USER`S MANUAL - Bison Gear and Engineering Corporation
Contents
1. e f J H 0 93 24 1 85 47 0 84 18 7 3 50 89 pees 0 125 3 REF H i E JJ Optional 170 990 0200 Heatsink Dimensions 9 8 x 6 9 x 1 Figure 1 170 303 0010 and 170 303 0003 Dimensions 6 90 175 6 30 160 ja i 10 20 259 BRAKE OFEVERSE O FORWARD 9 80 249 FOUR 4 EACH MOUNTING SLOTS 6 3 160 x 7 0 178 ON CENTERS D Ara 5 50 140 4 78 121 ALL DIMENSIONS IN INCHES 2 30 58 1 50 38 L 1 50 38 THREE 0 88 22 KNOCKOUTS MILLIMETERS 1 40 36 Ht O QQ mm A gee Figure 2 170 343 0010 and 170 343 0003 Dimensions 5 Regenerative Drives In most non regenerative variable speed DC drives control cur rent flows 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 page 6 Motors must stop before reversing direction Non regenerative drives cannot oppose an overhauling load and cannot decelerate a load faster than coasting to a2. Figure 13 INHIBIT Terminals 24 Bison Gear amp Engineering offers an accessory plug harness for the INHIBIT terminals Bison Part Number Description 170 998 0100 Inhibit plug with 36 in 91 cm wires Twist inhibit wires and separate them from other power carrying wires or sources of electrical noise Use shielded cable if the inhibit wires are longer 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 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 see Figure 15 page 25 Each drive is assembled with INHIBIT INHIBIT RUN terminals 2 and 3 jumpered These terminals must Figure 14 Inhibit be connected for the motor to run Run Jumper Settings 25 COAST TO 0 gt RUN STOP i COAST RUN SWITCH Qu Or 1 2 8 INH RUN adaga
3. I7 Selector Switch Locations 21 Regenerative Deceleration Switch Connection 22 INHIBIT Terminals cer e REDDERE RR HER EUREEEGGG 23 Inhibit Run Jumper Settings 24 Inhibit Run Terminals Location and Run Coast Switch 25 Run Decelerate to Zero Speed Switch 26 Typical FWD TQ REV TQ and IR COMP Settings 34 Deadband Settings 0 0 0 cece eee eee ee 35 Connections to 170 993 0200 38 Forward Reverse Switch 39 Forward Stop Reverse Switch 39 Independent Adjustable Speeds 40 Independent Forward and Reverse Speeds 41 Independent Forward and Reverse Speeds with a Forward Stop Reverse Switch 42 Prewired Connections to L1 L2 115 and L2 230 47 Prewired Speed Adjust Potentiometer Connections 48 Tables Table 1 Field Output Connections Table 2 Fuse Chart Table 3 Corcom Filters Specifications Max Armature HP Range HP Range Current with 115 VAC with 230 VAC Model Amps DC Applied Applied 170 343 0010 170 303 0010 10 0 t 1 4 1 t 1 2 2 t 170 343 0003 170 303 0003 3 0 1 20 1 8 1 10 1 4 T Maximum armature curr
4. ra N m INHIBIT RUN mw m per TERMINALS e ET e e epe MEE al 5 d HE g c sd Figure 15 Inhibit Run Terminals Location and Run Coast Switch Decelerate to zero speed The circuit shown in Figure 16 may be used to decelerate a motor to a zero speed Closing the switch between S2 and SO decelerates the motor from set speed to zero speed The DECEL trimpot setting determines the rate at which the drive deceler ates Set the switch to the RUN position to accelerate the motor to set speed at a rate determined by the ACCEL trimpot setting 10K OHM SPEED ADJUST REV POTENTIOMETER DECEL TO ZERO SPEED 3 S2 S1 SO Figure 16 Run Decelerate to Zero Speed Switch shown with bidirectional speed adjust potentiometer connection 27 A Warning For frequent starts and stops use regenerative deceleration shorting RB1 and RB2 regenerative braking shorting INHIBIT terminals to each other coasting to a stop short ing INHIBIT RUN terminals 1 and 2 or decelerating to minimum speed shorting S2 to S0 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 accept
5. 17 All drives have line fuses installed Line fuses are rated for max imum rated curent Use line fuses rated for 20 A or less Voltage follower The drive may be wired to follow a isolated 0 to 3 10V signal instead of using a speed adjust potentiometer Connect the signal input to S2 and the signal common to RB1 see Figure 10 10 VDC _ 82 S1 COMMON RB1 Figure 10 Voltage Follower Connecti on 18 Operation A Warning Dangerous voltages exist on the drive when it is powered BE ALERT High voltages can cause serious or fatal injury For your safety use personal protective equipment PPE when operating this drive 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 fol lowing section for selector switch settings 19 Selector switch settings 1 Set the line voltage selector switches 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 to ARM for armature feedback Note You may be required to
