Bodine OEM Series User manual

See Safety Warning,
on pages 8 and 9.
Note: The drive is factory set for
60 Hz motors. For 50 Hz motors,
see Section 6.2, on page 25.
Installati n & Operati n Manual
OEM Series Chassis/IP-20 AC Drives
This manual c vers M del 2982, 2983, 2984 2987
The information contained in this manual is intended to be accurate. The manufacturer
retains the right to make changes in design which may not be included herein.
www.bodine-electric.com
07401080 Rev.D

TABLE OF CONTENTS
Section Page
1 Quick-StartInstructions ...................................................... 6–8
2 SafetyWarning............................................................. 8–9
3 Introduction............................................................... 9–20
4 ImportantApplicationInformation............................................. 20–22
5 Finger-SafeCover......................................................... 22–23
6 SettingSelectableJumpers ................................................. 23–27
7 MountingInstructions...................................................... 27–28
8 Recommended igh Voltage Dielectric Withstand Testing ( i-Pot Testing) . . . . . . . . . . . . . . 28 – 30
9 WiringInstructions ........................................................ 30–35
10 ACLineFusing............................................................... 35
11 DriveOperation........................................................... 36–37
12 DiagnosticLEDs.......................................................... 37–38
13 TrimpotAdjustments....................................................... 38–43
LimitedWarranty.............................................................. 44
Table Page
1 ElectricalRatings.............................................................. 14
2 GeneralPerformanceSpecifications............................................... 15
3 FaultRecoveryandResettingtheDrive............................................. 36
4 Drive Operating Condition and Status LED Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure Page
1 Quick-StartConnectionDiagram .................................................. 5
2A Models 2982, 2983, 2984 Mechanical Specifications and Control Layout . . . . . . . . . . . . . . . . . . 16
2B Models 2982, 2983, 2984 Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
ii

TABLE OF CONTENTS (Continued)
Figure Page
3A Model2987MechanicalSpecifications............................................. 18
3B Models,2987MechanicalSpecifications............................................ 19
4 ExpandedViewofJumpersandTrimpots........................................... 20
5 MaximumAllowedMotorTorquevs.Speed ......................................... 21
6 Open Ventilated Motor with External Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7 Models 2984, 2987 AC Line Input Voltage Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
10 60 zand50 zMotorSelection................................................. 25
11 AvailableTorquevs.OutputFrequency............................................. 26
12 120 z and 100 z Drive Output Frequency Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
13 AutomaticStart............................................................... 27
14 Forward/ReverseSpeedSelection ................................................ 27
15 Typical i-PotSetup........................................................... 29
16 AC Line Input, Motor, and Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
17 MainSpeedPotentiometerConnection............................................. 32
18 VoltageFollowingConnection.................................................... 33
19 ManualStartSwitchConnection.................................................. 34
20 Forward-Stop-Reverse Switch Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
21 EnableSwitchconnection....................................................... 35
22 MinimumSpeedTrimpot(MIN)Range.............................................. 39
23 MaximumSpeedTrimpot(MAX)Range............................................. 39
24 AccelerationTrimpot(ACC)Range ................................................ 39
25 DecelerationTrimpot(DEC/B)Range .............................................. 40
26 SlipCompensationTrimpot(COMP)Range.......................................... 40
iii

TABLE OF CONTENTS (Continued)
Figure Page
27 Boost Trimpot (DEC/B) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
30 Models 2982, 2983, 2984 Current Limit Trimpot (CL) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
31 Models 2987 Current Limit Trimpot (CL) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Items Included in this Package:
Bodine Adjustable Frequency Drive, Bodine Series Installation and Operation Manual, Main Speed
Potentiometer Kit with Insulator and Mounting ardware, Main Speed Potentiometer Terminals
(3 Orange), Motor and AC Line Terminals (5 Blue), 2-Wire and 3-Wire Connector Kit, Status Indicator
Label, Trimpot Adjustment Tool, CE Approved Product Information Card, Warranty Registration Card.
iv
230 VAC Controls
Suitable or use on a circuit capable o delivering not more than 5 kA RMS
symetrical amperes, 230 Volts maximum.
Use copper conductors rated 75° C.
Suitable or operation in a maximum surrounding air temperature o 40°C.
UL Notice
Reconditioning the Bus Capacitors
If this drive has been in storage for over one year it is necessary to recondition the
power supply bus capacitors. To recondition the bus capacitors, apply the AC
Line, with the drive in the Stop Mode, for a minimum of one hour. Not following
this procedure will cause the bus capacitor to fail.

5
FIGURE 1 – QUICK-START CONNECTION DIAGRA
L2W L1U V
see Section 3.5, on page 13.
Communication Port for Accessories and Programming:
see Section 9.1,
on page 30.
Single-Phase, 50/60 Hz
AC Line Input:
see Section 9.3,
on page 31.
Motor Connection:
see Section 9.2,
on page 31.
Ground (Earth):
For 60 Hz or 50 Hz Motor Operation:
For Two Times the Rated Motor RPM:
see Section 6.2.1, on page 25.
see Section 6.2.2, on pages 25 and 26.
see Section 6.3, on page 26.
Automatic Start:
see Section 9.6, on page 33.
Manual Start Switch Connection:
Forward/Reverse Speed Selection:
Forward-Stop-Reverse Switch Connection:
Voltage Following Signal Input
in Lieu of Main Speed Potentiometer:
see Section 12, on pages 37 and 38.
see Section 6.4, on page 27.
see Section 9.7, on page 34.
see Section 9.5, on pages 32 and 33.
Diagnostic LEDs:
see Section 9.8, on pages 34 and 35.
Enable Switch Connection,
AC Line Input Voltage Selection
Main Speed Potentiometer (5 KW)
see Section 9.4, on pages 31 and 32.
(Supplied) (Front View):
(Dual Voltage Models Only):
see Section 13, on pages 38 – 43.
Adjustable Trimpots:
see Section 6.1, on page 24.
High
Wiper
Low
Chassis
B+
AC LINEMOTOR
B-
J1
CON3
J2
PWR
ST
50/60Hz
F-S-R
CON2
A/M
J1
P2 P3
CON1
X1 X2
P1
DEC/BMINMAXCL ACC COMP
230V 115V
Motor

See Figure 1 on page 5. Also see Section 4 – Important Application Information, on pages 20 – 22.
WARNING! Disconnect main power when making connections to the drive.
1.1 AC Line Connection – Wire the single-phase AC line input to Terminals “L1” and “L2”, as
shown in Figure 16, on page 31. See Section 9.1, on pages 30 and 31.
App ication Note: Do not wire this drive to a GFCI. If operation with a GFCI is required,
contact our Sa es Department.
Model 2982 – Rated for 115 Volt AC line input only.
Model 2983 – Rated for 208/230 Volt AC line input only.
Models 2984, 2987 – Rated for 208/230 Volt AC line input with Jumper J1 (on upper PC
board) set to the “230V” position (factory setting). Rated for 115 Volt AC line input with
Jumper J1 (on upper PC board) set to the “115V” position ).
1.2 Ground Connection – Connect the ground wire (earth) to the ground screw, as shown in
Figure 16, on page 31. See Section 9.2, on page 31.
6
1 QUIC -START INSTRUCTIONS
Important – You must read these simplified instructions before proceeding. These instructions
are to be used as a reference only and are not intended to replace the details provided herein.
You must read the Safety Warning on, pages 8 and 9, before proceeding.

