FM50 Working TECO Manual

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Instruction Manual & User Manual

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

P2 = HP

1/4

03 = 3HP

C = Chassis

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) 1/41/212 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*1

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*2

Accel/Decel Time 0.1 ~ 999 Sec

V/F Pattern 6 Patterns

Torque 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/S2)

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)

2.0mm22.0mm23.5mm23.5mm2

Terminal Screw Terminal Screw Terminal Screw Terminal Screw

M3 M3/M4 M4 M4

Signal Terminal (TM2) Wire Dimension 0.75 mm2(#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.

T1 L1 T2 L2 T3

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 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.

❙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.

3ø

Multi-Function Output

(a) correct (b) correct (c) incorrect

External 24V Supply

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

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

Terminal Symbol Function Description

1TRIP Fault relay output terminal (Multi-Function output terminal) (see parameter F_21)

2RELAY Connection point rated capacity 250VAC/1A (30VDC/1A)

3FWD (FW) Operation control terminals (see parameter F_03)

4REV (RE)

5+ 12V(12) Common point for terminals 3 / 4 / 6 / 7

6SP1(SP) Multi-Function input terminals (see parameter F_19)

7RESET(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

10 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

DIMENSIONS

FM50 NEMA 4X (IP65 Indoor Duty) with operators (115V, 230V 1/4 - 1HP models)

FLUXMASTER 50 INSTRUCTION MANUAL

INSTALLATION

FM50 NEMA 4X (IP65 Indoor Duty) with operators (115V, 230V, 1/4 -1HP models)

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 (2.0mm2)

3. Motor cable: #16 AWG (1.25mm2)

4. Tightening torque values for terminals

(1). Power/Motor cable (plug-in) terminal: 4.34in-lb (5kg-cm)

(2). Remote control wire: 3.47in-lb (4kg-cm)

50/60 Hz

Single Phase

L1 L2

3 Phase

T1 T2 T3

SWITCH

POWER

RES ET

RUN

STOP

Potentiometer

REV-0-FWD

ENT

DSP

FUN

DATA

SWITCH

7.83" (198.80mm)

4.86" (123.40mm)

CONNECTION

Circuit Diagram

FM50 NEMA 4X (IP65 Indoor Duty) with operators (115V, 230V, 1/4 - 1HP models)

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 (2.0mm2)

3. Motor cable: #16 AWG (1.25mm2)

4. Tightening torque value for terminals:

(1). Power/Motor cable (plug-in) terminal: 4.34in-lb (5kg-cm)

(2). Remote control wire: 3.47in-lb (4kg-cm)

(3). Outer cover (M4): 5.20in-lb (6kg-cm)

5. 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)

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.

FLUXMASTER 50 INSTRUCTION MANUAL

CONNECTION

FM50 NEMA 4X (IP65 Indoor Duty) (115V, 230V, 1/4 - 1HP models)

MOUNTING

CONNECTION

FM50 NEMA 4X (IP65 Indoor Duty) with operators (115V, 230V, 1/4 - 1HP models)

MOUNTING

FLUXMASTER 50 INSTRUCTION MANUAL

DIMENSIONS

FM50 NEMA 4X (IP65 Indoor Duty) with operators (230V 2, 3HP, 460V 1 - 3HP models)

INSTALLATION

FM50 NEMA 4X (IP65 Indoor Duty) with operators (230V 2, 3HP, 460V 1 - 3HP models)

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 (3.5mm2); 460V #16 AWG (1.25mm2)

3. Motor cable:230V #14 AWG (2.0mm2); 460V #16 AWG (1.25mm2)

4.Tightening torque values for terminals:

(1). Power/Motor cable (TM1,TM3) Terminal: 6.94in-lb (8kg-cm)

(2). Remote control wire: 3.47in-lb (4kg-cm)

(3). Outer cover (M4): 6.94in-lb (8kg-cm)

*Models FM50-202-N4FS & FM50-203-N4FS with operator devices are single phase input only.

