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Service Manual - Carotron, Inc.

1. 52 11 1 Componient Substitution uuu Sn 52 11 2 Printed Circuit Assemblies 5 u gesu iwa aaa 53 11 3 Connector Cable Assemblies 2 2 53 FUSES 54 11 3 Power Components da aaa 55 A A 56 D11312 sh 1 Control Board ee mese eee 56 D11312 sh 2 Control Board 57 D11312 sh 3 Control Board Schematic 22 22 22 58 D11312 sh 4 Control Board 22 2 222 59 C11133 E06000 Personality Board 5 22 2 2 60 C11112 E12000 Personality Board Schematic 61 C11124 Current Transformer Board Schematic 22 2 62 1115 Relay Board Schematic iii ste b ka lee un 63 C11118 Power Supply Board Schematic pp 64 C11127 Fuse Board Schematic ene esee 65 D11351 sh 1 Trigger Board 9 66 D11351 sh 2 Trigger Board 67 D11168 Wiring Diagram E06000 Series 20 75 0000 0 4 68 D11167 Wiring Diagram E12000 Series 20 75 e emn enne 69 D11494 Wiring Diagram E06000 Series 100 150
2. ELITE CONTROL Service Manual Elite Series Drives L ABOUT THIS GUIDE sau Bus a a 2 2 GENERAL DESCRIPTION u a en ara uam 2 3 SPECIFICATIONS sie een 5 4 MODEL IDENTIFICATION ans A AW A as 7 5 CONVENTIONS GLOSSARY amp ABBREVIATIONS 14 6 DESCRIPTION OE OPERATION AW 16 6 JiArmatare Power Bridge i i aaa 16 A SS A a RO 17 6 3 Relay Logic and Control Voltage Supply 2 22 18 6 4 Power Supplies ans sas ee ns Aes 19 6 3 spede SSS db dts 19 6 6 Feedback Circuitry and Isolation 9 21 6 7 Velocity OP a Na SA 26 6 8 Current Limit and Overcurrent Functions 2 eene eene 27 OVCE OO u s nuka usa etes aet TN 29 6 10 Trigger A re in Ree e A e 30 6 11 Special Signals and Circuit 2 2 33 6 12 Fault Circuits aaa gs 36 7 DRIVE PROGRAMMING amp CALIBRATION 39 COMPONENT TESTING sn se A ERE P EUER 44 9 TROUBLESHOOTING eae serie 45 10 TEST POINTS amp CHECK POINTS sen ne en 48 11 REPLACEMENT PARTS amp COMPONENT SUBSTITUTIONS
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4. 100 200 BASIC CHASSIS MODEL 125 250 BASIC CHASSIS MODEL 150 300 BASIC CHASSIS MODEL 5 10 5 20 OPTION CHASSIS 15 20 25 40 CONTACTOR OPTION CHASSIS 25 30 50 60 CONTACTOR OPTION CHASSIS TABLE 1 MODEL NUMBERS MODEL NUMBER DESCRIPTION E06075 C75 E12075 C75 E06100 C100 E12100 C100 E06125 C125 E12125 C125 E06150 C150 E12150 C150 E06200 C200 E12200 C200 E06250 C250 E12250 C250 E06300 C300 E12300 C300 40 75 CONTACTOR OPTION CHASSIS 50 100 CONTACTOR OPTION CHASSIS 60 125 CONTACTOR OPTION CHASSIS 75 150 CONTACTOR OPTION CHASSIS 100 200 CONTACTOR OPTION CHASSIS 125 250 CONTACTOR OPTION CHASSIS 150 300 CONTACTOR OPTION CHASSIS NOTE The options listed in TABLES 2 3 and 4 are used with and mounted on the chassis of the contactor option chassis models listed above TABLE 2 BLOWER STARTER OPTIONS OPTION BLOWER MODEL USED WITH DESCRIPTION NUMBER 0 6 TO 1 0 AMP OVERLOAD E612BS 001 MTP FVB2180 230 1PH RANGE FOR 1 PHASE BLOWER MTP FVB3210 460VAC 3PH 0 4 TO 0 6 OVERLOAD E612BS 002 25 460VAC 3PH RANGE FOR 3 PHASE BLOWER MTP FVB3210 230VAC 3PH E612BS 003 MTP FVB3250 230VAC 3PH MTP FVB4280 460VAC 3PH 0 6 1 0 AMP OVERLOAD RANGE FOR 3 PHASE BLOWER MTP FVB4280 230VAC 3PH E612BS 004 MTP FVB6320 460VAC MTP FV
5. 70 D11495 Wiring Diagram E12000 Series 100 150 71 D11510 Wiring Diagram E06000 Series 200 300 72 D11511 Wiring Diagram E12000 Series 200 300 HP 73 C11564 General 3 235 a Oe vba dre 74 This guide is meant to supplement ELITE Instructions Manual and DCM100 Users Guide for the ELITE Series of DC Drives Installation wiring and start up The ELITE series of DC motor controls provides full range speed and torque control of 5 300 DC motors rated for NEMA type power supplies The 06000 regenerative series and the E12000 regenerative series are offered in compact panel mounted assemblies There are ten basic models in each series Each model is customer connectable for operation at 230 380 or 460 VAC input Semiconductor line fuses are provided for AC line protection with auxiliarv line fuses for optional equipment and the field supplv Fuse protection is also provided for the 115 VAC control voltage input Standard relav logic interfaces with customer supplied operators for Emergency Stop Ramp Stop Run and Jog The E12000 information is found in these manuals This manual will address problems with operation drive failure and how to correct these situations regenerative models also have a Forward Reverse direction
6. Level range Condition Parameter Level range Condition Parameter Level range Condition Parameter Level range Condition Parameter Level range Condition supplv 6 VDC 0 30 VDC Fixed within line variation of 10 Total reference setpoint 0 to 10 6 VDC Polarity direction Sum of Run Jog Sum and Min Speed signals trimmed by MAX speed pot s reference 0 VDC 0 speed 9 VDC 100 FWD reference 9 VDC 100 REV reference Forward Accel Decel output 0 to 10 VDC Equal to speed pot setting after ramp time 0 VDC 0 reference 10 VDC full reference Reverse Accel Decel output regen models only 0 to 10 VDC Equal to speed pot setting after ramp time 0 VDC 0 reference 10VDC full reference Scaled armature voltage Oto 5 VDC pol FWD pol REV 0 VDC 0 rated armature voltage 5 VDC 100 rated armature voltage Parameter Level range Condition Parameter Level range Condition Parameter Level range Condition Parameter Level range Condition Scaled tachometer voltage when used 0 to 5 VDC pol FWD pol REV 0 VDC 0 motor speed 5 VDC 100 rated motor speed Scaled encoder voltage when used 0 105 VDC pol FWD pol REV 0 VDC 0 motor speed 5 VDC 100 rated motor speed Velocity integrator 0 to 13 5 VDC pol torq Load and speed dep
7. The armature voltage sensing circuit uses high impedance exactly 9 9 megohms for isolation on the TRIGGER board 9 9 megohms is the total of three series connected resistors in each of the Al and A2 sensing inputs on 1 Refer to FIGURE 14 The signal then connects to the CONTROL board where it provides a polarity signal to the tach and encoder feedback circuits Programming jumper JI selects gain of A5 C to give 5 VDC output measured at TP15 K when at the respective full rated armature voltage of 240 415 or 500VDC This scaled armature voltage 15 used for the zero speed circuit input see SECTION 6 11 and as input to the armature feedback circuit The counter voltage generated by a motor armature is not an ideal velocity feedback I R losses in the armature cause speed to drop as load increases with armature voltage held constant To compensate for the losses the IR COMP pot and circuit uses some of the armature load signal from the current amplifier to subtract from the armature feedback voltage See FIGURE 14 The reduction in feedback acts the same as an increase in velocity reference and will cause an increase in armature voltage with an increase in load to keep the speed constant A4 A sums the inverted scaled armature voltage via A4 B with the current amplifier output from A8 D A4 A has a FET clamp to disable 1t when a tach
8. 206 FLA 60 240VDC 125HP 4 500VDC E12150 000 256 FLA 75 240VDC 150HP 4 500VDC E12200 000 340 FLA 100HP 240VDC 200 500VDC E12250 000 425 FLA 125HP 4 240VDC 250HP 4 500VDC E12300 000 510 FLA 150HP 240VDC 300HP 500VDC ELITE series controls offered in additional option dash numbers These model basic chassis models and contactor models and option numbers are shown in the following available with factorv installed options The tables basic drive will have a model number label NOTE The contactor option chassis models with applicable rating information Contactor listed below include the control voltage 115 models will have an additional level showing VAC transformer as well as the armature the contactor horsepower rating and any contactor TABLE 1 MODEL NUMBERS HP RATING MODEL NUMBERS 230 460 INPUT DESCRIPTION 06020 000 12020 000 5 10 5 20 BASIC CHASSIS MODEL E06040 000 E12040 000 06060 000 12060 000 06075 000 12075 000 06100 000 12100 000 06125 000 12125 000 06150 000 12150 000 06200 000 12200 000 06250 000 12250 000 06300 000 12300 000 06020 20 12020 20 06040 40 12040 40 06060 60 12060 60 15 20 25 40 BASIC CHASSIS MODEL 25 30 50 60 BASIC CHASSIS MODEL 40 75 BASIC CHASSIS MODEL 50 100 BASIC CHASSIS MODEL 60 125 BASIC CHASSIS MODEL 75 150 BASIC CHASSIS MODEL
9. E06300 000 510 AMPS C11126 009 E12300 000 The current signal 15 then scaled and buffered before connecting to the CONTROL board The next stage A8 B uses programming jumper J4 to allow amplification of the current signal in 2096 increments This is done to scale the current related circuits to match the rating of the motor For example An E12020 000 drive has a full load rating of 36 amperes or 10 horsepower with a 240 VDC motor When the drive is used with a 36 amp 10 HP motor the J4 100 position is used If used with a 28 1 ampere 7 5 HP motor 28 divided by 36 equals approximately 78 so the closest range 80 should be selected This will make the current feedback signal measured at TP21 S equal to 5 0 VDC at an armature current of 28 8 amperes The polarity of the current signal is controlled by the positive negative bridge selection signal which connects to a polarity control circuit LEDs Iland I2 on the CONTROL board indicate which bridge has been selected and the polarity of the current signal Refer to SECTION 6 11 fora description of this polarity circuit The bi polar current feedback signal connects to the current loop error amplifier and the IR COMP circuit AMP AS8 C buffers the current feedback signal which can be monitored at TP21 S and TB2B 18 Refer to FIGURE 12 amp 13 for typical waveforms under no load and full load VOLTAGE SENSING
10. consent of an authorized Company representative make a change in specifications to products parts or systems covered by a purchase order accepted by the company In the event of any such changes the Company shall be entitled to revise its price and delivery schedule under such order 8 Returned material If the Purchaser desires to return any product or part written au thorization thereof must first be obtained from the Company which will advise the Purchaser of the credit to be allowed and restocking charges to be paid in regard to such return No product or part shall be returned to the Company without a RETURNTAG attached thereon which has been issued by the Company 9 Packing Published prices and quotations include the Company s standard packing for domestic shipment Additional expenses for special packing or overseas shipments shall be paid by the Purchaser If the Purchaser does not specify packing or accepts parts unpacked no allowance will be made to the Purchaser in lieu of packing 10 Standard transportation policy Unless expressly provided in writing to the contrary products parts and systems are sold f o b first point of shipment Partial shipments shall be permitted and the Company may invoice each shipment separately Claims for non delivery of products parts and systems and for damages thereto must be filed with the carrier by the Purchaser The Company s responsibility therefor shall cease when the carrier s
11. 000 11126 002 Models 06075 000 12075 000 11126 003 Models E06100 000 and 12100 000 C11126 004 Models E06125 000 and E12125 000 C11126 005 Models 06150 000 and 12150 000 C11126 006 Models 6200 000 and 12200 000 C11126 007 Models 06250 000 and 12250 000 C11126 008 Models 06300 000 and 12300 000 C11126 009 11 3 CONNECTOR CABLE ASSEMBLIES SAME FOR ALL MODELS A11178 000 CNT1065 00 A11179 000 CNT1066 00 CNT1066 00 CNT1067 00 CNT1065 00 MODEL DEPENDENT Cable 8 E06000 Series 20 150 HP Models A11180 001 E12000 Series 20 150 Models A11180 000 06000 Series 200 300 Models 11523 000 E12000 Series 200 300 Models A11524 000 E06000 Series 20 150 HP Modes A11181 000 All E12000 Series 20 150 HP Models A11182 000 All E06000 Series 200 300 HP Models A11525 000 All E12000 Series 200 300 HP Models A11526 000 Cable 10 E06000 Series 40 75 HP Models A11183 000 All E12000 Series 60 75 HP Models A11183 00 E06000 Series 100 150 HP Models A11183 001 All E12000 Series 100 150 HP Models A11183 001 Cable 10 cont E06000 Series 200 300 HP Models A11527 000 All E12000 Series 200 300 HP Models A11528 000 Cable 11 All E06000 Series 20 75 HP Models A11184 000 All E12000 Series 20 75 HP Models A11184 000 E06000 Series 100 150 HP Models A11184 001 All E12000 Series 100 150 HP Models A11184 001
