User`s Manual - Leeson Electric Corporation
Contents
1. O 6 O O 6 6 O 6 MIN SPD FWDTO REVTO IRCOMP MAX SPD FWD ACC REV ACC TACH Figure 18 Calibration Trimpot Layout 30 Calibration Minimum Speed MIN SPD The MIN SPD setting determines the minimum speed when the speed adjust potentiometer is turned full CCW It is factory set to zero speed The minimum speed feature applies only when the drive is operating in unidirectional mode To calibrate set the speed adjust potentiometer full CCW Adjust the MIN SPD trimpot until the motor turns at the desired minimum speed Maximum Speed MAX SPD The MAX SPD setting determines the maximum motor speed when the speed adjust potentiometer is turned full CW It is factory set for maximum rated motor voltage To calibrate set the speed adjust potentiometer full CW Adjust the MAX SPD trimpot until the motor turns at the desired maximum speed Calibration 31 Forward Torgue FWD TO A Warning FWD TQ should be set to 120 of the motor nameplate current rating Continuous operation beyond this rating may damage the motor The decision to change the forward torque setting must be made after considering the gearbox and drivetrain ratings duty cycle and motor characteristics The FWD TQ setting determines the maximum torque for accelerating and driving the motor in the forward direction It also sets the maximum torque for decelerating the motor in the reverse direction Refer to the recommended FWD TQ settings in Fi2. B Disclaimer The provisions of Paragraph A are the Corporation s sole obligation and exclude all other warranties of merchantability for use express or implied The Corporation further disclaims any responsibility whatsoever to the customer or to any other person for injury to the 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 for breech of any of the Corporation s obligations whether express or implied and particularly of any other claim or breech of warranty contained in Paragraph A or of any other warranties express or implied or claim of liability that might despite Paragraph B be decided against the Corporation by lawful authority the Corporation shall under no circumstances be liable for any consequential damages losses or expense arising in connection with the use of or inability to use the Corporation s product for any purpose whatsoever An adjustment made under warranty does not void the warranty nor does it imply an extension of the original one 1 year or 3 000 hour warranty period Products serviced and or parts replaced on a no charge basis during the warranty period carry the unexpired portion of the original warranty only If for any reason any of the foregoing provisions shall be ineffective the Corporation
3. ELECTRIC MOTORS GEARMOTORS AND DRIVES User s Manual Models 175720 00 175721 00 SCR Dual Voltage Adjustable Speed Regenerative Drives for DC Brush Motors Copyright O 2003 by Leeson Corporation All rights reserved No part of this manual may be reproduced or transmitted in any form without written permission from Leeson Corporation The information and technical data in this manual are subject to change without notice Leeson Corporation and its Divisions make no warranty of any kind with respect to this material including but not limited to the implied warranties of its merchantability and fitness for a given purpose Leeson Corporation and its Divisions assume no responsibility for any errors that may appear in this manual and make no commitment to update or to keep current the information in this manual mvdo72103 Printed in the United States of America Safety Warnings A X ar SHOCK AVOID KEEP AVOID HAZARD HEAT DR VIBRATION Throughout this manual this symbol A denotes an important safety message Please read these messages carefully before performing any instructions contained herein Have a qualified electrical maintenance technician install adjust and service this eguipment 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 eguipment Reduce the chance of an electrical fire
4. or in two directions bidirectional depending on how the speed adjust potentiometer is connected to the drive Connect the speed adjust potentiometer as shown in Figure 8 a for speed control in one direction Connect the speed adjust potentiometer as shown in Figure 8 b for speed control in two directions The motor does not rotate when the wiper is in the center position Turning the wiper CW from the center position causes the motor to rotate in one direction while turning the wiper CCW from the center position causes the motor to rotate in the opposite direction Refer to the Application Notes section page 37 for additional speed adjust potentiometer connections so FWD CW CW S1 S1 s2 g S2 zx 9 3 sa N S3 10K REV 10K a b Figure 8 Speed Adjust Potentiometer Connections for Unidirectional Operation a and Bidirectional Operation b 14 Installation c0S8 L S3 S2 S1 SO RB1 RB2 15 15 T1 T2 Figure 9 TB502 Terminal Assignments 15 and 15 terminals 17572x Series drives can supply a regulated 15 and 15 VDC signal each sourcing 25 mA maximum to isolated external devices These voltage supply terminals are located on terminal block TB502 A Warning Do not short the 15 and 15 terminals for any reason Shorting these terminals will damage the drive Installation 15 Line Fusing Leeson drives
