Installation & Operating Procedures
Opal OP-STOP
Series
DC INJECTION BRAKE
FOR 3 PHASE INDUCTION MOTORS
OP-STOP DC INJECTION BRAKE
Opal OP-Stop SERIES
DC INJECTION BRAKE
FOR 3 PHASE INDUCTION MOTORS
INSTALLATION & OPERATING PROCEDURE
Revision 1.03 - 07/2011
OP-STOP DC INJECTION BRAKE
FOR YOUR SAFETY
Only qualified personnel should install this equipment, after first reading and
understanding all the information in this manual. All instructions should be strictly
adhered to. The user should consult SAF Drives Inc. or a SAF OPAL Starters
supplier for clarification of the contents of this manual should any doubt or
questions arise.
The installation of this equipment must be conducted in accordance with all
national, regional and local electrical codes.
All drawings and technical representations included in this manual are for typical
installations and should not in any way be considered for specific applications or
modifications. Consult SAF OPAL Starters for supplemental instructions.
SAF Drives Inc. accepts no liability for any consequences resulting from
inappropriate, negligent or incorrect installation, application or adjustment of this
equipment.
The contents of this manual are believed to be correct at the time of printing. In
following with our commitment to the ongoing development and improvement of
our products SAF OPAL Starters reserves the right to change the specification of
this product and/or the content of this instruction manual without notice.
OP-STOP DC INJECTION BRAKE
TABLE OF CONTENTS
1 DESCRIPTION..............................................................................................................1
1.1 OVERVIEW........................................................................................................................1
1.2 APPLICATION NOTES......................................................................................................2
1.3 CONTROLS....................................................................................................................... 3
1.3.1 CA398 LOGIC................................................................................................................3
1.3.2 CA398 REGULATION....................................................................................................3
2 SPECIFICATIONS ........................................................................................................4
2.1 POWER RATING...............................................................................................................4
2.2 CURRENT AND FUSE RATING........................................................................................4
2.2.1 NOTES...........................................................................................................................4
2.3 SERVICE CONDITIONS....................................................................................................5
2.4 DIMENSIONS ....................................................................................................................5
2.5 SCR INSTALLATION SPECIFICATIONS..........................................................................6
3 CARD FUNCTIONS ......................................................................................................7
3.1 CARD LAYOUT .................................................................................................................7
3.2 LED AND NEON INDICATIONS........................................................................................7
3.3 ADJUSTMENTS ................................................................................................................8
3.3.1 POTENTIOMETERS......................................................................................................8
3.3.2 1LINK SELECTION........................................................................................................8
3.3.3 PUSHBUTTON ..............................................................................................................8
3.4 TERMINALS ......................................................................................................................9
3.4.1 CUSTOMER TERMINALS.............................................................................................9
3.4.2 TERMINALS FOR INTERNAL USE...............................................................................9
3.5 FAULTS...........................................................................................................................10
3.5.1 PHASE LOSS ..............................................................................................................10
3.5.2 INSTANTANEOUS OVER CURRENT (IOC)...............................................................10
4 INSTALLATION AND START UP............................................................................... 11
4.1 INSPECTION...................................................................................................................11
4.2 SAFETY PRECAUTIONS................................................................................................11
4.3 MOUNTING GUIDELINES...............................................................................................11
4.4 WIRING GUIDELINES.....................................................................................................13
4.5 START UP.......................................................................................................................13
4.5.1 CHECKS BEFORE POWER-UP..................................................................................13
4.5.2 WITH POWER ON.......................................................................................................14
5 TYPICAL CONNECTIONS..........................................................................................15
5.1 STAND ALONE DC INJECTION UNIT WITH ZERO SPEED DISABLE..........................15
5.2 OPAL STARTER WITH DC INJECTION .........................................................................16
5.3 REVERSING OPAL STARTER WITH DC INJECTION, 125 AMPS AND BELOW..........17
5.4 REVERSING OPAL STARTER WITH DC INJECTION, 200 AMPS AND ABOVE..........18
6 SPARE PARTS...........................................................................................................19
-i -
OP-STOP DC INJECTION BRAKE
1 DESCRIPTION
1.1 OVERVIEW
The OP-STOP braking units provide smooth braking for AC induction motors. The brake units
offer adjustable braking because they are current controlled. Unlike a mechanical brake, an
electrical brake will never wear out. The brake operates by injecting DC current in two phases
of the motor to rapidly decelerate it to zero speed.
