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Reliance electric DC2 VS series Installation, Operation And Maintenance Manual

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  • Page 6 The consignee is responsible for making claim against the Carrier for any shortage or damage occurring in transit. Claims for loss or damage in shipment must not be deducted from the Reliance Electric invoice, nor should payment of the Reliance invoice be withheld while awaiting adjustment of such claims since the carrier guarantees safe delivery.
  • Page 7 2. Do not return equipment without a numbered authorization form (ERA form) from Reliance Electric. 3. Reliance Electric reserves the right to inspect the equipment on site to verify any claims. To find the nearest sales/service office, call toll free 1 800 245 4501.
  • Page 8 Introduction to the Controller Controller Configurations The controller converts single phase A C line power to adjustable D C power for either speed or torque control of D C motors rated 1/4 through 2 HP . The controller is specifically performance matched to Reliance D C Motors to provide a compact controller/motor package.
  • Page 9 Table 2 2. NEMA 12 Enclosed Controllers Listed by Features and Configuration. Controller Model Number by Configuration Controller Features Speed Control Torque Control Basic DC2 60U DC2 63U DC2 65U DC2 73U@ DC2 70U 2 DC2 75U Basic with Jog DC2 60U Not Available DC2 79U...
  • Page 10 Controller Features Standard DC2 controllers available are listed in Tables 2 1, 2 2 and 2 3. Basic Controller Features (All Models) A C line power reconnectable for single phase 115 or 230 volts: - 115 volts A C: 90 volt armature/50 volt field supply - 230 volts A C: 180 volt armature/100 volt field supply 50 or 60 cycle power without modification Full wave, half controlled armature voltage rectifier with back diode...
  • Page 11 CAUTION: The drive must be at zero speed before changing the direction of rota tion. Failure to observe this precaution could result in damage to, or destruction of, the equipment. Speed Control with Isolated Process Control Interface (Models DC2 42, 46, 52, 56, 62, 66, 72, 82, 92, 97) All features listed in Basic Controller Features (All Models)"...
  • Page 12 Process Interface (PI) bias adjustment Ramp generator Auxiliary form C contact for run indication Jog Functions (Models DC2 40, 50, 60, 78, 79, 80, 98, 99) All features listed in Basic Controller Features (All Models)" Controller offers Run/Jog capability for local or remote requirements.
  • Page 13 Controller Performance Efficiency (at rated speed and load): - Controller - Controller and motor Displacement power factor (at rated speed and load): 70% Table 2 4. Controller Ratings by Motor Horsepower. 115 Volt A C Input 230 Volt A C Input Rated Available Motor...
  • Page 14 Speed Control Adjustment Ranges NOTE: Full rotation of potentiometers may exceed the range specified. Maximum speed: 50 to 100% of motor base speed with speed setting pot at its maximum setting Minimum speed: 10 to 50% of maximum speed with speed setting pot at its minimum setting.
  • Page 15 Table 2 6. Speed Regulation Characteristics. Field Line Load Regulated Heating Type of Temperature Voltage Change Speed Cold Regulation +10 C Range +10% Normal Armature Feedback 0.1% 2 5% 20:1 1.0% 5 12% (Voltage) Tachometer Feedback 0.1% 30:1 1.5% 0.5% (Speed) All percentages expressed relative to maximum speed.
  • Page 16 Install and Wire the Drive DANGER ONLY QUALIFIED ELECTRICAL PERSONNEL FAMILIAR WITH THE CON STRUCTION AND OPERATION OF THIS EQUIPMENT AND THE HAZARDS IN VOLVED SHOULD INSTALL, ADJUST, OPERATE AND/OR SERVICE THIS EQUIPMENT. READ AND UNDERSTAND THIS MANUAL IN ITS ENTIRETY BE FORE PROCEEDING.
  • Page 17 4. Route power and control/signal wiring through separate conduit openings provided in the bottom of the enclosed controller. The area above the controller must be kept clear of live electrical circuits to avoid accidental contact. (See Figures 3 2A and B.) 5.
