User`s Manual - Leeson Electric Corporation

User`s Manual - Leeson Electric Corporation
User’s Manual
Models:
175720.00
175721.00
SCR, Dual Voltage, Adjustable-Speed Regenerative
Drives
for DC Brush Motors
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. Leeson Electric and its Divisions assume no
responsibility for any errors that may appear in this manual and make no
commitment to update or to keep current the information in this manual. mvd082103
Printed in the United States of America.
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. Follow the National
Electrical Code and all other applicable electrical and safety
codes, including the provisions of the Occupational Safety
and Health Act (OSHA), when installing equipment.
•
Reduce the chance of an electrical fire, shock, or explosion
by proper grounding, over-current protection, thermal
protection and enclosure. Follow sound maintenance
procedures.
•
It is possible for a drive to run at full speed as a result
of a component failure. To stop the drive in an
emergency, please ensure that a master switch has been
placed in the AC line.
•
This drive is not isolated from earth ground. Circuit
potentials are at 115 VAC or 230 VAC above earth ground.
Avoid direct contact with the printed circuit board or with
circuit elements to prevent the risk of serious injury or
fatality. Use a non-metallic screwdriver for adjusting the
calibration trimpots.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Field output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Tachogenerator feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Speed adjust potentiometer installation . . . . . . . . . . . . . . . . . . . .12
Speed adjust potentiometer connections . . . . . . . . . . . . . . . . . . .13
+15 and –15 terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Line Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Factory Prewired Connections
16
Operation
18
Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Check selector switch settings . . . . . . . . . . . . . . . . . . . . . . . . . .18
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Block Diagram
22
Starting and Stopping Methods
24
Line Starting and Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Automatic restart upon power restoration . . . . . . . . . . . . . . . . . .24
Regenerative deceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Regenerative brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Coast to a stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Decelerate to minimum speed . . . . . . . . . . . . . . . . . . . . . . . . . . .27
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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Forward Acceleration (FWD ACC) . . . . . . . . . . . . . . . . . . . . . . . .33
Reverse Acceleration (REV ACC) . . . . . . . . . . . . . . . . . . . . . . . .34
Deadband (DB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Tach Generator (TACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Forward-Reverse Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Forward-Stop-Reverse Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Independent Adjustable Speeds . . . . . . . . . . . . . . . . . . . . . . . . .39
Independent Forward and Reverse Speeds . . . . . . . . . . . . . . . .40
Independent Forward and Reverse Speeds
with FWD-STOP-REV Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Voltage follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Check the following steps before proceeding . . . . . . . . . . . . . . .43
Line fuse blows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Line fuse does not blow, but the motor does not run . . . . . . . . .45
Motor pulsates or surges under load . . . . . . . . . . . . . . . . . . . . . .46
Motor runs too fast at the maximum speed setting . . . . . . . . . . .46
Motor will not reach the desired speed . . . . . . . . . . . . . . . . . . . .46
Limited Warranty
inside back cover
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 . . . . . . . . . . . . . . . . . . . . . . . .8
Cased Drive Connections . . . . . . . . . . . . . . . . . . . . . . . . .9
Cage-Clamp Terminal Block . . . . . . . . . . . . . . . . . . . . . .10
Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . . .12
Speed Adjust Potentiometer Connections for Unidirectional
Operation (a) and Bidirectional Operation (b) . . . . . . . . .13
9. TB502 Terminal Assignments . . . . . . . . . . . . . . . . . . . . .14
10. Prewired Connections to L1, L2 (with 115 VAC input) and
L2 (with 230 VAC input) . . . . . . . . . . . . . . . . . . . . . . . .16
11. Prewired Speed Adjust Potentiometer Connections . . .17
12. Selector Switch Locations . . . . . . . . . . . . . . . . . . . . . . .19
13. Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
14. Regenerative Deceleration Switch Connection . . . . . .24
15. Inhibit Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
16. Inhibit-Run Terminals . . . . . . . . . . . . . . . . . . . . . . . . . .26
17. Run / Decelerate to Minimum Speed Switch
(shown with bidirectional connection) . . . . . . . . . . . . . .27
18. Calibration Trimpot Layout . . . . . . . . . . . . . . . . . . . . . .29
19. Typical FWD TQ, REV TQ, IR COMP and Deadband
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
20. Forward-Reverse Switch . . . . . . . . . . . . . . . . . . . . . . . .37
21. Forward-Stop-Reverse Switch . . . . . . . . . . . . . . . . . . .38
22. Independent Adjustable Speeds
(Forward Direction) . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
23. Independent Forward and Reverse Speeds . . . . . . . . .40
24. Independent Forward and Reverse Speeds with a
Forward-Stop-Reverse Switch . . . . . . . . . . . . . . . . . . .41
25. Voltage Follower Connection . . . . . . . . . . . . . . . . . . . .42
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.
AC Line Voltage
115/230 VAC, ±10%, 50/60 Hz, single phase
Armature Voltage (115 VAC Input)
0 – 90 VDC
Armature Voltage (230 VAC Input)
0 – 180 VDC
Form Factor
1.37 at base speed
Field Voltage (115 VAC Input)
50 VDC (F1 to L1); 100 VDC (F1 to F2)
Field Voltage (230 VAC Input)
100 VDC (F1 to L1); 200 VDC (F1 to F2)
Max. Field Current
1 ADC
Accel. Time Range (with no load)
0.5 –10 seconds
Decel. Time Range (with no load)
0.5 –10 seconds
Analog Input Voltage Range (isolated; RB1 to S2)
Input Impedance (S0 to S2)
0 –10 VDC
32K ohms
Load Regulation
with Armature Feedback
with Tachogenerator Feedback
1% of base speed or better
0.1% of base speed
Ambient Temp. Range (chassis drive)
10°C – 55°C
Ambient Temp. Range (cased drive)
10°C – 40°C
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. 175721.00 (Chassis) Dimensions
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. 175720.00 (Cased Drive) Dimensions
3
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. Unless dynamic braking is
used, non-regenerative drives cannot oppose an overhauling
load, and cannot decelerate a load faster than coasting to a
lower speed.
Regenerative drives operate in two additional quadrants:
Quadrant 2 and Quadrant 4. In these quadrants, motor torque
is in the opposite direction of motor rotation.
Regenerative drives can reverse a motor without contactors,
switches, brake resistors, and inhibit plugs. They can also
control an overhauling load and decelerate a load faster than it
would take to coast to a lower speed.
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. Four Quadrant Operation
5
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.
Provide sufficient room for access to the terminal block and
calibration trimpots.
Mount the drive away from heat sources. Operate the drive
within the specified ambient operating temperature range.
Prevent loose connections by avoiding excessive vibration of
the drive.
Mount the drive with its board in either a horizontal or
vertical plane. Six 0.188 inch (4.8 mm) wide slots in the chassis
accept #8 pan head screws. Fasten either the large
base or the narrow flange of the chassis to the subplate.
The chassis must be earth grounded for noise suppression. To
ground the chassis, connect earth ground to the GND terminal
on terminal block TB501.
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. For access to the terminal strip, turn the slotted screw on
the front cover counterclockwise until it is free from the
case. The right side of the cover is hinged to the case. Lift
or pull the slotted screw to open the case.
3. Carefully remove the conduit knockouts by tapping them
into the case and twisting them off with pliers.
4. Install conduit hardware through the 0.88 inch (22 mm)
conduit holes. Connect external wiring to the terminal block.
5. Grasp the slotted screw and tilt the front cover back into
place. Avoid pinching any wires between the front cover and
the case.
6. Turn the slotted screw clockwise until tight to secure the
front cover.
7. Set the POWER switch to the “O” or OFF position before
applying the AC line voltage.
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. Use 16 AWG or 18 AWG standard wire
when connecting the field of a shunt-wound motor. Strip the
wire insulation 0.25 inches (6 mm). See Figures 4 and 5 for
AC line (115 VAC or 230 VAC) and motor connections to
chassis and cased drives.
C503
IC502
S3 S2
SW501
TB501
C504
TB502
C505
L1
L2
230V
L2
115V
GND
F1
F2
A2
230 VAC
AC INPUT
VOLTAGE
A1
MOTOR
115 VAC
FIELD OUTPUT
For shunt wound
motors only. See field
output section for details.
