TECO FM501P2-X, FM501P5-X, FM502P5-X, FM50201-X, FM50202-X Instructions & User's Manual

...

Instruction Manual & User Manual

www.tecowestinghouse.com

TABLE OF CONTENTS

Foreword .......................................................................................................................................................................................................................................... 3

1. Safety Precaution ............................................................................................................................................................................................................ 3

2. Examination before Installation ................................................................................................................................................................................ 4

1. Safety Precautions

1.1 Precautions for Operation............................................................................................................................................................................................ 5

1.2 Environmental Precautions ........................................................................................................................................................................................ 8

2Hardware Instruction and Installation

2.1 Operational Environment ............................................................................................................................................................................................ 9

2.2 Sample Model No.Identification .............................................................................................................................................................................. 10

2.3 Specifications .................................................................................................................................................................................................................... 11

2.4 Wiring Diagram ................................................................................................................................................................................................................ 17

2.5 Dimensions & Location of Terminal Block ............................................................................................................................................................ 20

2.6 Mounting Instructions .................................................................................................................................................................................................. 33

3. Software Index

3.1 Keypad Operating Instructions.................................................................................................................................................................................. 35

3.2 Parameters List.................................................................................................................................................................................................................. 36

3.3 Parameter Function Description .............................................................................................................................................................................. 37

3.4 Malfunction Indication and Countermeasure .................................................................................................................................................... 49

3.5 General Malfunction Examination Method .......................................................................................................................................................... 52

4. Troubleshooting Procedure

4.1 Flow chart............................................................................................................................................................................................................................ 53

4.2 Routine Examination and Periodical Examination............................................................................................................................................ 60

4.3 Maintenance Examination .......................................................................................................................................................................................... 61

4.4 Voltage Current Measurement ................................................................................................................................................................................ 62

4.5 EMI Filter (Class B) Specification................................................................................................................................................................................ 63

4.6 DIN Rail Specification .................................................................................................................................................................................................... 63

4.7 Specification of Braking Resistor and Input Reactor........................................................................................................................................ 63

4.8 Specification of Braking Resistor .............................................................................................................................................................................. 64

4.9 Parameters Table .............................................................................................................................................................................................................. 65

Contents

FLUXMASTER 50 INSTRUCTION MANUAL

Forward

FLUXMASTER 50 INSTRUCTION MANUAL

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 carefully 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

❙ Do not touch the PCB or components on the PCB right after turning off power and before the charging indicator goes off. ❙ Do not attempt to wire circuits while power is on.Do not attempt to examine the components and signals on the PCB

while the AC drive is operating.

❙ Do not attempt to disassemble or 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. ❙ This product may cause radio interference.The user may be required to take adequate measures for RFI protection.

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.

❙ 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 PCB

of the AC drive.

2. Examination Before Installation

FLUXMASTER 50 INSTRUCTION MANUAL

Every AC Drive has been fully tested and examined before shipment.Please carry out the following examination procedures after unpacking your FM50 AC Drive.

❙ Check to see if the model number of the AC Drive matches the model number that you ordered. ❙ 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.

1. Safety Precautions

FLUXMASTER 50 INSTRUCTION MANUAL

1.1 Precautions For Operation Before Turning On Power

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 be mistakenly connected to T1,T2 or T3 output terminals.This may damage the AC drive when the power is turned on.

CAUTION

❙ Do not attempt to transport the FM50 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.

❙ Install the drive onto a firm metal base plate or another 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 ˚C (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.

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.

❙ 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 F_10 and the condition of external switch. This is considered to be a restart as pertaining to the following paragraphs.

❙ 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 F_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 F_23 and F_24.

(1) When F_10=0, the AC drive will not start in restart mode.

(2) When F_10=1 and the external switch (FWD/REV button) is OFF,the inverter will not start in restart mode.

(3) When F_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

WARNING

Do not use a separate device to switch motor ON or OFF during operation.Otherwise, the AC drive may experience an overcurrent breakdown.

WARNING

❙ 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.

When Power is Applied

FLUXMASTER 50 INSTRUCTION MANUAL

CAUTION

❙ Do not touch the heatsink base during operation. ❙ The FM50 can be 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.

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˚C ~ +40˚C),humidity under 95% RH without condensing.

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.