These units can be supplied as an option to the OPAL solid state starter, or as stand alone units
for new or retrofit installations.
SAF's OP-STOP braking modules offer a unique combination of features that make it very
reliable, easy to use, and energy efficient. These features include:
• Closed Loop Current Regulation:
The brake, operating with a closed loop current regulator, provides consistent torque
every time. This torque is independent of line voltage variations.
• Direct Power Connection:
The brake's power input is connected directly to the AC line, and the power output is
connected directly to the motor, no contactors are required. The unit adapts itself to any
input voltage between 200 and 600 VAC with no adjustments required.
• Efficient Power Circuit:
The power circuit is an efficient four Silicon Controlled Rectifier ( SCR ) configuration
which uses some of the SCR's as a "free wheeling diode", thus maximizing the DC
current through the motor coils generated by the AC input current.
With every benefit there is usually a trade-off. Although the OP-STOP brake unit will never
wear out like a mechanical brake, the trade-off is that should there be a loss of power, the brake
unit will not operate without battery back-up. SAF can supply a reliable battery back-up to
overcome this disadvantage.
Braking is initiated when the motor starter is opened and the voltage across the motor has
dropped to below 30% or 80% of the line supply. DC injection is removed after an adjustable
period has elapsed. It does not provide zero speed sensing, although a normally closed contact
from a zero speed switch may be connected to the Disable Input.
If braking is released before the motor stops, the motor will coast to rest. If the braking remains
on after the motor stops, the DC supply will provide a holding brake.
Page 1
T
OP-STOP DC INJECTION BRAKE
1.2 APPLICATION NOTES
The motor torque/speed characteristic of an induction motor under DC supply is similar to the
normal curve published for constant frequency, at 50 or 60 Hz, but this time having
"synchronous speed" zero RPM. This is illustrated below.
ORQUE
SPEED
S 100%
0=N
For smooth braking the DC current is typically adjusted to 300% of the motor nameplate
current. The stopping time depends on the torque setting and also the inertia of the mechanical
system.
Electric braking is not recommended for continuous or repetitive operation. The kinetic energy
of the mechanical system is transformed into heat during braking ( energy conservation ). That
heat is dissipated in the rotor of the motor.
On wound rotor motors the external rotor resistance will absorb most of the energy. On squirrel
cage motors, overheating of the motor is a real danger if frequent operation is used.
Keeping DC current on the motor stator for a short time after the motor has stopped is quite
acceptable. The heat produced by the I2R losses are not significant, and they are dissipated in
the stator only, not in the rotor where the rotational energy is dissipated.
Page 2
OP-STOP DC INJECTION BRAKE
1.3 CONTROLS
The OP-STOP unit contains two major parts, the power circuit and the control card.
The power circuit is a 4 SCR single phase full wave controlled rectifier. This configuration
optimizes the DC current injected to the motor per input current.
The control is contained in a single PC board, CA398. This board is common to all OP-STOP
models.
1.3.1 CA398 LOGIC
DC injection will be applied to the motor when two conditions are met. The starter is
opened and the motor terminal voltage has decayed to 30% or 80%, jumper dependent, of
the line voltage. The starter can not be energized for a period of 1-2 seconds after the DC
injection cycle.
This design has the significant advantage that the braking module will remain off in the
case of having an open auxiliary contact from either a broken wire or faulty contact. The
braking action can be externally defeated at any time by applying 115 VAC to the
Disable Input.
The braking action is inhibited when an instantaneous over current is detected. The IOC
fault is detected and latched until the Reset switch is pressed. A form C relay contact is
available to interlock the brake unit from the motor starter. The starter cannot be
energized while DC current is being applied to the motor or during a fault condition.
1.3.2 CA398 REGULATION
The brake module operates in current control at all times. The current is adjusted via an
internal potentiometer and the current feedback signal is generated by a current
transformer mounted on the AC line. A unique circuitry reconstructs the free wheeling
current in the DC output for accurate current regulation.
