Saftronics DF8 PLUS Series User manual

DF8 PLUS SERIES
¼ to 5 HP
Full Wave Regenerative Reversing
SCR Speed Controls
for DC Motors
CAUTION
Equipment is at possibly lethal AC line voltage when AC power is
connected. 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.
5580EnterprisePkwy.,Ft.Myers,Fl33905
Telephone:[phone]
Fax:[phone]
SAFTRONICS
P/NX010034REV:5
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DF8 PLUS
INSTRUCTION MANUAL
CONTENTS
Section 1.0: Description
1.1 Overview ...................................................................................................... 1
1.2 Standard Features ......................................................................................... 2
Section 2.0: Specifications
2.1 Electrical....................................................................................................... 2
2.2 Electrical protection ..................................................................................... 3
2.3 Mechanical ................................................................................................... 3
2.4 Adjustments................................................................................................. 4
2.5 Jumper selections......................................................................................... 5
Section 3.0: Receiving & Installation
3.1 Installation ................................................................................................... 6
3.2 Deratingdata ................................................................................................ 6
3.3 Wiring........................................................................................................... 6
Section 4.0: Startup
4.1 Inspection .................................................................................................... 7
4.2 Pre-start adjustments ................................................................................... 7
4.3 Starting ......................................................................................................... 7
Section 5.0: Troubleshooting
..................................................................................................................... 8
Section 6.0: Wiring diagrams
6.1 DF8P-10 & DF8P-15 .................................................................................. 9
6.2 DF8P-25..................................................................................................... 10
6.3 Typical torque control connection ............................................................. 11
6.4 Motor connections ..................................................................................... 12
Section 7.0: Dimensional outlines
7.1 DF8P-10 & DF8P-15 Chassis ................................................................... 13
7.2 DF8P-25 Chassis ....................................................................................... 14
7.3 NEMA 1 Enclosed with operators ............................................................ 15
Section 8.0: Spare parts
................................................................................................................... 16
Section 9.0: Warranty
................................................................................................................... 17
Eff Date: 25Aug97
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SAFTRONICS
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1.0 DESCRIPTION
1.1 Overview DF8 "Plus" series fully regenerative four quadrant thyristor control-
lers are designed to control the speed of wound field or permanent
magnet dc motors from ¼ to 5 hp. These drives can also be modified
to become torque control regulators. DF8 "Plus" drives are supplied
in either chassis or Nema 1 enclosed formats.
••
••
•Control block diagram
••
••
•Four quadrant operation
Note:
Arrows same direction
Motoring
Arrows opposite
Braking
Motor rotation
Torque
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••
••
•Isolated current feedback
AC current transformers sense current in each bridge.
••
••
•Impedance-isolated armature voltage feedback
High impedance resistive voltage divider network used for arma-
ture voltage feedback.
••
••
•Tachogenerator feedback
50 volt/1000 rpm tachometers may only be used for speed
feedback.
••
••
•Dual AC line voltage
120 or 240 vac line voltages are plug selectable.
••
••
•Dual field voltage
100/50 or 200/100 volt field supplies for 120 or 240 ac line
voltages.
••
••
•Matched +12V and -12V reference supply
••
••
•Regenerative braking to zero speed with signal contact
output
••
••
•LED indication
Power on (DS8 red)
Forward speed reference (DS5 green)
Reverse speed reference (DS4 red)
Forward amplifier output (DS7 green)
Reverse amplifier output (DS6 red)
Run relay energized (DS2 red)
Inhibit (DS3 red)
Zero speed (DS1 red)
1.2 Standard Features
••
••
•Power
Single phase 120 or 240 vac, 50/60 Hz., (±10%).
••
••
•Speed range
30:1 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.
••
••
•Regenerative braking
Upon application of a stop signal the drive will regeneratively
brake and stop at zero speed. This feature depends on the setting
of jumper P1 (see page 5).
2.1 Electical
2.0 SPECIFICATIONS
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••
••
•Rectifier configuration
The DF8 "Plus" employs two single phase, full-wave, fully
controlled, (4 SCR) bridges to allow extremely rapid motor
armature reversing.
••
••
•HP & Current rating
MODEL
HP AMPS
120 VAC 240 VAC INPUT OUTPUT
DF8P-10 1 2 18 10
DF8P-15 1.5 3 25 15
DF8P-25 2.5 5 37 25
••
••
•Voltage rating
INPUT
OUTPUT VDC
ARMATURE FIELD
120 VAC (J6) 90090 100/50
240 VAC (J5) 1800180 200/100
••
••
•Short circuit rating
Suitable for use on a circuit capable of delivering not more than
5000 rms symmetrical amperes, 240 V maximum.
••
••
•Fusing
One fast-acting fuse in each AC leg.
••
••
•Current limit
Adjustable current limit circuit for each bridge.
