Carotron EP2020-000 User manual

Instruction Manual
Models
EP2020-000 EP4020-000
EP2040-000 EP4040-000
EP2060-000 EP4060-000
EP2075-000 EP4075-000
EP2100-000 EP4100-000
EP2125-000 EP4125-000
EP2150-000 EP4150-000
EP2200-000 EP4200-000
EP2250-000 EP4250-000
EP2300-000 EP4300-000
EP2400-000 EP4400-000
EP2500-000 EP4500-000
EP2600-000 EP4600-000
EP2700-000 EP4700-000
V3

2
Table of Contents
1. General Description .......................................................................................................................................... 4
2. Specifications .................................................................................................................................................... 4
2.1 Electrical............................................................................................................................................. 4
2.2 Physical.............................................................................................................................................. 5
3. Installation ......................................................................................................................................................... 7
3.1 Control Installation ............................................................................................................................. 7
3.2 Wiring Guidelines............................................................................................................................... 7
4. Terminal Connections & Functions ................................................................................................................... 7
4.1 AC Power Connections & Fusing....................................................................................................... 7
4.2 Motor Connections ............................................................................................................................. 9
4.3 Signal Connections .......................................................................................................................... 11
5. Human Machine Interface (HMI)..................................................................................................................... 14
5.1 Description of Interface .................................................................................................................... 14
5.2 Menu Structure................................................................................................................................. 15
6. Start Up Procedure ......................................................................................................................................... 17
6.1 Pretest.............................................................................................................................................. 17
6.2 Adjustment Procedure: Velocity (Speed) Regulator.........................................................................17
6.3 Adjustment Procedure: Constant Horsepower.................................................................................19
6.4 Adjustment Procedure: Torque (Current) Regulator........................................................................19
6.5 Calibration & Fine Tuning.................................................................................................................19
6.4 Password Protection ........................................................................................................................ 21
7. Programming & Adjustments .......................................................................................................................... 22
7.1 A: Options ........................................................................................................................................ 22
7.2 B: Digital Inputs ................................................................................................................................ 23
7.3 C: Analog Inputs............................................................................................................................... 29
7.4 D: Digital Outputs ............................................................................................................................. 34
7.5 E: Analog Outputs ............................................................................................................................ 38
7.6 F: Motor Data ................................................................................................................................... 40
7.7 G: Control Loops .............................................................................................................................. 44
7.8 H: Start/Stop Logic ........................................................................................................................... 52
7.9 I: Setpoints ....................................................................................................................................... 56
7.10 J: Ramps........................................................................................................................................ 58
7.11 K: Fault Logic ................................................................................................................................. 62
7.12 L: Applications................................................................................................................................ 68
7.13 M: Thresholds ................................................................................................................................ 78
7.14 N: Timers ....................................................................................................................................... 81
7.15 O: Logic Gates ............................................................................................................................... 83
7.16 P: Switches .................................................................................................................................... 86
7.17 Q: Internal Links ............................................................................................................................. 87
7.18 R: Communications........................................................................................................................ 88
7.19 S: Zero Speed ................................................................................................................................ 91
7.20 T: System ....................................................................................................................................... 92
7.21 U: Auxiliary ..................................................................................................................................... 94
7.22 Parameter Table ............................................................................................................................ 95
8. Troubleshooting ............................................................................................................................................ 109
9. Serial Network Communications................................................................................................................... 113
9.1 Physical.......................................................................................................................................... 113
9.2 Modbus® Protocol.......................................................................................................................... 113
10. Spare Parts ................................................................................................................................................. 115
10.1 Printed Circuit Assemblies ........................................................................................................... 115
10.2 Fuses ........................................................................................................................................... 115
10.3 Power Components...................................................................................................................... 117
11. Prints ........................................................................................................................................................... 118
D14171 Control Board Assembly......................................................................................................... 118
D14163 Trigger Board Assembly......................................................................................................... 119
D14177 Regulator Board Assembly..................................................................................................... 120
C14188 Snubber Board Assembly....................................................................................................... 121
C14166 CT ID Board Assembly........................................................................................................... 122
C14045 Processor Board Assembly .................................................................................................... 123

