WPM 0792 User guide

Instructions for Installation and Operation
Type WPM
Type WPMType WPM
Type WPM Enclosed Speed Control
Enclosed Speed ControlEnclosed Speed Control
Enclosed Speed Control
for Permanent Magnet DC Motors
for Permanent Magnet DC Motorsfor Permanent Magnet DC Motors
for Permanent Magnet DC Motors
Model 0792, 7/16 HP, without Direction Control
Model 0796, 3/4 HP, with Direction Control
Model 0797, 3/4 HP, without Direction Control
P/N 074 01042 E (FZ)

2
IMPORTANT SAFETY PRECAUTIONS
This manual contains the basic information needed to install and operate
Bodine DC Motor Speed Control models 0792, 0796, and 0797. This
manual does not profess to cover all details or variations in equipment, or
to provide for every possible contingency associated with installation,
operation, or maintenance. No warranty of fitness for purpose is
expressed or implied. Should further information be desired or should
particular problems arise which are not covered sufficiently for the user’s
purpose, the matter should be referred to the Bodine Electric Company.
IMPORTANT
Read this manual completely and carefully. Pay special attention to
all warnings, cautions, and safety rules. Failure to follow the
instructions could produce safety hazards that could injure
personnel or damage the control, motor, or other equipment.
Models 0792, 0796, and 0797 have been evaluated by Underwriters
Laboratories for conformance to UL standard 508 and CSA standard
C22.2 No. 14 and bear the UL Recognized Component mark.
The DC control is a power electronic device. For safety reasons, please
read through this operations manual in detail and observe those
paragraphs with the safety alert symbol, such as the following one.
WARNING
• Do not touch printed circuit board (PCB) right after turning
off power. Wait until green LED turns off.
• Do not attempt to wire circuitry while power is on.
• Do not attempt to examine components and signals on the
PCB while the control is operating.
• Do not attempt to disassemble or modify internal circuitry,
wiring, or components of the control.
• Enclosure must be properly grounded.

3
SPECIFICATIONS
ABOUT THIS PRODUCT - Bodine Models 0792, 0796, and 0797 are
designed to provide variable speed control of standard Permanent
Magnet DC motors. Adjustable acceleration and deceleration are
provided, making the drive suitable for soft start applications. The full-
featured drive is easy to install and operate. Simple trim pot adjustments
eliminate the computer-like programming required on other drives.
However, for most applications, no adjustments are necessary.
TABLE 1 – Control Specifications
Model Number: 0792 0796 0797
Input Voltage: 115 VAC +/-10%, 50/60 Hz, Single Phase
Drive Type: PWM
Output Voltage: Adjustable, 0 to 130 VDC
Motor Type: Permanent Magnet Brush DC
Max. Input Current,
Continuous:
5.7 Amps RMS 8.0 Amps RMS
Max. Output Current,
Continuous:
3.2 Amps DC 5.0 Amps DC
Max. Output Current,
Peak:
5.0 Amps DC 7.5 Amps DC
Max. Motor HP Rating,
Motors rated 1725
RPM @ 90 VDC:
1/3 HP (.23 kW) 1/2 HP (.37 kW)
Motors rated 2500
RPM @ 130 VDC:
7/16 HP (.33
kW)
3/4 HP (.50 kW)
Operating Temperature: 0°C to +40°C (32°F to 122°F)
Speed Regulation
Adjustment:
1% of rated speed obtainable with most DC motors
Diagnostics: green power LED, red current limit LED
Direction Control: NO YES NO

