USER`S MANUAL - Leeson Electric Corporation
Contents
1. D esee os Figure 1 M1740009 00 Dimensions Installation Mounting Protect the drive from dirt moisture and accidental contact Provide sufficient room for access to the terminal block and calibration trimpots Mount the drive away from heat sources Operate the drive within the specified ambient operating temperature range Prevent loose connections by avoiding excessive vibration of the drive Mount drive with its board in either a horizontal or vertical plane Six 0 19 in 5 mm wide slots in the chassis accept 8 pan head screws Fasten either the large base or the narrow flange of the chassis to the subplate The chassis must be earth grounded Use a star washer beneath the head of at least one of the mounting screws to penetrate the anodized chassis surface and reach bare metal 4 Installation Wiring Use 18 AWG wire for speed adjust potentiometer wiring Use 16 AWG wire for motor and AC line voltage wiring Twist logic wires for speed adjust potentiometer and inhibit to avoid picking up unwanted elertrical noise Use shielded cable if wires are longer than 18 in 46 cm Keep logic wires away from power carrying lines or sources of electrical noise that can cause erratic operation Never run speed adjust potentiometer or inhibit wires in the same conduit as the motor and AC line voltage wires t may be necessary to earth ground the shielded cable If noise is produced by devices2. Troubleshooting Motor will not stop when the speed adjust potentiometer is full counterclockwise 1 Turn the MIN SPD trimpot CCW until the motor stops Motor runs in the opposite direction 1 Remove AC line voltage 2 Reverse connections to the motor armature Motor slows under load 1 Check that the drive has been correctly calibrated for the motor 2 Check that the motor is not overloaded 3 Re adjust the IR COMP slightly CW until the motor runs at proper speed Motor is unstable under load 1 Re adjust the IR COMP setting slightly CCW until motor speed is stabliized Motor only runs at full speed 1 Check that S2 and S3 are not shorted together For additional assistance contact your local LEESON distributor or the factory direct 262 377 8810 FAX 262 377 9025 25 Block Diagrams S3 H1 S1 H2 L1 L2 FU501 MAX MIN PM POWER Al SPEED CIRCUIT SWITCHING CIRCUIT CIRCUIT A2 VBUS IRCOMP CIRCUIT POWER BRIDGE CIRCUIT 4 CURRENT LIMIT CIRCUIT Figure 16 Block Diagram 26 weibeig 11n919 du 771 anpa Ove VG LOSNA a p 4 LAOW E gt n renga 10544 Sz 0zz 1059 MS ta nord YOEE 91H as E MOEE SIH Ms NIN MEB y LA e bly gt 2H 1S S ads X004
3. actual settings may vary with each application 16 Multiple Fixed Speeds 2ceuieuiuu ses aude ya ama e ra yana yi 17 Adjustable Fixed Speeds Using Potentiometers in Series 18 ndependent Adjustable Speeds 19 RUNIJOG Switch ConhectOn erse Dali e dee vetet imb RO is 20 Reversing Circuit Connection 21 Block Diagrams 2 eise prr nm e dona erp ayakla 25 nput Circuit Diagram se ss ERR Rem er see bee baisse bale 26 Specifications Model M1740009 00 AC Line Voltage 115 VAC 110 50 60 Hz single phase Horsepower Range with 130 VDC motors 1 20 1 3 HP Armature Voltage 0 130 VDC Maximum Continuous Armature Current 2 ADC Form Factor at base speed 1 05 Acceleration Time with load 1 second Deceleration Time with load 2 seconds Analog Input Voltage Range isolated S1 to S2 0 5 VDC Input Impedance S1 to S2 gt 100K ohms Speed Regulation 1 of base speed or better Ambient Temperature Range 10 C 40 C Weight 0 6 Ibs Dimensions 0196 E gem Iu 1 75 44 5 a um E le F088 161 0 74 19 HBEBEBEH 3 80 97 4 30 109 0 19 5 2 15 55 1 28 33 0 97 25
4. Remove power from the drive The motor will coast to a stop If the motor or drive does not perform as described disconnect the AC line voltage immediately Refer to the Troubleshooting section page 22 for further assistance Operation 11 Diagnostic LEDs This drive is equipped with two diagnostic LEDs power status PWR and current limit mode CUR LIM See Figure 7 for LED locations POWER PWR Green LED lights whenever AC line voltage is applied to the drive CURRENT LIMIT CUR LIM Red LED lights whenever the drive reaches current limit VL HEBHBEBH scr H2 L2 A1 A2 S3 S2 S1 HI Q msro 4 IR COMP POWER CURRENT LED LIMIT LED Figure 7 Diagnostic LEDs 12 Operation Line starting and stopping Line starting and stopping applying and removing AC line voltage is recommended for infrequent starting and stopping of a drive only When AC line voltage is applied to the drive the motor accelerates to the speed set by the speed adjust potentiometer When AC line voltage is removed the motor coasts to a stop Inhibit switch An inhibit switch allows the motor to decelerate to zero speed when the switch is closed Connect a single pole single throw switch between H1 and H2 see Figure 8 Page 13 Close the switch to decelerate the motor to zero speed Open the switch to accelerate the motor to set speed An isolated NPN open collector transistor rated for at least 10 mA I may also be used