6. AC line and motor connections Use 14 AWG or 16 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 page 10 for AC line and motor connections to chassis and cased drives SE i f AC LINE om 35 9 ARMATURE INPUT 115 VAC FIELD OUTPUT 115 OR 230 VAC For Shunt Wound Motors Only See field output section for connections Figure 4 Chassis Drive Connections 10 230 VAC AC LINE INPUT 115 OR 230 VAC Yaa ARMATURE OUTPUT FIELD OUTPUT For shunt wound motors only See field output sec tion for connections Figure 5 Cased Drive Connections 11 Cage clamp terminal block Connections to these drives are made to a cage cla
7. 39 Forward Reverse Switch 39 Independent Adjustable Speeds Forward Direction Only 40 Independent Forward and Reverse Speeds 41 Independent Forward and Reverse Speeds with FWD STOP REV Switch 42 Troubleshooting 2 Desc z EIER oe pa reap Ene xe 43 Factory Prewired Connections 47 Certificate of Compliance 49 Unconditional Warranty inside back cover iv 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 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 170 303 0010 and 170 303 0003 Dimensions 3 170 343 0010 and 170 343 0003 Dimensions 4 Four Quadrant Operation 6 Chassis Drive Connections 9 Cased Drive Connections 10 Cage Clamp Terminal Block 11 Speed Adjust Potentiometer 13 Speed Adjust Potentiometer Connections 14 TB502 Terminal Assignments 15 Voltage Follower Connection
8. Forward Stop Reverse Switch 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 The AC line voltage must match the voltage on the drive nameplate 2 On dual voltage drives check that the voltage switches are set to the correct position 3 The 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 4 The motor must be rated for the drive s rated armature all motors and field outputs shunt wound motors only 5 Do not make any connections to F1 and F2 if using a perma nent magnet motor 6 Terminal block connections should be consistent with the connections shown in this manual 7 Check that line fuse FU501 and FU502 for 230 VAC line voltage is properly sized and not blown 8 Check that field fuse FU503 is 1 5 A and not blown 44 Line fuse blows 1 Disconnect AC line voltage from the drive 2 Check that the motor cable and armature is not shorted or grounded a The motor s armature resistance should measure approxi mately 1 to 100 ohms depending on motor horsepower b A resistance reading from the motor frame to either armature side should show open when an ohmmeter is used on its high resistance scale 3 C
9. 21 xx I IHE Feedback Selector Switch j Toot Armature Voltage Selector Switch mo dni Toot T IHE IT IHHI TE IHE I IHHI Line Voltage Selector Switches A Uo Figure 11 Selector Switch Locations 22 Starting and Stopping Methods Line starting and line stopping Line starting and line stopping applying and removing AC line voltage is recommended for infreguent 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 Automatic restart upon power restoration All drives automatically run to set speed when power is applied Wiring a latchin
10. CCW to decrease the forward acceleration time REVERSE ACCELERATION REV ACC The REV ACC trimpot 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 avail able torque The REV ACC setting is factory set for its fastest reverse acceleration time Turn the REV ACC trimpot CW to increase the reverse accelera tion time and CCW to decrease the reverse acceleration time 34 170 303 0010 170 343 0010 1 HP C D 2 HP s 2 awe FWD TQ REV TQ IR COMP 10 ADC FWD TQ REV TQ IR COMP 9 2 ADC 3 4 HP 1 HP FWD TQ REV TQ IR COMP 7 6 ADC FWD TQ REV TQ IR COMP 5 ADC 1 2 HP 3 4 HP 9 Q vx E iovo FWD TQ REV TQ IR COMP 5 ADC FWD TQ REV TQ IR COMP 3 8 ADC av iow 90 VDC 180 VDC Lj los UM 27 apc Lj od CY 25 ADC FWD TQ REV TQ IR COMP FWD TQ REV TQ IR COMP 170 303 0003 170 343 0003 90 VDC Mao DG ES ES FWDTQ REVTQ RCON 1 3 ADC FwDTa RevTa ircomp 1 4 ADC 1 10 HP 1 8 HP gre QQQ i FwoTa REevra mcowe 1 1 ADC FwoTa revta Rcomp 0 67 ADC ne FWD TQ REV TQ IR COMP 0 56 ADC Figure 17 Typical FWD TQ REV TQ and IR COMP Settings actual settings may vary with each application 35 DEADBAND DB The deadband trimmer potentiometer determines