1.3 AC Line Fusing – It is recommended that a fuse(s) or circuit breaker be installed in the AC
line. Fuse each conductor that is not at ground potential. For the recommended fuse size, see
Table 1, on page 14. Also see Section 10, on page 35.
1.4 Motor Connection – Wire the motor to quick-connect Terminals “U”, “V”, “W”, as shown in
Figure 16, on page 31. (Special reactors may be required for cable lengths over 100 ft. (30 m)
– consult our Sales Department.) See Section 9.3, on page 31.
Note: The drive is programmed to operate 3-phase AC induction motors. For PSC motors,
optional software is required – contact our Sales Department.
1.5 60 Hz and 50 Hz Motor Operation (Jumpers J1 and J2 On the Lower PC Board) – The
drive is factory set for 60 z motor operation (Jumper J1 set to the “60 z” position and
Jumper J2 set to the “X1” position). For 50 z motor operation, set Jumper J1 to the “50 z”
position and be sure Jumper J2 is set to the “X1” position. See Section 6.2.1, on page 26.
1.6 Trimpot Settings – All trimpots have been factory set for most applications, as shown in
Figure 4, on page 20. Some applications require adjustment of the trimpots in order to tailor
the drive for a specific requirement. See Section 13, on pages 38 – 43.
1.7 Main Speed Potentiometer Connection – For unidirectional speed operation, wire the 5 kΩ
potentiometer (supplied) to Terminals “P1” (low), “P2” (wiper), “P3” (high). See Section 9.4, on
pages 31 and 32.
1.8 Voltage Following – An iso ated* 0 – 5 Volt DC analog signal input can be used to control
motor speed in lieu of the Main Speed Potentiometer. The drive output will linearly follow the
analog signal input. Connect the signal input positive lead (+) to Terminal “P2” and the nega-
tive lead (–) to Terminal “P1”. See Section 9.5, on pages 32 and 33.
*If a non-isolated signal is used, install the SIVFR — Signal Isolator. The SIVFR accepts volt-
age (0 to ±2.5 thru 0 to ±25 Volts DC) or current (4 – 20 mA DC) signal inputs. See Section
3.5, on page 13. 7

Note: For signal following operation, the inimum Speed Trimpot ( IN) must be set fully
counterclockwise.
WARNING! The signal input must be isolated from the AC line. Earth grounding
signal wiring will damage the drive and void the warranty. It is recommended
that the SIVFR — Signal Isolator and Run/Fault Relay be installed when using signal
following.
2 SAFETY WARNING
Definition of Safety Warning Symbols
Electrical Hazard Warning Symbol – Failure to observe this warning could result in electri-
cal shock or electrocution.
Operational Hazard Warning Symbol – Failure to observe this warning could result in
serious injury or death.
8

3 INTRODUCTION
Thank you for purchasing the Bodine Adjustable Frequency Drive. Bodine Electric Company is com-
mitted to providing total customer satisfaction by producing quality products that are easy to install
and operate. The Bodine is manufactured with surface mount components incorporating advanced
circuitry and technology. A Finger-Safe Cover is included for added liability protection.
9
This product should be installed and serviced by a qualified technician, electrician, or electrical
maintenance person familiar with its operation and the hazards involved. Proper installation,
which includes installation of the Finger-Safe Cover, wiring, mounting in proper enclosure, fusing or other
current protection, and grounding can reduce the chance of electrical shocks, fires, or explosion in this
product or products used with this product, such as electric motors, switches, coils, solenoids, and/or
relays. Eye protection must be worn and insulated adjustment tools must be used when working with
drive under power. This product is constructed of materials (plastics, metals, carbon, silicon, etc.) which
may be a potential hazard. Proper shielding, grounding, and filtering of this product can reduce the emis-
sion of radio frequency interference (RFI) which may adversely affect sensitive electronic equipment. It is
the responsibility of the equipment manufacturer and individual installer to supply this Safety Warning to
the ultimate end user of this product. (SW/FSC 5/2005) Be sure to follow all instructions carefully. Fire
and/or electrocution can result due to improper use of this product.
This product complies with all CE directives pertinent at the time of manufacture. Contact
our Sales Department for Declaration of Conformity. Installation of a CE approved RFI filter is
required. See RFI Filters & Chokes Selection Guide D-321 for selection of filters to meet the
Industrial or Residential Standard. Additional shielded cable and/or AC line cables may be required
along with a signal isolator).

