choice d.c.motor control

Use WithInstruction Manual

ModelsCDC320-000CDC340-000CDC360-000CDC375-000

CDC3150-000

CHOICED.C.MOTORCONTROL SERVICE MANUAL

Choice® Series Drives

Table of Contents1. ABOUT THIS GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22. GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34. MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45. CONVENTIONS, GLOSSARY & ABBREVIATIONS . . . . . . . . . . . . . . . . . . 76. DESCRIPTION OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6.1 Armature Power Bridge 96.2 Field Supply 116.3 Relay Logic and Control Voltage Supply 116.4 Power Supplies 136.5 Reference Circuitry 136.6 Feedback Circuitry and Isolation 146.7 Velocity and Current Loops 186.8 Static Current and Overcurrent Functions 196.9 Trigger Circuit 216.10 Special Signals and Circuit Functions 246.11 Fault Circuits 26

7. DRIVE PROGRAMMING & CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . 288. COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .329. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3210. TEST POINTS & CHECK POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3511. REPLACEMENT PARTS & COMPONENT SUBSTITUTION . . . . . . . . . . 37

11.1 Component Substitution 3711.2 Printed Circuit Assemblies 3711.3 Connector/Cable Assemblies 3811.4 Fuses 3811.5 Power Components 38

12. PRINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40D10483 Control Board Schematic 40D10492 Power/Trigger Board Schematic 41C10489 Fuse Board Schematic 42C10815 IFB Board Schematic 43C10486 Relay Board Schematic, CDC320-000 – CDC375-000 44C10793 Relay Board Schematic, CDC3150-000 45D10535 Wiring Diagram, CDC320-000 – CDC375-000 46D10800 Wiring Diagram, CDC3150-000 47D10612 Wiring Diagram, CDC320-R15 – CDC360-R60 48D10837 Wiring Diagram, CDC375-R75 – CDC150-R150 49D10613 Wiring Diagram, CDC320-C15 – CDC360-C60 50D10838 Wiring Diagram, CDC375-C75 – CDC3150-C150 51D10521 Connection Diagram 52

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----------About This Guide---------- This guide is meant to supplement the CHOICE Instruction Manual and DCM100 Users Guide forCHOICE® Series DC Drives. Installation, wiring and start-up information is found in these othermanuals. Here we will address problems in operation, drive failure, also how to correct thesesituations.

General Description

--------------Features---------------

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The CHOICE® CDC300 Series of non-regenerative DC motor controls (drives)provides a full range of speed or torque controlfor 5-150 HP DC motors rated for NEMA type"D" power supplies.

Five basic models are offered in a compactpanel mount assembly. Each model iscustomer connectable for operation at 230 or460 VAC input. Semiconductor fuses areprovided for AC line protection with auxiliaryline fuses for optional equipment. Fuseprotection is also provided for the 115 VACinput and for the field supply circuits.

Standard relay logic interfaces withcustomer supplied operators for EmergencyStop, Ramp Stop, Run Forward, Jog Forwardand also Run Reverse and Jog Reverse whenthe unit is operated with separately suppliedforward and reverse armature contactors. Additional models include options such asarmature contactor(s), brake resistors,disconnect switches, blower starters,enclosures and field economy or field regulatorsupplies.

An accessory drive circuit monitor,DCM100-000, is available to assist in set-upand troubleshooting by plugging in to theCONTROL board to access 20 separatesignals.

• Programmable for 230 or 460 VDC threephase line input.

• Hall Effect sensor for isolated armaturecurrent feedback

• 10 megohm impedance isolation forarmature voltage feedback

• Independently adjustable linearacceleration and deceleration from 1-60seconds

• Electrically isolated power modules rated

at 1400 volts PIV and 1000volts/microsecond dv/dt

• Semiconductor fuses for power circuitprotection

• R/C networks for AC line transientprotection

• 10 ampere rated field supply• Provisions for interfacing an optional field

supply or field regulator with the FieldLoss protection circuit

2

Specifications3

• Foldback current limit to allow 1 minuteoverload and then foldback to 112% of thecurrent range selected

• Overcurrent Trip when motor current issustained at 112% of range selected for 5minutes

• Speed feedback is jumper selectable forarmature voltage, DC tachometer voltage(7, 50 or 100V/1000 RPM), AC tachometervoltage (45 or 90V/1000 RPM), or digitalencoder (300 PPR)

• Tachometer feedback is insensitive to inputpolarity

• 12 VDC @ 50 mA encoder power supply• Summing input for auxiliary input signals

with on board trim pot for scaling andjumper selection for polarity

• Terminal strip access to Accel/Decel

output, Velocity Loop output and CurrentLoop input for versatile control functions

• Inner Current Loop for responsive andprecise control of motor torque

• Insensitive to phase rotation of the line• Status LED's for Run, Zero Speed, Jog and

Foldback• 115 VAC logic for pushbutton operator

interface• Zero Speed logic for ramp to stop and anti-

plugging protection• Jog Delay circuit to allow rapid jogging

without de-energizing the armaturecontactor to give longer contactor life

• 5 selectable armature current range tomatch motor armature current

• High frequency multi-pulse trigger forreliable SCR triggering

A.C. INPUT• 230 VAC ± 10%, 3 phase, 50/60 Hz ± 2 Hz• 460 VAC ± 10%, 3 phase, 50/60 Hz ± 2 Hz

A.C. INPUT-SINGLE PHASE CONTROL VOLTAGE SUPPY• 115 VAC ± 10%, 1 phase, 50/60 Hz ± 2 Hz

ARMATURE OUTPUT• 0 to 240 VDC @ 230 VAC input• 0 to 500 VDC @ 460 VAC input

FIELD OUTPUT• 150 VDC, 10 amps max, @ 230 VAC input• 300 VDC, 10 amps max, @ 460 VAC input

HORSEPOWER RANGE• Model CDC320-00: 36 FLA, 10 HP @ 240 VDC, 20 HP @ 500 VDC

• Model CDC340-000: 71 FLA, 20 HP @ 240 VDC, 40 HP @ 500 VDC• Model CDC360-000: 107 FLA,

30 HP @ 240 VDC, 60 HP @ 500 VDC• Model CDC375-000: 140 FLA,

40 HP@ 240 VDC, 75 HP @ 500 VDC• Model CDC3150-000: 256 FLA,

75 HP @ 240 VDC, 150 HP @ 500 VDC

SPEED REGULATION• Armature Feedback: ± 1.0% of base speed• Tachometer Feedback: ± 0.5% of base

speed• Encoder Feedback: ± 0.5% of base speed

TORQUE REGULATION• ± 2.0% of current range selected

SPEED RANGE• 20:1 motor dependent

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Model Identification

TABLE 1: MODEL NUMBERSMODEL NUMBER HP RATING

230/460 INPUTDESCRIPTION

CDC320-000 5-10/5-20 BASIC CHASSIS MODELCDC340-000 15-20/25-40 BASIC CHASSIS MODELCDC360-000 25-30/50-60 BASIC CHASSIS MODELCDC375-000 40/75 BASIC CHASSIS MODEL

CDC3150-000 50-75/100-150 BASIC CHASSIS MODELCDC320-C15 5-7.5/10-15 CONTACTOR RUN-BRAKE CHASSICCDC320-C20 10/20 CONTACTOR RUN-BRAKE CHASSICCDC340-C30 15/25-30 CONTACTOR RUN-BRAKE CHASSISCDC340-C40 20/40 CONTACTOR RUN-BRAKE CHASSISCDC360-C60 25-30/50-60 CONTACTOR RUN-BRAKE CHASSISCDC375-C75 40/75 CONTACTOR RUN-BRAKE CHASSIS

CDC3150-C100 50/100 CONTACTOR RUN-BRAKE CHASSISCDC3150-C125 60/125 CONTACTOR RUN-BRAKE CHASSISCDC3150-C150 75/150 CONTACTOR RUN-BRAKE CHASSIS

CDC320-R15 5-7.5/10-15 CONTACTOR REVERSING CHASSISCDC320-R20 10/20 CONTACTOR REVERSING CHASSISCDC340-R30 15/25-30 CONTACTOR REVERSING CHASSISCDC340-R40 20/40 CONTACTOR REVERSING CHASSISCDC360-R60 25-30/50-60 CONTACTOR REVERSING CHASSISCDC375-R75 40/75 CONTACTOR REVERSING CHASSIS

CDC3150-R100 50/100 CONTACTOR REVERSING CHASSISCDC3150-R125 60/125 CONTACTOR REVERSING CHASSISCDC3150-R150 75/150 CONTACTOR REVERSING CHASSIS

NOTE: The options listed in TABLES 2, 3 and 4 are used with and mount on thechassis of the contactor run-brake and reversing models listed above.

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The CHOICE® series controls are offered inbasic chassis models and contactor modelsavailable with factory installed options. Thebasic model will have a model number labelwith applicable rating information. Contactormodels will have an additional label showingthe contactor horsepower rating and anyadditional option dash numbers. These model

and option numbers are shown in the followingtables.

NOTE: The contactor run-brake andreversing models listed below include thecontrol voltage (115 VAC) transformer aswell as the armature contactor(s).

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TABLE 2: BLOWER & STARTER OPTIONSOPTIONNUMBER

BLOWER MODELS USEDWITH

DESCIPTION

CDC3BS-001 MTP-FVB2180, 230VAC, 1PH 0.6 TO 1.0 AMP OVERLOAD RANGEFOR 1 PHASE BLOWER

CDC3BS-002 MTP-FVB3210, 460VAC, 3PHMTP-FVB3250, 460VAC, 3PH

0.4 TO 0.6 AMP OVERLOAD RANGE FOR 3 PHASE BLOWER

CDC3BS-003 MTP-FVB3210, 230VAC, 3PHMTP-FVB3250,230VAC, 3PHMTP-FVB4280, 460VAC, 3PH

0.6 TO 1.0 AMP OVERLOAD RANGEFOR 3 PHASE BLOWER

CDC3BS-004 MTP-FVB4280, 230VAC, 3PHMTP-FVB6320, 460VAC, 3PHMTP-FVB6400, 460VAC, 3PH


CDC3BS-005 MTP-FVB6320, 230VAC, 3PHMTP-FVB6400, 230VAC, 3PH


TABLE 3: FIELD ECONOMY, SUPPLY & REGULATOR OPTIONSOPTIONNUMBER

MODELS USED WITH DESCRIPTION

CDC3FE-001 230/460 VAC INPUT CHOICE MODELS FIELD ECONOMY UNIT150VDC @ 230VAC 3 PHASE INPUT300VDC @ 460 VAC 3 PHASE INPUT

CDC3FE-002 230 VAC INPUT CHOICE MODELS FIELD ECONOMY UNIT200VDC @ 230VAC 1 PHASE INPUT

CDC3FE-003 230 VAC INPUT CHOICE MODELS FIELD ECONOMY UNIT240VDC @ 230VAC 3 PHASE INPUT

CDC3FS-000 230 VAC INPUT CHOICE MODELS FIELD SUPPLY UNIT150/240VDC @ 230VAC 3 PHASE INPUT

FR1000-000 ALL CHOICE MODELS FIELD REGULATOR UNIT230/460VAC 1 PHASE INPUT

TABLE 4: DISCONNECT SWITCH OPTIONS

OPTIONNUMBER

MODELS USED WITH DESCIPTION

CDC3DS-150 CDC320-C15, C20, R15, R20CDC340-C30, C40, R30, R40

CDC360-C60, R60, CDC375-C75, R75

150 AMP 600 VAC MOLDEDCASE DISCONNECT SWITCH

CDC3DS-225 CDC3150-C100, C125CDC3150-R100, R125

225 AMP 600 MOLDEDCASE DISCONNECT SWITCH

CDCEDS-400 CDC3150-C150, R150 400 AMP 600 VAC MOLDEDCASE DISCONNECT SWITCH

TABLE 5: ENCLOSURE OPTIONS

OPTIONNUMBER

MODELS USED WITH DESCRIPTION

CDC3EN-001 CDC320-C15, C20, R15, R20; CDC340C30, C40, R30, R40; CDC360-C60, R60

NEMA 12 ENCL.

