Control Techniques 3750 East Market Street York, PA 17402-2798
717-751-4200, FAX 717-751-4263 www.fincor.net
Series 2230 MKII
Single-Phase
Adjustable-Speed
Regenerative
DC Motor Controllers
(1/6 – 5 HP)
BOOK 0960-B
BOOK 0960-B
SERIES 2230 MKII
SINGLE-PHASE
ADJUSTABLE-SPEED
REGENERATIVE
DC MOTOR CONTROLLERS
(1/6 - 5 HP)
Control Techniques
York Drive Center
3750 E Market Street
York, PA 17402-2798
USA
Tel 717.751.4200
Fax 717.751.4263
www.fincor.net
BOOK 0960-B
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BOOK 0960-B |
|
TABLE OF CONTENTS |
|
SECTION |
TITLE |
PAGE |
I .......................................... |
GENERAL INFORMATION ................................................................... |
1 |
|
Introduction ............................................................................................... |
1 |
|
General Description................................................................................... |
1 |
|
Motor Selection ......................................................................................... |
1 |
|
Description of Operation........................................................................... |
1 |
|
Model Types.............................................................................................. |
2 |
II.......................................... |
INSTALLATION...................................................................................... |
3 |
|
Installation Guidelines............................................................................... |
3 |
|
Installing the Controller ............................................................................ |
5 |
|
Initial Startup........................................................................................... |
16 |
III ......................................... |
OPERATION .......................................................................................... |
17 |
|
Power On/Off .......................................................................................... |
17 |
|
Run .......................................................................................................... |
17 |
|
Stop ......................................................................................................... |
17 |
|
Controlled Stop ....................................................................................... |
17 |
|
Zero Speed Detection .............................................................................. |
17 |
|
Speed Control.......................................................................................... |
18 |
|
Torque Control ........................................................................................ |
18 |
|
Jog ........................................................................................................... |
19 |
|
Reverse.................................................................................................... |
19 |
|
Armature Voltage and Current Outputs .................................................. |
19 |
|
Load Monitor (Motor Timed Overload).................................................. |
20 |
|
Direction Output...................................................................................... |
20 |
|
Speed Regulator Input............................................................................. |
20 |
|
Inoperative Motor.................................................................................... |
20 |
IV ......................................... |
MAINTENANCE AND REPAIR........................................................... |
21 |
|
General .................................................................................................... |
21 |
|
Adjustment Instructions .......................................................................... |
21 |
|
Troubleshooting Instructions................................................................... |
23 |
V.......................................... |
PARTS LIST........................................................................................... |
27 |
VI ......................................... |
RATINGS AND SPECIFICATIONS ..................................................... |
29 |
|
Ratings..................................................................................................... |
29 |
|
Operating Conditions .............................................................................. |
30 |
|
Performance Characteristics.................................................................... |
31 |
|
Adjustments............................................................................................. |
31 |
|
Specifications .......................................................................................... |
31 |
VII ........................................ |
DRAWINGS ........................................................................................... |
33 |
|
INDEX .................................................................................................... |
36 |
iii
BOOK 0960-B |
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|
|
LIST OF TABLES |
|
TABLE |
TITLE |
PAGE |
1................... |
Series 2230 MKII Model Matrix........................................................................................... |
2 |
2................... |
Jumper J4 Position........................................................................................................................ |
5 |
3.................... |
