Summary of Contents for Ace VFD Series
- Page 1 VF D S eries USER MANUAL V FD 100-2. 4 V FD 100-4 V FD 300-2. 4 V FD 300-4 V FD 600-2. 4 V FD 600-4 w w w . a m e r i c a n c o n t r o l e l e c t r o n i c s . c o m...
- Page 2 Dear Valued Consumer: Congratulations on your purchase of the VFD Series drive. This User Manual was created for you to get the most out of your new device and assist with the initial setup. Please visit www.americancontrolelectronics.com to learn more about our other drives.
- Page 3 VFD Series Safety First! S A F E T Y W A R N I N G S Text in gray boxes denote important safety tips or warnings. Please read these instructions carefully before performing any of the procedures contained in this manual.
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Page 4: Table Of Contents
VFD Series Table of Contents Section 1. Variable Frequency Drives........1 Section 2. Specifications ............. 2 Section 3. Dimensions ............4 Section 4. Installation ............8 Mounting ..................8 Speed Adjust Potentiometer ..........9 Wiring ..................10 Shielding Guidelines.............11 Line Fusing ................12 Connections.................13... - Page 5 VFD Series Torque (TQ LIMIT) ................27 Boost (BOOST) ................28 Acceleration (ACCEL) ..............29 Deceleration (DECEL) ..............29 Section 6.Application Notes ..........30 Multiple Fixed Speeds ..............30 Adjustable Speeds Using Potentiometers In Series ......31 Independent Adjustable Speeds ............32 Independent Adjustable Speeds with a Direction Switch ....33 RUN/JOG Switch - Enable Connection..........34...
- Page 6 VFD Series List of Tables Table 1 Recommended Line Fuse Sizes ..........12 Table 2 KTP-0108 Capacitor Values and Carrier Frequency .....45...
- Page 7 VFD Series List of Figures Figure 1 VFD100-2.4 and VFD300-2.4 Dimensions ......4 Figure 2 VFD600-2.4 Dimensions ............. 5 Figure 3 VFD100-2.4 and VFD300-2.4 Dimensions ......6 Figure 4 VFD600-4 Dimensions............7 Figure 5 Speed Adjust Potentiometer ..........9 Figure 6 VFD100 and VFD300 AC Line Connections......13...
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Page 8: Section 1. Variable Frequency Drives
VFD Series Section 1. Variable Frequency Drives The VFD Series drives are solid-state, variable frequency AC motor controls. They utilize a 115 or 230 VAC, 50/60 Hz, single phase input to operate any 115 or 208/230-volt, three-phase AC-induction or single- phase permanent split capacitor motor and can be user calibrated for 0 through 120 Hz output. -
Page 9: Section 2. Specifications
VFD Series Section 2. Specifications Input Output Maximum Voltage Voltage Armature Model (ADC) (ADC) Current HP Range VFD100-2.4 115 VAC 115 VAC 1/16 - 1/4 VFD300-2.4 230 VAC 230 VAC 1/8 - 1/2 115 VAC VFD600-2.4 230 VAC 1/8 - 1/2... - Page 10 VFD Series Safety Certifications UL/cUL Listed Equipment, File # E132235 Ambient Temperature Range 10°C - 40°C * An isolation board option that allows for a non-isolated 0-5 VDC, 0-10 VDC, or 4-20 mA input signal is available; part number ISO301-1. This option is mounted in the field directly above the...
