Saftronics DG2 PLUS Series User manual

DG2 PLUS SERIES
¼ to 5 HP
SCR Speed Controls
for DC Motors
CAUTION
EquipmentisatpossiblylethalAClinevoltagewhenACpowerisconnected.
Pressing the STOP pushbutton does not remove AC line voltage. Both
phases must be disconnected before it is safe to touch motor terminals or
control equipment parts.
Saftronics, Inc.
5580 Enterprise Pkwy., Ft. Myers, Fl 33905
Telephone:[phone]
Fax:[phone]
P/N X010031
Rev: 5

DG2 PLUS
INSTRUCTION MANUAL
CONTENTS
Section 1.0: Description
1.1 Overview .......................................................................................................... 1
1.2 Standard Features ............................................................................................. 1
Section 2.0: Specifications
2.1 Electrical ........................................................................................................... 2
2.2 Electrical protection .......................................................................................... 3
2.3 Mechanical ........................................................................................................ 3
2.4 Adjustments ..................................................................................................... 3
Section 3.0: Receiving & Installation
3.1 Installation ........................................................................................................ 4
3.2 Derating data ..................................................................................................... 4
3.3 Wiring ............................................................................................................... 4
Section 4.0: Startup
4.1 Inspection ......................................................................................................... 5
4.2 Pre-start adjustments ........................................................................................ 5
4.3 Starting .............................................................................................................. 6
Section 5.0: Troubleshooting
.......................................................................................................................... 7
Section 6.0: Wiring diagrams
6.1 DG2P-10 & DG2P-15 ...................................................................................... 8
6.2 DG2P-25 .......................................................................................................... 9
6.3 Typical torque control connection ................................................................. 10
6.4 AA1128 Control card schematic .................................................................... 11
6.5 Motor connections ......................................................................................... 12
Section 7.0: Dimensional outlines
7.1 DGP2-10 & DG2P-15 .................................................................................... 13
7.2 DG2P-25 ........................................................................................................ 14
7.3 Enclosed .......................................................................................................... 15
Section 8.0: Spare parts
........................................................................................................................ 16
Section 9.0: Warranty
........................................................................................................................ 17
Eff Date: 07Jan97

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1.0 DESCRIPTION
1.1 Overview DG2 PLUS series non-regenerative two quadrant thyristor controllers
are designed to control the speed of wound field or permanent magnet
dcmotors from ¼to5 hp. Thesedrivescanalso bemodifiedto become
torque control regulators.
·Impedance-isolated armature voltage feedback
Highimpedanceresistivevoltagedividernetworkusedforarmature
voltagefeedback.
·Tachogenerator feedback
50 volt/1000 rpm tachometers may be used for speed feedback.
·Dual AC line voltage
120 or 240 vac line voltages are plug selectable.
·Dual field voltage
50/100 or 100/200 volt field supplies are link selectable.
·10V reference supply
·LED indication
Run relay energized
Power "ON"
1.2 Standard Features
Control block diagram

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2.0 SPECIFICATIONS
·Power
Single phase 120 or 240 vac, 50/60 Hz., (±10%).
·Speed range
10:1 with armature feedback, 50:1 with tachometer feedback.
·Load regulation
±3% with armature voltage, (±10% line voltage change).
·Acceleration/Deceleration
Adjustable: 0.1-30 seconds from 0 to full speed.
·Temperature range
32°F - 104°F (0-40°C).
·Altitude
2000 feet (600m) maximum without derating.
·Rectifier configuration
The DG2 PLUS employs a single phase, half-wave bridge.
·HP & Current rating
MODEL HP AMPS
120 VAC 240 VAC INPUT OUTPUT
DG2P-10 1 2 18 10
DG2P-15 - 3 25 15
DG2P-25 - 5 34 25
·Voltage rating (selectable via JMP1, see P.5.)
INPUT OUTPUT VDC
ARMATURE FIELD
120 VAC 0-90 50/100
240 VAC 0-180 100/200
·Short circuit rating
Suitableforuseonacircuitcapableofdelivering notmorethan5000
rms symmetrical amperes, 240 V maximum.
2.1 Electical