12. 2 380 VAC input 300 VDC 10 amps max 2 460 VAC input NOTE With the drive stopped Field Economy function reduces field voltage by 35 after adjustable time delay Horsepower Range Non Regenerative Models e E06020 000 36 FLA 10 HP 240 VDC 20 HP 500 VDC Horsepower Range Non Regenerative Models Cont E06040 000 E06060 000 06075 000 06100 000 06125 000 06150 000 06200 000 06250 000 06300 000 71 FLA 20 HP 4 240 VDC 40 500 VDC 107 FLA 30 HP 4 240 VDC 60 HP 500 VDC 140 FLA 40 HP 240 VDC 75 HP 500 VDC 174 FLA 50 240 VDC 100HP 2500 VDC 206 FLA 60HP 240 VDC 125 500VDC 256 FLA 75HP 240 VDC 150 2500 VDC 340 FLA 100 9240 VDC 200HP 2500VDC 425 FLA 125HP 240VDC 250HP 2500VDC 510 FLA 150HP 240VDC 300HP 2500VDC Speed Range e 20 1 Motor Dependent Speed Regulation Armature Feedback 0 1 of base speed Tachometer Feedback 0 5 of base speed Encoder Feedback 0 5 of base speed Torque Regulation e 2 0 of current range selected Horsepower Range Regenerative Models 12020 000 36 10 4 240 VDC 20 500 VDC 12040 000 71 FLA 20 4 240 VDC 40HP 500 VDC 12060 000 107 FLA 30 4 240 VDC 6OHP 4 500 VDC 12075 000 140 FLA 40 240 VDC 75 4 500 VDC E12100 000 174 FLA 50 240 VDC 100HP 0 500 VDC E12125 000
13. 2 and 13 of rated or Base speed Slowly increase the IR COMP adjustment clockwise until the loaded speed equals the unloaded speed measured in the previous step Making this adjustment may now cause the unloaded speed to be slightly higher Repeat this procedure until there is no difference between loaded and unloaded speed levels Use care to prevent setting the adjustment too high or speed may increase with load and instability may result NOTE For this adjustment do not use SCALED ARMATURE VOLTAGE to measure speed Armature voltage is not an exact indication of loaded motor speed INTEGRAL NULL Adjustment of the INTEGRAL NULL pot is Sometimes required when the control is continually operated in the RUN mode with a zero speed reference or when very rapid stopping is required With maintained zero reference creeping occur and depending on dvnamics of the load and response of the control rapid stopping can cause an overshoot through zero speed or back up in motor rotation at stop If either of these conditions is apparent increase the INTEGRAL NULL in the clockwise direction to minimize the svmptoms Because there is a small reduction in speed regulation DO NOT make this adjustment unless these svmptoms are apparent in normal operation NOTE ELITE drives manufactured with a revision F or later CONTROL board incorporate an integral null circuit that is locked out above zero speed This eliminates t
14. E06000 Series 200 300 HP Models A111529 000 All E12000 Series 200 300 HP Models A11530 000 11 4 FUSES SAME FOR ALL MODELS FUI FU2 FU3 10 ampere dual element time delay 500 VAC located on the FUSE board CAROTRON FUS1008 03 BUSSMANN LITTELFUSE FU4 5 ampere 250 dual element time delay located on the FUSE board CAROTRON BUSSMANN LITTELFUSE FUS 0 5 ampere 120 dual element time delay located on the POWER SUPPLY board CAROTRON FUS1006 05 BUSSMANN MDL 1 2 LITTELFUSE 313 500 MODEL DEPENDENT FUS FU6 FU7 current rating per model 500 VAC semiconductor types Model E12020 000 and 06020 000 50 amp CAROTRON FUS1009 00 BUSSMANN SHAWMUT Model E12040 000 and E06040 000 100 amp CAROTRON FUS1009 01 BUSSMANN FWH100 SHAWMUT 5005100 4 Model 12060 000 and 06060 000 150 amp FUS1009 02 BUSSMANN FWH150 SHAWMUT 5005150 4 Model 12075 000 06075 000 175 amp FUS1009 03 BUSSMANN FWH175 SHAWMUT A50QS175 4 Models E12100 000 amp E06100 000 250 amp CAROTRON FUS1009 05 BUSSMANN FWH250 LITTELFUSE L508250 Models E12125 000 amp E06125 000 300 amp CAROTRON FUS1009 06 BUSSMANN FWH300 LITTELFUSE L508300 Models E12150 000 amp E06150 000 350 amp CAROTRON FUS1009 04 BUSSMANN FWH350 LITTELFUSE L508350 Models E12200 000 amp E06200 000 450 amp CAROTRON FUS1009 07 BUSSMANN FWH450 LITTELFUSE 1505450 Models 12250 000 amp 06250 0
15. L1 6 V 12 at lower potential than L1 Positive phase B sync signal 6 V p p 50 duty cycle square wave 6 V 12 at higher potential than L3 6 V L2 at lower potential then L3 Negative phase B sync signal 6 V p p 50 duty cycle square wave 6 V L3 at higher potential than L2 6 V L3 at lower potential than L2 Parameter Level range Condition Parameter Level range Condition Parameter Level range Condition Parameter Level range Condition Parameter Level range Condition Positive phase C sync signal 6 V p p 50 duty cycle square wave 6 V L3 at higher potential than L1 6 V L3 at lower potential than 1 1 Negative phase C sync signal 6 V p p 50 duty sync signal 6 V LI at higher potential than L3 6 V 11 at lower potential than L3 Voltage controlled oscillator output 6 p p 50 duty cycle square wave 0 to 220 kHz Load and speed dependent 200 rpm N L 46 kHz 200 rpm F L 55 kHz 1750 rpm N L 85 kHz 1750 rpm F L 106 kHz Reverse power bridge enable 6 to 6 VDC 6 VDC reverse bridge enable 6 VDC reverse bridge disabled Forward power bridge enable 6 to 6 VDC 6 VDC forward bridge enabled 6 VDC forward bridge disabled 11 1 COMPONENT SUBSTUTION Manv components of an ELITE drive are interchangeable with other ELITE horsepower models The following section lists CARO
16. Proportional 10 turns CW Positive I Current Limit full CCW Integral Null full CCW Fwd Max Max Speed Rev Accel mid range mid range Rev Decel Min Speed mid range Programming Jumper Presets Jumper 14 16 110 and should be placed in the positions appropriate to the line motor and feedback device rating J5 should be placed initially in the AFB position until proper encoder or tachometer operation is verified Jumper J2 J3 J7 J8 19 and J12 will be placed according to the specific application requirements 10 turns CW 10 turns CW 10 turns CW mid range Negative I Current Limit mid range full CCW mid range Fwd Accel Accel Time mid range mid range Fwd Decel Decel Time mid range full CCW 7 2 Calibration and Fine Tuning IR COMP The IR COMP is functional only in the AFB mode and is used to keep motor speed from decreasing as load is increased Adjustment is best performed when the motor or machine can be loaded normally If the motor is normally operated at a particular speed adjust the IR COMP while running at that speed If the motor operates under load over a wide speed range pick a speed near mid range to make the adjustment Adjust as follows Operate the unloaded motor at the normal or mid range speed and note the exact speed While still monitoring speed apply normal load The reduction in speed of a fully loaded motor will usually fall between
17. VDC ARM NEMA 12 ENCLOSED 3 4 Ohm 4000 WATT BRAKE RESISTOR TABLE 6 DYNAMIC BRAKING OPTIONS CONT OPTION NUMBER MOTOR USED WITH DESCRIPTION E612BR 475 75 HP 500 VDC ARM EXPANDED METAL ENCLOSED 2 6 Ohm 4160 WATT BRAKE RESISTOR E612BR 4150 100 150 HP 500 VDC ARM EXPANDED ENCLOSED 1 24 Ohm 4464 WATT BRAKE RESISTOR E612BR 4200 200 HP 500 VDC ARM EXPANDED METAL ENCLOSED 1 02 Ohm 6500 WATT BRAKE RESISTOR E612BR 4250 250 HP 500 VDC ARM EXPANDED METAL ENCLOSED 0 82 Ohm 11 000 WATT BRAKE RESISTOR E612BR 4300 300 HP 500 VDC ARM EXPANDED METAL ENCLOSED 0 65 Ohm 14 600 WATT BRAKE RESISTOR CONVENTIONS The following conventions will be used throughout this manual measurements are referenced to circuit common unless otherwise noted Circuit common is not earth or chassis ground Please refer to the svmbols below e Circuit Common e Chassis Ground e Earth Ground All signal level wiring such as tachometer encoder and potentiometer should use fully insulated shielded cable whether or not shown in this manual The shield should be connected at one end only to circuit common The other end of the shield should be clipped and insulated to prevent the possibility of accidental grounding All internal relays have suppression devices in parallel with coil whether or not shown in this manual The arrows on potentiom
18. VDC and allows C83 to quickly charge When the command signal is removed the 15 VDC causes a slow discharge capacitor a 330K Ohm resistor to produce the delayed drop out of the relay As shown in FIGURE 27 a control signal is applied to the non inverting amplifier A3 A Its output is used to turn FET Q20 on or off When a positive control signal is applied FET Q20 clamps the non inverting input of A9 B This causes the A9 B summing amplifier to have a gain of 1 which inverts the tachometer signal With a negative control signal FET Q20 is unclamped and the A9 B amplifier has gains of 1 on the inverting input and 2 the non inverting input Thus the total gain equates to 1 and the polarity of the tachometer signal is not changed The tachometer and encoder feedback circuits use the inverted armature feedback signal for polarity control The current feedback circuit uses the bridge selection signal for control POLARITY CONTROL CIRCUIT The armature current feedback tachometer feedback and encoder feedback signals all use a polarity control circuit This circuit is required on the current and tachometer feedback signals since both are sensed by circuits that are insensitive to polarity The encoder feedback signal is unipolar and therefore requires polarity control 6 12 FAULT CIRCUITS There are four fault conditions on all ELITE control models Refer to FIGURE 28 Each fault circuit OVERCURRENT
19. amplifier and to jumper J2 so that the summing signal can be programmed to add or subtract from the TOTAL REFERENCE SETPOINT This circuit is clamped when the drive is stopped in the JOG mode NOTE Jumper J3 can be used to defeat the clamp when the drive is in the JOG mode Once all of these signals are summed together they connect to the velocity error amplifier A4 D The TOTAL REFERENCE SETPOINT which measures 10 VDC at 100 reference can be monitored at TP19 H and TB2B 16 6 6 FEEDBACK CIRCUITRY AND ISOLATION ELITE drives continuously monitor feedback signals that are related to motor velocity and current They also precisely sense the AC line voltage and frequency in order to properly synchronize gating of the SCRs At the same time the drive is isolated from the sensing signal for ease of interface noise immunity and safety LINE VOLTAGE SENSING Sensing of the three phase line voltage is achieved by connecting impedance isolating resistors and OP AMPs in a delta configuration across the line Refer to FIGURE 10 The outputs are used to derive synchronized gating signals for the SCRs and for PHASE LOSS protection Refer to SECTION 6 10 for a description of the trigger circuit and SECTION 6 12 concerning the PHASE LOSS fault circuit ARMATURE CURRENT SENSING Motor armature current on the ELITE is detected by sensing the AC current in two of the three line inputs This is possible since all of the m
20. control enabling them to provide full four quadrant operation This means direction of motor rotation can be electronically reversed without switching the motor contactor and motoring or braking torque can be supplied in both the forward and reverse directions Additional models include options such as armature contactors brake resistors disconnect switches blower starters enclosures and field regulator supplies An accessory drive circuit monitor DCM 100 000 is available to assist in set up and troubleshooting by plugging in to the CONTROL board This allows 20 separate signals to be monitored Programmable for 230 380 or 460 VAC 3 phase line input Insensitive to phase rotation of A C input Full 10 ampere rated field supplv with provisions for interfacing the Field Loss circuit to an external supplv or regulator Automatic Field Economv with customer adjustable delav after stop to reduce idling field voltage by 35 Current transformers for isolated armature current sensing High impedance isolation for armature and line voltage sensing Electrically isolated power modules rated at 1400 volts PIV and 1000 volts microsecond dv dt Individual SCR R C networks for transient protection Semiconductor line fuses for power circuit protection Thermostatically controlled fan on forced ventilated models to extend life of the fan Latching FAULT logic for safety shutdown with form C contact output and L