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D14270 Assembly Drawing, 20-60HP Models .....................................................................................124
D14316 Assembly Drawing, 75-150HP Models ...................................................................................125
DXXXXX Assembly Drawing, 200-400HP Models ...............................................................................126
D14356 Assembly Drawing, 500-700HP Models .................................................................................127
D14263 Assembly, Heatsink Chassis, 20-60HP Non-Regen Models ..................................................128
D14264 Assembly, Heatsink Chassis, 20-60HP Regen Models..........................................................129
D14347 Assembly, Heatsink Chassis, 75-150HP Non-Regen Models ................................................130
D14318 Assembly, Heatsink Chassis, 75-150HP Regen Models........................................................131
DXXXXX Assembly, Heatsink Chassis, 200-300HP Non-Regen Models............................................132
DXXXXX Assembly, Heatsink Chassis, 400HP Non-Regen Model.....................................................133
DXXXXX Assembly, Heatsink Chassis, 200-300HP Regen Models....................................................134
DXXXXX Assembly, Heatsink Chassis, 400HP Regen Model.............................................................135
D14350 Assembly, Heatsink Chassis, 500-700HP Non-Regen Models ..............................................136
D14351 Assembly, Heatsink Chassis, 500-700HP Regen Models......................................................137
D14248 Wiring Diagram, 20-60HP Non-Regen Models ......................................................................138
D14249 Wiring Diagram, 20-60HP Regen Models ..............................................................................139
D14322 Wiring Diagram, 75-150HP Non-Regen Models ....................................................................140
D14314 Wiring Diagram, 75-150HP Regen Models ............................................................................141
DXXXXX Wiring Diagram, 200-400HP Non-Regen Models ................................................................142
DXXXXX Wiring Diagram, 200-400HP Regen Models ........................................................................143
D14353 Wiring Diagram, 500-700HP Non-Regen Models ..................................................................144
D14354 Wiring Diagram, 500-700HP Regen Models ..........................................................................145
D14308 General Connections ..............................................................................................................146
D14306 RS422/485 Network Connections ..........................................................................................147
C14307 Sonic Transducer Option Connections...................................................................................148
D14309 Software Block Diagram .........................................................................................................150
12. Standard Terms & Conditions of Sale.........................................................................................................155
List of Tables
Table 1: Model Rating Data...................................................................................................................................9
Table 2: HMI Description.....................................................................................................................................14
Table 3: Drive Monitor Descriptions ....................................................................................................................16
Table 4: Common Digital Input Functions ...........................................................................................................23
Table 5: Common Analog & Freq Input Functions ..............................................................................................29
Table 6: Analog Input Status Readings...............................................................................................................30
Table 7: Common Relay & Digital Output Functions...........................................................................................34
Table 8: Common Analog & Freq Output Functions ...........................................................................................38
Table 9: Analog Output Status ............................................................................................................................39
Table 10: Drive Modes ........................................................................................................................................54
Table 11: Reference Select.................................................................................................................................56
Table 12: Faults 1................................................................................................................................................64
Table 13: Faults 2................................................................................................................................................64
Table 14: Alarms 1 ..............................................................................................................................................65
Table 15: Inertia Sensitivity .................................................................................................................................75
Table 16: Logic Gates Truth Table......................................................................................................................85
Table 17: Parameters..........................................................................................................................................95
Table 18: Faults.................................................................................................................................................109
Table 19: Supported Modbus® Functions.........................................................................................................114
Table 20: Field Fuses........................................................................................................................................115
Table 21: Recommended Line Fuses ...............................................................................................................116
Table 22: Armature Bridge Modules .................................................................................................................117
Table 23: Field Supply Modules ........................................................................................................................117