FLUXMASTER 50 INSTRUCTION MANUAL

CONNECTION

Circuit Diagram

NEMA 4X (IP65 Indoor Duty) with operators (230V 2, 3HP, 460V 1 -3HP models)

NOTE :

1. Power switch, REV-0-FWD switch and potentiometer are only for NEMA 4X units with operator devices

2. Power supply cable: #12 AWG (3.5mm2)

3. Motor cable:#16 AWG (1.25mm2)

4.Tightening torque values for terminals:

(1). Power/Motor cable (plug-in) terminal: 4.34in-lb (5kg-cm)

(2). Remote control wire: 3.47in-lb (4kg-cm)

(3). Outer cover (M4): 5.20in-lb (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 & 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.

CONNECTION

FM50 NEMA 4X (IP65 Indoor Duty) (230V 2,3HP, 460V 1 -3HP models)

MOUNTING

NOTE:

For ALL MODELS WITH FILTERS, additional items will be found inside the box including: QTY 1 of EMC waterproof conformed

(IP65) ferrite core; QTY 1 of metal fastener; QTY 1 of MF Zin 5-C screw.

CAUTION

If the EMC regulation must be met, constrain the motor cables with the ferrite core onto the motor cable outside the plastic

enclosure as indicated in the above diagram.

Please Note: The length of the motor cable CANNOT exceed 5M under EMC regulation.

FLUXMASTER 50 INSTRUCTION MANUAL

CONNECTION

FM50 NEMA 4X (IP65 Indoor Duty) with operators (230V 2,3HP, 460V 1 -3HP models)

EMC MOUNTING

NEMA 4X (IP65 Indoor Duty) with operators ((230V 2,3HP, 460V 1 -3HP models)

FLUXMASTER 50 INSTRUCTION MANUAL

2.6 Mounting Instructions

Din Rail Mounting Diagram

DIN Rail Installation

A mounting clamp and a 1.38”width rail must be used to install the drive on the rail.

FLUXMASTER 50 INSTRUCTION MANUAL

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

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

1. Pull the mounting plate downward.

2. Rotate the inverter module to dismount it.

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.

3. Software Index

FLUXMASTER 50 INSTRUCTION MANUAL

3.1 Keypad Operating Instructions

Keypad Description

CAUTION

To avoid damage, do not operate keypad by screwdriver or other sharp-ended tool.

Keypad Operation Flowchart

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

FLUXMASTER 50 INSTRUCTION MANUAL

Function F_ Function Description Unit Range Factory Page Note

Setting

Factory Setting 0 Factory Adjustment

Accel.Time 1 Accel.Time 0.1Sec 0.1 ~ 999S 5.0 37 *1 *3

Decel.Time 2 Decel.Time 0.1Sec 0.1 ~ 999S 5.0 37 *1 *3

Operation Mode 30: Forward / Stop, Reverse / Stop

1: Run/Stop, Forward / Reverse 10

~1038

Motor Rotation 40: Forward

Direction: 1: Reverse 10 ~ 1038*1

V/F Pattern 5 V/F pattern setting 1 1 ~ 6 1/4 39 *2

Frequency 6 Frequency upper limit 0.1Hz 1 ~ 200 50/60Hz 40 *2 *3

Upper/Lower Limit 7 Frequency lower limit 0.1Hz 1 ~ 200 0.0Hz 40 *3

SP1 Frequency 8 SP1 frequency 0.1Hz 1 ~ 200 10Hz 40 *3

JOG Frequency 9 JOG frequency 0.1Hz 1 ~ 200 6Hz 40

Start / Stop Control 10 0: Keypad 10 ~ 1041

1:Terminal (TM2)

0: Keypad

Frequency Control 11 1:Terminal (0~10V / 0~20mA) 1 0 ~ 2 0 41

2:Terminal (4~20mA)

