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Bodine OEM Series Installation & Operation Manual

Chassis/ip-20 ac drives
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Installation & Operation Manual
OEM Series Chassis/IP-20 AC Drives
This manual covers Model 2982, 2983, 2984 2987
See Safety Warning,
on pages 8 and 9.
www.bodine-electric.com
The information contained in this manual is intended to be accurate. The manufacturer
retains the right to make changes in design which may not be included herein.
Note: The drive is factory set for
60 Hz motors. For 50 Hz motors,
see Section 6.2, on page 25.
07401080 Rev.D

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Summary of Contents for Bodine OEM Series

  • Page 1 Installation & Operation Manual OEM Series Chassis/IP-20 AC Drives This manual covers Model 2982, 2983, 2984 2987 See Safety Warning, Note: The drive is factory set for on pages 8 and 9. 60 Hz motors. For 50 Hz motors, see Section 6.2, on page 25.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Section Page Quick-Start Instructions ............6 – 8 Safety Warning .
  • Page 3 TABLE OF CONTENTS (Continued) Figure Page 3A Model 2987 Mechanical Specifications ..........18 3B Models, 2987 Mechanical Specifications.
  • Page 4 31 Models 2987 Current Limit Trimpot (CL) Range ........43 Items Included in this Package: Bodine Adjustable Frequency Drive, Bodine Series Installation and Operation Manual, Main Speed Potentiometer Kit with Insulator and Mounting Hardware, Main Speed Potentiometer Terminals (3 Orange), Motor and AC Line Terminals (5 Blue), 2-Wire and 3-Wire Connector Kit, Status Indicator Label, Trimpot Adjustment Tool, CE Approved Product Information Card, Warranty Registration Card.

  • Page 5: Quick-Start Connection Diagram

    FIGURE 1 – QUICK-START CONNECTION DIAGRAM Ground (Earth): AC Line Input Voltage Selection see Section 9.2, Chassis (Dual Voltage Models Only): on page 31. see Section 6.1, on page 24. Adjustable Trimpots: see Section 13, on pages 38 – 43. Motor Main Speed Potentiometer (5 KW ) (Supplied) (Front View):...

  • Page 6: Quick-Start Instructions

    QUICK-START INSTRUCTIONS Important – You must read these simplified instructions before proceeding. These instructions are to be used as a reference only and are not intended to replace the details provided herein. You must read the Safety Warning on, pages 8 and 9, before proceeding. See Figure 1 on page 5.
  • Page 7 AC Line Fusing – It is recommended that a fuse(s) or circuit breaker be installed in the AC line. Fuse each conductor that is not at ground potential. For the recommended fuse size, see Table 1, on page 14. Also see Section 10, on page 35. Motor Connection –...

  • Page 8: Safety Warning

    Note: For signal following operation, the Minimum Speed Trimpot (MIN) must be set fully counterclockwise. WARNING! The signal input must be isolated from the AC line. Earth grounding signal wiring will damage the drive and void the warranty. It is recommended that the SIVFR —...

  • Page 9: Introduction

    INTRODUCTION Thank you for purchasing the Bodine Adjustable Frequency Drive. Bodine Electric Company is com- mitted to providing total customer satisfaction by producing quality products that are easy to install and operate. The Bodine is manufactured with surface mount components incorporating advanced...
  • Page 10 Adjustable linear acceleration and deceleration are provided, making the drive suitable for soft-start applications. Due to its user-friendly design, the Bodine AC drive is easy to install and operate. Tailoring to specif- ic applications is accomplished with selectable jumpers and trimpots, which eliminate the computer- like programming required on other drives.
  • Page 11 Notes: 1. Optional software is required for PSC motors — contact our Sales Department. 2. UL approved as an electronic overload protector for motors. 4. In 50 Hz Mode, the DEC/B Trimpot automatically becomes Adjustable Boost. Standard Features • Simple to Operate – Does not require programming. Uses trimpots and jumpers, which are factory set for most applications.
  • Page 12 • Short Circuit – Prevents drive failure if a short circuit occurs at the motor (phase-to-phase). • Motor Filter – Reduces harmful voltage spikes to the motor. • Regeneration – Eliminates nuisance tripping due to bus overvoltage caused by rapid deceleration of high inertial loads.
  • Page 13 Trimpot Adjustments • Minimum Speed (MIN) – Sets the minimum speed of the motor. See Sec. 13.1, on pg. 39. • Maximum Speed (MAX) – Sets the maximum speed of the motor. See Sec. 13.2, on pg. 39. • Acceleration (ACC) – Sets the amount of time for the motor to accelerate from zero speed to full speed.