CDC3EN-002 CDC375-C75 & R75 NEMA 12 ENCL.

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TABLE 5: ENCLOSURE OPTIONS (cont.)CDC3EN-003 CDC3150-

C100, C125, C150, R125, R150NEMA 12 ENCL.

CDC3EN-H01 CDC3DS-150 OPTION ON MODELS:CDC320-C15, C20, R15, R20; CDC340

C30, C40, R40; CDC360-C60, R60

NEMA 12 ENCL. W/ DISCONNECTHANDLE

CDC3EN-H01 CDC3DS-150, OPTION ON MODELS:CDC320-C15, C20, R15, R20; CDC340C30, C40, R30, R40; CDC360-C60, R60

NEMA 12 ENCL. W/DISCONNECTHANDLE

CDC3EN-H02 CDC3DS-150 OPTION ON MODELS:CDC375-C75 & R75


CDC3EN-H03 CDC3DS-225 OPTION ON MODELS:CDC3150-C100, C125, R100, R125


CDC3EN-H04 CDC3DS-400 OPTION ON MODELS:CDC3150-C150 & R150


TABLE 6: DYNAMIC BRAKING OPTIONS

OPTIONNUMBER

MOTOR USED WITH DESCRIPTION

CDC3BR-205 5 HP, 240 VDC ARM. NEMA 12 ENCLOSED 10 Ohm300 WATT BRAKE RESISTOR

CDC3BR-207 7.5 HP 240 VDC ARM. NEMA 12 ENCLOSED 5Ohm600 WATT BRAKE RESISTOR

CDC3BR-210 10 HP 240 VDC ARM. NEMA 12 ENCLOSED 4.4 Ohm750 WATT BRAKE RESISTOR

CDC3BR-215 15 HP 240 VDC ARM. NEMA 12 ENCLOSED 3 Ohm1000 WATT BRAKE RESISTOR




CDC3BR-240 40 HP 240 VDC ARM. EXPANDED METAL ENCLOSED1.3 Ohm 2080 WATTBRAKE RESISTOR

CDC3BR-275 75 HP 240 VDC ARM. EXPANDED METAL ENCLOSED0.62 Ohm 2232 WATT

BRAKE RESISTORCDC3BR-405 5 HP 500 VDC ARM. NEMA 12 ENCLOSED 40 Ohm

375 WATT BRAKE RESISTORCDC3BR-407 7.5 HP 500 VDC ARM. NEMA 12 ENCLOSED 20 Ohm

750 WATT BRAKE RESISTORCDC3BR-410 10 HP 500 VDC ARM. NEMA 12 ENCLOSED 20Ohm

750 WATT BRAKE RESISTORCDC3BR-415 15 HP 500 VDC ARM. NEMA 12 ENCLOSED 14 Ohm




2000 WATT BRAKE RESISTOR

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TABLE 6: DYNAMIC BRAKING OPTIONS (cont.)

CDC3BR-440 40 HP 500 VDC ARM. NEMA 12 ENCLOSED 5 Ohm3000 WATT BRAKE RESISTOR



CDC3BR-475 75 HP 500 VDC ARM. EXPANDED METAL ENCLOSED2.6 Ohm 4160 WATTBRAKE RESISTOR

CDC3BR-4150 150 HP 500 VDC ARM. EXPANDED METAL ENCLOSED1.24 Ohm 4464 WATT

BRAKE RESISTOR

Conventions, Glossary & Abbreviations

5

CONVENTIONS

The following conventions will be usedthroughout this manual:

All measurements are referenced to circuitcommon unless otherwise noted. Circuitcommon is not earth or chassis ground. Pleaserefer to the symbols below:

Circuit Common

Chassis Ground

Earth Ground

All signal level wiring, such as tachometer,encoder, and potentiometer, should use fullyinsulated shielded cable whether or not shownin this manual. The shield should beconnected at one end only to circuit common. The other end of the shield should be clippedand insulated to prevent the possibility ofaccidental grounding.

All internal relays have suppression devicesin parallel with coil whether or not shown inthis manual.

The arrows on potentiometers signify theCW terminal. The opposite lead is the CCWterminal, and the middle lead is wiper.

OP-AMP IC packages have been given theprefix designation "A" instead of the "IC"found on all other IC packages. Furthermore,many ICs are double, quad, or hex packages. In these cases, each section is given a letterdesignation to distinguish it from the other OP-AMPs in the same IC package. For example,the first two OP-AMPs in A1 would be A1-Aand A1-B. The bold letters in the schematic diagramsrefer to the DCM100-000 check points. Referto SECTION 10.

GLOSSARY

Drive The electronic device used to control thespeed, torque, horsepower, and direction of aDC motor. It is also referred to as the control.

Electromotive Force (EMF) This is another name for the armaturevoltage generated by the drive. The voltagegenerated by the motor is called counter EMF.

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Full Load Amps (FLA) The amount of current necessary to producerated horsepower at full speed.

Horsepower (HP) The measure of the amount of work a motorcan perform during a given time period.

Regenerative Control A drive capable of controlling the flow ofpower to and from the motor. Regenerationoccurs when the counter EMF produced by themotor is greater than the voltage applied to themotor by the drive.

Silicon Controlled Rectifier (SCR) A solid-state switch, also called a thyristor,that can be used to provide controlledrectification of large current at high voltages.

Abbreviations

CW ClockwiseCCW Counter clockwisedv/dt Rate of change in voltage

versus per rate of change intime

FL Full loadHz HertzIC Integrated CircuitIR Internal resistanceNL No loadPIV Peak Inverse Voltagepot PotentiometerPPR Pulses Per RevolutionR/C Resistor/CapacitorRPM Revolutions Per MinuteFET Field Effect TransistorDB Dynamic BrakingCRDB Contactor Reversing/Dynamic Braking

8

Description of Operation6

6.1 ARMATURE POWER BRIDGE The armature power bridge of the CHOICE® is a full wave semiconverter, type "D",configuration that consists of three SCR's and four diodes. Refer to FIGURE 1.

Each phase of the AC line connects to anSCR and a diode housed in an isolated powermodule. A fourth diode-only module is inparallel with the bridge output and acts as afreewheeling or flyback diode. As asemiconverter, only half (the three SCR's) of the rectifier components are controlled whichgives an output ripple frequency equal to threetimes the AC line frequency – 180 Hz for 60

Hz lines and 150 Hz for 50 Hz lines. Becauseof this, the output is sometimes mistakenlycalled a half-wave output.

Refer to FIGURE 2 – 5 for typical bridgeoutput waveforms at various unloaded andloaded speeds.

FIGURE 1

9

The power modules are some of the fewcomponents that must be sized according to thehorsepower rating of the control. They are allrated at 1400 volts PIV with 1000volts/microsecond dv/dt to permit reliableoperation over a wide range of AC linevoltage. They are directly controlled by gatingsignals from the POWER/TRIGGER board andare temperature protected by a thermostat onthe same heatsink. There are several vendors that can be used

as replacements for these parts. Specialattention should be paid to the terminalconnections for the gate and cathode signalleads coming from CN6A on thePOWER/TRIGGER board. CAROTRONroutinely manufactures with EUPEC orSEMIKRON brand devices that do not have aseparate "cathode signal' terminal. Althoughdevices with these terminals can be used withlittle difficulty, some do place the terminals indifferent order and may cause problems if the

FIGURE 4 FIGURE 5

FIGURE 2 FIGURE 3

10

proper connections are not made. Refer toSECTION 8 for information on testing thesecomponents and SECTION 11 for makingsituations.

6.2 FIELD SUPPLY

The field supply voltage and current isactually taken from the diodes in the loweruncontrolled half of the armature power bridgedescribed in SECTION 6.1. See FIGURE 1.

Circuitry on the FUSE board connects thepositive, F1, motor lead through currentsensing components and fuse FU2 to the L1line input. The F2 motor lead is connectedthrough fuse FU3 to the diode or A2 side of thepower bridge. This gives a field voltagederived from two of the three phase lines beinghalf wave rectified with respect to the third,L1, line. The diode connected to L1 acts as afreewheeling diode for the field winding. Thefield voltage level is approximately 0.65 timesthe AC line voltage and this waveform can be

seen in FIGURE 6.

The presence of field current is sensed bypassing the current through four 25 ampererated diodes to derive a voltage drop which isused to drive an optoisolator. The diodes areenclosed – two each in doubler modules, DB1and DB2, mounted on the left side panel of thecontrol next to the FUSE board. Jumper J7 onthe FUSE board can break the connection ofthe F1 circuit from L1 to allow an externalfield supply to be connected through thecurrent sensing circuitry via TB2-4.

6.3 CONTROL VOLTAGE SUPPLYAND RELAY LOGIC

The control voltage transformer is suppliedby the customer when using basic CHOICE®

models and is included with contactor models– refer to TABLE 1. When the three phasepower is applied to the drive, the transformerprimary voltage should be appliedsimultaneously to prevent a PHASE LOSS tripcondition. CAROTRON recommendsconnecting the primary to one phase of theauxiliary, output at TB2-8 & 9 on the RELAYboard. The 115 VAC secondary connects to

FIGURE 6

11

TB2-2 & 3 and is fused by FU1, a MDA 5Afuse. The fused secondary can be measured atTB3-20 & 21 on the RELAY board.