4
INSTALLATION
This control should only be installed by a qualified person familiar
with its operation and associated hazards. The National Electrical
Code (NEC), local electrical and safety codes, and when applicable,
the Occupational Safety and Health Act (OSHA) should be observed
to reduce hazards to personnel and property.
CAUTION
Do not connect the control to the power supply if there is any
sign of shipping damage. Notify the carrier and your
distributor immediately.
Step 1: Mounting the Control
The control may be mounted using any two or all four mounting holes.
The mounting holes will accommodate either 1/4-20 or M6 screws. See
Figures 1 and 2 for distances between the mounting holes.
Although the control is designed for industrial applications, avoiding
certain installation sites can prolong the lifespan of the control.
 Avoid areas where surrounding air temperature exceeds 40OC (direct
sunlight or near heating equipment or inside a panel without a cooling
fan.
 Avoid locations where the front panel dial and switch may be bumped
and accidentally turned on/off or damaged.
 Avoid environments with corrosive gas.
 Avoid locations near radioactive matter or flammable material.
 Avoid locations near equipment that generate electromagnetic
interference (soldering or power machinery).
 Avoid mounting the control to a surface that vibrates.

5
FIGURE 1 - Control mounting dimensions for Model 0792
FIGURE 2 - Control mounting dimensions for Models 0796 and 0797. Cords not shown,
but they are the same as on Model 0792 (see Figure 1).

6
Step 2: Preliminary Setup
CAUTION
Exposed circuit boards must be protected from electrostatic
discharge during handling to prevent component damage.
MOTOR SIZE SELECTOR SWITCHES - Control Models 0792, 0796,
and 0797 are packaged with the enclosure cover in place, but not
attached. Remove the cover to set the motor size selector switches. Fig.
4 shows the location of a bank of 8 dip switches. Set switches 1 through
6 to match the type, speed, and current ratings on the motor nameplate
per Table 2.
TABLE 2 - Setup of Dip Switches 1 through 6
MOTOR RATINGS CONTROL SETUP
Motor
Mfr.
Motor
Type
Armature
RPM / Volts1
Rated
Amps2
HP Dip
Switches
ON
Peak
Output
Amps3
Cont.
Input
Amps
Control Model 0792
24A4... 2500 / 130 0.45 1/17 none 1.0 1.1
33A3...
32A3...
2500 / 130 0.71 1/12 1 1.2 1.4
32A4... 2000 / 130 0.62 1/12 1 1.0 1.4
Bodine 33A5...
32A5...
2500 / 130 1.00 1/8 3 2.1 1.9
42A3... 2500 / 130 1.00 1/8 1, 3 2.0 2.0
42A4... 2000 / 130 1.20 1/6 2, 3 2.0 2.5
42A5... 2500 / 130 1.80 1/4 3, 5 4.1 3.6
42A7... 2500 / 130 2.30 1/3 2, 3, 5 4.9 4.0
Other PM 2500 / 130 2.2 1/4 1, 2, 3, 5 5.3 4.0
Control Models 0796 and 0797
Other PM 2500 / 90 5.0 1/2 1,2,3,4,5,6 7.5 8.0
Notes:
1. To calculate the armature speed of a geared motor, multiply the output
speed at the driveshaft by the gear ratio.
2. If the user desires to install their own armature fuse on the control output to
protect motor from continuous overloads, then the rating of that fuse should
be based on the motor rating in this column.
3. Peak current available with TORQ pot in fully CW position (factory setting).
This current, which exceeds the continuous rating of the motor, is intended
for intermittent overload conditions only, such as infrequent starting of
inertial loads.

7
ACCEL/DECEL SELECTOR SWITCHES – Fig. 3 shows the location of a
bank of 8 DIP switches. Set switches 7 and 8 to select the acceleration
and deceleration time range per Table 3.
TABLE 3 – Setup of DIP switches 7 and 8.
Switch Number Acceleration/Deceleration Time Range
(seconds)1
7 8 ACC pot fully CCW
(factory setting)
ACC pot fully CW
OFF OFF 0.1 0.3
OFF ON 0.5 2.0
ON OFF 3.5 12.0
ON ON 4.0 15.0
1. 1. The time for voltage across A1 and A2 to ramp up from 0 to 130 VDC
when voltage across S1 & S2 switches instantly from 0 to 5 VDC; or the
time to ramp down from 130 to 0 VDC when voltage across S1 & S2
switches from 5 to 0 VDC.
Step 3: Electrical Connections
WARNING
Do not attempt to wire circuitry while power is on.

