Bodine 3912, ABL-3912E, 3913, ABL-3913E Instructions For Installation And Operation Manual
Instructions for Installation and Operation
Filtered SCR Brushless DC
Motor Speed Controls (NEMA-12)
Model 3912, 0-2,500 rpm
Model 3913, 0-10,000 rpm
SPECIFICATIONS
Product Type.......................................... ABL-3912E/ABL-3913E
Input Voltage: ......................................... 115 VAC ± 10%, 50/60 Hz (Single Phase)
Input Current: ......................................... 12 Amps rms
Output Voltage: .......................................0 to 130 VDC
Continuous Output Current.............................. 3.0 Amps
Peak Output Current ...................................6.0 Amps
Ambient Temperature: .................................0° to 40° C (Maximum)
Control Hp Range: .....................................Up to 3/8 Hp
Control Speed Range: .................................. Up to 30:1
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07400212.C
IMPORTANT
Read this manual completely and carefully. Pay special attention to all
warnings, cautions, and safety rules. Failure to follow the instructions
could produce safety hazards which could injure personnel or damage
the control, motor, or other equipment. If you have any doubts about
how to connect the control or motor, refer to the detailed sections of
this manual.
QUICK REFERENCE
HAVE YOU?
❑ Read the installation and operation instructions contained
in this manual.
❑ Read and understood all of the precautions outlined in this
manual pertaining to potential hazards to personal safety
and equipment.
❑ Mounted the control properly. Details on Page 9.
❑ Connected the circular connector on the control output
cable to the corresponding circular connector on the
Bodine Brushless DC motor. Details on Page 9.
❑ Selected the proper control horsepower settings for the
motor being used. Details on Page 9.
❑ Installed the motor fuse. Details on Page 11.
❑ Provided an adequate grounded source of AC power.
Details on Page 11.
❑ Refer to the Operation Section of this manual for
preliminary start-up details and specific control functions.
Page 12.
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TABLE OF CONTENTS
QUICK REFERENCE CHECK LIST ..............................................2
GENERAL INFORMATION ...................................................4
CONTROL DESCRIPTION AND FEATURES ......................................4
SPECIFICATIONS ...........................................................5
IMPORTANT SAFETY PRECAUTIONS ..........................................6
INSTALLATION INSTRUCTIONS ..............................................9
Mounting the Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Electrical Connections ...................................................9
Motor Cable Connection ..................................................9
Horsepower (DIP Switch) Settings .........................................9
Line Fuse Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Motor Fuse Installation ..................................................11
Control Input Connections ...............................................11
AC Power Connections ..................................................11
OPERATING INSTRUCTIONS ................................................12
Preliminary Checks .....................................................12
Operating the Control ...................................................12
Internal Adjustments ....................................................13
Minimum and Maximum Speed ........................................13
Torque (Current) Limiting Adjustment ...................................14
Acceleration Adjustment .............................................14
Deceleration Adjustment .............................................14
TROUBLESHOOTING .......................................................15
SPECIALIZED WIRING APPLICATIONS .......................................17
Motor Cable ...........................................................18
Connecting Control Inputs From Remote Locations .........................19
Remotely Located Speed Control .........................................19
Remotely Located Braking (Disable), Direction of Rotation and
Deceleration Controls ...................................................20
Electronic Control Input Connections .....................................20
Electronic Speed Control ................................................21
Logic Signal Control of Braking, Direction of Rotation, and Deceleration .......21
Signal Isolation Using a Bodine Model 3984 Interface Module ................21
WARRANTY ...............................................................23
FIGURES
Figure 1 – Detail of Control Circuit Board in Enclosure ..........................10
Figure 2 – DIP Switch 7 and 8 Speed Range Settings ...........................10
Figure 3 – Horsepower (DIP Switch) Settings and Fuse Selection Chart ..........10
Figure 4 – Speed/Torque Curve Showing Reduced Torque at Lower Speeds .......14
Figure 5 – Interface Connector Detail ........................................19
Figure 6 – Remote Speed Control Connections ................................19
Figure 7 – Manual Switch and Relay Control Inputs ............................20
Figure 8 – Manual Speed Potentiometer/Interface Details ......................21
© 2017 Bodine Electric Company.
All rights Reserved. All data subject to change without notice. Printed in U.S.A.
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GENERAL INFORMATION
Thank you for selecting a Bodine Type ABL Encased Brushless DC Motor
Control. Your new control will provide the same excellent performance and
reliability that have been a Bodine tradition since 1905. Bodine Electric
Company takes pride in the quality of its products and in satisfying its
customers. Every effort has been made to provide you with a product free
of defects in design, workmanship, and materials. In order for us to maintain
our tradition of quality, please report any cases of unsatisfactory service or
products to Bodine Electric Company promptly.
