Page 1
Models:
175720.00
175721.00
SCR, Dual Voltage, Adjustable-Speed Regenerative
Drives
for DC Brush Motors
User’s Manual
Page 2
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.
Page 3
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
Page 4
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
Page 5
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
Page 6
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
Page 7
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
Page 8
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]
Page 9
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]
Page 10
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.
Page 11
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
Page 12
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.
Page 13
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
Page 14
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
Page 15
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
Page 16
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.
Page 17
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
Page 18
12
Installation
Speed adjust potentiometer installation
On chassis drives, install the circular insulating disk between
the panel and the 10KΩ speed adjust potentiometer. Mount the
speed adjust potentiometer through a 0.38 in. (0.96 cm) hole
with the hardware provided (see Figure 7). Twist the speed
adjust potentiometer wire to avoid picking up unwanted
electrical noise. If the potentiometer leads are longer than 18
in. (46 cm), use shielded cable. Speed adjust potentiometers
are installed on all cased drives.
Figure 7. Speed Adjust Potentiometer
Warning
Be sure that the potentiometer tabs do not make contact
with the potentiometer enclosure. Grounding the input will
cause damage to the drive.
C
S
JUST
R
SK
STAR
R
UT
E
UNT THROUGH A 0.38 IN. (10 MM) HOL
W
N
WASHE
INSULATING DI
PEED AD
POTENTIOMETE
Page 19
13
Installation
Speed adjust potentiometer connections
The motor can operate in one direction (unidirectional) or in two
directions (bidirectional) depending on how the speed adjust
potentiometer is connected to the drive.
Connect the speed adjust potentiometer as shown in Figure
8(a) for speed control in one direction.
Connect the speed adjust potentiometer as shown in Figure
8(b) for speed control in two directions. The motor does not
rotate when the wiper is in the center position. Turning the
wiper CW from the center position causes the motor to rotate in
one direction, while turning the wiper CCW from the center
position causes the motor to rotate in the opposite direction.
Refer to the Application Notes section (page 37) for additional
speed adjust potentiometer connections.
Figure 8. Speed Adjust Potentiometer Connections for
Unidirectional Operation (a) and Bidirectional Operation (b)
(a)
(b)
CW
S0
S1
S2
TB502
FWD
CW
S1
S2
S3
10K
S3
REV
10K
TB502
Page 20
14
Installation
Figure 9. TB502 Terminal Assignments
+15 and –15 terminals
17572x Series drives can supply a regulated +15 and –15 VDC
signal (each sourcing 25 mA maximum) to isolated, external
devices. These voltage supply terminals are located on
terminal block TB502.
Warning
Do not short the +15 and - 15 terminals for any reason!
Shorting these terminals will damage the drive.
TB502
S3
S2 S1 S0 RB1 RB2 -15 +15 T1 T2
Page 21
15
Installation
Line Fusing
Leeson drives require fuses for protection. Use fast acting fuses
rated for 250 VAC or higher, and approximately 150% of the
maximum armature current. Fuse both L1 and L2 when the line
voltage is 230 VAC.
The fuse table below lists the recommended line fuse sizes.
Fuse Table
90 VDC Motor 180 VDC Max. DC Armature AC Line Fuse
Horsepower Horsepower Current (amps) Size (amps)
1/20 1/10 0.5 3
1/15 1/8 0.8 3
1/8 1/4 1.5 5
1/6 1/3 1.7 5
1/4 1/2 2.5 8
1/3 3/4 3.5 8
1/2 1 5.0 10
3/4 1 1/2 7.5 15
1 2 10 20
Page 22
16
Factory Prewired Connections
(for Cased Drives)
Figure 10. Prewired Connections to L1, L2 (with 115 VAC input)
and L2 (with 230 VAC input)
12 3
WHITE/BLACK
BLACK
WHITE/BLACK
BLACK
BLACK
WHITE/BLACK
POWER
LIGHT
BLACK/WHITE
L2 (230)
L1
L2 (115)
Page 23
Factory Prewired Connections
17
Figure 11. Prewired Speed Adjust Potentiometer Connections
BRAKE
FWD
REV
BLUE/
WHITE
CW
S0
S1
GREY
GREY/WHITE
BROWN
S2
PURPLE
S3
TB502
10K
Page 24
Check selector switch settings
1. Set both line voltage selector switches (SW501 and SW502)
to 115 if using 115 VAC line voltage, or to 230 if using 230
VAC line voltage.
