USER’S GUIDE for the Focus 2 SINGLE PHASE CONTROL FOR DC MOTORS 1/44 TO 5 HP ROL TECH, Oa SS Ue, WoRLDWIDE‘SECTION TABLE OF CONTENTS PAGE 1.2 Installation Satety 1.3 Start-up Safety... GENERAL INFORMATION... 2.4 Introductior 22 General Descrigtion 23 Typical Packagin 2.4 Equipment identification CONTROL SPECIFICATIONS ‘AND FEATURES 3.1. Equipment Ratings 3.2 Service Condtions nn vvnonncnsT 3.3 Performance Speciications Bed Oporator FUNCIONS wn 35 Potentiometer Adjustments 3.6 Customer Programmable Selections (Uumpers). 3.7 Standard Features 3.8 Pre-Engineered Mod 3.8.1 "M" Contactor Kit 3.8.2 Jog at Jog Speed Ki 318.3 Magnetic Reversing 3.84 Current Signal Follower 3.8.5 Voltage Signal Follower 3.8.6 Torque Taper/Remote Current Limit 3.8.7 Dynamic Braking 3.8.8 AC Power Disconnect Switch 3.8.9 End Cover Plates 3.8.10 Spare Parts Kit 3.8.11 Remote Stator 3.8.12 Ton-Tum Poteniiomeier Kit 3.8.18 Speed Meter Kits, 3.8.14 Option Mounting Par 3.8.15 Dead Front. INSTALLATION 4.1 Safety Wamings 42 Initial Checks 4.3 Control Jumper Programming 43.1. Operating Voltage Selection 43.2 Mode of Control Selection... 43.3 Armature or Tachometer Feodback Selectior 43.4 Voltage Feedback Selection... 438 Gurrent Feedback 455 Instaling Panel Mount and Less Operators Controls 48 Instaling Enclosed 47 Power Wiring 4.7.1 Incoming Power Requirements 4.7.2 Output Power Range: 47.3 Output Terminal installation Checks. 4.7.4 Output Power Connections 4.8 Panel Mount and Less Operators, Control Logic and Signal Wiring 4.9 Enclosed Control Logic and: ‘Signal Wiring . ‘4.10 Installing Modifications. ‘SECTION 5 10 TE OPERATION AND ‘STARTUP PROCEDURI 5.1 Introduction 5.2 Start-up Procedur 5.2.1 ProStar Equipme 5.2.2 Operation and Adjustment. FUNCTIONAL DESCRIPTION. 6.1. Power Bridge and Field Suppiy 6.2. Runtlog and Star’Stop Logic 83 AccalDecel Circut.. 6.4 Regulating Circuitry 65 Feedback Scaling Circuits 66 Current Limit Circuit. 87 Firing Circus 6.8 Power Supplies 629 indicators MAINTENANCE AND TROUBLESHOOTING .. 7.1 Important Safeguards 72 Routine Maintenance 73 Troubleshooting Overview .. 7.3.1 Suggested Training.. 73.2 Maintenance Records. 73.3 General Troubleshooting 73:4 Notes for a Troubleshooting Technician 7.4 Basic Troubleshooting ORDERING SPARE PARTS... ‘SUPPLEMENTARY ‘TECHNICAL INFORMATION. BASIC APPLICATION INFORMATION. 10.1 Basic Mechanics. 10.1.1 Torque 10.1.2 Horsepower 10.2 Torque vs. Horsepower 10.3 Matching the Drive to the Machine 10.3.1 Breakaway Torque 103.2 Accelerating Torque 10.3.3 Running Torque 10.4.1 Constant Torque Apr 10.4.2 Constant Horsepower Applications 10.5 Other Mechanical 10.5.1 Constant Torque Speed Range 10.5.2 Torque Limtations. 10.5.3 Duty Cycle 105.4 Overhauling Load 10.6 Motor Application Formulas. 10.6.1 Calculating Horsepower . 10.6.2 Inertia (WK®) 10.6.3 WK? of Rotating Elements 10.8.4 WK?of Linear Motior 10.7 Electrical Formulas . 10.8 Other Useful Formulas. S8ooseeaaseee geeseeesane APPENDIX A Glossary.FIGURE a3 914 245, to 102 103 10-4 105 108 LIST OF ILLUSTRATIONS Te PAGE Oscilloscope Connections. Enclosed Control Panel Mount Control. Enclosed Control Product Nameplate Location ‘Typical Enclosed Control Product Nameplate... Less Operators Control Product Nameplate Locatio ‘Typical Less Operators Control Product Nameplate... Panel Mount Control Product Nameplate Location ‘Typical Panel Mount Control Product Nameplate Control Modification Kits. Main PC Board Jumper Locations Connection of Motor Leads to Enclosed, Less Operators, and Panel ‘Mount Controls... Power Bridge Assambiy RuniJog and Start/Stop Logic Control Citcuit Block Diagram Outline and Mounting Dimensions for Panel Mount, Loss Operators, and Enclosed Controls. Connection Diagram for Low HP Pana Mount and Less Operators Controls ‘Connection Diagram for High HP. Panel Mount and Less Operators Controls .39 Connection Diagram for Low HP Enclosed Controls ‘Connection Diagram for High HP Enclosed Controls Panel Mount and Less. HP Controls Wth *M" Contactor... Panel Mount and Less Operators Fi HP Controls With *M" Contactor. Panel Mount and Less Operators: HP Controls With Reversing Kit anol Mount and Less Operators High HP Controls With Reversing Kit... Enclosed Low HP Control With "M" Contactor Enclosed High HP Control With SMP Contactor eon Enclosed Low HP Control With Reversing Ki... Enclosed High HP Control With Reversing Kit ‘Schematic Diagram, Main PC Boar ‘Schematic Diagram, Shunt Resistor Board for High HP Enclosed and Less Operators Controls Examplo of 10 lb-ft Applied Torque. Constant Torque. Constant Horsepower Variable Torque. Motor Armature Voltage and Field Control Constant Torque’ Ran TABLE a4 at ot 92 to 102 LIST OF TABLES Tme Control Rating Table... Jumper Programming for ‘Speed Regulated Operation Jumper Programming for Toraue Regulated Operation . Control Standard Connecti Scheme Terminal Blocks TB1 and TB2. Customer Jumper Programming Char. Inertia of Stoel Shatting Density FactorsSECTION 1 Safety This section outlines procedures necessary to insure safe opera tion of any AC or DC drive. For further information, contact the Service Department at the address shown on the inside back ‘cover of this manual. 1.1 GENERAL SAFETY PRECAUTIONS ‘WARNING ‘THIS CONTROL AND ASSOCIATED MOTOR CON- TAINS HAZARDOUS VOLTAGES AND ROTATING MECHANICAL PARTS. EQUIPMENT DAMAGE OR PERSONAL INJURY CAN RESULTIF THEFOLLOW- ING GUIDELINES ARE NOT OBSERVED. 1. Only qualifiad personnel familiar wth this equipment and the information supplied with it should be permitted to install, op- crate, troubleshoot r repair the apparatus. Aqualified person ‘must be previcusly trained in the following procedures: 2) Energizing de-serizng, larng, grounding snd tugging heute and equpment in accordance wth etabihed Safety practices. ) Caring and using protective equipment such as rubber gloves, hard hat, safety glasses or face shields, flash Clothing, etc, in accordance with established safety prac- tices. ©) Rendering first aid, 2. Installation ofthe equipment mustbe done in accordance with the National Electrical Code and any other state or focal ‘codes. Proper grounding, conductor sizing and short circutt protection must be installed for sate operation. 8. During normal operation, keep all covers in place and cabinet doors shut, 4, When performing visual inspections and maintenance, be sure the incoming AC power is turned off and locked out. The dive and motor will have hazardous voltages present untilthe ‘AC power is turned off. The drive contactor does not remove hazardous voltages when itis opened. 5. When itis necessary to make measurements with the power turned on, do not touch any electrical connection points. Remove all jowalry from wrists and fingers. Make sure test ‘equipment is in good, sate operating condition. 6. While servicing with the power on, stand on some type of insulation, being sure you are not grounded. 7. Follow the instructions given in this manual carefully and observe all warning and caution notices. 1.2 INSTALLATION SAFETY \When moving this contol and associated motor int the instala- tion postion, do any required iting only with adequete equip- mentandttained personnel. Eysbots o iting hooks, when sup piled, ar Intanded for lting the product oni and must not be Used to lit addtional weight. Improper liting can cause eauib- WARNING HAZARDOUS VOLTAGES MAY BE PRESENT ON EXTERNAL SURFACES OF UNGROUNDED CON- TROLS. THIS CAN RESULTIN PERSONAL INJURY (OR EQUIPMENT DAMAGE. the drive cabinet or open chassis unitis mounted such that tis, ‘not grounded, a ground wire must be connected to the panel or enclosure frame for personnel safety. Also any motor frame, transformer enclosure and operator station mustbe connected to earth ground. Consult the National Electrical Code and other local codes for spectic equipment grounding requirements. Protective guards must be installed around all exposed rotating parts. ‘CAUTION Drilling or punching can create loose metal chips. ‘This can result in shorts or grounds that can dam- age the equipment. Ifit is necessary to drill or punch holes in the equipment encio- ‘sures for conduit entry, be sure that metal chips do not enter the circuits. Circuits shown on the drawings that require shielded cable are sensitive to pick-up from other electrical circuits. Examples include wiring from the tachometer and from the speed setting device. Erratic or improper operation ofthe equipment is ikaly if ‘the following precautions are not observed: 1. Where shielded cable is required, use 2- or 3- conductor ‘twisted and shielded cable with the shield ether connected as shown in the drawings, or ‘floating’, itso specified. If the shiald is to be connected, do so only atthe specified terminal in the drive unt. Do not connect at a remote location. 