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1. NOAMOS 11 35435 C CAEN IMAN INIAIANS indino 7 MZ 288 09 184 x08 08H 2001 J NYY J IN 4 z GE pa SCT x DE KC ee 4010 lt 90 er am rl LANT Oe DER O04 Liy A AAA AAA c6vola NOUNOU 68 OI9 30uanaoxg fiq usd
2. NOTES Standard Terms amp Conditions of Sale 1 General The Standard Terms and Conditions of Sale of Carotron Inc here inafter called Company are set forth as follows in order to give the Company and the Purchaser a clear understanding thereof No additional or different terms and conditions of sale by the Company shall be binding upon the Company unless they are expressly consented to by the Company in writing The acceptance by the Company of any order of the Purchaser is expressly conditioned upon the Purchaser s agreement to said Standard Terms and Conditions The acceptance or acknowledgement written oral by conduct or otherwise by the Company of the Purchaser s order shall not constitute written consent by the Company to addition to or change in said Standard Terms and Conditions 2 Prices Prices discounts allowances services and commissions are subject to change without notice Prices shown on any Company published price list and other published literature issued by the Company are not offers to sell and are subject to express confirmation by written quotation and acknowledgement All orders of the Purchaser are subject to acceptance which shall not be effective unless made in writing by an authorized Company representative at its office in Heath Springs S C The Company may refuse to accept any order for any reason whatsoever without incurring any liability to the Purchase
3. CHOICE D C MOTOR CONTROL SERVICE MANUAL Choice Series Drives Use With Instruction Manual Models CDC320 000 CDC340 000 CDC360 000 CDC375 000 CDC3150 000 CAROTRON __ Driven by Excellenc VES A C INVER SOLID STATE STARTERS SYSTEM INTERFACE CIRCUITS AND ENGINEERED SYSTEMS 15 ABOUT THIS GUIDE a a I e 2 2 GENERAL DESCRIPTION es d ea a a EN es 2 3 SPECIFICATIONS rosno aj a a a 3 4 MODEL IDENTIFICATION asus ei oa ii a a 4 5 CONVENTIONS GLOSSARY ABBREVIATIONS 7 6 DESCRIPTION OF OPERATION sssssssssssssssssse 9 6 1 Armature Power Bridge 9 6 2 Field Supply 11 6 3 Relay Logic and Control Voltage Supply 11 6 4 Power Supplies 13 6 5 Reference Circuitry 13 6 6 Feedback Circuitry and Isolation 14 6 7 Velocity and Current Loops 18 6 8 Static Current and Overcurrent Functions 19 6 9 Trigger Circuit 21 6 10 Special Signals and Circuit Functions 24 6 11 Fault Circuits 26 7 DRIVE PROGRAMMING CALIBRATION sssssss 28 8 COMPONENT TESTING 2 2 Saeed gees ae eee ere daa 32 9 TROUBLESHOOTING sei ad DAA u ga 32 10 TEST POINTS CHECK POINTS ccc ccc cece eee cece 35 11 REPLACEMENT PARTS COMPONENT SUBSTITUTION 37 11 1 Component Substitution 37 11 2 Printed Circuit Assemblies 37 11 3 Connector Cable Assemblies 38 11 4 Fuses 38 11 5 Power Components 38 ENN EN RE A0 D10483 Control Board Schematic 40 D10492 Power Tr
4. Improper wiring of the motor Does the motor have a SERIES armature winding If it does its polarity is critical Are the field windings connected correctly Most motors used with CHOICE drive models have dual field windings that must have the same polarity to work properly Incorrect armature current scaling Has the proper motor current range been selected by J6 on the CONTROL board The scaled current range of the control must match the nameplate current rating of the motor If used is the velocity feedback tachometer or encoder selected connected and scaled properly If in armature feedback is the IR COMP adjusted too high Is the speed reference to the control a stable noise free signal Know what your starting point is before making an adjustment Make only one adjustment at a time If an adjustment has no affect or appears not to help be sure to return it to its starting point before making any other adjustment When loop adjustments are required start first with the I current loop adjustment IR COMP The IR COMP is functional only in the AFB mode and is used to keep motor speed from decreasing as load is increased Adjustment is best done when the motor or machine can be loaded normally If the motor is normally operated at a particular speed adjust the IR COMP while running at that speed If the motor operates under load over a wide speed range pick a speed near mid range to make the adjustment
5. Pi i re 11 i pa LI LI AR pa pa e e ke e D pp Y PAPE FIGURE 1 Each phase of the AC line connects to an SCR and a diode housed in an isolated power module A fourth diode only module is in parallel with the bridge output and acts as a freewheeling or flyback diode As a semiconverter only half the three SCR s of the rectifier components are controlled which gives an output ripple frequency equal to three times the AC line frequency 180 Hz for 60 Hz lines and 150 Hz for 50 Hz lines Because of this the output is sometimes mistakenly called a half wave output Refer to FIGURE 2 5 for typical bridge output waveforms at various unloaded and loaded speeds FIGURE 2 FIGURE 4 The power modules are some of the few components that must be sized according to the horsepower rating of the control They are all rated at 1400 volts PIV with 1000 volts microsecond dv dt to permit reliable operation over a wide range of AC line voltage They are directly controlled by gating signals from the POWER TRIGGER board and are temperature protected by a thermostat on the same heatsink There are several vendors that can be used FIGURE 3 as replacements for these parts Special attention should be paid to the terminal connections for the gate and cathode signal leads coming from CN6A on the POWER TRIGGER board CAROTRON routinely manufactures
6. 6 4 POWER SUPPLIES The power supplies are located on the POWER TRIGGER board Refer to FIGURE 7 The supplies are isolated by a 24 VA transformer which is powered from the 115 VAC control voltage via FUI on the FUSE board The transformer dual 17 VAC secondaries are rectified and filtered to give unregulated 24 VDC supplies which are used directly by 6 5 REFERENCE CIRCUITRY the pulse transformers ZERO SPEED relay and clamping logic on the CONTROL board Two IC regulators further reduce the supplies to 15 VDC which power most of the circuitry in the drive Also zener diodes are used on the CONTROL board to establish 10 VDC for the speed pot and 12 VDC for an encoder supply The 24 24 15 amp 15 VDC supplies can be measured at TB2 5 and DCM check points A D CHOICE drive can make use of several voltage signals to control the speed of a motor Refer to FIGURE 8 FIGURE 8 Signals from an external speed pot trimmed by the MAX SPEED the MIN SPEED SUM INPUT and JOG SPEED can all be part of the TOTAL SETPOINT for speed Normal operation with a speed pot connected to TB1 1 2 amp 3 uses a 10 VDC signal from TB1 3 This signal is trimmed by the speed pot to set the input to the accel decel circuit at TB1 2 The terminal 2 signal is given noise immunity by the R93 C26 R C network OP AMPs A3 B and A3 D form a closed loop circuit that uses the reference level to
7. A stage of the hex inverter IC2 inverts this logic to set the fault latch output high Refer to SECTION 6 11 for more information on the fault circuits NOTE The timers for FOLDBACK and OVERCURRENT FAULT operate when the current demand has exceeded 112 continuously for their respective time periods During time out a dip below 112 demand will reset the timers and start the timing cycle over again A decrease below FIGURE 16 d 112 automatically brings the control out of a FOLDBACK condition OVER CURRENT FAULT though is a latch function and must be reset STATIC CURRENT LIMIT The STATIC CURRENT LIMIT feature is programmable with J8 on the CONTROL board See FIGURE 16 This feature allows setting the level of current limiting statically or without actually supplying armature current to the motor As detailed in previous sections control of motor current is based on calibration to give a scaled 5 0 VDC current amplifier signal at 100 of the programmed current range Selection STATIC C L with J8 will disable the current loop and trigger circuit Then starting the control with the speed reference turned up will cause velocity integrator to saturate demanding maximum torque which can be trimmed to the desired current limit level by monitoring TP19 K This level is factory set to 7 5 VDC which equates to 150 current 6 9 TRIGGER CIRCUIT The trigger circuit accepts a voltage
8. point coinciding with the peak of the triangle and stays high for that portion of the triangle ramp that exceeded the positive bias A similar output occurs when the positive output from the current integrator is applied to the non inverting input of the section A1 C comparator The signal adds to the effect of the triangle wave shifting the output positive where it coincides with the peak and slope of the waveform In this fashion the current integrator output controls the width of the gating signal and therefore the SCR conduction time for each cycle of the AC line The variable width conduction pulse is modulated by the oscillator output at the IC3 3 input AND gate A series pass 2N3904 transistor amplifies the gate current to drive a TIP47 transistor into saturation This TIP47 sinks current through a parallel resistor capacitor network and the primary of the trigger transformer to induce a gate pulse on the secondary The initial pulse of current through the capacitor and then mainly through the primary is high due to current flow through the capacitor and then mainly through the resistor since the capacitor does not have time to completely discharge at the 9 4 KHz rate Refer to FIGURE 18 for a timing diagram of the POWER TRIGGER board signals and FIGURES 19 amp 20 for typical SCR gate pulse with the drive at no load and full load 6 10 SPECIAL SIGNALS AND CIRCUIT