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General Description
The ElitePro V3 Series is Carotron's 3rd generation of microprocessor based D.C. motor controls.
The series provides control of speed and torque control of 5-700HP D.C. motors rated for NEMA
type "C" power supplies. The EP2 (non-regenerative) series and the EP4 (regenerative) series are
offered in compact panel mounted assemblies.
Specifications
2.1 Electrical
A.C. Input Voltage Range
• 3 phase, 230-460 VAC ± 10%, 50/60 Hz ± 2 Hz
• 1 phase, 115 VAC ± 10%, 50/60 Hz ± 2 Hz, 5A
A.C. Line Field Supply - 1 Phase (Optional)
• 230-460 VAC ± 10%, 50/60 Hz ± 2 Hz
Armature Output
• 0-240VDC @ 230 VAC input
• 0-415VDC @ 380 VAC input
• 0-500VDC @ 460 VAC input
Field Output
• Voltage
0-200VDC @ 230 VAC input
0-330VDC @ 380 VAC input
0-400VDC @ 460 VAC input
• Current
EPx020-000 thru EPx060-000: 8A max
EPx075-000 thru EPx150-000: 10A max
EPx200-000 thru EPx700-000: 12A max
Power Supplies
• +24V (TB1-1): 50mA
• +12V (TB1-17): 100mA
• +10V (TB1-16): 50mA
• -10V (TB1-46): 50mA
Digital Inputs (Qty: 7)
• Sink Mode
V
ih
=20.0 VDC max
V
il
=0.0 VDC min to 17.0 VDC max
• Source Mode
V
ih
=8.0 VDC min to 30.0 VDC max
V
il
=5.0 VDC max
Analog Inputs (Qty: 5)
• Voltage Mode
Max Input:±10 VDC
Input Impedance: 1MΩ
• Current Mode
Max Input: ±20 mADC
Input Impedance: 250Ω
• Resolution: 12 bit
Tachometer Feedback Input
• Max Input: ±200 V (AC or DC)
Encoder Feedback Input
• Frequency: 200kHz max
• Uni-directional (single channel) or Quadrature
• Single ended or differential
• Voltage: 12 VDC max
Frequency Input
• Frequency: 40kHz max, square wave
• Voltage: 12 VDC max
V
il
=0.0 VDC to 1.5 VDC max
V
ih
=2.5 VDC min to 12.0 VDC max
Relay Outputs (Qty: 3)
Form-C contact:
• 2 A @ 115 VAC (resistive)
• 2 A @ 60 VDC (resistive)
Armature Pilot Relay Output
• 30 A @ 120 VAC (resistive)
• 30 A @ 28 VDC (resistive)
Analog Outputs (Qty: 2)
• ±10 VDC max, 20mADC max
• Resolution: 12 bit + sign
Frequency/Digital Output
• Frequency: 10kHz max, square wave
• Sink current: 100mA max
• Voltage: 30VDC max
Speed Regulation
• Armature Feedback: ±1%
• Tachometer Feedback: ±0.01%
• Encoder Feedback: ±0.01% (with 1024 min ppr)
Torque Regulation
• ±1% of Range Selected
Speed Range
• 100:1 typical when using tachometer or encoder
feedback. May be less depending upon motor
characteristics
Temperature Range
• Chassis: 0-55C
• Enclosed: 0-40C
1
11
1
2
22
2