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Page 11: Section 3. Dimensions
VFD Series Section 3. Dimensions J503 J502 0.97 [25] 2.72 [69] 3.70 [94] E2 E1 S1 S2 S3 D Model VFD02-115AC 2.68 [68] VFD02-230AC 2.48 [63] ALL DIMENSIONS IN INCHES [MILLIMETERS] Figure 1. VFD100-2.4 and VFD300-2.4 Dimensions... -
Page 12: Figure 2 Vfd600-2.4 Dimensions
VFD Series 4.30 [109] 3.80 [97] 0.97 [25] 2.72 [69] 3.70 [94] E2 E1 ALL DIMENSIONS IN INCHES [MILLIMETERS] Figure 2. VFD600-2.4 Dimensions... -
Page 13: Figure 3 Vfd100-2.4 And Vfd300-2.4 Dimensions
VFD Series J503 J502 E2 E1 S1 S2 S3 D ALL DIMENSIONS IN INCHES [MILLIMETERS] Figure 3. VFD100-4 and VFD300-4 Dimensions... -
Page 14: Figure 4 Vfd600-4 Dimensions
VFD Series 4.40 [112] 3.00 [72] 0.70 [18] 6.90 [175] 6.30 [160] 4.45 [113] E2 E1 S1 S2 S3 D 1.00 [25] 0.13 [3] ALL DIMENSIONS IN INCHES [MILLIMETERS] Figure 4. VFD600-4 Dimensions... -
Page 15: Section 4. Installation
VFD Series Section 4. Installation Do not install, rewire, or remove this control with input power applied. Failure to heed this warning may result in fire, explosion, or serious injury. Make sure you read and understand the Safety WARNING! Precautions on page i before attempting to install this product. -
Page 16: Speed Adjust Potentiometer
VFD Series Speed Adjust Potentiometer Be sure that the potentiometer tabs do not make contact with the potentiometer’s body. Grounding the input will cause damage to the drive. WARNING! If using a remote potentiometer with a chassis drive, mount the speed adjust potentiometer through a 0.38 in. -
Page 17: Wiring
VFD Series Wiring Do not install, rewire, or remove this control with input power applied. Failure to heed this warning may result in fire, explosion, or serious injury. WARNING! Circuit potentials are at 115 or 230 VAC above ground. To prevent the risk of injury or fatality, avoid direct contact with the printed circuit board or with circuit elements. -
Page 18: Shielding Guidelines
VFD Series Shielding Guidelines Under no circumstances should power and logic level leads be bundled together. Induced voltage can cause unpredictable behavior in any electronic device, including motor controls. WARNING! As a general rule, it is recommended to shield all conductors. If it is not practical to shield power conductors, it is recommended to shield all logic-level leads. -
Page 19: Line Fusing
VFD Series Line Fusing The drives should be fused for protection. Use fast acting fuses rated for 250 VAC or higher and 150% of maximum armature current. Fuse HOT L1 only when the line voltage is 115 VAC. Fuse both L1 and L2 when the line voltage is 230 VAC. -
Page 20: Connections
VFD Series Connections Do not connect this equipment with power applied. Failure to heed this warning may result in fire, explosion, or serious injury. American Control Electronics strongly recommends the WARNING! installation of a master power switch in the voltage input line, as shown in Figures 6, 7, and 8 (pages 13 and 15). -
Page 21: Power Input (Vfd600)
VFD Series Power Input (VFD600) Do not connect a 230 VAC line input when the drive is set for a 115 VAC input. This will result in severe damage to the motor and the drive, and can lead to explosion and/or injury. Check jumper WARNING! settings before connecting the AC power input. -
Page 22: Figure 7 Vfd600 115 Vac Line Connections
VFD Series TB501 TH501 DECEL ACCEL C501 TQ LI J501 Voltage Doubler Mode Setting (115 VAC in - 230 VAC out) J501 JMP501 C502 START/STOP J501 SWITCH IC502 115 VAC LINE INPUT FUSE Figure 7. VFD600 Connections for a 115 VAC Line... -
Page 23: Motor Connections (Single Phase Operation)
VFD Series Caution should be taken when operating fan-cooled motors at low speeds because their fans may not move sufficient air to properly cool the motor. It is recommended to use “inverter- WARNING! duty” rated motors when the speed range is beyond 10:1. -
Page 24: Figure 9 Single Phase Motor Connections
VFD Series PREWIRED MOTOR WINDINGS CAPACITOR NOTE This connection may be internal to the motor (2 wire leads). If not, you must make this connection yourself. DO NOT use a DIRECTION switch with this set-up. See Figure 10 for setup using a DIRECTION switch. -
Page 25: Speed Adjust Potentiometer
VFD Series Speed Adjust Potentiometer Use a 10K ohm, 1/4 W potentiometer for speed control. Connect the counter-clockwise end of the potentiometer to S1, the wiper to S2, and the clockwise end to S3. If the potentiometer works inversely of the desired functionality (e.g. -
Page 26: Analog Input Signal
VFD Series Analog Input Signal Instead of using a speed adjust potentiometer, the drive may be wired to follow an analog input voltage signal that is isolated from earth ground (Figure 13). Connect the signal common (–) to S1. Connect the signal reference (+) to S2. -
Page 27: Section 4. Operation