CAUTION

1.2 Environmental Precautions

FLUXMASTER 50 INSTRUCTION MANUAL

Avoid direct sunlight Keep away from corrosive gases

or liquids

Keep away from oil grease and gas

Keep away from salty environments

Keep away from rain or where dripping water may get into the AC Drive

Avoid dusty environments

Avoid high temperature environments

Avoid exessive direct heatAvoid excessive vibration

Keep away from high electromagnetic waves

Keep away from radioactive matter Keep away from flammable

material

2. Hardware Instructions and Installation

FLUXMASTER 50 INSTRUCTION MANUAL

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 drive. 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˚C ~ +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.

❙ 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.

❙ Installation must be compliant to the following requirements.

Cooling Fan Cooling Fan Cooling Fan

Cooling Fan

Note: Maximum temperature in the enclosure is 122˚F (50˚C) with Shield Sticker removed

2.2 Sample Model No. Identification

FLUXMASTER 50 INSTRUCTION MANUAL

C = Chassis

P2 = HP

03 = 3HP

N4 = NEMA 4 OC = Chassis with Filter N4FS = NEMA 4 with Operator Devices

2.3 SPECIFICATIONS

FLUXMASTER 50 INSTRUCTION MANUAL

2.3.1 Product Specifications

Model: FM50 1P2-X 1P5-X 101-X

Suitable Motor Power

0.2 0.4 0.75

Rating (KW)

Motor (HP) 1/4 1/2 1

Rated

Output Current (A) 1.4 2.3 4.2 Capacity (KVA) 0.53 0.88 1.6

Weight (lb) 2 2 2 Input Voltage Max. Single Phase 100-120V (+10%, -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 EMC Specification Without Filter

Model: FM50 2P2-X 2P5-X 201-X 202-X 203-X

Suitable Motor Power Rating (KW)

0.2 0.4 0.75 1.5 2.2

Motor (HP)

2 12 3

Output Current (A) 1.4 2.3 4.2 7.5 10.5 RatedCapacity (KVA) 0.53 0.88 1.6 2.9 4.0

Weight (lb) 2 2 2 5 5

Input Voltage Max. Single/Three Phase 200-240V (+10%, -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 401-X 402-X 403-X

Suitable Motor Power

Rating (KW)

0.75 1.5 2.2

Motor (HP) 1 2 3

Output Current (A) 2.3 3.8 5.2 RatedCapacity (KVA) 1.7 2.9 4.0

Weight (lb) 4 4 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 x 4.63 x 6.77 EMC Specification Without Filter

FLUXMASTER 50 INSTRUCTION MANUAL

2.3.2 Functional Specifications

Item Specification

Input Signal Type (SOURCE) input (External 24VDC Input is allowed) (PNP type) Control Method Sinusoidal wave PWM control

Frequency Range 1 ~ 200Hz*

Resolution Setting

Digital: 0.1Hz (1 ~ 99.9Hz); 1Hz (100 ~ 200Hz)

Frequency Analog: .06Hz / 60Hz Control Keypad Setting Directly setup by ▲ ▼ buttons.

External Signal Setting 0 ~ 10V, 4 ~ 20mA, 0 ~ 20mA Other Function Frequency upper and lower limit Carrier Frequency 4 - 16KHz*

Accel/Decel Time 0.1 ~ 999 Sec V/F Pattern 6 Patterns Tor que Control Adjustable Torque boost level (manual torque boost)

2 Programmable Inputs,to be used as multi-speed 1(SP.1) / multi-speed

Control

Multi-Function Input 2(SP.2) *1/ Jog / External emergency stop / External Base Block Command/

Characteristics

Reset Command

Multi-Function Output One output contact available as Fault / Running / At speed signals.

Braking Torque

1P2~101/2P2~201: Approximately 20% 202/203/401/402/403: 20% ~ 100%, built-in braking transistor

Built-In Functions

Decelerate or free run stop, Auto reset,DC braking frequency / Voltage / Time can be setup by constants.

Display

Three digit 7 segment LED display frequency / functions constants /

fault record /CPU version. Operating Temperature 14 ~ 104˚F (-10 ~ 40˚C); 14 ~ 122˚F ( -10 ~ 50˚C) without shield sticker Humidity 0 ~ 95% RH non-condensing. Vibration Under 1G (9.8m/S

) EMC Specification EN50081-1, EN50081-2, EN50178,EN61800-3 + All UL UL508C

Overload Protection 150% for 1 minute Overvoltage DC Bus voltage > 410V(100/200 series);DC Bus voltage > 800V(400 series) Undervoltage DC Bus voltage < 200V(100/200 series); DC Bus voltage < 400V(400 series)

Protection Momentary

Power-loss 0 ~ 2 sec: AC drive can be restarted with Speed Search.

