MaxPak Plus Analog DC V S Drive

Transcription

1 Three-Phase HP non-regenerative and HP regenerative drives Designed to accommodate a wide range of industrial requirements, the DC V S Drive has been widely applied worldwide. Selected ratings through 600 HP, with power matched RPM III motors as well as motor and controller modification kits, are available for delivery right from our stock. controllers are easily modified during manufacture, from stock at our V S Sprint stock modification center, or right in your plant from a wide range of prepackaged modification kits. Operable without modification on either 50 or 60 Hz power and factory modifiable for operation on any line voltage between 200 and 575 VAC. Drives satisfy drive requirements worldwide. Standard Features Compact chassis or NEMA 1 Enclosure. Easy installation and service. 50/60 Hz plant power. Full-wave, full-control S-6 power conversion for smooth, efficient operation and high performance. Easy jumper re-connection allows operation as either an armature voltage regulator or speed regulator using tachometer feedback. Isolated voltage and current feedbacks provide drive reliability and versatility. Separately adjustable rates of linear acceleration and deceleration provide smooth speed changes. Adjustable minimum and maximum speed adjustments to preset machine speed limits. Adjustable current limit control protects the drive and driven machine from damaging current or torque levels. Motor field excitation loss protection disables drive upon a loss of shunt field voltage. Solid-state motor thermal overload protects the drive from sustained low level overloads. Instantaneous Electronic Trip (IET) disables drive under severe output overload conditions. AC line Current limiting fuses. Full modular construction employs plug-in card regulator and easily replaced SCR assemblies. Fully rated armature loop contractor provides motor disconnect from incoming line power. Surge protection from AC line and DC load transients. Phase sequence interlock and indicator light. Line loss protection. Field (voltage) loss protection. Isolated feedback. 115 VAC control transformer and control circuits. Drive start-stop and speed control. Jog at adjustable preset speed by pushbutton or selector switch. 150% one-minute current rating. Unidirectional operation, coast-to-rest on stop command. (Non-regenerative controller only) Full, four-quadrant control. Capable of contactorless reversing in response to the operators forward-reverse selector switch and providing regenerative power flow in the presence of overhauling loads. Coast-to-rest on stop command. (Regenerative Controller) Two independently adjustable current limit circuits. Limit 1 active during forward motoring and reverse regeneration. Limit 2 active during forward regeneration and reverse motoring. (Regenerative Controller) loop DC circuit breaker for inverting fault protection. (Regenerative Controller) CC2-4 Effective January 2, 2004

2 Available Options Many Options are available as pre-engineered kits including the following which are UL listed: Motor Field current regulator kit for constant horsepower applications. Controller tester kit. voltage and current metering kits. E.S.P. Brush Monitor System. Dynamic Braking for quick stopping AC disconnect with external operating handle and door interlock Open panel construction for built-in application. Floor mounted cabinet. Totally enclosed NEMA 4 or NEMA 12 cabinets. Improved speed regulation by tachometer feedback Amature shunt. High capacity control circuit transformer. Contactor cover Fan loss detector. Remote current limit adjustment. Drive to rest on stop Fused blower motor starter standard with stock force ventilated motors. Auxiliary contact on DC contactors. Reversing by armature contactor. (Non-regenerative) Isolation transformer. Master Isolated Reference. Process Controller Interface. Engineering Data Controller Enclosures 230 VAC Input 240 VDC Drive Rating (HP) 460 VAC Input 500 VDC 575 VAC Input 600 VDC Open-Panel Chassis Controller Wall-Mounted Enclosures Floor-Mounted Enclosures Controller Enclosures Open- Panel Chassis NEMA 1 Non- Regen Regen Non- Regen Regen A D W30 W B D W36 W B D W42 W B D W48 W C - FD FD86 - Panel Size Height Approximate Dimensions (in./mm) Power Unit Width Auxiliary Panel Depth Combined Weight A 22/559 14/356 10/254 12/305 90lb/44kg B 28/711 14/356 10/254 12/ lb/62kg C 31/787 14/356 16/406 12/ lb/99kg D 31/787 14/356 10/254 12/ lb/60kg Enclosure Approximate Dimensions (in./mm) Height Width Depth Weight W / / / lb/77kg W / / / lb/123kg W / / / lb/145kg W / / / lb/181kg Approximate Dimensions (in./mm) Enclosure Height Width Depth Weight FD68 68/ /813 20/ lb/272kg FD68 86/ /837 24/ lb/330kg Effective January 2, 2004 CC2-5

