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CAUTION - Electric Regulator Corporation

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1. HP Full Load Minimum Wire Size Circuit Breaker HP Full Load Minimum Wire Size Circuit Breaker AC Amps for 40 ft length AC Amps at 250V AC Amps for 40 ft length AC Amps at 600V ac 5 17 12AWG 25 5 8 6 14 AWG 10 7 5 25 10AWG 30 7 5 11 14 AWG 15 10 32 8 AWG 40 10 13 5 12 AWG 20 15 49 6 AWG 70 15 21 10 AWG 30 20 63 4 AWG 90 20 27 8 AWG 35 25 79 3 AWG 100 25 34 8 AWG 40 30 93 1 AWG 125 30 40 6 AWG 50 40 124 00 AWG 175 40 54 4 AWG 70 50 156 000 AWG 200 50 67 4 AWG 90 60 184 0000 AWG 225 60 80 3 AWG 100 75 229 300 300 75 99 1 AWG 125 100 300 500 400 100 133 00 AWG 175 125 380 2 250 500 125 167 0000 AWG 225 150 450 2 350 600 150 202 250 300 200 266 2 000 AWG 400 250 375 2 250 500 240 Armature 500 Armature HP Full Load Minimum Wire Size DC Fuse Amps Full Load Minimum Wire Size DC Fuse Amps DC Amps for 40 ft length Gf used DC Amps for 40 ft length if used 5 19 10 AWG 25 5 10 12 AWG 15 7 5 28 8 AWG 40 7 5 12 12 AWG 20 10 36 6 AWG 50 10 15 10 AWG 25 15 54 4 AWG 70 15 23 8 AWG 35 20 70 2 AWG 100 20 30 8 AWG 45 25 87 150 25 38 6 AWG 60 30 105 0 AWG 150 30 45 4 AWG 70 40 139 0000 AWG 200 40 60 3 AWG 100 50 173 250 250 50 75 2 AWG 150 60 205 300 300 60 90 1 AWG 150 75 254 500 400 75 110 00 AWG 200 100 337 2 250 600 100
2. 1 v0 eev 09 6 8 86 092 191 VSN WO V M2 Model Physical Diagram Page 35 ELECTRIC REGULATOR Carlsbad CA 92009 USA Tel 760 438 7873 Fax 760 438 0437 information electricregulator com M3 Model Ratings Model Max 230VAC 460VAC Number Amps MaxHP Max HP M3 550 125 250 575VAC Max HP 312 375mm 14 25 32 256mm RAM 98mm 103 32 3 27 32 BE EIL Y 1 EL ES tla S d 50 T gt 9 2 Els 4 58 9 5 5 Qo L2 L3 1 1 8mm DIA 5 16 DIA 50mm 50mm 2 2 230 9 1 16 256mm 103 32 160 6 5 16 M3 Model Physical Diagram Page 36 86 11 11508 99814 9 22 0 22222212222 dH00S OVASZS dHOOF OVAOSYT dH00c OVAOEC 024 sduy 7 49 129140 429 4 0 8 092 6 8 092 191 YSN 60026 VO aono L1 Model Physical Diagram Page 37 49UL 06 0 8 964 dH amp Sc9 OVAS G dH00S OVAOST OVAOYC 016 sduy 071 9
3. TACH FEEDBACK APMLIFIER TACH GENERATOR EXT CURRENT REF 4 100 IA SPEED METER 1 100 FORWARD CURRENT LIMIT AMMETER 3 4 100 IA 1 150 2V 1 150 FIELD FIELD REVERSE FUNCTION CURRENT CURRENT LIMIT GENERATOR CONTROL THYRISTOR AV 100 Fe THYRISTOR DRIVER FIELD WEAKENING ENABLE ON DISABLE OFF ARMATURE FEEDBACK CIRCUIT 0042 REGULATOR CONTROL BLOCK DIAGRAM DWG 9044 9044 iagram Regulator Card Control Block D Page 42 1 IV ONIZIOYINI SAYS S NOUVINGOR 303 NO NOUO3JA 100 c 001 g9 133 1 LG 4 01 81 BL 0 0 130 1 WO 330 x3 330 338 1 212 1 SMMOUNS GNO Regulator Block Diagram DWG 9042 1 Page 43 e 8 28 1 5 47v 220K 9 1V gt 55 2 beh 8 419 9 2 9 Ed gt 1 1 1 1 1 1 1 1 1 1 1 t 1 H 1 1 1 1 1 1 1 1 1 1 2 _5 9 5 55 8 4 5 0 111 Regulator Block Diagram DWG 9042 2 Page 44 a 521 31211 x 31 7 086 022 Regulator Block Diagram DWG 9042 3 Page 45 ELEMENTARY CONTROL CIRCUIT ES RESET NM FT BM TS qp Fa
4. 26 6181 22 9 429 1870 87 09 4 48 8 v 09 9 VSN 60026 VO Model Physical Diagram Page 37A _2 37 IFC 1084 card connections Regulator Card 1059C IFC 1084 Card CN 9 123456 5 123 V3HG V3 V2LG GA FWD 41FS Auxiliary Field Supply for High Current Fields DC drive Auxiliary Field Supply Model series 41xxx x Model series 41FSx x 1112 38 The Synchronization Card 1058C i e SYNC CARD 1059C can be modified to work with different model drives and input voltages by changing resistor values and jumpers Part Number Input Voltage Armature Voltage 1058C 01 200V 240V 240V 1058C 02 380V 480V 500V Input Voltage 200V 240V 3 Armature 240V M 1 Resistors Resistors Transformers ode eh R1 R2 R3 R50 R51 TRI TR2 TR3 pie ii Field Amps Number R5 R6 R7 R8 R73 R
5. 33 5 V Watt 13 J3S J3R OFF tol 2 2 JAT 148 JAR ON m 17 23 5 tol 1 tol 5 lt E 4 Jumper 8 1 42NM3 4 5 25 AREA 190 san 12 128 J2R OFF 5 75 42NL2 4 475 No Resistor F4 25 5 1 Watt 13 138 J3R OFF 42RM3 4 5 14 Watt Open Circuit F5 2 25 DELIA tol 2 oie 148 JAR ON 13 2 42RL2 4 F1 0 __ 33 e 51 R50A 74 7 SYNCHRONIZATION CARD 1058 Note When soldering 10 be careful to keep the soldering iron away from ws hear by capacitors Jar 333 ob TR2 TR1 T4 S4 H A BLUE WHITE RED WHITE Page 39 R4 RED Oscilloscopes Viewing the armature voltage with a oscilloscope requires special care The oscilloscope can not be grounded The oscilloscopes power can not be grounded or connected to the neutral The oscilloscope and step down transformer can not rest on a grounded surface such as the floor or metal electrical enclosure Resting the oscilloscope and transformer on a sheet of plywood or thick card board often provides sufficient isolation from ground A expensive oscilloscope is not require a inexpensive oscilloscope is recommended L1 L2 Don t rest the ocilloscope Don t Ground or transformer on grounded Step
6. Check the following Recommendations e The acceleration or deceleration is Adjust ACC or DEC pots too short despite the load s large See Section 5 13 Acceleration and Deceleration inertia Adjustment e Excessive overshoot undershoot Improper adjustment of the speed regulation loop and unstable level speed Adjust SR SG and PI pots See section 5 14 5 14A 5 14B and 5 15 Section 6 8 Problem Overload fault OL signal light Check the following Recommendations e Overload of motor The OL signal light may turn on if an intermittent load exceeds the square root mean value of 100 Check the intermittent load of the motor Check field current Low field current reduces the power of the motor e Improper setting of IA pot See section 5 12C Page 30 ERC Statohm Manual Section 6 Trouble Shooting Section 6 9 Problem Check the following Plug on the Regulator card and SYNC card maybe loose Check voltage from terminal board positions 35 amp 38 to B The voltage should be 25Vpc 3 Voc The ES OH VL signal lights are on and can not be reset Recommendations Check CNI is plugged on properly If 25Vpc is not present the 115 transformer may be damaged check the transformer If the transformer output voltages are good The SYNC card should be replaced buzz Check the following Check the armature connections
7. Section 6 10 Problem Signal lights R and PC are on the F AP ZD flash and the relays Recommendations The armature circuit is bad or open Trouble shoot and correct the problem Check the following Check the motor s name plates field specifications Measure the field current and voltage to determine if they are comply with the specifications Note Remember to disable field economy when making field measurements Field loss only in field weakening but the drive works normally in armature feedback If the system has an armature contractor and it is not completely closed when terminal 34 receives the run signal this will result in a field loss light Be certain that the sequence is contactor closed first 120V power second and run signal third We strongly recommend AC contactors over armature contactors Section 6 11 Problem Field Loss is detected Recommendations If the field current is too low and the voltage corresponds to the field resistance The F jumper is set too low If the field current and voltage are correct The F jumper could be set too high Explanation The field has a current regulation circuit but the field voltage will not exceed 7096 5 of the AC input voltage connected to terminals L1F and L2F The current is limited to the voltage available First example The 42NS 1 4 is connected to a motor witha 1 amp field and the F jumper is set for 7 1 amps F1 The voltage will
8. Check if RN1 RN2 JOG and ES relays circuits are wired properly When RN1 RN2 JOG and ES relays are open Check if test point B is 25Vpc Jumper JP 10 must be off The motor will not run when this jumper is on Test point 4 is the acceleration and deceleration ramp signal When starting the signal should ramp up to 8V or for reverse 8V Section 6 3 Problem Motor Runaway Check the following e TG Jumper Tach Generator circuit Tach feedback Check voltage of test point 1 The normal voltage range is 0 02 to 8 5 Vpc Armature feedback Check voltage of test point 2 The normal voltage range is 0 02 to 8 5 Voc Armature feedback Check the armature voltage plug connected to the bottom left corner of the synchronization card Measure the field current Phase to the field is not correct The motor s field is not correctly connected e Check jumper settings and continuity Recommendations The TG jumper must be on for both Armature and Tachometer feedback TG On Check if the tach generator circuit wiring is faulty Check if the polarity is correct See section 4 11 DC Tach Generator If no voltage is present at test point 1 Check wire connections If wire connections are good The regulator card may need to be replaced If no voltage is present at test point 2 Check wire connections If wire connections are good The regulator card ma
9. 139 166 277 330 560 2 A4 Off 4 5 7 5 14A 23 60 100 120 200 240 400 Al 4 Off 3 5 5 9 19 46A 78 93A 150A 190A 300A fo Al A2 A4 Off 28 4 12A 38A 62 5 75 125 150 250 Al 2 Off 4 5 Field Connections See the motor s data plate for the field s amp rating Then select the wire size from the Wire Size Table at the beginning of section 4 We also strongly recommend reading page 41 The polarity of the field determines the motor s direction of rotation Connect the motor field wires F1 and F2 to the terminal strip points F and F according to the required direction of rotation Note The American industry standard for determining if a motor s rotation is clockwise or counterclockwise is to view the motor from the commutator end The commutator end of a standard DC motor is the opposite end from the drive shaft The field current is selected by setting the appropriate jumper in the table below See motor s name plate for the motor s field current Note The field current is limited by the input voltage The field voltage will not 71 of the input voltage Example With 460V connected to L1F and L2F the field voltage will not exceed 327 volts S1 Model S2 amp S4 Models M2 amp M3 Models L1 amp L2 Models Jumper Settings Current Range Cu
10. ES STOP START Note All relays are showen when 110V 120V 1 PHASE the power is off Exsample When the power is on the ES contact will close 2 QUADRANT 6 SCR BOL DC MOTOR ARMATURE AMMETER INPUT 0 to 2V SPEED METER INPUT 0 to 1mA FIELD PC Enable ES INPUT 0 to 2V ROTATION SIGNAL SPDT RELAY AC 250V 0 5A FAULT SPDT RELAY AC 250V 0 5A FIELD LOSS SPDT RELAY AC 250V 0 5A 4 QUADRANT 12 SCR REVERSING amp REGENERATIVE BRAKING ELEMENTARY CONTROL CIRCUIT ES RESET FT BM TS 5 110V 120V PC Note All relays are showen when the power is off Exsample When the power is on the ES contact will close Elementary Circuit Diagrams of 2 Quadrant 6 SCR and 4 Quadrant 12 SCR drives MAIN BOL BM MCB MCB 0 12 13 1 189 22 11 0 0 G JO RUN V Q PC Enable 5 Q E E Q 5 40 E STOP Page 46 170 1 DC MOTOR ARMATURE AMMETER INPUT 0 to 2V SPEED METER INPUT 0 to 1 INPUT 0 to 2V ROTATION SIGNAL SPDT RELAY AC 250V 0 5A FAULT SPDT RELAY AC 250V 0 5A FIELD LOSS SPDT RELAY AC 250V 0 5A Regulator Terminal Table TERMINAL DESCRIPTION 1 Input DC Tach Generator Feedback 2 Input DC Tach G
