VFD Series - American Control Electronics
Contents
1. L 1 00 25 ALL DIMENSIONS IN INCHES MILLIMETERS Figure 3 VFD100 4 and VFD300 4 Dimensions VFD Series 4 40 112 _ 3 00 G l 0 70 18 II l WI l 4 45 113 E2 E1 1 s2 82 D 1 00 25 0 13 3 ALL DIMENSIONS IN INCHES MILLIMETERS Figure 4 VFD600 4 Dimensions 1 VFD Series Section 4 Installation applied Failure to heed this warning may result in fire explosion or serious injury Make sure you read and understand the Safety Precautions on page i before attempting to install this product Y Do not install rewire or remove this control with input power WARNING Mounting e Drive components are sensitive to electrostatic discharge Avoid direct contact with the circuit board Hold the drive by the chassis or heat sink only Protect the drive from dirt moisture and accidental contact Provide sufficient room for access to the terminals and calibration trim pots Mount the drive away from heat sources Operate the drive within the specified ambient operating temperature range Prevent loose connections by avoiding excessive vibration of the drive Mount the drive with its board in either a horizontal or vertical plane Six 0 19 5 mm wide slots in the2. bouncing in and out of torque limit Defective DIRECTION switch connection Reversing circuit not working properly Load may exceed rating of motor drive Nominal input voltage may be too low for motor SUGGESTED SOLUTIONS Compare motor voltage to input voltage replace motor is necessary Check motor load Resize the motor if necessary Make sure the motor is not undersized for load adjust TQ LIMIT setting CW page 27 Check DIRECTION switch connection Check reversing circuit by shorting TB501 D terminal and EN terminal with jumper wire Fix load i e straighten mounting coupling etc or replace motor and drive with motor and drive rated for higher horsepower Compare motor voltage to input voltage Replace motor if necessary VFD Series Section 9 Accessories amp Replacement Parts Displays Closed Loop ee OLD100 1 Open Loop CLD100 1 Kits Potentiometer amp 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 KTF 0003 2 8 Amp 250V 3AG Fast blow Glass Fuses KTF 0004 2 10 Amp 250V 3AB Normal blow Ceramic Fuses KTF 0005 2 15 Amp 250V 3AB Normal blow Ceramic Fuses KTF 0006 Logic Cards Isolation Cards Adder Board IS0301 1 Unidirectional 8 outputs ISO101 8 VFD Series Section 10 Optional C510 C
3. ANA Yi T TT TT TT TT TT U W F 18oosr ra LIMIT Figure 25 Diagnostic LED Locations 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 Before Troubleshooting Perform the following steps before starting any procedure in this section Disconnect AC line voltage from the drive Check the drive closely for damaged components Check that no conductive or other foreign material has become lodged on the printed circuit board Verify that every connection is correct and in good condition Verify that there are no short circuits or grounded connections Check that the selection switch settings are correctly set Check that the drive s rated armature is consistent with the motor ratings For additional assistance contact your local American Control Electronics distributor or the factory direct 844 AMCNTRL or FAX 800 394 6334 PROBLEM Line fuse i blows Line fuse does i not blow but i the motor does not run Motor cable or armature is shorted to ground Nuisance tripping caused by a combination of ambient conditions and high current spikes i e reversing Speed adjust potentiometer or input voltag
4. J501 for 115V as shown in Figure 7 If the input voltage is 230 VAC and the motor is rated for 230 VAC set the drive for non voltage doubler mode Set jumper J501 for 230V as shown in Figure 8 VFD Series UI 2300 ny ll O o J501 Voltage Doubler Mode Setting 115 VAC in 230 VAC out START STOP SWITCH LL l I 115 VAC l LINE INPUT l L Oo UST o bT zv OS Figure 7 VFD600 Connections for a 115 VAC Line o J501 Voltage Non Doubler Mode Setting 230 VAC in 230 VAC out START STOP FUSE SWITCH H kormo l 230 VAC LINE INPUT l 1 O Ii Figure 8 VFD600 Connections for a 230 VAC Line VFD Series low speeds because their fans may not move sufficient air to properly cool the motor It is recommended to use inverter duty rated motors when the speed range is beyond 10 1 Caution should be taken when operating fan cooled motors at The following motor types MAY NOT be used Split Phase Anv motor with a starting switch Repulsion Induction centrifugal or relay and or a Series Universal AC DC seperate starting winding In general the drive can work with capacitor start