3 Controller Selection Full Load Rated RMS AC Line Current (Amperes) Full Load Rated DC Current (Amperes) Rated Field Current (Amperes) HP Ratings 230 VAC 460 VAC 550 VAC 240 VDC 500 VDC 600 VDC 150 VDC 300 VDC 360 VDC / Service Conditions Altitude... To 3300 feet (1000m) Ambient Temperature Range: Cabinet s to 104 F (0 to 40 C) Panel Mounted s to 131 F (0 to 55 C) AC Line Voltage Variation... ±10% of rated AC Line Frequency to 62 Hz Adjustments Acceleration Rate to 30 seconds linear Deceleration Rate to 30 seconds linear Minimum Speed (Percent of rated)...0 to 40% Maximum Speed (Percent of rated)...80 to 120% Jog Speed...0 to 50% Current Limit...50 to 150% IR Drop Compensation...0 to 10% Application Data Service Factor Maximum Load % for 1 minute Minimum Load for assured Stable Operation... 5% Speed Regulation (95% load change) Voltage Feedback...2 to 5% Tachometer Feedback... 1% or 0.5% (1) Improved Regulation Modification...Up to 0.1% (1) Speed Range Voltage... 20:1 Speed... 30:1 to 200:1 Efficiency Rectified Power Module... 97% Complete Drive Including Motor (Typical)... 87% (1) Depending on tachometer used CC2-6 Effective January 2, 2004

4 Controller Only Pricing The controller without motor prices tabulated below may be used in instances where a controller is required for use with an existing motor. Observe the following cautions when applying these controllers to existing motors: 1. Be certain that the voltage and current requirements of the motor armature and field are satisfied with the armature and field output capability of the controller. 2. The may be selected when a controller is required for use with older motors designed specifically for use on rotating power. Its six pulse power bridge provides armature power with a waveform generally acceptable to these motors. Normally, a non-standard 240 VDC field supply is required. 3. When motor is DPG-FV; a blower motor starter kit should be added. Pricing 230 VAC Input-240 VDC -150 VDC Field Non-Regenerative Regenerative HP Basic Basic and DB Reversing and DB Basic with DB List List List List 5 5C57 (2) 5C58 (2) 5C59 (2) 5C658 (2) 7-1/2 7C57 (2) 7C58 (2) 7C59 (2) 7C658 (2) 10 10C57 (2) 10C58 (2) 10C59 (2) 10C658 (2) 15 15C57 (2) 15C58 (2) 15C59 (2) 15C658 (2) 20 20C57 (2) 20C58 (2) 20C59 (2) 20C658 (2) 25 25C57 (2) 25C58 (2) 25C59 (2) 25C658 (2) 30 30C57 (2) 30C58 (2) 30C59 (2) 30C658 (2) 40 40C57 (2) 40C58 (2) 40C59 (2) 40C658 (2) 50 50C57 (2) 50C58 (2) 50C59 (2) 50C658 (2) 60 60C57 (2) 60C58 (2) 60C59 (2) 60C658 (2) 75 75C57 (2) 75C58 (2) 75C59 (2) 75C658 (2) 460 VAC Input-500 VDC -300 VDC Field Non-Regenerative Basic Basic and DB Reversing and DB Basic with (1) Extruder Features Regenerative Basic With DB HP List List List List List 5 5C60 (2) 5C61 (2) 5C62 (2) 5C64 (2) 5C661 (2) 7-1/2 7C60 (2) 7C61 (2) 7C62 (2) 7C64 (2) 7C661 (2) 10 10C60 (2) 10C61 (2) 10C62 (2) 10C64 (2) 10C661 (2) 15 15C60 (2) 15C61 (2) 15C62 (2) 15C64 (2) 15C661 (2) 20 20C60 (2) 20C61 (2) 20C62 (2) 20C64 (2) 20C661 (2) 25 25C60 (2) 25C61 (2) 25C62 (2) 25C64 (2) 25C661 (2) 30 30C60 (2) 30C61 (2) 30C62 (2) 30C64 (2) 30C661 (2) 40 40C60 (2) 40C61 (2) 40C62 (2) 40C64 (2) 40C661 (2) 50 50C60 (2) 50C61 (2) 50C62 (2) 50C64 (2) 50C661 (2) 60 60C60 (2) 60C61 (2) 60C62 (2) 60C64 (2) 60C661 (2) 75 75C60 (2) 75C61 (2) 75C62 (2) 75C64 (2) 75C661 (2) C60 (2) 100C61 (2) 100C62 (2) 100C64 (2) 100C661 (2) C60 (2) 125C61 (2) 125C62 (2) 125C64 (2) 125C661 (2) C60 (2) 150C61 (2) 150C62 (2) 150C64 (2) 150C661 (2) (1) Number includes auxiliary contact and meter filter card. Price also includes, a blower motor starter. Specify correct model starter from page CC2-9. (2) Refer to Numeric Section 1 for Pricing. Effective January 2, 2004 CC2-7