5. Si MOOE ELH XVIN MO LOGd HOSE ziH ife XSL zs 98 yee eu XOSE 4H n LH es gt Yel SU MOLASI LOSHL zos NAM y NE ASL NOTES 27 28 NOTES NOTES 29 DISCLAIMER The information and technical data in this manual are subject to change without notice LEESON Electric makes no warranty of any kind with regard to this material including but not limited to the implied warranties of merchantability and fitness for a particular purpose LEESON Electric assumes no responsibility for any errors that may appear in this manual and makes no commitment to update or to keep current the information in this manual LEESON SPEEDMASTER 2100 Washington Street Grafton WI 53024 0241 U S A TEL 262 377 8810 FAX 262 377 9025 Document number 250 0256 Rev 1 Printed in the U S A August 2003
6. any claim of a breach of warranty claimed in Paragraph A or of any other warranties express or implied or claim of liability that might despite Paragraph B be decided against us by any lawful authority LEESON shall under no circumstances be liable for any consequential damages losses or expense arising in connection with the use of or inability to use LEESON s product for any purpose whatsoever An adjustment made to the warranty does not void the warranty nor does it imply an extension of the original one 1 year warranty period Product serviced and or parts replaced by a no charge basis during the warranty period carry the unexpired portion of the original warranty only If for any reason any of the forgoing provisions shall be ineffective LEESON s liability for damages arising out of its manufacture or sale if equipment or use thereof whether such liability is based on warranty contract negligence strict liability in tort or otherwise shall not in any event exceed the full purchase of such equipment Any action against LEESON based upon any liability or obligation arising hereunder or under any law applicable to the sale of equipment or the use thereof must be commenced within one year after the cause of such action arises o Safety Warnings A X x 2 This symbol A denotes an important safety tip or warning Please read these instructions carefully before performing any of the procedures contained in this manual Hav
7. as an inhibit switch Wire the collector to H1 and the emitter to H2 Dynamic braking Dynamic braking may be used to rapidly stop a motor Figure 9 page 13 For the RUN BRAKE switch use a double pole double throw switch rated for at least the maximum DC armature voltage and maximum braking current A Warning Wait for the motor to completely stop before switching it back to RUN This will prevent high armature currents from damaging the motor or drive Operation 13 e pp me E 11501 P503 1502 P504 CUR m w H2 A A2 S3 S2 S HI O MIN SPD O IRCOMP 12 INHIBIT SWITCH optional Q STOP RUN Figure 8 Inhibit Switch A 1 Ohm 1 W resistor is used as the dynamic brake resistor For motors rated 1 17 BRAKE horsepower and lower RESISTOR a dynamic brake resistor is not necessary since the RUN i ae BRAKE armature resistance is I OO high enough to stop I the motor without demagnetization In this case replace the A dynamic brake resistor with 12 gauge wire Figure 9 Dynamic Brake Connection 14 Calibration Each drive is factory calibrated to its maximum current rating Re adjust the calibration trimpot settings to accomodate lower current motors All adjustments increase with CW rotation and decrease with CCW rotation Use a non metallic screwdriver for calib
8. other than the drive ground the shield at the drive end If noise is generated by a device on the drive ground the shield at the end away from the drive Do not ground both ends of the shield Installation 5 Line fuse The M1740009 00 drive is protected by a 5A 250V AC line fuse The fuse does not have to be resized as long as the motor used is within the drive s specified horsepower range The fuse is mounted in the fuseholder see Figure 2 To replace a blown fuse use a screwdriver to turn the fuseholder knob counterclockwise Remove the blown fuse and replace with a new fuse Figure 2 Fuseholder 6 Installation Speed adjust potentiometer Mount the speed adjust potentiometer through a 0 38 in 10 mm hole with the hardware provided see Figure 3 Install the circular insulating disk between the panel and the 10K ohm speed adjust potentiometer Twist the speed adjust potentiometer wire to avoid picking up unwanted electrical noise If the potentiometer leads are longer than 18 in 457 mm use shielded cable see Wiring section A Warning Be sure that the potentiometer tabs do not make contact with the potentiometer enclosure Grounding the input will cause damage to the drive MOUNT THROUGH A 0 38 IN 10 MM HOLE WIE STAR WASHER SPEED ADJUST POTENTIOMETER INSULATING DISK POT TAB ASSIGNMENTS PANEL Figure 3 Speed Adjust Potentiometer Installation 7 Q
