Motortronics ABC Series Electronic Motor Brake User Manual
Contents
1. A 0 oes 20 5 near Seana 23 5 1 Time Adjustment PTOCGBOUFBS 100 1 000 10 9 tane 23 5 2 JOO RME AGUS ERG E EEUU RE ER 23 5 9 Brake H A 24 5 4 Brake C rrent ejui ipe 24 6 SAUD aaa 26 6 1 Ec 26 6 2 a 26 6 3 RL 26 6 4 Check Normal Sequence of Operation pp 26 APPENDIX A TECHNICAL SPECIFICATIONS et 27 WARRANTY INFORMATION ts 29 Page 1 CTi Automation Phone 800 894 0412 Fax 208 368 0415 Web www ctiautomation net Email info ctiautomation net gt Motortronics Your Role in Product Safety This equipment is designed and manufactured to the highest standards to provide safe and reliable operation for its intended use Only qualified personnel should install maintain and service this equipment and only after reading and fully understanding all of the information in this manual All instructions should be strictly followed All Warnings Cautions and Notes must be taken into acco2. 123 4 5 6 7 Time sec 1 2 4 8 16 32 64 CAUTION Damage to the motor equipment brake and or electrical circuit may occur if this adjustment is not correct Setting this switch to less than the factory setting may involve risk to the equipment and affect normal operations Setting the jog time too long may result in equipment operating without the benefit of the DC injection brake The jog time should typically be set to equal the time it takes the motor to accelerate the load on start across the line plus approximately two seconds Page 23 CTi Automation Phone 800 894 0412 Fax 208 368 0415 Web www ctiautomation net Email info ctiautomation net Motortronics 5 3 Brake Time Setting Factory Setting seconds The brake time is programmable from 1 to 127 seconds Set the switches marked Brake Time to the brake time required Typical brake time settings should be 1 2 of the load s coast to stop time or less as necessary Each dip switch represents a binary time value Add the times together for the final brake time setting Switch Positions Example On Setting dip switch positions 1 2 and to ON 1 2 4 Brake Time f seconds total brake time 123 4 5 6 7 Time sec 12 4 8 16 32 64 NOTE Stop times shorter than 4 seconds will not allow enough time for the Zero Speed Sensing circuit to accurately sense that the motor has stopped Brake Time must be used
3. Web www ctiautomation net Email info ctiautomation net Motortronics 2 Operation 2 1 Sequence of Operation The ABC Series brake becomes Armed when the motor starter turns On and then braking occurs when the starter is turned Off An Operator Interface Module has two large LEDs to indicate Braking or Fault condition plus six smaller LEDs to indicate the following modes of operation BRAKE OFF DISABLED OVERLOAD WIRING ERROR BRAKING FAULT OVER TEMP ON JOG TIME ON MIN CM BRAKE TIME BRAKE CURRENT 2 1 1 Power On The ABC Series brake is self powered from the available motor branch circuit as derived from Terminals L1 and L2 If fuses are used this LED will indicate a blown fuse condition in either of these circuits by being off when power is applied to the starter see section 4 2 1 This LED does NOT indicate motor starter or ABC Series brake unit operational status 2 1 2 Jog Armed The ABC Series receives a Brake Command from an input wired to the motor starter which indicates the starter status see section 4 3 1 The ABC Series can be programmed to wait a period of time before going into the Armed condition using the Jog feature This feature allows for user setup and testing of systems during the jog time with out the braking cycle interfering The Jog time is set via the Jog Time dip switches This LED will flash once per second until the end of the jog time If the Mot
4. fed to terminals L1 and L2 directly from the line side of the motor starter terminals and is converted to DC within the ABC Series Once the motor starter has been turned off opened and the residual energy in the motor has dissipated the DC current from the ABC Series is applied injected to starter terminals T1 and T2 respectively This creates a stationary magnetic field in the AC motor stator windings The braking torque will increase in proportion to the amount of current allowed to flow The DC injection level can be adjusted using the Brake Current Potentiometer on the operator interface module This modulates the applied voltage based upon an RMS closed loop current feedback signal from the integral sensors The rotor then pulls into alignment with this stationary field and brings the load to a stop faster than if it coasted to a stop 1 3 Brake Sizing and Selection ABC Series brakes are suitable for use in most AC motor applications where coast to stop times are undesirable or unacceptable The ABC Series is a current controlling brake so various sizes of brake units can be applied to various motor sizes Because DC injection means applying power to the AC motor after turning it Off motor heating although minimal will continue during the braking cycle and should be considered when selecting the motor AC motor manufacturers recommend that each braking cycle over 10096 FLA be considered as an additional starting cycle when calculating