Function Power Loss

Stall Prevention During Acceleration / Deceleration/ Constant speed Output Short-circuit Electronic circuit protection Ground Fault Electronic circuit protection Other Protection Heatsink overheat protection, Current limit

Installation Direct installation or DIN rail (Option).

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.

2.3.3 Options and Wiring Specifications

FLUXMASTER 50 INSTRUCTION MANUAL

Molded-Case Circuit Breaker / Magnetic Contactor

❙ 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.

Model Type 1P2/1P2/2P2/2P5 101/201/202 203 401/402/403

Molded-Case Circuit Breaker 15A 20A 30A 15A

Primary Circuit Terminal Wire Dimension Wire Dimension Wire Dimension Wire Dimension

(#14 AWG) (#14 AWG) (#12 AWG) (#12 AWG)

2.0mm

3.5mm

Terminal Screw Terminal Screw Terminal Screw Terminal Screw

M3 M3/M4 M4 M4

Signal Terminal (TM2)

Wire Dimension 0.75 mm

(#18 AWG),Terminal Screw

1~11

Recommended Wire Type

Use Copper Conductors Only. Size Field Wire Based on 167˚F (75˚C) Wire Only. Wire Voltage Rating Must Be a Minimum of 300V.

❙ 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.

❙ Do not install phase advancing capacitors,LC, or RC components between the AC drive and the motor.

From the Power Source:

❙ Apply the power source at the correct rated voltage to prevent damage to the AC drive. ❙ A 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:

❙ 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:

❙ If a large capacity power source is applied (over 600KVA), an additional AC reactor may be added to improve the

power 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 T3 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.)

2.3.4 Application and Recommendations for Installing Auxiliary Equipment

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.

❙ Use a metal grounding plate and place the AC drive and the EMI filter on the plate. ❙ Use a shielded motor cable with 4 connectors (U,V,W, & 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 solder a conductor to the shielding. ❙ 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 (< 11.8").If 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.

❙ 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.

Filter (Optional)

❙ 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 x 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.

❙ To r educe 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.

❙ 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.

❙ 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

❙ 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

Wire Terminations to the AC drive must be made with either UL listed field wiring lugs or UL listed crimp type ring terminals.

*Note: Only for 230V 2,3HP and 460V 1-3HP models.

(a) correct

(b) correct

3ø

Multi-Function Output

External 24V Supply

FLUXMASTER 50 INSTRUCTION MANUAL

Inverter Terminal Descriptions, Primary Circuitry Terminal Block (TM1) Description

Te rminal Symbol Function Description

L1/L (R) Primary power source input to Drive

L2 (S) Single phase: L1/L2 or L/N

L3/N (T) Three phase: L1/L2/L3

PExternal braking resistor terminal

R (230V, 2/3HP and 460V,1-3HP models only) T1 (U) T2 (V) Inverter output to Motor

T3 (W)

Tightening torque for TM1 is 1lb-ft or 12lbs-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

Te rminal Symbol Function Description

1 TRIP Fault relay output terminal (Multi-Function output terminal) (see parameter F_21) 2 RELAY Connection point rated capacity 250VAC/1A (30VDC/1A) 3 FWD (FW)

Operation control terminals (see parameter F_03)

4REV (RE) 5+ 12V(12) Common point for terminals 3 / 4 / 6 / 7 6 SP1(SP)

Multi-Function input terminals (see parameter F_19)

7 RESET(RS) 8 +10V Power terminal for potentiometer (Pin 3)

Analog input wire

Analog frequency signal input terminal (Pin 2 of

9potentiometer or positive terminal of 0~10V /

4~20mA / 0~20mA)

Wiper

0V(FM -)

Analog common

Analog signal common point (Pin 1 of potentiometer) or negative terminal of 0~10V / 4~20mA / 0~20mA)

11 FM+

Analog output positive Analog frequency signal output terminal connection point Output terminal signal is 0 ~ 10VDC/Fn_6

Tightening torque for TM2 is 0.42lb-ft 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

Switch 1 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 & Location of Terminal Block

115V 1/4 - 1HP, 230V 1/4 - 1HP models

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.

Unit: inches

5.20 4.57 5.12 0.32 4.65 2.40 2.83

FLUXMASTER 50 INSTRUCTION MANUAL

230V, 2, 3HP, 460V 1 - 3HP

Dimensions & Installation of Class B Filter

2.36

2.99

0.98

+ 47 hidden pages

TECO FM501P2-X, FM501P5-X, FM502P5-X, FM50201-X, FM50202-X Instructions & User's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual