Please read and save these instructions. Read carefully before attempting … · 2019. 12. 23. · under normal motor loading, on voltages up to 10% of the specified voltage. For

Form 5S7031 Printed in U.S.A03338Version 0

LT92 A-5-3674B(1111)

Dayton® AdjustableSpeed Motors

Operating Instructions & Parts Manual 4Z248H, 1F800H, 1F796H, 2Z846H, 1F798H and 4Z226H

Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for future reference.

DescriptionDayton adjustable speed permanent magnet DC motors, equipped with a motor control, is designed for use on constant (or diminishing) torque applications such as conveyors, fans, blowers, etc.

Models

Figure 1 - Adjustable Speed Motor Control Mounted on Motor

Motor Control Features• Speed Range: 50 to 1 constant torque

• Speed Regulation: Within 1% of base speed

• Full-Wave Rectification

• Current/Torque Limit: Preset (Adjustable)

• IR Compensation: Preset (Adjustable)

• Max Speed: Preset (Adjustable)

• Min Speed: Preset (Adjustable)

• Soft Start Acceleration: Preset (Fixed)

Model # Voltage Horsepower RPM

4Z248 90 1/4 1750

1F800 90 1/2 1750

1F796 90 ¾ 1750

2Z846 90 ¾ 2500

1F798 90 1 1750

4Z226 180 1.5 2500

• MOV Transient and Surge Protection

• All Control Circuitry on One Printed Board

• Control Protection: Fused (Front Panel)

• Run/Stop Switch: Run CW / Stop / Run CCW

• Power On Indicator Light

• NEMA 1 Enclosure

• Remote Mountable Controller

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Dayton Operating Instructions and Parts Manual

Dayton® DC Motor Control4Z248H, 1F800H, 1F796H, 2Z846H, 1F798H and 4Z226H

Application InformationIf replacing another motor with this motor and control, make sure that the full load torque rating of the DC motor is equal to, or greater than, the full load torque rating of the motor being replaced. Also, consider how much starting torque is required. This control is adjusted to limit the motor starting torque to 150% of the motor's full load torque rating.

Do not operate motor and contol near high capacitive discharge electrical equipment such as SCR heaters, electrical welding equipment, etc.

Tampering with or any attempt to modify this control will void the warranty. Incorrect wiring and accidental grounds will seriously damage the control and/or motor and will void the warranty.

General Safety Information

Disconnect power before installing or servicing.

1. Lock and tag the power disconnect to OFF to prevent unexpected application of power.

2. Follow all local electrical and safety codes as well as the National Electrical Code (NEC) and the Occupational Safety and Health Act (OSHA).

3. Motor and control must be securely and adequately grounded. This

can be accomplished by plugging into a properly wired and grounded three prong receptacle, wiring with a grounded, metal-clad raceway system, by using a separate ground wire connected to the bare metal of the motor and control frame, or other suitable means. Refer to NEC Article 250 (Grounding) for additional information.

4. Provide guarding for all moving parts.

5. Do not touch the frame of an operating motor or control. When fully loaded they may run at very hot temperatures. Modern-designed motors normally run hot at rated voltage and load.

6. Protect the power cable from sharp objects.

7. Do not kink the power cable, and never allow it to touch oil, grease, hot surfaces, or chemicals.

8. Make certain that the power source conforms to the requirements of your equipment.

9. Keep dirty cleaning rags and flammable waste materials in a tightly closed metal container or dispose of in the proper fashion.

10. If needed, clean the front of the control enclosure with a mild solution.

PreinstallationThe adjustable speed motor was given a thorough electrical and mechanical inspection before shipment. To make sure that no damage has occured during shipment, the following check procedure should be made before installing the unit:

1. Rotate the shaft manually to make

sure that it turns freely. Due to magnetic field, a slight resistance will be noticed.

2. Carefully remove key from motor shaft.

Motor shaft keyway edges may be sharp and it is recommended that only qualified electricians or service people should install, troubleshoot, maintain, or service the control, motor, and interconnect wiring.

3. Clamp motor base to work bench or table and plug control into the correct VAC power source. After supplying power to the control, turn the power switch to Run CW and gradually advance the speed control knob clockwise. The motor shaft should begin to rotate.