5. intended to be followed without exception CAUTION Caution labels are intended to alert the user to specific issues that MAY cause damage or personnel risks under circumstances as described These items are critical in some installations but not all The user is responsible for identifying the applicable installation issues NOTE Notice labels are intended to alert the user to issues that require particular attention with regard to the proper use and long term reliability of the equipment Page 2 CTi Automation Phone 800 894 0412 Fax 208 368 0415 Web www ctiautomation net Email info ctiautomation net Motortronics 1 About the Motortronics ABC Series 1 1 General The ABC Series is a solid state DC injection brake for stopping three phase AC induction motors This full wave DC brake design offers smooth low peak level braking for quiet steady operation and optimal performance Designed to handle even high inertia loads the ABC Series eliminates costly and potentially dangerous coast to stop times A built in microprocessor provides system supervision that includes digital timing control for jogging and braking The integral Operator Interface Module provides LED indication of the unit s operating status and easy adjustments for quick setup Standard features include interlocks and mechanical brake release relays a brake disable input and zero speed sensing with override 1 2 Theory of Operation Incoming AC power is
6. stops the load and the mechanical brake holds it Holding the load after it comes to a stop All DC injection brakes inherently lose braking torque when the motor comes to a complete stop and therefore CANNOT BE USED AS HOLDING BRAKE f braking must be applied continuously while the load is at rest mechanical Parking Brakes are required The ABC Series includes a Mechanical Brake Release Relay to facilitate proper coordination of the mechanical brake in these applications otop times shorter than start times Like all DC injection brakes the ABC Series waits for the residual motor energy to dissipate from the windings before DC current can be applied otherwise damage to the brake or circuit devices may occur The length of this wait state depends on the motor s residual magnetism and the motor frame size but can be as much as 5 seconds This combined with the limits on braking torque makes DC injection braking ineffective if braking time must be shorter than the starting time Across the Line WARNING DC Injection brakes cannot be used for holding a load after it comes to a stop The ABC Series includes a Mechanical Brake Release Relay that can be used to coordinate the operation of a mechanical brake for use in these applications Page 5 CTi Automation Phone 800 894 0412 Fax 208 368 0415 Web www ctiautomation net Email info ctiautomation net Motortronics 1 6 ABC Series Model Number Rating and Dimensions r
7. the starts per hour ratings for the selected motor If the selected ABC Series is sized to deliver 20096 of motor rated current consider each brake cycle to be 2 start cycles for these calculations and 300 FLA 3 starts per brake Never size any DC injection brake to exceed 400 of the motor nameplate FLA without first consulting the motor manufacturer Additional guidelines for applying ABC Series brakes follow Page 3 CTi Automation Phone 800 894 0412 Fax 208 368 0415 Web www ctiautomation net Email info ctiautomation net Motortronics 1 3 1 Standard Duty Sizing Applying an ABC Series brake that is rated for lt 115 of the FLA Full Load Amp rating of the motor allows maximum length of braking time without exceeding the thermal capacity of the stator windings Since current is controlled by the ABC Series throughout the braking cycle braking torque will vary as the motor circuit impedance decreases with speed Braking torque will be highest at the beginning of the cycle and can be as much as 100 of the FLT Full Load Torque when set to motor FLA As the motor slows the braking torque slowly decreases reducing the mechanical stresses as much as possible Sizing a brake in this manner is typically good for machine tools saws conveyors lumber machinery and most chippers where the coast to stop time does not exceed 5 minutes Stop times vary greatly with load and friction but can be expected to be 1 2 of the coast
8. 4 0412 Fax 208 368 0415 Web www ctiautomation net Email info ctiautomation net Motortronics Outputs Starter Coil Interlock Two sets of FORM C relay contacts for us in interlocking the starter coil and or other devices to prevent energizing as the braking power is applied Mechanical brake Release N O relay contact for use in controlling electro mechanical brake as a holding brake When the ABC Series is disabled this circuit controls the mechanical brake normally as if it is the only brake the system Aux Contact Ratings 5 Amps 250 VAC max LED Status Indicators Large LEDs braking green Fault Red Small LEDs Power On Jog Armed Brake Off Disabled Over Temp and Wiring Error Operating Design Temperature 32 F 122 F 0 C to 50 C Storage Temperature 4 F 176 F 20 C to 80 C Ambient Conditions 5 to 95 relative humidity 0 3300ft 1000m elevation Approval UL cUL Listed Page 28 CTi Automation Phone 800 894 0412 Fax 208 368 0415 Web www ctiautomation net Email info ctiautomation net Motortronics Warranty information Motortronics warrants its products to be free from defects in material and or workmanship for a period of one year from the date of installation to a maximum of 18 months from the date of shipment as indicated by the unit s date code The Company reserves the right to repair or replace any mal functioning units under warranty at their op