9. 112 current signal refer to ARMATURE CURRENT SENSING in SECTION 6 6 The comparator output measured at DCM check point R is used to control two current related protection circuits FOLDBACK and OVERCURRENT FAULT The FOLDBACK circuit uses IC1 A of a 556 dual timer to control the amount of time the drive has exceeded 112 or rated armature current After 60 seconds the drive will enter the FOLDBACK mode and clamp the output to a maximum of 112 Normally the timer output is triggered into a high state upon power up This high level exceeds the positive voltage divider level on the non inverting input of comparator A1 C and causes it to stay at a negative saturation level When the demand voltage level into the inverting input of AS A exceeds the 5 6 VDC level on the non inverting input the output switches negative and turns off transistor Q1 which was clamping the timing capacitor CS If the demand has exceeded 112 for approximately 60 seconds C5 completes its charge and drives the timer output low The low level causes A1 C and Q5 to switch the 5 6 volt zener into operation which now limits the current reference at TP6 L to 112 OVERCURRENT FAULT The OVERCURRENT FAULT circuit is similar to the FOLDBACK circuit Transistor Q2 and timer IC1 B are controlled by the demand sensing circuit in the same way except that the 112 level must be exceeded for five minutes before the timer output drops low
10. 60 HP 500 VDC Model CDC375 000 140 FLA 40 HP 240 VDC 75 HP 500 VDC Model CDC3150 000 256 FLA 75 HP 240 VDC 150 HP 500 VDC SPEED REGULATION Armature Feedback 1 0 of base speed Tachometer Feedback 0 5 of base speed Encoder Feedback 0 5 of base speed TORQUE REGULATION e 2 0 of current range selected SPEED RANGE e 20 1 motor dependent The CHOICE series controls are offered in and option numbers are shown in the following basic chassis models and contactor models tables available with factory installed options The basic model will have a model number label NOTE The contactor run brake and with applicable rating information Contactor reversing models listed below include the models will have an additional label showing control voltage 115 VAC transformer as the contactor horsepower rating and any well as the armature contactor s additional option dash numbers These model TABLE 1 MODEL NUMBERS MODEL NUMBER HP RATING DESCRIPTION 230 460 INPUT CDC320 000 5 10 5 20 BASIC CHASSIS MODEL CDC340 000 15 20 25 40 BASIC CHASSIS MODEL CDC360 000 25 30 50 60 BASIC CHASSIS MODEL CDC375 000 40 75 BASIC CHASSIS MODEL CDC3150 000 50 75 100 150 BASIC CHASSIS MODEL CDC320 C15 5 7 5 10 15 CONTACTOR RUN BRAKE CHASSIC CDC320 C20 10 20 CONTACTOR RUN BRAKE CHASSIC CDC340 C30 15 25 30 CONTACTOR RUN BRAKE CHASSIS CDC340 C40 20 40 CONTACTOR RUN BRAKE CHASSIS CDC360 C60 25 30 50 60 CONTACTOR RUN BRAK
11. CDC375 C75 amp R75 NEMA 12 ENCL TABLE 5 ENCLOSURE OPTIONS cont CDC3EN 003 CDC3150 C100 C125 C150 R125 R150 NEMA 12 ENCL CDC3EN HOI CDC3DS 150 OPTION ON MODELS CDC320 C15 C20 R15 R20 CDC340 C30 C40 R40 CDC360 C60 R60 NEMA 12 ENCL W DISCONNECT HANDLE CDC3EN CDC3DS 150 OPTION ON MODELS CDC320 C15 C20 R15 R20 CDC340 C30 C40 R30 R40 CDC360 C60 R60 NEMA 12 ENCL W DISCONNECT HANDLE CDC3EN CDC3DS 150 OPTION ON MODELS CDC375 C75 amp R75 NEMA 12 ENCL W DISCONNECT HANDLE CDC3EN CDC3DS 225 OPTION ON MODELS CDC3150 C100 C125 R100 R125 NEMA 12 ENCL W DISCONNECT HANDLE CDC3EN CDC3DS 400 OPTION ON MODELS CDC3150 C150 amp R150 NEMA 12 ENCL W DISCONNECT HANDLE TABLE 6 DYNAMIC BRAKING OPTIONS OPTION NUMBER MOTOR USED WITH DESCRIPTION CDC3BR 205 5 HP 240 VDC ARM NEMA 12 ENCLOSED 10 Ohm 300 WATT BRAKE RESISTOR CDC3BR 207 7 5 HP 240 VDC ARM NEMA 12 ENCLOSED 5Ohm 600 WATT BRAKE RESISTOR CDC3BR 210 10 HP 240 VDC ARM NEMA 12 ENCLOSED 4 4 Ohm 7 50 WATT BRAKE RESISTOR CDC3BR 215 15 HP 240 VDC ARM NEMA 12 ENCLOSED 3 Ohm 1000 WATT BRAKE RESISTOR CDC3BR 220 20 HP 240 VDC ARM NEMA 12 ENCLOSED 2 2 Ohm 1500 WATT BRAKE RESISTOR CDC3BR 225 25 HP 240 VDC ARM NEMA 12 ENCLOSED 1 7 Ohm 2000 WATT BRAKE RESISTOR CDC
12. MOBLOG FE L y 99012 LOEN NOELLDEN HFH 997012 1000000000 66402 xy fig uanng NOLON SESOLA pen Nossa sed Zesold mt g EISOIQ ELGEN 17314 34 10900 Nolla
13. is set by jumper J4 The labeling of J4 refers to the rating per 1000 RPM of DC tachometers 45 VAC and 90 VAC tachometers can be used with the 50 and 100 V jumper positions The jumper is set to scale the full speed tach voltage to 7 7 VDC Following the scaled signal A4 A and A4 B form a precision rectifier circuit which always keeps the output polarity positive regardless of input polarity The output can be measured at TP12 H ENCODER FEEDBACK EFB A 12 VDC 300 PPR encoder connected to TB1 9 can also be selected by J3 in the EFB position reference FIGURE 14 1750 RPM equates to 8750 Hz input which is processed FIGURE 14 by IC7 a frequency to voltage converter IC7 sources a current signal into A7 B an active filter circuit and then through an inverting amplifier A7 A where we can see 7 7 VDC on TP8 I at 1750 RPM 6 7 VELOCITY AND CURRENT LOOPS Speed regulation and current regulation are critical operations performed within CHOICE drives by individual loop control circuits They are known as velocity or current loops because the circuits actively use a feedback signal that is looped around or fed back for comparison to the reference Faster response and improved speed and torque regulation are the results Both the velocity and current loops use a hybrid or stepped integrator OP AMP circuit Refer to FIGURE 15 They operate with a rate of integration determined by the resi
14. party other than the Purchaser The Company makes no other warranties or representation expressed or implied of merchantability and of fitness for a particular purpose in regard to products manufactured parts repaired and systems engineered by it 3 Terms of payment Standard terms of payment are net thirty 30 days from date of the Company invoice For invoice purposed delivery shall be deemed to be complete at the time the products parts and systems are shipped from the Company and shall not be conditioned upon the start up thereof Amounts past due are subject to a service charge of 1 5 per month or fraction thereof 6 Order cancellation Any cancellation by the Purchaser of any order or contract between the Company and the Purchaser must be made in writing and receive written approval of an authorized Company representative at its office in Heath Springs S C In the event of any cancellation of an order by either party the Purchaser shall pay to the Company the reasonable costs expenses damages and loss of profit of the Company incurred there by including but not limited to engineering expenses and expenses caused by commitments to the suppliers of the Company s subcontractors as determined by the Company 7 Changes The Purchaser may from time to time but only with the written consent of an authorized Company representative make a change in specifications to products parts or systems covered by a purchase order acce
15. rating of 37 A Adjust P9 until TP11 M reads I VDC Adjust P6 until the ammeter reads 7 4 ADC 20 of 37 A WARNING Do not exceed the maximum current rating of the ammeter On higher current drives it may also be necessary to tap armature current down in order not to exceed smaller ammeter current ratings This is done by moving jumper J6 to a lower percentage and adjusting P6 to a lower percentage Example A CDC3150 000 has a maximum rating of 256 A In the above example P6 would then be adjusted until the ammeter would read 51 2 ADC However if jumper J6 was placed in the 20 range instead of the 100 range P6 would have to be adjusted to only 10 2 ADC 20 of 51 2 ADC After calibration remove power and reconnect the field and armature wires as before Return J1 J6 and P9 to their previous positions BAL 1 amp BAL 2 These two adjustments are preset at the factory to equalize the conduction angle of the 3 SCRs and the loading of the 3 phase AC line input The BAL 1 pot is used to adjust SCH while the BAL 2 pot is used to adjust SCR2 These two adjustments are used to equalize their conduction angles with SCR3 which is not adjustable If these adjustments are unknown or in doubt the following procedure can be used to balance the SCRs An oscilloscope and or ammeter s will be required to balance the SCRs The SCRs can be balanced in one of two ways The first option is to balance the conduction angle or on tim
16. 2 begins a timing cycle and the output goes high The train of input pulses continually resets and re triggers the timer so that it normally cannot complete a timing cycle One missing pulse gives enough time for a cycle to complete If this happens IC2 output goes low and is inverted by the ICIgate A high level from ICI then signals a delay circuit that a sync pulse is missing Experience has shown us that normal industrial line supplies and branch circuits are constantly being subjected to notches or hole in the line The delay circuit provides immunity from such intermittent and short losses of line voltage that do not adversely 7 1 ADJUSTMENT AND PROGRAMMING PRESETS CAROTRON CHOICE controls are all functionally tested and calibrated with motor loads and should require further calibration only to tailor operation for a specific application The adjustment presets are listed in the event that the condition of the control and its adjustments are unknown or in doubt Potentiometer Presets e Min Speed e Max Speed full CCW mid range affect drive operation A capacitor charge must build up from repeated loss of line for a time equal to about 3 cycles or 50 60 milliseconds before reaching the level necessary to operate the fault latch of IC3 Several IC2 inverter gates are used to square up the signal from the detector and into the latch OVERTEMP OVERTEMP operates from a thermostat switch located on the po
17. 3BR 230 30 HP 240 VDC ARM NEMA 12 ENCLOSED 1 7 Ohm 2000 WATT BRAKE RESISTOR CDC3BR 240 40 HP 240 VDC ARM EXPANDED METAL ENCLOSED 1 3 Ohm 2080 WATT BRAKE RESISTOR CDC3BR 275 75 HP 240 VDC ARM EXPANDED METAL ENCLOSED 0 62 Ohm 2232 WATT BRAKE RESISTOR CDC3BR 405 5 HP 500 VDC ARM NEMA 12 ENCLOSED 40 Ohm 375 WATT BRAKE RESISTOR CDC3BR 407 7 5 HP 500 VDC ARM NEMA 12 ENCLOSED 20 Ohm 750 WATT BRAKE RESISTOR CDC3BR 410 10 HP 500 VDC ARM NEMA 12 ENCLOSED 200hm 750 WATT BRAKE RESISTOR CDC3BR 415 15 HP 500 VDC ARM NEMA 12 ENCLOSED 14 Ohm 1000 WATT BRAKE RESISTOR CDC3BR 420 20 HP 500 VDC ARM NEMA 12 ENCLOSED 10 Ohm 1500 WATT BRAKE RESISTOR CDC3BR 425 25 HP 500 VDC ARM NEMA 12 ENCLOSED 7 Ohm 2000 WATT BRAKE RESISTOR CDC3BR 430 30 HP 500 VDC ARM NEMA 12 ENCLOSED 6 Ohm 2000 WATT BRAKE RESISTOR TABLE 6 DYNAMIC BRAKING OPTIONS cont CDC3BR 440 40 HP 500 VDC ARM NEMA 12 ENCLOSED 5 Ohm 3000 WATT BRAKE RESISTOR CDC3BR 450 50 HP 500 VDC ARM NEMA 12 ENCLOSED 3 4 Ohm 4000 WATT BRAKE RESISTOR CDC3BR 460 60 HP 500 VDC ARM NEMA 12 ENCLOSED 3 4 Ohm 4000 WATT BRAKE RESISTOR CDC3BR 475 75 HP 500 VDC ARM EXPANDED METAL ENCLOSED 2 6 Ohm 4160 WATT BRAKE RESISTOR CDC3BR 4150 CONVENTIONS The following conventions will be used throughout this manual Al
