User`s Manual - Bison Gear and Engineering Corporation

User`s Manual - Bison Gear and Engineering Corporation
User’s Manual
Models:
170-203-0002
170-203-0005
Pulse-Width Modulated, Adjustable Speed
Drives for DC Brush Motors
Copyright © 2006 by
Bison Gear & Engineering
All rights reserved. No part of this manual may be reproduced or transmitted in any
form without written permission from Bison Gear & Engineering. The information and
technical data in this manual are subject to change without notice. Bison Gear &
Engineering 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. Bison Gear & Engineering 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.
Printed in the United States of America.
i
Safety Warnings
SHOCK
HAZARD
AVOID
HEAT
KEEP
DRY
AVOID
VIBRATION

•
This symbol
denotes an important safety tip or warning.
Please read these instructions carefully before performing
any of the procedures contained in this manual.
•
DO NOT INSTALL, REMOVE, OR REWIRE THIS
EQUIPMENT WITH POWER APPLIED. Have a qualified
electrical 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. Bison strongly recommends the
installation of a master switch in the main power input to stop
the drive in an emergency.
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. Use approved personal protective
equipment and insulated tools if working on this drive with
power applied.
ii
Contents
Safety Warnings
i
Specifications
1
Dimensions
2
Installation
3
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Shielding guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Line fusing
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Speed adjust potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Power, fuse and motor connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Master power switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Line fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Voltage Follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Operation
12
Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Starting and Stopping Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Line starting and line stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Automatic restart upon power restoration . . . . . . . . . . . . . . . . . . . . . . . . . .15
Inhibit terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Inhibit plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Decelerating to minimum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Dynamic braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
iii
RUN/BRAKE switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Dynamic brake resistor sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Calibration
20
Calibration procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
MINIMUM SPEED (MIN SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
MAXIMUM SPEED (MAX SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
ACCELERATION (ACCEL)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
DECELERATION (DECEL)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
REGULATION (IR COMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
CURRENT LIMIT (CURR LIM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Application Notes
Multiple fixed speeds
31
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Adjustable speeds using potentiometers in series . . . . . . . . . . . . . . . . . . . . . .32
Independent adjustable speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
RUN/JOG switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
RUN/JOG option #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
RUN/JOG option #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Leader-follower application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Troubleshooting
38
Before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
CURRENT LIMIT (CL/FLT)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
iv
Certificate of Compliance
43
CE Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
AC Line Filters
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Unconditional Warranty
inside back cover
v
Illustrations
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.
9.
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Voltage Follower Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Inhibit Terminal Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Run/Decelerate to Minimum Speed Switch . . . . . . . . . . . . . . . . . . . . . .17
Dynamic Brake Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Calibration Trimpot Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Approximate CURRENT LIMIT and IR COMP Settings
for 120 VAC in, 90 VDC out (actual settings may vary) . . . . . . . . . . . .27
10. Approximate CURRENT LIMIT and IR COMP Settings
for 120 VAC in, 130 VDC out (actual settings may vary) . . . . . . . . . .28
11. Approximate CURRENT LIMIT and IR COMP Settings
for 240 VAC in, 180 VDC out (actual settings may vary) . . . . . . . . . . .29
12. Approximate CURRENT LIMIT and IR COMP Settings
for 240 VAC in, 240 VDC out (actual settings may vary) . . . . . . . . . .30
13. Multiple Fixed Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
14. Adjustable Speeds Using Potentiometers In Series . . . . . . . . . . . . . .32
15. Independent Adjustable Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
16. RUN/JOG Option #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
17. RUN/JOG Option #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
18. Leader-Follower Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
19. Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
20. Diagnostic LED locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
21. CE Filter Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
vi
Tables
Table
Table
Table
Table
1.
2.
3.
4.
Recommended Line Fuse Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Inhibit Plug Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Dynamic Brake Resistor Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . .19
AC Line Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
1
Specifications
Model
170-203-0002
170-203-0005
AC
Line
Voltage
120 OR 240
120 OR 240
Max. Continuous HP Range
Armature
with 120
Current
VAC
(Amps DC)
Applied
2
1/20 – 1/4
5
1/4 – 1/2
HP Range
with 240
VAC
Applied
1/10 – 1/2
1/2 – 1
AC Line Voltage
120/240 VAC ± 10%, 50/60 Hz, single phase
Armature Voltage Range
120 VAC input
0-130 VDC
240 VAC input
0 – 240 VDC
Form Factor (at base speed)
1.05
Acceleration/Deceleration Time Range (no load)
0.5 – 6 seconds
Analog Input Voltage Range* [S1(–) to S2(+)]
0 – 5 VDC
Input Impedance (S1 to S2 with 5 VDC input)
approximately 70K ohms
Speed Regulation
1% base speed or better
Ambient Temp. Range (chassis drive)
10°C – 40°C
Vibration
0.5g max (20 – 50 Hz)
0.1 g max (>50 Hz)
Weight
170-203-0002
170-203-0005
* Signal must be isolated.