21. dependent 200 rpm N L 4 0VDC 200 rpm F L 3 7VDC 1750 rpm N L 2 7 VDC 1750 rpm F L 1 2 VDC Current loop error signal 0 to 13 5 VDC Sum of current demand and current feedback Circuit common Circuit common Circuit common NOTE Voltage levels given are measured with respect to circuit common TP24 Parameter Level range Condition TP25 Parameter 25 Parameter TP26 Parameter Level range Condition Parameter Level range Condition Regulated power supply 6 VDC 0 30 Fixed within line variation of 10 Circuit common Circuit common Phase A conduction angle 6 V p p pulses First start pulse and end stop pulse determine the phase A conduction angle Phase B conduction angle 6 V p p pulses First start pulse and end stop pulse determine the phase B conduction angle Parameter Level range Condition Parameter Level range Condition Parameter Level range Condition Parameter Level range Condition Parameter Level range Phase C conduction angle 6 V p p pulses First start pulse and end stop pulse determine the phase C conduction angle Positive phase A svnc signal 6 V p p 50 dutv cvcle square wave 6 V LI at higher potential than L2 6 V 11 at lower potential than 12 Negative phase A svnc signal 6 V p p 50 dutv cycle square wave 6 V 12 at higher potential than
22. fuse will not voltage drop while a blown fuse will SCRs The power devices mav be tested with a meter and a small 1 5 or 9V batterv First remove the component to be tested from the circuit and simplv measure the resistance from the anode to the cathode to check for a shorted SCR Depending on the current rating of the module a good SCR will read anvwhere from approximatelv 400k Ohms to an open circuit Set the meter to the diode check and again read across the anode and cathode terminals Place the positive meter probe on the anode and the common or negative meter probe on the cathode Connect the negative of the 9V batterv to the cathode terminal Momentarilv connect the positive batterv lead to the gate terminal The diode check voltage should read around 0 6 to 0 7 VDC NOTE that the SCR not latch or remain in conduction when the batterv is disconnected due to the small amount of current being supplied by the meter When troubleshooting a problem the first step is to eliminate the motor This can best be done by substituting another motor or a dummy load and checking to see if the problem persist An emergency dummy load can be created by placing two 115 VAC light bulbs in series for 230 VAC operation or four in series for 480 VAC operation Higher wattage loads will perform better as dummy loads Use bulbs of the same wattage so they will have balanced voltage NOTE The control m
23. its office in Heath Springs S C The Company may refuse to accept any order for any reason whatsoever without incurring any liability to the Purchaser The Company reserves the right to correct clerical and stenographic errors at any time 3 Shipping dates Quotation of a shipping date by the Company is based on conditions at the date upon which the quotation is made Any such shipping date is subject to change occasioned by agreements entered into previous to the Company s acceptance of the Purchaser s order governmental priorities strikes riots fires the elements explosion war embargoes epidemics quarantines acts of God labor troubles delays of vendors or of transportation inability to obtain raw materials containers or transportation or manufacturing facilities or any other cause beyond the reasonable control of the Company In no event shall the Company be liable for consequential damages for failure to meet any shipping date resulting from any of the above causes or any other cause In the event of any delay in the Purchaser s accepting shipment of products or parts in accordance with scheduled shipping dates which delay has been requested by the Purchaser or any such delay which has been caused by lack of shipping instructions the Company shall store all products and parts involved at the Purchaser s risk and expense and shall invoice the Purchaser for the full contract price of such products and parts on the date schedu
24. switch used above across TB2B terminals 14 and 15 and place in the closed position Monitor the Scaled Tachometer Feedback signal at TP18 with the oscilloscope and trigger on the TB2B 14 signal If a tachometer is not used and the Armature Feedback signal can be monitored at TP15 Note that the armature feedback signal will not be as clean as a tachometer signal Apply AC power to the drive and place in the RUN mode Open the switch to apply the 60 signal to the SUMMING input and observe the response of the drive As before the signal should respond quickly without any overshoot as seen in Figure 33 Adjust the velocity Integral and Proportional pots amp P2 to obtain a critically dampened waveform Figure 34 shows the response with the proportional gain to low Turn P1 CW to correct Too short of an integral time can also cause overshoot as seen in Figure 35 Turn P2 CW to correct The current and velocitv loop adjustment is now complete Remove power from drive and remove all jumpers pots and switches that were connected below FUSES Due to other circuit paths that mav interfere with measurements it is not recommended that fuses be tested with an ohmmeter while still in the circuit Remove the fuse and then check the resistance with an ohmmeter A fuse mav also be checked bv applving power to the drive and carefully measuring the voltage across the fuse Remember that a good
25. to allow an external field supply to be connected through the current sensing circuitry via TB3 3 The base ELITE drive includes 10 relavs for isolated interfacing of customer operators or logic such as pushbuttons selectors relay contacts motor thermostats and the armature contactor Refer to the RELAY board schematic in Section 12 Most of these relays are located on the RELAY board and all that are controlled directly by customer supplied logic are powered by the control voltage transformer The relay circuitry is designed to provide safe sequencing of the armature contactor for emergency stop and ramp to stop Improper sequencing of the contactor by external logic can cause severe drive problems The RUN and JOG relays on the RELAY board are interlocked to prevent the RUN relay from being energized when the JOG relay 15 being used and vice versa These relays are used to control and JOG logic relavs on the CONTROL board and the M PILOT relav that energizes the external contactor The DIR relay is used to switch the internal reference supplv for the speed and jog pots from 10 VDC to 10 VDC The CONTROL board operates the FAULT ZERO SPEED and JOG DELAY relays on the RELAY board The FAULT relay is normally energized to supply 115 VAC at TB1 1 for all of the operator relay and contactor logic A fault condition causes the relay to de energize and stop operation See SECTION 6 12 for informatio
26. 00 fiq NOY Notes Standard Terms amp Conditions of Sale 1 General The Standard Terms and Conditions of Sale of Carotron Inc here inafter called Company are set forth as follows in order to give the Company and the Purchaser a clear understanding thereof No additional or different terms and conditions of sale by the Company shall be binding upon the Company unless they are expressly consented to by the Company in writing The acceptance by the Company of any order of the Purchaser is expressly conditioned upon the Purchaser s agreement to said Standard Terms and Conditions The acceptance or acknowledgement written oral by conduct or otherwise by the Company of the Purchaser s order shall not constitute written consent by the Company to addition to or change in said Standard Terms and Conditions 2 Prices Prices discounts allowances services and commissions are subject to change without notice Prices shown on any Company published price list and other published literature issued by the Company are not offers to sell and are subject to express confirmation by written quotation and acknowledgement All orders of the Purchaser are subject to acceptance which shall not be effective unless made in writing by an authorized Company representative at
27. 00 600 amp FUS1009 08 BUSSMANN FWH600 LITTELFUSE 1505600 Models 12300 000 amp 06300 000 700 amp BUSSMANN LITTELFUSE FUS1009 09 FWH700 L50S700 11 5 POWER COMPONENTS NOTE For anv AEG EUPEC KOF tvpe device listed the equivalent LOF tvpe device mav be substituted ARMATURE BRIDGE Model 12020 000 amp 06020 000 31 amp CAROTRON PMD1025 00 AEG EUPEC TT31N14KOF SEMIKRON SKKT42 14E Model E12040 000 06040 000 56 amp CAROTRON PMD1026 00 AEG EUPEC TT56N14KOF SEMIKRON 5 57 14 Model 12060 000 06060 000 91 amp CAROTRON PMD1027 00 AEG EUPEC TT92N14KOF SEMIKRON SKKT92 14E Model E12075 000 amp E06075 000 105 amp CAROTRON PMD1019 00 AEG EUPEC TTIOSNI4KOF SEMIKRON SKKT106 14E Model 12100 000 amp 06100 000 131 amp CAROTRON PMD1019 00 AEG EUPEC TT105N14KOF SEMIKRON SKKT106 14E Models E12125 000 E12150 000 E06125 000 E06150 000 162 amp CAROTRON AEG EUPEC PMD1021 00 TT162N14KOF IRKT162 14 Models E12200 000 06200 000 210 amp CAROTRON AEG EUPEC SEMIKRON PMD1030 00 TT210N14KOF SKKT210 14E Models E12250 000 E12300 000 E06250 000 E06300 000 251 amp CAROTRON AEG EUPEC SEMIKRON PMD1031 00 TT251N14KOF SKKT250 14E FIELD SUPPLY The field supply uses the same power components for all models PMDO dual diode 22 ampere 1400 volts CAROTRON PMD1024 00 AEG EUPEC DD22S14K K IRKC61 14 P
28. 50 E06300 C300 12300 300 NAMA 12 ENCL TABLE 5 ENCLOSURE OPTIONS OPTION NUMBER MODELS USED WITH DESCRIPTION E06020 C20 E12020 C20 E06040 C40 E12040 C40 NEMA 12 ENCL W E06060 C60 E12060 C60 DISCONNECT HANDLE E06075 C75 E12075 C75 E612EN HO1 NEMA 12 ENCL W E612EN H02 E06100 C100 E12100 C100 DISCONNECT HANDLE NEMA 12 ENCL W E612EN H03 E06125 C125 E12125 C125 DISCONNECT HANDLE NEMA 12 ENCL W E612EN H04 E06150 C150 E12150 C150 DISCONNECT HANDLE NEMA 12 ENCL W E612EN H05 E06200 C200 E12200 C200 DISCONNECT HANDLE E06250 C250 E12250 C250 NEMA 12 ENCL W AN 06300 300 E12300 C300 DISCONNECT HANDLE TABLE 6 DYNAMIC BRAKING OPTIONS OPTION NUMBER MOTOR USED WITH DESCRIPTION NAMA 12 ENCLOSED 10 Ohm E612BR 205 5 HP 240 VDC ARM 300 WATT BRAKE RESISTOR NEMA 12 ENCLOSED 5 Ohm E612BR 207 1 5 HP 240 VDC ARM 600 WATT BRAKE RESISTOR NEMA 12 ENCLOSED 4 4 Ohm 750 WATT BRAKE RESISTOR E612BR 210 10 HP 240 VDC ARM TABLE 6 BRAKING OPTIONS CONT OPTION NUMBER MOTOR USED WITH DESCRIPTION NEMA 12 ENCLODED 3 Ohm E612BR 215 15 HP 240 VDC ARM 1000 WATT BRAKE RESISTOR NEMA 12 ENCLOSED 2 2 Ohm E612BR 220 20 240 VDC ARM 145900 WATT BRAKE RESISTOR NEMA 12 ENCLOSED 1 7 Ohm 2000 WATT BRAKE RESISTOR E612BR 225 25 HP 240 VDC ARM NEMA 12 ENCLOSED 1 7 Oh
29. B terminal 21 When the switch is closed the 10 VDC source is shorted to common By opening the switch the 10 VDC signal is applied to the current loop Place the switch in the closed position Connect an oscilloscope in the normal or signal sweep mode and monitor the Armature Current Feedback signal at TP21 If using a dual trace scope it may be helpful to trigger on the TB2B terminal 26 signal Apply AC power to the drive and place in the RUN mode by momentarily closing the contacts on the RELAY BOARD Momentarilv open the switch to allow the 10 VDC signal to be applied The Current Feedback signal should respond quickly without any overshoot as seen in Figure 30 Adjust the Current Integral and Current Proportional pots P3 to obtain a critically dampened response Figure 31 shows an under damped response due to a low proportional gain Turn P3 CW to correct An over damped response with the integral time too long can be seen in Figure 32 Turn P4 CCW to correct VELOCITY LOOP ADJUSTMENT Remove AC power from the drive and reconnect the field wires Place the Field Loss jumper J10 in the normal position Remove the mechanical lock from the motor shaft and connect the normal load if possible Remove the jumper switch configuration used above and replace jumper at TB2B terminals 25 and 26 Connect a 10k Ohm pot at TB2B across terminals 11 and 13 with the wiper to terminal 14 and adjust to the 60 position Connect the
30. B6400 460VAC 3PH 1 4 1 8 AMP OVERLOAD RANGE FOR 3 PHASE BLOWER MTP FVB6320 230VAC 3PH 2 8 TO 4 0 AMP OVERLOAD E612BS 005 MTP FVB6400 230VAC 3PH RANGE FOR 3 PHASE BLOWER TABLE 3 FIELD REGULATOR OPTION OPTION NUMBER MODELS USED WITH DESCRIPTION FR1000 000 ALL ELITE MODELS FIELD REGULATOR UNIT 230 460VAC 1 PH INPUT TABLE 4 DISCONNECT SWITCH OPTIONS OPTION NUMBER E612DS 150 MODELS USED WITH E06020 C20 E12020 C20 06040 40 12040 40 06060 60 12060 60 06075 75 12075 75 DESCRIPTION 150 AMP 600 VAC MOLDED CASE DISCONNECT SWITCH E612DS 225 E06100 C100 E12100 C100 E06125 C125 E12125 C125 225 AMP 600 VAC MOLDED CASE DISCONNECT SWITCH E612DS 400 E612DS 600 06150 150 12150 150 06200 200 12200 200 06250 250 12250 250 E06300 C300 12300 300 400 600 MOLDED CASE DISCONNECT SWITCH 600 AMP 600 VAC MOLDED CASE DISCONNECT SWITCH TABLE 5 ENCLOSURE OPTIONS OPTION NUMBER MODELS USED WITH DESCRIPTION E612EN 001 E06020 C20 E12020 C20 E06040 C40 E12040 C40 E06060 C60 E12060 C60 E06075 C75 E12075 C75 NEMA 12 ENCL E612EN 002 E06100 C100 E12100 C100 NAMA 12 ENCL E612EN 003 E06125 C125 E12125 C125 E06150 C150 E12150 C150 NAMA 12 ENCL E612EN 004 E06200 C200 E12200 C200 06250 250 12250 2
