Carotron BLAZER IV User manual

Instruction Manual
Models
BRC702-000 BRC705-000
BRC702-0B0 BRC705-0B0
BRC702-E00 BRC705-E00
BRC702-EB0 BRC705-EB0
BRC702-E0C BRC705-E0C
BRC702-EBC BRC705-EBC
BLAZER IV
BRC700 Series

Table of Contents
1. General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Standard Features………………………………………………………………………... 2
1.2 Additional Features for Enclosed Models……………………………………………….. 3
1.3 Optional Features…………………………………………………………………………3
1.4 Programmable Features………………………………………………………………….. 3
2. Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.1 Circuit Protection ……………………………………………………………………….. 5
3.2 Connection Information……………………………………………………………….….6
3.3 Terminal connections……………………………………………………………………..6
4. Programming and Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Programming Jumpers: Power Board………………………………………………….…8
4.2 Programming Jumpers: Control Board…………………………………………………. 9
4.3 Potentiometers: ………………………………………………………………………… 9
4.4 Adjustment Procedure: Speed Regulator………………………………………………. 10
4.5 Adjustment Procedure: Torque Regulator………………………………………………12
4.6 DCM Checkpoints, Circuit Test Points and Buffered Outputs………………………….13
5. Run-Brake Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
6. Spare Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7. Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
A11097 – Myers Hub Installation………………………………………………………….. 17
D11265 – Control Board Schematic, All Models……………………………………...........18
D11267 – Control Board Assembly, All Models……………………………………………20
D11268 – Power Board Schematic, All 2 HP Models………………………………………21
D11270 – Power Board Assembly, All 2 HP Models……………………………………… 22
D11384 – Final Assembly, BRC702, All 2 HP Chassis…………………………………….23
D11378 – Dimension Drawing, All 2 HP Chassis……………………………………….… 24
D11388 – Final Assembly, All 2 HP Enclosed with Controls……………………………... 25
D11386 – Final Assembly, All 2 HP Models without Controls……….……………………26
D11377 – Dimension Drawing, All 2 HP Enclosed……………….………………………..27
D11380 – Connection Drawing, 2 HP Models without Controls….…...…………………...28
D11379 – Connection Drawing, 2 HP Models with Controls………………………………29
D11271 – Power Board Schematic, All 5 HP Models………………………………………30
D11273 – Power Board Assembly, All 5 HP Models……………………………………… 31
D11442 – Final Assembly, All 5 HP Chassis……………………………………………….32
D11445 – Dimension Drawing, All 5 HP Chassis…………………………………………. 33
D11443 – Final Assembly, All 5 HP Enclosed with Controls……………………………... 34
D11444 – Final Assembly, All 5 HP Enclosed without Controls………………………….. 35
D11446 – Dimension Drawing, All 5 HP Enclosed………………………………………...36
D11381 – Connection Drawing, 5 HP Models with Controls………………………………37
D11382 – Connection Drawing, 5 HP Chassis and no Controls Models…………………...38
1