5. Phase Motor Connections 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 to increase motor speed you must turn the potentiometer counterclockwise power off the drive and swap the S1 and S3 connections Refer to Figure 12 Enable Switch Connect a single pole single throw ENABLE switch between terminals E1 and E2 Open the switch to disable the drive and coast the motor to a stop Close the switch to enable the drive and accelerate to set speed at a rate determined by the ACCEL trim pot Direction Switch Connect a single pole single throw DIRECTION switch between terminals E1 and D Open the switch to run the motor in the forward direction Close the switch to run the motor in the reverse direction TB501 E2 O ENABLE SWITCH Close to Run E1 S1 S2 10K OHM SPEED ADJUST POTENTIOMETER s3 CW O D DIRECTION SWITCH G Figure 12 Potentiometer and Switch Connections 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 S
6. Series Section 5 Calibration Dangerous voltages exist on the drive when it is powered When possible disconnect the voltage input from the drive before adjusting the trim pots If the trim pots must be adjusted with power applied use insulated tools and the appropriate personal protection equipment BE ALERT High voltages can cause serious or fatal injury WARNING 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 All adjustments increase with CW rotation and decrease with CCW rotation Use a non metallic screwdriver for calibration Each trim pot is identified on the printed circuit board 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 Adjust MAX until the desired maximum speed is reached 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 American Control Electronics representative for assistance The T
7. chassis and 4 in the heat sink accept 8 pan head screws Fasten either the large base or the narrow flange of the chassis to the subplate The chassis or heat sink should be earth grounded Use a star washer beneath the head of at least one of the mounting screws to penetrate the anodized surface and to reach bare metal 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 If using a remote potentiometer with a chassis drive mount the speed adjust potentiometer through a 0 38 in 10 mm hole with the hardware provided Figure 5 Install the circular insulating disk between the panel and the 10K ohm speed adjust potentiometer Twist the speed adjust potentiometer wire to avoid picking up unwanted electrical noise If the speed adjust potentiometer wires are longer than 18 in 46 cm use shielded cable Keep the speed adjust potentiometer wires separate from power leads L1 L2 U V W MOUNT THROUGH A 0 38 IN 10 MM HOLE a NUT STAR WASHER SPEED ADJUST POTENTIOMETER INSULATING DISK POT TAB ASSIGNMENTS PANEL Figure 5 Speed Adjust Potentiometer VFD Series 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 Circuit potentials are at 115 or 230 VAC above ground T
8. motors but it is conditional on the current pull when the capacitor is in effect and how long the application calls for a speed that the capacitor will stay in the auxiliary winding It is recommended to contact the motor manufacturer to see if the motor can be ran with a VFD Motor Connections Single Phase Operation For single phase operation connect the motor as shown in Figure 9 Ensure that the prewired capacitor and its associated motor coil are connected to terminals U and V as shown This connection may be internal if using a 2 wire motor If the motor has 3 leads you may need to make this connection yourself To reverse a single phase split capacitor motor connect the motor as shown in Figure 10 The motor run cap must be removed from the circuit Motor Connections Three Phase Operation Connect the motor to terminals U V and W as shown in Figure 11 VFD Series moror PREWIRED UN 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 rn Ww Figure 9 Single Phase Motor Connections MOTOR WINDINGS NYA AUXILLARY WINDING WITHOUT CAPACITOR V Figure 10 Single Phase Motor Connections Reversing MOTOR WINDINGS PNA V Figure 11 Three
