reduce the emission of radio frequency interference RFI which may adversely affect sensitive electronic equipment If further information is required on this product contact the factory It is the responsibility of the equipment manufacturer and individual installer to sup ply this Safety Warning to the ultimate end user of this product SW effective 11 1992 GL SAFETY WARNING Please read carefully This control contains electronic Start Stop circuits that can be used to start and stop the con trol However these circuits are never to be used as safety disconnects since they are not fail safe Use only the AC line for this purpose Be sure to follow all instructions carefully Fire and or electrocution can result due to improp er use of this product C This product complies with all CE directives pertinent at the time of manufacture CE approved RFI filter is required Additional shielded motor cable and or AC line cables may be required along with a signal isolator ID5SI 2 Contact factory
21. is control does not contain AC line fuses Most electrical codes require that each ungrounded conductor contain circuit protection It is recommended to install a 20 Amp fuse Littelfuse 326 Buss ABC or equivalent or a circuit breaker in series with each ungrounded conductor Check all electrical codes that apply to the application Do not fuse motor leads TRIMPOT ADJUSTMENTS The control circuit board contains trimpots which are factory set for most applications Figure 2 on page 3 illustrates the location of the trimpots and their approximate factory calibrated positions Some applications may require readjustment of the trimpots in order to tailor the control for a specific requirement Readjust trimpots as described below WARNING If possible do not adjust trimpots with the main power applied If adjustments are made with the main power applied an insulated adjustment tool must be used and safety glasses must be worn High volt age exists in this control Fire and or electrocution can result if caution is not exercised Safety Warning on page 1 must be read before proceeding A Minimum Speed MIN Acceleration ACCEL Maximum Speed MAX Sets the maximum speed of the motor The MAX trimpot is factory set for 100 of base motor speed For a higher maximum speed setting rotate the MAX trimpot clockwise For a lower maximum speed setting rotate the MAX trimpot counterclockwise See
22. it is necessary to momentarily set the Start Stop Switch to the START position If the Start Stop function has been eliminated by installing a jumper between RUN and COM terminals then it will be necessary to either disconnect the AC line until the STA TUS LED indicates an undervoltage fault approximately 20 seconds or use the Start Stop Switch if installed TABLE 4 FAULT RECOVERY A RESETTING THE CONTROL Fault Auto Mode with Start Stop Switch Installed Manual Mode with Start Stop Switch Installed Auto or Manual Mode with Start stop Switch Removed Undervoltage Control will automatically reset Reset the control with the Start Stop Switch Control will automatically reset Overvoltage Control will automatically reset Reset the control with the Start Stop Switch Control will automatically reset Short Circuit Control will automatically reset Reset the control with the Start Stop Switch Control will automatically reset Pt Reset the control with the Start Stop Switch Reset the control with the Start Stop Switch Disconnect and reconnect the AC line Fault must be cleared before the control can be reset VII VIII WARNING The motor will automatically start when the AC line is applied or a fault is cleared if Jumper J4 is set to the AUTO or MAN position and the Start Stop Switch is eliminated AC LINE FUSING Th
23. l cause the motor to run at the Main Speed Potentiometer setting when the AC line is applied Voltage Following Connection An isolated O 5 Volt DC analog signal can also be used to control motor speed See Figure 8 Note If an isolated signal voltage is not availab an optional signal isolator can be installed ID5SI 2 Connect the isolated signal voltage to P2 and P1 terminals The MIN trimpot must be set fully counterclockwise Enable Circuit Connection The control can also be started and stopped with an Enable circuit close start See Figure 9 The Enable function is established by wiring a FIGURE 9 ENABLE CIRCUIT CONNECTION FIGURE 8 VOLTAGE FOLLOWING CONNECTION 0 5VDC le ISOLATED R NS to switch in series with the orange Main Speed Potentiometer lead which connects to P2 terminal When the Enable switch is closed the control will accelerate to the Main Speed Potentiometer setting When the Enable switch is opened the motor will coast to stop BACK VIEW MAIN SPEED POTENTIOMETER ENABLE SWITCH OR RELAY WHITE LOW CLOSE TO START ORANGE WIPER VIOLET HIGH coni P3 P2 PI SETTING SELECTABLE JUMPERS The control circuit board has customer selectable jumpers which must be set before the motor control c