About This Manual
This manual contains the basic information needed to install and operate
a Bodine Type ABL-3912E and ABL-3913E Brushless DC Motor Control. It is
organized in a systematic, step-by-step fashion so that the system may be set
up safely in the shortest possible time. It does not profess to cover all details
or variations in equipment, nor to provide for every possible contingency
associated with installation, operation, or maintenance. No warranty of fitness
for purpose is expressed or implied. Should further information be desired or
should particular problems arise which are not covered sufficiently for the
user’s purpose, the matter should be referred to the Bodine Electric Company.
The issuance of this manual does not confer to the recipient any license
to manufacture under any patents owned or controlled by the Bodine
Electric Company.
Safety Standards
Bodine products are designed and manufactured to comply to applicable
safety standards and in particular to those issued by ANSI (American
National Standards Institute), NEMA (National Electrical Manufacturers
Association), U.L. (Underwriters Laboratories, Inc.), and CSA (Canadian
Standards Association).
Bodine equipment “recognized by U.L., Inc.” are either labeled
with the UR or cURus marks. In addition, products that are CSA
certified are identified by the CSA mark. If you need specific
information regarding the third-party approval status of Bodine
products, contact the nearest Bodine representative, or the
home office.
CONTROL DESCRIPTION AND FEATURES
The ABL-3912E, and ABL-3913E Brushless DC Motor Controls are encased
style controls. They are supplied in their own enclosure to simplify mounting.
The controls operate from a nominal 115 VAC, 50/60 Hz. power source. They
provide electronic commutation and phase current switching needed to
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operate brushless DC motors. DIP switch selectable current limit settings
allow the ABL-3912E and ABL-3913E to be used with a wide range of fractional
horsepower motors and gearmotors.
The ABL-3912E and ABL-3913E provide a 130-Volt filtered output for improved
form factor, plus a built-in dynamic braking module. Motor speed is controlled
by a speed potentiometer mounted on the enclosure front panel. Direction
of rotation and braking are controlled from a “Forward-Brake-Reverse”
(F-B-R) switch also located on the front panel. Trim potentiometers on the
control circuit board allow additional fine tuning of minimum and maximum
speed settings, torque, acceleration and deceleration times. A built-in “Smart
Reverse™” circuit prevents plug reversing by dynamically braking the motor
to a stop before changing its direction. A built-in shutdown circuit disables
the control during over-voltage, under-voltage, or invalid commutation sensor
state conditions. Specific Bodine motor sizes which can be used with these
controls are listed in the Chart in Figure 3.
Accessory Items
• Model 3982 Extension Cable – extends cable between motor and control by six feet.
Both ends equipped with circular connectors for simplified connection. Length: 6 ft.
• Model 0895 Enclosure Sealing Kit – seals the ABL-3912E enclosure to provide
IP-44 level splash proof protection.
• Model 3984 Isolation Module – isolates the control from system controller
inputs, which may be at different potentials. This module is not required unless
the ABL-3912E is connected to a separate control system. See the “Specialized
Application Wiring” section of this manual.
Parameter Specification
Product Type ABL-3912E/ABL-3913E
Input Voltage: 115 VAC ± 10%, 50/60 Hz (Single Phase)
Input Current: 12 Amps rms
Output Voltage: 0 to 130 VDC
Continuous Output Current 3.0 Amps
Peak Output Current 6.0 Amps
Ambient Temperature: 0° to 40° C (Maximum)
Control Hp Range: Up to 3/8 Hp
Control Speed Range: Up to 30:1
Control Speed Regulation: Less than 1% of rated (Typical)
Line Voltage Compensation: Negligible speed change with changes
in line voltage
Acceleration Time Range: (Model 3912): 0.2 to 10 seconds
(0 to full speed)
(Model 3913): 0.5 to 30 seconds
(0-full speed)
Dimensions: inches: ( 6.2 W x 4.0 D x 8.5 H);
cm: (15.8 W x 10.2 D x 21.6 H)
Net Weight: 7.5 lbs. (3.4 kg.)
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IMPORTANT SAFETY PRECAUTIONS
The following safety precautions must be observed during all phases of
installation, operation, service, and repair of this motor control product.
Failure to comply with these precautions or with specific warnings elsewhere
in this manual violates safety standards of design, manufacture and intended
use of the products. Bodine Electric Company assumes no liability for the
customer’s failure to comply with safety requirements and practices.
The use of electric motors and generators, like that of all utilization of
concentrated power, is potentially hazardous. The degree of hazard can
be greatly reduced by proper design, selection, installation, and use but all
hazards cannot be completely eliminated. The reduction of hazards is a joint
responsibility between the user, the manufacturer of the driven or driving
equipment and the manufacturer of the control or motor.