••
••
•Surge suppression
MOV surge suppressor.
For dimensional information see pages 13 & 14.
2.1 Electrical cont'd
2.3 Mechanical
2.2 Electrical Protection
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••
••
•RV1 +12V reference
Thisfactory presetadjustment willvery seldomneed adjustment.
It is used to match the +12 volt reference supply to the -12 volt
supply.
••
••
•RV2 Current stability
This control, which has been factory preset, adjusts the stability
of the current loop. The normal position of this trimpot is
approximately 1/2 turn clockwise.
••
••
•RV3 Acceleration/Deceleration
This control adjusts both acceleration and deceleration time. In
thefully clockwise position,acceleration/deceleration time is0.1
seconds,andin thefully counterclockwise position,acceleration/
deceleration time is 30 seconds.
••
••
•RV4 Maximum speed
This adjustment is used to set the maximum armature voltage or
motor speed.
••
••
•RV5 Zero speed offset
Thisadjustmentisusedtominimizecreepingofthemotorwiththe
speed reference set to "zero".
••
••
•RV6 IR Compensation
Factory set to CCW for Tach Feedback, this control rarely needs
tobeused. However,whenusingarmaturevoltagefeedbackwith
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
the drive. Adjust RV6 until the motor speed returns to its
unloaded speed. Remove the load and ensure motor speed is
stable.
••
••
•RV7 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
1/2 turn clockwise.
••
••
•RV8 I Forward
This adjustment is factroy preset for the maximum allowable DC
currentintheforwardmotoringdirection.Thistrimpot willadjust
the current limit setting from 20 - 150% of the drive rating.
••
••
•RV9 I Reverse
This adjustment is factroy preset for the maximum allowable DC
current in the reverse motoring direction. This trimpot will adjust
the current limit setting from 20 - 150% of the drive rating.
2.4 Adjustments
CAUTION: Adjusting RV6
to over 50% clockwise rota-
tion, may cause drive insta-
bility which cannot be cor-
rected by RV7 voltage sta-
bility. In such a case, back
off slightly from the posi-
tion where RV6 causes in-
stability. This may result in
a slight decrease in speed
holding.
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2.5 Jumper Selections
AUX SPD
Note: If P1 is in the “IN”
position, the drive will still
regeneratewhenthespeed
reference command is re-
duced.
••
••
•J5 & J6 AC Input selection
This jumper is used to select the correct AC line input voltage.
J5: 240 vac (factory default)
J6: 120 vac
••
••
•P1 Stopping mode
Motorcoasts to zero speed on stop command. Connect
P1 on the AA1152 control card to the “IN” position.
Motor regenerates to zero speed on stop command.
("OUT" position, factory default).
••
••
•JP1 Programmable input
Thisjumperisusedtoselecteithertachometerfeedback50v/1000
rpm)orauxiliaryspeedreferenceinput.Theauxiliaryspeedinput
will allow the user to trim (±) the main speed reference. The
auxiliary input is not affected by the accel/decel circuit.
Auxiliary speed input
With JP1 in the "AUX SPD" position, the drive is configured to
acceptanauxiliaryspeedcommand.Thespeedinputwill
then be accepted on input terminals J1-1 and J1-2.
Tachometer feedback
WithJP1inthe"TACH"position,thedriveisconfigured
to accept a 50v/1000 rpm analog DC tachometer only.
Thetachometerinputwillbeacceptedoninputterminals
J1-1 and J1-2.
Locatejumpers E1 andE2 abovethe control transformer
T1. These jumpers will be connected to a black wire
terminal. Separate the plug from the socket for tachom-
eter feedback.
To set the drive back to armature feedback, insert the plug into the
socketandremovethetachwiresfromterminalsJ1-1andJ1-
2.
IN
OUT
Caution: This drive can not
be configured to accept ta-
chometer feedback and an
auxiliary speed command
together.
TACH
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3.0 RECEIVING & INSTALLATION
3.1 Installation ThecabinetcontainingtheDF8Plusmustbeinstalledinanareawhere
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
minimum of 1 foot (30.48 cm) is required around the air inlet and
outlet, on ventilated units.
The DF8 Plus has been designed for 50ºC maximum inside the
enclosure.
Whentheunitisinstalledinpoorenvironmentalconditions,itmustbe
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 DF8 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 8, 9, and 10 show typical connections for speed
controlled wound field motors. For permanent magnet motors, there
will be no connections to F+ and F-.
See page 11 for typical torque control connections.
Note: For motor field connections of 100/50 or 200/100, refer to page
12.
3.2 Derating Data
3.3 Wiring
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4.0 STARTUP
4.1 Inspection Ensure that the drive has been installed according to the previous
guidelines. Also, ensure that the unit has been wired according to the
schematics.Checkthatallconnectionsaretightandthatthemotorcan
rotate freely.