0.66 lb [0.30 kg]
0.72 lb [0.32 kg]
2
Dimensions
C505
C504
C503
C502
A1
S3
R501
T501
L2
INHIBIT
D
Q503
C501
3.64 [92]
A2
S2
S1
IL502
CURRENT
LIMIT
POWER
L1
0.19 [5]
1.75 [44]
TH501
IL501
CURRENT LIMIT
MAX SPD MIN SPD IR COMP
DECEL
ACCEL
0.70 [18]
3.80 [97]
4.30 [109]
A
0.82 [21]
2.10 [53]
0.19 [5]
0.96 [24]
MODEL
DIMENSION “A”
HEIGHT
170-203-0002
170-203-0005
2.50 [62]
3.20 [81]
ALL DIMENSIONS IN INCHES
[MILLIMETERS]
Figure 1. Dimensions
3
Installation
Mounting
 Warning
Do not install, rewire, or remove this control with input
power applied. Doing so may cause fire or serious injury.
Make sure you have read and understood the Safety Warnings
before attempting installation.
•
Drive components are sensitive to electrostatic fields. Avoid
direct contact with the circuit board. Hold 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 drive with its board in either a horizontal or vertical
plane. Six 0.19 in. (5 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.
4
•
The chassis must be earth grounded. Use a star washer
beneath the head of at least one of the mounting screws to
penetrate the anodized chassis surface and to reach bare
metal.
Wiring
 Warning
Ꮨ
Do not install, remove, or rewire this equipment with power
applied. Failure to heed this warning may result in fire,
explosion, or serious injury.
Circuit potentials are at 115 or 230 VAC above ground. To
prevent the risk of injury or fatality, avoid direct contact with
the printed circuit board or with circuit elements.
Do not disconnect any of the motor leads from the drive
unless power is removed or the drive is disabled. Opening
any one motor lead may destroy the drive.
•
Use 16–20 AWG wire for speed adjust potentiometer wiring.
Use 14–16 AWG wire for AC line (L1, L2) and motor (A1 and
A2) wiring.
5
Shielding guidelines
 Warning
Under no circumstances should power and logic leads be
bundled together. Induced voltage can cause unpredictable
behavior in any electronic device, including motor controls.
As a general rule, Bison recommends shielding of all conductors.
If it is not practical to shield power conductors, Bison recommends
shielding all logic-level leads. If shielding logic leads is not
practical, the user should twist all logic leads with themselves to
minimize induced noise.
It may be necessary to earth ground the shielded cable. If noise is
produced by devices other than the drive, ground the shield at the
drive end. If noise is generated by a device on the drive, ground
the shield at the end away from the drive. Do not ground both ends
of the shield.
If the drive continues to pick up noise after grounding the shield, it
may be necessary to add AC line filtering devices, or to mount the
drive in a less noisy environment.
Logic wires from other input devices, such as motion controllers
and PLL velocity controllers, must be separated from power lines in
the same manner as the logic I/O on this drive.
6
Line fusing
Protect all Bison drives with AC line fuses. Use fast acting AC line
fuses rated for 250 volts, and approximately 150% – 200% of the
maximum armature current. Fuse only the “hot” side of the AC line
(L1) if using 115 VAC line voltage. Do not add line fuses to L2
unless you use 240 VAC line voltage. See Table 1 below for
recommended line fuse sizes:
Table 1. Recommended Line Fuse Sizes
Maximum Armature
AC Line Fuse
Current (DC Amps)
Rating (AC Amps)
1.5 and below
3
2.6
5
3.5
8
5.0
10
7
Speed adjust potentiometer
 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 the speed adjust potentiometer through a 0.38 in. (10 mm)
hole with the hardware provided (Figure 2). Install the circular
insulating disk between the panel and the 10K ohm speed adjust
potentiometer. Twist the speed adjust potentiometer wire to avoid
picking up unwanted electrical noise. If speed adjust potentiometer
wires are longer than 18 in. (457 mm), use shielded cable. Keep
speed adjust potentiometer wires separate from power leads (L1,
L2, A1, A2).