9. Adjustment Ranges Inputs Inputs Models rated from 208 600 10 Selectable for 50 60 Hz 2Hz 50 1000A 90 100 200 300 400 550 800 1000A 25 duty cycle at 100 unit rating Fu wave bridge 4 SCRs designed for use without isolation contactors RC snubber dv dt circuit on each SCR device Approved for use with existing motor starter fusing when unit is sized for motor FLA Consult NEC for any other fusing requirements Self powered directly from line terminals No separate control voltage required Microprocessor unit control sequencing I O monitoring and status annunciation Braking current is adjustable via true RMS regulated control using phase angle firing of SCRs Brake Time and Jog Time 7 position binary dip switch Brake Current potentiometer Brake Jog Time 0 127 seconds in 1 sec increments Brake Current Up to 100 of unit rating Starter Monitor Dry input for auxiliary contact from motor starter Jumper selectable for N O or N C contact Brake Disable Dry input for N O contact to disable braking before or during operation Can be wired to the starter thermal overload N O auxiliary contact to prevent braking of overloaded motor Jumper selectable for N O or N C contact Motor Power Sensor T3 Voltage input used for sensing motor power presence in sequencing status circuit and for zero speed sensing during braking Page 27 CTi Automation Phone 800 89
10. Motortronics 2 2 Fault Conditions The FAULT LED will illuminate when any of the following conditions occur 2 2 1 Disabled The DISABLED mode is activated when the ABC Series receives a command on the Brake Disable input a N O dry contact at TB1 see section 4 3 2 This mode can be used to remove the electronic brake from the system and is useful in applications that only require braking at certain times during the process and during system setup Note The ABC Series is a smart brake and will sense a running motor and automatically arm itself if released from the DISABLED mode Under these circumstances the ABC Series will go through the JOG and ARMED sequence again If the unit has determined the motor is stopped the brake will return to the normal ready state NOTE The ABC Series Mechanical Brake Release Relay will set the mechanical brake if the ABC Series brake unit is disabled during the braking mode 2 2 2 Wiring Error The ABC Series unit will recognize when the interface connections or monitored signals are not correct with respect to the proper operation sequence If the brake detects a miswire or an improper sequence of events it will self disable to prevent any conflicts with the existing systems and indicate WIRING ERROR If this occurs the Fault LED and Wiring Error LEDs will illuminate Once the miswire or wrong sequence is corrected the brake will automatically enable itself and resume
11. Solid State AC Motor Cortrols W gees 50 to 1000 Amp Models Electronic Motor Brake INSTALLATION amp OPERATION MANUAL Motortronics Table of contents 1 TETTE 2 1 1 TERRE 3 1 2 FREON Ol OG ION WEN 3 1 3 Braking SIZING and SeleCUON ssn 3 1 4 Auecaughnse TE 4 1 5 Where Mechanical Brakes Should be Used pp 5 1 6 ABC Model Numbers Ratings and 6 2 I EM r 12 2 1 C 12 2 2 c 14 2 3 Mechanical Brake 8 8 n oran rnnrnnrnne 15 3 aaa A aA 16 3 1 vor EHE No 16 3 2 a Ea 16 3 3 mo ESL SLE EARS 16 4 17 4 1 0006 Mee 17 4 2 LIRE ANA Eoad CORECOR science 17 4 3
12. TION Power Factor Correction Capacitors should NOT be connected to the load side of the motor starter when used with an ABC Series brake PFC Capacitors should only be connected to the line side and must include a separate isolation contactor Page 19 CTi Automation Phone 800 894 0412 Fax 208 368 0415 Web www ctiautomation net Email info ctiautomation net Motortronics 4 3 Control Connections Control wire should be run in a separate conduit from power lines twisted shielded cable should be adequate Whenever possible conduits containing control and power conductors should cross at right angles to each other Control connections are made to terminal blocks mounted on the printed circuit boards inside the unit case TB1 is on the Logic Board see page 11 with the terminals for Starter Monitor Brake Command and Brake Disable TB2 is located on the Power Board and contains terminals for the Interlock Contacts and Mechanical Brake Relay WARNING The motor starter must never be operated manually when the brake unit is connected Blown fuses and or damage to the unit may result 4 3 1 Starter Monitor Input Provides a brake command signal from the motor starter refer to section 2 1 3 Connect either the normally open or normally closed user preference dry auxiliary contact on the motor starter to TB1 terminals 1 and 2 on the logic board To utilize a normally closed contact select Jumper X1 factory default For
13. al brake When the stop command is given the ABC Series brake unit will continue to keep the mechanical brake released proceed with the DC injection braking sequence then engage the mechanical brake at the end of the braking cycle If the disable feature is engaged while in BRAKING mode the ABC Series will automatically set the mechanical brake Page 22 CTi Automation Phone 800 894 0412 Fax 208 368 0415 Web www ctiautomation net Email info ctiautomation net Motortronics 9 Adjustments 5 1 Time Adjustment Procedures Time settings for Jog Time and Brake Time are adjusted by use of dip switches on the front mounted Operator Interface Module Time settings are in seconds set in binary code Each switch denotes a binary digit from 1 7 positions totalling 127 seconds maximum when all are switched to the On position BRAKE OFF DISABLED OVERLOAD BRAKING FAULT ON JOG TIME IT BRAKE TIME ON MIN OW BRAKE CURRENT Operator Interface Module 5 2 Jog Time Setting Factory Setting 7 seconds The jog time is adjustable from 0 127 seconds and is made using the 7 position dip switch SW2 labeled Jog Time Set the switches according to the jog time required Setting all the switches to the Off position Jog Time 0 will disable this function Switch Positions Example On Setting dip switch positions 1 2 and 3 to ON 1 2 4 Jog Time f seconds total jog time
