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    339 views24 pages

    Danfoss Manual

    Uploaded by

    Elizabeth Ag

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    Danfoss drive manual cr. Graham TRANSMISSIONS, Inc. Installation,Operation and Maintenance Manual Cycletrol’ 150 TABLE OF CONTENTS Forward 1 Specifications 2 Operational Characteristics 4 Application Wiring Diagram 7 Programmable Switch 8 Installation 10 Start Up Procedure " Adjustments Atter Start Up 2 Trouble Shooting Guide 8 General Wiring Di 15 Component Location Photos 16418 Dimensions. 7819 Recommended AC Line Protection 20 Replacement Parts and Fuses 20 Motor Operation and Maintenance Instructions 21 CE Labeling 2 Line Fitter Er WARNING FORWARD ‘The Cycletrol 150 is a convenient way to start and stop a DC motor rapidly and repeatedly and at the same time contol its running speed. This control continuousiy adjusts the electrical power to the motor fo maintain the desired speed regardless of the load on the motor provided, of course, that the motor load is less than the Current limit setting. On command this control turns off ower to the motor and tums on an electronic dynamic brake for rapid stopping. To simplify the use of this control its features include: 1. Speed control, the speed may be continuously varied by a potentiometer or by process signal 2. Intemal adjustments to limit minimum and maximum speed and to limit maximum motor current; 3. Stam/Stop logic that operates directly from ‘momentary push buttons or other signals without using a latching relay; 4. Rapid acceleration starts at currents in excess of running current limit and rapid dynamic braking stops; 5. A brake or coast to stop switch that allows gentle stops; 6. Atimer that may be used for automatic restart or timed run; 7. Color coded light emitting diodes to indicate contro! actions, The remainder of in much mare detail is manual will cover the Cycletral 160 Doe Ree eee eee een errr) tolir Pr eo er erae ra eae hack eee eee eae ee ee ee ee meee ast! ices acc bi Follow this manual and National Electrical Codes and local safety codes. CAUTION Its the responsibility of the user or the person installing the controller to provide proper grounding, as well as motor overload and branch circuit protection according 4 1 a ae SPECIFICATIONS INPUT POWER... OUTPUT. ENCLOSURE... AMBIENT TEMPERATURE RANGE. POWER DISSIPATION... MOUNTING POSITION. OPERATOR CONTROL PROVISIONS. INTERNAL CONTROLS. PROCESS SIGNAL INPUT. TACHOMETER GENERATOR FEEDBACK INPUT. ‘SPEED VARIATIONS DUE TO LINE FLUCTUATIONS. ‘SPEED VARIATIONS DUE TO THERMAL DRIFT. ‘SPEED VARIATIONS DUE TO LOADING. (90% LOAD CHANGE) MAX RUN SPEED... MIN RUN SPEED..... 85 TO 195VAC on 120VAG Models 195 to 2B0VAG on 240VAG Models 50/60 Hz Single Phase (Refer to table on facing page) Armature: (0-30VDC on 120VAC Models 0-12.2A, 1/810 1 HP (0-180VDC on 240VAC Models 0-10.8A, 1/4 102 HP or 0-16A, 1/4 10 3 HP intermittent (Refer to table on facing page) ‘Chassis (IP00) or NEMA 12 (IPS4) 0" to 50°C Chassis (P00) at rated load, (0° to 40°C NEMA 12 (IP54) at rated load, 90° to 65°C storage and transport. Chassis (P00) est. 115 Watt at 3 HP NEMA 12 (IP54) got, 80 Watt at 2 HP Vertical ‘Star, Stop, Jog. Override Stop, Reset, Run Speed, Timer Max. Speed, Min. Speed, Current Limit, Programmable Switches (0-10 V de control signal input. Input resistance 200K ‘ohm, Also usable for 1-5 mA, 4-20 mA 10-60 mA with external rasistor. 21VDCr1000 RPM ‘The control will compensate to less than 1% armature voltage change in less than 500 milliseconds within input power range. Controt: Less than 8% Motor: Depends on motor and application ‘System with Tachometer Feedback: Less than 1%. ‘Amature Feedback: Typical application $% of full speed. Tachometer Feedback: lass than + 0.5% of Sel Speed or +£0.25% of full speed, which ever is greater. Adjustable from approx. 1/2 to tull speed. Adjustable trom © to approx. 1/2 of full speed ACCELERATION Fixed at approx. 