The output of the current regulator is used in a comparator circuit that performs the phase
control on two SCR's. The other two SCR's are fully phased on to provide free wheeling
action, minimizing the ripple current.
Two opto-couplers are used to generate the line synchronization signal. Each opto output
is used to generate a ramp that is used in the comparator with the current regulator
output.
The motor voltage feedback is used to sense voltage levels for proper sequencing and not
to perform any regulation.
Page 3
OP-STOP DC INJECTION BRAKE
2 SPECIFICATIONS
2.1 POWER RATING
POWER
CONTROL
RATING
300% for 30 seconds, once every 30 minutes
All models have 1600V PIV SCR's
CONTACTS
PROTECTION
Voltage surge protection by snubber's and MOV's across the SCR's
200-600VAC, 50/60 Hz
115 VAC, 50 Hz or 120 VAC, 60 Hz
Intermittent duty, See Section 2.2
DC injection relay contacts rated at 1A, 120VAC
Short circuit by HRC fuses or circuit breaker
(supplied upon request)
2.2 CURRENT AND FUSE RATING
DCI-20 20.0 20.0 15.0 20.0 Module
DCI-40 40.0 40.0 30.0 40.0 Module
DCI-80 80.0 75.0 60.0 80.0 Module
DCI-125 125.0 125.0 100.0 125.0 Module
DCI-200 200.0 200.0 150.0 200.0 Disc
DCI-300 300.0 300.0 250.0 300.0 Disc
DCI-500 500.0 500.0 400.0 500.0 Disc
DCI
MODEL
AMPS MOTOR
CURRENT RATING
MOTOR
HP @ 575 V
HP @ 460V
FUSE
AMPS
SCR
TYPE
2.2.1 NOTES
2.2.1.1 The HP listing is for reference only. For proper selection use the current rating.
2.2.1.2 The fuses recommended are Class J time-delay type. This fuse is being suggested even
though it may not protect the SCR in an output shorted condition while braking. It will
protect the unit when starting to operate into a shorted output. In the case of a shorted
SCR, the fuse is there to clear the fault only.
2.2.1.3 The RMS AC line current is equal to : AC RMS = DC Amps x √ Duty Cycle Assuming
10A motor, OP-STOP set at 300% current (30 A DC), free wheeling for 70% of the
cycle, then the AC current is 16A.
2.2.1.4 All OP-STOP models are built without cooling fans because they are short duty rated.
Page 4
2.3 SERVICE CONDITIONS
OP-STOP DC INJECTION BRAKE
ELEVATION
For altitudes in excess of 2000 meters / 6600 feet above sea
level, all assemblies must be derated 1% for every 100 meters /
330 feet above
AMBIENT
TEMPERATURE
Do not install in areas where ambient temperature falls below
0°C / 32°F or exceeds 40°C / 104°F
2.4 DIMENSIONS
16" × 8.5" × 6" 13" × 8.5" × 7"
17" × 10" × 8.5" 17" × 12" × 8.5"
17" × 10" × 8.5" 17" × 12" × 10.5"
21" × 10.5" × 9" 21" × 12" × 10.5"
11" × 13" × 10.5" 24" × 24" × 12"
16.5" × 14.5" × 11" 30" × 24" × 12"
17.5" × 16.5" × 14" 30" × 24" × 12"
NOTE: For dimensions of OP-STOP units in conjunction with SAF's OPAL solid state starter, refer to the OPAL
manual reversing chassis dimensions.
