gp1200

gp1200
Installing, Operating
and Maintaining
Three-Phase Input
Three-Phase Output
General Purpose GP-1200
A-C VxS Drives
460 VAC
2 HP, 3 HP, 5 HP, 71/2 HP. 10 HP
x
DRIVES
Instruction Manual D2-3103-2
July 1988
RELIANCE
ELECTRIC EL]
© Copyright Reliance Electric
Reliance and VxS are Trademarks of Reliance Electric
Table of Contents
Chapter/Topic | Page
1: Receive and Accept the Controller
identify the Controller ...........e 2. aaanaxoeaeoeaaooororoc, 1:1
Receive and Accept the Shipment ..............oé_ee.X?eceororoo. 1:1
Store the Controller until Installation .......... ee ee ee ae ee eee. 1:1
File a Return Request . . . ........ uni 1:1
2: Know the Controller
Terminology Used in This Manual ..............ooéececeoooeexodeeo, 2:1
Definitions and Abbreviations . . . ................ . eno, 2:1
Dangers, Warnings, and Cautions . . ................. uuu... 2:1
Related Publications . . .......... ie is 2:1
Drive Components . ....... ite ee ee LL 1111110 2:1
Controller Features ............_ i iit eee LL LL 2:2
Available Controller Options . . . . ..... ise иене вееннее 2:2
Local Operator's Control Station . . . . ...... 0 uu. 2:2
Remote Operator's Control Station . . ........... ui. 2:3
Customer Interface Module . ................ iii... 2:3
Dynamic Braking . ............ 0 не еее 2:3
Digital Meter .. Le LL ALL 2:3
Extended Line DipModule . . ............. nn 2:3
Cabinet Conversion . .. ..... LL V LL La ALL LL 2:3
Voltmeter «Le ee a da aa a A LA A ALL LL LL 2:3
Ammeter .....222 0121211 2 a 4 ae da a a Va a ALL LL LS 2:3
Frequency Meter (Analog) .................. uuu... 2:3
Controller Specifications . .. ............ se coaocaoeRdadr, 2:3
Controller Ratings . ...........o ime, 2:3
Service Conditions + a LL LL LL a LL ALL 2:4
Controller Application Data ................. 0. 2:4
3: Install the Drive
Plan and Complete the Installation. ...........í.—.. o... e .dedo, 3:1
Select the Controller Enclosure Location . 0... 3:1
Install the Controller ................ e. .edecxocsrecwocroe, 3:1
Install a Transformer (if needed) ................ . . ... .. . .... 3:3
Install an Input Disconnect . .. 0. .rereñrzeaoo, 3:3
Install the Motor ............ .—...... ed<eocadcarecedorereo, 3:4
Ground the Controller and Enclosure, Motor, Remote Operator's
Control Station, and Regulator Transformer .............. ....... 3:4
Suppress Electrical Noise . . . .... ..... 2 н аи и иван, 3:4
Wirethe Drive. . . .. ee 111. 3:4
Power Wiring .......2211 01 LL LL ALL LL LL 1110 3:7
Controland Signal Wiring . . . .. .. .. Lt н еек кк ев. 3:7
Controller Regulator Modifications .. .............. uuu. ui... 3:10
Extended Speed Range ............... 0... un, 3:11
Variable Torque Curve . . . . LL LL La LL LL 3:11
Variable Carrier Frequency . . . . .. .. .. em. nocc0roseraa, 3:11
26 VDC Grounding . . . .. oi LA LA LS 3:11
Output Contactor Turn-off Delay... ............. 0.0... .. 3:11
Process Control Lo. i a aa a Ra LL ALL LL LL 3:11
Extended Line Dip Ride Thru . . .. .. ......... 0. 3:11
Regenerative Voltage Limit . .... ............. i. 3:11
D-COffsetat Zero Hertz .................... eee. 3:12
Ramp-to-Rest .. .. ....e..a0a0rerarererecer, 3:12
Extended Acceleration and Deceleration Times . . ................. 3:12
©Copyright Reliance Electric Company 1987
Chapter/Topic Page
4: Start and Adjust the Drive
Test Equipment Needed . ©... . 022 ALL LL LL LS 4:1
Check the Installation .......... ii ee eee a, 4:1
Check the Motor ......... ee LL 1120 4:1
Check the Transformer (if used) ................. ecreverda,s 4:2
Check the Controller and Enciosure ...... 111111111111 10 4:2
Check the Grounding . ............. in... 4:2
Start the Controller Purchased as Drive Package ..................... 4:4
Start the Controller Purchased Separately ................. uu... 4:4
5: How the Controller Operates
Fundamentals of Variable Voltage, Variable Frequency Controllers ........ 5:1
Power Circuit Operation... .... ieee eee. 5:1
Controller Regulator Operation . 5:2
Fundamentals of Controller Operator's Controls . . .......... vv... 5:4
Start/Stop Control . ee LS 5:4
Speed Control . . ee eee ee 5:4
Run/Jog Switch ©... ee 5:5
Automatic/Manual Switch (Option) .. .... .. ... .. 5:5
Forward/Reverse Switch (Option) . .. ..... ii. 5:5
6: Troubleshoot the Controller
Controller LEDs . . . . a 6:1
Test Equipment Needed . . . . ... 0. i aacaroarenocoo 6:1
General Troubleshooting Procedure . . .. ........... 0. uuu... 6:2
Fault Synptom Troubleshooting Flow Charts .............” er... 6:2
List of Figures
Figure/Description
Figure 3-1. Physical Dimensions and Weights for NEMA 1 Enclosed and
Chassis Controllers . 0 ii ..
Figure 3-2. Wiring Locations in NEMA 1 Controller with
Basic Local Operation Control Station ..................
Figure 3-3. Wiring Locations in Chassis Controller with
Customer Interface Module .........................
Figure 34. Interconnection Diagram of Controller with
Local Operator's Control Station Functions . , . ............
Figure 3-5. Interconnection Diagram Using Customer Interface Module ....
Figure 3-6. Location of Modification Jumpers and
Switches on the Regulator . .........................
Figure 4-1. Regulator Pots, LED and Checkpins . . ..................
Figure 4-2. Volts/Hertz Pot Adjustable Region for 460V Input ..........
Figure 4-3. Relationshipof Min HzandMax Hz . ...................
Figure 5-1. Power Circuit Schematic ................ 0... ..
Figure 5-2. Controller Regulator Block Diagram . . . .................
Figure 5-3. Theory of Generating PWM ,........ ................
Figure 6-1. Motor Will not Run e nerxrecarera
Figure 6-2. Motor Will not Reach Maximum Speed . .................
Figure 6-3. Controller IET Occurs during Controlled Deceleration ........
Figure 6-4. Controller IET Occurs Occasionally while Running but
CanBeRestarted ............. nun...
Figure 6-5. Motor Overheats above Allowable Temperature ............
Figure 6-6. Typical Component Identification (2to 5 HP) .............
Figure 6-7. Typical Component Identification (7% to 10 HP) ...........
Figure 6-8. Typical Wiring Diagram of Standard NEMA 1
Enclosed Controller... ..... ee...
Figure 6-9. Typical Wiring Diagram of Chassis Controller ...........—...
Figure 6-10. Typical Regulator PC Board Schematic . . . ...............
Figure 6-11. Typical Customer Interface PC Board Schematic ...........
Figure 6-12. Typical Component Layout of Regulator PCBoard . . . .......
List of Tables
Table/Description
Table 2-1. Standard Kit Options . . . .... ... i inn,
Table 2-2. Local Operator's Control Station Kits . . .................
Table 2-3. Controller Current Ratings . .. ..... oo ov vue...
Table 3-1. Sizing the Metal Enclosure That Will House the Chassis .......
Table 3-2. Motor Derating Data for Centrifugal Loads . ..............
Table 3-3. Regulator Modifications. ..........oPeÑXde.oeoereooa ao.
Table 3-4. Possible Speed Ranges ........... 7.0. r.Q.cceseee
Table 3-5. Extended Acceleration and Deceleration Time Selection ......
Table 4-1. Controller Pot Settings ............—..2.ccd0ñaedxocooo
Table 6-1. Possible Causes of IET Trips ............. . . . e. .ace.
Table 6-2. Replacement Parts List .......... e... 7. aa
Table 6-3. Recommended Spare Parts for Every 6 Controllers ..........
iv
Page
3:2
3:5
6:6
6:7
6:9
6:10
6:11
6:12
6:13
6:14
6:15
1: Receive and Accept the Controller
Identify the Controller
Each Reliance Electric GP-1200 A-C
VxS® Controller can be positively iden-
tified by its model number (standard
controller) or sales order number (cus-
tomer specified controller). This num-
ber appears on the shipping label and is
stamped on the controller nameplate.
Refer to this number whenever dis-
cussing the equipment with Reliance
Electric personnel.
The standard model number describes
the controller as follows:
1AG xxx -X
First Generation
A-C V*S Drive
Controller
Voltage (460 VAC)
Enclosure
0 or blank = Chassis
1 = МЕМА 1
Controller Horsepower
02=2 HP
03=3 HP
05 = 5 HP
07 = 74 HP
10 = 10 НР
UL Listed/CSA Approved
C = CSA
U=UL
no suffix = not UL Listed;
not CSA Approved
The sales order number is a six-digit
number following a plant code that
uniquely describes a controller manu-
factured to customer specifications.
Receive and Accept
the Shipment
Reliance Electric's terms of sales, in all
instances, are F.O.B. point of origin.
The user is responsible for thoroughly
inspecting the equipment before ac-
cepting shipment from the transporta-
tion company.
if all the items called for on the bill of
lading or on the express receipt are not
included or if any items are obviously
damaged, do not accept the shipment
until the freight or express agent makes
an appropriate notation on your freight
bill or express receipt.
If any concealed loss or damage is dis-
covered later, notify your freight or
express agent within 15 days of receipt
and request that he make an inspection
of the shipment. Keep the entire ship-
ment intact in its original shipping
container.
The Consignee is responsible for making
claim against the Carrier for any short-
age or damage occurring in transit.
Claims for loss or damage in shipment
must not be deducted from the Reliance
Electric invoice, nor should payment of
the Reliance® invoice be withheld while
awaiting adjustment of such claims since
the Carrier guarantees safe delivery.
If considerable damage has been in-
curred and the situation is urgent, con-
tact the nearest Reliance Electric Sales
Office for assistance.
Store the Controller
until Installation
After receipt inspection, repack the
GP-1200 A-C VXS Controller in its
shipping container until installation. If
a period of storage is expected, store in
the original shipping container with its
internal packing.
To ensure satisfactory drive operation
at startup and to maintain warranty
coverage, store the equipment:
e in its original shipping container in a
clean, dry, safe place.
e within an ambient temperature range
of —40° to 65°C (—40° to 149°F).
e within a relative humidity range of
5 to 95% without condensation.
e away from a highly corrosive atmos-
phere. In harsh environments, cover
the shipping/storage container.
e away from construction areas.
File a Return Request
1. Toreturn equipment, send a written
request to Reliance Electric within
ten days of receipt.
2. Do not return equipment without a
numbered authorization form (ERA
form) from Reliance Electric.
Reliance Electric reserves the right
to inspect the equipment on site.
V*x5 and Reliance are registered trademarks of
Reliance Electric Company.
1:1
2: Know the Controller
Terminology Used in
This Manual
Definitions and Abbreviations
CCW: The abbreviation for counter-
clockwise.
CEC: The abbreviation for the Canadian
Electrical Code,
CIF: The abbreviation for the Customer
Interface Module, which is an option.
Controller: The term substituted
throughout this manual for “GP-1200
A-C V*S Drive Controiler”” to make the
manual easier to read and understand.
CW: The abbreviation for clockwise.
Drive: The reference to the controller
and the motor combined as one system.
GP-1200 A-C V+*S Drive Controller: See
“controller.”
IET: The abbreviation for instanta-
neous electronic trip,
NEC: The abbreviation for the National
Electrical Code. -
Pot: The shortened reference for poten-
tiometer.
PWM: The abbreviation for Pulse Width
Modulation.
Dangers, Warnings, and Cautions
Dangers, warnings, and cautions point
out potential trouble areas. All three of
these forms are enclosed in a box to call
attention to them.
e À danger alerts a person that high
voltage is present which could result
in severe bodily injury or loss of life.
e A warning alerts a person of potential
bodily injury if procedures are not
followed.
e A caution alerts a person that, if
procedures are not followed, damage
to, or destruction of, equipment
could result,
Related Publications
For more information about the appli-
cation and operation of this controller
and related equipment and service, refer
to these publications:
e “Long Term Storage for Control
Cabinets” (D-8079)
e “GP-1200 Data Sheet” (D-2769)
e “Selection and Application of A-C
V*xS Drives” (D-9084)
* “A-C Motor Efficiency” (8-7087)
e “Duty Master Energy Efficient XE
A-C Motors” (B-2639)
e “Installation, Operation and Care of
Reliance Standard integral Horse-
power Induction Motors’’ (B-3620)
These publications are available through
your Reliance Electric Sales Office.
Drive Components
The Reliance Electric drive consists of a
controller with local operator controls
and a three-phase A-C motor. When
purchased as a drive system, the
GP-1200 Controller is performance-
matched with a Reliance Duty Master®
XE Motor. The controller and/or motor
can be purchased separately.
Operator Control Devices. The enclosed
controller is equipped with a Basic
Loca! Operator's Control Station
mounted on the front of the enclosure.
This station provides a Speed pot, a
Start/Stop switch and a Run/Jog switch.
The chassis controller option is provided
with a Blank Local Operator's Control
Station. Both of these stations include
two LEDs: RUN and IET.
Duty Master is à registered trademark of
Reliance Electric Company.
2:1
Controller Features
Two LEDs, located on the Local
Operator's Control Station, indicate
the drive status (RUN) and a fault
condition (IET).
Line transient protection prevents
power line transients from harming
the controller.
Line-to-line and line-to-ground out-
put short circuit protection.
Standard fuses for easy replacement.
IET on high D-C bus voltage, high
motor current, high or low input A-C
line, phase loss, low regulator power
supply voltage, or function loss input.
Isolated start/stop and function loss
circuitry.
Loca! devices (standard) for speed,
start/stop and run/jog control.
Coast-to-rest on Stop as standard or
ramp-to-rest with a switch change.
Torque boost for increased starting
torque.
Automatic correction of output
voltage for input voltage fluctuations.
Variable torque V/Hz curve selection.
Motoring current limit and regenera-
tive voltage limit.
Adjustment pots:
acceleration rate (1P)
deceleration rate (2P)
maximum hertz (3P)
minimum hertz (4P)
torque boost (BP)
current limit (6P)
volts per hertz = (7P)
Hybrid-based regulator.
NEMA 1 enclosure (standard); chassis
available as an option.
Operates with standard off-the-shelf
NEMA B and synchronous motors.
Other features available; contact your
Reliance Electric Sales Office for
information.
2:2
Available Controller
Options
This controller is designed to accept the
pre-engineered options listed in Table
2-1. The options can be added either at
the factory or in the field. Each option
Is packaged separately and has its own
model number identification. Installa-
tion instructions are provided with each
option.
Table 2-1. Standard Kit Options.
Local Operator's Control Station
The controller has a Local Operator's
Control Station on the front of the
cabinet. Ten Local Operator's Control
Stations are available. See Table 2-2.