Carrier frequency 12 Carrier Frequency Setting 1 1 ~ 5 542*4

Control (1~10)*4

Torque Compensation 13 Torque compensation gain 0.1% 0.0 ~ 10.0% 0.0% 42 *1

Stop Method 14 0: Controlled deceleration stop 10 ~ 1043

1: Coast to stop

15 DC braking time 0.1S 0.0 ~ 25.5S 0.5S 43

DC Braking Setting 16 DC braking injection frequency 0.1Hz 1 ~ 10Hz 1.5Hz 43

17 DC braking level 0.1% 0.0 ~ 20.0% 8.0% 43

Electronic Thermal 18 Protection based on motor rated 50 ~ 100%

Overload Protection current 1% (0~200) 100% 44 *4

Multi-Function input terminal 1 1: Jog

19 (SP1) function 2: SP1 2 33

Multi-Function Input 3: Emergency Stop

Connection Point Multi-Function input terminal 2 4: External Base Block

20 (RESET) function 5: Reset 5 45

6: SP2*4

1: Operating

Multi-Function Output 21 Multi-Function output terminal 2: Frequency Agreed 3 46

3: Fault

FLUXMASTER 50 INSTRUCTION MANUAL

Function F_ Function Description Unit Range Factory Note Page

Setting

Reverse Lock-Out 22 0: REV run 10

~ 1046

1: REV run Lock-Out

Momentary Power 23 0: Enabled

Loss 1: Disabled 10 ~ 1046

Auto Restart 24 Number of Auto-restart times 1 0 ~ 5 0 47

Restore factory settings 25 010: Constants initialization to 50Hz system 47 *2

020: Constants initialization to 60Hz system

SP2 Frequency 26 SP2 frequency 0.1Hz 1.0 ~ 200Hz 20 48 *4

SP3 Frequency 27 SP3 frequency 0.1Hz 1.0 ~ 200Hz 30 48 *4

Power Up Start 28 0: Enable 10 ~ 1148*4

1: Disable

Software Version 29 CPU program version 48

Fault Log 30 Fault log for three faults. 48

NOTE:

*1 : Parameters that can be adjusted while running the drive.

*2 : Please refer to parameters F_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.

F_01 : Acceleration Time = 0.1 ~ 999 sec

F_02 : Deceleration Time = 0.1 ~ 999 sec

1. Acceleration / Deceleration time calculation formula:

Acceleration time = F_01 x Frequency Setting

60Hz

Deceleration time = F_02 x Frequency Setting

60Hz

FLUXMASTER 50 INSTRUCTION MANUAL

F_03: Operation Mode Selection = 0 : Forward / Stop, Reverse / Stop

1: Run / Stop, Forward / Reverse

NOTE 1: F_03 takes effect only when F_10 = 1 (external operation control)

Note: Reverse command is ignored when F_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 F_22 = 1: Reverse is disabled. F_04 cannot be set to 1.

The keypad indication will display "LOC".

NOTE: F_04 takes effect only when F_10 = 0 (Keypad start/stop control mode)

FLUXMASTER 50 INSTRUCTION MANUAL

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 Decreasing Torque

F_5 1 2 3

50Hz System

V/F pattern

Specification 60Hz System

Application General Application High Starting Torque Decreasing Torque

F_5 4 5 6

60Hz system

V/F pattern

F_5 B C

1/4 10% 8%

2/5 15% 10.5%

3/6 25% 7.7%

F_06: Frequency Upper Limit Range = 1 ~ 200Hz

F_07: Frequency Lower Limit Range = 1 ~ 200Hz

F_06: Factory setting refer to F_25.

NOTE:

If F_07 = 0Hz, the frequency instruction is equal to 0Hz; the AC drive will stop at 0 speed.

If F_07 > 0Hz, the AC drive will output a minimum speed according to the setting in F_07.

F_08: SP1 Frequency = 1 ~ 200Hz

F_09: JOG Frequency = 1 ~ 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.