11. 50 amps This sets the scale to 1 volt equals 50 amps If after the ammeter is calibrated the IMX pot is changed to 70 amps This changes the scale to 70 amps equals 1 volt If the ammeter is not recalibrated the ammeter will read 50 amps when the armature current is actually 70 amps The ammeter always must be recalibrated after the IMX pot is adjusted REGULATOR CARD IMX 1 4 Note Regulator 1059F and later jumpers 2 and 3 were eliminated 5 dd 55 lt 0 2 AMMETER 123 1718 39 40 INPUT POS Page 13 ERC Statohm IV Manual Section 4 Power amp Control Circuit Wiring Section 4 15 Field Ammeter Wiring and Calibration Selecting a meter The ammeter is a voltmeter with a 0 to 2 volt range input meters are available from ERC e The motor s field current rating determines the scale of the meter s face plate For example 0 to 2 volt meter with 10 Amp scale face plate Jumper and Potentiometer Settings Before calibrating the ammeter make all final jumper settings and pot adjustments e Make final settings to jumpers F1 F2 F3 F4 and F5 Set jumper FI on and FV off Note Regulator cards 1059F and later jumpers FI and FV were eliminated Make final adjustments to potentiometer pot IF of these settings are changed after calibratin
12. LIF 7 7 L2F L1C 12 7 Lis L2S L3S F F 7 2 The field isolation is deteriorating and beginning to fail The current is jumping from one winding to the next The is field controlled by an current regulation circuit The current is held at normal but not making enough ampere turns resulting in the field being too weak replace the motor Section 6 12B Problem During acceleration or heavy load the field is too low Check the following Diagram Check the motor terminal box for leads S1 and S2 The letter 5 stands for Stabilizing field Not all motors have leads 51 and 52 If S1 and S2 are present and not connected the diagram to the right shows how to connect them If the motor doesn t have leads S1 and S2 then the stabilizing field is connected internally Elementary Motor Connection Diagram STABILIZING FIELD _ si 52 1 300 VOLT FIELD E f TT ges e 1 SF uq us 2 133 F F 150 VOLT FIELD 4 Y Y Y rs E Es lt lt 2 Y gt lt 32 Section 6 13 Problem The PH light is on Check the following Diagram Several problems are possible 1 Lines L1 L2 and L3 should be connected respectively to term
13. adjustable trip voltage SPDT 0 5A 250Vac Fault Trip relay FT relay SPDT 250 Field Loss relay FL relay SPDT 0 5A 250V Armature Ammeter output 0 2V Field Ammeter output 0 2V Speed Meter output 0 Master Slave operation Instantaneous Overload Trip OC One master drive and one slave drive One master drive and one slave drive with master speed gain ST overload relay i e Shunt Trip is triggered at 250 SPDT 0 5A 250Vac One Minute Delay Over Current OL 150 of the motors rating exceeded for more than one minute High Low Input Voltage LVL 15 of input voltage Phase Error PH Detects phase sequence error or phase lost Tachometer Generator Loss TG User has choice of stop or full speed when TG loss is detected Field Loss FL Detects when field current is 13 below normal SCR Thyristor Over Heat OH 85 C 185 F thermostat switches off motor Fuse Blown FU Signal light indicates when AC input fuse has blown Environment Storage Temperature 40 to 140 40 C to 4609 Ambient Operating Temperature 14 F to 104 F 10 to 40 C Relative Humidity 95 max no condensation allowed Atmosphere Avoid iron dust particles and corrosive gases example Ocean air Ventilation Mount lengthwise vertical position 5 125 mm air space on all sides a
14. go up to maximum available and the current will be 1 amp The field loss circuit will detect the current is too low Second example The 42NS1 4 is connected to a motor with a amp field and the F jumper is set for 1 4 amps F4 When the motor has rapid load increase the field will drop momentarily and trigger the field loss detection circuit The best setting for a motor with 1 amp field would be 0 6 1 2 amps F5 If the field current is too low and the voltage is too high for the field s specified resistance The field possibly has bad connections or is beginning to fail Page 31 ERC Statohm Manual Section 6 Trouble Shooting Section 6 12A Problem The armature current is too high at low speed and small load Check the following Recommendations Read the field specifications on the motor s name plate Then measure the field current and voltage to determine if they comply with the specifications Note Remember to disable field economy when measuring the field Field economy is disabled by placing the FE jumper on One of two problems are possible 1 If the field input power is incorrectly connected The field power will be too low The motor will draw too much current during start and run too fast if the load is not too large Common mistakes are L3 is connected to LIF or L2F or the single phase 110V 120V is connected to or L2F The correct connections are shown below
15. pickup on the control circuit wiring can cause erratic operation e Never use solid wire Use shielded wires or twisted wires for the control circuit Connect shielding to common terminal of each circuit Run the control circuit wires in a separate duct or conduit Maintain a space of 2 inches 50 mm or more from the general power circuit 4 6 PC Enable Drive The PC terminal number 36 enables the drive before start This is a safety to detect when external Pre operational Conditions PC are engaged before the DC drive is able to start Example A safety door has a micro switch connected to terminals 36 PC and 35 COM When the door is open the micro switch is open When the door is closed PC is engaged PC must remain closed during motor operation PC should not be used to start and stop the motor If your application doesn t require PC connect a jumper wire from 35 to 36 4 7 Speed Reference amp Reverse Speed Reference has two options Option 1 The factory default setting is 0 to 8 volts with the power supplied by the regulator card A potentiometer typically a 500 pot is connected to terminals 7 8 and 9 The pot s wiper is connected to terminal 8 Speed Reference If you have a 12 SCR drive Reverse is activated by connecting terminal 37 Reverse to 35 Com This changes the polarity of the speed reference voltage terminals 7 and 9 and the motor changes direction Option 2 If an external speed refere
16. scale If the motor is frequently reversed with light load adjust the HS pot clockwise The Hysteresis circuit is an imprecise adjustment Set the pot and wait for the drive to stabilize before making another adjustment Avoid making an excessive number of adjustments 5 9 Maximum Speed Adjustment for Armature Feedback See the motor s data plate to confirm the maximum armature voltage The drive is preset at the factory for the typical motor See section 3 for the parameters of your motor and drive If the drive requires adjustment follow the procedure below e When the motor is stopped Adjust the CROS pot full counter clockwise 0 10 and the MAX pot to full clockwise 10 10 e Start the motor adjust the speed reference to maximum speed and observe the armature voltage When the motor s speed has stabilized at maximum speed proceed to the next step e Adjust the CROS pot to the maximum permissible armature voltage This calibrates the range of the pot The pot will not exceed the setting of the CROS pot calibration setting Another way of describing this is When the pot is full clockwise 10 10 It is equal to the setting of CROS pot If a maximum speed below the maximum permissible armature voltage is required Adjust the pot to required speed Note If a speed above base speed above the maximum armature voltage is required Motor s with tach g
17. the regulator card for constant field See section 3 3 Motor Feedback Check the tach s mounting coupling and wiring Check for noise pick up on the tach s wiring Check for instability of power supply input voltage If present correct the problem See sections 5 14 5 14 and 5 14B Field weakening applications The field should not go below 1 3 to 1 6 of normal full field Example Full field is 300Vpc Field weakening to 100V pc or less will cause unstable motor speed A special regulator card PN 1059A 11 is required The drive is repeatedly reaching current limit bouncing against current limit A thyristor has failed and must be replaced Page 29 ERC Statohm Manual Section 6 Trouble Shooting Section 6 6 Problem Motor will not go to full speed Check the following Recommendations e Insufficient voltage Readjust the pot Do not exceed motor s rating e Insufficient current Refer to section 3 1 Armature Current Do not exceed motor s rating Measure voltage of test point 4 Normal is about 8 volts Measure 3 phase input voltage Should be within 10 e Improper calibration of speed Check the speed with another calibrated meter for meter comparison e Excessive field current Check with calibrated ammeter and compare with motor s ratings Load is greater than motor s rating Section 6 7 Problem Excessive overshoot and undershoot
18. 148 0000 AWG 250 125 325 2 350 600 125 185 300 300 150 504 2 500 800 150 218 2 000 AWG 400 150 Voc Field 200 295 2 250 MCM 600 Wire Size for 40 ft Length 250 408 2 350 MCM 600 5 75 H P 14 AWG 300 Voc Field 100 200 H P 12 AWG Wire Size for 40 ft Length 5 75 H P 14 AWG 100 200 H P 14 AWG Elementary Power Connection Diagram Page 6 DC Motor A DC Drive A FIELD 3A L1 2 9 ES 12 21 115 L1 L2 L3 L1C and L2C are alternately marked 115V ERC Statohm IV Manual Section 4 Power amp Control Circuit Wiring Section 4 Power amp Control Circuit Wiring Introduction The ERC Statohm IV is only one part of an entire drive system The drive system engineer should supply a wire diagram and or wire connection net list i e net list for the drive system s control panel switch panel DC motor and other auxiliary equipment For easier installation we recommend the power circuit should be installed first and the control circuitry second WARNING Separate over current protection is required by the national electric code The user is responsible for conforming with the national electric codes and all applicable local codes which govern such practices such as wiring pr
19. 2 Regulator Card Block Diagram 9042 3 Regulator Card Control Block Diagram 9044 Regulator Card Physical Diagram Regulator Card Tables for Pots Jumpers Signal Lights and Test Points Reverse Current Limit Adjustment Reversing 12 SCR Elementary Diagram Reversing Mechanical for 6 SCR drives RL Potentiometer S Model Physical Diagram S1 and S2 motor leads 51 54 Jumpers Series Field and Armature Motors see field disable SF Jumper SG Potentiometer Signal Light Table Signal lights R and PC ZD flash and relays buzz Slave Master Operation Speed Meter Wiring and Calibration Speed Overshoot Adjustment i e Speed Response Speed Overshoot and Stability Adjustment Overview Speed Reference amp Reverse Speed Stability Adjustment i e Speed Gain SR Potentiometer Page 53 Pg 41 Pg 41 Pg 12 Section 4 13 Pg 25 and Pg 49 Pg 25 and Pg 49 Pg 25 and Pg 49 Pg 19 Section 5 12C Pg 16 Section 5 5 Pg 3 Section 2 1 Pg 15 Section 5 Pg 40 Pg 30 Section 6 8 Pg 30 Section 6 7 Pg 20 and Pg 30 Pg 26 Section 6 1A Pg 9 Section 4 6 Pg 8 Section 4 5A Pg 18 Section 5 11C Pg 25 Pg 33 Pg 33A and Pg 49 Pg 33A Section 6 16 Pg 25 Section 6 1 Pg 7 Section 4 3 Pg 21 Section 5 15 Pg 21 Section 5 16 Pg 21 Section 5 15 Pg 49 Pg 7 Section4 Pg 15 Section 5 2 Pg 49 Potentiometer Table Pg 3 Section Pg 54 Pg 43 Pg 44 Pg 45 Pg 42 Pg 48 Pg 49 Pg 19 Section 5 12B Pg 54 Pg