5
EPx075-000 thru EPx150-000
EPx020-000 thru EPx060-000
PRO
2.2 Physical
PRO

6
EPx500
-
000 thru EPx600
-
000
PRO
EPx200
-
000 thru EPx400
-
000
PRO

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Installation
3.1 Control Installation
Elite Pro motor controls require mounting in an upright position in an area that will permit adequate
airflow for cooling and ready access for making connections and for servicing. Because cooler air is
drawn in from the bottom and exhausted from the top, these areas should be kept clear for about a
six inch distance. Stacking of controls with one mounted above the other should be minimized so that
the upper control is not ventilated with hot exhaust air from the lower control.
Enclosures should be sized to provide adequate surface area for dissipating heat or provided with
forced ventilation with outside air from a duct system or enclosure fan. They should be mounted to a
cool surface not exposed to heat generated by nearby equipment.
Excess ambient temperatures within enclosures can reduce the life expectancy of electronic
components and can cause a heatsink over temperature fault on the Elite Pro control. Contact
Carotron for assistance in sizing enclosures for particular horsepower ratings.
3.2 Wiring Guidelines
To prevent electrical interference and to minimize start-up problems, adhere to the following
guidelines.
Make no connections to ground other than the designated terminal strip location.
Use fully insulated and shielded cable for all signal wiring. The shield should be connected at one
end only to circuit common. The other end of the shield should be clipped and insulated to prevent
the possibility of accidental grounding.
Signal level wiring such as listed above should be routed separately from high level wiring such as
armature, field, and relay control wiring. When these two types of wire must cross, they should cross
at right angles to each other.
Any relays, contactors, starters, solenoids or electro-mechanical devices located in close proximity to
or on the same line supply as the motor control should have a transient suppression device such as
an MOV or R-C snubber connected in parallel with its coil (for AC coils). Diode suppression should
be used for DC coils. The suppressor should have short leads and should be connected as close to
the coil as possible.
Terminal Connections & Functions
4.1 AC Power Connections & Fusing
Terminals L1, L2, and L3 are the AC line inputs for the armature power bridge. High speed
semiconductor fuses must be provided externally. Refer to Figure 1 and Figure 2 on the next page
and Table 21 in the Spare Parts Section on page 116 for common manufacturers and part numbers.
In most cases, the drive will use the internal field supply wiring scheme (Figure 1). The field bridge
is powered from the auxiliary L1 and L2 output terminals via factory installed jumpers. However, in
some cases, the field voltage required by a motor exceeds the maximum obtainable field voltage that
can be produced using the required AC line voltage for the motor armature. In these cases, an
external single phase AC supply for the field bridge must be used. The factory supplied terminal
jumpers should be removed and the external supply connects to FL1 and FL2 (Figure 2). Note the
external supply must be in phase with the L1 and L2 armature supply terminals.
3
33
3
4
44
4

8
For example, consider the motor that has a rated armature voltage of 240VDC and a rated field of
240VDC. The rated armature voltage requires that an input supply of 230VAC be connected to L1,
L2, and L3. However, the maximum field voltage attainable from the field bridge using the internal
supply would be 200VDC. In order to obtain the required 240VDC field, an external single phase
460VAC supply (obtained via a transformer) can be connected to FL1 and FL2.
The drive also requires a fused single phase 115VAC control power on terminals L and N.
Carotron recommends the use of three phase DIT, drive isolation type transformers. While Elite Pro
controls do not require these transformers for proper operation, they can be helpful in reducing the
effects of line transients on this control and generated by this control on other products and can
provide fault current limiting in the event of severe motor or control failure. Refer to Table 1 as a
general guide in sizing line supply transformers and wiring.
Figure 2: External Field Supply Wiring
Figure 1: Internal Field Supply Wiring