4. Adjust the speed by rotating the speed control knob on the control. Observe that the motor speed changes properly as the control is rotated from zero speed to maximum.

5. Disconnect the control from the temporary power source.

Installation

Be sure power is disconnected or OFF at Fuse box or circuit breaker before installing unit.

MOUNTING THE MOTOR

Do not install the control and motor where the atmosphere is (or may become) explosive.

1. The motor should be installed in a location as cool and dry as possible and should be protected against excessive moisture or deposits of dust or dirt. The motor must NOT be confined in a small space that will

3

Models: 4Z248H, 1F800H, 1F796H, 2Z846H, 1F798H and 4Z226H


restrict the flow of cooling air over the motor.

2. Before tightening the motor mounting bolts, make sure all four mounting points of the base are in contact with the surface to which the motor is being attached. If the motor base does not contact the mounting surface properly, add shims where required.

3. After the motor has been properly adjusted to the mounting surface, tighten all motor mounting bolts securely.

4. Motor may be mounted to any right angle or in-line speed reducer with NEMA 56C face mounting dimensions. Base may be removed if required. The speed reducer should be capable of accepting the maximum motor speed.

RELOCATING CONTROL (If necessary)

1. The control is mounted on the end of the motor with brackets. It can be removed from the brackets and mounted on any convenient vertical surface (metal preferred). A location should be chosen that is away from hot surfaces and where a natural flow of air can pass over the control.

2. To remove the control from the motor, remove the four machine screws that fasten it to the brackets.

3. Once removed, the control can be mounted in a new location by means of the four holes in the flanges on the back of the control.

4. The brackets may be removed from the motor fan guard by removing the four nuts that fasten them to the fan guard.

Avoid locating the control where vibration, temperature, moisture, oil, and/or dust will affect control operation or damage control components.

When attaching brackets to the fan guard, use the original machine screws or screws of equal length. Screws longer than 1/4 inch will extend in the fan guard and cause damage to the fan.

OPERATING PROCEDURES

Failure to follow this procedure may cause damage to control components.

1. To start and run the motor, proceed as follows:

a. Select OFF position on control direction switch.

b. Turn ON AC power, and place control power switch in Run CW position.

c. Set desired motor speed with speed control dial. Motor will accelerate to selected speed.

d. Change motor speed with speed control dial.

2. To reverse motor when it is running, proceed as follows:

a. Switch control direction to OFF position. Wait for motor to come to a complete stop.

b. Switch direction control to opposite direction. Motor will accelerate to selected speed in opposite direction.

3. To shut down motor and control for longer periods, proceed as follows:

a. Turn control power switch to OFF.

b. Turn OFF AC power to control, if desired.

This unit is not intended for applications requiring rapid reversing. Motor must come to a complete stop before applying power in the opposite direction.

The soft start circuit in the control limits motor acceleration, ensuring smooth acceleration to the set speed. The speed control setting and the amount of inertia in the system affect the acceleration rate.

When the motor is not loaded, speed pulsations may occur in some portion of the motor speed range. Such pulsations are normal, and will disappear when load is applied to the motor.

FUSING

Recommended Fuse Replacement:

Use Bussman ABC or Littlefuse 314 series or equivalent fusing when replacement of the fuse is required. Refer to the chart below for fusing size requirements of each model.

Do not substitute higher rated or "slow blow" fuses. Frequent fuse blowing is indicative of overloading or a defective motor or control unit.

MOTOR

1. The ball bearing in both endshields of the motor have been lubricated at the factory with the correct lubricant.

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No additional lubrication is required for the life of the unit.

2. Different applications result in different rates of wear on the brushes. Experience will dictate the proper interval for inspection. A 200 hour interval is recommended for vacuuming/removing brush dust and inspection of the brushes until wear rate is established. Replacement brushes should be installed before old brushes wear down to 3/8" long. After replacing brushes, run the motor near rated speed for 1/2 hour with no load to seat the new brushes.

Failure to properly seat new brushes may cause commutator damage and rapid wear of the new brushes. If the commutator becomes rough, scored, or out of round, a competent motor shop should disassemble the motor and resurface the commutator or replace the armature.