5. 0 196 of base speed Ambient Temp Range chassis drive 10 55 Ambient Temp Range cased drive 10 40 C 2 Dimensions 8 90 226 8 38 213 E 1 86 47 L 4 0 92 23 ALL DIMENSIONS IN INCHES MILLIMETERS Figure 1 175720 00 Chassis Dimensions Dimensions 6 90 175 6 30 160 l 1 40 36 f BRAKE O REVERSE FORWARD 10 20 259 9 80 249 SPEEOMASTER FOUR 4 EACH MOUNTING SLOTS 6 3 160 x 7 0 178 ON CENTERS D Or 5 50 140 4 78 121 C G 6 L 414537 2 30 58 Rn T isope 1 50 38 THREE 0 88 22 KNOCKOUTS ALL DIMENSIONS IN INCHES MILLIMETERS Figure 2 175721 00 Cased Drive Dimensions 3 Regenerative Drives Most non regenerative variable speed DC drives control current flow to a motor in one direction The direction of current flow is the same direction as the motor rotation Non regenerative drives operate in Quadrant 1 and also in Quadrant 3 if the drive is reversible see Figure 3 Motors must stop before reversing direction Unless dynamic braking is used non regenerative drives cannot oppose an overhauling load and cannot decelerate a load faster than coasting to a lower speed Regenerative drives operate in two additional guadrants Quadrant 2 and Quadrant
6. heat sink p n 175722 when the continuous armature current is above 7 ADC Model 175721 00 has sufficient heat sinking in its basic configuration Use a thermally conductive heat sink compound such as Dow Corning 340 Heat Sink compound between the drive chassis and the heat sink surface for optimum heat transfer AC line and motor connections Use 12 AWG or 14 AWG standard wire for connecting the line and the armature Use 16 AWG or 18 AWG standard wire when connecting the field of a shunt wound motor Strip the wire insulation 0 25 inches 6 mm See Figures 4 and 5 for AC line 115 VAC or 230 VAC and motor connections to chassis and cased drives lag Wii lH css 0502 TB501 8 TB502 Lit zw vv GND F1 F2 A2 Al A J 230 VAC deb J AC INPUT 1415 VAC VOLTAGE 53 82 FIELD OUTPUT For shunt wound lt motors only See field output section for details Figure 4 Chassis Drive Connections SIS 50502 INH RUN Installation 50501 o o INHIBIT
7. motor is not undersized for the load adjust FWD TO and REV TO trimpots Motor runs too fast at the maximum speed setting 1 Check that the MIN SPD and MAX SPD settings are not set too high 2 If using a shunt wound motor check that the field output connections are secure Motor will not reach the desired speed 1 Check the MAX SPD setting and increase if necessary 2 Check that the IR COMP setting is not set too low 3 Check that the motor is not overloaded For additional assistance contact your local Leeson distributor or the factory direct phone 262 377 8810 fax 262 377 9025 NOTES 47 48 NOTES Limited Warranty A Warranty Leeson Corporation referred to as Corporation warrants that this product will be free from defects in workmanship and material for one 1 year or 3 000 hours whichever comes first from date of shipment thereof Within this warranty period the Corporation will repair or replace such products that are 1 returned to Leeson Corporation 2100 Washington Street Grafton WI 53024 0241 U S A and 2 determined by the Corporation to be defective 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 The Corporation is not responsible for removal installation or any other incidental expenses incurred in shipping the product to and from the repair point
8. require fuses for protection Use fast acting fuses rated for 250 VAC or higher and approximately 150 of the maximum armature current Fuse both L1 and L2 when the line voltage is 230 VAC The fuse table below lists the recommended line fuse sizes Fuse Table 90 VDC Motor 180 VDC Max DC Armature AC Line Fuse Horsepower Horsepower Current amps Size amps 1 20 1 10 0 5 3 1 15 1 8 0 8 3 1 8 1 4 1 5 5 1 6 1 3 1 7 5 1 4 1 2 2 5 8 1 3 3 4 3 5 8 1 2 1 5 0 10 3 4 11 2 7 5 15 1 2 10 20 16 Factory Prewired Connections for Cased Drives o o e 1 2 3 WHITE BLACK get o WHITE BLACK SEN BLACK POWER BLACK l LIGHT a o BLACK m BLACK WHITE WHITE BLACK L2 115 Figure 10 Prewired Connections to L1 L2 with 115 VAC input and L2 with 230 VAC input TB502 Factory Prewired Connections 17 GREY FWD S0 BRAKE GREY WHITE S1 REV O BROWN S2 PURPLE S3 Figure 11 Prewired Speed Adjust Potentiometer Connections 18 Operation Before applying power 1 Check connections before applying AC line voltage to the drive 2 Check that no conductive material is present on the printed circuit board 3 Verify that all selector switches are set correctly see the following section for selector switch settings Check selector switch settings 1 Set both line voltage selector switc