2. Shielded cables outside the drive enclosure should be run ‘separate steol conduit, and should not be mixed in with other Cirouts that are not wired with shielded cab 3, Inside the drive equipment, whenever possible, avoid running the shiolded cable close to other circuts. Avoid long paralel runs to other non-shielded circuts, and cross other cable bundles at right angles. Donot connect any external circuits othe drive or its associated ‘equipment other than those shown on the diagrams supplied Connection of external devices to the tachometer or speed setting device can significantly atfect drive performance. ‘CAUTION Meggering circuits connected othe drivecan cause damage to electronic components. Do not megger or hk-pot this equipment. Use a battery operated Volt-Ohm-Meter (VOM) to check for shorts, opens or miswiring. Connection of unsuppressed inductive devices to the drive power feed or control circuits can cause mis-operation and possible component damage to the equipment. Do not connect power factor correction capacitors: with this equipment, as this may cause high volt- ‘ages that can damage the drive.1.3 START-UP SAFETY Detailed startup procedures are described in the Operation and ‘Startup section of this manual, Before and during startup, itis imperative that all of the following safety procedures be ob- served, ‘WARNING ‘AC POWER MUST BE DISCONNECTED FROM THE DRIVE CABINET TO ELIMINATE THE HAZARD OF ‘SHOCK BEFORE IT IS SAFE TO TOUCH ANY OF ‘THE INTERNAL PARTS OF THE DRIVE. CIRCUITS MAY BE AT LINE POTENTIAL WHETHER THE ENCLOSED DRIVE IS OPEN OR CLOSED. USE EXTREME CAUTION. ALSO, HAZARDOUS VOLTAGES ARE PRESENT ON THE MOTOR UNTIL ALL POWER TO THE CON- ‘TROL IS DISCONNECTED. ‘TURN OFF AND LOCK-OUT ALL POWER TO THE CONTROL BEFORE TOUCHING ANY INTERNAL CIRCUITS ON THE MOTOR. 1. The use of unauthorized parts in the repair ofthis equipment cr tampering by unqualified personnel wil result indangerous conditions which can cause equipment damage or personal injury. Follow all safety precautions contained in this manual and all safety warning labels on the product. Oscilloscope 2. Loose rotating parts can cause personal injury or equipment damage. Bofors starting the motor, remove all unused shaft keys and ‘other loose parts on the motor orthe rotating mechanical load, Be sure all covers and protective devices are in place, Refer to the instruction manual supplied with the motor for further information and precautions. 3, When using an oscilloscope to make measurements in the ‘power circuits, use the connections shown in Figure 1-1 and the procedures described in step 4. Failure to foliow this, [procedure could resutin the case ofthe oscilloscope being at, line potential. Onty qualified personnel should be allowed to use the oscilioscope and other test equipment. 4, Referring to Figure 1-1, set the oscil to.add channels A&B, and invert channel B. Before making measurements, ‘connect both probes together and set the "zero" line. ‘This connection allows the oscilloscope case to be connected to ground for safe operation. Channel Channel a Ground Scope Case Connect o Creut 2-X100 Probes Under Test ones Ground Clips) Figure 11. Oscilloscope ConnectionsSECTION 2 General Information 2.1 INTRODUCTION ‘This instruction manual contains installation information, operat- ing instructions, and troubleshooting procedures for this adjust- able voltage DC drive. Italso includes a complete description of the control with detailed product specifications and a complete description of all customer selectable functions and customer installable option kits. For most drive applications, the information contained in this instruction manual will completely describe all drive system sot- up and operating procedures. It should also provide all the information required by the customer to install and maintain the ‘control. Inafew applications, additional drive system set-up and ‘operating information may be required. This information wil ‘generally be furnished in the form of system schematic and ‘system interconnection diagrams. An overall Systems Installa- tion Manual may also be furnished. This instruction manual should be read in its entirety before beginning installation and before porforming any start-up or maintenance on the drive system. NOTE ‘The information in this manual applies to the enclosed, Jess operators and panel mount controls except where specifically stated otherwiss 2.2 GENERAL DESCRIPTION ‘The control is a high performance DC drive. It contains all the required circuitry to control he speed of, or tocontrol the current supplied to, small horsepower shunt wound or permanent mag- net DC motors. It includes many standard featuras that are {vellable only as options on other single phase DC drives. This, allows the control to be used in custom engineered applications 4s well as standard speed regulated applications. ‘The DG motor speed is controlled by varying the DC voltage applied to the motor armature, of the motor torque is controlled by varying the current applied to the motor armature. Single phase AC input power is converted to variable voltage DC output power by the control. In speed regulated applicator DC oufput voltage vaties as a function of an input reference voltage. Typically, the input reference voltage is provided by an ‘operator adjustable potentiometer. Changing the potentiometer setting (reference) rasults in a motor speed change. In torque regulated applications, the DC output current varies as afunction ‘of an input reference voltage. Changing the torque reference ‘changes the current suppliedto the motor and resultsinachange in motor torque output. ‘The control is designed to handle most single phase drive applications without the need for costly, time-consuming engi= neering, Simple umper programming allowsfor maximum versatiliyinthe rive, Functions such as input voltage selection (1/4 to 2 HP only), armeture/tachometer feedback, voltage feedback level, ‘motor current range, and speedorque regulation are achieved by customer selection ofthe jumper postions. Each control also has standard adjustments for minimum/maximum speed, IR compensation, acceleration/deceleration time and current limit, ‘An enclosed, less operators, and panel mount control design is available, Two models are provided for each design — a low horsepower (1/4-2HP) model and a high horsepower (3-SHP) model. 2.3 TYPICAL PACKAGING ‘The enclosed controls are furnished in a standard enclosure ratedtomeetor exceed NEMA type 1, 4, 12nd 13 requirements. ‘The enclosure package consists of two halves of a hinged shell which are opened by releasing a spring loaded serewon the right, side of the cover. AS shown in Figure 2-1, the inside of the cover the switches and heatsink. The inside of the base the main PC board, the functions of which are described indetallin Sections 4 and 5. The inside ofthe base on the 3-SHP enclosed and less operators models also contains the shunt resistor PC board. Figure 2-1. Enclosed Control The enclosed controls are equipped with pre-installed On/Ott, Runilog, and Start/Stop switches, and a 1-turn speed potenti- ometer. ‘The less operators controls are furnished in the same enclosure dasign as the enclosed controls except for ventilation holes provided in each end of the cover. End cover plates can be installed as an option tocover these ventilation holes and convert this control to @ NEMA 4/12 enclosure without operators. A emote operator station must then be used for operator controls. (A loose speed pot is furnished with the control) The pane! mount controls are suitable for subpanel mounting inside a customer supplied control enclosure (See Figure 2-2). eee Panel Mount Control‘The operators for the panel mount control are customer supplied ‘except for the speed potentiometer which is supplied loosely with the contro 2.4 EQUIPMENT IDENTIFICATION | 1s imporant tently th contra eomplaaly and accurately | whenever ordering spare parts or requesting assistance in serv- ice, ae a ‘The enclosed controls include a product nameplate located on thabottom edgeotthe coverasshownin Figure £3. The todoc es nameplao sheuidappoa’ sa ttnosarle namoplats crow Figure 24 Figure 25. Less Operators Control Product Nameplate Location PN2450-8002 REV! DATE, 14 =1 HP (IISVAC) / 1/2=2HP (230VAC) INPUT SO/EOHZ_—14.A MAK OUTPUT 90/I80Voc_I0A MAX FIELD I00/200VDG_1A MAX Figure 2-3. INDUSTRIAL CONTROL EQUIP Enclosed Control Product Nameplate Location Figure 26. ‘Typical Less Operators Control Product Nameplate ‘Thepane! mountcontols include aproduet nameplate locatedon the ight edgeofthe chassis as shown in Figure 27. The product nameplate should appear simiartothe sample nameplate chown in Figure 2.8. PN2450-8000 REVERIE OATE Hl 174—1 HP (1ISVAC) / 1/2—2HP (230VAC) INPUT SO/SOHZ 14 MAX Output S0/180Voc 108 MAK FIELD 100/200v0G TA MAK INDUSTRIAL CONTROL EQUIP Figure 2-4. Typieal Enclosed Control Product Nameplate The [ass operators controls include a product nameplate located onthe rontcoveras shown in Figure 2-5. Theproduct nameplate should appear similar to the sample nameplate shown in Figure 26. Figure 2-7. Panel Mount Control Product Nameplate LocationPN2450-8010 REVEREMEIE DATE Ea 1/4-1HP(I20VAC) 1/2 -2HP(240VAC) IwPuT 80/0024 AMAX OUTPUT sovieovoe 1OAMAX FIELD toarz00v—e | TAMA L Monona Figure 2-8. ‘Typical Panel Mount Control Product Nameplate For any of these controls, record the part number (PN), revision, level (REV), and DATE for future reference in the front of this manuel. ithe contol i part of an engineered drive system, the system cabinet will also include a product nameplate. Record the part number (P/N), ander number (S/N) ofthe engineered systom {nd inludothis formation withthe information on te ndhidl Contols whenever contacting the factory.SECTION 3 Control Specifications and Features 3.1 EQUIPMENT RATINGS ‘Tho 1/4-2HP enclosed, less operators and panel mount controls, ccan be programmed for 120VAC input (1/4-1HP) or for 240VAC input(1/2-2HP), The 3-SHP enclosed, less operators, and panel mount controls can be programmed only for a 240VAC input. ‘Table 3-1 summarizes the horsepower outputs available in each programming moda. Table 3-1 Control Rating Table ry ‘Clu Armano oc res HP ‘Ouput ‘Ouput a vous Arps" | vers _[amos™ yo] 36 | 14 | 90 | 26 | 100 | 1 vac,| 52 | 18 | 90] 37 | 100] 4 1, | 77 | 12 | 90 | 55 too | 4 soeo| 10s | 3 | 90 | 75 too | 4 Hz | 14 | 1 | 90 | 10 soo | + _| 240 | 36 | 12 | 180/26 | 200] + vac,| 52 | a4 | 120] 37 | 200] 1 | 77 | 1 | 120] 55 | 200 | 1 soro| 10s | 1-172] 180] 75 | 200 | 1 Hz | 14 | 2 | 180] 10 200 | 1 a 3 | 190] 15 200 | 4 a5_| 5 | 180] 25 200 | 1 * These are typical motor current ratings. See motor nameplate for exact current ratings. “The input voltage and current (amp) values are approximate, ‘Actual valuas may vary depending on input voltage, input line impedance, and actual motor efficiency. 