Instruction Manual & User Manual - TECO
Contents
1. Wire Terminations to the AC drive must be made with either UL listed field wiring lugs UL listed crimp type ring terminals Note Only for 230V 2 3HP and 460V 1 3HP models FLUXMASTER 50 INSTRUCTION MANUAL External 24V Supply TM2 FLUXMASTER 50 INSTRUCTION MANUAL Inverter Terminal Descriptions Primary Circuitry Terminal Block TM1 Description Terminal Symbol Function Description L1 L R Primary power source input to Drive L2 S Single phase L1 L2 or L N Three phase L1 L2 L3 External braking resistor terminal 230V 2 3HP and 460 1 3HP models only Inverter output to Motor Tightening torque for TM1 is 1Ib ft 12Ibs in all 115VAC models and 230V 1 4 1HP Tightening torque for TM1 is 1 3lbs ft or 16lbs in 230V 2 3HP and 460V 1 3HP Wire voltage rating must be a minimum of 300V 200V series 600V 400V series Control Circuitry Terminal Block TM2 Description Terminal Symbol Function Description TRIP Fault relay output terminal Multi Function output terminal see parameter F_21 RELAY Connection point rated capacity 250VAC 1A 30VDC 1A FWD FW REV RE 12V 12 Common point for terminals 3 4 6 7 5 1 5 RESET RS Operation control terminals see parameter 03 Multi Function input terminals see parameter 19 OU 10V Power terminal for potentiometer Pin 3 Analog input wire Analog frequency signal input terminal Pi2. F LU X MA S TER o M Instruction Manual amp User Manual Westinghouse www tecowestinghouse com FLUXMASTER 50 INSTRUCTION MANUAL Contents TABLE OF CONTENTS IR T ed 7 3 3 2 Examination before 5 4 1 Safety Precautions Tell PRECAUTIONS OF 6 311001 1 2 Environmental Precautions 2 Hardware Instruction and Installation 2 1 Operational ENVIrONMENE MM 2 2 Sample Model No Identification CD RR 2 4 2 5 Dimensions amp Location of Terminal Block 2 6 Mounting InstructlOls 3 Software Index 3 1 Keypad Operating Instructions 2 35 3 2 E E LIS 36 3 3 Parameter Function Description sssssescsssssccssssssccsssseccssssnsccsssssscessssssccsssssccssssusccesssusscsssssscssssuscessssuscessssusccesssuscesssnusessssusccesssnucessssu
3. 2 21 FLUXMASTER 50 INSTRUCTION MANUAL 14 37 365 00mm LL DIMENSIONS FM50 NEMA 4X IP65 Indoor Duty with operators 115V 230V 1 4 1HP models 11 02 280 00mm 15 66 397 80mm 16 98 431 20mm 0 16 00 17 4 04 2 22 9 72 246 80mm 11 07 281 20mm 8 49 215 60mm e 9 66 245 40mm FLUXMASTER 50 INSTRUCTION MANUAL INSTALLATION FM50 NEMA 4X IP65 Indoor Duty with operators 115V 230V 1 4 1HP models 1 Potentiometer 3 E REV 0 FWD gt SWITCH gt SWITCH 4 4 4 y 4 86 123 40mm L1 L2 50 60 Hz Single Phase NOTE 1 Power switch REV 0 FWD switch and potentiometer are only available for NEMA 4X units with operator devices 2 Power supply cable 14 AWG 2 0mm 3 Motor cable 16 AWG 1 25mm 4 Tightening torque values for terminals 1 Power Motor cable plug in terminal 4 34 5kg cm 2 Remote control wire 3 47 4kg cm 23 FLUXMASTER 50 INSTRUCTION MANUAL CONNECTION Circuit Diagram FM50 NEMA 4X IP65 Indoor Duty wit
4. Is output current of all phases balanced conditio Drive is defective YES EE Detailed examination is required The Drive is operating correctly 55 FLUXMASTER 50 INSTRUCTION MANUAL Error handling of fault indication of OV LV Drive display OV LV Is there any visual breakage YES Replace defective board NO Switch ON power supply Is there any PEE Replace control board Fault indication NO Input operation instruction Input frequency instruction Is the output NO frequency of controller Replace control board displayed YES Is there output voltage on T1 T2 and T3 terminals NO Replace control board Is the problem corrected by replacing control board NO Connect motor Is the motor operating Is there any Fault indication Is output current of all phases balanced YES The Drive is defective The Drive is Detailed examination is required operating correctly 56 FLUXMASTER 50 INSTRUCTION MANUAL 1 Motor inoperative Is the circuit breaker MCCB switched O YES NO Does the NO stay on Wiring short circuit without tripping 5 the Voltage between NO Power source L1 L2 power input terminals normal abnormality Poor wiring YES within 10 of nominal value NO FM50 malfunction Is Power LED off NO Place the operation
5. Braking Specification Braking Braking Model of Resistor of Braking Resistor Resistor Torque Model W 9 ED 50 202 FM100 2BR2 FM50 203 FM100 2BR3 FM50 401 FM100 4BR1 FM50 402 FM100 4BR2 FM50 403 FM100 4BR3 Note 1 Braking level 385 770VDC for FM50 200 400 series 2 Braking resistor mounting is below 1 97 Drive TM1 Braking Resistor 64 FLUXMASTER 50 INSTRUCTION MANUAL Special Condition Description Customer Application Telephone Address F_ Value Setting Value Setting F_ Value Setting F_00 F_22 65 FLUXMASTER 50 INSTRUCTION MANUAL Notes FLUXMASTER 50 INSTRUCTION MANUAL Notes Westinghouse TECO Westinghouse Motor Company 5100 N IH 35 Round Rock Texas 78681 Toll Free 800 279 4007 Phone 512 255 4141 Fax 512 244 5512 www tecowestinghouse com 04 05
6. Auto Restart Number of Auto restart times 010 Constants initialization to 50Hz system 020 Constants initialization to 60Hz system SP2 Frequency SP2 frequency 0 1Hz 200Hz SP3 Frequency SP3 frequency 0 1Hz 200Hz Power Up Start j 1 0 1 1 Disable Software Version CPU program version Fault Log Fault log for three faults Reverse Lock Out Restore factory settings NOTE 1 Parameters that can be adjusted while running the drive 2 Please refer to parameters 25 3 If the setting range is above 100 the setting unit becomes 1 4 New features for CPU versions V2 1 and above 3 3 Parameter Function Description F 00 Factory Adjustment Parameter Do not change 01 Acceleration Time 0 1 999 sec 02 Deceleration Time 0 1 999 sec 1 Acceleration Deceleration time calculation formula Acceleration time 01 x Frequency Setting 60Hz Deceleration time 02 x Frequency Setting 60Hz 60Hz F 01 37 FLUXMASTER 50 INSTRUCTION MANUAL 03 21 control method F 03 Operation Mode Selection 0 Forward Stop Reverse Stop 1 Stop Forward Reverse NOTE 1 F 03 takes effect only when 10 1 external operation control 0 3 FWD Stop 3 Run Stop control 4 REV Stop 4 FWD REV method 5 COM 5 COM TM2 PINS TM2 PIN4 F_03 0 Output 1 Output No
7. 1 Warranty does not apply to damage caused by the following situations 1 Damage to the AC drive caused by the lack of appropriate molded case circuit breaker or when an oversized circuit is installed between the power supply and the AC drive 2 Damage to the AC drive caused by the magnetic contactor phase advancing capacitor or surge protector installed between the AC drive and the motor 1P2 1P2 2P2 2P5 101 201 202 401 402 403 15A 20A 30A 15A Wire Dimension Wire Dimension Wire Dimension Wire Dimension 414 AWG 414 AWG 412 AWG 412 AWG 2 0mm 2 0mm 3 5mm 3 5mm Terminal Screw Terminal Screw Terminal Screw Terminal Screw M3 M3 M4 M4 M4 Wire Dimension 0 75 mm 18 AWG Terminal Screw ws Use Copper Conductors Only Size Field Wire Based on 16777 75 C Wire Only Wire Voltage Rating Must Be a Minimum of 300V Model Type Molded Case Circuit Breaker Primary Circuit Terminal 6 Signal Terminal TM2 1411 Recommended Wire Type 1 Please utilize three phase squirrel cage induction motor with appropriate capacity If the AC drive is used to drive more than one motor the total capacity must be smaller than the capacity of the AC drive Additional thermal overload relays must be installed in front of each motor Set Fn 18 at 1 0 times of the rated value specified on the motor nameplate at 50Hz 1 1 times of the rated value specified on the motor nameplate at 60Hz 1 Do not install phase advanci