20. 2 5 75 125A 150A 250A DM Al 2 Off 3 3 Motor Feedback 3 5 Field Regulation Feedback Jumper Settings Field Operation Jumper Settings VF TG On Constant Field J8 On Armature SF TL Off default J7 Off DC Tachometer Generator Field Weakening J7 J8 On VE Off Tach Feedback Only Enable Off default Field Econom Sabie 3 4 DC Tach Generator Voltage Disable FE On Example DC tach is 50Vpc 1000 rpm and DC motor s maximum FL On speed is 2150 rpm 2 15 x 50 107 5 Volts select voltage range Disabling Field Don t connect 88v 127V jumpers S2 1 S3 4 Off power to F and F Standard Setting Special Setting R2 amp RS are R2 amp R5 are zero Jumper Settings 220 resistors ohm jumpers 3 6 Acceleration amp Deceleration Time Range 41V 60V 27V 2720 Time Range Jumper Setting S1 On T1 On 60V 88V 41V 60V S2 S3 S4 Off 0 7 6 Sec T2 T3 T4 Off S2 On T2 On 88V 127V 60V 88V S1 S3 S4 Off 3 20 Sec default T1 T3 T4 Off S3 On T3 On 127V 172V 88V 127V S1 S2 S4 Off 7 60 Sec T1 T2 T4 Off S4 On T3 T4 On 172V 250V 127V 172V S1 S2 S3 Off 14 120 Sec T1 T2 Off Page 5 Wire Size Tables 230 Vac 3 Phase 60 Hz Input 460 Vac 3 Phase 60 Hz Input
21. 33B Section 6 17 Pg 19 Section 5 12A Pg 34 Pg 41 Pg 5 Sec 3 4 and Pg 10 Sec 4 11 Pg 18 Section 5 11C Pg 5 Sec 3 3 and Pg 17 Sec 5 10 Pg 20 Section 5 14A Pg 49 Pg 31 Section 6 10 Pg 22 Section 5 17 Pg 12 Section 4 13 Pg 20 Section 5 14A Pg 20 Section 5 14 Pg 9 Section 4 7 Pg 20 Section 5 14B Pg 20 Section 5 14A Alphabetical Index Continued Stabilizing field winding Start amp Stop i e Run amp Stop Synchronization Card 1058C T1 T4 Jumpers Tach Feedback Jumper Settings Terminal Table for Regulator Card Test Point Table Test Run TG Jumper TG light i e TGL TG Voltage Jumpers The ES OH VL signal lights are on and can not be reset TL Jumper Troubleshooting Undershoot and Overshoot Unstable Speed VF Jumper Wire Size Tables Wiring ZD Zero motor rotation Detection relay and signal light Adjustment ZERO Potentiometer Zero Speed Hysteresis Adjustment 12 SCR Regenerative Drives Only Zero Speed Adjust 12 SCR Regenerative Drives Only Page 54 Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg 4 Section 3 4 Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg 17 Section 5 8 Pg 32 Section 6 12B and Pg 41 10 Section 4 9 39 5 Sec 3 6 and Pg 10 Sec 4 11 5 Section 3 3 47 49 15 Section 5 3 5 Section 3 3 25 and Pg 49 31 Section 6 9 5 Sec 3 3 and Pg 18 Sec 5 11C 25 Section 6 30 Section 6 7 29 Section 6 5 5 Section 3 3 6 7 Section 4 16 Section 5 6 16 Se
22. 5 7 Section 4 2 3 Section 1 1 17 Section 5 8 19 Section 5 12C 18 Sec 5 11A and Pg 14 Sec 4 15 Jumper Table 21 Section 5 16 19 Sections 5 12 5 12A 5 12B 3 Section2 19 Section 5 12D 10 Section 4 8 15 Section 5 4 15 Section 5 4 5 Section3 5 and Pg 49 37 37A 3 Section2 25 and Pg 49 35 36 22 Section 5 17 18 Sec 5 11A and Pg 17 Sec 5 9 17 Section 5 9 17 Section 10 33B Section 6 17 11 Section 4 12 3 Section 1 1 Section 6 3 Section 6 6 Alphabetical Index Continued Motor information Motor connections NA Potentiometer OC light OH light OL light One Minute Timed Overload Shut off Adjustment OP Potentiometer Operating Environment Operation and Adjustment Oscilloscope Overload OL signal light Overshoot and Undershoot Overshoot and Undershoot P1 P6 Potentiometer PC Pre Operational Conditions 1 e Enable Drive Permanent Magnet Field Permanent Magnet Field see field disable PH light Phase loss or phase sequence error PH light disable Phase Load Balancing Phase Sequence Test PI Potentiometer PID Current Regulation i e Current Gain Loop Adjustment PID Speed Regulation See ASR Feedback Loop Adjustment Potentiometer Table Power and Control Circuit Wiring Introduction Pre Operation Voltage Checks R Potentiometer Receiving amp Storage Regenerative 12 SCR Elementary Diagram Regulator Card Block Diagram 9042 1 Regulator Card Block Diagram 9042
23. 5 amps 25096 of FL setting of 6 amps 5 12C One Minute Amperage Overload Shut Off Adjustment The overload current can be set up to of current limit for a fixed period of one minute e When the power is on and the motor is not running Adjust IA according to table below Potentiometer 150 1 Minute 200 1 Minute IA 7 10 scale 9 10 scale 5 12D Instantaneous Current Overload Shut Off When the motor exceeds 250 of it s rated current calibrated with the IMX pot The regulator will instantaneously shut off the motor This circuit is not adjustable and cannot be overridden 5 12E Armature Ammeter Wiring and Calibration See section 4 14 Page 19 ERC Statohm Section 5 Operation amp Adjustment 5 13 Acceleration amp Deceleration Time Adjustment The jumper settings for accelerate and decelerate time ranges were covered in section 3 6 Adjust ACC and DEC pots full clockwise slowest Start the motor and set the master speed control to desired speed Adjust the ACC pot slowly counter clockwise until desired acceleration is achieved After the motor has reached full desired speed set the master speed control to zero speed Adjust the DEC pot slowly counter clockwise until desired deceleration is achieved 5 14 Speed Overshoot and Stability Adjustment Overshoot and stability are adjusted at the factory but operating conditions at the site may require additional adjustment 5 14A Speed Over
24. 74 Jumpers P F1 4 3 7 1 66 50 each gach 12 128 J2R ON F2 21 43 42NS1 2 Ux 237 47 5 14 21 Watt J3T 138 J3R OFF 42RS1 2 4 Watt Watt F4 07 14 tol 2 eee 148 JAR OFF 05 17 B No Jumper 0 3 0 6 42NS2 2 FI 6 10 1 E 3 6 A2NS3 2 47 50 cach sarti JOT 128 J2R ON 2 3 42NS4 2 237 47 5kQ B V Watt J3T 138 J3R OFF 42RS2 2 tol 2 14 Watt V2 Watt 148 J4R OFF F5 0 8 1 0 470 42RS3 2 tol 1 tol 5 TUE NM 42RS4 2 280 sach cach 12 128 J2R ON E EO 42NM2 2 237 47 5 F3 3 3 5 V Watt J3T 138 J3R OFF 42RM2 2 gt 14 V Watt F4 17 33 tol 2 oU UE Mp 148 JAR OFF oa 2 No Jumper 0 8 1 3 Input Voltage 440V 480V 3 Armature 500V M 1 Resistors Resistors Transformers ode R1 R2 R3 R50 R51 TRI TR2 Field Amps Number R5 R6 R7 R8 R73 R74 Jumpers P F1 4 3 7 1 66 50 PH 12 125 J2R OFF 2 21 43 42NS1 4 475 95 BI 335 14 21 42RS1 4 P 4 Watt Watt F4 07 14 tol 1 tol 7 5 ES 06217 5 No Jumper 0 3 0 6 42NS2 4 Fl 6 10 _ 2 3 6 AZNS3 4 47 50 gach each JOT 128 J2R OFF 2 3 42NS4 4 475 95 F4 1 2 Watt 13 J3S J3R OFF 42RS2 4 4 Watt Ys Watt FS 08 10 42RS3 4 tol 1 tol 5 JAT AION A2RS4 4 No Jumper 0 5 0 8 1 10 17 280 cachi sach 12 J2S J2R OFF F2 5 10 42NM2 4 475 95
25. Down surface Transformer Neutral can not be used to power the oscilloscope Don t Ground Oscilloscope e L3 10X Probe L DC Drive Armature Viewing the field voltage with an oscilloscope also requires the same special care plus additional precautions Before starting the motor first view the field voltage to ensure the oscilloscope is set up correctly Take extra precautions so that the field can not be accidentally grounded while the motor is running If the field were accidentally grounded while the motor is running will result in catastrophic damage to the motor and the drive that would requiring replacement of the drive and rewinding the motor Page 40 Supplemental Field Information Field Power The field power is vital to DC motors Never disconnect the field power when the motor is running Also if the field does not have power don t apply power to the armature Why is the field vital The field induces resistance in the armature without the field the armature has virtually no resistance Example A 100 HP DC motor is running at full load the armature is 500 volts 150 amps The armature has an effective resistance of 3 333 ohms If the field power is disconnected the armature resistance will drop to about 0 08 ohms virtually zero and the armature current will immediately go up to 6 250 amps Within mille seconds both the motor and dr
26. ERC Statohm Introduction amp Table of Contents INTRODUCTION Before installation and operation of the ERC Statohm IV DC drive read this instruction manual carefully Installation should only be done by a fully qualified licensed electrician The ERC Statohm IV DC drive is only a portion of a complete drive system Refer to the instruction manuals of the other components in the drive system for details about auxiliary equipment and the DC motor This user s manual does not purport to cover all details or variations of DC drive installation operation or maintenance CAUTION Before MEGGER or DIELECTRIC testing the DC motor Disconnect the DC motor from the Statohm IV control Megger or dielectric testing will damage the semiconductors in the control Table of Contents Pg 3 Section 1 Receiving amp Storage Pg 3 Section 1 1 Model Number Scheme Pg 3 Section 2 Installation Location Pg 3 Section 2 1 Operating Environment Pg 5 Section 3 Jumper Settings Pg 4 Jumper Setting Diagram Pg 5 Section 3 1 Field Current Jumpers Pg 5 Section 3 2 Armature Current Jumpers Pg 5 Section 3 3 Motor Feedback Jumper Pg 5 Section 3 4 DC Tach Voltage Jumpers Pg 5 Section 3 5 Field Regulation Jumpers Pg 5 Section 3 6 Acceleration and Deceleration Time Range Jumpers Pg 7 Section 4 Wiring Pg 6 Wire Size Tables Pg 6 Elementary Power Connection Diagram Pg 7 Section 4 Power and Control Circuit Wiring Introduction
27. Economy When stopped the field is reduced to 50 this feature can be disabled Output Power Only for motors with DC tachometers The field can be reduce down to of full field Field Weakening Crossover voltage can be adjusted down to of full armature voltage Notes Field Weakening is used to extend speed and or adjust torque The crossover voltage is the armature voltage when field weakening begins Armature feedback regulation 2 Ratio 1 100 Speed Regulation DC tachometer feedback regulation 0 5 Ratio 1 100 Motor DC tachometers from 18V 1000RPM up to 100V 1000RPM Regulation Acceleration amp Deceleration 0 7 to 120 seconds each independently adjustable Features Braking 12 SCR drives only Regenerates power to lines Current Limit Adjustable 120 12 SCR drives have independent forward and reverse current limits Vrer 0 to 8V with internal voltage supply 100kQ Speed Reference Vrer 0 to 10V auxiliary voltage supply required 100kQ Vrer 8 and 10V auxiliary voltage supply required Rian 100kQ Reverse Terminal Reverse 12 SCR drives only Speed Reference Polarity 8 and 10V Aux Power Supply Required Jog 0 20 of maximum speed independent acceleration adjustment Control Emergency Stop E Stop Controlled deceleration or coast to stop Input amp Output PC i e Enable Safety feature to detect Pre operation Conditions are met before the Features drive is enabled to start ZD relay has
28. Pg 7 Section 4 1 AC Power Connections Pg 7 Section 4 2 Grounding Pg 7 Section 4 3 Phase Sequence Test Pg 7 Section 4 3A Fuse Replacement Pg 7 Section 4 4 Armature Connections Pg 8 Section 4 5 Field Connections Pg 8 Section 4 5A Field Disable Pg 9 Section 4 6 PC Pre Operational Conditions i e Enable Drive Pg 9 Section 4 7 Speed Reference amp Reverse Pg 10 Section 4 8 Jog Pg 10 Section 4 9 Start amp Stop i e Run amp Stop Pg 10 Section 4 10 Emergency Stop E Stop Pg 10 Section 4 11 DC Tach generator Feedback Pg 11 Section 4 12 Meter Dimensions Pg 12 Section 4 13 Speed Meter Wiring and Calibration Pg 13 Section 4 14 Armature Ammeter Wiring and Calibration Pg 14 Section 4 15 Field Ammeter Wiring and Calibration Page 1 ERC Statohm Table of Contents Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg 15 15 15 15 15 16 16 16 17 17 17 18 18 18 18 18 18 19 19 19 19 19 20 20 20 20 21 21 22 25 25 27 27 28 29 30 30 30 31 31 31 32 32 33 33 Pg 33A Pg 33A Section 5 Section 5 1 Section 5 2 Section 5 3 Section 5 4 Section 5 5 Section 5 6 Section 5 7 Section 5 8 Section 5 9 Section 10 Section 5 11 Section 5 11A Section 5 11B Section 5 11C Section 5 11E Se