The user should refer to Publication No. ANSI C5.1/NEMA MG 2. Safety
Standard for Construction and Guide for Selection, Installation and Use of
Electric Motors and Generators available from:
National Electrical Manufacturers Association
www.nema.org
Warnings (such as the example below) highlight procedures which present
potential danger to people. Cautions highlight possible danger to equipment.
Both are used throughout this manual and must always be followed.
WARNING
Dangerous voltages may be present in the electronic control and motor.
These voltages could cause serious injury or death. Use extreme caution
during handling, testing, and adjusting. Properly guard the electronic
control and motor to prevent accidental contact by all persons.
The chance of explosions, fires, or electric shocks can be reduced
with thermal and over-current protection, proper grounding, enclosure
selection, and good maintenance. The following safety considerations
are not intended to be all-inclusive. Specific references throughout this
manual should also be consulted.
CAUTION
These controls are designed to provide optimum performance when
used with Bodine Electric Company motors. They should not be used with
other manufacturer’s motors without first contacting the Bodine Electric
Company. Failure to contact Bodine in advance could cause damage to
the control or the motor.
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Inspecting the Control
Check the items you received against your purchase order. Carefully examine
the control (and any optional kits or parts) for shipping damage. Parts errors
should be reported to Bodine. Shipping damage claims should be made to the
freight carrier.
Before installation, review the application to confirm that the proper motor
and control have been selected. This should be done after reading this
manual and all applicable safety standards. If in doubt, contact your Bodine
representative, or the home office if there is no representative in your area.
Although Bodine Electric Company assists its customers in selecting motors
and controls for specific applications, determination of fitness for purpose or
use is solely the customer’s responsibility.
Normal Operating Conditions
Unless otherwise agreed to by Bodine, all control nameplate ratings are
based on the following normal operating conditions. Consult Bodine Electric
Company if variations beyond these limits are anticipated.
1. Continuous Duty: without frequent reversals or starts and stops.
2. Maximum Ambient Temperature: 50° C (122° F) for chassis controls; 40° C
(104° F) for all encased controls.
3. Voltage: Within 10% of nameplate rating.
4. Frequency: Within 5% of nameplate rating.
5. Combined Variation of Voltage and Frequency: Within a total of 10%
providing frequency variation does not exceed 5%.
Grounding
Both electronic controls and motors must be securely mounted and adequately
grounded. Failure to ground properly may cause serious injury to personnel.
Fusing
Both the control input and output are fused. When fuses are replaced, they
must always conform to the values and ratings specified on the control’s
nameplate or in the fuse chart in Figure 4.
Live Circuitry
Open-type electronics should be properly guarded or enclosed to prevent
accidental human contact with live circuitry. No work should be performed on
or close to the control or motor while the control is connected to the AC line.
If an AC line switch is used, it should be a Double Pole Single Throw (DPST),
so that both sides of the AC line are disconnected
Note: Motor over temperature sensing is not provided by this control.
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Environment
Open controls or controls in ventilated enclosures may emit flame during
failure. Bodine’s totally enclosed products are not explosion-proof, and Bodine
does not offer an explosion-proof motor, gearmotor, or control for hazardous
locations (e.g., in an environment of flammable or explosive gas, vapor, or
dust). Bodine recommends use of only approved explosion-proof products
in hazardous locations. The National Electric Code (NEC) allows exceptions,
but NEC and NEMA safety standards should be studied thoroughly before
exercising this option.
Moisture increases the electrical shock hazard of electrical insulation.
Therefore, open-type or unsealed controls not specifically designed for such
use, should be protected from contact with liquids or moisture.
Ventilated Products
Open, ventilated products are suitable for clean, dry locations where cooling air is
not restricted. Do not insert anything into a product’s ventilation openings.
Servicing
Emergency field repairs must be made only by authorized Bodine service
representatives. Repairs made by persons not authorized by the Bodine
Electric Company will void the warranty. Field repairs must be limited to
replacing an entire printed circuit board assembly. Because of the danger
of introducing safety hazards, do not install substitute parts or perform any
unauthorized modifications to electronic PC boards, components or motors.
To ensure continued compliance with the design specifications and safety
standards, the electronic control or motor should be returned to Bodine
Electric Company or an Authorized Service Center for servicing.
WARNING
To avoid injury because of unsuspected mechanical motion, always
disconnect the 115 VAC power to the control before performing any
service procedures on the motor, control, or driven equipment.
This manual does not purport to cover all details or variations in equipment,
nor to provide for every possible contingency to be met in connection with
installation, operation, or maintenance — no warranty of fitness for purpose
is expressed or implied. Should further information be desired or should
particular problems arise which are not covered sufficiently for the user’s
purpose, the matter should be referred to the Bodine Electric Company.
The issuance of this manual does not confer to the recipient any license to
manufacture under any patents owned or controlled by the Bodine Electric
Company.
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