14. anical brake Page 4 CTi Automation Phone 800 894 0412 Fax 208 368 0415 Web www ctiautomation net Email info ctiautomation net Motortronics 1 4 Applications The ABC Series electronic brake is ideal for machine and process equipment control applications for efficiency increased safety and reduced equipment maintenance costs Among the benefits Efficiency is improved because you no longer have to wait through long coast to stop times for blade changes batch loading or maintenance shutdowns Productive time increases as overall operating costs decrease because the load stops more quickly The ABC Series eliminates the common practice of jamming the load to a stop which seriously reduces the life and effectiveness of saw blades molding heads and knives Increase Safety by eliminating the need to jam stop equipment This will prevent any personnel injuries caused by kickbacks and broken blades Use the ABC Series in conjunction with safety inter lock devices to stop the motor as quickly as possible reducing the risk of contact with dangerous rotating elements of machinery Prevent premature wear or component failure and eliminate the need for hasty repairs that can put maintenance personnel in potentially dangerous situations ABC Series brakes can be used as part of a system to facilitate OSHA General Industry Standards 29 CFR1910 Subpart O requiring that workers not be exposed to hazardous moving parts They can also be uti
15. d side safety disconnect switch with one that is rated for DC voltage at the motor line voltage rating or greater As an alternative disconnect incoming line power before opening any load side disconnect switches in the motor circuit during braking and post warning labels at all affected devices Failure to observe this precaution may result in damage to the disconnect and or bodily injury Page 18 CTi Automation Phone 800 894 0412 Fax 208 368 0415 Web www ctiautomation net Email info ctiautomation net Motortronics 4 2 2 Load Power Connections Connect the motor leads to the output terminals T1 and T2 provided on the unit The unit will operate on either a Wye or a Delta connected motor An additional control wire must be run from motor lead T3 of the starter to the voltage sensing circuit of the ABC Series The terminal for this is marked T3 This terminal carries very little current so 20 wire or higher can be used Fuse protection ad equate for the field wiring used must be provided per code NOTE If the ABC Series brake is being used with 2 speed Wye Delta or Reduced Voltage starter consult factory for additional load connection information Lind Power Existing otarter Start Stop Control Starter Interlock Brake Command pee On Optional Disable d E E te O L V X x Mechanical Brake Relay Mechanical Brake Coil CAU
16. damage which may have occurred during shipping and handling Report any damage immediately and file a claim with the freight carrier within 15 days of receipt Do not attempt to continue installation CAUTION Do not operate or install the ABC Series Brake if it appears to be damaged or visually defective Doing so may result in personnel injury or equipment damage 3 3 Location Proper location of the ABC Series is necessary to achieve specified performance and normal operation lifetime The unit should always be installed in an area where the following conditions exist Ambient operating temperature Chassis unit 0 to 50 C 32 to 122 F Enclosed unit 0 to 40 C 32 to 104 F e Humidity 5 to 95 non condensing Free from metallic particles conductive dust and corrosive gas Free from excessive vibration below 0 5G Open panel units must be mounted in the appropriate type of en closure Enclosure size and type must be suitable to dissipate heat generated by the unit Contact factory for details 3 4 Mounting and Cleaning The unit is air cooled and must be properly mounted to allow for unrestricted airflow across the heat sink The unit should be mounted with the heat sink fins in a vertical plane with a minimum of five 5 inches 127mm of free space around the unit for adequate ventilation The ambient air should be free of any contaminants which can clog louvers or coat the unit As with all electrical equipment the unit mu
17. lized to satisfy braking requirements of the British Columbia Workers Compensation Amendment Act Book 3 Part 27 42 for rotating knife machinery such as planers chippers and hogs Reduce maintenance costs by using the ABC Series Eliminate the need to plug reverse a load and reduce the associated damage to gear boxes and other power train components The ABC Series can be used to stop or slow down the load in one direction before reversing to the other On machines where mechanical brakes are used to stop or hold a load use the ABC Series to stop it first then set the mechanical brake as a parking brake This eliminates the normal wear and tear to the brake pads or shoes On loads such as vibrating feeders screens or separators damage from mechanical harmonics that occur during coast down can be eliminated by using an ABC Series It allows the motor load to quickly pass through any dangerous speeds and come to a stop 1 5 Where Mechanical Brakes should be used Power loss during braking The ABC Series like all DC injection brakes requires power to be applied during the braking cycle If the incoming line power is lost from the utility an upstream circuit protective device trips or an emergency shutdown routine is initiated no braking will take place If braking is still necessary for safety reasons even in the event of a power failure consider using mechanical brakes as a backup device Under normal operation conditions the ABC Series