0.20 seconds, nonlinear. Other times are available, consul factory. CURRENT LIMIT. Adjustable from 0-125% of full rated output Four times setting permitted for 0.2 seconds during starting acceleralion. Four times feature may be defeated. APPROVALS. UL, cUL, CE [ [RATED INPUT RATED OUTPUT. | ASASPEED CONTROL ASA GYCLING CONTROL | | STEADY DRIVE | | STATE PART | Max | TOTAL INERTIA® | MOTOR NUMBER | VOLTS AMPS | HP | vouTs | amps | cPM= | LeWIN? [kGeME | CURRENT NEMA 12 (IP54) | VERSIONS: | +7886000 120 | 17 | 1 | 090 |122cont] 60 | 134 jo003 | 240 47eB8021 : 3 tea6o01 | 240 | e5 | 1 |o180 | e1cont| 0 | 134 [0.0009 | 142A 11786002 240 | 15 | 2 | 0-480 |108conT} 20 | 431 oor | 220 reaso0s | 240 | 22 | 3 | o1ao | 1601Inr™) 16 | 50.1 [0.0147] | 324 ‘CHASSIS (IP00) | VERSIONS |__17epso0a | 120 | 17 | 1 | 090 | 122CONT 13.4 [0.003] | 24a s7epeo0s | 240 | 22 | 3 | 0-160 | 16.0CONT 50.1 [0.0147] B2A \ Intermittent duty as a speed control operating at full load only. Duty Cycle: 40% at 16 A, not longer than 24 minutes continuously, 60% stopped This does not atfect cyciing. Cycling rates (Cycles Per Minute) are based on Graham Transmissions eycling duty DC motors accelerating from ze"0 to rated speed and braking to zere with: + Armotor having the same HP rating as the drive + Alcad inertia reflected to the motor shaft of not more than 25% of the motor inertia; and + Asteady state friction load corresponding to a motor current of not fore than 20% of drive current rating ‘while operating at rated motor speed. Motor inertia + Load Inertia refelected to the motor shaft Special OPERATIONAL CHARACTERISTICS EXTERNAL CONTROLS START (Terminals 4 & 4, Normally Open Contact) ‘A start contact closure latehes the Cycletrol 150 into 2 1un mode and lights the RUN mode LED (yellow) indicator. A START corumand can be overridden by a STOP or OVERRIDE STOP command, ‘STOP (Terminal 3 & 4, Normally Closed Contac!) ‘An open contact at STOP unlatches the RUN command and causes the motor to stop. This {unction can be modified by changing the “O° and “V" switches foune on the printed ciccut assembly. See page 5. The units are shipped from the factory with te °O" and "J" switches inthe closed (up) position. 0G (Terminals 2 & 4, Normally Open Contact) ‘A contact clesure in JOG causes a Cycletrol 150 10 0 into the RUN mode and jights the RUN LED (Gellow) 2s long as the contact is closed. Jag does Rotlatch. The Gycletro! 150 will sop when JOG is opened. JOG may be maintained for continuous running. OVERRIDE STOP and STOP override a JOG command. OVERRIDE STOP (Terminals 6 & 4, Normally Closed} (OVERRIDE STOP is an aiternate means of stopping the Cycietrol 160. OVERRIDE STOP always overrides a START, JOG or a timer generated START command. A momentary contact opening of ‘OVERRIDE STOP laiches the Cycletral 150 into the OVERRIDE STOP mode and lignts the BRAKE LED (fed). OVERRIDE may be reset by momentarily closing RESET or by cycling AC power. OVERRIDE STOP overrides RESET. OVERRIDE STOP always causes the Cycletrl to brake to a stop. Ve eae NN Use em ten ett a PN eves eiaeite sail ere to os Cea Cg anal a Sapesommat EQUIPMENT SHOULD ALWAYS RE ovement ae Pea) 5 RESET (Terminals 5 & 4, Normally Open Contact) RESET unlatcnes an OVERRIDE STOP condition. OVERRIDE STOP will override RESET, ‘These five external control logic terminals have a nominal ‘open circut voltage of about 24 volts DG measured trom terminal 4 (COMMON) which is (-), and a closed cireut Current of about 13 mA each. Use switch or relay Contacts that are designed to operate rellably at these levels. Gold, gold alloy, and fine silver switch or relay Contacts and mest silver cadmium-oxide pilot duty switch and relay contacts wil perform adequately Solid state devices may be used to operate these circuits provided they meet the folowing specifications: 1. OFF stato voltage withstand 36 VOC minimum: 2. OFF state leakage less than 1 mA, 3. ON state current rating is greater than 15 mA; and 4. ON state voltage drop less than 1 V at 15 mA Alllogie and speed control terminals are isolated from power circuits and from ground. The lagie commen {terminal (4) or the speed common terminal (11) may be connected to earth/qround. Enclosed controls have a START-JOG/STOP switch on the cover wired to the START, JOG and COMMON terminals. Press up to siart, press down and release to stop oF jog. Adkitional control wiring from external equipment can be connected in addition to the front cover STARTJOGISTOP switch. The STOP and OVERRIDE ‘STOP terminals must be jumpered to COMMON unless, extemal circuits are connected for those functions, SPEED CONTROL The Cycletrol_ 150 provides infinitely variable speed ‘control, There is compensation for line voltage variation and variations in motorlcading. Ata given speed potentiometer setting and with a constant load, the motor armature voltage will vary less than 1% with an input voltage change of + 10% of nominal. If tachometer feedback is used, the speed variations will be less than 12% regardless of motor temperature or load. A major design parameter of this control was to limit oversticot, undershoct and settling time, These characteristics are ‘more than adequate for almost all applications. PROCESS CONTROL SIGNALS ‘A.0-10V de control signal input may be used by connecting process signal (+) to SP2 and process (-} to ‘SP3. With tachometer feedback, the motor speed will tack the process voltage to betfer than 1% linearity. The input impecance is approx. 