VFD Series Section 4. Operation Change voltage switch settings only when the drive is disconnected from AC line voltage. Make sure both switches are set to their correct position. If the switches are improperly set to a lower voltage position, the motor will not run at full voltage WARNING! and may cause damage to the transformer. -
Page 28: Select Switches
VFD Series Select Switches Input Voltage Select (J501) (VFD600 models only) Set the input voltage select jumper J501 to either 115 or 230 to match the AC line voltage. See Figure 14. WARNING: Do not connect a 230 VAC line input when the drive is set for 115V. -
Page 29: Startup
VFD Series Startup Turn the speed adjust potentiometer full counterclockwise (CCW) or set the input voltage signal to minimum. Apply AC line voltage. Slowly advance the speed adjust potentiometer clockwise (CW) or increase the input voltage signal. The motor slowly accelerates as the potentiometer is turned CW or as the input voltage signal is increased. -
Page 30: Starting And Stopping Methods
VFD Series Starting and Stopping Methods Dynamic braking, coasting to a stop, or decelerating to minimum speed is recommended for frequent starts and stops. Do not use any of these methods for emergency stopping. They may not stop WARNING! a drive that is malfunctioning. -
Page 31: Decelerating To Zero Speed
VFD Series Decelerating to Zero Speed The switch shown in Figure 15 may be used to decelerate a motor to zero speed. The DECEL trim pot setting determines the rate at which the drive decelerates. By opening the switch, the motor accelerates to set speed at a rate determined by the ACCEL trim pot setting. -
Page 32: Section 5. Calibration
BE ALERT. High voltages can cause serious or fatal injury. VFD series drives have user-adjustable trim pots. Each drive is factory calibrated to its maximum current rating. Readjust the calibration trim pot settings to accommodate lower current rated motors. -
Page 33: Maximum Speed (Max)
VFD Series Maximum Speed (MAX) The MAX setting determines the maximum motor speed (voltage/ frequency) when the speed adjust potentiometer or input voltage signal is set for maximum speed. To calibrate MAX: Set the MAX trim pot full CCW. Set the speed adjust potentiometer or input voltage signal for maximum speed. -
Page 34: Torque (Tq Limit)
VFD Series Torque (TQ LIMIT) TQ LIMIT should be set to 120% of motor nameplate current rating. Continuous operation beyond this rating may damage the motor. If you intend to operate beyond the rating, contact your WARNING! American Control Electronics representative for assistance. -
Page 35: Boost (Boost)
VFD Series Boost (BOOST) The BOOST trim pot is used to increase motor torque at low speeds. The minimum setting is sufficient for most applications and does not need to be adjusted. If the motor stalls or runs erratically at very low speeds (below 10 Hz), the boost trim pot may need adjustment. -
Page 36: Acceleration (Accel)
VFD Series Acceleration (ACCEL) The ACCEL setting determines the time the motor takes to ramp to a higher speed. See Specifications on page 1 for approximate acceleration times. ACCEL is factory set for the shortest acceleration time (full CCW). To set the acceleration time: Set the speed adjust potentiometer or input voltage signal for minimum speed. -
Page 37: Section 6.Application Notes
VFD Series Section 6.Application Notes Multiple Fixed Speeds Replace the speed adjust potentiometer with a series of resistors with a total series resistance of 10K ohms (Figure 16). Add a single pole, multi- position switch with the correct number of positions for the desired number of fixed speeds. -
Page 38: Adjustable Speeds Using Potentiometers In Series
VFD Series Adjustable Speeds Using Potentiometers In Series Replace the speed adjust potentiometer with a single pole, multi- position switch, and two or more potentiometers in series with a total series resistance of 10K ohms. Figure 17 shows a connection for high and low speed adjust potentiometers. -
Page 39: Independent Adjustable Speeds
VFD Series Independent Adjustable Speeds Replace the speed adjust potentiometer with a single pole, multi- position switch, and two or more potentiometers in parallel, with a total parallel resistance of 10K ohms. Figure 18 shows the connection of two independent speed adjust potentiometers that can be mounted at two separate operating stations. -
Page 40: Independent Adjustable Speeds With A Direction Switch
VFD Series Independent Adjustable Speeds with Direction Switch Replace the speed adjust potentiometer with two single-pole, double throw switches, and two potentiometers in parallel with a total parallel resistance of 10K ohms. Figure 19 shows the connection of two independent speed adjust potentiometers that can be mounted at two seperate operating stations. -
Page 41: Run/Jog Switch - Enable Connection
VFD Series RUN/JOG Switch - Enable Connection Connect the RUN/JOG switch and the JOG pushbutton as shown in Figure 20. When the RUN/JOG switch is set to JOG, the motor coasts to zero speed. Press the JOG pushbutton to jog the motor. Return the RUN/JOG switch to RUN for normal operation. -