11. derate a 90 VDC motor when 230 VAC is applied to the drive Contact the factory for details See Figure 11 page 21 for all switch locations Startup Chassis drives 1 Set the speed adjust potentiometer for zero speed 2 Apply AC line voltage 3 Slowly advance the speed adjust potentiometer clockwise CW The motor slowly accelerates 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 20 Cased drives 1 AUN Set the FORWARD BRAKE REVERSE switch to the BRAKE position Set the speed adjust potentiometer to 0 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 slowly accelerates 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 O OFF position To reverse direction a Set the FORWARD BRAKE REVERSE switch to the BRAKE position b After the motor comes to a complete stop set the FOR WARD BRAKE REVERSE switch to the desired direc tion of rotation 10 Set the POWER switch to O OFF to remove power from the drive
12. lower speed Regenerative drives operate in two additional quadrants Quadrant 2 and Quadrant 4 In these quadrants 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 Figure 3 Four Quadrant Operation 7 Installation Mounting chassis drives Drive components are sensitive to electrostatic fields Avoid con tact with the circuit board directly 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 cali bration trimpots Mount the drive away from other 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 18 inch 4 57 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 for noise suppression To ground the chassis connect earth ground to the GND terminal on terminal block TB501 Mounting cased drives NEMA 4X cased drives come with three 0 88 inch 22 mm con duit knockout ho
13. 0416 Revision 0 May 2006
14. BISON USER S MANUAL Models 170 303 0003 170 303 0010 170 343 0003 170 343 0010 SCR Dual Voltage Adjustable Speed Regenerative Drives for DC Brush Motors Copyright 2006 by Bison Gear 8 Engineering All rights reserved No part of this manual may be reproduced or transmitted in any form without written permission from Bison Gear amp Engineering The information and techni cal data in this manual are subject to change without notice Bison Gear amp Engineering 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 Bison Gear amp Engineering 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 Printed in the United States of America A Safety Warnings This symbol A denotes an important safety tip or warning Please read these sections carefully prior to performing any of the instructions contained in that section Have 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 explosio
15. Operation iunio KA ce ae nae AP hk Dro TA A ee 18 Before applying power 18 Selector switch settings 19 StartUp 2 6 us erst apne he see ee age Velden eb UE teat AA 19 Chassis drives aa IAA Sei ee ha pa baw Re ea 19 Cased drives fo doe dee pe bos aaa 20 Starting and Stopping Methods 22 Line starting and line stopping 22 Automatic restart upon power restoration 22 Regenerative deceleration 22 Regenerative brake 23 Coast to a stop ces edie eis e 24 Decelerate to zero speed 26 Calibratioti 5 22 mo e Les etre crt CS eo RD ns 28 MINIMUM SPEED MIN SPD 29 MAXIMUM SPEED MAX SPD 29 FORWARD TORGUE FWDTO 30 REVERSE TOROUE REVTO 31 IRCOMPENSATION IRCOMP 32 FORWARD ACCELERATION FWD ACC 33 REVERSE ACCELERATION REV ACC 33 DEADBAND DB 35 TACHOGENERATOR TACH 36 Application Notes es ee detest AE Ea a fetes asad pate 38 Connection to other Bison devices 38 Optional speed adjust potentiometer connections 39 Forward Stop Reverse Switch
16. able method for emergency stopping CURRENT LIMIT FWD TQ and REV TQ on regenerative drives is still active while the drive is regeneratively braking Frequent regenerative deceleration regenerative braking coast ing 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 28 Calibration A Warning Dangerous voltages exist on the drive when it is powered When possible disconnect the voltage input from the drive before adjusting the trimpots If the trimpots must be adjust ed with power applied use insulated tools and the appropriate personal protection equipment BE ALERT High voltages can cause serious or fatal injury 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 29 MINIMUM SPEED MIN SPD The MIN SPD trimpot setting determines the motor 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 mot