18. A1 D to give 7 7 VDC output measured at TP10 G when at the respective full rated armature voltage This scaled armature voltage is used for the zero speed circuit input see SECTION 6 10 and as input to the armature feedback circuit ARMATURE FEEDBACK AFB The counter EMF voltage generated by a motor armature is not an ideal velocity feedback because IR losses in the armature cause speed to drop as load increases with armature voltage held constant To compensate for the losses the IR COMP pot and circuit uses some of the armature load signal from the current amplifier to subtract from the armature feedback voltage See FIGURE 13 The reduction in feedback acts the same as an increase in velocity reference and will cause an increase in armature voltage with an increase in load to keep the speed constant A2 B sums the scaled armature voltage with inverted current amplifier A4 C output via A6 C A6 C has a FET clamp to disable it in a stop condition The output of A2 B goes through the A2 A inverter stage before connecting to the J3 feedback selection jumper This signal can be monitored at TB13 S TACHOMETER FEEDBACK TFB Another velocity feedback mode selectable by J3 is TACHOMETER FEEDBACK TFB Refer to FIGURE 14 An AC or DC FIGURE 13 tachometer output can be connected to TB1 12 and common The tach voltage is noise de coupled and applied to the A4 D amplifier where the gain
19. AL These two adjustments are preset at the factory to give a calibrated current amplifier signal versus armature current signal These adjustments are critical to all current related functions i e current feedback current feedback current limiting IR Compensation current foldback and overcurrent fault WARNING Altering the factory settings of these pots may result in loss of protection and overload operation of the control and motor If the adjustments are unknown or in doubt the following procedure can be used to calibrate the control Disconnect the F1 and F2 field terminals from the control and place jumper J1 in the BYPASS position Connect an ammeter in series with the armature leads Apply power to the control With jumper J6 in the 100 position monitor TP11 M and adjust the I Current OFFSET pot P3 to read 5 mV or 005 VDC Adjust the external speed pot to approximately 20 and the CURRENT LIMIT pot P9 fully CCW Run the control while still monitoring TP11 M Slowly adjust the CURRENT LIMIT pot P9 CW until 1 0 VDC is reached at TP11 M Since all current signals are scaled to 5 VDC at 100 of the jumper J6 range the 1 0 VDC level corresponds to 20 Slowly adjust the I CURRENT CAL pot P6 until the ammeter reads 20 of the rated armature current of the control Please note that CW rotation will decrease armature current while CCW rotation will cause an increase Example A CDC320 000 has a maximum
20. Adjust as follows Operate the unloaded motor at the normal or mid range speed and note the exact speed While still monitoring speed apply normal load The reduction in speed of a fully loaded motor will usually loaded motor will usually fall between 2 and 13 of rated or Base speed Slowly increase the IR COMP adjustment clockwise until the loaded speed equals the unloaded speed measured in the previous step Making this adjustment may now cause the unloaded speed to be slightly higher Repeat this procedure until there is no difference between loaded and unloaded speed levels Use care not to set the adjustment too high or speed may increase with load and instability may result NOTE For this adjustment do not use SCALED ARMATURE VOLTAGE to measure speed Armature voltage is not an exact indication of loaded motor speed Fuses Due to other circuit paths that may interfere with measurements it is not recommended that fuses be tested with an Ohmmeter while still in the circuit Remove the fuse and then check the resistance with an Ohmmeter A fuse may also be checked by applying power to the drive and carefully measuring the voltage across the fuse Remember that a good fuse will not have a voltage drop while a blown fuse will SCRs The power devices may be tested with a meter and a small 1 5 or 9 VDC battery First remove the component to be tested from the circuit and simply measure the resistance f
21. CE CIRCUITS AND ENGINEERED SYSTEMS 3204 Rocky River Road Heath Springs SC 29058 Phone 803 286 8614 Fax 803 286 6063 Email saleserv carotron com Web www carotron com MAN1001 2B Issued 10 14 2004
22. E CHASSIS CDC375 C75 40 75 CONTACTOR RUN BRAKE CHASSIS CDC3150 C100 50 100 CONTACTOR RUN BRAKE CHASSIS CDC3150 C125 60 125 CONTACTOR RUN BRAKE CHASSIS CDC3150 C150 75 150 CONTACTOR RUN BRAKE CHASSIS CDC320 R 15 5 7 5 10 15 CONTACTOR REVERSING CHASSIS CDC320 R20 10 20 CONTACTOR REVERSING CHASSIS CDC340 R30 15 25 30 CONTACTOR REVERSING CHASSIS CDC340 R40 20 40 CONTACTOR REVERSING CHASSIS CDC360 R60 25 30 50 60 CONTACTOR REVERSING CHASSIS CDC375 R75 40 75 CONTACTOR REVERSING CHASSIS CDC3150 R100 50 100 CONTACTOR REVERSING CHASSIS CDC3150 R125 60 125 CONTACTOR REVERSING CHASSIS CDC3150 R150 75 150 CONTACTOR REVERSING CHASSIS NOTE The options listed in TABLES 2 3 and 4 are used with and mount on the chassis of the contactor run brake and reversing models listed above TABLE 2 BLOWER amp STARTER OPTIONS OPTION NUMBER BLOWER MODELS USED WITH DESCIPTION CDC3BS 001 MTP FVB2180 230VAC 1PH 0 6 TO 1 0 AMP OVERLOAD RANGE FOR 1 PHASE BLOWER CDC3BS 002 MTP FVB3210 460VAC 3PH MTP FVB3250 460VAC 3PH 0 4 TO 0 6 AMP OVERLOAD RANGE FOR 3 PHASE BLOWER CDC3BS 003 MTP FVB3210 230VAC 3PH MTP FVB3250 230VAC 3PH MTP FVB4280 460VAC 3PH 0 6 TO 1 0 AMP OVERLOAD RANGE FOR 3 PHASE BLOWER CDC3BS 004 MTP FVB4280 230VAC 3PH MTP FVB6320 460VAC 3PH MTP FVB6400 460VAC 3PH 1 4 TO 1 8 AMP OVE
23. FUNCTIONS OPERATING MODE CONTROL As covered in SECTION 6 3 RUN and JOG operating modes are commanded by 115 VAC relay logic on the RELAY board A third operating mode controlled by the ZERO SPEED circuit on the CONTROL board takes D gt D D D gt i W gt gt gt gt e Lk D _ gt gt FIGURE 20 over from the RUN mode when the RAMP STOP pushbutton has been depressed The mode commands are interfaced with various electronic reference and controlling with various electronic reference and controlling circuits as depicted in FIGURE 21 There are ten of these circuits listed in TABLE 8 that are shut off or clamped by FETs field effect transistor when not turned on or released by the mode control signals as shown in the table FIGURE 21 The PN4092 FETs that are used are on or clamping when their gates are at positive or zero volts potential They are turned off by the application of the 24 VDC through the steering diode as shown in the figure TABLE 8 OPERATING MODE CONTROL MODE JOG ACCEL MIN SUM VEL IR VEL POT DECEL SPD POT SET COMP INT RUN JOG ZERO SPD non indicates that the respective circuit be turned on by the MODE control signal X indicates that it has no effect ZERO SPEED FUNCTION ACCEL DECEL stays on Its output will ramp A typical operation in the
24. JOG FORWARD and JOG REVERSE relay coils are also current limited rectified and filtered to drive optoisolators on the CONTROL board for RUN and JOG enabling of the control circuitry Refer to OPERATING MODE CONTROL in SECTION 6 10 for detail on this control circuitry The CONTROL board doesn t need to know which direction has been selected Reversing is controlled by armature voltage polarity which is determined by the FIGURE 7 armature contactors as selected by the relays listed above The CONTROL board the FAULT PILOT PILOT ZERO SPEED and JOG DELAY relays on the RELAY board The FUALT PILOT relay is normally energized to supply 115 VAC at TB3 1 for all of the operator relay and condition causes the relay to de energize and stop operation See SECTION 6 11 for information on the fault circuits The ZERO SPEED relay provides interlocking of all RUN and JOG relay to prevent the energization of one relay when the other is in use It also allows ramping to stop by holding the armature contactor energized until zero speed is reached This function is defeated in the event of a fault or emergency stop by the E STOP relay The JOG DELAY relay is timer controlled to keep the armature contactor energized for 3 4 seconds after jogging to prevent unnecessary cycling of the contactor during rapid and repeated jogging See SECTION 6 10 for more information on the zero speed and jog delay circuits gt 000
25. MODEL DEPENDENT FU7 FU8 FU9 current rating per model 500 VDC semiconductor types Model CDC320 000 50 ampere CAROTRON BUSSMANN SHAWMUT LITTELFUSE A50QS50 4 L50850 Model CDC340 000 100 ampere CAROTRON BUSSMANN SHAWMUT LITTELFUSE FUS1009 01 FWH100 A50QS100 4 L50S100 Model CDC360 000 150 ampere CAROTRON BUSSMANN SHAWMUT LITTELFUSE FUS1009 02 FWH150 A50QS150 4 L50S150 Model CDC375 000 175 ampere CAROTRON BUSSMANN SHAWMUT LITTELFUSE AS0QS175 4 L508175 Model CDC3150 000 350 ampere CAROTRON FUS1009 04 BUSSMANN FWH350 SHAWMUT A50Q8350 4 LITTELFUSE L50S350 11 5 POWER COMPONENTS Freewheeling flyback diode 1 per model Models CDC320 000 CDC375 000 80 ampere CAROTRON PMD1011 00 SKKE81 14 IRKE8 1 14 Model CDC3150 000 165 ampere CAROTRON PMD1015 00 AEG EUPEC D171N1400K IRKE166 1400 SCR DIODE 3 per model Model CDC320 000 25 ampere CAROTRON AEG EUPEC SEMIKRON PMD1010 02 TD25N1400KOF SKKH26 14E IRKH26 14 S90 Model CDC340 000 55 ampere CAROTRON AEG EUPEC SEMIKRON PMD1010 01 TD56N1400KOF SKKH56 14E IRKH56 14 S90 Model CDC360 000 90 ampere CAROTRON AEG EUPEC SEMIKRON PMD1010 00 TD92N1400KOF SKKH91 14E IRKH91 14 S90 Model CDC375 000 105 ampere CAROTRON AEG EUPEC SEMIKRON PMD1010 00 TD105N1400KOF SKKH105 14E Model CDC3150 000 135 ampere CAROTRON PMD1014 03 AEG EUPEC TD142N1400KOF IRKH136 14S90 FIELD SUPPLY Th
26. RLOAD RANGE FOR 3 PHASE BLOWER CDC3BS 005 MTP FVB6320 230VAC 3PH MTP FVB6400 230VAC 3PH 2 8 TO 4 0 AMP OVERLOAD RANGE FOR 3 PHASE BLOWER TABLE 3 FIELD ECONOMY SUPPLY amp REGULATOR OPTIONS OPTION NUMBER MODELS USED WITH DESCRIPTION CDC3FE 001 230 460 VAC INPUT CHOICE MODELS FIELD ECONOMY UNIT 150VDC 230VAC 3 PHASE INPUT 300VDC 460 VAC 3 PHASE INPUT CDC3FE 002 230 VAC INPUT CHOICE MODELS FIELD ECONOMY UNIT 200VDC 230VAC 1 PHASE INPUT CDC3FE 003 230 VAC INPUT CHOICE MODELS FIELD ECONOMY UNIT 240VDC 230VAC 3 PHASE INPUT CDC3FS 000 230 VAC INPUT CHOICE MODELS FIELD SUPPLY UNIT 150 240VDC 230VAC 3 PHASE INPUT FR1000 000 ALL CHOICE MODELS FIELD REGULATOR UNIT 230 460VAC I PHASE INPUT TABLE 4 DISCONNECT SWITCH OPTIONS OPTION NUMBER MODELS USED WITH DESCIPTION CDC3DS 150 CDC320 C15 C20 R15 R20 CDC340 C30 C40 R30 R40 CDC360 C60 R60 CDC375 C75 R75 150 AMP 600 VAC MOLDED CASE DISCONNECT SWITCH CDC3DS 225 CDC3150 C100 C125 CDC3150 R100 R125 225 AMP 600 MOLDED CASE DISCONNECT SWITCH CDCEDS 400 CDC3150 C150 R150 400 AMP 600 VAC MOLDED CASE DISCONNECT SWITCH TABLE 5 ENCLOSURE OPTIONS OPTION NUMBER MODELS USED WITH DESCRIPTION CDC3EN 001 CDC320 C15 C20 R15 R20 CDC340 C30 C40 R30 R40 CDC360 C60 R60 NEMA 12 ENCL CDC3EN 002