8
FIGURE 3 – Control shown with cover removed to identify locations of electrical
connections, DIP switches, trim pots, and diagnostic lights (LEDs). Model number 0792
is shown. Models 0796 and 0797 use the same printed circuit board.
WARNING
The AC power line to the control should be the very last
connection made.
INHIBIT SWITCH (OPTIONAL) - A mechanical switch or relay with low
voltage contacts may be connected to 0.25” spade terminals “H1” and
“H2”. The motor will run with the switch open. Closing the switch will
stop the motor.
WARNING
The inhibit switch should not be used to disable motor or
control when servicing these or driven equipment.
Disconnect AC power instead.
CAUTION
The control board signal common is not at ground potential.
Any external signal or equipment connected to the control
must be electrically isolated from ground.
MOTOR CONNECTIONS - Models 0792, 0796, and 0797 have a six foot
long cable with a plug-in connector at the end. A mating connector, AMP
#206429-1 or equivalent, must be installed on the motor cable. To
reverse motor direction, remove the control enclosure cover and
transpose the wire connections at “A1” and A2”. The factory connection
of the cable has the white wire in the cable connected to pin 1 of the AMP
connector and to “A2” in the control. The black wire is connected to pin 2
of the AMP connector and to “A1” in the control. The green & yellow wire
is connected to pin 3 of the AMP connector and to the ground screw in
the control. See Fig. 3 for location of tabs.
LINE FUSE - Models 0792, 0796, and 0797 have a fuseholder on the
front panel of the enclosure. Model 0792 uses an 8 amp fuse and
Models 0796 and 0797 use a 15 amp fuse.
AC POWER CONNECTIONS - Models 0792, 0796, and 0797 have a six
foot long cable with a standard connector for a 115 VAC outlet. When all
other connections are made, plug it in.

9
OPERATION
Step 4: Preliminary Checks Before Starting
1. Recheck all fuses, connections, and adjustments.
2. Check that motor is securely mounted.
3. Test the motor unloaded first to verify proper connections (follow
instructions in Step 5). If the motor operates properly unloaded, then
proceed with testing it loaded.
4. Check all rotating members. Be sure keys, pulleys, etc. are securely
fastened and safety guards are in place.
5. Check for proper mounting and alignment of products, and verify safe
loading on shafts and gears.
Step 5: Operating the Control
1. With AC power switch OFF, set the speed pot to ZERO (fully
counterclockwise).
2. Turn the AC power switch ON. If an optional inhibit switch is being
used, open it.
3. Turn speed pot until motor rotates at desired speed. Note that “SCR
rated” motors (motors rated at 90 VDC) will run faster with a filtered
control because of the 130 VDC max. output voltage.
4. If the motor does not start promptly and run smoothly, refer to
“TROUBLESHOOTING” below.
Step 6: Internal Adjustments
Most users will find the factory settings of the control to be acceptable for
their application. For those who want to fine-tune the control, four trim
potentiometers on the PC board can be adjusted. First, remove the
enclosure cover. Fig. 3 shows the locations of the trim pots.
WARNING
Use a non-metallic or insulated adjustment tool for internal
adjustments. Circuit components are at high potential and
accidental short circuiting and shock hazard may occur with
conductive tools.
MINIMUM SPEED LIMIT - Turn the MIN pot clockwise (CW) to make the
motor run faster than 0 rpm when the speed pot is set at “0”. With MIN

