Bodine 2982 Installation & Operation Manual Download

Page: 1 / 44

See Safety Warning,
on pages 8 and 9.

Note: The drive is factory set for
60 Hz motors. For 50 Hz motors,
see Section 6.2, on page 25.

Installation & Operation Manual

OEM Series Chassis/IP-20 AC Drives

This manual covers Model 2982, 2983, 2984 2987

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.

www.bodine-electric.com

07401080 Rev.D

Summary of Contents for 2982

Page 1: ... page 25 Installation Operation Manual OEM Series Chassis IP 20 AC Drives This manual covers Model 2982 2983 2984 2987 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 www bodine electric com 07401080 Rev D ...

Page 2: ...g 28 30 9 Wiring Instructions 30 35 10 AC Line Fusing 35 11 Drive Operation 36 37 12 Diagnostic LEDs 37 38 13 Trimpot Adjustments 38 43 Limited Warranty 44 Table Page 1 Electrical Ratings 14 2 General Performance Specifications 15 3 Fault Recovery and Resetting the Drive 36 4 Drive Operating Condition and Status LED Indicator 38 Figure Page 1 Quick Start Connection Diagram 5 2A Models 2982 2983 29...

Page 3: ...uency 26 12 120 Hz and 100 Hz Drive Output Frequency Selection 26 13 Automatic Start 27 14 Forward Reverse Speed Selection 27 15 Typical Hi Pot Setup 29 16 AC Line Input Motor and Ground Connections 31 17 Main Speed Potentiometer Connection 32 18 Voltage Following Connection 33 19 Manual Start Switch Connection 34 20 Forward Stop Reverse Switch Connection 34 21 Enable Switch connection 35 22 Minim...

Page 4: ...s Indicator Label Trimpot Adjustment Tool CE Approved Product Information Card Warranty Registration Card iv 230 VAC Controls Suitable for use on a circuit capable of delivering not more than 5 kA RMS symetrical amperes 230 Volts maximum Use copper conductors rated 75 C Suitable for operation in a maximum surrounding air temperature of 40 C UL Notice Reconditioning the Bus Capacitors If this drive...

Page 5: ...ection Forward Reverse Speed Selection Forward Stop Reverse Switch Connection Voltage Following Signal Input in Lieu of Main Speed Potentiometer see Section 12 on pages 37 and 38 see Section 6 4 on page 27 see Section 9 7 on page 34 see Section 9 5 on pages 32 and 33 Diagnostic LEDs see Section 9 8 on pages 34 and 35 Enable Switch Connection AC Line Input Voltage Selection Main Speed Potentiometer...

Page 6: ...2983 Rated for 208 230 Volt AC line input only Models 2984 2987 Rated for 208 230 Volt AC line input with Jumper J1 on upper PC board set to the 230V position factory setting Rated for 115 Volt AC line input with Jumper J1 on upper PC board set to the 115V position 1 2 Ground Connection Connect the ground wire earth to the ground screw as shown in Figure 16 on page 31 See Section 9 2 on page 31 6 ...

Page 7: ...he 50Hz position and be sure Jumper J2 is set to the X1 position See Section 6 2 1 on page 26 1 6 Trimpot Settings All trimpots have been factory set for most applications as shown in Figure 4 on page 20 Some applications require adjustment of the trimpots in order to tailor the drive for a specific requirement See Section 13 on pages 38 43 1 7 Main Speed Potentiometer Connection For unidirectiona...

Page 8: ...e and void the warranty It is recommended that the SIVFR Signal Isolator and Run Fault Relay be installed when using signal following 2 SAFETY WARNING Definition of Safety Warning Symbols Electrical Hazard Warning Symbol Failure to observe this warning could result in electri cal shock or electrocution Operational Hazard Warning Symbol Failure to observe this warning could result in serious injury...

Page 9: ... or relays Eye protection must be worn and insulated adjustment tools must be used when working with drive 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 emis sion of radio frequency interference RFI which may adversely affect sensitive electronic equipme...

Page 10: ...sation with Static Auto Tune and Boost provides high torque and excellent load regulation over a wide speed range Power Start delivers over 200 motor torque to ensure startup of high frictional loads Electronic Inrush Current Limit EICL eliminates harmful AC line inrush current The drive is suitable for machine or variable torque HVAC applications With optional Drive Link software the drive can be...