Dip Switch (SW3) ........................................................................................................................ |
6 |
4.................... |
Initial Potentiometer Settings..................................................................................................... |
16 |
5.................... |
Dynamic Braking Characteristics .............................................................................................. |
18 |
6.................... |
Troubleshooting.................................................................................................................... |
23-26 |
7.................... |
Parts List, Series 2230 MKII Controllers .................................................................................. |
27 |
8.................... |
Typical Application Data ........................................................................................................... |
29 |
9.................... |
Operating Voltages and Signals................................................................................................. |
30 |
10................... |
Controller Weights ..................................................................................................................... |
30 |
11................... |
Speed Regulation Characteristics............................................................................................... |
31 |
12................... |
Shunt Field Data......................................................................................................................... |
32 |
13................... |
Tachometer Feedback Voltage Selection .................................................................................. |
22 |
|
LIST OF ILLUSTRATIONS |
|
FIGURE |
TITLE |
PAGE |
1................... |
Controller Mounting Configurations ..................................................................................... |
7 |
2................... |
Controller Mounting Dimensions ................................................................................................ |
8 |
3.................... |
Logic Connection Diagram, Run-Stop-Jog Switch..................................................................... |
9 |
4.................... |
Logic Connection Diagram, Forward-Reverse Switch and Run-Stop-Jog Switch .................... |
9 |
5.................... |
Logic Connection Diagram, Run-Stop-Controlled Stop Pushbuttons and Run-Jog Switch....10 |
|
6.................... |
Logic Connection Diagram, Run-Stop-Controlled Stop Pushbuttons and Forward / |
|
|
Reverse Switch . ......................................................................................................................... |
10 |
7.................... |
Logic Connection Diagram, Optional Contactor Using Run-Stop-Jog Switch........................ |
11 |
8.................... |
Logic Connection Diagram, Optional Contactor Using Run-Stop Pushbuttons and ............... |
11 |
|
Run-Jog Switch |
|
9.................... |
Logic Connection Diagram, Line Starting With Motor Speed Potentiometer ......................... |
12 |
10................... |
Signal Connection Diagram, Motor Speed Potentiometer, Unidirectional .............................. |
12 |
11................... |
Signal Connection Diagram, Motor Speed Potentiometer, Bidirectional................................. |
13 |
12................... |
Signal Connection Diagram, Tachometer Feedback................................................................. |
13 |
13................... |
Signal Connection Diagram, External Current (Torque) Reference Potentiometer................. |
13 |
14................... |
Signal Connection Diagram, External Current Limit Potentiometers ...................................... |
14 |
15................... |
Signal Connection Diagram, Line Starting Without a Motor Speed Potentiometer ................ |
14 |
16................... |
Signal Connection Diagram, External PID Controller with Auto/Manual Switch .................. |
14 |
17................... |
Signal Connection Diagram, 4-20mA Outputs – Armature Amps and Volts.......................... |
15 |
18................... |
Signal Connection Diagram, 0-±10Vdc Outputs – Armature Amps and Volts....................... |
15 |
19................... |
Functional Schematic, Series 2230 MKII.................................................................................. |
34 |
20................... |
Series 2230 MKII Control Board, 1/6 – 3HP............................................................................ |
35 |
21................... |
2233 MKII Connection Terminals - 5HP.................................................................................. |
36 |
iv
BOOK 0960-B
Blank Page
v
BOOK 0960-B
WARNING
The following must be strictly adhered to at all times.
1.YOU AS THE OWNER OR OPERATOR OF FINCOR EQUIPMENT HAVE THE RESPONSIBILITY TO HAVE THE USERS OF THIS EQUIPMENT TRAINED IN ITS OPERATIONS AND WARNED OF ANY POTENTIAL HAZARDS OF SERIOUS INJURY.
2.THE DRIVE EQUIPMENT SHOULD BE INSTALLED, OPERATED, ADJUSTED, AND SERVICED ONLY BY QUALIFIED PERSONNEL FAMILIAR WITH THE CONSTRUCTION AND OPERATION OF THE EQUIPMENT AND THE HAZARDS INVOLVED INCLUDING THOSE DESCRIBED BELOW. FAILURE TO OBSERVE THIS WARNING CAN RESULT IN PERSONAL INJURY, LOSS OF LIFE, AND PROPERTY DAMAGE.
3.THE NATIONAL ELECTRICAL CODE REQUIRES THAT AN AC LINE FUSED DISCONNECT OR CIRCUIT BREAKER BE PROVIDED IN THE AC INPUT POWER LINES TO THE CONTROLLER. THIS DISCONNECT MUST BE LOCATED WITHIN SIGHT OF THE CONTROLLER. DO NOT OPERATE THE CONTROLLER UNTIL THIS CODE REQUIREMENT HAS BEEN MET.
4.THE DRIVE EQUIPMENT IS AT AC LINE VOLTAGE WHENEVER AC POWER IS CONNECTED TO THE DRIVE EQUIPMENT. CONTACT WITH AN ELECTRICAL CONDUCTOR INSIDE THE DRIVE EQUIPMENT OR AC LINE DISCONNECT CAN CAUSE ELECTRIC SHOCK RESULTING IN PERSONAL INJURY OR LOSS OF LIFE.
5.BE SURE ALL AC POWER IS DISCONNECTED FROM THE DRIVE EQUIPMENT BEFORE TOUCHING ANY COMPONENT, WIRING, TERMINAL, OR ELECTRICAL CONNECTION IN THE DRIVE EQUIPMENT.
6.ALWAYS WEAR SAFETY GLASSES WHEN WORKING ON THE DRIVE EQUIPMENT.
7.DO NOT REMOVE OR INSERT CIRCUIT BOARDS, WIRES, OR CABLES WHILE AC POWER IS APPLIED TO THE DRIVE EQUIPMENT. FAILURE TO OBSERVE THIS WARNING CAN CAUSE DRIVE DAMAGE AND / OR PERSONAL INJURY.
8.ALL DRIVE EQUIPMENT ENCLOSURES, MOTOR FRAMES, AND REMOTE OPERATOR STATIONS MUST BE CONNECTED TO AN UNBROKEN COMMON GROUND CONDUCTOR. AN UNBROKEN GROUNDING CONDUCTOR MUST BE RUN FROM THE COMMON GROUND CONDUCTOR TO A GROUNDING ELECTRODE BURIED IN THE EARTH OR ATTACHED TO A PLANT GROUND. REFER TO THE NATIONAL ELECTRICAL CODE AND LOCAL CODES FOR GROUNDING REQUIREMENTS.
9.THE ATMOSPHERE SURROUNDING THE DRIVE EQUIPMENT MUST BE FREE OF COMBUSTIVE VAPORS, CHEMICAL FUMES, OIL VAPOR, AND ELECTRICALLY CONDUCTIVE OR CORROSIVE MATERIALS.
10.SOLID-STATE DEVICES IN THE CONTROLLER CAN BE DESTROYED OR DAMAGED BY STATIC ELECTRICITY. THEREFORE, PERSONNEL WORKING NEAR THESE STATICSENSITIVE DEVICES MUST BE APPROPRIATELY GROUNDED.
vi
BOOK 0960-B
SECTION I
GENERAL INFORMATION
INTRODUCTION
This manual contains installation, operation, and maintenance and repair instructions for Fincor Series 2230 MKII Single-Phase Adjustable-Speed Regenerative DC Motor Controllers. A parts list, ratings and specifications, and drawings are also included.
GENERAL DESCRIPTION
Series 2230 MKII Controllers statically convert AC line power to regulated DC for adjustable-speed armature control of shunt-wound and permanent-magnet motors.
Applications include those requiring controllable bi-directional torque for overhauling loads, contactor-less reversing, and position control.
Series 2230 MKII Controllers comply with applicable standards established by the National Electrical Code and NEMA for motor and industrial control equipment. The controllers are Underwriters Laboratories Listed (File No. E184521) UL/cUL.
MOTOR SELECTION
Series 2230 MKII Controllers control the operation of general purpose DC motors designed for use with solid-state rectified power supplies. The motor may be shunt-wound, stabilized shunt-wound, or permanent magnet. For maximum efficiency, the motor should be rated for operation from a NEMA Code K power supply.
DESCRIPTION OF OPERATION
Series 2230 MKII Regenerative Controllers, also known as four-quadrant controllers, not only control motor speed and direction of rotation, but also the direction of motor torque.
Referring to Figure 1, when the drive (controller and motor) is operating in Quadrants I and III, motor rotation and torque are in the same direction and the drive functions as a conventional non-regenerative drive. In Quadrants II and IV, motor torque opposes the direction of motor rotation, which results in controlled braking. The drive can switch rapidly from motoring to braking modes while simultaneously controlling the direction of motor rotation. Under braking conditions, the controllers convert the mechanical energy of the motor and connected load into electrical energy, which is returned (regenerated) to the AC power source.
FIGURE 1. Four-Quadrant Operation
1
BOOK 0960-B
MODEL TYPES
TABLE 1. SERIES 2230 MKII MODEL MATRIX
|
FUNCTION |
CONFIGURATION |
OPERATOR CONTROLS |
POWER SOURCEa & |
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HP RANGE |
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MODEL |
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|
RUN/STOP |
ARMATURE |
OPEN |
|
LOCAL |
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|
||||
|
JOG |
CONTACT |
ENCLOSED |
REMOTE |
115V |
230V |
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|
CHASSIS |
INTEGRAL |
||||||
|
SWITCHb |
AND DBc |
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2231 |
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X |
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X |
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|
2231B |
|
X |
X |
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X |
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2231P0 |
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X |
|
X |
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2231P1 |
X |
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|
X |
X |
|
1/6 -1 |
1/3 - 2 |
2231BP0 |
|
X |
|
X |
|
X |
||
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2231BP1 |
X |
X |
|
X |
X |
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2235 |
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|
X |
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X |
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2235B |
|
X |
X |
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X |
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2232 |
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|
X |
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|
X |
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|
2232B |
|
X |
X |
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X |
1/6 - 1 |
1/3 - 3 |
2236 |
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X |
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X |
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2236B |
|
X |
X |
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X |
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2233 |
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X |
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X |
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2233B |
|
X |
X |
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|
X |
|
|
2233P0 |
|
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|
X |
|
X |
1/2 - 2 |
1 - 5 |
2233P1 |
X |
|
|
X |
X |
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2233BP0 |
|
X |
|
X |
|
X |
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2233BP1 |
X |
X |
|
X |
X |
|
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|
a.Units are reconnectable
b.No armature contactor
c.Includes armature contactor
2
BOOK 0960-B
SECTION II
INSTALLATION
Before starting the installation, read this section thoroughly. In addition, a thorough review of the Ratings and Specifications (Section VI) is recommended. The following installation guidelines should be kept in mind when installing the controller.
INSTALLATION GUIDELINES
1. CONTROLLER MOUNTING - The controller may be mounted either vertically or horizontally. However, never mount the controller upside down, immediately beside or above heat generating equipment, or directly below water or steam pipes.
The controller must be mounted in a location free of vibration.
Multiple controllers may be mounted side by side, as close to each other as the mounting feet will allow.
The minimum clearance at the top and bottom of the controller may be as narrow as the conduit fittings allow.
2. ATMOSPHERE - The atmosphere surrounding the controller must be free of combustible vapors, chemical fumes, oil vapor, and electrically conductive or corrosive materials.
The air surrounding an enclosed controller must not exceed 40 degrees C (104 degrees F), and the air surrounding an open-chassis controller must not exceed 55 degrees C (131 degrees F). Minimum air temperature is 0 degree C (32 degrees F) for enclosed and open-chassis controllers.
3. CONTROLLER CONSTRUCTION - Enclosed controllers are totally enclosed, non-ventilated, and comply with NEMA Type 4 and 12 standards. There is an oil resistant synthetic rubber gasket between the cover and base. Those models with integral operator controls include flexible boots to seal the switches, and a seal for the MOTOR SPEED potentiometer.
Model 2235MKII and 2236MKII controllers are unenclosed open-chassis units with the printed wiring board mounted on an aluminum bracket.
The small controller base is made of die-cast aluminum with a powdered epoxy finish, and the cover is made of a diecast aluminum alloy. The larger controller base is made of extruded aluminum and the cover is made of Noryl®, a strong engineering plastic with outstanding mechanical, thermal, and electrical properties.
4. LINE SUPPLY - The controller should not be connected to a line supply capable of supplying more than 5,000 amperes short-circuit current. Short-circuit current can be limited by using an input supply transformer of 50 KVA or less, or by using correctly sized current limiting fuses in the supply line ahead of the controller. Do not use a transformer with less than the minimum transformer KVA listed in Table 8, page 29.
If rated line voltage is not available, a line transformer will be required. If the line supply comes directly from a transformer, place a circuit breaker or disconnect switch between the transformer secondary and the controller. If power is switched in the transformer primary, transients may be generated which can damage the controller. See Table 8 (page 29) for minimum transformer KVA.
Do not use power factor correction capacitors on the supply line to the controller.
A 20 Joule metal oxide varistor (MOV) is connected across the controller terminals. If higher energy transients are present on the line supply, additional transient suppression will be required to limit transients to 150% of peak line voltage.
3
BOOK 0960-B
When a 115 VAC line supply is used, connect the white (common) wire to Terminal L2 and connect the remaining (hot) wire to Terminal L1.
5. ISOLATION TRANSFORMER - While not required, an isolation transformer can provide the following advantages:
a.Reduce the risk of personal injury if high voltage drive circuits are accidentally touched.
b.Provide a barrier to externally generated AC supply transients. This can prevent controller damage from abnormal line occurrences.
c.Reduce the potential for damaging current if the motor armature, motor field, or motor wiring becomes grounded.
6. GROUNDING - Connect the green or bare (ground) wire of the line supply to the ground screw located near the top conduit entry hole in the controller base. Then ground the controller base by connecting the ground screw to earth ground.
The motor frame and operator control stations must also be grounded.
Personal injury may occur if the controller, motor, and operator stations are not properly grounded.
7. WIRING PRACTICES - The power wiring must be sized to comply with the National Electrical Code, CSA, or local codes. Refer to the controller data label for line and motor current ratings.
Do not use solid wire.
Signal wiring refers to wiring for potentiometers, tachometer generators, and transducers. Control wiring refers to wiring for operator controls, e.g., switches and pushbuttons. Signal and control wiring may be run in a common conduit, but not in the same conduit as the power wiring. In an enclosure, signal and control wiring must be kept separated from power wiring and only cross at a 90 degree angle to reduce electrical noise.
If shielded wire (such as Alpha 2422 - two conductor, 2423 - three conductor, 2424 - four conductor) is used for the signal and control wiring, connect the shields to chassis ground (ground screw on the controller base) and tape the opposite ends of the shields. Twisted cable is also suitable for signal and control wiring.
The small base models provide two 3/4-14 NPT threaded holes for conduit entry, one each in the top and bottom of the controller.
The large base models provide two 3/4 inch conduit entry for the power in and out wiring, and one 1/2 inch conduit entry for signal wiring.
4
BOOK 0960-B
INSTALLING THE CONTROLLER
1.Remove the controller front cover (if used) by removing the four cover screws.
2.Check components in the controller for shipping damage. Report shipping damage to the carrier.
3.Check the controller and motor data labels to be sure the units are electrically compatible.
4.Be sure the controller has been calibrated correctly for the motor being used. The initial calibration is performed by changing the position of a Jumper J4 on the controller control board to comply with Table 2. To change the position of Jumper J4, pull the jumper from the control board and then push it onto the appropriate two pins on the board. Select the position closest, but not less then, the motor nameplate armature current rating. The final calibration can be fined tuned, if needed, by the current limit potentiometer. For the location of J4 and the current limit potentiometer, see Figure 20 (page 35).
