NOTE: 1) The wire diagram shows the wiring set up for a high voltage (460VAC) three phase system. To wire the system as a low voltage (230VAC or 208VAC) three phase system, see the transformer diagram in Detail F and motor wiring in Details D & E.. Different drives are required for 460VAC and 230VAC. 2) Fork Terminals are used to connect to the transformer. The green contacts are grounding terminal blocks and must connect to bare, unpainted DIN rail. 3) The transformer uses IP 2X finger safe protection guards. The electrical box has a keyed cam latch and lift off hinge to secure the door. The transformer is a class 2 transformer and the disconnect / emergency shut off is rated as a motor breaking switch. 4) Primary branch circuit protection consisting of an inverse time fixed trip circuit breaker rated at 30kA IC trip must be provided by the end user. A WS-5 must be attached to a breaker properly sized for the equipment. A single weld station unit must not be attached to a breaker greater than 250% of the FLA of the motor according to NEC Code. The breaker should be rated at 125% of the unit FLA rounded up to the next standard breaker size.
Valve #2 (70")
Valve #1 (50")
Motor Power (80")
To Light Junction Box (45")
To Com. Junction Box (45")
Dirty Air Line [To air fitting on divider panel.] (55”)
Incoming Power run by customer (54" to top of unit) ¾” EMT Compression Connector
2
2
1 GND
1 GND
Motor
[See Detail C]
[See Detail ?]
Clean Air
3/4"
1/2"
1/2"
1/2"
3/8"
3/8"
27 28
2223
0
29
5) Clear flexible tubing is run from the pressure sensor to the air fittings. All air lines must be run free of kinks.
21
0
4 33
0 2 12
0 2 11
6) The disconnect / emergency shut off device is rated at 20 Amps. Additional disconnecting means must be rated at least 20A.
5
6
27 28 29
5
5
6
6
21
22
23
0
0
7) The DIN connectors on the valves must seal with the SOOW cord using the grommet provided with the connector.
2 1 0
L N G
L1 L2 L3
2
2
11
12
0
0
0
8) The light on the Start / Stop double push button must illuminate when the safety relay is activated. The push button is wired so that the normally closed contact (NC) is 'STOP' and the normally open contact (NO) is 'START' and activates the motor / VFD. 9) See Details D and E for motor wiring. Clean Air America has standardized on "Wye" or "Star" voltage wiring method. Wiring connections in the motor’s pecker head must be made using the screw terminals of the distribution block. The distribution block must be screwed to the inside of the pecker head. 10) All wires and air tubing leaving the electrical box should be bound together and prevented from laying lose on the cabinet floor. The wires must be routed out of the electrical box and attached to the floor of the cabinet using the wire routing tracks. The cables should then turn up the first valve and route under the reservoir to the second valve. The motor cable is attached to the conduit and then through the 3/4" strain relief. Wires should be tight, but not stressed. 11) The high voltage wires from the disconnect to the VFD and from the VFD to the motor must be routed behind the VFD (NOT as drawn) to isolate the high voltage from the low voltage wires. 12) Once attached, the door must open fully at least 90 degrees without interference. The door is also removable for eased maintenance. 13) The safety relay is activated by the single green and red pushbuttons. When power is going to the safety relay, the single light is illuminated. When the safety relay is activated, the double light is illuminated. 14) Main power for the lights is drawn from the electrical box to a main junction box in the valve compartment. The lights for the main unit are connected directly to the terminal strip inside this junction box. A similar junction box is located on the top of secondary booths. Power for the lights in the secondary booth is run from the junction boxes back though the conduit and wire tracks to the main light distribution box and connected to the terminal strip. Electrical connection for the secondary booth to the main booth is done using the quick connects shown in Detail C. These connectors are located inside the wire track beneath the intake. 15) WIKA and Dwyer sensors are wired and operate identically. If a Kavlico sensor is used, a voltage regulator is used to drop the 24VDC down to 5VDC. If a Dwyer sensor is used see Detail J; no voltage regulator is needed. If Dwyer sensor is used, an additional mounting hole must be drilled. See Detail M for wiring of the Kavlico sensor. 16) The following labels must be applied: (2) “Ground Symbol” labels applied to the box next to the grounding terminal blocks. (1) “Danger High Voltage, Disconnect power before servicing” label applied to the outside of the electrical door next to the disconnect. (1) “Laminated Electrical Diagram” applied to the inside of the electrical door. (1) “NEMA 12” label applied to the inside of the electrical box. 17) When adding an economizer, a hole must be drilled in the bottom of the electrical box. Next, 18-2 SOOW cable is run as shown in Details G and K. There is no polarity on the economizer. 18) When adding a Remote Start / Stop button, a hole must be drilled in the bottom of the electrical box. Next, 16-3 SOOW cable is run as shown in Details H and L. The jumper from 19 to 34 must be removed. 19) When adding a Remote Safety Relay button, a hole must be drilled in the bottom of the electrical box. Next, 16-4 SOOW cable is run as shown in Details I and M. The jumper from 50 to 51 must be removed. 20) SOOW cable and THHN wires are rated for 600V. All 480V wires are isolated from other wires by 30mm. Wires for the pressure sensor are isolated from all wires carrying voltage higher than 24VDC by at least 30mm; additionally, the sensor circuit is protected using a 3A breaker.