MOUNT THROUGH A 0.38 IN. (10 MM) HOLE
CW
WIPER
CCW
NUT
STAR
WASHER
SPEED ADJUST
POTENTIOMETER
INSULATING DISK
POT TAB ASSIGNMENTS
PANEL
Figure 2. Speed Adjust Potentiometer
8
Connections
 Warning
Do not connect this equipment with power applied.
Failure to heed this directive may result in fire or serious injury.
Bison strongly recommends the installation of a master
power switch in the voltage input line, as shown in
Figure 3 (page 10). The switch contacts should be rated at a
minimum of 200% of motor nameplate current and 250 volts.
Power, fuse and motor connections
Connect the power input leads, an external line fuse and a DC
motor to the drive’s printed circuit board (PCB) as shown in Figure
3, page 10.
Master power switch
Decelerating to minimum speed or coasting to a stop may not stop
a drive that is malfunctioning. Removing AC line power (both L1
and L2) is the only acceptable method for emergency stopping.
For this reason, Bison strongly recommends installing an
emergency stop switch on both the L1 and L2 inputs. The switch
contacts must be rated at a minimum of 250 volts and 200% of
maximum drive current.
9
Motor
Bison drives supply motor voltage from A1 and A2 terminals. It is
assumed throughout this manual that, when A1 is positive with
respect to A2 , the motor will rotate clockwise (CW) while looking at
the output shaft protruding from the front of the motor. If this is
opposite of the desired rotation, simply reverse the wiring of A1 and
A2 with each other.
Connect a DC motor to PCB terminals A1 and A2 as shown in
Figure 3. Ensure that the motor voltage rating is consistent with the
drive’s output voltage.
Power input
Connect the AC line power leads to PCB terminals L1 and L2, or to
a double-throw, single-pole master power switch (recommended).
Line fuse
Wire an external line fuse between the stop switch (if installed) and
the L1 terminal the circuit board. An additional line fuse should be
installed on L2 if the input voltage is 230VAC. The line fuse(s)
should be rated at 250 volts and 150 - 200% of maximum motor
nameplate current. Refer to the line fuse chart on page 6 for fuse
ratings.
10K OHM
SPEED ADJUST
POTENTIOMETER
CW
INHIBIT
IL502
C504
C501
DECEL
C502
ACCEL
POWER
C505
C503
TH501
IL501
R501
Figure 3. Connections
MIN SPD IR COMP
CURRENT
LIMIT
CURRENT LIMIT
S2
S1
S3
D
L1
L2
A2
A1
MOTOR
FUSE
STOP
SWITCH
120/240 VAC
LINE VOLTAGE
*
* NOTE:
FUSE L2
ONLY IF LINE
VOLTAGE IS
240 VAC.
+
10
T501
11
Voltage follower
Instead of using a speed adjust potentiometer, the drive may be
wired to follow a 0 – 5 VDC isolated voltage signal (Figure 4).
Connect the signal return (–) to S1. Connect the signal high or (+)
to S2. Make no connection to S3. A potentiometer can be used to
scale the analog input voltage.
0 - 5 VDC
VOLTAGE SIGNAL
C505
C
C502
REF (+)
R501
C504
S2
S1
C501
INHIBIT
COM (-)
IL502
CURRENT
LIMIT
POWER
CURRENT LIMIT
MAX SPD MIN SPD IR COMP
Figure 4. Voltage Follower Connections
DECEL
ACCEL
TH50
IL50
12
Operation
 Warning
Ꮨ
Dangerous voltages exist on the drive when it is powered,
and up to 30 seconds after power is removed and the motor
stops. BE ALERT. High voltages can cause serious or fatal
injury. For your safety, use personal protective equipment
(PPE) when operating this drive.
If the motor or drive does not perform as described,
disconnect the AC line voltage immediately. Refer to the
Troubleshooting section on page 38 for further assistance.
Before applying power
•
Verify that no conductive material is present on the printed
circuit board.
13
Startup
To start the drive:
1.
Turn the speed adjust potentiometer full counterclockwise
(CCW). If the drive is following a voltage signal, set the
voltage signal to 0 VDC.
2.
Apply AC line voltage.
3.
Slowly advance the speed adjust potentiometer clockwise
(CW). If the drive is following a voltage signal, slowly increase
the voltage signal. The motor slowly accelerates as the
potentiometer is turned CW, or the voltage signal is increased.
Continue until the desired speed is reached.
4.
Remove AC line voltage from the drive to coast the motor to a
stop.
14
Starting and Stopping Methods
 Warning
Decelerating to minimum speed or coasting to a stop is
recommended for frequent starts and stops. 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.
For this reason, Bison strongly recommends installing an
emergency stop switch on both the L1 and L2 inputs
(see Connections on page 10).