18. mail info ctiautomation net Motortronics 19 957 0 44 DIA HOLES 4 PLACES BEEN 56 000 i r N4 12 Outline ABC 300 400 E 0 44 DIA HOLES 125227 4 PLACES i 34 341 36 000 N4 12 Outline ABC 550 800 E Page 8 CTi Automation Phone 800 894 0412 Fax 208 368 0415 Web www ctiautomation net Email info ctiautomation net Motortronics 9 22 DIA Panels Outline ABC 50 100 1 gt E ele E 519 EA o z Panels Outline 60 0 Page 9 CTi Automation Phone 800 894 0412 Fax 208 368 0415 Web www ctiautomation net Email info ctiautomation net Motortronics 0 50 DIA 10 00 m ITI me re LH Panels Outline ABC 300 400 25 00 C C D an DIA 9 59 Panels Outline 550 800 Page 10 CTi Automation Phone 800 894 0412 Fax 208 368 0415 Web www ctiautomation net Email info ctiautomation net Motortronics 0 9 ce 09 0 406 TYPICAL 34 50 36 00 toa Panels Outline ABC 1000 Page 11 CTi Automation Phone 800 894 0412 Fax 208 368 0415
19. n E OC l Brake Amps Voltage Enclosure 50 1000 A 240 208 240V 400 380 415V P Panel Mount 480 440 480 600 575 600V E NEMA 4 12 Sealed ABC SERIES Typical Horsepower Usage Model 240V 480V Number NEMA 4 12 Std Extra Std Std i Dim Ref 9 5 o e e n 0 c et lt ABC 50 ABC 100 O N 2 N ja jw IN 0 5 a Ia 5 E NO 1 Never exceed the Full Load Amp rating of the motor without checking the motor manufacturer s data with regards to appropriateness of the application and duty cycle 2 If duty cycle is not known Motortronics recommends using the Extra Duty Brake since braking current can be adjusted down to meet the actual load requirements N B IN Dimensions Inches A es usus os Page 6 CTi Automation Phone 800 894 0412 Fax 208 368 0415 Web www ctiautomation net Email info ctiautomation net U 44 DIA HOLES 4 PLACES ZO DUE 155800 N4 12 Outline ABC 50 100 E 22 000 0 447 m DIA HOLES 4 PLACES N4 12 Outline ABC 200 E 20 000 n Motortronics 8 930 en 24 000 7 CTi Automation Phone 800 894 0412 Fax 208 368 0415 Web www ctiautomation net E
20. ne and Load Connections Power conductors for the Line and Load connections should be at a minimum sized at 125 of the current rating Brake sizing and duty cycling should be considered when determining if conductors should be oversized for your application For example high torque fast stop applications with maximum duty cycle may require conductors sized for the maximum output capability of the ABC Series and motor lead wires should match Page 17 CTi Automation Phone 800 894 0412 Fax 208 368 0415 Web www ctiautomation net Email info ctiautomation net Motortronics 4 2 1 Line Power Connections Connect the line leads to the input terminals L1 and L2 provided on the unit The line power must be supplied from a source with suitable Short Circuit Protective Devices SCPD conforming to local and national electric codes Additional fusing is necessary only when the motor circuit is fused at a level too low to protect the ABC series per code Recommendations for commonly available SCPDs are as follows SCPD SIZED AS OF ABC UNIT RATING SCPD UNIT RATING Class RK5 Fuse No greater than 250 10 100 Amps Class J Fuse No greater than 40096 Circuit breaker No allowable fuses required Class RK5 Fuse No greater than 25096 200 1000 Amps Class J Fuse No greater than 400 Circuit breaker No greater than 25096 WARNING Many motor safety disconnect switches are not rated to interrupt DC current Replace any loa
21. normal operation 2 2 3 Over Temp The ABC Series has thermal sensors built into the heat sink assembly If the heat sink approaches temperatures too high for the SCRs the sensors will cause a Fault and illuminate the Fault and Over Temp LEDs Page 14 CTi Automation Phone 800 894 0412 Fax 208 368 0415 Web www ctiautomation net Email info ctiautomation net Motortronics 2 3 Mechanical Brake Control The ABC Series includes a Mechanical Brake Release Relay that can be utilized to control an electro mechanical brake coil This relay has a Form A contact 1 N O that changes state as follows see section 4 3 4 OPERATION RELAY STATUS Jog Armed Energizes follows motor starter coil Braking Time Completed De energizes Zero Speed Override Disabled Before or During Jog Armed Remains Energized follows motor starter coil 15 CTi Automation Phone 800 894 0412 Fax 208 368 0415 Web www ctiautomation net Email info ctiautomation net Motortronics 3 Installation 3 1 Receiving and Unpacking Upon receipt of the product you should immediately do the following Carefully unpack the unit from the shipping carton and inspect it for shipping damage Verify that the model number on the unit matches your purchase order Check all electrical terminals to be sure screws are tight 3 2 Initial Unit Inspection Complete a visual check of the unit for