9. Ee USER S MANUAL M1 740009 00 Pulse Width Modulated Adjustable Speed Drives for DC Brush Motors LIMITED WARRANTY A Warranty LEESON Electric warrants that its products will be free from defects in material and workmanship for a period of one 1 year from the date of shipment thereof Within the warranty period LEESON will repair or replace such products that are returned to LEESON or to the nearest Branch Office with shipping charges prepaid At our option all return shipments are F O B LEESON or its Branch Office This warranty shall not apply to any product that has been subject to misuse negligence or accident or misapplied or repaired by unauthorized persons or improperly installed LEESON is not responsible for removal installation or any other incidental expenses incurred in shipping the product to or from the repair point B Disclaimer The provisions of Paragraph A are LEESON s sole obligation and exclude all other warranties of MERCHANTABILITY or use express or implied LEESON further disclaims any responsibility whatsoever to the customer or any other persons for injury to person or damage or loss of property of value caused by any product that has been subject to misuse negligence or accident or misapplied or modified by unauthorized persons or improperly installed C Limitations of Liability In the event of any claim or breach of any of LEESON s obligations whether expressed or implied and particularly of
10. UR acta send adie 10 Diagnostic LEDS LE de aro doped e li azat de ace dosi dodo qutd dort 11 Lie Staring and SIODDInO excess ee eur ER py RR Re autant en Rm rs 12 olere iro Dn 12 Dynamic braking aee ROO e vu KR EORR serra 12 Calibration 14 Maximum Speed MAX SPD 54 cios bride oS pm eee 14 Minimum Speed MIN SPD 14 Regulation IR GOMP sei alk geni ste Rien eque td deste Be 15 TORQUE ark Er 15 Application Notes Multiple fixed speeds Adjustable speeds using potentiometers in series Independent adjustable speeds RUN JOG Switch Feversing sese eek pm eed Troubleshooting Before troubleshooting Block Diagrams Contents iii V Illustrations Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 M1740009 00 Dimensions 4 22 442242442028 ph oto sdb khen deme kb nib Eg E ima 2 Euseholdei artara eite a des oibus k dele il lee 5 Speed Adj st Potentiometer esmek ge muet UE Ru pe euh nee kd et 6 Quick Connect Terminal BIOCK 5s eren dade geo aire Res a olt 7 Divo Connections cerro hee eeu ob tok dar mek bce dre dud 8 Voltage Follower Connections Diagnostic LEDs Inhibit SWitohi oo src a e se me aki kemi o DERRE RA Dynamic Brake Gonnectioni iss reidans ue 6 e ass nerami ai Typical TORQUE and IR COMP Settings
11. ction 1 Disconnect AC line voltage from the drive 2 Check the drive closely for damaged components 3 Check that no conductive or other foreign material has become lodged on the printed circuit board Verify that every connection is correct and in good condition Verify that there are no short circuits or grounded connections Check that the drive s rated armature output is consistent with the motor ratings Troubleshooting 23 Motor does not run 1 2 Check for blown fuses or tripped circuit breaker Verify that the speed adjust potentiometer is not set to zero speed position Verify that the inhibit terminals H1 and H2 are not shorted together Verify that the drive is receiving AC line voltage Check that the drive is not in current limit The red current limit CUR LIM LED must be off If the red current limit LED is on verify that the motor is not jammed It may be necessary to increase the TORQUE setting if it is set to a value lower than the current rating of the motor Fuses or circuit breaker blows Check all wiring for shorts grounds or misconnections Check that the drive is configured to match the motor rating Check that the motor is not jammed or restricted from movement Check that the fuse size is correct for the motor being driven Motor runs too fast at the maximum speed setting i Check that the MIN SPD and MAX SPD setting are not set too high 24