3.2 SERVICE CONDITIONS ENCLOSURE: (Chassis (panel mount) (Open Enclosure (lass operator) with NEMA 4/12 Option * NEMAAN2" (enclosed) HORSEPOWER RATINGS: Input Power: Y2OVAC, 1 phase, SOIGO He: 1/4-1HP ‘2AOVAC, 1 phase, SO/60 Hz: 1/2-2HP (Peconnectable dual voltage) ‘2AOVAC, 1 phase, 50/60 Hz: 8-SHP{singlo voltage) LINE VOLTAGE VARIATION: 410% LINE FREQUENCY VARIATION: ‘2-62H2 FIELD SUPPLY: Amp MAXIMUM ALTITUDE (Without Derating): 3,200 leet above sea level AMBIENT TEMPERATURE: Panel Mount and Less Operators: 0°C to SSC (G2F wm 131°F) Enclosed Contra: °C to 40°C. (32°F to 108-7) ‘SPACE REQUIREMENT FOR PANEL MOUNT CONTROL IN TOTALLY ENCLOSED NON-VENTILATED (TENV) ENCLOSURE: 20%20"%8" or 241208" “Designed io meet NEMA 4 and 12 requirements but not submited fisting 7 ‘AG LINE FUSES: Yen BHP: 15A, 250 3-5 HP: 408, 500V 3.3 PERFORMANCE SPECIFICATIONS ‘SERVICE FACTOR: 1.0 maximum rating ‘SPEED REGULATION: For a 95% Load Change using Armature Voltage Feedback with IR ‘Compensation: £1% of maximum speed For All Other Variables (Voltage Regulated): Changes up to 15% of top speed can resuitfromtemp- erature, voltage, frequency Variations plus dri. ‘With AC Tachometer ** Feedback: 412% of base speed due te load variations. + 1% of ‘base spoed dus to vari- ations in ambient conditions oF line voage. With DC Tachometer Feedback: +1/2% of base speed due 10 variations in load, line voltage or ambient conditions. OVERLOAD CAPACITY (as a percent of maximum rating): 150% for one minute EFFICIENCY: Control Only (Minimum) 98% Motor and Control (Typical) 86% (CURRENT LIMIT: 0-150% of selected rating ACCELERATION’ DECELERATION TIME: 2 t0 30 seconds (neat) 3.4 OPERATOR FUNCTIONS ‘SPEED ADJUSTMENT: ‘Standard POWER ON/OFF: Enclosed: ‘Standard Less Operators: Optional Panel Mount: ‘Customer supplied ‘START/STOP, RUNKJOG: Enclosed: Standard Less Operators: ‘Customer supplied Panel Mount: Customer suppliad FORWARD/REVERSE, AUTO/MANUAL: Optional ~ pcual percentages may vary depending on the ype ef achoretor ued3.5 POTENTIOMETER ADJUSTMENTS ‘Tho standard control includes five (5) customer adjustable potentiometers which are located on the main PC board. ‘The potentiometers hava been preset. Howaver, for proper operation in some applications, minor readjustments may be necessary during drive installation and startup. MAXIMUM SPEED: 0 to 120% of rated speed MINIMUM SPEED: 0 t0 30% of maximum speed IR COMPENSATION: 0 to 20% of rated voltage (at rated current) CURRENT LIMIT: 0 to 150% of selected rating ‘ACCELERATION/ DECELERATION: 2 t0 30 seconds (linear) 3.6 CUSTOMER PROGRAMMABLE SELECTIONS (JUMPERS) MODE OF CONTROL: ‘Speed o torque regulation OPERATING VOLTAGE: 120 or 240VAC (1/4-2HP controls only) FEEDBACK METHOD: ‘Armature or tachometer feodback VOLTAGE FEEDBACK LEVEL: High, Medium, or Low CURRENT FEEDBACK LEVEL: High; Medium, or Low 3.7 STANDARD FEATURES + Gontrol relay providing momentary Star/Stop operation. Con- {tol cannot restart without pushing Start button if AC power is. ‘momentarily disconnected and restored. + Both AC lines fused for maximum semiconductor protection in ‘case of short circuit. + Designed for use with 50 or 60 Hz AC power. * LED (light emitting dioda) indicator lights to indicate if controls in current limit and to indicate SCR gate triggering. + Continuous ull rated torque available over a20:1 speed range. + Tachometer feedback circuitry standard. Addition of AC or DC tachometer generator to the motor converis the drive from armature to tachometer feedback for improved speed regula- tion. + Selectable current limit ranges to match control to the motor being used. Provides overload protection and smooth accelera- tion of high inertia loads, * Varister transient voltage protection providing trouble-troo ‘operation. + Jog at 1un speed standard, + Zener regulated control power supply provides compensation {or line voltage fluctuation, + UL listed and CSA approved, 3.8 PRE-ENGINEERED MODIFICATION KITS ‘The control can be purchased alone or with a selected group of pre-engineered modification kis. These kits allow the customer to create a custom engineered control to meet individual specitic requirements. Each modification kit is individually packagod, Identified, and includes all mounting hardware, wire, terminals, cable ties, labels and instructions. Paragraphs 3.8.1 through 3.8.15 provide a brief description of the modification kits currently available, ‘CAUTION ‘These modification kits aro the only kits designed for use with this control. Any modifications oth than those specified by ICD volds all warranties, stated or impliod. 9.8.1 "M" Contactor Kit ‘This kit is @ magnetic contactor mounted on a printed circut board. (See Figure 3-1.) provides a positive disconnect ofthe motor armature when the control is stopped, motor ‘umover in case the SCRs should false fra. In addition, an auxiliary form C contactratod for 1 ampat 120VACis includedfor ‘customer use wen needed. Note that this kt may be required by local andior national electrical codes. The option mounting panel is needed with panel mount contro. 3.8.2 Jog at Jog Speed Kit ‘This ki provides a separate intornal potentiometer for controling the motor speed when operating in the jog mode (see Figure 3-1). The kit automatically switches speed control from the ‘normal run speed potentiometer to the jog speed potentiomotor ‘when the control switches to the jog mode. The jog speed is adjustable from 0t0 30% of the control maximum speed setting, 3.8.3 Magnetic Reversing Kit ‘This kit provides full armature reversing using a forward and a reverse contactor mounted on aprinted.ircuitboard with an anti- plugging circuit (see Figure3-1). Aforward/raverse toggle switch 's included to select the direction of motor rotation, The electrical ‘code requirements for an °M" contactor are also satisfied since the forward and reverse contactors disconnect the motor arma- ture from the control when the motor is stopped. An auxiliary form C contact rated for 1 amp at 120VAC is included on the printed cireut board for customer use when needed. The option mount- ing panel is needed with panel mount controls. 3.8.4 Current Signal Follower ‘This kit permits the speed of the OC motor to be controlled by a mniliampore signal from a commarcially available transducer, The signal may be any one of the following: 1—5mA 420A 10-50 mA, ‘Transducers which produce these current ranges are available for sensing temperature, weight, flow rate, prossure, pH and ‘many other variables, and mustbe supplied by tho customer. The applied current signal must be ungrounded and isolated from the ‘contro! AC power sources, or an isolation transformer must be sed. This kit also provides an auto/manual switch so that control ‘can be switched from the external signal to manual spoed adjustment using the speed potentiometer. 3.8.5 Voltage Signal Follower This kit allows the motor speed to be controlled by a voltage signal from an AC or DC tachometer genorator or a process voltage signal (see Figure 3-1). The kitconsists of aprintod orcult board and an autoymanual toggle switch for ewithcing from ‘automatic control by the voltage signal to manual control by the ‘speed potentiometer. The printod circuit board is designed to ‘acceat voltage signal inputs with a range of 0 to 200 volts AC of DCwith a calibration potentiometer provided to adjust the unitfor the signal that is available.The voltage signal input must be \ungrounded and isolated from the AC power source and from ay ‘ther controls which use the signal. the signalis notisolated, an isolation transformer must be used.3.8.6 Torque Taper/Remote Current Limit Kit Tis kt consists of a printed cieuit board with two related functions: ‘A. Remote Current Limit Adjustment—permits adjustment of the contro current limt setting wth an external 5000 ohm, 2 watt potentiometar (not provided in ki). B, Torque Taper Adjustment—provides an intemal means of adjusting the speed vs. torque limit relationship ofthe drive sothathemaorequelinkwilgraalyropoas motor “This kit is shown in Figure 3-1. 3.8.7 Dynamic Braking Kit This is for use with ether the "M" Contactor Kitor the Magnetic Reversing Kit. Dynamic braking causes the motor to decelerate rapidly toa stop with braking torque of approximately 150% of the motor fllload torque rating at ful speed. Thiss accomplished by ?| 9 For 8-SHP Panel Mount Controle‘Terminals F1 and F20n TBI are or the customer-supplied shunt fiold connections as shown in Figures 9-2through 6-5. The shunt fieid willbe at 100VDC field voltage when the control is operated 2a 120VAG and 200VDC field voltage when tha control is oper- ated at 240VAC. The motor shunt field supply is rated at 1 amp. NOTE ‘Terminals F1 and F2 are not used with permanent magnet motors. I the motor has a buit-in thermal overload protection device, ‘connect the thermal averioad leads to TB2-1 and -2 onthe main PC board. ‘CAUTION if moter thermal overload protection is not desired, ‘terminals 1 and 20fTB2mustbe jumpered together, or the control will not operate. H, with the motor connected, the wrong rotational direction is ‘observed, the rotational problem canbe corrected in any of three @) possible ways: 1. Exchanging the A1 and A2 output leads to the motor. 