User Manual - Galco Industrial Electronics
Contents
1. Open to stop close to COMMON to run WARNING RUN is an electronic armature current inhibit function The field output remains energised and all power terminals live RUN must not be relied on to ensure the machine is stationary during hazardous operations The 4 Model K340XRi K680XRi K1220XRi DC drive product manual motor FIELD output remains energised with RUN open please beware of overheating the motor when stopped Does not apply to permanent magnet motors Opening T9 RUN will cause immediate drive inhibit and hence if the motor is rotating at the time it will coast to zero speed 10 COM Common 0 Volts 11 TACH input The tach must be opposite polarity to speed input 1 5 Mohms input impedance Will accept full scale feedback voltages between 40V 200V using Spd x 2 switch with Max spd preset 12 RLOP Relay driver 10 5V active high Flywheel diode to COM Note The output is current limited When in current limit the output voltage achieved depends on the resistance of the load multiplied by the available current limit at that voltage according to the table below voltage current lim resistance 10 5V 1mA Greater than 10 0V 1000 Ohms This diode allows relay outputs to be OR d together if desired Output termina 633 Ohms gt 450 Ohms j E a When driving relays ensure the coil operating range is suitable E g a 12V relay with a coil operating range of 80 110 will energise at voltages2. Terminal 7 for non invert or PB Terminal 8 for invert mode The mode remains latched when the common connection is re established To implement connect T1 10V to T6 IP and use the T4 OP as the reference to the external max speed pot Then connect the normally closed pushbutton contacts to the pushbutton inputs T7 PB and T8 PB Model K340XRi K680XRi K1220XRi DC drive product manual 7 EMC Special consideration must be given to installations in member states of the European Union regarding noise suppression and immunity According to IEC 1800 3 EN61800 3 the drive units are classified as Basic Drive Modules BDM only for professional assemblers and for the industrial environment Although CE Marking is made against the EMC Directive application of EN 61800 3 means that no RF emission limits apply The drive manufacturer is responsible for the provision of installation guidelines The resulting EMC behaviour is the responsibility of the manufacturer of the system or installation The units are also subject to the LOW VOLTAGE DIRECTIVE 73 23 EEC and are CE marked accordingly Following the procedures outlined will normally be required for the drive system to comply with the European regulations some systems may require different measures Installers must have a level of technical competence to correctly install Power supply port The power supply port is subject to alternative guidelines as described below Compliance with e
3. IR comp EXTERNAL CONTROLS Armature 200 Volts DC or 50V DC for LV60 models Models K340XRi K680XRi K1220XRi 3 4 6 8 12 2 Amps Field Volts DC 0 9 x AC supply volts 1 Amp Max 0 45 x AC for field connected to F and N 1 Amp Max 110V AC or 240V AC 10 50 60 Hz 30V AC or 60V AC 10 50 60Hz for LV60 models Speed range 0 100 motor dependant Load Regulation typically 0 2 tach 2 Arm Volts Presets accessible under lift up cover Clockwise rotation for linear increase in parameter 0 5 to 105 10 5V Symmetrical about zero 40V 200V span with Spd x 2 switch Avf Tach fb volts LV60 models have an Avf range 10 50V O to 30 of maximum speed With 10K external pot 20 to 1 seconds up ramp rate For O to 10V 20 to 1 seconds down ramp rate For 10 to OV Gain 1 to 10 O to 100 current limit 0 to 25 Speed setpoint from external 10K Ohms pot External RUN contact for electronic STOP START Built in functions are channel with pushbutton control inputs and relay driver with variable threshold Pot kit available with graduated dial and knob CONTROL ACTION INSTALLATION Speed loop Full P l armature voltage or tach feedback Current loop Full P I isolated current feedback Use correctly rated cable minimum 600V AC 1 5 times armature current HG502079 iss 14 23 06 12 N Model K340XRi K680XRi K1220XRi DC drive product manual Semi conductor fuse parts FUSING