Figure 4. Chassis Drive Connections
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. Cased Drive Connections
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. Cage-Clamp Terminal Block
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. Field Output Connections
Line Voltage
(VAC)
115
115
230
230
Approximate
Field Voltage (VDC)
50
100
100
200
Connect Motor
Field To
F1 and L1
F1 and F2
F1 and L1
F1 and F2
Tachogenerator feedback
Using tachogenerator feedback improves speed regulation from
approximately 1% of motor base speed to approximately 0.1%
of motor base speed. Use tachogenerators rated from 7 VDC
per 1000 RPM to 50 VDC per 1000 RPM. Connect the
tachogenerator to terminals T1 and T2 of terminal block TB502.
The polarity is positive (+) for T1 and negative (–) for T2 when
the motor is running in the forward direction. The polarity is
reversed when the motor is running in the reverse direction.
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. Speed adjust potentiometers
are installed on all cased drives.
 Warning
Be sure that the potentiometer tabs do not make contact
with the potentiometer enclosure. Grounding the input will
cause damage to the drive.
MOUNT THROUGH A 0.38 IN. (10 MM) HOLE
CW
WIPER
W
NUT
STAR
WASHER
SPEED ADJUST
POTENTIOMETER
INSULATING DISK
PANEL
Figure 7. Speed Adjust Potentiometer
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. Turning the
wiper CW from the center position causes the motor to rotate in
one direction, while turning the wiper CCW from the center
position causes the motor to rotate in the opposite direction.
Refer to the Application Notes section (page 37) for additional
speed adjust potentiometer connections.
S0
CW
FWD CW
S1
S1
10K
(a)
S2
S3
TB502
S3
TB502
S2
REV 10K
(b)
Figure 8. Speed Adjust Potentiometer Connections for
Unidirectional Operation (a) and Bidirectional Operation (b)
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
5.0
10
1 1/2
7.5
15
2
10
20
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. Prewired Connections to L1, L2 (with 115 VAC input)
and L2 (with 230 VAC input)
Factory Prewired Connections
S0
GREY
FWD
BRAKE
S1
BLUE/
WHITE
GREY/WHITE
REV
CW
BROWN
TB502
S2
PURPLE
S3
10K
Figure 11. Prewired Speed Adjust Potentiometer Connections
17
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. Set the armature voltage selector switch (SW503) to 90 if
using a 90 VDC motor, or to 180 if using a 180 VDC motor.
3. Set the feedback selector switch (SW504) to TACH if using
a tachogenerator; otherwise, set it to ARM for armature
feedback.
Note: You may be required to derate a 90 VDC motor when
230 VAC is applied to the drive. Contact Leeson for details.
See Figure 12 on page 19 for switch locations.
Operation
VOLTAGE
SELECT SWITCHES
ARMATURE
SELECT SWITCH
FEEDBACK SELECT
SWITCH
Figure 12. Selector Switch Locations
19
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. Slowly turn the speed adjust potentiometer either
clockwise for forward direction, or counterclockwise for
reverse direction. The motor will accelerate as the
potentiometer is turned. Continue until the desired
speed is reached.
4. Remove AC line voltage from the drive to coast the
motor to a stop.
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. To brake the motor, set the FORWARD / BRAKE /
REVERSE switch to the BRAKE position. To coast the
motor to a stop, set the POWER switch to the “ 0 ” (OFF)
position.
9. To reverse direction:
a. Set the FORWARD / BRAKE / REVERSE switch to
BRAKE.
b. After the motor comes to a complete stop, set the
FORWARD / BRAKE / REVERSE switch to the desired
direction of rotation.
10. Set the POWER switch to “ 0 ” (OFF) to remove power
from the drive.
22
Block Diagram
Figure 13. Block Diagram
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. Wiring a latching relay into the AC line is one way to
prevent automatic restarting following a power outage.
Regenerative deceleration
Short terminals RB1 and RB2 to
regeneratively decelerate a motor
to a stop (Figure 14). Since
terminal RB1 bypasses the MIN
SPD circuit, shorting RB1 and
RB2 will decelerate a motor to a
stop instead of minimum speed.
Calibrate the deceleration time by
adjusting the opposite-direction
acceleration trimpot.
RB1
STOP
RB2
RUN
Figure 14. Regenerative
Deceleration Switch
Connection
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. Inhibit Terminals
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).
To restart the motor, jumper INHIBIT–RUN terminals 2 and 3. A
single-pole, double-throw switch may be used as a COAST /
RUN switch.