2. Exchanging the shunt field F1 and F2 leads on shunt wound motors only. 3, Changing the position of the Forward/Reverse switch, if this option kt is being used, [Note that exchanging the incoming power leads to terminals L1 ‘and L2 wil not affect the direction of motor rotation. 4.8 PANEL MOUNT AND LESS OPERATORS CONTROL LOGIC AND SIGNAL WIRING The local On/Off, Runidog, and Start/Stop controls required for these drives are customer supplied. “An unidirectional speed potentiometer is supplied loosely with the drive. Forward/Re- Verse operation can be accomplished through the use of the optional Magnetic Reversing Kit. The On/Off switchs installed by the customer inthe incoming L1- 2 ine tothe control. On less operators controls, this switch can be installed on the enclosure cover. ‘The controlcircuity allows the customer to wire the Runklog and. Start/Stop logic with the supplied unidirectional potentiometer with or without a Forward/Reverse switch. The RuniJog, Start’ ‘Stop, and potentiometer controls are wired into terminal block ‘TB2, located along the left edge of the main PC board as shown in Figure 4-1. The basic Run/Jog, Start/Stop, and potentiometer connections are shown in Figures 9-2 and 9-3. If Forward/ Reverse switch wiring is desired, refar to Figures 9-8 and 9-9, NOTE Itis recommended that shielded wire be used for rofor- ence, andother signal wire connections. Belden #83304 (conductor) and Beldon #83395 (3 conductor) shielded wire (or equivalent) is recommended. The shields should be taped off at the remote end. At the drive Control, the shields should be connected to circuit common, TB-2 terminal 11. Additional consideration is recommended to route this wiring away from high cur- rent lings (Le., AC lines and armature wiring). 18 4.9 ENCLOSED CONTROL LOGIC AND SIGNAL WIRING “The local On/OH, RuniJog, Start/Stop, and speed potentiometer controls associated with enclosed drives are pre-installed on the enclosure cover. A Forward/Raverse switch, installable on the enclosure cover, is available as an option kit. The On/Oft switch 's wired into the 1FU and 2FU fuses located in the top cover half of the enclosure. ‘The StarStop and Runilog logic is pre-wired as shown in Figure 6-2. Terminal block TB2, shown in this figure, is located {as shown in Figure 4-1. If a Fonward/Raverse switch is desired, wire t'as shown in Figures 9-12 and 9-13. 4.10 INSTALLING MODIFICATIONS When modifications are shipped loose as kits for feldinstalltion, ‘each kit is individually packaged, identified, and includes ali ‘mounting hardware, wire, terminals, cable ties, labels and in- structions. Figures 9-6 through 9-13 can be used as a guide in Connecting these kis tothe control. Refer to paragraph 3.8 for a listing of the modification kits.SECTION 5 Operation and Startup Procedure 5.1 INTRODUCTION ‘This section describes the startup procedure for the control and the advsinet of potentiometers that may be necessary forthe application ead this section thoroughly to develop an understanding of the ‘operation and logic incorporated into the contrl 5.2 START-UP PROCEDURE To insure maximum efficiency with a minimum amount of delay in production, factory star-up assistance by afactory engineeris available, Contact the factory to make arrangements. ‘CAUTION ‘The following start-up instructions are intended ‘only asa guide and should be clearly understood by the responsible installation personnel before pro- ceeding with them. 5. 1 Pre-Start Equipment Checks Before starting the control, allof the following pre-start conditions ‘must be met. 1. Insure thatthe 1/4-2HP controls have been propery pr {grammed for 120VAC or 240VAC oporation as described in Paragraph 4.3.1. Insure that the S-SHP controls are pro- grammed aaly for 240VAC operation. 2. Check that all the jumpers have been set correctly as described in Paragraph 4.3. 3. Complete all the wiring procedures described in Paragraphs 47, 48, and 49, ‘After ail of the above pre-start conditions have been satisfied, ‘proceed tothe start-up procedure described in Paragraph 5.2.2. ‘This start-up procedure is equally applicableforthe panel mount, less operators, and enclosed controls. 5.2.2 Operation and Adjustment 1. Turn the speed potentiometer extreme counterclockwise. Insure thattheremote disconnectis admiting AC powertothe control. 2. Set the On/OF switch (f used) to the ON position. This will apply power to the control but it will not start the motor. The DC POWERED indicator light on the main control board will be off. 8. For initial startup, setthe Runidog switch (used) tothe RUN, position. If the process requires a jog operation, disconnect ‘the motor shaft from the load. 4, Set the StarvStop switch to the START position to start the motor. The green DC POWER LED indicator light wil ilumi- rato. NOTE ‘On the enclosure mount controls, the provided Start/ ‘Stop switch will spring back to a middle position after it has been placed in the START position and released. ‘This switch must be momentarily held in the START position to start the motor. 19 ‘Adjustihe speed potentiometer slowly clockwise until rotation begins. "i the motor rotates in the wrong direction, simply place the Stary/Stop swich in the STOP postion, place the OrvOHlswitchinihe OFF positon, lockoutpower tine remot disconnect and exchange the Ai and A2 output leads tothe ‘motor, On shunt wound motors, exchange the shunt field Ft and F2 loads. CAUTION I backward rotation of the motor could damage the driven machine, then direction of motor rotation ‘should be determined before connecting the motor shaft to the load. Ifthe dive trips off, the motor wll coasttoa stop orfallto star. ‘Adrivettpofis usually caused by incorrect wring. Italsocan be caused by ether (1) a faulty motor or (2) a mafunetioning drive. Proceed to Basic Troublashooting (Section 7, Para- graph 7.4), With the motor rotating, adjust the operator speed potentiome- ter up and down. Changing the potentiometer setting (rofer- ‘ence) results in a motor RPM change when operating in the UN or JOG mode. Check that the motor follows this speed reference. When the unit is used as a torque control, the potentiometer, ‘sets the motor torque level, and the moter acceleratesor do- ccolerates until the load torque equals the torque setting 3. At this point, place the RuniJog switch in the JOG postion if jog operation is desired. Connectthe motor shaft tothe load. In this position, the motor operates only when the StarlStop ‘switch is held in the START postion. ‘The control can be stopped in one of two (2) ways as follows: ‘A. A coast stop is initiated by either placing the StarvStop ‘switch in the STOP position or by removing the AC power at the local On/OHf switch or at the remote disconnect. ‘Once AC power is removed and then restored, the Start! ‘Stop switch must be momentarily set to the START posi- tion to restart the motor. B. A taster coast stop can be accomplished by installing the Dynamic Braking Kit. The "M” Contactor Kit or Magnetic Reversing Kit is required in this application. Refer to Figures 9-6 through 9-13 and the instruction sheets pro- vided wit the individual kts for installation information. Five (5) customer adjustable potentiometers are located on the main PCboard as shownin Figure 4-1, These potentiome- ters have been preset. However, for propor operation in some, applications, minor readjustments may be necessary. Before making final adjustments, allow the motor to warm up {oratleast 15 minutes. Withthe control driving amotor, do nat, ‘exceed ten (10) dogrees of potentiometer rotation per second. Clockwise adjustment will cause an increase in the adjust- ment parameter.WARNING DO NOT ALLOW THE ADJUSTING SCREW DRIVER ‘TOTOUCH ANYTHING OTHER THAN THE POTENTI- OMETER WHILE THE CONTROL IS OPERATIVE. USE ONLY ANINSULATEDSCREWDRIVER TOMINI- MIZE THE HAZARDS OF ELECTRIC SHOCK. 4, Acceleration/Deceleration Time Adjustment - 1a. The "ACCELIDECEL” adjustment on the main PC. Board may be used to vary the motor acceleration ‘and deceloration times linearly from 2-30 seconds. ‘Turn the adjustment clockwise to increase the time. . Note that the controlled deceleration time occurs When the speed potentiometer is turned down, but Steps A and B describe, respectively, the potentiometer adjust- ot when the startstop switch is placed inthe STOP. tent procedure for operation inthe speed or torque (curent) position. mode of contro ‘A. ADJUSTMENT PROCEDURE FOR OPERATION IN 5. Current Limit Adjustment - THE SPEED MODE: NOTE Wthe voltage or currant signal folower kt is being used, perform thase adjustments with the auto/manual switch in the MANUAL position. 1. IR Compensation Adjustment - 1. IR Compensation is provided to overcome the mo- tor’s natural tendency to slow down as the load increases. l'the motor slows down excessively as t is loaded, the potentiometer marked “IR COMP" should be adjusted clockwise. ». Ifthe I compensation is adjusted too far clockwise, ‘the motor wil bogin to oscillate in speed or *hunt.”H this pulsing of speed occurs, adjust the IR Compen- gation counterclockwise unt the metor speed stabi . Ifthe control has AG or DC tachometer feadback, adjust the IR COMP potentiometer fully count clockwise. 