  • Page 14: Electrical Ratings

    TABLE 1 – ELECTRICAL RATINGS AC Line Input Drive Output Fuse or Voltage Maximum Circuit Net Wt. Maximum Range Continuous Maximum Breaker Volts AC Phase Current (Nominal) Load Current Horsepower Rating Model (50/60 Hz) (Amps AC) (Volts AC) (RMS Amps/Phase) (HP (kW)) (Amps) 2982...

  • Page 15: General Performance Specifications

    TABLE 2 – GENERAL PERFORMANCE SPECIFICATIONS Factory Description Specification Setting 115 Volt AC Line Input Voltage Operating Range (Volts AC) 115 (±15%) — 208/230 Volt AC Line Input Voltage Operating Range (Volts AC) 208 (–15%) / 230 (+15%) — Maximum Load (% Current Overload for 2 Minutes) —...

  • Page 16: Models 2982, 2983, 2984 Mechanical Specifications And Control Layout

    FIGURE 2A – MODELS 2982, 2983, 2984 MECHANICAL SPECIFICATIONS & CONTROL LAYOUT (Inches/mm) (See Figure 4, On Page 20, for Expanded View of Jumpers and Trimpots) 3.90 99.0 0.25 3.00 76.2 (2 Places) 1.25 31.8 (10 Places) 12.7 4.30 3.80 96.5 230V 115V CON3...

  • Page 17: Models 2982, 2983, 2984 Mechanical Specifications

    FIGURE 2B – MODELS 2982, 2983, 2984 MECHANICAL SPECIFICATIONS (Inches/mm) (See Figure 4, On Page 20, for Expanded View of Jumpers and Trimpots) FINGER-SAFE COVER RETAINING CLIPS* (2 Places) Chart 3.80 96.5 0.95 24.1 Side View Shown with Finger-Safe Cover Installed Maximum Height Models 2982, 2983, 2984 2.75...
  • Page 18 FIGURE 3A – MODEL 2987 MECHANICAL SPECIFICATIONS (INCHES/MM) (Shown with Finger-Safe Cover Installed) (See Figure 4, On Page 20, for Expanded View of Jumpers and Trimpots) 3.90 0.08 (2 Places) 99.0 10.2 (2 Places) FINGER-SAFE COVER RETAINING CLIPS 1.32 33.5 3.07 77.9 3.82...
  • Page 19 FIGURE 3B – MODEL 2987 MECHANICAL SPECIFICATIONS (INCHES/MM) (Shown with Finger-Safe Cover Installed) (See Figure 4, On Page 20, for Expanded View of Jumpers and Trimpots) Chart A - Maximum Length Chart B - Maximum Height Model 2987 Models 2987 4.30 5.00 4.70...

  • Page 20: Important Application Information

    FIGURE 4 – EXPANDED VIEW OF JUMPERS AND TRIMPOTS 230V 115V CON3 50/60Hz X1 X2 CON1 CON2 F - S - R DEC/B COMP Jumpers and Trimpots Line Voltage Selection Jumper J1 (Shown in Factory Setting) (Located on Upper PC Board) (Models 2984, 2987 Only) (Located on Lower PC Board) IMPORTANT APPLICATION INFORMATION...

  • Page 21: Maximum Allowed Motor Torque Vs. Speed

    It is recommended FIGURE 5 – MAXIMUM ALLOWED MOTOR TORQUE VS. SPEED that the drive be used with Inverter Duty or TENV motors. Inverter Duty and TENV Motors Inverter duty and most Fan Cooled TEFC and Open Ventilated totally enclosed non- Motors ventilated (TENV) motors can provide full rated...