Page 11: ...ion 7 on pages 27 and 28 Finger Safe Cover Meets IP 20 standard See Section 5 on pages 22 and 23 Note GFCI Operation This control can operate with GFCIs optional software required 3 2 Performance Features Power Start Provides more than 200 starting torque which ensures startup of high frictional loads Slip Compensation with Static Auto Tune and Boost Provides excellent load regulation over a wide ...

Page 12: ...es to the motor Regeneration Eliminates nuisance tripping due to bus overvoltage caused by rapid deceleration of high inertial loads Undervoltage and Overvoltage Shuts down the drive if the AC line input voltage goes above or below the operating range MOV Input Transient Suppression Microcontroller Self Monitoring and Auto Reboot 12 ...

Page 13: ... zero speed See Section 13 4 on pages 39 and 40 Slip Compensation COMP Maintains set motor speed under varying loads See Section 13 5 on pages 40 and 41 Boost DEC B In 50 Hz mode the trimpot automatically becomes Adjustable Boost which can be used to set the Volts Hz Curve for 50 Hz motors to obtain maximum perform ance In 50 Hz Mode the deceleration time is automatically set to the same as the ac...

Page 14: ...t RMS Amps Phase Maximum Horsepower HP kW lbs kg 2982 115 1 9 6 0 230 2 4 1 2 37 15 1 3 0 6 2983 208 230 1 6 0 0 230 2 4 1 2 37 10 1 3 0 6 2984 115 1 9 6 0 230 2 4 1 2 37 15 1 3 0 6 208 230 1 6 0 10 2987 115 1 14 0 0 230 4 0 1 75 20 2 2 1 0 208 230 1 10 0 15 Note All models contain Motor Filter and Quick Connect Terminals for AC line and motor wiring The Signal Isolator and Run Fault Relay is opti...

Page 15: ...mpot MIN Range Frequency Setting 0 40 0 Maximum Speed Trimpot MAX Range Frequency Setting 70 110 100 Acceleration Trimpot ACC and Deceleration Trimpot DEC B Range Seconds 3 20 1 5 Boost Trimpot DEC B Range 50 Hz Only Volts Hz 0 30 5 Slip Compensation Trimpot COMP Range at Drive Rating Volts Hz 0 3 1 5 Current Limit Trimpot CL Range Amps AC 2982 2983 2984 1 5 4 5 3 8 2987 2 5 7 5 6 4 Motor Frequenc...

Page 16: ...S R CON2 A M J1 P2 P3 CON1 X1 X2 P1 DEC B MIN MAX CL ACC COMP 230V 115V 1 25 31 8 2 Places 0 5 12 7 0 25 6 4 10 Places 0 2 5 1 3 00 76 2 99 0 3 90 3 80 96 5 4 30 109 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 ...

Page 17: ...3 2984 Side View Shown with Finger Safe Cover Installed Maximum Height 70 2 75 3 80 96 5 FINGER SAFE COVER RETAINING CLIPS FIGURE 2B MODELS 2982 2983 2984 MECHANICAL SPECIFICATIONS Inches mm See Figure 4 On Page 20 for Expanded View of Jumpers and Trimpots ...

Page 18: ...SAFE COVER RETAINING CLIPS 0 2 5 1 6 Places 0 4 10 2 33 5 1 32 3 82 97 0 See Chart A on page 19 77 9 3 07 2 Places 0 08 2 0 2 Places 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 ...

Page 19: ...Chart A Maximum Length Chart B Maximum Height 5 00 127 Models 2987 Chart B See 119 4 70 112 4 40 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 ...

Page 20: ... cause overheating and winding failure under light load or no load conditions If the motor is operated in this manner for an extended period of time it is recommended that the unloaded motor current be checked from 2 15 Hz 60 450 RPM to ensure motor current does not exceed the name plate rating Do not use motor if the motor current exceeds the nameplate rating FIGURE 4 EXPANDED VIEW OF JUMPERS AND...

Page 21: ...eve an extended speed range at full rated torque A box fan or blower with a mini mum of 100 CFM is rec ommended Mount the fan or blower so the motor is surrounded by the airflow See Figure 6 Motors and TENV Inverter Duty Maximum Allowed Motor Torque TEFC and Open Ventilated Motors Fan Cooled 100 60 70 80 50 30 40 10 0 20 90 Motor Speed 40 0 20 60 80 100 FIGURE 5 MAXIMUM ALLOWED MOTOR TORQUE VS SPE...