9. shock or explosion by proper grounding over current protection thermal protection and enclosure Follow sound maintenance procedures It is possible for a drive to run at full speed as a result of a component failure To stop the drive in an emergency please ensure that a master switch has been placed in the AC line This drive is not isolated from earth ground Circuit potentials are at 115 VAC or 230 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 Specifications 1 Dimensions 2 Regenerative Drives 4 Installation 6 Mounting chassis drives sw mg r 9 RR R Y 0 0 EE R 9 R eel 6 Mounting cased drives 1 1 cee cee eee rennene 7 Heat sinking orm re hme RR Re sed ea Sete 8 AC line and motor connections lille 8 Cage clamp terminal block lille 10 Fleldioutp t ea sen antem x Reb pac me een P eu necs 11 Tachogenerator feedback 0000 cece eee eens 11 Speed adjust potentiometer installation 12 Speed adjust potentiometer connections 13 15 and 15 terminals 2 coste Reese ee ees 14 Line FUSING ius eg eme Rer tn b Rae tes 15 Factory Prewired Connections 16 Operation 18 Before applying power soks kkk nnen 18 Check selector switch settings llle 18 Startup usse e beter eee
10. 4 In these guadrants motor torque is in the opposite direction of motor rotation Regenerative drives can reverse a motor without contactors switches brake resistors and inhibit plugs They can also control an overhauling load and decelerate a load faster than it would take to coast to a lower speed Quadrant II Regenerative Drives 5 Quadrant I Quadrant III Quadrant IV MOTOR ROTATION NOTE ARROWS IN SAME DIRECTION MOTOR ACTION ARROWS IN OPPOSITE DIRECTION REGENERATIVE ACTION MOTOR TORQUE Figure 3 Four Quadrant Operation Installation Mounting chassis drives AN Warning Do not install rewire or remove this control with power applied Doing so may cause fire or serious injury Read and understand the Safety Warnings on pg i before attempting installation Drive components are sensitive to electrostatic fields Avoid direct contact with the circuit board Hold the drive by the chassis only 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 the drive with its board in either a horizontal or vertical plane Six 0 188 inch 4 8 mm wide slots in the chassis accept 48 pan head s
11. ACC setting determines the time the motor takes to ramp to either a higher speed in the forward direction or a lower speed in the reverse direction within the limits of available torque The FWD ACC setting is factory set for its fastest forward acceleration time 34 Calibration Turn the FWD ACC trimpot CW to increase the forward acceleration time and CCW to decrease the forward acceleration time Reverse Acceleration REV ACC The REV ACC setting determines the time the motor takes to ramp to either a higher speed in the reverse direction or a lower speed in the forward direction within the limits of available torgue The REV ACC setting is factory set for its fastest reverse acceleration time Turn the REV ACC trimpot CW to increase the reverse acceleration time and CCW to decrease the reverse acceleration time Deadband DB The deadband trimmer potentiometer determines the time that will elapse between the application of current in one direction before current is applied in the opposite direction The deadband trimmer potentiometer affects the resistance that a motor has to changes in shaft position at zero speed It does this by applying AC voltage to the motor armature Deadband is factory calibrated to approximately the 3 o clock position for 60 Hz AC line operation Recalibrate the deadband to the 9 o clock position for 50 Hz AC line operation See Figure 19 on page 36 for recommended deadband settings Calibrati
12. ER REN A RR E S RR 20 Block Diagram 22 Starting and Stopping Methods 24 Line Starting and Stopping asana naea 24 Automatic restart upon power restoration 24 Regenerative deceleration e aunan 24 Regenerative brake 9 Rr RRR ee RR nh 25 Goast to Stop sess resi DUCERE RE RR RD Sok RIN HUS A 26 Decelerate to minimum speed e x x e e K x x x e ee 27 Contents iii Calibration 29 Minimum Speed MIN SPD essere 30 Maximum Speed MAX SPD 30 Forward Torque FWD TO sssese eR 31 Reverse Torque REV TO loss kake 32 Regulation IR COMP ssa 33 Forward Acceleration FWD ACC 0 00 eee eee 33 Reverse Acceleration REV ACC 34 Deadband DB a crgo Tamines adada D EE Baiia nn 34 Tach Generator TACH sos son 35 Application Notes 37 Forward Reverse Switch 000 e eee eee 37 Forward Stop Reverse Switch lt nnen 38 Independent Adjustable Speeds iles 39 Independent Forward and Reverse Speeds 40 Independent Forward and Reverse Speeds with FWD STOP REV Switch 0 00 ee eee eee 41 Voltage folloWGt isi re r ssa assa aa yer 42 Troubleshooting 43 Check the following steps before proceeding 43 Field fuse DlOWS ias eee mer nrbe rare eve d 44 Line Tuse DIOWS escis armeria a neS onera rane Ee d 44 Line fuse does not blow but the motor does not run 45 Motor pulsates or surges under load naana 46 Motor runs too fast at the ma
