Bodine 3912 Instructions For Installation And Operation Manual Download Page 3

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TABLE OF CONTENTS

QUICK REFERENCE CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

CONTROL DESCRIPTION AND FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

IMPORTANT SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Mounting the Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Motor Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Horsepower (DIP Switch) Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Line Fuse Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Motor Fuse Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Control Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

AC Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Operating the Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Internal Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Minimum and Maximum Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Torque (Current) Limiting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Acceleration

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Deceleration

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

SPECIALIZED WIRING APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Motor Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Connecting Control Inputs From Remote Locations . . . . . . . . . . . . . . . . . . . . . . . . .19

Remotely Located Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Remotely Located Braking (Disable), Direction of Rotation and

Deceleration Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Electronic Control Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Electronic Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Logic Signal Control of Braking, Direction of Rotation, and Deceleration . . . . . . .21

Signal Isolation Using a Bodine Model 3984 Interface Module . . . . . . . . . . . . . . . .21

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

FIGURES

Figure 1 – Detail of Control Circuit Board in Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . .10

Figure 2 – DIP Switch 7 and 8 Speed Range Settings . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Figure 3 – Horsepower (DIP Switch) Settings and Fuse Selection Chart . . . . . . . . . .10

Figure 4 – Speed/Torque Curve Showing Reduced Torque at Lower Speeds . . . . . . .14

Figure 5 – Interface Connector Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Figure 6 – Remote Speed Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Figure 7 – Manual Switch and Relay Control Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Figure 8 – Manual Speed Potentiometer/Interface Details . . . . . . . . . . . . . . . . . . . . . .21

Summary of Contents for 3912

Page 1: ...ions for Installation and Operation SPECIFICATIONS Product Type ABL 3912E ABL 3913E Input Voltage 115 VAC 10 50 60 Hz Single Phase Input Current 12 Amps rms Output Voltage 0 to 130 VDC Continuous Output Current 3 0 Amps Peak Output Current 6 0 Amps Ambient Temperature 0 to 40 C Maximum Control Hp Range Up to 3 8 Hp Control Speed Range Up to 30 1 ...

Page 2: ...ained in this manual Read and understood all of the precautions outlined in this manual pertaining to potential hazards to personal safety and equipment Mounted the control properly Details on Page 9 Connected the circular connector on the control output cable to the corresponding circular connector on the Bodine Brushless DC motor Details on Page 9 Selected the proper control horsepower settings ...

Page 3: ...eration Adjustment 14 TROUBLESHOOTING 15 SPECIALIZED WIRING APPLICATIONS 17 Motor Cable 18 Connecting Control Inputs From Remote Locations 19 Remotely Located Speed Control 19 Remotely Located Braking Disable Direction of Rotation and Deceleration Controls 20 Electronic Control Input Connections 20 Electronic Speed Control 21 Logic Signal Control of Braking Direction of Rotation and Deceleration 2...

Page 4: ...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 The issuance of this manual does not confer to the recipient any license to manufacture under any patents owned or controlled by the Bodine Electric Company Safety Standards Bodine products are de...

Page 5: ... listed in the Chart in Figure 3 Accessory Items Model3982ExtensionCable extendscablebetweenmotorandcontrolbysixfeet Both ends equipped with circular connectors for simplified connection Length 6 ft Model 0895 Enclosure Sealing Kit seals the ABL 3912E enclosure to provide IP 44 level splash proof protection Model 3984 Isolation Module isolates the control from system controller inputs which may be...

Page 6: ...n Installation and Use of Electric Motors and Generators available from National Electrical Manufacturers Association www nema org Warnings such as the example below highlight procedures which present potential danger to people Cautions highlight possible danger to equipment Both are used throughout this manual and must always be followed WARNING Dangerous voltages may be present in the electronic...

Page 7: ...ons beyond these limits are anticipated 1 Continuous Duty without frequent reversals or starts and stops 2 Maximum Ambient Temperature 50 C 122 F for chassis controls 40 C 104 F for all encased controls 3 Voltage Within 10 of nameplate rating 4 Frequency Within 5 of nameplate rating 5 Combined Variation of Voltage and Frequency Within a total of 10 providing frequency variation does not exceed 5 G...

Page 8: ...ctric Company will void the warranty Field repairs must be limited to replacing an entire printed circuit board assembly Because of the danger of introducing safety hazards do not install substitute parts or perform any unauthorized modifications to electronic PC boards components or motors To ensure continued compliance with the design specifications and safety standards the electronic control or...

Page 9: ...DIP Switch Settings Figure 1 shows the Horsepower Select switch on the main control board It containseightswitchleversnumbered1through8 ThechartinFigure3shows the proper DIP switch settings for various Bodine motor types Determine the first four digits of the motor s type number from the nameplate Find the same four digits in the chart in Figure 3 to determine the proper settings of the DIP switch...

Page 10: ...Speed Levers in the Fuse Fuse Input Number Type Hp RPM On Position F1 F2 Current 22B2 1 16 2 6 8 MDA 6 10 2 7 22B3 1 11 1 2 6 8 MDA 8 10 3 6 ABL 3912E 22B4 1 8 2500 1 3 6 8 ABC 15 MDA 1 1 4 4 8 34B3 1 5 1 2 3 6 8 MDA 1 1 2 6 7 34B4 1 4 2 4 6 8 MDA 2 8 0 34B6 3 8 1 5 6 8 MDA 2 1 2 11 1 ABL 3913E 22B4 1 5 10 000 1 2 3 6 8 ABC 15 MDA 1 1 2 6 7 34B4 1 3 1 3 4 6 8 MDA 2 1 2 9 5 Figure 2 Horsepower DIP ...