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2.2 Electrical Protection
2.3 Mechanical
2.4 Adjustments
·Fusing
One fast-acting fuse in each AC leg.
·Current limit
Adjustable current limit circuit 0 - 125%.
·Surge suppression
MOV surge suppressor.
For dimensional information see page 13.
·RV1 Acceleration
Thiscontroladjustsbothaccelerationand deceleration time. In the
fully clockwise position, acceleration/deceleration time is 0.1
seconds,and in thefullycounter-clockwiseposition, acceleration/
deceleration time is 30 seconds.
·RV2 Current stability
This control, which has been factory preset, adjusts the stability
of the current loop.
·RV3 Voltage stability
This is factory preset and very seldom needs adjustment. If the
motor should hunt, rotate this trimpot until the motor runs
smoothly. The normal position of this trimpot is approximately
1/5 turn clockwise.
·RV4 IR Compenstaion
Factory set to CCW for Tach Feedback, this control rarely needs
to be used. However, when using armature voltage feedback with
cyclical loading applications where there is a speed drop due to
operation from high to low load, the IR Comp adjustment
corrects for voltage changes inside the DC motor when load is
applied. If speed variations with load are a problem, set the
SPEED control knob to the desired operating speed. Now load
thedrive. Adjust RV4untilthe motor speedreturns to itsunloaded
speed. Remove the load and ensure motor speed is stable.
·RV5 Current limit
Thiscontrolis preset atfactoryandseldom needs fieldadjustment.
·RV6 Maximum speed
This adjustment is used to set the maximum armature voltage or
motor speed.
·RV7 Minimum speed
This control sets the minimum armature voltage or motor speed.
CAUTION: Adjusting
RV4 to over 50% clock-
wise rotation, may cause
drive instability which
cannot be corrected by
RV3 voltage stability. In
such a case, back off
slightly from the position
where RV4 causes insta-
bility. This may result in
a slight decrease in speed
holding.

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ThecabinetcontainingtheDG2PLUSmustbeinstalled inanareawhere
the following conditions exist:
Ambient temperature does not exceed 40ºC (104ºF).
Ambient temperature is not less than 10ºC (50ºF).
Altitude above sea level is 2000 feet (600m) or less.
Ambient air is reasonably clean, dry and free of flammable or
combustible vapors, steam, or corrosive gases, etc.
The cabinet must be installed away from any heat source, and a
minimumof1foot(30.48cm)isrequiredaroundtheair inlet and outlet,
on ventilated units.
The DG2 PLUS has been designed for 50ºC maximum inside the
enclosure.
When the unit is installed in poor environmental conditions, it must be
derated as follows:
1.5% per Cº above 40ºC, or 0.75% per Fº above 104ºF.
15% per 1000 feet (300m) above 2000 feet (600m).
The DG2 PLUS is to be connected according to the NEC and any other
applicable Electrical Codes in the customer's area. The chassis must
be bonded to earth ground.
Section 6 pages 7, 8, and 9 show typical connections for speed
controlled wound field motors. For permanent magnet motors, there
will be no connections to F+ and F-.
See page 10 for typical torque control connections.
3.0 RECEIVING & INSTALLATION
3.1 Installation
3.2 Derating Data
3.3 Wiring

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4.0 STARTUP
Ensure that the drive has been installed according to the previous
guidelines. Also, ensure that the unit has been wired according to the
schematics. Check that all connections are tight and that the motor can
rotate freely.
AC input voltage selection
Before power is applied, confirm that the voltage selection plug on the
AA1128 card matches the supply voltage. DG2P-15 drives are factory
setfor240VACinputandarenotreconfigurable.DG2P-10drives may
beconfiguredforeither120VACor240VACasfollows.Locate2wire
jumpers and a nylon plug housing in a plastic bag attached to the
heatsink. Insert the wire jumpers into the housing according to one of
the two drawings below depending on the AC input voltage. Insert the
plug into connector JMP1. If the input voltage is 240 VAC then
jumper J4 must be removed.
120 VAC 240 VAC
Field voltage selection
Confirm that the field voltage is configured to match the field voltage
of the motor according to its nameplate rating. Permanent magnet
motors do not require field voltage configuration. Terminals 12 and 13
are jumpered as the factory standard default.
INPUT TERMINALS 12-13
REMOVED INSTALLED
120 VAC 50 VDC 100 VDC
240 VAC 100 VDC 200 VDC
All controls have been preset at the factory and should not require
further adjustment.
TheDG2PLUShasbeenfactory set for armaturevoltage feedback. To
use tachometer feedback, remove the "ARM" link and install the
"TACH" link (LK-3).
The"IRCOMP"trimpot is not usedwith tachogeneratorfeedback, and
must remain fully counterclockwise.
4.1 Inspection
4.2 Prestart adjustments
Topreventdrive runaway,
be very careful to estab-
lish tachogenerator po-
larity with the motor ro-
tating in the desired di-
rection. Then connect
tach (+) to terminal 2 and
tach (-) to terminal 1.

