Carotron Trooper Pro User manual

Instruction Manual
Models
TPR902-000
TPR902-E00

2
Table of Contents
1. General Description .......................................................................................................................................... 3
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 ...................................................................................................................... 7
4.2 Motor Connections ............................................................................................................................. 8
4.3 Signal Connections .......................................................................................................................... 10
5. Human Machine Interface (HMI)..................................................................................................................... 12
5.1 Description of Interface .................................................................................................................... 12
6. Start Up Procedure ......................................................................................................................................... 15
6.1 Pretest.............................................................................................................................................. 15
6.2 Adjustment Procedure: Velocity (Speed) Regulator.........................................................................15
6.3 Adjustment Procedure: Torque (Current) Regulator........................................................................16
6.4 Calibration & Fine Tuning.................................................................................................................16
6.5 Password Protection ........................................................................................................................ 17
7. Programming & Adjustments .......................................................................................................................... 18
7.1 A: Options ........................................................................................................................................ 18
7.2 B: Digital Inputs ................................................................................................................................ 19
7.3 C: Analog Inputs............................................................................................................................... 24
7.4 D: Digital Outputs ............................................................................................................................. 27
7.5 E: Analog Outputs ............................................................................................................................ 29
7.6 F: Motor Data ................................................................................................................................... 31
7.7 G: Control Loops .............................................................................................................................. 33
7.8 H: Start/Stop Logic ........................................................................................................................... 38
7.9 I: Setpoints ....................................................................................................................................... 42
7.10 J: Ramps........................................................................................................................................ 44
7.11 K: Fault Logic ................................................................................................................................. 48
7.12 L: Applications................................................................................................................................ 53
7.13 M: Thresholds ................................................................................................................................ 63
7.14 N: Timers ....................................................................................................................................... 64
7.15 O: Logic Gates ............................................................................................................................... 66
7.16 P: Switches .................................................................................................................................... 69
7.17 Q: Internal Links ............................................................................................................................. 70
7.18 R: Communications........................................................................................................................ 71
7.19 S: Zero Speed ................................................................................................................................ 74
7.20 T: System ....................................................................................................................................... 75
7.21 U: Auxiliary ..................................................................................................................................... 77
7.22 Parameter Table ............................................................................................................................ 78
8. Troubleshooting .............................................................................................................................................. 90
9. Spare Parts ..................................................................................................................................................... 92
9.1 Printed Circuit Assemblies ............................................................................................................... 92
9.2 Fuses ............................................................................................................................................... 92
10. Prints ............................................................................................................................................................. 93
D14605 Control Board Assembly........................................................................................................... 93
D14602 Regulator Board Assembly....................................................................................................... 94
D14599 Power Board Assembly ............................................................................................................ 95
C14608 Keypad Board Assembly .......................................................................................................... 96
C14701 General Connections................................................................................................................ 97
D14702 Software Block Diagram ........................................................................................................... 98
11. Standard Terms & Conditions of Sale......................................................................................................... 103

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List of Tables
Table 1: Model Rating Data...................................................................................................................................7
Table 2: HMI Description.....................................................................................................................................12
Table 3: Drive Monitor Descriptions ....................................................................................................................14
Table 4: Common Digital Input Functions ...........................................................................................................19
Table 5: Common Analog & Freq Input Functions ..............................................................................................24
Table 6: Analog Input Voltage Status Readings..................................................................................................25
Table 7: Analog Input 2 Current Status Readings...............................................................................................26
Table 8: Common Relay & Digital Output Functions...........................................................................................27
Table 9: Common Analog & Freq Output Functions ...........................................................................................29
Table 10: Analog Output Status ..........................................................................................................................30
Table 11: Drive Modes ........................................................................................................................................40
Table 12: Reference Select.................................................................................................................................42
Table 13: Faults 1................................................................................................................................................49
Table 14: Faults 2................................................................................................................................................49
Table 15: Alarms 1 ..............................................................................................................................................50
Table 16: Inertia Sensitivity .................................................................................................................................60
Table 17: Logic Gates Truth Table......................................................................................................................68
Table 18: Parameters..........................................................................................................................................78
Table 19: Faults...................................................................................................................................................90
Table 20: Recommended Line Fuses .................................................................................................................92
General Description
The TrooperPro Series is a microprocessor based D.C. motor control. The series provides control
of speed and torque control of 1/8HP-2HP D.C. motors. The controls are offered in chassis (-000)
and NEMA 4 enclosed (-E00) assemblies. Some standard features are listed below:
•Operates at 115/230VAC input for 90/180VDC motor armatures
•Same footprint/package as analog Trooperseries
•Armature voltage feedback, tachometer feedback, and encoder feedback
•Power On/Off switch (enclosed models only)
•9 button keypad with 2 line by 16 character display
•USB connectivity
•Compatible with Carotron's free CaroLink software
•Option port
1