5
6
0
3A 3A
21
22
23
2
0
11
12
T1 T2 T3
5
5
6
6
21
22
23
0
5 6 7
3
+ -
5
6
4
2
2
11
12
0
0
0
120VAC Single Phase Transformer
Metal jumper included with transformer
2
5
52
1
52
6
Variable Frequency Drive (VFD)
See Note 11
See Note 11
12 18 19 27 1920 4 44
30
56
61 68 69 535455
33 20 29 42 50 53 55
60
1 1
1 1
1
2 2
2 2
2
3 3 3
3 3 3 3 3 4 4 4
3
3 3
L1 L2 L3 5 6 7
GND
01 02 03 Relay
4 4 4 4
4
12
1
0
U V W 21 22 23
21) Breakers are active when showing red and tripped or deactivated when showing green.
44 44 45 20 33 19 19 20
33 19 20 34 44 45 47 49 50 51
19 34 34 33
22) Use the following chart to determine breaker type:
Breaker Location
QTY Type
Size Voltage 3A 600VAC 3A 600VAC 3A 600VAC 3A 600VAC
B1 Terminal Strip, Trans Primary
2 UL489
44 45
B2 Terminal Strip, Trans Secondary 1 UL489
B3 Terminal Strip, Lighting Circuit B4 Terminal Strip, Pressure Sensor 23) All wires are 16ga THHN stranded wire EXCEPT: a) Motor cables is 12-4 SOOW cable. b) Valve leads are 16-3 SOOW cable.
1 UL489 1 UL489
47 47 49 49
47
24) Use the following chart to identify the VFD:
49
51 51
50 50
Incoming Power
Part Number 132F0026 132F0022 132F0016
c) Wires between the disconnect and contactor are 12ga wires from SOOW cable or THHN. d) Light cables are 18-2 SOOW. e) Kavlico Sensor and the voltage regulator wires. f) Incoming power wiring is run by customer and must be rated at 600V.
5HP, 460VAC, 3 Phase: 3HP, 460VAC, 3 Phase: 5HP, 230VAC, 3 Phase: 3HP, 230VAC, 3 Phase: 5HP, 208VAC, 3 Phase: 3HP, 208VAC, 3 Phase:
50
A2 34 24 14
K2
33 23 13 A1
45
49 45 47
S22 S34 S12
S21 S33 S11
K1
3
47
44
47
4
3
132F0014 132F0016 132F0014
3
11 1
4 56
15 18
A1
4 NO
A2
19 4
20
33
Solid State Relay
19 3 X1 1 4 X2 2 NO NC
52
52
49
3
Breaker B2
4 NO
3
3
Breaker B3
Wire Number Index: 0: Ground 1: +110VAC Supply 2: -110VAC Supply 3: +24VDC Supply 4: -24VDC Supply
3 44 3
3
3
3
50
Breaker B4
27: 480VAC, Phase 1, Incoming 28: 480VAC, Phase 2, incoming 29: 480VAC, Phase 3, incoming 30: Pressure Sensor Signal 31: Motor Start Signal 32: Pushbutton Light Signal 33: Light Power Wire 34: Remote Stop Jumper ... 40: +5VDC Supply ... 44: Safety Interlock Signal 45: Safety Relay Jumper 46: N/A 47: Safety Interlock Common 48: N/A 51: Safety Int. Remote Jumper 52: Trans. Secondary O.C.P. 53: Communications + 54: Communications - 55: Communications GND 49: Safety Interlock NO 50: Safety Interlock NC
4
4 4
1
Color Sample List
4
PHASE 1 PHASE 2 PHASE 3 PHASE 1 PHASE 2 PHASE 3
2 NC
Black: White: Gray: Yellow: Orange: Red: Pink: Purple: Blue: Brown: Green:
40 40 30 30
30
5: 480VAC, Phase 1, Switched 6: 480VAC, Phase 2, Switched 7: 480VAC, Phase 3, Switched
3
40
Dirty Air
