Leeson SPEEDMASTER WASHGUARD 174102 User manual

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SPEEDMASTER
®
174102, 174103 & 174107
NEMA 4X SCR MOTOR CONTROLS
Operation Manual
®

LIMITED WARRANTY
A. Warranty - LEESON Electric warrants that its products will be free from defects in
material and workmanship for a period of one (1) year from the date of shipment
thereof. Within the warranty period, LEESON will repair or replace such products that
are returned to LEESON or to the nearest Branch Office, with shipping charges
prepaid. At our option, all return shipments are F.O.B. LEESON or its Branch Office.
This warranty shall not apply to any product that has been subject to misuse,
negligence, or accident; or misapplied; or repaired by unauthorized persons; or
improperly installed. LEESON is not responsible for removal, installation, or any other
incidental expenses incurred in shipping the product to or from the repair point.
B. Disclaimer - The provisions of Paragraph A are LEESON’s sole obligation and
exclude all other warranties of MERCHANTABILITY or use, express or implied.
LEESON further disclaims any responsibility whatsoever to the customer or any other
persons for injury to person or damage or loss of property of value caused by any
product that has been subject to misuse, negligence, or accident, or misapplied or
modified by unauthorized persons or improperly installed.
C. Limitations of Liability - In the event of any claim or breach of any of LEESON’s
obligations, whether expressed or implied, and particularly of any claim of a breach of
warranty claimed in Paragraph A, or of any other warranties, express, or implied, or
claim of liability that might, despite Paragraph B, be decided against us by any lawful
authority, LEESON shall under no circumstances be liable for any consequential
damages, losses, or expense arising in connection with the use of, or inability to use,
LEESON’s product for any purpose whatsoever. An adjustment made to the warranty
does not void the warranty, nor does it imply an extension of the original one (1) year
warranty period. Product serviced and/or parts replaced by a no-charge basis during
the warranty period carry the unexpired portion of the original warranty only.
If for any reason any of the forgoing provisions shall be ineffective, LEESON’s liability
for damages arising out of its manufacture or sale if equipment, or use thereof, whether
such liability is based on warranty, contract, negligence, strict liability in tort, or
otherwise, shall not in any event exceed the full purchase of such equipment.
Any action against LEESON based upon any liability or obligation arising hereunder or
under any law applicable to the sale of equipment or the use thereof must be
commenced within one year after the cause of such action arises.

i
SPEEDMASTER™ OPERATION MANUAL
Safety Warnings
• This symbol denotes an important safety tip or
warning. Please read these instructions carefully before
performing any of the procedures contained in this manual.
• DO NOT INSTALL, REMOVE, OR REWIRE THIS
EQUIPMENT WITH POWER APPLIED. Have a qualified
electrical technician install, adjust and service this
equipment. Follow the National Electrical Code and all other
applicable electrical and safety codes, including the
provisions of the Occupational Safety and Health Act
(OSHA), when installing equipment.
• Reduce the chance of an electrical fire, shock, or explosion
by proper grounding, over-current protection, thermal
protection, and enclosure. Follow sound maintenance
procedures.
Warning
It is possible for a drive to run at full speed as a result
of a component failure. LEESON strongly recommends
the installation of a master switch in the main power input
to stop the drive in an emergency.
Circuit potentials are at 115 VAC or 230 VAC above earth
ground. Avoid direct contact with the printed circuit board
or with circuit elements to prevent the risk of serious injury
or fatality. Use a non-metallic screwdriver for adjusting the
calibration trimpots. Use insulated tools if working on this
drive with power applied.