22. normally open con tact move the Jumper to X2 For reversing starters use 2 N O contacts in parallel or 2 N C contacts 1 from each contactor in series to this input Circuit voltage potential 15 000 maximum Logic Board Starter Brake Monitor Disable Page 20 CTi Automation Phone 800 894 0412 Fax 208 368 0415 Web www ctiautomation net Email info ctiautomation net Motortronics 4 3 2 Brake Disable Input Disables electronic braking functions before during or after operation refer to section 2 2 1 To utilize this feature wire a N O dry contact to TB1 terminals 3 and 4 on the logic board The disable feature will activate as long as the contact is closed and will resume operation sequence only when the disable command is released i e the contact is opened Once the ABC Series has resumed operation it will evaluate the status of the motor and re enter the JOG mode if conditions are correct Circuit voltage potential 15VDC maximum Logic Board Monitor Disable Note The Brake Disable can and should be used to disable the ABC Series brake in the event of a motor thermal overload by wiring normally open contacts from the overload relay to these terminals This will prevent the brake from operating if a motor over load trip Condition occurs Page 21 CTi Automation Phone 800 894 0412 Fax 208 368 0415 Web www ctiautomation net Email info ctiautomation net Motortronics 4 3 3 Interlock Co
23. ntacts The ABC Series unit must be interlocked with the motor starter coil circuit to disable the motor starter during the braking cycle for proper operation refer to 2 1 3 Two sets of FORM C contacts are provided on TB2 on power board to interlock the motor starter with the brake Terminals 1 2 and 3 are the first set and terminals 4 5 and 6 are the second Use both sets for reversing starters each in one of the contactor coil circuits The second set may be used as a status indicator in non reversing starter applications Never connect the interlock contacts parallel to the contactor coil or across the power line Circuit voltage potential same as starter control circuit 240VAC maximum Power Board C C Mech NO NO Brake NC NC Release Relay WARNING If this wiring is done incorrectly or not at all severe damage to the unit may occur and the warranty on the unit may be voided 4 3 4 Mechanical Brake Release Relay The ABC Series brake unit can work in conjunction with a mechanical brake by interfacing with the motor and allowing for mechanical brake control The ABC Series brake can be used for stopping and the mechanical brake can be used for holding The Mechanical Brake Release contacts are N O relay contacts rated for 5A 250VAC and are located at terminals 7 and 8 of TB2 on the Power Board see section 2 3 for additional operating details The unit will detect the motor start command and release the mechanic
24. or Starter is turned off again while the ABC Series is still in the Jog mode the brake will NOT arm and DC injection will not take place setting this time to zero will turn off this feature After the Jog Time expires the ABC Series will enter the Armed mode indicated when the JOG ARMED LED illuminates in a steady state The ABC Series is now ready to begin DC injection braking the next time the motor starter is turned off The Armed mode has no time limit and will be maintained for the duration of the motor run time Page 12 CTi Automation Phone 800 894 0412 Fax 208 368 0415 Web www ctiautomation net Email info ctiautomation net Motortronics 2 1 3 Braking The ABC Series will enter the braking mode when the motor is given a stop command after being Armed see JOG ARMED above To prevent damaging current spikes a factory programmed delay allows the existing motor magnetic field to decay before DC is applied see section 5 1 During the BRAKING mode a set of N C interlock contacts change state and disable the motor starter control circuit during the braking cycle see section 4 2 2 The ABC Series begins injecting a regulated DC braking current and simultaneously digitally times controls the Interlock Relay and monitors the Zero Speed Sense Circuit Braking will continue until the first one of three events occurs 1 the Zero Speed Sense circuit determines the motor has stopped 2 the Brake Time expi
25. res or 3 the unit receives a Brake Disable signal input When braking is complete the ABC Series releases the Interlock Relay and is ready for another cycle 2 1 4 Brake OFF This LED illuminates whenever the ABC Series is not actively braking either because the motor is on or the previous braking cycle has been completed The ABC Series provides a built in closed loop sensing circuit that accurately determines when the motor has stopped based on the subtle signals received from the unused motor winding If the Zero Speed Sensing circuit determines that the motor has come to a stop before the Brake Time has expired it will override the brake time setting and shut the ABC Series off The BRAKE OFF LED will then illuminate NOTE Since the Brake Time may expire prior to the Zero Speed override coming into play this circuit should not be used as a true Zero Speed indicator WARNING The ABC Series DC Injection Brake requires AC power for braking Power loss before or during braking will result in the loss of braking ability which can be hazardous to personnel and or equipment If braking to a stop is critical regardless of the availability of electrical power mechanical braking should be provided as a backup system The ABC Series brake offers a Mechanical Brake Release Relay specifically for this purpose Page 13 CTi Automation Phone 800 894 0412 Fax 208 368 0415 Web www ctiautomation net Email info ctiautomation net