The basic CHOICE® drive includes tenrelays for isolated interface of customeroperators or logic such as pushbuttons,selectors, relay contacts, motor thermostatsand the armature contactor. Refer to theRELAY board schematic in SECTION 12. Most of these relays are located on the RELAYboard and all that are controlled directly bycustomer supplied logic are powered by thecontrol voltage transformer. The relaycircuitry is designed to provide safesequencing of the armature contactor(s) foremergency stop, ramp to stop and reversing.

The 115 VAC voltage signals applied to theRUN FORWARD, RUN REVERSE, JOGFORWARD and JOG REVERSE relay coilsare also current limited, rectified and filtered todrive optoisolators on the CONTROL boardfor RUN and JOG enabling of the controlcircuitry. Refer to OPERATING MODECONTROL in SECTION 6.10 for detail onthis control circuitry. The CONTROL boarddoesn't need to know which direction has beenselected. Reversing is controlled by armaturevoltage polarity which is determined by the

armature contactors as selected by the relayslisted above.

The CONTROL board the FAULT PILOT,PILOT ZERO SPEED and JOG DELAY relayson the RELAY board. The FUALT PILOTrelay is normally energized to supply 115 VACat TB3-1 for all of the operator, relay andcondition causes the relay to de-energize andstop operation. See SECTION 6.11 forinformation on the fault circuits. The ZERO SPEED relay provides interlockingof all RUN and JOG relay to prevent theenergization of one relay when the other is inuse. It also allows ramping to stop by holdingthe armature contactor energized until zerospeed is reached. This function is defeated inthe event of a fault or emergency stop by theE-STOP relay.

The JOG DELAY relay is timer controlledto keep the armature contactor energized for 3– 4 seconds after jogging to preventunnecessary cycling of the contactor duringrapid and repeated jogging. See SECTION6.10 for more information on the zero speedand jog delay circuits.

FIGURE 7

12

6.4 POWER SUPPLIES

The power supplies are located on thePOWER/TRIGGER board. Refer to FIGURE7. The supplies are isolated by a 24 VAtransformer which is powered from the 115VAC control voltage via FU1 on the FUSEboard.

The transformer dual 17 VAC secondariesare rectified and filtered to give unregulated±24 VDC supplies which are used directly by

the pulse transformers, ZERO SPEED relayand clamping logic on the CONTROL board. Two IC regulators further reduce the suppliesto ±15 VDC which power most of the circuitryin the drive. Also, zener diodes are used on theCONTROL board to establish +10 VDC forthe speed pot and +12 VDC for an encodersupply. The +24, -24, +15, & -15 VDCsupplies can be measured at TB2-5, and DCMcheck points A – D.

6.5 REFERENCE CIRCUITRY CHOICE® drive can make use of several voltage signals to control the speed of a motor. Refer toFIGURE 8.

FIGURE 8

13

Signals from an external speed pot trimmedby the MAX SPEED, the MIN SPEED, SUMINPUT and JOG SPEED can all be part of theTOTAL SETPOINT for speed.

Normal operation with a speed potconnected to TB1-1, 2 & 3 uses a +10 VDCsignal from TB1-3. This signal is trimmed bythe speed pot to set the input to the accel/decelcircuit at TB1-2. The terminal 2 signal isgiven noise immunity by the R93/C26 R/Cnetwork. OP AMPs A3-B and A3-D form aclosed loop circuit that uses the reference levelto control the charge and discharge time ofcapacitor C18. The charge and dischargefollows a linear ramp and the time can changedby varying the resistance of the ACCEL andDECEL pots. This ACCEL/DECEL output isconnected to the MAX SPEED pot and throughthe A2-D buffer stage to TB1-4. This signalcan also be measured at DCM check point E. A FET clamps the input to theACCEL/DECEL circuit when the drive is atstop and in the JOG mode. See SECTION6.10 for information on the FET clamps. The MAX SPEED pot wiper connects tosumming amplifier A3-C. Also summed arethe MIN SPEED, SUM TRIM and JOGSPEED pot signals. The MIN and JOG pots

trim the +15 VDC signals to set their levelsand each has FET's to clamp their signals atstop and when in the RUN mode for JOG pot. The JOG pot wiper also has the R86/C24 R/Cnetwork to soften start-up in the JOG mode. See SECTION 6.10 for information on FETclamps.

The SUM TRIM pot receives input fromTB1-7. Its wiper is connected to the A2-Cinverting amplifier and to the J5 programmedto add or subtract from the TOTALSETPOINT. This signal can be monitored atTP14 (F). It also has a FET clamp.

6.6 FEEDBACK CIRCUITRY ANDISOLATION CHOICE® drive continuously monitorfeedback signals that are related to motorvelocity and current. They also precisely sensethe AC line voltage and frequency in order toproperly synchronize gating of the SCRs. Atthe same time, the drive must be isolated fromthe sensed signals for ease of interface, noiseimmunity and safety.

FIGURE 9

14

TABLE 7: CURRENT SENSOR/SCALING RESISTORDRIVE

MODEL NO.MODEL FULL

LOAD RANTINGCURRENT

SENSOR VENDORP/N

SENSORSENSITIVITY

ZERO OhmLOCATION

CDC320-000 36 AMPS CSLA1DJ 13.2 m V/AMP R1CDC340-000 71 AMPS CSLA1DJ 13.2 m V/AMP R2CDC360-000 107 AMPS CSLA1DJ 13.2 m V/AMP R3CDC375-000 140 AMPS CSLA1DK 9.1 m V/AMP R3

CDC3150-000 256 AMPS CSLA1EL 5.6 m V/AMP R3

LINE VOLTAGE SENSING Sensing of the three phase line voltage isdone by connecting impedance isolatingresistors and optoisolators in a deltaconfiguration across the line. Refer toFIGURE 9. The outputs are used to derivesynchronized gating signals for the SCRs andfor PHASE LOSS protection. Refer toSECTION 6.9 for a description of the triggercircuit and SECTION 6.11 concerning thePHASE LOSS fault circuit.

ARMATURE CURRENT SENSING Motor armature current is sensed bythreading the positive bridge output conductorthrough a hall effect type sensor. It gives anisolated output voltage that is an accuratereproduction of the current signal. Refer toFIGURE 10. Three sensor rating andsensitivities are used to cover the range ofcurrents for motors up to 150 HP – see TABLE7 for a listing. The Model CDC3150-000 drivehas an IFB board, P/N C10748-003, to power

and mount the sensor while all other modelshave the sensor mounted on the RELAY board. The output at zero armature current isapproximately 50% of the +15 VDC sensorsupply voltage. An increase in current willcause a decrease in the output according to thesensitivity of the sensor being used. It isbuffered by a non-inverting OP- AMP. A2-Aon the IFB board and A1-B on RELAY board. The buffered signal is conducted to theCONTROL board where it can be monitored at TP9 (0). Here it is summed at A5-C with anegative polarity OFFSET voltage to make theno-load signal equal to zero. This signal canbe monitored at TP7 (P). The next stage, A6-A uses the I CAL pot and factory installed"model scaling" zero Ohm resistors to selectthe gain of the amplifier depending on the fullload current rating of the drive and the ratingof the sensor. Its output can be measured atTP18 (Q). See TABLE 7 for drive currentrating and "model scaling' resistor location onthe CONTROL board.

FIGURE 10

15

The combination of sensor rating andselected gain are used to give a scaled currentfeedback equal to +5.0 VDC at the full loadrating of a particular control model. The nextstage, A4-C, uses the programming jumper J6to allow amplification of the current signal in20% increments to scale operation of thecurrent related circuits according to the ratingof the motor used. Refer to TP11 (M) andFIGURE 11 & 12 for typical waveforms underno load and full load conditions.

For example: The CDC320-000 drive listed inTABLE 7 as a full load rating of 36 amperes or10 horsepower with a 240 VDC motor. Whenthe drive is used with a 10 HP motor, J6 –100% position is used. If used with a 28.1

ampere 7.5 HP motor, 28 divided by 36 equalsapproximately 78% so the closest range, 80%,should be selected. This will make the currentamplifier signal – measured at TP11 (M) –equal to +5.0 VDC at a armature current of28.8 amperes.

Accurate adjustment of the I OFFSET and ICAL pots is critical to proper operation of thecurrent feedback and protection circuits. These pots are factory adjusted and sealed. Should they require readjustment, refer toSECTION 7 for calibration instructions.

ARMATURE VOLTAGE SENSING The armature voltage sensing circuit useshigh impedance, exactly 9.4 megohms, for

isolation. 9.4 megohms is the total of twoseries connected resistors in each of the A1 andA2 sensing inputs. Refer to FIGURE 13. TheA2 signal is detected by R8 on the FUSEboard. It passes through thePOWER/TRIGGER board to R4 on theCONTROL board. The A1 signal is detectedby R4 on the POWER/TRIGGER board and isconnected to R18 on the CONTROL board.

On the CONTROL board R4 and R18 areinputs to the A1-A differential amplifier. Theoutput of A1-A is 4.59 VDC at 240 VDCarmature and 9.57 VDC at 500 VDC armature. Programming jumper J2 selects the gain ofA1-D to give 7.7 VDC output – measured atTP10(G) – when at the respective full ratedarmature voltage. This scaled armaturevoltage is used for the zero speed circuit input

FIGURE 11 FIGURE 12

16

– see SECTION 6.10 - and as input to thearmature feedback circuit.

ARMATURE FEEDBACK (AFB) The counter EMF voltage generated by amotor armature is not an ideal velocityfeedback because IR losses in the armaturecause speed to drop as load increases – witharmature voltage held constant. Tocompensate for the losses, the IR COMP potand circuit uses some of the armature loadsignal from the current amplifier to subtractfrom the armature feedback voltage. SeeFIGURE 13. The reduction in feedback actsthe same as an increase in velocity reference

and will cause an increase in armature voltagewith an increase in load to keep the speedconstant. A2-B sums the scaled armaturevoltage with inverted current amplifier, A4-C,output via A6-C. A6-C has a FET clamp todisable it in a stop condition. The output ofA2-B goes through the A2-A inverter stagebefore connecting to the J3 feedback selectionjumper. This signal can be monitored at TB13 (S).

TACHOMETER FEEDBACK (TFB) Another velocity feedback mode selectableby J3 is TACHOMETER FEEDBACK, TFB. Refer to FIGURE 14. An AC or DC

FIGURE 13

tachometer output can be connected to TB1-12and common. The tach voltage is noise de-coupled and applied to the A4-D amplifierwhere the gain is set by jumper J4. Thelabeling of J4 refers to the rating per 1000RPM of DC tachometers. 45 VAC and 90VAC tachometers can be used with the 50 and100 V jumper positions. The jumper is set toscale the full speed tach voltage to 7.7 VDC. Following the scaled signal, A4-A and A4-B

form a precision rectifier circuit which alwayskeeps the output polarity positive – regardlessof input polarity. The output can be measuredat TP12 (H).