10
pot fully CW and speed pot set at “0”, control output will be about 50
VDC. Increasing the minimum speed will also increase the maximum
speed, so the MAX pot may need to be adjusted.
MAXIMUM SPEED LIMIT - Turn the MAX pot counterclockwise to make
the motor run slower than full speed when the speed pot is set at “100”.
With the MAX pot fully counterclockwise and the speed pot set at “100”,
the motor will run at about 60% of its full speed. The factory setting of
Model 0792 is for 130V motors. The factory setting of Models 0796 and
0797 is for 90V motors.
TORQUE LIMIT - Turn the TORQ pot counterclockwise to reduce the
peak torque capability of the motor. Most Bodine motors will produce
about 200% of rated torque with the horsepower switches set per Table 2
and with the TORQ pot turned fully clockwise. The motor must be
properly sized for the application so that it only produces this peak torque
intermittently. Turning the TORQ pot fully counterclockwise will produce
0% torque (stall).
ACCELERATION & DECELERATION TIME – The ACC pot
simultaneously adjusts both the acceleration and deceleration times
within the range selected by DIP switches 7 and 8 per Table 3. Turn CW
to increase times.
SPEED REGULATION - The REG pot sets the gain of the IR
compensation. It is factory-set so that the speed of most Bodine motors
varies no more than 2% from no load to full load at full speed when the
horsepower switches are set per Table 2. The REG pot normally
requires no adjustment by the user unless better speed regulation is
needed or no speed regulation is needed. Turn the REG pot clockwise to
increase IR compensation. Turning it too much will make the system
unstable. If that happens, turn the REG pot counterclockwise to reduce
IR compensation. When using the WPM control in a closed-loop system
with another control device, turn the REG pot fully counterclockwise to
eliminate IR compensation.

11
TROUBLESHOOTING
WARNING
Disconnect the control from the AC power source and wait
seven minutes before working on the control, motor, or driven
equipment.
If the motor does not operate, first carefully remove the enclosure cover
and observe the condition of the two diagnostic LEDs.
1. If the green “PWR” LED is not illuminated, the control is not getting
power from the AC line. Turn the ON/OFF switch off and double
check all connections and fuses.
2. If both the green “PWR” LED and the red “LMT” LED are illuminated,
make sure the TORQ pot is not turned fully counterclockwise. If the
motor is overloaded, reduce the load or use a larger motor.
3. If a fuse is blown and the motor is overloaded, reduce the load and
replace the fuse with a new one of the same type and rating.
4. If a fuse is blown and the motor is not locked (stalled) or overloaded,
do not replace the fuse. The control may be damaged.
5. If the problem persists, contact your source of purchase or a Bodine
Authorized Service Center and describe the problem in detail.
Include all nameplate data for both motor and control.

12
BODINE LIMITED WARRANTY
The Bodine Electric Company warrants all products it manufactures to be free of defects
in workmanship and materials when used under Normal Operating Conditions and when
applied in accordance with nameplate specifications.
When Bodine motors and gearmotors have been purchased with and used only with
appropriately applied Bodine controls, this warranty shall be in effect for a period of
twenty-four months from date of purchase or thirty months from date of manufacture,
whichever comes first. Bodine motors and gearmotors used with non-Bodine motors and
gearmotors are covered by the standard twelve-month warranty period.
The Bodine Electric Company will repair or replace at its option, any of its products which
has been found to be defective and is within the warranty period, provided that the
product is shipped freight prepaid, with previous authorization, to Bodine’s plant in
Chicago, Illinois 60618 U.S.A., or to the nearest Bodine Authorized Service Center. At its
option, all return shipments are F.O.B. Bodine’s plant or Authorized Service Center.
Bodine is not responsible for removal, installation, or any other incidental expenses
incurred in shipping the products to or from Bodine.
This warranty is in lieu of any other expressed or implied warranty - including (but not
limited to) any implied warranties of merchantability and/or fitness for a particular use or
purpose.
Bodine’s liability under this warranty shall be solely limited to repair or replacement of the
Bodine product within the warranty period and Bodine shall not be liable, under any
circumstances, for any consequential, incidental or indirect damages or expenses
associated with the warranted products.
Commutator and/or brush wear and its associated effects are normal occurrences and
are not covered by this warranty unless otherwise agreed to by Bodine in writing.
Proof of purchase of motor or gearmotor and matching control as a system must be
provided with any claim.
2500 W. Bradley Place
Chicago, IL 60618
Phone: [phone], Fax: [phone]
www.bodine-electric.com
P/N 074 01042 E (FZ)