Carotron P22194-1 User manual

P22194-1
DC DRIVE
Instruction Manual

1. General Description .....................................……………………………… 2
2. Specifications ..........................................…………………………………. 3
2.1 Electrical Specifications ............................…………………………………………...3
2.2 Physical Specifications ..............................………………………………………….. 3
3. General Installation ....................................……………………………….. 4
3.1 Control Installation .................................……………………………………………. 4
3.2 Wiring Guidelines ....................................……………………………………………4
4. Terminal Connections and Functions ......................……………………… 5
4.1 A.C. Power Connections and Fusing ....................…………………………………... 5
4.2 Motor Connections ....................................…………………………………………...5
4.3 Interlock Connections ................................………………………………………….. 6
4.4 Operator Connections .................................…………………………………………. 7
4.5 Signal Wiring Connections ............................………………………………………..8
5. Programming and Adjustment Descriptions ..................………………….. 9
5.1 Programming Jumpers ...................................……………………………………….. 9
5.2 Adjustment Potentiometers ............................………………………………………. 9
5.3 Circuit Test points ..................................……………………………………………. 12
6. Start Up Procedure ......................................………………………………. 15
6.1 Adjustment and Programming Presets ...................…………………………………..15
6.2 Initial Pretest and Power Up .........................………………………………………... 15
6.3 Motor Start Up .......................................…………………………………………….. 16
6.4 Calibration and Fine Tuning ..........................……………………………………….. 16
7. Fault Conditions ........................................………………………………... 19
8. Spare Parts .............................................…………………………………...20
8.1 Printed Circuit Board Assemblies .....................……………………………………...20
8.2 Fuses ................................................………………………………………………… 20
8.3 Power Components .....................................…………………………………………. 20
9. Drawings ................................................………………………………….. 21
D11980 - SIZE AND MOUNTING DIMENSIONS …………………………………….21
C11977 - POWER AND SIGNAL CONNECTIONS …………………………………... 22
D11978 - POWER COMPONENT LOCATION ……………………………………….. 23
D11964 - CONTROL BOARD COMPONENT LOCATION …………………………. 24
C11979 - WIRING DIAGRAM ………………………………………………………… 25
Table of Contents
1

General Descri
p
tion
1
The P22194-1 non-regenerative
D.C. motor control provides full range
speed and torque control of 5-20 HP
D.C. motors rated for NEMA type "D"
power supplies. It is rated for operation
on 230 VAC line supplies and will
supply a variable armature voltage up to
240 VDC and a selectable fixed field
supply of 150, 240, or 300 VDC.
A semiconductor fuse is provided
for armature protection. Also provided
is fuse protection for the 230 VAC
control voltage input.
Standard logic interfaces with
customer supplied operators for Start,
Stop, Jog, Override Stop, and Reset
functions.
Features
•Insensitive to phase rotation of A.C.
input.
•Full 10 ampere rated field supply,
150/240/300 VDC selectable.
•Current transformers for isolated
armature current sensing.
•High impedance isolation for
armature and line voltage sensing.
•Electrically isolated power modules
rated at 1400 volts PIV and 1000
volts/microsecond dv/dt.
•Semiconductor armature fuse for
power circuit protection.
•Latching Fault logic provides safety
shutdown with form "C" contact
output and LED indicators for Low
Line/Phase Loss, Field Loss, and
Over Current Trip conditions.
•Interlock logic with form “C”
contact output and LED indicators
for Current Limit and Motor
Output.
•5 jumper selectable armature
current (HP) ranges to match motor
rated armature current.
•Independently adjustable linear
acceleration and deceleration for
Run function with range of 0.5 to 30
seconds.
•Adjustable linear
acceleration/deceleration for Jog
function with range of 0.5 to 30
seconds.
•Speed feedback is jumper selectable
for Armature Voltage or D.C.
Tachometer voltage (21 VDC/1000
RPM).
•D.C. Tachometer voltage input is
insensitive to polarity.
•Inner current loop type control
circuit for responsive and precise
control of motor speed and torque.
•Zero speed logic for controlled
ramp-to-stop.
•Additional LEDs for operating
status: Power On, Run, Jog, Current
Mode, Armature Feedback, Motor
Output, O-Stop.
2