ENCODER FEEDBACK (EFB) A 12 VDC 300 PPR encoder connected toTB1-9 can also be selected by J3 in the EFBposition – reference FIGURE 14. 1750 RPMequates to 8750 Hz input which is processed

17

FIGURE 14

and improved speed and torque regulation arethe results.

Both the velocity and current loops use ahybrid or stepped integrator OP-AMP circuit. Refer to FIGURE 15. They operate with a rateof integration determined by the resistor andcapacitor values at the input and in theamplifier feedback loop. They additionallyhave a pot in series with the loop capacitor thatcauses the circuit to initially respond like asumming amplifier. The amplifier action causes an initial step in output based on thepredominate input signal and gain setting andthen it integrates up or down based oncontinuing conditions. Thus, the response of

by IC7, a frequency to voltage converter. IC7sources a current signal into A7-B, an activefilter circuit, and then through an invertingamplifier, A7-A where we can see 7.7 VDC onTP8 (I) at 1750 RPM.

6.7 VELOCITY AND CURRENTLOOPS

Speed regulation and current regulation arecritical operations performed within CHOICEdrives by individual "loop" control circuits. They are known as velocity or current loopsbecause the circuits actively use a feedbacksignal that is "looped around" or fed back forcomparison to the reference Faster response

FIGURE 15 18

the circuit can be altered by changing the sizeof the step taken.

VELOCITY INTEGRATOR A3-A is the velocity integrator and includesthe VOLTAGE (VELOCITY) GAIN pot in itsfeedback loop. It receives reference input fromthe A3-C amplifier – see SECTION 6.5 - andfeedback from the velocity signal selected byJ3 – see SECTION 6.6. The output is based onthe initial difference between these two inputsand the continuing level required to minimizethe difference. It therefore equates to thetorque required by the motor to make thevelocity feedback equal to the velocityreference and is used as the reference to thecurrent loop. It can be monitored at TP15 (J)or at TB1-6 where it is normally jumpered tothe current loop input at TB1-5.

CURRENT INTEGRATOR

The current integrator, A6-B, uses theCURRENT (TORQUE) GAIN pot in itsfeedback loop. Its reference normally comesfrom the velocity loop as described above andis trimmed by the CURRENT LIMIT pot tolimit the highest current level demanded. Additional circuitry senses this signal and canlimit it and cause a fault condition if the levelis excessive for too long of a time period. SeeSECTION 6.8 for details on these functions. The feedback is from the current amplifier. The output is based on the initial differencebetween these inputs and the continuing levelrequired to minimize the difference betweenthem. The output directly controls the triggercircuit and relates to the triggering orconduction angle of the SCRs necessary toproduce an armature current feedback equal tothe current demand.

NOTE: For special applications such ascenter winders that require direct torquecontrol of the motor, the current loop input at TB1-5 can be connected to an alternatesource of reference. The velocity loopsection will be non-functional and the drive

will have no adjustable maximum speed orarmature voltage.

6.8 STATIC CURRENT LIMIT ANDOVERCURRENT FUNCTIONS

FOLDBACK

Refer to FIGURE 16. The current demandsignal from the Current Limit pot goes to ademand level sensing circuit, A5-A, and to abuffer stage, A5-B. The buffer output can bemeasured at TP19 (K) and is connected to a 5.6volt zener that can be switched into operationby transistor Q5 and comparator A1-C. Thesignal then is inverted by A5-D and can bemonitored at TP6 (L) before being applied tothe integrator, A6-B. At the sensing circuit, the demand signal iscompared to a 5.6 zener volt level which isequivalent to 112% current signal - refer toARMATURE CURRENT SENSING inSECTION 6.6. The comparator output,measured at DCM check point R, is used tocontrol two current related protection circuits. FOLDBACK and OVERCURRENT FAULT.

The FOLDBACK circuit uses IC1-A, ½ ofa 556 dual timer, to control the amount of timethe drive has exceeded 112% or rated armaturecurrent. After 60 seconds, the drive will enterthe FOLDBACK mode and clamp the output toa maximum of 112%. Normally the timeroutput is triggered into a high state upon powerup. This high level exceeds the positivevoltage divider level on the non-inverting inputof comparator A1-C and causes it to stay at anegative saturation level. When the demandvoltage level into the inverting input of A5-Aexceeds the 5.6 VDC level on the non-inverting input, the output switches negativeand turns off transistor Q1 which was clampingthe timing capacitor C5. If the demand hasexceeded 112% for approximately 60 seconds,C5 completes its charge and drives the timeroutput low. The low level causes A1-C andQ5 to switch the 5.6 volt zener into operation

19

which now limits the current reference at TP6(L) to 112%.

OVERCURRENT FAULT

The OVERCURRENT FAULT circuit issimilar to the FOLDBACK circuit. TransistorQ2 and timer IC1-B are controlled by thedemand sensing circuit in the same way exceptthat the 112% level must be exceeded for fiveminutes before the timer output drops low. Astage of the hex inverter, IC2, inverts this logicto set the fault latch output high. Refer toSECTION 6.11 for more information on thefault circuits.

NOTE: The timers for FOLDBACK andOVERCURRENT FAULT operate when thecurrent demand has exceeded 112%continuously for their respective timeperiods. During time-out, a dip below 112%demand will reset the timers and start thetiming cycle over again. A decrease below

112% automatically brings the control outof a FOLDBACK condition. OVER-CURRENT FAULT though is a latchfunction and must be reset.

STATIC CURRENT LIMIT

The STATIC CURRENT LIMIT feature isprogrammable with J8 on the CONTROLboard. See FIGURE 16. This feature allowssetting the level of current limiting statically orwithout actually supplying armature current tothe motor. As detailed in previous sections,control of motor current is based on calibrationto give a scaled 5.0 VDC current amplifiersignal at 100% of the programmed currentrange. Selection STATIC C. L. with J8 willdisable the current loop and trigger circuit. Then starting the control with the speedreference turned up will cause velocityintegrator to saturate demanding maximumtorque – which can be trimmed to the desiredcurrent limit level by monitoring TP19 (K).

FIGURE 16

20

This level is factory set to 7.5 VDC whichequates to 150% current.

6.9 TRIGGER CIRCUIT

The trigger circuit accepts a voltagecommand from the current integrator - seeSECTION 6.7 and 6.8 – to control theconduction angle of the SCRs. The voltage isapplied to three identical circuits – one foreach SCR. Each circuit uses all four sectionsof a quad OP-AMP – either A1, A2, or A3. The A1 section is described here and shown inFIGURE 17.

Each circuit is synchronized with one phaseof the three phase line by use of line sensingoptoisolators – see FIGURE 9 in SECTION6.6. All circuits are connected to a commonoscillator which generates a 9.4 kHz"multipulse" gating frequency for the SCR's. The oscillator, ½ of 556 dual timer IC2-A, isturned on by FET Q1 when it is turned off byone of the operating mode control signals. SeeSECTION 6.10 for a discussion on the variousoperating mode control signals.

Each optoisolator output is a "sync pulse"that is low for time equal to 2/3 of the linefrequency period – 11.1 msec for a 60 Hz lineand 13.3 msec for a 50 Hz line. It wouldappear initially that the "on" time periodshould be for ½ of the line period but we seeadditional time at the beginning of our syncsignal from our main phase optiosolator photo-diode conducting in series with one of theother photo-diodes. The additional time isirrelevant because the power bridge SCR's anddiodes are biased by the phase to phase voltagepotentials instead of just the line to linepotentials sensed by the optoislators. Thisdifference in phasing requires that the signal bedelayed or phase shifted > 1.3 msec by the 10kOhm/.47 uF R/C network at each isolatoroutput. The effect of the capacitor can be seenon the rising edge of each pulse; refer toFIGURE 18. The result is a logic level lowpulse in sync with the AC voltage forwardbiasing the SCR.

FIGURE 17

21

The sync signal is squared up and invertedby an IC7 schmidt trigger gate and applied toIC3-B, a three input AND gate, and to theinput of the conduction angle or phasingcontrol circuit. It is additionally applied to thePHASE LOSS circuit which is explained inSECTION 6.11. The AND gate requires thepresence of the sync, oscillator and phasingsignal to drive the output section of the triggercurrent. The phasing signal is controlled bythe output of the current integrator and isproduced in the following manner.

The A1-B OP AMP section inverts andclips the sync pulse to 10.6 VDC. The outputcharges the A1-A section integrator capacitorslowly through a 100K Ohm resistor. Theresult is a positive polarity triangle wave witha linear charge ramp and sharp cutoff. It isinverted to negative by the A1-D sectionamplifier and then summed with a slightlygreater positive bias at the A1-C section so thatthe output is normally saturated negativepolarity. If a portion of the triangle wave ishigh enough in negative polarity, it overcomesthe positive bias and causes the amplifieroutput to saturate positive. This occurs at apoint coinciding with the peak of the triangleand stays high for that portion of the triangleramp that exceeded the positive bias.

A similar output occurs when the positiveoutput from the current integrator is applied tothe non-inverting input of the section A1-Ccomparator. The signal adds to the effect ofthe triangle wave-shifting the output positivewhere it coincides with the peak and slope ofthe waveform. In this fashion, the currentintegrator output controls the width of thegating signal and therefore the SCR conductiontime for each cycle of the AC line. Thevariable width conduction pulse is modulatedby the oscillator output at the IC3 3-input ANDgate. A series pass 2N3904 transistoramplifies the gate current to drive a TIP47transistor into saturation. This TIP47 sinkscurrent through a parallel resistor/capacitornetwork and the primary of the triggertransformer to induce a gate pulse on thesecondary. The initial pulse of current throughthe capacitor and then mainly through theprimary is high due to current flow through thecapacitor and then mainly through the resistorsince the capacitor does not have time tocompletely discharge at the 9.4 KHz rate. Refer to FIGURE 18 for a timing diagram ofthe POWER/TRIGGER board signals andFIGURES 19 & 20 for typical SCR gate pulsewith the drive at no load and full load.

22

FIGURE 18

23

FIGURE 19 FIGURE 20

6.10 SPECIAL SIGNALS ANDCIRCUIT FUNCTIONS

OPERATING MODE CONTROL

As covered in SECTION 6.3, RUN andJOG operating modes are commanded by 115VAC relay logic on the RELAY board. Athird operating mode controlled by the ZEROSPEED circuit on the CONTROL board takes

over from the RUN mode when the RAMPSTOP pushbutton has been depressed. Themode commands are interfaced with variouselectronic reference and controlling withvarious electronic reference and controllingcircuits as depicted in FIGURE 21. There areten of these circuits – listed in TABLE 8 – thatare shut off or clamped by FETs (field effecttransistor) when not turned on or released bythe mode control signals as shown in the table.

