User’s Manual Models: 175720.00 175721.
Copyright 2003 by Leeson Electric All rights reserved. No part of this manual may be reproduced or transmitted in any form without written permission from Leeson Electric. The information and technical data in this manual are subject to change without notice. Leeson Electric and its Divisions make no warranty of any kind with respect to this material, including, but not limited to, the implied warranties of its merchantability and fitness for a given purpose.
i Safety Warnings SHOCK HAZARD AVOID HEAT KEE DR OID ATION • Throughout this manual, this symbol denotes an important safety message. Please read these messages carefully before performing any instructions contained herein. • Have a qualified electrical maintenance technician install, adjust and service this equipment.
ii Contents Specifications 1 Dimensions 2 Regenerative Drives 4 Installation 6 Mounting chassis drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Mounting cased drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Heat sinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 AC line and motor connections . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Cage-clamp terminal block . . . . . . . . . . . . . . . . . .
Contents iii Calibration 29 Application Notes 37 Troubleshooting 43 Minimum Speed (MIN SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Maximum Speed (MAX SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Forward Torque (FWD TQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Reverse Torque (REV TQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Regulation (IR COMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iv Illustrations Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure 1. 2. 3. 4. 5. 6. 7. 8. 175721.00 (Chassis) Dimensions . . . . . . . . . . . . . . . . . . .2 175720.00 (Cased Drive) Dimensions . . . . . . . . . . . . . . .3 Four Quadrant Operation . . . . . . . . . . . . . . . . . . . . . . . . .5 Chassis Drive Connections . . . . . . . . . . . . . . . . . . . . . . . .
1 Specifications Model Max. Armature Current (Amps DC) HP Range with 115 VAC Applied HP Range with 230 VAC Applied 175720.00 10.0 † 1/4 – 1 † 1/2 – 2 † 175721.00 10.0 † 1/4 – 1 † 1/2 – 2 † † Maximum armature current and horsepower range apply when drive is attached to additional heat sink part number 175722. Use heat sink when armature current is above 7 ADC. Heat sinks are pre-mounted on cased drives.
2 Dimensions 8.90 [226] 8.38 [213] 3.53 [90] 4.75 [120] 1.86 [47] 0.92 [23] ALL DIMENSIONS IN INCHES [MILLIMETERS] Figure 1. 175721.
Dimensions 6.90 [175] 6.30 [160] SPEED POWER BRAKE 10.20 [259] REVERSE FORWARD 9.80 [249] FOUR (4) EACH MOUNTING SLOTS, 6.3 [160] x 7.0 [178] ON CENTERS 5.50 [140] 4.78 [121] 1.45 [37] 2.30 [58] 0.12 [3] 1.50 [38] 1.50 [38] THREE 0.88 [22] KNOCKOUTS ALL DIMENSIONS IN INCHES [MILLIMETERS] Figure 2. 175720.
4 Regenerative Drives Most non-regenerative, variable speed, DC drives control current flow to a motor in one direction. The direction of current flow is the same direction as the motor rotation. Non-regenerative drives operate in Quadrant 1, and also in Quadrant 3 if the drive is reversible (see Figure 3). Motors must stop before reversing direction.
Regenerative Drives Quadrant II Quadrant I Quadrant III Quadrant IV MOTOR ROTATION MOTOR TORQUE NOTE: ARROWS IN SAME DIRECTION = MOTOR ACTION ARROWS IN OPPOSITE DIRECTION = REGENERATIVE ACTION Figure 3.
6 Installation Mounting chassis drives Warning Do not install, rewire, or remove this control with power applied. Doing so may cause fire or serious injury. Read and understand the Safety Warnings on pg i before attempting installation. Drive components are sensitive to electrostatic fields. Avoid direct contact with the circuit board. Hold the drive by the chassis only. Protect the drive from dirt, moisture, and accidental contact.