Description Model Number Instruction Sheet
Local Operator's Control Station Kit (1) See Table 2-2 D2-3105
Remote Operator's Control Station
NEMA 1 with Start/Stop, Run/Jog,
Forward/Reverse, Automatic/Manual,
Speed Pot, Analog Frequency Meter 1R$2000 D2-3065
Customer Interface Module Kit (1) 1C12001 D2-3104
Dynamic Braking Kit
460 V, 2 thru 5 HP (UL) 1DB4005U D2-3106
460 V,2 thru 5 HP (CSA) 1DB4005C D2-3106
460 V, 7% thru 10 HP (UL) 1DB4010L) D2-3106
460 V, 7% thru 10 HP (CSA) 1DB4010C D2-3106
Digital Meter with First Fault Indication 1DM2000 D2-3113
Extended Line Dip Module Kit 1LD4000 D2-3107
Output Frequency Meter 2FM4000 D2-3108
Output Ammeter
2 HP 2AM4002 D2-3109
3 thru 5 HP 2AM4005 D2-3109
7% thru 10 HP 25M4010 D2-3109
Qutput Voltmeter 2VM4000 D2-3110
Cabinet Conversion (NEMA 1 to Chassis ) Kit (1)
2 thru 5 HP 1CK4005 D2-3112
7% thru 10 HP 1CK4010 D2-3112
(1) Mounts to or has components that mount to the controller.
Table 2-2. Local Operator's Control Station Kits.
Function Digital
Description Start/Stop Run/IET Meter Model
Run/Jog | FWD/REV | AUTO/MAN | LEDs Cutout Number
Speed Pot (1)
Blank NO NO NO YES NO 1LS2000A
NO NO NO NO YES 1LS2004
Basic YES NO NO YES NO 1LS2010
YES NO NO NO YES 1LS2011
Reversing YES YES NO YES NO 1LS2012
YES YES NO NO YES 1152013
Automatic YES NO YES YES NO 1152014
YES NO Y ES NO YES 1.52015
All Function YES YES YES YES NO 1LS2002A
YES YES YES NO YES 1LS2016
(1), Operator's Control Stations with a cutout for the Digital Meter are not supplied with the
meter. The Digital Meter with First Fault Indication (Model 1DM2000) must be ordered
along with the station.
Remote Operator's Control
Station
The Remote Operator's Contro! Station
includes the Start/Stop, Run/Jog,
Forward/Reverse, and Automatic/
Manual function switches; a Speed pot;
and an Analog Frequency Meter, Use of
the remote station requires the Cus-
tomer Interface Module and a Blank
Local Operator's Station options. The
frequency meter on the Remote Opera-
tor's Control Station connects to the
Customer Interface Module in the con-
troller. |
Customer Interface Module
The Customer Interface Module is
required when using the Remote Opera-
tor's Control Station or user-supplied
operators devices and/or a separately
mounted Analog Frequency Meter. It
provides isolation for operator’s devices
and for a process control input signal
of 4 to 20 mA, 0 to 20 mA or O to
10 VDC.
Normally open and normally closed IET
contacts and a normally open RUN
contact are provided for customer use.
The contacts are rated 1 amp at
250 VAC and 2 amps at 30 VDC. The
kit can be used with an operator's sta-
tion: 1LS2000A or 1LS2004. The
chassis controller is supplied with a
Blank Local Operator's Control Station
and a Customer Interface Module.
Dynamic Braking
The Dynamic Braking Kit provides
rapid deceleration of the drive motor by
providing 150% intermittent braking of
the motor. The kit dissipates the power
regenerated by the motor during decel-
eration through a resistor.
Model 1DB4005 for 2 to 5 HP control-
lers is rated for 2.6 Ib-ft“ ; Model
1DB4010 for 7.5 to 10 HP controllers
is rated for 6.6 Ib-ft*. Each is designed
for six starts/stops per minute. The kits
are provided in a separate enclosure for
field wiring.
Digital Meter
The Digital Meter displays not only
the controller output frequency but
also the first fault causing an IET.
Local Operator's Control Station with
cutout for the meter is required.
Extended Line Dip Module
The kit consists of capacitors to backup
control power supply. If provided con-
troller is capable to extend to 330 milli-
seconds from 10 milliseconds of line dip
ride-thru without IET.
Cabinet Conversion
This option provides the necessary hard-
ware to allow converting the NEMA 1
enclosure to the chassis configuration.
It consists of a Blank Local Operator's
Control Station, a Customer interface
Module, and the chassis enclosure's top
and bottom plates.
Voltmeter
The voltmeter connects directly to the
output of the controller. It measures
0 to 500 VAC.
Table 2-3. Controller Current Ratings.
Ammeter
The ammeter, using a current trans-
former as its input, measures current in
one of the output lines of the control-
ler. The ampere scale depends on the
controller rating.
Frequency Meter (Analog)
The frequency meter monitors the con-
trolier output terminals. It indicates the
actual output frequency of the control-
ler.
Controller Specifications
Controller Ratings
The controller operates on three-phase,
460 VAC and can be set to operate on
50 or 60 Hz {ine frequency. The con-
troller provides three-phase variable
voltage (0 to 460 VAC), variable fre-
quency (3 to 60 Hz). Current ratings are
listed in Table 2-3.
Nominal Controller Max Max Max
Horsepower input Input Motor Controller
Range KVA Amps Sine Wave Amps (1) | Output Amps
1/4 to 2 3.3 4.2 3.2 3.4
3 7.0 8.8 5.0 5.3
5 9.8 12.3 7.8 8.2
7% 10.7 13.4 10.5 11.1
10 13.6 17.2 13.5 14.2
(1) To obtain motor nameplate horsepower, the controller's sine wave output ampere rating
should be equal to or greater than the motor nameplate current. If the motor nameplate
amperes are higher than the controller sine wave rating, the motor horsepower should be
derated by the ratio of the controller sine wave ampere rating to the motor nameplate
current. Refer to “Single-Motor Applications” and “Multi-Motor Applications” for more
details.
2:3
Service Conditions
e Ambient temperature: 0° to 40°C
(32° to 104°F) for enclosed control-
lers and 0° to 55°C (32° to 131°F)
for chassis controllers.
e Storage temperature: —40° to 65°C
(—40° to 149°F)
e Atmosphere: 5 to 95% non-con-
densing relative humidity
e Elevation: To 3300 feet (1000 meters)
above sea level without derating, For
every 300 feet (91.4 meters) above
3300 feet, derate the current rating
by 1%. Consult your Reliance
Electric Sales Office for operation
above 10,000 feet.
e Line frequency: 50/60 Hz +2 Hz
e Line voltage variation: —10% to
+10%
e A-C line distribution system capacity
(Maximum): 1,000 KVA, three-phase
with 25,000 amps symmetrical fault
current capacity.
2:4
Controller Application Data
Pulse Width Modulation (PWM): sine
wave
Service Factor: 1.0
Displacement Power Factor: 0.96
Maximum Load: 150% for one minute
Volts/Hz (60 Hz base): 6.8 to 16.0
V/Hz
IET: 200% load
Current Limit Adjustment: 50 to 150%
Speed reference to output frequency
(linearity): +1%
Minimum Frequency: 0 to 40 Hz (1)
Maximum Frequency: 15 to 90 Hz (2)
Acceleration Adjustment: 1.5 to 20
seconds (3)
Deceleration Adjustment: 1.5 to 20
seconds (3)
Torque Boost: 0 to 80 volts
(1) Minimum frequency adjustment
is additive to Maximum fre-
quency adjustment up to 90 Hz.
(2) Higher output frequency ranges
are available. Contact your
Reliance Electric Sales Office for
assistance when operation above
60 Hz is required.
(3) 4.5 to 60 seconds selectable by
switch.
Single-Motor Applications
The controller and motor must be sized
for the specific application load and
speed requirements. Refer to ‘Selection
and Application of A-C V*S Drives”
(D-9084) for assistance.
}f the motor is overframed, the motor
operating current must not exceed the
controller's rated output current and
the motor horsepower must not be
more than one size larger than the con-
troller’s horsepower rating. A motor
overload relay, sized to be equal to or
less than the controller output current
rating, must be connected between the
motor and the controller output.
If the motor will be operated at speeds
below one half the motor’s rated speed,
the motor overload relay may not pro-
tect the motor because of the reduction
in motor cooling action due to the
reduced speed. A motor thermostat
built into or connected to the motor
windings should be instalied because it
monitors the actual temperature of the
motor windings.
Multi-motor Applications
One controller can run two or more
motors. Adhere to the following re-
quirements to assure correct drive
operation:
When all the motors connected to the
output of the controller are to start and
stop at the same time, the sum of the
sine wave currents of all the motors
must be less than or equal to the maxi-
mum motor sine wave current rating of
the controller.
When one or more of the motors con-
nected to the output of the controller
are to start and stop independently,
e Any motor that starts or stops while
the controller is running must have a
current rating less than 10% of the
maximum motor sine wave current
rating of the controlier.
oe The sum of the sine wave currents of
all the motors connected continu-
ously on the output of the controller
and the locked rotor sine wave cur-
rent of any motor which is to start
and stop independently must be less
than or equal to the maximum motor
sine wave current rating of the con-
troller.
2:5
3: Install the Drive
DANGER
ONLY QUALIFIED ELECTRICAL
PERSONNEL FAMILIAR WITH THE
CONSTRUCTION AND OPERATION
OF THIS EQUIPMENT AND THE
HAZARDS INVOLVED SHOULD IN-
STALL THIS EQUIPMENT. FAIL-
URE TO OBSERVE THIS PRECAU-
TION COULD RESULT IN SEVERE
BODILY INJURY OR LOSS OF
LIFE.
DANGER
THE USER IS RESPONSIBLE FOR
CONFORMING TO THE NEC AND
ALL OTHER APPLICABLE LOCAL
CODES WITH RESPECT TO WIR-
ING, GROUNDING, DISCONNECTS,
AND OVERCURRENT PROTEC-
TION. FAILURE TO OBSERVE THIS
PRECAUTION COULD RESULT IN
SEVERE BODILY INJURY OR LOSS
OF LIFE.
Plan and Complete
the Installation
Read and understand this chapter in its
entirety before beginning the actual
installation. Follow these guidelines and
procedures to minimize both installa-
tion and operating problems.
The controller is shipped standard as an
enclosed unit, fully assembled in its own
NEMA 1 enclosure. The chassis control-
ler is shipped fully assembled for
mounting in a NEMA 1 enclosure.
Select the Controller Enclosure
Location
1.
Verify that the controller can be
kept clean, cool, and dry.
Check that the enclosure is away
from oil, coolant, and other air-
borne contaminants.
Check that temperatures in the
controller vicinity are between 0°
to 40°C (32° to 104°F) for en-
closed controllers and 0° to 55°C
(32° to 131°F) for chassis control-
lers.
Check that relative humidity is be-
tween 5 and 95% (non-condensing).
Do not install above 3300 feet
(1000 meters) without derating.
For every 300 feet (91.4 meters)
above 3300 feet, derate the current
rating 1%. Consult your Reliance
Electric Sales Office for operation
above 10,000 feet.
Install the Controller
Enclosed Controller
1. In the location selected, mount the
enclosed controller vertically with
the input/output terminals at the
bottom.
2. Make sure the door or other com-
ponents do not hinder service
access. See Figure 3-1 for mounting
dimensions.
Provide adequate clearance for air
ventilation:
e At least 2 inches from the sides
and 4 inches from the top and
bottom of the controller to adja-
cent non-heat producing equip-
ment, such as a cabinet wall.
® Atleast 2 inches from the sides
and 10 inches from the top and
bottom of adjacent controllers.
For the best air movement with
three or more controllers, do not
mount the controllers in a ver-
tical stack; offset the controllers.
3:1
0277
= (7 mm)
| __ 0.59"
(15 mm)
MOUNTING HOLE
be
(FOR EXTERNAL
CONTROL WIRING]
a
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BASIC LOCAL OPERATOR'S
CONTROL STATION
FRONT VIEW
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RIGHT SIDE VIEW
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BLANK LOCAL OPERATOR'S
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FRONT VIEW
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peces aaa aa
RIGHT SIDE VIEW
BOTTOM VIEW BOTTOM VIEW
NEMA 1 CHASSIS
HP Unit Diameter of Conduit Openings
a b с d
mm 22.2 22.2 22.2 22.2
EU nches | 7/8” 7/8” 7/8" 7/8"
mm 27.8 22.2 22.2 27.8
7% thru 10
inches 1.3/32" 7/8” 7/8" 1-3/32”
HP Model Number Dimensions in mm Weight
Chassis NEMA 1 A B С D E F G in kg
2 1АС4002-х | 1АС4102-х | 248.4 350 220 212.5 336 311 148 11.5
3 1AC4003-x | 1AC4103-x | 2484 350 220 212.5 336 311 148 11.5
5 1АС4005-х | 1AC4105-x | 248.4 350 220 212.5 336 311 148 11.5
7% 1AC4007-x | 1AC4107-x | 278 406 250 238 392 370 179 15.0
10 1AC4010-x | 1AC4110-x | 278 406 250 238 392 370 179 15.0
HP Model Number Dimensions in Inches Weight
Chassis NEMA 1 A B с D E F G in lbs
2 1AC4002-x | 1AC4102-x 9.78 13.78 8.66 8.37 13.23 12.24 5.83 25.4
3 1AC4003-x | 1AC4103-x 9.78 13.78 8.66 8.37 13.23 12,24 5.83 25.4
5 1AC4005-x | 1AC4105-x 9.78 13.78 8.66 8.37 13.23 12.24 5.83 25.4
7% 1AC4007-x | 1AC4107-x 10.94 15.98 9.84 9.37 15.43 14.57 7.05 33.1
10 1AC4010-x | 1AC4110-x 10,94 15.98 9.84 9.37 15.43 14.57 7.05 33.1
Figure 3-1. Physical Dimensions and Weights for NEMA 1 Enclosed and Chassis Controllers.
3:2
Chassis Controller
CAUTION: Complete all drilling, cut-
ting, welding, etc., before mounting
the chassis in the metal enclosure.
During installation protect the chassis
from metal chips, weld splatters and
other debris. Failure to observe these
precautions could result in damage to,
or destruction of, the equipment.
1. In the location selected, mount the
metal enclosure in which the chassis
will be mounted. If the enclosure is
totally enclosed, size the metal
enclosure using the following equa-
tion along with Table 3-1:
S =Ss +=. +56
where:
Ss = Area of enclosure's four
side surfaces
St = Area of enclosure’s ceiling
surface
Seb = Area of enclosure's bottom
surface
(1) If a surface does not have at least a
1/2 layer of air beside it, it does
not have any cooling effect, Use a
zéro area in the equation for any
such surface.
For example, if you want to en-
close a 2 HP chassis in an enclosure
that is 30” high by 20” wide by
16” deep and the back side is 1/2”
off the mounting wall, solve the
equation and verify the answer with
the Table 3-1 specifications.
S = 2(30 x 20) + 2(30 x 16) +
4 2
= 2800 sq. in.
Referring to Table 3-1, note that
a 2 HP controller requires 2.8 times
10° or 2800 sq. in. of surface area.
The example enclosure meets the
size requirements.
2. Mount the chassis directly to the
enclosure mounting panel. Stand-
off hardware is not necessary. See
Figure 3-1 for mounting dimen-
sions.
3. Provide adequate clearance for air
ventilation within the enclosure:
eo Atleast 2 inches from the sides
and 4 inches from the top and
bottom of the controller to adja-
cent non-heat producing equip-
ment, such as a cabinet wall.
eo At least 2 inches from the sides
and 10 inches from the top and
bottom of adjacent controllers.
For the best air movement with
three or more controllers, do not
mount the controllers in a vertical
stack; offset the controllers.
Table 3-1. Sizing the Metal Enclosure
That Will House the Chassis.
Effective
Hp | Power Loss Surface (S) Area
(watts)
sq cm sq in.
2 100 18x10% | 2.8 х 10?
3 150 2.7 х 10° | 4.2 x 10°
5 200 3.6 х 10° | 5.6 x 10°
TA 250 4.5 х 10% | 7.0 х 10°
10 300 5.4 х 10° | 8.4 х 10°
Install a Transformer (if needed)
in all applications requiring the use of
an output transformer, contact your
Reliance Electric Sales Office for assis-
tance.
Input transformers step up or step down
input voltage and can be either auto-
transformers or isolation transformers.
Isolation transformers help eliminate
eo Damaging A-C line voltage transients
from reaching the controller.
e Damaging currents, which could
develop if a point inside the control-
ler becomes grounded.
CAUTION: If an input transformer is
installed ahead of the controller, a
power disconnecting device must be
Installed between the power line and
the primary of the transformer. If this
power disconnecting device is a circuit
breaker, the circuit breaker trip rating
must be coordinated with the inrush
current (10 to 12 times full-load cur-
rent) of the input transformer. Do not
connect an input transformer rated at
more than 1000 KVA to the control-
ler. Distribution system capacity above
the 1000 KVA requires using an isola-
tion transformer, a line reactor, or
other means of adding similar imped-
ance. Failure to observe these precau-
tions could result in damage to, or
destruction of, the equipment.
Install an Input Disconnect
DANGER
THE NEC REQUIRES THAT AN IN-
PUT DISCONNECT BE PROVIDED
IN THE INCOMING POWER LINE
AND EITHER BE LOCATED WITHIN
SIGHT OF THE CONTROLLER OR
BE LOCKABLE. FAILURE TO OB-
SERVE THIS PRECAUTION COULD
RESULT IN SEVERE BODILY IN-
JURY OR LOSS OF LIFE.
1. Install an input disconnect in the
incoming power line according to
the NEC. It must either be located
within sight of the controller or be
lockable.
2. Size the disconnect to handle the
transformer primary as well as any
additional loads the disconnect may
supply.
3. Wire this disconnect in the primary
circuit of the controller isolation
transformer (if used).
3:3
Install the Motor
1. Verify the motor is the appropriate
size to use with the controller.
Derate the A-C motor to com-
pensate for additional heating in
the motor caused by harmonics.
Refer to D-9084 “Selection and
Application of A-C V«S Drives” for
application guidelines for constant
torque loads. Refer to Table 3-2 for
motor derating values for centrifu-
gal loads.
2. Install the A-C motor according to
its instruction manual.
3. According to NEC requirements,
install an overload protection
device responsive to motor current
in each power line of the motor
{motor overload relay) or verify
that a thermal protection device
responsive to motor heat is built
into or connected to the motor
windings.
If the motor is overframed, verify
that the motor operating current
does not exceed the controller's
output current and the motor
horsepower is not more than one
size larger than the controller's
horsepower rating. Then connect a
motor overioad relay, sized to be
equal to or less than the controller
output current rating.
If the motor will be operated at
speeds below one half the motor's
rated speed, use the thermal respon-
sive type of protection device be-
cause it monitors the actual tem-
perature of the motor windings.
The motor overload relay may not
protect the motor because of the
reduction in motor cooling action
due to the reduced speed.
4. Make sure the motor is properly
aligned with the driven machine to
minimize unnecessary motor
loading from shaft misalignment.
5. If the motor is accessible while it is
running, install a protective guard
around all exposed rotating parts.
3:4
Ground the Controller and
Enclosure, Motor, Remote
Operator’s Control Station, and
Regulator Transformer
DANGER
THE USER 1S RESPONSIBLE TO
MEET ALL CODE REQUIREMENTS
WITH RESPECT TO GROUNDING
ALL EQUIPMENT. FAILURE TO
OBSERVE THIS PRECAUTION
COULD RESULT IN SEVERE BODI-
LY INJURY OR LOSS OF LIFE.
1. Open the enclosure door by loos-
ening the two screws.
2. Run asuitable equipment
grounding conductor or bonding
jumper unbroken from the chassis
GND terminal (Figure 3-2 or 3-3)
to the grounding electrode con-
ductor (earth ground).
3. Connect a suitable equipment
grounding conductor or bonding
jumper to the motor frame, the
remote operator's control station
(if used), the regulator transformer,
and the controller enclosure. Run
this conductor or jumper unbroken
to the grounding electrode conduc-
tor (earth ground).
4. If code requires the 24 VDC Start/
Stop circuit be grounded, connect
a green wire between 2TB-5 and
chassis ground and move jumper J9
to JB.
Suppress Electrical Noise
Electrical noise from nearby relays,
solenoids, or brake coils can cause
erratic drive behavior. To keep this from
happening, add an R-C suppressor, such
as Reliance part 600686-33A, across the
coils of these devices. If the circuit is
115 to 230 VAC, a 220-ohm, 0.5 watt
resistor in series with a 0.5 microfarad,
600-vo!t capacitor can be used as the
Suppressor.
Wire the Drive
1. Verify that the input power to the
controller corresponds to the con-
trolier nameplate voltage and fre-
quency and that the plant supply 1s
of sufficient ampacity to support
the input current requirements of
the controller.
CAUTION: If the incorrect voltage is
applied to the controller, an IET could
result from a variation in line voltage
within the +10% range. Failure to ob-
serve this precaution could result in
damage to, or destruction of, the con-
troller.
2. Provide a transformer between the
plant power supply and the control-
ler if the correct input line voltage
is not available. Refér to “Provide a
Transformer’ in this chapter.
3. Use a tightening torque of 20 in-Ibs
for wire connections to input ter-
minals and output terminals in the
controller.
4. Refer to the wiring locations
{Figure 3-2 or 3-3).
Table 3-2. Motor Derating Data for Centrifugal Loads.
Motor Insulation Class
Motor Service Factor
Motor Derating Percentage of
Nameplate HP
B 1.0 15%
B 1.15 10%
F 1.0 5%
F 1.15 0%
6 J (isolated) O ©
1> TERMINAL 2TB
~d = 01D
Bus
1 1 Output Contactor Seguencing Contact
2) Auxiliary Contact Input
(Isolated)
3 1 Qutput Contactor Output
4 J (Isolated)
5 Ground for Start/Stop circuitry if required.
Refer to 24 VDC Grounding” in
Chapter 3.
1> TERMINAL 1TB
1 Process Control Input
2 J 4 to 20 mA, 0 to 20 MA or O0 to 10 VDC
(Non-isolated) ¡O С] осо ®
31 Function Loss Input ооо
4) (Isolated) ооо
5 1 DB Signal to DB Kit (Option) CJ m
CHASSIS GROUND
INPUT TERMINALS
TERMINALS FOR DB (OPTION)
(181, 182, 183) (13, 14, 147, 45)
1> Any wiring connected to this terminal board must be rated at 600 volts or greater because
this wiring may make contact with un-insulated (460 VAC) components.
OUTPUT
TERMINALS
(601, 602, 603)
Figure 3-2. Wiring Locations in NEMA 1 Controller with Basic Local Operation Control Station.
3:5
2> TERMINAL 1TB
1 .
>} Do not use with CIF.
3 | Function Loss Input <1
4 J (Isolated)
5 1 DB Signal to DB Kit (Option)
6 J (Isolated)
2) Auxiliary Contact Input
(Isolated)
3 | Output Contactor Qutput
4 { (Isolated)
5 Ground for Start/Stop circuitry if required,
Refer to “24 VDC Grounding’ in
Chapter 3.
CHASSIS GROUND
2> TERMINAL 2TB ON CIF
1
2 > Form C IET Relay Contact Output
3
а }Run Relay Contact Output
2> TERMINAL 1TB ON CIF
Start/Stop
Reset IET
Run/Jog
Common of Sequence Circuit
Function Loss Input <1
Forward/Reverse
Frequency Meter
Speed Reference
Refer to Figure 3-5.
—
NODOS — С) Сл В ©) В) —
lt
2> TERMINAL 2TB
1 \ Output Contactor Sequencing Contact >
| [666600606600
O
TERMINALS
(181, 182, 183)
/
TERMINALS OUTPUT
FOR DB (OPTION) TERMINALS
(13, 14, 147, 45) (601, 602, 603)
1> If function loss input wiring is connected at 1TB-4 and 1TB-5 on the CIF, remove the jumper
across these terminals and install a jumper between 1TB-3 and 1TB-4 on the regulator. If function
loss input wiring is connected at 1TB-3 and 1TB-4 on the regulator, remove the jumper across
these terminals and install a jumper between 1TB-4 and 1TB-5 on the CIF.
2> Any wiring connected to this terminal board must be rated at 600 volts or greater because this
wiring may make contact with un-insulated (460 VAC) components.
Figure 3-3. Wiring Locations in Chassis Controller with Customer Interface Module.
3:6
Power Wiring
Size and install afl wiring in conform-
ance with the NEC and ali other appli-
cable local codes.
1. Use only copper wire rated
60/75°C.
2. Size input and output power
wiring, according to applicable
codes, to handle the maximum con-
troller current as listed under “Con-
troller Current Information’ in
Chapter 2.
3. Install the power wiring according
to the interconnection diagram
(Figure 34 or 3-5).
4. Route A-C input leads through the
bottom left opening of the control-
ler (Figure 3-1) to terminals 181,
182 and 183.
5. Route motor leads through the bot-
tom right opening of the controller
(Figure 3-1) to terminals 601, 602,
and 603.
Control and Signal Wiring
Size and install all wiring in conform-
ance with the NEC and all other appli-
cable local codes,
1. Use twisted wire having two to
three twists per inch. If you use
shielded wire rather than twisted
wire, the shields should not attach
to any ground point; they should
“float.”
2. For distances of less than 150 feet,
use a minimum of #22 AWG. For
distances of more than 150 feet and
less than 300 feet, use a minimum
of #16 AWG. For distances of more
than 300 feet, contact your
Reliance Electric Sales Office.
3. If aseparately mounted operator's
control station or a Remote Opera-
tors Control Station is required,
disconnect the control devices from
the Basic Local Operator's Control
Station. Remove this control sta-
tion panel and replace it with a
Blank Local Operator's Control
Station and a Customer Interface
Module (CIF).
4, Wire control and signal wiring, rated
at 600 volts or greater, according to
the interconnection diagram. Use
Figure 3-4 (controller with Local
Operator's Control Station) or
Figure 3-5 (controller with CIF).
CAUTION: It is important to use wire
rated at 600 volts or greater because
this wiring may make contact with
uninsulated (460 VAC) components.
Failure to observe this precaution
could result in damage to, or destruc-
tion of, the equipment.
5. Route user-supplied interlock and
function loss input wiring (if any)
through either of the center
openings in the bottom of the con-
troller. See Figure 3-1.
Connection can be made at 1 TB-3
and 1TB-4 on the regulator or, if
the CIF is installed, at 1TB-4 and
1TB-5 on the CIF. Both of these
terminal sets have a factory-in-
stalled jumper between the two
terminals. Remove only the jumper
between the two terminals where
the interlock and function loss
input wiring will be made. Connect
the wiring. See Figure 34 or 3-5.
6. Route external control wiring, rated
at 600 volts or greater, on the CIF
(isolated from the logic circuit)
through the remaining center
opening in the bottom of the con-
troller in separate steel conduit to
eliminate electrical noise pick-up.
The conduit can be rigid steel or
flexible armored steel. See Figure
3-1. Terminal 1TB-4 on the CIF is
common for the wiring of start/
stop, run/jog, forward/reverse,
function loss and analog frequency.
Terminal 1TB-10 on the CIF is
common for the wiring of the Speed
pot, Auto/Man and process control.
Note that the Speed pot must be
5K ohms and 0.5 watt minimum.
CAUTION: It is important to use wire
rated at 600 volts or greater because
this wiring may make contact with
uninsulated (460 VAC) components.
Failure to observe this precaution
could result in damage to, or destruc-
tion of, the equipment.
DANGER
EXTERNAL POWER WIRING MAY
REMAIN ENERGIZED WHEN THE
MAIN A-C POWER IS DISCONNECT-
ED. IDENTIFY ALL SUCH EXTER-
NAL WIRING. FAILURE TO OB-
SERVE THIS PRECAUTION COULD
RESULT IN SEVERE BODILY IN-
JURY OR LOSS OF LIFE.
WARNING
IF THE FACTORY-INSTALLED
JUMPER IS NOT REMOVED WHEN
FUNCTION LOSS INPUT OR INTER-
LOCKS ARE USED, THESE CON-
TACTS WILL NOT OPEN TO STOP
THE CONTROLLER ON AN IET.
FAILURE TO OBSERVE THIS PRE-
CAUTION COULD RESULT IN BOD-
ILY INJURY.
7. Ifrequired, connect user-supplied
RUN and IET contacts to 2TB on
the CIF. Identify this as external
power wiring (Reliance normaliy
uses yellow wire.}. Provide a means
to disconnect this external wiring.
8. Do not route signal wire through
junction or terminal boxes that
contain power or control wire.
9. Do not route signal wire in close
proximity to devices producing
external magnetic fields.
3:7
su r------------------------------------ 1
vi
USER -SUPPLIED l 1
460VAC N CONTACTOR Do
THREE - PHASE POWER | |
v9 % RH |
x д | _ 4 ] |
ISOLATION | Г | |
TRANSFORMER Do |
OR LINE REACTOR И OVERLORD o
USER -SUPPLIED Eo \y N USER-SUPPLIED |
т т т ol CONTROLLER EU E---IE---X-—= a
INPUT à 5 5 Poy | \
DISCONNECT }-23--73 | | VAL o!
SER 97 © q l 10 602(VE---JE--C-— |!
во meee LY igi VA |
o] UV s031W [——— 00 MOTOR o
po bd 418219) OUTPUT y
| Ÿ CONTACTOR | |
Lee 183(7) USER -SU! PLIED | |
J TID TID DWE Sm нс сн лс = em Em Em SER EEL le GEL me ты ет сн че == === == == === wm CU A Е 1 4 | |
» REGULATOR BOARD \/ ı
FROM V NAUX | ]
Om mmm PROCESS CONTROL HI KO
process { ©! (COMMON ____-000000000 (NON-ISOLATED) Fb |
TT] FUNCTION. LOSS 8 TT - |
AE Ho (1SOL ATED) п-т) +; —
CUSTOMER MOTOR | p<
INTERLOCK OVERLOAD ue R_ |
USER-SUPPLIED USER-SUPPLIED 6CN CONNECTOR 13CN | L—Jé-——{_F+-
= y | 0.5pF 2200(172W)
_i'lel3jalsje]7]e) 901 NISfAS eN [+ 273] OUTPUT CONTACTOR
; USER — SUPPLIED
1. Use only copper wire rated 60/75” C.
The recommended terminal tightening mmm [=m ——— A mn,
torque is 20 in-Ibs. | x |
| =" | *
2. Process control input is available with an START RUN REV AUTOL À
optional Local Operator's Control Sta- | © JOG wo |
tion which has an Auto/Man switch. | MAN] pon eT |!
When the Auto/Man switch is set at | 7 |
AUTO, the controlier speed reference is | o STOP |
i
changed to the process control 4 to | SPEED |
20 mA, O to 20 mA or 0 to 10 VDC |
signal. ! LOCAL OPERATOR'S CONTROL STATION FUNCTIONS
3. When usersupplied function loss input Emm 7
or interlocks are connected, remove the
factory-installed jumper between 1TB-3
and 1TB-4 in order for these contacts to
be operational. When these contacts
open, the controller stops on an IET and
the motor coasts to rest.
CAUTION: Only the MCR relay shouid| *-
WARNING
IF THE FACTORY-INSTALLED JUMPER
IS NOT REMOVED BETWEEN 1TB-3 AND
1TB-4 WHEN FUNCTION LOSS INPUT OR
INTERLOCKS ARE USED, THESE CON-
TACTS WILL NOT OPEN TO STOP THE
CONTROLLER ON AN IET. FAILURE TO
OBSERVE THIS PRECAUTION COULD
RESULT IN BODILY INJURY.
control the N contactor. Do not add any ex-
ternal switches or contacts in series with the
N contactor or coil. Failure to observe this 6.
precaution could result in damage to, or de-
struction of, this equipment.
Remove the factory-installed jumper
between 2TB-1 and 2TB-2 and connect
the contactor’s Naux contact. After the
START command is given, the Naux
4. When auser-supplied output "N” con-
tactor is installed, the following condi-
tions must be met:
Provide power (having the capacity
required for the coil) to the N contactor
coi! from the input disconnect used for
the controller. This power should be
fused according to NEC and ail codes.
contact closes and the controller output
follows the input speed reference.
The MCR contact {rated for 1 amp at a
maximum of 250 VAC (PF = 0.4, L/R
= 7 ms) or 2 amps at 30 VDC] provides
sequencing control for the N contactor.
The MCR contact makes sure the con-
troller output transistors are OFF.
This is an optional grounding connec-
tion. Refer to Section 3 “24 VDC
Grounding.”
Any wiwing connected to this terminal
board must be rated at 600 volts or
greater because this wiring may make
contact with uninsulated (460 VAC)
components.
Figure 34.
3:8
Interconnection Diagram of Controller with Local Operator's Control Station Functions.
Vo a
A60VAC USER SUPPL ED |
THREE - PHASE N ea Pol
9 © © !
| o |
1 -—J lod
ISOLATION pr ho
TRANSFORMER , | | |
OR i SH Do OVERLOAD |!
1
USER-SUPPLIED | SJ N USER-SUPPLIED Do!
Do CONTROLLER 8010) >-—dE--X-— bo
DISCONNECT © Do DON \ 3
I \/ |
SUP J > > 9 Ш \/ 6021viE——dk--XC-— | |
Eo 1 18118) Gon Mo 1
LY AL. И Ан |
| L ———— У. 182(5) 5939) JF 2х MOTOR Pog
| OUTPUT a ЧЕ
\/ CONTACTOR
Eso mT 183(T) USER - SUPPLIED Pol
Unos о
REGULATOR BOARO \/ |
NAUX l 1
DO NOT USE --— k= ol
1. Use only copper wire rated 60/75” C. UNCT ON 1088 LIT — - |
The recommended terminal tightening (ISOLATED) <7 —— ee —_———
torque is 20 in-lbs. | Q |
1 |+ |
2. When the Auto/Man switch is set at ECN CONNECTOR 13CN Y E 5 FO 220007 2W)
pm = 1 "
AUTO, the controller speed reference is 1 [21514 |516 1718 |9 |101! !2 1314151617)! 2 3); OUTPUT CONTACTOR
changed to the process control 4 to USER - SUPPLIED
20 mA, O to 20 mA or O to 10 VDC Г ré
signal. r-- =
9 ICN
3. When user-supplied function loss input
or interlocks are connected, remove the | ISOLATED ©
factory-installed jumper between 1TB-4 ! INTERFACE 0 <6
and 1TB-5 on the CIF in order for these | out ©
contacts to be operational. When these | . 3 o
8 FUNCTION <e
contacts open, The controller stops on an Y LOSS ©
IET and the motor coasts 10 rest. ı TB
[213415 [e] Ele O |
WARNING
IF THE FACTORY-INSTALLED JUMPER = <?
- OL
ON THE CIF IS NOT REMOVED WHEN + 0
FUNCTION LOSS INPUT OR INTER- —<3
LOCKS ARE USED, THESE CONTACTS =} AE ERE RR 1
| — 1! t
TROLLER ON AN JET. FAILURE TO o › 1 |
OBSERVE THIS PRECAUTION COULD | RUN" 406 Man AUTO ou fr CUSTOMER | }
1 SPEED |! 1 INTERFACE ! !
RESULT IN BODILY INJURY. 1 ti | = } \
| REY Т 1171819 Ге y
4. When a user-supplied output №’ соп- | STOP ED ANALOG FREQUENCY
tactor is installed, the following condi- | METER = 1H |
tions must be met: | р
| "ii RUT
1 1 4 1 I |
Provide power (having the capacity | CUSTOMER WIRING г, e control | 1
required for the coil) to the N contactor | R 9 ! | !
. ) REMOTE OPERATOR'S CONTROL
coil from the input disconnect used for | STATION WITH FREQ. METER !
the controller. This power should be 2 (OPTIONAL) MN |
fused according to NEC andall codes. TT TT TS
CAUTION: Only the MCR relay should The MCR contact [rated for 1 amp ata 7. If function loss input is made at 1TB-4
control the N contactor. Do not add any ex- maximum of 250 VAC (PF = 0.4, L/R and 1TB-5 on the CIF, install a jumper
ternal switches or contacts in series with the = 7 ms) or 2 amps at 30 VDC] provides between 1TB-3 and 1TB-4 on the regula-
N contactor or coil. Failure to observe this sequencing control for the N contactor. tor and do not use. See note 3.
precaution could result in damage to, or de- The MCR contact makes sure the con- 8. Any wiring connected to this terminal
struction of, this equipment. troller output transistors are OFF. board must be rated at 600 volts or
. his i i i - reater be e thi inn ke
Remove the factory -installed jumper > T 's Is an optional grounding connec greater b cats ! Is wIrIN9 May Ma
between 2TB-1 and 2TB-2 and connect tion. Refer to Section 3 ‘24 VDC contact with uninsulated (460 VAC)
ing.” components.
the contactor’s Naux contact. After the Grounding. Р
START command is given, the Naux 6. The contact rating is 1 amp at 250 VAC
contact closes and the controller output (PF = 0.4, L/R = 7 ms) or 2 amps at
follows the input speed reference. 30 VDC.
Figure 3-5. Interconnection Diagram Using Customer Interface Module.
3:9
Controller Regulator Table 3-3. Regulator Modifications.
Modifications Modification Jumper Switch
Extended Speed Range * —
The controller regulator has several
built-in modifications which can be Variable Torque Curve 14, J5 _
made by connecting a jumper or setting Variable Carrier Frequency JG, J7 —
a DIP switch on the regulator PC board. 24 VDC Grounding J8, J9 _
The modifications are listed in Table 3-3 Output Contactor Turn-off Del 10 mi
. . u a ur a , —
and are located in Figure 3-6. P у
Process Control J12, J13 —
Extended Line Dip Ride Thru 314, 115 —
Regenerative Voltage Limit -— 18W (1)
D-C Offset at Zero Hertz _ 1SW (2)
Ramp-to-Rest — 1SW (3)
Extended Acceleration and Deceleration Times — 1SW (4)
* Factory set at 60 Hz with wirewrap jumpered at J1. Extended speed requires
application assistance; contact Reliance Electric.
EXTENDED
LINE DIP
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OUTPUT CONTACTOR PROCESS CONTROL REGENERATIVE D-C OFFSET RAMP-TO-REST EXTENDED
OFF DELAY (J12, J13) VOLTAGE LIMIT AT ZERO HERTZ 15W (3) ACCEL AND
(JTO, JT1) TSW (1) TSW (2) DECEL TIME
1SW (4)
* When this input is in use, remove the jumper wiring,
Figure 3-6. Location of Modification Jumpers and
3:10
Switches on the Regulator.
Extended Speed Range
The controller is factory set to provide a
60 Hz base frequency with a 90 Hz
(150%) maximum. An 80 Hz base fre-
quency with a 120 Hz (150%) maxi-
mum is available (Table 3-4); however,
contact Reliance Electric for application
assistance with and instructions for this
modification.
WARNING
THE USER 1S RESPONSIBLE FOR
ENSURING THAT DRIVEN MA-
CHINERY, ALL DRIVE-TRAIN ME-
CHANISMS, AND PROCESS LINE
MATERIAL ARE CAPABLE OF
SAFE OPERATION AT AN APPLIED
FREQUENCY OF 150% OF THE
MAXIMUM SELECTED BASE FRE-
QUENCY TO THE A-C MOTOR.
FAILURE TO OBSERVE THIS PRE-
CAUTION COULD RESULT IN
BODILY INJURY,
If a fault occurs, the controller is de-
signed so that, regardless of the base
frequency selected (60 Hz or 80 Hz),
the maximum output frequency to the
motor will be limited to 150% (90 Hz or
120 Hz, respectively) of the selected
base frequency.
Table 34. Possible Speed Ranges.
Base Frequency Frequency Range
60 (standard) О то 90
80* O to 120*
* Requires application assistance; contact
Reliance Electric.
Variable Torque Curve
The controller has been designed for
general purpose applications. For varia-
ble torque applications with energy
savings at speeds below base speed,
move jumper J4 to J5. A variable torque
curve for 460-volt input is shown in
Figure 4-2.
Variable Carrier Frequency
The controller is factory set to provide a
constant carrier frequency of 1.0 kHz
above a preset speed range. This high
value lessens acoustic noise but pro-
duces a rather small fundamental output
voltage in a low speed range. Adjusting
the Torque Boost pot can provide more
starting or breakaway torque. If the
Torque Boost pot cannot provide
enough voltage boost, move jumper J6
to J7 for the variable carrier frequency
modification.
With this modification, the carrier fre-
quency automatically decreases in pro-
portion to the decrease in speed, pro-
viding enough starting torque in a low
speed range (but with higher acoustic
noise) to have smooth operation. See
Figure 5-3.
24 VDC Grounding
The secondary winding for the 24 VDC
start/stop circuit is isolated from other
logic circuits. If code requires that the
24 VDC power supply for the start/stop
circuit be grounded to earth, move
jumper J9 to J8. Connect a green wire
between 2TB-5 and the chassis ground
terminal (green).
CAUTION: Do not use this ground
unless code requires it. If grounding is
required, make sure a green wire is
connected between 2TB-5 and the
chassis GND terminal and the jumper
is at JB. Failure to observe these pre-
cautions could result in damage to, or
destruction of, this equipment.
Output Contactor Turn-off Delay
The controller includes output contac-
tor sequencing. As shipped, the contac-
tor opens when the Stop switch is
pressed and closes when the Start switch
is pressed. There is a slight time delay
before closing and opening to ensure the
output is at zero when the contactor is
opened. To hold the contactor closed
for up to 1.5 seconds after pressing the
Stop switch, move jumper J10 to J11.
Process Control
To provide a speed reference from a
user-supplied process control signal
(4 to 20 mA, 0 to 20 mA or 0 to
10 VDC), the controller must have
a Local Operator's Control Station
with an Auto/Man switch. The switch
changes the speed reference from the
Speed pot (MAN) to the process con-
trol signal (AUTO). The standard
controller provides only non-isolated
input; isolated input with Bias and
Gain pots is available with the CIF
option.
Connect the process control signal at
1TB-1 and 1TB-2 (non-isolated). See
Figure 3-4. Verify the jumper is at J12
with a 4 to 20 mA signal or at J13 with
a 0 to 20 mA or 0 to 10 VDC signal. If
the 0 to 10 VDC signal cannot handle
a 500-ohm load, do not have a jumper
at J12 or J13.
When the controller includes the
optional CIF (includes isolated input),
1TB-1 and 1TB-2 are inoperable, Refer
to the Customer Interface Module Kit
Instruction Sheet D2-3104 for wiring
details.
Extended Line Dip Ride Thru
If the {ine power supply is interrupted
or dipped for more than 10 milli-
seconds, an IET (low line) will occur. If
an Extended Line Dip Module Kit
{option} is additionally installed outside
the controller to back up capacitor, itis
possible to extend the !ine-dip-rise-thru
from 10 milliseconds to 330 milli-
seconds.
There are two jumpers, J14 and J15, on
the controller’s regulator PC board. The
jumper is usually located at J14, when
an IET will occur at a typical line dip of
10 milliseconds or more. Be sure relocate
the jumper from J14 to J15, when the
Extended Line Dip Module Kit is em-
ployed.
Regenerative Voltage Limit
The controller is factory set to provide
regenerative voltage limit by extending
the deceleration time when the D-C bus
voltage exceeds a nominal preset value.
This feature prevents an IET during de-
celeration. If the Dynamic Braking Kit
is installed, this circuit must be turned
off. Move Dip Switch 18W (1) to the
OFF position.
D-C Offset at Zero Hertz
For the controller to operate a perma-
nent magnet synchronous motor, move
the Dip Switch 1SW (2) to the ON
position. This mode will provide D-C
offset voltage at 0 Hz, which is required
to synchronize the motor rotor at
starting to avoid high current demand.
Adjusting the Torque Boost pot pro-
vides 0 to 80 VAC at O Hz.
Controllers are shipped with Dip Switch
1SW (2) in the OFF position for opera-
tion of standard induction motors.
Ramp-to-Rest
The controller is factory set to provide
a coast-to-rest stop. Move Dip Switch
15W (3) to the ON position to provide
a ramp-to-rest stop.
tors with Dip Switch 1SW (2) in the
observe this precaution could result in
equipment.
CAUTION: Operating induction mo-
ON position could result in excessive
motor heating at low speeds. Failure to
WARNING
THE RAMP-TO-REST FUNCTION
REQUIRES PROPER OPERATION
OF REGULATOR ELECTRONICS
AND IS NOT FAIL-SAFE. WHEN
THE RAMP-TO-REST STOP FUNC-
TION IS REQUIRED, A COAST-STOP
PUSHBUTTON IS REQUIRED. THE
COAST-STOP PUSHBUTTON DIS-
ABLES THE REGULATOR AND AL-
LOWS THE MOTOR TO COAST-TO-
REST. FAILURE TO OBSERVE THIS
PRECAUTION COULD RESULT IN
damage to, or destruction of, this
3:12
BODILY INJURY.
When ramp-to-rest is selected, a coast-
stop pushbutton must be wired to the
function loss input terminals.
Extended Acceleration and
Deceleration Times
The controller is factory set to provide
an acceleration and deceleration time
~ from 1.5 to 20 seconds. To extend the
minimum time from 1.5 to 4.5 seconds
and the maximum time from 20 to 60
seconds, move Dip Switch TSW (4) то
ON. See Table 3-5.
Table 3-5. Extended Acceleration and
Deceleration Time Selection.
Switch Min. Time Max. Time
1SW (4) (Seconds) (Seconds)
OFF 1.5 20
ON 4.5 60
4: Start and Adjust the Drive
DANGER
ONLY QUALIFIED ELECTRICAL
PERSONNEL FAMILIAR WITH THE
CONSTRUCTION AND OPERATION
OF THIS EQUIPMENT AND THE
HAZARDS INVOLVED SHOULD
START AND ADJUST THIS EQUIP-
MENT. FAILURE TO OBSERVE THIS
PRECAUTION COULD RESULT IN
SEVERE BODILY INJURY OR LOSS
OF LIFE.
Test Equipment Needed
CAUTION: Do not use a megger to
perform continuity checks in the drive
equipment. Failure to observe this pre-
caution could result in damage to, or
destruction of, the equipment.
1. Two volt-ohmmeters each having a
sensitivity of 20,000 ohms-per-volt,
such as a Triplett Model 630.
2. A volt-ohmmeter with a 10 meg-
ohm input impedance on all ranges,
such as a Fluke 8022B. (This unit
provides an accuracy of £15% when
measuring controlier output voltage
at terminals 601, 602, and 603.)
The most common voltmeters in use
are digital and analog voltmeters.
However, these two voltmeters use
several different methods of measuring
the RMS voltage of a waveform, thus
producing a wide range of RMS readings
for a particular PWM waveform.
A fundamental voltmeter is best suited
for measuring output voltage of PWM
waveforms because it filters out un-
wanted harmonics. An accurate meas-
urement is important since the funda-
mental waveform is the main con-
tributor to the power conducted to
the motor. Therefore, in this manual,
voltages given are fundamental voltages.
In comparison testing, the Fluke 8022B
provides an RMS measurement nearly
equivalent to that of the fundamental
voltmeter; the Triplett 630 provides an
RMS measurement that is 20 volts
higher than that of the fundamental
voltmeter.
Follow these guidelines when measuring
the output voltage of this PWM con-
troller:
e Keep voltmeter lead lengths as short
as possible,
e When using an analog voltmeter, use
the 500-750 VAC scale.
e When using a digital voltmeter, use
the 200 VAC scale for measuring
output voltages up to 200 VAC and
the 750 VAC scale for measuring
output voltages above 200 VAC.
* When using a Triplett 630 voltmeter,
subtract 20 volts from the reading to
determine the fundamental output
voltage.
e When using a Fluke 8022B voltmeter,
the meter reading can be used as an
approximate fundamental voltage.
Check the Installation
DANGER
THIS EQUIPMENT IS AT LINE
VOLTAGE WHEN A-C POWER IS
CONNECTED TO THE CONTROL-
LER. DISCONNECT ALL UN.
GROUNDED CONDUCTORS OF
THE A-C POWER LINE FROM THE
CONTROLLER. AFTER POWER IS
REMOVED, VERIFY WITH A VOLT-
METER AT TERMINALS 147(+)
AND 45(—) THAT THE D-C BUS CA-
PACITORS ARE DISCHARGED BE-
FORE TOUCHING ANY INTERNAL
PARTS OF THE CONTROLLER.
FAILURE TO OBSERVE THESE
PRECAUTIONS COULD RESULT IN
SEVERE BODILY INJURY OR LOSS
OF LIFE.
1. Make sure the input disconnect is in
the OFF position (power OFF).
2. Make sure the drive shutdown inter-
locks, such as safety switches in-
stalled around the driven machine,
are operational. When activated,
they should shut down the drive.
CAUTION: Make sure electrical com-
mons are not intermixed when moni-
toring voltage and current points in the
controller. Failure to observe this pre-
caution could result in damage to, or
destruction of, the equipment.
Check the Motor
1.
Verify that motor nameplate data
corresponds to the controller
output ratings:
e Voltage: 460 VAC; three-phase.
If the motor has dual voltage
capability, verify that it is con-
nected for the voltage corre-
sponding to the input voltage.
e Current: Verify that full-load
current does not exceed the con-
troller's motor sine wave current
rating. If the motor is over-
framed, verify that the motor
operating current does not
exceed the controller's rated cur-
rent and the motor horsepower
rating is not more than one size
larger than the controller's horse-
power rating.
e Frequency: 60 or 50 hertz or
other frequency consistent with
the controller output frequency.
For synchronous motor applica-
tions, consult your Reliance Electric
Sales Office.
Check that the motor is installed
according to the motor instruction
manual,
Disconnect any power factor cor-
rection capacitors connected to the
motor,
If possible, uncouple the motor
from the driven machinery.
Rotate the motor shaft by hand to
check that the motor is free from
any binding or mechanical load
problem.
Check that no loose items, such as
shaft keys, couplings, etc., are
present.
Check all connections for tightness
and proper insulation.
Check that any motor thermal
switch or overload device is wired
according to the interconnection
diagram (Figure 3-4 or 3-5).
4:1
Motor Overspeed
WARNING
THE USER IS RESPONSIBLE FOR
ENSURING THAT DRIVEN MA-
CHINERY, ALL DRIVE-TRAIN
MECHANISMS, AND PROCESS LINE
MATERIAL ARE CAPABLE OF SAFE
OPERATION AT AN APPLIED FRE-
QUENCY OF 150% OF THE MAXI-
MUM SELECTED BASE FREQUEN-
CY TO THE A-C MOTOR. FAILURE
TO OBSERVE THIS PRECAUTION
COULD RESULT IN BODILY IN-
JURY,
Check the Transformer (if used)
1. Check that the rating of the trans-
former (if used) matches the con-
troller requirements. Refer to
“Install a Transformer” in Chapter
3.
2. Check that the transformer is con-
nected for the proper voltages.
4:2
Check the Controller and
Enclosure
1. Remove the controller enclosure
cover, If not already open.
2. Look for physical damage, re-
maining installation debris, wire
strands, etc.
3. Use clean, dry, low pressure air
(below 25 PSI) for removing debris
from the controller.
4. Check that there is adequate clear-
ance around the controller for air
flow.
5. Check that the controller is wired
according to the interconnection
diagram (Figure 34 or 3-5).
6. If a user-supplied output contactor
and/or user-supplied interlocks or
function loss devices are installed,
make sure the respective factory-
installed jumpers are removed.
7. Using a voltmeter, check that
460 VAC power is available on the
incoming line side of the input dis-
connect.
8. Check that all contro! and power
terminal connections are tight
(20 in-Ibs torque for input and out-
put power terminal connections).
9. Check that all fuses are in place and
properly seated in the fuseholders.
10. Check the continuity of all fuses. If
any fuse reads open, replace the
defective fuse. Refer. to Table 6-2
for fuse data.
Check Settings of Adjustment Pots
1. Make sure power is OFF.
2. Verify that the adjustment pots on
the regulator are as listed in Table
4-1. The location of these pots are
shown in Figure 4-1.
3. Do not adjust pots 8P, 9P, 10P,
11P, 12P, 13P and 14P. They are
factory set and sealed; any readjust-
ment could degrade the perform-
ance of the controller.
Check the Grounding
DANGER
THE USER IS RESPONSIBLE TO
MEET ALL CODE REQUIREMENTS
WITH RESPECT TO GROUNDING
ALL EQUIPMENT. FAILURE TO
OBSERVE THIS PRECAUTION
COULD RESULT IN SEVERE BODI-
LY INJURY OR LOSS OF LIFE.
1. Verify that a properly sized ground
wire is installed between the chassis
ground terminal, the controller en-
closure, and a suitable earth ground
and that the connections are tight.
2. With an ohmmeter, check for and
eliminate any grounds between the
input power leads to the chassis
ground and between the output
power leads to the chassis ground.
3. Verify that a properly sized ground
wire is installed between the motor
frame and a suitable earth ground
and that the connections are tight.
4. With an ohmmeter, check for and
eliminate any grounds between the
motor frame and the motor power
leads.
5. Verify that a properly sized ground
wire is installed between the trans-
former (if used} and a suitable earth
ground and that the connections
are tight.
6. Verify the above ground wires are
run unbroken.
Table 4-1. Controller Pot Settings.
Adjustment a.
Functional Description Control Range Initial Fact ory
Name Abbreviation Pot Setting
1SW(4) OFF: 1.5 to 20 seconds from
‚ Sets rate to accelerate from zero to
Acceleration ACC 1p maximum hertz. (Current limit O to 60 hertz 1SW(4) OFF
Rate e 1SW(4) ON: 4.5 to 60 seconds from 20 sec.
overrides this function.)
0 to 60 hertz
1SW(4) OFF: 1.5 to 20 seconds from
. Sets rate to decelerate from maximum
Deceleration DEC 2p to zero hertz. (Voltage limit overrides 60 to 0 hertz 1SW(4) OFF
Rate . Co 9 15W(4) ON: 4.5 to 60 seconds from 20 sec.
this function.)
60 то О hertz
i Set tor f h ed
Maximum MAX HZ 3p e $ то or requency when Spe 11: 1510 90 hertz (1) 60 Hz
Hertz pot is fully clockwise.
Minti e o fre h
inımum MIN HZ AP S ts m tor frequency w en Speed J1: O to 40 hertz (1) 6 Hz
Hertz pot is fully counterclockwise,
To e Increases voltage in order to increase
rau TBST 5P п age О то 80 МАС 20 МАС
Boost motor starting torque. (3)
Current LLMT GP Limits controller output frequency 50 to 150% of controller current 100% (2)
Limit dependent upon D-C bus current. rating
Volt f f i
s per V/HZ 7p Sets output frequency for a given 6.8 10 16.0 V/Hz (1) 7.6 V/Hz
Hertz output voltage.
(1)
(2)
(3)
This is the V/Hz with the base frequency set at 60 Hz (J1). If a base frequency above 60 Hz is required, contact your Reliance Electric Sales
Office for assistance, The V/Hz will change inversely as the base frequency increases.
This is 100% of the controller's maximum output amps (RMS) and is equal to 110% of the controller's maximum motor sine wave current rating.
In most cases, adjustment is not necessary. Should the application require adjustment, turn the 5P pot slightly and check the performance of
the controller over the entire normal load range. Remember that motor current cannot exceed 150% of controller current rating for more than
one minute.
CHECKPIN (0V) COMMON
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: ACCELERATION RATE
DECELERATION RATE
MAXIMUM HERTZ
MINIMUM HERTZ
TORQUE BOOST
CURRENT LIMIT
VOLTS PER HERTZ
Figure 4-1. Regulator Pots, LED and Checkpins.
4:3
Start the Controller
Purchased as Drive
Package
Use this simplified procedure only when
the controller and motor are purchased
together as a drive package; otherwise,
proceed to “Start the Controller Pur-
chased Separately.”
The controller is shipped with a NEMA
B induction motor sized to the control-
ler‘s horsepower rating and is pre-
adjusted to operate this motor. In most
cases, thrs startup procedure will locate
any shipping damage, verify proper in-
stallation and field wiring, provide a
second check of adjustments, and suc-
cessfully start the controller.
DANGER
ALTHOUGH ZERO SET ADJUST-
MENT ON THIS CONTROLLER AL-
LOWS FOR ADJUSTMENT DOWN
TO ZERO SPEED, THIS ZERO
SPEED SETTING MUST NOT BE
USED WHERE THE OPERATOR
MAY RELY ON A MAINTAINED
ZERO SPEED. ELECTRICAL NOISE,
IMPROPER WIRING, POWER LINE,
OR MALFUNCTIONING COMPO-
NENTS COULD CAUSE THE CON-
TROLLER TO TURN ON WHILE
AT THE ZERO SPEED SETTING.
FAILURE TO OBSERVE THIS PRE-
CAUTION COULD RESULT IN SE-
VERE BODILY INJURY OR LOSS
4. 1f the controller has been stored for
less than six months, proceed to
Step 5. if the controller has been
stored for over siX months, form
the capacitor as follows:
DANGER
THE REMAINING STEPS TO FORM
THE CAPACITOR ARE MADE WITH
POWER ON. EXERCISE EXTREME
CAUTION BECAUSE HAZARDOUS
VOLTAGE EXISTS. FAILURE TO
OBSERVE THIS PRECAUTION
COULD RESULT IN SEVERE BOD-
ILY INJURY OR LOSS OF LIFE.
e Turn the Speed pot fully CCW.
Turn the power ON.
e Observe that the voltmeter
reading is 621 VDC with respect
to 460 VAC input.
eo Let the controller sit undisturbed
for fifteen minutes while the
capacitor charges. Put a tag on
the controller that power is ON
and hazardous voltage exists.
e Turn the power OFF, Verify the
D-C bus voltage is zero (read the
voltmeter).
5. With power OFF, connect the
motor power leads, if not already
connected, to the controller. Couple
the driven equipment to the motor,
if not already coupled,
OF LIFE.
1. Follow all of the “Check the In-
stallation” procedures if not already
performed.
2. Make sure all power is OFF,
3. Seta voltmeter on the 1000 VDC
scale or a similar high voltage scale.
Connect the voltmeter to terminals
147(+) and 45(—).
Read this voltmeter every time you
turn power OFF to verify the D-C
bus capacitor 15 fully discharged.
Within one minute after power is
turned OFF, the bus voltage should
measure about 50 VDC.
4:4
DANGER
THE REMAINING STEPS ARE MADE
WITH POWER ON. EXERCISE EX-
TREME CAUTION BECAUSE HAZ-
ARDOUS VOLTAGE EXISTS. FAIL-
URE TO OBSERVE THIS PRECAU-
TION COULD RESULT IN SEVERE
BODILY INJURY OR LOSS OF
LIFE.
6. Turn the Speed pot fully CCW,
Turn the power ON.
7. Press the Start switch. Note: Do not
press the Start switch while the
motor is rotating. An {ET trip will
occur (The IET LED will fight and
the drive will stop.). Always wait
for the motor to completely stop.
To reset the controller after an IET,
press the Stop switch and wait for
the motor to completely stop.
8. Turn the Speed pot slowly CW to
check the motor shaft rotation. If
shaft rotation is correct, go to Step
9. If shaft rotation is incorrect,
change the motor shaft rotation
direction as follows:
e Press the Stop switch and wait
until the motor has completely
stopped.
e Turn the power OFF.
e After verifying the D-C bus volt-
age is Zero, reverse any two of
the three motor power leads.
e Turn power ON and press the
Start switch.
9. Run the drive across the speed range
under load. If the drive operates
satisfactorily, startup is compiete.
H the motor draws unnecessarily
high current, operation is unstable,
or the motor does not break away
when starting; proceed to “Start the
Controller Purchased Separately’
for more detailed startup instruc-
tions.
Minor user adjustments may be
necessary for satisfactory opera-
tion. Refer to Steps 23 through 33
in “Start the Controller Purchased
Separately’ and Table 4-1.
10. Press the Stop switch.
11. Turn the input power OFF. After
verifying the D-C bus voltage is
zero, remove the voltmeter and any
other instrumentation connected
during startup.
12. Close and secure the controller
enciosure cover.
Start the Controller
Purchased Separately
Use this startup procedure when you
purchase the controller separately to
use with an existing motor or a separate-
ly ordered motor. If any of the fol-
lowing steps cannot be made because of
a controller problem, go to “Section 6,
Troubleshooting,” in this manual.
1. Follow all of the “Check the Instal-
lation” procedures if not already
performed.
2. Make sure all power is OFF.
3. Set a voltmeter on the 1000 VDC
scale or a similar high voltage scale,
Connect the voltmeter to terminals
147 (+) and 45(—).
Read this voltmeter every time you
turn power OFF to verify the D-C
bus capacitor is fully discharged.
Within one minute after power is
turned OFF, the bus voltage should
measure about 50 VDC.
4. Disconnect the motor power leads
from the controller, if connected.
5. Ifthe controller has been stored for
less than six months, proceed to
Step 6. If the controller has been
stored for over six months, form the
capacitor as follows:
DANGER
THE REMAINING STEPS TO FORM
THE CAPACITOR ARE MADE WITH
POWER ON. EXERCISE EXTREME
CAUTION BECAUSE HAZARDOUS
VOLTAGE EXISTS. FAILURE TO
OBSERVE THIS PRECAUTION
COULD RESULT IN SEVERE BOD-
ILY INJURY OF LOSS OF LIFE.
e Put the Run/Jog switch in the
RUN position.
e Turn the Speed pot fully CCW.
Turn the power ON.
e Observe that the voltmeter
reading is 621 VDC with respect
to 460 VAC input.
e Let the controller sit undisturbed
for fifteen minutes while the
capacitor charges. Put a tag on
the controller that power is ON
and hazardous voltage exists.
e Turn the power OFF. Verify the
D-C bus voltage is zero (read the
voltmeter).
6. With power OFF, set a second volt-
meter on the 500 VAC scale. Con-
nect this voltmeter to any two of
the three output power terminals
(601, 602, and 603).
7. With the Speed pot fully CCW, turn
the power ON.
8. Press the Start switch. The green
RUN LED (Figure 4-1) should
light. The controller output fre-
quency is 6 Hz (minimum hertz
preset with 4P). The second volt-
meter should read about 66 VAC
(fundamental output voltage
preset with 5P).
9.
10.
11.
12.
Gradually turn the Speed pot CW
while reading the voltmeter. As the
speed increases, the voltage in-
creases. When the Speed pot
reaches fully CW, the output volt-
age should about equal the input
voltage. Output frequency should
be 60 Hz. Note: The output volt-
age of the PWM controller equals
the fundamental voltage plus the
harmonics.
Quickly turn the Speed pot fully
CCW. The voltage and frequency
will decrease to 66 VAC (funda-
mental voltage) and 6 Hz in about
20 seconds.
Quickly turn the Speed pot fully
CW. The voltage and frequency will
increase to the rated voltage and
60 Hz in about 20 seconds.
Note that the V/Hz (volts per
hertz) pot is factory adjusted to
produce 460 fundamental output
voltage at 60 Hz output frequency
for 460 volts input using funda-
mental reading voltmeters. Do not
adjust the V/Hz unless your appli-
cation requires a different voltage
at 60 Hz. The factory adjustment
will maintain the required 7.6 V/Hz
characteristic over the speed range
(the voltage will be slightly higher
than this below 40 Hz due to the
torque boost adjustment which is
set to provide up to 150% torque
capability for starting).