2. Maximum Speed Adjustment - ‘a. Run the motor with the load applied. b. Turnthe speed potentiometer on the operator control panel fully clockwise. ‘&. Adjust the potentiometer on the main PC Board marked "MAX" to set the maximum motor speoc ‘This may be adjusted from approximately 70-120% ‘of motor base speed. DO NOT EXCEED THE MOTOR NAMEPLATE MAXIMUM SPEED RAT- ING, <4. Using a hand held tachometer or by visually obsorv- ing machine operation, adjust "MAX" to the desired maximum setting. 3. Minimum Speed Adjustment - ‘speed potentiometer on the operator control panel fully counterclockwise bb. Adjust the potentiometer on main PC board marked °MIN" to desired lowest motor speed setting. This adjustment may be set at 0.30% of the maximum speed setting a. Current Limit is factory set at 100% of the range Selected by jumper JP1 (Low/Mediun High). the motor nameplate rating. This setting should rep- resent the lowest level consistent wih eatistatory operation. «. Ifthe motor stalls or slows down under load, chock the motor armature current using a DG ammeter. ‘Stalling at less than the motor nameplate armature ‘current rating indicates that the current limitissettoo low. Slowly rotate the potentimeter clockwise until the motor returnsto the set speed, but do not exceed the motor rated armature current, Stalling with more than the nameplate armature ccurrent flowing indicates that the motor is over- loaded. ‘CAUTION ‘The current limit may be set as high as 150% of the motor armature current rating for amaximum of one (1) minute. The current should exceed the motor rating only during starting or brief overloads. Re- eatedorextendedoverioadswill damagethe control and/or motor. 4. The yellow CURRENT LIMIT LED indicator light on the main PC Board wil iluminate when the armature ‘current reaches 95-100% of the current mit setting. B. ADJUSTMENT PROCEDURE FOR OPERATION IN ‘THE TORQUE (CURRENT) MODE. 41. Turnthe potentiometers on the main PC board marked “IR Comp" and "MAX" fully counterclockwise, These pots serve no purpose in this mode. 2, Start motor and turn the main torque potentiometer on ‘operator control panel fully counterclockwise. 8. Adjust the potentiometer on the main PC board marked "MIN" to a minimum torque level i desired. 4, The “CURRENTLIM" adjustment onthe main PC board ‘should be set atful clockwise positon. Itcould be used tosetthe maximum torque (current level withthe main torque potentiometer on the operator control panol turned fully clockwise). This will over-ride the main torque (current) reference potentiometer.5. The “ACCELIDECEL" potentiometer adjusts howaquickly the motor torque level changes as the main torque potentiometer is varied. 9, After Steps Aor B above are done, the potentiometer in the ‘operator control panel may be used to adjust either: ‘A. Motor speed from the minimum to maximum speed setting if contro is in the speed regulation mode, or B, Motor torque level from the minimum torque setting to the ‘maximum torque level forthe current range selected ifthe control has been set up as a torque control. 10. Ifthe control has been equipped with the optional Magnetic, Reversing Kit, a “forward/reverss” selector switch is sup plied which changes the direction of motor rotation. (NOTE: Motor must be restarted after the position of the “forward/ reverse" switch is changed.) Flip this switch to verily that the ‘motor follows direction change commands. at22SECTION 6 Functional Description ‘This section describes, in detail, the following circuits included in the control: |. Power Bridge and Field Supply Runiog and Starv’Stop Logic ‘Accel/Decel Circuit Regulating Circuitry Feedback Scaling Circuits Current Lim#t Cireut Firing Circuits Power Supplies . Indicators ‘Throughout this section, reference to the schematic diagrams in Figures 9-14 and 9-15 is recommended. 6.1 POWER BRIDGE AND FIELD SUPPLY ‘Throughout this paragraph, refer to Figure 6-1. . Cur Three functional details are shown in Figure 6-1 as follows: 1. Armature Voltage Feedback Signal - This signal is used in determining when the correct drive operating speed (voltag is reached as required by the operator speed potentiometer. sit Feedback Signal - This signal provides current infor- mation to the drive inner current loop. ‘Control Circuit Common - This s tied to the positive terminal of the power bridge. NOTE ‘Component designations in Figure 6-1, such as “D1 ‘and "D2", are for reference purposes only. They do not ‘correspond to actual component designations on the contro. ‘CAUTION ‘The control circuit common is floating and must never be tied to earth ground. Attempting this will cause equipment damage or failure. Figure 6-1 also shows the motor shunt field supply. Diodes D1, 'D2,D4andDS ormasinglephasaful waveuncontoliodrecter ri ‘operated at 240 VAC and a 10VDC field voltage when operated at 120 VAC. The motor shunt field supply rating is 1 amp. 6.2 RUN/JOG AND START/STOP LOGIC When the RuniJog and StartStop switches are pre-installed (such as in enclosed controls), Figure 6-2 shows the logic re- uired to provide these functions. ‘when This bridge produces a 200VDC field volag ‘© Figure 6-1 Power Bridge Assembly “The power bridge supplied inthe control consists of an encapsu- lated SCR power cube containing two (2) SCRs and three (3) diodes. The basic operation consists of the following sequence. When Lis more positive with respect toL2, SCRI is gated "on" at a paficular phase angle commanded by the drive regulator circuitry. Currentthen flows from 1, through SCRI, the shunt re- sistor, the drive motor, diode 02, and back to L2.’ When L2 is ‘more positive with respect to L1, SCR2 is gated ‘on’. Current flows from L2, through SCR2, the shunt resistor, diode D1, and back to Li. This results in a positive current flow through the motor. Diode D3 is called a “free wheeling” diode which insures continu- ity of the load current when the previously “fired” SCR becomes reverse biased, This diode also helps the SCR retum to its blocking sta ey BBs] Figure 6-2. Suridog and StartStop Logie ‘The run sequence is as follows: A. Switch StarStop switch to START momentarily. B. CAR picks up and is sealed in through its normally open contacts. ©. The accoldecel circu, the regulator circulty, and the ‘speed pot reference supply are released.\Whenthe stop pushbutton is depressed, CRRis dropped out and all tems mentioned in "C* above are clamped. When "jog" (at run speed) is selected, the Star/Stop switch iniates the same sequence as detailed above (A, B& C) with the ‘exception that CAR does not seal in and thus drops out when the Starv/Stop switch is released. 6.3 ACCEL/DECEL CIRCUIT ‘The accel/decel circuit accepts a 0 to +10 volt (1mA maximum) signal from either an isolated external voltage source or an internal +10 vot zener regulated supply, with operator's speed potentiometer connected as shown in Figure 6-3. This circuit is ‘non-inverting, and has a single linear acce/decel time adjust- ment from 2 to 30 seconds. The output is then used as a reference to the control's velocty error amplifier. A clamp circult is provided to clamp the cutput to zero whenever the drive is not inthe run mode. Also note that the +10 volt speed potentiometer ‘supply is only present in the run mode. 6.4 REGULATING CIRCUITRY ‘Throughout this paragraph, refer to Figure 6-3. ‘The mutt-loop regulator circuitry consists of aninner currentloop and an outer voltage (or speed) loop. ‘The current error amplifier is a proportional plus integral contro!- ler. Theinputto this amplifiers an errorcurrent, tis derived fram the addition of a negative current reference (trom the velocity error amplifier) and a posttive feedback current (from the current scaling amplifier). This error current ramps the current error ampitfiarto a positive voltage. When fed tothe fring circuits, this will enable the gated firing pulse generator at a phase angle which will provide the amount of current demanded by the velocity error amplifier. The remaining input to this amplifier is a positive signal which is only present in a stop condition. Its purpose is to clamp (or reset) the current amplifier whenever a stop command is given. The velocity error ampitier is also a proportional plus integral controler. itfunctions in the same manner as the current error ‘ampitier, with this exception. tts error currentis derived from the sum of a positive reference current trom the accelidecel circuit) ‘anda negative feedback current (rom either the armature ortach generator). The output of this amplifier is the negative current reference voltage. There ara also two additional inputs to this, amplifier. The fist one is the IR compensation signal. This is a Positive feedback signal and is derived from the current scaling ampliior. ts purpose is to compensats for the IR drop in the motor. This allows the motorto maintain aconstant speed (within +£1%ofbase speed) from no oad tofullload. The secondo! these inputs isthe jog input. This allows the drive to be stepped to jog speed (0:30% of maximum speed). 6.5 FEEDBACK SCALING CIRCUITS ‘There are two scaling circuits, one for the voltage (or speed) feedback and one for the current feedback. The voltage scaling Circuitis a passive network with three ranges: high, medium and low. This network also fiters the voltage feedback, The curtent feedback scaling network consists of an adjustablo gain inverting amplifier. This circuit has three ranges: high, medium and ow. ‘The ranges mentioned above can be found in Tables 4-1 and 42 of this manual. 24 6.6 CURRENT LIMIT CIRCUIT Current limting is achieved by limiting the current reference voltage. As shown in Figure 6-3, the output of the volocty error _amplfioris divided by the currentlimit potentiometer whose wiper then feeds the current error amplifier. The divider ratio can be adjusted from 0 to 1 which will allow a 0 to 5.6 volt maximum ‘current reference signal. 