8. 3 Fault Function Description Factory Adjustment Accel Time Decel Time 0 Forward Stop Reverse Stop 1 Run Stop Forward Reverse 0 Forward 1 Reverse V F pattern setting Frequency upper limit Frequency lower limit SP1 frequency JOG frequency 0 Keypad 1 Terminal TM2 0 Keypad 1 Terminal 0 10 0 20mA 2 Terminal 4 20mA Carrier Frequency Setting Torque compensation gain 0 Controlled deceleration stop 1 Coast to stop DC braking time DC braking injection frequency DC braking level Protection based on motor rated current Multi Function input terminal 1 SP1 function Multi Function input terminal 2 RESET function Multi Function output terminal 36 FLUXMASTER 50 INSTRUCTION MANUAL Function Factory Setting Accel Time Decel Time Operation Mode Motor Rotation Direction V F Pattern Frequency Upper Lower Limit SP1 Frequency JOG Frequency Start Stop Control Frequency Control Carrier frequency Control Torque Compensation Stop Method DC Braking Setting Electronic Thermal Overload Protection Multi Function Input Connection Point Multi Function Output FLUXMASTER 50 INSTRUCTION MANUAL Note Time Factory Setting Function Function Description Unit Range 0 REV run 1 REV run Lock Out Momentary Power 0 Enabled Loss 1 Disabled
9. To reduce the noise interference and avoid possible operational problems shielded twisted pair cable should be used to wire the control circuitry Please refer to following diagram Connect the shield wire to the grounding terminal Connect only one end of the shield To Control Machine To Inverter Terminal Connect Shield Do not connect the Shielding Wrapped with Wire at this end Insulating Tape Connect to system grounding terminal Wiring distance of 164ft 50m or under is recommended The grounding terminal of the AC Drive must be correctly grounded in compliance with 200V class type three grounding Grounding wire should be wired in accordance to electrical equipment AWG with the length of the grounding wire as short as possible 1 The grounding wire of the AC drive must not be grounded together with other large current loads such as soldering machines or large current motors They should be grounded separately FLUXMASTER 50 INSTRUCTION MANUAL O gt lt a correct b correct c incorrect 1 Ground circuit must not be formed when grounding several AC drives together D Wire specification Apply appropriate wire with correct diameter for primary power circuitry and control circuitry in compliance with NEC or other applicable codes 2 4 Wiring Diagram Braking Resistor Option see note Multi Function Inputs 10k Speed Pot 0k 0 10V 0 20 4 20mA
10. 5 1 Terminal 2 SP1 Terminal Output Frequency 44 FLUXMASTER 50 INSTRUCTION MANUAL 3 F 19 F 20 3 External Emergency Stop When the external emergency stop signal is activated the AC drive proceeds to decelerate and stop ignoring the stopping method setting of 14 The AC drive E S light will flash after stopping After the emergency stop signal is deactivated turn the RUN switch OFF and then ON again to cycle it in the terminal mode F 10 1 Or press the RUN key in the keypad mode 10 0 The AC drive will then resume operation and restart If the emergency stop signal is removed before the AC drive stops the AC drive will still execute the emergency stop 4 F 19 F 20 4 External Base Block Immediate Shut Down When the external base block signal is activated the AC drive output will be immediately shut off ignoring the stopping method setting of F 14 and flash b b Light After the base block signal is deactivated turn the RUN switch OFF and then ON again 10 1 or press the RUN key 10 0 the inverter will restart from the original starting frequency Run Stop F 3 External Emergency Stop RuvStp on oft on Hz Time F 20 4 of on External Base Block 5 F 19 F 20 5 Auto Reset when drive faults 21 Multi Function Output Terminal Control 1 3 1 212 1 Run mode signal 2 F 21 2 2 At Frequency Speed Si
11. Factor Calculate power factor by the input voltage input current and input power i Output Voltage 5 Rectifier Moving iron Maximum voltage difference Vo not allowed between wires under 396 Moving iron Under the drive s rated current s dads Power meter Po W3 W4 Po Output Power Factor PFo X100 3 0 lo 62 FLUXMASTER 50 INSTRUCTION MANUAL 4 5 EMI Filter Class B Specification Dimension in Current A Inverter model FM50 2P2 MSDF 2102 6 14 x 3 0 x 0 99 FM50 2P5 FM50 201 FM50 202 FM50 203 FM50 401 MSDF 4103 6 77 x 4 73 x 0 43 FM50 402 FM50 403 MSDF 2202 6 77 x 4 73 x 0 43 4 6 Din Rail Specification Dimension in FM50 model FM50 DIN 201 5 12 2 83 x 0 30 ALL FM50 MODELS 4 7 of Braking Resistor and Input Reactor Specification Braking Braking Transistor Resistor Built in Built in Braking Input AC Reactor Resistor Current Inductance mH Note 1 Note 1 Note 1 BRN2 202 BRN2 203 BRN2 401 BRN2 402 BRN2 403 Braking Torque FM50 2P2 FM50 2P5 FM50 201 FM50 202 FM50 203 FM50 401 FM50 402 FM50 403 Built in X Not Built in Note 1 No transistor and resistor built in 63 FLUXMASTER 50 INSTRUCTION MANUAL 4 8 Braking Resistor Specification
12. KVA 29 Weight Ib 4 Input Voltage Max Three Phase 380 480V 10 15 50 60Hz 5 Output Voltage Max Three Phase 380 480V Proportional to input voltage Dimension H W D inches 5 63 4 63 6 77 Specification Without Filter FLUXMASTER 50 INSTRUCTION MANUAL 2 3 2 Functional Specifications Specification SOURCE input External 24VDC Input is allowed PNP type Sinusoidal wave PWM control 1 200Hz Digital 0 1Hz 1 99 9Hz 1Hz 100 200Hz Analog 06Hz 60Hz Directly setup by A buttons O 10V 4 20mA 0 20mA Frequency upper and lower limit 4 16KHz 0 1 999 Sec 6 Patterns Adjustable Torque boost level manual torque boost 2 Programmable Inputs to be used as multi speed 1 SP 1 multi speed 2 SP 2 1 Jog External emergency stop External Base Block Command Reset Command One output contact available as Fault Running At speed signals 1P2 101 2P2 201 Approximately 20 202 203 401 402 403 20 100 built in braking transistor Decelerate or free run stop Auto reset DC braking frequency Voltage Time can be setup by constants Three digit 7 segment LED display frequency functions constants fault record CPU version 14 104 F 10 40 C 14 122 F 10 50 without shield sticker 0 95 RH non condensing Under 1G 9 8m S EN50081 1 EN
13. Time 0 25 5 sec F_16 DC Braking Starting Frequency 1 10Hz 17 DC Braking Level 0 20 14 0 When the AC drive receives the stop command it decelerates to the preset frequency set by 16 After this the output voltage level that is set in 17 will determine the amount of DC voltage that is injected into the motor The time duration to perform this stopping function is set in F 15 Run Command LL Output Frequency Pe Time DC Braking Frequency DC Braking Time IfF_14 1 The inverter stops output immediately after receiving the stop command The motor will enter into a coast to stop state until it comes to a complete stop 18 Motor Rated Current 50 200 1 The electronic thermal overload protection for the motor is as follows 1 Motor rated current AC drive rated current 18 18 Motor rated current AC drive rated current 2 When the load is within 10096 of the motor s rated current the operation continues When the load reaches 15096 of the motor rated current the operation is allowed to continue for 1 minute Refer to curve 1 in Figure 3 3 After protecting the motor with the electronic thermal switch activated the AC drive is cut off immediately The OL1 light will flash To resume operation push the RESET button or activate an external reset contact wired to Terminal 2 4 When the motor is operating at low speeds the heat dissipation efficiency is lower The electron