5 Modifications The following modifications can be added to any standard at the time it is manufactured. Certain modifications are also listed as kits. These kits may be easily installed by the customer. Shunt shunts provide a millivolt level signal proportional to DC armature amperes. Output from the shunt may be used to operate an ammeter or to drive an instrument requiring a millivolt input proportional to armature current. Available with 50 or 100 millivolt output. Shunts through 300 amperes... (5) Shunts 400 through 750 amperes... (5) Shunts 750 through 2000 amperes on HP controllers... (5) Shunt Kits Current (Amperes) (1) Regenerative controllers 5-20 HP at 230 volts and 5-40HP at 460 require a BUS BAR KIT (23C331) along with the shunt for proper installation. See Bus Bar option kit. Acceleration and Deceleration (Same or separate Rates) Shunt Kits Number 50 mv. 100 mv. For installation in the following controllers 25 23C18 23C8 (1) 5 through 20 HP 50 23C19 23C9 at 230 VAC input 75 23C20 23C10 (1) C21 23C11 5 through 40 HP at 460 VAC input C22 23C C23 23C C24 23C C25 23C C26 23C C27 23C C28 23C C29 23C39 25 through 75 HP at 230 VAC input 50 through 150HP at 460 VAC input C34 23C through 300 HP C35 23C37 at 460 VAC input C C C C C C65 Linear acceleration and deceleration at separately adjustable rates are standard. Normal stop is by coast-to-rest or dynamic braking. If normal stop by motoring down to rest under controlled linear rate is desired. (5) Refer to Numeric Section for Pricing through 600 HP at 460 VAC input Auxiliary Contacts Auxiliary Contacts for interlocking with external devices may be added to the motor armature contactor and can be used N.O. or N.C. They are available at all horsepowers (400 through 600 HP drives contains the auxiliary contact as standard part of drive.) Description For non-reversing and regenerative drives. Provides one contact for customer user. For reversing drives. Provides one contact for each of the two armature contactors (forward and reverse). (2) Used with Joslyn Clark contactor. (3) Used with Asea Contactors. (4) One Per Contactor AC Disconnect with Through-the-door Handle and Door Interlock AC Disconnect with magnetic trip and rotary through-the- door operator and mechanical door interlock. Select and price per the table below. Bus Bar Support Kit This kit must be supplied when installing shunt kits on regenerative controllers 5-20 HP at 230V and 5-40 HP at 460V. 23C331 Number of Contacts HP C102 (2) C104 (3) 2 (4) C105 (3) C103 (2) AC Disconnect Selection for Non-Regenerative Controllers Controller Horsepower Incoming Line Voltage 230 VAC 460 VAC Number 5-20 HP 5-40 HP 23C C C C C C C C C56 AC Disconnect Selection for Regenerative Controllers Controller Horsepower Incoming Line Voltage 230 VAC 460 VAC Number 5-25 HP 5-50 HP 23C C C C304 CC2-8 Effective January 2, 2004