27. RUN mode down as controlled by the DECEL pot until the would de clamp all of the circuits and signals armature voltage falls below 6 armature except for the JOG pot When above 6 voltage the ZERO SPEED setpoint At this motor speed depressing the RAMP STOP level the ZERO SPEED circuit will de button will cause the drive to drive to drop out energize the armature contactor and cause the of the RUN mode and continue in the ZERO remaining circuits and signals to be clamped SPEED mode TABLE 8 shows that the FIGURE 22 is a simplified schematic of the SPEED pot is clamped in this mode but ZERO SPEED circuit FIGURE 22 The R7 R23 resistor divider controls the JOG DELAY FUNCTION ZERO SPEED setpoint and keeps the output of This function serves to extend the the Al B comparator positive when the scaled mechanical life of armature contactors by armature voltage is below 6 The positive reducing the number of mechanical operations voltage cause Q10 NPN to light the ZERO in an application where a high rate of repeats SPEED LED When the scaled armature voltage exceeds the setpoint A1 B switches negative and causes Q21 and Q16 PNP s to energize their respective relays jogging is performed When the JOG button is pressed and released the reference is immediately clamped to stop the motor but the contactor is held energized for four seconds Pressing the JOG button again within the four second d
28. Under light load conditions this may cause the SCR to momentarily drop out of conduction or to not conduct at all However this problem is easily eliminated by the application of load and or choosing a substitute device with a minimal difference in the current rating 11 2 PRINTED CIRCUIT ASSEMBLIES CONTROL BOARD Model CDC320 000 D10485 001 Model CDC340 000 D10485 002 Models CDC360 000 CDC3150 000 D10485 003 RELAY BOARD Model CDC320 000 CDC360 000 D10488 000 D10488 001 D10488 002 FUSE BOARD Model CDC320 000 CDC375 000 D10491 000 D10491 001 POWER TRIGGER BOARD All model D10494 000 IFB CURRENT FEEDBACK BOARD Model CDC3150 000 only C10748 003 11 3 CONNECTOR CABLE ASSEMBLIES SAME FOR ALL MODELS A10527 000 A10528 000 A10530 000 MODEL DEPENDENT Cable 3 Models CDC320 000 CDC375 000 A10529 000 A10805 000 Cable 5 Model CDC320 000 CDC375 000 A10531 000 A10806 000 Cable 6 Models CDC320 000 CDC375 000 A10532 000 A10807 000 Cable 7 Model CDC3150 000 only A10808 000 11 4 FUSES SAME FOR ALL MODELS FU1 5 ampere 250 VAC dual element time delay located on the FUSE board CAROTRON BUSSMANN LITTELFUSE FU2 FU3 10 ampere class CC time delay 500 VDC located on the FUSE board CAROTRON LITTELFUSE FUS1012 00 CCMR 10 FU4 FU6 10 ampere dual element time delay 500 VAC located on the FUSE board CAROTRON FUS 1008 03 BUSSMANN LITTILFUSE
29. a component from one drive may be substituted on another If needed the CONTROL board can be modified with minimal effort to operate any model The location of a zero Ohm resistor in position R1 R2 or R3 determines the CONTROL board model Simply remove the zero Ohm resistor and replace it in the correct location Please refer to TABLE 7 for placement The FUSE boards for all models are identical except for the wire lengths and lug sizes The CDC3150 000 FUSE board requires longer wire lengths and larger ring lugs than the other models ALL SCR DIODE isolated power modules are rated at 1400 volts repetitive peak off state and inverse voltage and have 1000 volts microsecond dv dt There are 3 each per model The power modules listed in SECTION 11 5 are pin for pin compatible with all CHOICE drives Consult the factory for assistance in making substitutions with components other than the recommended spares listed below in SECTION 11 5 A higher rated current and or voltage TP16 Parameter IR Comp Level range 0 to 2 0 VDC Condition Load and speed dependant component may be substituted for any power component For example the CDC320 000 model uses a 25 ampere 1400 volt SCR DIODE module If this module is not available a 55 ampere 1400 volt or a 25 ampere 1600 volt SCR DIODE module could be substituted NOTE A higher current rated module will normally require a higher latching current for the device to operate correctly
30. ach balance pot affects the line currents of all 3 phases Alternately adjust each balance pot until all 3 AC line phase currents are equal VOLTAGE GAIN amp CURRENT GAIN The VOLTAGE and CURRENT adjustments P2 amp P5 as preset by CAROTRON will provide stable and responsive performance under most load conditions When required the drive performance can be optimized for a particular application or to correct undesirable operation by use of these adjustments The adjustments are complex though and can adversely affect operation if not properly set In general the settings that give the most stable operation do not always give the fastest response Problems correctable by these pots can usually be separated into those related to stability of steady state operation i e constant speed and load conditions and those that occur with speed or load changes that are related to balanced operation of the SCR power bridge Refer to the following guidelines when re adjustment is required When instability is observed it should first be evaluated as a possible load induced condition Cyclic variation in armature current and in motor speed can indicate mechanical coupling or machine loading conditions If mechanically induced the instability repetition rate or frequency can usually be related to a motor or machine rotation rate or loading cycle In this situation the instability frequency will change in coincidence with any motor speed c
31. age 45 or 90V 1000 RPM or digital encoder 300 PPR Tachometer feedback is insensitive to input polarity 12 VDC 50 mA encoder power supply Summing input for auxiliary input signals with on board trim pot for scaling and jumper selection for polarity Terminal strip access to Accel Decel A C INPUT e 230 VAC 10 3 phase 50 60 Hz 2 Hz e 460 VAC 10 3 phase 50 60 Hz 2 Hz A C INPUT SINGLE PHASE CONTROL VOLTAGE SUPPY e 115 VAC 10 I phase 50 60 Hz 2 Hz ARMATURE OUTPUT e 0 to 240 VDC a 230 VAC input e 010 500 VDC 460 VAC input FIELD OUTPUT e 150 VDC 10 amps max 230 VAC input e 300 VDC 10 amps max 460 VAC input HORSEPOWER RANGE e Model CDC320 00 36 FLA 10 HP 240 VDC 20 HP 500 VDC output Velocity Loop output and Current Loop input for versatile control functions Inner Current Loop for responsive and precise control of motor torque Insensitive to phase rotation of the line Status LED s for Run Zero Speed Jog and Foldback 115 VAC logic for pushbutton operator interface Zero Speed logic for ramp to stop and anti plugging protection Jog Delay circuit to allow rapid jogging without de energizing the armature contactor to give longer contactor life 5 selectable armature current range to match motor armature current High frequency multi pulse trigger for reliable SCR triggering Model CDC340 000 71 FLA 20 HP 240 VDC 40 HP 500 VDC Model CDC360 000 107 FLA 30 HP 240 VDC
32. amping various circuits This is explained in SECTION 6 10 The FAULT PILOT relay contact explained in SECTION 6 3 removes the 115 VAC from the pushbutton operator logic and the contactor OVERCURRENT The OVERCURRENT FAULT will occur when the control has continuously demanded more than 112 armature current for five minutes It acts in concert with the FOLDBACK circuit and is explained in detail in SECTION 6 8 FIELD LOSS The FIELD LOSS circuit detects the presence of field current flow not voltage by the circuit shown in FIGURE 1 SECTION 6 2 gives an explanation of this circuit PHASE LOSS The PHASE LOSS circuit is shown in FIGURE 25 Each phase of the line supply is detected through the use of optoisolators as shown in FIGURE 9 in SECTION 6 6 The sync pulses from this circuit are described with the trigger circuit in SECTION 6 9 FIGURE 25 The three 50 or 60 Hz depending on line frequency sync signals maintain their 120 degree phase relationship through the IC7 schmidt trigger logic gates and are converted to narrow pulse by capacitive coupling to the input of additional IC7 gates The three sets of pulse are all added by the IC8 AND gate to give a regular pulse train at three times the line voltage frequency Each pulse then coincides with one cycle of one of the input phases Y of IC2 a 556 dual timer is used as a missing pulse detector and monitors the pulse train When powered up IC
33. as the control Electromotive Force EMF This is another name for the armature voltage generated by the drive The voltage generated by the motor is called counter EMF Full Load Amps FLA The amount of current necessary to produce rated horsepower at full speed Horsepower HP The measure of the amount of work a motor can perform during a given time period Regenerative Control A drive capable of controlling the flow of power to and from the motor Regeneration occurs when the counter EMF produced by the motor is greater than the voltage applied to the motor by the drive Silicon Controlled Rectifier SCR A solid state switch also called a thyristor that can be used to provide controlled rectification of large current at high voltages Abbreviations CW Clockwise Counter clockwise Rate of change in voltage versus per rate of change in time Full load Hertz Integrated Circuit Internal resistance No load Peak Inverse Voltage Potentiometer Pulses Per Revolution Resistor Capacitor Revolutions Per Minute Field Effect Transistor Dynamic Braking Contactor Reversing Dynamic Braking 6 1 ARMATURE POWER BRIDGE The armature power bridge of the CHOICE is a full wave semiconverter type D configuration that consists of three SCR s and four diodes Refer to FIGURE 1 D MEA 14 A kA i fai i i i e i i i i this li i pa