9. rate determined by the DECEL trim pot Press the JOG pushbutton to jog the motor Return the RUN JOG switch to RUN for normal operation 10K OHM SPEED ADJUST POTENTIOMETER JOG PUSHBUTTON Figure 21 RUN JOG Switch Connection to Speed Adjust Potentiometer 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 An optional ratio potentiometer may be used to scale the ISO202 1 output voltage cc 9 2 s2 ISO202 1 1 Follower Drive TB502 Ohi RB1 10K Ohm optional Figure 22 Leader Follower Application 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 ratio pot A optional 10K Ohms 10K Ohms ratio pot B optional 10K Ohms ISO101 8 ratio pot H optional 10K Ohms Figure 23 Single Speed Potentiometer Control of Multiple Drives VFD Series Quick
10. 1 Connect the signal reference to S2 Make no connection to S3 A potentiometer can be used to scale the analog input voltage Adder board ISO301 1 may be used to isolate an analog input voltage An analog input voltage range of 0 5 VDC is required to produce an voltage range of 0 full speed E1 Signal Common S1 Signal Reference 62 S3 D ti Figure 13 Analog Input Signal Connections 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 and may cause damage to the transformer If the switches are improperly set to a higher voltage position the motor will overspeed which may cause motor damage or result in bodily injury or loss of life Dangerous voltages exist on the drive when it is powered BE ALERT High voltages can cause serious or fatal injury For your safety use personal protective equipment PPE when operating this drive If the motor or drive does not perform as described disconnect the AC line voltage immediately Refer to the Troubleshooting section page 41 for further assistance Before Applying Power 1 Verify that no foreign conductive material is present on the pri
11. N 0017 Rev 0
12. Q LIMIT setting determines the maximum torque for accelerating and driving the motor To calibrate TQ LIMIT With the power disconnected from the drive connect a DC ammeter in series with the armature Set the TQ LIMIT trim pot to minimum full CCW Set the speed adjust potentiometer full CW or input voltage signal to maximum speed Carefully lock the motor armature Be sure that the motor is firmly mounted Apply line power The motor should be stopped Slowly adjust the TQ LIMIT trim pot CW until the armature current is 120 of motor rated armature current Turn the speed adjust potentiometer CCW or decrease the input voltage signal Remove line power Remove the stall from the motor Remove the ammeter in series with the motor armature if it is no longer needed 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 To calibrate BOOST 1 Run the motor at the lowest continuous frequency speed required Monitor the motor phase current with a true RMS meter while very slowly turning the BOOST trim pot CW until the motor operates properly or 100 of the motor nameplate current is reached NOTE Use the absolute minimum amount of BOOST necessary to achieve proper m
13. 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 E2 ENABLE DPDT CENTER OFF SWITCH E1 COMMON S1 S2 3 D La NINI Figure 24 Quick Reversing Circuit Wiring VED 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 Fault FAULT Red LED lights whenever one of the following conditions has occurred 1 Undervoltage 115 VAC line DC bus dropped below 100 VDC 93 5 VAC rms 230 VAC line DC bus dropped below 200 VDC 187 VAC rms 2 Overvoltage 115 VAC line DC bus exceeded 200 VDC 152 5 VAC rms 230 VAC line DC bus exceeded 400 VDC 302 VAC rms 3 Instantaneous Overcurrent Trip Inverter output current has exceeded safe levels To remove a fault condition the enable must be cycled Cycling the AC line power will remove a fault as well but the capacitors must completely discharge before re applying power for the fault to clear Refer to Figure 25 on page 40 for LED locations VFD Series
14. TM AMERICAN CONTROL Xa ELECTRONICS VED Series USER MANUAL VFD100 2 4 VFD100 4 VFD300 2 4 VFD300 4 VFD600 2 4 VFD600 4 www americancontrolelectronics com 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 Thank you for choosing American Control Electronics No part of this document may be reproduced or transmitted in any form without written permission from American Control Electronics The information and technical data in this document are subject to change without notice American Control Electronics makes no warranty of any kind with respect to this material including but not limited to the implied warranties of its merchantability and fitness for a given purpose American Control Electronics assumes no responsibility for any errors that may appear in this document and makes no commitment to update or to keep current the information in this document VFD Series Safety First SAFETY WARNINGS 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 DO NOT INSTALL REMOVE OR REWIRE THIS EQUIPMENT WITH POWER APPLIED Have a qualified electrica
