Mercury Blower Line User Guide - SFEG · Mercury line. The motor speed can be controlled using an...

2268 Fairview Blvd. Fairview, TN 37062

(615) 799-0551 (800) 753-2753

FAX: (615) 799-9670 www.northlandmotor.com

[email protected]

Mercury Blower Line User Guide

Table of Contents 1 Safety Information ..................................................................... 3

1.1 Warnings, Cautions, and Notes ........................................... 3 1.2 Mechanical Safety – General Warning ............................... 3 1.3 Electrical Safety – General Warning .................................. 3 1.4 Warranty Information ......................................................... 4

2 Introduction ................................................................................ 5 2.1 Benefits of Brushless vs. Brushed DC Motors ................... 5 2.2 Mercury Blower Line ......................................................... 7

3 Installation .................................................................................. 9 3.1 Blower Installation.............................................................. 9 3.2 Electrical Connections ...................................................... 10

4 Operation .................................................................................. 11 4.1 Operational Specifications ................................................ 12 4.2 Speed Control ................................................................... 12 4.3 Initial Start ........................................................................ 12

5 Troubleshooting ........................................................................ 14 5.1 Motor will not start ........................................................... 14 5.2 Motor runs, but will not reach desired speed .................... 14

Mercury Blower Line User Guide P/N 26020 Rev .03

14

5 Troubleshooting

5.1 Motor will not start Cause SolutionAC power is not applied Check AC power input connection

Ensure electrical interlock is not enabled (if applicable)Electrical connector is mis-wired Check electrical connections (Figure 3/4)Polarity of speed control input is reversed Switch speed control input polarity (See figure 3/4)In electrical model, combination of internal Adjust internal potentiometer clockwise potentiometer setting and input voltage prevents Increase DC speed control input voltage unit from startingMotor is stalled; blower impeller is blocked Check blower inlet or impeller for blockageInternal temperature still exceeds +85°C due to Wait for the blower to cool (~30 mins) operating point, ambient temperature, or bothController is not reset. Remove AC power, wait 60 seconds before

reapplying.

Table 5 - Troubleshooting: Motor will not start

5.2 Motor runs, but will not reach desired speed Cause SolutionAC Line voltage is outside normal range Increase AC input voltageIn mechanical control, internal potentiometer isimproperly adjusted

Adjust internal potentiometer clockwise

In electrical control, internal potentiometer is Adjust internal potentiometer clockwise improperly adjusted or speed command input Increase DC speed control input voltage voltage is insufficientBlower inlet, impeller or motor shaft is blocked Check blower inlet or impeller for blockageBlower output capability is undersized for the Select a larger blower for the specific application application

Table 6 - Troubleshooting: Motor will not reach desired speed


3

1 Safety Information READ AND SAVE THESE INSTRUCTIONS

1.1 Warnings, Cautions, and Notes

A Warning , noted by this image, contains information which is essential for avoiding a safety hazard.

A Caution, noted by this image, contains information which is essential for avoiding a risk of damage to the product or other equipment.

A Note, noted by this text, contains information which helps to ensure correct operation of the product.

1.2 Mechanical Safety – General Warning The Mercury blowers covered in this guide spin at high speeds.

All blowers should be properly mounted before starting. Extreme care is necessary when working with or near to them while they are in use. The blower must never be tampered with while running. All persons near a running blower should be aware of the inlet and never insert anything or allow for anything to be sucked into it, eg. loose clothing, hair, etc.... In addition, these blowers should never be used in a safety critical application without additional high integrity protection against hazards arising from a malfunction. No Mercury blowers should be disassembled for any reason; doing so could potentially lead to an unsafe blower and will void the manufacturer’s warranty.

Specific warnings are given at the relevant places in this user guide.

1.3 Electrical Safety – General Warning The blowers covered in this guide operate at high voltages.

These voltages can cause fire, severe electrical shock and /or burns, and could be lethal. Extreme care is necessary when working with or near these blowers anytime that they are attached to power, not only when


4

they are in use. The blower should never be installed or moved unless power is disconnected. If a safety hazard could arise from unexpected starting of the blower, an interlock that electrically isolates the blower from the AC supply must be installed to prevent the motor from being inadvertently started.

Specific warnings are given at the relevant places in this user guide.