Page 42: Run/Jog Switch - Potentiometer Connection
VFD Series RUN/JOG Switch - Potentiometer Connection Connect the RUN/JOG switch and the JOG pushbutton as shown in Figure 21. When the RUN/JOG switch is set to JOG, the motor decelerates to zero speed at a rate determined by the DECEL trim pot. Press the JOG pushbutton to jog the motor. -
Page 43: Leader-Follower Application
VFD Series Leader-Follower Application In this application, use a ISO202-1 to monitor the speed of the leader motor (Figure 22). The ISO202-1 isolates the leader motor from the follower drive, and outputs a voltage proportional to the leader motor armature voltage. The follower drive uses this voltage reference to set the speed of the follower motor. -
Page 44: Single Speed Potentiometer Control Of Multiple Drives
VFD Series Single Speed Potentiometer Control Of Multiple Drives Multiple drives can be controlled with a single speed adjust potentiometer using a ISO101-8 at the input of each drive to provide isolation (Figure 23). Optional ratio potentiometers can be used to scale the ISO101-8 output voltage, allowing independent control of each drive. -
Page 45: Quick Reversing
VFD Series Quick Reversing To reverse the direction of the motor shaft rotation, install a DPDT center off switch as shown below (Figure 24). The drive will brake the motor before reversing, so there is no need to wait for the motor to coast to a stop before changing direction. -
Page 46: Section 7. Diagnostic Leds
VFD Series Section 7. Diagnostic LEDs VFD series drives are equipped with three diagnostic LEDs: • Power (POWER): Green LED lights whenever AC line voltage is applied to the drive. • Current Limit (TQ): Yellow LED lights whenever the drive reaches current limit. -
Page 47: Figure 25 Diagnostic Led Locations
VFD Series Current Limit Fault LED TB501 BOOST DECEL ACCEL TQ LIMIT FAULT J501 JMP501 POWER IC502 Power LED C510 Figure 25. Diagnostic LED Locations... -
Page 48: Section 8. Troubleshooting
VFD Series Section 8. Troubleshooting Dangerous voltages exist on the drive when it is powered. When possible, disconnect the drive while troubleshooting. High voltages can cause serious or fatal injury. WARNING! Before Troubleshooting Perform the following steps before starting any procedure in this section: Disconnect AC line voltage from the drive. - Page 49 VFD Series PROBLEM POSSIBLE CAUSE SUGGESTED SOLUTIONS Line fuse 1. Line fuse is the wrong size. 1. Check that the line fuse is correct for the motor size. blows. 2. Motor cable or armature is 2. Check motor cable and shorted to ground.
- Page 50 VFD Series PROBLEM POSSIBLE CAUSE SUGGESTED SOLUTIONS Motor runs too 1. MAX trim pot is not 1. Calibrate the MAX trim pot calibrated correctly. (page 26). slow or too fast at set speed. Motor will 1. MAX setting is too low.
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Page 51: Section 9. Accessories & Replacement Parts
VFD Series Section 9. Accessories & Replacement Parts Displays Closed Loop ................OLD100-1 Open Loop................CLD100-1 Kits Potentiometer & Connector Pot Kit ................. KTP-0108 Fuse 2 1.5 Amp 250V 3AG Fast-blow Glass Fuses ....... KTF-0001 2 3 Amp 250V 3AG Fast-blow Glass Fuses ......KTF-0002 2 5 Amp 250V 3AG Fast-blow Glass Fuses ...... -
Page 52: Section 10. Optional C510 Capacitor Kit
American Control Electronics provides an optional capacitor kit for lowering the carrier frequency. The default carrier frequency on a VFD series control is 16 kHz. Using one of the capacitors supplied in kit KTP-0108, the carrier frequency can be lowered to a range of 12 kHZ to 4 kHz. -
Page 53: Figure 26 Carrier Frequency Capacitor Location
VFD Series TB501 BOOST DECEL ACCEL TQ LIMIT Cap Label 3n3 J100 FAULT J501 JMP501 POWER IC502 C510 CARRIER FREQUENCY CAPACITOR (C510) Insert the 2-pins of the carrier frequency capacitor into the 2 socket-holes (C510) located on bottom board. Figure 26. Carrier Frequency Capacitor Location... -
Page 54: Notes
VFD Series Notes... -
Page 55: Unconditional Warranty
VFD Series Unconditional Warranty A. Warranty American Control Electronics warrants that its products will be free from defects in workmanship and material for twelve (12) months or 3000 hours, whichever comes first, from date of manufacture thereof. Within this warranty period, American Control Electronics will repair or replace, at its sole discretion, such products that are returned to American Control Electronics, 14300 De La Tour Drive, South Beloit, Illinois 61080 USA. - Page 56 VFD 1 00- 2. 4 V F D3 00-2 .4 V F D 600- 2.4 VFD1 00- 4 V F D 300- 4 VF D 60 0-4 w w w. a m erican co nt ro l el ec t ro ni c s. com 1 430 0 D E L A TOU R D R IV E S OU TH B ELO IT, IL 6 1080 ( 844) A MC NTR L...
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