13. Figure 17 Run Decelerate to Minimum Speed Switch shown with bidirectional connection 28 Starting and Stopping Methods A Warning For frequent starts and stops use regenerative deceleration shorting RB1 and RB2 regenerative breaking shorting INHIBIT terminals to each other coasting to a stop shorting INHIBIT RUN terminals 1 and 2 or decelerating to minimum speed shorting S2 to SO Do not use any of these methods for emergency stopping They may not stop a drive that is malfunctioning Removing AC line power both L1 and L2 is the only acceptable method for emergency stopping Certain Leeson drives regenerative and non regenerative coast to minimum speed when the inhibit terminals are shorted to each other IR COMP and CURRENT LIMIT FWD TQ and REV TQ on regnerative drives are still active while the drive is in the inhibit mode Frequent regenerative deceleration regenerative braking coasting to a stop or decelerating to minimum speed produces high torque This may cause damage to motors especially gearmotors that are not properly sized for the application 29 Calibration Each drive is factory calibrated to its maximum current rating Readjust the calibration trimpot settings to accommodate lower current rated motors All adjustments increase with CW rotation and decrease with CCW rotation Use a non metallic screwdriver for calibration Each trimpot is identified on the printed circuit board
14. ISIS cn 10501 S 1 2 3 I s FU501 FU502 FU503 g FAST ACTING 2 IT B FUSES ONLY amp 1 Ala L1 L2 FID ja SW501 C503 10502 a 3 TB501 3 J E p 230 La 1 L HI L LT LT Lt HL VAC L1 aw sw GND F1 F2 A2 A1 115 a VAC AC LINE INPUT CEL cre Figure 5 FIELD OUTPUT For shunt wound motors only See field output section for details Cased Drive Connections 10 Installation Cage clamp terminal block Connections to drives are made to a cage clamp terminal block Figure 6 To insert a wire into the terminal block press down on the lever arm using a small screwdriver Insert stripped wire into the large opening in front of the terminal block Release the lever arm to clamp the wire Press down on the lever arm using a small screwdriver Insert wire into the wire clamp Release the lever arm to clamp the wire Figure 6 Cage Clamp Terminal Block Installation 11 Field output The field output is for shunt wound motors only Do not make any connections to F1 and F2 when using a permanent magnet motor Use 18 AWG wire to connect the field output to a shunt wound motor Table 1 lists the field output connections Table 1 Field Output Connections Line Voltage Approximate Connect Motor VAC Field Voltage VDC Field To 115 50 F1 and L1 115 100 F1 and F2 230 100 F1 and L1 230 200 F1 and F2 Tachogenerator feedback Using tac
15. N O 1 4 HP 1 2 HP A N 90 VDC 180 VDC 2 7 ADC 2 5 ADC FWDTO REVTO IRCOMP 60 Hz 50 Hz Applications Applications Figure 19 Typical FWD TO REV TO IR COMP and Deadband Settings 37 Application Notes Forward Reverse Switch Use a single pole two position switch with a single speed adjust potentiometer to plug reverse the motor Figure 20 The MIN SPD setting is in effect for either direction SO S1 S2 10K OHM Sr REV B S3 O D O FWD Figure 20 Forward Reverse Switch 38 Application Notes Forward Stop Reverse Switch Use a single pole three position switch with a single speed adjust potentiometer to stop a motor between reversals Figure 21 Set the switch to the center position to decelerate the motor to a stop SO S1 S2 TB502 S3 CW STOP FWD 10K OHM Figure 21 Forward Stop Reverse Switch Application Notes 39 Independent Adjustable Speeds TB502 Connect two speed adjust potentiometers with a single pole two position switch to select between two independent speeds shown in the forward direction Figure 22 The speed adjust potentiometers can be mounted at two separate operating stations SO S1 SPEED 1 S2 mO P1 P2 20K OHM 20K OHM CW CW SPEED 2 Figure 22 Independent Adjustable Speeds Forward Direction 40 Application Notes Independent Forward and Reverse Speeds Connect two speed adjust poten