4. cable screen should connect directly to the metal of the cabinet 3 Do not run filtered and unfiltered AC supply cables together 4 The AC input filter has earth leakage currents RCD devices may need to be set at 5 of rated current 5 The AC supply filter must have a good earth connection to the enclosure back plane Take care with painted metal Remove paint and ensure good connection 8 Model K340XRi K680XRi K1220XRi DC drive product manual MECHANICAL DETAILS The product is enclosed in a stylish DIN rail mounted enclosure with plug in screw terminal connections Ea Fan exhaust For models K680XRi K1220XRi Comparator Level preset Alarm lamp DIN rail Max Speed release catch Swi AVF with bottom Sw2 Spd x 2 Min Speed rear access slot Unplug terminals to Stall lamp gain access Increasing brightness for imminent trip Wax Curent p Power ON lamp Brighter for positive current Up Ramp Down Ramp Terminals 12 to 21 Terminals 1 to 11 Basic single direction speed control with tach feedback A A F Height _ K680XRi K1220XRi Earthing A clean signal earth connection should be made to Terminal 10 Common The motor earth should be connected to the earth in the system enclosure See Page 6 for forward reverse operation methods Health and safety at work Electrical devices constitute a safety WARNINGS hazard It is the
5. electronically shut down if the internal fan fails T15 TRIP alarm output available WARNING This alarm is an electronic armature current inhibit function The field output remains energised and all power terminals live hence it must not be relied on to ensure the machine is stationary during hazardous operations Also the motor FIELD output remains energised please beware of overheating the motor when stopped Does not apply to permanent magnet motors For frequent stopping or jogging it is recommended to use T9 RUN JOGGING input When using a mains contactor connect a spare Normally Open en contact from the contactor in series with T9 RUN input This opens T9 RUN when the contactor drops out Model K340XRi K680XRi K1220XRi DC drive product manual BLOCK DIAGRAM Showing wiring for Ramped Forward Stop Reverse switch Current P l error AC supply must be 7 _ semi conductor fused amp with phase f stability preset S amp S Output provides A y angle controlled AC 240V or 110V X lt current demand i x anti parallel a bridge Max Current K340 680 1 220 XRi Speed P l error amplifier with Total speed demand DEM on T17 ve 30 Sec Stall timer with logic outputs TRIP on T15 and Overload on T14 Arm Amps Isolation Amplifier IOP on T19 Arm Volts Speed Output Isolation SOP on T18 Amplifier Up Down Ramp OP on T1
6. pass near other sensitive apparatus and the screening should be bonded to the motor housing and the point of entry of the cabinet using 360 gland techniques It is understood that the bonding of both ends of the screening and earth conductors may result in significant earth current flow if the motors and control cabinet are in widely different locations so that there are large earth potential differences In these circumstances it is recommended that a separate parallel earth conductor PEC which may be a bonded metal conduit is used alongside the drive cables to give a preferential route for this current See IEC 61000 5 2 for more detail Installation in conformance with this standard is regarded as good practice and will result in improved EMC of the whole system WARNING Safety earthing always takes precedence over EMC earthing Guidelines when using filters Filter Part number FRLN16 IMPORTANT SAFETY WARNINGS The AC supply filters must The drive and AC filter must only be The AC supply filter contains high not be used on supplies that used with a permanent earth voltage capacitors and should not be are un balanced or float with connection No plugs sockets are touched for a period of 20 seconds after DANGER respect to earth allowed in the AC supply the removal of the AC supply ELECTRIC SHOCK RISK 1 The AC connections from the filter to the drive must be less than 0 3m or if longer correctly screened 2 The AC filter and motor
7. speed feedback 1K Ohm output impedance NOTE Prior to LA issue 11 2011 see side of terminal block the output at this terminal was 0 to 10V 19 IOP Current output O to 5V output for 0 to 100 armature current Maximum output 7 5V for 150 current 1K Ohm output impedance 20 SPD Auxiliary speed input Added to main input Input impedance 100K Ohm O to 10V input for 0 to 100 speed demand direct input fast response 21 TRQ Torque input 100K Ohms pull up to 12V O to 5V input for 0 to 100 current demand This input acts as a clamp on the current demand produced by the speed loop Also if the speed loop current demand falls below the input clamp level then the speed loop has priority For the clamp to operate the speed loop current demand must be arranged to exceed the clamp level by ensuring the speed demand is high enough A Motor armature Form Factor typically 1 5 Load dependant A Motor armature F Motor Field No connection required for permanent magnet motors F Motor Field For half wave field volts 0 45 X AC connect field to F and N N AC supply 110V AC or 240V AC 10 50 60 Hz 30 60VAC for type LV60 L AC supply 110V AC or 240V AC 10 50 60 Hz 30 60VAC for type LV60 Terminal tightening torques A A F F NL 4 4in lb 0 50Nm Terminals 1 to 21 2 2in lb 0 25Nm Models K680XRi and K1220XRi use an internal fan for cooling The Alarm ALARMS lamp will come ON and the drive will