General Description
1
The Carotron Blazer IV

BRC700 Series of
motor controls provide a full range of
regenerative speed or torque control of shunt
wound or permanent magnet D. C. motors.
Model BRC702 operates motors between 1/4
and 2 horsepower. Model BRC705 operates
motors between 1/2 and 5 horsepower. Each
model group has six standard models: two in a
compact chassis, and four in an enclosed
NEMA 12 assembly. The BRC702 models are
customer connectable for operation at 115
VAC or 230 VAC single phase input. When
operated at 115 VAC input, each unit supplies
variable armature voltage up to 90 VDC and
fixed field voltage of 100 VDC. For operation
at 230 VAC input, each model supplies up to
180 VDC for armature voltage and a fixed field
supply of 200 VDC. The BRC705 models are
customer connectable for 230 VAC input
operation only and has outputs of up to 180
VDC for the armature voltage and 200 VDC
for the field voltage.
1.1 STANDARD FEATURES
•Regenerative action provides four quadrant
speed control
•Isolation amplifier for providing isolated
armature current feedback
•Impedance isolation, 5 Meg Ohms, for
armature voltage feedback isolation
•Tachometer and encoder feedback are
insensitive to direction of motor rotation
•Encoder power supply, +12 VDC @ 100
mA, terminal strip accessible
•Jog delay to allow rapid jogging without
de-energizing the armature contactor to
extend contactor life
•Bridge delay circuitry built in to extend
contactor life
•Terminal strip access to the Total
Reference Setpoint, Velocity Loop Output
and Current Loop Input for systems
interface applications
•Internal jog pot for adjustment of Jog
Speed
•Summing Input with on board trim pot to
allow voltage summing with Speed
Reference
•Jumper selection to allow Summing Input
to be clamped or not clamped while
jogging
•Jumper selection to control summing signal
polarity
•45
ο
angle de-pluggable terminals for all
customer connections except Line,
Armature, and Field connections
•Terminal strip connections for Forward
Run, Reverse Run, Forward Jog, Reverse
Jog, Ramp Stop, and Emergency Stop
•Jumper selectable logic for Ramp Stop
•LED indicators for Power, Forward and
Reverse directions
•DCM connector and signal test points for
easy troubleshooting
•Inner current loop for fast, stable response
to load change
•Metal film resistors and cermet pots for
temperature stability
•I. C. regulated power supplies
•High frequency multi-pulse gating
•Conservative power device rating
•R – C de-coupling of signal level inputs for
superior noise rejection
•A. C. line fuses
•Armature contactor for safety disconnect
in stopped condition
•Line MOV and snubber for transient
protection
•Functional terminal strip labeling and
logical P. C. board layout
•Independent adjustable linear acceleration
and deceleration in both the forward and
reverse directions from 1 to 60 seconds
•Independent maximum speed adjustments
2

for forward and reverse directions
•Independent current limit adjustments for
forward and reverse directions
•Integral null adjustment
•Adjustable IR compensation
•Current range programmable by jumper
•Armature or tachometer feedback
programmable by jumper
•Two tachometer feedback voltages
programmable by jumper
•7 or 50 VDC per thousand RPM tach
feedback
•300 PPR Encoder Feedback
1.2 ADDITIONAL FEATURES FOR
ENCLOSED MODELS
•Power On/Off switch for control circuit
•Membrane switch control panel for Run
Forward, Run Reverse, Jog Forward, Jog
Reverse and Ramp Stop. Mushroom style
locking button for Emergency Stop
•NEMA 12 Enclosure
1.3 OPTIONAL FEATURES
•Dynamic Braking for positive stopping in
emergency situations
•Enclosed models offered in two styles; one
with controls on the enclosure and the other
without
1.4 PROGRAMMABLE FEATURES
Power Board
J1 – Current Range selector. Choose from four
different current ranges on BRC702 and six on
BRC705.
J2 – Select voltage range for Dynamic Brake
Resistor.
J3 – 115/230 VAC scaling jumper
J4 & J5 – 115/230 VAC input voltage selectors
Note: J2, J3, J4 and J5 are not on the BRC705
models.
Control Board
J6 – Reserved for future use.
J7 – R-STOP Ramp Stop selector. Allows the
use of a normally open (NO) or normally
closed (NC) contact to activate the Ramp to
Stop state
J8 – TACH TYPE Tach type selector. 7 VDC
or 50 VDC per 1000 RPM
J9 – SUM SIGNAL The Summing Signal
selector programs the summing signal to be
ADDED to or SUBTRACTED from the
Reference Signal
J10 -JOG DEL Jog Delay selector chooses
whether armature contactor drops out
immediately or after a 2.5 sec. delay when Jog
button is released.
J11- JOG & SUM The Jog & Sum selector
chooses whether or not the Summing Signal is
added to the Jog Signal.
J12 - FEEDBACK Choose between Armature
(AFB), Tachometer (TFB) or Encoder
(EFB) feedback.
J13 –FWD A/D & J14 – REV A/D These
jumpers select the accel/decel range.
Choose between 1 – 8 seconds ramp or 8 – 60
seconds ramp.
3