2. Set the armature voltage selector switch (SW503) to 90 if
using a 90 VDC motor, or to 180 if using a 180 VDC motor.
3. Set the feedback selector switch (SW504) to TACH if using
a tachogenerator; otherwise, set it to ARM for armature
feedback.
Note: You may be required to derate a 90 VDC motor when
230 VAC is applied to the drive. Contact Leeson for details.
See Figure 12 on page 19 for switch locations.
18
Before applying power
1. Check connections before applying AC line voltage to the drive.
2. Check that no conductive material is present on the printed
circuit board.
3. Verify that all selector switches are set correctly (see the
following section for selector switch settings).
Operation
Page 25
19
Operation
Figure 12. Selector Switch Locations
VO LTAGE
SELECT SWITCHES
ARMATURE
SELECT SWITCH
FEEDBACK SELECT
SWITCH
Page 26
20
Operation
Startup
Chassis drives
Uni-directional Operation
1. Set the speed adjust potentiometer to minimum (full
CCW).
2. Apply AC line voltage.
3. Slowly turn the speed adjust potentiometer clockwise
(CW). The motor will accelerate as the potentiometer is
turned CW. Continue until the desired speed is
reached.
4. Remove AC line voltage from the drive to coast the
motor to a stop.
Bi-directional Operation
1. Set the speed adjust potentionmeter to minimum
(center position).
2. Apply AC line voltage.
3. Slowly turn the speed adjust potentiometer either
clockwise for forward direction, or counterclockwise for
reverse direction. The motor will accelerate as the
potentiometer is turned. Continue until the desired
speed is reached.
4. Remove AC line voltage from the drive to coast the
motor to a stop.
Page 27
21
Operation
Cased drives
1. Set the FORWARD / BRAKE / REVERSE switch to BRAKE.
2. Set the speed adjust potentiometer to minimum (full CCW).
3. Apply AC line voltage.
4. Set the POWER switch to the “ I ” (ON) position.
5. Set the FORWARD / BRAKE / REVERSE switch to the
desired direction of rotation.
7. Slowly advance the speed adjust potentiometer clockwise
(CW). The motor will accelerate as the potentiometer is
turned CW. Continue until the desired speed is reached.
8. To brake the motor, set the FORWARD / BRAKE /
REVERSE switch to the BRAKE position. To coast the
motor to a stop, set the POWER switch to the “ 0 ” (OFF)
position.
9. To reverse direction:
a. Set the FORWARD / BRAKE / REVERSE switch to
BRAKE.
b. After the motor comes to a complete stop, set the
FORWARD / BRAKE / REVERSE switch to the desired
direction of rotation.
10. Set the POWER switch to “ 0 ” (OFF) to remove power
from the drive.
Page 28
22
Block Diagram
Figure 13. Block Diagram
Page 29
23
Block Diagram
Page 30
24
Regenerative deceleration
Short terminals RB1 and RB2 to
regeneratively decelerate a motor
to a stop (Figure 14). Since
terminal RB1 bypasses the MIN
SPD circuit, shorting RB1 and
RB2 will decelerate a motor to a
stop instead of minimum speed.
Calibrate the deceleration time by
adjusting the opposite-direction
acceleration trimpot.
Figure 14. Regenerative
Deceleration Switch
Connection
Automatic restart upon power restoration
All drives automatically run to set speed when power is
applied. Wiring a latching relay into the AC line is one way to
prevent automatic restarting following a power outage.