29. S2 42NS3 42RS3 42NS4 42RS4 42NM2 42RM2 42NM3 42RM3 42NL1 42RL1 42NL2 42RL2 42NL4 42NL5 42NL7 Max Current 37A 70 110 180 400 550 720 910 1100 1400 1800 Input 208 240V Arm 240 7 15 25 45 100 HP 125 HP 200 250 HP 300 HP Input 440 480V Arm 500V 14 30HP 50 90HP 200HP 250 HP 400 HP 500 HP 600 HP 750 HP 11 000 HP Input 575 600V Arm 600 36 HP 60 HP 108 HP 240 HP 300 HP 480 HP 600 HP 720 HP 900 HP 1 200 Section 2 Installation Location Section 2 1 Operating Environment The ERC Statohm IV control should be located in a operating environment that meets the following conditions Ambient Temperature between 14 to 104 Fahrenheit 10 to 40 Celsius Relative Humidity Avoid locations exceeding RH 90 Condensation Do not locate the unit where condensation occurs Corrosion Avoid locations with corrosive gases or liquids example ocean air Contamination Avoid locations subject to dust or iron particles Hazardous Gases amp Liquids Do not locate the unit were it is subject to combustible or flammable gases or liquids Ventilation Mount the unit in a lengthwise vertical position to ensure proper cooling ventilation Provide not less than 5 inches 125 mm of clear space on all sides of the unit If the unit is in a s
30. YNC card and test again Additional phase sequence tests are covered in section 6 13 Problem PH Light is on 4 3A Fuse Replacement When replacing fuses on the M3 and L model drives keep the fuse relay G310000 MS3V 2 5 attached to the side of the fuse The replacement fuse doesn t include the fuse relay The fuse relay can be used again Note 5 models and the 2 model don t have fuse relays If you can not get replacement fuses from your local electrical supply Replacement fuses are available from Electric Regulator Page 7 ERC Statohm IV Manual Section 4 Power amp Control Circuit Wiring 4 4 Armature Connections See the motor data plate for the armature s amp rating Then select the wire size from the Wire Size Table at the beginning of section 4 Connect the motor s armature to the power busses marked A and A Current Range is selected from jumper the table below For instructions bout adjusting the Current Limit see section 5 12 S1 Model S2 Model 93 amp S4 Model M2 amp M3 Model L1 amp L2 Model Jumper Settings Current Range Current Range Current Range Current Range Current Range 14 23 48A 81A 183A 300A 366A 600A 730A 1 200A Al A2 A3 A4 On 12 20 35A 58A 161A 269A 322A 538A 640A 1 100 8 6 14 25 42 115 192 230A 384A 460A 770A 2 4 Off 6 10 18A 30 8
31. conomy enabled or disabled S1 Model S2 S3 amp 54 2 amp M3 Models M4 Model 11 amp L2 Models Current Range Models Current Current Range Current Range Jumper Settings Range Current Range F1 On 4 3 7 1 6A 10 10 17 15 25 F2 F3 F4 F5 Off F2 On 21 43 6 5 10 7 5 15 F1 F4 F5 Off F3 On 14 24 5 SA 7 5 F1 F2 F4 F5 Off F4 On 0 7 1 4 1 2 1 7 2 2 5 F1 F2 F3 F5 Off F5 On 0 6 1 2 0 8A 1A 13 1 1 3 2A F1 F2 F3 F4 Off 3 2 Armature Current see section 5 12 for Armature Current Calibration S1 Model S2 Model 53 amp S4 Model M2 amp M3 Model L1 amp L2 Model 1 Current Range Current Range Current Range Current Range 14 23 48A 81A 183A 300A 366A 600A 730A 1 200 Al es 12 20 35A 58A 161A 269A 322A 538A 640A 1 100A AE 9n A1 A3 On 8 6 14 25 42 115 192 230 384 460 770 A2 A4 Off 6 10 18A 30 83A 139A 166A 277A 330A 560A ATON A2 A3 A4 Off 4 5 7 5 14 23 60 100 120 200 240 400 Al A4 Off 3 5 5 9 19 46 78 93A 150A 190A 300A Doe Al A2 A4 Off 2 8 47 12 38 6
32. controlled E Stop set the EF jumper ON and make jumper connections from terminals 21 to 35 and 23 to 36 The E Stop deceleration time can be set to equal to or less than the DEC pot setting The FT pot adjusts the E Stop deceleration time Note FT also equally adjusts Jog s acceleration time See section 4 8 Proper adjustment of the OP pot is required for a complete stop see section 5 5A The OP pot sets the point when the regulator card power is switched off Setting the OP pot too low will cause the ZD relay to buzz REGULATOR CARD Emergency Stop mode Jumper Setting Power Off Uncontrolled Coast to Stop Jumper EF EF Jumper and OP Pot Controlled ZD relay terminals Deceleration Stop are connected FT Pot 21 to 35 and 23 to 36 FT Relay See diagram to the right 3 1239 4 21 22 23 35 36 40 4 11 DC Tach generator Feedback The factory default setting is armature feedback 1 Voltage Feedback VF If tach feedback 1 Speed Feedback SF is used Move the jumper on VF to SF Next calculate the maximum tach voltage Example the tach is 50V per 1000 rpm and the base speed of the motor is 1750 rpm The maximum voltage will be 87 5V 1 75 x 50 The table shows jumper S1 60 88V would be appropriate The speed will not to exceed 88 volts or 1760 RPM If field weakening is used and 2200 rpm is required Then cal
33. ction 5 11F Section 5 12 Section 5 12A Section 5 12B Section 5 12C Section 5 12D Section 5 13 Section 5 14 Section 5 14A Section 5 14B Section 5 15 Section 5 16 Section 5 17 Section 6 Section 6 1 Section 6 2 Section 6 3 Section 6 4 Section 6 5 Section 6 6 Section 6 7 Section 6 8 Section 6 9 Section 6 10 Section 6 11 Section 6 12A Section 6 12B Section 6 13 Section 6 14 Section 6 15 Section 6 16 Pg 34 Pg 35 Pg 36 Operation and Adjustment Check prior to operation Pre Operation Voltage Checks Test Run Jog Speed amp Ramp Adjustment Emergency Stop E Stop ZD Zero motor rotation Detection relay and signal light adjustment Zero Speed Adjust 12 SCR Regenerative Drives Only Zero Speed Hysteresis Adjustment 12 SCR Regenerative Drives Only Maximum Speed Adjustment for Armature Feedback Maximum Speed Adjustment for DC Tach Feedback Field Amperage Adjustment Field Weakening Adjustment Tach Feedback Only Field Economy Field Disable Field Loss Field Voltage Regulation Armature Current Calibration Current Limit Adjustment Forward and Reverse Current Limit Adjustment One Minute Timed Overload Shut off Adjustment Instantaneous Overload Current Shut off Adjustment Acceleration amp Declaration Time Adjustment Speed Overshoot and Stability Adjustment Overview Speed Overshoot Adjustment i e Speed Response Speed Stability Adjustment i e Speed Gain ASR Feedback Lo
34. ction 5 7 16 Section 5 7
35. culate 2 2 x 50 110 jumper S2 88 127V is in this range This range will permit the speed to go up to but not exceed 2540 RPM 127 50 1000 2540 00000 Tach Generator ___ ___ Jumper R2 and 5 are 220k ohms standard setting R2 and R5 are zero ohm jumpers special setting Settings AIV 60V 27 S1 S2 3 4 Off 1 On 60V 88V 41V 60V S2 S3 S4 Off S2 On 88V 127V 60V 88V S1 S3 S4 Off 3 127V 172V 88V 127V S1 S2 S4 Off S4 172V 250V 127V 172V S1 S2 S3 Off Page 10 ERC Statohm Manual Section 4 Power amp Control Circuit Wiring Section 4 12 Meter Dimensions 4 33 110 4 3 55 0 79 20mm 0 218 0 63 16 3 15 90mm 5 5mm 80mm 3 86 98mm 0 60 15mm gt X M5x 0 8 Meter Dimentions Meters are an optional accessories available from Electric Regulator Meters are stocked in the following scales Scale of face plate 0 to 50 Amps 0 to 100 Amps 0 to 200 Amps 0 to 400 Amps 100 0 100 Amps Center Zero 200 0 200 Amps Center Zero to 100 0 to 150 150 0 150 Center Zero 0 to 2000 RPM 0 to 100 100 0 100 Center Zero 0 to 600 Volts 0 to 300 Volts Input 0 to 2 volts 0 to 2 volts 0 to 2 volts 0 to 2 volts 0 to 2 volts 0 to 2 volts 0 to 2 volts 0 to 2 volts 0 to 2 volts Oto
36. e Ramp 8 Voc Max OC Instantaneous Over Current Shut Off see IA pot TP 5 ASR Voltage 4 Voc Rated Current OL 60 Sec Current Overload TP 6 ACR Voltage 8 Voc Max PH Phase Loss amp Phase Sequence Error TP 7 Field Current Reference Voltage 2 IF TGL Tach Generator Signal Loss TP 8 Field Current Reference 7 9 1 3Vpc TP 9 Reference Input for Fire Block Test factory use only 10 Armature Current Oscilloscope Connection Point YELLOW SIGNAL LIGHT TABLE 15 15 Volt Power Supply 0 5 V Light Description 15 15 Volt Power Supply 40 5 V AP Auto Precondition Internal Relay Power 19 5 1V F Forward B External Relay Signal Voltage 20 Voc 1V JOG Jog in Operation P PI Gain for special applications only PC Pre Condition i e Enable System before start R Reverse 12 SCR Regenerative Only RUN Run i e Start ZD Zero Detect Detects Motor Rotation Statohm DC Drive Common Specifications Input Power 3 Phase Input Voltage 230V 380Vac 460 600Vac Nominal range 10 1 Phase Input Voltage 115Vac or 230Vac Input Frequency 50 Hz and 60 Hz Armature Starting amp Starting Regenerating Current Adjustable up to 200 for up to one minute Field 1 phase SCR phase control Current Regulation Circuit 0 8A 30A Fault Diagnosis and Protection Zero speed Detect relay Field
37. ealed enclosure provide adequate ventilation for air flow from top to bottom Shock amp Vibration Avoid mounting the unit in a location subject to shock or vibration Page 3 REGULATOR CARD 10590 and earlier depicted REGULATOR CARD 1059F eliminated jumpers 2 3 6 FV Fl and added jumpers 11 and 12 _ UU CO io v d VU v B S jo IMX 10 Ole 9 USER SELECT S ARMATURE CURRENT EXTRA JUMPERS USER SELECT S FIELD CURRENT O TERMINALS 1 TO 40 eae one Armature Feedback Jumper Settings User Selects JUMPERS ON CA FE FI IFR TG VF 1 2 4 6 8 Regulator card 1059F does not require jumpers 2 and 6 for armature feedback Page 4 Section 3 Jumper Setting Tables The jumper settings must be made prior to applying power Complete the blanks below to determine the jumper settings for your application Consult the jumper tables below or Master Jumper Table to the left Armature Voltage Field Current 9 Feedback Vpc Field Regulation Jumper Tables 3 1 Field Current Arm or Tach Armature Current Limit Acceleration Time Deceleration Time A Sec Sec constant current field weakening permanent magnet Field E
38. enerator Feedback 3 Master Speed Reference output 8 Volts 100 N 4 Auxiliary Speed Feedback input 8 Volts 100 N 5 Common for 4 6 Slave Speed Gain input 4V 100 IA 7 8V Speed Reference Power Supply 8 Speed Reference Input 9 Common for Speed Reference Power Supply 10 Master Speed Gain Output 4 100 IA 11 Auxiliary Reverse Current Limit Reference Input 4V 100 IA 12 SCR Only 12 Auxiliary Forward Current Limit Reference Input 44V 100 IA 13 Master Slave and Auxiliary Common for Terminals 3 6 11 12 14 and 15 14 Slave Speed Reference Input 8 Volts 100 15 Auxiliary Field Current Reference Input 8 Volts 100 N 16 Not Used 17 Armature Ammeter Output 0 2 100 IA 18 Common for Terminals 17 19 and 20 19 Speed Meter Output 0 1 100 N 20 Field Ammeter Output 0 2 100 21 ZD SPDT Relay Tc Center Pole Rating 250Vac 0 5 A 22 ZD SPDT Relay Tb Normally Closed Motor Rotation opens it 23 ZD SPDT Relay Normally Open Motor Rotation closes it 24 FT SPDT Relay Tc Center Pole Rating 250Vac 0 5 A 25 SPDT Relay Normally Open when 115 power is 26 SPDT Relay Normally Closed when 115V power is on 27 FL SPDT Relay Tc Center Pole Rating 250V 0 5 A 28 FL SPDT Relay Tb Normally Closed when 115V power is on 29 FL SPDT Relay Normally Open when 115V power is 30 ST SPST Relay Nor mally Ope
39. enerator feedback have the option of field weakening See Sections 3 5 Field Regulation and 5 11A Field Weakening Adjustment 5 9A Armature Ammeter Wiring and Calibration See section 4 14 5 10 Maximum Speed Adjustment for DC Tach Generator Feedback See the motor s data plate to confirm the maximum armature voltage base speed and maximum mechanical speed See the DC tach generator s data plate to confirm the volts per 1000 RPM Check the tables below to confirm jumpers are set for DC tach feedback and the correct voltage range for the maximum tach generator voltage Example If you have 50 1000 RPM Tach and your application requires 2 250 RPM Multiply 2 25 X 50 112 5 Select the voltage range of 88V 127V Motor Feedback Jumper Settings DC Tach Generator Voltage Jumper VE R2 and R5 220k ohms R2 and R5 are zero ohm S tti Armature Standard Set Up jumper Special Set Up ings SF TL Off 41V 60 27V 41 51 52 3 S4 Off SF TL On S1 On DC Tach Generator VF Off 60V 88V 41V 60V 52 3 S4 Off 52 On 88V 127V 60V 88V S1 S3 S4 Off S3 On 127V 172V 88V 127V S1 S2 S4 Off S4 On 172V 250V 127V 172V S1 S2 S3 Off 5 10 Speed Meter Wiring amp Calibration See section 4 13 Page 17 ERC Statohm IV Section 5 Operation amp Adjustment 5 11 Field Amperage Adjustment Warning never disconnect the field power whi