24. n J1 and J2 LL 7 11 Motor Horsepower Selection ORE 7 12 Beset Mode Selection J4 eguz cic eee eee ie ee he ee eee eee 8 19 Motor Frequency Selection J5 ere as ett i b Baden Ee beta 8 14 Motor Frequency Multiplier Selection LEO 8 15 Boost Mode Selection J7 arreca na 8 RREA DEA EAEE 9 IZ MAX Timpot Rangas en fee tec ca ce tects tae wy eels tases tte ae E E E ari 10 IE MIN Timpot Range ceca E E EEEa 10 19 ACCEL Trimpot Range cr la nears tron E E 10 20 DECEL Trimpot Range orina ro i eee acta e 11 21 ECOMPTIMPORRANIS aea a E ii 11 22 GL mimpotRange a TE e E e E Coen 11 23 EEH Time vs Motor EUNE EEE Sr be ZE e Ee e e E deez 11 24 BOOST Trimpot Range xiao i a ace 12 SIMPLIFIED OPERATING INSTRUCTIONS IMPORTANT You must read these simplified operating instructions before proceeding These instructions are to be used as a reference only and are not intended to replace the detailed instructions provided herein You must read the Safety Warning below before proceeding EZ 4 A WARNING Disconnect main power when making connections to the control gt AC Line Connection Connect the AC line to L1 and L2 terminals of Terminal Block TB1 and the ground wire Earth to the green ground screw as shown in Figure 4 on page 6 and as described in Section IIA on page 6 and Section IIB on page 6 Set Jumpers J1 and J2 to the corresponding AC line input voltage 115 or 208 230 Volts AC B Motor
25. peed during a momentary power loss Diagnostic LEDs Power on POWER and control status STATUS Barrier Terminal Block Facilitates wiring of motor and AC line Protection Features Undervoltage and overvoltage protection MOV input transient pro tection Microcontroller self monitoring and auto reboot Short circuit protected phase to phase at motor Industrial Duty Die Cast Aluminum Case Holding Torque at Zero Speed Resists motor shaft rotation when the control is in stop mode Note UL approved as an electronic overload protector for motors FIGURE 1 CONTROL LAYOUT Illustrates Factory Setting of Jumpers and Approximate Trimpot Settings WHITE y gt ORANGE gt VIOLET JA MAIN SPEED POTENTIOMETER BACK VIEW MIN ACCEL DECEL COMP CL BOOST EEE START STOP SWITCH BACK VIEW NOTES 1 REV TERMINAL IS USED FOR OPTIONAL FWD STOP REV SWITCH 2 R F B AND B TERMINALS ARE USED FOR OPTIONAL ID5SI 2 SIGNAL ISOLATOR o B BC BCO BC B TISV 230V POWER ON OFF SWITCH BLUE WHITE LIA LIB DA BLUE WHITE FIGURE 2 ENLARGED VI
26. re the FIGURE 4 POWER CONNECTIONS AC line input to L1 and L2 terminals of Terminal Block TB1 as shown in Figure 4 Be sure both Jumpers J1 and J2 are set to the 115V posi tion for 115 Volt AC line input or to the 230V position for 208 230 Volt AC line input Ground Connection Earth ground the control chassis using the green ground screw that is pro vided on the inside of the control to the right side of Terminal Block TB1 AN TS Gr 7 ST d MOTOR _U Y w L1 GROUND MOTOR AC LINE EARTH as shown in Figure 4 Motor Connection Wire the motor leads to U V and W termi FIGURE 5 REMOTE MAIN SPEED POTENTIOMETER CONNECTION nals of Terminal Block TB1 as shown in Figure 4 Be sure Jumper J3 is set to the correspon ding motor horsepower rating DE OR Remote Main Speed Potentiometer Connection The control is supplied with a BACK VIEW MAIN SPEED POTENTIOMETER WHITE LOW ORANGE WIPER VIOLET HIGH prewired Main Speed Potentiometer mounted on the front cover To operate the control from a remote potentiometer 5kQ remove the white orange and violet potentiometer leads from P1 P2 and P3 termi nals The leads may be taped and left inside the control The
27. set the control to automatically reset after a fault has been cleared set Jumper J3 to the AUTO position See Figure 12 Also see section VIB on page 9 and Table 4 on page 10 WARNING The motor will automatically restart when the AC line is applied if Jumper J4 is set to the AUTO or MAN position and the Start Stop Switch is eliminated with a jumper installed between the RUN and COM terminals Motor Frequency Selection J5 Jumper J5 is facto ry set to the 60Hz position for 60 Hz motors For 50 Hz motors set Jumper J5 to the 50Hz position See Figure 13 E Motor Frequency Multiplier Selection J6 Jumper J6 is factory set to the 1X position for motor frequency corresponding to the frequency setting of Jumper J5 50 or 60 Hz To double the output frequency to the motor set Jumper J6 to the 2X position 100 or 120 Hz See Figure 14 Note When doubling the motor frequency the motor will produce full torque up to its base speed The torque will be linearly reduced to 50 at the maximum doubled frequency F Boost Mode Selection J7 Jumper J7 is factory set to the FIX position for fixed boost voltage For adjustable boost voltage using the BOOST trimpot set Jumper J7 to the ADJ position See Figure 15 See section VIIIG on page 12 IV MOUNTING INSTRUCTIONS WARNING This motor control is not designed to be used in an explosion proof application It is recommended
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