  • Page 18 1> Functional on 0 57210 31 Regulator Boards only. 1> 1> Figure 3 1A. Controller Terminal Board Locations (0 57210 31 and 0 57210 32 Regulator Boards Only)
  • Page 19 CHASSIS DESIGN (DC2 Series 40) Side View FRONT VIEW Restricted Area 4.0" (102) 12.5" FUSE (321) 0.625" 7.735" (16) (188) 6.5" 7.875" (167) (200) 5.0" (128 4.875 " 7.0" (125) (179 Bottom View 4.875" (125) 3.5" 0.875" (90) (22) Open Chassis 1.5"...
  • Page 20 4.875" (125) 5.5" 3.5" (141) 0.875" (90) (22) 2 PLACES 1.5" (38) Bottom View Restricted Area 4.0" (103) 0.875" (22) 0.625" 14.75" (16) (378) 9.625" (247) 8.75" (224) Dimensions shown in Inches (Millimeters) 5.0" (128) Front View 7.0" (179) FUSE NOTE: OPERATOR'S DEVICES SUPPLIED ONLY ON MODEL DC2 70...
  • Page 21 5.50" 3.29" 6.25" 4.50" 4.25" 4.25" 6.50" 8.66" Figure 3.2C. HSI 50 Heatsink Dimensions Install the Motor 1. Verify that the motor is the appropriate rating to use with the controller. 2. Install the D C motor in accordance with its own installation instructions.
  • Page 22 1. Any fused disconnect or circuit breaker in the incoming A C line must accommodate a maximum symmetrical A C fault current of 10,000 amperes. See Figure 3 3. 2. Some drive models are shipped without a fuse on the panel (Exception - drive models DC2 71, 78, 91 and 98) therefore the customer must provide an external fuse (Class J UL listed and CSA certified 20 amp, 600 V time delay fuse).
  • Page 23 Wire the Drive DANGER THE USER IS RESPONSIBLE FOR CONFORMING TO THE NATIONAL ELEC TRICAL CODE AND ALL OTHER APPLICABLE LOCAL CODES. WIRING PRACTICES, GROUNDING, DISCONNECTS AND OVERCURRENT PROTEC TIONS ARE OF PARTICULAR IMPORTANCE. FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE.
  • Page 24 Wire A C Power to the Controller DANGER DO NOT OPERATE THE CONTROLLER WITH AVAILABLE SHORT CIRCUIT CURRENTS IN EXCESS OF 10,000 AMPERES. FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE. 1. Size the A C line supply conductors for the specific controller rating and according to all applicable codes.
  • Page 25 A2 5 Motor Shunt Field Motor Armature Motor Thermostat (1) Place a jumper between terminals 32 and 132 if a motor thermostat is not used. Drive will not operate with an open circuit between terminals 32 and 132. Figure 3 4. Armature, Field and Thermostat (CCW Rotation) Connections 5.
  • Page 26 A2 5 HIGH VOLTAGE SHUNT FIELD WIRING A2 5 LOW VOLTAGE SHUNT FIELD WIRING Figure 3 5. Connection for Dual Voltage Fields Wire the Start/Stop Circuit For drives without operator devices on the controller: 1. Run the Start/Stop pushbutton or normally open contact wiring in the remaining conduit entry separate from the A C and D C power wiring.
  • Page 27 4. If start/stop control is remote, remove the factory installed jumper between terminals TB2 35 and TB2 132. See Figure 3 6. With the operator's start/stop controls mounted remotely from the controller, the A C fused disconnect or circuit breaker must be mounted in close proximity to the operator controls.
  • Page 28 Wire the Run/Jog Circuit For drives without operator devices on the controller: 1. Run the Run/Jog wiring in conduit separate from the A C and D C power wiring. 2. Use the appropriate tightening torque as listed in Table 3 2 for wire connections to input and output terminals.