Installation 7 Mounting cased drives Leeson cased drives come with three 0.88-inch (22 mm) conduit knockout holes on the bottom of the case. The units may be vertically wall mounted using the four 0.25-inch (6 mm) slotted holes on the attached heat sink. For motor loads less than 5 ADC, the drive may be bench mounted horizontally, or operated without mounting. 1. Install the mounting screws. 2.
8 Installation Heat sinking Model 175721.00 requires an additional heat sink, p/n 175722, when the continuous armature current is above 7 ADC. Model 175720.00 has sufficient heat sinking in its basic configuration. Use a thermally conductive heat sink compound (such as Dow Corning® 340 Heat Sink compound) between the drive chassis and the heat sink surface for optimum heat transfer. AC line and motor connections Use 12 AWG or 14 AWG standard wire for connecting the line and the armature.
9 SO501 T1 T2 INH-RUN SO502 INHIBIT Installation FU502 FU503 S0 FLD S1 115 C503 IC502 S2 SW501 S3 L2 230 FAST ACTING FUSES ONLY L1 IC501 RB1 RB2 -15 3 230 FU501 2 +15 C502 1 TB501 TB502 C504 230 VAC C505 L1 L2 230V L2 115V GND F1 F2 A2 A1 115 VAC MOTOR AC LINE INPUT FIELD OUTPUT For shunt wound motors only. See field output section for details. Figure 5.
10 Installation Cage-clamp terminal block Connections to drives are made to a cage-clamp terminal block (Figure 6). To insert a wire into the terminal block, press down on the lever arm using a small screwdriver. Insert stripped wire into the large opening in front of the terminal block. Release the lever arm to clamp the wire. Press down on the lever arm using a small screwdriver. 1 2 Insert wire into the wire clamp. 3 Release the lever arm to clamp the wire. Figure 6.
Installation 11 Field output The field output is for shunt wound motors only. Do not make any connections to F1 and F2 when using a permanent magnet motor. Use 18 AWG wire to connect the field output to a shunt wound motor. Table 1 lists the field output connections. Table 1.
12 Installation Speed adjust potentiometer installation On chassis drives, install the circular insulating disk between the panel and the 10KΩ speed adjust potentiometer. Mount the speed adjust potentiometer through a 0.38 in. (0.96 cm) hole with the hardware provided (see Figure 7). Twist the speed adjust potentiometer wire to avoid picking up unwanted electrical noise. If the potentiometer leads are longer than 18 in. (46 cm), use shielded cable.
13 Installation Speed adjust potentiometer connections The motor can operate in one direction (unidirectional) or in two directions (bidirectional) depending on how the speed adjust potentiometer is connected to the drive. Connect the speed adjust potentiometer as shown in Figure 8(a) for speed control in one direction. Connect the speed adjust potentiometer as shown in Figure 8(b) for speed control in two directions. The motor does not rotate when the wiper is in the center position.
14 Installation TB502 S3 S2 S1 S0 RB1 RB2 -15 +15 T1 T2 Figure 9. TB502 Terminal Assignments +15 and –15 terminals 17572x Series drives can supply a regulated +15 and –15 VDC signal (each sourcing 25 mA maximum) to isolated, external devices. These voltage supply terminals are located on terminal block TB502. Warning Do not short the +15 and - 15 terminals for any reason! Shorting these terminals will damage the drive.
Installation 15 Line Fusing Leeson drives require fuses for protection. Use fast acting fuses rated for 250 VAC or higher, and approximately 150% of the maximum armature current. Fuse both L1 and L2 when the line voltage is 230 VAC. The fuse table below lists the recommended line fuse sizes. Fuse Table 90 VDC Motor Horsepower 1/20 1/15 1/8 1/6 1/4 1/3 1/2 3/4 1 180 VDC Max. DC Armature AC Line Fuse Horsepower Current (amps) Size (amps) 1/10 0.5 3 1/8 0.8 3 1/4 1.5 5 1/3 1.7 5 1/2 2.5 8 3/4 3.5 8 1 5.