DCI
MODEL
DCI-20
DCI-40
DCI-80
DCI-125
DCI-200
DCI-300
DCI-500
Height × Width × Depth
CHASSIS NEMA 1 / NEMA 12
43cm × 22cm × 15cm 33cm × 22cm × 18cm
43cm × 25cm × 19cm 33cm × 22cm × 18cm
43cm × 27cm × 21cm 43cm × 30cm × 27cm
53cm × 27cm × 23cm 53cm × 30cm × 27cm
28cm × 33cm × 27cm 61cm × 61cm × 30cm
42cm × 37cm × 28cm 76cm × 61cm × 30cm
45cm × 42cm × 36cm 76cm × 61cm × 30cm
Page 5
OP-STOP DC INJECTION BRAKE
2.5 SCR INSTALLATION SPECIFICATIONS
2.5.1.1 SCR TIGHTENING PROCEDURE
2.5.1.2 Clean both heat sink and SCR surfaces.
2.5.1.3 Apply a thin layer of joint compound (Noalox) to both SCR surfaces.
2.5.1.4 Observe correct SCR polarity.
2.5.1.5 Install SCR so that roll pins engage dimples on both sides of the SCR.
2.5.1.6 Tighten clamp bolts evenly until finger-tight.
2.5.1.7 Tighten each bolt according to table below (based on number of spring bars and size of
bars).
* Note: SMALL clamps are 4.25 inches / 10.5 cm and LARGE clamps are 5 inches / 12.5 cm.
CLAMP SIZE SPRING BARS
BOLT TURNS PAST
FINGER TIGHT
SMALL 1 0.8
SMALL 2 1
LARGE 3 1.8
LARGE 4 1.8
Page 6
1 2
CURRENT FBK
RESET
IOC
PWR
INJCT
L1 N
INPUT 120VAC
1 2 3 4 5 6
MOTOR VFBK1 2
RZ24
DC INJECTION BRAKE CARD
CAUTION !!!
MAINS VOLTAGE POTENTIAL
SAF
K1
G1
K2
G2
K3
G3
K4
G4
2
4
6
8
10
12
14
16
18
20
BRAKING
TORQUE
LO
7
+24V
COM
1A 250V
VOLTAGE LEVEL
BURDEN
CA398-3
TIME
DC
L1 N
1
1A 250V
16
20
18
14
12
10
8
6
4
2
IOC
RESET
DC
INJCT
PWR
BURDEN
COM
+24V
TIME
K2
31 2 4 65 7
2
RZ24
G4
K4
G3
G2
K3
VOLTAGE LEVEL
LO
CURRENT FBK
1 2
G1
K1
PRI
SEC
A
A
A
1 2 3
PRI
SEC
A
A
A
1 32
U11
OPT
SCR1
SCR2
SCR3
SCR4
T2
T3
T4
T5
U7
U6
LD3
LD1
K1
U12
U10
SW1
U2
J3
R7
RV2
J2
LD2
T1
U3
ISO1
ISO2
U5
RV1
J5
FU1
K2
JP1
J1
J4
U4
NE1
U8
U9
ISO3
ISO4
J2
T1
FU1
ISO2
ISO1
OPT
LD2
LD3
SW1
LD1
U3
U2
U6
U5
R7
J1
U4
RV1
RV2
T3
J4
K2
U10
U8
U12
ISO4
K1
ISO3
J5
T5
T4
SCR3
NE1
SCR4
SCR2
JP1
U7
U9
U11
J3
T2
SCR1
OP-STOP DC INJECTION BRAKE
3 CARD FUNCTIONS
3.1 CARD LAYOUT
VOLTAGE LEVEL
RV2
RV2
TIME
TIME
L1
L1
CA398 – DC INJECTION CARD
RED On when unit is braking
GREEN Must be ON when 115VAC is applied
RED
ORANGE Phase loss indication when neon not glowing
BURDEN
BURDEN
R7
R7
SW1
SW1
T1
T1
SEC
SEC
PRI
PRI
RV1
RV1
BRAKING
BRAKING
U2
U2
U3
U3
J1
J1
COM
COM
+24V
+24V
DC
INJCT
LD1
PWR
PWR
LD2
LD2
IOC
IOC
RESET
RESET
LD3
LD3
OPT
OPT
LED NAME COLOUR DESCRIPTION
LD1
LD2
3.2 LED AND NEON INDICATIONS
LD3
NE1
10
10
12
12
14
14
16
16
18
18
20
20
FU1
FU1
1A 250V
1A 250V
DC INJCT
PHASE OK
INPUT 120VAC
INPUT 120VAC
PWR
IOC
VOLTAGE LEVEL
HIHILO
HIHILO
CA398-3
U7
U7
U8
U8
J2
J2
TORQUE
TORQUE
U4
U4
U5
U5
U6
U6
DC INJECTION BRAKE CARD
DC INJECTION BRAKE CARD
ISO2
ISO2
ISO1
ISO1
JP1
JP1
U9
U9
U10
U10
Instantaneous Over-Current fault indication when
illuminated
J3
J3
CURRENT FBK
CURRENT FBK
U11
U11
K1
T2
T2
T3
T3
U12
U12
T4
T4
T5
T5
CAUTION !!!
MAINS VOLTAGE POTENTIAL
MAINS VOLTAGE POTENTIAL
K2
K2
J4
J4
SAF
K1
K1
RZ24
RZ24
ISO3
ISO3
ISO4
ISO4
J5
J5
MOTOR VFBK
MOTOR VFBK
K1
SCR1
SCR1
G1
G1
K2
K2
SCR2
SCR2
G2
G2
K3
K3
SCR3
SCR3
NE1
NE1
G3
G3
K4
K4
SCR4
SCR4
G4
G4
Page 7
OP-STOP DC INJECTION BRAKE
3.3 ADJUSTMENTS
3.3.1 POTENTIOMETERS
POT NAME RANGE DEFAULT
DESCRIPTION
SETTING
RV1 BRAKING
TIME
RV2 TORQUE 100-300% 50% Adjust DC current
1-60 sec 30% Adjust the braking time
CW rotation increases the time
CW increases the braking torque
(current)
3.3.2 1LINK SELECTION
LINK
JP1 VOLTAGE
HI Braking action starts when motor starter has opened
HI setting is only used when the stopping time is critical and must be around 1-2 seconds. For this
application 300% DC current is not adequate. Consult factory before using this jumper position.
When the OP-STOP is set on the HI level a current surge could occur due to the motor CEMF and
the free wheeling action of the power circuit.
NAME POSITION DESCRIPTION
LEVEL
LO
(Normal)
Braking action starts when motor starter has opened
and the motor terminal voltage has decreased to
30% of the line voltage.
and the motor terminal voltage has decreased to
80% of the line voltage. See important notes below.
3.3.3 PUSHBUTTON
Page 8
PUSHBUTTON NAME DESCRIPTION
SW1 RESET Reset IOC fault trip
OP-STOP DC INJECTION BRAKE
3.4 TERMINALS
3.4.1 CUSTOMER TERMINALS
TERMINAL NO. DESCRIPTION
J2 L1, N 115 VAC control voltage input, L1 being hot and N, neutral
L1 input is protected with internal fuse, 1A 250VAC
J4 1, 2 115 VAC supply for external interlock contacts
3.0 A normally open contact from the motor starter auxiliary must
be connected between this teminal and terminals 1 or 2 to sense
when the starter is de-energized to enable braking action
When using a SAF OPAL starter in conjuction with the OPSTOP, this terminal is to be jumpered to terminal 1 or 2
4.0 When 115VAC from terminals 1 or 2 is applied to this input,
braking is disabled
Apply 115 VAC to this input to disable the brake
5.0 Common DCI relay contact
The Form-C relay is de-energized while braking and when a
fault exists
6.0 Normally open DCI relay auxiliary contact
-7.0 Normally closed DCI relay auxiliary contact
R7 1, 2 Burden resistor terminals for calibration of DC injection
current
See table in Section 4.4
3.4.2 TERMINALS FOR INTERNAL USE
TERMINAL NO. DESCRIPTION
J1 24V, COM This terminal is used by SAF as a 24V input to provide
battery back up for DC injection in case of power loss
J3 1, 2 CURRENT FBK
From current transformer for motor current feedback
J5 1, 2 MOTOR VFBK
From T1, T2 motor terminals for motor voltage feedback
SCR1 G1, K1 Gate connection to SCR 1
SCR2 G2, K2 Gate connection to SCR 2
SCR3 G3, K3 Gate connection to SCR 3
SCR4 G4, K4 Gate connection to SCR 4
OPT 1-20 Provided for ribbon cable link to SAF's OPAL starter
This provides signals from the OPAL to the OP-STOP that
indicate the run status of the starter, replacing the auxiliary
input and prevents starting during DC injection or a fault
Page 9
OP-STOP DC INJECTION BRAKE
3.5 FAULTS
When a fault exists the OP-STOP DCI relay is de-energized, preventing a properly interlocked
starter from being activated. When an OP-STOP is used in conjunction with a SAF OPAL starter,
this interlock is also carried out through signals passed by the ribbon cable at OPT. When no faults
exist and DC injection is not active, the DCI relay is energized. Therefore, if the 115 VAC supply
is not present the "fail-safe" interlock will prevent the use of the starter. The faults are explained
below.