Each drive is assembled with INHIBIT-RUN terminals 2 and
3 jumpered. These terminals must be connected for the
motor to run.
INHIBIT/RUN
TERMINALS
Figure 16. Inhibit-Run Terminals
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. Set the switch to the RUN position to accelerate
the motor to set speed at a rate determined by the ACCEL
trimpot setting.
REV
10K
S3
RUN
S2
DECEL TO
MIN SPD
S1
CW
S0
TB502
FWD
Figure 17. Run / Decelerate to Minimum Speed Switch
(shown with bidirectional connection)
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.
Certain Leeson drives (regenerative and non-regenerative)
coast to minimum speed when the inhibit terminals are shorted
to each other. IR COMP and CURRENT LIMIT (FWD TQ and
REV TQ on regnerative drives) are still active while the drive is
in the inhibit mode.
Frequent regenerative deceleration, regenerative braking,
coasting to a stop, or decelerating to minimum speed produces
high torque. This may cause damage to motors, especially
gearmotors that are not properly sized for the application.
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. Calibration Trimpot Layout
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.
Maximum Speed (MAX SPD)
The MAX SPD setting determines the maximum motor speed
when the speed adjust potentiometer is turned full CW. It is
factory set for maximum rated motor voltage.
To calibrate, set the speed adjust potentiometer full CW. Adjust
the MAX SPD trimpot until the motor turns at the desired
maximum 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. It
also sets the maximum torque for decelerating the motor in the
reverse direction. Refer to the recommended FWD TQ settings
in Figure 19 on Page 36, or recalibrate using the following
procedure:
1. With the power disconnected from the drive, connect a DC
ammeter in series with the armature.
2. Set the FWD TQ trimpot to minimum (full CCW).
3. Set the speed adjust potentiometer for maximum forward speed.
4. Carefully lock the motor armature. Be sure that the motor is
firmly mounted.
5. Apply line power. The motor should be stopped.
6. Slowly adjust the FWD TQ trimpot CW until the armature
current is 120% of the motor nameplate current rating.
7. Turn the speed adjust potentiometer CCW until the motor stops.
8. Remove line power.
9. Remove the stall from the motor.
10. Remove the ammeter in series with the motor armature if it
is no longer needed.
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. It
also sets the maximum torque for decelerating in the forward
direction. Refer to the recommended REV TQ settings in
Figure 19 on Page 36, or recalibrate using the following
procedure:
1. With the power disconnected from the drive, connect a DC
ammeter in series with the armature.
2. Set the REV TQ trimpot to minimum (full CCW).
3. Set the speed adjust potentiometer for maximum reverse speed.
4. Carefully lock the motor armature. Be sure that the motor is
firmly mounted.
5. Apply line power. The motor should be stopped.
6. Slowly adjust the REV TQ trimpot CW until the armature
current is 120% of the motor nameplate current rating.
7. Turn the speed adjust potentiometer CCW until the motor stops.
8. Remove line power.
9. Remove the stall from the motor.
10. Remove the ammeter in series with the motor if it is no
longer needed.
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. Set the speed adjust potentiometer to run at mid-speed
without load (for example, 900RPM for an 1800 RPM
motor). A hand held tachometer may be used to measure
motor speed.
3. Load the motor to the nameplate current rating (full load).
The motor should slow down.
4. While keeping the load on the motor, adjust the IR COMP
trimmer pot CW until the motor runs at the speed measured
in step 2.
5. Unload the motor.
Forward Acceleration (FWD ACC)
The FWD ACC setting determines the time the motor takes to
ramp to either a higher speed in the forward direction or a
lower speed in the reverse direction, within the limits of
available torque. The FWD ACC setting is factory set for its
fastest forward acceleration time.
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.
Turn the REV ACC trimpot CW to increase the reverse acceleration
time, and CCW to decrease the reverse acceleration time.
Deadband (DB)
The deadband trimmer potentiometer determines the time that
will elapse between the application of current in one direction
before current is applied in the opposite direction.
The deadband trimmer potentiometer affects the
resistance that a motor has to changes in shaft position at
zero speed. It does this by applying AC voltage to the motor
armature.
Deadband is factory calibrated to approximately the
3 o’clock position for 60 Hz AC line operation. Recalibrate
the deadband to the 9 o’clock position for 50 Hz AC line
operation. See Figure 19 on page 36 for recommended
deadband settings.