With every third brush charge, have a competent motor shop resurface the commutator or replace the armature, and blow the carbon dust out of the motor. Make sure to use Dayton brand replacement brushes in this motor. Call your local Grainger branch for replacement parts

3. Every effort should be made to prevent foreign material from accumulating on the motor and around its fan. (Such accumulations divert cooling air flow away from the motor.)

Motors used on woodworking tools are particularly susceptible to the accumulation of sawdust and wood chips and should be blown out or

vacuumed frequently to prevent interference with normal motor ventilation.

Use eye protection when using air pressure.

OPERATING PROBLEMS

If high voltage surges (or transients) are present on the supply power line, connect the control input to an isolation transformer or to other line filters.

Most motor problems are caused by one of the following conditions:

1. Loose connections at control or motor.

2. Overloading the motor.

3. Low voltage at motor input terminals.

Most motor troubles can be traced to loose or incorrect connections, overloading, or reduced input voltage which results when small size wires are used in the supply circuit, or when the supply circuit lead length is too long for the wire size being used.

Always check connections, load, and supply circuits if motor fails to perform satisfactorily. Although the control is designed to operate on the voltage/frequency AC power specified on its nameplate, it will also operate safely, under normal motor loading, on voltages up to 10% of the specified voltage.

For heavy motor loads, however, do NOT operate the control on AC voltages lower than the specified nameplate voltage.

Some common causes of low voltage

not previously mentioned are:

1. AC supply circuit overloaded by lights, electrical appliances, or other motors.

2. Low incoming line voltage caused by distribution system overloads.

3. Undersized AC lines in building where control is being used.

Some effects of low voltage are:

1. Motor power loss.

2. Slow motor starting.

3. Slow motor running (won't reach base speed).

4. Motor overheating.

5. Frequent fuse blowing and/or circuit breaker opening

NOTE: Effects 2 through 5 can also be caused by motor overloads.

MAINTENANCE

Make certain that the power supply is disconnected before attempting to service or remove any components! If the power disconnect point is out-of-sight, lock it in the OPEN position and tag it to prevent unexpected application of power. Only a qualified electrician or service person should perform any electrical troubleshooting or maintenance.

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TRIMPOT SETTINGS

The controller has been factory tuned and set for the optimum performance and protection of the motor it is running. The control trim pots should closely reflect the default factory trimpot chart shown above for each model. However some applications may require slight adjustments to the trimpot settings to suit the specific needs of that application. Trimpots can be adjusted based on the setup guidelines outlined below.MIN. - Sets minimum motor speed when speedpot is set at zero. CW rotation will increase min speed setting. To set:1. Set Speedpot to zero (fully CCW). 2. Rotate MIN trimpot CW until motor starts to turn.3. Slowly rotate MIN trimpot CCW until motor stops or continue CW to desired MIN speed.

MAX. - Sets maximum motor speed with speedpot set fully CW. A CW rotation of MAX increases Maximum motor speed. Note: Do not exceed motor voltage rating. To set:1. Set speedpot to full CW setting.2. Connect a DC Voltmeter: + to +ARM, - to -ARM. 3. Adjust MAX trimpot to desired maximum setting or to the rated motor voltage.

IR COMP - Provides a means of improving motor speed regulation with changing load. If speed regulation with load change is of no concern, then set fully CCW. NOTE: An IR Comp trimpot set too high can cause oscillation. To set:1. Set Speedpot at 50%.2. Observe motor speed at no load condition.3. Apply full load to motor. 4. Turn IR COMP trimpot CW to obtain the same motor speed as with no load.

CUR.LIM. - Limits DC motor current to prevent damage to the motor or control. CW rotation of this trimpot increases the maximum allowable armature current (or torque produced). To set:1. Connect a DC current meter between A1 on motor and +ARM on the control (in series with the motor).2. Set Speedpot at 50% or above. 3. Turn CL trimpot full CCW.4. Stall and lock motor shaft so it can not spin. 5. With motor stalled, set current at 125% of rated motor current by adjusting C.L. trimpot CW.

