motortronics ABC-100 User manual

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Table of contents
1 Introduction ............................................................................................................................................... 2
1.1 General ............................................................................................................................................... 3
1.2 Theory of Operation ............................................................................................................................ 3
1.3 Braking Sizing and Selection .............................................................................................................. 3
1.4 Applications ........................................................................................................................................ 4
1.5 Where Mechanical Brakes Should be Used ....................................................................................... 5
1.6 ABC Model Numbers, Ratings and Dimensions ................................................................................. 6
2 Operation ................................................................................................................................................ 12
2.1 Sequence of Operation ..................................................................................................................... 12
2.2 Fault Conditions ................................................................................................................................ 14
2.3 Mechanical Brake Control ................................................................................................................ 15
3 Installation ............................................................................................................................................... 16
3.1 Fault History ...................................................................................................................................... 16
3.2 Fault Code Table .............................................................................................................................. 16
3.3 Event Records .................................................................................................................................. 16
4 Wiring ...................................................................................................................................................... 17
4.1 Introduction ....................................................................................................................................... 17
4.2 Line and Load Connections .............................................................................................................. 17
4.3 Control Connections ......................................................................................................................... 20
5 Adjustements ......................................................................................................................................... 23
5.1 Time Adjustment Procedures ........................................................................................................... 23
5.2 Jog Time Adjustment ........................................................................................................................ 23
5.3 Brake Time Adjustment .................................................................................................................... 24
5.4 Brake Current Adjustment ................................................................................................................ 24
6 Start-Up................................................................................................................................................... 26
6.1 Start-up Check List ........................................................................................................................... 26
6.2 Equipment ......................................................................................................................................... 26
6.3 Setup Sequence ............................................................................................................................... 26
6.4 Check Normal Sequence of Operation ............................................................................................. 26
APPENDIX A: TECHNICAL SPECIFICATIONS ........................................................................... 27
WARRANTY INFORMATION ....................................................................................................... 29
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Your Role in Product Safety
This equipment is designed and manufactured to the highest standards to provide safe and reliable operation
for its intended use. Only qualified personnel should install, maintain, and service this equipment, and only after
reading and fully understanding all of the information in this manual. All instructions should be strictly followed.
All Warnings, Cautions, and Notes must be taken into account for your particular installation. Users should
consult Motortronics or a Motortronics distributor/service centre if there are any questions.
All installation instructions may be superseded by applicable local, regional, or national electrical codes.
Drawings, application information, and technical representations included in this manual are for typical
installations, and should not in any way be considered specific to your application or conditions. Consult
Motortronics for supplemental information if necessary.
Contents of this manual are believed to be correct at the time of printing. In following with our on-going
commitment to meeting customer needs and developing our products to suit them, Motortronics reserves the
right to change specifications of this product and/or the contents of this manual without notice. As a result,
supplemental data sheets and/or drawings may be associated with this equipment. Please contact Motortronics
and have the unit serial number available if you notice conflicts with what is depicted in the manual and what is
installed in the field.
Phasetronics (dba Motortronics) accepts no liability for any consequences resulting from inappropriate, negligent,
or incorrect installation, application, adjustment, or maintenance of this equipment.
Notice Label Explanation:
W ARNING!
Warning labels such as this denotes specific concerns for life/ safety/damage issues associated with this
area of the manual. These statements are intended to be followed without exception.
CAUTION!
Caution labels are intended to alert the user to specific issues that MAY cause damage or personnel risks
under circumstances as described. These items are critical in some installations but not all. The user is
responsible for identifying the applicable installa tion issues.
NOTE: Notice labels are intended to alert the user to issues that require particular attention with regard
to the proper use and long term reliability of the equipment.
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1 About the Motortronics ABC Series
1.1 General
The ABC Series is a solid state DC injection brake for stopping three- phase AC induction motors. This full-wave
DC brake design offers smooth, low peak level braking for quiet, steady operation and optimal performance.
Designed to handle even high inertia loads, the ABC Series eliminates costly and potentially dangerous "coast-
to- stop" times. A built-in microprocessor provides system supervision that includes digital timing control for
jogging and braking.
The integral Operator Interface Module provides LED indication of the unit's operating status and easy
adjustments for quick setup. Standard features include interlocks and mechanical brake release relays, a brake
disable input and zero speed sensing with override.
1.2 Theory of Operation
Incoming AC power is fed to terminals L1 and L2 directly from the line side of the motor starter terminals and is
converted to DC within the ABC Series. Once the motor starter has been turned off (opened) and the residual
energy in the motor has dissipated, the DC current from the ABC Series is applied (injected) to starter terminals
T1 and T2 respectively. This creates a stationary magnetic field in the AC motor stator windings.
The braking torque will increase in proportion to the amount of current allowed to flow. (The DC injection level
can be adjusted using the Brake Current Potentiometer on the operator interface module. This modulates the
applied voltage based upon an "RMS" closed loop current feedback signal from the integral sensors.) The rotor
then pulls into alignment with this stationary field and brings the load to a stop faster than if it coasted to a stop.
1.3 Brake Sizing and Selection
ABC Series brakes are suitable for use in most AC motor applications where coast-to-stop times are undesirable
or unacceptable. The ABC Series is a current controlling brake, so various sizes of brake units can be applied to
various motor sizes. Because DC injection means applying power to the AC motor after turning it "Off", motor
heating (although minimal) will continue during the braking cycle and should be considered when selecting the
motor. AC motor manufacturers recommend that each braking cycle over 100% FLA be considered as an
additional starting cycle when calculating the starts- per-hour ratings for the selected motor.
If the selected ABC Series is sized to deliver 200% of motor rated current, consider each brake cycle to be 2
start cycles for these calculations (and 300% FLA = 3 "starts" per brake). Never size any DC injection brake to
exceed 400% of the motor nameplate FLA without first consulting the motor manufacturer. Additional guidelines
for applying ABC Series brakes follow:
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1.3.1 Standard Duty Sizing
Applying an ABC Series brake that is rated for <115% of the FLA (Full Load Amp) rating of the motor allows
maximum length of braking time without exceeding the thermal capacity of the stator windings. Since current is
controlled by the ABC Series throughout the braking cycle, braking torque will vary as the motor circuit
impedance decreases with speed. Braking torque will be highest at the beginning of the cycle, and can be as
much as 100% of the FLT (Full Load Torque) when set to motor FLA.
As the motor slows, the braking torque slowly decreases, reducing the mechanical stresses as much as
possible. Sizing a brake in this manner is typically good for machine tools, saws, conveyors, lumber machinery,
and most chippers where the coast-to-stop time does not exceed 5 minutes. Stop times vary greatly with load
and friction, but can be expected to be 1/2 of the coast-to-stop time or less. Keep in mind that the maximum
brake time is setting is 127 seconds. In heavily loaded, high inertia machines and long coast-to-stop times, the
Standard Duty model may not stop the load. Consider using the Extra Duty rating instead.
1.3.2 Extra Duty Sizing
For heavier machine loads such as large chippers, punch presses and other flywheel based machines, selecting
an ABC Series brake based on 200-250% of the motor nameplate FLA allows faster braking. The maximum
developed braking torque can be as much as
200% of the motor rated Full Load Torque. In this case, the load can typically stop in twice the Across-the-Line
starting time. Duty cycling of the motor is a much more important consideration in applications since additional
thermal stresses due to higher current levels are applied to the motor.
1.3.3 Custom Sizing
Extreme loads (such as overhauling conveyors or large centrifuges), or short stop times (approaching the
across-the-line starting time of the motor) may require sizing the ABC Series for 300% of the motor FLA or
greater, and should be done with careful consideration of motor heating, duty cycle, and limitations of
mechanical stress on the drive train components.
1.3.4 Emergency Stopping
An ABC Series brake used in conjunction with a mechanical brake should be considered if the stop times must
be equal to or shorter than the across-the-line start time, consider using and ABC Series brake in conjunction
with a mechanical brake.
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1.4 Applications
The ABC Series electronic brake is ideal for machine and process equipment control applications for efficiency,
increased safety, and reduced equipment maintenance costs. Among the benefits:
Efficiency is improved because you no longer have to wait through long coast-to-stop times for blade changes,
batch loading, or maintenance shutdowns. Productive time increases as overall operating costs decrease
because the load stops more quickly. The ABC Series eliminates the common practice of jamming the load to a
stop which seriously reduces the life and effectiveness of saw blades, molding heads, and knives.
Increase Safety by eliminating the need to "jam-stop" equipment. This will prevent any personnel injuries
caused by kickbacks and broken blades. Use the ABC Series in conjunction with safety inter- lock devices to
stop the motor as quickly as possible, reducing the risk of contact with dangerous rotating elements of
machinery. Prevent premature wear or component failure and eliminate the need for hasty repairs that can put
maintenance personnel in potentially dangerous situations. ABC Series brakes can be used as part of a system
to facilitate O S H A General Industry Standards ( 29 CFR1910 Subpart O) requiring that workers not be
exposed to hazardous moving parts. They can also be utilized to satisfy braking requirements of the British
Columbia Workers Compensation Amendment Act (Book 3 Part 27.42) for rotating knife machinery such
as planers, chippers, and hogs.
Reduce maintenance costs by using the ABC Series. Eliminate the need to plug-reverse a load and reduce
the associated damage to gear boxes and other power train components. The ABC Series can be used to stop
or slow down the load in one direction before reversing to the other. On machines where mechanical brakes are
used to stop or hold a load, use the ABC Series to stop it first, then set the mechanical brake as a "parking
brake". This eliminates the normal wear and tear to the brake pads or shoes. On loads such as vibrating
feeders, screens, or separators, damage from mechanical harmonics that occur during coast-down can be
eliminated by using an ABC Series. It allows the motor/load to quickly pass through any dangerous speeds and
come to a stop.
1.5 Where Mechanical Brakes should be used
Power loss during braking - The ABC Series, like all DC injection brakes, requires power to be applied during
the braking cycle. If the incoming line power is lost from the utility, an upstream circuit protective device trips, or
an emergency shutdown routine is initiated, no braking will take place. If braking is still necessary for safety
reasons (even in the event of a power failure), consider using mechanical brakes as a backup device. Under
normal operation conditions, the ABC Series stops the load and the mechanical brake holds it.
Holding the load after it comes to a stop - All DC injection brakes inherently lose braking torque when the
motor comes to a complete stop and therefore CANNOT BE USED AS HOLDING BRAKE. If braking must be
applied continuously while the load is at rest, mechanical "Parking Brakes" are required. The ABC Series
includes a Mechanical Brake Release Relay to facilitate proper coordination of the mechanical brake in these
applications.
Stop times shorter than start times - Like all DC injection brakes, the ABC Series waits for the residual motor
energy to dissipate from the windings before DC current can be applied (otherwise damage to the brake or
circuit devices may occur). The length of this "wait state" depends on the motor's residual magnetism and the
motor frame size, but can be as much as 5 seconds. This, combined with the limits on braking torque, makes DC
injection braking ineffective if braking time must be shorter than the starting time (Across-the-Line).
W ARNING!
DC Injection brakes cannot be used for holding a load after it comes to a stop. The ABC Series includes a
Mechanical Brake Release Relay that can be used to coordinate the operation of a mechanical brake for
use in these applications.
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1.6 ABC Series Model Number, Rating and Dimensions
ABC - 200 - - E
Voltage
240 = 208 – 240V, 400 = 380 – 415V
480 = 440 – 480V, 600 = 575 – 600V
Enclosure
P = Panel Mount
E = NEMA 4/12 Sealed
Max. Brake Amps
50 – 1000 A.
ABC SERIES
Model
Number*
Max
Amps
Typical Horsepower Usage
Dimensions
208 V
240V
480V
600V
Panel
Dim Ref.#
NEMA 4/12
Dim Ref. #
Std.
Duty
Extra
Duty
Std.
Duty
Extra
Duty
Std.
Duty
Extra
Duty
Std.
