ABC User Manual
Contents
1. MOTORTRONICS Solid State AC Motor Control Series 10 to 1000 Amp Models Electronic Motor Brake INSTALLATION amp OPERATION MANUAL Motortronics Table of contents 1 INTTOGUEt onice bolina DEREN 2 1 1 Geniale RR 3 1 2 EM DU t m mu 0RR03 te 3 1 3 Brake SIZING and SelectlOl z cucine nett sone Extent eoa I DoD EHI edd ta epe aede 3 1 4 PAD DIC AMON sanare A AIT 5 1 5 Where Mechanical Brakes Should be Used 5 1 6 ABC Model Numbers Ratings and DIMENSIONS i 6 2 elo f 1110 PA M 12 2 1 Seguence of DS SITOD iii 12 2 2 FCG OCU ONS eta aah seu See MEE ECOL LM ILE LU OLI ER Eel 14 2 3 Mechanical Control o oct it dece eon En Ear ete E 15 3 ilnsialialio eat 16 3 1 ReceVvng and UNPACKING ede ea cea 16 3 2 UR IAS OC EC NO RT M x iaia ai 16 3 3 Borse ENTRETIENS RR FORET ERREUR MORTE alia 16 3 9 Mounting and Cleaning emm EM 16 4 WING dla cai 17 4 1 Inifoduefions finali ili la EDEN 17 4 2 Line andiLoad GonnectionS GAT a a 17 4 3 Control COnneclions silla ila li i 20 5 AGIUSIEMENIS rinite 23 5 1 Time Procedures alari 23 5 2 JogrTime Adjusiment Lele en em ela 23 5 3 Brake Tim Adjusiment loi iii lillo ilaele ales 24 5 4 Brake Curreni AdjIUSIMEnt a shoot lilla lia 24 6 StartUpri cale 26 6 1 StartUp s2. alignment with this stationary field This creates braking action which 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 100 FLA be considered as an additional starting cycle when calculating the starts per hour ratings for the selected motor If the selected ABC Series is sized to deliver 200 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 www motortronics com Page 3 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 con
3. seconds maximum when all are switched to the On position e BRAKE OFF DISABLED OVERLOAD WIRING ERROR 8 BRAKING FAULT OVER TEMP ON JOG TIME ON BRAKE TIME NON BRAKE CURRENT Operator Interface Module 5 2 Jog Time Adjustment Factory Setting 3 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 and 2 to ON 1 2 Jog Time z I z 3 seconds total jog time 12 34 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 to full speed across the line plus approximately two seconds www motortronics com Page 23 Motortronics 5 3 Brake Time Adjustment Factory Setting 7 seconds The brake time is programmable from 1 to 127 seconds Set the switches marked Brake Time to the br
4. 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 www motortronics com Page 16 Motortronics 4 Wiring 4 1 Introduction Installation of the brake unit should be done by properly qualified personnel e 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 Line and Load Connections Power conductors for the Brake 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 www motortronics com Page 17 Mot
5. CES 8 930 d ZO DUE RUD N4 12 Outline ABC 10 24 50 100 E 18 500 L 20 000 12 937 22000 24 000 0 44 DIA HOLES 4 PLACES N4 12 Outline ABC 200 E www motortronics com Page 7 Motortronics NEN 12 057 0 44 DIA HOLES 4 PLACES 5 oo JOU 2 N4 12 Outline ABC 300 400 E 0 44 DIA HOLES 22927 4 PLACES 34 541 36 000 N4 12 Outline ABC 550 800 E www motortronics com Page 8 Motortronics 7 00 0 22 DIA 10 50 10 00 BEEN Panels Outline ABC 10 24 50 100 026 DIA 159 00 Panels Outline ABC 200 www motortronics com Page 9 0 50 DIA Panels Outline ABC 300 400 0 50 DIA Panels Outline ABC 550 800 www motortronics com Motortronics 21 00 d T ATTI 2 X Page 10 0 9 ce 0405 DIA TYFICAL Panels Outline ABC 1000 il www motortronics com Motortronics 36 00 Page 11 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 o
6. 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 www motortronics com Page 12 Motortronics 2 1 3 Braking After the ABC is Armed and the motor starter is given a STOP Commend the ABC Series will enter the Braking mode see JOG ARMED above To prevent damaging current spikes the ABC monitors the motor until the stator magnetic field decays before DC is applied see section 5 1 Immediately upon the motor starter opening and throughout the BRAKING mode a set of N C interlock contacts change state open and disable the motor starter control circuit during the braking cycle see section 4 2 2 The ABC Series begins injecting a True RMS 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 expires or 3 the unit receives a Brake Disable signal input When braking is complete the ABC Series releases the Interlock Relay and enters the Brake Off mode 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 clos
7. ake 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 3 to ON 1 2 4 Brake Time z seconds total brake time 12 34 56 7 Time sec 1 2 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 For stopping times shorter than 4 seconds Brake Time must be used to turn the ABC Series off to insure proper stopping 5 4 Brake Current Adjustment Factory Setting 5096 of Unit Rating It is strongly recommended that you try the factory settings first before making any adjustments First determine if adjustments are necessary by verifying the motor came to a stop during the braking cycle If not first increase the Brake Time setting and repeat the test If after increasing the Brake Time setting to the desired maximum the motor still does not come to a stop during braking increasing the Brake Current may be necessary To do so a True RMS AC clamp on ammeter is needed to measure the current supplied to the motor while braking To monitor the current place the meter on one of the ABC Series input power lines Start the motor by energizing the motor starter contactor A