Line Starting and Stopping
Line starting and stopping (applying and removing AC line
voltage) is recommended only for infrequent starting and
stopping of a drive. When AC power is applied to the
drive, the motor accelerates to the speed set by the speed
adjust potentiometer. When power is removed, the motor
coasts to a stop.
Starting and Stopping Methods
RB1
STOP
RB2
RUN
Page 31
25
Starting and Stopping Methods
Regenerative brake
Short the INHIBIT terminals to regeneratively brake the motor
(see Figure 15 for INHIBIT terminal location). Reopening the
INHIBIT terminals causes the motor to run at set speed.
The INHIBIT terminals bypass both the MIN SPD circuit and
the deceleration circuit. This causes the motor to stop rapidly
when the INHIBIT terminals are shorted. Braking torque is
determined by the opposite-direction torque setting.
Figure 15. Inhibit Terminals
INHIBIT
TERMINALS
Page 32
Starting and Stopping Methods
26
Twist inhibit wires and separate them from other power-carrying
wires or sources of electrical noise. Use shielded cable if the
inhibit wires are longer than 18 in. (46 cm). If shielded cable is
used, ground only one end of the shield to earth ground. Do
not ground both ends of the shield.
Coast to a stop
To coast the motor to a stop without removing power to the
drive, jumper INHIBIT–RUN terminals 1 and 2 (see Figure 16).
To restart the motor, jumper INHIBIT–RUN terminals 2 and 3. A
single-pole, double-throw switch may be used as a COAST /
RUN switch.
Each drive is assembled with INHIBIT-RUN terminals 2 and
3 jumpered. These terminals must be connected for the
motor to run.
Figure 16. Inhibit-Run Terminals
INHIBIT/RUN
TERMINALS
Page 33
Figure 17. Run / Decelerate to Minimum Speed Switch
(shown with bidirectional connection)
Decelerate to minimum speed
The circuit shown in Figure 17 may be used to decelerate a
motor to a minimum speed. Closing the switch between S2 and
S0 decelerates the motor from set speed to a minimum speed
determined by the MIN SPD trimpot setting. If the MIN SPD
trimpot is set full CCW, the motor decelerates to zero speed
when the switch between S2 and S0 is closed. The DECEL
trimpot setting determines the rate at which the drive
decelerates. Set the switch to the RUN position to accelerate
the motor to set speed at a rate determined by the ACCEL
trimpot setting.
27
Starting and Stopping Methods
REV
10K
S3
RUN
S2
DECEL TO
FWD
MIN SPD
CW
S1
S0
TB502
Page 34
28
Starting and Stopping Methods
Certain Leeson drives (regenerative and non-regenerative)
coast to minimum speed when the inhibit terminals are shorted
to each other. IR COMP and CURRENT LIMIT (FWD TQ and
REV TQ on regnerative drives) are still active while the drive is
in the inhibit mode.
Frequent regenerative deceleration, regenerative braking,
coasting to a stop, or decelerating to minimum speed produces
high torque. This may cause damage to motors, especially
gearmotors that are not properly sized for the application.
Warning
For frequent starts and stops, use regenerative
deceleration (shorting RB1 and RB2), regenerative
breaking (shorting INHIBIT terminals to each other),
coasting to a stop (shorting INHIBIT-RUN terminals 1 and
2), or decelerating to minimum speed (shorting S2 to S0).
Do not use any of these methods for emergency stopping.
They may not stop a drive that is malfunctioning.
Removing AC line power (both L1 and L2) is the only
acceptable method for emergency stopping.
Page 35
Calibration
Each drive is factory calibrated to its maximum current rating.
Readjust the calibration trimpot settings to accommodate lower
current rated motors.
All adjustments increase with CW rotation, and decrease with
CCW rotation. Use a non-metallic screwdriver for calibration.
Each trimpot is identified on the printed circuit board.