8. 6 ROP Armature For armatures J Invert Centre zero comparator with window with a time 5 Non invert threshold from 50mV to 10 5V constant of K OP ip Goes high on T12 0 10V 10mA if less than 5mS signal input T13 exceeds window a DC choke must be wired RLOP RiP foveo rip J ROP DEM SOP 10P SP0 in series 2 pole AC supply switch Semi conductor fuse Forward Reverse RUN switch Close Optional bi polar Optional bi polar Optional bi polar Stop Centre off to COMMON Open TACH for speed speed indicator current indicator change over switch for coast to STOP feedback 5V 100 7V5 150 The 10V ref is inverted by connecting T1 to T6 to produce a 10V ref on T4 The changeover centre zero switch can then select 10V for forward 10V for reverse or centre off for a ramp to zero Note The AVF tach select switch must be set and the appropriate speed scale range selected for the max feedback volts depending on the source of speed feedback If a tachogenerator is used the polarity on T11 must be opposite to the speed reference on T3 Do not use an AC rectified tachogenerator as they are unsuitable for bi directional feedback A protective earth connection is made to terminal 10 Forward Reverse using pushbuttons If both PB Terminal 7 and PB Terminal 8 are connected to common then forward reverse pushbutton operation can be established by momentarily opening PB
9. Model K340XRi K680XRi K1220XRi DC drive product manual 1 K340XRi K680XRi K1220XRi Bardac DC Motor Controller Product Manual dri Ve S This drive is an isolated 4 Quadrant speed controller for shunt wound or permanent magnet motors It utilises speed feedback from the armature voltage Avf or from a shaft mounted tachogenerator It incorporates a fully controlled anti parallel thyristor bridge with a current loop to protect the drive and motor It can be used in speed or current control modes The drive can motor or regenerate during forward or reverse rotation Please obtain expert help if you are not qualified to install this equipment Make safety a priority This component is hazardous All specifications in this document are nominal POWER RATING K340XRi 0 55KW 0 5 HP at 180 Volts DC 3 4 Amps K680XRi 0 75KW 1 0 HP at 180 Volts DC 6 8 Amps K1220XRi 1 80KW 2 0 HP at 180 Volts DC 12 2 Amps The KW HP ratings are typical motor ratings at or below the available terminal rating of Watts Varm x larm Versions that work from 60V 30V AC supply are also available for motors rated up to 48V DC These are K340XRi LV60 K680XRi LV60 and K1220XRi LV60 MAXIMUM OUTPUT AC SUPPLY INPUT SPEED RANGE USER ADJUSTMENTS Relay driver Threshold Level Maximum Speed Max spd Minimum Speed Min spd Up Ramp Ramp Down Ramp Ramp Stability Stab Maximum Current I max IR compensation
10. REQUIREMENT K340XRi DIN Mount Fuse Kit FLNR 6 3 FLLR 6 3 n A K680XRi DIN Mount Fuse Kit FLNR 20 FLLR 20 K1220XRi DIN Mount Fuse Kit FLNR 20 FLLR 20 Suitable for use on a circuit capable of delivering not more than 5000A RMS symmetrical amperes when protected by an aR class fuse WARNING The drive can only be protected by fitting an external AC supply semi conductor fuse with an I t rating below 150 A s CONTROL SIGNALS Control signals are isolated from the supply and the unit may be connected to other isolated instruments temperatures outside 10 and 40C Protect the unit from pollutants Ensure there is an adequate supply of clean cool air to ventilate the unit and the enclosure it is mounted in Dissipation in Watts 5 x Armature Amps MECHANICAL The unit is designed to clip onto a DIN rail Avoid vibration and ambient Foot mounted motors must be level and secure Protect motors from MOTOR ingress of foreign matter during installation Ensure accurate alignment of motor shaft with couplings Do not hammer pulleys or couplings onto the motor shaft Before running motor complete the following check list Warning isolate the supply first 1 Correct insulation between all motor windings and earth 2 Check inside connection box for foreign objects damaged terminals etc 3 Check that brushes are in good condition correctly seated and free to move in brush boxes Check correct action of brush springs 4 Motor vents mu
11. al speed pot slowly to maximum The motor should slowly ramp up to around 40V on the motor armature 10V for LV60 models Now set the correct 100 armature voltage and hence speed by using Spd x 2 switch ON left for speed X 2 and the Max spd preset Clockwise to increase Note if you change the Spd x 2 switch position whilst running the speed will undergo an immediate step change AA The up down ramp presets can now be set between 20 and 1 seconds RAMP and MIN SPEED and the Min spd adjusted up to 30 Note down ramp becomes up ramp for negative input Model K340XRi K680XRi K1220XRi DC drive product manual 3 Speed droop on heavy loads may occur when armature voltage feedback IR COMP is used This is compensated for by clockwise rotation of IR comp Excessive rotation may lead to instability Note IR comp is not used with tach feedback leave preset anticlockwise TACH FEEDBACK The tach feedback signal on terminal 11 must be negative with respect to terminal 10 COMMON for a positive speed demand input Whilst still in AVF mode and running at 100 speed measure the tach volts on the wire intended for T11 Warning possible high voltage This is the tach full speed voltage Make a note of it to assist in selecting the speed range Stop the motor and turn off the supply Set Avf tach switch OFF right to disconnect AVf and then re connect the tach wire to T11 By using the tach voltage reading just obtained yo