40. er Connections ACC Potentiometer Acceleration and Deceleration Time Range Jumpers AM Potentiometer AP Jumper Armature Ammeter Wiring and Calibration Armature and Field in series see field disable Armature Connections Armature Current Calibration Armature Current is too high at low speed and normal load Armature Current Jumpers Armature Current Limit Adjustment Armature Feedback Jumper Settings Armature Feedback Jumper Settings Armature Voltage Adjustment ASR Feedback Loop Adjustment i e Speed PID Balancing Phase Load CA Jumper Check prior to operation CROS Potentiometer Current Gain Loop Adjustment i e Current PID Current Limit Adjustment DC Contactor DC Tach Generator Feedback DC Tach Voltage Jumpers DEC Potentiometer Deceleration and Acceleration Time Range Jumpers DG Potentiometer Dynamic Braking EF Jumper Elementary Circuit Diagrams Elementary Diagram of DC Drive Power Connections Emergency Stop E Stop Emergency Stop E Stop Environment Operation ES light Emergency Stop Page 51 Pg 9 Section 4 7 Pg 49 Jumper Table Pg 39 Pg 48 Pg 13 Sec 4 14 and Pg 49 Pg 54 Pg 13 Sec 4 14 and Pg 49 Pg 49 Jumper Table Pg 54 Pg 49 Jumper Table Pg 49 Jumper Table Pg 49 Jumper Table Pg 5 Sec 3 5 and Pg 18 Sec 5 11A Pg 5 Sec 3 5 and Pg 18 Sec 5 11A Pg 49 Jumper Table Pg 43 Pg 44 Pg 45 Pg 42 Pg 5 Sec 3 2 and Pg 8 Sec 4 4 Pg 23 Section 5 18 Pg 7 Sectio
41. etween them should be about 100kQ If the resistance is low the SCR modules may need to be replaced Contact the factory for assistance Check if jumpers 1 4 are set right and the continuity is good See sections 3 2 Armature Current and 5 12 Armature Current Calibration If voltage is present when the motor is stopped the regulator card may need to be replaced The normal resistance is only a few ohms or less Check the machine load and motor commutator If a surge is present Connect a noise suppresser to the external contactor and relays contactor or relays Page 28 ERC Statohm Manual Section 6 Trouble Shooting Section 6 5 Problem Unstable Speed Check the following Measure the regulator card test points and to com Measure the voltage of regulator card test point 4 Unstable field voltage Improper installation of the tach generator Armature feedback only Improper adjustment of SR or SG Excessive field weakening Current Limit Thyristor SCR has failed Recommendations The normal voltages are 15 Vpc and 15Vpc respectively If they are not nominal the SYNC card may need to be replaced Test point 4 is the speed reference voltage if the voltage does not match the voltage measured at the speed pot check the speed pot wiring If the regulator is set for field weakening with armature feedback the speed will be unstable Set
42. g Section 6 Trouble Shooting Trouble shooting may require the following test equipment Digital Multimeter e DC Ammeter e Oscilloscope with a isolation transformer and 10X probe or higher When a problem occurs Write detailed notes of the operating conditions when the problem occurred Check the Regulator card if any of the red signal lights are on Refer to the list below and correct the problem After the problem has been corrected it may be necessary to press the reset button before operation Tach Generator Loss Light s when the regulator card is not receiving a signal voltage from the DC tach generator Instantaneous Over Current When 250 of the motor s rated current is exceeded The instantaneous over current circuit will shut off the motor OL One Minute Delay Over Current Shut Off When 150 of the motor s rated current is exceeded for more than one minute The time delay over current circuit will shut off the motor FU Fuse Blown One or both of the AC input fuses have blown LV Low input Voltage The AC input voltage is more than 10 below normal Phase Loss Phase Sequence Error Indicates the loss or low voltage of one of the three phases Also indicates if L1 L2 and L3 are not in correct sequence See section 4 Wiring FL Field Loss The field input current is below 13 of normal SCR Over Heat A thermostat on the SCR
43. g the field ammeter recalibration of the field ammeter is required How to calibrate the ammeter Anindependent ammeter is required as a reference to calibrate the field ammeter The FM pot calibrates the ammeter Energize the field and adjust the FM pot until the ammeter equals the reference ammeter The IF pot sets the field regulation circuits internal reference point The FM pot sets the scale of the field ammeter circuits output voltage scale For example If the motor s field is 6 amps and the meter has a 0 to 2 volt input with a face plate scale of 0 to 10 amps With the field energized the FM pot is adjusted until the field ammeter equals the reference ammeter 6 amps This sets the output voltage to 1 2 volts at 6 amps After the field ammeter is calibrated if the IF pot or F jumpers are changed so that the field is 4 amps This changes the scale to 4 amps equals 1 2 volts If the field ammeter is not recalibrated the ammeter will read 6 amps when the field current is actually 4 amps The field ammeter always must be recalibrated after the IF pot is adjusted REGULATOR CARD Note Regulator Cards 1059F and later jumpers FI and FV were eliminated F1 F5 Co FV IF Pot T 1 5 14 ERC Statohm IV Section 5 Operation amp Adjustment Section 5 Operation and Adjustment 5 1 Check prior
44. habetical Index Page 2 ERC Statohm Manual Section 1 amp 2 Receiving amp Storage and Installation Location Section 1 Receiving amp Storage When you receive the ERC Statohm IV DC drive avoid shock or vibration when unloading and transporting the unit This can damage the semiconductors or other components Immediately upon receipt inspect the unit for the following Check to be certain the unit is clean of packing materials Check for damage incurred during shipment dents scratches ect Inspect mechanical the parts loose screws terminals hinges ect Inspect the circuit cards damaged loose or shorted electronic components or connections If you find damage do not connect power to it The unit must be replaced or repaired Connecting power could result in fire or further damage and void the warranty Promptly report damage or problems you found during inspection to Electric Regulator Corp Telephone 760 438 7873 Fax 760 438 0437 Store the ERC Statohm IV control in a clean dry place in the package it was shipped Avoid storing the unit in a location with high temperatures humidity dust or corrosive gases Outdoor storage is not recommended Section 1 1 Model Number Scheme DC42NS3 4 Input Voltage 2 208 240V 4 440 480V 5 575 600V Power Rating Number Chassi Size N 6SCR R 12SCR Model Number Model Ampere and Horsepower Ratings Model Number 42NSI 42RS1 42NS2 42R
45. he motor s data plate Note the motor speed will not exceed the DC tach jumper setting see page 5 section 3 4 5 11B Field Economy When the motor is not running full field power is not necessary Field economy reduces the field power when the motor is stopped and the PC light has been off approximately six to eight seconds When the motor is started full field power is automatically reapplied If you want to disable field economy put the jumper FE on 5 11C Field Disable The field 15 disabled when the motor has a permanent magnet field or series field and armature To disable the field loss detection circuit put the jumper FL on and don t connect power to L1F and L2F Note The yellow light will remain on when the field is disabled 5 11D Field Ammeter Wiring and Calibration See section 4 15 5 11E Field Loss The 1059A regulator card has field loss protection circuit that shuts off the motor if the field goes below 6 of full field 5 11F Field Voltage Regulation If the application requires field voltage regulation to interface with your equipment The optional IFC 1084 card is available Page 18 ERC Statohm Section 5 Operation amp Adjustment 5 12 Armature Voltage and Amperage Calibration The CROS pot sets the maximum armature voltage When field weakening is used see section 5 11A for more details about the CROS pot When you set the armature amperage jumpers in section 3 2 only the amperage
46. heat sink trips at 185 F 85 C shutting off the motor ES Emergency Stop Signals when the emergency stop system is engaged Page 25 ERC Statohm IV Manual Section 6 Trouble Shooting 6 1 Phase Load Balance Phase load balance settings are made at the factory If a phase load balance problem should occur Check the following two items before adjusting the phase balance Insufficient gain of the ACR amplifier e Improper tach generator coupling 6 1A Observing and Adjusting Phase Load Balance To observe the phase load balance connect an oscilloscope to test points 10 and com Run the motor at a steady speed and observe the wave from Adjust the speed and load until a stable wave form is displayed e If an unbalanced current wave form is displayed Adjust pots PH1 to PH6 in the following sequence PHI PH6 PH2 4 PH3 PH5 Ifimprovement is not sufficient adjust the IG pot slightly counter clockwise and repeat adjusting the PH pots Unbalanced Balanced Page 26 ERC Statohm Manual Section 6 Trouble Shooting Check the following e AC input voltage Control circuit relay sequence e Jumper JP 10 e Measure the ramp reference signal at test point 4 Section 6 2 Problem Motor won t start but none of the red signal lights are on Recommendations Check if the unit is receiving power Check if the other drive system components are working properly
47. inals LIS L2S and L3S Also check the plugs on the synchronization card L1S goes to R4 red wire 1 25 goes to S4 white wire L3S goes to T4 blue wire See diagram to the left 2 Possibly transformer TR1 TR2 or TR3 has failed Disconnect leads to terminals L1S 1 25 and L3S and measure the resistance between these terminals The normal resistance should be 1kQ 10 Also visually inspect the legs on the transformers for breakage 3 When the motor is running if the PH light switches on The phase load may not be balanced The most common reason for this problem is unequal phase voltage This occurs when the voltage of one phase is 25 below the others This problem is often caused by loose power connections 4 When the motor is running if the PH light switches on The SCR thyristors may not be phase correctly See sections 6 1 and 6 1 5 On rare occasions the incoming power is faulty Shut off the power disconnect L1 L2 and L3 from the drive and connect them to a AC motor a 5 HP AC motor should be sufficient Switch on the power if the motor does not run or does not run normally then the incoming power is faulty Lac 7 27 115 1125 135 Lic 2 QFN Section 6 14 The FL light is dimly lite but field loss is not detected Check the following An erro