16. crews Fasten either the large base or the narrow flange of the chassis to the subplate The chassis must be earth grounded for noise suppression To ground the chassis connect earth ground to the GND terminal on terminal block TB501 Installation 7 Mounting cased drives Leeson cased drives come with three 0 88 inch 22 mm conduit knockout holes on the bottom of the case The units may be vertically wall mounted using the four 0 25 inch 6 mm slotted holes on the attached heat sink For motor loads less than 5 ADC the drive may be bench mounted horizontally or operated without mounting 1 2 Install the mounting screws For access to the terminal strip turn the slotted screw on the front cover counterclockwise until it is free from the case The right side of the cover is hinged to the case Lift or pull the slotted screw to open the case Carefully remove the conduit knockouts by tapping them into the case and twisting them off with pliers Install conduit hardware through the 0 88 inch 22 mm conduit holes Connect external wiring to the terminal block Grasp the slotted screw and tilt the front cover back into place Avoid pinching any wires between the front cover and the case Turn the slotted screw clockwise until tight to secure the front cover Set the POWER switch to the O or OFF position before applying the AC line voltage 8 Installation Heat sinking Model 175720 00 reguires an additional
17. deadband DB must be set approximately at the 3 o clock position for 60 Hz AC line frequency or at 9 o clock for 50 Hz AC line frequency The motor must be rated for the drive s rated armature all motors and field outputs shunt wound motors only Do not make any connections to F1 and F2 if using a permanent magnet motor Terminal block connections should be consistent with the connections shown in this manual Check that line fuse FU501 and FU502 for 230 VAC input is properly sized and not blown Check that field fuse FU503 is 1 5 A and not blown 44 Troubleshooting Field fuse blows 1 Disconnect AC line voltage from the drive 2 Verify that the fuse is rated at 1 5 A 3 Check motor cable for shorts 4 Check motor field for shorts as follows a Disconnect field leads from terminals F1 and F2 b Check motor field resistance with an ohmmeter Resistance should be approximately 100 to 1000 ohms depending on motor horsepower c A resistance reading from the motor frame to either side of the field should show open when an ohmmeter is used on its high resistance scale 5 Reconnect field leads to the drive 6 Reconnect AC line voltage to the drive 7 Advance the speed adjust potentiometer to the desired speed Line fuse blows 1 Disconnect AC line voltage from the drive 2 Check that the motor cable and armature are not shorted or grounded a Armature resistance should measure approximately 1 to 100 ohms de
18. e REY lt JE SPD ADJ POT ET FWD ACC REV ACC 40K KI T CIRCUIT Ow MAX si H 10 FELIZ MAXIMUM SPEED x SUMMING D REVACC SPD CIRCUIT 2 CIRCUIT En T ZERO SPEED so w REF 45 15 VALUE E MIN SPD cw c CURRENT LIMIT TORQUE jo toT CIRCUIT T FIELD oo CIRCUI 10 VOC INTERNAL SUPPLY LL mm PoweR DONN 230 VAG POWER DISCHARGE t Caan av e 4551448 119230 230 115 T7 sm SW502 SW501 Figure 13 Block Diagram Block Diagram 23 FEEDBACK SW504 TACH ARM TY ARMATURE SW503 939 VOLTAGE FEEDBACK CIRCUIT IR COMP ow IR COMPENSATION REGULATION CIRCUIT FWD TRIGGERING CIRCUIT ad I LEN O wimum SPEED s SUMMING DEADBAND DB POWER BRIDGE FEEDBACK a cw cw E FWD TO GREN REVTQ Ay ZI 15 T8502 24 Starting and Stopping Methods A Line Starting and Stopping Line starting and stopping applying and removing AC line voltage is recommended only for infrequent starting and stopping of a drive When AC power is applied to the drive the motor accelerates to the speed set by the speed adjust potentiometer When power is removed the motor coasts to a stop A Automatic restart upon power restoration All drives automatically run to set speed when power is applied Wir
19. gure 19 on Page 36 or recalibrate using the following procedure 1 With the power disconnected from the drive connect a DC ammeter in series with the armature 2 Set the FWD TQ trimpot to minimum full CCW 3 Set the speed adjust potentiometer for maximum forward speed 4 Carefully lock the motor armature Be sure that the motor is firmly mounted 5 Apply line power The motor should be stopped Slowly adjust the FWD TQ trimpot CW until the armature current is 120 of the motor nameplate current rating Turn the speed adjust potentiometer CCW until the motor stops Remove line power Remove the stall from the motor 0 Remove the ammeter in series with the motor armature if it is no longer needed o O 0 32 Calibration Reverse Torgue REV TO A Warning REV TQ should be set to 120 of the motor nameplate current rating Continuous operation beyond this rating may damage the motor The decision to change the reverse torque setting must be made after considering the gearbox and drivetrain ratings duty cycle and motor characteristics The REV TQ setting determines the maximum torque for accelerating and driving the motor in the reverse direction It also sets the maximum torque for decelerating in the forward direction Refer to the recommended REV TQ settings in Figure 19 on Page 36 or recalibrate using the following procedure 1 With the power disconnected from the drive connect a DC ammeter in series w