Specifications
2
A. C. INPUT:
Model BRC702:
•115 VAC ±10%, 50/60 Hz ±2 Hz
•230 VAC ±10%, 50/60 Hz ±2 Hz
Model BRC705:
•230 VAC ±10%, 50/60 Hz ±2 Hz
Note: Suitable for use on a circuit capable of
delivering not more than 5000 RMS
symmetrical amps, 240V maximum.
ARMATURE OUTPUT:
Model BRC702:
•0 to 90 VDC, 0 to 10 Amperes continuous
for 115 VAC input
•0 to 180 VDC, 0 to 10 Amperes continuous
for 230 VAC input
Model BRC705:
•0 TO 180 VDC, 0 to 25 Amperes
continuous for 230 VAC input
FIELD OUTPUT:
Model BRC702:
•100 VDC @ 1 Amp for 115 VAC input
•200 VDC @ 1 Amp for 230 VAC input
Model BRC705:
•200 VDC @ 1 Amp for 230 VAC input
HORSEPOWER RANGE:
Model BRC702:
•1/4 to 1 HP @ 115 VAC
•1/2 to 2 HP @ 230 VAC
Model BRC705:
•1/2 TO 5 HP @ 230 VAC
SPEED REGULATION:
• Armature Feedback: ±1.0% of base speed
• Tachometer Feedback or Encoder
Feedback:
±0.5% of base speed
TORQUE REGULATION:
•±2% of range selected
ADJUSTMENTS:
•Max Speed: - 20 to + 10% of base speed
•Current Limit: 0 to 150% of current range
•IR Compensation: range set by current
range jumper
•ACCEL and DECEL: linear, independently
adjustable forward and reverse, 2 ranges, 1
– 8 sec., or 8 – 60 sec.
•Jog Speed: 0 to 25% of base speed
•Sum Trim: 0 to 150% of base speed
•Integral Null: adjust to eliminate motor
creeping and backup
SPEED RANGE:
•20:1, motor dependent
TEMPERATURE:
•Chassis: 0 to 55º C
•Enclosed 0 to 40º C
DIMENSIONS:
•Refer to dimension drawings D11377,
D11378, D11445 & D11446 in Section 7
for complete mounting and dimension
information on all models.
4

Installation
INPUT REQUIREMENTS – CONTROL MODEL BRC702
HP Input Voltage Input A. C. Current
@ F. L. Recommended Fuse
1/4 115 VAC 4.3 AMPS 5 AMP, MDA
1/2 115 VAC 7.9 AMPS 8 AMP, MDA
3/4 115 VAC 11.7 AMPS 15 AMPS, MDA
1 115 VAC 15.0 AMPS 20 AMP, MDA
1/2 230 VAC 4.3 AMPS 5 AMP, MDA
1 230 VAC 7.9 AMPS 8 AMP, MDA
1 1\2 230 VAC 12.2 AMPS 15 AMP, MDA
2 230 VAC 15.0 AMPS 20 AMP, MDA
NOTE:Fuses shown are manufactured by Bussman. Littelfuse type 326 may be substituted.
INPUT REQUIREMENTS – CONTROL MODEL BRC705
HP Input Voltage Input A. C. Current
@ F. L. Recommended Fuse
3 230 VAC 25 AMPS 35 AMP, SC - 35
5 230 VAC 42 AMPS 50 AMPS, SC - 50
NOTE: Fuses shown are manufactured by Bussman. Littelfuse type SLC may be substituted.
3
3.1 Circuit Protection
All BRC700 models should be installed in
accordance with the National Electrical Code
and any applicable local or state codes.
All wiring should be rated at a min. of 90ºC.
Field wiring terminal TB1 should be torqued
to 12 in.-lbs. Field wiring terminals TB2 and
TB3 should be torqued to 7 in.-lbs. Field
wiring lug terminals on BRC705 models
should be torqued to 20 in.-lbs.
Wire size and fusing should be based on
local electrical codes at each installation. Input
requirements with recommended fuse size and
type per horsepower are listed in the following
tables. All models are supplied from the
factory with line fuses sized to allow use at the
maximum horsepower rating of control.
5