14. easily operated from a low speed to high speed range Please reconfirm the operating range of the motor and machinery you are controlling Do not examine the signals on the PCB of the AC drive during operation All AC drives are properly adjusted and factory set before delivery A CAUTION Do not proceed with disassembly or examination procedure before ensuring that the power is off and the Power LED is extinguished CAUTION AC drive ambient temperature should be within temp 14 F 104 F 10 40 C humidity under 95 RH without condensing A CAUTION After the removal of shield sticker the AC drive ambient temperature should be within 14 F 122 F 10 C 50 C and humidity under 95 RH without condensing In addition the FM50 should be free from dripping water and or metal dust FLUXMASTER 50 INSTRUCTION MANUAL 1 2 Environmental Precautions a 2 rem 29 Avoid direct sunlight Keep away from corrosive gases or liquids Keep away from rain or where dripping water may get into the AC Drive x VAR N aN Keep away from high Keep away from radioactive matter Keep away from flammable electromagnetic waves material FLUXMASTER 50 INSTRUCTION MANUAL 2 Hardware Instructions and Installation 2 1 Operational Environment The installation site of the FM50 is very important It relates directly to the functionality and the life span of your AC dri
15. high 2 Detection circuitry defective 1 Power source voltage too low 2 Detection circuitry defective 1 Detection circuit defective 2 Environment overheat or poor ventilation 1 Non Resettable Faults CONTENT Program error EEPROM error Voltage too high while not operating Voltage too low while not operating AC drive over heat while not operating INDICATION 2 Manually Resettable Faults Not Auto resettable POSSIBLE CAUSE Detection circuit malfunction 1 Loading too large 2 Improper V F model setting 05 3 Improper F_18 setting Motor Rated Current 1 Loading too large 2 Improper V F model setting F_05 49 CONTENT Overcurrent at stop condition Motor overload AC drive overload INDICATION FLUXMASTER 50 INSTRUCTION MANUAL COUNTERMEASURE 1 Examine motor 2 Examine wiring 3 Replace transistor module 1 Adjust acceleration time to longer setting 2 Adjust to a proper V F curve 3 Replace and install another AC drive with appropriate capacity 1 Examine the loading configuration 2 Install inductor on power supply input side Adjust to a longer acceleration time Adjust to reduce settings of DC Braking F 15 F 16 0rF 17 1 Adjust to a longer deceleration time 2 Install a inductor on the power supply input side 3 Increase the capacity of AC drive 1 Improve
16. power source quality 2 Adjust to use a longer acceleration time 3 Increase capacity of AC drive 4 Install a reactor on the power supply input side 1 Examine the load 2 Increase capacity of AC drive 3 Improve ventilation POSSIBLE CAUSE 1 Motor coil short circuit with external casing 2 Motor connection wire short circuit with grounding 3 Transistor module damaged 1 Acceleration time setting too short 2 Improper V F function selection 3 Applied motor capacity exceeds AC drive capacity 1 Transient change in load 2 Transient change in power supply Deceleration setting too short DC Braking frequency braking voltage or braking time setting too long 1 Deceleration time setting too short or inertial loading too large 2 Power supply voltage variation too large 1 Power supply voltage too low 2 Power supply voltage variation too large 1 Loading too heavy 2 Ambient temperature too high or poor ventilation 50 3 Manual and Auto reset Faults CONTENT Transient overcurrent at start Overcurrent at acceleration Overcurrent at steady speed Overcurrent at deceleration Overcurrent at braking Overvoltage at operation deceleration Insufficient voltage level at operation Heat sink over heated at operation INDICATION FLUXMASTER 50 INSTRUCTION MANUAL INDICATI
17. the WA buttons on the keypad are disabled Original settings will be restored after the SP1 connection or jog input is removed NOTE 2 During the contact closure of the jog function the keypad control remains inactive until the jog contact connection is reopened OmA 4mA 20mA 41 FLUXMASTER 50 INSTRUCTION MANUAL F 12 Carrier Frequency 10 Carrier Frequency B Carrier Frequency Carrier Frequency 8 kHz 15 kHz 1 10 kHz 1 16 kHz 1 12 kHz 1 14 4 kHz 1 NOTE 1 Available for CPU version V1 9 and above 2 _12 7 10 the inverter must operate with light loads Although an IGBT TYPE AC drive can provide a low audible noise level during its operation it is possible that the switching of the high carrier frequency may interfere with external electronic components or other controllers or even cause vibration in the motor Adjusting the carrier frequency can usually correct this problem 13 Torque Compensation Gain 0 10 To enhance AC drive output torque patterns according to the B C voltage points on the V F pattern refer to F_05 description and the F_13 for this feature Voltage 100 1 2 5 3 0 50 60 NOTE When 13 0 the torque boost function is disabled 42 FLUXMASTER 50 INSTRUCTION MANUAL 14 Stopping Method 0 Controlled deceleration stop 1 Coast to stop 15 DC Braking
18. 50081 2 EN50178 EN61800 3 All UL508C 150 for 1 minute DC Bus voltage gt 410V 100 200 series DC Bus voltage gt 800V 400 series DC Bus voltage lt 200V 100 200 series DC Bus voltage lt 400V 400 series Power loss 0 2 sec AC drive can be restarted with Speed Search During Acceleration Deceleration Constant speed Electronic circuit protection Electronic circuit protection Heatsink overheat protection Current limit Direct installation or DIN rail Option Frequency Range Resolution Setting Keypad Setting External Signal Setting Other Function Carrier Frequency Accel Decel Time V F Pattern Torque Control Multi Function Input Multi Function Output Braking Torque Built In Functions Input Signal Type Control Method Frequency Control Control Characteristics Display Operating Temperature Overload Protection Overvoltage Undervoltage Momentary Power Loss Stall Prevention Output Short circuit Ground Fault Other Protection Humidity Vibration EMC Specification UL Protection Function Installation Note 1 CPU version v1 9 and above 2 Carrier Frequency Range CPU Version v1 6 is 4 8kHz CPU Version v1 9 and above are 4 16kHz FLUXMASTER 50 INSTRUCTION MANUAL 2 3 3 Options and Wiring Specifications Molded Case Circuit Breaker Magnetic Contactor
19. 7 mln f 1 2 27 Ventilation Ventilation amp Installation Direction Front View Note Maximum temperature in the enclosure is 122 F 50 C with Shield Sticker removed 2 2 Sample Model No Identification C Chassis N4 NEMA 4 OC Chassis with Filter N4FS NEMA 4 with Operator Devices Fuso x xx Drive Type Voltage 1 115V 2 230V 4 460 Horsepower P2 1 4 03 FLUXMASTER 50 INSTRUCTION MANUAL 2 3 SPECIFICATIONS 2 3 1 Product Specifications 50 Suitable Motor Power Rating KW 02 04 Motor HP 1 4 1 2 Output Current A 14 2 3 Capacity KVA 0 53 0 88 Weight Ib 2 2 Input Voltage Max Single Phase 100 120V 1 0 1 5 50 60Hz 5 Output Voltage Max Three Phase 200 240V Proportional to input voltage Dimension H W D inches 5 20 x 2 84 x 4 65 EMC Specification Without Filter Rated Model FM50 Suitable Motor Power Rating KW Motor HP 1 Output Current A 2 3 4 2 7 5 0 75 Capacity KVA 0 88 1 6 29 Weight 16 2 2 5 Input Voltage Max Single Three Phase 200 240V 4 1096 15 50 60Hz 5 Output Voltage Max Three Phase 200 240V Proportional to input voltage Dimension H W D inches 5 20 x 2 84 x 4 65 5 63 x 4 65 x 4 65 x 6 77 EMC Specification Without Filter Model FM50 Suitable Motor Power Rating KW Motor HP Output Current A Capacity
20. B of the AC drive FLUXMASTER 50 INSTRUCTION MANUAL 2 Examination Before Installation Every AC Drive has been fully tested and examined before shipment Please carry out the following examination procedures after unpacking your FM50 AC Drive 1 Check to see if the model number of the AC Drive matches the model number that you ordered 1 Check to see whether any damage occurred to the AC Drive during shipment Do not connect the AC Drive to the power supply if there is any sign of damage Contact your local distributor or regional sales representative if you find any abnormal conditions as mentioned above FLUXMASTER 50 INSTRUCTION MANUAL 1 Safety Precautions 1 1 Precautions For Operation Before Turning On Power A CAUTION Choose the appropriate power source with correct voltage settings for the input voltage specification of the AC drive WARNING Special care must be taken while wiring the primary circuitry panel The L1 and L2 terminal must be connected to the input power source and must not mistakenly connected to T1 T2 or T3 output terminals This may damage the AC drive when the power is turned on A CAUTION Do not attempt to transport the 50 by the front of the cover Securely hold AC Drives by the heat sink mounting chassis to prevent it from falling This may cause personal injury or damage to the AC drive 1 Install the drive onto a firm metal base plate or anothe