TABLE 2. JUMPER J4 POSITION
JUMPER |
MOTOR ARMATURE CURRENT RATING (AMPERES) |
||
|
|
|
|
POSITIONa |
2231 - 2235 |
2232 - 2236 |
2233 |
|
2 HP Maximum |
3 HP Maximum |
5 HP Maximum |
|
|
|
25 |
100% |
10 |
15 |
|
80% |
8 |
12 |
20 |
60% |
6 |
9 |
15 |
40% |
4 |
6 |
10 |
20% |
2 |
3 |
5 |
5. Check the positions of Jumpers J1, J2, and J3 on the control board. For the locations of J1, J2, and J3, see Figure 20, page 35. For a 230 VAC line supply and a 180V armature motor, Jumper J1 must be in the 230V position, and Jumpers J2 and J3 must be in the 180V position. For a 115 VAC line supply and a 90V armature motor, J1 must be in the 115V position, and J2 and J3 must be in the 90V position. To change the position of J1, J2, or J3 pull the jumper from the control board and then push it onto the appropriate pins on the board.
NOTE: If Option 1001 (Armature Contactor), or 1775 (Signal Interface) is to be installed in the controller, do not offset the five-position plug (supplied with the option) at Connector J1 on the control board. Do not confuse Connector J1 with Jumper J1. Refer to the Instruction Sheet (ISP0703, ISP0653, respectively) supplied with the option for connection instructions.
6.If the controller is to operate from a 50 Hz supply, set segment 6 of the DIP Switch (SW3) to the “OFF” position on the controller control board. For the location of DIP Switch SW3, see Figure 20, page 35.
7.The controller may be surface mounted or panel mounted as shown in Figure 1, page 7. Mount the controller. Mounting dimensions are shown in Figure 2, page 8.
8.Conduit entry is made by punching out the knockout at the top or bottom of the controller base. To prevent component damage from knockout fragments, apply masking tape to the inside of the knockout before punching.
9.Connect the power wiring to Terminals L1, L2, A1, A2, F+ and F-. Be sure to observe Installation Guidelines 4 and
7on pages 3 and 4. If half-wave shunt field voltage is desired, connect one of the motor shunt field leads to Terminal L1 (see Table 12 on page 32).
Note: Low inductance motors require a full-wave field to prevent current instability.
5
BOOK 0960-B
10.If the controller contains any options that require external wiring, follow the wiring instructions in the instruction sheet supplied with the option.
11.If remote operator control wiring and/or signal wiring is required, connect the controller as shown in the appropriate connection diagram (Figures 3 through 18). Figures 3 through 9 show operator control connections, and Figures 10 through 18 show signal connections.
12.The controller can be programmed for various applications by throwing switches on dip switch SW3
TABLE 3. DIP SWITCH (SW3)
Switch Position
ON
1
OFF
ON
2
OFF
ON
3
OFF
4
ON
OFF
5
ON
OFF
6
ON
OFF
7
ON
OFF
FACTORY DEFAULT SETTING IS UNDERLINED
Selects anti-restart mode. Prevents controller from restarting automatically after an AC line power interruption.
Disables anti-restart mode. Used for line starting applications (jumper TB2:9 to TB2:8 to enable drive).
Selects internal Forward current (torque) reference pot.
Selects use of an external Forward current (torque) reference pot. (Set internal Forward current limit pot at 100%)
Adds ≈2% zero speed reference deadband to prevent motor creeping.
No zero speed deadband; enabled drive may creep with zero speed reference
Selects torque regulator mode.
Selects speed regulator mode.
Low voltage (3Vdc - 30Vdc) tachometer scaling
High voltage (31 Vdc - 175Vdc) tachometer scaling.
Selects 60Hz line input frequency.
Selects 50Hz line input frequency.
Selects internal Reverse current (torque) reference pot.
Selects use of an external Reverse current (torque) reference pot. (Set internal Reverse current limit pot at 100%)
13. Install the controller cover, if used.
6
BOOK 0960-B
FIGURE 1. CONTROLLER MOUNTING CONFIGURATIONS
BR1 - FWD
|
G3 |
G1 |
G4 |
|
G2 |
|
G3 |
G1 |
G4 |
G2
BR2 - REV
2233 DRIVE
FIGURE 2. CONTROLLER MOUNTING DIMENSIONS
7
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