15. ably reduced because the phases are 120 apart Althought the VFD uses this method of connection its fundamental design enables it to operate efficiently under these conditions Although VFD inverters can operate over their full speed range most motors will operate with constant torque over a 10 1 speed range 6 60 Hz and constant horsepower above 60 Hz Inverter duty rated motors may operate satisfactorily over a 20 1 speed range Some motors can be satisfactorily operated at speeds as low as 50 RPMs 50 1 speed range Below 50 RPMs some motors may show signs of stepping or cogging and may run warmer In addition to standard 3 phase induction motors the following motor types may be used with a VFD Permanent Split Capacitor PSC Shaded Pole AC Synchronous VFD Series Section 2 Specifications Maximum Voltage Voltage Armature Current HP Range VFD300 2 4 230 VAC 230 VAC S 1 8 1 2 115 VAC VFD600 2 4 230 VAC 230 VAC 2 4 1 8 1 2 VFD100 4 115 VAC 115 VAC 115 VAC 230 VAC AC Line Voltage 115 or 230 VAC 10 50 60 Hz 10 AC Motor Voltage 115 or 230 VAC 50 60 Hz 10 or 30 Output Frequency Range Analog Input Range signal must be isolated S1 to 2 Vibration 0 5G maximum 0 50 Hz 0 1G maximum gt 50 Hz VFD Series 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 mo
16. apacitor Kit In some applications lower carrier frequency reduces switching losses and increases bearing life in some motors 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 Note Audible noise will be increase as carrier frequency is lowered To lower the carrier frequency on a VFD series control install one of the following 2 pin capacitors C510 on the bottom board Refer to Figure 26 on page 46 Table 2 KTP 0108 Capacitor Values and Carrier Frequency 0 0033 uF 10 kHz 0 0068 uF 8 kHz 0 01 uF VFD Series TQ LIMIT Cap Label ZN 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 VFD Series 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 ma
17. d in step 2 is not the desired deceleration time turn the DECELtrim pot CW for a longer deceleration time or CCW for a shorter deceleration time Repeat steps 1 through 2 until the deceleration time is correct 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 R1 R2 TOTAL SERIES RESISTANCE R3 10K OHMS R4 Figure 16 Multiple Fixed Speeds VFD Series Adjustable Speeds Using Potentiometers In Series Replace the speed adjust potentiometer with a series of resistors with a total series resistance of 10K ohms Figure 17 Add a single pole multi position switch with the correct number of positions for the desired number of fixed speeds CW 5K OHM Figure 17 Adjustable Speeds Using Potentiometers In Series 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 O SPEED 1 Figure 18 Independent Adjustable Speeds VFD Series Independ
18. e signal is set to zero speed Speed adjust potentiometer or input voltage signal is not properly connected to drive input connections are open Drive is disabled Drive is not receiving AC line voltage Motor is not connected VFD Series SUGGESTED SOLUTIONS Check that the line fuse is correct for the motor size Check motor cable and armature for shorts Add a blower to cool the drive components decrease TQ LIMIT settings resize motor and drive for actual load demand or check for incorrectly aligned mechanical components or jams See page 27 for information on adjusting the TQ LIMIT trim Increase the speed adjust potentiometer setting or input voltage signal Check connections to input Verify that connections are not Verify that the motor is not jammed Increase TQ LIMIT setting if set too low Disable and then re enable 6 Make sure there is a short between terminals COM and EN Apply AC line voltage Remove power Connect the motor to U V and W Reapply power VFD Series PROBLEM Motor runs too i slow or too fast at set speed Motor will not reach the desired speed Motor pulsates i or surges under load Motor does not i reverse TQ LIMIT is unsatisfactory at high speeds MAX trim pot is not calibrated correctly Nominal input voltage may be too low for motor Motor
19. ent 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 FORWARD SPEED 20K OHM E1 REVERSE SPEED 20K OHM S1 o o S2 S3 FORWARD D DIRECTION NAIA REVERSE C Figure 19 Independent Adjustable Speeds with a Direction Switch 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 NORMALLY OPEN RUN JOG PUSHBUTTON RUN JOG SWITCH JOG motor coasts to stop o 2 E2 ENABLE RUN E1 COMMON S1 S2 S3 D Figure 20 RUN JOG Switch Connection to Speed Adjust Potentiometer 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