3.5.1 PHASE LOSS
If the single phase power ( 200-600V ) to L1 and L2 terminals is not present, NE1 will be off
and the DCI relay de-energized. When this condition is corrected the unit will allow the starter
to be energized.
3.5.2 INSTANTANEOUS OVER CURRENT (IOC)
If the current feedback exceeds 1000% of the current setup by the burden resistor (Rb), the unit
will trip on IOC and de-energize the DCI relay. LD2 will be illuminated to indicate an IOC
fault and is reset via SW1, RESET. Causes of this fault may be a shorted output or simply a
burden resistor sized too small. Refer to Section 4.4 for burden table.
Page 10
OP-STOP DC INJECTION BRAKE
y
4 INSTALLATION AND START UP
4.1 INSPECTION
The OP-STOP has been packaged to protect it from damage caused by normal handling during
shipping; however mishandling may cause damage to the OP-STOP. Unpack the unit as soon
as it is received and check for any shipping or storage damages. If damage is found, notify the
carrier. Any damage claim must be filed by the customer since all shipments are F.O.B. SAF
plant unless otherwise specified.
If the OP-STOP is not installed when received, store it in a clean, dry, well ventilated area, free
from heat, humidity, oil, dust and metal particles.
4.2 SAFETY PRECAUTIONS
CAUTION
Equipment is at line voltage when AC power is connected. Pressing "STOP"
pushbutton does not remove AC mains potential. All phases must be
disconnected before it is safe to work on machiner
control equipment parts.
or touch motor terminals or
CAUTION
Disconnect incoming voltage from unit before opening load side during DC
injection. Failure to observe this precaution can result in damage to
disconnecting device and/or bodily injury.
The electrical code requires all equipment, starter motor, operator station, brake, etc... to be
grounded properly. An incoming circuit breaker or disconnect switch must be locked open before
wiring and servicing this electrical brake, motor, or other related equipment. This equipment must
be installed and serviced only by qualified personnel, familiar with this unit. The user is
responsible for ensuring that proper short circuit protection is provided by either a circuit breaker or
HRC fuses.
4.3 MOUNTING GUIDELINES
Standard Nema 1 OP-STOP units must be installed indoors in a well ventilated area, free from
heat, humidity, oil, dust and metal particles.
One foot of clearance must be kept around the perimeter of the unit in a naturally cooled setup.
The equipment must be mounted away from any heat source. See Section 2 for additional
specifications and derating. Be aware that the heatsink may reach temperatures of 70°C /
158°F during normal operation. Do not install the unit in contact with any material that can not
accept this temperature.
Page 11
OP-STOP DC INJECTION BRAKE
The OP-STOP must be mounted vertically and where it will not experience excessive shock or
vibration.
Page 12
OP-STOP DC INJECTION BRAKE
4.4 WIRING GUIDELINES
Follow all local electrical codes for installation requirements and wire sizing. Size the power wiring
as per local code and on long wire runs it is recommended to use a larger wire size.
Power factor correcting capacitors MUST NOT be connected to the OP-STOP output. If desired,
they must be connected on the line side of the unit. Capacitors can be connected before starting or
preferably after the motor has reached full speed.
4.5 START UP
4.5.1 CHECKS BEFORE POWER-UP
4.5.1.1 Ensure that all electrical connections are completed as shown on schematics in section 6,
and that connections are properly tightened. The most important connection is the
interlock between the OP-STOP and the starter.