S
p
ecifications
2
2.1 Electrical Specifications
A.C. Line Input
•195 to 260 VAC, 3 phase, 50/60 Hz
+ 2 Hz, 65 Amp Full Load Max
Armature Output
•0 to 240 VDC, 72 Amp Full Load
Max / 90 Amp Overload Max
Field Output
•150/240/300 VDC, 10 Amp max
Accessory Outputs
•Power Supplies
+ 10 VDC @ 5 mA Run Speed
pot reference supply
+ 10 VDC @ 5 mA Jog Speed
pot reference supply
6.4 VDC @ 5 mA Torque Limit
pot reference supply
•Fault relay output : SPDT, 3 Amp
@ 30 VDC /120 VAC
•Current Mode relay output : SPDT,
3 Amp @ 30 VDC /120 VAC
•Motor relay output : SPDT, 3 Amp
@ 30 VDC /120 VAC
Horsepower Range
•5 to 20 HP @ 240 VDC
Speed Regulation
•Armature Feedback : + 1% of base
speed
•Tachometer Feedback : + 0.5% of
base speed
Torque Regulation
•+ 2% of range selected
Speed Range
•20:1 motor dependent
Temperature Range
•Chassis : 0 to 50 degrees C
Control Board Adjustments
•P1 Integral Null
•P2 Slope
•P3 IR Comp
•P4 I (Current) Integral
•P5 I (Current) Proportional
•P6 Max Jog Speed
•P7 Jog Accel/Decel
•P8 Max Run Speed
•P9 Over Current
•P10 Min Run Speed
•P11 Velocity Proportional
•P12 Start Accel
•P13 Stop Decel
•P14 Max Torque
•P15 Velocity Integral
2.2 Physical Specifications
Refer to Drawing D11980 for size
and mounting dimensions. The P22194-
1 control provides clearance holes for
1/4 inch mounting hardware. Shipping
weight is 35 lbs.
3

General Installation
3
3.1 Control Installation
The P22194-1 motor control must
be mounted in an upright position in an
area that will permit adequate airflow
for cooling and ready access for making
connections and for servicing.
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.
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 and
the NEC.
Make no connections to ground
other than the designated grounding
screw located in the upper left corner of
the drive.
Use fully insulated and shielded
cable for all signal wiring. This includes
all potentiometer (pot) and tachometer
wires. The shield should be connected
at one end only to circuit common at
terminals 15, 18, 23, or 26. 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, operator control and relay control
wiring. When these two types of wire
must cross, they should cross at right
angles to each other.
Any relay, contactor, starter,
solenoid or electro-mechanical device
located in close proximity to or
connected to 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.
4

TABLE 1: THREE PHASE LINE CURRENT AND TRANSFORMER RATINGS
MOTOR
HP
ARM
VOLTS
APPROXIMATE FULL
LOAD LINE AMPS
3 PHASE DIT KVA
RATING
5 240 18 7.5
7.5 240 26 11
10 240 34 14
15 240 50 20
20 240 65 27
Note: TABLE 1 is intended to be a general guide for sizing the AC line supply
transformer and wiring.
Terminal Connections and
Functions
4
4.1 A.C. Power Connections
and Fusing
Terminals L1, L2, and L3 are the
AC line input terminals for the drive.
The line must be fused per code
requirements. The 100 Amp
semiconductor fuse provides protection
for the armature circuit only and is
sized according to the armature current
rating of the control.
Protection is provided for the power
supplies by a ½ ampere, 250 VAC fuse
on the POWER/TRIGGER BOARD.
Refer to Drawing C11977 for AC
power connections. Refer to Drawing
D11978 for power component location.
NOTE : Carotron recommends the use
of a three phase DIT (drive isolation
transformer). While the P22194-1
control does not require this transformer
for proper operation, it 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.
4.2 Motor Connections
Refer to Drawing C11977 for motor
connections.
Field
Most motor field circuits consist of
two windings that are connected in
parallel for 150 VDC operation or in
series for 300 VDC operation. Refer to
FIGURE 2 for typical connections to
Field Terminals F+1, F+2, and F-. 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
5