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. Set the speed adjust potentiometer full CW. Measure the
armature voltage across A1 and A2 using a voltmeter.
4. Set the speed adjust potentiometer to 0 (zero speed).
5. Set switch SW504 to TACH for tachogenerator feedback.
6. Set the IR COMP trimpot full CCW.
7. Set the TACH trimpot full CW.
8. Set the speed adjust potentiometer full CW.
9. Adjust the TACH trimpot until the armature voltage is the
same value as the voltage measured in step 3.
Check that the tachogenerator is properly calibrated. The motor
should run at the same set speed when SW504 is set to either
armature or tachogenerator feedback.
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. Typical FWD TQ, REV TQ, IR COMP and Deadband
Settings
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. Forward-Reverse Switch
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. Forward-Stop-Reverse Switch
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. Independent Adjustable Speeds
(Forward Direction)
P2
20K OHM
CW
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. Independent Forward and Reverse Speeds
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. Independent Forward and Reverse Speeds with a
Forward-Stop-Reverse Switch
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. Voltage Follower Connection
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. The deadband (DB) must be set approximately at the 3
o’clock position for 60 Hz AC line frequency or at 9 o’clock
for 50 Hz AC line frequency.
4. The motor must be rated for the drive’s rated armature (all
motors) and field outputs (shunt wound motors only).
5. Do not make any connections to F1 and F2 if using a
permanent magnet motor.
6. Terminal block connections should be consistent with the
connections shown in this manual.
7. Check that line fuse FU501 (and FU502 for 230 VAC input)
is properly sized and not blown.
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. A combination of ambient conditions and frequent
high-current spikes (i.e., reversing) causes fuse to
“nuisance trip”. Consider using a slow-blow fuse or
increasing the fuse rating to 120% of motor
current as stated on the nameplate.
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. If the
drive is in current limit, verify that the motor is not
jammed. It may be necessary to increase the
FWD TQ or REV TQ setting if it is set lower than
the current rating of the motor.
7. Check that the speed adjust potentiometer
connections to the terminal block are correct and
not open.
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.
Motor will not reach the desired speed
1. Check the MAX SPD setting and increase if
necessary.
2. Check that the IR COMP setting is not set too low.
3. Check that the motor is not overloaded.
For additional assistance, contact your local Leeson
distributor, or the factory direct: phone (262) 3778810; fax (262) 377-9025.
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.
This warranty shall not apply to any product that has been subject to misuse, negligence, or
accident; or misapplied; or repaired by unauthorized persons; or improperly installed.
Leeson Electric is not responsible for removal, installation, or any other incidental expenses incurred in shipping the product to and from the repair point.
B. Disclaimer - The provisions of Paragraph A are Leeson Electric’s sole obligation and exclude
all other warranties of merchantability for use, express or implied. Leeson Electric further
disclaims any responsibility whatsoever to the customer or to any other person for injury to the
person or damage or loss of property of value caused by any product that has been subject to
misuse, negligence, or accident, or misapplied or modified by unauthorized persons or improperly
installed.
C. Limitations of Liability - In the event of any claim for breech of any of Leeson Electric’s
obligations, whether express or implied, and particularly of any other claim or breech of warranty
contained in Paragraph A, or of any other warranties, express or implied, or claim of liability that
might, despite Paragraph B, be decided against Leeson Electric by lawful authority,
Leeson Electric shall under no circumstances be liable for any consequential damages, losses,
or expense arising in connection with the use of, or inability to use, Leeson Electric’s product for
any purpose whatsoever.
An adjustment made under warranty does not void the warranty, nor does it imply an extension of
the original one (1) year or 3,000 hour warranty period. Products serviced and/or parts replaced
on a no-charge basis during the warranty period carry the unexpired portion of the original warranty
only.
If for any reason any of the foregoing provisions shall be ineffective, Leeson Electric’s liability for
damages arising out of its manufacture or sale of equipment, or use thereof, whether such liability
is based on warranty, contract, negligence, strict liability in tort, or otherwise, shall not in any event
exceed the full purchase price of such equipment.
Any action against Leeson Electric based upon any liability or obligation arising hereunder or
under any law applicable to the sale of equipment or the use thereof, must be commenced within
one year after the cause of such action arises.
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.A – May 2007
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