S
H
OCK
HAZARD
AV
O
I
D
HEAT
KEE
DR
O
I
D
A
TI
ON

Warranty Statement Inside Front Cover
Safety Warnings i
Specifications 1
Dimensions 2
Overview 3
Installation 4
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Removing the Plastic Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Line fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Field Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Voltage Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Calibration 10
Calibration procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
MINIMUM SPEED (MIN SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
MAXIMUM SPEED (MAX SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
REGULATION (IR COMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
TORQUE LIMIT (TORQUE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
ACCELERATION (ACCEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
DECELERATION (DECEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Calibration procedure conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Operation 17
Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
174102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
ii SPEEDMASTER™ OPERATION MANUAL
Contents

174103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
174107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Application Notes 21
Inhibit circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Decelerating to minimum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Dynamic Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Multiple Fixed Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Adjustable speeds using potentiometers in series . . . . . . . . . . . . . . . . . .27
Independent adjustable speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
RUN/JOG switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
RUN/JOG option #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
RUN/JOG option #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Leader-follower application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Single speed potentiometer control of multiple drives . . . . . . . . . . . . . . .32
Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Troubleshooting 34
Before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Power and Current Limit LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
iii
SPEEDMASTER™ OPERATION MANUAL Contents

Figure 1. 174102, 174103 & 174107 Dimensional Diagrams . . . . . . . . . . . . .2
Figure 2. Cover removal for terminal strip access . . . . . . . . . . . . . . . . . . . . .6
Figure 3. Drive connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Figure 3a. External Signal Connections, 174103.00 . . . . . . . . . . . . . . . . . . .8
Figure 4. Voltage Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Figure 5. Calibration Trimpot Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Figure 6. Recommended TORQUE and IR COMP Settings . . . . . . . . . . . .16
Figure 7. Inhibit Plug with Run/Coast to Minimum Speed . . . . . . . . . . . . . .22
Figure 8. Run/Decelerate to Minimum Speed Switch . . . . . . . . . . . . . . . . . .23
Figure 9. Dynamic Brake Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Figure 10. Multiple Fixed Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Figure 11. Adjustable Fixed Speeds Using Potentiometers in Series . . . . . .27
Figure 12. Independent Adjustable Speeds . . . . . . . . . . . . . . . . . . . . . . . . .28
Figure 13. RUN/JOG Switch Option #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Figure 14. RUN/JOG Switch Option #2 Connection to
Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Figure 15. Leader-Follower Application . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Figure 16. Single Speed Potentiometer Control of Multiple Drives . . . . . . .32
Figure 17. Reversing Circuit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Figure 18. Current Limit LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Tables
Table 1. Recommended Line Fuse Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Table 2. Field Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Table 3. Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
iv SPEEDMASTER™ OPERATION MANUAL
Illustrations

1
SPEEDMASTER™ OPERATION MANUAL
Specifications
Max.
Armature HP Range HP Range
Current with 115 VAC with 230 VAC
Model (Amps DC) Applied Applied Style
174102 10.0 1/8–1 1/4–2 NEMA 4X
174103 10.0 1/8–1 1/4–2 NEMA 4X
174107 10.0 1/8–1 1/4–2 NEMA 4X
AC Line Voltage 115 VAC or 230 VAC ±10%, 50/60 Hz, single phase
Armature Voltage (115 VAC Input) 0–90 VDC
Armature Voltage (230 VAC Input) 0–180 VDC
Form Factor 1.37 at base speed
Field Voltage (115 VAC Input) 50 VDC (F1 to L1); 100 VDC (F1 to F2)
Field Voltage (230 VAC Input) 100 VDC (F1 to L1); 200 VDC (F1 to F2)
Max. Field Current 1 ADC
Accel. Time Range:
for 0–90 VDC Armature Voltage 1 – 15 seconds
for 0–180 VDC Armature Voltage 1 – 15 seconds
**Analog Input Voltage Range (signal must be isolated; S1 to S2):
for 0–90 VDC Armature Voltage 0 – 1.4 VDC
for 0–180 VDC Armature Voltage 0 – 2.8 VDC
Decel. Time Range:
for 0-90 VDC Armature Voltage 1 – 15 seconds
for 0–180 VDC Armature Voltage 1 – 15 seconds
Current Limit Range:
for 0–90 VDC Armature Voltage 0 – 14 A
for 0–180 VDC Armature Voltage 0 – 13.5 A
Input Impedance (S1 to S2) 3M ohms
Load Regulation 1% base speed or better
Vibration 1G max (0–50 Hz)
Ambient Temp. Range (cased drive) 10°C–40°C
**Does not Apply to 174103