  • Page 22: Finger-Safe Cover

    Electronic Motor Overload Protection – The drive contains Modified I t Overload Protection.* Part of this function consists of a Current Limit (CL) circuit, which limits the drive current to a factory preset level of 160% of the rated drive current. The CL Trimpot is used to recalibrate the drive current from 60% thru 200%.

  • Page 23: Setting Selectable Jumpers

    Removing the Finger-Safe Cover – The Finger-Safe Cover may have to be removed before wiring the drive or setting selectable jumpers. All trimpots can be readjusted with the Finger- Safe Cover installed. Notice the orientation of the Finger-Safe Cover before removing it. Note: The Finger-Safe Cover is designed with a removable panel (on the trimpots side) which must be removed for installation of optional accessories SIVFR Signal Isolator and Run/Fault Relay or Multi-Speed Board.

  • Page 24: Models 2984, 2987 Ac Line Input Voltage Selection

    AC Line Input Voltage FIGURE 7 – MODELS 2984, 2987 Selection (Jumper J1 [2984, AC LINE INPUT VOLTAGE SELECTION 2987 only]) – Jumper J1 is facto- 230 Volt AC Line Input ry set to the “230V” position for (Factory Setting) 115 Volt AC Line Input 208/230 Volt AC line input.

  • Page 25: Automatic Start

    60Hz and 50 Hz Motor Operation and Drive Output Frequency Selection (Jumpers J1 and J2) – Both jumpers must be set for the appropriate motor nameplate frequency rating. Jumpers J1 and J2 are located on the lower PC board. 6.2.1 Setting the Drive for 60 Hz or 50 Hz Motor Operation – The drive is factory set to operate 60 Hz motors.
  • Page 26 start when power is applied FIGURE 11 – AVAILABLE TORQUE vs. OUTPUT FREQUENCY and a run command is given. The drive will automatically restart after a recovered fault due to undervoltage, overvolt- age, or short circuit. 50/60 100/120 Output Frequency (Hz) FIGURE 12 –...

  • Page 27: Mounting Instructions

    FIGURE 13 – AUTOMATIC START For an I t Trip, due to a prolonged overload, the drive must (Jumper Installed) be manually restarted. See Section 11.2, on page 36. Also see Section 12.2, on pages 37 and 38. CON1 For Manual Start, a momentary contact must be installed onto CON1, as described in Section 9.6, on pages 33 and 34.

  • Page 28: Recommended High Voltage Dielectric Withstand Testing (Hi-Pot Testing)

    Application Note – The enclosure should be large enough to allow for proper heat dissipation so that the ambient temperature does not exceed 45 °C (113 °F). Leave enough room to allow for AC line, motor connection, and other wiring that is required. See Figures 2A, 2B, 3A and 3B, on pages 16 –19.

  • Page 29: Typical Hi-Pot Setup

    FIGURE 15 – TYPICAL HI-POT SETUP High Voltage Dielectric Withstand Tester (Hi-Pot Tester) LEAKAGE AC KILOVOLTS 10mA RETURN TEST VOLTAGE H. V. RESET Connect All Drive Terminals Together (Main Power Disconnected) ZERO Adjustable Frequency Drive AC Line Input Motor Wires Frame Connect Hi-Pot Auxiliary Equipment...

  • Page 30: Wiring Instructions

    WIRING INSTRUCTIONS WARNING! Read Safety Warning, on pages 8 and 9, before using the drive. Disconnect main power when making connections to the drive. To avoid electric shock, be sure to properly ground the drive. Application Note – To avoid erratic operation, do not bundle the AC line and motor wires with each other or with wires from signal following, start/stop contacts, or any other signal wires.
  • Page 31 Ground Connection – FIGURE 16 – AC LINE INPUT, MOTOR, & GROUND CONNECTIONS Connect the ground wire (earth) to the green ground screw. The MOTOR AC LINE ground screw is located on the heat sink. See Figure 16. Motor Connection – Chassis Wire the motor to Terminals “U”, “V”, “W”.