Page 22: ...while providing maximum motor protection If the motor is overloaded to 120 of full load 75 of the CL setting the I2 t Timer starts If the motor continues to be overloaded at the 120 level the timer will shut down the drive after 30 minutes If the motor is overloaded to 160 of full load the drive will trip in 6 sec onds UL approved as an overload protector for motors 5 FINGER SAFE COVER The drive i...

Page 23: ...Speed Board Complete instructions are provided with the accessories Models 2982 2983 2984 2987 To remove the Finger Safe Cover gently lift up on the four retainer clips until the cover disengages from the base See Figures 2B and 3A on pages 17 and 18 5 2 Installing the Finger Safe Cover To install the Finger Safe Cover be sure to properly align the retainer clips or push ins Gently push the Finger...

Page 24: ...put For 115 Volt AC line input set Jumper J1 to the 115V position Jumper J1 is located on the upper PC board See Figures 7 and 8 24 FIGURE 7 MODELS 2984 2987 AC LINE INPUT VOLTAGE SELECTION 230 Volt AC Line Input Factory Setting J1 Installed in 230V Position 115 Volt AC Line Input J1 Installed in 115V Position J1 230V 115V 230V 115V J1 ...

Page 25: ...operate the motor up to two times the rated RPM However constant horse power will result when operating the drive in the X2 mode above the motor rated fre quency See Figure 11 on page 26 For 120 Hz output with 60 Hz motor be sure Jumper J1 is set to the 60Hz position and set Jumper J2 to the X2 position For 100 Hz output with 50 Hz motor set Jumper J1 to the 50Hz position and set Jumper J2 to the ...

Page 26: ...GURE 12 120 Hz 100 Hz DRIVE OUTPUT FREQUENCY SELECTION 120 Hz Output with 60 Hz Motor J1 Installed in 60Hz Position J2 Installed in X2 Position 100 Hz Output with 50 Hz Motor J1 Installed in 50Hz Position J2 Installed in X2 Position J2 J1 50 60Hz X1 X2 J2 J1 50 60Hz X1 X2 50 60 Output Frequency Hz Torque 0 0 2 50 100 100 120 FIGURE 11 AVAILABLE TORQUE vs OUTPUT FREQUENCY ...

Page 27: ...OUNTING INSTRUCTIONS Warning This drive must be mounted in an enclosure Care should be taken to avoid extreme hazardous locations where physical damage to the drive can occur due to moisture metal chips dust and other contamination including corrosive atmosphere that may be harmful See Safety Warning on pages 8 and 9 To prevent acci dental contact with high voltage it is required that the Finger S...

Page 28: ...setup is shown in Figure 15 on page 29 All drives have been factory hi pot tested in accordance with UL requirements Warning All equipment AC line inputs must be disconnected from the AC power 8 1 Connect all equipment AC power input lines together and connect them to the H V lead of the Hi Pot Tester Connect the RETURN of the Hi Pot Tester to the frame on which the drive and other auxiliary equip...

Page 29: ...er 10mA 0mA LEAKAGE AC KILOVOLTS RESET TEST ZERO MAX VOLTAGE 0 2 1 3 to Both AC Line Inputs Main Power Disconnected Connect Hi Pot AC Line Input H V RETURN Machine Equipment or Frame L2 L1 Auxiliary Equipment Chassis Connect All Drive Terminals Together Motor Wires Frame Main Power Disconnected FIGURE 15 TYPICAL HI POT SETUP ...

Page 30: ...use neutral or grounded conductors A separate AC line switch or contactor must be wired as a disconnect so that each ungrounded conductor is opened For fuse or circuit breaker selection see Table 1 on page 14 Also see section 10 on page 35 9 1 AC Line Connection Wire the single phase AC line input to Terminals L1 and L2 The terminals are located on the upper PC board See Figure 16 on page 31 GFCI ...

Page 31: ... Note The drive is programmed to operate 3 phase AC induction motors For PSC motors optional software is required contact our Sales Department 9 4 Main Speed Potentiometer Connection The drive is supplied with a 5 kΩ Main Speed Potentiometer to control motor speed Wire the Main Speed Potentiometer to Terminals P1 low P2 wiper P3 high The terminals are located on the lower PC board See Figure 17 on...