FIGURE 21

24

The PN4092 FETs that are used are on or clamping when their gates are at positive or zero voltspotential. They are turned off by the application of the –24 VDC through the “steering" diodeas shown in the figure.

TABLE 8: OPERATING MODE CONTROL

MODE SPDPOT

JOGPOT

ACCELDECEL

MINSPD

SUMPOT

VELSET

IRCOMP

VELINT

CURRINT

9.4 KHzOSC

RUN · X · · · · · · · ·JOG X · X · · · · · · ·

ZERO SPD X X · · · · · · · · "·" indicates that the respective circuit be turned on by the MODE control signal.

"X" indicates that it has no effect.

FIGURE 22

The R7/R23 resistor divider controls theZERO SPEED setpoint and keeps the output ofthe A1-B comparator positive when the scaledarmature voltage is below 6%. The positivevoltage cause Q10 (NPN) to light the ZEROSPEED LED. When the scaled armaturevoltage exceeds the setpoint, A1-B switchesnegative and causes Q21 and Q16 (PNP's) toenergize their respective relays.

JOG DELAY FUNCTION This function serves to extend themechanical life of armature contactors byreducing the number of mechanical operationsin an application where a high rate of repeats"jogging" is performed. When the JOG buttonis pressed and released, the reference isimmediately clamped to stop the motor but thecontactor is held energized for four seconds.

ACCEL/DECEL stays on. Its output will rampdown as controlled by the DECEL pot until thearmature voltage falls below 6% armaturevoltage, the ZERO SPEED setpoint. At thislevel the ZERO SPEED circuit will de-energize the armature contactor and cause theremaining circuits and signals to be clamped. FIGURE 22 is a simplified schematic of theZERO SPEED circuit.

ZERO SPEED FUNCTION A typical operation in the RUN modewould de-clamp all of the circuits and signalsexcept for the JOG pot. When above 6%motor speed, depressing the RAMP STOPbutton will cause the drive to drive to drop outof the RUN mode and continue in the ZEROSPEED mode. TABLE 8 shows that theSPEED pot is clamped in this mode but

25

Pressing the JOG button again within the foursecond "delay" period will cause the motor toimmediately jog and will reset the four secondsdelay.

Refer to FIGURE 23. The JOG DELAY relay

is energized via A7-D when the –24 VDC JOGcommand input is applied through a 10K Ohmresistor to quickly charge C46. When thecommand signal is removed, +15 VDC causesslow discharge of the capacitor via a 220KOhm resistor to produce the delayed drop out

of the relay. The charge on capacitor C46 canbe monitored at DCM check point T.NOTE: the ZERO SPEED and JOGDELAY functions are dependent on the useof a contactor auxiliary contact at TB3-15and additionally at TB3-18 on reversingmodels. Delete these contacts to defeat these

functions.

6.11 FAULT CIRCUITS

There are four fault conditions on all CHOICEcontrol models.Refer to FIGURE 24.

FIGURE 24

26

FIGURE 23

Each fault circuit, OVERCURRENT,FIELD LOSS, PHASE LOSS andOVERTEMP, drive a latching circuit whichindicates the specific fault and cause operationof the FAULT relays. The latching circuitsalso maintains the faulted status of the driveuntil it is reset by the RESET pushbutton onthe CONTROL board, an external RESETcontact connected to TB1-13 & 14 or bycycling the 115 VAC power to the drive.

The FAULT relays act to shut off thearmature voltage output and de-energize thearmature contactor. The FAULT LOGIC relaycontact, as shown in FIGURE 21, removes the–24 VDC used by the mode control circuitryfor de-clamping various circuits. This isexplained in SECTION 6.10. The FAULTPILOT relay contact, explained in SECTION6.3, removes the 115 VAC from thepushbutton operator logic and the contactor.

OVERCURRENT The OVERCURRENT FAULT will occurwhen the control has continuously demandedmore than 112% armature current for fiveminutes. It acts in concert with theFOLDBACK circuit, and is explained in detailin SECTION 6.8.

FIELD LOSS The FIELD LOSS circuit detects thepresence of field current flow, not voltage, bythe circuit shown in FIGURE 1. SECTION 6.2gives an explanation of this circuit.

PHASE LOSS The PHASE LOSS circuit is shown inFIGURE 25. Each phase of the line supply isdetected through the use of optoisolators asshown in FIGURE 9 in SECTION 6.6. Thesync pulses from this circuit are described withthe trigger circuit in SECTION 6.9.

FIGURE 25

27

Drive Programming & Calibration7

The three 50 or 60 Hz (depending on linefrequency) sync signals maintain their 120degree phase relationship through the IC7schmidt trigger logic gates and are convertedto narrow pulse by capacitive coupling to theinput of additional IC7 gates. The three sets ofpulse are all added by the IC8 AND gate togive a regular pulse train at three times the linevoltage frequency. Each pulse then coincideswith one cycle of one of the input phases.

½ of IC2, a 556 dual timer, is used as amissing pulse detector, and monitors the pulsetrain. When powered up, IC2 begins a timingcycle and the output goes high. The train ofinput pulses continually resets and re-triggersthe timer so that it normally cannot complete atiming cycle. One missing pulse gives enoughtime for a cycle to complete. If this happens,IC2 output goes low and is inverted by theIC1gate. A high level from IC1 then signals adelay circuit that a sync pulse is missing.

Experience has shown us that normalindustrial line supplies and branch circuits areconstantly being subjected to notches or "holein the line". The delay circuit providesimmunity from such intermittent and shortlosses of line voltage that do not adversely

affect drive operation. A capacitor chargemust build up from repeated loss of line for atime equal to about 3 cycles or 50 – 60milliseconds before reaching the levelnecessary to operate the fault latch, ½ of IC3. Several IC2 inverter gates are used to squareup the signal from the detector and into thelatch.

OVERTEMP OVERTEMP operates from a thermostatswitch located on the power bridge heatsink. The 77 degrees Centigrade rating and theplacement of the thermostat cause it to open ifthe temperature on the base of theSCR/DIODE modules exceeds 85 degreesCentigrade. The size of the heatsink and fanforced ventilation on some models will permitcontinuous operation at full armature currentrating in a 55 degree ambient without thishappening.

NOTE: The 55 degree rating refers to theambient temperature around the heatsink. Antotally enclosed drive is specified with amaximum of 40 degrees ambient outside theenclosure to allow for heat trapped within theenclosure.

7.1 ADJUSTMENT ANDPROGRAMMING PRESETS

CAROTRON CHOICE® controls are allfunctionally tested and calibrated with motorloads and should require further calibrationonly to tailor operation for a specificapplication. The adjustment presets are listedin the event that the condition of the controland its adjustments are unknown or in doubt.

Potentiometer Presets• Min Speed……………………....full CCW• Max Speed……………………...mid-range

• Jog Speed………………………..full CCW• Sum Trim………………………..full CCW• Accel……………………………mid-range• Decel……………………………mid-range• Voltage Gain……………………...1/3 CW• Current Gain………………………1/3 CW• IR Comp………………………...full CCW• Current Limit…………………...mid-range• Current Offset…...…Do not adjust-Refer to SECTION 7.2 if altered• Current Cal………...Do not adjust-Refer to SECTION 7.2 if altered

28

Programming Jumper Presets Jumpers J1, J2, J4, J6 & J7 should be placedin the positions appropriate to the line, motorand feedback device rating. J3 should beplaced initially in the AFB position untilproper encoder or tachometer operation isverified. Place Jumper J8 in the NORMALposition.

Jumper J5 will be placed according to thespecific application requirements.

7.2 CALIBRATION AND FINE TUNING

CURRENT OFFSET & CURRENT CAL These two adjustments are preset at thefactory to give a calibrated current amplifiersignal versus armature current signal. Theseadjustments are critical to all current relatedfunctions, i.e. current feedback, currentfeedback, current limiting, IR Compensationcurrent foldback, and overcurrent fault.WARNING!!! Altering the factory settingsof these pots may result in loss of protectionand overload operation of the control andmotor. If the adjustments are unknown or indoubt, the following procedure can be used tocalibrate the control.

Disconnect the F1 and F2 field terminalsfrom the control, and place jumper J1 in theBYPASS position. Connect an ammeter inseries with the armature leads. Apply power tothe control. With jumper J6 in the 100%position, monitor TP11 (M), and adjust the I(Current) OFFSET pot P3 to read +5 mV or+.005 VDC.

Adjust the external speed pot toapproximately 20% and the CURRENT LIMITpot P9 fully CCW. Run the control, while stillmonitoring TP11 (M). Slowly adjust theCURRENT LIMIT pot P9 CW until 1.0 VDCis reached at TP11 (M). Since all currentsignals are scaled to 5 VDC at 100% of thejumper J6 range, the 1.0 VDC levelcorresponds to 20%. Slowly adjust the I(CURRENT) CAL pot P6 until the ammeter

reads 20% of the rated armature current of thecontrol. Please note that CW rotation willdecrease armature current while CCW rotationwill cause an increase.

Example: A CDC320-000 has a maximumrating of 37 A. Adjust P9 until TP11 (M)reads 1 VDC. Adjust P6 until the ammeterreads 7.4 ADC, 20% of 37 A.

WARNING!!! Do not exceed the maximumcurrent rating of the ammeter. On highercurrent drives it may also be necessary to taparmature current down in order not to exceedsmaller ammeter current ratings. This is doneby moving jumper J6 to a lower percentageand adjusting P6 to a lower percentage.

Example: A CDC3150-000 has a maximumrating of 256 A. In the above example, P6would then be adjusted until the ammeterwould read 51.2 ADC. However, if jumper J6was placed in the 20% range instead of the100% range, P6 would have to be adjusted toonly 10.2 ADC, 20% of 51.2 ADC.

After calibration, remove power andreconnect the field and armature wires asbefore. Return J1, J6 and P9 to their previouspositions.

BAL 1 & BAL 2 These two adjustments are preset at thefactory to equalize the conduction angle of the3 SCRs and the loading of the 3 phase AC lineinput. The BAL 1 pot is used to adjust SCR1while the BAL 2 pot is used to adjust SCR2. These two adjustments are used to equalizetheir conduction angles with SCR3, which isnot adjustable. If these adjustments areunknown or in doubt, the following procedurecan be used to balance the SCRs. Anoscilloscope and /or ammeter(s) will berequired to balance the SCRs.

The SCRs can be balanced in one of twoways. The first option is to balance theconduction angle or "on time" of each SCR.

29

This is best done by viewing the armatureoutput (A1 with respect to A2) with anoscilloscope.

WARNING!!! High voltage potentials arepresent on the armature. Do not connectany grounded instrument to the CHOICEcontrol. Please follow the oscilloscopemanufacturer's recommendations onmeasuring high voltage potentials notreferenced to earth or machine ground.