31. DC and 7 5 VDC respectively and can be seen in FIGURE 17 Since all ELITE current signals are scaled to 5 VDC at 100 this 7 5 VDC level corresponds to 150 of the drive s rated armature current The positive current limit output is at TB2A 5 and is normally jumpered to TB2A 6 Likewise the negative current limit output at TB2A 7 is normally jumpered to TB2A 8 These voltage levels are the inputs to the positive and negative current limit pots The POSITIVE CURRENT LIMIT pot trims the 7 5 VDC signal and it is then buffered and summed together at A15 D with the current demand signal When the drive 15 producing positive motor torque the current demand signal has a negative polarity Therefore the output of A15 D 15 the difference between the two signals When the current demand signal 15 less than the positive current limit signal the net positive result 18 inverted at the output of A15 D This negative polarity signal is blocked by D69 and the current demand signal 15 not effected However when the current demand signal tries to exceed the positive current limit signal a net negative result is inverted to positive at A15 D This positive signal will add to the current demand signal through D69 and clamp it to the level set by the positive current limit pot The negative current limit circuit works in the same manner but with opposite polarity signals FOLDBACK As seen in FIGURE 17 the scaled current feedback signal is b
32. ED indicators for Phase Loss Field Loss Heatsink Overtemp and Overcurrent 5 jumper selectable armature current ranges for each model to match motor rated armature current Timed Foldback current limiting and Overcurrent Trip with four programmable time periods Allows operating current up to 150 of selected current range for chosen time period then after time period 15 30 45 or 60 seconds folds back current to 112 Continued operation with load sustained above 105 current for the chosen time period 1 min 15 sec 2 min 30 sec 3 min 45 sec or 5 minutes will result in Overcurrent Trip Control of positive and negative regen model only motor torque from external pot or voltage reference Lockout of either direction of motor rotation from external contact reverse on regen model only Independently adjustable linear acceleration and deceleration for both forward and reverse directions with two ranges I 8 seconds and 8 60 seconds for each Speed feedback 15 jumper selected for Armature Voltage D C Tachometer voltage 7 50 or 100 V 1000 RPM A C Tachometer voltage 45 or 90 V 1000 RPM or Digital Encoder 300 PPR D C Tachometer voltage is insensitive to polarity 12 VDC 100mA rated encoder power supply Summing input for auxiliary input signals with on board trim pot for scaling and jumper selection for polarity Buffered armature current signal output Buffered velocity signal output Buffered v
33. ENT FAULT circuit is similar to the FOLDBACK circuit Comparator 11 also controls an identical timer circuit However the 105 level must be exceeded for five times as long before the timer output drops low This signal is used to set a latching fault circuit and shuts the drive off Refer to SECTION 6 12 for more information on the fault circuits NOTE The timers for FOLDBACK and OVERCURRENT FAULT operate when the current feedback has exceeded 105 continuously for their respective time periods During timeout a dip below 105 demand will reset the timers and start the timing cycle over again A decrease below 105 will automatically bring the control out of a FOLDBACK condition OVERCURRENT FAULT though is a latched function and must be reset 6 9 CURRENT LOOP Armature current in ELITE drives is also controlled closed circuitrv Refer to FIGURE 18 NOTE For special applications such as center winders that require direct torque control of the motor the current loop input at TB2B 26 FIGURE 17 can be connected to an alternate source of reference The velocity loop section will be non functional and the drive will have no adjustable maximum speed or armature voltage CURRENT ERROR The opposite polarity current demand and the current feedback signals sum together at A10 B The output is based on the initial difference between these inputs and the continuing level required
34. FIELD LOSS PHASE LOSS and drives a latching flip flop circuit high This in turn lights the specific fault LED removes the TRIGGER board enable signal and de energizes the FAULT relay The latching circuits also maintain the faulted status of the drive until it is reset by the RESET pushbutton on the CONTROL board an external RESET contact connected to TB2B 23 amp 24 or by cycling the 115 VAC power to the drive The FAULT circuit acts to shut off the armature voltage output and de energize the armature contactor The FAULT relav contact de energizes the RUN JOG and ZERO LOGIC relavs on the CONTROL board This removes 24 VDC used the mode control circuitrv for de clamping various circuits This is explained in SECTION 6 11 The FAULT contact also removes the 115 VAC from the pushbutton operator logic and the armature contactor OVERCURRENT The OVERCURRENT FAULT will occur when the control has continuously demanded more than 105 armature current for the programmed time period it acts in concert with the FOLDBACK circuit and is explained in detail in SECTION 6 8 FIELD LOSS The FIELD LOSS circuit detects the presence of field current flow not voltage bv the circuit shown in FIGURE 1 SECTION 6 2 explains this circuit PHASE LOSS PHASE LOSS circuit is shown in FIGURE 29 Each phase of the line supplv is detected bv the use of the positive phase sign
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36. MD10 SCR diode 25 ampere 1400 volts CAROTRON PMD1010 02 AEG EUPEC TD25N14KOF SEMIKRON SKKH26 14E PMD7 and PMDS diode doubler 25 amp 50 volts CAROTRON PMD1009 00 FPID2505 L HS WS 1081 09 031113 IILVWIHIS asumen umaq 1 9 093 198 093 A AG 1 6 6EG 21 ABS 00 2 2 196 a Am 1 6 92 01 dy c LAAHS OL gt 9 o TAT una IV 13345 ANDNDO 045 432 4402 l 8 2 lt 4 AEIND lt lt V ZAL ald LIALT SINIOdMO3HO MIO OL 83434 58531131 00 111 19 WO H N3HOS 133 5 310 5 8 gt AGE 0 24 1322 gt 02 89182 1437 4409 AI 504 JIN3yano JIN Alddns 438 AJA 100 8007 4015 ana Bar Wy Tad 43 21 OT OE 250 13930 gt gt vl gt AY NI
37. S B and AS A A RUN or JOG command will remove the clamp and allow the scaled signal to be compared with the R81 R82 resistor divider network The network controls the ZERO SPEED setpoint and keeps the output of A5 D comparator positive when the scaled armature voltage is below 590 The positive voltage saturates Q12 and connects to the PERSONALITV board to control the ZERO SPEED LED When the scaled armature voltage exceeds the setpoint AS D switches negative and causes Q9 to energize the zero logic relay Refer to FIGURE 24 amp 25 Q1 I also turns on and energizes the ZERO SPEED relay on the RELAY board When the RAMP STOP command is given the ZERO LOGIC relay keeps the clamp removed until the drive falls below the ZERO SPEED setpoint JOG DELAY FUNCTION This function serves to extend the mechanical life of armature contactor by reducing the number of operations in an application where a high rate of repeat jogging is performed When the JOG button is pressed and then released the reference is immediately clamped to stop the motor but the contactor is held energized for three to four seconds Pressing the JOG button again within this delay period will cause the motor to immediately jog and will reset the delay Refer to FIGURES 24 26 When the JOG button is pressed the JOG relav is energized which in turn energizes the JOG relav on the CONTROL board This de clamps Q13 bv the application of 24
38. TRON s part number and the manufacturer s part number if applicable of the drive s major components This section can be used to order additional parts or to determine if a component from one drive mav be substituted on another If needed the E12000 Series regenerative PERSONALITY board and TRIGGER board can be substituted on an E06000 non regenerative drive However the reverse direction adjustments will have no affect on the drive The C T board can be modified with minimal effort to operate on any model The value of resistors R3 and R4 on the C T board determine the current scaling Please refer to Table 7 for the correct values The transient surge suppression resistor capacitor networks on the FUSE board can also be easily modified to be compatible with other models Please refer to the chart on the FUSE board Schematic in Section 12 for the proper resistor values All armature bridge devices are dual SCR isolated power modules rated at 1400 volts repetitive peak off state and inverse voltage and have 1000 volts microsecond dv dt There are 3 each on the E06000 Series PMD1 3 and an additional 3 on the E12000 Series PMD4 6 The power modules listed below are pin for pin compatible with all ELITE drives SEMIKRON IR International Rectifier and CRYDON manufacture power modules with similar ratings but are not all pin for pin compatible The gate and cathode signal leads are reversed on the second SCR device Consult t
39. als as shown in FIGURE 10 in SECTION 6 6 The sync pulses from this circuit are described with the trigger circuit in SECTION 6 10 The three 50 or 60 hertz depending on line frequencv signals maintain their 120 degrees phase relationship through the IC14 Schmidt trigger logic gates Thev are converted to narrow positive going pulses bv capacitivelv coupling the signal to the inputs of IC27 The three sets of pulse are inverted and combined by the IC29 AND gates to give a regular pulse train at three times the line voltage frequency Each pulse then coincides with one cycle of one of the input phases One half of IC31 a 556 dual timer is used as a missing pulse detector and monitors the pulse train When powered up IC31 begins a timing cycle and the output goes high The train of input pulses continually resets and re triggers the timer so that 1 normally cannot complete a timing cycle One missing pulse gives enough time for a cycle to complete If this happens the IC3 1 s output momentarily goes low and turns off Q12A This allows a delay capacitor C78 to begin charging If enough pulses are missing the capacitor completes its charge and sets the phase loss fault latch Experience has shown us that normal industrial line supplies and branch circuits are constantly being subjected to notches or holes in the line The delay circuit provides immunity from such intermittent and short losses of line voltage that do n
40. als to control the speed and direction of motor rotation Refer to FIGURE 9 Signals from SPEED REFERENCE INPUT the SUMMING INPUT the JOG SPEED pot and the MIN SPEED pot are all summed together to form the TOTAL REFERENCE SETPOINT NOTE MIN SPEED pot is available only on E06 non regen models manufactured with a revision F or later CONTROL board Normal use with a speed pot connected to TB2B 11 12 13 takes a 10 VDC signal 10 VDC in the forward direction 10 VDC in the reverse direction from TB2B 11 This signal is trimmed by the speed pot to set the input to the forward or reverse accel decel circuits at TB2B 12 NOTE The polarity of externally connected reference signals will determine the direction of motor rotation not the FWD REV selector position The terminal 12 signal is given noise immunity by the R132 C40 R C network and used as an input to the accel decel circuits The forward accel decel and reverse accel decel circuits are enabled by the polarity of the armature feedback signal This polarity signal clamps the reverse accel decel circuit in the forward direction and the forward accel decel circuit in the reverse direction In the forward accel decel circuit OP AMPs 16 and A16 D form a closed loop circuit that uses the reference level to control the charge and discharge time of capacitor C74 The charge and discharge follows a linear ramp and the time can be changed by jump