4.5.1.2 Ensure that the burden resistor is equal or larger than the value listed in the table below or
calculated by the following equation:
Rb = Effective Current Transformer Ratio ÷ Motor Nameplate Amps
4.5.1.3 Set JP1 link to LO.
4.5.1.4 Adjust RV2, braking torque, and RV1, braking time to 50%
4.5.1.5 Install a Disable switch between terminals 2 and 4 of J3 in the open position. Switch is to
be closed once the motor has reached zero speed or if any problems occur during
braking.
4.5.1.6 If a Disable switch is not used, then set RV2 to 30%, about 20 seconds or lower.
WARNING!
DO NOT OPEN LOAD SIDE DISCONNECT DEVICE DURING DC
INJECTION CYCLE. FAILURE TO OBSERVE THIS WARNING WILL
RESULT IN DAMAGE TO THE DISCONNECTING DEVICE AND MAY
CAUSE PERSONAL INJURY.
Page 13
OP-STOP DC INJECTION BRAKE
MODEL
MOTOR
AMPS
SS6-15 with DCI 10.0
15.0
DCI-20 or
20.0
SS6-30 with DCI
30.0
DCI-40 or
40.0
SS6-50 with DCI
50.0
DCI-80 or
60.0
SS6-80 with DCI
80.0
DCI-125 or
100.0
SS6-125 with DCI
125.0
DCI-200 or
150.0
SS6-200 with DCI
200.0
DCI-300 or
200.0
SS6-360 with DCI
300.0
DCI-500 or
400.0
SS6-500 with DCI
500.0
BURDEN
RESISTOR (¼ W)
68 Ω
47 Ω
39 Ω
27 Ω
39 Ω
33 Ω
39 Ω
33 Ω
27 Ω
22 Ω
18 Ω
12 Ω
27Ω
18 Ω
22 Ω
18 Ω
EFFECTIVE CT
RATIO
750 : 1
750 : 1
1500 : 1
2500 : 1
2500 : 1
2500 : 1
5000 : 1
8500 : 1
4.5.2 WITH POWER ON
4.5.2.1 Run the motor up to full speed and command the starter off. If the motor reaches zero
speed from the DC injection cycle, close the switch to the Disable Input to disable the
braking.
4.5.2.2 Re-adjust the braking torque pot, RV2, if the actual braking time has to be increased or
decreased to bring the motor to zero speed.
4.5.2.3 Once the braking torque is set, then adjust RV1 to match the DC injection time with the
actual stopping time of the motor. Typically, the injection should decease when the motor
is at zero speed or shortly after. LD1, DC INJCT is an indication of braking. Each 10%
graduation in RV1 corresponds to approximately 6 seconds.
WARNING!
ALLOW TIME FOR THE MOTOR TO COOL BEFORE ANOTHER
START / STOP SEQUENCE IS INITIATED
FREQUENT START / STOP COULD CAUSE MOTOR DAMAGE
DUE TO OVERHEATING
Page 14
OP-STOP DC INJECTION BRAKE
5 TYPICAL CONNECTIONS
5.1 STAND ALONE DC INJECTION UNIT WITH ZERO SPEED DISABLE
Page 15
OP-STOP DC INJECTION BRAKE
5.2 OPAL STARTER WITH DC INJECTION
MOTOR
3 PHASE
INDUCTION
T1
CT1
T2
CT2
T3
SCR1 SCR8 SCR4 SCR9
CT3
K4G1 K1 G2 K2 G3 K3 G4
FBK
12
CURRENT
J3
VFB
1
J5
43 21
K6
TIME
BRAKING
DC
2
1
R7
BURDEN
INJECTION
RATE
CA392-2
2
RESISTOR
TORQUE
BRAKING
CA398-3
+V
OPT
OPT
STEP
7
DCI
MX DISABLE
123 45 6
J4
NL1
IOC
J2
START
STOP
Page 16
SCR9
MOV
MOV
SCR8
SCR1
MOV
SCR2
L1
SCR3
CT4
MOV
PROTECTED
L2
200-600V
SCR4
50/60HZ
3 PHASE
SCR5
MOV
SCR6
FAULT
AC1
PROTECTED
110V ,50Hz
120V, 60Hz/
FAULT RUN
RUN
123456 7
TB
N
SUPPLY
TO SCR GATES
G1 K1 G2 K2 G3 K3 G4 K4 G5 K5 G6
L3
OP-STOP DC INJECTION BRAKE
5.3 REVERSING OPAL STARTER WITH DC INJECTION, 125 AMPS AND
BELOW
1
2
TIME
BRAKING
R7
BURDEN
RESISTOR
BRAKING
3 PHASE
INDUCTION
MOTOR
K4G1 K1 G2 K2 G3 K3 G4
SCR1 SCR8 SCR4 SCR9
CA398-3
FBK
T1
T2
T3
12
CURRENT
J3
VFB
1
J5
K10G7 K7 G8 K8 G9 K9 G10
DC
INJECTION
2
TORQUE
+V
TIME DELAY
REVERSING
7
DCI
MX DISABLE
123 45 6
J4
NL1
IOC
OPT
J2
AC
4321
FWD/REV
SWITCH
FWD/REV
SCR9
MOV
SCR10
SCR7
MOV
SCR8
SCR1
NEUT.