50K ohms. Current process signals may be used with an additional resistor, A 1-5 mA signal can be accommodated by shunting SP2 and SP3 with a 2.0K ohms, 1/2 watt resistor; for 4-20 mA, use a 500 ohms , 1/2 watt. Set the “P* switch in the closed (up) position, to allow the Cycletrol 150 to operate with current process signals. TACHOMETER FEEDBACK For application reauiring more accurate speed regulation and/or wider speed range of full torque, the Cycletro! 150 ‘can accept an analog tachometer feedback signal. By removing the RA resistor, (See page 18 for location) a 20.8 VOC/100 RPM tach can be usad for close-loop ‘operation. The tachometer leads shouid be appropriately connected to TB1 terminals T+ and T- | CAUTION: Connect correct polarity. Reversed | tachometer polarity wil cause the drive to accelerate | the motor to the maximum speed the available AC line | voltage will suppor. Shielded twisted pair cable is recommended for the tachometer. The shield should be fully insulated from {ground along its full angth. The shield should be ‘rounded atthe crive end at the earthground terminal. PGA ae Ra eee eras RECTIFIED AG LINE VOLTAGE (-) AT ALL TIMES sgl ae=earehn ah Ua asi ale NOT THE DRIVE IS TURNING THE MOTO! TIMER Most application requiring ausiomatic cycles such as timed run or cycle on demand or requiring delayed start ‘or delayed stop can be accomplished using the programming switch sections A, B, C, 0, and. The time is set by a resistor connected between terminals V + (7) and TIME (8). A direct connection results in minimum time, approximately 1/4 second. The maximum recommended resistance, 2 meg chms, yialds about 20 seconds The control is shipped with the timer disabled (T is up) and completely disengaged trom the rest of the circuit (AB, C, and D are down), For automatic cycles see the application section. For other timer applications, consult the factory. Tm cn scm ca cme (ose mel dake Maken emi Eile Rea te Nero =a} EDM e) ol gela is foresee Na! WITH BOTH C AND D NES olsen MeN oe N otro NOT OPERATE WITH el Mit eT eli) eters INTERNAL CONTROLS MIN SPEED: The speed corresponding to the minimum setting of the SPEED CONTROL may be adjusted by this trim potentiometer on the printed circult assembly. The range is from zero to about 1/2 speed. MAX SPEED: The speed corresponding to maximum seiting of the RUN SPEED CONTROL is adjusted by this trim potentiometer and can be seta any value between about 12 and full output, The SPEED CONTROL agiusiment will vary the motor speed smoothly and linearly between the speeds set by the MIN SPEED and MAX SPEED. (CURRENT LIMIT: ‘The Gycletrol 180 is provided with an adjustment current limit circuit which can be set to limit the torque output of the motor over a range of near zero 10 125% of control rating, This circuit will not affect ‘the motor speed until the motor current (loading) increase to the set point. When the motor current is greater than the current limit setting, the control wil reduce tha motor speed as much 4s necessary to keep motor current from exceeding the set value; even to zero speed. For about .2 seconds fcllowing, a START type command, the current limit will permit motor currents up to 4 times setting. This extra inrush allows faster cyciing and may be defeated by moving resistor R40 when not desired (see page 16 {or location), PROGRAMING SWITCHES: ‘Several switches have been designed into the Cycietrol 150 to allow it to be tailored to many applications, The unit is shipped configured for the most common use but may be changed by opening ‘or olosing the switches . COAST BRAKE: ‘The solid state dynamic brake may be turned off by moving the COAST-BRAKE switch on the printed circuit assembly fo the COAST position. This allows the motor to coast to a stop following JOG or STOP operations. OVERRIDE STOP or POWER OFF will always operate the bake with the switch in either Position. T (TIMER DISABLE): ‘Aullomatic timing is disabled by having this switch closed (up). Once opened (down) the timer will always be active unless disabled by external circuit or by OVERRIDE STOP. The contro! is shipped with this switch closed (up), and with a jumper installed between TB2 terminals 4 and 8, which will need to be removed to use the limer function. {A,B (TIMER INITIATION) “These switches determine whether the control stops or stats following the timer interval. Normal factory shipments have the "A" and "B* switches in the open (down) position. For automatic restart, place the “A’ switch closed (up) and "B* switch open (down). Fora timed run followed by automatic stop, open (down) “At switch and close (up) "B" switch, ‘CAUTION: Do not operate with both Aand B ewitches closed (up) since timer operation will be unpredictabi. C, D (TIMER FUNCTION): The action initiating the timer intervat is selected by these switches. Normal factory shipments °C" and. "D" switches in the open (down) position. For and. automatic restart after a delay in initiated by the STOP circuit, close (up) switch "C”. The closed (up) "D” switch should be used when the START clrcult is to start the mator and also the timer. This switch may be opened and extemal circuits to the TIMER terminal can then be used for delayed start or delayed stop operations. Consult the factory. CAUTION: Do not operate with both C and D switches closed (up) since timer operation will be unpredictable. This may include unstoppable run while power is, applied, J (STOP FUNCTION): Leaving the *J" switch in the closed }up) position. allows the drive logic to continuously act on any switch or relay contact connected to the STOP terminal. Changing the "J switch to the open (down) Position forces the dive to ignore ali but the opening transition of the STOP contact. Cycle on demand applications may be simpliied by ‘opening the "J" switch since the drive will ignore a continuing STOP signal even if system motion stops. Quickly enough to leave the STOP contacts open. Use in conjunction with the *O* switch © (LOGIC PRIORITY): The *O" switch, when closed (up), causes a STOP command to override STAAT, or JOG. Opening (Gown) the “O" switch causes a START or JOG command to override STOP. Normal factory shipments have “O" switch closed (up). (PROCESS SIGNAL OFFSET): The °P* switch modifies voltage offset at terminal ‘SP2 (speed control input). Normal factory shipments have "P* switch open (down). When using a process signal such as 4-20 mA, close (up) the "P switch. Applications Because of the many possibie circuits enly these typical Circuits for each type of operation ara shawn. If you have any questions about these or other control circuits, please consult the factory, This circuit shows the use of all functions and tach feedback. Many applications do not require ail these features. All toatures need not ke connected. The OVERRIDE STOP terminal (4) must be jumpered to the COM terminal (6) i the OVERRIDE STOP feature is not used OVERRIDE STOP a TIMER OFF) ON CAM oS Ww % sok | Time ew Layee — tive | @ —| spi | 9 srezo [ow control = ~-o0—_| Ky =~ + opTIoNAL mer | oT tach i | GENERATOR PaCS Sia Nee eG Se seta seV edn ao Nera Ve ae SY agal oh aaa ee sro emesis) I Te2 Tee sTaRT| 1 start | 1 END OF CYCLE Joa | 2 Joa | 2 sie —s_e——_| stor | 9 +} stop | 3 SS coe et + oom | 4 RESET| 5 aoe ees eT lstoP\ AUTO I STOP, AUTO — Ve osror| « els ostor| 6 wf? wiz START DELAY TIME RUNTIME: time | 8 Aw— TIME | 8 spi | ° spi | 0 speep [CW speep (OW POT S=~<0-——| sp2 | 10 POT S~+o——{ sp2 | 10 5K *K TF spa | 11 ‘Typical Automatic Cycle Typical Automatic Cycle Time dwell between cycles with automatic start Timed run following stan. ‘Open (down) switch "T*, close (up) switches: ‘Open (down) switch *T", open (down) switches "A" & *C*, apen (down) switches "B&D" close (up) switches "B&D" i Wr Gaacouae) No aMeoe rote )aI ‘Switch positions shown in configuration as they are shipped from the factory, ASWITCH B SWITCH O-SWITCH SWITCH = ——— tauren ‘ alta CLOSED (UP) SS apes " PUSH IN FOR ¥y OPEN (DOWN) eee P SWITCH (GIDE VIEW) D SWITCH SWITCH \_—— coasr-anake swirci TBe TB2 oar TB2 L ° staat | 1 stant | 1 stant Joa 2 1 wos |2 soe STOP. ja stop | 3 stop |3 t—o==70. STOP t com | 4 com | 4 com | | faeele - RESET | § RESET | 5 RESET ostop| 6 stop] 6 ostop v w |? w TE | 8 Time | 8 TIME sPi | 9 SP SPEED speep [OW speep Por pot Z

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