41. ate VELOCITV PROPORTIONAL VELOCITY PROPORTIONAL gives a 4 to 1 change in the velocity loop proportional gain Clockwise rotation increases the gain The VELOCITY INTEGRAL and VELOCITY PROPORTIONAL signals are summed to produce the VCO input signal CURRENT LOOP ADJUSTMENT This procedure describes static tuning of the current loop by directly applying a stepped reference and monitoring the current feedback The POS C L pot can turned down to permit testing at a lower current level Remove all power from the drive and disconnect the motor field wires from TB3 terminals 4 and 5 If you are using an external field current regulator disconnect the field wires from the regulator Place the Field Loss jumper in the BYPASS position NOTE The motor can now be operated in the stalled condition In order to prevent damage the motor do not run the drive under these conditions longer than a few seconds Although field is disconnected from the motor residual flux in the field windings mav cause slight rotation of the motor In order to prevent this mechanicallv lock the motor shaft or applv load to prevent rotation Remove the jumper from TB2B terminals 25 and 26 A 0 to 10 VDC stepped signal will need to be applied to the Current Loop Input TB2B terminal 26 This can be accomplished by placing a jumper from TB2A terminal 9 to TB2B terminal 26 and placing a switch from TB2B terminal 26 to TB2
42. city feedback from incorrect programming of J1 J6 and or encoder with higher than 300PPR used as feedback Monitor SCALED ARMATURE SCALED TACH or SCALED ENCODER at TP15 K TP18 L or TP20 M respectively to verify 5 0 VDC at rated speed of motor Excessive loading of the motor or wrong current range programmed by J4 Monitor CURRENT FEEDBACK signal at 21 5 and check for 5 0 VDC level at 100 of range selected by J4 Overloading the motor for the J7 time period will cause FOLDBACK which may limit the motor speed Motor drops in speed when loaded Excessive loading of the motor or wrong current range programmed by J4 Monitor CURRENT FEEDBACK signal at TP21 S and check for 5 0 VDC level at 100 of range selected by J4 Incorrect field wiring SEE NEXT SECTION Motor draws a high level of armature current but will not produce rated torque One of the dual field winding polarities may be reversed When connecting the field a low voltage operation 150 VDC the field windings should be connected in parallel The FI and leads positive polarity should be connected together and the F2 and F4 negative polarity leads should be connected together For high voltage operation 300 VDC the field windings should be connected in series Only the F2 and F3 leads should be connected together If the field polarity is unknown or in doubt a simple test with a voltmeter and a small battery 1 5 or 9V can be use
43. d to determine the proper polarity Disconnect all wires from the motor and connect the voltmeter across one set of the field windings Connect the negative battery terminal to one lead of the other field winding Momentarily connect the other field winding to the positive battery terminal If the voltage the field winding initiallv goes positive and then swings negative the field leads connected to the positive batterv terminal and the positive lead of the voltmeter have the same polaritv If the voltage first swings negative and then positive reverse one of the windings Motor is unstable and becomes worse when load is applied The series field mav be connected incorrectiv Series field winding SI and S2 leads should not be used with regenerative drives E12 models Only non regenerative drives should use the series field by connecting it in series with the armature windings The polarity of the FI lead and 51 lead should be the same Velocity and or current loops not adjusted properly signals the ELITE drive can easilv be monitored by test points on the various PC boards Many of the signals on the CONTROL CONTROL BOARD NOTE Letters refer to DCM100 000 Check board are also easily accessible via CAROTON s DCM 100 000 C T BOARD TP1 Parameter Level range Condition FUSE BOARD TP1 Parameter Level range Condition Parameter Level range Co
44. e signals are not passed to the remaining triggering circuitry The gating signals produced from the delta configuration are also routed to both inputs of an EXCLUSIVE gate of IC24 However one signal is delayed by an R C time constant This produces a narrow non coincidence or end stop pulse each time the line to line phase voltage crosses the zero point The conduction angle demand voltage signal or VCO reference signal from the CONTROL board is applied to 25 a voltage controlled oscillator As the input increases in voltage the output frequency 15 increased proportionally This frequency signal 15 tied to the clock input on the 12 bit binary counter and can be measured at TP35 The normal output range is between 40 and 220 kHz This frequency signal causes the binary counter to drive its output momentarily high after accumulating 256 pulses The output is ORed with the end stop signal and serves as a RESET signal to the counter Thus the counter will be reset at every end stop pulse and after it completes a counting cycle When the VCO output is at low frequencies the counters cannot complete a cycle before being reset and only the end stop pulse are passed through the NOR gate As the VCO frequency rises the counters complete a cycle and start pulse is passed along with the end stop pulse At higher frequencies the counter completes 118 cycle quicker which causes the start pulse to shift to an earlier star
45. elocity reference signal output Inner current loop type control circuit for responsive and precise control of motor speed and torque 115 VAC logic for customer operator interface Zero speed logic for controlled ramp to stop braking torque supplied by regen models only Jog Delay circuit to allow rapid jogging with out de energizing armature contactor to give longer contactor life Terminal strip access to velocity loop output and current loop input for versatile control functions Additional LED s for operating status Run Jog Zero Speed and Foldback All important adjustment potentiometers mounted on de pluggable PERSONALITY board to allow CONTROL board replacement while preserving crucial set up parameters Critical pots are multiturn and common customer adjustments are single turn with a knob Multilevel construction with hinged cover and sub panel allows ready access to all printed circuit boards fuses and power components for ease of service and replacement A Input 230 VAC 10 3 phase 50 60 Hz 2Hz 380 41096 3 phase 50 60 Hz 2Hz 460 VAC 41096 3 phase 50 60 Hz 2Hz A C Input Single Phase Control Voltage Supplv 115 1095 1 phase 50 60 Hz 2Hz Armature Output 010240 VDC 230 VAC input 010415 VDC 380 VAC input e 010500 VDC 460 VAC input Field Output 150 VDC 10 amp max 230 VAC input 247 10 amps max
46. endent 200 rpm N L 0 1 VDC 200 rpm F L 5 3 VDC 1750 rpm N L 0 2 VDC 1750 rpm F L 5 5 VDC Velocity proportional 0 to 13 5 VDC pol torq torq Load and speed dependent 200 rpm N L 10 mVDC 200 rpm L 20 mVDC 1750 rpm N L 15 mVDC 1750 rpm F L 20 mVDC Parameter 12 Level range Condition Q Parameter TP16 Level range Condition Parameter Level range Condition Parameter Level range Condition Current integrator 0 to 13 5 VDC pol torq Load and speed dependent 200 rpm N L 1 9 VDC 200 rpm F L 2 2 VDC 1750 rpm N L 43 5 VDC 1750 rpm F L 44 5 VDC Current proportional 0 to 13 5 VDC pol torq Load and speed dependent 200 rpm N L 3 mVDC 200 rpm L 4 mVDC 1750 rpm N L 3 mVDC 1750 rpm L 4 mVDC Current demand 0 to 7 5 VDC pol torq Load Dependent 5 0 VDC 100 demand 7 5 VDC 150 demand Current feedback 0 to 7 5 pol torq Load dependent 5 0 VDC 100 demand 7 5 VDC 150 demand T Parameter 6 Level range Condition TP23 Parameter Level range Condition TP1 Parameter TP1A Parameter TP7 Parameter TRIGGER BOARD Voltage controlled oscillator reference 6 to 6 VDC Load and speed
47. er J8 and by varying the resistance of the FWD ACCEL and FWD DECEL pots This FWD ACCEL DECEL output which can be measured at TP13 1 is connected to the FWD MAX pot and can be clamped when the drive is stopped in the reverse direction in the JOG mode or when the FWD ENABLE contacts are open Similarly the reverse accel decel circuit uses AMPs 16 and 16 to control the charge on capacitor C75 The REV ACCEL and REV DECEL pots are used in conjunction with jumper J9 to control the charge and discharge time The REV ACCEL DECEL output which can be measured at TP22 J is connected to the REV MAX pot and can be clamped when the drive is stopped in the forward direction in JOG mode or when the REV ENABLE contacts are open See SECTION 6 11 for information on the FET clamps The FWD MAX and REV MAX pot wiper signals are summed together at the summing amplifier A3 C Also summed are the JOG SPEED MIN SPEED and the SUM TRIM signals The JOG SPEED pot trims the 10 VDC reference signal It 15 clamped when drive is stopped or in the RUN mode The JOG SPEED pot wiper also has the R16 C2A R C network to soften start up in the JOG mode The MIN SPEED pot is available only on the E06000 non regenerative Series This signal which allows up to 30 minimum speed setpoint is clamped when the drive is stopped The SUM TRIM pot receives input from TB2B 14 Its wiper is connected to the 9 inverting
48. er or encoder selected connected and scaled properly If in armature feedback is the IR COMP adjusted too high F Is the speed reference to the control a stable noise free signal 2 Know what your starting point is before making an adjustment Note the setting of a pot before changing it If it is a multiturn pot and you are not sure of the setting turn it down ccw while counting turns until you hear the clicking sound noting end of rotation or until you ve gone more than 25 turns Then turn it back clockwise for ten turns or to your desired starting point 3 Make only one adjustment at a time If an adjustment has no effect or appears not to help be sure to return it to its starting point before making any other adjustment 4 When loop adjustments are required start first with the I current loop adjustments The factory presets 1 P4 at 10 turns clockwise approximately 33 of their range IINTEGRAL I INTEGRAL controls 10 to 1 change in the current loop integral time constant Clockwise rotation increases the time or decreases the response rate I PROPORTIONAL The I PROPORTIONAL controls 2 to I change in the current loop proportional gain Clockwise rotation increases the gain and response VELOCITY INTEGRAL The VELOCITY INTEGRAL is a trimming pot that gives 20 to 1 change in the velocity loop integral time constant Clockwise rotation increases the time or decreases the response r
49. eter signify the CW terminal The opposite lead is the CCW terminal and the middle 15 the wiper IC packages have been given the prefix designation A instead of IC found on all other IC packages Furthermore many ICs are double quad or hex packages In these cases each section is given a letter designation to distinguish it from the other OP AMPs in the same IC package For example the first two OP AMPs in Al would be 1 and 1 The bold letters in the schematic diagrams refer to the DCM100 000 check points Refer to SECTION 10 GLOSSARY DRIVE The electronic device used to control the speed torque horsepower and direction of a DC motor It is also referred to as the control ELECTROMOTIVE FORCE This 15 another name for the armature voltage generated by the drive The voltage generated by the motor is called counter or FULL LOAD AMPS FLA The amount of current necessary to produce rated horsepower at full speed HORSEPOWER HP The measure of the amount of work a motor can perform during a given time period HP Torque x RPM 5250 REGENERATIVE CONTROL A drive capable of controlling the flow of power to and from the motor Regeneration occurs when the counter EMF produced by the motor 15 greater than the voltage applied to the motor by the drive SILICON CONTROLLED RECTIFIER SCR A solid state switch also called a thyristor tha