5.6 volt value corresponds to 150% (of control nominal rating. 6.7 FIRING CIRCUITS The tiring circuits consis of three pars; 1) a timing ramp crcut, 2) acomparatorcrout, and 3) agated 855 osclator. Tho timing ramp is produced by allowing a capactoro charge to 10 vols in 10 mSec. This is reset to zero volts at ever lina zor0 crossing. ‘This ramp votage is then compared to the output voltage of tre current ertor ampifier. When the ramp voltage exceeds the Current eror voltage the comparator toggles to + 1S volts DCand enables the gated oscilator. This oscillator will produce fring pulses 40 See wide and 800 uSec apar. 6.8 POWER SUPPLIES Four (4) power supplies are available. These supplies are +24 \VDC and 315 VDC. Te unit power supply transtormeris jumper programmable on the main PC board for 240VAC or 120 VAC and's rated a VA. These power supplies are not for customer use except fr pre-engineered option kits. 6.9 INDICATORS ‘There aretwo indicators provided on the main control board. The first of the CURRENT LIMIT indicator. When this LED lights, it indicates thatthe drive has reached the current level as ‘setby the current mit potentiomoter. The second indicator pro- vided is the DC POWER LED. This LED willbe on any time gate pulses are present at the SCR gate terminals,A oss26SECTION 7 Maintenance and Troubleshooting 7.1 IMPORTANT SAFEGUARDS ‘All work on the drive should be performed by personnelfamiliar with itand its application. Before performing any maintenance or ‘troubleshooting, read the instructions and consult the system iagrams. WARNING MAKE SURE THAT ALL POWER SOURCES HAVE BEEN DISCONNECTED BEFORE MAKING CONNEC- TIONS OR TOUCHING INTERNAL PARTS. LETHAL VOLTAGES EXISTINSIDE THE CONTROL ANYTIME INPUT POWER IS APPLIED, EVEN IF THE DRIVE IS IN A STOP MODE. A TURNING MOTOR GENER. ATES VOLTAGE IN THE DRIVE EVEN IF THE AC LINE 1S DISCONNECTED. EXERCISE CAUTION WHEN MAKING ADJUSTMENTS. WITH THE CON- TROL DRIVING A MOTOR, DO NOT EXCEED TEN (10) DEGREES OF POTENTIOMETER ROTATION PER SECOND. NEVER INSTALL OR REMOVE ANY PC BOARD WITH POWER APPLIED TO THE CON. 7.2 ROUTINE MAINTENANCE Only minor adjustments should be necessary on intial start-up, depending on the application. In addition, some common sense ‘maintenance needs to be followed. KEEP IT CLEAN: The control should be kept free of dust, dir, oll, ‘caustic atmosphere and excassive moisture, KEEP IT COOL: The control should be located away from machines having ahigh ambienttemperature (On panel mount controls, air flow across heatsinks mustnotberestriciedby other equip- ‘ment within the enclosure. KEEP CONNECTIONS TIGHT: The equipment should be kept away from high vibration areas that loosen connections or causa chafing of wires. Allinterconnections should be re-tighton time of intial star-up and at least every six months. WARNING ‘THE DC MOTOR MAY BE AT LINE VOLTAGE EVEN. WHEN IT IS NOT IN OPERATION. THEREFORE, NEVER ATTEMPT TO INSPECT, TOUCH OR RE- MOVE ANY INTERNAL PART OF THE DC MOTOR (SUCH AS THE BRI WITHOUT FIRST MAK- ING SURE THAT ALL AC POWER TO THE CONTROL ‘ASWELL AS THE DG POWER TO THE MOTOR HAS. BEEN DISCONNECTED. ‘The motor should be inspected at regular intervals and the following checks must be made: ‘A. Soe that both the inside and outside of the motor are not ex- cessively dirty. This can cause added motor heating, and therefore, can shorten motor life. B. amotorblower is used, make sure that the air passages are clean and the impeller is free to rotate. I air fiers are used, they should be cleaned at regular intervals or replaced i thay are disposable. Any reduction in cooling air will increase ‘motor heating, ©. Inspect the commutator and brushes. Replace the brushes ‘needed. Make sure that the proper brush grade is used. D. The motor bearing should be greased per the manufacturer's instructions as to type of grease and maintenance frequency. ‘Overgreasing can cause excessive bearing heating and fal- ure, Consul the instructions supplied with the motor for more details. 7.3 TROUBLESHOOTING OVERVIEW Fast and effective troubleshooting requires welltrained person- nel supplied with the necessary test instruments as well as a sufficient stock of racommended sparepparts. Capableelectronic technicians who have received training in the control operation and who are familiar with the application are well qualified to ‘service this equipment. 7.34 Suggested Training ‘A. Study the system instruction manual and control drawings. B. Obtain practical experience during the system installation and in future servicing. . Train in the use of test instruments, 7.3.2 Maintenance Records It fs strongly recommended that the user keops records of downtime, symptoms, results of various checks, meter readings, te. Such records will often help a service engineor locate the ‘problem in the minimum time, should such services be required 7.3.3 General Troubleshooting ‘The most frequent causes of drive failure are: ‘A, Interconnect wire discontinuity, caused by a broken wire or loose connection. 'B. Circuit grounding within the interconnections or the power wiring. ©. Mechanical failure at the motor. DO NOT make adjustments or replace components before ‘checking all wiring. Also monitor all LED indicator ights before proceeding with troubleshooting checks, and check for blown 08. tt should be noted that modern solid state electronic circuitry is highly reliable. Otten problems which appear tobe electrical are actually mechanical. It's advised that the motor be checked in the event of any drive problems. Refer to the motor owner's manual for maintenance and repair procedures. 7.3.4 Notes for a Troubleshooting Technician ‘Arminimum knowledge of system operation is required, but itis Necessary tobe able o read tho system schematics and connec: tion diagrams.‘An oscilloscope (Tektronix 214 or equivalent) may be needed to locate problem areas and to make adjustments. However, the ‘majority of problems can be solved by using a multimeter and by parts substitution, Multimeters having a sensitivity of 1000 ohms per volt on DC or ‘moreare recommended, such as a Triplet Model 630, a Simpson Model 260, or equivalent. WARNING WHEN A TESTINSTRUMENTIS BEING USED, CARE MUST BE TAKEN TO INSURE THATITS CHASSISIS. NOT GROUNDED EITHER BY A GROUNDING PLUG. CONNECTION OR BY ITS CASE BEING IN CON TACT WITH A GROUNDED SURFACE. EXTREME CARE MUST BE TAKEN WHEN USING THE OSCIL- LOSCOPE SINCE ITS CHASSIS WILL BE ELECTRI- CALLY HOT TO GROUND WHEN CONNECTED TO. ‘THE CONTROL SYSTEM. 7.4 BASIC TROUBLESHOOTING ‘Ths paragraph contains abasiclistof symptoms of animproperly ‘functioning control. Included in thelist are possible causes and corrective measures for each symptom describe WARNING BEFORE PROCEEDING WITH ANY MAINTENANCE OR TROUBLESHOOTING ACTIVITY, ALL POWER SOURCES MUST BE DISCONNECTED AS DE- SCRIBED IN PARAGRAPH 7.1. all either a jumper or a motor thermal be- terminals. B. No AC power - apply AC power C. Blown line fuses - replace line fuses. D: Loose connections -tum off AC power and tighten connec tions. . Control incorrectly wired - recheck all wiring. F. Defective Star/Stop switch, componenton main PC board, or rectifier cube - replace bad components as required. G. Speed potentiometer setozer0-slowly advance from zero 10 begin motor rotation. LINE FUSES BLOW OR MAIN CIRCUIT BREAKER ‘TRIPS WHEN APPLYING AC POWER: ‘A. Control is wired to AC voltage exceeding control rating - fevire contrlto proper AC vokageorusestep-downtrans- 5m BB. Rectifier cube, field diodes on main PC board, motor winding or suppressor network shorted, or a short 10 ‘ground is present - locate and remove short. Improper wiring or jumper programming during installation refer to Section 4 of this manual. Defective main PC board component -replace.as required. : Motor shaft jammed - determine cause and correct. "Excessive carbon dust from brushes in motor - determine cause and correct. mmo 9 FUSES BLOW WHEN SPEED POTENTIOMETER IS ADVANCED FROM ZERO: ‘A. Motor is overloaded - reduce load as required. 8B, Motor is defective - consut motor instruction manual and ‘repair or replace motor as required. . Current limit adjustment set too high - readjust as de- scribed in Paragraph 5.2.2. ACCELDECEL RAMPISMUCH LONGER THANEXPECTED: ‘A. Motor overioadedioverhauling - reduce load or apply op- tonal braking kit. MOTOR DOES NOT REACH FULL SPEED: ‘A. Motors overloaded - correct overload condition. BB. Maximum Speed potentiometer (MAX) is st foo low - adjust MAX potentiometer clockwise. ©. Low AC line voltage (more than 10% below nominal) - chock AC lino voltage and correct. D. Current limit set too low - Paragraph 5.22. E, Incorrect jumper programming -folow programming procedure described in Paragraph 4:3. F, Defective rectifier cube - replace as required. . Motor brushes worn replace as spectid in motor instruction manual. MOTOR RUNS IN WRONG DIRECTION: ‘A. The At and A2 output leads to the motor are incorrectly wired - exchange these leads. B. On shunt wound motors only, the shunt field F1 and F2. leads are incorrectly wired - exchange these loads. ©. The Forward/Revarse switch (if used) is in the wrong position - change this position. MOTOR DOES NOT MAINTAIN SPEED UNDER LOAD: ‘A. IRCOMP potentiometers set toolow-adjustclockwise as, described in Paragraph 5.2.2. B. Motor is overloadad - correct overload condition. . Incorrect jumper programming - follow procedure doscribed in Paragraph 4.3. D. Detective component on main PC board - replace as required. E. Current limit set too low - readjust as described in Par ‘graph 5.2.2. F. Motor brushes worn - replace as specified in motor instruction manual. just as described in MOTOR IS UNSTABLE OR OSCILLATE! ‘A. IRCOMP potentiometer settoo high - adjust IR COMP po- tentiometer counterclockwise untithe motor speed stabi izes without oscliatng. B, Defective motor - consult motor instruction manual and repair or roplace as required C. Loads loosely coupled to motor or misaligned check and correct load coupling. D. Loose wire connections -tighten connections (to motor. E_ Defective component on regulator PC board - replace as required. F. Motor overloadedioverhauling - decrease or increase load a required. 