Figure 18. Calibration Trimpot Layout
29
P501
P502
P503
P504
P505
P506
P507
P508DBP509
MIN SPD
FWD TQ
REV TQ
IR COMP
MAX SPD
FWD ACC
REV ACC
TAC H
Page 36
Calibration
30
Minimum Speed (MIN SPD)
The MIN SPD setting determines the minimum speed when the
speed adjust potentiometer is turned full CCW. It is factory set
to zero speed. The minimum speed feature applies only
when the drive is operating in unidirectional mode.
To calibrate, set the speed adjust potentiometer full CCW.
Adjust the MIN SPD trimpot until the motor turns at the desired
minimum speed.
Maximum Speed (MAX SPD)
The MAX SPD setting determines the maximum motor speed
when the speed adjust potentiometer is turned full CW. It is
factory set for maximum rated motor voltage.
To calibrate, set the speed adjust potentiometer full CW. Adjust
the MAX SPD trimpot until the motor turns at the desired
maximum speed.
Page 37
Forward Torque (FWD TQ)
The FWD TQ setting determines the maximum torque for
accelerating and driving the motor in the forward direction. It
also sets the maximum torque for decelerating the motor in the
reverse direction. Refer to the recommended FWD TQ settings
in Figure 19 on Page 36, or recalibrate using the following
procedure:
1. With the power disconnected from the drive, connect a DC
ammeter in series with the armature.
2. Set the FWD TQ trimpot to minimum (full CCW).
3. Set the speed adjust potentiometer for maximum forward speed.
4. Carefully lock the motor armature. Be sure that the motor is
firmly mounted.
5. Apply line power. The motor should be stopped.
6. Slowly adjust the FWD TQ trimpot CW until the armature
current is 120% of the motor nameplate current rating.
7. Turn the speed adjust potentiometer CCW until the motor stops.
8. Remove line power.
9. Remove the stall from the motor.
10. Remove the ammeter in series with the motor armature if it
is no longer needed.
Warning
FWD TQ should be set to 120% of the motor nameplate
current rating. Continuous operation beyond this rating may
damage the motor. The decision to change the forward
torque setting must be made after considering the gearbox
and drivetrain ratings, duty cycle, and motor characteristics.
31
Calibration
Page 38
Calibration
32
Reverse Torque (REV TQ)
The REV TQ setting determines the maximum torque for
accelerating and driving the motor in the reverse direction. It
also sets the maximum torque for decelerating in the forward
direction. Refer to the recommended REV TQ settings in
Figure 19 on Page 36, or recalibrate using the following
procedure:
1. With the power disconnected from the drive, connect a DC
ammeter in series with the armature.
2. Set the REV TQ trimpot to minimum (full CCW).
3. Set the speed adjust potentiometer for maximum reverse speed.
4. Carefully lock the motor armature. Be sure that the motor is
firmly mounted.
5. Apply line power. The motor should be stopped.
6. Slowly adjust the REV TQ trimpot CW until the armature
current is 120% of the motor nameplate current rating.
7. Turn the speed adjust potentiometer CCW until the motor stops.
8. Remove line power.
9. Remove the stall from the motor.
10. Remove the ammeter in series with the motor if it is no
longer needed.
Warning
REV TQ should be set to 120% of the motor nameplate
current rating. Continuous operation beyond this rating may
damage the motor. The decision to change the reverse
torque setting must be made after considering the gearbox
and drivetrain ratings, duty cycle, and motor characteristics.
Page 39
Regulation (IR COMP)
The IR COMP setting determines the degree to which motor
speed is held constant as the motor load changes. It is factory
set for optimum motor regulation. Recalibrate the IR COMP
setting when using a lower horsepower motor. See Figure 19
on page 36 for typical IR COMP settings, or recalibrate using
the following procedure:
1. Set the IR COMP trimmer pot to minimum (full CCW).
2. Set the speed adjust potentiometer to run at mid-speed
without load (for example, 900RPM for an 1800 RPM
motor). A hand held tachometer may be used to measure
motor speed.