Line starting and line stopping
Line starting and line stopping (applying and removing AC
line voltage) is recommended for infrequent starting and stopping
of a drive only. When AC line voltage is applied to the drive,
the motor accelerates to the speed set by the speed adjust
potentiometer. When AC line voltage is removed, the motor coasts
to a stop.
15
Automatic restart upon power restoration
All drives automatically run to set speed when power is applied and
the drive is enabled. The drive will accelerate at a rate controlled
by the ACCEL trimpot. Refer to the Calibration section for
information on adjusting this setting.
Inhibit terminals
 Warning
Inhibit is used for frequent starts and stops. It must never
be used as an emergency stop because it may not stop a
drive that is malfunctioning. Removing AC power (L1 and
L2) is the only acceptable method for emergency stopping.
Jumper the inhibit terminals to coast the motor to a stop
(Figure 5). Remove the jumper to accelerate the motor to set
speed.
16
Inhibit plug
Bison offers an accessory plug harness for use with the inhibit
terminals:
Table 2. Inhibit Plug Part Numbers
Bison®
Part Number
170-998-0100
Description
Inhibit plug with 36-in. (91 cm) wires
Twist inhibit plug wires and separate them from other powercarrying wires or sources of electrical noise. Use shielded cable if
the inhibit plug wires are longer than 18 inches (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.
INHIBIT
TERMINAL
C505
C503
C502
R501
C504
IL502
CURRENT
Figure 5. Inhibit Terminal Location
D
Q503
C501
INHIBIT
T501
S2
S1
17
Decelerating to minimum speed
A switch may be used to decelerate the motor to minimum speed.
Connect the switch as shown in Figure 6. Close the switch
between S1 and S2 to decelerate the motor from set speed. Open
the switch to accelerate the motor to set speed. The ACCEL and
DECEL trimpot settings determine the rate at which the motor
accelerates and decelerates, respectively.
CW
S3
10K OHM
SPEED ADJUST
POTENTIOMETER
S2
S1
RUN
DECEL TO
MIN SPEED
Figure 6. Run/Decelerate to Minimum Speed Switch
18
Dynamic braking
 Warning
Wait for the motor to come to a complete stop before setting
the RUN/BRAKE switch to RUN. This will prevent high
armature currents from damaging the motor or drive.
Dynamic braking may be used to rapidly stop a motor (see
Figure 7 on page 19). For the RUN/BRAKE switch, use a doublepole, double throw switch rated for at least the maximum DC
armature voltage and maximum braking current.
RUN/BRAKE switch
Install a double-pole, double-throw switch between the INHIBIT
terminals and a dynamic brake resistor as shown in Figure 7 on
page 19. Set the switch to the BRAKE position to dynamically brake
the motor to a stop. Set the switch to the RUN position to accelerate
the motor to set speed at a rate controlled by the ACCEL trimpot.
Dynamic brake resistor sizes
Size the dynamic brake resistor according to the motor current
rating (refer to Table 3 on page 19). The dynamic brake resistance
listed in the table is the smallest recommended resistance allowed
to prevent possible demagnetization of the motor. The motor stops
less rapidly with higher brake resistor values.
19
Table 3. Dynamic Brake Resistor Part Numbers
Minimum
Motor Armature
Current Rating
Less than 2 ADC
2–3 ADC
3–5 ADC
5–10 ADC
Minimum
Dynamic Brake
Resistor Value
1 ohm
5 ohm
10 ohm
20 ohm
Dynamic Brake
Resistor Wattage
1W
5W
10W
20W
For motors rated 1/17 horsepower and lower, a brake resistor is not
necessary since the armature resistance is high enough to stop the
motor without demagnetization. Replace the dynamic brake with 12
gauge wire.
A1
A2
RUN
MOTOR
DYNAMIC BRAKE
RESISTOR
BRAKE
INHIBIT
Figure 7. Dynamic Brake Connection
20
Calibration
Each drive is factory calibrated to its maximum current rating.
Readjust the calibration trimpot settings to accommodate lower
current 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.
A1
R501
C502
S2
S1
INHIBIT
T501
A2
L2
Q503
C501
D
L1
IL502
CURRENT
LIMIT
POWER
TH501
IL501
CURRENT LIMIT
CURRENT
LIMIT
MAX SPD MIN SPD IR COMP
MAX
SPEED
MIN
SPEED
IR COMP
DECEL
ACCEL
DECELERATION
Figure 8. Calibration Trimpot Layout
ACCELERATION
21
Calibration procedure
Before applying power
1.
Verify that no conductive material is present on the printed
circuit board.
2.
Set all trimpots full except CURRENT LIMIT full
counterclockwise (CCW).