16 Factory Prewired Connections (for Cased Drives) 1 2 3 WHITE/BLACK WHITE/BLACK L2 (230) BLACK BLACK POWER LIGHT BLACK L1 BLACK/WHITE WHITE/BLACK L2 (115) Figure 10.
Factory Prewired Connections S0 GREY FWD BRAKE S1 BLUE/ WHITE GREY/WHITE REV CW BROWN TB502 S2 PURPLE S3 10K Figure 11.
18 Operation Before applying power 1. Check connections before applying AC line voltage to the drive. 2. Check that no conductive material is present on the printed circuit board. 3. Verify that all selector switches are set correctly (see the following section for selector switch settings). Check selector switch settings 1. Set both line voltage selector switches (SW501 and SW502) to 115 if using 115 VAC line voltage, or to 230 if using 230 VAC line voltage. 2.
Operation VOLTAGE SELECT SWITCHES ARMATURE SELECT SWITCH FEEDBACK SELECT SWITCH Figure 12.
20 Operation Startup Chassis drives Uni-directional Operation 1. Set the speed adjust potentiometer to minimum (full CCW). 2. Apply AC line voltage. 3. Slowly turn the speed adjust potentiometer clockwise (CW). The motor will accelerate as the potentiometer is turned CW. Continue until the desired speed is reached. 4. Remove AC line voltage from the drive to coast the motor to a stop. Bi-directional Operation 1. Set the speed adjust potentionmeter to minimum (center position). 2. Apply AC line voltage. 3.
Operation 21 Cased drives 1. 2. 3. 4. 5. Set the FORWARD / BRAKE / REVERSE switch to BRAKE. Set the speed adjust potentiometer to minimum (full CCW). Apply AC line voltage. Set the POWER switch to the “ I ” (ON) position. Set the FORWARD / BRAKE / REVERSE switch to the desired direction of rotation. 7. Slowly advance the speed adjust potentiometer clockwise (CW). The motor will accelerate as the potentiometer is turned CW. Continue until the desired speed is reached. 8.
22 Block Diagram Figure 13.
Block Diagram 23
24 Starting and Stopping Methods Line Starting and Stopping Line starting and stopping (applying and removing AC line voltage) is recommended only for infrequent starting and stopping of a drive. When AC power is applied to the drive, the motor accelerates to the speed set by the speed adjust potentiometer. When power is removed, the motor coasts to a stop. Automatic restart upon power restoration All drives automatically run to set speed when power is applied.
Starting and Stopping Methods 25 Regenerative brake Short the INHIBIT terminals to regeneratively brake the motor (see Figure 15 for INHIBIT terminal location). Reopening the INHIBIT terminals causes the motor to run at set speed. The INHIBIT terminals bypass both the MIN SPD circuit and the deceleration circuit. This causes the motor to stop rapidly when the INHIBIT terminals are shorted. Braking torque is determined by the opposite-direction torque setting. INHIBIT TERMINALS Figure 15.
26 Starting and Stopping Methods Twist inhibit wires and separate them from other power-carrying wires or sources of electrical noise. Use shielded cable if the inhibit wires are longer than 18 in. (46 cm). If shielded cable is used, ground only one end of the shield to earth ground. Do not ground both ends of the shield. Coast to a stop To coast the motor to a stop without removing power to the drive, jumper INHIBIT–RUN terminals 1 and 2 (see Figure 16).
Starting and Stopping Methods 27 Decelerate to minimum speed The circuit shown in Figure 17 may be used to decelerate a motor to a minimum speed. Closing the switch between S2 and S0 decelerates the motor from set speed to a minimum speed determined by the MIN SPD trimpot setting. If the MIN SPD trimpot is set full CCW, the motor decelerates to zero speed when the switch between S2 and S0 is closed. The DECEL trimpot setting determines the rate at which the drive decelerates.
28 Starting and Stopping Methods Warning For frequent starts and stops, use regenerative deceleration (shorting RB1 and RB2), regenerative breaking (shorting INHIBIT terminals to each other), coasting to a stop (shorting INHIBIT-RUN terminals 1 and 2), or decelerating to minimum speed (shorting S2 to S0). Do not use any of these methods for emergency stopping. They may not stop a drive that is malfunctioning. Removing AC line power (both L1 and L2) is the only acceptable method for emergency stopping.