FLUXMASTER 50 INSTRUCTION MANUAL

Frequency Setting Signal

Internal

Frequency

Signal

(Note)

F_06 (Freq.Upper Limit)

F_07 (Freq.Lower Limit)

FLUXMASTER 50 INSTRUCTION MANUAL

F_10: Start / Stop Control = 0 : Keypad

=1:Terminal (TM2)

NOTE: When F_10 = 1 (Terminal Control), emergency stop on the Keypad is enabled.

To avoid injuries to personnel or equipment damage when F_10 = 1, please refer to the descriptions of F_23/24 (Momentary

power loss ride-through and number of auto restart attempts).

Priority of selections for JOG, multi-function, and keypad/external frequencies

F_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

by SP1 speed and the frequency set up via the ▼▲ 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.

F_06

0mA 4mA 20mA

0V 10V

Fn_11=1

Fn_11=2

F_12: Carrier Frequency = 1 ~ 10

F_12 Carrier Frequency F_12 Carrier Frequency F_12 Carrier Frequency

14 kHz 5 8 kHz 9 15 kHz*1

2 5 kHz 6 10 kHz*1 10 16 kHz*1

36 kHz 7 12 kHz*1

47.2 KHz 8 14.4 kHz*1

NOTE:

*1: Available for CPU version V1.9 and above.

2: If F_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.

F_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.

NOTE: When F_13 = 0, the torque boost function is disabled.

FLUXMASTER 50 INSTRUCTION MANUAL

Voltage

F_13= B

100%

12.5/3.0 50/60

FLUXMASTER 50 INSTRUCTION MANUAL

F_14 Stopping Method = 0 : Controlled deceleration stop

= 1 : Coast to stop

F_15 DC Braking Time = 0 ~ 25.5 sec

F_16 DC Braking Starting Frequency = 1 ~ 10Hz

F_17 DC Braking Level = 0 ~ 20%

If F_14 = 0

When the AC drive receives the stop command,it decelerates to the preset frequency set by F_16.After this, the output voltage

level that is set in F_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.

If F_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.

F_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 x F_18. (F_18 = Motor rated current / AC drive rated current)

(2) When the load is within 100% of the motor’s rated current, the operation continues.When the load reaches 150% of the

motor’s 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 electronic 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.

2.The electronic thermal protection for the AC Drive is as follows:

(1) When the load is within 103% of the AC drive rated current, the operation continues.When the load reaches 150% 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.

F_19: Multi-Function Input Terminal 1 = 1~ 5 (1 ~ 6: CPU version v1.9 and above)

F_20: Multi-Function Input Terminal 2 = 1~ 5 (1 ~ 6: CPU version v1.9 and above)

1. F_19 = 1 or F_20 = 1: JOG control (refer to F_09; Jog Frequency Setting):

2. F_19, F_20 = 2 or 6 Multi-speed control (refer to F_08, F_26, F_27; Multi-speeds 1-3 settings):

F_19 = 2 & F_20 = 6:

TM2 SP1 Terminal TM2 SP1 Terminal Output Frequency

ON OFF F_08

OFF ON F_26

ON ON F_27

F_19=6 & F_20=2:

TM2 SP1 Terminal TM2 SP1 Terminal Output Frequency

ON OFF F_26

OFF ON F_08

ON ON F_27

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 F_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 (F_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 (F_10 = 1) or press the RUN key (F_10 = 0), the inverter will restart from the original starting frequency.

5. F_19, F_20 = 5: Auto Reset when AC drive faults.

F_21: Multi-Function Output Terminal Control = 1 ~ 3

1. F_21 = 1: Run mode signal

2. F_21 = 2: At Frequency Speed Signal

3. F_21 = 3: Fault signal

Terminals 1 and 2 of TM2 are activated for the following faults: CPF, OL1, OL2, OCS, OCA, OCC,Ocd , Ocb ,OVC , LVC , OHC.