20. hes SW501 and SW502 to 115 if using 115 VAC line voltage or to 230 if using 230 VAC line voltage 2 Set the armature voltage selector switch SW503 to 90 if using a 90 VDC motor or to 180 if using a 180 VDC motor 3 Set the feedback selector switch SW504 to TACH if using a tachogenerator otherwise set it to ARM for armature feedback Note You may be required to derate a 90 VDC motor when 230 VAC is applied to the drive Contact Leeson for details See Figure 12 on page 19 for switch locations Operation 19 ARMATURE FEEDBACK 90 18D ARM lt TACH 3W503 SW504 VOLTAGE ARMATURE FEEDBACK SELECT SELECT SWITCHES SELECT SWITCH SWITCH Figure 12 Selector Switch Locations 20 Operation Startup Chassis drives Uni directional Operation 1 Set the speed adjust potentiometer to minimum full CCW 2 Apply AC line voltage 3 Slowly turn the speed adjust potentiometer clockwise CW The motor will accelerate as the potentiometer is turned CW Continue until the desired speed is reached 4 Remove AC line voltage from the drive to coast the motor to a stop Bi directional Operation 1 Set the speed adjust potentionmeter to minimum center position 2 Apply AC line voltage 3 Slowly turn the speed adjust potentiometer either clockwise for forward direction or counterclockwise for reverse direction The motor will accelerate as the potentiometer is turned Continue until the desired s
21. hogenerator feedback improves speed regulation from approximately 1 of motor base speed to approximately 0 1 of motor base speed Use tachogenerators rated from 7 VDC per 1000 RPM to 50 VDC per 1000 RPM Connect the tachogenerator to terminals T1 and T2 of terminal block TB502 The polarity is positive for T1 and negative for T2 when the motor is running in the forward direction The polarity is reversed when the motor is running in the reverse direction 12 Installation Speed adjust potentiometer installation On chassis drives install the circular insulating disk between the panel and the 10KQ speed adjust potentiometer Mount the speed adjust potentiometer through a 0 38 in 0 96 cm hole with the hardware provided see Figure 7 Twist the speed adjust potentiometer wire to avoid picking up unwanted electrical noise If the potentiometer leads are longer than 18 in 46 cm use shielded cable Speed adjust potentiometers are installed on all cased drives AN 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 Fa NUT STAR WASHER SPEED ADJUST POTENTIOMETER INSULATING DISK POT TAB ASSIGNMENTS PANEL Figure 7 Speed Adjust Potentiometer Installation 13 Speed adjust potentiometer connections The motor can operate in one direction unidirectional
22. ing a latching relay into the AC line is one way to prevent automatic restarting following a power outage Regenerative deceleration Short terminals RB1 and RB2 to regeneratively decelerate a motor RB1 to a stop Figure 14 Since STOP terminal RB1 bypasses the MIN RB2 SPD circuit shorting RB1 and 0 RB2 will decelerate a motor to a RUN stop instead of minimum speed Calibrate the deceleration time by Figure 14 Regenerative adjusting the opposite direction Deceleration Switch acceleration trimpot Connection Starting and Stopping Methods 25 Regenerative brake Short the INHIBIT terminals to regeneratively brake the motor see Figure 15 for INHIBIT terminal location Reopening the INHIBIT terminals causes the motor to run at set speed The INHIBIT terminals bypass both the MIN SPD circuit and the deceleration circuit This causes the motor to stop rapidly when the INHIBIT terminals are shorted Braking torgue is determined by the opposite direction torgue setting P50 OE 50502 i J INHIBIT coz J TERMINALS mos Lip c502 OP la 2 SL Les f Oels i 118 H o Figure 15 Inhibit Terminals 26 Starting and Stopping Methods Twist inhibit wires and separate them from other power carrying wires or sources of electrical noise Use shielded cable if the inhibit wires are longe
23. ith the armature 2 Set the REV TQ trimpot to minimum full CCW 3 Set the speed adjust potentiometer for maximum reverse speed 4 Carefully lock the motor armature Be sure that the motor is firmly mounted 5 Apply line power The motor should be stopped Slowly adjust the REV TQ trimpot CW until the armature current is 120 of the motor nameplate current rating Turn the speed adjust potentiometer CCW until the motor stops Remove line power Remove the stall from the motor 0 Remove the ammeter in series with the motor if it is no longer needed o 2 OWEN Calibration 33 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 set for optimum motor regulation Recalibrate the IR COMP setting when using a lower horsepower motor See Figure 19 on page 36 for typical IR COMP settings or recalibrate using the following procedure 1 Set the IR COMP trimmer pot to minimum full CCW 2 Set the speed adjust potentiometer to run at mid speed without load for example 900RPM for an 1800 RPM motor A hand held tachometer may be used to measure motor speed 3 Load the motor to the nameplate current rating full load The motor should slow down 4 While keeping the load on the motor adjust the IR COMP trimmer pot CW until the motor runs at the speed measured in step 2 5 Unload the motor Forward Acceleration FWD ACC The FWD