20. ilure to heed this warning may result in fire explosion or serious injury recommends the Power Input VFD100 or VFD300 Connect the AC line power leads to terminals L1 and L2 American Control Electronics recommends the use of a single throw double pole master power switch The switch should be rated at a minimum of 250 volts and 200 of motor current Refer to Figure 6 wk L laisses serere Do not add fuse to L2 unless line voltage is 230 VAC FUSE 0 o D Iil 115 230 VAC i LINE INPUT Leo START STOP SWITCH Figure 6 VFD100 and VFD300 AC Line Connections 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 The VFD600 series drives are equipped with a voltage doubling feature which converts a 115 VAC input into a 230 VAC output for use with 230 VAC motors The drive output current rating remains the same User caution when connecting this input If the input voltage is 115 VAC and the motor is rated for 230 VAC set the drive for voltage doubler mode Set jumper
21. imensions Speed Adjust Potentiometer VFD100 and VFD300 AC Line Connections VFD600 115 VAC Line Connections VFD600 230 VAC Line Connections Single Phase Motor Connections Single Phase Motor Connections Reversing Three Phase Motor Connections Potentiometer and Switch Connections Analog Input Signal Connections J501 Settings Run Decelerate to Minimum Speed Switch Multiple Fixed Speeds Adjustable Speeds Using Potentiometers in Series Independent Adjustable Speeds Independent Adjustable Speeds with a Direction Switch RUN JOG Switch Enable Connection RUN JOG Switch Potentiometer Connection Leader Follower Application Single Speed Potentiometer Control of Multiple Drives Quick Reversing Circuit Wiring Diagnostic LED Locations Carrier Frequency Capacitor Location 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 Many 3 phase inverter manufacturers claim that they can run single phase motors effectively This is normally accomplished by wiring only 2 phases however this method may cause instabilities due to the lack of feedback from one of the motor connections Furthermore motor torque will be consider
22. l technician install adjust and service this equipment Follow the National Electrical Code and all other applicable electrical and safety codes including the provisions of the Occupational Safety and Health Act OSHA when installing equipment Reduce the chance of an electrical fire shock or explosion by using proper grounding techniques over current protection thermal protection and enclosure Follow sound maintenance procedures It is possible for a drive to run at full speed as a result of a N component failure American Control Electronics strongly recommends the installation of a master switch in the main power input to stop the drive in an emergencv Circuit potentials are at 115 VAC or 230 VAC above earth ground Avoid direct contact with the printed circuit board or with circuit elements to prevent the risk of serious injurv or fatalitv Use a non metallic screwdriver for adjusting the calibration trim pots Use approved personal protective equipment and insulated tools if working on this drive with power applied VFD Series Table of Contents Section 1 Variable Frequency Drives Section 2 Specifications Section 3 Dimensions Section 4 Installation Mounting Speed Adjust Potentiometer Power Input VFD100 or VFD300 Power Input VFD600 Motor Connections Single Phase Operation Motor Connections Three Phase Operation Speed Adjust Potentiometer Enable Switch Direction Switch Analog I
23. nput Signal Section 4 Operation Before Applying Power Select Switches Input Voltage Select J501 Startup Starting and Stopping Methods Line Starting and Stopping Decelerating to Zero Speed Coast to Zero Speed Enable Section 5 Calibration Maximum Speed MAX VFD Series Torque TQ LIMIT Boost BOOST Acceleration ACCEL Deceleration DECEL Section 6 Application Notes Multiple Fixed Speeds Adjustable Speeds Using Potentiometers In Series Independent Adjustable Speeds Independent Adjustable Speeds with a Direction Switch RUN JOG Switch Enable Connection RUN JOG Switch Potentiometer Connection Leader Follower Application e Single Speed Potentiometer Control Of Multiple Drives Quick Reversing Section 7 Diagnostic LEDs Section 8 Troubleshooting Before Troubleshooting Section 9 Accessories amp Replacement Parts Section 10 Optional C510 Capacitor Kit VFD Series List of Tables Table 1 Recommended Line Fuse Sizes Table 2 KTP 0108 Capacitor Values and Carrier Frequency VFD Series List of Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 O WON DUN E WM RP GO VFD100 2 4 and VFD300 2 4 Dimensions VFD600 2 4 Dimensions VFD100 2 4 and VFD300 2 4 Dimensions VFD600 4 D