CA388-4
FWD
RATE
CA392-2
AC1
120V
REV
OPT
P1
P1
OPT
STEP
STOP
START
FAULT RUN
RUN
12345 6 7
TB
N
TO SCR GATES
SCR2
MOV
CT1
L1
SCR3
SCR4
MOV
CT2
CT4
L2
SCR5
SCR6
MOV
K6
TO SCR GATES
G1 K1 G2 K2 G3 K3 G4 K4 G5 K5 G6
CT3
FAULT
43 21
L3
PROTECTED
200-600V
3 PHASE
50/60HZ
PROTECTED
110V ,50Hz
120V, 60Hz/
SUPPLY
Page 17
OP-STOP DC INJECTION BRAKE
5.4 REVERSING OPAL STARTER WITH DC INJECTION, 200 AMPS AND
ABOVE
1
2
TIME
BRAKING
R7
BURDEN
BRAKING
RESISTOR
3 PHASE
INDUCTION
MOTOR
K4G1 K1 G2 K2 G3 K3 G4
SCR1 SCR8 SCR4 SCR9
CA398-3
FBK
T1
T2
T3
12
CURRENT
J3
VFB
1
J5
K10G7 K7 G8 K8 G9 K9 G10
DC
INJECTION
2
TORQUE
+V
TIME DELAY
REVERSING
7
DCI
MX DISABLE
123 45 6
J4
NL1
IOC
OPT
J2
AC
4321
FWD/REV
SWITCH
FWD/REV
SCR9
MOV
SCR10
SCR7
MOV
SCR8
SCR1
NEUT.
CA388-4
FWD
P1
P1
RATE
CA392-2
AC1
120V
REV
OPT
OPT
STEP
STOP
START
FAULT RUN
RUN
12345 6 7
TB
N
TO SCR GATES
CT3
CT2
CT1
SCR2
MOV
L1
SCR3
SCR4
MOV
CT4
L2
SCR5
SCR6
MOV
L3
43 21
K6
TO SCR GATES
FAULT
G1 K1 G2 K2 G3 K3 G4 K4 G5 K5 G6
Page 18
PROTECTED
200-600V
3 PHASE
50/60HZ
PROTECTED
120V, 60Hz/
SUPPLY
110V ,50Hz
OP-STOP DC INJECTION BRAKE
6 SPARE PARTS
DCI-20 1500:1 T261123 N10SP03 CA524 CA398
DCI-40 1500:1 T261123 N10SP06 CA524 CA398
DCI-80 2500:1 T262230 N10SP16 CA524 CA398
DCI-125 2500:1 T262230 N20SP06 CA524 CA398
DCI-200 2500:1 T262230 N728452 CA232 CA398
DCI-300 5000:1 T265320 N718602 CA232 CA398
DCI-500 8500:1 T268320 N718133 CA232 CA398
OP-STOP
MODEL
CT
RATIO
CT
PART NO.
SCR
PART NO.
SNUBBER
CARD
CONTROL CARD
DESCRIPTION
Page 19
18 Neville Street, Unit C
New Hamburg, ON N3A 4G7
Tel: 519-662-6489
Fax: 1-866-280-5247
www.safdrives.com
www.opalstarters.com
email: answers@opalstarters.com
(Replies given within 24 hours)
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