8. atus 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 Motor Power Sensor T3 Voltage input used for sensing motor power presence in sequencing status circuit and for zero speed sensing during braking www motortronics com Page 27 Motortronics Outputs Starter Coil Interlock Two sets of FORM relay contacts for use in interlocking the starter coil and or other devices to prevent energizing while 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 in 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 D
9. c field to decay The rate of decay varies with motor 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 DO NOT disconnect the sensing lead to the T3 terminal as that will cause a Wiring Error fault disabling the brake Therefore this 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 required to operate at 50 Hz Logic Board Power Board Starter Monitor Disable NO NO Brake NC NC Release Relay CAUTION Some adjustments and devices 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 www motortronics com Page 25 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 tha
10. ciita aaa 26 6 2 E GUIDI nn ira ia aaa nera e ara 26 6 3 DCP Sequence Eo D OO m At a os 26 6 4 Check Normal Sequence of nennen nennen nnns nnn nnns 26 APPENDIX A TECHNICAL SPECIFICATIONS e eere enne nennen nn 27 WARRANTY INFORMATION nina 29 www motortronics com Page 1 gt D 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 account for your particular installation Users should consult Motortronics or a Motortronics distributor service center if there are any questions 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 tim
11. ckbacks 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 machine elements Prevent premature wear or component failure and eliminate the need for hasty repairs that can put maintenance personnel in potentially dangerous situations Reduce maintenance cosis by using the ABC Series The ABC series brakes can eliminate the need to plug reverse a load and 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 resonance that occur during coast down can be eliminated by using an ABC Series By not allowing the system to coast to a stop the motor load quickly pass through any dangerous speeds where resonance can occur and come to a controlled 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 an upstream circuit protective device trips or an emergency shutdo
12. e for use in these applications www motortronics com Page 5 Motortronics 1 6 ABC Series Model Number Rating and Dimensions ABC 200 Pr Max Brake Amps Voltage Enclosure 10 1000 A 240 208 240V 400 380 415V P Panel Mount 480 440 480V 600 575 600V E NEMA 4 12 Sealed NEMA 4 12 Dim Ref mom alia a lor ABC 00 200 75 40 75 so 150 100 200 125 3 ABC 00 300 100 60 125 75 250 150 300 200 4 9 ABC 400 400 150 75 150 100 350 200 400 250 4 9 550 550 250 125 200 150 soo 300 eoo 350 5 10 _ ABc 800 800 350 200 350 200 700 450 900 500 s 10 _ABC 1000 1000 400 250 400 900 500 1000 600 5 10 NOTES 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 Dim Dimensions Inches Ref i A 2 aos 79 72 10 ise 4 i 16 10 157 a s 2 104 pes 9 24 16 945 22 10 36 30 16 945 26 www motortronics com Page 6 Motortronics 0 44 DIA HOLES 4 PLA
13. e 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 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 www motortronics com Page 2 Motortronics 1 About the Motortronics ABC Serie
14. ecessary 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 Ventilated Enclosure 0 to 50 C 32 to 122 F Non Ventilated Enclosure 0 to 40 C 32 to 104 F 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 enclosure Enclosure size and type must be suitable for environmental conditions and heat dissipated 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 must 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 must be protected from water and condensing humidity to prevent possible damage 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
15. ed 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 www motortronics com Page 13 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 I
16. esign 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 www motortronics com Page 28 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 option 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 www mo