6. Low AC line votage (more than 10% below nominal) - check AC line voltage and correct. H. Incorrect jumper programming ~ follow procedure de- scribed in Paragraph 4.3. |. Current iit set too low - adjust as desorbed in Paragraph 522, MOTOR DOES NOT COME TO FULL STO} ‘A. Minimum Spoed potentiometer (MIN) is set too high - readjust as described in Paragraph 8, Detective speed or torque potentiometer, component on regulator PG board, Starv/Stop switch, ofrecer cube replace as required.YELLOW CURRENT LIMIT LED LIGHTS ON THE MAIN PC BOARD OF A 3-5 HP CONTROL: ‘A. The At and A2 motor leads have been wired directly to ‘TB1-A1 and-A2 onthe main PC board - remove these con- nections and re-wire as described in Paragraph 4.7.4. NO SPEED CONTROL: A. Dolectivorecifiar cube replace as roquied fective component on main PC board - replace as required. ©. Incorectly wired or detective speed potentiometer -check the wiring procedure as described in Sections 4 and 9 of manual or replace as required, D. Incorrect jumper programming - check procedure described in Paragraph 4.3, E, lithe contro (after rechacking all the wiring for proper and secure connections) isstill inoperative, make the following Voltage checks. Double check to make sure that armature leads At and A2 are not grounded VOLTAGE CHECK CHART Normal Terminal Step Funetion Voltage Reading or Point Probable Cause 1 Votage to | 120VAC — 240VAC Act Detective switch or loose| with onvott Rectifiers #10% £10% ace ‘or broken wire to oF from ‘switch "ont on power | switch ‘cube 2 Oto410 oto +10 on Defective speed adjust- voc voc ‘ment potentiometer or circuit board assembly 3 Field Supply | 1o0v0c —2o0voc | +t Defective fiold diodes Vokage “F2 defective encapsulated bridge rectifior assombly 4 ‘Armature | o-90vDC — o-sovoc | +At Defective encapsulated Voltage “#2 bridge rectifier assy, or circult board assembly “Depends on the ering of te spved alusenent ob, 2930SECTION 8 Ordering Spare Parts Spare parts kt numbers 2400-9901, 2450-9901, and 2450-9902 provide, for most customers, allthe spare parts ever required. These kis contain the following componer COMPONENT — DESIGNATION QUANTITY PART NUMBER Kit #2400-9901 - for 14-2HP Enclosed and Less Operators controls Power Cube, 230V 1 3720-004 Fuse, 154 1FU, 2FU 6 3705-032 Heat Sink Compound 1 3464-003 Kit #2450-9901 - for 1/4-2HP Pane! Mount controls Powor Cube, 230V 1 3720-004 Fuse, 158 1FU, 2FU 6 9707-60150 Heat Sink Compound 1 3464-003 Kit #2450-9902 - for all-SHP controls Power Cubs, 230V. 1 3720-0108 Fuse, 40A, 500V 1FU, 2FU 6 '8701-504000 Heat Sink Compound 1 3464-003 a more sophisticated level of troubleshooting is required, see the part numbers listed on the following pages for ret ENCLOSED CONTROL (PIN 2450-8000W, 1/4-2HP) ASSEMBLY COMPONENTS MOLDED UPPER/FRONT CHASSIS: Blue cover only 1 2450-5001 Label for cover 1 12450-5004 Gover gasket 1 2450-5019 Fuse, 15A, 250V 1FU, 2FU 2 ‘3705-032 Power cubs, 230V. 1 3720-004 FACEPLATE ASSEMBLY: ‘Switch, toggle "ON/OFF" 3 9550-004 ‘Switch, toggle "RUNJOG" 1 ‘3550-003 ‘Switch, toggle “START/STOP” 1 3550-005 Potentiometer, SK.2W "SPEED" 1 9533-0502 ‘Speed pot push-on knob 1 3549-002 Switch boot 3 3555-001, Seal, pot shaft 1 3555-002 MOLDED LOWER/BACK CHASSIS: Blue molded chassis 1 2450-5000 PC BOARD ASSEMBLY: 1 12450-4000 ENCLOSED CONTROL (PIN 2450-8001W, 3-SHP) ASSEMBLY COMPONENTS MOLDED UPPER/FRONT CHASSIS: Blue cover only 1 2450-5005 Label for cover, 1 2450-5007 Cover gasket 1 2450-5019 Fuse, 40A, 500V 1FU, 2FU 2 3701-04000 Power Cube, 230V. 1 3720-0108, FACEPLATE ASSEMBL\ ‘Switch, toggle 1 3550-006 Switch, toggle 1 3550-003, ‘Switch, toggle 1 '3550-005, Potentiometor, SK,2W 1 3533-0502 ‘Speed pot push-on knob 1 "3549-002, ‘Switch boot 2 3555-001 ‘Seal, pot shat 1 ‘3555-002 MOLDED LOWERVBACK CHASSIS: Blue molded chassis 1 12450-5000 PC BOARD ASSEMBLY: 1 2450-4000 ‘Shunt Resistor Board 1 2450-4010 Resistor only, .005 ohm, SW RY, R2 2 (0916-R005-005 anCOMPONENT = DESIGNATION = QUANTITY, «= PART NUMBER LESS OPERATORS CONTROL (P/N 2450-8002W, 1/4-2HP) ASSEMBLY COMPONENTS: MOLDED UPPER/FRONT CHASSIS: Blue cover only 1 2450-5005, Label for cover 1 2450-5017 ‘Cover gasket 1 2450-5019 Fuse, 158, 250V 1FU.2FU 2 ‘3705-032 Power cube, 230V 1 3720-004 Potentiometer, 5K, 2W "SPEED" 1 3593-0502 ‘Speed pot push-on knob 1 ‘9549-002 MOLDED LOWERVBACK CHASSIS: Blue molded chassis 1 2450-5000 PC BOARD ASSEMBLY: 1 12450-4000 LESS OPERATORS CONTROL (PIN 2450-8003W, 3-5HP) ASSEMBLY COMPONENTS MOLDED UPPER/FRONT CHASSIS: Biue cover only 1 2450-5005 Label for cover 1 2450-5018 Cover gasket 1 2450-5019 Fuse, 40A, 500V 1FU, 2FU 2 3701-50400 Power cube, 230V 1 3720-0108 Potentiometer, SK, 2W "SPEED" 1 3533-0502 Speed pot push-on knob 1 9549-002, MOLDED LOWER/BACK CHASSIS: Blue molded chassis 1 12450-5000 PC BOARD ASSEMBI 1 2450-4000 ‘Shunt Resistor PC Assembly 1 2450-4010 2 (0916-R005-005 Resistor only, .005 ohm, SW, Rt, R2 PANEL MOUNT CONTROL (PIN 2450-8010W, 1/4 - 2HP) ASSEMBLY COMPONENTS. Fuse, 15A, 600V FU, 2FU 2 3707-601500 Power cube, 230V 1 3720-004 Potentiometer, 5K, 2W "SPEED" 1 13593-0502 ‘Speed pot push-on knob 1 3549-002, PC BOARD ASSEMBLY: 1 2450-4000 PANEL MOUNT CONTROL (PIN 2450-8015W, 3 - SHP) ASSEMBLY COMPONENTS Fuse, 40A, 500V 1FU, 2FU 2 9701-504000 Power cube, 230. 4 3720-0100 Potentiometer, 5K, 2W/ "SPEED" 1 ‘3583-0502 ‘Speed pot push-on knob 1 3549-002 PC BOARD ASSEMBLY: 1 2450-4000 ‘Shunt Resistor Assembly 1 2450-6010 Resistor only, 005 ohm, 5W 2 (0916-R-005-005, 32MAIN PC BOARD (PIN 2450-4000) COMPONENTS. ‘This board is used on all control models. The part numbers onthe components may differ from this parts list because vendor numbers, hhave been replaced by ICD numbers in many cases, COMPONENT DESIGNATION QUANTITY PART NUMBER CAPACITORS: Consult factory with the value and board designation DIODES: 3A, 600v 01,2 2 4020-D030x06 0mA, 75 03,4,6-8, 14.21 8 1NQ14 1A, 200V Ds, 9.13 6 1N4o03 1A, 600V 022.25 4 ‘1N4005 LED (green) ‘Dc POWER™ 1 4030-310 LED (yellow) "CURRENT LIM" 1 4030-410 DIODES, ZENER: 5.6V, 1W bzt 1 1NA734A 18V, 1W 0223.5 3 4N47A4A 10V, 1W za 1 1N47408 12V, Ww zs 1 1N47428 Op amp, dual u24 3 4041-0958 Timer circuit is 1 4041-0555 POTENTIOMETERS: 5K "MIN, “CURRENT LIM 3 9545-053, "IR COMP" 250K "MAX, “ACCELIDECEL* 2 9545-254 RELAY: 2A, 24VDC, DPDT CAR 1 9516-026 RESISTORS: Consul factory with value and board designation RESISTORS, SHUNT: 61 ohm, SW Ra 1 (0916-8R01-005 RC NETWORK: “Im, 47 ohm Ret 1 9084-118 TERMINAL BLOCKS: 6-pin TB 1 3792-1606 13in Tez 1 37921513, ‘TRANSFORMER: 1 1 3082-496 TRANSISTORS: NPN a4 4 (0991-003 FET a5 1 ‘3970-001 VARISTOR: avert 1 4017-2515Terminal blocks TB1 and TB2 BL FI, F2 AN AZ 25 347 10 " 12,13 SECTIONS ‘Supplementary Technical Information Table 4 Control! Standard Connection Scheme Terminal Blocks TB1 and TB2 instalad on the main PC board 2450-4000, This board is used on all six control models. ‘Shunt field connections DC Motor connections for 1/4 - 2HP controls only. Do not wire directly to TB1-At, and -A2 with 3-5HP controls. For M-Contactor and Reversing Kit installations on 3-SHP controls. N.C. Motor thermal contact, (if required). if contact is. not used, terminals 1 and 2 myst be jumpered together. N.C. Stop contact undlog switch contacts on Enclosed controls. On Less Operators and Panot Mount modals, tarminals 3 and 4 become the Runilog contact, if used (or they are jumpered and become with terminal 5, the N.O. Start contact it a RuniJog ‘switch is not used), and terminal 7 is not used. Tied to N.C. contact of CRR relay ‘OW side of speed potentiometer Wiper contact of speed potentiometer CCW side of speed potentiometer (Min speed) Shield connection for speed pot wiring ‘ACIDG Tachometer connections Table 9-2 Customer Jumper Programming Chart (filled out by customer) JUMPER GROUP POSITION AT START-UP, JA JB. aPt Ja, PS) PaALL DIMENSIONS ARE IN INCHES. ‘QUTLINE AND MOUNTING DIMENSION DATA, ENCLOSED CONTROL, DIMENSION DATA LESS OPERATORS CONTROL curune ato mounrwa | B Figure 9-1. Cutline and Mounting Dimensions for Panel Mount, Less Operators, and Enclosed Controls. 36{aru su WITH OPTION COVER OUTLINE AND MOUNTING DIMENSTION DATA PANEL MOUNT CONTROL, Figure 9-1. Outline and Mounting Dimensions for Panel Mount, Less Operators, and Enclosed Controls 37Yeu "roo! -o6¥e‘slonueo exveiedo 6677 pu unoy eued JH Ho 20} weHBeI YoNeULOD 76 ounbly 38‘Vy n0u ‘+4011-08¥2 ‘slonuog sioyesedo 8807 ue non euea dH YO 0} cwiBea ueeUe9 “es einbig 39|W "Re ‘F0001-0962 ‘slosuOD Pesojoua dH Mo7 10} WeLBeIQ UoHDeUED “re eunbiyV“A0u ‘-Lo01-08¥2 ‘stoxuo9 pesoioua aH YBIH 10} wesB9IQ UojoeuUD “se emnbig “1V "A0H ‘FZOLL-O8b2 ‘YOIDEIUED . 