LEESON Chassis Mount Regenerative User Manual
Models:
175720.00
175721.00
SCR, Dual Voltage, Adjustable-Speed Regenerative
Drives
for DC Brush Motors
User’s Manual
Copyright 2003 by
Leeson Electric
All rights reserved. No part of this manual may be reproduced or transmitted in
any form without written permission from Leeson Electric. The information and
technical data in this manual are subject to change without notice. Leeson
Electric and its Divisions make no warranty of any kind with respect to this
material, including, but not limited to, the implied warranties of its merchantability
and fitness for a given purpose. Leeson Electric and its Divisions assume no
responsibility for any errors that may appear in this manual and make no
commitment to update or to keep current the information in this manual. mvd082103
Printed in the United States of America.
i
Safety Warnings
• Throughout this manual, this symbol denotes an
important safety message. Please read these messages
carefully before performing any instructions contained
herein.
• Have a qualified electrical maintenance technician install,
adjust and service this equipment. Follow the National
Electrical Code and all other applicable electrical and safety
codes, including the provisions of the Occupational Safety
and Health Act (OSHA), when installing equipment.
• Reduce the chance of an electrical fire, shock, or explosion
by proper grounding, over-current protection, thermal
protection and enclosure. Follow sound maintenance
procedures.
• It is possible for a drive to run at full speed as a result
of a component failure. To stop the drive in an
emergency, please ensure that a master switch has been
placed in the AC line.
• This drive is not isolated from earth ground. Circuit
potentials are at 115 VAC or 230 VAC above earth ground.
Avoid direct contact with the printed circuit board or with
circuit elements to prevent the risk of serious injury or
fatality. Use a non-metallic screwdriver for adjusting the
calibration trimpots.
SHOCKAVOID
OID
ON
TI
ii
Contents
Specifications 1
Dimensions 2
Regenerative Drives 4
Installation 6
Mounting chassis drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Mounting cased drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Heat sinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
AC line and motor connections . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Cage-clamp terminal block . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Field output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Tachogenerator feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Speed adjust potentiometer installation . . . . . . . . . . . . . . . . . . . .12
Speed adjust potentiometer connections . . . . . . . . . . . . . . . . . . .13
+15 and –15 terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Line Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Factory Prewired Connections 16
Operation 18
Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Check selector switch settings . . . . . . . . . . . . . . . . . . . . . . . . . .18
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Block Diagram 22
Starting and Stopping Methods 24
Line Starting and Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Automatic restart upon power restoration . . . . . . . . . . . . . . . . . .24
Regenerative deceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Regenerative brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Coast to a stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Decelerate to minimum speed . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Contents
Calibration 29
Minimum Speed (MIN SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Maximum Speed (MAX SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Forward Torque (FWD TQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Reverse Torque (REV TQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Regulation (IR COMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Forward Acceleration (FWD ACC) . . . . . . . . . . . . . . . . . . . . . . . .33
Reverse Acceleration (REV ACC) . . . . . . . . . . . . . . . . . . . . . . . .34
Deadband (DB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Tach Generator (TACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Application Notes 37
Forward-Reverse Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Forward-Stop-Reverse Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Independent Adjustable Speeds . . . . . . . . . . . . . . . . . . . . . . . . .39
Independent Forward and Reverse Speeds . . . . . . . . . . . . . . . .40
Independent Forward and Reverse Speeds
with FWD-STOP-REV Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Voltage follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Troubleshooting 43
Check the following steps before proceeding . . . . . . . . . . . . . . .43
Line fuse blows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Line fuse does not blow, but the motor does not run . . . . . . . . .45
Motor pulsates or surges under load . . . . . . . . . . . . . . . . . . . . . .46
Motor runs too fast at the maximum speed setting . . . . . . . . . . .46
Motor will not reach the desired speed . . . . . . . . . . . . . . . . . . . .46
Limited Warranty inside back cover
iii
Illustrations
Figure 1. 175721.00 (Chassis) Dimensions . . . . . . . . . . . . . . . . . . .2
Figure 2. 175720.00 (Cased Drive) Dimensions . . . . . . . . . . . . . . .3
Figure 3. Four Quadrant Operation . . . . . . . . . . . . . . . . . . . . . . . . .5
Figure 4. Chassis Drive Connections . . . . . . . . . . . . . . . . . . . . . . . .8
Figure 5. Cased Drive Connections . . . . . . . . . . . . . . . . . . . . . . . . .9
Figure 6. Cage-Clamp Terminal Block . . . . . . . . . . . . . . . . . . . . . .10
Figure 7. Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . . .12
Figure 8. Speed Adjust Potentiometer Connections for Unidirectional
Operation (a) and Bidirectional Operation (b) . . . . . . . . .13
Figure 9. TB502 Terminal Assignments . . . . . . . . . . . . . . . . . . . . .14
Figure 10. Prewired Connections to L1, L2 (with 115 VAC input) and
L2 (with 230 VAC input) . . . . . . . . . . . . . . . . . . . . . . . .16
Figure 11. Prewired Speed Adjust Potentiometer Connections . . .17
Figure 12. Selector Switch Locations . . . . . . . . . . . . . . . . . . . . . . .19
Figure 13. Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Figure 14. Regenerative Deceleration Switch Connection . . . . . .24
Figure 15. Inhibit Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Figure 16. Inhibit-Run Terminals . . . . . . . . . . . . . . . . . . . . . . . . . .26
Figure 17. Run / Decelerate to Minimum Speed Switch
(shown with bidirectional connection) . . . . . . . . . . . . . .27
Figure 18. Calibration Trimpot Layout . . . . . . . . . . . . . . . . . . . . . .29
Figure 19. Typical FWD TQ, REV TQ, IR COMP and Deadband
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Figure 20. Forward-Reverse Switch . . . . . . . . . . . . . . . . . . . . . . . .37
Figure 21. Forward-Stop-Reverse Switch . . . . . . . . . . . . . . . . . . .38
Figure 22. Independent Adjustable Speeds
(Forward Direction) . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Figure 23. Independent Forward and Reverse Speeds . . . . . . . . .40
Figure 24. Independent Forward and Reverse Speeds with a
Forward-Stop-Reverse Switch . . . . . . . . . . . . . . . . . . .41
Figure 25. Voltage Follower Connection . . . . . . . . . . . . . . . . . . . .42
iv
1
Specifications
Max.