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Before applying power, refer to section 6.0 and ensure that all control
and power wiring is correct, the power source, motor, and drive are
matched, and that all links are properly set. Turn the speed pot to the
zero reference position and ensure that the run circuit is disabled.
1. Measure and confirm that the AC supply voltage is correct
according to the table on page 2. Confirm that the field voltage is
correct according to the motor nameplate. Apply power and
observe that LED1 "POWER" is illuminated.
2. Press the "START" pushbutton. Observe that LED2, "RUN", is
illuminated and that the motor does not rotate. To set minimum
speed, slowly increase RV7 until the motor reaches the desired
speed. The external speed reference should be set at zero.
3. With the speed reference set at maximum, the motor should rotate
at rated speed and/or voltage. If not, adjust RV6 for the correct
setting.
4. Iftheaccelerationand decelerationratesarenotsuitable,seesection
2.4, p.3, for adjustment.
4.3 Starting

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SYMPTOM PROBABLE CAUSE
Motor does not run
- No Run command.
- Speed reference at 0 volts.
- Blown fuses or no AC source.
AC line fuse/fuses blown
- SCR block shorted.
- Field diodes shorted.
- Grounded motor armature or
field.
Motor runs at slow speed with
the speed pot set fully cw.
- Max speed set too low.
- Drive in current limit.
- Bad speed pot.
Motor unstable.
- IR comp turned too high
- Voltage stability set
incorrectly.
- Current stability set
incorrectly.
- Max speed set too high.
Motor overspeeds with low
speed reference
- Max speed set too high.
- Tach input reversed (if used).
- No tach feedback if in tach
mode.
Motor drifts at zero speed - Requires anti-drift board
p/n AA1060-B
5.0 TROUBLESHOOTING

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6.0 WIRING DIAGRAMS
6.1 DG2P-10 & DG2P-15

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6.0 WIRING DIAGRAMS CONT'D
6.2 DG2P-25

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6.0 WIRING DIAGRAMS CONT'D
6.3 Typical Torque control connection

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6.0 WIRING DIAGRAMS CONT'D
6.4 AA1128 schematic

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6.0 WIRING DIAGRAMS CONT'D
6.5 MOTOR CONNECTIONS

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7.0 DIMENSIONAL OUTLINES
7.1 DG2P-10 & DG2P-15

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7.0 DIMENSIONAL OUTLINES CONT'D
7.2 DG2P-25

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7.0 DIMENSIONAL OUTLINES CONT'D
7.3 DG2P-10, 15, 25 Enclosed

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8.0 SPARE PARTS
Note:
When replacing the controller card AA1128, ensure that
1) Incoming voltage selection plug is in the proper location.
2) Links match those of the previous card.
SPARE PART MODEL
DG2P-10 DG2P-15 DG2P-25 QTY
Controller Card
AA1128 AA1128 AA1128-B AA1128-B 1
SCR Bridge Assy N500004 N500007 N500002 1
Fuses F1, F2 F601011-17 (20A) F601012-36 (30A) F601011-10 (5A) 2
Field Diodes D3001-11 D3001-11 D3001-11 4
Power Fuses __ __ F602003-05 (60A) 2

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9.0 WARRANTY
Saftronics warrants to buyer that products, and any services furnished
hereunderwill befree from defectsin material, workmanshipand title,
and will be of the kind and quality specified in the quotation. The
foregoingshallapplyonlytofailures to meet saidwarranties(excluding
any defects in title) which appear within one year from the date of
shipment hereunder, provided, however, that if buyer, in the course of
its regular and usual business, transfers title to or leases such products
(including equipment incorporating such products) to a third party,
such period shall run until one year from such transfer or lease or
eighteen months from shipment by Saftronics whichever occurs first.
The warranties and remedies set forth herein are conditioned upon (a)
proper storage, installation, use and maintenance, and conformance
with any applicable recommendations of Saftronics and, (b) buyer
promptlynotifyingSaftronicsofanydefects and, if required,promptly
making the product available for correction.
Ifanyproductsorservicesfails to meet theforegoingwarranties(except
title), Saftronics shall thereupon correct any such failure either, at its
option, (i) by repairing any defective or damaged part or parts of the
products, or (ii) by making available FOB Saftronics plant or other
point of shipment, any necessary repaired or replacement parts. The
precedingparagraphsets forththeexclusiveremediesforclaims(except
as to title) based on defect in or failure of products or services, whether
claimincontractortort(including negligence) and howeverinstituted.
Upon expiration of the warranty period, all such liability shall termi-
nate. The foregoing warranties are exclusive and in lieu of all other
warranties, whether written, oral, implied or statutory. No implied
statutory warranty of merchantability or fitness for particular purpose
shall apply and Saftronics will not be liable for any consequential
damage arising from any product defect or failure to deliver on time.
Saftronics does not warrant any products or services of others which
buyer has designated.