3.
Set the CURRENT LIMIT trimpot full clockwise (CW).
4.
Set the speed adjust potentiometer or input signal to zero
speed.
5.
Set the INHIBIT switch to INHIBIT, or install the jumper
between the INHIBIT terminals of SO501.
6.
Apply line voltage to the drive. The green POWER LED shall
light, but the motor should remain stopped.
7.
Set the INHIBIT switch to ENABLE, or remove the jumper
between the INHIBIT terminals of SO501.
22
MINIMUM SPEED (MIN SPD)
MIN SPD determines the minimum speed when the speed
adjust potentiometer is turned full CCW. It is factory set to
zero speed. To calibrate MIN SPD:
1.
Set the speed adjust potentiometer full CCW.
2.
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 speed. To
calibrate MAX SPD:
1.
Set the MAX trimpot full CCW.
2.
Turn the speed adjust potentiometer full CW.
3.
Adjust the MAX SPD trimpot until the desired
maximum motor speed is reached.
23
ACCELERATION (ACCEL)
The ACCELERATE setting determines the time the motor takes to
ramp to a higher speed. See Specifications on page 1 for
approximate acceleration times. The ACCELERATE setting is
factory set to its minimum value (full CCW).
Turn the ACCEL trimpot CW to increase the acceleration time and
CCW to decrease the acceleration time.
DECELERATION (DECEL)
The DECELERATE setting determines the time the motor takes to
ramp to a lower speed. See Specifications on page 1 for
approximate deceleration times. The DECELERATE setting is
factory set to its minimum value (full CCW).
Turn the DECEL trimpot CW to increase the deceleration time and
CCW to decrease the deceleration time.
24
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 current rated motor. Refer to Figures 9 - 12 (pp 27 30) for typical IR COMP settings, or recalibrate using the following
procedure:
If the motor does not maintain set speed as the load changes,
gradually rotate the IR COMP trimpot CW. If the motor oscillates
(overcompensation), the IR COMP trimpot may be set too high
(CW). Turn the IR COMP trimpot CCW to stabilize the drive.
25
CURRENT LIMIT (CURR LIM)
 Warning
Although the current limit trimpot can be set to exceed the
motor's maximum armature current rating, Bison recommends
you do not run the motor continuously beyond that rating.
Continuous operation beyond the maximum armature current
rating may cause thermal degradation of the motor and drive.
The CURRENT LIMIT setting determines the maximum torque for
accelerating and driving the motor. CURRENT LIMIT is factory set
at 120% of maximum drive current. You must recalibrate the
CURRENT LIMIT setting if using a lower current rated motor.
Refer to Figures 9 - 12 (pp 27 - 30) for typical CURRENT LIMIT
settings.
1.
With no power applied to the drive, connect a DC ammeter in
series with the motor armature.
2.
Set the CURRENT LIMIT trimpot to full CCW.
3.
Carefully lock the motor armature. Ensure that the motor is
firmly mounted.
4.
Apply line power. The motor should be stopped.
5.
Set the speed potentiometer or reference signal to maximum
speed. The motor should remain stopped.
26
CURRENT LIMIT (cont.)
6.
Slowly rotate the CURRENT LIMIT trimpot clockwise (CW)
until the ammeter reads 120% of maximum motor armature
current.
7.
Set the speed adjust potentiometer or reference signal to zero
speed.
8.
Remove power from the drive.
9.
Remove the lock from the motor shaft.