48. ings are only approximate 5 12C Forward and Reverse Current Limits Reverse 4 Quadrant 12 SCR Regenerative Drives Only Four pots are used in the adjustment of current limit IMX FL RL and IA The pot sets the motor s rated current e The FL pot sets the forward current limit e The RL pot sets the reverse current limit e The JA pot sets the one minute timed current overload shut off Example The motor is rated at 10 amps Typically regenerative drives are set with the forward amperage limit set to the motor s rating of 10 amps The reverse amperage limit is often set higher in this example 13 amps for extra braking power Short time periods of over amperage for regenerative braking should not damage the motor Make sure the FL and RL pots are set at 4 10 scale or 100 see Section 5 9B details Run the motor forward underload and adjust the IMX pot to 10 amps Then run the motor in reverse and adjust the RL pot to 13 amps If for example you want to reduce forward current limit to be 6 amps run the motor forward and adjust the FL pot to 6 amps Now you have a forward current limit of 6 amps and a reverse current limit of 13 amps Setting the IMX pot to 10 amps calibrates the regulator card s over amperage protection circuits If the motor should suddenly exceed 25 amps the instantaneou s shut off circuit will activate based on 250 of motor s rating of 10 amps Not at 32 5 amps 250 of setting of 13 amps and not at 1
49. ive will incurred serious damage that is often irreparable Field Voltage The field is a ampere circuit the field voltage will vary with temperature Example The 3212AT frame 100 HP DC motor field current is specified to be 3 5 amps When the motor is cold 20 C 68 F the field resistance is 66 8 ohms the voltage would be 234 volts When the motor warms up to 40 C 104 F the field resistance will increase to 85 7 ohms and the field voltage would be 300 volts Stabilizing field winding Modern DC motors have the stabilizing field connected internally Older DC motors sometimes have the field stabilizing terminals giving the user a choice Below is a diagram of how to connect the stabilizing field winding Elementary Motor Connection Diagram STABILIZING FIELD 222 many motors don t have leads 51 and 52 A2__si 182 A 5 A1 x T uid tad Fs 300 VOLT FIELD e Ves re Y Y e SF 150 VOLT FIELD 2 e Page 41 M3 gt 22u LINEAR TIME SPEED CURRENT n CONTROL CONTROL THYRISTOR 4 ARMATURE SPEED THYRISTOR REFERANCE DRIVER 8V 100 N DEC CURRENT CURRENT FEEDBACK TRANSFORMER 0 7to6Sec oL T 1 3 to 20 Sec fo_o T 2 7 to 60 Sec fo_o T 3 ARMATURE 1410 120 5 T4 FEEDBACK CIRCUIT
50. l mA Oto I mA 1 mA 1 mA Oto 1 mA The Statohm IV has meter outputs for Armature current Field current and Motor Speed See page 13 17 for instructions 48 See page 12 19 for instructions 18 See page 14 20 for instructions 18 11 ARMATURE AMMETER INPUT 0 TO 2V SPEED METER INPUT 0 TO 1mA FIELD AMMETER INPUT 0 TO 2V ERC Statohm IV Manual Section 4 Power amp Control Circuit Wiring Section 4 13 Speed Meter Wiring and Calibration Selecting a meter The speed meter is an ammeter with a 0 to 1 mA input meters are available from ERC The application determines the units and the scale of the meter s face plate For example units RPM scale 2000 For one direction rotation left is zero and full clockwise is 2000 RPM If you are reversing the motor a meter with a center zero with right and left scales is required Jumper and Potentiometer Settings Before calibrating the ammeter make all final jumper settings and pot adjustments Make final settings to jumpers Al A2 and A4 Set Jumpers SF on VF off and user selects JP 7 Make final adjustments to potentiometers pots MAX and CROS e If any of these settings are changed after calibrating the speed meter recalibration of the speed meter is required How to calibrate the speed meter Anindependent speed measurement for reference is required to calibrate the speed meter You can improvise by using an voltmeter
51. lay to buzz when the motor is stopped 5 7 Zero Speed Adjust 12 SCR Regenerative Drives Only Regenerative drives that start and stop with a small load may require special adjustment to make smooth starts stops and remain stationary when stopped This problem is common with tach feedback systems To obtain best results we recommend using an oscilloscope to view the signal across and Turn the acceleration and deceleration pots full clockwise Set the speed reference to zero volts and engage E Stop and PC If the motor turns adjust the ZERO pot until the motor is at a standstill Regenerative drives with tach feedback sometimes exhibit instability is at low speeds and during start and stop Removing the AP jumper will stabilize the problem by placing a capacitor in parallel with the speed feedback opamp resistor If problems persists see section 5 8 Zero Speed Hysteresis Adjustment Page 16 ERC Statohm IV Section 5 Operation amp Adjustment 5 8 Zero Speed Hysteresis Adjustment 4 Quadrant 12 SCR Regenerative Drives Only The regulator card switches the motor from forward to reverse by changing the polarity of the speed amplifier output The output of the speed amplifier includes ripple form the tach or arm feedback To minimize the effect of ripple from this feedback A Hysteresis circuit adjusts the input sensitivity of the to the reverse switch logic The HS pot is usually set on or about 2 5 10
52. le the motor is running We strongly recommend reading page 41 before continuing Instructions for connecting the field power and jumper settings are on page 8 section 4 5 Temporally disable field economy by putting on jumper FE The IF pot adjusts the field amperage within the jumper settings range We recommend using a ammeter if one is not available then calculate the motor s cold field voltage and quickly adjust the field while the field is cold Important note Note the field voltage will not exceed 71 of the input voltage connected to terminals L1F and L2F 5 11A Field Weakening Adjustment DC Tach Feedback Only Field weakening offers both constant power and extended speed Field weakening is only available for motors with tach generator feedback To enable field weakening jumpers J7 and J8 must be on If the field weakening is below half V2 of full field put jumper CA on The field weakening minimum is of full field The optional 1059A 11 regulator card permits field weakening to about 4 to s of full field e Adjust the ACC and DEC pots full clockwise slow e Adjust the speed reference to maximum speed and observe the armature and tach generator voltages When the armature and tach voltages stabilize at maximum proceed to the next step e Adjust the CROS pot to the desired maximum armature voltage e Adjust the MAX pot to the desired maximum speed Warning do not exceed the motor s maximum speed listed on t
53. n Input Circuit Breaker Shunt Trip 31 ST SPST Relay Normally Open Rating 250Vac 0 5 A 32 Not Used 33 Jog Input 34 Run i e Start Input 35 Common for 33 34 and 37 36 PC Enable Input 37 Reverse Input Regenerative Only 38 Common for 36 39 and 40 39 Auxiliary Reset Input 40 Emergence Stop Input Regulator Card Terminal Table Page 47 REGULATOR CARD 1059D and earlier depicted REGULATOR CARD 1059F eliminated jumpers 2 3 6 FV Fl and added jumpers 11 and 12 V 1 EXTRA JUMPERS CONNECTION TERMINALS 1 40 Regulator Card Physical Diagram Page 48 Note We strongly suggest the user not change the factory setting POTENTIOMETER TABLE JUMPER TABLE POT DESCRIPTION Jumper Function Factory Reserve Do not adjust 50H 50 Hz Power ON 60 Hz Power OFF ACC Acceleration Time Adjustment See Section 3 6 1 4 Armature Current Range Settings See section 3 3 AM Armature Ammeter Calibration See Section 4 14 AP PC Terminal Disable ON Enable OFF CROS Field weakening Crossover Point See Section 5 9 CA Field Weakening Ratio Below 1 2 ON Above OFF DEC Deceleration Time Adjustment See Section 3 6 EF E Stop Controlled Decel Enable ON Disable OFF DG PID Lead Compensation i e ASR Lead Comp FI F5 Field Current Range See section 3 5 FL Forward Cur
54. n 4 1 Pg 20 Section 5 13 Pg 5 Section3 6 Pg 13 Section 4 14 Pg 49 Jumper Table Pg 13 Section 4 14 Pg 18 Section 5 11C Pg 7 Section 4 4 Pg 19 Section 5 12 Pg 32 Section 6 12 Pg 5 Section 3 2 Pg 19 Section 5 12A Pg 5 Pg 4 Pg 19 Section 5 12 Pg 21 Section 5 15 Pg 25 Section 6 1 Pg 18 Sections 5 11A Pg 15 Section 5 1 Pg 18 Sec 5 11A amp Pg 19 Sec 5 12 Pg 21 Section 5 16 Pg 19 Section 5 12A Pg 23 Section 5 19 10 Section 4 11 Pg 5 Section3 4 Pg 20 Section 5 13 Pg 5 Section3 6 Pg 49 Potentiometer Table Pg 33B Section 6 17 Pg 16 Section 5 5 Pg 54 Pg 6 Pg 10 Section 4 10 Pg 16 Section 5 5 Pg 3 Section 2 1 Pg 25 and Pg 49 Section 5 11B Alphabetical Index Continued Field Ammeter Wiring and Calibration Field Amperage Adjustment Field and Armature in Series see field disable Field Connections Field Current Jumpers Field Disable Field Economy Field Loss Field Loss is Detected Field Overview Field Regulation Jumpers Field Weakening Adjustment Tach Feedback Only FL Jumper FL light FL Potentiometer FM Potentiometer Forward and Reverse Current Limit Adjustment FT Potentiometer FU light Fuse Replacement Fuses blow immediately after start and the OC signal lights FV Jumper Grounding Horsepower Rating HS Potentiometer IA Potentiometer IF Potentiometer IFC 1084 card IFR Jumper IG Potentiometer IMX Potentiometer Installation Location Instanta
55. nce power supply is used You have the choice of 8V or 10V by setting jumper JP 1 see the jumper table below Connect the speed reference signal to terminals 8 and 9 The motor is reversed by changing the polarity of the speed reference voltage 0 8 or 8V speed reference voltage Jumper ON default 8V requires external power supply 0 10 or 10V speed reference voltage Jumper OFF External 10 or 10 power supply required Jumper JP 1 Page 9 ERC Statohm IV Manual Section 4 Power amp Control Circuit Wiring 4 8 Jog Jog will run up to 20 of full speed The FT pot adjusts Jog s acceleration time equal to or faster than ACC setting Important note FT also adjusts E Stop s deceleration time See section 4 10 option 2 The user must decided the priority when making this setting The control circuit should be designed so that Jog and Start Run are not on simultaneously They should only be on alternately 4 9 Start Run and Stop To start the drive close terminals 34 Run to 35 Com For normal stop with deceleration time controlled by the Deceleration pot open terminals 34 and 35 Note Don t open PC to stop the motor see section 4 6 4 10 Emergency Stop E Stop Emergency Stop has two options Option 1 Freewheeling stop is the factory default setting The motor is allowed to coast to a stop and the regulator card power is switched off Option 2 Controlled deceleration stop To enable
56. nd 27 50 mm air space on front side in ventilated enclosure Model Ampere and Power Ratings ER ETE S E 51 25 54 5125 80125 5 212 2 21212 2121 212 212 5 5 5 2113 214 SISIS SISINSISISIS SI SIS 55151515 9 9 9 37 70 110 180 400 550 720 910A 1 100 1 400 1 800A 5 Input 208 240 Arm 240 7 15 25 45 100 125 200 250 300 Input 380 410V Arm 440V 3 kW 20 32 58 130 165 kW 233 kW 375 kW 255 2 Input 440 480 Arm 500 14 30 HP 50 90 200 250 400 500 600 750 HP 1 000 HP Input 575 600V Arm 6007 M 36 HP 60 HP 108 HP 240 HP 300 HP 480 HP 600 HP 720 HP 900 HP 1 200 HP Paee 50 Alphabetical Index 1 Jumper JP 1 10 Jumper JP 10 1058C Synchronization Card 1059A Regulator Card Physical Diagram 2 Jumper JP 2 2 Quadrant 6 SCR Elementary Diagram 3 Jumper JP 3 4 Jumper JP 4 4 Quadrant 12 SCR Elementary Diagram 5 Jumper JP 5 50H Jumper 6 Jumper JP 6 7 Jumper JP 7 8 Jumper JP 8 9 Jumper JP 9 9042 1 Regulator Card Block Diagram 9042 2 Regulator Card Block Diagram 9042 3 Regulator Card Block Diagram 9044 Regulator Card Control Block Diagram A1 A4 Jumpers AC contactor AC Pow