50. he factory for assistance in making substitutions with components other that the recommended spare listed below A higher rated current and or voltage component may be substituted for any given power component For example the E12020 000 model uses a 3lampere 1400 volts dual SCR module If this module is not available a 56 ampere 1400 volts or a 31 ampere 1600 volts dual SCR module could be substituted NOTE A higher current rated module may have a higher latching current rating Under light load conditions this may cause the SCR to drop out of conduction or to not conduct at all However this problem is easily eliminated by the application of the load and or choosing a substitute device with a minimal difference in the current rating 11 2 PRINTED ASSEMBLIES CONTROL BOARD 06000 and E12000 Series D11111 000 PRESONALITY BOARD E06000 Series models All E12000 Series models C11135 000 C11114 000 RELAY BOARD All 06000 and E12000 Series models D11117 000 POWER SUPPLY BOARD All 06000 and E12000 Series models 11120 000 TRIGGER BOARD E06000 Series D11123 000 E12000 Series models D11123 001 FUSE BOARD Models E06020 000 and E06040 000 D11129 000 Models E12020 000 and E12040 000 D11129 000 D11129 001 C T CURRENT TRANSFORMER BOARD Models E06020 000 and E12020 000 C11126 000 Models E06040 000 and E12040 000 1126 001 Models 06060 000 and 12060
51. he reduction in speed regulation above zero speed I PROPORTIONAL I INTEGRAL VELOCITY PROPORTIONAL amp VELOCITY INTEGRAL The INTEGRAL and PROPORTIONAL adjustments P1 P4 as preset by CAROTRON will provide stable and responsive performance under most load conditions When required the drive performance can be optimized for a particular application or to correct undesirable operation by use of these adjustments The adjustments are complex and can adversely affect operation if not properly set In general the settings that give the most stable operation do not always give the fastest response Problems correctable by these pots can usually be separated into those related to stability of steady state operation 1 constant speed and load conditions and those that occur with speed or load changes that are related to balanced operation of the SCR power bridge Refer to the following guidelines when re adjustment is required When instability is observed it should first be evaluated as possible load induced condition Cyclic variation in armature current and in motor speed can indicate mechanical coupling or machine loading conditions If mechanically induced the instability repetition rate or frequency can usually be related to motor or machine rotation rate or loading cycle In this situation the instability frequency will change in coincidence with any motor speed change Instability in the control output due t
52. igns for and accepts the shipment CAROTRON Driven by Excellence D C DRIVES A C INVERTERS SOLID STATE STARTERS SYSTEM INTERFACE CIRCUITS AND ENGINEERED SYSTEMS 3204 Rocky River Road Heath Springs SC 29058 Phone 803 286 8614 Fax 803 286 6063 Email saleserv carotron com Web www carotron com MAN1000 3A Issued 10 11 2004
53. lav circuit that removes the gating signal from SCR in 10 This essentiallv removes line L2 from the field supplv circuit The field voltage is now derived from line L1 being half wave rectified with respect to line L3 The economized or reduced field voltage level is now approximatelv 0 42 times the AC line to line voltage and can be seen in Figure 7 presence of field current is passing the current through four 25 ampere rated diodes to derive a voltage drop that is used to drive an optoisolator The diodes are enclosed two in each doubler module PMD7 and PMD8 and mounted on the left side of 6 3 CONTROL VOLTAGE SUPPLV AND LOGIC The control voltage transformer is supplied bv the customer when using basic ELITE models and is included on all contactor models refer to TABLE 1 When the three phase power is applied to the drive the transformer primarv voltage should be applied simultaneously to prevent a PHASE LOSS trip condition CAROTRON recommends connecting the primary of the control transformer to one phase of the auxiliary output at TB3 7 8 on the FUSE board The 115 secondary connects to TB3 1 amp 2 and is fused by FU4 an MDA 5A fuse The fused secondary can be measured at TB1 across terminals 9 15 on the RELAY board heatsink above the FUSE board Jumper J11 on the FUSE board can break the connection of the Fl circuit from the internal supply
54. ld differ from those stated above under certain conditions For example if instability or sluggish response resulted from the Velocity Proportional gain setting being too low adjusting the Velocity Integral might give some improvement during steadv state operation However it could make things worse when load or speed changes are introduced To prevent confusion and minimize anxietv when making loop adjustments use the following guidelines 1 Make sure the problems are not due to things other than adjustments Operation similar to that caused bv incorrect adjustment can be caused but are not limited to the following problems A Leakage due to insulation breakdown in the motor A motor with insulation breakdown mav operate correctly when cool at light loads but may cause problems when conditions change Improper wiring of the motor Does the motor have a SERIES armature winding If it does it should not be used with a regenerative drive model Its polarity is critical on non regen models Are the field windings connected correctly Most motors used with ELITE drive models have dual field windings that must have the same polarity to work properly Incorrect armature current scaling Has the proper motor current range been selected at J4 on the CONTROL board The scaled current range of the control must match the nameplate current rating of the motor D If used is the velocity feedback tachomet
55. led for shipment or on the date on which the same is ready for delivery whichever occurs later 4 Warranty The Company warrants to the Purchaser that products manufactured or parts repaired by the Company will be free under normal use and maintenance from defects in material and workmanship for a period of one 1 year after the shipment date from the Company s factory to the Purchaser The Company makes no warranty concerning products manufactured by other parties As the Purchaser s sole and exclusive remedy under said warranty regard to such products and parts including but not limited to remedy for consequential damages the Company will at its option repair or replace without charge any product manufactured or part repaired by it which is found to Company s satisfaction to be so defective provided however that a the product or part involved is returned to the Company at the location designated by the Company transportation charges prepaid by the Purchaser or b at the Company s option the product or part will be repaired or replaced in the Purchaser s plant and also provided that Cc the Company is notified of the defect within one 1 year after the shipment date from the Company s factory of the product or part so involved The Company warrants to the Purchaser that any system engineered by it and started up under the supervision of an authorized Company representative will if properly installed operated a
56. m E612BR 230 30 HP 240 VDC ARM 4000 WATT BRAKE RESISTOR EXPANDED METAL E612BR 240 40 HP 240 VDC ARM ENCLOSED 1 3 Ohm 2080 WATT BRAKE RESISTOR EXPANED METAL E612BR 275 50 75 HP 240 VDC ARM ENCLOSED 0 62 Ohm 2232 WATT BRAKE RESISTOR EXPANED METAL E612BR 2100 100 HP 240 VDC ARM ENCLOSED 0 47 Ohm 4700 WATT BRAKE RESISTOR EXPANED METAL E612BR 2125 125 HP 240 VDC ARM ENCLOSED 0 37 Ohm 5300 WATT BRAKE RESISTOR EXPANED METAL E612BR 2150 150 HP 240 VDC ARM ENCLOSED 0 31 Ohm 7000 WATT BRAKE RESISTOR NEMA 12 ENCLOSED 40 Ohm E612BR 405 5 HP 500 VDC ARM 375 WATT BRAKE RESISTOR TABLE 6 BRAKING OPTIONS CONT E612BR 407 7 5 HP 500 VDC ARM NEMA 12 ENCLOSED 20 Ohm 750 WATT BRAKE RESISTOR E612BR 410 10 HP 500 VDC ARM NEMA 12 ENCLOSED 20 Ohm 750 WATT BRAKE RESISTOR E612BR 415 E612BR 420 15 HP 500 VDC ARM 20 HP 500 VDC ARM NEMA 12 ENCLOSED 14 Ohm 1000 WATT BRAKE RESISTOR NEMA 12 ENCLOSED 10 Ohm 1500 WATT BRAKE RESISTOR E612BR 425 25 500 VDC NEMA 12 ENCLOSED 7 Ohm 2000 WATT BRAKE RESISTOR E612BR 430 30 HP 500 VDC ARM NEMA 12 ENCLOSED 6 Ohm 2000 WATT BRAKE RESISTOR E612BR 440 40 HP 500 VDC ARM NEMA 12 ENCLOSED 5 Ohm 3000 WATT BRAKE RESISTOR E612BR 450 50 HP 500 VDC ARM NEMA 12 ENCLOSED 3 4 Ohm 4000 WATT BRAKE RESISTOR E612BR 460 60 HP 500
57. mp 10 Verifv that FWD DIR is enabled bv jumper at 2 1 2 REV DIR is enabled jumper at 2 3 amp 4 Verifv presence of POS and NEG CURRENT LIMIT jumpers at 2 terminals 5 Band that CURRENT LIMIT pots are not adjusted too low If non regen model E06000 Series verifv jumper at 1 9 10 Motor runs too fast or runs awav Lack of velocity feedback can cause run away and insufficient feedback can cause excessive speed Check position of J1 according to motor armature nameplate rating The SCALED ARMTURE VOLTAGE TP15 K should measure about 5 0 VDC at rated armature output either 240 415 or 500 VDC Tachometer feedback TFB or encoder feedback EFB signals can be monitored at TP18 L and 20 respectively while the control is operated in armature feedback AFB Each signal should measure about 5 0 VDC at rated armature output Check tightness of the coupling For TFB verify that the position of J6 matches the voltage rating of the tachometer being used For EFB confirm use of a 300PPR encoder Check level of TOTAL REFERENCE SETPOINT TP19 H Setting the MAX SPEED pots too high or excessive summing input signals can cause outputs over 100 Over speed when in armature feedback can be caused by improperly wired or defective motor fields Make sure the polarities of multi winding fields are correct Refer below for correct field connections Motor runs too slow Excessive velo
58. n on the fault circuits The ZERO SPEED relay allows ramping to stop by holding the armature contactor energized until zero speed is reached This function is defeated in the event of a fault or The dual 17 transformer secondaries are rectified and filtered to give unregulated 24 VDC These supplies are used directly by the pulse transformers and clamping logic on the TRIGGER and CONTROL boards IC regulators further reduce the supplies to 15 VDC and 6 VDC in order to power the remaining drive circuitry An additional IC regulator is used to supply the 12 VDC relays A separate 12 VDC supply from a zener diode is used for an encoder supply emergency stop by the E STOP relay The JOG DELAY relay 15 timer controlled to keep the armature contactor energized for 3 4 seconds after jogging to prevent unnecessary cycling of the contactor during rapid and repeated jogging See SECTION 6 11 for more information on the zero and jog delay circuits 6 4 POWER SUPPLIES The power supplies are located on the POWER SUPPLY board refer to FIGURE 8 The supplies are isolated by a 48 VA transformer that is powered from the 115 VAC control voltage and is protected by FUS an MDA 0 5 A fuse Also other zener diodes are used on the CONTROL board to establish 10 VDC for the speed and jog pots and 7 5 VDC for the current limit circuit 6 5 REFERENCE CIRCUITRY ELITE drives can make use of several voltage sign
59. nd maintained perform in compliance with such svstem s written specifications for a period of one 1 year from the date of shipment of such system As the Purchaser s sole and exclusive remedy under said warrant in regard to such systems including but not limited to remedy for consequential damages the Company will at its option cause without charges any such system to so perform which system is found to the Company s satisfaction to have failed to so perform or refund to the Purchaser the purchase price paid by the Purchaser to the Company in regard thereto provided however that a Company and its representatives are permitted to inspect and work upon the system involved during reasonable hours and b the Company is notified of the failure within one 1 year after date of shipment of the system so involved The warranties hereunder of the Company specifically exclude and do not apply to the following a Products and parts damaged or abused in shipment without fault of the Company b Defects and failures due to operation either intentional or otherwise 1 above or beyond rated capacities 2 in connection with equipment not recommended by the Company or 3 in an otherwise improper manner Defects and failures due to misapplication abuse improper stallation or abnormal conditions of temperature humidity abrasives dirt or corrosive matter d Products parts and systems which have been in any way tampered
