motortronics ABC-100, ABC-300, ABC-50, ABC-200, ABC-550 Operation Manual

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Motortronics

Page 1

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1 Introduction ............................................................................................................................................... 2

1.1 General ............................................................................................................................................... 3

1.2 Theory of Operation ............................................................................................................................ 3

1.3 Braking Sizing and Selection .............................................................................................................. 3

1.4 Applications ........................................................................................................................................ 4

1.5 Where Mechanical Brakes Should be Used ....................................................................................... 5

1.6 ABC Model Numbers, Ratings and Dimensions ................................................................................. 6

2 Operation ................................................................................................................................................ 12

2.1 Sequence of Operation ..................................................................................................................... 12

2.2 Fault Conditions ................................................................................................................................ 14

2.3 Mechanical Brake Control ................................................................................................................ 15

3 Installation ............................................................................................................................................... 16

3.1 Fault History ...................................................................................................................................... 16

3.2 Fault Code Table .............................................................................................................................. 16

3.3 Event Records .................................................................................................................................. 16

4 Wiring ...................................................................................................................................................... 17

4.1 Introduction ....................................................................................................................................... 17

4.2 Line and Load Connections .............................................................................................................. 17

4.3 Control Connections ......................................................................................................................... 20

5 Adjustements ......................................................................................................................................... 23

5.1 Time Adjustment Procedures ........................................................................................................... 23

5.2 Jog Time Adjustment ........................................................................................................................ 23

5.3 Brake Time Adjustment .................................................................................................................... 24

5.4 Brake Current Adjustment ................................................................................................................ 24

Table of contents

6 Start-Up................................................................................................................................................... 26

6.1 Start-up Check List ........................................................................................................................... 26

6.2 Equipment ......................................................................................................................................... 26

6.3 Setup Sequence ............................................................................................................................... 26

6.4 Check Normal Sequence of Operation ............................................................................................. 26

APPENDIX A: TECHNICAL SPECIFICATIONS ........................................................................... 27

WARRANTY INFORMATION ....................................................................................................... 29

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Page 2

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Your Role in Product Safety

This equipment is designed and manufactured to the highest standards to provide safe and reliable operation
for its intended use. Only qualified personnel should install, maintain, and service this equipment, and only after
reading and fully understanding all of the information in this manual. All instructions should be strictly followed.
All Warnings, Cautions, and Notes must be taken into account for your particular installation. Users should
consult Motortronics or a Motortronics distributor/service centre if there are any questions.

All installation instructions may be superseded by applicable local, regional, or national electrical codes.
Drawings, application information, and technical representations included in this manual are for typical
installations, and should not in any way be considered specific to your application or conditions. Consult
Motortronics for supplemental information if necessary.

Contents of this manual are believed to be correct at the time of printing. In following with our on-going
commitment to meeting customer needs and developing our products to suit them, Motortronics reserves the
right to change specifications of this product and/or the contents of this manual without notice. As a result,
supplemental data sheets and/or drawings may be associated with this equipment. Please contact Motortronics
and have the unit serial number available if you notice conflicts with what is depicted in the manual and what is
installed in the field.

Phasetronics (dba Motortronics) accepts no liability for any consequences resulting from inappropriate, negligent,
or incorrect installation, application, adjustment, or maintenance of this equipment.

Notice Label

Explanation:

W

ARNING!

Warning labels such as this denotes specific
area of the

manual.

These

statements

are

intended

concerns

to be

for

life/

safety/damage

followed without exception.

issues associated with this

CAUTION!

Caution labels are
under

circumstances as described.

responsible

intended

for

identifying

to alert the user to

These items are

the

applicable installa

specific

critical

tion

issues.

issues that MAY cause damage or

in some

installations

but

not

personnel
all. The user is

risks

NOTE: Notice labels are
to the proper use and

intended

long

term

to alert the user to issues that require particular

reliability

of the

equipment.

attention

with regard

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Page 3

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1 About the Motortronics ABC Series

1.1 General

The ABC Series is a solid state DC injection brake for stopping three- phase AC induction motors. This full-wave
DC brake design offers smooth, low peak level braking for quiet, steady operation and optimal performance.
Designed to handle even high inertia loads, the ABC Series eliminates costly and potentially dangerous "coast­to- stop" times. A built-in microprocessor provides system supervision that includes digital timing control for
jogging and braking.

The integral Operator Interface Module provides LED indication of the unit's operating status and easy
adjustments for quick setup. Standard features include interlocks and mechanical brake release relays, a brake
disable input and zero speed sensing with override.