34. command from the current integrator see SECTION 6 7 and 6 8 to control the conduction angle of the SCRs The voltage is applied to three identical circuits one for each SCR Each circuit uses all four sections of a quad OP AMP either Al A2 or A3 The A1 section is described here and shown in FIGURE 17 Each circuit is synchronized with one phase of the three phase line by use of line sensing optoisolators see FIGURE 9 in SECTION 6 6 All circuits are connected to a common oscillator which generates a 9 4 kHz multipulse gating frequency for the SCR s The oscillator Y of 556 dual timer IC2 A is turned on by FET Q1 when it is turned off by one of the operating mode control signals See SECTION 6 10 for a discussion on the various operating mode control signals FIGURE 17 Each optoisolator output is a sync pulse that is low for time equal to 2 3 of the line frequency period 11 1 msec for a 60 Hz line and 13 3 msec for a 50 Hz line It would appear initially that the on time period should be for Y of the line period but we see additional time at the beginning of our sync signal from our main phase optiosolator photo diode conducting in series with one of the other photo diodes The additional time is irrelevant because the power bridge SCR s and diodes are biased by the phase to phase voltage potentials instead of just the line to line potentials sensed by the optoislators This difference in phasing requi
35. conducted to the CONTROL board where it can be monitored at TP9 0 Here it is summed at A5 C with a negative polarity OFFSET voltage to make the no load signal equal to zero This signal can be monitored at TP7 P The next stage A6 A uses the I CAL pot and factory installed model scaling zero Ohm resistors to select the gain of the amplifier depending on the full load current rating of the drive and the rating of the sensor Its output can be measured at TP18 Q See TABLE 7 for drive current rating and model scaling resistor location on the CONTROL board TABLE 7 CURRENT SENSOR SCALING RESISTOR DRIVE MODEL FULL CURRENT SENSOR MODEL NO LOAD RANTING SENSOR VENDOR SENSITIVITY P N CSLAIDJ CSLAIDJ CSLAIDJ CSLAIDK CSLAIEL ZERO Ohm LOCATION CDC320 000 36 AMPS CDC340 000 71 AMPS CDC360 000 107 AMPS CDC375 000 140 AMPS CDC3 150 000 256 AMPS 13 2 m V AMP RI 13 2 m V AMP R2 13 2 m V AMP R3 9 1 m V AMP R3 5 6 m V AMP R3 The combination of sensor rating and selected gain are used to give a scaled current feedback equal to 5 0 VDC at the full load rating of a particular control model The next stage A4 C uses the programming jumper J6 to allow amplification of the current signal in 20 increments to scale operation of the current related circuits according to the rating of the motor used Refer to TP11 M and FIGURE 11 amp 12 for typical waveforms under no l
36. control the charge and discharge time of capacitor C18 The charge and discharge follows a linear ramp and the time can changed by varying the resistance of the ACCEL and DECEL pots This ACCEL DECEL output is connected to the MAX SPEED pot and through the A2 D buffer stage to TB1 4 This signal can also be measured at DCM check point E A FET clamps the input to the ACCEL DECEL circuit when the drive is at stop and in the JOG mode See SECTION 6 10 for information on the FET clamps The MAX SPEED pot wiper connects to summing amplifier A3 C Also summed are the MIN SPEED SUM TRIM and JOG SPEED pot signals The MIN and JOG pots e D gt gt LL VW V trim the 15 VDC signals to set their levels and each has FET s to clamp their signals at stop and when in the RUN mode for JOG pot The JOG pot wiper also has the R86 C24 R C network to soften start up in the JOG mode See SECTION 6 10 for information on FET clamps The SUM TRIM pot receives input from TB1 7 Its wiper is connected to the A2 C inverting amplifier and to the J5 programmed to add or subtract from the TOTAL SETPOINT This signal can be monitored at TP14 F It also has a FET clamp 6 6 FEEDBACK CIRCUITRY AND ISOLATION CHOICE drive continuously monitor feedback signals that are related to motor velocity and current They also precisely sense the AC line voltage and frequency in order to properly synchronize gating of the SCRs At the same time th
37. ding fields are correct Refer below for correct field connections Motor runs too slow Excessive velocity feedback from incorrect programming of J2 or J4 and or encoder with higher than 300PPR used as feedback Monitor SCALED ARMATUE SCALED TACH or SCALED ENCODER at TP10 G TP12 H or TP8 1 respectively to verify 7 7 VDC at rated speed of motor Excessive loading of the motor or wrong current range programmed by J6 Monitor CURRENT FEEDBACK signal at TP11 M and check for 5 0 VDC level at 100 or range selected by J6 Over loading the motor for 60 seconds will cause FOLDBACK which may limit the motor speed Motor drops in speed when loaded Excessive loading of the motor or wrong current range programmed by J6 Monitor CURRENT FEEDBACK signal at TP11 M and check for 5 0 VDC level at 100 of range selected by J6 Operating in armature feedback and not compensating for IR losses in motor Refer to SECTION 7 2 for adjusting the IR COMP pot Motor draws a high level of armature current but will not produce rated torque One of the dual field winding polarities may be reversed When connecting the field in a low voltage operation 150VDC the field windings should be connected in parallel The Fl and F3 positive polarity leads should be connected together and the F2 and F4 negative polarity leads should be connected together For high voltage operation 300 VDC the field windings should be connected in s
38. e of each SCR This is best done by viewing the armature output Al with respect to A2 with an oscilloscope WARNING High voltage potentials are present on the armature Do not connect any grounded instrument to the CHOICE control Please follow the oscilloscope manufacturer s recommendations on measuring high voltage potentials not referenced to earth or machine ground Turning the BAL 1 pot CW will increase the conduction angle of SCR1 Notice as the conduction angle is increased on SCRI the other two SCR conduction angles are decreased to keep the armature output current the same Likewise if SCR2 is increased the conduction angles of SCR 1 and SCR3 are decreased Since each balance pot affects all 3 SCRs both balance pots will have to be adjusted in conjunction with each other Alternately adjust each balance pot until all 3 SCR conduction angles are equal The second option is to balance the currents of the 3 phase AC line inputs This is best done by using ammeters to measure the current in each phase If the 3 AC line phase voltages are equal balancing of the conduction angles as described above would also equalize the 3 phase line currents However if the 3 phase AC line voltages are not equal balancing of the conduction angles will not produce equal currents in the 3 phase AC lines Simply adjust the balance pots as described in the above procedure while monitoring the AC line currents As above e
39. e drive must be isolated from the sensed signals for ease of interface noise immunity and safety i A LA 4 n L N e i FIGURE 9 LINE VOLTAGE SENSING Sensing of the three phase line voltage is done by connecting impedance isolating resistors and optoisolators in a delta configuration across the line Refer to FIGURE 9 The outputs are used to derive synchronized gating signals for the SCRs and for PHASE LOSS protection Refer to SECTION 6 9 for a description of the trigger circuit and SECTION 6 11 concerning the PHASE LOSS fault circuit ARMATURE CURRENT SENSING Motor armature current is sensed by threading the positive bridge output conductor through a hall effect type sensor It gives an isolated output voltage that is an accurate reproduction of the current signal Refer to FIGURE 10 Three sensor rating and sensitivities are used to cover the range of currents for motors up to 150 HP see TABLE 7 for a listing The Model CDC3150 000 drive has an IFB board P N C10748 003 to power and mount the sensor while all other models have the sensor mounted on the RELAY board The output at zero armature current is approximately 50 of the 15 VDC sensor supply voltage An increase in current will cause a decrease in the output according to the sensitivity of the sensor being used It is buffered by a non inverting OP AMP A2 A on the IFB board and A1 B on RELAY board The buffered signal is
40. e field supply uses the same power components for all models DB1 amp DB2 diode doubler 25 ampere 50 V 2 per model PMD1009 00 FPID2505 CSB2505 eevold SINIOd A03H9 MIA 310N30 SNOLIVN9IS30 831131 ANY NNOO OLNO 3LON3O lt I SILON 5507 ol DH zal Y IMA lt GO ee 216 HOSEN Linws NINNI 4310 gt HOBENZ S Oppe NOLO Re E o DIU See y ON N A ST 420 L L PLAATZ an amp Sen ovedlod LE c A Er 13638 17 Ezy n INENI HOWL ang HIOOONI HIVL VINOS DON ze fs ZUM L 2 Cho 10051 M300DN3
41. ed before the control loops are enabled Likewise the control loops should be allowed to clamp before opening the contactor Shorted or excessively loaded control voltage transformer The 115 VAC secondary must be rated to handle any customer added auxiliary loads in addition to the normal requirements of the control The external armature contactor inrush adds to this load upon start up Transient induced uncontrolled gating of the SCR s The coils of electromechanical devices such as relays and solenoid that are energized when the drive is started should have transient suppressors This is achieved by placing MOV s or snubbers in parallel with the coil All internal relay coils on CHOICE drives are suppressed Drive will not RUN or JOG RUN and JOG LEDs will not light Check 115 VAC power at TB2 2 amp 3 on the FUSE board If not present check control voltage transformer and primary supply from two of either FU4 FUS or FU6 on the FUSE board Check 115 VAC power at TB3 20 amp 21 If not present check FU1 on the FUSE board and check status of FAULT LEDs Observe the ZERO SPEED LED It should be on when the motor is stopped If not the ZERO SPEED relay may locking out the run commands due to SCR leakage voltage appearing at the power bridge output Refer to drawing A10552 The 40K Ohm 10 watt resistor connected across the armature busbars may be open Verify proper operation of RUN and JOG contacts Check power supp