Duty
Extra
Duty
ABC-50
50
15
7.5
20
10
40
25
50
30
2
7
ABC -100
100
30
20
40
25
75
50
100
60
2
7
ABC-200
200
75
40
75
50
150
100
200
125
3
8
ABC-300
300
100
60
125
75
250
150
300
200
4
9
ABC-400
400
150
75
150
100
350
200
400
250
4
9
ABC-550
550
250
125
200
150
500
300
600
350
5
10
ABC -800
800
350
200
350
200
700
450
900
500
5
10
ABC-1000
1000
400
250
400
300
900
500
1000
600
5
10
NOTES:
1. Never exceed the Full Load Amp rating of the motor without checking the motor manufacturer's data
with regards to appropriateness of the application and duty cycle.
2. If duty cycle is not known, Motortronics recommends using the Extra Duty Brake since braking current
can be adjusted down to meet the actual load requirements.
Dim
Ref. #
Dimensions (Inches)
A
B
C
D
E
F
2
10.5
7.9
7.2
10
6.8
0.21
3
16.5
10
10
15.9
9
0.28
4
16
16
10
15
15
0.5
5
21
26
10.4
20
25
0.5
6
16
12
9
14.5
10.5
0.5
7
20
16
9
18.5
14.5
0.5
8
24
20
16
22.5
18.5
0.5
9
36
24
16
34.5
22.5
0.5
10
36
30
16
34.5
28.5
0.5
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N4/12 Outline: ABC-50/100-E
N4/12 Outline: ABC-200-E
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N4/12 Outline: ABC-300/400-E
N4/12 Outline: ABC-550/800-E
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Panels Outline: ABC-50/100
Panels Outline: ABC-200
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Panels Outline: ABC-300/400
Panels Outline: ABC-550/800
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Panels Outline: ABC-1000
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2 Operation
2.1 Sequence of Operation
The ABC Series brake becomes "Armed" when the motor starter turns "On” and then braking occurs when the
starter is turned "Off". An Operator Interface Module has two large LEDs to indicate "Braking" or "Fault"
condition, plus six smaller LEDs to indicate the following modes of operation:
2.1.1 “Power On”
The ABC Series brake is self-powered from the available motor branch circuit as derived from Terminals L1 and
L2. If fuses are used, this LED will indicate a blown fuse condition in either of these circuits by being off when
power is applied to the starter (see section 4.2.1). This LED does NOT indicate motor starter or ABC Series
brake unit operational status.
2.1.2 Jog / Armed
The ABC Series receives a Brake Command from an input wired to the motor starter which indicates the starter
status (see section 4.3.1). The ABC Series can be programmed to wait a period of time before going into the
"Armed" condition using the "Jog" feature. This feature allows for user setup and testing of systems during the jog
time with- out the braking cycle interfering. (The "Jog" time is set via the "Jog Time" dip switches.) This LED will
flash once per second until the end of the jog time. If the Motor Starter is turned off again while the ABC Series
is still in the "Jog" mode, the brake will NOT arm and DC injection will not take place (setting this time to zero
will turn off this feature). After the "Jog Time" expires, the ABC Series will enter the "Armed" mode (indicated
when the JOG/ARMED LED illuminates in a steady state). The ABC Series is now ready to begin DC injection
braking the next time the motor starter is turned off. The "Armed" mode has no time limit and will be
maintained for the duration of the motor run time.
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2.1.3 “Braking”
The ABC Series will enter the braking mode when the motor is given a stop command after being "Armed" (see
"JOG / ARMED" above). To prevent damaging current spikes, a factory programmed delay allows the existing
motor magnetic field to decay before DC is applied (see section 5.1). During the "BRAKING" mode, a set of N.C.
interlock contacts change state and disable the motor starter control circuit during the braking cycle (see section
4.2.2).
The ABC Series begins injecting a regulated DC braking current and simultaneously digitally times, controls the
Interlock Relay and monitors the Zero Speed Sense Circuit. Braking will continue until the first one of three
events occurs: 1) the Zero Speed Sense circuit determines the motor has stopped, 2) the "Brake Time" expires,
or 3) the unit receives a "Brake Disable" signal input. When braking is complete, the ABC Series releases the
Interlock Relay and is ready for another cycle.