3.2 Connection Information
Refer to the following connection diagrams
for appropriate model:
•For Model BRC702-E0C, –EBC, -E00 and
-EB0 refer to Connection Diagram D11379
•For Models BRC702-000 and -0B0 refer to
Connection Diagram D11380
•For Models BRC705-000 and -0B0, refer
to Connection Diagram D11382
•For Models BRC705-E0C, –EBC, -E00
and -EB0, refer to Connection Diagram
D11381
Wiring Precautions
WARNING!
Although the Blazer
®
IV Control Circuits
are isolated, high voltage potentials can be
present between earth or chassis ground
and any point in the circuit depending on
what the control circuit is connected to. All
test instruments should be isolated from
ground to prevent damage to the instrument
or control.
•Ground the control only at GND position
on TB-1.
•Use shielded cable for all speed pot,
tachometer, encoder, forward run, reverse
run, forward jog, reverse jog, ramp stop,
emergency stop and special wiring.
Connect the shield to circuit common at the
control end only. The shield should not be
connected to ground at either end.
Connecting the shield to ground may result
in noise problems. These wires should be
routed away from all A. C. power,
armature, field, and relay coil wiring.
•Any relays, contactors, motor starters,
solenoids, etc. located in close proximity to
or on the same A. C. line as the Blazer
®
IV
control should have a transient suppression
device in parallel with the coil to minimize
interference with the control.
3.3 Terminal Connections
L1 and L2 (A. C. Line Connections): These
terminals are used for the A. C. line input.
For Models BRC702, either 115 VAC or
230 VAC input can be connected to terminals
TB1-1 and TB1–2. If 115 VAC is to be used
as input, place J2, J3, J4 & J5 in the 115V
position. If 230 VAC is to be used as input,
place J2, J3, J4 & J5 in the 230V position.
For Models BRC705, only 230 VAC may
be used, and there are no jumpers to set.
Connect the line to terminal lugs L1 and L2.
A1 and A2 (Armature Connections): Motor
lead A1 connects to terminal A1 and motor
lead A2 connects to terminal A2. When the
drive is engaged in the forward direction, these
connections will produce CCW motor rotation
when viewed from the commutator end. The
armature leads should be switched if reverse
rotation is desired.
F1 and F2 (Field Connections): Motor field
lead F1 connects to terminal F1 and motor
field lead F2 connects to terminal F2. There is
no connection required to these terminals when
a permanent magnet type motor is used.
TB2 – 1 through 7 (External Logic Control
Connections): These connections are provided
so that a remote station or PLC can be used to
control the drive. The Ramp Stop terminal can
be programmed to accept a NO (active high)
signal or a NC (active low) signal. Signals
provided to any of these terminals can be
momentary or maintained signal.
TB2 – 1: Emergency Stop
TB2 – 2: Ramp Stop
TB2 – 3: Run Forward
TB2 – 4: Run Reverse
TB2 – 5: Jog Forward
TB2 – 6: Jog Reverse
TB2 – 7: +15 VDC (logic power)
6