Armature HP Range HP Range
Current with 115 VAC with 230 VAC
Model (Amps DC) Applied Applied
175720.0
0 10.0 † 1/4 – 1 † 1/2 – 2 †
175721.0
0 10.0 † 1/4 – 1 † 1/2 – 2 †
† Maximum armature current and horsepower range apply when drive is attached to
additional heat sink part number 175722. Use heat sink when armature current is
above
7 ADC. Heat sinks are pre-mounted on cased drives.
AC Line Voltage 115/230 VAC, ±10%, 50/60 Hz, single phase
Armature Voltage (115 VAC Input) 0 – 90 VDC
Armature Voltage (230 VAC Input) 0 – 180 VDC
Form Factor 1.37 at base speed
Field Voltage (115 VAC Input) 50 VDC (F1 to L1); 100 VDC (F1 to F2)
Field Voltage (230 VAC Input) 100 VDC (F1 to L1); 200 VDC (F1 to F2)
Max. Field Current 1 ADC
Accel. Time Range (with no load) 0.5 –10 seconds
Decel. Time Range (with no load) 0.5 –10 seconds
Analog Input Voltage Range (isolated; RB1 to S2) 0 –10 VDC
Input Impedance (S0 to S2) 32K ohms
Load
Regulation
with
Armature Feedback 1% of base speed or better
with Tachogenerator Feedback 0.1% of base speed
Ambient Temp. Range (chassis drive) 10°C – 55°C
Ambient Temp. Range (cased drive) 10°C – 40°C
2
Dimensions
Figure 1. 175721.00 (Chassis) Dimensions
8.90 [226]
8.38 [213]
1.86 [47]
0.92 [23]
3.53 [90]
4.75 [120]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
3
Dimensions
Figure 2. 175720.00 (Cased Drive) Dimensions
6.90 [175]
6.30 [160]
SPEED
BRAKE
6.3 [160] x 7.0 [178]
ON CENTERS
1.45 [37]
1.50 [38]
5.50 [140]
10.20 [259]
4.78 [121]
9.80 [249]
2.30 [58]
POWER
REVERSE FORWARD
FOUR (4) EACH MOUNTING SLOTS,
1.50 [38]
THREE 0.88 [22] KNOCKOUTS
ALL DIMENSIONS IN INCHES [MILLIMETERS]
0.12 [3]
4
Regenerative Drives
Most non-regenerative, variable speed, DC drives control
current flow to a motor in one direction. The direction of current
flow is the same direction as the motor rotation.
Non-regenerative drives operate in Quadrant 1, and also in
Quadrant 3 if the drive is reversible (see Figure 3). Motors
must stop before reversing direction. Unless dynamic braking is
used, non-regenerative drives cannot oppose an overhauling
load, and cannot decelerate a load faster than coasting to a
lower speed.
Regenerative drives operate in two additional quadrants:
Quadrant 2 and Quadrant 4. In these quadrants, motor torque
is in the opposite direction of motor rotation.
Regenerative drives can reverse a motor without contactors,
switches, brake resistors, and inhibit plugs. They can also
control an overhauling load and decelerate a load faster than it
would take to coast to a lower speed.
5
Regenerative Drives
ON
OR
E
ON
OR
I
I
V
I
Figure 3. Four Quadrant Operation
uadrant I
uadrant II
T
TATI
ARROWS IN OPPOSITE DIRECTION = REGENERATIVE ACTI
uadrant
uadrant I
MOT
TORQU
Installation
Mounting chassis drives
Drive components are sensitive to electrostatic fields. Avoid
direct contact with the circuit board. Hold the drive by the
chassis only.