Note: The output voltage of the
PWM controller equals the funda-
mental voltage plus the harmonics.
If a different volts/hertz ratio is
required (See Figure 4-2), adjust
the V/Hz (7P) pot as follows:
e Make sure the motor is discon-
nected.
e Turn the T.BST (5P) pot fully
CCW.
e Turn the MIN Hz (4P) pot fully
CW.
e With the Speed pot fully CCW,
push the Start switch. The con-
troller will ramp to approxi-
mately 40 Hz (Min Hz pot fully
CW). Allow the controller to
reach steady-state speed.
e While reading the second volt-
meter, adjust the V/Hz pot until
the voltage determined by the
following equation is obtained:
Motor's
Fund Rated x 40 Hz
Inca Voltage
mental = -
Voltage Motor's Rated
Frequency
Note: The output voltage of the
PWM controller equals the funda-
mental voltage plus the har-
monics.
DANGER
ALTHOUGH ZERO SET ADJUST-
MENT ON THIS CONTROLLER AL-
LOWS FOR ADJUSTMENT DOWN
TO ZERO SPEED, THIS ZERO
SPEED SETTING MUST NOT BE
USED WHERE THE OPERATOR
MAY RELY ON A MAINTAINED
ZERO SPEED, ELECTRICAL NOISE,
IMPROPER WIRING, POWER LINE,
OR MALFUNCTIONING COMPO-
NENTS COULD CAUSE THE CON-
TROLLER TO TURN ON WHILE
AT THE ZERO SPEED SETTING.
FAILURE TO OBSERVE THIS PRE-
CAUTION COULD RESULT IN SE-
VERE BODILY INJURY OR LOSS
OF LIFE.
13. If a minimum frequency other than
6 Hz is required, adjust the Min Hz
(4P) pot as follows (See Figure
4-3):
eo Turn the Min Hz pot fully CCW.
e Turn the Speed pot fully CCW.
eo While observing the frequency
meter, if supplied, adjust the Min
Hz pot until the desired frequen-
cy is obtained. If the controller is
not equipped with a frequency
meter, determine the required
pot position with the following
equation and turn the Min Hz
pot to that position:
Desired
Min Hz
40 Hz
Note that the pot has 10 divi-
sions with 0 equal to O Hz and
10 equal to approximately
40 Hz. Therefore, each division
equals 4 Hz.
4P Position = x8+1
4:5
14. If a maximum frequency other than
60 Hz is required or if minimum
frequency was changed in Step 13,
adjust the Max Hz (3P) pot as fol-
lows (See Figure 4-3): Note that
the Min Hz pot must always be
adjusted before adjusting the Max
Hz pot.
e Turn the Max Hz pot fully CCW.
e Turn the Speed pot fully CW.
e While observing the frequency
meter, if supplied, adjust the
Max Hz pot until! the desired fre-
quency is obtained. If the con-
troller is not equipped with a fre-
quency meter, determine the re-
quired pot position with the fol-
lowing equation and turn the
Max Hz pot to that position:
1.2 18 \ 6 + 1
“Desired Desired | x
Max Hz Min Hz
For example, if the desired mini-
mum Hz is 30 Hz and the desired
maximum Hz is 60 Hz, the re-
quired pot position is 5.8:
12- 8
sa)
Note that the application may re-
quire further adjustment.
Note: You can obtain a precise
reading of the output frequency
by connecting a frequency
counter having an input imped-
ance of more than 1 megohm be-
tween checkpins FO and 0 V
(common) on the regulator. See
Figure 4-1. It should measure
256 times the controller output
frequency.
4:6
500 =
© À
< %0- a A 7
5 77 |/ Aa — 68 V/Hz (41)
TORQUE
5 BOOST 7 / 9
= 200 + /
— / ar.
3 / /
# ~~
-
7 Y V
1004 , JA: CONSTANT TORQUE
Pe 7 J5: VARIABLE TORQUE
L Pg
E
7
0 kh I 1 T Т | 1 1
0 10 20 30 aû 50 60 80 90
OUTPUT FREQUENCY
Figure 4-2. Volts/Hertz Pot Adjustable Region for 460 V Input.
MINIMUM FREQUENCY ADJUSTMENT 1S ADDITIVE TO
JUMPER J1 MAXIMUM FREQUENCY ADJUSTMENT UP TO 90 HZ.
: 90
80 -
N
= 60 ++ ADJUSTABLE REGION
= —
= li
x 40 = mr
«<
I
о 7 : T — JUMPER J1
0 10 20 30 40
MINIMUM HERTZ
Figure 4-3. Relationship of Min Hz and Max Hz.
15. Note the reading on the second
voltmeter. Put the Forward/Reverse
switch, if applicable, in the REV
position. The reading should de-
crease to zero and then return to
the original reading. Return the
Forward/Reverse switch to the
FWD position.
16. Put the Auto/Man switch, if ap-
plicable, in the AUTO position. The
Speed pot is now ineffective; speed
is controlled by a process control
reference signal of 4 to 20 mA, 0 to
20 mA, or O to 10 VDC. Return the
Auto/Man switch to the MAN posi-
tion.
17. Turn the Speed pot fully CCW and
press the Stop switch.
18. Turn the power OFF. Verify the
D-C bus voltage is zero (read the
first voltmeter).
19. With power OFF, connect the
motor power leads to the controller
and couple the driven machinery to
the motor, if not already coupled.
DANGER
THE REMAINING STEPS ARE MADE
WITH POWER ON. HAZARDOUS
VOLTAGE EXISTS. FAILURE TO
OBSERVE THIS PRECAUTION
COULD RESULT IN SEVERE BOD-
ILY INJURY OR LOSS OF LIFE.
20. With the Speed pot fully CCW, turn
the power ON.
21. Press the Start switch.
22. Turn the Speed pot slowly CW to
check the motor shaft rotation. If
shaft rotation is correct, go to Step
23. If shaft rotation is incorrect,
change the motor shaft rotation
direction as follows:
Note: Do not press the Start switch
while the motor is rotating. An |ET
trip will occur (The IET LED will
light and the drive will stop.).
Always wait for the motor to com-
pletely stop. To reset the controller
after an IET, press the Stop switch
and wait for the motor to com-
pletely stop.
e Press the Stop switch and wait
until the motor has completely
stopped.
e Turn the power OFF.
e After verifying the D-C bus volt-
age is zero, reverse any two of
the three motor power leads.
e Turn power ON and press the
Start switch.
23. Note that T.BST (5P) pot is factory
adjusted to produce the required
voltage to produce up to 150%
starting torque for Reliance Electric
standard and energy efficient
motors. This setting should, in most
cases, produce 150% starting torque
for other motors too. Adjust the
Torque Boost pot for the following
applications.
e With the drive coupled to the
machine, the torque boost may
not be high enough to break
away or accelerate the load
Within the current limit of the
drive. The torque boost should
be increased until either the
‘motor performs properly or cur-
rent limit is reached.
e If the V/Hz was adjusted in Step
12, the torque boost may not be
high enough to break away or
accelerate the load within the
current limit of the drive.
e If the motor does not run
smoothly in a low speed range,
turn power OFF and wait until
the D-C bus capacitors are fully
discharged. Relocate jumper J6
to J7. Set the Torque Boost pot
at zero. Turn power ON and
restart the drive. Using the
Torque Boost pot, gradually in-
crease the voltage until the
motor runs smoothly.
Note: Acoustic noise may be-
come high as the carrier frequen-
cy becomes low in a low speed
range at jumper J7. Consult
Reliance Electric if satisfactory
performance cannot be obtained.
24. Current limit is preadjusted for
110% of the motor sine wave cur-
rent rating. To adjust current limit
between the range of 50% (fully
CCW) and 150% (fully CW), turn
the Current Limit (6P) pot as
necessary.
25. Turn the Speed pot to the maxi-
mum CW position and the motor
will accelerate slowly to maximum
speed (60 hertz). Maximum speed
may not be reached due to current
limit. The controller is not designed
to supply 150% of the current
rating for more than one minute.
If satisfactory adjustment cannot
be reached, contact your Reliance
Electric Sales Office.
26.
27.
28.
29.
30.
31.
Turn the Speed pot fully CCW and
the motor will decelerate to the
minimum speed set with the Min
Hz pot.
With the Speed pot fully CCW,
quickly turn the Speed pot fully
CW. If the acceleration time is too
long, turn the Acceleration Rate
(1P) pot a quarter turn CW and
accelerate the motor again. Repeat
the motor acceleration process until
the desired acceleration time is
achieved.
Note: The shortest acceleration
time is limited by the current limit
circuit. When the Acceleration
Rate pot no longer has any effect,
the acceleration rate is at its maxi-
mum for the application. When the
motor is in acceleration while the
current is limited, the acceleration
will not be smooth. To smooth the
acceleration, turn the Acceleration
Rate pot slightly CCW. |
Turn the Speed pot fully CW and
wait until the motor reaches top
speed. Quickly turn the Speed pot
fully CCW. If the deceleration time
is too long, turn the Deceleration
Rate (2P) pot a quarter turn CW
and decelerate the motor again.
Repeat the motor deceleration
process until the desired decelera-
tion time is achieved.
Note: The shortest deceleration
time is limited by the voltage limit
circuit. When the Deceleration Rate
pot no longer has any effect, the
deceleration rate is at its maximum
for the application. When the
motor is in deceleration while the
D-C bus voltage is limited, the
deceleration will not be smooth.
To smooth the deceleration, turn
the Deceleration Rate pot slightly
CCW.
Turn the Speed pot CCW and wait
until the motor completely stops.
Then put the Run/Jog switch in the
JOG position.
Turn the Speed pot a quarter turn
CW and press the Start switch. The
motor will rotate while the Start
switch ts held in the START posi-
tion. The speed depends on the
Speed pot setting.
Turn the Speed pot CCW, and put
the Run/Jog switch in the RUN
position. Press the Stop switch.
4:7
32.
33.
4:8
Turn the power OFF. After veri-
fying the D-C bus voltage is zero,
remove the two voltmeters and any
other instrumentation connected
during startup.
Close and secure the controller
enclosure cover.
5: How the Controller Operates
Fundamentals of
Variable Voltage,
Variable Frequency
Controllers
An A-C motor is a fixed-speed machine
operating from a constant voltage, con-
stant frequency source, such as 460
VAC and 60 Hz. To vary the speed of
the motor, the voltage and frequency
of the source to the motor must be
variable. A controller provides this
source. The controller transforms its
input (three-phase, constant A-C volt-
age, constant frequency) into an output
compatible with the A-C adjustable
speed requirement of the A-C motor
(three-phase, variable voltage, variable
frequency).
The operating frequency of the control-
ler, along with the basic design of the
motor, determines the operating speed
(rpm) of the motor. The output voltage
of the controller establishes the mag-
netic flux level within the motor to
meet the torque demands of the load
over the entire speed range. The basic
equation to determine motor synchro-
nous speed Is:
Controller
Synchronous _ Output Frequency x 120
RPM Number of
A-C Motor Poles
The relationship between output voltage
and operating frequency is the “Volts
per Hertz” ratio (V/Hz). Except at low
speed, this ratio is usually a constant
determined by this equation:
Motor Nameplate Voitage
V/Hz =
Motor Nameplate Frequency
The two major sections of a controller
are the power circuit and the regulator.
The power circuit consists of a diode
bridge that converts A-C to D-C voltage
and a solid state transistor module that
transforms the constant voltage, con-
stant frequency input power into varia-
ble voltage, variable frequency output
power. The regulator controls when the
solid state transistor module switches in
the power circuit turn ON or OFF,
Power Circuit Operation
Figure 5-1 shows the power circuit
schematic divided into three sections.
The first section is the input rectifier.
A-C power is applied to terminals 181,
182 and 183 and is fuil-wave rectified
by the diode cube to constant D-C
voitage. This voltage is approximately
621 VDC. Three input fuses (1FU,
2FU, 3FU) protect the power circuit
from any ground faults. A suppressor
(MOV) limits voltage transients within
the maximum voltage rating of the
diodes.
The rectified voltage is then filtered by
the D-C bus filter, The capacitors are
charged through a precharge resistor to
limit the charging current. Relay DCR is
energized and shorts out the precharge
resistor when the bus filter capacitor
voltage reaches approximately 90% of
the rated bus voltage. Two discharge
resistors discharge the bus voltage when
the input power is removed.
The positive and negative D-C bus volt-
age lines run through the Hall Effect
Current Sensor to detect D-C bus cur-
rent. The D-C bus current feedback
protects against an overload or a short
circuit in the output inverter section.
The fittered D-C bus voltage is fed into
the output inverter section. This section
transforms D-C bus voltage into three-
phase A-C variable voltage, variable fre-
quency by switching transistors in the
transistor module. The transistor
module, consisting of six transistors
with anti-parallel diodes around them,
provides a path for reactive motor cur-
rent.
In summary, constant D-C voltage is
produced by rectifying and filtering the
incoming A-C power line, Variable
voltage, variable frequency is produced
by six output transistors inverting the
constant D-C voltage to a PWM voltage
waveform.
5:1
FROM D-C VOLTAGE D-C CURRENT
PRECHARGE CONTROL FEEDBACK FEEDBACK
A
a TT — — a
© | (ос D-C BUS |
| INPUT FILTER |
| RECTIFIER | DCR | +
; e—| Ho 4 i | me
| |||
| Г] |
| | | PRÉCHARGE 1121318 |
| RESISTOR
| a Tar |
META | ‘ |
R
181 | A |
S eb | + a HALL
182 mov | T = EFFECT |
SF < AMPL
T | or <
183 == e |
| = ыы 45 145 |
| | nS = mr
23 5 |
| | + 1 18
=
| | |
as | | | — "y
Le ee cduccU0uu— — a Tm |
DA 7
INVERTER
p
|
|
|
|
|
|
Figure 5-1. Power Circuit Schematic.
Controller Regulator Operation
Figure 5-2 shows the regulator block
diagram. It is divided into nine sections
as described below.
The first section is the input signal con-
ditioner. The input to this section is the
speed reference signal (This section is
not isolated; use the Customer Interface
Module when isolation is required.). The
first conditioning that is done on the
input is to set minimum and maximum
hertz using the Min and Max Hz pots.
These adjustments limit the reference
between minimum hertz and maximum
hertz.
5:2
The reference signal goes into the ramp
control, which controls the length of
time the motor takes to accelerate to
full speed and decelerate to zero speed.
The length of time can be adjusted
from 1.5 to 20 seconds using the Ac-
celeration and Deceleration Rate pots,
respectively. Typical voltage output
of the ramp control is 6 volts equals
60 hertz. Acceleration and deceleration
times can be extended to three times
the maximum time of 20 seconds.
The current limiter sets the required
limit value using the Current Limit pot.
The current limit circuit compares the
current limit value with the D-C bus cur-
rent feedback. If the D-C bus current
exceeds the limit value, the current
limit circuit modifies the ramp control
to limit the D-C bus current and extend
acceleration or deceleration time.
The voltage limiter has a fixed limit
reference. When in the regenerative
mode, the D-C bus voltage will rise as
the motor decelerates. If the D-C bus
voltage exceeds the limit reference, the
signal conditioner generates a limit
signal. This signal goes to the ramp
control to limit the D-C voltage and
extend the deceleration time. This
limit function operates if the D-C bus
voltage exceeds 750 VDC.
This function may be selected by
switching Dip Switch 1SW(1) to the ON
position, If the dynamic braking option
is used, the Dip Switch should be in the
OFF position to remove this function
from the circuit,
The timed reference provides the refer-
ence for the inverter control section.