  • Page 29 Wire the Process Control and/or Automatic/Manual Devices (if required) Selected controller models have a high impedance input to interface with process signals. If both manual control (controller responds to a reference potentiometer) and process control (controller responds to an automatic signal) are desired, an Automatic/Manual switch is included in selected controller models.
  • Page 30 WIRING REVERSE CONNECTION WILL CAUSE THE MOTOR TO RUN AT MAXIMUM UNCONTROLLED SPEED. THE D C TACHOMETER MUST BE CONNECTED SUCH THAT THE TACH LEAD CONNECTED TO TERMINAL 519 IS MORE POSITIVE THAN THE NEGATIVE TACH LEAD CONNECTED TO TERMINAL 419 FOR THE DESIRED DIRECTION OF ROTATION.
  • Page 31 419 519 Motor Mounted D C Tachometer Figure 3 8. D C Tachometer Connection. 3 16...
  • Page 32 Setup and Adjust the Drive DANGER ONLY QUALIFIED ELECTRICAL PERSONNEL FAMILIAR WITH THE CON STRUCTION AND OPERATION OF THIS EQUIPMENT AND THE HAZARDS IN VOLVED SHOULD INSTALL, ADJUST AND/OR SERVICE THIS EQUIPMENT. READ AND UNDERSTAND THIS MANUAL IN ITS ENTIRETY BEFORE PRO CEEDING.
  • Page 33 J200: Tachometer Scaling Jumper NOTE: This jumper is on all controller models and is factory set for 7 VDC/1000 tachometer scaling (pins 1 and 2). 1. If 20.8 VDC/1000 tachometer scaling is desired, relocate jumper to the 21V position (pins 3 and 4). 2.
  • Page 34 NOTE: Rotate jumper 90 to select 5, 20, or 50 mA input signals. (50mA) (20mA) (5mA) J201: Minimum Speed Disable WARNING THE DRIVE IS INTENDED TO OPERATE AT A PREDETERMINED MINIMUM SPEED UNLESS DISCONNECTED FROM THE POWER SOURCE. IF THE APPLICATION REQUIRES ZERO SPEED OPERATION WITHOUT SUCH DIS CONNECTION, THE USER IS RESPONSIBLE FOR ASSURING SAFE CONDI TIONS FOR OPERATING PERSONNEL BY PROVIDING SUITABLE GUARDS,...
  • Page 35 1> DO NOT USE Figure 4 1. Controller Circuit Board Jumper, Pin and Potentiometer Locations (0 57210 30 Regulator Boards only).
  • Page 36 1> Functional on 0 57210 31 Regulator Boards only. 1> 1> Figure 4 1A. Controller Circuit Board Jumper, Pin and Potentiometers Locations (0 57210 31 and 0 57210 32 Regulator Boards only)
  • Page 37 Startup and Adjust the Controller NOTE: This procedure covers Speed Control, Process Control, and Torque Control controllers. Therefore, you will find references to speed, process or torque" when the type of control is important. 1. Verify that the circuit board pots (Figure 4 1) are set as indicated below: With Speed Control models: MAX - fully CCW...
  • Page 38 6. Check the direction of motor rotation: Press START and quickly press STOP to verify correct motor rotation. If the motor shaft doesn't rotate because all potentiometers are set to minimum levels, turn the Speed or Torque potentiometer slightly CW and repeat this start/stop operation.
  • Page 39 With Speed Control models: Use a hand held tachometer to monitor motor speed; or use a multimeter to measure armature voltage, which is approximately proportional to speed (115 volt control: 90 VDC = 100% speed; 230 volt control: 180 VDC = 100% speed). Press the Start button and slowly turn the Speed potentiometer to maximum (fully CW).
  • Page 40 ROLL WEIGHT MOTOR Figure 4 2. Pre loaded Dancer Loop Preceding Winder. 9. Adjust the current or speed limit: With Speed Control models: The maximum D C current output from the controller with CURRENT LIMIT potentiometer set full CW is greater than 150%, possibly 200% maximum, of the J5 armature current setting.