24. nted circuit board Ensure that all switches jumpers are properly set 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 This will result in severe damage to the drive and can lead to explosion and or injury 501 Voltage Set to 115V if using a 115 VAC line Set to 230V if using a 230 VAC line Figure 14 J501 Settings 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 Continue until the desired speed is reached Remove AC line voltage from the drive to coast the motor to a stop 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 a drive that is malfunctioning Removing AC line
25. nufacture 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 This warranty applies only to standard catalog products and does not apply to specials Any returns of special controls will be evaluated on a case by case basis American Control Electronics is not responsible for removal installation or any other incidental expenses incurred in shipping the product to and from the repair point B Disclaimer The provisions of Paragraph A are American Control Electronics s sole obligation and exclude all other warranties of merchantability for use expressed or implied American Control Electronics further disclaims any responsibility whatsoever to the customer or to any other person for injury to the person or damage or loss of property of value caused by any product that has been subject to misuse negligence or accident or misapplied or modified by unauthorized persons or improperly installed C Limitations of Liability In the event of any claim for breach of any of Americn Control Electronics s obligations whether expressed or implied and particularly of any other claim or breach of warranty contained in Paragraph A or of any other warranties expressed or implied or claim of liability that might despite Paragraph B be decided against American Cont
26. o prevent the risk of injury or fatality avoid direct contact with the printed circuit board or with circuit elements Do not disconnect any of the motor leads from the drive unless power is removed or the drive is disabled Opening any one motor lead while the drive is running may destroy the drive This product does not have internal solid state motor overload protection It does not contain speed sensitive overload protection thermal memory retention or provisions to receive and act upon signal from remote devices for over temperature protection If motor over protection is needed in the end use product it needs to be provided by additional equipment in accordance with NEC standards Use 18 24 AWG wire for logic wiring Use 14 16 AWG wire for AC line and motor wiring 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 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 If shielding of all logic level leads is not practical the user should twist all logic leads with themselves to minimize induced noise It may be necessary to earth ground the shielded cable If noise is produced by devices other than the drive ground the shield a
27. otor operation Improper use of the BOOST feature may cause motor and or drive overheating and failure VED 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 1 Set the speed adjust potentiometer or input voltage signal for minimum speed The motor should run at minimum speed Set the speed adjust potentiometer or input voltage signal for maximum speed Measure the time it takes the motor to go from minimum to maximum speed If the time measured in step 2 is not the desired acceleration time turn the ACCEL trim pot CW for a longer acceleration time or CCW for a shorter acceleration time Repeat steps 1 through 2 until the acceleration time is correct Deceleration DECEL The DECEL setting determines the time the motor takes to ramp to a lower speed See Specifications on page 1 for approximate deceleration times DECEL is factory set for the shortest deceleration time full CCW To set the deceleration time 1 Set the speed adjust potentiometer or input voltage signal for maximum speed The motor should run at maximum speed Set the speed adjust potentiometer or input voltage signal for minimum speed Measure the time it takes the motor to go from maximum to minimum speed If the time measure