17. ct for either Em 2 e direction FWD Figure 20 Forward Reverse Switch Forward Stop Reverse Switch Use a single pole three posi tion switch with a single so speed adjust potentiometer to S1 stop a motor between rever sals Figure 21 Set the S2 Sn switch to the center position REV S3 Cw to decelerate the motor to a STOP Ca stop FWD Figure 21 Forward Stop Reverse Switch 40 Independent Adjustable Speeds Forward Direction Only 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 poten tiometers can be mounted at two separate operating stations e S0 P1 P2 20K OHM 20K OHM 1 SPEED 1 cw cw e S2 gt SPEED 2 Figure 22 Independent Adjustable Speeds Forward Direction 41 Independent Forward and Reverse Speeds Connect two speed adjust potentiometers as shown in Figure 23 to select between independent forward and reverse speeds e so FWD REV 10K OHM 10K OHM si FORWARD CW GW S2 gt REVERSE S3 Figure 23 Independent Forward and Reverse Speeds 42 Independent Forward and Reverse Speeds with FWD STOP REV Switch Use a single pole three position switch to stop the motor when the switch is in the center position Figure 24 S0 FWD REV 10K OHM 10K OHM S1 cw cw FORWARD s2 gt STOP REVERSE S3 Figure 24 Independent Forward and Reverse Speeds with a
18. e to the drive 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 electri cal noise If potentiometer leads are longer than 18 in 46 cm use shielded cable Speed adjust potentiometers are installed on all cased drives MOUNT THROUGH A 0 38 IN 10 MM HOLE NUT STAR WASHER SPEED ADJUST POTENTIOMETER a INSULATING DISK POT TAB ASSIGNMENTS PANEL Figure 7 Speed Adjust Potentiometer 14 Speed adjust potentiometer connections The motor can operate in one direction unidirectional 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 direc tion while turning the wiper CCW from the center position causes the motor to rotate in the opposite direction Refer to the Applica
19. ent and horsepower range apply when drive is attached to addi tional heat sink Bison part number 170 990 0200 Use heat sink when armature current is above 7 ADC Heat sinks are pre mounted on cased drives See page 2 for part number descriptions AC Line Voltage 115 230 VAC 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 1 ADC Accel Time Range with no load 0 5 15 seconds Decel Time Range with no load 0 5 15 seconds Analog Input Voltage Range signal must be isolated S0 to S2 0 10 VDC Input Impedance S0 to S2 32K ohms Load Regulation with Armature Feedback with Tachogenerator Feedback 196 of base speed or better 0 196 of base speed Ambient Temp Range chassis drives 10 C 55 C Ambient Temp Range cased drives 10 C 40 C Vibration 0 5g max 0 50 Hz 0 1g max above 50 Hz 3 Dimensions 4 78 121 PTS 0 28 7 4 4 000 102 070118 l ae acq CALLELLELL in LOTDTOTCICTOTOTCTCMC pa Ol To JB Caan aa aaa 8 90 228
20. filtering is required Bison requires the Corcome filters listed in Table 3 If the exact fil ter is not available the specifications are as follows L 1 8 milliHenries C 0 01 microFarad Line to Ground 1 1 microFarads Line to Line Discharge Resistor 330Kohms Rated current 1 4 times maximum DC motor current Filter type Balanced 2 section Table 3 Corcom Filters Nameplate Current of Motor Wired to the Drive Corcom Filter Part Number 0 to 4 amps 6VV1 4 1 to 13 amps 20VV1 The filters in Table 3 should be wired to the AC line within 0 25 meters of the drive The ground connection from the filter must be wired to solid earth ground resistance less than 500 ohms not machine ground This is very important If the end user is using a CE approved motor the correct filter from Table 3 is all that is necessary to meet the EMC directives listed herein 51 The end user must use the filtration listed in Exhibit A to comply with CE The OEM may choose to provide alternative filtering that encompasses the Bison drive and other electronics within the same panel The OEM has this liberty because CE is a machinery directive Whether or not every component in the OEM s machinery meets CE the OEM must still submit his machine for CE approval meet CE the machine will not necessarily meet CE as a machine Thus no component must necessarily meet CE within the machine as long as the OEM takes the neces
21. g 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 RB1 motor to a stop Figure 12 Since terminal RB1 bypasses STOP the MIN SPD circuit shorting RB2 RBI and RB2 will decelerate a motor to a stop instead of mini RUN mum speed Calibrate the deceleration time Figure 12 Regenerative by adjusting the opposite direc Deceleration Switch tion acceleration trimpot Connection 23 Regenerative brake Short the INHIBIT terminals to regeneratively brake the motor see Figure 13 for INHIBIT terminal location Reopening the INHIBIT terminals causes the motor to accelerate to set speed The INHIBIT terminals bypass both the MIN SPD circuit and the deceleration circuit This causes the motor to stop rapid ly when the INHIBIT terminals are shorted Braking torgue is determined by the opposite direction torgue setting aa ET ET m m ILE Y Y Y E FU mit INHIBIT p di Terminals o o __ ax Eae B GA 8 Ha uds i Q