3. Load the motor to the nameplate current rating (full load).
The motor should slow down.
4. While keeping the load on the motor, adjust the IR COMP
trimmer pot CW until the motor runs at the speed measured
in step 2.
5. Unload the motor.
Forward Acceleration (FWD ACC)
The FWD ACC setting determines the time the motor takes to
ramp to either a higher speed in the forward direction or a
lower speed in the reverse direction, within the limits of
available torque. The FWD ACC setting is factory set for its
fastest forward acceleration time.
33
Calibration
Page 40
Calibration
Turn the FWD ACC trimpot CW to increase the forward
acceleration time, and CCW to decrease the forward acceleration
time.
Reverse Acceleration (REV ACC)
The REV ACC setting determines the time the motor takes to
ramp to either a higher speed in the reverse direction or a
lower speed in the forward direction, within the limits of
available torque. The REV ACC setting is factory set for its
fastest reverse acceleration time.
Turn the REV ACC trimpot CW to increase the reverse acceleration
time, and CCW to decrease the reverse acceleration time.
Deadband (DB)
The deadband trimmer potentiometer determines the time that
will elapse between the application of current in one direction
before current is applied in the opposite direction.
The deadband trimmer potentiometer affects the
resistance that a motor has to changes in shaft position at
zero speed. It does this by applying AC voltage to the motor
armature.
Deadband is factory calibrated to approximately the
3 o’clock position for 60 Hz AC line operation. Recalibrate
the deadband to the 9 o’clock position for 50 Hz AC line
operation. See Figure 19 on page 36 for recommended
deadband settings.
34
Page 41
Tach Generator (TACH)
Calibrate the TACH setting only when a tachogenerator is
used. The TACH setting, like the IR COMP setting, determines
the degree to which motor speed is held constant as the motor
load changes.
To calibrate the TACH trimpot:
1. Connect the tachogenerator to T1 and T2. The polarity is
positive (+) for T1 and negative (–) for T2 with the motor
running in the forward direction.
2. Set switch SW504 to ARM for armature feedback.
3. Set the speed adjust potentiometer full CW. Measure the
armature voltage across A1 and A2 using a voltmeter.
4. Set the speed adjust potentiometer to 0 (zero speed).
5. Set switch SW504 to TACH for tachogenerator feedback.
6. Set the IR COMP trimpot full CCW.
7. Set the TACH trimpot full CW.
8. Set the speed adjust potentiometer full CW.
9. Adjust the TACH trimpot until the armature voltage is the
same value as the voltage measured in step 3.
Check that the tachogenerator is properly calibrated. The motor
should run at the same set speed when SW504 is set to either
armature or tachogenerator feedback.
35
Calibration
Page 42
36
Figure 19. Typical FWD TQ, REV TQ, IR COMP and Deadband
Settings
Calibration
1 HP
90 VDC
FWD TQ
FWD TQ
FWD TQ
FWD TQ
REV TQ IR COMP
REV TQ IR COMP
REV TQ IR COMP
REV TQ IR COMP
10 ADC
3/4 HP
90 VDC
7.6 ADC
1/2 HP
90 VDC
5 ADC
1/4 HP
90 VDC
2.7 ADC
60 Hz
Applications Applications
FWD TQ IR COMPREV TQ
FWD TQ
REV TQ
FWD TQ
FWD TQ IR COMPREV TQ
50 Hz
DBDB
IR COMP
IR COMPREV TQ
2 HP
180 VDC
9.2 ADC
1 HP
180 VDC
5 ADC
3/4 HP
180 VDC
3.8 ADC
1/2 HP
180 VDC
2.5 ADC
Page 43
Application Notes
Forward-Reverse Switch
Use a single-pole, two-position switch with a single speed adjust
potentiometer to plug reverse the motor (Figure 20). The MIN SPD
setting is in effect for either direction.