MIN MAX I.R. C.L. HPMODEL VDC

4Z248

1F800

1F796

2Z846

1F798

4Z226

90

90

90

90

90

180

1/4

1/2

3/4

3/4

1

1.5

6



6

Figure 2 - Dimensions

MODEL: 4Z248H

MOTOR CONTROL

Power Input: 115VAC, 10%

Phase: Single 50/60 Hz

Full load continuous DC amps: 2.5

Fuse Type: 5 Amp

Speed Control dial increment: 0-100

Enclosure: NEMA 1

PERMANENT MAGNET DC MOTOR

HP: 1/4

RPM: 1750

Armature: 90 VDC

Insulation: Class F

Duty: Continuous

Maximum Ambient: 40oC

Enclosure: TEFC

Frame: NEMA 56 C

Mounting: All position

Service Factor: 1.0

OPERATION

This adjustable speed motor is designed for operation on 115 VAC, 10%, 50/60 Hz power only. The control is equipped with a three-prong connector plug for safety, and should be plugged directly into a properly grounded three prong receptacle.

If the line plug must be removed, connect the line cord as follows: Black or brown and white or blue conductors to hot 115VAC power leads and green or green/yellow conductor to the grounded (green) lead of the power source. Refer to the General Safety Information section, No. 3, for additional grounding information. Connection to any other source of power will permanently damage the control and void the warranty.

If the correct voltage is not available at the point of installation, a suitable dry type isolation transformer should be installed. The primary voltage should match the available voltage and the secondary voltage should be 115 volts. The minimum capacity of this transformer should be 500 volt amperes (0.5 KVA).

The motor load for continuous operation, at various speeds, should not exceed the values listed in the Motor Load Table.

MOTOR LOAD TABLE

Speed RPM

Cont. Duty HP

F/L Torque LB. In.

Percent F/L Torque

1750 1/4 9.1 100%1300 3/16 9.1 100%865 1/8 9.1 100%430 1/16 9.1 100%340 1/20 9.1 100%230 1/30 9.1 100%170 1/40 9.1 100%86 1/80 9.1 100%

4.8806.500

6.500

45

(4) 3/8-16 UNC-2BON A 5.875 BC

.119

3.50

0

45

6.000

5.125 6.931

15.412

2.750 3.000

8.750

.625

2.060

8

0 10

2

4 6

DC Speed Control

POWER ON

LINE FUSE

ROTATIONFACING SHAFT

RUNCW

RUNCCW

STOP

1.2202.440

7



7

Dayton Operating Instructions and Parts Manual 4Z248H, 1F800H, 1F796H, 2Z846H, 1F798H and 4Z226H

MODEL: 1F800H

4.8806.500

6.500

45

(4) 3/8-16 UNC-2BON A 5.875 BC

.119

3.50

0

45

6.000

5.125 6.931

16.412

2.750 3.000

9.750

.625

2.060

8

0 10

2

4 6

DC Speed Control

POWER ON

LINE FUSE


RUNCW

RUNCCW

STOP

1.2202.440

MOTOR CONTROL



Full load continuous DC amps: 5

Fuse Type: 10 Amp


Enclosure: NEMA 1


HP: 1/2

RPM: 1750

Armature: 90 VDC

Insulation: Class F

Duty: Continuous


Enclosure: TEFC

Frame: NEMA 56 C


Service Factor: 1.0

OPERATION





MOTOR LOAD TABLE

Speed RPM

Cont. Duty HP

F/L Torque LB. In.

Percent F/L Torque

1750 1/2 18.2 100%1300 3/8 18.2 100%865 1/4 18.2 100%430 1/8 18.2 100%220 1/16 18.2 100%170 1/20 18.2 100%


8



8

MODEL: 1F796H

4.8806.500

6.500

45

(4) 3/8-16 UNC-2BON A 5.875 BC

.119

3.50

0

45

6.000

5.125 6.931

18.412

2.750 3.000

11.750

.625

2.060

8

0 10

2

4 6

DC Speed Control

POWER ON

LINE FUSE


RUNCW

RUNCCW

STOP

1.2202.440

MOTOR CONTROL




Fuse Type: 12 Amp


Enclosure: NEMA 1


HP: 3/4

RPM: 1750

Armature: 90 VDC

Insulation: Class F

Duty: Continuous


Enclosure: TEFC

Frame: NEMA 56 C


Service Factor: 1.0

OPERATION






MOTOR LOAD TABLE

Speed RPM

Cont. Duty HP

F/L Torque LB. In.