24. on Tach Generator TACH Calibrate the TACH setting only when a tachogenerator is used The TACH setting like the IR COMP setting determines the degree to which motor speed is held constant as the motor load changes To calibrate the TACH trimpot 1 9m O c nos Connect the tachogenerator to T1 and T2 The polarity is positive for T1 and negative for T2 with the motor running in the forward direction Set switch SW504 to ARM for armature feedback Set the speed adjust potentiometer full CW Measure the armature voltage across A1 and A2 using a voltmeter Set the speed adjust potentiometer to 0 zero speed Set switch SW504 to TACH for tachogenerator feedback Set the IR COMP trimpot full CCW Set the TACH trimpot full CW Set the speed adjust potentiometer full CW Adjust the TACH trimpot until the armature voltage is the same value as the voltage measured in step 3 35 Check that the tachogenerator is properly calibrated The motor should run at the same set speed when SW504 is set to either armature or tachogenerator feedback 36 Calibration 1 HP 90 VDC O O 6 a E xy xx YoY Cod uj FWDTO REVTO IRCOMP 10ADG FWD TQ REVTO IRCOMP SERDE O O Q ax mv 90 VDC 180 VDC Guy Cod wo Se O xx x 5 ADC FWDTO REVTO IRCOMP FWDTQ REVTQ IRCOMP O O OQ 7 O O O mn 90 VDC 180 VDC Lay Guy Lx SADC xy xj Lx S RADE FWDTO REVTO IRCOMP FWDTO REVTO IRCOMP
25. peed is reached 4 Remove AC line voltage from the drive to coast the motor to a stop Operation 21 Cased drives AN R NNE Set the FORWARD BRAKE REVERSE switch to BRAKE Set the speed adjust potentiometer to minimum full CCW Apply AC line voltage Set the POWER switch to the I ON position Set the FORWARD BRAKE REVERSE switch to the desired direction of rotation Slowly advance the speed adjust potentiometer clockwise CW The motor will accelerate as the potentiometer is turned CW Continue until the desired speed is reached To brake the motor set the FORWARD BRAKE REVERSE switch to the BRAKE position To coast the motor to a stop set the POWER switch to the 0 OFF position To reverse direction a Set the FORWARD BRAKE REVERSE switch to BRAKE b After the motor comes to a complete stop set the FORWARD BRAKE REVERSE switch to the desired direction of rotation 10 Set the POWER switch to 0 OFF to remove power from the drive 22 Block Diagram TACH FEEDBACK TACH yon TACH FEEDBACK FEEDBACK SW504 TACH ARM T CIRCUIT INPUT OPTIONAL n V TB502 50501 00 INHIBIT TB502 FWD n JUL oo s
26. pending on motor horsepower b Aresistance reading from the motor frame to Troubleshooting 45 either armature side should show open when an ohmmeter is used on its high resistance scale 3 Check that the field circuit is not open 4 A combination of ambient conditions and frequent high current spikes i e reversing causes fuse to nuisance trip Consider using a slow blow fuse or increasing the fuse rating to 120 of motor current as stated on the nameplate Line fuse does not blow but the motor does not run 1 Verify that the speed adjust potentiometer is not set to its zero speed position 2 Check the speed adjust potentiometer for continuity 3 Verify that the inhibit terminals are not shorted together 4 Check that INHIBIT RUN terminals 2 and 3 are connected See figure 16 page 25 5 Verify that the drive is receiving AC line voltage 6 Check that the drive is not in current limit If the drive is in current limit verify that the motor is not jammed It may be necessary to increase the FWD TO or REV TO setting if it is set lower than the current rating of the motor 7 Check that the speed adjust potentiometer connections to the terminal block are correct and not open 46 Troubleshooting Motor pulsates or surges under load 1 IR Comp may be set too high Adjust the IR COMP setting slightly CCW until the motor speed stabilizes 2 Motor bouncing in and out of torque limit Make sure the
27. r than 18 in 46 cm If shielded cable is used ground only one end of the shield to earth ground Do not ground both ends of the shield Coast to a stop To coast the motor to a stop without removing power to the drive jumper INHIBIT RUN terminals 1 and 2 see Figure 16 To restart the motor jumper INHIBIT RUN terminals 2 and 3 A single pole double throw switch may be used as a COAST RUN switch Each drive is assembled with INHIBIT RUN terminals 2 and 3 jumpered These terminals must be connected for the motor to run R BE OG Figure 16 Inhibit Run Terminals P5 P501 xx y MID SPD FWD INHIBIT INHIBIT RUN TERMINALS INH RUN LLL Starting and Stopping Methods 27 Decelerate to minimum speed The circuit shown in Figure 17 may be used to decelerate a motor to a minimum speed Closing the switch between S2 and 50 decelerates the motor from set speed to a minimum speed determined by the MIN SPD trimpot setting If the MIN SPD trimpot is set full CCW the motor decelerates to zero speed when the switch between S2 and S0 is closed The DECEL trimpot setting determines the rate at which the drive decelerates Set the switch to the RUN position to accelerate the motor to set speed at a rate determined by the ACCEL trimpot setting REV 10K S3 RUN C 9 S2 DECEL TO MIN SPD S1 FWD cw 3 so