6 Blower Motor Starter for DPFV or TEAO Motors Provides a fused AC starter and interlocking for control of the three-phase blower motor used to cool the DC motor. Number Kit... Contact Reliance Note: The blower motor starter kit cannot be installed in a standard non-regenerative reversing controller of 20 HP or less of 230 VAC input or 40 HP or less at 460 VAC input if a field current regulator has also been specified. If both a blower motor starter and field current regulator are required with a reversing controller in this HP range, they can be supplied on a factory order. Some applications require a larger cabinet. Contact Cover The contactor cover mounts in front of the armature contactor(s) on the controller auxiliary panel. Note: A contactor cover must be provided when adding a Number 23C193 and 23C195 Field Current Regulator kit to any drive controller or when adding any field regulator kit to a drive furnished with armature reversing. Select and price from the tables below. Contact Reliance for Pricing VAC, VAC Blower F.L. Amps 23C C C C C C C C C C C VAC, VAC Number Blower F.L. Amps 23C C C C C C C Controller Horsepower Incoming Line Voltage 230 VAC 460 VAC Cover Selection Non-Regenerative Number C C C112 Controller Horsepower Incoming Line Voltage 230 VAC 460 VAC Cover Selection Regenerative Number C310 Control Circuit Transformer - High Capacity Provides a 350 VA control transformer in place of the 150 Va transformer supplied as standard allowing 200 VA of 115 volt AC control power for customer use. Complete with 3.2 ampere control circuit fuse. Suitable for use with non-regenerative controllers rated 25 through 75 horsepower, 230 volt AC or 50 through 150 horsepower, 460 volt AC and all regenerative controllers. 23C70... Contact Reliance Current Limit Control (Remote) for Non-regenerative Controllers 9C48... Contact Reliance Drive to Rest on Stop Provides normal stop by motoring down to a low speed under a controlled linear rate as set by the deceleration rate adjustment, and then coasting (or dynamic braking) to rest. Emergency stop by coasting (or dynamic braking). Factory Installed... Contact Reliance Fan Loss Detector The fan loss detector monitors air flow through the power unit and causes the drive to stop in the event of a fan failure. Available HP on 230 VAC Controllers and HP on 460 VAC controllers. Standard on 400 through 600 horsepower controllers. 23C80... Contact Reliance Field Current Regulator In order to operate the motor above base speed in its constant horsepower range, the motor field current regulator varies the motor field. This modification includes the field controller, transfer circuitry and tachometer loss and overspeed protection. Tachometer feedback must be used with this function. Note: A circuit breaker, 23C1-23C7 and 23C301-23C304 or contactor cover, 23C110-23C112 and 23C310 must be specified and priced when adding field current regulators 23C193 or 23C195 to any controller with armature reversing. The mounting surface provided by this cover is needed to mount the current feedback resistors. Tach loss and overspeed protection is included with this option. Contact Reliance For Pricing For all Controllers Through 300 HP Number Motor Field Voltage Hot Field Current 23C VDC Amperes 23C VDC Amperes For all Controllers Through 300 HP Number Motor Field Voltage Hot Field Current 23C VDC Amperes 23C VDC Amperes Effective January 2, 2004 CC2-9