2.1.4 Brake OFF
This LED illuminates whenever the ABC Series is not actively braking (either because the motor is on or the
previous braking cycle has been completed). The ABC Series provides a built-in, closed-loop sensing circuit that
accurately determines when the motor has stopped based on the subtle signals received from the unused motor
winding. If the Zero Speed Sensing circuit determines that the motor has come to a stop before the Brake Time
has expired, it will override the brake time setting and shut the ABC Series off. The "BRAKE OFF" LED will then
illuminate. NOTE: Since the Brake Time may expire prior to the Zero Speed override coming into play, this
circuit should not be used as a true Zero Speed indicator.
W ARNING!
The ABC Series DC Injection Brake requires AC power for brak ing. Power loss before or during braking
will result in the loss of braking ability, which can be hazardous to personnel and/or equipment. If braking
to a stop is critical regardless of the avail ability of electrical power, mechanical braking should be
pro vided as a backup system. The ABC Series brake offers a Me chanical Brake Release Relay specifically
for this purpose.
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2.2 Fault Conditions
The “FAULT” LED will illuminate when any of the following conditions occur:
2.2.1 “Disabled”
The "DISABLED" mode is activated when the ABC Series receives a command on the Brake Disable input (a
N.O. dry contact at TB1) (see section 4.3.2). This mode can be used to remove the electronic brake from the
system, and is useful in applications that only require braking at certain times during the process and during
system setup. Note: The ABC Series is a "smart brake" and will sense a running motor and automatically arm
itself if released from the "DISABLED" mode. Under these circumstances, the ABC Series will go through the
"JOG" and "ARMED" sequence again. If the unit has determined the motor is stopped, the brake will return to the
normal ready state.
NOTE: The ABC Series Mechanical Brake Release Relay will set the mechanical brake if the ABC Series
brake unit is disabled during the braking mode.
2.2.2 “Wiring Error”
The ABC Series unit will recognize when the interface connections or monitored signals are not correct with
respect to the proper operation sequence. If the brake detects a miswire or an improper sequence of events, it
will "self-disable" to prevent any conflicts with the existing systems and indicate "WIRING ERROR". If this
occurs, the "Fault" LED and "Wiring Error" LEDs will illuminate. Once the miswire or wrong sequence is
corrected, the brake will automatically enable itself and resume normal operation.
2.2.3 “Over Temp”
The ABC Series has thermal sensors built into the heat sink assembly. If the heat sink approaches temperatures
too high for the SCRs, the sensors will cause a Fault and illuminate the "Fault" and "Over Temp" LEDs.
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2.3 Mechanical Brake Control
The ABC Series includes a Mechanical Brake Release Relay that can be utilized to control an electro-
mechanical brake coil. This relay has a Form “A” contact (1 N.O.) that changes state as follows (see section
4.3.4):
OPERATION
RELAY STATUS
Power On
No Change (de-energized)
Jog / Armed
Energizes (follows motor starter coil)
Braking
Remains energized
Braking Time Completed /
Zero Speed Override
De-energizes
Disabled – Before or During Jog / Armed
Remains Energized (follows motor starter coil)
Disabled – During Braking
De-energizes
Fault
De-energizes
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3 Installation
3.1 Receiving and Unpacking
Upon receipt of the product you should immediately do the following:
• Carefully unpack the unit from the shipping carton and inspect it for shipping damage.
• Verify that the model number on the unit matches your purchase order.
• Check all electrical terminals to be sure screws are tight.
3.2 Initial Unit Inspection
Complete a visual check of the unit for damage which may have occurred during shipping and handling. Report
any damage immediately and file a claim with the freight carrier within 15 days of receipt. Do not attempt to
continue installation.
CAUTION!
Do not operate or install the ABC Series Brake if it appears to be damaged or visually defective. Doing so
may result in per sonnel injury or equipment damage.
3.3 Location
Proper location of the ABC Series is necessary to achieve specified performance and normal operation lifetime.