22. he motor is not overloaded For additional assistance contact your local Bison distributor or the factory direct at PHONE 1 800 AT BISON 47 Factory Prewired Connections for Cased Drives WHITE WHITE BLACK L2 230 BLACK POWER LIGHT BLACK BLACK e L1 BLACK WHITE WHITE BLACK L2 115 Figure 25 Prewired Connections to L1 L2 115 and L2 230 so GREY si GREY WHITE FWD S2 GREEN REV s3 BLUE 48 10K OHM Figure 26 Prewired Speed Adjust Potentiometer Connections 49 Certificate of Compliance Bison Gear amp Engineering hereby certifies that the series of drives covered in this manual have been approved to bear the CE mark provided the conditions of approval listed in Exhibit A have been met by the end user This series has been tested to the following test specifications EN55011 1991 emissions and EN50082 1 1992 immunity Compliance allows this series to bear the CE mark The end user as described herein falls into one of two categories 1 The Consumer will deploy a stand alone unit as an inte gral yet external portion of the machine he she is operat ing 2 The Original Equipment Manufacturer OEM will imple ment the product as a component of the machine being manufactured 50 Exhibit A In addition to EMI RFI safeguards inherent in this series design external
23. heck that the field circuit is not open 45 Motor pulsates or surges under load 1 2 Readjust the IR COMP setting slightly CCW until the motor speed is stabilized Verify that the motor is not going in and out of current limit If so re adjust FWD TQ and REV TQ pots Line fuse does not blow but the motor does not run 1 Gv p tS Verify that the speed adjust potentiometer is not set to its zero speed position If in voltage follower mode verify that refer ence voltage is not set to zero Check the speed adjust potentiometer for continuity Verify that the inhibit pins are not shorted together Check that INHIBIT RUN terminals 2 and 3 are connected Verify that the drive is receiving AC line voltage 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 TQ or REV TO setting if it is set lower than the current rating of the motor Check that the speed adjust potentiometer connections to the terminal block are correct and not open Motor runs too fast at the maximum speed setting 1 2 Check that the MIN SPD and MAX SPD setting are not set too high Check that the field output connections are secure if you are using a shunt wound motor 46 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 t
24. input leads to the T1 and T2 terminals on TB502 Apply power to the drive The motor should be running at minimum speed Rotate the main speed potentiometer to full speed in the for ward direction Turn the maximum speed trimmer pot clockwise until the desired maximum speed is reached Remove all power from the drive The motor should stop Place the Feedback selector switch SW504 to the Tachogenerator TACH position 37 13 Apply power to the drive The motor should run in the for ward direction 14 Rotate the TACH trimmer pot CCW so that the maximum speed is reached this is the same speed as was obtained in step 10 15 Rotate the main speed potentiometer to the reverse direction S2 should be negative with respect to S1 The motor speed should follow the speed potentiometer position 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 38 Application Notes Connection to other Bison devices TB502 TB501 S2 REGENERATIVE DRIVE RB1 1 170 993 0200 SIGNAL ISOLATOR Figure 19 Connections to 170 993 0200 39 Optional speed adjust potentiometer connec tions Forward Reverse Switch Use a single pole two posi tion switch with a single speed adjust potentiometer to 1 plug reverse the motor 10K Figure 20 The MIN SPD S2 IS OHM setting Is in effe
25. les at 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 Set the POWER switch to the 0 or OFF position before applying the AC line voltage 2 Install the mounting screws 3 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 4 Carefully remove the conduit knockouts by tapping them into the case and twisting them off with pliers 5 Install conduit hardware through the 0 88 inch 22 mm con duit holes Connect external wiring to the terminal block 6 Grasp the slotted screw and tilt the front cover back into place Avoid pinching any wires between the front cover and the case 7 Turn the slotted screw clockwise until tight to secure the front cover 9 Heat sinking 170 303 0010 models require an additional heat sink when the continuous armature current is above 7 ADC Use Bison part number 170 990 0200 All cased drives have suffi cient heat sinking in their basic configurations 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