21. Is the operation Switch to RUN Switch on the RU position position YES NO any output voltage 50 malfunction T1 T2 T2 T3 T3 T1 NO gutput voltage balanced FM50 malfunction YES When the motor is not connected and the voltage differences between wires are within 3 consider system as balanced Motor overload Defective motor Poor wiring 57 Reduce loading Increase FM50 and motor capacity Select another motor 50 malfunction Remove obstacles affecting motor cooling Correct the connection 58 YES YES NO YES YES FLUXMASTER 50 INSTRUCTION MANUAL 2 Motor overheat Is there overloading condition or does the load current exceeds rated current NO Extended operation at low speeds voltage level between T1 T2 T2 T3 and normal YES Is there anything that might affect motor cooling Poor connection between FM50 and motor FLUXMASTER 50 INSTRUCTION MANUAL Is the Increase or decrease acceleration deceleration time YES Reduce load Increase FM50 and motor capacity FM50 malfunction acceleration deceleration time setting appropriate 3 Unstable motor operation Does this occur during acceleration or deceleration YES NO Is the voltage level between T1 T2 T2 T3 and T3 T1 normal NO YES The differen
22. ON CONTENT DESCRIPTION When speed 11 0 Frequency lower limit F_7 0 and frequency setting gt 1Hz Zero Speed Stopping When speed F_11 1 Frequency lower limit F_7 lt F_6 100 and frequency setting lt Frequency upper limit F_6 100 1 If the inverter is set to external operation F_10 1 and direct start is disabled 28 1 the AC drive cannot be started and will flash Failure to start directly SP1 when the run command is attempted after applying power see descriptions of F_28 power up start 2 Direct start is possible when F_28 0 The inverter setup to external operation F_10 1 the STOP Keypad emergency key in the keypad is pressed during operation the AC drive stops according the stop stop method F_14 and flashes 5 2 after stop The RUN switch must be turned OFF then ON to restart the machine When the external emergency stop signal is activated through the multi function input terminal the AC drive decelerates and stops E S flashes after AC drive stops Refer to instruction for F_19 for detail When the external BASE BLOCK signal is activated through External BASE BLOCK the multi function terminal the AC drive stops output immediately and flashes b b for indication Refer to instruction for F_19 for detail External emergency stop Keypad Operation Error Instruction INDICATION CONTENT POSSIBLE CAUSE COUNTERMEASURE Attempt to reverse direction 1 Adjust F_22 0 Mot
23. X units with operator devices 2 Power supply cable 12 AWG 3 5mm 3 Motor cable 16 AWG 1 25 2 4 Tightening torque values for terminals 1 Power Motor cable plug in terminal 4 34in Ib 5kg cm 2 Remote control wire 3 47 4kg cm 3 Outer cover M4 5 20in Ib 6kg cm 5 Input source single phase or three phase L1 L2 L3 ensuring that it is connected to a 200 230V or a 400 460V supply Models FM50 202 N4FS 8 FM50 203 N4FS with operator devices are single phase input only 6 Output motor three phase T1 T2 T3 CAUTION Do not start or stop the AC drive using the main circuit power NEMA 4X with operators Always maintain REV 0 FWD switch at 0 position This will ensure that the AC drive is stopped before power up again after power supply interruption Otherwise injury may result to personnel 29 FLUXMASTER 50 INSTRUCTION MANUAL CONNECTION FM50 NEMA IP65 Indoor Duty 230V 2 3HP 460V 1 3HP models 4 Outer cover screw MOUNTING Power supply cable 3 Motor cable 3 Ferrite Core NOTE For ALL MODELS WITH FILTERS additional items will be found inside the box including QTY 1 of EMC waterproof conformed IP65 ferrite core OTY 1 of metal fastener QTY 1 of MF Zin 5 C screw If the regulation must met constrain the motor cables with the ferrite core onto the motor cable outside the plastic enclosure as indicated in the above diagr
24. am Please Note The length of the motor cable CANNOT exceed 5M under EMC regulation 30 FLUXMASTER 50 INSTRUCTION MANUAL CONNECTION FM50 NEMA 4X IP65 Indoor Duty with operators 230V 2 3 460V 1 3HP models 4 x Outer cover screw pee ee E 31 FLUXMASTER 50 INSTRUCTION MANUAL EMC MOUNTING NEMA 4X IP65 Indoor Duty with operators 230V 2 3HP 460V 1 3HP models p Power supply ut Pun oe cable pou 111213 Ze d _ m Motor cable TA 3 32 AC Drive with class B filter amp rail AC Drive with class B filter mounted 2 p rm o c c o lt lt gt W e un cc LU lt 26 LL FLUXMASTER 50 INSTRUCTION MANUAL Step1 Use a small screwdriver inserting it into the middle rib of DIN rail and press the screwdriver in order to remove the DIN rail from the AC drive pull mounting plate 1 be pe lt gt Inserting hole 1 Din Mounting Diagram Step 1 Aim and insert the 4 retention ribs of the DIN rail at the 4 holes in rear panel of AC drive Step 2 Push the DIN rail forward until the middle rib grips firmly with back panel DIN Rail Installation A mounting clamp and a 1 38 width rail must be used to install the dri
25. arameters Carry out parameter initialization Designate operation control method Frequency instruction setting Does the controller display equency setting Replace control board Is there voltage output on UVW terminals Connect to motor and proceed with operation Is there any abnormality indication Replace control board No The problem is not corrected Does replacing control board correct the problem Yes the problem has been corrected YES output current of all phases balanced YES The Drive 15 Operating Correctly The Drive is defective Detailed examination is required 54 FLUXMASTER 50 INSTRUCTION MANUAL Error handling of fault indication of OC OL Inverter displays Fault indication OC OL Is the primary NO circuit I G B T Replace G B T YES NO Is the appearance Replace defective PCB YES Switch ON power supply Is there any Fault indication YES 15 the current NO detector normal NO Input operation instruction YES Replace control board Input frequency setting Is the output frequency E Replace control board displayed Replace detector YES Is there output voltage on UVW terminals NO Replace control board Does replacing control board correct thi NO Connect motor and proceed with operation Is there any Fault indication
26. ces between different wires are within 3 Reduce loading variation or install fly wheel Improve mechanical system FM50 malfunction 59 Is there any loading YES ariation condition NO 15 there any excess vibration YES at transmission parts uch as gears NO FLUXMASTER 50 INSTRUCTION MANUAL Routine and Periodical Examination AC Drive requires routine and periodical examination and maintenance Carry out the examination only after the Power LED indicator goes off for at least 5 minutes Countermeasure Improve environment Installation site environment Tighten loose screws Improve grounding Improve input power source Tighten loose screw or return for repair Replace or return for repair Clean up dust or dirt Clean up or replace PCB Replace cooling fan Clean up Clean up Replace capacitor or inverter Criterion Temperature 10 40 C Humidity under 95 non condensing No foreign object No foreign object Resistance under 100 ohm to ground Voltage level conforming specification No abnormality No abnormality No abnormality No abnormality No abnormality No abnormality No abnormality Examination Refer to installation instructions and measure with thermometer and hygrometer Visual inspection Visual and audio Inspection Measure resistance by multi meter Measure voltage by multi meter Visual inspecti