29 Calibration Each drive is factory calibrated to its maximum current rating. Readjust the calibration trimpot settings to accommodate lower current rated motors. All adjustments increase with CW rotation, and decrease with CCW rotation. Use a non-metallic screwdriver for calibration. Each trimpot is identified on the printed circuit board. P501 P502 P503 MIN SPD FWD TQ REV TQ P504 P505 P506 IR COMP MAX SPD FWD ACC P507 P508 P509 REV ACC DB TACH Figure 18.
30 Calibration Minimum Speed (MIN SPD) The MIN SPD setting determines the minimum speed when the speed adjust potentiometer is turned full CCW. It is factory set to zero speed. The minimum speed feature applies only when the drive is operating in unidirectional mode. To calibrate, set the speed adjust potentiometer full CCW. Adjust the MIN SPD trimpot until the motor turns at the desired minimum speed.
Calibration 31 Forward Torque (FWD TQ) Warning FWD TQ should be set to 120% of the motor nameplate current rating. Continuous operation beyond this rating may damage the motor. The decision to change the forward torque setting must be made after considering the gearbox and drivetrain ratings, duty cycle, and motor characteristics. The FWD TQ setting determines the maximum torque for accelerating and driving the motor in the forward direction.
32 Calibration Reverse Torque (REV TQ) Warning REV TQ should be set to 120% of the motor nameplate current rating. Continuous operation beyond this rating may damage the motor. The decision to change the reverse torque setting must be made after considering the gearbox and drivetrain ratings, duty cycle, and motor characteristics. The REV TQ setting determines the maximum torque for accelerating and driving the motor in the reverse direction.
Calibration 33 Regulation (IR COMP) The IR COMP setting determines the degree to which motor speed is held constant as the motor load changes. It is factory set for optimum motor regulation. Recalibrate the IR COMP setting when using a lower horsepower motor. See Figure 19 on page 36 for typical IR COMP settings, or recalibrate using the following procedure: 1. Set the IR COMP trimmer pot to minimum (full CCW). 2.
34 Calibration Turn the FWD ACC trimpot CW to increase the forward acceleration time, and CCW to decrease the forward acceleration time. Reverse Acceleration (REV ACC) The REV ACC setting determines the time the motor takes to ramp to either a higher speed in the reverse direction or a lower speed in the forward direction, within the limits of available torque. The REV ACC setting is factory set for its fastest reverse acceleration time.
Calibration 35 Tach Generator (TACH) Calibrate the TACH setting only when a tachogenerator is used. The TACH setting, like the IR COMP setting, determines the degree to which motor speed is held constant as the motor load changes. To calibrate the TACH trimpot: 1. Connect the tachogenerator to T1 and T2. The polarity is positive (+) for T1 and negative (–) for T2 with the motor running in the forward direction. 2. Set switch SW504 to ARM for armature feedback. 3.
36 FWD TQ FWD TQ FWD TQ FWD TQ Calibration REV TQ REV TQ REV TQ REV TQ IR COMP IR COMP IR COMP IR COMP 1 HP 90 VDC 10 ADC FWD TQ 3/4 HP 90 VDC 7.6 ADC FWD TQ 1/2 HP 90 VDC 5 ADC FWD TQ 1/4 HP 90 VDC 2.7 ADC FWD TQ 60 Hz Applications 50 Hz Applications DB DB REV TQ REV TQ REV TQ REV TQ IR COMP IR COMP IR COMP IR COMP 2 HP 180 VDC 9.2 ADC 1 HP 180 VDC 5 ADC 3/4 HP 180 VDC 3.8 ADC 1/2 HP 180 VDC 2.5 ADC Figure 19.
37 Application Notes Forward-Reverse Switch Use a single-pole, two-position switch with a single speed adjust potentiometer to plug reverse the motor (Figure 20). The MIN SPD setting is in effect for either direction. S0 S1 10K OHM TB502 S2 REV CW S3 FWD Figure 20.