  • Page 41 100% 100% LOAD Figure 4 3. Fixed Speed Droop With Load Change With Torque Control models: IR drop compensation is used to reduce the speed rise above the speed limit threshold due to a loss of load torque. Turn IR DROP to minimize speed rise due to loss of load. Note that excessive IR drop compensation can cause motor instability and hunting.
  • Page 42 3. Verify that jumper J8 is properly positioned for your reference signal. 4. Apply A C input power and then press the Start button. WARNING ADJUSTMENT OF THE PROCESS INTERFACE BIAS POTENTIOMETER COULD RESULT IN ZERO SPEED OPERATION OF THE CONTROLLER. THE DRIVE IS INTENDED TO OPERATE AT A PREDETERMINED MINIMUM SPEED UNLESS DISCONNECTED FROM THE POWER SOURCE.
  • Page 43 Electric Distributor or 54, -56, 64, 74, 84, 94 0 57210 31 direct from Reliance. DC2 52, 62, 66, Reliance Electric Industrial Company Cleveland Service Center 72, 76, 82, 92, 97 4950 East 49th Street DC2 43, 53, 63, Cleveland, Ohio 44125...
  • Page 44 Reliance Electric Distributor or Conduit Hole Plugs for direct from Reliance. NEMA 12 Controllers 197308A Reliance Electric Industrial Company Conduit Hubs for NEMA Cleveland Service Center 4/4X/12 Controllers 608826 2A 4950 East 49th Street Cleveland, Ohio 44125...
  • Page 45 DANGER SERVICING IS DONE WITH POWER ON. EXERCISE EXTREME CARE AS HAZ ARDOUS VOLTAGE EXISTS. FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE. Table 5 2. Servicing Steps. Indication Possible Cause Corrective Action Controller incoming Faulty incoming A C line wir Check all incoming A C wires...
  • Page 46 Table 5 2. Servicing Steps. (Continued) Indication Possible Cause Corrective Action Motor does Start/Stop or Forward/Off/ Investigate and/or replace not rotate. Reverse switch faulty or in the switch as necessary. (Continued) incorrect position. Motor thermostat open. Check for continuity with Open on 32 &...
  • Page 47 Table 5 2. Servicing Steps. (Continued) Indication Possible Cause Corrective Action Motor does not Low line voltage. Check for rated line voltage reach top speed and correct if not within 10% or deliver rated of the input voltage rating. torque. With Process Control models, Reset maximum speed pots.
  • Page 48 Figure 5 1. Wiring Diagram of Basic Speed Controller (0 57210 30).
  • Page 50 Figure 5 1A. Wiring Diagram of Torque and Process Interface Controller (0 57210 31 and 57210 32 Regulator Boards only)
  • Page 52 STANDARD BASIC SWITCH CONNECTION START/STOP SWITCH 49869 17A STANDARD DB/REV SWITCH CONNECTION MOTOR THERMOSTAT START/STOP OR JUMPER SWITCH 49869 17 D/B REV RUN JOG SWITCH CONNECTION DB REV JOG SWITCH MOTOR SWITCH 49869 20 THERMOSTAT ASSY OR JUMPER 608870 90R START/STOP SWITCH 49869 17A...
  • Page 53 DEVICE INTERCONNECTIONS BACK OF REVERSING SWITCH Figure 5 3. Operator Device Interconnections. 5 11...
  • Page 54 REAR SIDE SPEED POT REAR VIEW OF START/STOP SWITCH Figure 5 3. Operator Device Interconnections. (Continued) 5 12...
  • Page 55 Use this form to give us your comments concerning this publication or to report an error that you have found. For convenience, you may attach copies of the pages with your comments. After you have completed this form, please return it to: Reliance Electric Technical Documentation 24800 Tungsten Road Cleveland, Ohio 44117 Fax: 216.266.7785...
  • Page 56 / 24701 Euclid Avenue / Cleveland, Ohio 44117 / 216 266 7000 Printed in U.S.A. D2 3231 3 March, 1994...

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