The reference signal goes to the signal
conditioner, which defines the Volts/
Hertz ratio, dependent upon the Volts/
Hertz pot and the Torque Boost pot
settings. It also goes to the voltage-to-
frequency converter and the frequency
divider, These blocks determine the out-
put frequency of the controller. The
torque boost is required to offset the IR
drop of the A-C motor at a low speed
to produce a constant torque capability.
D-C offset at zero hertz may be selected
by Dip Switch 1SW(2). In the standard
OFF position, A-C torque boost is
provided for operation of standard
induction motors. In the ON position,
D-C offset at zero hertz is provided for
operation of permanent magnet syn-
chronous motors to provide synchro-
nous operation from starting. This limits
the current demand during acceleration.
The additional function section provides
automatic output voltage correction for
A-C line power voltage fluctuations and
either automatic torque boost for con-
stant torque loads or an energy saver
function generator for centrifugal
torque loads.
The automatic torque correction cir-
cuit (J4) compares the timed reference
to the D-C bus voltage feedback and
automatically corrects output voltage
for A-C line voltage fluctuations up to
95% output voltage. The automatic
torque boost circuit monitors D-C cur-
rent feedback and adjusts the output
voltage with the D-C bus current.
The function generator block is pro-
vided for saving energy and reducing
acoustic noise on centrifugal pump and
fan applications. This is done by means
of a V/Hz curve which is approxi-
mately reduced with the square of the
speed reduction since torque is pro-
portional to speed squared on a centri-
fugal toad. See Figure 4-2. This function
should not be used for constant torque
applications because the controller
would not be able to produce full load
torque at low speeds. Jumper J5 should
be used for centrifugal torque applica-
tions.
The PWM generates the sine wave pulse-
width modulation signal corresponding
to the V/Hz and frequency signals.
Figure 5-3 illustrates the principle of
generating the PWM sine wave. Jumper
J6 selects “constant” carrier frequency
of the PWM while J7 selects “variable”
carrier frequency of the PWM. With the
“variable” selection, the carrier fre-
quency is automatically decreased in
Tov ——e
PHASE LOSS ——m
LOW POWER SUPPLY
FUNCTION LOSS
LOW LINE
A TT
Ш
ENT ——
F | D-C BUS
EEDBACK SNA | SIONAL | VOLTAGE PLZ
CURRENT NDITIONE: |ONE FEEDBACK
LIMIT | | | BASE DRIVER |
| CURRENT LIMITER | VOLTAGE LIMITER
br m — —— — — — io щен —— — — — — —
+ BC EUS D-C BUS +
INPUT SIGNAL | VOLTAGE CURRENT TRANS S TORS |
| CONDITIONER | FEEDBACK FEEDBACK |
SIGNAL RAM } | | | | | |
| [CONDITIONER CONTROL | |
INVERTER
= | SIGNAL SIGNAL |
SPEED POT O" Max hz "| ACCEL | |CONDITIONER| | [TT] CONDITIONER | ВОЕН |
MIN HZ DECEL | | À Et EN
LOT dd я —
Dee A 7 ob nea |
- | | | PULSE WIDE IT J6 |
START/STOP O—-e[ sequence RUN Y J Sow | | МОИ
RUN/JOS CONTROL | TaoosT |CONDITIONER| | | | FUNCTION | |
FUNCTION LOSS RR | : | GENERATOR | | Î |
OUTPUT gel Y ( — HZ OUTPUT
CONTACTOR $ OUTPUT DISABLE и DISABLE |
ET SEQUENCING INVERTER CONTROL , ADDITIONAL PWM |
р FUNCTION |
Г CONTROLLER | — ———_ --—T
| D-C BUS _ 1 D-C BUS FAULT
VOLTAGE FEEDBACK | OVERVOL TAGE | |
0-C BUS _.| MOTOR i
| CURRENT FEEDBACK ~™ OVERCURRENT | „| SHIRE e] FREQUENCY
, LOW LINE ET RTE |
| 2ВМАС ——— EICH LINE pe LE | CONVERTER |
Figure 5-2, Controller Regulator Block Diagram.
5:3
proportion to a decrease in speed. It is
possible to have torque increase in a low
speed range though the acoustic noise
may also increase.
The base driver section is an amplifier
for switching the six inverter transistors
to produce the required pulse widths.
The signal from the regulator is isolated
by an optical coupler. The output of
the optical coupler is current amplified
by a drive transistor which supplies the
required base driver to the power tran-
sistor. These base drivers require an
isolated power supply that is supplied
by additional secondaries of the driver
transformer.
The controller fault section monitors
selected signals within the controlier
and generates an IET fault signal when-
ever the following signals exceed preset
limits:
e D-C bus voltage (621 VDC nominal)
exceeds 800 volts.
e D-C bus current exceeds 200% of full
load current.
e Regulator A-C input voltage (28 VAC
nominal) is not within +15%, —15%.
e Regulator D-C power supply (+12
VDC nominal) is 9.6 volts or less.
e Function Loss input is open.
e Input phase loss occurs.
The output of the IET circuit turns
OFF the regulator in a controlled man-
ner by turning off the sequencing con-
trol, the ramp contro! and the PWM
modulator. This redundancy assures the
controller turns OFF when a fault
occurs. The controller can only be reset
by pressing the Stop switch or turning
power OFF and then ON again. If an
external IET contact is required, an
external IET contact (form C) is availa-
ble by adding the Customer Interface
Module Kit.
The sequencing section is the interface
between the regulator and the Start/
Stop inputs from the operator's contro!
devices. Input circuits for Start/Stop,
Run/Jog and Function Loss are isolated
by an RR relay and an isolated second-
ary winding. The Start/Stop switch
picks up the RR relay if the function
loss input is closed. Contacts from the
RR relay are connected to the sequence
logic as a start/stop input.
There are two Stop modes: coast-to-rest
and ramp-to-rest. The normal Stop
mode is coast-to-rest set with Dip
Switch 1SW(3) in the OFF position.
This stop mode instantly turns OFF the
controller and the motor coasts to rest.
If the controller is restarted while the
motor is still in motion, an ¡ET may
occur.
The ramp-to-rest Stop mode is set with
Dip Switch 1SW(3) in the ON position.
With this setting the Stop switch will
cause a ramp-to-rest. With this method
the controller can be restarted while the
motor is still in motion without causing
an IET because the motor voltage and
frequency are kept under control until
the motor stops rotating. A Coast-Stop
pushbutton must be provided to the
function loss input,
Opening the function loss input causes
an IET, which instantly turns OFF the
controller causing the motor to coast to
a rest. To restart, the Stop switch must
be pressed to reset the IET, and the
motor must be completely stopped.
Then the Start switch is pressed to start
the controller.
Normaliy, the Run/Jog switch is in
RUN. In the Jog mode, the run relay
(RR) will not latch by pressing the Start
switch. Therefore, the controller oper-
ates only while the Start switch is held
in.
Fundamentals of
Controller Operator's
Controls
Start/Stop Control
With power ON, pressing the Start
switch causes the motor to accelerate to
the speed determined by the speed ref-
erence. The length of time for the
motor to accelerate to this speed de-
pends on the time set with the Accelera-
tion 1P pot.
Pressing the Stop switch causes the
motor to coast to a rest. The standard
Stop mode is coast-to-rest, but ramp-to-
rest is available.
If the controller is stopped because of
an IET, restart by pressing the Stop
switch, waiting for the motor to com-
pletely stop, and pressing the Start
switch.
Speed Control
WARNING
THIS CONTROLLER CAN BE AD-
JUSTED DOWN TO ZERO SPEED.
DO NOT USE THIS ZERO SPEED
SETTING TO STOP DRIVEN EQUIP-
MENT. CHANGING CONDITIONS
COULD RESULT IN UNEXPECTED
ROTATION. FAILURE TO OB-
SERVE THIS PRECAUTION COULD
RESULT IN BODILY INJURY.
VOLTAGE
REFERENCE
COMP
CARRIER
FREQUENCY
CARRIER
FREQUENCY
DUAN
YY Y NARA
ООО
VOLTAGE
REFERENCE
INPUT
guruoo
OUTPUT
Figure 5-3. Theory of Generating PWM,
5:4
The speed of the motor is controlled by
the speed reference set with the Speed
pot. When the controller is ON and the
Start switch is pressed, the motor will
accelerate to the speed set with the
Speed pot. While the motor is running,
the speed can be increased or decreased
by turning the Speed pot CW or CCW,
respectively. (If speed control is pro-
vided by a 4 to 20 mA, 0 to 20 mA, or
0 to 10 VDC process control signal, the
speed is increased or decreased by in-
creasing or decreasing the process
signal.) The length of time for the
motor to accelerate or decelerate to the
set speed depends on the time set with
the Acceleration 1P pot or Deceleration
2P pot.
Run/Jog Switch
When this switch is in the RUN posi-
tion, the controller controls motor
speed until the Stop switch is pressed.
When this switch is in the JOG position,
the motor runs only while the Start
switch is pressed and held in. Releasing
the Start switch stops the controlier.
The motor will stop in a coast-to-rest
or ramp-to-rest mode depending on the
mode selected.
Automatic/Manual Switch
(Option)
The Auto/Man switch option changes
the speed reference from the Speed pot
(MAN) to an external reference from a
process control (AUTO). The standard
controller includes the means to con-
vert a 4 to 20 mA or 0 to 20 mA signal
to 0 to 10 VDC.
Forward/Reverse Switch
(Option)
This option is provided for changing
motor phase rotation direction electron-
ically. To operate the controller in the
REVERSE mode, put the Forward/
Reverse switch in the REVERSE posi-
tion. This can be done while the motor
is at full speed in the forward direction.
The motor will decelerate to zero speed
and then accelerate in the opposite
direction to the set speed. Note that the
forward/reverse input circuit is not
isolated on the controller regulator; if
isolation is required, use the CIF option.
5:5
6: Troubleshoot the Controller
DANGER
ONLY QUALIFIED ELECTRICAL
PERSONNEL FAMILIAR WITH THE
CONSTRUCTION AND OPERATION
OF THIS EQUIPMENT AND THE
HAZARDS INVOLVED SHOULD
SERVICE THIS EQUIPMENT. FAIL-
URE TO OBSERVE THIS PRECAU-
TION COULD RESULT IN SEVERE
BODILY INJURY OR LOSS OF LIFE.
Table 6-1. Possible Causes of IET Trips.
Type of IET Possible Cause
Controller LEDs
1. The controller has 2 LED indica-
tors:
e RUN (green) — normally ON
e [ET (red) — OFF; ON when fault
occurs
The RUN and IET LEDs are lo-
cated on the Local Operator's Con-
trol Station. The Digital Meter with
First Fault Indication (option),
when used, is mounted where the
RUN and IET LEDs normally are
located. A RUN LED also is pro-
vided on the regulator board.
2. Alt IET LED indicates a fault has
occurred, If a Digital Meter with
First Fault Indication (option) is
used, the display will indicate the
first fault causing the IET. If an
IET has occurred, refer to Table 6-1
for possible cause.
e Clear the fault.
e Reset the controller by pressing
the Stop switch, waiting for the
motor to completely stop, and
pressing the Start switch. Note
that the controller cannot start
until the fault is cieared and the
controller is reset.
Output line-to-ground or
line-to-line short
Motor current higher than
200% of the controller
sine wave current rating
Overcurrent
Acceleration time too
short
Hall effect amplifier card
is faulty
Input voltage too high
Overvoltage Deceleration time too
short
Input voltage too low
Low Line Momentary power drop
Input phase loss
+12 VDC on reguiator
Power |
Supply board too low
Function Function loss input
Loss (1TB 3-4) is open
Test Equipment Needed
CAUTION: Do not use a megger to
perform continuity checks in the drive
equipment. Failure to observe this pre-
caution could result in damage to, or
destruction of, the equipment.
1. Two volt-ohmmeters each having a
sensitivity of 20,000 ohms-per-volt,
such as a Triplett Model 630.
2. A volt-ohmmeter with a 10 meg-
ohm input impedance on all ranges,
such as a Fluke 8022B. (This unit
provides an accuracy of +15% when
measuring controller output voltage
at terminals 601, 602, and 603.)
The most common voltmeters in use
are digital and analog voltmeters.
However, these two voltmeters use
several different methods of measuring
the RMS voltage of a waveform, thus
producing a wide range of RMS readings
for a particular PWM waveform.
A fundamental voltmeter is best suited
for measuring output voitage of PWM
waveforms because it filters out un-
wanted harmonics. An accurate meas-
urement is important since the funda-
mental waveform is the main con-
tributor to the power conducted to
the motor. Therefore, in this manual,
voltages given are fundamental voltages.
In comparison testing, the Fluke 8022B
provides an RMS measurement nearly
equivalent to that of the fundamental
voltmeter; the Triplett 630 provides an
RMS measurement that is 20 volts
higher than that of the fundamental
voltmeter,
Follow these guidelines when measuring
the output voltage of this PWM con-
troller:
eo Keep voltmeter lead lengths as short
as possible.
eo When using an analog voltmeter, use
the 500-750 VAC scale.
e When using a digital voltmeter, use
the 200 VAC scale for measuring
output voltages up to 200 VAC and
the 750 VAC scale for measuring
output voltages above 200 VAC.
e When using a Triplett 630 voltmeter,
subtract 20 volts from the reading to
determine the fundamental output
voltage.
e When using a Fluke 8022B voltmeter,
the meter reading can be used as an
approximate fundamental voltage.
6:1
DANGER
THIS EQUIPMENT IS AT LINE
VOLTAGE WHEN A-C POWER IS
CONNECTED TO THE CONTROL -
LER. DISCONNECT ALL UN-
GROUNDED CONDUCTORS OF
THE A-C POWER LINE FROM THE
CONTROLLER. AFTER POWER IS
REMOVED, VERIFY WITH A VOLT-
METER AT TERMINALS 147(+)
AND 45(—) THAT THE D-C BUS CA-
PACITORS ARE DISCHARGED BE-
FORE TOUCHING ANY INTERNAL
PARTS OF THE CONTROLLER.
FAILURE TO OBSERVE THESE
PRECAUTIONS COULD RESULT IN
SEVERE BODILY INJURY OR LOSS
OF LIFE.
General Troubleshooting
Procedure
1. Verify that an IET has not oc-
curred; the IET LED will be lit and
the drive shut down. If an IET has
occurred, refer to Table 6-1 for pos-
sible causes of the {ET
e Clear the fault.
e Reset the controller by pressing
the Stop switch, waiting for the
motor to completely stop, and
pressing the Start switch. Note
that the controller cannot start
until the fault is cleared and the
controller is reset.
e |f the controller does not restart,
proceed to Step 2.
Turn power off.
Open the enclosure cover.
4. With power OFF, make a complete
physical inspection of all control
and motor wiring for correct and
tight connections. Be sure that con-
nectors on the regulator are cor-
rectly positioned and tight.
5, Verify that the input power voltage
is in the 10% tolerance range. If
not, add a transformer between the
plant power supply and the con-
troller.
6:2
10.
Check for and correct poor wiring
conditions:
e Input and output leads routed
through the same conduit.
e Input or output leads running
paraliel or in the same conduit
with control signal wiring.
e Control signal wire that is not
twisted.
Make sure that all nearby relays,
solenoids, or brake coils are sup-
pressed.
Check that the ambient tempera-
ture does not exceed 40°C (104°F)
for enclosed controllers or 55°C
(131°F) for chassis controllers.
The Torque Boost bP pot may need
adjustment if the following condi-
tions are true:
e Too much torque boost caused
high no-load and full-load motor
current, causing excessive heating
in the motor and overloading of
the controller.
e Notenough torque boost resulted
in abnormally high current during
hard starting, fast acceleration,
and/or transient load operations.
Readjust the 5P pot as needed. Note
that the controller is designed to
supply 150% of the current rating
for not more than one minute; an
[ET will occur should current reach
200%.
If satisfactory operation still can-
not be obtained, proceed to “Fault
Symptom Troubleshooting Flow
Charts.”