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Drive
Model
Arm
Volts
Motor
HP
Approx. Full Load
Line Amps
3 Phase DIT
KVA Rating
Arm
Amps
Contactor
Rating
D.B. Resistor
Rating
5 18 7.5 18 10Ω, 300W
7.5 26 11 28.1 5Ω, 600W
240
10 34 14 36
40 Amps
4.4Ω, 750W
5 9 7.5 8.5 40Ω, 375W
7.5 14 11 13.2 20Ω, 750W
10 18 14 17.2 20Ω, 750W
15 25 20 25.2 14Ω, 1000W
EPx020-000
500
20 34 27 36
40 Amps
10Ω, 1500W
15 50 20 55 3Ω, 1000W
240 20 65 27 71 75 Amps 2.2Ω, 1500W
25 40 34 43 7Ω, 2000W
30 47 40 51 6Ω, 2000W
EPx040-000
500
40 63 51 71
75 Amps
5Ω, 3000W
25 84 34 91.1
240 30 98 40 107 110 Amps 1.7Ω, 2000W
50 78 63 83.7
EPx060-000
500 60 93 75 107 110 Amps 3.4Ω, 4000W
240 40 118 51 180 Amps 1.3Ω, 2080W
EPx075-000 500 75 106 93 140 180 Amps 2.6Ω, 4160W
240 50 148 63 180 Amps 0.62Ω, 2232W
EPx100-000 500 100 141 118 174 180 Amps 1.24Ω, 4464W
240 60 174 75 260 Amps 0.62Ω, 2232W
EPx125-000 500 125 177 145 206 260 Amps 1.24Ω, 4464W
240 75 93 260 Amps 0.62Ω, 2232W
EPx150-000 500 150 213 175 256 260 Amps 1.24Ω, 4464W
240 100 118 360 Amps 0.47Ω, 4700W
EPx200-000 500 200 283 220 340 360 Amps 1.02Ω, 6500W
240 125 145 535 Amps 0.37Ω, 5300W
EPx250-000 500 250 354 275 425 535 Amps 0.82Ω, 11000W
240 150 175 535 Amps 0.31Ω, 7000W
EPx300-000 500 300 426 330 510 535 Amps 0.65Ω, 14600W
240 200 220
EPx400-000 500 400 555 440 688 Consult
Factory
Consult
Factory
240 250 275
EPx500-000 500 500 694 550 850 Consult
Factory
Consult
Factory
240 300 330
EPx600-000 500 600 832 660 1020 Consult
Factory
Consult
Factory
240 350 385
EPx700-000 500 700 950 770 1165 Consult
Factory
Consult
Factory
Table 1: Model Rating Data
x=2 for non-regenerative models
x=4 for regenerative models
4.2 Motor Connections
Field
Most motor fields consist of two windings that are connected in parallel for low voltage operation and
in series for high voltage operation. Refer to Figure 3. The winding leads are individually marked
and have a polarity that must be observed for proper and safe operation. Since direction of rotation is
controlled by field polarity as well as armature polarity, it is sometimes more convenient to swap the
smaller field leads when making corrections to the direction of rotation during initial installation. An
energized field should never be switched by relay, contactor, switch or any other manual or electro-
mechanical device.
In most cases, when the Elite Pro is supplied with 230VAC, the field should be wired for low voltage
operation. When supplied with 460VAC, the motor field is typically wired for high voltage operation.
The F1 and F3 leads should always have the same polarity regardless of the mode used.

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Armature
The armature leads are usually the highest current wires associated with the drive and warrant
special attention to sizing based on current rating as well as length of run. Extra care should be used
where terminations and splices are made. Refer to Table 1 for typical armature voltage, current,
contactor and dynamic braking resistor ratings. Figure 4 shows a typical armature wiring scheme
using a contactor. An optional dynamic breaking resistor is also shown.
Series Field
When present, the S1 and S2 for the SERIES field winding is placed in series with the armature
leads on non-regenerative models only! They should NOT be used with the EP4 Series
regenerative models. On regenerative models, the leads should not be connected and should be
individually insulated. On non-regenerative models the series field winding polarity must be kept at
the same polarity as the shunt field winding, i.e. F1 and S1 the same, F2 (or F4) and S2 the same. If
during startup the field windings are reversed to change direction of the motor, the series windings
should also be reversed to maintain the proper polarity. Figure 5 shows a typical wiring scheme
using the series field with a non-regenerative drive. Note the polarity of the shunt field and series
field windings (S1 is positive with respect to S2, F1 is positive with respect to F2).
Figure 4
Figure 3