Carotron Elite Pro Series User manual

Instruction Manual
Models
EPN020-000 EPR020-000
EPN040-000 EPR040-000
EPN060-000 EPR060-000
EPN075-000 EPR075-000
EPN100-000 EPR100-000
EPN125-000 EPR125-000
EPN150-000 EPR150-000
EPN200-000 EPR200-000
EPN250-000 EPR250-000
EPN300-000 EPR300-000
EPN400-000 EPR400-000
EPN500-000 EPR500-000
EPN600-000 EPR600-000

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Table of Contents
1. General Description .......................................................................................................................................... 4
2. Specifications .................................................................................................................................................... 4
2.1 Electrical............................................................................................................................................. 4
2.2 Physical.............................................................................................................................................. 5
3. Installation ......................................................................................................................................................... 6
3.1 Control Installation ............................................................................................................................. 6
3.2 Wiring Guidelines............................................................................................................................... 6
4. Terminal Connections & Functions ................................................................................................................... 7
4.1 AC Power Connections & Fusing....................................................................................................... 7
4.2 Motor Connections ............................................................................................................................. 8
4.3 Signal Connections ............................................................................................................................ 9
5. Human Machine Interface (HMI)..................................................................................................................... 11
5.1 Description of Interface .................................................................................................................... 11
6. Start Up Procedure ......................................................................................................................................... 14
6.1 Pretest.............................................................................................................................................. 14
6.2 Adjustment Procedure: Velocity Regulator ...................................................................................... 14
6.3 Adjustment Procedure: Constant Horsepower.................................................................................16
6.4 Adjustment Procedure: Torque Regulator ....................................................................................... 16
6.5 Adjustment Procedure: CTCW (Constant Tension Center Winder) ................................................ 16
6.6 Calibration & Fine Tuning.................................................................................................................18
6.7 Password Protection ........................................................................................................................ 19
7. Programming & Adjustments .......................................................................................................................... 19
7.1 Accel/Decel Block ............................................................................................................................ 20
7.2 Setpoints Block ................................................................................................................................ 21
7.3 Setpoint Sum Block.......................................................................................................................... 22
7.4 Start/Stop Logic Block...................................................................................................................... 22
7.5 Zero Speed Logic Block ...................................................................................................................24
7.6 Velocity Loop Block .......................................................................................................................... 25
7.7 Current Loop Block .......................................................................................................................... 27
7.8 Field Loop Block...............................................................................................................................30
7.9 Field Crossover Block ...................................................................................................................... 31
7.10 Digital Inputs Block......................................................................................................................... 32
7.11 Analog Inputs Block ....................................................................................................................... 33
7.12 Frequency Input Block ................................................................................................................... 35
7.13 Relay Outputs Block....................................................................................................................... 38
7.14 Analog Outputs Block..................................................................................................................... 39
7.15 Frequency/Digital Output Block...................................................................................................... 41
7.16 Calibration Block ............................................................................................................................ 43
7.17 Diagnostics Block........................................................................................................................... 44
7.18 Miscellaneous Block - Internal Links .............................................................................................. 45
7.19 Miscellaneous Block - Communications ........................................................................................ 46
7.20 Miscellaneous Block - MOP ........................................................................................................... 47
7.21 Miscellaneous Block - System Parameters.................................................................................... 48
7.22 Miscellaneous Block - Thresholds ................................................................................................. 49
7.23 Miscellaneous Block - Timer .......................................................................................................... 50
7.24 Miscellaneous Block - Min Max...................................................................................................... 52
7.25 Miscellaneous Block - Auxiliary Parameters .................................................................................. 52
7.26 Miscellaneous Block - General Parameters................................................................................... 53
7.27 Miscellaneous Block - Set Time & Date......................................................................................... 53
7.28 Fault Logic Block............................................................................................................................ 54
7.29 Fault Log Block .............................................................................................................................. 55
7.30 Applications Block - Auxiliary PI Loop............................................................................................ 56
7.31 Applications Block - Winder Speed Calculator...............................................................................57
7.32 Applications Block - CTCW (Constant Tension Center Winder) ...................................................58
7.33 Parameter Tables .......................................................................................................................... 60
8. Serial Network Communications..................................................................................................................... 76
9. Spare Parts ..................................................................................................................................................... 77
9.1 Printed Circuit Assemblies ............................................................................................................... 77