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Specifications
2.1 Electrical
A.C. Input Voltage Range
• 1 phase, 115-230VAC ± 10%, 50/60 Hz ± 2 Hz, 15A
Armature Output
• 0-90VDC @ 115VAC input
• 0-180VDC @ 230VAC input
Field Output
• 50/100VDC, 1A @ 115VAC input
• 100/200VDC, 1A @ 230VAC input
Horsepower Range
• 1/8-1HP @ 90VDC
• 1/4-2HP @ 180VDC
Power Supplies
• +24 VDC (TB1-1): 50mA
• +15 VDC (TB1-10): 50mA
• +10 VDC (TB1-4): 50mA
Digital Inputs (Qty: 5)
• 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
• Current Consumption
5mA each (with 24V supply)
Analog Inputs (Qty: 2)
• Voltage Mode
Max Input:±11 VDC
Input Impedance: 100KΩ
• Current Mode (AI2 only)
Max Input: ±22 mADC
Input Impedance: 150Ω
• Resolution: 12 bit
Tachometer Feedback/High Voltage Analog Input
• Max Input: ±200 VDC
Encoder Feedback/Frequency Input
• Frequency: 50kHz max, square wave
• Uni-directional (single channel)
• Single ended
• Voltage: 15 VDC max
• V
il
=0.0 VDC to 1.5 VDC max
• V
ih
=2.5 VDC min to 15.0 VDC max
Relay Outputs (Qty: 2)
• 2 A @ 115 VAC (resistive)
• 2 A @ 60 VDC (resistive)
• 1 Form A, 1 Form C
Analog Outputs (Qty: 2)
• ±10 VDC max, 20mADC max
• Resolution: 12 bit
Speed Regulation
• Armature Feedback: ±0.5% of base speed
• Tachometer Feedback: ±0.25% of base speed
• Encoder Feedback: ±-0.25% of base speed
Torque Regulation
• ±1% of Range Selected
Speed Range
• 20:1 typical when using tachometer or encoder
feedback. May be less depending upon motor
characteristics
Temperature Range
• Chassis: 0-55C
• Enclosed: 0-40C
2

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Figure 1: Chassis Models
Figure 2: Enclosed Models
2.2 Physical

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Installation
3.1 Control Installation
Trooper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 failure of the Trooper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.
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Drive
Model
Motor
HP
AC Input
Voltage
Approx. Full Load
Line Amps
Recommended
Fuse (Amps)
Armature
Amps
Armature
Volts
1/8 2.3 3 1.5
1/4 4.3 5 3
1/2 7.9 8 6
3/4 11.7 15 8
1
115
15 15 10
90
1/4 2.3 3 1.5
1/2 4.3 5 3
1 7.9 8 6
1-1/2 12.2 15 8
TPR902-000
2
230
15 15 10
180
Table 1: Model Rating Data
Terminal Connections & Functions
4.1 AC Power Connections
Terminals L1 and L2 are the AC line inputs. Refer to Figure 3 below. Fusing is provided on board.
Refer to Table 1 above for recommended fuse sizing.
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Figure 3: Power Connections

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4.2 Motor Connections
Field
Many small motors are permanent magnet type or "PM" motors. These motors use magnets instead
of an electro-magnet winding. When using these motors, no connections are made to the F1 and F2
terminals.
A motor that has an electro-magnetic field winding will typically come in two types: single or dual
winding. A motor with a single field winding will be connected as shown in Figure 3. Most modern
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 4. 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.
When the TrooperPro is supplied with 115VAC, the field is typically wired for low voltage operation
(i.e. 100VDC). When supplied with 230VAC, the motor field is typically wired for high voltage
operation (i.e. 200VDC). The F1 and F3 leads should always have the same polarity regardless of
the mode used.
Although rarely needed, a half-voltage field output can be obtained from the drive by connecting the
motor field windings across terminals L1 and F2 (instead of F1 and F2). Refer to Figure 5 below. In
these cases, an AC input of 115VAC will produce a field voltage of 50VDC. An input of 230VAC will
produce a field voltage of 100VDC.
Figure 4: Motor Field Connections
Figure 5: Half Wave Motor Field Connections

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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 and current
ratings. Refer to Figure 3 for example connections w/o an armature contactor. Refer to Figure 6 for
example connections using an optional external armature contactor. Motor stopping time is
determined by inertia and friction characteristics of the load. This time can be decreased by use of
an optional dynamic braking (D.B.) resistor.
Motor Thermostat
Most motors include "J" or "P" leads that connect to an internal normally closed thermostat. When
used, these leads are typically connected in series with the E-STOP or RUN signals. This allows a
motor over-temperature condition to shut down the control.
Figure 6: Armature Connections with Optional Contactor

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4.3 Signal Connections
Figure 7 shows the typical signal connections to an Trooper® Pro drive. When operated, the
Emergency Stop contacts at terminal 3 will immediately clamp all control signals. If an armature
contactor is used (via Relay Output 1), it will also de-energize to disconnect the armature from the
bridge output.
Figure 7: Signal Connections