Turning the BAL 1 pot CW will increasethe conduction angle of SCR1. Notice as theconduction angle is increased on SCR1, theother two SCR conduction angles aredecreased to keep the armature output currentthe same. Likewise, if SCR2 is increased, theconduction angles of SCR1 and SCR3 aredecreased. Since each balance pot affects all 3SCRs, both balance pots will have to beadjusted in conjunction with each other. Alternately adjust each balance pot until all 3SCR conduction angles are equal.

The second option is to balance the currentsof the 3 phase AC line inputs. This is bestdone by using ammeters to measure the currentin each phase. If the 3 AC line phase voltagesare equal, balancing of the conduction anglesas described above would also equalize the 3phase line currents. However, if the 3 phaseAC line voltages are not equal, balancing ofthe conduction angles will not produce equalcurrents in the 3 phase AC lines. Simplyadjust the balance pots as described in theabove procedure while monitoring the AC linecurrents. As above, each balance pot affectsthe line currents of all 3 phases. Alternatelyadjust each balance pot until all 3 AC linephase currents are equal.

VOLTAGE GAIN & CURRENT GAIN The VOLTAGE and CURRENTadjustments, P2 & P5, as preset byCAROTRON will provide stable andresponsive performance under most loadconditions. When required, the driveperformance can be optimized for a particular

application or to correct undesirable operationby use of these adjustments. The adjustmentsare complex though and can adversely affectoperation if not properly set. In general, thesettings that give the most stable operation donot always give the fastest response. Problemscorrectable by these pots can usually beseparated into those related to stability ofsteady state operation; i.e., constant speed andload conditions; and those that occur withspeed or load changes that are related tobalanced operation of the SCR power bridge. Refer to the following guidelines when re-adjustment is required.

When instability is observed, it should firstbe evaluated as a possible load inducedcondition. Cyclic variation in armature currentand in motor speed can indicate mechanicalcoupling or machine loading conditions. Ifmechanically induced, the instability repetitionrate or frequency can usually be related to amotor or machine rotation rate or loadingcycle. In this situation, the instabilityfrequency will change in coincidence with anymotor speed change.

Instability in the control output due toincorrect adjustment would usually be presentover a range of speed and would not usuallychange frequency in coincidence with speed. Because the response of the control cansometimes be altered to partially compensatefor mechanically induced instability, it issometimes difficult to determine if the loadchange is affecting control output stability or ifcontrol output is affecting the load stability. De-coupling the load can help make thisdetermination.

If fuse blowing or tripping of breakersshould occur, it may be due to unbalancedoperation of the power bridge. This wouldusually be noticeable when rapid changes inoutput or surges of torque are being called foras opposed to steady state operation. Exampleswould be when quickly accelerating a load upto speed, or when a load is suddenly applied.

30

Typically the setting that provide the moststable and balanced bridge operation under allconditions do not give the fastest response.

To prevent confusion and minimize anxietywhen making loop adjustments, use thefollowing guidelines:

1. Make sure the problems are not due tothings other than adjustment. Operationsimilar to that can be caused by but are notlimited to the following problems.• Leakage due to insulation breakdown

in the motor. A motor with insulationbreakdown may operate fine when coolor at light loads but may causeproblems when conditions change.

• Improper wiring of the motor. Does themotor have a SERIES armaturewinding? If it does, its polarity iscritical. Are the field windingsconnected correctly? Most motors usedwith CHOICE® drive models have dualfield windings that must have the samepolarity to work properly.

• Incorrect armature current scaling. Hasthe proper motor current range beenselected by J6 on the CONTROLboard? The scaled current range of thecontrol must match the nameplatecurrent rating of the motor.

• If used, is the velocity feedbacktachometer or encoder selected,connected and scaled properly?

• If in armature feedback, is the IRCOMP adjusted too high?

• Is the speed reference to the control astable, noise free signal?

2. Know what your starting point is beforemaking an adjustment.

3. Make only one adjustment at a time. If anadjustment has no affect or appears not tohelp, be sure to return it to its starting pointbefore making any other adjustment.

4. When loop adjustments are required, startfirst with the I (current) loop adjustment.

IR COMP The IR COMP is functional only in theAFB mode and is used to keep motor speedfrom decreasing as load is increased. Adjustment is best done when the motor ormachine can be loaded normally. If the motoris normally operated at a particular speed,adjust the IR COMP while running at thatspeed. If the motor operates under load over awide speed range, pick a speed near mid-rangeto make the adjustment. Adjust as follows:

Operate the unloaded motor at the normal ormid-range speed and note the exact speed. While still monitoring speed, apply normalload. The reduction in speed of a fully loadedmotor will usually loaded motor will usuallyfall between 2 and 13% of rated or "Base"speed. Slowly increase the IR COMPadjustment clockwise until the loaded speedequals the unloaded speed measured in theprevious step. Making this adjustment maynow cause the unloaded speed to be slightlyhigher. Repeat this procedure until there is nodifference between loaded and unloaded speedlevels.

Use care not to set the adjustment too highor speed may increase with load and instabilitymay result.

NOTE: For this adjustment, do not useSCALED ARMATURE VOLTAGE tomeasure speed. Armature voltage is not anexact indication of loaded motor speed!

31

Component Testing

Troubleshooting9

Fuses Due to other circuit paths that may interferewith measurements, it is not recommended thatfuses be tested with an Ohmmeter while still inthe circuit. Remove the fuse, and then checkthe resistance with an Ohmmeter. A fuse mayalso be checked by applying power to the driveand carefully measuring the voltage across thefuse. Remember that a good fuse will not havea voltage drop, while a blown fuse will.

SCRs The power devices may be tested with ameter and a small (1.5 or 9 VDC) battery. First remove the component to be tested fromthe circuit, and simply measure the resistancefrom the anode to the cathode to check for ashorted SCR. Depending on the current ratingof the SCR model, a good SCR will readanywhere from approximately 400k Ohms toan open circuit. Set the meter to the diodecheck and once again read across the anode

and cathode terminals. Place the positivemeter probe on the anode and the common ornegative meter probe on the cathode. Connectthe negative of the battery to the cathodeterminal. Momentarily connect the positivebattery lead to the gate terminal. The diodecheck voltage should read around 0.6 to 0.7VDC. Note that the SCR may not latch intoconduction due to the small amount of currentbeing supplied by the meter.

DIODES Remove the component to be tested fromthe circuit, and simply measure the resistancefrom the anode to the cathode to check for ashort. Set the meter to the diode check andread across the anode and cathode terminals. Place the positive meter probe on the anodeand the common or negative meter probe onthe cathode. The diode check voltage shouldread around 0.6 to 0.7 VDC.

When trouble shooting a control problem,the first step is to eliminate the motor. Thiscan done best by substituting another motor ora "dummy" load and checking to see if theproblem still persists. An emergency"dummy" load can be created by placing two115 VAC light bulbs in series for 230 VACoperation, or 4 in series for 460 VACoperation. Higher wattage loads will performbetter as dummy loads.

NOTE; The control must be operated inarmature feedback when dummy load areused.

Drive blows fuses on power up• A drive that blows fuses when applying the

3 phase power likely has a shorted SCR ordiode in the armature or field supplybridges. Refer to SECTION 8 forinformation on testing these devices.

• A shorted motor or shorted wiring to themotor can be checked best with a megger. A Ohmmeter may also be used, but it maynot be able to detect high resistance pathsto ground that may break down at ratedoperating voltage.

• Disconnect the motor from the control. Measure the resistance from each motorterminal to machine or earth ground. Placeyour Ohmmeter in the RX 100k or greaterscale, and be suspicious of any reading lessthan 500k Ohms.

8

32

• Shorted or excessively loaded controlvoltage transformer. The 115 VACsecondary must be rated to handle anycustomer added auxiliary loads in additionto the normal requirements of the control.

Drive blows fuses when entering RUN orJOG mode.• Check the 3 phase supply voltage. Voltage

in excess of 506 VAC may cause randomfuse blowing Reduce the supply toapproximately 460 VAC.

• Improper operation of the armaturecontactor may cause the CHOICE® drive tohave improper start up. This can happenwhen the external armature contactor is notbeing controlled by the internal CHOICE®

relay logic. The normal start up procedureshould assure that the contactor isenergized before the control loops areenabled. Likewise, the control loopsshould be allowed to clamp before openingthe contactor.

• Shorted or excessively loaded controlvoltage transformer. The 115 VACsecondary must be rated to handle anycustomer added auxiliary loads in additionto the normal requirements of the control. The external armature contactor inrushadds to this load upon start-up.

• Transient induced uncontrolled gating ofthe SCR's. The coils of electromechanicaldevices such as relays and solenoid that areenergized when the drive is started shouldhave transient suppressors. This isachieved by placing MOV's or snubbers inparallel with the coil. All internal relaycoils on CHOICE® drives are suppressed.

Drive will not RUN or JOG (RUN and JOGLEDs will not light)• Check 115 VAC power at TB2-2 & 3 on

the FUSE board. If not present, checkcontrol voltage transformer and primarysupply from two of either FU4, FU5, orFU6 on the FUSE board.

• Check 115 VAC power at TB3-20 & 21. Ifnot present, check FU1 on the FUSE boardand check status of FAULT LEDs.

• Observe the ZERO SPEED LED. It shouldbe "on" when the motor is stopped. If not,the ZERO SPEED relay may locking outthe run commands due to SCR leakagevoltage appearing at the power bridgeoutput. Refer to drawing A10552. The40K Ohm 10 watt resistor connected acrossthe armature busbars may be open.

• Verify proper operation of RUN and JOGcontacts.

• Check power supplies (Refer to SECTION10). The power supply is fused by FU1 onthe POWER SUPPLY board.

Drive will not RUN or JOG (Run and JogLEDs will light)

• Check power supplies (Refer to SECTION10).

• Verify presence of signal at TOTALREFERENCE SETPOINT at TP14 (F). Ifnot present, check input at TB1-2 or 7depending on speed pot or summing inputoperation.

• Verify that the CURRENT LIMIT pot isnot adjusted too low.

Motor runs too fast or runs away• Lack of velocity feedback can cause run-

away and insufficient feedback can causeexcessive speed.

• Check position of J6 according to motorarmature nameplate rating. The SCALEDARMATURE VOLTAGE, TP10 (G)should measure about 7.7 VDC at ratedarmature output, either 240 or 500 VDC.

• Tachometer feedback (TFB) or encoderfeedback (EFB) signals can be monitoredat TP12 (H) and TP8 (I), respectively,while the control is operated in armaturefeedback (AFB). Each signal shouldmeasure about 7.7 VDC at rated armatureoutput. Check tightness of the coupling. For TFB, verify the position of J4 matchesthe voltage rating of the tachometer used,an d for used, and EFB, confirm use of a300PPR encoder.