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9.2 Fuses................................................................................................................................................77
9.3 Power Components..........................................................................................................................79
10. Prints .............................................................................................................................................................80
D12278 Assembly Drawing, 20-60HP Models .......................................................................................80
D12602 Assembly Drawing, 75-150HP Models .....................................................................................81
D12797 Assembly Drawing, 200-400HP Models ...................................................................................82
D12887 Assembly Drawing, 500-600HP Models ...................................................................................83
C12309 Assembly, Heatsink Chassis, 20-60HP Non-Regen Models ....................................................84
C12277 Assembly, Heatsink Chassis, 20-60HP Regen Models............................................................85
C12583 Assembly, Heatsink Chassis, 75-150HP Non-Regen Models ..................................................86
C12584 Assembly, Heatsink Chassis, 75-150HP Regen Models..........................................................87
D12874 Assembly, Heatsink Chassis, 200-300HP Non-Regen Models ................................................88
D12798 Assembly, Heatsink Chassis, 400HP Non-Regen Models .......................................................89
D12877 Assembly, Heatsink Chassis, 200-300HP Regen Models........................................................90
D12878 Assembly, Heatsink Chassis, 400HP Regen Models ...............................................................91
D12886 Assembly, Heatsink Chassis, 500-600HP Non-Regen Models ................................................92
D12885 Assembly, Heatsink Chassis, 500-600HP Regen Models........................................................93
D12323 Wiring Diagram, 20-60HP Non-Regen Models ........................................................................94
D12324 Wiring Diagram, 20-60HP Regen Models ................................................................................95
D12606 Wiring Diagram, 75-150HP Non-Regen Models ......................................................................96
D12607 Wiring Diagram, 75-150HP Regen Models ..............................................................................97
D12778 Wiring Diagram, 200-400HP Non-Regen Models ....................................................................98
D12809 Wiring Diagram, 200-400HP Regen Models ............................................................................99
D12789 Wiring Diagram, 500-600HP Non-Regen Models ..................................................................100
D12788 Wiring Diagram, 500-600HP Regen Models ..........................................................................101
C12272 General Connections ..............................................................................................................102
D12236 Example Connections.............................................................................................................103
D12586 Network Connections .............................................................................................................104
D12229 Software Block Diagram .........................................................................................................106
C12671 Sonic Transducer Option Connections...................................................................................108
11. Standard Terms & Conditions of Sale.........................................................................................................109
List of Tables
Table 1: Model Rating Data...................................................................................................................................7
Table 2: Navigation Softkey Functions................................................................................................................11
Table 3: Roll & Shift Functions ............................................................................................................................11
Table 4: Elite Pro Abbreviated Programming Chart ............................................................................................12
Table 5: Drive Monitor & Quick Programming Presets .......................................................................................14
Table 6: Reference Selection..............................................................................................................................21
Table 7: Drive Status...........................................................................................................................................24
Table 8: Velocity Gain Selection..........................................................................................................................26
Table 9: Drive Modes ..........................................................................................................................................28
Table 10: Analog Input Status Readings.............................................................................................................34
Table 11: Analog Output Readings .....................................................................................................................39
Table 12: Encoder Lines .....................................................................................................................................43
Table 13: System Status .....................................................................................................................................45
Table 14: Watchdog Status.................................................................................................................................45
Table 15: Fault Codes .........................................................................................................................................55
Table 16: Parameters by Tag..............................................................................................................................61
Table 17: Parameters by Name ..........................................................................................................................68
Table 18: SW4 DIP Switch Settings....................................................................................................................76
Table 19: Trigger Board Fuses ...........................................................................................................................77
Table 20: Power Supply Board Fuses.................................................................................................................78
Table 21: Recommended Line Fuses .................................................................................................................78
Table 22: Armature Bridge Modules ...................................................................................................................79
Table 23: Field Supply Modules ..........................................................................................................................79

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General Description
The ElitePro Series of D.C. motor controls provide microprocessor control of speed and torque
control of 5-600HP D.C. motors rated for NEMA type "C" power supplies. The EPN series for non-
regenerative applications and the EPR regenerative series are offered in compact panel mounted
assemblies.
Specifications
2.1 Electrical
A.C. Input Voltage Range - 3 Phase Supply
• 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
External A.C. Line Field Supply - 1 Phase Supply
(Optional)
• 230-460 VAC ± 10%, 50/60 Hz ± 2 Hz
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 EPx600-000: 12A max
Power Supplies
• +24V Unregulated Digital Input Supply: 50mA
• +12V Unregulated Encoder/Freq. Input Supply: 100mA
• +10V Regulated Reference Supply: 50mA
• -10V Regulated Reference Supply: 50mA
Digital Inputs (7 Total)
• Sink Mode
Vil=20.0 VDC max
Vih=0.0 VDC min to 17.0 VDC max
• Source Mode
Vil=5.0 VDC max
Vih=8.0 VDC min to 30.0 VDC max
Analog Inputs
• Voltage inputs (5 Total)
Max Input:±10 VDC
Input Impedance, Inputs 1-4: 1MΩ
Input Impedance, Input 5: 20kΩ
• Current inputs (4 Total)
Max Input: ±20 mADC
Input Impedance: 270Ω
• Tachometer input
Max Input: ±200 V (AC or DC)
Encoder Input
• Frequency: 200kHz max, quadrature square
wave (single ended or differential)
• Voltage: 12 VDC max
Frequency Input
• Frequency: 40kHz max, square wave
• Voltage: 12 VDC max
Vil=0.0 VDC to 2.0 VDC max
Vih=3.0 VDC min to 12.0 VDC max
Relay Outputs (3 Total)
Form-C contact:
• 2 A @ 115 VAC
• 2 A @ 60 VDC
Armature Pilot Relay Output
• 30 A @ 120 VAC
• 30 A @ 28 VDC
Analog Outputs (2 Total)
• ±10 VDC max, 20mADC max
Frequency/Digital Output
• Frequency: 2kHz max, square wave
• Output current: 20mA max
• Output voltage: 16VDC max
Speed Regulation
• Armature Feedback: ±1%
• Tachometer Feedback: ±0.01%
• Encoder Feedback (1024 min.): ±0.01%
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
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1
2
22
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EPx075-000 thru EPx150-000
EPx020-000 thru EPx060-000
EPx200
-
000 thru EPx400
-
000
2.2 Physical
PRO
PRO
PRO