The Bodine Adjustable Frequency Drives provide variable speed control for standard 3-phase and
Permanent Split Capacitor (PSC)1AC induction motors from subfractional thru 11⁄2P. This manual
covers models with single-phase AC line input only. The sine wave coded Pulse Width Modulated
(PWM) output operates at a carrier frequency of 16 k z, which provides high motor efficiency and
low noise. Adjustable linear acceleration and deceleration are provided, making the drive suitable for
soft-start applications.
Due to its user-friendly design, the Bodine AC drive is easy to install and operate. Tailoring to specif-
ic applications is accomplished with selectable jumpers and trimpots, which eliminate the computer-
like programming required on other drives. owever, for most applications no adjustments are nec-
essary. For more advanced programming, PC based Drive-Link™ software is available.
Main features include adjustable RMS Current Limit and I2t Motor Overload Protection.2In addition,
Adjustable Slip Compensation with Static Auto-Tune and Boost provides high torque and excellent
load regulation over a wide speed range. Power Start™ delivers over 200% motor torque to ensure
startup of high frictional loads. Electronic Inrush Current Limit (EICL™) eliminates harmful AC line
inrush current. The drive is suitable for machine or variable torque ( VAC) applications. With optional
Drive-Link™ software, the drive can be programmed for DC Injection Braking.
For AC line and motor wiring, quick-connect terminals are provided. Other features include:
adjustable trimpots (MIN, MAX, ACC, DEC/B4, COMP CL), customer selectable jumpers (Automatic-
Manual Start, Motor Frequency, Frequency Multiplier, Forward/Reverse, and Line Voltage (dual volt-
age models only)). Diagnostic LEDs are provided for power (PWR) and drive status (ST). A 5 kΩ
Main Speed Potentiometer is also included.
A Signal Isolator is optional on all models, which can be used for single-ended or bidirectional speed
control and accepts voltage or current signal input. Other optional accessories include: Class “A”
and “B” AC Line Filters, Dynamic Brake Module, Multi-Speed Board, Programming Kit, and Modbus
Communication Module. A connector is provided for easy installation of accessories.
10

Notes: 1. Optional software is required for PSC motors — contact our Sales Department. 2. UL
approved as an electronic overload protector for motors. 4. In 50 Hz ode, the DEC/B Trimpot
automatically becomes Adjustable Boost.
3.1 Standard Features
• Simple to Operate – Does not require programming. Uses trimpots and jumpers, which
are factory set for most applications.
• Diagnostic LEDs – Power on (PWR) and drive status (ST). See Sec. 12, on pgs. 37 & 38.
• Jumper Selection of Drive Output Frequency – Increases the motor speed up to two
times the rated RPM. See Section 6.2, on pages 25 and 26.
• Industry Standard Mounting. See Section 7, on pages 27 and 28.
• Finger-Safe Cover – Meets IP-20 standard. See Section 5, on pages 22 and 23.
Note: GFCI Operation – This control can operate with GFCIs (optional software required).
3.2 Performance Features
• Power Start™ – Provides more than 200% starting torque which ensures startup of high
frictional loads.
• Slip Compensation with Static Auto-Tune and Boost – Provides excellent load
regulation over a wide speed range.
•Speed Range – 60:1
3.3 Protection Features
• Motor Overload (I2t) with RMS Current Limit – Provides motor overload protection which
prevents motor burnout and eliminates nuisance trips. UL approved as an electronic overload
protector for motors. See Section 4.2, on pg. 22, and Section 13.7, on pgs. 42 & 43.
• Electronic Inrush Current Limit (EICL™) – Eliminates harmful inrush AC line current
during startup. 11

• Short Circuit – Prevents drive failure if a short circuit occurs at the motor (phase-to-phase).
• Motor Filter – Reduces harmful voltage spikes to the motor.
• Regeneration – Eliminates nuisance tripping due to bus overvoltage caused by rapid
deceleration of high inertial loads.
• Undervoltage and Overvoltage – Shuts down the drive if the AC line input voltage goes
above or below the operating range.
• MOV Input Transient Suppression.
• Microcontroller Self Monitoring and Auto-Reboot.
12