Figure 20. Forward-Reverse Switch
37
S0
S1
S2
REV
S3
TB502
FWD
10K OHM
CW
Page 44
Application Notes
Forward-Stop-Reverse Switch
Use a single-pole, three-position switch with a single
speed adjust potentiometer to stop a motor between
reversals (Figure 21). Set the switch to the center position
to decelerate the motor to a stop.
Figure 21. Forward-Stop-Reverse Switch
38
S0
S1
S2
S3
TB502
REV
STOP
FWD
10K
OHM
CW
Page 45
39
Independent Adjustable Speeds
Connect two speed adjust potentiometers with a single pole
two position switch to select between two independent speeds
shown in the forward direction (Figure 22). The speed adjust
potentiometers can be mounted at two separate operating
stations.
Figure 22. Independent Adjustable Speeds
(Forward Direction)
Application Notes
S0
S1
S2
TB502
P1
20K OHM
SPEED 1
SPEED 2
CW
P2
20K OHM
CW
Page 46
Application Notes
40
Independent Forward and Reverse Speeds
Connect two speed adjust potentiometers as shown in Figure
23 to select between independent forward and reverse.
Figure 23. Independent Forward and Reverse Speeds
S0
S1
FWD
FWD
10K OHM
CW
S2
TB502
S3
REV
REV
10K OHM
CW
Page 47
Independent Forward and Reverse Speeds
with FWD-STOP-REV Switch
Use a single pole, three position switch to stop the motor when
the switch is in the center position (Figure 24).
Figure 24. Independent Forward and Reverse Speeds with a
Forward-Stop-Reverse Switch
41
Application Notes
S0
S1
S2
S3
TB502
FWD
STOP
REV
FWD
10K OHM
CW
CW
REV
10K OHM
Page 48
42
Application Notes
Voltage follower
The drive may be wired to follow a floating (isolated)
0 to ±10V signal that is isolated from earth ground instead of
using a speed adjust potentiometer. Connect the signal input to
S2, and the signal common to RB1 (see Figure 25).
Figure 25. Voltage Follower Connection
±10 VDC
S2
S1
TB502
COMMON
RB1
Page 49
Troubleshooting
Check the following steps before proceeding
1. The AC line voltage must match the voltage on the drive
nameplate.
2. On
dual voltage drives, check that the voltage switches are
set
to the correct position.
3.
The deadband (DB) must be set approximately at the 3
o’clock
position for 60 Hz AC line frequency or at 9 o’clock
for
50 Hz AC line frequency.
4.
The motor must be rated for the drive’s rated armature (all
motors)
and field outputs (shunt wound motors only).
5. Do
not make any connections to F1 and F2 if using a
permanent
magnet motor.
6.
Terminal block connections should be consistent with the
connections
shown in this manual.
7. Check
that line fuse FU501 (and FU502 for 230 VAC input)
is
properly sized and not blown.
Warning
Dangerous voltages exist on the drive when it is powered.
When
possible, disconnect the drive while troubleshooting.
High
voltages can cause serious or fatal injury.
43
Page 50
Troubleshooting
44
Line fuse blows
1. Disconnect AC line voltage from the drive.
2. Check that the motor cable and armature are not
shorted or grounded.
a. Armature resistance should measure
approximately 1 to 100 ohms, depending on
motor horsepower.
b. A resistance reading from the motor frame to
either armature side should show open when
an ohmmeter is used on its high resistance
scale.
3. Check that the field circuit is not open.
4. A combination of ambient conditions and frequent
high-current spikes (i.e., reversing) causes fuse to
“nuisance trip”. Consider using a slow-blow fuse or
increasing the fuse rating to 120% of motor
current as stated on the nameplate.
Page 51
Line fuse does not blow, but the motor does not run
1. Verify that the speed adjust potentiometer is not
set to its zero speed position.
2. Check the speed adjust potentiometer for
continuity.
3. Verify that the inhibit terminals are not shorted
together.