38 Application Notes Forward-Stop-Reverse Switch Use a single-pole, three-position switch with a single speed adjust potentiometer to stop a motor between reversals (Figure 21). Set the switch to the center position to decelerate the motor to a stop. S0 S1 10K OHM TB502 S2 S3 REV CW STOP FWD Figure 21.
Application Notes 39 Independent Adjustable Speeds Connect two speed adjust potentiometers with a single pole two position switch to select between two independent speeds shown in the forward direction (Figure 22). The speed adjust potentiometers can be mounted at two separate operating stations. P1 20K OHM S0 TB502 S1 SPEED 1 CW S2 SPEED 2 Figure 22.
40 Application Notes Independent Forward and Reverse Speeds Connect two speed adjust potentiometers as shown in Figure 23 to select between independent forward and reverse. S0 FWD 10K OHM REV 10K OHM S1 TB502 FWD CW CW S2 S3 REV Figure 23.
Application Notes 41 Independent Forward and Reverse Speeds with FWD-STOP-REV Switch Use a single pole, three position switch to stop the motor when the switch is in the center position (Figure 24). S0 S1 TB502 S2 S3 FWD 10K OHM FWD CW REV 10K OHM CW STOP REV Figure 24.
42 Application Notes Voltage follower The drive may be wired to follow a floating (isolated) 0 to ±10V signal that is isolated from earth ground instead of using a speed adjust potentiometer. Connect the signal input to S2, and the signal common to RB1 (see Figure 25). ±10 VDC S2 S1 RB1 TB502 COMMON Figure 25.
43 Troubleshooting Warning Dangerous voltages exist on the drive when it is powered. When possible, disconnect the drive while troubleshooting. High voltages can cause serious or fatal injury. Check the following steps before proceeding 1. The AC line voltage must match the voltage on the drive nameplate. 2. On dual voltage drives, check that the voltage switches are set to the correct position. 3.
44 Troubleshooting Line fuse blows 1. Disconnect AC line voltage from the drive. 2. Check that the motor cable and armature are not shorted or grounded. a. Armature resistance should measure approximately 1 to 100 ohms, depending on motor horsepower. b. A resistance reading from the motor frame to either armature side should show open when an ohmmeter is used on its high resistance scale. 3. Check that the field circuit is not open. 4.
Troubleshooting 45 Line fuse does not blow, but the motor does not run 1. Verify that the speed adjust potentiometer is not set to its zero speed position. 2. Check the speed adjust potentiometer for continuity. 3. Verify that the inhibit terminals are not shorted together. 4. Check that INHIBIT–RUN terminals 2 and 3 are connected. (See figure 16, page 25) 5. Verify that the drive is receiving AC line voltage. 6. Check that the drive is not in current limit.
46 Troubleshooting Motor pulsates or surges under load 1. IR Comp may be set too high. Adjust the IR COMP setting slightly CCW until the motor speed stabilizes. 2. Motor “bouncing” in and out of torque limit. Make sure the motor is not undersized for the load; adjust FWD TQ and REV TQ trimpots. Motor runs too fast at the maximum speed setting 1. Check that the MIN SPD and MAX SPD settings are not set too high. 2. If using a shunt-wound motor, check that the field output connections are secure.
47 NOTES
48 NOTES
Limited Warranty A. Warranty - Leeson Electric warrants that this product will be free from defects in workmanship and material for one (1) year or 3,000 hours, whichever comes first, from date of shipment therof. Within this warranty period, Leeson Electric will repair or replace such products that are : (1) returned to Leeson Electric, 2100 Washington Street, Grafton, WI, 53024-0241 U.S.A ; and, (2) determined by Leeson Electric to be defective.
2100 Washington Street Grafton, WI 53024-0241 U.S.A. Phone: (262) 377-8810 Fax: (262) 337-9025 Document number 250–0254, Revision 4 Printed in the U.S.