57. neous Overload Current Shut off Adjustment Jog JOG Potentiometer Jog Speed amp Acceleration Adjustment Jumper Setting Diagram Jumper Settings Jumper Table 11 Model Physical Diagram L2 Model Physical Diagram Location Installation LV light i e LVL M2 Model Physical Diagram M3 Model Physical Diagram Master Slave Operation MAX Potentiometer Maximum Speed for Armature Feedback Adjustment Maximum Speed for DC Tach Feedback Adjustment Mechanical Reversing Meter Dimensions Model Number Scheme Motor Data and Elementary Motor Connection Diagram Motor Feedback Jumpers Motor Rotation Detection Relay and Signal Light Adjustment i e ZD Motor Speed Runaway Motor will not go to full speed Page 52 Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg 18 Sections 5 11C amp 5 11E Pg 14 Section 4 15 18 Section 5 11 18 Section 5 11C 8 Section 4 5 5 Section 3 1 18 Section 5 11C 18 Section 5 11B 18 Section 5 11E 31 Section 6 11 18 Section 5 11 5 Section 3 5 18 Section 5 11A Pg 25 Pg 33 Section 6 14 and Pg 49 Pg Pg Pg Pg 19 Section 5 12A 14 Section 4 15 19 Section 5 12B 15 Sec 5 4 and Pg 16 Sec 5 5 Pg 25 and Pg 49 Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg 41 5 3 3 16 Section 5 6 221 30 7 Section 4 3A 28 Section 6 4 14 Section 4 1
58. oop Adjustment i e Current PID The regulator card has two control loops The main voltage feedback loop speed feedback loop and a secondary minor current feedback loop The current feedback loop is adjusted by the IG pot i e Current Gain The IG pot is adjusted at the factory but if the current response and stability is poor adjust the IG pot according to the following instructions Connect a jumper to M3 and M4 Remember to remove jumper afterwards e Write down the settings of FL RL DEC ACC and JOG for readjustment after completion of IG adjustment Adjust FL and RL to 3 10 scale adjust DEC and ACC to full counter clockwise and adjust JOG to full clockwise If jog is not available set the master speed control to 2046 of full speed e Remove all the jumpers from T1 T2 T4 this sets acceleration time to 0 6 seconds Observe the wave form of the armature by connecting an oscilloscope to TP10 and COM Compare the wave form to figures a and b Ifthe wave form is unstable make small counter clockwise adjustments to the IG pot Ifthe current response is too slow make small clockwise adjustments to the IG pot Page 21 ERC Statohm Section 5 Operation amp Adjustment Section 5 17 Master Slave Operation The Statohm IV can be configured for Master Slave operation with or without Master speed gain Terminal 3 is the master speed reference output Terminal 14 is the slave speed refe
59. op Adjustment i e Speed PID Current Gain Loop Adjustment i e Current PID Master Slave Operation Troubleshooting Phase Load Balancing Motor won t start but non of the signal lights are on Motor Speed Runaway Fuses blow immediately after start and the OC signal lights Unstable Speed Motor will not go to full speed Excessive overshoot and undershoot Overload fault OL signal light The ES OH VL signal lights are on and can not be reset Signal lights R and PC are on F AP ZD flash and relays buzz Field loss is detected Armature current is too high at low speed and normal load During acceleration or heavy load the field is too low PH Light is on The F light is dimly lite but field loss is not detected Regulator card connections Utilty company transfer switch problems PH light disable ATTACHMENTS 5 Model Physical Diagram M2 Model Physical Diagram M3 Model Physical Diagram L1 Model Physical Diagram 12 Model Physical Diagram IFC 1084 Card 4 FS Auxiliary Field Supply Synchronization Card 1058C Oscilloscopes Regulator Card Control Block Diagram 9044 Regulator Card Block Diagram 9042 1 Regulator Card Block Diagram 9042 2 Regulator Card Block Diagram 9042 3 Elementary Circuit Diagrams Terminal Table for Regulator Card Regulator Card 1059A Physical Diagram Regulator Card Tables for Pots Jumpers Signal Lights and Test Points Common Specifications Alp
60. otection grounding disconnects and other current protection Power Circuit Wiring NOTICE Make all power circuit connections in accordance with the drive system engineer s wire diagram or the elementary wire diagrams provided in this manual The power circuit includes terminals L1 L2 L3 LIF L2F L1S L2S L3S A A F F and 115V 4 1 AC Power Connections e See on the Wire Size Tables on page 6 and Elementary Wiring Diagram below Connect the three phase AC power to the buss terminals marked L1 L2 L3 and to terminals LIS 1 25 L3S that supply the SYNC card and to LIF L2F that supply the field e Connect the single phase 110 120 Vac power to terminal block positions 115V alternately marked L1C and L2C 4 2 Ground in accordance with national and local electrical codes and regulations 4 3 Phase Sequence Test The Statohm IV PH signal light indicates if the phase of L1 L2 and L3 are in the same sequence L1S 1 25 and 1 35 Turn on the AC power if the PH light is off the phase sequence is correct If the PH light is on the phase sequence is wrong To correct the phase sequence Turn off the power Check with an Ohm meter the sequence of L1 L2 and L3 are in the same sequence 1 15 L2S and L3S and power test again If this fails change the sequence of L1 and L2 and test again If this fails check the plugs connections from 1 15 1 25 and 1 35 to the synchronization card 1 6 S
61. pplication determines the scale of the meter s face plate For example a 0 to 2 volt meter with 100 Amp scale face plate For one direction operation left is zero and full clockwise is 100A If you are reversing the motor a center zero with left and right scales is required Jumper and Potentiometer Settings Before calibrating the ammeter make all final jumper settings and pot adjustments Make final setting of jumpers Al A2 and A4 Set JP2 on JP3 off note Regulator Cards 1059F and later jumpers 2 and 3 were eliminated Make final adjustment of potentiometer pot IMX e If any of these settings are changed after calibrating the ammeter recalibration of the ammeter is required How to calibrate the ammeter Anindependent ammeter for reference is required to calibrate the ammeter The AM pot calibrates the ammeter the motor at a level speed and load and adjust the AM pot until the ammeter equals the reference ammeter Note The IMX pot sets the current limit circuit s internal reference point The AM pot sets the output voltage scale For example If a motor s rating is 50 amps the IMX pot calibrates the current limit circuit s internal reference point to 50 amps The meter has 0 to 2 volt input with 100 amp scale face plate Next with the motor running under a 50 amp load and using an external ammeter for reference The AM pot is adjusted until the ammeter reads equal to the reference meter
62. r was made connecting power to the field line 3 L3 is connected to either L1F or L2F The correct connections are shown in the diagram to the right 2 2 125 2 135 2 2 2 2 2 20002 5v Page 33 ERC Statohm Manual Section 6 Trouble Shooting Section 6 15 Regulator Card Connections Warning Diagram Incorrect connections will irreparably damage the regulator card synchronization card and pulse card Carefully refer to the diagram to ensure correct connections REGULATOR CARD 1058 its Ze CN3 CN24 PULSE CARD 1057 SYBCHRONIZATION CARD 1058 1 CN24 CN8 Section 6 16 Utility Company Transfer Switch Problems PH light disable Warning Diagram Disabling the PH light will not resolve incorrect input power connections Disabling the PH light and running the drive with improper phasing will eventually damage the motor and the drive If the drive runs normally for hours or days then suddenly displays PH light fault and resetting clears the PH light Then the drive runs normally until the same time the next day or until the same day and time each week This problem is typically the result of utility companies that have older transfer switch s
63. range was determined Now you must calibrate the regulator card to the motor s rated amperage by adjusting the IMX pot We strongly recommend the use of an ammeter when making these settings Turn the IMAX pot full counter clockwise Set the FL and RL pots to 4 10 scale e Run the motor at full load If running under full load is not possible See estimating adjustment below e When the motor is running with a load adjust the IMX pot to the motor s rated current All the following percentages are based on the calibrated current set by the IMX pot Estimating adjusting IMAX by determining the ratio of the current range Example The 42NS4 4 armature jumper is set 4 the IMX pot will set the current range from a minimum of 38 amps to a maximum of 62 amps If the motor is rated at 50 amps 62 38 24 and 38 12 50 half of 24 set the IMX pot at 5 10 midrange 5 12B Armature Amperage Limit Adjustment The FL Forward Current Limit and RL Reverse Current Limit for 12 SCR Regenerative drives only pots are preset at the factory We recommend leaving these pots set at the factory settings If a amperage limit other than the factory settings are required see the table below The scale on the table below is approximate fine adjustment should be made with an ammeter Potentiometer 100 150 200 FL 4 10 scale 6 10 scale 8 10 scale RL 12 SCR only 4 10 scale 6 10 scale 8 10 scale The above sett
64. rence input Terminal 13 is the commons for both master and slave Master Slave with out Master speed gain MASTER SLAVE DC drive DC drive Master Speed Gain permits the speed overshoot stability to be controlled by the master drive See sections 5 14 and 5 14B for more details Terminal 10 is the master speed gain output Terminal 6 is the slave speed gain input Master Slave with Master speed gain MASTER SLAVE DC drive DC drive 3 789 10 13 Page 22 ERC Statohm IV Section 5 Operation amp Adjustments Section 5 18 AC contactor Not all applications required contactors below is a elementary diagram of AC contactor circuit Elementary Power Connection Diagram with AC Contactor DC Motor DC Drive AC Contactor Connect L1S L2S and L3S befor the contactor to prevent the LV light switching on 1 4 Close the AC contactor befor activating Run terminal 34 simultaneously L1 L2 L3 Section 5 19 DC contactor Warning don t use a DC contactor with a 12 SCR 4 quadrant regenerative drive DC contactor can be used with a 6 SCR 2 quadrant drive A freewheeling rectifier is strongly advised Note Electric Regulator prefers AC contactors DC contactors can lead to a variety of problems Page 23 24 Statohm IV Manual Section 6 Trouble Shootin
65. rent Limit See Section 5 12 FE Field Economy Enable OFF Disable ON FT Jog and E Stop Accel amp Decel See Sections 5 4 amp 5 5 FI Field Ammeter Enable ON Disable OFF FM Field Ammeter Calibration See Section 4 15 FL Field Loss Signal Enable OFF Disable ON HS Zero Speed Hysteresis See Section 5 8 FV Aux Field Voltmeter Enable ON Disable OFF Instantaneous Over Current See Sections 5 12 4 5 128 IFR Internal Field Regulator ON External Field Regulator OFF IF Field Amps See Section 5 11A JP 1 Speed Reference Scale 8V ON 10V OFF IG Current Gain See Section 5 16 JP 2 Armature Ammeter Enable ON Disable OFF IMX Armature Current Reference Point See Section 5 12 JP 3 IA internal reference Enable OFF Disable ON JOG Jog Speed See Section 5 4 JP 4 Jog Signal Enable ON Disable OFF LV Low Input Voltage Shut Off Level set at factory JP 5 Jog PID Enable ON Disable OFF Max Speed i e Max Armature Voltage See Section 5 9 JP 6 PID Enable ON Disable OFF i e ASR Speed Gain NA Speed Meter Calibration See Section 4 13 JP 7 Field Weakening Enable ON Disable OFF OP ZD Relay Latch Point See Section 5 6 JP 8 Field Current Limit Enable ON Disable OFF PI PID See Section 5 15 JP 9 Driver Test Enable ON Disable OFF R For Rev Speed Balancing See Section 5 12 JP 10 Calibrate AM pot to zero Enable ON Disable OFF RL Reverse Current Limit Regenerative Drives Onl