27. dels 4 x Outer cover screw Motor cable Plug in terminals MOUNTING Motor cable T1 T2 T3 26 FLUXMASTER 50 INSTRUCTION MANUAL DIMENSIONS FM50 NEMA 4X IP65 Indoor Duty with operators 230V 2 3HP 460V 1 3HP models 8 32 211 4mm 832 211 4 7 11 180 5 0 2 5mm 27 FLUXMASTER 50 INSTRUCTION MANUAL INSTALLATION FM50 NEMA 4X IP65 Indoor Duty with operators 230V 2 3HP 460V 1 3HP models POWER SWITCH Potentiometer REV 0 FWD SWITCH 111213 220 240V 380 460 Single Three Phase NOTE 1 Power switch REV 0 FWD switch and potentiometer are only for NEMA 4X units with operator devices 2 Power supply cable 230V 12 AWG 3 5mm 460V 16 AWG 1 25mm 3 Motor cable 230V 14 AWG 2 0mm7 460V 16 AWG 1 25mmv 4 Tightening torque values for terminals 1 Power Motor cable TM1 TM3 Terminal 6 94in Ib 8kg cm 2 Remote control wire 3 47 4kg cm 3 Outer cover M4 6 94in Ib 8kg cm Models FM50 202 N4FS amp FM50 203 N4FS with operator devices are single phase input only 28 FLUXMASTER 50 INSTRUCTION MANUAL CONNECTION Circuit Diagram NEMA 4X IP65 Indoor Duty with operators 230V 2 3HP 460V 1 3HP models POWER switch 200 240 50 60 2 380 460 REV 0 FWD SWITCH Potentiometer NOTE 1 Power switch REV 0 FWD switch and potentiometer are only for NEMA 4
28. gnal 3 F 21 3 Fault signal Terminals 1 and 2 of TM2 are activated for the following faults OL2 OCS OCA OCC Ocb OVC LVC OHC Refer to Section 4 for information on faults 45 FLUXMASTER 50 INSTRUCTION MANUAL Hz Time F 1 Terminal 1 amp 2 F 21 2 Terminal 1 amp 2 F 22 Reverse Lockout 0 REV run command enabled 1 REV run command Lockout NOTE When 04 motor rotation direction is set to 1 reverse 22 cannot be set to 1 In order to properly lockout a motor direction 04 must be set at 0 before setting 22 to 1 23 Auto restart after Momentary Power Loss 0 Auto restart enabled 1 Auto restart disabled 1 When the AC power supply is temporarily below low voltage protection levels due to low line supply or unusually large demands on the power supply system the AC drive will stop immediately If the voltage level recovers within 2 seconds the AC drive can restart by using its speed search program 2 When 23 0 1 If the momentary power loss is less than 2 seconds the AC drive resumes operation automatically via speed search at 0 5 seconds after power up The number of auto restart times is not limited by 24 2 If the momentary power loss is long the operation of the AC drive is based on the setting of F 10 and the condition of the external switch 3 If the time of momentary loss is between the above two condit
29. h operators 115V 230V 1 4 1HP models POWER switch AC Single Phase 50 60 2 REV 0 FWD SWITCH Potentiometer NOTE 1 Power switch REV 0 FWD switch and potentiometer are only for NEMA 4X units with operator devices 2 Power supply cable 14 AWG 2 0mm 3 Motor cable 16 AWG 1 25mm 4 Tightening torque value for terminals 1 Power Motor cable plug in terminal 4 34in Ib 5kg cm 2 Remote control wire 3 47 4kg cm 3 Outer cover M4 5 20in Ib 6kg cm Input source single phase L1 L2 make sure that it is connected to the appropriate power supply 6 Output motor three phase T1 T2 T3 A CAUTION Do not start or stop the AC drive using the main circuit power NEMA 4X with operators Always maintain REV 0 FWD switch at 0 position This will ensure that the AC drive is stopped before power up after power supply interruption Otherwise injury may result to personnel 24 FLUXMASTER 50 INSTRUCTION MANUAL CONNECTION FM50 NEMA 4X IP65 Indoor Duty 115V 230V 1 4 1HP models 4 x Outer cover screw Motor cable T1T2 T3 MOUNTING Power supply cable L1 L2 2 Motor cable 83 Cable shielding connected to ground clamp Note TM2 Remote control cable should be connect to ground screw 25 FLUXMASTER 50 INSTRUCTION MANUAL CONNECTION FM50 NEMA 4X IP65 Indoor Duty with operators 115V 230V 1 4 1HP mo
30. ic thermal activation level is also reduced to change from curve 1 to curve 2 in Figure 3 Choose the appropriate F 05 setting according to the applied motor to reach the desired performance 43 FLUXMASTER 50 INSTRUCTION MANUAL 2 The electronic thermal protection for the AC Drive is as follows 1 When the load is within 10396 of the AC drive rated current the operation continues When the load reaches 15096 of rated current of the AC drive the operation will continue for 1 minute Refer to curve 1 of figure 3 2 After the activation of the electronic thermal switch the AC drive is shut off immediately The OL2 light will flash To resume the operation push RESET button or activate an external reset contact wired to Terminal 2 05 3 05 6 50Hz standard motors 60Hz standard motors Decay 96 Decay 96 Time Min 100 90 60 100 90 60 96 of 20 50 20 60 100 150 current In Percentage of Current Figure 1 Figure 2 Figure 3 19 Multi Function Input Terminal 1 1 5 1 6 CPU version v1 9 and above 20 Multi Function Input Terminal 2 1 5 1 6 CPU version v1 9 and above 1 F_19 1 or 20 1 JOG control refer to 09 Jog Frequency Setting 2 19 F 20 2 or 6 Multi speed control refer to 08 F 26 F 27 Multi speeds 1 3 settings 19 2 amp F 20 6 2 5 1 Terminal 2 SP1 Terminal Output Frequency 19 6 amp F 20 2 2
31. ill stop at 0 speed If 07 gt OHz the AC drive will output a minimum speed according to the setting in 07 08 SP1 Frequency 1 200Hz F_09 JOG Frequency 200Hz 1 When F_19 or F_20 2 multi function input setting and the multi function input terminal is ON the inverter operates at SP1 frequency F_08 2 When F_19 or F_20 1 multi function input setting and the multi function input terminal is ON the inverter operates at JOG frequency F_09 3 When multi function input terminals 1 and 2 are configured for SP1 frequency and JOG frequency the priority of the frequency setting is JOG SP1 Keypad setting external frequency signal using a speed pot 40 FLUXMASTER 50 INSTRUCTION MANUAL 10 Start Stop Control 0 Keypad 1 Terminal TM2 NOTE When 10 1 Terminal Control emergency stop on the Keypad is enabled To avoid injuries to personnel or equipment damage when 10 1 please refer to the descriptions of 23 24 Momentary power loss ride through and number of auto restart attempts Priority of selections for JOG multi function and keypad external frequencies 11 Frequency Control 0 Keypad 1 Analog Speed Pot Terminal TM2 0 10V 0 20mA 2 Analog Speed Pot Terminal TM2 4 20mA NOTE 1 If the jog when start stop control is set to keypad run or SP1 frequency is switched on the frequency is set F 06 by SP1 speed and the frequency set up via
32. ions whether the AC drive will auto restart depends on F 24 F 24 0 Auto restart disabled F_24 1 5 Auto restart enabled 1 5 times 46 FLUXMASTER 50 INSTRUCTION MANUAL When 23 1 1 Power up after momentary power loss the AC drive will not start Even 24 gt 0 2 If the momentary power loss is long the AC drive must be restarted manually The operation of the AC drive is based on the setup of F 10 and the condition of external switch When restarting the AC drive the operation of the AC drive is based on the setup of F 10 start stop control and the condition of external switches FWD REV button 1 When 10 0 the AC drive will not restart 2 WhenF 10 1 and the external switch FWD REV button is OFF the AC drive will not restart 3 When 10 1 and the external switch FWD REV button is ON the AC drive will automatically restart Attention Based on safety issues please turn off the external switch FWD REV button after power loss to avoid possible damage to personnel and the machine after sudden regeneration of power 24 Number of Auto Restart Times 0 5 When 24 0 the AC drive will not auto restart after a fault recovery Except for momentary power loss please refer to 23 for details When 24 1 5 the AC drive will resume operation via speed search at 0 5 seconds under auto restart after fault recovery Except for momentary power l