17. f 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 The ABC Series brake is self powered from the available motor branch circuit 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 monitors 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 specific amount of motor run time before going into the Armed mode by using the Jog feature This feature allows for user setup and testing of systems during the jog time without 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 Motor Starter is turned off 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 If the motor is run longer than the Jog Time and 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
18. he 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 starter re enter the JOG mode and ARM if conditions are correct Circuit voltage potential 15VDC maximum Logic Board Starter Brake 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 www motortronics com Page 21 Motortronics 4 3 3 Interlock Contacts 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 ci
19. lines Whenever possible conduits containing control and power conductors should cross at right angles to each other Control connections are made at terminal blocks mounted on the printed circuit boards inside the unit case TB1 is on the Logic Board with the terminals for the Starter Monitor Brake Command and Brake Disable inputs TB2 is located on the Power Board and provides 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 status signal from the motor starter to the CPU refer to sections 2 1 2 amp 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 a normally open contact move the Jumper to X2 For reversing starters use 2 N O contacts in parallel or 2 N C contacts in series 1 from each contactor to this input Circuit voltage potential 15VDC maximum Logic Board Starter Brake Monitor Disable www motortronics com Page 20 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 t
20. llow the motor to come up to full speed with the normal load Engage the brake by de energizing stopping the motor starter contactor Then measure the brake current If necessary slowly adjust the brake torque potentiometer P1 located in the Operation Interface Module clockwise to increase the braking current The braking Current and Time Settings should be adjusted so that the braking time expires at the same time the motor stops Adjust the brake Time and or Current 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 www motortronics com Page 24 Motortronics Application Specific Adjustments CAUTION These settings are factory preset to provide optimum performance in a wide variety of applications and should not be changed unless the user 15 specifically aware of the risks and consequences contact factory for details Disconnect all incoming power and observe anti static control measures when making any of the following configuration changes Brake On Delay Switch SW1 This DIP switch controls the amount of time the ABC Series brake waits prior to applying DC current to the motor windings It is Factory Configured for the Automatic Mode in order to allow the stator magneti
21. n LED should indicate that the line power is correct Both the Power On and the Brake Off LED should be illuminated Start the motor The Jog Armed LED should flash once per second to indicate programmed Jog Time Allow the motor to run until 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 begin braking and continue braking until the motor comes to a stop or the programmed brake time expires www motortronics com Page 26 Motortronics APPENDIX A Technical Specifications Voltage Rating Line Frequency Current Ratings Output Capacity Power Circuit Transient Protection Fusing Control Circuit Control Method Operator Adjustments Adjustment Ranges Inputs Inputs Models rated from 208 600 10 Selectable for 50 60 Hz 2Hz 10 1000A 10 24 50 100 200 300 400 550 800 1000A 25 duty cycle at 100 unit rating 10A 400A are UL duty cycles 10 amp 24A 100 50 thru 200A 25 300A thru 800A 15 1000A 25 Full wave bridge 4 SCRs designed for use without isolation contactors RC snubber dv dt circuit on each SCR device Refer to section 4 2 1 for branch circuit protection requirements oelf powered directly from line terminals No separate control voltage required Microprocessor unit control sequencing I O monitoring and st
22. ortronics 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 high to protect the ABC Series per code Recommendations for commonly available SCPDs are as follows meee Time Delay Fuse Non Time Delay Fuse NM SAEI Class RK5 Class J ABC 10 ABC 24 ABC 100 225A 225A ABC50 gt 225A 225A ABC 200 300A 300A ABC 300 1200A 1600A 900A ABC 400 1200A 1600A 900A ABC 550 150 of Max Unit Rating 150 of Max Unit Rating 200 of Max Unit Ratino ABC 800 150 of Max Unit Rating 150 of Max Unit Rating 200 of Max Unit Rating ABC 1000 150 of Max Unit Rating 150 of Max Unit Rating 200 of Max Unit Rating WARNING Many motor safety disconnect switches are not rated to interrupt DC current Replace any load 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 www motortronics com Page 18 Motortronic