26. mp terminal block see 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 Lever Arm Wire Clamp Figure 6 Cage Clamp Terminal Block 12 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 Fl and LI 230 200 F1 and F2 Tachogenerator feedback Using tachogenerator 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 for T1 and for T2 when the motor running in the forward direction The polarity is reversed when the motor is running in the reverse direction 13 Speed adjust potentiometer installation A Warning Be sure that the potentiometer tabs do not make contact with the potentiometer enclosure Grounding the input will cause damag
27. n by proper grounding over current protection thermal protection and enclosure Follow sound maintenance procedures t is possible for a drive to run at full speed as a result of a component failure Please ensure that a master switch has been placed in the AC line to stop the drive in an emergency 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 AA ee emere eR aua 1 Dimensions AA been d eR es 3 Regenerative Drives 5 Installation ee het e eb mach Im ee ace en 7 Mounting chassis drives 7 Mounting cased drives 8 Ideat sinking oe iue or mon eos LL SE bre xe 9 AC line and motor connections 9 Cage clamp terminal block 11 Field output sizes hb bh Sede bb de e neci 12 Tachogenerator feedback 12 Speed adjust potentiometer installation 13 Speed adjust potentiometer connections 14 15 and 15 terminals elles eese 15 Line Fusing Drives aa awa Aa 16 Voltage follower 17
28. o longer needed and re apply power to the drive Ww 32 IR COMPENSATION IR COMP The IR COMP trimpot 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 curernt rated motor See Figure 17 page 34 for typical IR COMP trimpot settings or recalibrate using the following procedure 1 Set the IR COMP trimpot to minimum full CCW 2 Rotate the speed adjust potentiometer until the motor runs at midspeed without load for example 900 RPM for an 1800 RPM motor A hand held tachometer may be used to meas ure motor speed Load the motor armature to its full load armature current rat ing The motor should slow down While keeping the load on the motor rotate the IR COMP trimpot until the motor runs at the speed measured in step 2 If the motor oscillates overcompensation the IR COMP trimpot may be set too high CW Turn the IR COMP trimpot CCW to stabilize the motor Unload the motor 33 FORWARD ACCELERATION FWD ACC The FWD ACC trimpot 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 avail able torgue The FWD ACC setting is factory set for its fastest forward acceleration time Turn the FWD ACC trimpot CW to increase the forward acceler ation time and
29. or turns at the desired mini mum 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 fac tory set for maximum rated motor speed To calibrate set the speed adjust potentiometer full CW Adjust the MAX SPD trimpot until the motor turns at the desired maxi mum speed 30 FORWARD TORQUE FWD TQ Warning FWD TQ should be set to 120 of drive nameplate current rating Continuous operation beyond this rating may damage the motor If you intend to operate beyond the rating contact your Bison representative for assistance The FWD TQ trimpot 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 Figure 17 page 34 for recommended FWD TQ trimpot settings 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 Set the speed adjust potentiometer to maximum forward speed 4 Lock the motor shaft Be sure that the motor is firmly mounted to withstand maximum torque generated by the motor 5 Apply line power The motor should be stopped 6 Slowly adjust the FWD TQ trimpot CW until the armature cur rent is 120 of rated drive current 7 Set the speed adjust