33. lder a conductor to the shielding 1 Use a metal clamp to connect the shielding from the motor cable with the metal grounding plate This ensures a perfect high frequency earth connection between AC drive grounding plate and EMI filter Keep the distance between the AC drive and EMI filter as short as possible lt 11 8 longer use a shielded cable with a metal coupling nut and a metal clamp to connect the shielded cable to the AC drive and metal grounding plate 1 The only earth connection between the LISN and the test plate should be via the EMI filter Use a motor rated at or below the AC drive rating Install a noise filter for AC drive on the output side of the primary circuit to suppress conducting noise Class B Maln Transformer Power Systeme DS Metol plate or panel MCCB Power Port EMI FILTER Drive R H 1 Above 12 Inch Signal wire Control machine Filter Optional 15 FLUXMASTER 50 INSTRUCTION MANUAL When the distance between the AC drive and motor is longer than 330ft 100m cable wire should be carefully chosen to reduce the wiring resistance below 3 and the voltage drop V 3 Wire resistance 52 ft x wire length ft x current Control circuitry wiring must be separately terminated and away from the primary power circuitry and other high voltage or large current power lines to avoid noise interference
34. lly those paragraphs with WARNING or CAUTION symbols They are important safety precautions to be aware of while transporting installing operating or examining the AC drive Please follow these precautions to ensure your safety WARNING Personal injury may result from improper operation CAUTION The AC Drive or mechanical system may be damaged by improper operation WARNING 1 Do not touch the or components the PCB right after turning off power and before the charging indicator goes off Do not attempt to wire circuits while power is Do not attempt to examine the components and signals on the PCB while the AC drive is operating 1 Do not attempt to disassemble modify internal circuitry wiring or components of the AC drive The grounding terminal of the AC drive must be grounded properly with 200V class type III standard This is a product of the restricted sales distribution class according to EN61800 3 1 This product may cause radio interference The user may be required to take adequate measures for protection A CAUTION Do not attempt to perform dielectric strength tests on internal components of the AC Drive There are sensitive semiconductor devices vulnerable to high voltages 1 Do not connect the output terminals T1 U T2 V and T3 W to AC power input The CMOS IC on the primary PCB of the AC drive is vulnerable to static electrical charges Do not touch the primary PC
35. n 2 of potentiometer or positive terminal of 0 10V Wiper 4 20 0 20mA Analog signal common point Pin 1 of potentiometer or negative terminal of 0 10V 4 20mA 0 20mA Analog output positive Analog frequency signal output terminal connection point Output terminal signal is 0 10VDC Fn_6 Analog common Tightening torque for TM2 is 0 420 or 5 03lbs in Wire voltage rating must be a minimum of 300V Control wiring should not run in the same conduit or raceway with any power or motor wiring Single Input and Output Terminals TM2 Ratings are ALL Class 2 Use copper conductors only Size field wiring based on 167 F 75 C wire only FLUXMASTER 50 INSTRUCTION MANUAL SW1 Function Description External Signal Type 0 20mA analog signal When F_11 is set to 1 4 20mA analog signal When F_11 is set to 2 0 10VDC analog signal When F_11 is set to 1 2 5 Dimensions amp Location of Terminal Block 115V 1 4 1HP 230V 1 4 1HP models Unit inches wos 6 NOTE For safety reasons we strongly recommend removing the M4 grounding screw then attach the enclosed metal frame grounding terminal on the same location to make a grounding bar to ensure proper grounding 20 FLUXMASTER 50 INSTRUCTION MANUAL 230V 2 3HP 460V 1 3HP Unit inches 6 76 6 76
36. ng capacitors LC or RC components between the AC drive and the motor FLUXMASTER 50 INSTRUCTION MANUAL 2 3 4 Application and Recommendations for Installing Auxiliary Equipment From the Power Source Apply the power source at the correct rated voltage to prevent damage to the AC drive Power Disconnect or Circuit breaker must be installed between the AC power supply and the AC drive Molded Case Circuit Breaker Utilize an appropriate circuit breaker that is suitable for the rated voltage and current ratings of the AC drive to switch ON OFF the power supply to the AC drive and as additional protection for the AC drive Do not operate the circuit breaker to switch ON or OFF the AC drive The circuit breaker should be used only to supply input power and should not be used for operational sequences Ground Fault Circuit Breaker 1 To ensure personnel safety a ground fault circuit breaker should be added to prevent false operation caused by leakage current Magnetic Contactor The Magnetic Contactor is not required for standard operation To utilize external control automatic restart or breaking controller the magnetic contactor must be added at the primary side Do not operate the magnetic contact to switch ON or OFF the AC drive Power Quality Improvement AC Reactor large capacity power source is applied over 600KVA an additional AC reactor may be added to improve the po
37. ng paragraphs 1 When the momentary power loss is short the AC drive still has enough storage power to control the circuit therefore when power is restored the drive will automatically start operation again depending on the setup of 23 When restarting the drive the operation is based on the setup of F 10 and the condition of external switch FWD REV button Attention the restart operation is determined by 23 and 24 1 When 1020 the AC drive will not start in restart mode 2 When 10 1 and the external switch FWD REV button is OFF the inverter will not start in restart mode 3 When 10 1 and the external switch FWD REV button is ON the inverter will start automatically in restart mode Attention Based on safety please turn off the external switch FWD REV button after power loss to avoid possible damage to the machine and personnel after sudden restoration of power Under Operation Hi WARNING Do not use a separate device to switch motor ON or OFF during operation Otherwise the AC drive may experience an overcurrent breakdown Hi WARNING 1 To avoid personal injury caused by electrical shock do not remove the front cover of the AC drive while the power is ON When the automatic restart function is enabled the motor and machinery will be restarted automatically FLUXMASTER 50 INSTRUCTION MANUAL A CAUTION Do not touch the heatsink base during operation The FM50 can be
38. on Use screwdriver to verify screw tightness Visual inspection Visual inspection Visual inspection Visual and audio inspection Visual inspection Visual inspection Visual inspection 60 EXAMINATION Period Method Routine 1 Year Maintenance Description Reconfirm environment temperature and humidity Check and remove any flammable material nearby Is there any abnormal vibration on the installation site Is the grounding resistance within acceptable range Is the voltage of the primary circuitry normal Are the tightened parts secured Is there any sign of breakage on the terminal panel Is there any visible rust Is it deformed or skewed Is the insulation of wire broken Is it accumulating dust or dirt Is it accumulating conductive metals or oils Is there any overheated or burnt components Is there any abnormal vibration or noise Is it accumulating dust or dirt Is it accumulating dust or dirt Is there any sign of strange odor or leakage Is there any sign of swelling or bulging Maintenance Item Installation Site Environment AC Drive Installation and Grounding Input Power Source Voltage AC Drive Terminal Mounting Screws Internal Wiring of Inverter Heatsink Cooling Fan Power Component Capacitor FLUXMASTER 50 INSTRUCTION MANUAL 4 3 Maintenance and Examination F