23. r 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 can 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 mechanical brake www motortronics com Page 4 Motortronics 1 4 Applications The ABC Series electronic brake is ideal for machine and process equipment control applications Benefits include improved efficiency increased safety and reduced equipment maintenance costs 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 while overall operating costs decrease because the load stops much sooner The ABC Series eliminates the common and dangerous practice of jamming the load to a stop which seriously reduces the life and effectiveness of saw blades molding heads and Knives Safety is improved by eliminating the need to jam stop equipment This will prevent personnel injuries caused by ki
24. rcuit 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 for holding The Mechanical Brake Release contacts are N O relay contacts rated for 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 mechanical 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 www motortronics com Page 22 Motortronics 5 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
25. ronics com Page 14 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 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 Closes Braking Time Completed De energizes Opens Zero Speed Override Disabled Before or During Jog Armed Follows motor starter Disabled During Braking De energizes Opens www motortronics com Page 15 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 no connections were damaged during shipping 3 2 Initial Unit Inspection Complete a visual check of the unit for 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 n
26. s 4 2 2 Power Connections The ABC Series unit will operate on either a Wye or a Delta connected motor Connect the brakes L1 amp L2 input terminals to the L1 amp L2 terminals on the motor starter Connect the T1 and T2 brake output terminals to the T1 and T2 terminals on the Motor starter An additional sensing wire must be run from T3 W terminal of the starter to the voltage sensing circuit of the ABC Series labeled This terminal carries very little current so a 14 wire can be used Proper fuse protection for the field wiring 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 Line Power Existing Starter Start Stop Control Starter Interlock Start Monitor Contact EM M v i Series Disable ___ OL Mechanical Brake Relay c c mc mc r m mo rn mc m m SJ Mechanical Brake Col CAUTION 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 www motortronics com Page 19 Motortronics 4 3 Control Connections Control wire should be twisted shielded cables and run in a separate conduit from power
27. s 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 Installation involves simply wiring the device into the motor s starter circuit which allows it to operate in parallel with the starter 1 2 Theory of Operation Incoming AC power is 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 rotor continuously attempts to pull into
28. t can also be used to cancel a Braking cycle that is already in progress 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 Some interface wiring may be needed depending on the voltage and current rating of the mechanical brake coil 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 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 shut down the brake and illuminate the Fault and Over Temp LEDs www motort
29. t 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 e A true RMS AC clamp on ammeter to check braking current A small screw driver to adjust braking torque if necessary Adigital volt meter Stop watch or other means of measuring time 6 3 Setup Sequence Start the motor by energizing the motor starter Allow the programmed jog time to expire Factory set for 3 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 true 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 Operation Apply power to the system The Power O
30. tortronics com Page 29 4 MOTORTRONICS Solid State AC Motor Controls For the latest product information visit www motortronics com Phasetronics Inc dba as Motortronics 1600 Sunshine Drive Clearwater Florida 33765 USA Tel 727 573 1819 or 888 767 7792 Fax 727 573 1803 or 800 548 4104 E Mail sales motortronics com Manual 0011002 Rev 2 0 0 4 08 30 12
31. trolled 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 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 moto
32. wn 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 stops the load and the mechanical brake holds it Regarding 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 If 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 mechanical brake in these applications Stop 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 several 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 brak
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