42. egative meter probe on the cathode The diode check voltage should read around 0 6 to 0 7 VDC Drive blows fuses on power up e A drive that blows fuses when applying the 3 phase power likely has a shorted SCR or diode in the armature or field supply bridges Refer to SECTION 8 for information on testing these devices A shorted motor or shorted wiring to the motor can be checked best with a megger A Ohmmeter may also be used but it may not be able to detect high resistance paths to ground that may break down at rated operating voltage Disconnect the motor from the control Measure the resistance from each motor terminal to machine or earth ground Place your Ohmmeter in the RX 100k or greater scale and be suspicious of any reading less than 500k Ohms Shorted or excessively loaded control voltage transformer The 115 VAC secondary must be rated to handle any customer added auxiliary loads in addition to the normal requirements of the control Drive blows fuses when entering RUN or JOG mode Check the 3 phase supply voltage Voltage in excess of 506 VAC may cause random fuse blowing Reduce the supply to approximately 460 VAC Improper operation of the armature contactor may cause the CHOICE drive to have improper start up This can happen when the external armature contactor is not being controlled by the internal CHOICE relay logic The normal start up procedure should assure that the contactor is energiz
43. elay period will cause the motor to immediately jog and will reset the four seconds delay Refer to FIGURE 23 The JOG DELAY relay is energized via A7 D when the 24 VDC JOG command input is applied through a 10K Ohm resistor to quickly charge C46 When the command signal is removed 15 VDC causes slow discharge of the capacitor via a 220K Ohm resistor to produce the delayed drop out of the relay The charge on capacitor C46 can be monitored at DCM check point T NOTE the ZERO SPEED and JOG DELAY functions are dependent on the use of a contactor auxiliary contact at TB3 15 and additionally at TB3 18 on reversing models Delete these contacts to defeat these functions 6 11 FAULT CIRCUITS There are four fault conditions on all CHOICE control models Refer to FIGURE 24 FIGURE 24 Each fault circuit OVERCURRENT FIELD LOSS PHASE LOSS and OVERTEMP drive a latching circuit which indicates the specific fault and cause operation of the FAULT relays The latching circuits also maintains the faulted status of the drive until it is reset by the RESET pushbutton on the CONTROL board an external RESET contact connected to TB1 13 amp 14 or by cycling the 115 VAC power to the drive The FAULT relays act to shut off the armature voltage output and de energize the armature contactor The FAULT LOGIC relay contact as shown in FIGURE 21 removes the 24 VDC used by the mode control circuitry for de cl
44. eries The F2 and F3 leads only should be connected together with F1 as positive and F4 as negative inputs If the field polarity is unknown or in doubt a simple test with a voltmeter and a small battery 1 5 or 9 VDC can be used to determine the proper polarity Disconnect all wires from the motor and connect the voltmeter across one of the field windings Connect the negative battery terminal to one lead of the other field winding to the positive battery terminal to one lead of the other field winding Momentarily connect the other field winding to the positive battery terminal If the voltage on the field winding initially goes positive and then swings negative the field leads connected to the positive battery terminal and the positive leads of the voltmeter have the same polarity If the voltage first swings negative and then positive reverse one of the connections WARNING When using a battery as described above the inductance of the field can produce a voltage shock when connections are made and broken Motor is unstable and becomes worse when load is applied The series field may be connected incorrectly Only non regenerative drives should use the series field S1 and S2 by placing it in series with the armature windings The polarity of the Fl lead and the S1 lead should always be the same Changing the direction of motor rotation by reversing the armature leads with contactors should not reverse the series field wi
45. hange Instability in the control output due to incorrect adjustment would usually be present over a range of speed and would not usually change frequency in coincidence with speed Because the response of the control can sometimes be altered to partially compensate for mechanically induced instability it is sometimes difficult to determine if the load change is affecting control output stability or if control output is affecting the load stability De coupling the load can help make this determination If fuse blowing or tripping of breakers should occur it may be due to unbalanced operation of the power bridge This would usually be noticeable when rapid changes in output or surges of torque are being called for as opposed to steady state operation Examples would be when quickly accelerating a load up to speed or when a load is suddenly applied Typically the setting that provide the most stable and balanced bridge operation under all conditions do not give the fastest response To prevent confusion and minimize anxiety when making loop adjustments use the following guidelines 1 Make sure the problems are not due to things other than adjustment Operation similar to that can be caused by but are not limited to the following problems e Leakage due to insulation breakdown in the motor A motor with insulation breakdown may operate fine when cool or at light loads but may cause problems when conditions change
46. igger Board Schematic 41 C10489 Fuse Board Schematic 42 C10815 IFB Board Schematic 43 C10486 Relay Board Schematic CDC320 000 CDC375 000 44 C10793 Relay Board Schematic CDC3150 000 45 D10535 Wiring Diagram CDC320 000 CDC375 000 46 D10800 Wiring Diagram CDC3150 000 47 D10612 Wiring Diagram CDC320 R15 CDC360 R60 48 D10837 Wiring Diagram CDC375 R75 CDC150 R150 49 D10613 Wiring Diagram CDC320 C15 CDC360 C60 50 D10838 Wiring Diagram CDC375 C75 CDC3150 C150 51 D10521 Connection Diagram 52 This guide is meant to supplement the CHOICE Instruction Manual and DCM100 Users Guide for CHOICE Series DC Drives Installation wiring and start up information is found in these other manuals Here we will address problems in operation drive failure also how to correct these situations The CHOICE CDC300 Series of non regenerative DC motor controls drives provides a full range of speed or torque control for 5 150 HP DC motors rated for NEMA type D power supplies Five basic models are offered in a compact panel mount assembly Each model is customer connectable for operation at 230 or 460 VAC input Semiconductor fuses are provided for AC line protection with auxiliary line fuses for optional equipment Fuse protection is also provided for the 115 VAC input and for the field supply circuits Programmable for 230 or 460 VDC three phase line input Hall Effect sensor for isolated armature cu
47. ional circuitry senses this signal and can limit it and cause a fault condition if the level is excessive for too long of a time period See SECTION 6 8 for details on these functions The feedback is from the current amplifier The output is based on the initial difference between these inputs and the continuing level required to minimize the difference between them The output directly controls the trigger circuit and relates to the triggering or conduction angle of the SCRs necessary to produce an armature current feedback equal to the current demand NOTE For special applications such as center winders that require direct torque control of the motor the current loop input at TB1 5 can be connected to an alternate source of reference The velocity loop section will be non functional and the drive will have no adjustable maximum speed or armature voltage 6 8 STATIC CURRENT LIMIT AND OVERCURRENT FUNCTIONS FOLDBACK Refer to FIGURE 16 The current demand signal from the Current Limit pot goes to a demand level sensing circuit A5 A and to a buffer stage AS B The buffer output can be measured at TP19 K and is connected to a 5 6 volt zener that can be switched into operation by transistor Q5 and comparator A1 C The signal then is inverted by AS D and can be monitored at TP6 L before being applied to the integrator A6 B At the sensing circuit the demand signal is compared to a 5 6 zener volt level which is equivalent to
48. l measurements are referenced to circuit common unless otherwise noted Circuit common is not earth or chassis ground Please refer to the symbols below Circuit Common Chassis Ground Earth Ground All signal level wiring such as tachometer encoder and potentiometer should use fully insulated shielded cable whether or not shown in this manual The shield should be connected at one end only to circuit common The other end of the shield should be clipped and insulated to prevent the possibility of accidental grounding All internal relays have suppression devices in parallel with coil whether or not shown in this manual 150 HP 500 VDC ARM EXPANDED METAL ENCLOSED 1 24 Ohm 4464 WATT BRAKE RESISTOR The arrows on potentiometers signify the CW terminal The opposite lead is the CCW terminal and the middle lead is wiper OP AMP IC packages have been given the prefix designation A instead of the IC found on all other IC packages Furthermore many ICs are double quad or hex packages In these cases each section is given a letter designation to distinguish it from the other OP AMPs in the same IC package For example the first two OP AMPs in Al would be A1 A and A1 B The bold letters in the schematic diagrams refer to the DCM100 000 check points Refer to SECTION 10 GLOSSARY Drive The electronic device used to control the speed torque horsepower and direction of a DC motor It is also referred to
49. lies Refer to SECTION 10 The power supply is fused by FUI on the POWER SUPPLY board Drive will not RUN or JOG Run and Jog LEDs will light Check power supplies Refer to SECTION 10 Verify presence of signal at TOTAL REFERENCE SETPOINT at TP 14 F If not present check input at TB1 2 or 7 depending on speed pot or summing input operation Verify that the CURRENT LIMIT pot is not adjusted too low Motor runs too fast or runs away Lack of velocity feedback can cause run away and insufficient feedback can cause excessive speed Check position of J6 according to motor armature nameplate rating The SCALED ARMATURE VOLTAGE TP10 G should measure about 7 7 VDC at rated armature output either 240 or 500 VDC Tachometer feedback TFB or encoder feedback EFB signals can be monitored at TP12 H and TP8 1 respectively while the control is operated in armature feedback AFB Each signal should measure about 7 7 VDC at rated armature output Check tightness of the coupling For TFB verify the position of J4 matches the voltage rating of the tachometer used an d for used and EFB confirm use of a 300PPR encoder Check level to TOTAL REFERENCE SETPOINT TP14 F Too high a setting of the MAX SPEED pot or excessive summing input signals can cause outputs over 100 Overspeed when in armature feedback can be caused by improperly wired or defective motor fields Make sure the polarities of multi win