Page 32: ... linearly follow the analog signal input Connect the signal input positive lead to Terminal P2 and the negative lead to Terminal P1 The terminals are located on the lower PC board With external circuitry a 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 S...

Page 33: ...on the lower PC board The connector must be wired to a momentary switch or contact as shown in Figure 19 on page 34 In the Manual Start Mode the drive will trip due to all faults Overvoltage Undervoltage Short Circuit and I2 t and remain tripped even when the fault is cleared To Start Reset the drive the switch or contact must be manually closed Also the drive must be restarted each time the AC li...

Page 34: ... stopped with an Enable Switch close to run open to stop Remove the factory installed jumper on CON2 and install the 3 wire connector supplied CON2 is located on the lower PC board The connector must be wired to a maintained switch or contact See Figure 21 on page 35 FIGURE 19 MANUAL START SWITCH CONNECTION Jumper Removed Connector Installed for Manual Start Switch CON1 A M Manual Start Switch Mom...

Page 35: ...ication 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 ENABLE SWITCH CONNECTION Jumper Removed Connector Installed for Forward Enable Switch Connector Installed for Reverse Enable Switch CON2 F S R Cl...

Page 36: ...he drive will automatically start fac tory setting after the fault has cleared Application Note In Manual Start Mode the drive must be manually reset for any fault Use the Manual Start Switch as described in Section 9 6 on pages 33 and 34 Also see Section 12 2 on pages 37 and 38 The fault must be cleared before the drive can be reset Fault Automatic Start Mode Factory Setting Undervoltage Drive wi...

Page 37: ...s necessary to have the MIN Trimpot set to zero fully counterclockwise 3 Open and close the Enable switch or contact See Section 9 8 on pages 34 and 35 12 DIAGNOSTIC LEDS The drive contains two diagnostic LEDs to display the drive s operational status See Figure 4 on page 20 for the location of the PWR and ST LEDs 12 1 Power On PWR The PWR LED will illuminate green when the AC line is applied to t...

Page 38: ...t be worn High voltage exists in this drive Fire and or electrocution can result if caution is not exercised Safety Warning on pages 8 and 9 must be read and understood before proceeding 38 Drive Operating Condition Flash Rate1 and LED Color Normal Operation Slow Flash Green Overload 120 160 Full Load Steady Red 2 I2 t Drive Timed Out Quick Flash Red Short Circuit Slow Flash Red Undervoltage Quick...

Page 39: ...rotate the ACC Trimpot clockwise For more rapid accel eration rotate the ACC Trimpot counterclockwise See Figure 24 Note Rapid acceleration settings may cause the current limit circuit to activate which will extend the acceleration time 13 4 Deceleration DEC B Sets the amount of time for the motor to decelerate from full speed to zero speed The DEC B Trimpot is factory set to 1 5 seconds For longe...

Page 40: ...regulation for most motors To increase the slip compensation rotate the COMP Trimpot clockwise To decrease the slip compensation rotate the COMP Trimpot counterclockwise See Figure 26 The slip compensation may be adjusted as follows 1 Wire an AC RMS ammeter in series with one motor phase 2 Run the motor and set the unloaded speed to approximately 50 900 RPM on 4 pole 1500 1725 RPM motors 3 Using a...

Page 41: ...st rotate the BOOST Trimpot clockwise To decrease the boost rotate the BOOST Trimpot counterclockwise See Figure 27 on page 40 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 DEC B Trimpot can be conservatively set at 8 9 o clock position Note In 50 Hz motor operation the deceleration time is automaticall...

Page 42: ... decrease the current limit rotate the CL Trimpot counterclockwise See Figures 28 29 on page 43 UL approved as an electronic overload protector for motors In order to ensure that the motor is properly protected with the I2t feature it is required that the CL Trimpot be set for 160 of the motor nameplate rating This is accomplished as follows Note This adjustment must be made within 6 seconds or th...

Page 43: ...ry Set to 6 4 Amps 3 8 2 5 Amps AC 5 7 5 6 4 FIGURE 29 MODEL 2987 CURRENT LIMIT TRIMPOT CL RANGE Shown Factory Set to 3 8 Amps 1 5 2 3 Amps AC 4 5 3 8 3 FIGURE 28 MODELS 2982 2983 2984 CURRENT LIMIT TRIMPOT CL RANGE ...

Page 44: ...ped 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 implied warranties of mer chantability and or fitness for a part...

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