7 Load Meter (Non-regenerative) Displays motor load as a percent of full load. Calibrated 0-200%. Requires Meter Filter Card. Without Enclosure, 23C Call Reliance With Enclosure, 23C Call Reliance Load Meter (Regenerative) Displays motor load as a percent of full load. Calibrated 200% %. Requires Meter Filter Card. Without Enclosure, 23C Call Reliance With Enclosure, 23C Call Reliance Master Isolated Reference Receiver Kit The master Isolated Reference Receiver Kit converts the pulse width modulated signal, from the Transmitter, to a 0-10 volt D- C reference signal. The kit also includes a relay for group starting and stopping. This Kit can be used with an Operator s Control panel containing an AUTO-MANUAL selector switch. In the MANUAL mode the manual speed potentiometer sets the drive speed. In AUTO mode the drive speed is determined by the master reference and the manual speed potentiometer acts as a trim adjustment. Factory Installed Only... Call Reliance Meter Filter Card (Non-regenerative) Provides isolated signals to drive Load Meter and Voltmeter. (For zero center meters.) 23C Call Reliance Meter Filter Card (Regenerative) Provides isolated signals to drive Load Meter and Voltmeter. (For zero center meters.) 23C Call Reliance Overspeed Protection Field Loss protection: Solid-state field excitation loss protection is standard. Field exciter voltage is monitored. Tachometer Loss and Overspeed Protection: This modification is already included as standard with field current regulator modifications. Tachometer signal is monitored electronically for loss of feedback and overspeed. May be added to any speed regulated. Speed Regulation Normal Voltage regulation using IR (load) Compensation gives 2-5% speed regulation due to Load changes. Speed changes due to all other variables voltage and frequency variations, temperature variations and drift can result in changes up to 15% of top speed. Speed regulation can be improved by adding tachometer feedback. With the addition of an RE-045 or 5PY tachometer, speed regulation due to load is improved to 1% and speed changes due to all other variables is improved to 2%. Addition of a BC-42 tachometer allows 0.5% regulation due to load and 0.5% due to all other variables. Simple jumper reconnection converts the controller for use as a speed regulator. Tester, Controller Controller rack always contains provisions for a tester. Measures all pertinent regulator signals, brings signals to terminals for oscilloscope and allows for signal input into controller. 9C49... Call Reliance Voltmeter Displays motor armature voltage. Requires Meter Filter Card. Voltage Voltmeter Selection Non-Regenerative Meter Full Scale Reading Without Enclosure With Enclosure 240 VDC VDC 23C131 23C VDC VDC 23C141 23C142 Voltage Voltmeter Selection Non-Regenerative Meter Full Scale Reading Without Enclosure With Enclosure 240 VDC VDC 23C171 23C VDC VDC 23C181 23C182 Factory Installed Only... Call Reliance CC2-10 Effective January 2, 2004

8 Analog DC V S Spindle Drive A three-phase compact chassis for HP regenerative applications Designed to accommodate a wide range of machine tool requirements, the DC Spindle Drive has been widely applied worldwide. With the V*S Spindle Drive in control, constant horsepower ranges of 6:1, 8:1 or even higher under certain conditions are available to increase productivity and reduce tool wear. This is due to a unique current limit function which allows drive characteristics to fully match motor capabilities. The current limit function extends the motor s constant horsepower range below base speed operation and provides automatic torque boost for difficult machining operations such as tapping or drilling. The static overload tracks the current limiting function to provide protection for the motor throughout its speed/torque range. Standard Features U/L listed and CSA certified. Compact chassis enclosure. Full four-quadrant operation provides motoring and regeneration in both directions without reversing contactors. Three-phase 480 volts four wire input and 0 to 240 VDC output. Jog-Start-Stop and speed selection. Power unit circuit breaker Fused control and field power Full capacity armature contactor. MOV and RC transient protection networks. Feed permissive logic tells you when the spindle is rotating at the proper speed for starting feeds and prevents feeding a tool into dead spindle. Feed permissive contact closure is selectable for desired feed band or to permit or inhibit feeds at zero speed as desired. Two independent low speed interlock contacts. (LS1 and LS2) Low torque mode for limiting torque for gear shift and tool changing. Adjustable linear Accel/Decel control with ability to add S curve function. Percent of command overspeed protection. Absolute overspeed detection. Motor stall detection. Motor tachometer voltage loss detection Motor field current loss detection. Drive over-temperature thermostat. Motor protection throughout the speed range static thermal overload threshold detector tracks the powermatched current limit for maximum motor utilization and protection Automatic field economy in standby for longer motor life and power savings. Minimum field voltage limit. Counter EMF overvoltage protection. Improved speed regulation by tachometer feedback. Optional Features Many options are available as pre-engineered kits including the following which are UL listed: Plug-in 32-point tester card for use during start-up and troubleshooting. Dynamic braking gives rapid deceleration and nonregenerative stop. Main contactor auxiliary contact. Extended HP in voltage range for constant HP of up to 10:1. Overlap function allows reversing motor current (and torque) without any dead band at zero speed. Spindle orientation for tool or part changing. Buffer Card for 1 ma meter drive signal. voltage and current metering kits. E.S.P. Brush Monitor System. Contact Reliance Electric for option pricing. Effective January 2, 2004 CC2-11