33

• Check level to TOTAL REFERENCESETPOINT, TP14 (F). Too high a settingof the MAX SPEED pot or excessivesumming input signals can cause outputsover 100%.

• Overspeed when in armature feedback canbe caused by improperly wired ordefective motor fields. Make sure thepolarities of multi-winding fields arecorrect. Refer below for correct fieldconnections.

Motor runs too slow• Excessive velocity feedback from incorrect

programming of J2 or J4 and/or encoderwith higher than 300PPR used as feedback. Monitor SCALED ARMATUE, SCALEDTACH, or SCALED ENCODER at TP10(G), TP12 (H), or TP8 (I), respectively, toverify 7.7 VDC at rated speed of motor.

• Excessive loading of the motor or wrongcurrent range programmed by J6. MonitorCURRENT FEEDBACK signal at TP11(M), and check for 5.0 VDC level at 100%or range selected by J6. Over-loading themotor for 60 seconds will causeFOLDBACK which may limit the motorspeed.

Motor drops in speed when loaded• Excessive loading of the motor or wrong

current range programmed by J6. MonitorCURRENT FEEDBACK signal at TP11(M), and check for 5.0 VDC level at 100%of range selected by J6.

• Operating in armature feedback and notcompensating for IR losses in motor. Refer to SECTION 7.2 for adjusting the IRCOMP pot.

Motor draws a high level of armature current,but will not produce rated torque• One of the dual field winding polarities

may be reversed. When connecting thefield in a low voltage operation (150VDC),the field windings should be connected inparallel. The F1 and F3 (positive polarity)leads should be connected together, and the

F2 and F4 (negative polarity) leads shouldbe connected together. For high voltageoperation (300 VDC), the field windingsshould be connected in series. The F2 andF3 leads only should be connected togetherwith F1 as positive and F4 as negativeinputs.

• If the field polarity is unknown or in doubt,a simple test with a voltmeter and a smallbattery (1.5 or 9 VDC) can be used todetermine the proper polarity. Disconnectall wires from the motor, and connect thevoltmeter across one of the field windings. Connect the negative battery terminal toone lead of the other field winding to thepositive battery terminal to one lead of theother field winding. Momentarily connectthe other field winding to the positivebattery terminal. If the voltage on the fieldwinding initially goes positive and thenswings negative, the field leads connectedto the positive battery terminal and thepositive leads of the voltmeter have thesame polarity. If the voltage first swingsnegative and then positive, reverse one ofthe connections.

WARNING! When using a battery asdescribed above, the inductance of the fieldcan produce a voltage shock whenconnections are made and broken.

Motor is unstable and becomes worse whenload is applied• The series field may be connected

incorrectly. Only non-regenerative drivesshould use the series field (S1 and S2) byplacing it in series with the armaturewindings. The polarity of the F1 lead andthe S1 lead should always be the same. Changing the direction of motor rotation byreversing the armature leads withcontactors should not reverse the seriesfield winding.

• Voltage and/or current loops not adjustedproperly.

34

Test Points & Check Points10

Many signals on the CHOICE® drive caneasily be monitored by test points on thevarious PC boards. Most of these signals onthe CONTROL board are also easily accessiblevia CAROTRON'S DCM100-000.

CONTROL BOARDNOTE: Letters refer to DCM100-000 CheckPoints.

A Parameter: Unregulated power supplyTP2 Level/range: +24 VDC, ±3.0 VDC

Condition: Can vary ±3.0 VDC withLine and load

Fluctuation

B Parameter: Unregulated power supplyTP4 Level/range: 24 VCD, ±3.0 VDC With line and load Fluctuations

C Parameter: Regulated power supplyTP3 Level/range: +15 VDC, ±0.75 VDC

Condition: Fixed within line Variation of ±10%

D Parameter: Regulated power supplyTP5 Level/range: -15 VDC, ±0.75 VDC

Condition: Fixed within line variation of ±10%

E Parameter: Accel/Decel outputLevel/range: 0 to +10.0 VDCCondition: Equal to speed setting

After ramp time0 VDC = 0% speedreference+10 VDC = 100% speedreference

F Parameter: Total reference (velocity) setpointTP14 Level/range: 0 to –10.0 VDC

Condition: Sum of all reference

signals reference0 VDC = 0% speedreference-10 VDC = 100% speedreference

G Parameter: Scaled armature voltageTP10 Level/range: 0 to +7.7 VDC

Condition: 0 VDC = 0% armatureOutput voltage+7.7 VDC = 100%armature outputvoltage

H Parameter: Scaled tachometer voltage (when used)TP12 Level/range: 0 to +7.7 VDC

Condition: 0 VDC =0% motor speed

+7.7 VDC = 100%motor speed

I Parameter: Scaled encoderVoltage (when used)

TP8 Level/range: 0 to +7.7 VDCCondition: 0 VDC = 0% motor

Speed+7.7 VDC = 100%motor speed

J Parameter: Velocity integratorOutput

TP15 Level/range: 0 to 13.5 VDCCondition: Load and speed

Dependent200 RPM N.L.=+0.44VDC200 RPM F.L.=+8.8VDC1750 RPM N.L =+0.44VDC1750 RPM F.L.=+8.9VDC

Motor stalled or current limited = +13.5 VDC

35

K Parameter: Torque demandTP19 Level/range: 0 to +8.0 VDC

Condition: Load dependent+5.0 VDC = 100%current demand+7.5 VDC= 150%current demand

L Parameter: Torque referenceTP6 Level/range: 0 to –8.0 VDC

Condition: Load dependent unlessLimit by foldback orCurrent limit functions-5.6 VDC = 112%foldback level-7.5 VDC = 150%current demand

M Parameter: Torque feedbackTP11 Level/range: 0 to +7.5 VDC

Condition: Load dependent+5.0 VDC = 100% of J6current range+7.5 VDC = 150% of J6current range

N Parameter: Current integrator outputTP17 Level/range: 0 to +6.25 VDC

Condition: Load & speed dependent200 RPM N.L.= +4.34

VDC200 RPM F.L. = +4.56

VDC1750 RPM N.L. = +5.22

VDC1750 RPM F.L. = +6.25

VDC

O Parameter: Hall effect outputTP9 Level/range: MV/Ampere-see

TABLE 7Condition: Signal decreases with

Armature currentIncrease

Output is model Dependent:

Approximately 7.6 to 8.2 VDC at 0 amps.

Current decreases about1.3 – 1.4 VDC at fullload

P Parameter: Current offset setpointTP7 Level/range: 0 to 1.0 VDC

Condition: Offsets hall effect outputAt O armature currentFactory setting, DO

NOT ADJUST, SeeSECTION 7.2

Q Parameter: Current scalingTP18 Level/range: 0 to –5.0 VDC

Condition: Signal proprotionalTo armature current-5.0 VDC = 100%

model rated loadcurrent

Factory setting, DO NOT ADJUST, See

SECTION 7.2

R Parameter: Torque demand sensingComparator

Level/range: +13 VDC ±1.5 VDC(before foldback)

Condition: Controls feedback andOver current faultcircuits

> 112% current demand = -13.0 VDC±1.5 VDC

S Parameter: Velocity feedbackTP13 Level/range: +7.7 VDC at full motor

SpeedCondition: Signal composed of

Armature voltageFeedback minus IRCompensation signal

T Parameter: Jog delay timer signalLevel/range: -5.0 VDC ±0.2 VDC

Or +13.5 VDCCondition: Provides contactor

delayedDrop out on jog –Approximately 4Seconds

36

Replacement Parts & Component Substitution11

Jogging = +13.5 VDCAfter contactor delay =-6.0 VDC

TP1 Parameter: Circuit common

TP16 Parameter: IR CompLevel/range: 0 to –2.0 VDCCondition: Load and speed

dependant

11.1 COMPONENT SUBSTITUTION

Many components of a CHOICE® drive areinterchangeable with other CHOICE® models. The following section lists CAROTRON's partnumbers and the manufacturer's part number(if applicable) of the drive's major components. This section can be used to order additionalparts or to determine if a component from onedrive may be substituted on another.

If needed, the CONTROL board can bemodified with minimal effort to operate anymodel. The location of a zero Ohm resistor inposition R1, R2, or R3 determines theCONTROL board model. Simply remove thezero Ohm resistor, and replace it in the correctlocation. Please refer to TABLE 7 forplacement. The FUSE boards for all modelsare identical, except for the wire lengths andlug sizes. The CDC3150-000 FUSE boardrequires longer wire lengths and larger ringlugs than the other models

ALL SCR/DIODE isolated power modulesare rated at 1400 volts repetitive peak off stateand inverse voltage and have 1000volts/microsecond dv/dt. There are 3 each permodel. The power modules listed in SECTION11.5 are pin-for-pin compatible with allCHOICE® drives. Consult the factory forassistance in making substitutions withcomponents other than the recommendedspares listed below in SECTION 11.5. A higher rated current and/or voltage

component may be substituted for any powercomponent. For example, the CDC320-000model uses a 25 ampere, 1400 voltSCR/DIODE module. If this module is notavailable, a 55 ampere 1400 volt or a 25ampere 1600 volt SCR/DIODE module couldbe substituted. NOTE: A higher current ratedmodule will normally require a higher latchingcurrent for the device to operate correctly. Under light load conditions, this may cause theSCR to momentarily drop out of conduction orto not conduct at all. However, this problem iseasily eliminated by the application of loadand/or choosing a substitute device with aminimal difference in the current rating.