28. s liability for damages arising out of its manufacture or sale of 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 price of such equipment Any action against the Corporation 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 ELECTRIC MOTORS GEARMOTORS AND DRIVES 2100 Washington Street Grafton WI 53024 0241 U S A Phone 262 377 8810 Fax 262 337 9025 Document number 250 0254 Revision 2 Printed in the U S A August 2003
29. tch ss 37 Figure 21 Forward Stop Reverse Switch onsen 38 Figure 22 Independent Adjustable Speeds Forward Direction esee 39 Figure 23 Independent Forward and Reverse Speeds 40 Figure 24 Independent Forward and Reverse Speeds with a Forward Stop Reverse Switch 41 Figure 25 Voltage Follower Connection oss 42 Specifications Max Armature HP Range HP Range Current with 115 VAC with 230 VAC Model Amps DC Applied Applied 175720 00 10 0 T 1 4 1 t 12 2 t 175721 00 10 0 T 1 4 1t 1 2 2 T Maximum armature current and horsepower range apply when drive is attached to additional heat sink part number 175722 Use heat sink when armature current is above 7 ADC Heat sinks are pre mounted on cased drives AC Line Voltage 115 230 VAG 10 50 60 Hz single phase Armature Voltage 115 VAC Input 0 90 VDC Armature Voltage 230 VAC Input 0 180 VDC Form Factor 1 37 at base speed Field Voltage 115 VAC Input 50 VDC F1 to L1 100 VDC F1 to F2 Field Voltage 230 VAC Input 100 VDC F1 to L1 200 VDC F1 to F2 Max Field Current 1ADC Accel Time Range with no load 0 5 10 seconds Decel Time Range with no load 0 5 10 seconds Analog Input Voltage Range isolated S1 to S2 0 10 VDC Input Impedance S0 to S2 32K ohms Load Regulation with Armature Feedback 196 of base speed or better with Tachogenerator Feedback
30. tiometers as shown in Figure 23 to select between independent forward and reverse S0 FWD REV k 10K OHM 10K OHM S1 FWD cw cw S2 Oa S3 TB502 Figure 23 Independent Forward and Reverse Speeds Application Notes 41 Independent Forward and Reverse Speeds with FWD STOP REV Switch TB502 Use a single pole three position switch to stop the motor when the switch is in the center position Figure 24 SO FWD REV 10K OHM 10K OHM S1 FWD CW CW __ O 2 O m O STOP O REV S3 Figure 24 Independent Forward and Reverse Speeds with a Forward Stop Reverse Switch 42 Application Notes Voltage follower The drive may be wired to follow a floating isolated 0 to 10V signal that is isolated from earth ground instead of using a speed adjust potentiometer Connect the signal input to S2 and the signal common to RB1 see Figure 25 10 VDC S2 S1 COMMON d RB1 8 Figure 25 Voltage Follower Connection 43 Troubleshooting A Warning Dangerous voltages exist on the drive when it is powered When possible disconnect the drive while troubleshooting High voltages can cause serious or fatal injury Check the following steps before proceeding 1 2 The AC line voltage must match the voltage on the drive nameplate On dual voltage drives check that the voltage switches are set to the correct position The
31. ximum speed setting 46 Motor will not reach the desired speed 0 46 Limited Warranty inside back cover iv Illustrations Figure 1 175720 00 Chassis Dimensions 2 Figure 2 175721 00 Cased Drive Dimensions 3 Figure 3 Four Quadrant Operation lille 5 Figure 4 Chassis Drive Connections sninen 8 Figure 5 Cased Drive Connections oss 9 Figure 6 Cage Clamp Terminal Block sossun 10 Figure 7 Speed Adjust Potentiometer lusus 12 Figure 8 Speed Adjust Potentiometer Connections for Unidirectional Operation a and Bidirectional Operation b 13 Figure 9 TB502 Terminal Assignments auaa 14 Figure 10 Prewired Connections to L1 L2 with 115 VAC input and L2 with 230 VAC input lessen 16 Figure 11 Prewired Speed Adjust Potentiometer Connections 17 Figure 12 Selector Switch Locations llis essen 19 Figure 13 Block Diagram 2e erm ees 22 Figure 14 Regenerative Deceleration Switch Connection 24 Figure 15 Inhibit Terminals seen 25 Figure 16 Inhibit Run Terminals lees 26 Figure 17 Run Decelerate to Minimum Speed Switch shown with bidirectional connection 27 Figure 18 Calibration Trimpot Layout 4 29 Figure 19 Typical FWD TQ REV TQ IR COMP and Deadband ele xo n tene bee ace save cer aoe nens 36 Figure 20 Forward Reverse Swi
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