50. nding Voltage and or current loops not adjusted properly Many signals on the CHOICE drive can easily be monitored by test points on the various PC boards Most of these signals on the CONTROL board are also easily accessible via CAROTRON S DCM 100 000 CONTROL BOARD NOTE Letters refer to DCM100 000 Check Points A Parameter Level range Condition Parameter Level range Parameter Level range Condition Parameter Level range Condition Parameter Level range Condition Parameter Level range Condition Unregulated power supply 24 VDC 3 0 VDC Can vary 3 0 VDC with Line and load Fluctuation Unregulated power supply 24 VCD 3 0 VDC With line and load Fluctuations Regulated power supply 15 VDC 0 75 VDC Fixed within line Variation of 10 Regulated power supply 15 VDC 0 75 VDC Fixed within line variation of 10 Accel Decel output 0 to 10 0 VDC Equal to speed setting After ramp time 0 VDC 0 speed reference 10 VDC 100 speed reference Total reference velocity setpoint 0 to 10 0 VDC Sum of all reference Parameter Level range Condition Parameter Level range Condition Parameter Level range Condition Parameter Level range Condition signals reference 0 VDC 0 speed reference 10 VDC 100 speed reference Scaled armature voltage 0 to 7 7 VDC 0 VDC 0 arma
51. oad and full load conditions ampere 7 5 HP motor 28 divided by 36 equals approximately 78 so the closest range 80 should be selected This will make the current amplifier signal measured at TP11 M equal to 5 0 VDC at a armature current of 28 8 amperes Accurate adjustment of the I OFFSET and I CAL pots is critical to proper operation of the current feedback and protection circuits These pots are factory adjusted and sealed Should they require readjustment refer to For example The CDC320 000 drive listed in SECTION 7 for calibration instructions TABLE 7 as a full load rating of 36 amperes or 10 horsepower with a 240 VDC motor When the drive is used with a 10 HP motor J6 100 position is used If used with a 28 1 ARMATURE VOLTAGE SENSING The armature voltage sensing circuit uses high impedance exactly 9 4 megohms for FIGURE 12 On the CONTROL board R4 and R18 are inputs to the A1 A differential amplifier The FIGURE 11 isolation 9 4 megohms is the total of two series connected resistors in each of the Al and A2 sensing inputs Refer to FIGURE 13 The A2 signal is detected by R8 on the FUSE board It passes through the POWER TRIGGER board to R4 on the CONTROL board The Al signal is detected by R4 on the POWER TRIGGER board and is connected to R18 on the CONTROL board output of A1 A is 4 59 VDC at 240 VDC armature and 9 57 VDC at 500 VDC armature Programming jumper J2 selects the gain of
52. pted by the company In the event of any such changes the Company shall be entitled to revise its price and delivery schedule under such order 8 Returned material If the Purchaser desires to return any product or part written au thorization thereof must first be obtained from the Company which will advise the Purchaser of the credit to be allowed and restocking charges to be paid in regard to such return No product or part shall be returned to the Company without a RETURNTAG attached thereon which has been issued by the Company 9 Packing Published prices and quotations include the Company s standard packing for domestic shipment Additional expenses for special packing or overseas shipments shall be paid by the Purchaser If the Purchaser does not specify packing or accepts parts unpacked no allowance will be made to the Purchaser in lieu of packing 10 Standard transportation policy Unless expressly provided in writing to the contrary products parts and systems are sold f o b first point of shipment Partial shipments shall be permitted and the Company may invoice each shipment separately Claims for non delivery of products parts and systems and for damages thereto must be filed with the carrier by the Purchaser The Company s responsibility therefor shall cease when the carrier signs for and accepts the shipment i Driven by Excellence D C DRIVES A C INVERTERS SOLID STATE STARTERS SYSTEM INTERFA
53. r The Company reserves the right to correct clerical and stenographic errors at any time 3 Shipping dates Quotation of a shipping date by the Company is based on conditions at the date upon which the quotation is made Any such shipping date is subject to change occasioned by agreements entered into previous to the Company s acceptance of the Purchaser s order governmental priorities strikes riots fires the elements explosion war embargoes epidemics quarantines acts of God labor troubles delays of vendors or of transportation inability to obtain raw materials containers or transportation or manufacturing facilities or any other cause beyond the reasonable control of the Company In no event shall the Company be liable for consequential damages for failure to meet any shipping date resulting from any of the above causes or any other cause In the event of any delay in the Purchaser s accepting shipment of products or parts in accordance with scheduled shipping dates which delay has been requested by the Purchaser or any such delay which has been caused by lack of shipping instructions the Company shall store all products and parts involved at the Purchaser s risk and expense and shall invoice the Purchaser for the full contract price of such products and parts on the date scheduled for shipment or on the date on which the same is ready for delivery whichever occurs later 4 Warranty The Company warrants to the Purcha
54. res that the signal be delayed or phase shifted gt 1 3 msec by the 10k Ohm 47 uF R C network at each isolator output The effect of the capacitor can be seen on the rising edge of each pulse refer to FIGURE 18 The result is a logic level low pulse in sync with the AC voltage forward biasing the SCR The sync signal is squared up and inverted by an IC7 schmidt trigger gate and applied to IC3 B a three input AND gate and to the input of the conduction angle or phasing control circuit It is additionally applied to the PHASE LOSS circuit which is explained in SECTION 6 11 The AND gate requires the presence of the sync oscillator and phasing signal to drive the output section of the trigger current The phasing signal is controlled by the output of the current integrator and is produced in the following manner The A1 B OP AMP section inverts and clips the sync pulse to 10 6 VDC The output charges the Al A section integrator capacitor slowly through a 100K Ohm resistor The result is a positive polarity triangle wave with a linear charge ramp and sharp cutoff It is inverted to negative by the Al D section amplifier and then summed with a slightly greater positive bias at the A1 C section so that the output is normally saturated negative polarity If a portion of the triangle wave is high enough in negative polarity it overcomes the positive bias and causes the amplifier output to saturate positive This occurs at a
55. rom the anode to the cathode to check for a shorted SCR Depending on the current rating of the SCR model a good SCR will read anywhere from approximately 400k Ohms to an open circuit Set the meter to the diode check and once again read across the anode When trouble shooting a control problem the first step is to eliminate the motor This can done best by substituting another motor or a dummy load and checking to see if the problem still persists An emergency dummy load can be created by placing two 115 VAC light bulbs in series for 230 VAC operation or 4 in series for 460 VAC operation Higher wattage loads will perform better as dummy loads NOTE The control must be operated in armature feedback when dummy load are used and cathode terminals Place the positive meter probe on the anode and the common or negative meter probe on the cathode Connect the negative of the battery to the cathode terminal Momentarily connect the positive battery lead to the gate terminal The diode check voltage should read around 0 6 to 0 7 VDC Note that the SCR may not latch into conduction due to the small amount of current being supplied by the meter DIODES Remove the component to be tested from the circuit and simply measure the resistance from the anode to the cathode to check for a short Set the meter to the diode check and read across the anode and cathode terminals Place the positive meter probe on the anode and the common or n
56. rrent feedback 10 megohm impedance isolation for armature voltage feedback Independently adjustable linear acceleration and deceleration from 1 60 seconds Electrically isolated power modules rated 2 General Description Standard relay logic interfaces with customer supplied operators for Emergency Stop Ramp Stop Run Forward Jog Forward and also Run Reverse and Jog Reverse when the unit is operated with separately supplied forward and reverse armature contactors Additional models include options such as armature contactor s brake resistors disconnect switches blower starters enclosures and field economy or field regulator supplies An accessory drive circuit monitor DCM 100 000 is available to assist in set up and troubleshooting by plugging in to the CONTROL board to access 20 separate signals at 1400 volts PIV and 1000 volts microsecond dv dt Semiconductor fuses for power circuit protection R C networks for AC line transient protection 10 ampere rated field supply Provisions for interfacing an optional field supply or field regulator with the Field Loss protection circuit Foldback current limit to allow I minute overload and then foldback to 112 of the current range selected Overcurrent Trip when motor current is sustained at 112 of range selected for 5 minutes Speed feedback is jumper selectable for armature voltage DC tachometer voltage 7 50 or 100V 1000 RPM AC tachometer volt