11.2 PRINTED CIRCUIT ASSEMBLIESCONTROL BOARDModel CDC320-000……………..D10485-001Model CDC340-000……………. D10485-002Models CDC360-000 – CDC3150-000……….. ……………...D10485-003

RELAY BOARDModel CDC320-000-CDC360-000. ……………..D10488-000Model CDC375-000……………..D10488-001Model CDC3150-000…...……….D10488-002

FUSE BOARDModel CDC320-000- CDC375-000…………... …………….D10491-000Model CDC3150-000……………D10491-001

37

POWER/TRIGGER BOARDAll model ………………………..D10494-000

IFB (CURRENT FEEDBACK BOARDModel CDC3150-000 only……….C10748-003

11.3 CONNECTOR /CABLE ASSEMBLIES

SAME FOR ALL MODELSCable 1………………………..….A10527-000Cable 2…...………………………A10528-000Cable 4…………...………………A10530-000

MODEL DEPENDENTCable 3Models CDC320-000 – CDC375-000………… …..………………………A10529-000Model CDC3150-000……………A10805-000

Cable 5Model CDC320-000 – CDC375-000 …...………………………A10531-000Model CDC3150-000……………A10806-000

Cable 6Models CDC320-000 – CDC375-000 …………………………..A10532-000Model CDC3150-000……………A10807-000

Cable 7Model CDC3150-000 only……....A10808-000

11.4 FUSESSAME FOR ALL MODELS

FU1: 5 ampere, 250 VAC, dual element, timedelay located on the FUSE boardCAROTRON……………………...FU1005-01BUSSMANN………………………….MDA-5LITTELFUSE……………………….326005

FU2, FU3: 10 ampere, class CC, time delay,500 VDC located on the FUSE boardCAROTRON…………………….FUS1012-00LITTELFUSE……………………...CCMR-10

FU4-FU6: 10 ampere, dual element, timedelay, 500 VAC located on the FUSE boardCAROTRON……………….……FUS1008-03BUSSMANN………………………....FNQ-10LITTILFUSE………………………….FLQ-10

MODEL DEPENDENTFU7, FU8, FU9 current rating per model, 500VDC semiconductor typesModel CDC320-000: 50 ampereCAROTRON…………………….FUS1009-00BUSSMANN………………………….FWH50SHAWMUT………………………A50QS50-4LITTELFUSE…………………………L50S50

Model CDC340-000: 100 ampereCAROTRON……...……………..FUS1009-01BUSSMANN……………………...…FWH100SHAWMUT……………………..A50QS100-4LITTELFUSE……………………..…L50S100

Model CDC360-000: 150 ampereCAROTRON…...………………..FUS1009-02BUSSMANN………………………...FWH150SHAWMUT...…………………...A50QS150-4LITTELFUSE……………………..…L50S150

Model CDC375-000: 175 ampereCAROTRON…………………….FUS1009-03BUSSMANN………………………..FWH175SHAWMUT…………………..…A50QS175-4LITTELFUSE………………………..L50S175

Model CDC3150-000: 350 ampereCAROTRON………………….…FUS1009-04BUSSMANN……………………..….FWH350SHAWMUT………………….….A50QS350-4LITTELFUSE………………………..L50S350

11.5 POWER COMPONENTSFreewheeling (flyback) diode: 1 per model

Models CDC320-000 – CDC375-000: 80ampereCAROTRON……………………PMD1011-00SEMIKRON…..………………….SKKE81/14IR……….…………………………IRKE81-14

38

Model CDC3150-000: 165 ampereCAROTRON……………………PMD1015-00AEG/EUPEC…………………...D171N1400KIR…….………………………..IRKE166-1400

SCR/DIODE: 3 per model

Model CDC320-000: 25 ampereCAROTRON……………………PMD1010-02AEG/EUPEC...……………..TD25N1400KOFSEMIKRON…………………....SKKH26/14EIR…………………………….IRKH26/14-S90

Model CDC340-000: 55 ampereCAROTRON……………………PMD1010-01AEG/EUPEC…….....………TD56N1400KOFSEMIKRON……………………SKKH56/14EIR…………………………….IRKH56/14-S90

Model CDC360-000: 90 ampereCAROTRON...………………….PMD1010-00AEG/EUPEC...……………..TD92N1400KOFSEMIKRON……………………SKKH91/14EIR…………………………….IRKH91/14-S90

Model CDC375-000: 105 ampereCAROTRON…………………....PMD1010-00AEG/EUPEC…...…………TD105N1400KOFSEMIKRON…………………..SKKH105/14E

Model CDC3150-000: 135 ampereCAROTRON...………………….PMD1014-03AEG/EUPEC…………...…TD142N1400KOFIR…..………………………..IRKH136-14S90

FIELD SUPPLYThe field supply uses the same powercomponents for all models.

DB1 & DB2, diode doubler, 25 ampere, 50 V,2 per model:

CAROTRON……………………PMD1009-00EDI…………………………………FPID2505HV….……………………………….CSB2505

39

PRINTS12

40

NOTES:

53

Standard Terms &Conditions of Sale

1. GeneralThe Standard Terms and Conditions of Sale of Carotron, Inc. (here-

inafter called “Company”) are set forth as follows in order to give theCompany and the Purchaser a clear understanding thereof. No additional ordifferent terms and conditions of sale by the Company shall be binding uponthe Company unless they are expressly consented to by the Company inwriting. The acceptance by the Company of any order of the Purchaser isexpressly conditioned upon the Purchaser’s agreement to said StandardTerms and Conditions. The acceptance or acknowledgement, written, oral,by conduct or otherwise, by the Company of the Purchaser’s order shall notconstitute written consent by the Company to addition to or change in saidStandard Terms and Conditions.

2. PricesPrices, discounts, allowances, services and commissions are subject to

change without notice. Prices shown on any Company published price listand other published literature issued by the Company are not offers to selland are subject to express confirmation by written quotation andacknowledgement. All orders of the Purchaser are subject to acceptance,which shall not be effective unless made in writing by an authorizedCompany representative at its office in Heath Springs, S.C. The Companymay refuse to accept any order for any reason whatsoever without incurringany liability to the Purchaser. The Company reserves the right to correctclerical and stenographic errors at any time.

3. Shipping datesQuotation of a shipping date by the Company is based on conditions at

the date upon which the quotation is made. Any such shipping date issubject to change occasioned by agreements entered into previous to theCompany’s acceptance of the Purchaser’s order, governmental priorities,strikes, riots, fires, the elements, explosion, war, embargoes, epidemics,quarantines, acts of God, labor troubles, delays of vendors or oftransportation, inability to obtain raw materials, containers or transportationor manufacturing facilities or any other cause beyond the reasonable controlof the Company. In no event shall the Company be liable for consequentialdamages for failure to meet any shipping date resulting from any of theabove causes or any other cause.

In the event of any delay in the Purchaser’s accepting shipment ofproducts or parts in accordance with scheduled shipping dates, which delayhas been requested by the Purchaser, or any such delay which has beencaused by lack of shipping instructions, the Company shall store all productsand parts involved at the Purchaser’s risk and expense and shall invoice thePurchaser for the full contract price of such products and parts on the datescheduled for shipment or on the date on which the same is ready fordelivery, whichever occurs later.

4. WarrantyThe Company warrants to the Purchaser that products manufactured or

parts repaired by the Company, will be free, under normal use andmaintenance, from defects in material and workmanship for a period of one(1) year after the shipment date from the Company’s factory to thePurchaser. The Company makes no warranty concerning productsmanufactured by other parties.

As the Purchaser’s sole and exclusive remedy under said warranty inregard to such products and parts, including but not limited to remedy forconsequential damages, the Company will at its option, repair or replacewithout charge any product manufactured or part repaired by it, which isfound to the Company’s satisfaction to be so defective; provided, however,that (a) the product or part involved is returned to the Company at thelocation designated by the Company, transportation charges prepaid by thePurchaser; or (b) at the Company’s option the product or part will berepaired or replaced in the Purchaser’s plant; and also provided that Cc) theCompany is notified of the defect within one (1) year after the shipment datefrom the Company’s factory of the product or part so involved.

The Company warrants to the Purchaser that any system engineered byit and started up under the supervision of an authorized Companyrepresentative will, if properly installed, operated and maintained, performin compliance with such system’s written specifications for a period of one(1) year from the date of shipment of such system.

As the Purchaser’s sole and exclusive remedy under said warrant inregard to such systems, including but not limited to remedy forconsequential damages, the Company will, at its option, cause, withoutcharges any such system to so perform, which system is found to theCompany’s satisfaction to have failed to so perform, or refund to thePurchaser the purchase price paid by the Purchaser to the Company in

regard thereto; provided, however, that (a) Company and its representativesare permitted to inspect and work upon the system involved duringreasonable hours, and (b) the Company is notified of the failure within one(1) year after date of shipment of the system so involved.

The warranties hereunder of the Company specifically exclude and donot apply to the following:

a. Products and parts damaged or abused in shipment without fault ofthe Company.

b. Defects and failures due to operation, either intentional or otherwise,(l) above or beyond rated capacities, (2) in connection with equipment notrecommended by the Company, or (3) in an otherwise improper manner.

c. Defects and failures due to misapplication, abuse, improper in-stallation or abnormal conditions of temperature, humidity, abrasives, dirtor corrosive matter.

d. Products, parts and systems which have been in any way tamperedwith or altered by any party other than an authorized Companyrepresentative.

e. Products, parts and systems designed by the Purchaser.f. Any party other than the Purchaser.

The Company makes no other warranties or representation, expressed orimplied, of merchantability and of fitness for a particular purpose, in regardto products manufactured, parts repaired and systems engineered by it.

3. Terms of paymentStandard terms of payment are net thirty (30) days from date of the

Company invoice. For invoice purposed, delivery shall be deemed to becomplete at the time the products, parts and systems are shipped from theCompany and shall not be conditioned upon the start up thereof. Amountspast due are subject to a service charge of 1.5% per month or fractionthereof.

6. Order cancellationAny cancellation by the Purchaser of any order or contract between the

Company and the Purchaser must be made in writing and receive writtenapproval of an authorized Company representative at its office in HeathSprings, S.C. In the event of any cancellation of an order by either party, thePurchaser shall pay to the Company the reasonable costs, expenses,damages and loss of profit of the Company incurred there by, including butnot limited to engineering expenses and expenses caused by commitmentsto the suppliers of the Company’s subcontractors, as determined by theCompany.

7. ChangesThe Purchaser may, from time to time, but only with the written

consent of an authorized Company representative, make a change inspecifications to products, parts or systems covered by a purchase orderaccepted by the company. In the event of any such changes, the Companyshall be entitled to revise its price and delivery schedule under such order.

8. Returned materialIf the Purchaser desires to return any product or part, written au-

thorization thereof must first be obtained from the Company which willadvise the Purchaser of the credit to be allowed and restocking charges to bepaid in regard to such return. No product or part shall be returned to theCompany without a ”RETURNTAG” attached thereon which has beenissued by the Company.

9. PackingPublished prices and quotations include the Company’s standard

packing for domestic shipment. Additional expenses for special packing oroverseas shipments shall be paid by the Purchaser. If the Purchaser does notspecify packing or accepts parts unpacked, no allowance will be made to thePurchaser in lieu of packing.

10. Standard transportation policyUnless expressly provided in writing to the contrary, products, parts

and systems are sold f.o.b. first point of shipment. Partial shipments shall bepermitted, and the Company may invoice each shipment separately. Claimsfor non-delivery of products, parts and systems, and for damages theretomust be filed with the carrier by the Purchaser. The Company’sresponsibility therefor shall cease when the carrier signs for and accepts theshipment.

3204 Rocky River RoadHeath Springs, SC 29058Phone: (803) 286-8614Fax: (803) 286-6063

Email: [email protected]: www.carotron.com

MAN1001-2BIssued 10-14-2004

choice d.c.motor control

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