39. or direction locked when F_22 reverse disable 1 2 Adjust F_04 to 0 Attempt to set F_22 to 1 when F_04 1 motor rotation direction Press A or V keys when _11 1 or under SP1 operation 1 Use A or V keys to adjust frequency Keypad operation error Attempt to modify F 29 setting only after F 11 0 Attempt to modify parameter keypad model that is not allowed to be modified 2 Do not modify F 29 during operation 3 Modify in stop mode only refer to parameter list F 6 F 7 upper frequency limit lt lower frequency limit Parameter setting error 1 SetF 65 F 7 51 FLUXMASTER 50 INSTRUCTION MANUAL COUNTERMEASURE 1 Check if the power source is on Turn power source OFF and then ON again Reconfirm the power voltage level l Turn power source OFF and then ON again Check motor wiring Refer to fault handling instructions to examine and correct wiring Check parameter 22 Check to see if wiring for analog frequency input signal is correct Check if the frequency input setting voltage is correct 1 Correct with motor rotation direction setting Fn 04 or FWD REV key 1 Wiring should be in accordance with the U V W terminals of motor l Examine the wiring and correct it 1 Check the Operation panel Reduce loading Reconfirm motor specification Reconfirm gear ratio Reconfirm highest out
40. oss please refer to 23 for details When the AC drive is set to deceleration or DC braking the transient restart procedure is not performed If either of following situations should develop the auto restart times will be reset 1 No additional faults in operation or stop occurs within 10 minutes 2 Press RESET button 010 Constants initialization to 50112 system F 25 Restore to Factory Settings 7 y _ 020 Constants initialization to 60112 system When 25 is set to 010 all parameters are restored to factory settings The settings of 05 1 and 06 50 F 25 is restored back to 000 after the reset process is complete 50Hz operation When 25 is set to 020 all parameters are restored to factory settings The settings of 05 4 and 06 60 F 25 is restored back to 000 after the reset process is complete 60Hz operation 47 UJ FLUXMASTER 50 INSTRUCTION MANUAL 26 SP2 1 200Hz Multi speed 2 Refer to 19 F 20 27 SP3 1 200Hz Multi speed Refer to 19 F 20 28 Power Up Start 0 Power Up start enabled when remote Run command on 1 Up start disabled when remote Run command on CPU version V2 1 and above When 28 1 and control mode is remote control 10 1 the AC drive can not start if the RUN switch is ON when power is engaged The run signal must be toggled off then on to run the AC drive F 29 CPU Program Ver
41. put frequency 1 Cheek wiring to motor Check DC bus voltage Reduce loading variation Increase AC drive and motor capacity Install AC reactor on the power supply input side CHECK POINT Is the power source voltage delivered to L1 L2 terminal is the charging indicator illuminated Is there voltage output from output terminal T1 T2 and T3 Is the motor wired correctly Is there any abnormal condition in the AC drive Has reverse rotation been disabled Is the analog frequency setting loaded Is the operation mode setting correct Is wiring on the output terminals T1 T2 and T3 correct Is the wiring for the forward and reverse signals correct Is the wiring for analog frequency input correct Is the operation mode setting correct Is the loading too heavy Is the specification of motor poles voltage correct Is the gear ratio correct Is the highest output frequency setting correct 15 the voltage on motor side significantly reduced Is the loading too heavy Is the loading variation too large Is the input power source steady and stable 52 CONDITION Motor Inoperative Motor Inoperative Motor runs in opposite direction Motor run speed does not change Motor runs at speed too high or too low Abnormal speed variation at operation FLUXMASTER 50 INSTRUCTION MANUAL 4 Troubleshoo
42. r non flammable type material Do not install the drive on or near any flammable material An additional cooling fan may need to be installed if several drives are installed on one control panel The temperature inside an enclosed panel should be below 40 6 104 F to avoid overheating Turn off the power supply before proceeding to remove or perform any work on any panel Carry out installation procedures according to instructions given This will help avoid a situation resulting in an operational malfunction The AC Drive is suitable for use on a circuit capable of delivering not more than 5000 RMS symmetrical amperes This product is not provided with overspeed protection This product is only intended for use in a clean dust and moisture free environment FLUXMASTER 50 INSTRUCTION MANUAL When Power is Applied H WARNING Do not attempt to install or remove input or output connectors of the AC drive when the power supply is turned on Otherwise it may be damaged due to the surge peak caused by the insertion or removal of power 1 When momentary power loss is longer than 2 seconds the larger the horsepower the the longer the time the AC drive does not have enough storage power to control the circuit therefore when power is restored the operation of the AC drive is based on the setup of 10 and the condition of external switch This is considered to be a restart as pertaining to the followi
43. requent examination and maintenance is not required for the FM50 To maintain appropriate reliability please proceed with the following periodical examination Remember to turn off the power supply and wait until the Power LED goes off before proceeding Due to the large amount of residual charge in the internal capacitors 1 Clean out internal dust and dirt 2 Check mounting screws on every terminal and part Tighten loose screws 3 Dielectric strength test a Remove all conducting wires between the Drive and the outside world Power must be turned OFF b The dielectric strength test inside the Drive should be carried out only for FM50 major circuitry Use a DC 500V high resistance meter Measured resistance should be higher than 100M ohm A CAUTION Do not perform dielectric strength test to the control circuit 50 L2 S Drive T2 V Input Power Source Grounding Terminal 61 FLUXMASTER 50 INSTRUCTION MANUAL 4 4 Voltage Current Measurement The voltage and current measurement on the primary and secondary side of the AC drive may be different due to instrumentation variations Refer to following diagram for measurement Single Phase Power Supply Different kinds of instruments MEASUREMENT MEASURING POINT INSTRUMENT nore MEASUREMENT CRITERION Input Voltage Moving iron VI Input Current Moving iron li i cd Power meter Input Power
