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. Different Drives are used for high and low voltage 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 Dual WeldStation 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")
Dirty Air Line [To air fitting on divider panel.] (55”)
Incoming Power run by customer (54" to top of unit) ¾” EMT Compression Connector
To Motor Mount (60") [See Notes]
2
2
1 GND
1 GND
Motor
[See Detail C]
Clean Air
3/4"
1/2"
1/2"
1/2"
3/8"
3/8"
0
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
0
0
5
6
21
22
23
7) The DIN connectors on the valves must seal with the SOOW cord using the grommet provided with the connector.
4 3
+ -
11
12
2 2
L1 L2 L3
0
0
0
8) See Details D and E for motor wiring. Clean Air Industries 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. 9) 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. 10) 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. 11) Once attached, the door must open fully at least 90 degrees with out interference. The door is also removable for eased maintenance. 12) 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. 13) 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. 14) 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. 15) When adding an economizer, a hole must be drilled in the bottom of the electrical box for each economizer lead. Next, 18-2 SOOW cable is run as shown in Details G. There is no polarity on the economizer. 16) When adding a Remote Manual Override Switch, a hole must be drilled in the bottom of the electrical box. Next, conduit must be run in the field to the desired location. The jumper from 34 to 36 must be removed. 17) When adding a Remote Safety Relay, a hole must be drilled in the bottom of the electrical box. Next, 18-4 SOOW cable must be run from the electrical box to the remote safety relay push buttons. The jumper from 50 to 51 must be removed. 18) 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
24VDC Power Supply
2
0
11
12
T1 T2 T3
L N G
0
5
5
6
6
21
22
23
2 1
5 6 7
5
6
2
11
12
0
0
0
0
120VAC Single Phase Transformer
Metal jumper included with transformer
2
5
52
1
6
52
Variable Frequency Drive (VFD)
See Note 11
See Note 11
1
4 3 3 3 3 3 3 3 3 3 1 1 1 1 2 2 2
1
4 4 4 4 3 3 3 3 2 2 2 3 3 3
12 18 19 27 39 4 44 38
32
30
33 20 29 42 50 53 55
60
2
61 68 69
3
L1 L2 L3 5 6 7
GND
01 02 03 Relay
3 43
0
U V W 21 22 23
19) Breakers are active when showing red and tripped or deactivated when showing green.
4
20)
Use the following chart to determine breaker type:
4 4
44 44 45 37 37 35 35 36 33 34
33 34
44 37 36 34 35 33 45 47 49 50 51
Breaker Location
QTY Type
Size Voltage 3A 600VAC 3A 600VAC 3A 600VAC 3A 600VAC
B1 Terminal Strip, Trans Primary
2 UL489
B2 Terminal Strip, Trans Secondary 1 UL489
B3 Terminal Strip, Lighting Circuit B4 Terminal Strip, Pressure Sensor
1 UL489 1 UL489
36
47
3 3
3
44 45
3
3 1 3 4 2 4 NO NO NO Auto 0 Man
4 NO
47 47 49 49
21) All wires are 16ga THHN stranded wire EXCEPT: a) Motor cables is 12-4 SOOW cable. b) Valve leads are 16-3 SOOW cable.
22) Use the following chart to identify the VFD:
47
49
35 34 37
49
Incoming Power
Part Number 132F0026 132F0022 132F0016
50 51
50 51
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:
33
50
51
A2 34 24 14
K2
33 23 13 A1
45
49 45 47
S22 S34 S12
S21 S33 S11
3
1
K1
3
4 NO
2 NC
132F0014 132F0016 132F0014
44
47
4
3
52
3
3
Breaker B2
52
3
Breaker B3
3
3
3 4
30
44
32
43
53
37
35
36
Breaker B4
3
30 30 30
30
Controller
Color Sample List
3 3
3
PHASE 1 PHASE 2 PHASE 3 PHASE 1 PHASE 2 PHASE 3
Wire Number Index: 0: Ground 1: +110VAC Supply 2: -110VAC Supply 3: +24VDC Supply 4: -24VDC Supply
3
Black: White: Gray: Yellow: Orange: Red: Pink: Purple: Blue: Brown: Green:
30: Pressure Sensor Signal 31: Motor Start Signal 32: VFD Running Signal 33: Light Power Wire 34: Remote Stop Jumper 35: Off Signal 36: Automatic Signal 37: Manual Override Signal 38: VFD Run Command Signal 39: VFD Sleep Command Signal 40: +5VDC Supply ... 43: Overload Signal 44: Safety Interlock Signal 45: Safety Relay Jumper 47: Safety Interlock Common 48: N/A 49: Safety Relay ‘ON’ Signal 50: Safety Relay ‘OFF’ Signal 51: Remote Safety Relay Jump. 52: Trans. Secondary O.C.P.