12. e a qualified electrical maintenance technician install adjust and service this equipment Follow the National Electrical Code and all other applicable electrical and safety codes including the provisions of the Occupational Safety and Health Act OSHA when installing equipment Reduce the chance of an electrical fire shock or explosion by proper grounding over current protection thermal protection and enclosure Follow sound maintenance procedures A It is possible for a drive to run at full speed as a result of a component failure LEESON strongly recommends the installation of a master switch in the main power input to stop the drive in an emergency This drive is not isolated from earth ground Circuit potentials are at 115 VAC above earth ground Avoid direct contact with the printed circuit board or with circuit elements to prevent the risk of serious injury or fatality Use a non metallic screwdriver for adjusting the calibration trimpots Contents Safety Warnings i Specifications 1 Dimensions Installation MOUNINO e gt 23 x x ERR a AGO He Seq Rx ace DE RE REY 3 WIFI sesane code A i teet dur Ro it ed 4 IMG FUSE A OE Rosae uL du due adus e secte 5 Speed adjust potentiometer 6 Quick connect terminal block 7 CONNSCHONG i AA 8 Voltage TolloWBr iss sss rr REA RA RO ERO RE d 9 Operation 10 Startup eese eek duet pad Montana E
13. ot CCW to stabilize the drive TORQUE The TORQUE setting determines the maximum armature current output of the drive It is factory calibrated for a 1 8 HP 90 VDC motor Recalibrate the TORQUE setting when using a lower current motor Refer to the recommended TORQUE settings in Figure 10 page 16 or recalibrate using the following procedure 1 With the power disconnected from the control connect a DC ammeter 0 15A minimum scale in series with the armature 2 Set the TORQUE trimpot to minimum full CCW 16 Calibration TORQUE cont 3 Lock the motor armature Be sure that the motor is firmly mounted 4 Connect power to the drive The motor should remain stopped 5 Set the speed adjust potentiometer to maximum full CW 6 Adjust the TORQUE trimpot CW slowly until the armature current is 12096 of motor rated armature current 7 Set the speed adjust potentiometer to minimum and remove power from the drive 8 Remove the stall from the motor 1 4 HP 1 10 HP YE Qe E zd 2500 RPM xx y oy Ux 1725 RPM TORQUE IR COMP 1 40 ADC TORQUE IR COMP 1 10 ADC 1 8 HP 1 15 HP ae QQ vx Y xx y 1800 RPM Cu xx y 1800 RPM TORQUE IR COMP 1 30 ADC TORQUE IR COMP 0 75 ADC 1 8 HP 1 20 HP 2 130 VDC A O 90 VDC Loy Coo 2500 RPM Toy Orj 1750 RPM TORQUE IR COMP 1 00 ADC TORQUE IRCOMP 0 56 ADC Figure 10 Typical TORQUE and IR COMP Settings actual settings may vary with each application 17 Application Notes M
14. ration Each trimpot is identified on the printed circuit board Minimum Speed MIN SPD The MIN SPD setting determines the motor speed when the speed adjust potentiometer is turned full CCW It is factory Set for zero speed To calibrate turn the speed adjust potentiometer full CCW Adjust the MIN SPD trimpot until the motor has stopped or is running at the desired minimum speed Maximum Speed MAX SPD The MAX SPD setting determines the motor speed when the speed adjust potentiometer is turned full CW It is factory set for maximum rated speed To calibrate set the MAX SPD trimpot full CCW Turn the speed adjust potentiometer full CW Adjust the MAX SPD trimpot until the desired maximum motor speed is reached NOTE Check the MIN SPD and MAX SPD adjustments after recalibrating to verify that the motor runs at the desired minimum and maximum speeds Calibration 15 Regulation IR COMP The IR COMP setting determines the degree to which motor speed is held constant as the motor load changes It is factory calibrated for a 1 8 HP 90 VDC motor Recalibrate the IR COMP setting when using a lower current motor Refer to the recommended IR COMP settings in Figure 10 or recalibrate using the following procedure If the motor does not maintain set speed as the load changes gradually rotate the IR COMP trimpot CW If the motor oscillates overcompensation the IR COMP trimpot may be set too high CW Turn the IR COMP trimp