  • Page 32: Main Speed Potentiometer Connection

    0 – 10 Volt DC analog signal can also be used. See Figure 18, on page 33. *If a non-isolated signal is used, use Bodine model number 3984 or equivalent.. Note: For signal following operation, the Minimum Speed Trimpot (MIN) must be set fully...

  • Page 33: Manual Start Switch Connection

    WARNING! The signal input must be isolated from the AC line. Earth grounding signal wiring will damage the drive and void the warranty. It is recommended that a — Signal Isolator and/or Run/Fault Relay or Bodine model number 3984 or equivalent be installed when using signal following.

  • Page 34: Forward-Stop-Reverse Switch Connection

    Forward-Stop-Reverse FIGURE 19 – MANUAL START SWITCH CONNECTION Switch Connection Connector Installed for (CON2) – To operate the Jumper Removed Manual Start Switch drive using a Forward- Stop-Reverse Switch, remove the factory CON1 Manual Start Switch (Push to Run) installed jumper on CON2 CON1 (Momentary Contacts) and install the 3-wire con-...

  • Page 35: 10 Ac Line Fusing

    For Forward Enable Operation, wire the switch to the white and black wires. For Reverse Enable Operation, wire the switch to the red and black wires. When the switch is closed, the drive will run. When the switch is opened, the drive will stop. FIGURE 21 –...

  • Page 36: 11 Drive Operation

    11 DRIVE OPERATION 11.1 Start-Up Procedure – After the drive has been properly setup (jumpers and trimpots set to the desired positions) and wiring completed, the startup procedure can begin. If the AC power has been properly brought to the drive, the power (PWR) LED will be illuminated green. The status (ST) LED will indicate drive status, as described in Section 11.2.

  • Page 37: 12 Diagnostic Leds

    11.3 Restarting the Drive After an I2t Fault Has Cleared – The drive can be restarted after an t Fault has cleared by any of the following methods. Note: If an I t Fault occurs, the motor may be overloaded. Check the motor current with an AC RMS responding ammeter.

  • Page 38: 13 Trimpot Adjustments

    TABLE 4 – DRIVE OPERATING CONDITION & STATUS LED INDICATOR Note: The drive is Drive Operating Condition Flash Rate and LED Color factory set to the Normal Operation Slow Flash Green Automatic Start Mode. Overload (120% – 160% Full Load) For Manual Start/Rest, Steady Red see Section 9.6, on...

  • Page 39: Figure

    13.1 Minimum Speed (MIN) – Sets the minimum speed of the FIGURE 22 – MINIMUM SPEED TRIMPOT (MIN) RANGE motor. The MIN Trimpot is factory set to 0% of frequency setting. For a higher minimum speed setting, rotate the MIN Trimpot clockwise.

  • Page 40: Deceleration Trimpot (Dec/B) Range

    FIGURE 25 – DECELERATION Application Note – On applications with high inertial loads, TRIMPOT (DEC/B) RANGE the deceleration may automatically increase in time. This will slow down the rate of speed of decrease to prevent the bus voltage from rising to the Overvoltage Trip point. This function is called Regeneration Protection.
  • Page 41 5. Adjust the COMP Trimpot until the loaded RPM is equal to the unloaded RPM. 6. The motor is now compensated to provide constant speed under varying loads. 13.6 Boost (DEC/B) – When the drive is set for 50 Hz Motor Operation (Jumper J1 installed in the “50Hz”...
  • Page 42 3. Increase the boost until the ammeter reaches the nameplate rated current (Amps AC). 4. Using the Main Speed Potentiometer, slowly adjust the motor speed over a 0 – 15 Hz (0 – 450 RPM) range. If the motor current exceeds the nameplate rating, decrease the boost setting.
  • Page 43 FIGURE 28 – MODELS 2982, 2983, 2984 FIGURE 29 – MODEL 2987 CURRENT CURRENT LIMIT TRIMPOT (CL) RANGE LIMIT TRIMPOT (CL) RANGE Amps AC Amps AC (Shown Factory Set to 3.8 Amps) (Shown Factory Set to 6.4 Amps)

  • Page 44: Limited Warranty

    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 mer- chantability and/or fitness for a particular use .

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