Before power is applied, confirm that the voltage selection plug (J5,
J6) on the AA1152 card matches the supply voltage. Factory default
setting is 240 vac.
The DF8 Plus drive has been preset for armature voltage feedback.
To use tachometer feedback refer to page 5, section 2.5, for complete
details.
Confirmthatalljumper selections havebeenmadecorrectly to ensure
proper drive performance (i.e. P1, JP1, JP5, JP6, see page 5).
All controls have been preset at the factory and should not require
further adjustment.
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. Applypower and observe that LED DS8is illuminated. Press the
start button. LED's DS2 (Run) and DS3 (Inh) should turn on and
themotorshouldnot rotate. Ifthemotorrotates, see troubleshoot-
ing.
2. Slowly rotate the speed pot so that a negative reference is applied
to J1-5 (see section 6.0). LED DS5 (Fwd ref) and DS7 (Fwd out)
will intensify as the speed pot is increased to full and the motor
should rotate in the forward direction. If motor rotation is incor-
rect, remove power completely and interchange the motor arma-
ture connections. With link P1 in the bottom position, LED DS1
(ZSA) will illuminate when the motor is above zero speed.
3. With a positive reference applied to J1-5 (see section 6.0), LED's
DS4 (Rev ref) and DS6 (Rev out) will intensify as the speed pot
is increased to full and the motor should rotate in the reverse
direction.
4. Withthespeed reference setatmaximum,themotor should rotate
at rated speed and/or voltage. If not, adjust RV4 for the correct
setting.
5. Press the stop button. With link P1 in the “IN” position, the motor
will coast to rest. If P1 is in the “OUT” position, the motor will
regenerate to zero speed.
6. If the acceleration and deceleration rates are not suitable, see
section 2.4, p.4, for adjustment.
4.2 Pre-start adjustments
Note: When tachometer
feedback is used, the auxil-
iary input is not available.
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 shorted.
- Field diodes shorted (D18).
- 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.
- Tach feedback resistor
incorrect (if used).
- Bad speed pot.
Motor unstable.
- IR comp turned too high
- Voltage stability set
incorrectly.
- Current stability set
incorrectly.
- Max speed set too high.
- Fwd/Rev current limits set
differently.
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 -Adjust RV5 potentiometer.
5.0 TROUBLESHOOTING
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6.0 WIRING DIAGRAMS
6.1 DF8P-10 & DF8P-15
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6.0 WIRING DIAGRAMS CONT'D
6.2 DF8P-25
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6.0 WIRING DIAGRAMS CONT'D
6.36.3
6.36.3
6.3 Typical Torque control connection
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6.0 WIRING DIAGRAMS CONT'D
6.46.4
6.46.4
6.4 MOTOR CONNECTIONS
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7.0 DIMENSIONAL OUTLINES
7.17.1
7.17.1
7.1 DF8P-10 & DF8P-15 CHASSIS
DF8P-10
DF8P-15
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7.0 DIMENSIONAL OUTLINES CONT'D
7.2 DF8P-25 CHASSIS
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7.0 DIMENSIONAL OUTLINES CONT'D
7.3 NEMA 1 ENCLOSED WITH OPERATORS
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SPARE PART
MODEL
DF8P-10 DF8P-15 DF8P-25 QTY
Controller card AA1152-1 AA1152-1 AA1152-1B 1
SCR N610016 N610016 4
SCR   N10SP03B 8
Fuse FU1, FU2 F601005-34 F601005-36 F601005-31 2
Field Bridge D1010-04 D1010-04 D1010-04 1
Fuse FU3, FU4   F602003-05 2
8.0 SPARE PARTS
Note:
When replacing the controller card AA1152-1, ensure that all
jumpers are configured the same way as the card being replaced.
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9.0 WARRANTY Saftronicswarrants to buyerthat products,and any servicesfurnished
hereunderwillbefreefromdefectsinmaterial,workmanshipandtitle,
and will be of the kind and quality specified in the quotation. The
foregoingshallapplyonlytofailurestomeetsaidwarranties(excluding
any defects in title) which appear within one year from the date of
shipmenthereunder,provided, however,that if buyer,in thecourseof
itsregular and usual business, transferstitle to or leases suchproducts
(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.
Thewarranties 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
promptlynotifyingSaftronicsofanydefectsand,ifrequired,promptly
making the product available for correction.
Ifanyproductsorservicesfailstomeettheforegoingwarranties(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
precedingparagraphsetsforththeexclusiveremediesforclaims(except
astotitle)basedondefectinorfailureofproductsorservices,whether
claimincontractortort(includingnegligence)andhoweverinstituted.
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
statutorywarranty ofmerchantability orfitness forparticular 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.
17
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Saftronics,Inc.
5580EnterprisePkwy.,Ft.Myers,Fl33905
Telephone:[phone]
Fax:[phone]
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