Protect the drive from dirt, moisture, and accidental contact.
Provide sufficient room for access to the terminal block and
calibration trimpots.
Mount the drive away from heat sources. Operate the drive
within the specified ambient operating temperature range.
Prevent loose connections by avoiding excessive vibration of
the drive.
Mount the drive with its board in either a horizontal or
vertical plane. Six 0.188 inch (4.8 mm) wide slots in the chassis
accept #8 pan head screws. Fasten either the large
base or the narrow flange of the chassis to the subplate.
The chassis must be earth grounded for noise suppression. To
ground the chassis, connect earth ground to the GND terminal
on terminal block TB501.
6
Warning
Do not install, rewire, or remove this control with power
applied. Doing so may cause fire or serious injury. Read
and understand the Safety Warnings on pg i before
attempting installation.
Mounting cased drives
Leeson cased drives come with three 0.88-inch (22 mm)
conduit knockout holes on the bottom of the case. The units
may be vertically wall mounted using the four 0.25-inch (6 mm)
slotted holes on the attached heat sink. For motor loads less
than 5 ADC, the drive may be bench mounted horizontally, or
operated without mounting.
1. Install the mounting screws.
2. For access to the terminal strip, turn the slotted screw on
the front cover counterclockwise until it is free from the
case. The right side of the cover is hinged to the case. Lift
or pull the slotted screw to open the case.
3. Carefully remove the conduit knockouts by tapping them
into the case and twisting them off with pliers.
4. Install conduit hardware through the 0.88 inch (22 mm)
conduit holes. Connect external wiring to the terminal block.
5. Grasp the slotted screw and tilt the front cover back into
place. Avoid pinching any wires between the front cover and
the case.
6. Turn the slotted screw clockwise until tight to secure the
front cover.
7. Set the POWER switch to the “O” or OFF position before
applying the AC line voltage.
7
Installation
8
Installation
Heat sinking
Model 175721.00 requires an additional heat sink, p/n 175722,
when the continuous armature current is above 7 ADC. Model
175720.00 has sufficient heat sinking in its basic configuration.
Use a thermally conductive heat sink compound (such as Dow
Corning
®
340 Heat Sink compound) between the drive chassis
and the heat sink surface for optimum heat transfer.
AC line and motor connections
Use 12 AWG or 14 AWG standard wire for connecting the
line and the armature. Use 16 AWG or 18 AWG standard wire
when connecting the field of a shunt-wound motor. Strip the
wire insulation 0.25 inches (6 mm). See Figures 4 and 5 for
AC line (115 VAC or 230 VAC) and motor connections to
chassis and cased drives.
Figure 4. Chassis Drive Connections
A
IC502
SW501
C504
L2
L2
L1 GND F1 F2 A2 A1
115V
230V
230 VAC
C INPUT
VOLTAGE
115 VAC
FIELD OUTPUT
For shunt wound
motors only. See field
output section for details.
C503
TB501
MOTOR
TB502
C505
S3 S2
9
Installation
Figure 5. Cased Drive Connections
230
VAC
115
VAC
AC LINE INPUT
SO502
INH-RUN
123
FLD
230
115 230
SW501
L2
L2
115V
230V
FU501 FU502 FU503
FAST ACTING
FUSES ONLY
L1 L2
C504
L1 GND F1 F2 A2 A1
FIELD OUTPUT
For shunt wound
motors only. See field
output section for details.
C502
C503
TB501
SO501
MOTOR
IC501
IC502
INHIBIT
TB502
C505
S3 S2 S1 S0 RB1 RB2 -15 +15 T1 T2
10
Installation
Cage-clamp terminal block
Connections to drives are made to a cage-clamp terminal block
(Figure 6). To insert a wire into the terminal block, press down
on the lever arm using a small screwdriver. Insert stripped wire
into the large opening in front of the terminal block. Release
the lever arm to clamp the wire.
Figure 6. Cage-Clamp Terminal Block
Press down on the
lever arm using
a small screwdriver.
1
Insert wire into the
2
wire clamp.
Release the lever arm
3
to clamp the wire.
11
Field output
The field output is for shunt wound motors only. Do not
make any connections to F1 and F2 when using a
permanent magnet motor.
Use 18 AWG wire to connect the field output to a shunt wound
motor. Table 1 lists the field output connections.
Table 1. Field Output Connections
Line Voltage Approximate Connect Motor
(VAC) Field Voltage (VDC) Field To
115 50 F1 and L1
115 100 F1 and F2
230 100 F1 and L1
230 200 F1 and F2
Tachogenerator feedback
Using tachogenerator feedback improves speed regulation from
approximately 1% of motor base speed to approximately 0.1%
of motor base speed. Use tachogenerators rated from 7 VDC
per 1000 RPM to 50 VDC per 1000 RPM. Connect the
tachogenerator to terminals T1 and T2 of terminal block TB502.
The polarity is positive (+) for T1 and negative (–) for T2 when
the motor is running in the forward direction. The polarity is
reversed when the motor is running in the reverse direction.
Installation
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