60. ndition Parameter Parameter Level range Condition Armature current feedback signal 0 to 1 5 VDC Load dependent 1 0 VDC 100 of total drive output current 1 5 VDC 150 of total drive output current Field economy feature 0 or 13 5 VDC Operating mode of drive 0 VDC Field economy 13 5 VDC Full field Field economy trigger 15V p p 11kHz square wave or 24 VDC Operating mode of drive 24VDC Field economy 11kHz Full field Circuit common Field loss 0 or 15 VDC Presence of field current 0 VDC Field current present 15 VDC No field current Parameter Level range Condition Parameter Level range Condition Parameter Level range Condition Parameter Level range Condition Parameter Level range Condition Parameter Level range Condition Parameter Points Unregulated power supply 24 VDC 4 0 VDC Can very 4 0 VDC with line and load fluctuations Unregulated power supply 24 4 0 VDC Can vary 4 0 VDC with line and load fluctuations Regulated power supply 15 VDC 0 75 VDC Fixed within line variation of 10 Regulated power supply 15 VDC 0 75 VDC Fixed with line variation of 10 Regulated power supply 12 VDC 0 60 VDC Fixed within line variation of 10 Regulated power supply 6 VDC 0 30 VDC Fixed within line variation of 10 Regulated power
61. o incorrect adjustment would usually be present over range of speed and would not usually change frequency in coincidence with speed Because the response of the control can sometimes be altered to partially compensate for mechanically induced instability it is sometimes difficult to determine if the load change is affecting control output stability or if control output is affecting the load stability De coupling the load can help make this determination If fuse blowing or tripping of breakers should occur it may be due to unbalanced operation of the power bridge This would usually be noticeable when rapid changes in output or surges of torque are being called for as opposed to steady state operation Examples would be when quickly accelerating load up to speed or when regenerating to prevent overshooting the set speed Rapid reversing or decelerations are also examples Excessive proportional gain settings and or too fast integral settings might cause such unbalanced operation Typically the settings that provide the most stable and balanced bridge operation under all conditions do not give the fastest response In general low proportional gains too far ccw rotation and too slow integral time constants too far cw would cause instability Bridge unbalance would usually result from just the opposite setup too high cw proportional gains and too fast ccw integral time Keep in mind that the symptoms and corrections cou
62. ometer or encoder is used for feedback When AFB is selected on J5 jumper the 24 VDC signal removes the clamp and allows the output signal of A4 A to connect to the velocity error amplifier A4 D TACHOMETER FEEDBACK TFB Another velocity feedback mode selectable 15 is TACHOMETER FEEDBACK TFB Refer to FIGURE 15 An AC or DC tachometer output can be connected to TB2B 22 and common The tach voltage 15 noise de coupled and applied to the A12 C amplifier where the gain is set by jumper J6 The jumper 15 set to scale the full speed tach voltage to 5 VDC Following the scaled signal AS B and 5 form a precision rectifier circuit which always keeps the output polarity positive regardless of input polarity The armature feedback signal is used to control the polarity of the tachometer signal by way of a polarity control circuit Refer to SECTION 6 11 for a description of this circuit The output connects to jumper J5 and can be measured at 18 L ENCODER FEEDBACK A 12 VDC 300PPR encoder connected to TB2B 20 can be selected 15 in the EFB position reference FIGURE 15 1750 RPM equates to an 8750 Hz input that is processed by 2 a frequency to voltage converter IC2 sources a current signal into A9 D an active filter circuit then through an inverting amplifier A9 A Just as above the armature feedback signal controls the polarity of the encoder feedback by way of a polarit
63. omponents that must be sized according to the horsepower rating of the control Thev are all rated at 1400 volts with 1000 volts microsecond dv dt to permit reliable operation over a wide range of AC line voltages They are directly controlled gating signals from the TRIGGER board and are temperature protected by a thermostat on the same heatsink Several vendors can be used as replacements for these parts Special attention should be paid to the terminal connections for the gate and cathode signal leads coming from 8 amp on the TRIGGER board CAROTRON routinely manufactures drives with EUPEC devices Some manufacturer s have the terminals in a different order and may cause problems if the proper connections not made Refer to SECTION 8 for information on testing these components and SECTION 11 for making substitutions 6 2 FIELD SUPPLY The field supply is derived from two of the three phase lines L1 12 being half wave rectified with respect to the third line 13 Refer to FIGURE 1 The rectifier modules 9 amp 10 are located directly below the armature bridge Circuitry on the FUSE board connects L1 to one of the diodes in PMD9 and 12 to the SCR in 10 The L3 lead or F2 is connected to the other diode in PMDO The field voltage level is approximatelv 0 65 times the AC line to line voltage and can be seen in Figure 6 The field economv feature is obtained bv an adjustable time de
64. or zero volts potential They are turned off by the application of 24 VDC through the steering diodes as shown in figure TABLE 8 OPERATING MODE CONTROL MODE RUN JOG ZERO SPEED SPEED POT JOG SPEED MIN SPEED POT SUM TRIM POT ACCEL DECEL FIELD IR COMP VEL PROP VEL INTEGRAL I PROP INTEGRAL JOG DELAV 6 indicates that the respective circuit can be turned by the MODE control signal X indicates that it has no effect J indicates that control is jumper selectable ZERO SPEED FUNCTION A typical operation in the RUN mode would de clamp all circuit and signals except for the JOG pot and the JOG delay circuit When above 5 motor speed depressing the RAMP STOP button will cause the drive to drop out of the RUN mode and continue in the ZERO SPEED mode TABLE 8 shows that the SPEED pot is clamped in this mode but the forward and reverse ACCEL DECEL stays on Its output will ramp down as controlled by the FWD DECEL or REV DECEL pot until the armature voltage falls below 5 armature voltage the ZERO SPEED setpoint At this level the ZERO SPEED circuit will de energize the armature contactor and cause the remaining circuits and signals to be clamped FIGURE 25 is a simplified schematic of the ZERO SPEED circuit The scaled armature voltage signal is rectified bv A
65. ot adversely affect drive operation A capacitor charge must build up from repeated loss of line for a time equal to about 3 cycles or 50 60 milliseconds before reaching the level necessary to operate the fault latch seen in FIGURE 28 Several IC3 inverter gates are used to square up the signal from the detector and into the latch OVERTEMP operates from a thermostat switch located on the power bridge heatsink The 77 degrees Centigrade rating and the placement of the thermostat cause it to open if the temperature on the base of the SCR modules exceeds 85 degrees Centigrade The size of the heatsink and the fan on some models will permit continuous operation at the full armature current rating in a 55 degrees ambient without this happening NOTE The 55 degrees rating refers to the ambient temperature around the heatsink A totally enclosed drive is specified with a maximum of 40 degrees ambient outside the enclosure to allow for heat trapped within the enclosure 7 1 ADJUSTMENT and PROGRAMMING PRESETS CAROTRON ELITE controls are all functionally tested and calibrated with motor loads and should only require further calibration to tailor operation for a specific application The adjustment presets are listed in the event that the condition of the control and its adjustments are unknown or in doubt Potentiometer Presets Velocity Integral Velocity Proportional I Current Integral I Current
66. otor armature current is taken from the three line phases The current is sensed bv threading two of the three line conductors through current transformers that are located on the C T board The secondaries of the current transformers are rectified to give a DC current signal Refer to FIGURE 11 The amplitude of this signal is scaled bv burden resistors R3 and R4 to 1 VDC at 100 of the drive rating This signal can be monitored at TPI on the C T board Each ELITE horsepower model has its own unique C T board to allow for precise scaling of the current feedback signal see TABLE 7 for a listing TABLE 7 CT BOARD CURRENT SCALING RESISTORS MODEL FULL R3 R4 CT BOARD LOAD RATING Ohms Ohms P N DRIVE MODLE NO E06020 000 E12020 000 11126 000 36 5 243 374 06040 000 12040 000 71 AMPS NOT USED C11126 001 TABLE 7 CT BOARD CURRENT SCALING CONT DRIVE MODEL NO MODEL FULL LOAD RATING R3 Ohms R4 Ohms CT BOARD P N E06060 000 E12060 000 107AMPS 100 100 C11126 002 E06075 000 E12075 000 140 AMPS 68 84 C11126 003 E06100 000 E12100 000 174 AMPS C11126 004 E06125 000 E12125 000 206 AMPS 47 C11126 005 E06150 000 E12150 000 256 AMPS NOT USED C11126 006 E06200 000 E12200 000 340 AMPS 34 C11126 007 E06250 000 E12250 000 425 AMPS 28 C11126 008
67. r is energized before the control loops are enabled Likewise the control loops should be allowed to clamp before opening the contactor Check for loading faults on control transformer See previous section Transient induced uncontrolled gating of the SCRs mav cause fuse blowing The coils of electromechanical devices such as relavs and solenoids that are energized when the drive is started should have transient suppressors This is achieved placing MOV s or snubbers in parallel with the coil All relay coils on ELITE drives are suppressed Drive will not RUN or JOG Run and Jog LEDs will not light Check 115 power at TB3 1 2 on the FUSE board If not present check control voltage transformer and primary supply from two of either FU2 or FU3 on the FUSE board Check 115 power at TB1 1 15 If not present check FU4 on the FUSE board and check status of FAULT LED s Verify proper operation of RUN and JOG contacts Check power supplies Refer to SECTION 10 The power supply is fused by FUS on the POWER SUPPLY board Drive will not RUN or JOG Run and Jog LED s will light Check power supplies Refer to SECTION 10 Verifv presence of the TOTAL REFERENCE SETPOINT signal at TP19 H If not present check input at TB2B 12 or 14 depending on speed pot or summing input operation Positive speed pot reference indicates that forward direction is selected bv contact closure at 1 9 a
68. s high and vice versa These signals are used to drive POS and NEG LEDs and connect to the TRIGGER board 6 10 TRIGGER CIRCUIT Most of the trigger circuit is powered by the 6VDC supplies The 6VDC level is treated as a logic low level and 6VDC as a logic high level This operation above and below zero volts allows symmetry with the AC line signals to be monitored It also requires that the 6VDC supply to be used as the reference point for some measurements when servicing the TRIGGER board As mentioned in SECTION 6 6 the delta configuration of OP AMPs A2 A B 8 C produce three 50 duty cycle sync signals They have been phase shifted to correspond to the phase to phase voltage potentials biasing the power bridge components Like the line phases these signals are 1207 out of phase with each other Refer to FIGURE 19 These sync pulses are squared up by Schmidt inverters to produce the positive phase A O A and negative phase A 2 A signals Similar signals are also produced for the B and C phases and each can be monitored at test points 29 34 on the TRIGGER board The positive and negative phase signals are routed through AND gates that require an enable signal from the CONTROL board 1C32 simply acts as a level changing circuit from CONTROL board voltage levels to the TRIGGER board voltage levels During a fault condition the enable signal is driven low and the positive and negative phas