26. s visible on the ABC Series boards are preset at the factory and should NOT be field adjusted without specific instructions from factory authorized service personnel These devices include P1 and P2 potentiometers and push button PB1 Tampering or altering these devices may void your warranty Page 25 CTi Automation Phone 800 894 0412 Fax 208 368 0415 Web www ctiautomation net Email info ctiautomation net Motortronics 6 Start up 6 1 Start up Check List Verify that the supply voltage matches the supply voltage of the ABC Series brake Confirm that the power lines are attached to the input terminals Verify that the output leads are connected to the output terminals Complete the appropriate control and interlock connections Clear the area of people and extra parts before start up NOTE For 50 Hz operation be sure that jumper X10n the Power Board is removed 6 2 Equipment The following equipment will be needed for start up A true RMS AC clamp on ammeter to check braking current e A small screw driver to adjust braking torque if necessary A digital volt meter Stop watch or other means of measuring time 6 3 Setup Sequence e Start the motor by energizing the motor starter Allow the programmed jog time to expire Factory set for 7 sec De energize the motor starter to initiate brake mode Monitor the input current to the ABC Series unit on any one of its input leads with the tr
27. st be protected from water and condensing humidity to prevent damage to the unit In damp or cold environments space heaters may be required WARNING Remove All Sources of Power Before Cleaning the Unit In dirty or contaminated atmospheres the unit should be cleaned on a regular basis to ensure proper cooling Do not use any chemicals to clean the unit To remove surface dust use 80 to 100 psi clean dry compressed air only A three inch high quality dry paint brush is helpful to loosen up the dust prior to using compressed air on the unit Page 16 CTi Automation Phone 800 894 0412 Fax 208 368 0415 Web www ctiautomation net Email info ctiautomation net Motortronics 4 Wiring 4 1 Introduction Installation of the brake unit should be done by properly qualified personnel Check local and other applicable codes to ensure that all installation requirements are met prior to operation Prior to beginning the installation verify that the motor and brake unit have the same voltage ratings Check the unit to verify that it is rated for the appropriate current approximately equal to the motor FLA if sized for Standard Duty see section 1 3 WARNING Do not service equipment with voltage applied Unit can be source of fatal electrical shocks To avoid shock hazard disconnect main power before working on the unit Warning labels must be attached to terminals enclosure and control panel to meet local codes 4 2 Li
28. t to provide optimum performance in a wide variety of applications and should not be changed unless the user is specifically aware of the risks and consequences contact factory for details Brake On Delay Switch SW1 This DIP switch controls the amount of time that the ABC Series brake waits prior to applying DC current to the motor windings in order to allow the magnetic field to decay The rate of decay varies with motor frame size so this SHOULD NOT BE CHANGED Changing this setting could result in damage to the ABC Series components and circuit protective devices If your application requires a specific delay time please contact the factory for assistance Zero Speed Sensing Disable Jumper X3 If for some reason you need to disable the Zero Speed Sensing remove this jumper The ABC Series will then continue braking for the entire Brake Time setting even if the motor has already come to a complete stop Disconnecting the sensing lead to the T3 terminal will cause a Wiring Error fault and therefore should not be used as a means of disabling the Zero Speed Sense circuit 50 Hz Operation Power Board Jumper X1 Remove this jumper on units ordered as 60 Hz but required to operate at 50 Hz Units ordered as 50 Hz will not have this jumper so it must be installed for testing on 60 Hz systems Logic Board Power Board Starter Monitor Disable NO NO Brake NC NC Release Relay CAUTION Some adjustments and device
29. tion All warranty repairs must be performed by the Company factory or on site by factory authorized service firms or personnel approved by the Company Solid state controls have different operating characteristics from those of electromechanical equipment Because of these differences and the wide variety of applications for solid state controls each application designer must verify that the solid state equipment is acceptable for his application In no event will Motortronics be liable or responsible for indirect or consequential damages resulting from the use or application of this equipment The diagrams and illustrations in this document are included solely for illustrative purposes Because of the number of different applications Motortronics cannot be responsible or liable for actual use based on the examples or diagrams Page 29 CTi Automation Phone 800 894 0412 Fax 208 368 0415 Web www ctiautomation net Email info ctiautomation net