2SPEEDMASTER™ OPERATION MANUAL
Dimensions
7
.50
[
191
]
5.63
[
143
]
0.19
[
5.00
]
S
L
O
TTED H
O
LE
S
4 PLA
C
E
S
B
OTTOM PLAT
E
P
O
WER
S
PEE
D
ON
O
F
F
2.2
0
[
55.9
]
3
.4
0
[
86.4
]
0.73
[
18.5
]
CO
ND
U
IT H
O
LE
S
2 PLA
C
E
S
ALL DIMENSIONS IN INCHES
[
MILLIMETERS
]
5.16
[
131
]
5.50
[
140
]
4.56
[
116
]
2.12
[
53.8
]
0
1
2
3
4
5
6
7
8
9
1
0
SPEEDMASTER
®

®
ADJUSTABLE SPEED
DC MOTOR CONTROL
Figure 1. 174102, 174103 & 174107 Dimensional Diagrams

3
SPEEDMASTER™ OPERATION MANUAL
Overview
The following is a quick-step guide to setting up the control. For
more detailed installation information, read the Installation (page
4) and Calibration (page 10) sections of this user’s manual.
1. Mount the control using the 4 slotted holes on the heat sink.
The slotted holes are 0.19 inches [5 mm] (see Figure 1).
2. Remove the plastic cover by unscrewing the 6 screws on the
front cover and 5 screws on the bottom plate. NOTE: Do not
remove the 3 screws securing the bottom plate to the
heatsink.
3. Change the line fuse if necessary. If the horsepower rating
of the motor being used is less than the maximum HP rating
of the drive, the line fuse may have to be replace with a lower
rated one.
3. Wire the control through the conduit holes, or optional
aluminum hardware. NOTE: Do not connect the control
while power is applied.
4. Assure that settings on voltage switches are correct (SW501
& SW502).
5. Apply power to the drive.
5. Calibrate the trimmer pots, if neccessary.
6. Re-install the plastic cover.

4SPEEDMASTER™ OPERATION MANUAL
Connections, calibration, and other settings must be made
internally. After mounting, use the following procedure to remove
the plastic cover and configure the control:
1. Remove the six (6) phillips screws on the front cover. NOTE:
The two shorter screws (#6 - 32 x 2 ½) are for the two lower
holes on the front of the cover (see Figure 2, page 6).
2. Remove the five (5) phillips screws on the bottom plate (see
Figure 2, page 6). NOTE: DO NOT remove the 3 screws
securing the bottom plate to the heatsink.
Line fusing
Line fuses are preinstalled on all 174102, 174103 and 174107
drives. If the horsepower rating of the motor being used is less
than the maximum horsepower rating of the drive, the line fuse
may have to be replaced with a lower rated one. Refer to Table 1
for recommended line fuse sizes.
Removing the Plastic Cover
Mounting
174102, 174103 and 174107 drives may be vertically wall
mounted using the four 0.19 inch (5 mm) slotted holes on the
attached heat sink (see Figure 1, Page 2). For motor loads less
than 5 ADC, the drive may be bench mounted horizontally, or
operated without mounting.
Installation

5
Installation
SPEEDMASTER™ OPERATION MANUAL
Table 1. Recommended Line Fuse Sizes
FUSE SIZE (AMPS) FUSE SIZE (AMPS)
MOTOR HP @ 115 VAC INPUT @ 230 VAC INPUT
1/4 5 3
1/3 8 3
1/2 8 5
3/4 10 8
115 8
1 1/2 – 10
2– 15
Connections
Warning
Do not connect this equipment with power applied.
Failure to heed this directive may result in fire or serious
injury.

1. Install conduit hardware through the two 0.73” (18.5 mm)
conduit holes or by using aluminum cord connectors attached
to the line seal plate on the bottom of the case.
2. Connect external wiring to the terminal block as shown in
Figure 3, page 7.