Refer to Section 4 for information on faults.

External Emergency Stop

External Base Block

F_22: Reverse Lockout = 0: REV run command enabled

= 1: REV run command Lockout

NOTE:

When F_04 (motor rotation direction) is set to 1 (reverse), F_22 cannot be set to 1.In order to properly lockout a motor direction,

F_04 must be set at 0 before setting F_22 to 1.

F_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 F_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 F_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 conditions,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.

FLUXMASTER 50 INSTRUCTION MANUAL

3. When F_23 = 1,

(1) Power up after momentary power loss,the AC drive will not start. Even if F_24 > 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.

4. 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 F_10 = 0, the AC drive will not restart.

(2) When F_10 = 1 and the external switch (FWD/REV button) is OFF, the AC drive will not restart.

(3) When F_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.

F_24: Number of Auto-Restart Times = 0 ~ 5

1. When F_24 = 0, the AC drive will not auto-restart after a fault recovery. (Except for momentary power

loss,please refer to F_23 for details)

2. When F_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 loss, please refer to F_23 for details).

3. When the AC drive is set to deceleration or DC braking, the transient restart procedure is not performed.

4. 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.

F_25: Restore to Factory Settings = 010: Constants initialization to 50Hz system

= 020: Constants initialization to 60Hz system

1. When F_25 is set to 010, all parameters are restored to factory settings.The settings of F_05 = 1 and F_06 = 50. F_25 is restored

back to 000 after the reset process is complete.(50Hz operation)

2. When F_25 is set to 020, all parameters are restored to factory settings.The settings of F_05 = 4 and F_06 = 60. F_25 is restored

back to 000 after the reset process is complete.(60Hz operation)

F_26: SP2 (1 ~ 200Hz) , Multi-speed 2 (Refer to F_19 / F_20)

F_27: SP3 (1 ~ 200Hz) , Multi-speed 3 (Refer to F_19 / F_20)

F_28: Power Up Start = 0 : Power Up start enabled when remote Run command on

= 1 : Power Up start disabled when remote Run command on

(CPU version V2.1 and above)

When F_28 = 1 and control mode is remote control (F_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 Version

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 ➔xxx.➔x.xx ➔xxx, consecutively.

3. After entering F_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.

FLUXMASTER 50 INSTRUCTION MANUAL

1. Non-Resettable Faults

INDICATION CONTENT POSSIBLE CAUSE COUNTERMEASURE

Install a RC surge absorber in

CPF Program error Outside noise interference parallel with the noise

generating magnetic contact

EPR EEPROM error EEPROM defective Replace EEPROM

Voltage too 1.Power source voltage too high. 1. Examine the power supply

OV high while not 2.Detection circuitry defective 2.Return the AC drive for repair

operating

Voltage too 1.Power source voltage too low. 1.Examining the power supply

LV low while not 2.Detection circuitry defective. 2.Return the AC drive for repair

operating

AC drive over- 1.Detection circuit defective. 1.Return the AC drive for repair

OH heat while not 2.Environment overheat or 2. Improve ventilation

operating poor ventilation

2. Manually Resettable Faults (Not Auto-resettable)

INDICATION CONTENT POSSIBLE CAUSE COUNTERMEASURE

OC Overcurrent at

stop condition Detection circuit malfunction Return the AC drive for repair

1. Loading too large 1. Increase capacity of motor

OL1 Motor overload 2. Improper V/F model setting (F_05) 2. Adjust to use a proper V/F