Percent F/L Torque

1750 3/4 27.0 100%1470 5/8 27.0 100%1155 1/2 27.0 100%875 3/8 27.0 100%577 1/4 27.0 100%295 1/8 27.0 100%140 1/16 27.0 100%

9



9


OPERATION





MOTOR LOAD TABLE

Speed RPM

Cont. Duty HP

F/L Torque LB. In.

Percent F/L Torque

2500 3/4 18.9 100%2100 5/8 18.9 100%1650 1/2 18.9 100%1250 3/8 18.9 100%825 1/4 18.9 100%425 1/8 18.9 100%200 1/16 18.9 100%125 1/20 18.9 100%


MODEL: 2Z846H

4.8806.500

6.500

45

(4) 3/8-16 UNC-2BON A 5.875 BC

.119

3.50

0

45

6.000

5.125 6.931

16.412

2.750 3.000

9.750

.625

2.060

8

0 10

2

4 6

DC Speed Control

POWER ON

LINE FUSE


RUNCW

RUNCCW

STOP

1.2202.440

MOTOR CONTROL




Fuse Type: 12 Amp


Enclosure: NEMA 1


HP: 3/4

RPM: 2500

Armature: 90 VDC

Insulation: Class F

Duty: Continuous


Enclosure: TEFC

Frame: NEMA 56 C


Service Factor: 1.0

10



10

OPERATION





MOTOR LOAD TABLE

Speed RPM

Cont. Duty HP

F/L Torque LB. In.

Percent F/L Torque

1750 1 36.6 100%1300 3/4 36.6 100%1080 5/8 36.6 100%865 1/2 36.6 100%650 3/8 36.6 100%430 1/4 36.6 100%220 1/8 36.6 100%110 1/16 36.6 100%85 1/20 36.6 100%


MODEL: 1F798H

4.8806.500

6.500

45

(4) 3/8-16 UNC-2BON A 5.875 BC

.119

3.50

0

45

6.000

5.125 6.931

20.412

2.750 3.000

13.750

.625

2.060

8

0 10

2

4 6

DC Speed Control

POWER ON

LINE FUSE


RUNCW

RUNCCW

STOP

1.2202.440

MOTOR CONTROL



Full load continuous DC amps: 10

Fuse Type: 15 Amp


Enclosure: NEMA 1


HP: 1

RPM: 1750

Armature: 90 VDC

Insulation: Class F

Duty: Continuous


Enclosure: TEFC

Frame: NEMA 56 C


Service Factor: 1.0

11



11


OPERATION





MOTOR LOAD TABLE

Speed RPM

Cont. Duty HP

F/L Torque LB. In.

Percent F/L Torque

2500 1 1/2 37.8 100%2100 1 1/4 37.8 100%1650 1 37.8 100%1250 3/4 37.8 100%825 1/2 37.8 100%425 1/4 37.8 100%200 1/8 37.8 100%125 1/13 37.8 100%83 1/20 37.8 100%