TB2 – 8 & 11 Circuit Common: This
terminal is the common connecting point for
all reference input signals and reference wiring
shields. Reference input signals can be disable
by connecting them to this point.
TB2 – 9 & 10 (Reference Reset): Closing a
Contact across these terminals will instantly
reset the ACCEL/DECEL circuit to zero and
cause the motor to regeneratively brake to a
stop at a rate determined by the CURRENT
LIMIT pots. This stopping method (normally
faster than the quickest controlled deceleration
) may subject the motor and A. C. line supply
to higher than normal peak currents. The time
to stop in Current Limit may not be consistent
due to variables such as motor speed, load
level, and load inertia.
TB2 – 12 Summing Input: This terminal
bypasses the ACCEL/DECEL circuits and is
connected directly to the signal summing point.
Any change in signal level is immediately
reflected in the motor speed (up to CURRENT
LIMIT). Input Signals should not exceed ±10
VDC and should be disabled by shorting
terminal TB2 – 12 to Common. These signals
are summed with the REFERENCE signals
(after their rates have been modified) and have
approximately the same input scaling as the
REFENENCE signals. The SUMMING input
can be programmed to add or subtract the
signals to REFERENCE. SEE WARNING
UNDER J9 IN SECTION 4.2.
TB3 – 1 Velocity Loop Output: This terminal
connects directly to the output of the velocity
loop integrator. If the drive is to be used as a
Speed Regulator, jumper this terminal to TB3 –
2. Refer to connection drawings D11379 or
D11380 in Section 7.
TB3 – 2 Current Loop In: This terminal
connects directly to the input of the current
integrator. If the drive is to be used as a Speed
Regulator, jumper this terminal to TB3 – 1. If
the drive is to be used as a Torque Regulator,
jumper this terminal to TB3 – 3. Refer to
connection drawings D11379 or D11380 in
Section 7. An external Torque Reference
Signal may also be applied to this terminal for
special engineered applications. The signal
applied should not exceed ±10 VDC. NOTE:
Jumpers must be removed if an external signal
is used.
TB3 – 3 Reference Out: This terminal
connects directly to the Total Reference
Setpoint. If the drive is to be used as a Torque
Regulator, jumper this terminal to TB3 – 2.
This terminal may also be used as a Reference
Output signal for special engineered
applications.
TB3 – 4, 5 & 6: Potentiometer Connections:
These three connections are designed so that a
potentiometer with a resistance between 2k and
10k can be connected and this pot will control
the speed in the direction which is indicated by
the logic and the direction LEDs. Terminal 4 is
circuit common and normally is connected to
the CCW lead on the potentiometer. Terminal
6 reference signal is controlled by the internal
logic of the drive and therefore is normally
connected to the CW potentiometer lead.
Terminal 5 is the REFERENCE INPUT to the
drive and should normally be connected to the
wiper of the pot. The REFERENCE INPUT
has its rate of change buffered by the
ACCEL/DECEL circuitry in the drive.
Forward direction acceleration is controlled by
the FWD ACCEL pot. Forward direction
deceleration is controlled by the FWD DECEL
pot. Reverse direction signals are controlled in
a similar fashion by the REV ACCEL and
REV DECEL potentiometers. Therefore, if
there is a step change in the reference signal,
the motor does not immediately change to
reflect the change in reference signal, but rather
changes more gradually as the ACCEL/DECEL
circuit adjust to the new reference level. Input
signals should not exceed ±10 VDC.
7

Programming & Adjustments
4
TB3 – 7 & 8 Auxiliary Reference
Connections: Terminal 7 is a –10 VDC source
and terminal 8 is a +10 VDC source. These
terminals are provided for applications that
require bipolar reference signals. NOTE: If
these terminals are used to connect a pot to the
drive, remember that the drive's internal
directional logic is being defeated. Therefore,
the directional LEDs may not indicate the
proper direction of the motor.
TB3 – 9 Tachometer Input: Operation of the
control in tachometer feedback requires
connection of a 7 or 50 VDC per thousand
RPM tachometer to terminal 9. The tachometer
inputs are polarity insensitive allowing the
tachometer to be wired with either the positive
or negative lead connected to terminal 9 and
the other lead connected to common. See
connection diagrams in Section 7.
TB3 – 10 Circuit Common: This common
connection is provided for use with either
tachometer or encoder feedback inputs.
TB3 – 11 & 12 Encoder Input: An optional
motor mounted 300 PPR encoder may be
connected to these terminals. See connection
diagrams in Section 7. Terminal 11 is for the
encoder signal input. Terminal 12 is a +12
VDC, 100 mA supply for powering the
encoder.
4.1 Programming Jumpers:
Power Board
J1 – Armature Current/Torque Range:
Used to program the control according to the
motor nameplate full load armature current.
The CURRENT LIMIT pots have a range up
to 150% of the current level selected. Refer to
the following table to select proper jumper
location based on motor horsepower and
control input voltage.
BRC702 BRC705 JUMPER
POSTION 115
VAC
230
VAC
230
VAC
3 AMP ¼ HP ½ HP ½ HP
5 AMP ½ HP 1 HP 1 HP
8 AMP ¾ HP 1 ½ HP 1 ½ HP
10 AMP 1 HP 2 HP 2 HP
15 AMP N/A N/A 3 HP
25 AMP N/A N/A 5 HP
J2 – Dynamic Brake Selector: For dynamic
braking models, this selector should be set to
the corresponding input voltage.
WARNING! Improper selection can cause
serious damage to control!
Note: Not applicable for Model BRC705.
J3 – Armature Feedback Voltage Selector:
Designates the armature feedback voltage level
according to the A. C. line voltage to be used.
Position at 115 VAC for 115 VAC or 230 VAC
for 230 VAC input.
Note: Not applicable for Model BRC705.
J4 & J5 – A. C. Input Voltage Jumper: To
program the power supply transformer according
to the A. C. line voltage to be used. Position each
at 115 for 115 VAC input or VAC for 230 VAC
input.
Note: Not applicable for Model BRC705.
8