3. Improper F_18 setting curve setting

(Motor Rated Current) 3. Adjust F_18 according to instruction

1. Loading too large 1. Increase capacity of AC drive

OL2 AC drive overload 2. Improper V/F model setting (F_05) 2. Adjust to use a proper V/F

curve setting

3.Manual and Auto-reset Faults

INDICATION CONTENT POSSIBLE CAUSE COUNTERMEASURE

1. Motor coil short-circuit with

Transient overcurrent external casing 1. Examine motor

OCS at start 2. Motor connection wire 2. Examine wiring

short-circuit with grounding 3. Replace transistor module

3. Transistor module damaged

1. Acceleration time setting too short 1. Adjust acceleration time to

Overcurrent 2. Improper V/F function selection longer setting

OCA at acceleration 3. Applied motor capacity 2. Adjust to a proper V/F curve

exceeds AC drive capacity 3. Replace and install another AC drive

with appropriate capacity

Overcurrent at 1. Transient change in load 1. Examine the loading configuration

OCC steady speed 2. Transient change in power supply 2. Install inductor on power supply

input side

OCd Overcurrent at Deceleration setting too short Adjust to a longer acceleration time

deceleration

OCb Overcurrent DC Braking frequency, braking voltage, Adjust to reduce settings of DC Braking

at braking or braking time setting too long F_15, F_16, or F_17

1. Deceleration time setting 1. Adjust to a longer

Overvoltage at too short or inertial loading too large deceleration time

OVC operation/deceleration 2. Power supply voltage 2.Install a inductor on the power

variation too large supply input side

3. Increase the capacity of AC drive

1. Improve power source quality

1. Power supply voltage too low 2. Adjust to use a longer

LVC Insufficient voltage 2. Power supply voltage acceleration time

level at operation variation too large 3. Increase capacity of AC drive

4. Install a reactor on the power

supply input side

Heat-sink over 1. Loading too heavy 1. Examine the load

OHC heated at operation 2. Ambient temperature too 2. Increase capacity of AC drive

high or poor ventilation 3. Improve ventilation

FLUXMASTER 50 INSTRUCTION MANUAL

INDICATION CONTENT DESCRIPTION

When speed F_11 = 0, Frequency lower limit F_7 = 0 and frequency setting < 1Hz

SP0 Zero Speed Stopping When speed F_11 = 1, Frequency lower limit F_7 < (F_6/100), and frequency setting

<Frequency upper limit (F_6/100)

1. If the inverter is set to external operation (F_10 = 1) and

direct start is disabled (F_28 =1),the AC drive cannot be started and will flash

SP1 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). If the STOP

SP2 Keypad emergency key in the keypad is pressed during operation, the AC drive stops according the

stop stop method F_14 and flashes SP2 after stop.The RUN switch must be turned

OFF then ON to restart the machine.

External emergency When the external emergency stop signal is activated through

E.S. stop 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

b.b. 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)

Keypad Operation Error Instruction

INDICATION CONTENT POSSIBLE CAUSE COUNTERMEASURE

1. Attempt to reverse direction 1. Adjust F_22 to 0

LOC Motor direction locked when F_22 reverse disable = 1 2. Adjust F_04 to 0

2. Attempt to set F_22 to 1 when F_04 = 1 (motor rotation direction)

1. Press ▲ or ▼keys when F_11 = 1

or under SP1 operation 1. Use ▲ or ▼keys to adjust frequency

Er1 Keypad operation error 2. Attempt to modify F_29 setting only after F_11 = 0

3. 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)

Er2 Parameter setting error 1. F_6 < F_7 (upper frequency limit< 1. Set F_6 > F_7

lower frequency limit)

FLUXMASTER 50 INSTRUCTION MANUAL

CONDITION CHECK POINT COUNTERMEASURE

Is the power source voltage delivered to ❙Check if the power source is on.

L1, L2 terminal (is the charging indicator ❙Turn power source OFF and then ON again.

illuminated)? ❙Reconfirm the power voltage level.

Motor Is there voltage output from output ❙Turn power source OFF and then ON again.

terminal T1,T2 and T3?

Inoperative Is the motor wired correctly? ❙Check motor wiring.

Is there any abnormal condition in the AC drive? ❙Refer to fault handling

instructions to examine and correct wiring.