57. ser that products manufactured or parts repaired by the Company will be free under normal use and maintenance from defects in material and workmanship for a period of one 1 year after the shipment date from the Company s factory to the Purchaser The Company makes no warranty concerning products manufactured by other parties As the Purchaser s sole and exclusive remedy under said warranty in regard to such products and parts including but not limited to remedy for consequential damages the Company will at its option repair or replace without charge any product manufactured or part repaired by it which is found to the Company s satisfaction to be so defective provided however that a the product or part involved is returned to the Company at the location designated by the Company transportation charges prepaid by the Purchaser or b at the Company s option the product or part will be repaired or replaced in the Purchaser s plant and also provided that Cc the Company is notified of the defect within one 1 year after the shipment date from the Company s factory of the product or part so involved The Company warrants to the Purchaser that any system engineered by it and started up under the supervision of an authorized Company representative will if properly installed operated and maintained perform in compliance with such system s written specifications for a period of one 1 year from the date of shipment of such sy
58. stem As the Purchaser s sole and exclusive remedy under said warrant in regard to such systems including but not limited to remedy for consequential damages the Company will at its option cause without charges any such system to so perform which system is found to the Company s satisfaction to have failed to so perform or refund to the Purchaser the purchase price paid by the Purchaser to the Company in regard thereto provided however that a Company and its representatives are permitted to inspect and work upon the system involved during reasonable hours and b the Company is notified of the failure within one 1 year after date of shipment of the system so involved The warranties hereunder of the Company specifically exclude and do not apply to the following a Products and parts damaged or abused in shipment without fault of the Company b Defects and failures due to operation either intentional or otherwise 1 above or beyond rated capacities 2 in connection with equipment not recommended by the Company or 3 in an otherwise improper manner c Defects and failures due to misapplication abuse improper in stallation or abnormal conditions of temperature humidity abrasives dirt or corrosive matter d Products parts and systems which have been in any way tampered with or altered by any party other than an authorized Company representative e Products parts and systems designed by the Purchaser f Any
59. stor and capacitor values at the input and in the amplifier feedback loop They additionally have a pot in series with the loop capacitor that causes the circuit to initially respond like a summing amplifier The amplifier action causes an initial step in output based on the predominate input signal and gain setting and then it integrates up or down based on continuing conditions Thus the response of FIGURE 15 the circuit can be altered by changing the size of the step taken VELOCITY INTEGRATOR A3 A is the velocity integrator and includes the VOLTAGE VELOCITY GAIN pot in its feedback loop It receives reference input from the A3 C amplifier see SECTION 6 5 and feedback from the velocity signal selected by J3 see SECTION 6 6 The output is based on the initial difference between these two inputs and the continuing level required to minimize the difference It therefore equates to the torque required by the motor to make the velocity feedback equal to the velocity reference and is used as the reference to the current loop It can be monitored at TP15 J or at TB1 6 where it is normally jumpered to the current loop input at TB1 5 CURRENT INTEGRATOR The current integrator A6 B uses the CURRENT TORQUE GAIN pot in its feedback loop Its reference normally comes from the velocity loop as described above and is trimmed by the CURRENT LIMIT pot to limit the highest current level demanded Addit
60. to the FUSE board Jumper J7 on the FUSE board can break the connection of the F1 circuit from L1 to allow an external field supply to be connected through the current sensing circuitry via TB2 4 6 3 CONTROL VOLTAGE SUPPLY AND RELAY LOGIC The control voltage transformer is supplied by the customer when using basic CHOICE models and is included with contactor models refer to TABLE 1 When the three phase power is applied to the drive the transformer primary voltage should be applied simultaneously to prevent a PHASE LOSS trip condition CAROTRON recommends connecting the primary to one phase of the auxiliary output at TB2 8 amp 9 on the RELAY board The 115 VAC secondary connects to TB2 2 amp 3 and is fused by FUl a MDA 5A fuse The fused secondary can be measured at TB3 20 amp 21 on the RELAY board The basic CHOICE drive includes ten relays for isolated interface of customer operators or logic such as pushbuttons selectors relay contacts motor thermostats and the armature contactor Refer to the RELAY board schematic in SECTION 12 Most of these relays are located on the RELAY board and all that are controlled directly by customer supplied logic are powered by the control voltage transformer The relay circuitry is designed to provide safe sequencing of the armature contactor s for emergency stop ramp to stop and reversing The 115 VAC voltage signals applied to the RUN FORWARD RUN REVERSE
61. ture Output voltage 7 7 VDC 100 armature output voltage Scaled tachometer voltage when used 0 to 7 7 VDC 0 VDC 0 motor speed 7 7 VDC 100 motor speed Scaled encoder Voltage when used 0 to 7 7 VDC 0 VDC 0 motor Speed 7 7 VDC 100 motor speed Velocity integrator Output 0 to 13 5 VDC Load and speed Dependent 200 RPM N L 0 44 VDC 200 RPM F L 8 8 VDC 1750 RPM N L 0 44 VDC 1750 RPM F L 8 9 VDC Motor stalled or current limited 13 5 VDC Parameter Level range Condition Parameter Level range Condition Parameter Level range Condition Parameter Level range Condition Parameter Level range Condition Torque demand 0 to 8 0 VDC Load dependent 5 0 VDC 100 current demand 7 5 VDC 150 current demand Torque reference 0 to 8 0 VDC Load dependent unless Limit by foldback or Current limit functions 5 6 VDC 112 foldback level 7 5 VDC 150 current demand Torque feedback 0 to 7 5 VDC Load dependent 5 0 VDC 100 of J6 current range 7 5 VDC 150 of J6 current range Current integrator output 0 to 6 25 VDC Load amp speed dependent 200 RPM N L 4 34 VDC 200 RPM F L 4 56 VDC 1750 RPM N L 5 22 VDC 1750 RPM F L 6 25 VDC Hall effect output MV Ampere see TABLE 7 Signal decreases with Armature current Increase Output is model Dependent Approximatel
62. wer bridge heatsink The 77 degrees Centigrade rating and the placement of the thermostat cause it to open if the temperature on the base of the SCR DIODE modules exceeds 85 degrees Centigrade The size of the heatsink and fan forced ventilation on some models will permit continuous operation at full armature current rating in a 55 degree ambient without this happening NOTE The 55 degree rating refers to the ambient temperature around the heatsink An totally enclosed drive is specified with a maximum of 40 degrees ambient outside the enclosure to allow for heat trapped within the enclosure e DEE full CCW Sum Kee EE full CCW EE mid range gt Derrame ee mid range e Voltage Gain 1 3 CW e Current GAM een 1 3 CW e TR Om NS full CCW e Current 11216 1 mid range e Current Offset Do not adjust Refer to SECTION 7 2 if altered e Current Cal Do not adjust Refer to SECTION 7 2 if altered Programming Jumper Presets Jumpers J1 J2 J4 J6 amp J7 should be placed in the positions appropriate to the line motor and feedback device rating J3 should be placed initially in the AFB position until proper encoder or tachometer operation is verified Place Jumper J8 in the NORMAL position Jumper J5 will be placed according to the specific application requirements 7 2 CALIBRATION AND FINE TUNING CURRENT OFFSET amp CURRENT C
63. with EUPEC or SEMIKRON brand devices that do not have a separate cathode signal terminal Although devices with these terminals can be used with little difficulty some do place the terminals in different order and may cause problems if the proper connections are not made Refer to SECTION 8 for information on testing these components and SECTION 11 for making situations 6 2 FIELD SUPPLY The field supply voltage and current is actually taken from the diodes in the lower uncontrolled half of the armature power bridge described in SECTION 6 1 See FIGURE 1 Circuitry on the FUSE board connects the positive F1 motor lead through current sensing components and fuse FU2 to the L1 line input The F2 motor lead is connected through fuse FU3 to the diode or A2 side of the power bridge This gives a field voltage derived from two of the three phase lines being half wave rectified with respect to the third L1 line The diode connected to L1 acts as a freewheeling diode for the field winding The field voltage level is approximately 0 65 times the AC line voltage and this waveform can be FIGURE 6 seen in FIGURE 6 The presence of field current is sensed by passing the current through four 25 ampere rated diodes to derive a voltage drop which is used to drive an optoisolator The diodes are enclosed two each in doubler modules DB1 and DB2 mounted on the left side panel of the control next
64. y 7 6 to 8 2 VDC at 0 amps Parameter Level range Condition Parameter Level range Condition Parameter Level range Condition Parameter Level range Condition Parameter Level range Condition Current decreases about 1 3 1 4 VDC at full load Current offset setpoint 0 to 1 0 VDC Offsets hall effect output At O armature current Factory setting DO NOT ADJUST See SECTION 7 2 Current scaling 0 to 5 0 VDC Signal proprotional To armature current 5 0 VDC 100 model rated load Factory setting DO NOT ADJUST See SECTION 7 2 Torque demand sensing Comparator 13 VDC 1 5 VDC before foldback Controls feedback and Over current fault circuits gt 112 current demand 13 0 VDC 1 5 VDC Velocity feedback 7 7 VDC at full motor Speed Signal composed of Armature voltage Feedback minus IR Compensation signal Jog delay timer signal 5 0 VDC 0 2 VDC Or 13 5 VDC Provides contactor delayed Drop out on jog Approximately 4 Seconds Jogging 13 5 VDC After contactor delay 6 0 VDC TP1 Parameter Circuit common 11 1 COMPONENT SUBSTITUTION Many components of a CHOICE drive are interchangeable with other CHOICE models The following section lists CAROTRON s part numbers and the manufacturer s part number if applicable of the drive s major components This section can be used to order additional parts or to determine if

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