12. missions limits on this port may or may not be required depending on the environment If required then compliance can be achieved by fitting a separate filter unit contact supplier for details EN61800 3 specifies 2 alternative operating environments These are the domestic 1 environment and industrial 2 environment There are no limits specified for conducted or radiated emissions in the Industrial environment hence it is usual for the filter to be omitted in industrial systems Definition of an industrial environment Includes all establishments other than those directly connected to a low voltage power supply network which supplies buildings used for domestic purposes In order to meet mains conducted emissions limits on this port for the 1 environment a separate filter is required Please refer to supplier for a suitable filter EN 61800 3 restricted distribution domestic environment Earthing and screening guidelines A separate earth conductor is taken from the motor housing and is run adjacent to the drive conductors right up to the main earth terminal in the enclosure This conductor should not be grounded separately to any other earth point The drive protective earth on Terminal 10 should be separately taken to the cabinet star earth point Motor drive and three phase supply cables should be segregated from other cables in the cabinet preferably by a distance of at least 300mm They can be screened or armoured especially if they
13. nput signals provided T8 PB is connected to T5 COM PB Pushbutton input 47K Ohm pull up to 12V Connect to T5 COM When opened it latches T4 to invert mode for positive and negative T6 input signals Note The PB function will operate when T7 PB is either open or connected to T5 COM See truth table below for T7 and T8 operation See terminal 6 IP for notes PB Terminal 7 PB Terminal 8 Input T6 to output T4 mode Closed to Common Invert 10 5V range Closed to Common Closed to Common Remains in prevailing mode Sedo common Goset to common powersupin invert mode a Hence if PB Terminal 7 remains open then a switch on PB Terminal 8 can be used to change modes b If both PB Terminal 7 and PB Terminal 8 remain open then the invert mode is established c If both PB Terminal 7 and PB Terminal 8 are connected to common then the desired mode can be established by momentarily opening PB Terminal 7 for non invert or PB Terminal 8 for invert mode The mode remains latched when the common connection is re established This is useful for end of travel reversal To implement connect T1 10V to T6 IP and use the T4 OP as the reference to the external max speed pot Then connect the normally closed contacts from microswitches on the track to the pushbutton inputs T7 PB and T8 PB such that when the load reaches and opens the microswitch it toggles the reference in the opposite direction RUN Internal 12K pull up to 12V
14. of 9 6V and above 80 of 12V Hence it must have coil resistance greater than 633 Ohms for the output to be capable of achieving the desired voltage A suitable UL approved relay is Hongfa type HF41F 9 13 RLIP Relay driver input Accepts 0 to 10 5V signal inputs The threshold to activate the relay driver is symmetrical around zero and is set by the RELAY preset between 0 05V and 10 5V When the T13 input exceeds the positive or negative threshold then the T12 RELAY DRIVER OUTPUT is turned ON Typical uses include zero speed detector zero current detector stall detector etc The input will accept any output provided on other control terminals 50K Ohm pull down to common 10 5V Level preset range 0 5 to 105 RLIP 50k Pull down Flywheel diode 47K resistor and 47nF capacitor 14 OVLD Overload This output goes high 10 5V if the current demand exceeds 110 and the stall timer Starts timing Flywheel diode to COM See T12 RLOP for details of the output drive capability and configuration Model K340XRi K680XRi K1220XRi DC drive product manual 5 Note OVLD stays high if the overload subsequently results in a stall trip condition The stall timer will allow 150 motor current for approximately 30 seconds before tripping The overload integrator can tolerate 50 overload x 30 secs 1500 units A 50 overload is 150 full motor current i e 1 5 times motor current set on Imax Stall timer Operation Minim