Has reverse rotation been disabled? Check parameter F_22

Is the analog frequency setting loaded? ❙Check to see if wiring for analog

Motor frequency input signal is correct.

Inoperative Is the operation mode setting correct? ❙Check if the frequency input setting

voltage is correct.

Is wiring on the output terminals T1,T2 ❙Correct with motor rotation direction setting

Motor runs in and T3 correct? (Fn_04) or FWD/REV key

opposite direction Is the wiring for the forward and reverse ❙Wiring should be in accordance with the

signals correct? U,V,W terminals of motor.

Is the wiring for analog frequency input correct? ❙Examine the wiring and correct it.

Motor run speed Is the operation mode setting correct? ❙Check the Operation panel.

does not change Is the loading too heavy? ❙Reduce loading.

Is the specification of motor (poles, ❙Reconfirm motor specification.

Motor runs voltage) correct?

at speed too Is the gear ratio correct? ❙Reconfirm gear ratio.

high or too low Is the highest output frequency setting correct? ❙Reconfirm highest output frequency.

Is the voltage on motor side significantly reduced? ❙Cheek wiring to motor. Check DC bus voltage.

Is the loading too heavy? ❙Reduce loading variation.

Abnormal speed Is the loading variation too large? ❙Increase AC drive and motor capacity.

variation at operation Is the input power source steady and stable? ❙Install AC reactor on the power supply

input side.

4. Troubleshooting Procedures

FLUXMASTER 50 INSTRUCTION MANUAL

4.1 Flow Chart

FLUXMASTER 50 INSTRUCTION MANUAL

(Continued)

FLUXMASTER 50 INSTRUCTION MANUAL

Error handling of fault indication of OC.OL

Error handling of fault indication of OV.LV

FLUXMASTER 50 INSTRUCTION MANUAL

(1). Motor inoperative

FLUXMASTER 50 INSTRUCTION MANUAL

(2). Motor overheat

FLUXMASTER 50 INSTRUCTION MANUAL

(3). Unstable motor operation

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.

EXAMINATION

Maintenance Maintenance Period Method Examination Criterion Countermeasure

Item Description Routine 1 Year

Refer to installation Temperature: -10~40˚C

Reconfirm environment ❍instructions and measure Humidity: under Improve

Installation Site temperature and humidity with thermometer and 95% non-condensing environment

Environment hygrometer Installation site

Check and remove any ❍Visual inspection No foreign object environment

flammable material nearby

Is there any abnormal

AC Drive vibration on the ❍Visual and audio Inspection No foreign object Tighten loose screws

Installation and installation site?

Grounding Is the grounding resistance ❍Measure resistance by Resistance under 100 Improve grounding

within acceptable range? multi-meter ohm to ground

Input Power Is the voltage of the primary ❍Measure voltage by Voltage level conforming Improve input

Source Voltage circuitry normal? multi-meter specification power source

AC Drive Are the tightened parts secured? ❍Visual inspection.Use

Terminal Is there any sign of breakage ❍screwdriver to verify Tighten loose

Mounting on the terminal panel? screw tightness No abnormality screw or return for

Screws Is there any visible rust? ❍repair

Internal Wiring Is it deformed or skewed? ❍Replace or return

of Inverter Is the insulation of wire ❍Visual inspection No abnormality for repair

broken?

Heatsink Is it accumulating dust ❍Visual inspection No abnormality Clean up dust

or dirt? or dirt

Is it accumulating conductive ❍

PCB metals or oils? Visual inspection No abnormality Clean up or replace

Is there any overheated or ❍PCB

burnt components?

Is there any abnormal ❍Visual and audio Replace cooling fan

Cooling Fan vibration or noise? inspection No abnormality

Is it accumulating dust ❍Visual inspection Clean up

or dirt?