9 Analog DC V S Spindle Drive Controller Weight Controller Rating Motor Weights (lb/kg) 5-20 HP 98/ HP 117/ HP 264/120 Rated AC Line Current (Amps) Three-Phase Four-Wire 480 VAC + 10% Hz Input KVA DC Voltage Rated Current (Amps) Available Field Voltage Available Field Current (Amps) 5-7-1/ Auxiliary Circuits Relay Interface & Overtemp Thermostat User M Auxiliary Contacts (If used) Control VA for external accessory use Logic Power for external accessory use Max Volts Max Amps Fuse Max Volts Max Amps Controller Dimensions (in./mm) 125 VAC 24 VDC 0.5 Amps AC Non Inductive 0.25 Amps AC Inductive at 0.5 P.F V DC Non Inductive Recommended External Source Fusing: 250V 1.0 Amps Class K5 Max. 125 VAC 120 VDC Pilot Duty 3 Amps AC 0.16 Amps DC Pilot Duty 10VA Available for use only with control circuits for sequence card (SSCC) Inputs 10 MA available for use only with external speed Ref. Pot Service Conditions Altitude... to 3300 feet (1000m) Ambient Temperature Range: Panel-Mounted s to 131 F (0 to 55 C) Atmosphere... Non-condensing relative humidity 5 to 95% AC Line Voltage Variation... ±10% of rated AC Line Frequency... 8 to 62 Hz Application Data Service Factor Maximum Load For 1 minute Minimum Load for Assured Stable Operation...5% Speed Regulation (95% load change) Tachometer Feedback... 1% or 0.5% Improved Regulation Modification...Up to 0.1% Speed Range... 20:1 Efficiency Rectified Power Module...97% Complete Drive Including Motor...87% Adjustments Acceleration Rate to 40 seconds linear Deceleration Rate to 40 seconds linear Jog Speed... 0 to 50% Current Limit...50 to 150% Field Economy... 25% in standby mode CC2-12 Effective January 2, 2004

10 Analog DC V S Spindle Drive Ordering Procedures Specify: 1. Horsepower 2. Controller Amps 3. Motor Frame (if applicable) 4. Motor Base and Top Speed (if applicable) 5. Transformer KVA (if included) 6. And Options Also supply the Custom adjustment info under Custom Component Card. Options Dynamic Braking (DB) reduces the stopping time of the motor during noncontrolled or fault stop sequences. During Dynamic Braking the motor operates as a generator; and the rotating mechanical energy is turned into electrical energy which is dissipated as heat in the dynamic braking resistor. Note: Dynamic braking is not as holding brake, and will not keep a motor from turning. The grids are supplied for separate mounting. DB provisions must be ordered on the drive from the factory. Pricing below includes grids and provisions. Overlap function allows reversing motor current (and torque) without any deadband at zero current. Separately mounted overlap reactors limit circulating currents during the transition period. Required for spindle positioning applications. The reactors are supplied for separate mounting Overlap provisions must be ordered on the drive from the factory. Pricing below includes reactors and provisions. Spindle Drive Pricing Drive HP Controller DC Amps Transformer KVA (S3R) Transformer List Price Controller List Price (1) (1) 7-1/ (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) Contact Reliance Custom Component Card: 1. reference volts for max speed 2. % max speed for LS 1 setting 3. % max speed for LS 2 setting 4. jog function FWD only Reverse Only 5. jog contactor delay sec. 6. feed zero speed 7. % set speed for feed permissive 8. lb ft2 connected inertia 9. amps low torque current limit 10. linear accel/decel range.4 to 4 sec 4 to 40 sec 11. S Curve accel Control Station Refer to Reliance Electric if required. Auxiliary Contacts For interlocking with external devices may be added to the motor armature contactor at the factory. 1 form C set of contacts is supplied. Meter Buffer Kit Provides 2 channels of buffering for speed and load metering. It increases the meter signal output driving capabilities from 100 microamps to 1 milliamp. Tester Card Provide access to 32 points within the regulator for monitoring and test signal injection. It includes a test reference adjustment pot and mounts in the regulator rack. Consult Reliance Electric for all options listed on this page. Effective January 2, 2004 CC2-13

11 Analog DC V S Spindle Drive CC2-14 Effective January 2, 2004