1.2 Theory of Operation

Incoming AC power is fed to terminals L1 and L2 directly from the line side of the motor starter terminals and is
converted to DC within the ABC Series. Once the motor starter has been turned off (opened) and the residual
energy in the motor has dissipated, the DC current from the ABC Series is applied (injected) to starter terminals
T1 and T2 respectively. This creates a stationary magnetic field in the AC motor stator windings.

The braking torque will increase in proportion to the amount of current allowed to flow. (The DC injection level
can be adjusted using the Brake Current Potentiometer on the operator interface module. This modulates the
applied voltage based upon an "RMS" closed loop current feedback signal from the integral sensors.) The rotor
then pulls into alignment with this stationary field and brings the load to a stop faster than if it coasted to a stop.

1.3 Brake Sizing and Selection

ABC Series brakes are suitable for use in most AC motor applications where coast-to-stop times are undesirable
or unacceptable. The ABC Series is a current controlling brake, so various sizes of brake units can be applied to
various motor sizes. Because DC injection means applying power to the AC motor after turning it "Off", motor
heating (although minimal) will continue during the braking cycle and should be considered when selecting the
motor. AC motor manufacturers recommend that each braking cycle over 100% FLA be considered as an
additional starting cycle when calculating the starts- per-hour ratings for the selected motor.

If the selected ABC
start cycles for these calculations (and 300% FLA = 3
exceed 400% of the motor nameplate FLA without first consulting the motor manufacturer. Additional guidelines
for applying ABC Series brakes follow:

Series

is sized to deliver 200% of motor rated current, consider each brake cycle to be 2

"starts"

per brake). Never size any DC injection brake to

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1.3.1 Standard Duty Sizing

Applying an ABC Series brake that is rated for <115% of the
maximum length of braking time without exceeding the thermal capacity of the stator windings. Since current is
controlled by the ABC
impedance decreases with speed. Braking torque will be highest at the beginning of the cycle, and can be as
much as 100% of the FLT (Full Load Torque) when set to motor FLA.

As the motor slows, the braking torque slowly decreases, reducing the mechanical stresses as much as
possible. Sizing a brake in this manner is typically good for machine tools, saws, conveyors, lumber machinery,
and most chippers where the coast-to-stop time does not exceed 5 minutes. Stop times vary greatly with load
and friction, but can be expected to be 1/2 of the coast-to-stop time or less. Keep in mind that the maximum
brake time is setting is 127 seconds. In heavily loaded, high inertia machines and long coast-to-stop times, the
Standard Duty model may not stop the load. Consider using the Extra Duty rating instead.

Series

throughout the braking cycle, braking torque will vary as the motor circuit

FLA

(Full Load Amp) rating of the motor allows

1.3.2 Extra Duty Sizing

For heavier machine loads such as large chippers, punch presses and other flywheel based machines, selecting
an ABC Series brake based on 200-250% of the motor nameplate FLA allows faster braking. The maximum
developed braking torque can be as much as

200% of the motor rated Full Load Torque. In this case, the load can typically stop in twice the Across-the-Line
starting time. Duty cycling of the motor is a much more important consideration in applications since additional
thermal stresses due to higher current levels are applied to the motor.

1.3.3 Custom Sizing

Extreme loads (such as overhauling conveyors or large centrifuges), or short stop times (approaching the
across-the-line starting time of the motor) may require sizing the ABC Series for 300% of the motor FLA or
greater, and should be done with careful consideration of motor heating, duty cycle, and limitations of
mechanical stress on the drive train components.

1.3.4 Emergency Stopping

An ABC Series brake used in conjunction with a mechanical brake should be considered if the stop times must
be equal to or shorter than the across-the-line start time, consider using and ABC
with a mechanical brake.

Series

brake in conjunction

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1.4 Applications

The ABC Series electronic brake is ideal for machine and process equipment control applications for efficiency,
increased safety, and reduced equipment maintenance costs. Among the benefits:

Efficiency
batch loading, or maintenance shutdowns. Productive time increases as overall operating costs decrease
because the load stops more quickly. The ABC Series eliminates the common practice of jamming the load to a
stop which seriously reduces the life and effectiveness of saw blades, molding heads, and knives.

Increase Safety by eliminating the need to "jam-stop" equipment. This will prevent any personnel injuries
caused by kickbacks and broken blades. Use the ABC Series in conjunction with safety inter- lock devices to
stop the motor as quickly as possible, reducing the risk of contact with dangerous rotating elements of
machinery. Prevent premature wear or component failure and eliminate the need for hasty repairs that can put
maintenance personnel in potentially dangerous situations. ABC Series brakes can be used as part of a system
to facilitate OS H A General
exposed to hazardous moving parts. They can also be utilized to satisfy braking requirements of the British
Columbia Workers Compensation
as planers, chippers, and hogs.