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Torque (force) without rotation is called static torque, since no motion is. produced. Torque is measured in b-in or lb-ft. It is the product of the force in pounds (i) x the distance in inches (in) or fest (t) from the Center ofthe point of apparent rotation. Figure 10-1 shows 120, lin (12 inches x 10) or 10 lb-ft of torque. | io tes Figure 10-1. Example of 10 lb-ft Applied Torque Bacause most power transmission is based upon rotating ele- torque is important as a moasuremont of the sffort required to produce work. 10.1.2 Horsepower Horsepower a measure ofthe rate at which works being done. When a force is applied in a manner that produces motion, work ‘can be measured. ‘One (1) horsepower (HP) is defined as the force required to litt 33,000 Ibs. one foot in one minute. 10.2 TORQUE VS. HORSEPOWER A simple formula exists that relates torque and horsepower to ‘each other. This formula is: ‘Toraue (bt) Speed (RPM) 5250 Horsepower = 10.3 MATCHING THE DRIVE TO THE MACHINE ‘The application of an adjustable speed drive to a machine is a mechanical, rather than an electrical problem. When applying the drive, the speed, torque, and horsepower characteristics de- veloped atthe motor shaft mustbe considered. These must meat or exceed the torque and horsepower requirements of the machine being driven. ‘The torque requirements of a machine fall into thr categories: major 1. Breakaway torque 2. Acealarating torque 8, Running Torque 10.3.1 Breakaway Torque Breakaway torque is the torque required to start a machine in ‘motion. tts almost always greater than the torque required to ‘maintain motion (running torque). In some applications, breaka- way torque is a very important parameter that cannot bo ne- glected. 53 10.3.2 Accelerating Torque This is the torque required to bring the machine to operating spoed within a given time. With most machinas, the toad is largely fiction and a standard drive rating may have adequate torque for salistacory acceleration. However, certain machines classified as“high inertia" with tywheols, bullgears or othe large rotating masses may require drive selection based upon the power required to accelerate the oad witin a given time 10.33 Running Torque This is the torque required to maintain machine motion after it accelerates to the desired operating speed. Running torque Usually a combination ofthe torque required to push, pul, com- press, strech or process the material plus the torque required to ‘overcome frictional forces and windage. Running torque may vary as a complex function of operating speed. It is very important to understand the torque requirements of the applica- tion bofore attempting to apply a drive. Ingeneral, most applica tions will fall into one of the following categories: A. Constant torque B. Constant horsepower . Variable torque ‘Alimited number of machines may have operating characteris- tics which are a composite ofthe basic typos. ‘A. Constant Torque - About 80% of all general industrial machines (otherthan pumps) areconstantterque systems. The machine torque requirements in- Buildup ‘Tension ib) x Line Speed (PM) Hl 33,000, It Taper X Field Range < Buildup HP =~ 88,000 Taper x Field Range ‘CAUTION ‘The above formulas for calculating horsepower do ot include any allowance for machine function ‘windage or other factors. These factors must be considered when selecting a drive for a machine application. E. For Fans and Blowers HP = OFMX Press '33,000 x (Eff. of Fan) Ect of sod on HP HP (RPI) © Horcepower vais a the Ge power of sped Ti PM Torun esos to Bn power el apoed From ky (RPM) Flow varies ect a he opued HP vie 229 x (Eff. of Fan) HP = 128 of Wat 6356 X (Eft. of Fan) F. For Pumps HP = ‘8960 X (Efficiency of Pump) Specific gravity of water = 1.0 Yeu. ft. per sec, = 443 GPM 1 PSI = A head of 2.309 f. for water weighing 62.36 lbs. ft? and 62°F Displacement pump efficiency: Displacement pumps may vary between 50% and 80% otf. ciency, depending on size of pumps. Centrifugal pump efficiency: {800 to 1000 gal. per min, = 70% to 75% 1000 to 1500 gal. per min, = 75% to 80% Larger than 1500 gal. per min. = 60% to 85% 10.6.2 Inertia (WK?) ‘The factor WK*is the weight (Ib) of an object mutiplied by the ‘square of the radius of gyration (K). The unit measurement ofthe radius of gyration is expressed in feet. For solid or hollow cylinders, inertia may be calculated by using the equations given here,The inertia ot solid steel! shatting per inch of shaft length is given Table 10-2 in Table 10-1. To calculate hollow shatis, take the difference Density Factors between the inertia values for the 0.0. and LD. For shatts of ‘materials other than steel, mutiply the value for steel by the SHAFTMATERIAL — FACTOR ‘appropriate factor given in Table 10-2. Rubber 121 Nylon 181 ‘Aluminum 348 Bronze 1135 sou, Cast Iron 822 ‘Steel 4.00 We = Bot? t Dis, Os ange = ‘The inetia of complex, concent rotating pars may be calov- p= Bolin lated by breaking the’ part up into simple rotating oylinders, WE = 000681. p LO‘ calculating their inertias and summing their values, as shown ia, (aluminum) = 0924 the folonng diagram ‘2 (bronze) = 320 pfeastivon) = 260, 2 steel) = 282 HOLLOW, eipapen) = 0289 Dy De WE = 000681 pL (Dit - Ost) Table 10-1. Inertia of Stee! Shatting (per inch of length) Diam. (in) |_WK(=1b-H) | Diam. Gn) Es 00006 10-12 1 0002 10-34 258 1414 ‘0005 1 2.83 412 001 11-14 3.09 134 002 112 3.38 2 008) 11376 ‘3.68 216 (005 12 4.00 242 (008 12418 435 2a ‘on 142 472 3 O18 12-314 at 342 0.029 13 558 3.3/4 0.038 13-414 5.98 a 0.089 312 Sad 446 0.063 19.314 a1 412 0.079 14 7.42, 5 0.120 14-118 797 5472 on77, 1412 854 e 0250 1434 915 64 0.298 5 375 612 0.345 16 1259 6/8 0.402 7 16.04 7 0.464 6 20.16 748 0.535 19 25.03 72 0.611 20 30.72 7314 0.699 21 37.35 e 0.791 2 44.99 e116 0.895 23 53.74 B12 1.00 24 63.71 8.3/8 113, 25 75.02 9 1.27 28 87.76 os vat 27 102.06 92 155 28 118.04 93/4 475 29 195.83, 10 1.93 30 155.55 10-14 243 . * 5610.6.3 WK? of Rotating Elements In practical mechanical systems, all the rotating parts do not operate at the same speed. The WK? of all moving parts erating at each speed must be reduced to an equivalent WK? at the motor shatt, so that they can all be added together and treated as a unt, as folows: Eovivaont WHE = WH ()# Where \W2 = inertia of the moving part Ne speed of the moving part (APM) 1, = $Peed of the driving motor (RPM) ns WEGe, = WIE + WIE + WEE When using speed reducers, and the machine inertia is reflected ‘back to the motor shalt, the equivalent inertia is equal to the machine inertia divided by the square of the drive reduction rat 10.6.4 WK? of Linear Motion Not ll driven systems involve rotating motion. The equivalent WK of linearly moving parts can also be reduced to the motor shaft speed as follows: Equivalent WK? = WAVE 39.5(N, where, W = woight of oad (Ib) \V= linear velocity of rack and load or conveyor and load (FPM) N, = speed of the driving motor (RPM) This equation can only be used where the linear speed bears a continuous fixed relationship to the motor speed, such as a conveyor, 10.7 ELECTRICAL FORMULAS ‘Ohms Law: Amperes = Volts Ohms = Volts ‘Ohms ‘Amperes Volts = Amperes x Ohms Power in DC Circuits: Watts = Votis X Amperes Horsepower = Volts X Amperes 746 Volts X Amperes 1000 Volts X Ampere Kitowatt Hours = 1000 Kilowatts = How Power in AC Circuits: Kilovolt - Amperes (kVA) Volts X Amperes KVA (Single-Phase) =" 1000 87 X Amy kVA (Three-Phase)= 1000 Kilowatts (kW) i KW (Single-Phase) = 1000 Volts X Amperes X Power Factor ‘Volis X Amperes X Power Factor X 1.73 KW (Three-Phase) = 1000 jt Power Factor= Rilovolts X Ampares 10.8 OTHER USEFUL FORMULAS 1KW = 58.88 BTUMIN AHP = 0.7457KW = 850 tt per sec 33,000 Ib-t per min = 2545 BTU per hour ‘TEMPERATURE CONVERSION Degrees C= (Degrees F-32) x 5/9 Degrees F = (Dogrees Cx 9/5) + 32Qvechaviing Load - Regenerative Drive - APPENDIX A. GLOSSARY ‘Aioad requiring high torque at low speeds, low torque athigh speeds, and thus constant horsepower at any speed. ‘Aload requiring the same amount of torque at low speed as at highspeed. ‘Torque remains constant throughout the speed range, and the horse~ ower increases and decreases in direct proportion to the speed. Control run relay ‘A measure ofthe rate at which work is being done, One (1) horsepower (HP)is defined as the force requiredito ft 33,000 lbs. one foot in one min- ute, ‘An adjustment that overcomes the natural tendency for a motor to decelerate with increasing load. Light emitting diode. (One which rotates the DC motor in only one direction to supply rotational energy oF torque into the load. ‘A load such as a process tension difference, a downhill bad or machine inertia that requires the motor to provide holdback torque fo brake the load. A regenerative drive or energy absorber kit is usually requited in these applications, ‘One which can both deliver and remove electrical energy to or from a ‘motor. In this manner, rotational mechanical energy can be supplied to or be removed from, load, Silicon controlled rectifier. Totally Enclosed Non-Ventilated. ‘A foree applied that tends to produce rotation. Breakaway torque is the torque required to start a machine in motion. Accelerating torque is the {torque required to bring the machine to operating speed within a given time. Running torque isthe torque required to maintain machine motion after it accelerates to the desired operating speed. ‘Aload requiring much lower torque at low speeds than at high speeds. Horsepower varies approximately as the cube of the speed, and the torque varies approximately as the square of the speed, 58AOL TECHNy, Ee, ‘2096 Alt Boulevard Grand Istana, New York 14072 USA (796) 773-2321 » Fax: (716) 779-6284 ESr2056 Pema in USA iy Ne08