28. power both lines is the only acceptable method for emergency stopping For this reason American Control Electronics strongly recommends installing an emergency stop switch on both AC line inputs see Figures 6 7 and 8 on pages 13 and 15 Frequent starting and stopping can produce high torque This may cause damage to motors especially gearmotors that are not properly sized for the application Automatic Restart Upon Power Restoration All drives automatically run to set speed when power is applied and the enable is closed Line Starting and Stopping Line starting and stopping applying and removing AC line voltage is recommended for infrequent starting and stopping of a drive only When AC line voltage is applied to the drive the motor accelerates to the speed set by the speed adjust potentiometer or analog signal When AC line voltage is removed the motor coasts to a stop 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 10K OHM SPEED ADJUST POTENTIOMETER DECEL TO MIN SPEED Figure 15 Run Decelerate to Minimum Speed Switch Coast to Zero Speed Enable The enable switch may be used to coast to a motor to a stop Refer to page 18 VFD
29. rol Electronics by lawful authority American Control Electronics shall under no circumstances be liable for any consequential damages losses or expenses arising in connection with the use of or inability to use American Control Electronics s product for any purpose whatsoever An adjustment made under warranty does not void the warranty nor does it imply an extension of the original 12 month warranty period Products serviced and or parts replaced on a no charge basis during the warranty period carry the unexpired portion of the original warranty only If for any reason any of the foregoing provisions shall be ineffective American Control Electronics s liability for damages arising out of its manufacture or sale of equipment or use thereof whether such liability is based on warranty contract negligence strict liability in tort or otherwise shall not in any event exceed the full purchase price of such equipment Any action against American Control Electronics based upon any liability or obligation arising hereunder or under any law applicable to the sale of equipment or the use thereof must be commenced within one year after the cause of such action arises mez S PZ E VFD100 2 4 ea 30 d VFD100 4 Fun VFD300 2 4 EK VFD300 4 AMERICAN CONTROL Eai ELECTRONICS VFD600 2 4 ee VFD600 4 www americancontrolelectronics com 14300 DE LA TOUR DRIVE SOUTH BELOIT IL 61080 844 AMCNTRL MA
30. t the drive end If noise is generated by a device on the drive ground the shield at the end away from the drive Do not ground both ends of the shield If the drive continues to pick up noise after grounding the shield it may be necessary to add AC line filtering devices or to mount the drive in a less noisy environment Logic wires from other input devices such as motion controllers and PLL velocity controllers must be separated from power lines in the same manner as the logic I O on this drive Line Fusing VFD Series 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 Table 1 lists the recommended line fuse sizes VFD100 2 4 VFD300 2 4 VFD600 2 4 VFD100 4 VFD300 4 VFD600 4 See Section 9 numbers Table 1 Recommended Line Fuse Sizes Single Phase i AC Line Maximum x Input Voltage Current Fuse Size Horsepower amps 230 115 230 Accessories and Replacement Parts for fuse kit part VFD Series Connections American Control Electronics strongly installation of a master power switch in the voltage input line as shown in Figures 6 7 and 8 pages 13 and 15 The switch contacts should be rated at a minimum of 200 of motor nameplate current and 250 volts Do not connect this equipment with power applied Fa
31. unted in the field directly above the main board maintaining the same footprint VFD Series Section 3 Dimensions Je tek N do O ngn lmer 6 90 175 6 30 160 las Creve D Q lo 97 25 2 72 69 3 70 94 0 96 24 H 2 12 54 O E2 E1 S1 2 3 D Mode H VFD02 115AC 2 68 68 VFDO2 230AC 2 48 63 ALL DIMENSIONS IN INCHES MILLIMETERS Figure 1 VFD100 2 4 and VFD300 2 4 Dimensions VFD Series 2 72 69 94 3 02 76 7 L 0 96 pa IA Q E2 E1 S1 S2 3 l 1 2 12 54 ALL DIMENSIONS IN INCHES MILLIMETERS Figure 2 VFD600 2 4 Dimensions VFD Series fh D SSSSS S 3 68 93 5
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