1.4 Warranty Information The Seller expressly warrants that equipment and material

manufactured by it will be free from defects in material, workmanship and title at the date of shipment. This Warranty is exclusive and is offered in LIEU OF ALL IMPLIED OR STATUTORY WARRANTIES (INCLUDING WITHOUT LIMITATION, WARRANTIES AS TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, OR ARISING FROM COURSE OF DEALING OR USAGE OF TRADE) or any other express or implied warranties or representations. All claims under this Warranty must be made in writing and delivered to the Seller prior to the expiration of twelve (l2) months from the date of manufacture or be barred. Upon receipt of a timely claim, the Seller shall inspect the item or items claimed to be defective, and Seller shall, at its option, modify, repair or replace, free of charge, any item or items which the Seller determines to have been defective at the time of shipment from the factory, excluding normal wear and tear. Inspection may be performed at the Seller's plant, and in such event, freight for returning items to the plant for inspection shall be paid by Buyer. Seller shall have no responsibility if such item has been improperly stored, installed, operated, maintained, modified and /or repaired by an organization other than the Seller. Adjustments for items of equipment and material not manufactured by Seller shall be made to the extent of any warranty of the manufacturer or supplier thereof. The foregoing shall be Seller's sole and exclusive liability and Buyer's sole and exclusive remedy for any breach of warranty or for any other claim based on any defect in, or non-performance of, the equipment and material, whether based on breach of contract or in tort, including negligence or strict liability.


13

For initial testing, or in order to check performance, the AC voltage may be increased slowly using an adjustable AC voltage source or variable transformer with the speed command set to maximum speed.

a) Mechanical Control 1. Set the internal potentiometer fully counter-

clockwise 2. Apply AC power to the unit. 3. Adjust the potentiometer clockwise to

increase motor speed in order to obtain the desired speed, pressure, or flow.

b) Electrical Control 1. Set the internal potentiometer fully

clockwise. 2. Apply the minimum speed control input

voltage (+0VDC). 3. Apply AC power to the unit. 4. Increase the speed control input voltage until

the motor begins to rotate. 5. Adjust the input voltage to reach the desired

speed, pressure, or flow. In addition to the input voltage, the internal potentiometer can be adjusted to vary the motor speed and reach the desired output.


12

4.1 Operational Specifications 120V MODELS 240V MODELS CONNECTIONS NOTES

50/60Hz, single phase

AMBIENT TEMP

-40 – +185°F

Operational: 0 – +50°C

Storage: -40 – +85°C+32 – +122°F

AC INPUT VOLTAGE

INPUT POWER

ANALOG SPEED CONTROL INPUT

90 – 132VAC

200 – 800W

+1.5 – +10VDC

400 – 1300W

180 – 264VAC

Pin 1(-), 2(+)Actual input voltage range will depend on the potentiometer setting

For 120VAC operation, neutral should be a grounded neutral

Thru-Flow – Pin 5(N/L), 6(L)Bypass – Pin 4(N/L), 5(L)

Actual power input will depend upon the application

Table 4 - Operational Specifications

4.2 Speed Control

Various speed control modes are available for blowers in the Mercury line. The motor speed can be controlled using an analog DC voltage (Pins 1(-) & 2(+)), or directly via an internal potentiometer. In addition to controlling the speed of the motor directly, the internal potentiometer can be used to adjust speed when using analog control.

The actual performance of the blower in the user’s system will depend upon the application. The ability to control motor speed provides several benefits. First, changing motor speed varies the blower output, allowing the user to adjust the blower output for a particular application. In addition, the blower may be part of an outer control loop in which the motor speed is varied using the output from the blower as an input to a control algorithm in order to maintain a desired output. For example, the user may adjust motor speed to maintain constant pressure.

4.3 Initial Start

WARNING – PLEASE FOLLOW THESE STEPS FOR STARTING THE BLOWER FOR THE FIRST TIME TO PREVENT INJURY TO PERSONS OR DAMAGE TO THE BLOWER


5

2 Introduction Thank you very much for choosing a high quality product from

Northland Motor Technology. Our four decades of designing and building motors has taught us that customers like you are the backbone of our company; which is why each motor we build is backed by a strong commitment to quality, design value and efficiency. High quality products are just one of the reasons customers keep coming back to Northland, and we hope you do too.

2.1 Benefits of Brushless vs. Brushed DC Motors

Those of you familiar with DC motors might wonder exactly what the difference between brushed and brushless motors is, besides what the name implies. Those of you familiar with permanent magnet brushed DC motors, might think of a brushless motor as an inside-out brushed PM motor. In a brushed PM motor, the permanent magnets are found on the outside, stationary part of the motor (stator), while the windings are found in the rotating part of the motor (rotor). In our Mercury brushless DC motor line, this is exactly the opposite; the permanent magnets are on the rotor, while the windings are found on the stator. In addition, brushless DC motors do not have brushes, as the name implies. In a brushed PM DC motor, brushes control the switching of the windings on the rotor in order to keep it moving or commutating. As the rotor spins, the brushes move too, which causes the windings to keep switching and the rotor to keep spinning. This form of commutation is simple and easy to implement, however it has it’s drawbacks which will be discussed later. In BLDC motors, there are no brushes to switch windings. The commutation is controlled electronically.