TABLE 2: ARMATURE CONTACTOR AND DYNAMIC BRAKE RISISTOR
RATING
MOTOR
HP
ARM
VOLTS
ARM
AMPS
CONTACTOR
RATING
D.B. RESISTOR
RATING
5 240 20 40 Amp 10 Ohms, 300 W
7.5 240 29 40 Amp 5 Ohms, 600 W
10 240 38 40 Amp 4.4 Ohms, 750 W
15 240 55 75 Amp 3 Ohms, 1000 W
20 240 72 75 Amp 2.2 Ohms, 1500 W
never be switched by relay, contactor,
switch or any other manual or electro-
mechanical device.
The Carotron P22194-1 motor
control is designed to sense field current
and will indicate an open circuit in the
field windings or wiring by initiating a
FIELD LOSS fault condition.
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 2 for typical
armature voltage, current, contactor,
and dynamic braking resistor ratings.
Drawing C11977 shows the
armature, contactor and brake resistor
connections to the A+ and A- terminals.
Note : When present, the Series field
winding (S1 and S2) is placed in series
with the armature leads. 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 in series with the O-Stop
circuit at Terminal 12 as shown in
Drawing C11977 will allow a motor
over-temperature condition to shut
down the control as in an O-Stop
condition.
4.3 Interlock Connections
Relay contact connections are
provided to interface with the Fault,
Current Limit, and Motor interlock
circuits. Refer to Drawing C11977 for
these connections.
TB1 Terminals 1-3 Motor Interlock
The Motor Interlock relay is
energized when power is applied and
releases when armature voltage is
greater than 6% of rated (about 15
VDC). The Motor LED also turns ON
at this point.
TB1 Terminals 4-6 Fault Interlock
The Fault Interlock relay is energized
when power is applied and releases
when a fault condition occurs (Field
Loss, Low Line/Phase Loss, or Over
Current Trip).
TB1 Terminals 7-9 Current Mode
Interlock
The Current Mode Interlock relay is
energized when power is applied and
during speed control operation. When
6

the motor current exceeds the level set
by the Torque Limit circuit, the control
changes to the current control mode.
After about one second of current
control operation, the relay releases.
This one second time delay begins only
after any controlled acceleration time
due to a start or a speed reference
change is completed.
4.4 Operator Connections
Refer to Drawing C11977 for
Operator Connections.
TB1 Terminal 10 Run
The drive will start when this
terminal is connected to common
(terminal 15) provided the O-Stop
circuit has been reset and no fault
conditions exist. If the Stop circuit
(terminal 11) is connected to common,
a momentary Run signal will latch the
start circuit; the motor will accelerate
to the speed selected by the Run Speed
potentiometer at the rate determined by
the Start Accel adjustment. If the Stop
circuit is open, a maintained Run signal
is required to start and run the drive.
Operation of the Jog circuit also
affects the Run function (see below).
TB1 Terminals 11 Stop
If a momentary Run signal was used
to start the drive, then a momentary
opening of the Stop circuit will
decelerate the motor to zero speed at the
rate determined by the Stop Decel
adjustment. If either the Run or Jog
circuits are maintained closed, the Stop
circuit will have no effect.
TB1 Terminals 12 O-Stop
The Override Stop circuit must be
closed (connected to common) for the
control to operate. If opened during
operation, O-Stop will immediately
terminate drive operation and the motor
will coast to a stop. When O-Stop is
reclosed the Reset circuit (Terminal 13)
must be closed to resume drive
operation.
TB1 Terminal 13 Reset
A momentary closure of the Reset
circuit resets the O-Stop function if the
O-Stop circuit has been reclosed. If the
Reset circuit is connected to common,
an automatic reset occurs when the O-
Stop circuit is reclosed.
TB1 Terminal 14 Jog
A contact closure between this
terminal and common will activate the
Jog function, assuming the O-Stop
circuit is closed and no fault condition
exists. The motor will accelerate to the
selected Jog speed at the rate
determined by the Jog Accel/Decel
adjustment. The Jog circuit does not
latch; when the circuit is opened, the
motor will decelerate to zero speed at
the selected rate.
If the Run circuit is latched when
the Jog circuit is closed, the Run
function will be released and the motor
will ramp to the selected Jog speed. If
the Run and Jog circuits are both
maintained closed, the larger of the two
speed reference signals is selected. If
the Run circuit is then opened, the
motor will decelerate to the Jog speed
(assuming the Jog speed is the lower of
the two) at the Run Decel rate.
TB1 Terminal 15 Com
This terminal is the common
connection for the above Run, Stop, O-
Stop, Reset, and Jog circuits.
7