Fault Symptom
Troubleshooting
Flow Charts
Identify the fault symptom from the
following list. Then turn to the flow
chart having the figure number cor-
responding to the symptom. If a part
needs to be replaced, refer to Table
6-2 and Figures 6-6 and 6-7. Figures 6-8
through 6-11 provide detailed wiring
diagrams, and Figure 6-12 locates com-
ponents of the regulator board.
1. Motor will not run, which includes
the following symptoms:
e Controller will not start.
e Input fuses are blown.
eo |ET trip occurs when the con-
troller is started.
eo Controller starts, but with a loud
humming noise, and then stops.
2. Motor will not reach maximum
speed, which includes the following
symptoms:
® Controller starts but motor stays
at low speed.
e Controller ET occurs during
acceleration.
3. Controller IET occurs during con-
trolled deceleration.
4, Controller |ET occurs occasionally
while running but can be restarted.
5. Motor overheats above allowable
temperature.
POWER ON |
INPUT
YES
FUSE BLOWN CHECK D-C BUS |
?
POWER OFF == 147.45,
NO
| START ON
1. REGULATOR OR BASE DRIVER
BOARD DAMAGEO.
YES 2. REGULATOR OR BASE DRIVER
TRANSFORMER DAMAGED.
3. TRANSISTOR MODULE DAMAGED.
INPUT
FUSE BLOWN
>
1. REGULATOR OR BASE DRIVER
BOARD DAMAGED.
2, REGULATOR OR BASE DRIVER
CONTROL
FUSE BLOWN
?
TRANSFORMER DAMAGED.
REGULATOR OR BASE DRIVER BOARD
OR PRECHAGE RELAY ASSEMBLY
DAMAGED.
D-C BUS
147-45 SHORTED
?
. TRANSISTOR MODULE DAMAGED.
. DIODE MODULE DAMAGED.
. FILTER CAPACITOR DAMAGED.
. BUS CLAMP BOARD DAMAGED.
, REGULATOR OR BASE DRIVER
BOARD DAMAGED.
6. PHASE LOSS DETECTOR BOARD
DAMAGED.
Nn BR GR
FUNCTION LOSS
INPUT OPEN
?
NO VERIFY THAT INPUT
VOLTAGE IS CONNECTED.
1. INPUT PHASE LOSS.
2. LINE VOLTAGE IS TOO
HIGH OR TOO LOW.
NO YES
CHECK FUNCTION LOSS
INPUTS).
. START/STOP SWITCH DAMAGED.
. CONTROL WIRING INCORRECT.
‚ REGULATOR BOARD DAMAGED.
. REGULATOR TRANSFORMER
DAMAGED.
Bu в) —
‘MEASURE VOLTAGE OF
D-C BUS 147.45,
. DIODE MODULE DAMAGED.
2. REGULATOR BOARD DAMAGED,
—
POWER OFF
|
DISCONNECT MOTOR
LEADS.
POWER ON AND THEN
RESTART.
|
WITH SPEED POT TURNED АТ
MID POINT, MEASURE VOLTAGE
AT QUTPUT 601, 602, 605
1. OUTPUT CURRENT LIMITED
e ADJUST |.LMT POT
e ADJUST T.BST POT
e CHECK MOTOR POWER AND
LOAD
2. MOTOR DAMAGED
e CHECK MOTOR LEADS
OUTPUT
FUND VOLTAGE
230 VAC
?
1. REGULATOR OR BASE DRIVER
BOARD DAMAGED,
2. REGULATOR OR BASE DRIVER
TRANSFORMER DAMAGED,
3. TRANSISTOR MODULE DAMAGED
. QUTPUT CONTACTOR AUXILIAR Y
CONTACT DAMAGED.
E
POWER OFF
|
DISCONNECT MOTOR
LEADS,
POWER ON AND THEN |
RESTART.
—
. TRANSISTOR DAMAGED.
2. REGULATOR OR BASE DRIVER
YES TRANSFORMER DAMAGED.
3. REGULATOR OR BASE DRIVER
BOARD DAMAGED.
4, PHASE LOSS DETECTOR
NO DAMAGED.
OUTPUT OVERCURRENT
e CHECK LINE-TO-LINE SHORT
e CHECK LINE-TO-GROUND SHORT
e ADJUST T.BST POT
e CHECK MOTOR POWER LEADS
Figure 6-1. Motor Will not Run.
6
3
| POWER ON |
START ON
ETT
LIGHTS DURING
ACCEL
?
Y
ES 1 RESET IET
| WITH STOP SWITCH,
|
— TURN § LMT POT
COUNTERCLOCKWISE.
J
TURN [.LMT POT
CLOCKWISE.
NO
START ON
NO IET” NO
Y ES LIGHTS
?
RESET LET WITH] _
STOP SWITCH.
YES y
SPEED INCREASES
TURN ACC POT SLIGHTLY
COUNTERCLOCKWISE.
MOTOR
REACHES MAX,
SPEED
?
YES
IF NO CHANGE AT
MOTOR SPD,
SLOWLY TURN
1LLLMT POTEWTO
ORIGINAL SCALE
POSITION,
START ON
STOP CONTROLLER
NOTE: ALLOWABLE
MAXIMUM LOAD IS
150% FOR ONE
MINUTE.
|
TURN MAX HZ POT
CLOCKWISE. |
1. CONTROLLER DAMAGED.
2. LOAD INERTIA TOO
LARGE.
3. CHECK MOTOR.
4. TORQUE BOOST AND V/HZ
ADJUSTED TOO HIGH.
MOTOR
REACHES MAX.
SPEED
?
MEASURE MOTOR
CURRENT.
MOTOR
SPEED INCREASES
?
|
VES CURRENT THIS 1S THE MINIMUM ACCELERATION
REVIEW SECTION 3 OVER 100% TIME PERMISSIBLE. A SMOOTHER AC.
“STARTUP ADJUSTMENT.” > CELERATION NEEDS A LONGER TIME,
y ChECK THE CURRENT WHEN THE MOTOR
| IS AT MAXIMUM SPEED.
1. REGULATOR OR BASE CONTACT YOUR
DRIVER BOARD RELIANCE ELECTRIC
DAMAGED, SALES OFFICE.
2. CIF MODULE (OPTION)
DAMAGED IF USED.
READJUST
CURRENT LIMIT
IF DESIRED.
Figure 6-2. Motor Will not Reach Maximum Speed.
6:4
CHECK 1SW(1) ON THE
REGULATOR BOARD.
NO
YES
| POWER ON |
TURN ON 1SW({1) WHEN D.B KIT (OPTION) IS NOT USED.
TURN SPEED POT
FULLY CLOCKWISE,
| START ON
TURN DEC POT
SLIGHTLY COUNTER:
CLOCKWISE.
|
TURN SPEED POT TO
ZERO QUICKLY.
“IET” LIGHTS
Y ES
RESET IET BY
STOP SWITCH.
DECEL RATE
MAX
DURING DECELERATION
?
1. THIS IS THE MINIMUM
DECELERATION TIME PER-
MISSIBLE.
2. ALLOW A LITTLE LONGER
TIME FOR SMOOTH DECELER-
ATION.
3. IF YOU WANT TO SHORTEN THE
DECELERATION TIME TO LESS
THAN THE MINIMUM SETING,
CONTACT RELIANCE ELECTRIC.
VERIFY THAT INPUT
VOLTAGE 1S CORRECT.
|
INPUT VOLTAGE IS
TOO HIGH: THERE
SHOULD BE AN IET AT
ONCE WHEN POWER
IS APPLIED. 1F NOT,
REPLACE THE REGU-
LATOR BOARD.
LOAD INERTIA IS TOO
LARGE. CONTACT
RELIANCE ELECTRIC
FOR ASSISTANCE.
Figure 6-3. Controller IET Occurs during Controlled Deceleration.
6:5
MONITOR INPUT VOLTAGE
FLUCTUATION WHEN
ET OCCURS.
VOLTAGE
FLUCTUATION
LARGE
(£15%)?
YES
ARE ANY RELAYS,
BRAKES, SOLENOIDS ETC.
OPERATING FROM THE
SAME LINE
?
AMBIENT
TEMPERATURE HIGH
YES
INTERMITTENT WIRING
FAULTS IN CONTROL
WIRING OR MOTOR WIRING.
|
2. HIGH VOLTAGE MAY
1, LARGE LINE DIPS
MAY CAUSE IET.
CAUSE ET,
NOISE MAY CAUSE IET,
TURN ON/OFF EACH
DEVICE INDIVIDUALLY
WHILE CHECKING THE
CONTROLLER.
INSTALL AN R.C SUPPRESSOR
(RELIANCE PART 600686-33A OR
A 220-O0HM RESISTOR IN SERIES
WITH A Q.5uF CAPACITOR) ACROSS
THE COILS OF THE DEVICE.
MEASURE THE AMBIENT TEMPERATURE
AROUND THE CONTROLLER. 40°C (104°F)
MAXIMUM FOR TOTALLY ENCLOSED
CONTROLLER: 55°C (131°F) MAXIMUM
FOR CHASSIS MODEL.
IMPROVE THE CONTROLLER
1.
DISCONNECT ALL POWER TO THE CONTROLLER.
WITH AN OHMMETER, CHECK FOR SHORTS
IN THE OPERATOR'S CONTROL DEVICES
WIRING. WITH MOTOR DISCONNECTED AT THE
CONTROLLER, CHECK FOR INTERMITTENT
SHORTS BETWEEN MOTOR LEADS AND GROUND
AND BETWEEN MOTOR LEADS. USE AMEGGER
ON THE MOTOR CIRCUIT ONLY WHEN DIS-
CONNECTED FROM CONTROLLER,
. THE CAUSE WILL BE INDICATED IF A FRE-
QUENCY METER WITH FIRST FAULT INDICA-
TION {KIT} IS INSTALLED.
VENTILATION OR RELOCATE
CONTROLLER.
Figure 6-4. Controller IET Occurs Occasionally while Running but Can Be Restarted.
6
6
| POWER ON |
1
| START ON |
Ÿ
MEASURE MOTOR
CURRENT.
YES
OVERCURRENT?
NO
MOTOR
OPERATED AT
LOW SPEED
FOR A LONG
TIME?
NO
3-PHASE
QUTPUT BALANCED
7
NO
YES
1S THERE
YES
YES
REDUCE THE LOAD OR
REPLACE WITH A HIGHER
HORSEPOWER CONTROLLER
AND MOTOR. CONTACT
RELIANCE ELECTRIC.
CONTACT RELIANCE
ELECTRIC.
ANYTHING PREVENTING
MOTOR
COOLING?
NO
CONTACT RELIANCE ELECTRIC
FOR ASSISTANCE.
|
REMOVE ANY
OBSTRUCTIONS,
POWER OFF, DISCONNECT
MOTOR LEADS AND THEN
POWER ON.
3-PHASE
CUTPUT BALANCED
MOTOR
DAMAGED.
NO
REGULATOR OR BASE
DRIVER BOARD
DAMAGED.
. BASE DRIVER TRANS:
FORMER DAMAGED.
Figure 6-5. Motor Overheats above Allowable Temperature.
6:7
Table 6-2. Replacement Parts List.
Description
Qty.
Per
Drive
Reliance
Part Number
Table 6-3. Recommended Spare Parts
for Every 6 Controllers.
Input Fuse
AOGOURLOS3OTT3
600V, 30A
Ferraz
2to 10HP
402410-500AC
Control Fuse
EJX
600V, 1.5A
Ferraz
2 10 TOHP
or ATQ 2/10A
[Gould )
402410-503AC
(402410-501 AC)
Le Qty. Reliance
Description or Part Number
Diode Cube
2 to 5HP 1 402410-100BA
7% to 10HP 1 402410-101BA
Transistor
Module
2HP 1 402410-200AS
3 to SHP 1 402410-201AS
7% to 10HP 3 402410-202AS
Capacitor
2HP 2 402410400AA
3HP 2 402410-401AA
5HP 2 402410-402AA
76HP 2 402410403AA
10HP 2 402410-404AA
Precharge Relay
Assembly
2HP 1 612180-100R
3 to 5HP 1 612180-1005
7%HP 1 612180-100T
10HP 1 612180-100V
input Suppressor
2 to 10HP 1 612180-500R
Bus Clamp
PC Board
2 to 10HP 1 0-48680-500
Discharge Resistor
Assembly
2HP 1 612180-200R
3 to SHP 1 612180-2005
7% 10 10HP 1 612180-200T
Regulator
PC Board
2 to 10HP 1 0-48680-101
Base Driver
PC Board
2HP 1 0-48680-200
3 to TOHP 1 0-48630-201
Regulator
Transformer
2 to 10HP 1 612180-500R
Base Driver
Transformer
2 to 10HP 1 612180-501R
Hall Effect
Amplifier
2HP 1 0-48680-501
3HP 1 0-48680-502
5HP 1 048680503
T'AHP 1 0-48680-504
10HP 1 0-48680-505
Phase Loss
Detector
PC Board
2 to 10HP 1 0-48680-506
6:8
Gould
( or ATQ 2108)
. Reliance
Description Qty. Part Number
Diode Cube
2 to 5HP 1 402410-100BA
7% to 10HP 1 402410-101BA
Transistor
Module
2HP 1 402410-200AS
3 to 5HP 1 402410-201AS
7% 10 TOHP 3 402410-202AS
Precharge Relay
Assembly
2HP 1 612180-100R
3 to SHP 1 612180-1008
74HP 1 612180-100T
10HP 1 612180-100V
Bus Clamp
PC Board
2 to 1TOHP 1 0-48680-500
Regulator
PC Board
2 to 10HP 1 0-48680-100
Base Driver
PC Board
2HP 1 0-48680-200
3 to 10HP 1 0-48630-201
Requiator
Transformer
2 to 10HP 1 612180-500R
Base Driver
Transformer
2 to 10HP 1 612180-601R
Input Fuse
ADEQUR LO3OT13
600V, 30A
Ferraz
2 to 10HP 12 402410-500AC
Control Fuse
6JX
600V, 1.5A
Ferraz
2 to 10HP 12 402410-503AC
(402410-501AC)
©]
me MODULE ó
BASE DRIVER
TRANSFORMER —
PHASE LOSS
DETECTOR —…
PC BOARD
INPUT
SUPPRESSOR
REGULATOR
TRANSFORMER —
CONTROL
FUSE =
PRECHARGE
RELAY —)
ASSEMBLY
(BEHIND)
о O
GROUND —
TERMINAL
—) ci
fe =
-
Gs
|
\
® ®
© 9 © 9 O 5
— ®
| | BUSCLAMP
® | PC BOARD
— © o |_— DIODE CUBE
|
mi ® © © ©
— e | Ulm
— A
70
— — — - lo
© E Sama
Se a
2.0 2 0 ¿€ ® o le
ga —o) CAPACITOR
(BEHIND)
Figure 6-6. Typical Component Identification (2 to 5 HP).
6:9
TRANSISTOR MODULE
® PROA
BASE DRIVER
| DISCHARGE
TRANSFORMER 69 RESISTOR
PHASE LOSS
DETECTOR
PC BOARD
REGULATOR
TRANSFORMER
o (a)
©
HALL EFFECT
DIODE @ | AMPLIFIER
CUBE
INPUT
SUPPRESSOR
CONTROL
FUSE
CAPACITOR
(BEHIND)
INPUT
FUSE
PRECHARGE
RELAY
ASSEMBL Y
(BEHIND)
GROUND
TERMINAL
Figure 6-7. Typical Component Identification (7% to 10 HP).
6:10
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6:15
Figure 6-12. Typical Component Layout of Regulator PC Board.
Reliance Electric / 24703 Euclid Avenue / Cleveland, Ohio 44117 / (216) 266-7000
NC Im
ELECTRIC MI)
Printed in U.S. A. instruction Manual D2-3103-2 07881M
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