The unit should always be installed in an area where the following conditions exist:
• Ambient operating temperature:
Chassis unit: 0 to 50°C (32 to 122°F)
Enclosed unit: 0 to 40°C (32 to 104°F)
• Humidity: 5 to 95% non-condensing
• Free from metallic particles, conductive dust and corrosive gas
• Free from excessive vibration (below 0.5G)
• Open panel units must be mounted in the appropriate type of en- closure. Enclosure size and type must be
suitable to dissipate heat generated by the unit. Contact factory for details.
3.4 Mounting and Cleaning
The unit is air cooled and must be properly mounted to allow for unrestricted airflow across the heat sink. The unit
should be mounted with the heat sink fins in a vertical plane, with a minimum of five (5) inches (127mm) of free
space around the unit for adequate ventilation. The ambient air should be free of any contaminants which can
clog louvers or coat the unit. As with all electrical equipment, the unit must be protected from water and
condensing humidity to prevent damage to the unit. In damp or cold environments, space heaters may be
required.
W ARNING!
Remove All Sources of Power Before Cleaning the Unit. In dirty or contaminated atmospheres the unit
should be cleaned on a regular basis to ensure proper cooling. Do not use any chemicals to clean the
unit. To remove surface dust, use 80 to 100 psi clean, dry compressed air only. A three inch, high
quality, dry paint brush is helpful to loosen up the dust prior to using compressed air on the unit.
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4 Wiring
4.1 Introduction
• Installation of the brake unit should be done by properly qualified personnel.
• Check local and other applicable codes to ensure that all installation requirements are met prior to operation.
• Prior to beginning the installation, verify that the motor and brake unit have the same voltage ratings.
• Check the unit to verify that it is rated for the appropriate current (approximately equal to the motor FLA if
sized for Standard Duty - see section 1.3).
W ARNING!
Do not service equipment with voltage a pplied! Unit can be source of fatal electrical shocks! To avoid
shock hazard, disconnect main power before working on the unit. Warning la bels must be attached to
terminals, enclosure and control panel to meet local codes.
4.2 Line and Load Connections
Power conductors for the Line and Load connections should be, at a minimum, sized at 125% of the current
rating. Brake sizing and duty cycling should be considered when determining if conductors should be oversized
for your application. For example, high torque, fast stop applications with maximum duty cycle may require
conductors sized for the maximum output capability of the ABC Series, and motor lead wires should match.
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4.2.1 Line Power Connections
Connect the line leads to the input terminals L1 and L2 provided on the unit. The line power must be supplied
from a source with suitable Short Circuit Protective Devices (SCPD) conforming to local and national electric
codes. Additional fusing is necessary only when the motor circuit is fused at a level too low to protect the ABC
Series per code. Recommendations for commonly available SCPDs are as follows:
UNIT RATING
SCPD
SCPD SIZED AS % OF ABC
UNIT RATING
10 – 100 Amps
Class RK5 Fuse
Class J Fuse
Circuit breaker
No greater than 250%
No greater than 400%
No allowable (fuses required)
200 – 1000 Amps
Class RK5 Fuse
Class J Fuse
No greater than 250%
No greater than 400%
Circuit breaker
No greater than 250%
W ARNING!
Many motor safety disconnect switches are not rated to inter rupt DC current. Replace any load side safety
disconnect switch with one that is rated for DC voltage at the motor line voltage rating or greater. As an
alternative, disconnect incoming line power before opening any load side disconnect switches in the
motor circuit during braking, and post warning labels at all af fected devices. Failure to observe this
precaution may result in damage to the disconnect and /or bodily injury
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4.2.2 Load Power Connections
Connect the motor leads to the output terminals T1 and T2 provided on the unit. The unit will operate on either a
Wye or a Delta connected motor. An additional control wire must be run from motor lead T3 of the starter to the
voltage sensing circuit of the ABC Series . The terminal for this is marked "T3". This terminal carries very little
current so #20 wire (or higher) can be used. Fuse protection ad- equate for the field wiring used must be
provided per code.
NOTE: If the ABC Series brake is being used with 2-speed, Wye- Delta or Reduced Voltage starter, consult
factory for additional load connection information.
CAUTION!
Power Factor Correction Capacitors should NOT be connected to the load side of the motor starter when
used with an ABC Series brake. PFC Capacitors should only be connected to the line side and must
include a separate isolation contactor .
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