3.4 Trimpot Adjustments
• Minimum Speed (MIN) – Sets the minimum speed of the motor. See Sec. 13.1, on pg. 39.
• Maximum Speed (MAX) – Sets the maximum speed of the motor. See Sec. 13.2, on pg. 39.
• Acceleration (ACC) – Sets the amount of time for the motor to accelerate from zero speed
to full speed. See Section 13.3, on page 39.
• Deceleration (DEC/B) – Sets the amount of time for the motor to decelerate from full
speed to zero speed. See Section 13.4, on pages 39 and 40.
• Slip Compensation (COMP) – Maintains set motor speed under varying loads. See
Section 13.5, on pages 40 and 41.
• Boost (DEC/B) – In 50 z mode, the trimpot automatically becomes Adjustable Boost,
which can be used to set the Volts/ z Curve for 50 z motors to obtain maximum perform-
ance. In 50 z Mode, the deceleration time is automatically set to the same as the accelera-
tion time. See Section 13.6, on pages 41 and 42.
• Current Limit (CL) – Sets the current limit (overload) which limits the maximum current
(torque) to the motor. See Section 13.7, on pages 42 and 43.
13

14
TABLE 1 – ELECTRICAL RATINGS
odel
AC Line Input Drive Output
Fuse or
Circuit
Breaker
Rating
(Amps)
Net Wt.
Volts AC
(50/60 Hz)
Phase
(f)
aximum
Current
(Amps AC)
Voltage
Range
(Nominal)
(Volts AC)
aximum
Continuous
Load Current
(R S Amps/Phase)
aximum
Horsepower
(HP (kW)) lbs kg
2982 115 1 9.6 0 – 230 2.4 1/2 (.37) 15 1.3 0.6
2983 208/230 1 6.0 0 – 230 2.4 1/2 (.37) 10 1.3 0.6
2984 115 1 9.6 0 – 230 2.4 1/2 (.37) 15 1.3 0.6
208/230 1 6.0 10
2987 115 1 14.0 0 – 230 4.0 1 (.75) 20 2.2 1.0
208/230 1 10.0 15
Note: All models contain Motor Filter and Quick-Connect Terminals for AC line and motor wiring. The Signal Isolator
and Run/Fault Rela is optional on all models.

15
Notes: 1. If a non-isolated signal is used, install the SIVFR – Signal Isolator. 2. Allows the motor to operate up to two times the rated RPM. Constant
motor horsepower will result when operating the drive in the “X2” mode above the motor rated fre uency. 3. Dependent on motor performance.
4. Do not operate the drive outside the specified AC line input voltage operating range.
Description Specification
Factory
Setting
115 Volt AC Line Input Voltage Operating Range (Volts AC) 115 (±15%) —
208/230 Volt AC Line Input Voltage Operating Range (Volts AC) 208 (–15%) / 230 (+15%) —
Maximum Load (% Current Overload for 2 Minutes) 150 —
Carrier, Switching Frequency (kHz) 16, 8 —
Signal Following Input Voltage Range1(Volts DC) 0 – 5 —
Output Frequency Resolution (Bits, Hz) 10, .06 —
Minimum Speed Trimpot (MI ) Range (% Frequency Setting) 0 – 40 0
Maximum Speed Trimpot (MAX) Range (% Frequency Setting) 70 – 110 100
Acceleration Trimpot (ACC) and Deceleration Trimpot (DEC/B) Range (Seconds) .3 – 20 1.5
Boost Trimpot (DEC/B) Range (50 Hz Only) (Volts/Hz) 0 – 30 5
Slip Compensation Trimpot (COMP) Range at Drive Rating (Volts/Hz) 0 – 3 1.5
Current Limit Trimpot (CL) Range (Amps AC): 2982, 2983, 2984 1.5 – 4.5 3.8
2987 2.5 – 7.5 6.4
Motor Frequency Setting (Hz) (Jumper J1) 50, 60 60
Output Frequency Multiplier (X1, X2) (Jumper J2)21, 2 1
Minimum Operating Frequency at Motor (Hz) 1 —
Speed Range (Ratio) 60:1 —
Speed Regulation (30:1 Speed Range, 0 – Full Load) (% Base Speed)32.5 —
Overload Protector Trip Time for Stalled Motor (Seconds) 6 —
AC Line Input Undervoltage/Overvoltage Trip Points for 115 Volt AC Line (±5%) (Volts AC)476 – 141 —
AC Line Input Undervoltage/Overvoltage Trip Points for 208/230 Volt AC Line (±5%) (Volts AC)4151 – 282 —
Operating Temperature Range (°C / ºF) 0 – 45 / 32 – 113 —
TABLE 2 – GENERAL PERFOR ANCE SPECIFICATIONS