66. rrent Range Current Range Current Range 4 3 7 1 6A 10A 10A 17A 15A 25A Off 2 1 4 3 5A 10A 7 5 15A Fl Off 1 4 2 1 3 3A 5A 7 Off 0 7 1 4 2 17 3 3 2 2 5 Off 0 6 1 2 8 1 3A 17 1 3A 2A EUH Off 4 5A Field Disable The field is disabled when the motor has a permanent magnet field or series field and armature To disable the field loss detection circuit put the jumper FL on and don t connect power to and L2F Note The yellow light will remain on when the field is disabled Field Weakening See Section 5 11A Page 8 ERC Statohm IV Manual Section 4 Power amp Control Circuit Wiring Control Circuit Wiring Elementary Control Circuit Functions Start Run terminal 34 Jog if used terminal 33 Emergency Stop terminal 40 PC Enable Drive terminal 36 Speed Reference terminals 7 8 and 9 DC Tach Feedback if used terminals 1 and 2 Reverse has two options 12 SCR drives only Option 1 Terminal 37 Option 2 Speed Reference Voltage Polarity NOTICE Make all control circuit connections in accordance with the drive system engineer s wire diagram or the elementary wire diagrams provided in this manual if applicable The control circuit terminals 1 though 40 are located on the regulator card WARNING Electrical noise
67. shoot Adjustment i e Speed Response To view the motor s overshoot and stability attach an oscilloscope to test points 10 and com or to the tach feedback wires e Adjust the ACC and DEC pots for fast operation turn the pots counter clockwise e Set the JOG pot full clockwise If jog is not available set the master speed control to 20 of full speed Start the motor while the motor is rapidly accelerating observe the oscilloscope and compare to the drawings in Fig 5 12 Optimum is one overshoot peak as in figure in 5 12 B To adjust overshoot use the SR pot fig 5 12 Stable but slow Stable and fast Fast but unstable 5 14B Speed Stability Adjustment i e Speed Gain e After the SR pot has been adjusted Return the ACCEL DECEL and JOG pots to their normal positions Start the motor and observe the oscilloscope After overshoot has occurred observe the stability of the motor e To adjust stability use the SG pot Page 20 ERC Statohm IV Section 5 Operation amp Adjustment 5 15 Speed Feedback Loop Adjustment i e Speed PID The ASR feedback loop is adjusted at the factory If adjustment of the SR and SG pot does not produce satisfactory results Adjustment of the PI pot may be necessary e Record the factory setting of the PI pot 10 To increase overshoot adjust the PI pot clockwise To decrease overshoot adjust the PI pot counterclockwise 5 16 Current Gain L
68. tart the motor using the jog control If the motor rapidly accelerates past 20 of the motor s base speed Stop and check if the tach feedback wires are connected properly and if the tach voltage jumper is correct see section 3 4 If the motor runs in the wrong direction for armature feedback check the polarity terminals F1 F2 For tach feedback check the polarity of the tach wires to terminals 1 and 2 When the motor operates properly continue 5 4 Jog Speed amp Acceleration and Deceleration Adjustment Start the motor using the jog control Note Jog operates only when the Run not activated Adjust the JOG pot until motor runs at desired speed Jog acceleration and deceleration time are adjusted by the FT pot Clockwise is slower Counter Clockwise is faster The scale of the FT pot is with in the range of the setting of the DEC pot Note Jog s deceleration time is the same as Emergency Stop s E Stop deceleration time The user must decided witch function has priority when setting this adjustment See section 5 5 Page 15 ERC Statohm IV Section 5 Operation amp Adjustment 5 5 Emergency Stop E Stop The Statohm IV has two options for emergency stop i e E STOP Option 1 Power Off E Stop uncontrolled coast to stop default setting Local regulations may require emergency stop to shut off the drive and let the motor to coast to a stop When EF jumper 18 off the motor will coast to stop and FT rela
69. to measure the armature voltage or DC tach voltage Then use the voltage to calculate the speed e The pot calibrates the speed meter Runthe motor at a level speed and adjust the NA pot until the speed meter equals the independent speed measurement The speed meter circuit is a current regulator circuit the NA pot sets the current limit Example The meter has a 0 to 2000 RPM face plate the input is 1 mA 2000 RPM 100 The motor s base speed is 1750 RPM The speed meter is calibrated by running the motor at base speed and adjusting the NA pot until the meter reads 1750 RPM The current limit is set to 0 875 mA 1750 RPM 0 875 mA If changes are made to extend the speed of the motor to 1900 RPM by using field weakening If the speed meter is not recalibrated The speed meter will read 1750 RPM when the motor is actually running 1900 RPM Creating a 8 5 error over the entire meter s range The speed meter must be recalibrated by adjusting the NA pot to read 1900 RPM at full speed 1900RPM 0 95 mA REGULATOR CARD JP 7 0 CROS 9 ES NA pot Page 12 ERC Statohm IV Manual Section 4 Power amp Control Circuit Wiring Section 4 14 Armature Ammeter Wiring and Calibration Selecting a meter The armature ammeter is a voltmeter with a 0 to 2 volt input meters are available from ERC The motor s rating and a
70. to operation Check all of the following before applying power Check for any loose connections on any of the control circuit terminals power circuit terminals and fuses Verify all connectors are correctly inserted in the regulator card s terminals Carefully inspect for frayed braids of wire Frayed wires that are and not inserted in the terminal can cause short circuits or intermittent shorts Use an Ohm meter to check the wiring continuity and the isolation between the wiring and control panel 5 2 Pre Operation Voltage Checks Never measure voltage test points when the motor is running Item Measuring Location Voltage 3 Phase AC Input Power AC Input Power Buss L1 L2 L3 or R S T Within 10 of Rated Voltage Field AC Input Power Terminal Block 1 15 and 1 25 L1F and L2F Within 10 of Rated Voltage Single Phase Input Power Terminal Block LIC and 120 110 Vac to 120 Vac Signal Relay Power Test Points on Regulator Card to Com 19 5 Voc 1V Positive and Negative Test Points on Regulator Card 5 Power Supplies 15 to Com 15 to Com 15 Voc 0 5V 5 3 Test Run The primary adjustments have been made at the factory prior to shipping The jumper settings were covered in section 3 Fine adjustments should be made in the following sequence prior to full operation Confirm the operation of emergency stop sequence Set the JOG pot to an intermediate position S
71. y JP 11 1059F card only Manufacturer test equipment use only 50 Speed Gain i e Speed Stability See Section 5 14B JP 12 1059F card only Manufacturer test equipment use only SR Speed Response i e Speed Overshoot See Section 5 14A S1 S4 DC Tach Generator Voltage See section 3 2 and 4 11 P1 1F 1R SCR Phasing Balancing See Section 6 1A SF Tach Feedback Enable ON Disable OFF ic Speed Feedback 2 2F 2R SCR Phasing Balancing See Section 6 1A T1 T4 Accel and Decel Time Range See Section 3 6 p3 3F 3R SCR Phasing Balancing See Section 6 1A TG Tach Feedback ASR Enable ON Disable OFF 4 4F 4R SCR Phasing Balancing See Section 6 1 TL Tach Loss Enable ON Disable OFF 5 5F 5R SCR Phasing Balancing See Section 6 1 VF Armature Feedback Enable ON Disable OFF P6 6F 6R SCR Phasing Balancing See Section 6 1A Note We strongly suggest the user not change the factory setting ZERO Zero Speed Adjustment Regulator Card Tables Page 49 RED SIGNAL LIGHT TABLE TEST POINT TABLE Light Description Test ES Emergency Stop Point Description FL Field Loss Lights when current is 13 or less TP 1 Tach Feedback Reference Voltage 8Vpc Max Speed FU Fuse Blown TP 2 Arm Feedback Reference Voltage 7 5Vpc Max Speed LVL Low Voltage Level Lights when voltage is 70 or less 4 Accel amp Decel Voltag
72. y need to be replaced If this plug is not connected or reversed the motor will run away The correct sequence is red wire right H and white wire left N See bottom of page 39 for details If field current is insufficient Check if jumpers F1 F5 set right and the continuity is good See section 3 1 Field Current and 3 5 Field Regulation Line L1 and L2 must be connected respectively to L1F and L2F If these connections are not correct the field voltage will be too low causing the motor to run fast See section 6 12B on page 32 Check if SF TG TL and S1 S4 are set right and the continuity is good See section 3 1 Motor Feedback Page 27 Statohm Manual Section 6 Trouble Shooting Check the following The DC armature circuit is shorted The load on the motor is stalled SCR failure i e thyristor Improper setting of current limit or current protection circuits Measure voltages of test points 1 6 Measure the resistance between CTIR amp CTIW and CT2R amp CT2W on the SYNC card Rapid change of load or motor flash over Check for the presence of a surge during the operation of the external Section 6 4 Problem Fuses blow immediately after start and the signal lights Recommendations Check the DC power circuit Check the load on the machine Disconnect L1 L2 L3 and A and measure the resistance between them The typical resistance b
73. y will switch Option 2 Controlled Deceleration E Stop with power switch off at zero speed Set the FE jumper on and make connections from terminals 21 to 35 and 23 to 36 see diagram The E Stop deceleration time can be set to equal to or less than the DEC pot deceleration time setting The pot adjusts the E Stop deceleration time Proper adjustment of the OP pot is required for a complete stop see section 5 6 The OP pot sets the point when the drive switches off REGULATOR CARD Emergency Stop mode Jumper Setting Power Off Uncontrolled Coast to Stop 0 Jumper EF Controlled and OP Pot Deceleration Stop with ZD relay terminals Power Switched Off at Zero are connected Speed 21 to 35 and 23 to 36 20 Relay See diagram to the right IUE EI 5 6 Zero motor rotation Detection relay and signal light adjustment The regulator card has a motor rotation detection circuit 1 e Zero Detection ZD The ZD circuit has a SPDT relay on terminals 21 center pole 22 normally closed 23 normally open and asignal light marked ZDL The switch point of the ZD circuit is set by the OP pot The switch point adjustable over a range of 0 to 2596 of full speed While the motor is stopping adjust the OP pot to the desired switching point The ZDL signal light will switch on Note Adjusting the OP pot too low can cause the ZD re
74. ystems As a last resort disabling the PH light circuit is a possible solution Bypass capacitor C125 by laying it on its left side and soldering a wire across it s leads REGULATOR CARD 1058 0125 2 4 Page 33A ERC Statohm Manual Section 6 Trouble Shooting Section 6 17 Problem Dynamic Braking and Mechanical Reversing Applying the Statohm IV two quadrant six thyristor drive to systems with dynamic braking and or mechanical reversing requires anti plugging relay to prevent damage to the drive The anti plugging relay detects when the armature voltage is zero Do not apply voltage to the drive s armature connections before the armature voltage reaches zero Page 33B ELECTRIC REGULATOR CARLSBAD CA USA Tel 760 438 7873 Fax 760 438 0437 information electricregulator com S Model Ratings Model Max 230VAC 460VAC 575VAC Number Amps MaxHP MaxHP Max HP 1 31 7 14 17 2 70 15 30 37 3 110 25 50 62 54 180 45 90 110 225mm 87 8 6 8mm DIA ere 13 4 13 4 210 81 4 256mm 10 3 32 S Model Physical Diagram Page 34 28601 uugsc 1901 6 WWE0E VIG 91 6 092 002 00 00 cN dH Xe dHXEN 9VA9Z9 VAOEZ XEN sBuney IPON

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