6SPEEDMASTER™ OPERATION MANUAL
P
O
WE
R
S
PEE
D
ON
O
F
F
0
1
2
2
3
4
5
6
7
8
9
1
0

12
56
34
CUSTOMER
SUPPLIED
WATERTIGHT CORD
CONNECTORS (2)
SPEEDMASTER
®
®
ADJUSTABLE SPEED
DC MOTOR CONTROL
S T E P # 2
REMOVE THE FIVE (5)
PHILLIPS SCREWS ON
THE BOTTOM PLATE.
S T E P # 1
NOTE: THE TWO SHORTER
SCREWS (#6 - 32 x 2 ½) ON
THE FRONT CASE ARE USED
AT HOLE LOCATIONS 5 & 6.
REMOVE THE SIX (6)
PHILLIPS SCREWS ON
THE FRONT CASE.
CUSTOMER SUPPLIED
WATERTIGHT CORD
CONNECTORS (2)
BOTTOM PLATE
DO NOT REMOVE
THE THREE (3) SCREWS SECURING
THE BOTTOM PLATE TO THE HEATSINK
45
2
1
3
Figure 2. Cover removal for terminal strip access
Installation

7
Installation
SPEEDMASTER™ OPERATION MANUAL
L2 FRM SW L1
L2 TO SW L1
L2-115
L2-230
L1 A2 F1 F2 A1
F501
TB501
MOV503
F502
M
O
MOV501
A2 TO SW A1
A2 FRM SW A1
115 VAC
LINE VOLTAGE INPUT
(115 or 230 VAC)
EARTH GROUND
(GREEN SCREW)
MOTOR
ARMATURE
+
230 VAC
FIELD
OUTPUT


FIELD OUTPUT CONNECTIONS
The field output is for shunt wound motors only. Do not make any
connections to F1 and F2 when using a permanent magnet motor.
For field motor connections, see Table 2 on Page 9.
Figure 3. Drive connections

8Installation SPEEDMASTER™ OPERATION MANUAL
RSH = 1000 OHM for 4 - 20 mA
RSH = 250 OHM for 10 - 50 mA
RSH = NOT USED for 1 - 5 mA
RSH = NOT USED for 0 - 10V signal
TERMINAL 2
+ 0 - 10V
SPEED ADJUST
SIGNAL INPUT
TERMINAL 3
(-) COMMON
RSH
2
3
1
123 4
SIG MAXSIG MIN.
TQ LIMIT ACCEL DECEL
IR COMP MIN. SPD MAX SPD
PL501
SO501
TB501
R9
R6
R2
R1
R4
R3
R7
R5
R8
Q2
Q1
IC1
C4
C2
C1
T501
P502 P501
D502
D501
C3
PCM CARD
Figure 3a. External Signal Connections
For 174103.00 Only

9
Installation
SPEEDMASTER™ OPERATION MANUAL
SO501 INHIBIT
MIN SPD
ACCEL
T501
O
V502
R502
C503
SW501
230 - 115
TQ LIMIT
IR COMP
DECEL
MAX SPD
SO502
S3 S2 S1 SW502180 - 90
IC502C501
C504
R501
MAX ARMATURE VOLTAGE SWITCH
SW502 (90 or 180 VDC)
AC LINE VOLTAGE SWITCH
SW501 (115 or 230 VAC)
Figure 4. Voltage Switches
Voltage Switches
• Set voltage switch SW501 to either 115 or 230 to match the
AC line voltage (see Figure 4 below).
• Set voltage switch SW502 to either 90 or 180 to match the
maximum armature voltage (see Figure 4 below).
Field Output
The field output is for shunt wound motors only. Do not make
any connections to F1 and F2 when using a permanent magnet
motor. Use 18 AWG wire to connect the field output to a shunt
wound motor. Table 2 lists the field output connections.
Table 2. Field Output Connections
Line Voltage Approx. Field Connect Motor
(VAC) Voltage (VDC) Field To
115 50 F1 and L1
115 100 F1 and F2
230 100 F1 and L1
230 200 F1 and F2