Reduce maintenance costs by using the ABC Series. Eliminate the need to plug-reverse a load and reduce
the associated damage to gear boxes and other power train components. The ABC
or slow down the load in one direction before reversing to the other. On machines where mechanical brakes are
used to stop or hold a load, use the ABC Series to stop it first, then set the mechanical brake as a "parking
brake". This eliminates the normal wear and tear to the brake pads or shoes. On loads such as vibrating
feeders, screens, or separators, damage from mechanical harmonics that occur during coast-down can be
eliminated by using an ABC Series. It allows the motor/load to quickly pass through any dangerous speeds and
come to a stop.

is improved because you no longer have to wait through long coast-to-stop times for blade changes,

Industry Standards (

Amendment Act

29 CFR1910 Subpart O) requiring that workers not be

(Book 3 Part 27.42) for rotating knife machinery such

Series

can be used to stop

1.5 Where Mechanical Brakes should be used

Power loss
the braking cycle. If the incoming line power is lost from the utility, an upstream circuit protective device trips, or
an emergency shutdown routine is initiated, no braking will take place. If braking is still necessary for safety
reasons (even in the event of a power failure), consider using mechanical brakes as a backup device. Under
normal operation conditions, the ABC Series stops the load and the mechanical brake holds it.

during braking

- The ABC Series, like all DC injection brakes, requires power to be applied during

Holding

motor comes to a complete stop and therefore CANNOT BE USED AS HOLDING BRAKE. If braking must be

applied continuously while the load is at rest, mechanical "Parking Brakes" are required. The ABC Series
includes a Mechanical Brake Release Relay to facilitate proper coordination of the mechanical brake in these
applications.

Stop times
energy to dissipate from the windings before DC current can be applied (otherwise damage to the brake or
circuit devices may occur). The length of this "wait state" depends on the motor's residual magnetism and the
motor frame size, but can be as much as 5 seconds. This, combined with the limits on braking torque, makes DC
injection braking ineffective if braking time must be shorter than the starting time (Across-the-Line).

the load after it comes to a stop - All DC injection brakes inherently lose braking torque when the

shorter

than start times - Like all DC injection brakes, the ABC Series waits for the residual motor

W

ARNING!

DC

Injection
Mechanical Brake
use in these

brakes cannot be used for

Release Relay that can be used to

applications.

holding

a load after

coordinate

it

comes to a stop. The ABC Series

the

operation

of a

mechanical

includes

brake for

a

Motortronics

Page 6

ABC - 200 - - E

Voltage

240 = 208 – 240V, 400 = 380 – 415V
480 = 440 – 480V, 600 = 575 – 600V

Enclosure

P = Panel Mount
E = NEMA 4/12 Sealed

Max. Brake Amps

50 – 1000 A.

ABC SERIES

Model

Number*

Max

Amps

Typical Horsepower Usage

Dimensions

208 V

240V

480V

600V

Panel

Dim Ref.#

NEMA 4/12

Dim Ref. #

Std.

Duty

Extra

Duty

Std.

Duty

Extra

Duty

Std.

Duty

Extra

Duty

Std.

Duty

Extra

Duty

ABC-50

50

15

7.5

20

10

40

25

50

30 2 7

ABC -100

100

30

20

40

25

75

50

100

60 2 7

ABC-200

200

75

40

75

50

150

100

200

125 3 8

ABC-300

300

100

60

125

75

250

150

300

200 4 9

ABC-400

400

150

75

150

100

350

200

400

250 4 9

ABC-550

550

250

125

200

150

500

300

600

350 5 10

ABC -800

800

350

200

350

200

700

450

900

500 5 10

ABC-1000

1000

400

250

400

300

900

500

1000

600 5 10

Dim

Ref. #

Dimensions (Inches)

A B C D E

F

2

10.5

7.9

7.2

10

6.8

0.21

3

16.5

10

10

15.9

9

0.28 4 16

16

10

15

15

0.5 5 21

26

10.4

20

25

0.5 6 16

12 9 14.5

10.5

0.5 7 20

16 9 18.5

14.5

0.5 8 24

20

16

22.5

18.5

0.5

9

36

24

16

34.5

22.5

0.5

10

36

30

16

34.5

28.5

0.5

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1.6 ABC Series Model Number, Rating and Dimensions

NOTES:

1. Never exceed the Full Load Amp rating of the motor without checking the motor manufacturer's data
with regards to appropriateness of the application and duty cycle.

2. If duty cycle is not known, Motortronics recommends using the Extra Duty Brake since braking current
can be adjusted down to meet the actual load requirements.

Motortronics

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N4/12 Outline: ABC-50/100-E

N4/12 Outline: ABC-200-E

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N4/12 Outline: ABC-300/400-E

N4/12 Outline: ABC-550/800-E