Page 11: ...tion The control output contains a motor fuse F2 shown in Figure 1 The rating of F2 will vary with the size of the motor used To determine the proper rating locate the first four digits of your motor s type number on the motor nameplate Find the same four digits in the chart in Figure 3 and use only the fuse which is recommended The ABL 3912E and ABL 3913E are supplied with a motor fuse kit contai...

Page 12: ...per connections have been made Operating the Control WARNING The 115 VAC line cord should be disconnected before starting 1 Toggle the input power switch to OFF and set the speed potentiometer to ZERO fully counterclockwise 2 Set the F B R switch to the Brake position 3 Connect the 115 VAC power cord to the external power source Then toggle the 115 VAC input power switch to the ON position 4 Set F...

Page 13: ...te initial settings If you need to readjust the control for your specific applications proceed as follows Minimum and Maximum Speed The MIN and MAX trim potentiometers have been factory calibrated The lowest MIN trim potentiometer setting fully counterclockwise corresponds to 0 RPM and the highest MIN setting fully clockwise corresponds to approximately 30 of rated speed The lowest MAX trim potent...

Page 14: ... overloads Turn the TORQ trim potentiometer counterclockwise to decrease the torque and clockwise to increase the torque Acceleration Adjustment Adjusting the ACCEL trim potentiometer See Figure 1 counterclockwise decreases the motor s acceleration time down to a minimum of approximately 0 2 seconds ABL 3912E or 0 5 seconds ABL 3913E A clockwise adjustment increases the rate up to a maximum of app...

Page 15: ...unauthorized repairs or removing screws will void the Warranty ABNORMALITY CHECK POINT COUNTERMEASURE CONTROL BLOWS LINE FUSE Control or motor connected to or shorted to earth ground Check for shorts and repair as required Shorted phase leads wiring incorrect Correct wiring DamagedcontrolComponents Contact Bodine for assistance MOTOR WILL NOT START Open line fuse or motor fuse Replace fuse Refer t...

Page 16: ...m alignment Damaged motor Repair or replace motor Speed potentiometer set too low Increase speed potentiometer setting MOTOR WILL NOT MAINTAIN SPEED UNDER LOAD Wrong horsepower setting Check DIP switch setting page 10 TORQ trim pot is out of adjustment Visually check setting Figure 1 Adjust TORQ trim pot page 13 Motor overloaded Re examine the load parameters MOTOR WILL NOT STOP WITH SPEED POT ADJ...

Page 17: ...ng electronic control or operation from a remote control panel the model ABL 3910C or ABL 3921C or ABL 3911C Chassis Type Controls are recommended If however the ABL 3912E and ABL 3913E must be adapted to fit a unique situation the following information should be reviewed carefully and understood before proceeding with any wiring changes WARNING The 115 VAC power line to the control should be the ...

Page 18: ...n Yel Tracer 24 Chassis ground 10 Black 24 Circuit Common 12 Brown 24 Hall Sensor A 9 Red 24 12 VDC 13 White 24 Hall Sensor B 14 Green 24 Hall Sensor C 11 Shield 24 Drain The drain is terminated at the control board Do not terminate the drain at the motor WARNING The shield common is at a dangerous potential above ground and presents a voltage hazard Contact with the shield could cause serious inj...

Page 19: ...emale quick disconnect terminals to the other ends of the three potenti ometer leads 3 Mount the potentiometer in the desired location 4 Connect the speed pot leads to the ABL control board as follows Blue to Terminal S1 Orange to Terminal S2 Yellow to Terminal S3 F1 C3 R94 R91 R90 LED2 D2 D3 R93 R92 R95 PILOT CAL SPEED POT S3 S2 S1 C 1992 60618 USA CHICAGO IL COMPANY ELECTRIC BODINE LINE FUSE TOR...

Page 20: ...lly braked 2 A Smart Reverse Circuit prevents plug reversing when the DIR switch is opened or closed The motor will brake to a stop before changing direction 3 The DECEL switch controls soft stops and starts The degree of acceleration and deceleration can be varied with the trim potentiometers on the control board See Page 14 4 The output shafts of gearmotors with odd number of stages Bodine type ...

Page 21: ... PLC In such cases the PLC outputs should be isolated from the ABL control by a relay or by an electronic isolation module to prevent damage to the PLC or the ABL control If a Programmable Controller with a relay output module is not available AC or DC outputs from the PLC can be used to drive separate relay coils See PLC user s manual for application information See Figure 6 to determine how to c...

Page 22: ...NOTES ...

Page 23: ...within the warranty period provided that the product is shipped freight prepaid with previous authorization to Bodine or to a Bodine 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 impl...

Page 24: ...D CAD drawings or to order online visit bodine electric com 201 Northfield Road Northfield IL 60093 U S A Tel 773 478 3515 Fax 773 478 3232 info bodine electric com www bodine electric com 07400212 C Visit www bodine electric com for our large selection of 24 VDC brushless DC motors and gearmotors Bodine offers over 1 200 standard gearmotors motors and system matched speed controls ...

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