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EPx500
-
000 thru EPx600
-
000
Figure 1
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 cause 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
3
33
3
PRO

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the possibility of accidental grounding.
Signal level wiring such as listed above should be routed separately from high level wiring such as
armature, field, operator control 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. 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 3 on the next page and Table 21 in
the Spare Parts Section on page 78 for common manufacturers and part numbers.
Table 1: Model Rating Data
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 51 140 180 Amps 1.3Ω, 2080W
EPx075-000 500 75 106 93 140 180 Amps 2.6Ω, 4160W
240 50 148 63 174 180 Amps 0.62Ω, 2232W
EPx100-000 500 100 141 118 174 180 Amps 1.24Ω, 4464W
240 60 174 75 206 260 Amps 0.62Ω, 2232W
EPx125-000 500 125 177 145 206 260 Amps 1.24Ω, 4464W
240 75 212 93 256 260 Amps 0.62Ω, 2232W
EPx150-000 500 150 213 175 256 260 Amps 1.24Ω, 4464W
240 100 282 118 340 360 Amps 0.47Ω, 4700W
EPx200-000 500 200 283 220 340 360 Amps 1.02Ω, 6500W
240 125 354 145 425 535 Amps 0.37Ω, 5300W
EPx250-000 500 250 353 275 425 535 Amps 0.82Ω, 11000W
240 150 426 175 510 535 Amps 0.31Ω, 7000W
EPx300-000 500 300 423 330 510 535 Amps 0.65Ω, 14600W
240 200 555 220 688
EPx400-000 500 400 555 440 688
Consult
Factory
Consult
Factory
240 250 694 275 850
EPx500-000 500 500 694 550 850
Consult
Factory
Consult
Factory
240 300 832 330 1020 Consult
EPx600-000 500 600 832 660 1020 Factory
Consult
Factory
4
44
4

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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.
4.2 Motor Connections
Field
Most motor fields consist of two windings that are connected in parallel for 150 VDC operation and in
series for 300 VDC operation. Refer to Figure 2. 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 use 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.
Figure 2

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In some cases, the field voltage required by a motor exceeds the maximum obtainable field voltage
that can be derived with 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 supply connects to FL1 and
FL2 and must be in phase with the armature supplies L1 and L2. Refer to Figure 3. Jumpers J8 and
J9 on the trigger board need to be moved from internal to external.
For example, if a motor has a 240VDC armature rating, 230VAC lines must be connected to L1, L2,
and L3. The maximum field voltage attainable from the field bridge with 230VAC input is 200VDC. In
order to obtain the required 240VDC field, a single phase 460VAC supply can be connected to FL1
and FL2.
Figure 3
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.
Note : When present, the S1 and S2 for the SERIES field winding is placed in series with the
armature leads on the non-regenerative models. It should not be used with the EPR Series
regenerative models and 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.
Motor Thermostat
Most motors include "J" or "P" leads that connect to an internal normally closed thermostat.
Connecting the thermostat to TB1-38 & 39 as shown in Figure 4 will allow a motor over-temperature
condition to shut down the control as in an Emergency Stop condition.
4.3 Signal Connections
Figure 4 shows the typical signal connections to an Elite Pro drive. When operated, the Emergency
Stop contacts at terminals 6 and 7 will immediately clamp all control signals. The armature contactor
will also de-energize to disconnect the armature from the bridge output. Motor stopping time is
determined by inertia and friction characteristics of the load and can be decreased by use of a brake
resistor. Refer to Table 1 for recommended resistor values. If a maintained Emergency Stop push-
button is used, the E-Stop Reset contacts at TB1-8 & 9 can be jumpered. Otherwise, a momentary
push-button E-Stop can be reset by closing the E-Stop Reset contacts.

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Figure 4