16
Top View Shown without Finger-Safe Cover Installed
L2W L1U V
B+
AC LINEMOTOR
B-
J1
CON3
J2
PWR
ST
50/60Hz
F-S-R
CON2
A/M
J1
P2 P3
CON1
X1 X2
P1
DEC/BMINMAXCL ACC COMP
230V 115V
1.25
31.8
(2 Places)
0.5
12.7
0.25
6.4
(10 Places)
0.2
5.1
3.00
76.2
99.0
3.90
3.80
96.5
4.30
109
FIGURE 2A – ODELS 2982, 2983, 2984 ECHANICAL SPECIFICATIONS &
CONTROL LAYOUT (Inches/mm)
(See Figure 4, On Page 20, for Expanded View of Jumpers and Trimpots)

17
0.2
(2 Places)
24.1
0.95
5.1
See
Chart
Models 2982, 2983, 2984
Side View Shown with Finger-Safe Cover Installed
Maximum Height
70
2.75
3.80
96.5
FINGER-SAFE COVER RETAINING CLIPS*
FIGURE 2B – ODELS 2982, 2983, 2984 ECHANICAL SPECIFICATIONS
(Inches/mm)
(See Figure 4, On Page 20, for Expanded View of Jumpers and Trimpots)

18
3.90
99.0
RETAINING CLIPS
DO NOT USE
THESE FOUR
FINGER-SAFE COVER RETAINING CLIPS
FINGER-SAFE COVER RETAINING CLIPS
0.2
5.1
(6 Places)
0.4
10.2
33.5
1.32
3.82
97.0
See
Chart A
on page 19
77.9
3.07
(2 Places)
0.08
2.0
(2 Places)
FIGURE 3A – ODEL 2987 ECHANICAL SPECIFICATIONS (INCHES/ )
(Shown with Finger-Safe Cover Installed)
(See Figure 4, On Page 20, for Expanded View of Jumpers and Trimpots)

19
FINGER-SAFE COVER RETAINING CLIPS
109
4.30
Model 2987
Chart A - Maximum Length Chart B - Maximum Height
5.00
127
Models 2987
Chart B
See
119
4.70
112
4.40
FIGURE 3B – ODEL 2987 ECHANICAL SPECIFICATIONS (INCHES/ )
(Shown with Finger-Safe Cover Installed)
(See Figure 4, On Page 20, for Expanded View of Jumpers and Trimpots)

20
4 IMPORTANT APPLICATION INFORMATION
4.1 Motor with External Fan Cooling – Most totally enclosed fan-cooled (TEFC) and open
ventilated 3-phase AC induction motors will overheat if used beyond a limited speed range at
full torque. Therefore, it is necessary to reduce motor load as speed is decreased.
Note: Some fan-cooled motors can be used over a wider speed range. Consult the motor
manufacturer for details.
WARNING! Some motors have low speed characteristics which cause overheating and
winding failure under light load or no load conditions. If the motor is operated in this
manner for an extended period of time, it is recommended that the unloaded motor current be
checked from 2–15 z (60 – 450 RPM) to ensure motor current does not exceed the name-
plate rating. Do not use motor if the motor current exceeds the nameplate rating.
FIGURE 4 – EXPANDED VIEW OF JU PERS AND TRI POTS
J1
CON3
J2
PWR
ST
50/60Hz
F-S-R
CON2
A/M
J1
P2 P3
CON1
X1 X2
P1
DEC/BMINMAXCL ACC COMP
230V 115V
(Models 2984, 2987 Only)
Jumpers and Trimpots
(Located on Lower PC Board)
Line Voltage Selection Jumper J1
(Located on Upper PC Board)(Shown in Factory Setting)