44. sion F_30 Fault log for last three faults 1 Last three faults indicate the sequence of the occurrence of faults by the location of decimal point x xx indicates a recently occurred fault xx x indicates the prior fault event xxx Indicates the earliest fault in the record 2 After entering the F 30 function the x xx trip record will be displayed first After that press button and you can read activity in a chronological order xx x gt x xx consecutively 3 After entering 30 function if the RESET button is pressed the trip record will be cleared Indication display and results 4 When the content of trip indicates O CC it will indicate the latest trip code is OC C and so on 48 FLUXMASTER 50 INSTRUCTION MANUAL COUNTERMEASURE Install a RC surge absorber in parallel with the noise generating magnetic contact Replace EEPROM 1 Examine the power supply 2 Return the AC drive for repair 1 Examining the power supply 2 Return the AC drive for repair 1 Return the AC drive for repair 2 Improve ventilation COUNTERMEASURE Return the AC drive for repair 1 Increase capacity of motor 2 Adjust to use a proper V F curve setting 3 Adjust 18 according to instruction 1 Increase capacity of AC drive 2 Adjust to use a proper V F curve setting POSSIBLE CAUSE Outside noise interference EEPROM defective 1 Power source voltage too
45. te Reverse command is ignored when 22 1 Reverse lockout F 04 Motor Rotation Direction Setting 0 Forward 1 Reverse Although there is no Forward Reverse pushbutton on the digital control panel it is possible to adjust forward reverse function by changing the F 04 setting NOTE When 22 1 Reverse is disabled F 04 cannot be set to 1 The keypad indication will display LOC NOTE 04 takes effect only when 10 0 Keypad start stop control mode 38 FLUXMASTER 50 INSTRUCTION MANUAL Decreasing Torque 3 F_05 V F Pattern Setting 1 6 Select F_05 1 6 to select one of the six preset V F patterns refer to the following tables Specification 50Hz System Application General Application High Starting Torque F5 2 50Hz System V F pattern Specification 60Hz System Application High Starting Torque F5 5 60Hz system V F pattern 896 10 5 7 7 39 FLUXMASTER 50 INSTRUCTION MANUAL 06 Frequency Upper Limit Range 1 200Hz F_07 Frequency Lower Limit Range 1 200Hz F_06 Factory setting refer to F_25 7 vL F 06 Freq Upper Limit Internal Frequency Signal fo 7 F 07 Fre Lower Limit Note 1 Frequency Setting Signal NOTE If 07 OHz the frequency instruction is equal to OHz the AC drive w
46. ting Procedures 4 1 Flow Chart Examine component for sign of burn or breakage Replace DM circuitry L G B T Replace G B T normal 707 0 8 Replace current surge absorber Examining terminals and wiring Replace driver board AC Drive Fault Detailed examination required Any sign of burn or breakage NO Is the primary NO circuitry DM normal Is the primary YES Replace defective board NO Does LED2 illuminate YES DC input voltage of control power upply normal NO YES Is the control power source 45V normal NO NORMAL Replace control board digital controller Does replacing control board solve the problem NO YES 53 Drive Fault Clearly defined Fault NO YES Sign of burn NO or breakage YES NO Indication of abnormality Proceed examination according to Fault indication Control board driver board carry out visual inspection Appearance YES abnormal NO Switch power ON NO Any illuminated indicator on the control panel YES NO Any Fault indication Fault YES indication Review the Fault Log Three Fault YES records in Fn 30 Check to see the three Fault records in Fn 30 Continued FLUXMASTER 50 INSTRUCTION MANUAL Continued Examine AC Drive p
47. ucessssueceessaneces 37 3 4 Malfunction Indication and 49 3 5 General Malfunction Examination Method 52 4 Troubleshooting Procedure 53 4 2 Routine Examination and Periodical Examination csscssssssssssssssesssssssesssssssesssssssesssssssessssssecsssssseccesssseccessssecessssecsesssssccessassesssssnseessssseeessensecss 60 4 3 Maintenance Examination 7 61 62 4 5 EMI Filter Class B 63 4 6 DIN Specification ES EE 63 4 7 Specification of Braking Resistor and Input Reactor 63 4 8 Specification of Braking Resistor 49 Parameters FLUXMASTER 50 INSTRUCTION MANUAL Forward To fully employ all functions of this AC drive and to ensure the safety for its users please read through this operations manual in detail Should you have any further questions please feel free to contact your local distributor or regional sales representative 1 SAFETY PRECAUTION The AC Drive is a power electronic device For safety reasons please read carefu
48. ve Please carefully choose an installation site that meets the following requirements Mount the unit vertically Environment temperature 14 F 104 F 10 C 40 C without shield sticker 14 F 122 F 10 50 C Avoid placing FM50 close to any heating equipment Avoid dripping water or humid environment Avoid direct sunlight Avoid oil grease and gas Avoid contact with corrosive gases and liquids Prevent foreign dust flecks or metal scraps from contacting the AC drive Avoid electric magnetic interference soldering or power machinery Avoid excessive vibration if vibration cannot be avoided an anti rattle mounting device should be installed to reduce vibration If the FM50 is installed in an enclosed control panel please remove the shield sticker located at the top of the AC drive This will allow additional airflow and cooling External Fan Placement Needs To Be Located Over The Top Of The FM50 Cooling Fan Cooling Fan Cooling Fan Cooling Fan Correct Alignment Incorrect Alignment Correct Alignment Incorrect Alignment 1 For proper Installation of the FM50 you must place the front side of the AC Drive facing front and the top of the AC drive in the up direction for better heat dissipation 1 Installation must be compliant to the following requirements FLUXMASTER 50 INSTRUCTION MANUAL 2 0 CmIn5 Side View 4 72 Cmin gt Installation direction 4 72 min 2 2
49. ve on the rail 3 5 lt A screwdriver 1 Pull the mounting plate downward 2 Rotate the inverter module to dismount it 34 Installing Drive mounting plate ISSN First place the groove on the back of module on the upper edge of din rail then push the module down to lock up position Finally press the mount ing plate upward into module FLUXMASTER 50 INSTRUCTION MANUAL 3 Software Index 3 1 Keypad Operating Instructions Keypad Description POWER LED A CAUTION To avoid damage do not operate keypad by screwdriver or other sharp ended tool Keypad Operation Flowchart a v gg FREQ READ a DATA v ENT Fxx dem WRITE AFTER 0 5 SEC DATA 4 ENT v END Note 1 Displays setting of frequency when stopped Displays output frequency when running Note 2 The setting of the frequency can be modified either when stopped or when running 3 2 Parameter List Factory Setting 0 1 9995 0 1 9995 1 4 50 6072 0 0Hz 1 45 1 10 4 0 0 10 0 0 1 0 15 0 0 25 55 0 55 0 1Hz 1 10Hz 1 2 0 1 0 0 20 096 8 0 50 100 1 100 0 200 1 2 5 1 3 Emergency Stop 4 External Base Block 5 Reset 6 SP2 4 1 Operating 2 Frequency Agreed
50. wer factor Inverter Power supply input terminals L1 and L2 are not differentiated on phase sequence They can be arbitrarily connected Output terminal T1 T2 and should be connected to the U V and W terminals of the motor respectively If motor turns in opposite direction of the inverter command exchange two of the three wire connections to correct this problem Output terminal T1 T2 and T3 should never be connected to power source Otherwise damage to the AC drive could result Properly ground the grounding terminal in compliance to 200V class type three grounding The 400V class type has special grounding FLUXMASTER 50 INSTRUCTION MANUAL External wiring should be carried out in accordance with the following requirement Check and reassure the wiring is correct after completion Do not utilize the control circuitry buzzer to check the wiring EMI Connections It is very important that the connections between the AC drive the shielded motor cable and the EMI filters are tested as follows 1 Use a metal grounding plate and place the AC drive and the EMI filter on the plate 1 Use a shielded motor cable with 4 connectors V W amp Earth Don t use the shielding as safety earth shield is high frequency earth Remove any paint around the two metal coupling nut holes to ensure that the metal coupling nuts and the shielding make contact with the AC drive and the motor Don t so
Download Pdf Manuals
Related Search