PowerIs it accumulating dust or dirt? ❍Visual inspection No abnormality Clean up

Component

Is there any sign of strange ❍

Capacitor odor or leakage? Visual inspection No abnormality Replace capacitor

Is there any sign of swelling ❍or inverter

or bulging?

4.3 Maintenance and Examination

FLUXMASTER 50 INSTRUCTION MANUAL

Frequent 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.

CAUTION

Do not perform dielectric strength test to the control circuit.

FLUXMASTER 50 INSTRUCTION MANUAL

4.4 Voltage Current Measurement

V4 V5 V6

A4 A5 A6

W3 W4

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:

MEASUREMENT MEASURING POINT INSTRUMENT NOTE

(MEASUREMENT CRITERION)

Input Voltage Moving-iron

Input Current Moving-iron

Input Power Power-meter P=W1

Input Power Factor Calculate power factor by the input voltage, input current and input power.

PFi

Output Voltage Rectifier (Moving iron Maximum voltage difference

Vo not allowed) between wires under 3%

Output Current Moving-iron Under the drive’s

Io rated current

Output Power Power-meter Po=W3+W4

Output Power Factor

4.5 EMI Filter (Class B) Specification

FLUXMASTER 50 INSTRUCTION MANUAL

Model Dimension (in) Current (A) Inverter model

FM50-2P2

MSDF-2102 6.14 x 3.0 x 0.99 10A FM50-2P5

FM50-201

MSDF-2202 6.77 x 4.73 x 0.43 20A FM50-202

FM50-203

FM50-401

MSDF-4103 6.77 x 4.73 x 0.43 10A FM50-402

FM50-403

4.6 Din Rail Specification

Model Dimension (in) FM50 model

FM50-DIN-201 5.12 x 2.83 x 0.30 ALL FM50 MODELS

4.7 of Braking Resistor and Input Reactor Specification

Braking Braking Braking Braking Input AC Reactor

Model Transistor Resistor Torque Resistor Current Inductance

Built-in Built-in Model (A) (mH)

FM50-2P2 X X 20% Note 1 3 7.0

FM50-2P5 X X 20% Note 1 5.2 4.2

FM50-201 X X 20% Note 1 9.4 2.1

FM50-202 ❍X20% BRN2-202 19 1.1

FM50-203 ❍X20% BRN2-203 25 0.71

FM50-401 ❍X20% BRN2-401 2.5 8.4

FM50-402 ❍X20% BRN2-402 5.0 4.2

FM50-403 ❍X20% BRN2-403 7.5 3.6

❍:Built-in X: Not Built-in

Note 1: No transistor and resistor built-in.

4.8 Braking Resistor Specification

FLUXMASTER 50 INSTRUCTION MANUAL

Braking Motor Specification Braking Braking

Model of Resistor (HP) of Braking Resistor Resistor Torque

Model (W) (Ω)ED(%) (%)

FM50-202 FM100-2BR2 2 150 100 10 119

FM50-203 FM100-2BR3 3 200 70 9 116

FM50-401 FM100-4BR1 1 60 750 8 125

FM50-402 FM100-4BR2 2 150 400 10 119

FM50-403 FM100-4BR3 3 200 250 8 128

Note:

1. Braking level: 385/770VDC for FM50-200/400 series

2. Braking resistor mounting is below:

Special Condition Description

FLUXMASTER 50 INSTRUCTION MANUAL

Customer Model

Application Telephone

Address

F_## Value Setting F_## Value Setting F_## Value Setting

F_00 F_11 F_22

F_01 F_12 F_23

F_02 F_13 F_24

F_03 F_14 F_25

F_04 F_15 F_26

F_05 F_16 F_27

F_06 F_17 F_28

F_07 F_18 F_29

F_08 F_19 F_30

F_09 F_20

F_10 F_21

Notes

FLUXMASTER 50 INSTRUCTION MANUAL

Notes

FLUXMASTER 50 INSTRUCTION MANUAL

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

FM50 Working TECO Manual

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