Calibration
All drives have six user-adjustable trimpots: Torque Limit
(TORQUE), Acceleration (ACCEL), Deceleration (DECEL),
Regulation (IR COMP), Minimum Speed (MIN SPD), and
Maximum Speed (MAX SPD). Each drive is factory calibrated to
its maximum current rating. Readjust the calibration trimpot
settings to accommodate lower current rated motors.
All adjustments increase with CW rotation, and decrease with
CCW rotation. Use a non-metallic screwdriver for calibration.
Each trimpot is identified on the printed circuit board. Refer to
Figure 5 (page 11) for trimpot locations and Figure 6 (page 16)
for typical TORQUE LIMIT and IR COMP settings.
10 SPEEDMASTER™ OPERATION MANUAL
Warning
Dangerous voltages exist on the drive when it is powered.
When possible, disconnect the voltage input from the drive
before adjusting the trimpots. If the trimpots must be
adjusted with power applied, use insulated tools and the
appropriate personal protection equipment. BE ALERT.
High voltages can cause serious or fatal injury.


11
SPEEDMASTER™ OPERATION MANUAL Calibration
Figure 5. Calibration Trimpot Layout
SO50
1
INHIBIT
L2 FRM
S
W L
1
F
501
TB
501
F
502
MOV502
R50
2
C
503
A2 T
OS
W A
1
A2 FRM
S
W A
1
SO502
S3 S
2
S
1
S
W
50
2
I
C501
I
C50
2
PO
WER
IL
502
IL
501
CU
RREN
T
LIMIT
C50
4
R
501
A
CC
E
L
T
Q
LIMI
T
DE
C
E
L
TRIMMER POTS
TORQUE LIMIT (TQ LIMIT)
ACCELERATION (ACCEL)
DECELERATION (DECEL)
REGULATION (IR COMP)
MINIMUM SPEED (MIN SPD)
MAXIMUM SPEED (MAX SPD)

12 SPEEDMASTER™ OPERATION MANUALCalibration
Calibration procedure
Calibrate the drive using the following procedure:
1. Set the MIN SPD, IR COMP, ACCEL and DECEL trimpots
to zero (full CCW).
2. Set the TORQUE trimpot to maximum (full CW).
3. Set the MAX SPD trimpot to midrange (approximate 12
o’clock position).
4. Turn the speed adjust potentiometer on front cover to zero.
5. Apply power to the drive.
6. Calibrate the trimpots as follows:
MINIMUM SPEED (MIN SPD)
The MIN SPD setting determines the motor speed when the
speed adjust potentiometer is turned full CCW or reference
signal is as its minimum. It is factory set to zero speed.
To calibrate, turn the speed adjust potentiometer full CCW or
until reference signal is at its minimum. Adjust the MIN SPD
trimpot until the motor has stopped, or is running at the desired
minimum speed.

13
SPEEDMASTER™ OPERATION MANUAL Calibration
MAXIMUM SPEED (MAX SPD)
The MAX SPD setting determines the motor speed when the
speed adjust potentiometer is turned full CW or reference signal
is at its maximum. It is factory set for maximum rated speed.
To calibrate, set the MAX SPD trimpot full CCW. Turn the speed
adjust potentiometer full CW or reference signal to its maximum.
Adjust the MAX SPD trimpot until the desired maximum motor
speed is reached.
Note: Check the MIN SPD and MAX SPD adjustments after
recalibrating to verify that the motor runs at the desired minimum
and maximum speed. When using 174103 drives in signal
mode, calibrate SIG MAX first. Refer to page 19.
REGULATION (IR COMP)
The IR COMP setting determines the degree to which motor
speed is held constant as the motor load changes. It is factory
set for optimum motor regulation.
Recalibrate the IR COMP setting when using a lower
horsepower motor. Refer to the recommended IR COMP settings
in Figure 6 (page 16), or recalibrate using the following
procedure:
If the motor does not maintain set speed as the load changes,
gradually rotate the IR COMP trimpot CW. If the motor oscillates
(overcompensation), the IR COMP trimpot may be set too high.
Turn the IR COMP trimpot CCW to stabilize the motor.