Figure 1 - PMDC vs. BLDC Motor Construction


6

There are many reasons for switching from a brushed PMDC motor to a BLDC. A number of these are due to the elimination of the brushes for commutation in BLDC motors. When the brushes move from one winding to the next in a PMDC motor, there is an arc created. This arcing is not possible to eliminate and has several downsides. First, the arc created requires a lot of power, which in turn makes the motor less efficient. The arcing will eventually wear the brushes over time, which will require that the brushes to be replaced. The typical lifespan of these brushes is lower than that of the commutator; requiring replacement of the brushes at least once during the life of the motor. This arcing also increases the electric noise generation of the motor, which generates noise in any electrical signal nearby. Simply using brushes for commutation limits the maximum speed of the motor and changes its speed/torque curves. As motor speed increases, the friction caused by the brushes also increases; giving less power at higher speeds and lowers the overall possible speed of a PMDC motor. A BLDC motor, on the other hand does not use brushes for commutation, and as such, all of these problems are eliminated. This gives the BLDC motor a longer life, a flat speed/torque curve, a higher maximum speed, all while requiring very little to no maintenance.

Two more reasons for “going brushless” are related to the reversed locations of the permanent magnets and the windings. In DC motors, the armature is the source of most of the heat generated by the motor. In a PMDC motor, the armature is located on the rotor of the motor and the heat is dissipated by the air gap. This increases the temperature in the air gap which limits the power/size ratio of the motor. In a BLDC motor the windings are on the stator, which is attached to the case. This allows for much more efficient removal of heat from the motor allowing BLDC motors to have a higher power/size ratio. The other benefit is decreased rotor inertia. In DC motors, the windings are much heavier than the permanent magnets used. In a BLDC motor, the permanent magnets are on the rotor, which makes the rotor easier to spin than in a PMDC motor. This allows the motor to accelerate/decelerate much more quickly.

Overall, a BLDC motor has many benefits over a PMDC motor. In general, one can find a BLDC motor that is smaller, more powerful, requires less maintenance, and has a longer lifespan than a PMDC motor can offer.


11

b) Bypass Blower Connections AMP plug part number 1-480763-0 or equivalent may be

used for mating connector. Safety Ground connections can be made through the blower frame or through pin 3.

Figure 4 - Bypass Electrical Post Header Assembly

4 Operation

CAUTION – APPLICATION OF MAIN POWER TO THE SPEED CONTROL INPUT PINS OR APPLICATION OF OPPOSITE POLARITY VOLTAGES TO THE SPEED CONTROL INPUT PINS MAY RESULT IN THE DESTRUCTION OF THE CONTROL CIRCUITRY. CHECK ALL CONNECTIONS BEFORE APPLYING POWER

IF AC POWER IS REMOVED OR INTERRUPTED

DURING OPERATION, AND THE BLOWER DOES NOT RESTART; DISCONNECT AC POWER FOR 60 SECONDS AND RECONNECT.


10

Air Inlet & Length (L) Air Inlet & Length (L) Outlet Dia. mm / in. Outlet Dia. mm / in.

mm / in. mm / in.

1 Stage 129 / 5.1 132 / 5.2

2 Stage 152 / 6.0 160 / 6.3

3 Stage 175 / 6.9 185 / 7.3

1 Stage 69 / 2.7 73 / 2.9

2 Stage 92 / 3.6 99 / 3.9

BYPASS

THRU-FLOW

STANDARD FLOW HIGH FLOW

31.8 / 1.25 44.5 / 1.75

Table 3 - Mercury Line Blower Dimensions

3.2 Electrical Connections

WARNING – TO PREVENT INJURY TO PERSONS OR DAMAGE TO THE BLOWER, ENSURE IT IS PROPERLY MOUNTED BEFORE APPLYING POWER

All electrical connections are made through external ports.

Safety ground connections should be made by connecting to the blower frame or through pin 3. Through-flow blowers use a 6-Pin nylon PCB mount connector and bypass blowers use a 5-Pin nylon PCB mount connector for all electrical connections.

a) Through-Flow Blower Connections AMP housing part number 640251-6 or equivalent may

be used for mating connector. Safety ground connections should be made by connecting to the blower frame or pin 3.