10. Remove the ammeter in series with the motor armature.
27
170-203-0002
MOTOR
HP:
VOLTS
RPM:
AMPS:
1/4
90 VDC
1750
2.5 ADC
170-203-0005
MOTOR
HP:
VOLTS
RPM:
AMPS:
CURR
LIM
I/R
COMP
CURR
LIM
I/R
COMP
I/R
COMP
CURR
LIM
I/R
COMP
CURR
LIM
I/R
COMP
1/3
90 VDC
1750
3.5 ADC
MOTOR
HP:
VOLTS
RPM:
AMPS:
CURR
LIM
1/2
90 VDC
1750
5.0 ADC
MOTOR
HP:
VOLTS
RPM:
AMPS:
1/8
90 VDC
1750
1.3 ADC
MOTOR
HP:
VOLTS
RPM:
AMPS:
I/R
COMP
1/20
90 VDC
1750
0.5 ADC
MOTOR
HP:
VOLTS
RPM:
AMPS:
CURR
LIM
1/4
90 VDC
1750
2.7 ADC
Figure 9. Approximate CURRENT LIMIT and IR COMP Settings
for 120 VAC in, 90 VDC out (actual settings may vary)
28
170-203-0002
MOTOR
CURR
LIM
170-203-0005
I/R
COMP
MOTOR
CURR
LIM
I/R
COMP
1/4
HP:
VOLTS: 130 VDC
RPM: 2500
AMPS: 1.8 ADC
CURR
LIM
I/R
COMP
MOTOR
CURR
LIM
I/R
COMP
CURR
LIM
I/R
COMP
1/3
HP:
VOLTS: 130 VDC
RPM: 2500
AMPS: 2.6 ADC
1/8
HP:
VOLTS: 130 VDC
RPM: 2500
AMPS: 1.0 ADC
MOTOR
MOTOR
1/2
HP:
VOLTS: 130 VDC
RPM: 2500
AMPS: 3.8 ADC
1/20
HP:
VOLTS: 130 VDC
RPM: 2500
AMPS: 0.4 ADC
CURR
LIM
I/R
COMP
MOTOR
1/4
HP:
VOLTS: 130 VDC
RPM: 2500
AMPS: 2.0 ADC
Figure 10. Approximate CURRENT LIMIT and IR COMP Settings
for 120 VAC in, 130 VDC out (actual settings may vary)
29
170-203-0002
MOTOR
CURR
LIM
170-203-0005
I/R
COMP
HP:
1/2
VOLTS: 180 VDC
RPM: 1750
AMPS: 1.4 ADC
MOTOR
MOTOR
CURR
LIM
I/R
COMP
CURR
LIM
I/R
COMP
CURR
LIM
I/R
COMP
HP:
1
VOLTS: 180 VDC
RPM: 1750
AMPS: 5.0 ADC
CURR
LIM
I/R
COMP
HP:
1/4
VOLTS: 180 VDC
RPM: 1750
AMPS: 1.0 ADC
HP:
1/8
VOLTS: 180 VDC
RPM: 1750
AMPS: 0.6 ADC
MOTOR
MOTOR
HP:
3/4
VOLTS: 180 VDC
RPM: 1750
AMPS: 3.5 ADC
CURR
LIM
I/R
COMP
MOTOR
HP:
1/2
VOLTS: 180 VDC
RPM: 1750
AMPS: 2.7 ADC
Figure 11. Approximate CURRENT LIMIT and IR COMP Settings
for 240 VAC in, 180 VDC out (actual settings may vary)
30
170-203-0002
MOTOR
CURR
LIM
170-203-0005
I/R
COMP
CURR
LIM
I/R
COMP
MOTOR
I/R
COMP
MOTOR
CURR
LIM
I/R
COMP
CURR
LIM
I/R
COMP
3/4
HP:
VOLTS: 240 VDC
RPM: 2500
AMPS: 2.7 ADC
1/3
HP:
VOLTS: 240 VDC
RPM: 2500
AMPS: 1.0 ADC
1/4
HP:
VOLTS: 240 VDC
RPM: 2500
AMPS: 0.75 ADC
CURR
LIM
1
HP:
VOLTS: 180 VDC
RPM: 1750
AMPS: 5.0 ADC
1/2
HP:
VOLTS: 240 VDC
RPM: 2500
AMPS: 1.9 ADC
MOTOR
MOTOR
CURR
LIM
I/R
COMP
MOTOR
1/2
HP:
VOLTS: 240 VDC
RPM: 2500
AMPS: 2.0 ADC
Figure 12. Approximate CURRENT LIMIT and IR COMP Settings
for 240 VAC in, 240 VDC out (actual settings may vary)
31
Application Notes
Multiple fixed speeds
Replace the speed adjust potentiometer with series resistors
having a total series resistance of 10 K ohms (Figure 13). Add a
single pole, multi-position switch with the correct number of
positions for the desired number of fixed speeds.
R1
S3
R2
S2
R3
S1
TOTAL SERIES
RESISTANCE
10K OHMS
R4
Figure 13. Multiple Fixed Speeds
32
Adjustable speeds using potentiometers in
series
Connect two speed adjust potentiometers as shown in
Figure 14 to select between high speed and low speed.
CW
S3
HIGH
SPEED
5K
OHM
LOW
SPEED
CW
S2
S1
5K
OHM
Figure 14. Adjustable Speeds Using Potentiometers In Series
33
Independent adjustable speeds
Connect two speed adjust potentiometers with a single-pole, multiposition switch and two or more potentiometers in parallel, with a
total resistance of 10K ohms. Figure 15 shows the connection of
two independent speed adjust potentiometers that can be mounted
at two separate operating stations.