4.2 Programming Jumpers:
Control Board
J6 – Reserved for future use.
J7 – Ramp Stop Jumper: Allows the use of a
normally open (NO) or normally closed (NC)
contact to activate the Ramp Stop when
external operators are used.
J8 – Tach Voltage: Used when operating in
tachometer feedback. Use J8 to select 7 or 50
VDC/1000 RPM according to the rating of the
tachometer used.
J9 – Sum Signal: Allows the polarity of the
summing signal to be controlled. The signal is
trimmed by the Sum Trim pot and combined
with the speed reference to make the Total
Reference Setpoint and will add or subtract
from it depending on the position of J9 and the
drive direction command. A positive signal
from the speed or jog pot normally calls for
forward rotation of the motor and a negative
signal normally calls for reverse motor
rotation. With SUM ADD selected at J9, a
positive Summing Signal will add to a positive
(forward) reference. A negative Summing
signal would subtract. With SUM SUB
selected, like polarities subtract from each
other and unlike polarities add.
WARNING! With SUM ADD selected, a
negative Summing Signal greater than the
positive reference would cause a net
negative Total Reference Setpoint. This
causes reverse rotation at the summing
input level even with forward direction
selected. The same situation could occur if
the Summing Signal was positive and the
Sum Sub was selected at J9. With SUM
ADD selected, like polarities add and unlike
polarities subtract from each other.
J10 – Jog Delay: Activates or deactivates the
contactor disengage delay. This delay is
provided to help increase the service life of the
armature contactor. The normal setting is in the
ACTIVATE position, but for some
applications, deactivate may be required.
J11 - Jog & Sum: Programs the control to
allow the Sum signal to be added to the Jog
signal if J11 is set to JOG SUM. If J11 is set to
NOT JOG SUM (JOG SUM with a line over
it), then the summing signal will not be added
to the jog speed signal.
J12 – Feedback: Sets the control for the
method of feedback. If there is no external
feedback attached to the control, set J12 to
AFB (armature feedback). If a 7 or 50
VDC/1000 RPM tachometer is used, set J12 to
TFB. If a 300 PPR encoder is used, set J12 to
EFB.
J13 – Forward Accel/Decel and J14 –
Reverse Accel/Decel: Sets the ranges of
adjustment for the Accel and Decel pots in
each direction. The time ranges are 1 to 8
seconds and 8 to 60 seconds.
4.3 Potentiometers
P1 – Sum Trim: Controls the percentage
affect of a signal applied to the SUM INPUT,
TB2 – 12. It can trim this signal to 0 or
increase to approximately 150%.
P2 – Jog Speed: Controls the speed of the
drive only when in the Jog mode and can
produce up to 25% of the maximum output of
the drive.
P3 – I. R. Comp: Functional only when
operating in the AFB (armature feedback)
mode. It is used to improve motor speed
regulation by using some of the current
amplifier output as a positive feedback signal
with the speed reference signal. Its effect is to
keep motor speed from dropping as load is
increased. This drop in speed is due to IR
losses in the motor. Individual motors have
different IR losses and those losses are usually
9