69. shot mode The capacitor causes the input signal to be momentarily negative which drives the 556 output high for 1 ms Since each SCR is gated conjunction with two other SCRs per cycle each SCR requires two gating signals The appropriate gating signals are ORed together through the steering diodes The gating signals are then used to drive a TIP47 transistor into saturation This TIP47 sinks current through the primary of the trigger transformer The induced gate pulse on the secondary triggers SCR Refer to FIGURE 21for a timing diagram of the TRIGGER board signals and FIGURES 22 23 for typical SCR gate pulse with the drive at no load and full load 6 11 SPECIAL SIGNALS AND CIRCUIT FUNCTIONS OPERATING MODE CONTROL As covered in SECTION 6 3 the RUN and JOG operating modes are commanded bv 115 VAC relay logic on the RELAY board A third operating mode controlled by the ZERO SPEED circuit on the CONTROL board takes over control from the RUN mode when the RAMP STOP pushbutton has been depressed The mode commands are interfaced with various electronic reference and controlling circuits as depicted in FIGURE 24 There are 12 of these circuits listed in TABLE 8 that are shut off or clamped by FETs field effect transistors when not turned on or released by the mode control signals as shown in the table The PN4092 FETs that are used are or clamping when their gates are at positive
70. speeds The output of A4 D is based on the initial difference between the inputs and the continuing level required to minimize the difference At ideal speed regulation this output is at zero volts The signal is the input to the velocity integral and proportional stages VELOCITY INTEGRAL A1 D 15 the velocity integral amplifier Its integrated output a capacitor charge 18 controlled by the input resistance and loop capacitance The VELOCITY INTEGRAL pot is used to vary the integration time of the signal that can be monitored at TP17 N Ata steady state load condition this signal equates to the torque required by the motor to make the velocity feedback equal to the velocity reference VELOCITY PROPORTIONAL AI C is the velocity proportional amplifier Its output is an initial stepped response based on the input level the input resistance and the loop resistance The VELOCITY PROPORTIONAL pot is used to adjust the amplitude of the incoming signal Its output can be monitored at TP14 O and would be close to zero volts at best speed regulation The outputs from the velocity integral and velocity proportional amplifiers sum together at A10 A The output can be monitored at TB2B 25 where it is normally jumpered to TB2B 26 This signal is used as an input to the current loop circuit 6 8 CURRENT LIMIT AND OVERCURRENT FUNCTIONS CURRENT LIMIT The positive and negative current limit voltage outputs 47 5 V
71. t can be used to provide controlled rectification of large currents at high voltages ABBREVIATIONS CW Clock Wise CCW Counter Clock Wise dv dt Rate of change in voltage versus rate of change in time ABBREVIATIONS CONT Hz IC IR FET PIV pot PPR R C RPM NL FL Hertz Integrated Circuit Internal Resistance Field Effect Transistors Peak Inverse Voltage Potentiometer Pulses Per Revolution Resistor Capacitor Revolutions Per Minute No Load Full Load 6 1 ARMATURE POWER BRIDGE The armature power bridge of the ELITE E12000 Series is a full wave double converter tvpe configuration As seen in FIGURE 1 it consists of six SCRs on the positive bridge Each of the AC lines connects to two SCRs in each bridge Since the ELITE E06000 Series has only one bridge it is called a full wave single converter As a single or double converter all of the rectifier components six SCRs in the bridge are controlled and give and six SCRs on the negative bridge The bridge being controlled is signified by the POS and NEG LEDs on the CONTROL board On E06 the NEG LED will light when the POS bridge is turned off an output rippled frequency equal to six times the AC line frequency 360 Hz for 60 2 lines and 300 Hz for 50 Hz lines Refer to FIGURES 2 5 for typical positive bridge output waveforms at various unloaded and loaded speeds power modules are some of few c
72. ting point As the start pulse occurs earlier this allows the counter to complete multiple cycles and other start pulses will appear in between the first start pulse and the end stop pulse These pulses can be ignored since first start pulse and end stop pulse are used to control the conduction angle of the SCRs This signal is squared up and inverted by the Schmidt inverter gate and used as a clock input to a dual flip flop Refer to FIGURE 20 The dual flip flop converts the conduction angle signals to a single pulse By using the positive and negative phase signals as reset signals two separate conduction angle signals are produced from each dual flip flop Each of these signals connects to two AND gates These gates are used in conjunction with a forward or reverse enable signals to operate the forward or reverse bridge circuitry The forward and reverse bridge select signals See SECTION 6 9 from the CONTROL board are routed through level changing Schmidt trigger opto couplers The signals are inverted and used as the enables to the AND gates The forward and reverse enable signals also connect to an S R flip flop The flip flop output is buffered and used to control the polarity of the current feedback signal See SECTION 6 6 After the forward or reverse bridge has been enabled the conduction angle is inverted and capacitively coupled to a 556 timer that is configured in the monostable or one
73. to minimize the difference between them This signal is the input to the current loop and can be monitored at 23 CURRENT INTEGRAL Al A is the current integral amplifier The integrated output is controlled bv the input resistance and loop capacitance The CURRENT INTEGRAL pot is used to varv the integration time of this signal that mav be monitored at TP12 P CURRENT PROPORTIONAL A l B is the current proportional amplifier Its output is a stepped response based on the input level the input resistance and the loop resistance The CURRENT PROPORTIONAL pot is used to varv the amplitude of the input signal The output can be monitored at TP16 Q BRIDGE SELECTION The outputs of the current integrator and current proportional amplifiers are summed together bv A2 D to produce the SCR conduction angle demand signal This signal is routed through a precision rectifier and biased down close to 6 VDC low state logic level of the TRIGGER board It can be monitored at TP6 T The conduction angle demand signal is also used as an input to the bridge selection circuit 6 uses a positive feedback to obtain a verv fast changing polaritv signal This signal is used to charge and discharge capacitors C10 and C11 The diodes D5 and D11 allow for rapid discharging of the capacitor with respect to the charge time This allows for the forward bridge select signal to go low before the reverse bridge signal goe
74. uffered by A11 A and enters a precision rectifier consisting of A11 D 11 This positive output signal is then compared at A11 B to a 5 25 VDC level which equates to 105 of rated armature current The comparator is used to control two current related protection circuits FOLDBACK and OVERCURRENT FAULT The FOLDBACK circuit uses IC1 A 1 2 of a 556 dual timer to control the amount of time the drive has exceeded 105 of rated armature current After a selectable time period the drive will enter the FOLDBACK mode and clamp the output to a maximum of 112 The timer output is triggered into a high state upon normal power up This high level exceeds the positive voltage divider level on the non inverting input of comparator A13 A and causes its output to stay at a negative saturation level When the IFB signal into the inverting input of A11 B exceeds the 5 25 VDC level on the non inverting input the output switches negative turns off transistor Q23 which was clamping the timing capacitor C51 When the demand has exceeded 105 for the time period selected J7 51 completes its charge and drives the timer output low The low level drives 13 high and causes Q27 and Q28 to switch the 5 6 volt zener diodes into the current limit circuit The zener diodes override the current limit pots and limit the current demand signal to 11290 which can be monitored at TP5 R OVERCURRENT FAULT The OVERCURR
75. ust be operated in armature feedback when dummv loads used Drive blows fuses on power up A drive that blows fuses when applying the 3 phase power likely has a shorted SCR or shorted diode in the armature or field supply bridges Refer to SECTION 8 for information on testing these devices A shorted motor or shorted wiring to the motor can be checked best with a megger An ohmmeter may also be used but it may not be able to detect very high potential paths to ground Disconnect the motor from the control Measure the resistance from each motor terminal to machine or earth ground Place the ohmmeter in the R X 100k or greater scale and be suspicious of any reading less than 500k Ohms Shorted or excessivelv loaded control voltage transformer mav cause fuse blowing The 115 VAC secondarv must be rated to handle anv customer added auxiliarv load in addition to the normal requirements of the control The external armature contactor in rush adds to this load upon start up Drive blows fuses when entering RUN or JOG mode Check the 3 phase supplv voltages Voltages in excess of 506 VAC mav cause random fuse blowing Reduce the supplv to approximatelv 460 VAC Improper operation of the armature contactor mav cause the ELITE drive to have improper start up This can happen when the external armature contactor is not being controlled bv the internal ELITE relav logic The normal start up procedure should assure that the contacto
76. with or altered by any party other than an authorized Company representative e Products parts and systems designed by the Purchaser f Any party other than the Purchaser The Company makes no other warranties or representation expressed or implied of merchantability and of fitness for a particular purpose in regard to products manufactured parts repaired and systems engineered by it 3 Terms of payment Standard terms of payment are net thirty 30 days from date of the Company invoice For invoice purposed delivery shall be deemed to be complete at the time the products parts and systems are shipped from the Company and shall not be conditioned upon the start up thereof Amounts past due are subject to a service charge of 1 5 per month or fraction thereof 6 Order cancellation Any cancellation by the Purchaser of any order or contract between the Company and the Purchaser must be made in writing and receive written approval of an authorized Company representative at its office in Heath Springs S C In the event of any cancellation of an order by either party the Purchaser shall pay to the Company the reasonable costs expenses damages and loss of profit of the Company incurred there by including but not limited to engineering expenses and expenses caused by commitments to the suppliers of the Company s subcontractors as determined by the Company 7 Changes The Purchaser may from time to time but only with the written
77. y control circuit The output which measures 5 VDC at 20 at 1750 RPM to jumper 15 6 7 VELOCITY LOOP Speed regulation operations are performed within ELITE drives by individual loop control circuits that can be seen in FIGURE 16 They are known as velocity loops because the circuits actively use a feedback signal that is around or fed back for comparison to the reference Faster response and improved speed regulation are the results This explanation of loop 15 similar to the use of a capacitor or resistor connected from the output to the input of an OP AMP integrator or amplifier VELOCITY ERROR The TOTAL REFERENCE SETPOINT is summed together at A4 D with the opposite polarity armature tachometer or encoder feedback signal depending on the placement of J5 Also summed is the INTEGRAL NULL signal Due to the high gain of the velocity loop motor creepage and or overshoot when ramping to stop may be noticeable Adjusting the INTEGRAL NULL pot can reduce this effect by simply using a small amount of the current loop output as negative feedback to the velocity loop A drawback is a reduction in the speed regulation of the drive To compensate for this drives with a revision F or later CONTROL board use the ZERO SPEED logic relay to clamp the INTEGRAL NULL signal above the zero speed setpoint This allows the INTEGRAL NULL circuit to operate in the only region it is needed 1 e very low

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