4. Check that INHIBIT–RUN terminals 2 and 3 are
connected. (See figure 16, page 25)
5. Verify that the drive is receiving AC line voltage.
6. Check that the drive is not in current limit. If the
drive is in current limit, verify that the motor is not
jammed. It may be necessary to increase the
FWD TQ or REV TQ setting if it is set lower than
the current rating of the motor.
7. Check that the speed adjust potentiometer
connections to the terminal block are correct and
not open.
45
Troubleshooting
Page 52
46
Troubleshooting
Motor pulsates or surges under load
1. IR Comp may be set too high. Adjust the IR
COMP setting slightly CCW until the motor speed
stabilizes.
2. Motor “bouncing” in and out of torque limit. Make
sure the motor is not undersized for the load;
adjust FWD TQ and REV TQ trimpots.
Motor runs too fast at the maximum speed setting
1. Check that the MIN SPD and MAX SPD settings
are not set too high.
2. If using a shunt-wound motor, check that the field
output connections are secure.
Motor will not reach the desired speed
1. Check the MAX SPD setting and increase if
necessary.
2. Check that the IR COMP setting is not set too low.
3. Check that the motor is not overloaded.
For additional assistance, contact your local Leeson
distributor, or the factory direct: phone (262) 3778810; fax (262) 377-9025.
Page 53
NOTES
47
Page 54
48
NOTES
Page 55
Limited Warranty
A. Warranty - Leeson Electric warrants that this product will be free from defects in workmanship
and material for one (1) year or 3,000 hours, whichever comes first, from date of shipment therof.
Within this warranty period, Leeson Electric will repair or replace such products that are : (1)
returned to Leeson Electric, 2100 Washington Street, Grafton, WI, 53024-0241 U.S.A ; and,
(2) determined by Leeson Electric to be defective.
This warranty shall not apply to any product that has been subject to misuse, negligence, or
accident; or misapplied; or repaired by unauthorized persons; or improperly installed.
Leeson Electric is not responsible for removal, installation, or any other incidental expenses incurred in shipping the product to and from the repair point.
B. Disclaimer - The provisions of Paragraph A are Leeson Electric’s sole obligation and exclude
all other warranties of merchantability for use, express or implied. Leeson Electric further
disclaims any responsibility whatsoever to the customer or to any other person for injury to the
person or damage or loss of property of value caused by any product that has been subject to
misuse, negligence, or accident, or misapplied or modified by unauthorized persons or improperly
installed.
C. Limitations of Liability - In the event of any claim for breech of any of Leeson Electric’s
obligations, whether express or implied, and particularly of any other claim or breech of warranty
contained in Paragraph A, or of any other warranties, express or implied, or claim of liability that
might, despite Paragraph B, be decided against Leeson Electric by lawful authority,
Leeson Electric shall under no circumstances be liable for any consequential damages, losses,
or expense arising in connection with the use of, or inability to use, Leeson Electric’s product for
any purpose whatsoever.
An adjustment made under warranty does not void the warranty, nor does it imply an extension of
the original one (1) year or 3,000 hour warranty period. Products serviced and/or parts replaced
on a no-charge basis during the warranty period carry the unexpired portion of the original warranty
only.
If for any reason any of the foregoing provisions shall be ineffective, Leeson Electric’s liability for
damages arising out of its manufacture or sale of equipment, or use thereof, whether such liability
is based on warranty, contract, negligence, strict liability in tort, or otherwise, shall not in any event
exceed the full purchase price of such equipment.
Any action against Leeson Electric based upon any liability or obligation arising hereunder or
under any law applicable to the sale of equipment or the use thereof, must be commenced within
one year after the cause of such action arises.
Page 56
2100 Washington Street
Grafton, WI 53024-0241 U.S.A.
Phone: (262) 377-8810
Fax: (262) 337-9025
Document number 250–0254, Revision 4
Printed in the U.S.A – May 2007
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