30. potentiometer to minimum 8 Remove the power from the drive and unlock the motor shaft 9 Remove the ammeter in series with the motor armature if it is no longer needed and re apply power to the drive Ww 31 REVERSE TORQUE REV TQ A Warning REV TQ should be set to 120 of drive nameplate current rating Continuous operation beyond this rating may damage the motor If you intend to operate beyond the rating contact your Bison representative for assistance The REV TQ trimpot setting determines the maximum torque for accelerating and driving the motor in the reverse direction It also sets the maximum torque for decelerating the motor in the forward direction Refer to Figure 17 page 34 for recommended REV TQ trimpot settings 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 REV TQ trimpot to minimum full CCW Set the speed adjust potentiometer to maximum reverse speed 4 Lock the motor shaft Be sure that the motor is firmly mounted to withstand maximum torque generated by the motor 5 Apply line power The motor should be stopped 6 Slowly adjust the REV TQ trimpot CW until the armature cur rent is 120 of rated drive current 7 Set the speed adjust potentiometer to minimum 8 Remove the power from the drive and unlock the motor shaft 9 Remove the ammeter in series with the motor armature if it is n
31. sary steps to quar antee the machine does meet CE By the same token even if every component in the OEM s machine does meet CE the machine will not necessarily meet CE as a machine Use of CE approved wiring practices such as proper shielding and the filters listed in Exhibit A guarantee the drive will meet EN55011 1991 emissions standard and EN50082 1 1992 immu nity standard 52 Bison Warranty Policy The Company warrants to the Buyer the products sold hereunder to be free of defects in material and workmanship under normal use and service for a period of one 1 year from the date of shipment The obligation of the Company under this warranty is limited to repair or replacing at its option any part or parts which upon examination shall disclose to the reasonable satisfaction of the Company to have been defective in material or workman ship Buyer must return the products to the Company s factory shipping charges prepaid and with complete information as to alleged defects and the installation operation and service of the products Except as otherwise expressly stated herein the Company makes no representation of warranty of any kind express or implied as to merchantability fitness for a particular purpose or any other matter with respect to the products sold hereunder BISON Bison Gear amp Engineering Corp 3850 Ohio Ave St Charles IL 60174 Phone 1 800 AT BISON www bisongear com Document Number 250
32. the time that will elapse between the application of current in one direc tion 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 approzimately 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 opera tion See Figure 18 for recommended deadband settings 60 Hz 50 Hz APPLICATIONS APPLICATIONS Figure 18 Deadband Settings 36 TACHOGENERATOR 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 2 3 4 10 11 12 Remove power from the drive Rotate the TACH trimmer pot to full clockwise full CW Rotate the MAX SPD trimmer pot to full counterclockwise full CCW Rotate the IR COMP trimmer pot to full CCW Place the feedback selector switch SW504 to the ARMA TURE ARM position Rotate the main speed potentiometer to midrange Wire the DC tach to the drive Note The polarity of the Tach voltage input to the drive should be T1 and T2 This polarity may be measured with a DC voltmeter If the polarity is incorrect swap the two tach
33. tion Notes section for additional speed adjust potentiometer connections 10K OHM 2W 10K OHM T8302 SPEED ADJUST SPEED ADJUST POTENTIOMETER TB502 POTENTIOMETER S2 REV S3 1 S2 so l 81 FWD cw CCW a b Figure 8 Speed Adjust Potentiometer Connections for a Unidirectional Operation and b Bidirectional Operation 15 15 and 15 terminals A Warning Do not short the 15 and 15 terminals for any reason Shorting these terminals may damage the drive These drives can supply a regulated 15 and 15 VDC signal each sourcing 15 mA maximum to isolated external devices These voltage supply terminals are located on terminal block TB502 see figure 9 C e S3 S2 S1 SO RB1 RB2 15 15 T1 T2 cosa Figure 9 TB502 Terminal Assignments 16 Line Fusing Bison drives reguire fuses for protection Use fast acting fuses rated for 250 VAC or higher and approximately 150 of the maximum armature current Fuse L1 when using 115 VAC line voltage Fuse both L1 and L2 when the line voltage is 230 VAC The fuse chart below lists the recommended line fuse sizes Table 2 Fuse Chart 90 VDC Motor 180 VDC AC Line Fuse Horsepower Horsepower Size amps 1 20 1 10 3 1 15 1 8 3 1 8 1 4 5 1 6 1 3 5 1 4 1 2 8 1 3 3 4 8 1 2 1 10 3 4 1 1 2 15 1 2 20
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