15. responsibility of the user to ensure compliance with any acts or bylaws in force Only skilled persons should install this equipment Bardac Drives does not accept any liability whatsoever for the installation fitness for purpose or application of its products It is the users responsibility to ensure the unit is correctly used and installed CE UL file E168302 Bardac drives iji Bardac Corporation 40 Log Canoe Circle Stevensville MD 21666 USA Phone 410 604 3400 Fax 410 604 3500 www bardac com
16. st be freed of any obstruction or protective covers prior to running Please note that this drive does not provide motor over temperature protection If required equip your motor with a thermal sensor device that can remove the supply when activated by over temperature To avoid damage ensure the supply selection jumper on the drive matches the incoming supply 110V or 240V AC For models with LV60 suffix 30V AC or 60V AC AC SUPPLY f Set the I max Max Current preset to approximately match the motor PRESET POT settings armature rating Fully clockwise is 100 drive model rating K340XRi 3 4A K680XRi 6 8A K1220XRi 12 2A Fully anticlockwise is 0 E g for a K340XRi unit a midway setting is 50 1 7A More accurate setting requires a suitable current meter in series with the armature Set the Stab preset midway Clockwise rotation of the stab preset increases gain excessive rotation may lead to instability Set all the other presets anticlockwise to start off with Note LV60 models avf range 10 50V The preferred strategy for initial commissioning is in armature voltage feedback mode described as follows Set Avf Tach switch ON left for armature voltage feedback and set Spd x 2 switch OFF right for 40V max feedback For systems utilising tach feedback remove the terminal 11 tach connection and temporarily make wire end safe until later Check that the Power lamp lights POWER ON Close the run contact Increase the extern
17. u can adjust the full speed with the Spd x 2 switch and or Max spd preset With Spd x 2 switch OFF right the Max spd range 40 to 100V With Spd x 2 switch ON left the Max spd range 80 to 200V To do this re start and adjust Max spd as required within the selected range suggest starting anticlockwise TERMINAL LISTING AWUN oO UI 10V output 10mA max Use a 10K Ohm pot for external speed reference MIN SPEED Bottom end of external pot 5K Ohms preset to common IP Speed input 0 to 10V speed input from pot wiper 47K internal pull down OP 10 5V range Input from T6 Invert with pushbutton input T8 open Non invert with pushbutton input T7 open 10mA max COM Common 0 Volts IP Input to pushbutton controlled signal channel OP on T4 50K Ohms impedance for invert mode 10M input impedance in non invert mode The operating mode is controlled by PB on T7 and PB on T8 Note This channel can invert input signals in the range 10 5V It can also buffer i e non invert signals in the range OV to 10 5V It cannot buffer negative signals If you try to buffer a negative signal the output will be positive Note If using a high resistance external pot for positive signals e g greater than 20KOhms then this channel can be used to buffer it using the non invert mode PB Pushbutton input 47K Ohm pull up to 12V Connect to T5 COM When opened it latches T4 to buffer non invert mode for positive T6 i
18. um available overload time prior to trip 1500 Overload in seconds Overload time examples 125 Imax current for 60 secs 1500 25 60 112 5 Imax current for 120 secs 1500 12 5 120 Note The stall timer is actuated by current demand exceeding 110 when the desired speed remains unsatisfied E g Excess load insufficient supply volts loss of feedback saturated feedback insufficient torque jammed shaft This allows the protection to be more comprehensive than overcurrent alone 15 TRIP This output goes high 10 5V and latches high when the stall timer has timed out in which case T14 OVLD will also be high OR if the fan alarm has operated in which case T14 OVLD will be low Flywheel diode to COM See T12 RLOP for details of the output drive capability and configuration WARNING TRIP is an electronic armature current inhibit function The field output remains energised and all power terminals live TRIP must not be relied on to ensure the machine is stationary during hazardous operations The motor FIELD output remains energised with TRIP active please beware of overheating the motor when stopped Does not apply to permanent magnet motors 16 ROP Ramp output 0 to 10V output for 0 to 10V input 1K Ohm output impedance 17 DEM Demand output 0 to 10V output for 0 to 100 speed demand 1K Ohm output impedance Represents the inverted total speed demand 18 SOP Speed output O to 5V output for 0 to 100
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