53 53
3 3
3 3 3 3 3 3 3 3
53
53
3 3
To ‘MAN’ #4 (NO) To ‘AUTO’ #4 (NO)
Dirty Air
3 30 4
5: 480VAC, Phase 1, Switched 6: 480VAC, Phase 2, Switched 7: 480VAC, Phase 3, Switched
Gnd Out +Uv
To Econ. #1
3
3 3 3 3
To Econ. #1
39 3
1
11
1
12
38 3
To Econ. #2
Clean Air
8: N/A 9: N/A 10: N/A
Differential Pressure Sensor
To Econ. #2
11: Valve #1 Signal, +110VAC 12: Valve #2 Signal, +110VAC ...
34 35
37 37 35 34 35 36
34 35 36 37
To ‘0’ #2 (NC)
3
3
34
35
3637
120VAC Single Phase Transformer (see Note 1)
To ‘AUTO’ #3 (NO)
19: Start Signal 20: Stop Signal
Female Connector
Metal jumper included with transformer
Male Connector Male Pins
4 4 4
33 33 33
36 37
21: Motor #1 Power, Ph.1 22: Motor #1 Power, Ph.2 23: Motor #1 Power, Ph.3 ...
To ‘0’ #1 (NC) To ‘MAN’ #3 (NO)
Female Sockets
Electrical Box Body
4 33
4 33
5
2
33
4
27: 480VAC, Phase 1, Incoming 28: 480VAC, Phase 2, incoming 29: 480VAC, Phase 3, incoming
NOTE: Remove Jumper #34-#36
52 1
Main Unit Side
Secondary Booth Side
Detail L: Remote Start / Stop Terminal Strip Wiring
37 35 36
33 33 33
4 4 4
52
6
Internal jumper inside transformer
3/8"
3 1 3 4 2 4 NONO Auto 0 Man NO
Conduit Fitting
Detail C: Slave Booth Connection
3 34 3
To VFD input ‘53’
Detail F: Low Voltage Wiring
Detail H: R.S.S. Push Button Wiring
To Main terminal block ‘4’
9
8
7
3/8"
44 44 45 47 47 49 49 50 51
44
To R.S.R. #3 (NO)
3
3
4951
44 45 47 47 49 50 51
47
50
To Controller input ‘I8’
Breaker B4
3 53
4
4 4
3
3
45 47 49 50 51
To VFD input ‘53’
1/2"
Detail A: Unit Light Junction Box
4
To Main Terminal block ‘3’
To Main terminal block ‘4’
6 1
5 2
4 3
To R.S.R. #4 (NO)
5 VDC Voltage Regulator
40 40 30 30 30
Electrical Box Body
Electrical Box Body
30
1/2”
1/2”
30
Incoming from Elec. Box
To Controller input ‘I8’
40
To R.S.R. #1 (NC)
Dirty Air
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)
4
33
4 30 3
+ v -
Clean Air
3
3
Differential Pressure Sensor
4 NO
4 NC
NOTE: Remove Jumper #50-#51
Dirty Air
33
4
49
51
Economizer
4 7
5 8
6 9
Detail J: Dwyer Pressure Sensor Wiring
Detail K: Remote Safety Relay Term. Strip Wiring
Detail M: Kavlico Pressure Sensor Wiring
Detail G: Economizer Field Wiring
Detail I: Remote Safety Push Button
33 33
4 4
Schematic Number: WS5-L3
THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF Clean Air Industries , INC. AND MUST BE RETURNED UPON REQUEST. ANY REPRODUCTION OF THIS DOCUMENT, IN WHOLE OR PART, WITHOUT THE WRITTEN PERMISSION OF Clean Air Industries , INC. IS STRICTLY PROHIBITED.
DESCRIPTION:
Dual WeldStation / Flexi-booth / CAP-Ture WC-4 Full Electrical System, VFD, No HMI, No FSS
Conduit Fitting
1
2
3
FILENAME:
Page 114
T1
T2
T3
DRAWN DATE: Y:\ELECTRICAL DIAGRAMS\CURRENT\ Dual WeldStation SERIES [REV14].VSD SCALE: N.T.S. March 28, 2011 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
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