30. to stop time or less Keep in mind that the maximum brake time is setting is 127 seconds In heavily loaded high inertia machines and long coast to stop times the Standard Duty model may not stop the load Consider using the Extra Duty rating instead 1 3 2 Extra Duty Sizing For heavier machine loads such as large chippers punch presses and other flywheel based machines selecting an ABC Series brake based on 200 250 of the motor nameplate FLA allows faster braking The maximum developed braking torque can be as much as 200 of the motor rated Full Load Torque In this case the load can typically stop in twice the Across the Line starting time Duty cycling of the motor is a much more important consideration in applications since additional thermal stresses due to higher current levels are applied to the motor 1 3 3 Custom Sizing Extreme loads such as overhauling conveyors or large centrifuges or short stop times approaching the across the line starting time of the motor may require sizing the ABC Series for 300 of the motor FLA or greater and should be done with careful consideration of motor heating duty cycle and limitations of mechanical stress on the drive train components 1 3 4 Emergency Stopping An ABC Series brake used in conjunction with a mechanical brake should be considered if the stop times must be equal to or shorter than the across the line start time consider using and ABC Series brake in conjunction with a mech
31. to turn the ABC Series off t 2 seconds to insure proper stopping 5 4 Brake Current Setting Factory Setting 50 of Unit Rating It is strongly recommended that you try the factory settings first be fore making any adjustments If adjustments are necessary a true RMS AC clamp on ammeter should be used to check the current supplied to the motor while braking Place the meter on one of the ABC Series input power lines Start the motor by energizing the motor starter contactor Allow the motor to come up to full speed with the normal load Engage the brake by de energizing stopping the motor starter contactor Then increase the brake current if necessary by slowly adjusting the brake torque potentiometer P1 located in the Operation Interface Module in a clockwise direction The braking torque should be adjusted so that the braking time expires at the same time the motor stops Adjust the brake current and or brake time until acceptable Start and stop the motor several times to verify proper operation WARNING Never exceed the RMS full load current rating of the motor without first checking with the motor manufacturer for the maximum allowable amount of DC current that can be supplied to the motor during braking application Page 24 CTi Automation Phone 800 894 0412 Fax 208 368 0415 Web www ctiautomation net Email info ctiautomation net Motortronics Application Specific Adjustments These settings are factory prese
32. ue RMS AC clamp on ammeter Adjust the brake current if necessary If the brake times out before the motor stops increase the value of the brake time switch or increase the brake current Note Never exceed the RMS rating of the motor without checking with the motor manufacturer If the Zero Speed Sense option engages and turns off the brake before the programmed brake time expires adjust the brake time dip switch for approximately two 2 seconds longer than the actual stop time 6 4 Check Normal Sequence of Operations Apply power to the system The Power On LED should indicate that the line power is correct Both the Power On and the Brake Off LED should be illuminated e Start the motor The Jog Armed LED should flash once per second to indicate programmed Jog Time Allow the motor to run The Jog Armed LED should light solid Initiate the motor stop command The Brake Off LED should go out and the Brake On LED should illuminate The unit should continue braking until the motor comes to a stop or the programmed brake time expires Page 26 CTi Automation Phone 800 894 0412 Fax 208 368 0415 Web www ctiautomation net Email info ctiautomation net Motortronics APPENDIX A Technical Specifications Voltage Rating Line Frequency Current Ratings Output Capacity Power Circuit Transient Protection Fusing Control Circuit Control Method Operator Adjustments
33. unt for your particular installation Users should consult Motortronics or a Motortronics distributor service centre if there are any questions All installation instructions may be superseded by applicable local regional or national electrical codes Drawings application information and technical representations included in this manual are for typical installations and should not in any way be considered specific to your application or conditions Consult Motortronics for supplemental information if necessary Contents of this manual are believed to be correct at the time of printing In following with our on going commitment to meeting customer needs and developing our products to suit them Motortronics reserves the right to change specifications of this product and or the contents of this manual without notice As a result supplemental data sheets and or drawings may be associated with this equipment Please contact Motortronics and have the unit serial number available if you notice conflicts with what is depicted in the manual and what is installed in the field Phasetronics dba Motortronics accepts no liability for any consequences resulting from inappropriate negligent or incorrect installation application adjustment or maintenance of this equipment Notice Label Explanation WARNING Warning labels such as this denotes specific concerns for life safety damage issues associated with this area of the manual These statements are
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