4.5 Signal Wiring Connections
All signal level wiring connects to
TB1 on the CONTROL BOARD.
Observe the use of shielded cable and
other wiring guidelines detailed in
Section 3.2. Refer to Drawing C11977.
TB1 Terminals 16, 17, 18 Jog Speed
An external Jog Speed
potentiometer, if used, is connected to
terminals 16 (CW), 17 (wiper), and 18
(CCW - common). If an external
potentiometer is not required, a jumper
between terminals 16 and 17 will allow
the Jog Speed to be set by internal
potentiometer P6, Max Jog Speed
(reference section 5.2).
TB1 Terminals 19, 20, 21 Run Speed
An external Run Speed
potentiometer is connected to terminals
19 (CW), 20 (wiper), and 21 (CCW).
The adjustment range of this signal is
determined by internal potentiometers
P8, Max Run Speed, and P10, Min Run
Speed (reference section 5.2).
TB1 Terminals 22, 23 Tachometer
For DC tachometer feedback
connect the 21 VDC /1000 RPM
tachometer to terminals 22 and 23.
These terminals are not polarity
sensitive. The shield should be
connected to terminal 23 (common).
TB1 Terminals 24, 25, 26 Torque
Limit
An external Torque Limit
adjustment potentiometer is connected
to terminals 24 (CW), 25 (wiper), and
26 (CCW - common). If an external
potentiometer is not required, a jumper
between terminals 24 and 25 allows the
maximum torque limit to be set by
internal potentiometer P14, Max Torque
Limit (reference section 5.2).
8

Pro
g
rammin
g
Jum
p
ers
5
5.1 Programming Jumpers
Programming jumpers J1 through
J4 are located on the CONTROL
BOARD. Refer to Drawing D11964 for
component locations.
J1 OCT
This jumper is associated with
internal potentiometer P9, Over Current
Trip (reference section 5.2). If the
jumper is in the OCT position when the
armature current reaches the level set
by P9, an Over Current Trip occurs,
turning off all power to the motor
armature. This condition is indicated
by the Over Current LED. The Control
Board Reset button must be pressed (or
the power turned off momentarily) to
reset the drive and allow normal
operation. If the jumper is in the OCT
position, the drive will not trip and the
armature current will be limited to the
Over Current Trip level (causing the
motor to operate in a constant torque
mode). The Fault Interlock relay, K1,
will be released in both cases.
J2 Field Loss
With this jumper in the Normal
position, motor field current is
monitored when the drive is powered; a
loss of field current results in a Field
Loss fault condition. The circuit is
reset by pressing the Control Board
Reset button (or by turning power off
momentarily). For applications where
field current sensing is not appropriate,
the jumper must be placed in the
Bypass position.
J3 HP Select (reference section 5.2).
The operating range of armature
current is determined by the position of
this jumper. By selecting the position
corresponding to the motor used (5, 7.5,
10, 15, or 20 HP), the limits of the Max
Torque Limit and Over Current Trip
circuits are properly set.
J4 Velocity Feedback Select
Velocity (speed) feedback can come
from either of two sources.
AFB selects armature voltage
feedback and must be selected when no
tachometer is to be used. Even then it
should be selected during initial setup
until proper feedback from the
tachometer is verified.
TFB is selected when a DC
tachometer (21 VDC per 1000 RPM) on
the motor being controlled is used for
feedback. This is not to be confused
with a follower tachometer used on
another motor or location to provide a
speed reference to the control.
5.2 Adjustment Potentiometers
The CONTROL BOARD
potentiometer adjustments are listed in
TABLE 3. All potentiometers are multi-
turn (20 - 25 turns), screw driver adjust
type. Refer to Drawing D11964 for
component location.
Note: The description of
adjustments is divided into two
sections; the first being the more
common customer adjustments and the
latter those adjustments with more
complex functions.
9