Figure 3 – Through-Flow Electrical Post Header Assembly


7

2.2 Mercury Blower Line This user’s guide will provide information on all blowers available

in the Mercury line. All Mercury blowers feature protection for overtemperature and overcurrent conditions and will shutdown to prevent damage to itself. In addition, both through-flow and bypass versions are available. This user’s guide provides performance specifications on all Mercury blowers, the actual field performance will vary depending on the blower characteristics and the user’s application.

All mercury products are cULus recognized components under file number E312944 and were tested to the following safety agency requirements:

ANSI/UL STD. 1004 ANSI/UL STD. 2111 CSA C22.2 No. 77 CSA C22.2 No. 100 Additionally all mercury products meet the following safety

agency requirements: Conforms to ANSI/UL STD. 60950-1 Certified to CSA C22.2 No. 60950-1. Conforms to IEC 60950-1.

High watt bypass mercury products ONLY meet the following safety agency requirements:

Conforms to ANSI/UL STD. 1004 and ANSI/UL STD. 2111. Certified to CSA C22.2 No. 77 and CSA C22.2 No. 100.

a) Bypass Blowers The motor and control are not in the working air, but

clean air must be available for the motor/control cooling function. The available bypass blowers in the Mercury line are listed below. They are separated by flow, (standard/high), wattage (low: 200-500W / high: 800-1300W), AC input voltage (120/240V), and speed control (mechanical/electrical).


8

1 Stage 2 Stage 3 Stage 1 Stage 2 Stage 3 Stage

LOWWATT

(200 -500W)

HIGHWATT

(800 -1300W)

HIGH FLOW

240E

M

120E

M

E

BBA14-111SEB

120

C

O

N

T

R

O

L

240E

M

M

BBA14-112SEB BBA14-113SEB

BBA14-111SMB BBA14-112SMB BBA14-113SMB

V STANDARD FLOW

BBA14-111HEB

BBA14-111HMB

BBA14-211HEB

BBA14-211HMB

BBA14-211SEB BBA14-212SEB BBA14-213SEB


BBA14-113HEB

BBA14-113HMB

BBA14-213HEB

BBA14-213HMB

BBA14-112HEB

BBA14-112HMB

BBA14-212HEB

BBA14-212HMB





BBA14-121HEB BBA14-122HEB BBA14-123HEB

BBA14-121HMB BBA14-122HMB BBA14-123HMB

BBA14-221HEB BBA14-222HEB BBA14-223HEB

BBA14-221HMB BBA14-222HMB BBA14-223HMB

Table 1 - Available Mercury Bypass Blowers E: Electrical Control M: Mechanical Control

b) Through-Flow Blowers The motor and control are cooled by the air flow

through the blower. This type of unit is suitable for handling clean air only. The available through-flow blowers in the Mercury line are listed below. They are separated by flow, (standard/high), AC input voltage (120/240V), and speed control (mechanical/electrical). Only low watt (200-500W) versions of the through-flow blowers are available.

1 Stage 2 Stage 3 Stage 1 Stage 2 Stage 3 Stage

BBA14-213HET

BBA14-213HMT

BBA14-211HET

BBA14-211HET

BBA14-212HET

BBA14-212HET

BBA14-211SET BBA14-212SET BBA14-213SET

BBA14-211SET BBA14-212SET BBA14-213SMT

BBA14-111SMT BBA14-112SMT BBA14-113SMT BBA14-111HMT BBA14-112HMT BBA14-113HMT120

E

MLOW WATT (200 - 500W) 240

E

M

V

CONTROL

STANDARD FLOW HIGH FLOW

BBA14-113SET BBA14-111HET BBA14-112HET BBA14-113HETBBA14-111SET BBA14-112SET

Table 2 - Available Through-Flow Mercury Blowers

E: Electrical Control M: Mechanical Control

For models not shown or custom applications, contact Northland Motor Technology at (800) 753-2753.


9

3 Installation

WARNING - READ AND FOLLOW THIS SECTION CAREFULLY TO PREVENT DAMAGE TO THE MOTOR OR TO PERSONS INSTALLING/OPERATING THE MOTOR

3.1 Blower Installation

WARNING – TO PREVENT INJURY ENSURE THE BLOWER IS NOT CONNECTED TO POWER DURING THE ENTIRE INSTALLATION PROCESS

To install the blower, secure it at the bracket to prevent movement during startup and operation. For use in a pressure application, ensure that the fan covers are tightly secured before starting the blower.

Figure 2 - Blower Housing Diagram

Mercury Blower Line User Guide - SFEG · Mercury line. The motor speed can be controlled using an...

Documents

Transcript of Mercury Blower Line User Guide - SFEG · Mercury line. The motor speed can be controlled using an...