MODEL: 4Z226H

4.8806.500

6.500

45

(4) 3/8-16 UNC-2BON A 5.875 BC

.119

3.50

0

45

6.000

5.125 6.931

19.412

2.750 3.000

12.750

.625

2.060

8

0 10

2

4 6

DC Speed Control

POWER ON

LINE FUSE


RUNCW

RUNCCW

STOP

1.2202.440

MOTOR CONTROL




Fuse Type: 12 Amp


Enclosure: NEMA 1


HP: 1 1/2

RPM: 2500

Armature: 180 VDC

Insulation: Class F

Duty: Continuous


Enclosure: TEFC

Frame: NEMA 56 C


Service Factor: 1.0

12



12

LIMITED WARRANTY

DAYTON ONE-YEAR LIMITED WARRANTY. DAYTON® MODELS COVERED IN THIS MANUAL, ARE WARRANTED BY DAYTON ELECTRIC MFG. CO. (DAYTON) TO THE ORIGINAL USER AGAINST DEFECTS IN WORKMANSHIP OR MATERIALS UNDER NORMAL USE FOR ONE YEAR AFTER DATE OF PURCHASE. ANY PART WHICH IS DETERMINED TO BE DEFECTIVE IN MATERIAL OR WORKMANSHIP AND RETURNED TO AN AUTHORIZED SERVICE LOCATION, AS DAYTON DESIGNATES, SHIPPING COSTS PREPAID, WILL BE, AS THE EXCLUSIVE REMEDY, REPAIRED OR REPLACED AT DAYTON’S OPTION. FOR LIMITED WARRANTY CLAIM PROCEDURES, SEE “PROMPT DISPOSITION” BELOW. THIS LIMITED WARRANTY GIVES PURCHASERS SPECIFIC LEGAL RIGHTS WHICH VARY FROM JURISDICTION TO JURISDICTION.

LIMITATION OF LIABILITY. TO THE EXTENT ALLOWABLE UNDER APPLICABLE LAW, DAYTON’S LIABILITY FOR CONSEQUENTIAL AND INCIDENTAL DAMAGES IS EXPRESSLY DISCLAIMED. DAYTON’S LIABILITY IN ALL EVENTS IS LIMITED TO AND SHALL NOT EXCEED THE PURCHASE PRICE PAID.

WARRANTY DISCLAIMER. A DILIGENT EFFORT HAS BEEN MADE TO PROVIDE PRODUCT INFORMATION AND ILLUSTRATE THE PRODUCTS IN THIS LITERATURE ACCURATELY; HOWEVER, SUCH INFORMATION AND ILLUSTRATIONS ARE FOR THE SOLE PURPOSE OF IDENTIFICATION, AND DO NOT EXPRESS OR IMPLY A WARRANTY THAT THE PRODUCTS ARE MERCHANTABLE, OR FIT FOR A PARTICULAR PURPOSE, OR THAT THE PRODUCTS WILL NECESSARILY CONFORM TO THE ILLUSTRATIONS OR DESCRIPTIONS. EXCEPT AS PROVIDED BELOW, NO WARRANTY OR AFFIRMATION OF FACT, EXPRESSED OR IMPLIED, OTHER THAN AS STATED IN THE “LIMITED WARRANTY” ABOVE IS MADE OR AUTHORIZED BY DAYTON.

Technical Advice and Recommendations, Disclaimer. Notwithstanding any past practice or dealings or trade custom, sales shall not include the furnishing of technical advice or assistance or system design. Dayton assumes no obligations or liability on account of any unauthorized recommendations, opinions or advice as to the choice, installation or use of products.

Product Suitability. Many jurisdictions have codes and regulations governing sales, construction, installation, and/or use of products for certain purposes, which may vary from those in neighboring areas. While attempts are made to assure that Dayton products comply with such codes, Dayton cannot guarantee compliance, and cannot be responsible for how the product is installed or used. Before purchase and use of a product, review the product applications, and all applicable national and local codes and regulations, and be sure that the product, installation, and use will comply with them.

Certain aspects of disclaimers are not applicable to consumer products; e.g., (a) some jurisdictions do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you; (b) also, some jurisdictions do not allow a limitation on how long an implied warranty lasts, consequently the above limitation may not apply to you; and (c) by law, during the period of this Limited Warranty, any implied warranties of implied merchantability or fitness for a particular purpose applicable to consumer products purchased by consumers, may not be excluded or otherwise disclaimed.

Prompt Disposition. A good faith effort will be made for prompt correction or other adjustment with respect to any product which proves to be defective within limited warranty. For any product believed to be defective within limited warranty, first write or call dealer from whom the product was purchased. Dealer will give additional directions. If unable to resolve satisfactorily, write to Dayton at address below, giving dealer’s name, address, date, and number of dealer’s invoice, and describing the nature of the defect. Title and risk of loss pass to buyer on delivery to common carrier. If product was damaged in transit to you, file claim with carrier.

Manufactured for Dayton Electric Mfg. Co., 100 Grainger Parkway, Lake Forest, Illinois 60045-5201 U.S.A.


Documents

Please read and save these instructions. Read carefully before attempting … · 2019. 12. 23. · under normal motor loading, on voltages up to 10% of the specified voltage. For