8: N/A 9: N/A 10: N/A
To R.S.S. #3 (NO) To R.S.S. #1 (NC)
19
19 19 20 33 20 44 44 45
Clean Air
19 20 33 34 44 45 47
11: Valve #1 Signal, +110VAC 12: Valve #2 Signal, +110VAC
Differential Pressure Sensor
20 33 34
5 VDC Voltage Regulator
13: N/A 14: N/A 15: N/A 16: N/A 17: N/A 18: N/A
To R.S.S. #2 (NC)
19 34 20
120VAC Single Phase Transformer (see Note 1)
44 45
Female Connector
Metal jumper included with transformer
Male Connector Male Pins
19: Start Signal 20: Stop Signal
4 4 4
33 33 33
47 47
Female Sockets
Electrical Box Body
47
1/2”
21: Motor #1 Power, Ph.1 22: Motor #1 Power, Ph.2 23: Motor #1 Power, Ph.3
4 33
4 33
5
2
33
4
24: N/A 25: N/A 26: N/A
52 1
Main Unit Side
Secondary Booth Side
Detail L: Remote Start / Stop Terminal Strip Wiring
19
20
33 33 33
4 4 4
52
6
Internal jumper inside transformer
3
1
3/8"
4 NO
2 NC
Conduit Fitting
Detail C: Slave Booth Connection
3
3
34
34
34
To Main Terminal block ‘3’ To Main terminal block ‘4’
3 3 3
4
4 4
3 3 3 3
Detail F: Low Voltage Wiring
Detail H: R.S.S. Push Button Wiring
4
9
8
7
3/8"
44 44 45 47 47 49 49 50 51
3
44
To R.S.R. #3 (NO)
To VFD input ‘42’
4951
40 40 30 30
44 45 47 47 49 50 51
47
50
30
3 19
3 3
45 47 49 50 51
1/2"
Detail A: Unit Light Junction Box
To Econ.
6 1
5 2
4 3
40
To R.S.R. #4 (NO)
Electrical Box Body
Electrical Box Body
1/2”
1/2”
Incoming from Elec. Box
19 19 20 20 33
19 20 33 34
To Econ.
19 34 34 33
To R.S.R. #1 (NC)
T1
T2
T3
Dwyer MS-331 Differential Pressure Sensor
47
Detail D: High Voltage Motor Wiring HIGH VOLTAGE
50
Clean Air
To R.S.R. #2 (NC) NOTE: Remove Jumper #50
4
33
4 30 3
+ v -
3
3
4 NO
4 NC
Dirty Air
33
4
49
51
Economizer
4 7
5 8
6 9
Detail J: Dwyer Pressure Sensor Wiring
Detail K: Economizer Terminal Strip Wiring
Detail M: Remote Safety Relay Term. Strip Wiring
Detail G: Economizer Field Wiring
Detail I: Remote Safety Push Button
33 33
4 4
Schematic Number: WS5-CH3
THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF CLEAN AIR AMERICA, INC. AND MUST BE RETURNED UPON REQUEST. ANY REPRODUCTION OF THIS DOCUMENT, IN WHOLE OR PART, WITHOUT THE WRITTEN PERMISSION OF CLEAN AIR AMERICA, INC. IS STRICTLY PROHIBITED.
DESCRIPTION:
Weld Station / Flexi-booth / CAP-Ture WC-4 Full Electrical System, VFD to HMI, No FSS
Conduit Fitting
1
2
3
FILENAME:
T1
T2
T3
DRAWN DATE: Y:\ELECTRICAL DIAGRAMS\CURRENT\WELD STATION SERIES [REV14].VSD SCALE: N.T.S. Jan. 5, 2010 DRAWN BY: ZACHK SHEET SIZE: C
LOW VOLTAGE
Detail B: Secondary Booth Light Junction Box
3/8"
3/8"
STATION:
PAGE:
Detail E: Low Voltage Motor Wiring
To first light in Booth
To second light in Booth
Electrical
6 OF 10
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