15. this is opposite of the desired rotation simply reverse the wiring to the motor from A1 and A2 Installation 9 Voltage follower Instead of using a speed adjust potentiometer the drive may be wired to follow a 0 5 VDC voltage signal that is isolated from earth ground Figure 6 Connect the signal input to S2 Connect the signal common to S1 Make no connection to S3 A potentiometer can be used to scale the analog input voltage La R501 MAX SPD TORQUE pee aee 0501 11501 P503 1502 P504 CUR PWR LIM H2 Li L2 At A2 S3 S2 St Hi O n IR COMP 0 5 VDC ISOLATED VOLTAGE SIGNAL INPUT Figure 6 Voltage Follower Connections 10 Operation Startup Note Before applying power verify that no conductive material is placed on the printed circuit board To start the drive 1 Turn the speed adjust potentiometer full counterclockwise CCW If the drive is following a voltage signal set the voltage signal to 0 VDC Apply power Slowly advance the speed adjust potentiometer clockwise CW If the drive is following a voltage signal slowly increase the voltage signal The motor will slowly accelerate as the speed adjust potentiometer is turned CW or the voltage signal is increased Increase the signal until the desired speed is reached
16. tton for the JOG pushbutton see Figure 14 When the RUN JOG switch is set to JOG the motor decelerates to zero speed Press the JOG pushbutton to jog the motor Return the RUN JOG switch to RUN for normal operation R501 0501 MAX SPD TORQUE P501 P502 1L501 P503 502 P504 CUR PWR LIM L1 2 At A2 S3 S2 H2 S1 H1 C TR IRCOMP C cw 10K ohm Speed Pot JOG PUSHBUTTON Figure 14 RUN JOG Switch Connection Application Notes 21 Reversing A dynamic brake may be used when reversing the motor direction Figure 15 Use a three pole three position switch rated for at least the maximum DC armature voltage and maximum braking current Wait for the motor to stop completely before switching it to either the forward or reverse direction A2 T FORWARD O FORWARD BRAKE O TO REVERSE 1 1 Ohm 1 W Dynamic Brake Resistor 1 jj o e H1 Figure 15 Reversing Circuit Connection 22 Troubleshooting A Warning Dangerous voltages exist on the drive when it is powered When possible disconnect the AC line voltage from the drive while troubleshooting Be alert High voltages can cause serious or fatal injury Before troubleshooting Perform the following steps before starting any procedure in this se
17. uick connect terminal block The quick connect terminal block has an 8 pin header block and 8 screw terminal plug Figure 4 To use the quick connect terminal block 1 Carefully pull the terminal plug from the header block 2 With a small flat head screwdriver turn the terminal plug screw counterclockwise to open the wire clamp 3 Insert a stripped wire into the large opening in front of the plug 4 Turn the terminal plug screw clockwise to clamp the wire 5 Repeat steps 2 through 4 for each terminal until all connections are made 6 Insert the plug into the header until securely fastened TERMINAL PLUG HEADER BLOCK Figure 4 Quick Connect Terminal Block 8 Installation Connections R50 R501 3 MAX SPD TORQUE P501 P502 SO501 IL501 P503 j 5og P504 R CUI PWR LIM H2 JL L2 At A2 S3 S2 Si Hi O rg IR COMP i LINE VOLTAGE 115 VAC AX RUN 10K SPD ADJ POT o STOP INHIBIT SWITCH optional Figure 5 Drive Connections Assumptions This drive series supplies motor voltage from its A1 and A2 terminals It is assumed throughout this manual that when A1 is positive with respect to A2 the motor will rotate clockwise CW while looking at the output shaft protuding from the front of the motor If
18. ultiple fixed speeds Replace the speed adjust potentiometer with series resistors with a total series resistance of 10K ohms Figure 11 Add a single pole multi position switch with the correct number of positions for the desired number of fixed speeds V TOTAL SERIES RESISTANCE R3 10K OHMS Figure 11 Multiple Fixed Speeds 18 Application Notes Adjustable speeds using potentiometers in series Replace the speed adjust potentiometer with a single pole multi position switch and two or more potentiometers in series with a total series resistance of 10K ohms Figure 12 shows a connection for fixed high and low speed adjust potentiometers OHM Figure 12 Adjustable Fixed Speeds Using Potentiometers in Series Application Notes 19 Independent adjustable speeds Replace the speed adjust potentiometer with a single pole multi position switch and two or more potentiometers in parallel with a total parallel resistance of 10K ohms Figure 13 shows the connection of two independent speed adjust potentiometers that can be mounted at two separate operating stations SPEED 1 Figure 13 Independent Adjustable Speeds 20 Application Notes RUN JOG Switch Using a RUN JOG switch is recommended in applications where quick stopping is not needed and frequent jogging is required Use a single pole single throw switch for the RUN JOG switch and a single pole normally closed momentary operated pushbu
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