S3
SPEED 2
CW
CW
SPEED 1
20K
OHM
20K
OHM
S2
S1
Figure 15. Independent Adjustable Speeds
34
RUN/JOG switch
Using a RUN/JOG switch is recommended in applications where
quick stopping is not needed and frequent jogging is required. Use
a single pole, two position switch for the RUN/JOG switch, and a
single-pole, normally-closed, momentary operated pushbutton for
the JOG pushbutton.
RUN/JOG option #1
In option #1 (Figure 16), connect the RUN/JOG switch and the
JOG pushbutton to the INHIBIT terminals. When the RUN/JOG
switch is set to JOG, the motor coasts to minimum speed. Press
the JOG pushbutton to jog the motor. Return the RUN/JOG switch
to RUN for normal operation.
RUN
INHIBIT
JOG
PUSHBUTTON
JOG
Figure 16. RUN/JOG Option #1
35
RUN/JOG option #2
In option #2, connect the RUN/JOG switch to the speed adjust
potentiometer using a single-pole, two-position switch for the
RUN/JOG switch, and a single-pole, normally-closed, momentary
operated pushbutton for the JOG pushbutton as shown in
Figure 17. When the RUN/JOG switch is set to JOG, the motor
decelerates to minimum speed. Press the JOG pushbutton to jog
the motor. Return the RUN/JOG switch to RUN for normal
operation.
S3
CW
S2
10K OHM
SPEED ADJUST
POTENTIOMETER
S1
RUN
JOG
JOG
PUSHBUTTON
Figure 17. RUN/JOG Option #2
36
Leader-follower application
In this application, use a 170-993-0200 to monitor the speed of the
leader motor (Figure 18). The 170-993-0200 outputs a voltage
proportional to the leader motor armature voltage. The follower
drive uses this voltage reference to set the speed of the follower
motor. An optional ratio potentiometer may be used to scale the
170-993-0200 output voltage.
MOTOR
A2
(+) 2
9 (+)
A1
Leader
Drive
8
170-993-0200
7 (-)
TB501
S2
(-) 1
TB502
S1
10K Ohm
(optional)
Figure 18. Leader-Follower Application
Follower
Drive
37
Reversing
A dynamic brake may be used when reversing the motor direction
(Figure 19). Use a three-pole, three-position switch rated for at
least the maximum DC armature voltage and maximum braking
current. Wait for the motor to stop completely before switching it to
either the forward or reverse direction. See the Dynamic braking
section on page 18 for sizing the dynamic brake resistor.
A1
A2
DYNAMIC
BRAKE
RESISTOR
MOTOR
FWD
BRAKE
REV
INHIBIT
Figure 19. Reversing
38
Troubleshooting
 Warning
Dangerous voltages exist on the drive when it is powered, and
up to 30 seconds after power is removed. When possible,
disconnect the drive while troubleshooting. High voltages can
cause serious or fatal injury.
Before troubleshooting
Perform the following steps before starting any procedure in this
section:
•
Disconnect AC line voltage from the drive.
•
Check the drive closely for damaged components.
•
Check that no conductive or other foreign material has
become lodged on the printed circuit board.
•
Verify that every connection is correct and in good condition.
•
Verify that there are no short circuits or grounded connections.
•
Check that the voltage selection switch settings match the AC
line and output voltages.
•
Check that the drive's rated armature and field outputs are
consistent with the motor ratings.
For additional assistance, contact your local Bison distributor, or the
factory direct: Phone: 1-800-AT-BISON
39
Diagnostic LEDs
This series of drives are equipped with the following diagnostic
LEDs to aid in troubleshooting or monitoring equipment status.
Refer to Figure 20 below.
POWER
Green LED lights when AC line voltage is applied to the drive.
CURRENT LIMIT (CL/FLT)
Red LED lights when drive output current exceeds the threshold
set by the CURRENT LIMIT trimpot.
L2
2
INHIBIT
T501
A2
2
S2
S1
L1
Q503
C501
D
IL502
CURRENT
LIMIT
POWER
TH501
IL501
CURRENT LIMIT
MAX SPD MIN
I SPD IR COMP
DECEL
ACCEL
CURRENT
LIMIT LED
Figure 20. Diagnostic LED locations
POWER
LED
40
Symptom
Line fuse blows
Line fuse does not
blow, but the motor
does not run
Possible
Causes
Suggested
Solutions
1. Line fuses are the
wrong size.
1. Check that line fuses are
the proper size.
2. Motor cable or armature
is shorted to ground.
2. Check motor cable and
armature for shorts.
3. Nuisance tripping
caused by a
combination of ambient
conditions and highcurrent spikes.
3. Add a blower to cool the
drive components;
decrease CURRENT
LIMIT settings, or resize
motor and drive for actual
load demand, or check for
incorrectly aligned
mechanical components
or “jams”. See page 25
for information on
adjusting the CURRENT
LIMIT trimpot.
1. Reference signal or
speed adjust pot is set
to zero speed.
1. Increase reference signal
or speed adjust
potentiometer setting.
2. Reference signal or
speed adjust
potentiometer
connections are open.
2. Check that the reference
signal or speed adjust
potentiometer connections
are not open.
41
Symptom
Line fuse does not
blow, but the motor
does not run (cont.)
Possible
Causes
Suggested
Solutions
3. Drive is overloaded.
3. Verify that the motor is
not jammed. Increase
CURRENT LIMIT setting
(page 25).
4. Drive is not receiving
AC line voltage.
4. Apply AC line voltage to
L1 and L2.
5. Motor is not connected.
5. Connect motor to A1 and
A2.
Motor runs too fast at
maximum speed
setting
1. MIN SPD and MAX
SPD settings are too
high.
1. Recalibrate MIN SPD
(page 22) and MAX SPD
(page 22).
Motor runs too slow or
too fast
1. MIN SPD and MAX
SPD are not calibrated.
1. Recalibrate MIN SPD
(page 22) and MAX SPD
(page 22).
Motor will not reach
the desired speed.
1. MAX SPD setting is too
low.
1. Increase MAX SPD
setting (page 22).
2. IR COMP setting is too
low.
2. Increase IR COMP
setting (page 24).
3. Motor is overloaded.
3. Check motor load.
Resize the motor if
necessary.
42
Symptom
Motor pulsates or
surges under load
Possible
Causes
Suggested
Solutions
1. IR COMP is set too
high.
1. Adjust the IR COMP
setting slightly CCW until
the motor speed
stabilizes (page 24).
2. Control is in current
limit mode.
2. Check that motor and
drive are of sufficient
horsepower and
amperage. You may
need to replace the
motor and/or the drive.
43
Certificate of Compliance
CE Certification
Bison hereby certifies that this series of drives have been approved
to bear the CE" mark provided the conditions of approval have
been met by the end user.
The OEM must meet the following conditions:
•
All wires, including logic, AC power and motor leads, must be
shielded. Do not ground both ends of the shield.
•
This series motor control module must be enclosed in a solid
metal enclosure. The enclosure lid, body and backplane must
all be tied to a low-impedance earth ground.
•
A VV-series Corcom© filter (or equivalent) must be wired into
the AC main. (See Table 4 on page 44.)
•
The ground connection between the shielded cable, installed
line filter and metal enclosure must be wired to solid earth
ground (resistance less than 500 ohms), not
machine ground. This is very important!
44
Compliance allows this series to bear the CE mark.
The end user, as described herein, falls into one of two categories:
1.
The Consumer will deploy a stand-alone unit as an integral,
yet external, portion of the machine being operated.
2.
The Original Equipment Manufacturer (OEM) will implement
the product as a component of the machine being
manufactured.
AC Line Filters
In addition to EMI/RFI safeguards inherent in this series' design,
external filtering is required. To meet CE approval conditions, use
the line filters (or equivalent) listed in Table 4. Connect the filter as
shown in Figure 24.
Table 4. AC Line Filters
Drive
170-203-0002
170-203-0005
AC
Current
3A
7A
Corcom
Filter
6VV1
10VV1
45
VV1
FILTER
DRIVE
L1
L1
L2
L2
DRIVE
ENCLOSURE
GND
SCREW
SOLID EARTH
GROUND
Figure 21. CE Filter Connections
46
NOTES
47
NOTES
48
NOTES
49
NOTES
50
NOTES
Bison Warranty Policy
The Company warrants to the Buyer the products sold hereunder to be
free of defects in material and workmanship under normal use and service
for a period of one (1) year from the date of shipment. The obligation of
the Company under this warranty is limited to repair or replacing at its
option, any part or parts, which upon examination shall disclose to the
reasonable satisfaction of the Company to have been defective in material
or workmanship. Buyer must return the products to the Company’s
factory, shipping charges prepaid, and with complete information as to
alleged defects and the installation, operation and service of the products.
Except as otherwise expressly stated herein the Company makes no
representation of warranty of any kind, express or implied, as to
merchantability, fitness for a particular purpose, or any other matter with
respect to the products sold hereunder.
Bison Gear & Engineering Corp.
3850 Ohio Ave. -- St. Charles, IL 60174
Phone: 1-800-AT-BISON
www.bisongear.com
Document Number: 250-0417; Revision 0 -- May 2006
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