Eaton Cutler-Hammer TRU-START Operation And Installation Manual Download Page 3

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1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1.2 APPLICATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1.3 CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1.3.1 CA398-3 LOGIC

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1.3.2 CA398-3 REGULATION

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2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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2.1 POWER RATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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2.2 CURRENT AND FUSE RATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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2.2.1 NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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2.3 SERVICE CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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2.4 DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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2.5 SCR INSTALLATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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2.5.1 SCR TIGHTENING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3 CARD FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3.1 CARD LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3.2 LED AND NEON INDICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3.3 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3.3.1 POTENTIOMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3.3.2 LINK SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3.3.3 PUSHBUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3.4 TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3.4.1 CUSTOMER TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3.4.2 TERMINALS FOR INTERNAL USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3.5 FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3.5.1 PHASE LOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3.5.2 INSTANTANEOUS OVER CURRENT (IOC) . . . . . . . . . . . . . . . . . . . . . . . . . .

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TABLE OF CONTENTS

Summary of Contents for Cutler-Hammer TRU-START

Page 1: ...r engineering services call 1 800 498 2678 or visit www cutler hammer ca Eaton Corporation is a global 7 3 billion diversified industrial manufacturer that is a leader in fluid power systems electrical power quality distribution and control automotive engine air management and fuel economy and intelligent truck systems for fuel economyand safety Eaton has 48 000 employees and sells products in mor...

Page 2: ...epresentations included in this manual are for typical installations and should not in any way be considered for specific applications or modifications Consult Cutler Hammer for supplemental instructions Cutler Hammer Canada accepts no liability for any consequences resulting from inappropriate negligent or incorrect installation application or adjustment of this equipment The contents of this man...

Page 3: ...MENSIONS PAGE 6 2 5 SCR INSTALLATION SPECIFICATIONS PAGE 7 2 5 1 SCR TIGHTENING PROCEDURE PAGE 7 3 CARD FUNCTIONS PAGE 9 3 1 CARD LAYOUT PAGE 9 3 2 LED AND NEON INDICATIONS PAGE 9 3 3 ADJUSTMENTS PAGE 10 3 3 1 POTENTIOMETERS PAGE 10 3 3 2 LINK SELECTION PAGE 10 3 3 3 PUSHBUTTON PAGE 10 3 4 TERMINALS PAGE 11 3 4 1 CUSTOMER TERMINALS PAGE 11 3 4 2 TERMINALS FOR INTERNAL USE PAGE 11 3 5 FAULTS PAGE 1...

Page 4: ...EFORE POWER UP PAGE 14 4 5 2 WITH POWER ON PAGE 15 5 TYPICAL CONNECTIONS PAGE 17 5 1 STAND ALONE DC INJECTION UNIT WITH ZERO SPEED DISABLE PAGE 17 5 2 TRU START STARTER WITH DC INJECTION PAGE 18 5 3 REVERSING TRU START STARTER WITH DC INJECTION 125 AMPS AND BELOW PAGE 19 5 4 REVERSING TRU START STARTER WITH DC INJECTION 200 AMPS AND ABOVE PAGE 20 6 SPARE PARTS PAGE 21 TABLE OF CONTENTS ...

Page 5: ...actors are required The unit adapts itself to any input voltage between 200 and 600 VAC with no adjustments required Efficient Power Circuit The power circuit is an efficient four Silicon Controlled Rectifier SCR configuration which uses some of the SCR s as a free wheeling diode thus maximizing the DC current through the motor coils generated by the AC input current With every benefit there is us...

Page 6: ...s not recommended for continuous or repetitive operation The kinetic energy of the mechanical system is transformed into heat during braking energy conservation That heat is dissipated in the rotor of the motor On wound rotor motors the external rotor resistance will absorb most of the energy On squirrel cage motors overheating of the motor is a real danger if frequent operation is used Keeping DC...

Page 7: ... when an instantaneous over current is detected The IOC fault is detected and latched until the Reset switch is pressed A form C relay contact is available to interlock the brake unit from the motor starter The starter cannot be energized while DC current is being applied to the motor or during a fault condition 1 3 2 CA398 3 REGULATION The brake module operates in current control at all times The...

Page 8: ...PAGE 4 ...

Page 9: ... 125 Module TRU 200 DCI 200 200 150 200 Disc TRU 300 DCI 300 300 250 300 Disc TRU 500 DCI 500 500 400 500 Disc 2 2 1 NOTES 2 2 1 1 The HP listing is for reference only For proper selection use the current rating 2 2 1 2 The fuses recommended are Class J time delay type This fuse is being suggested even though it may not protect the SCR in an output shorted condition while braking It will protect t...

Page 10: ...cm 22cm 18cm 16 8 5 6 16 8 5 7 TRU 040 DCI 43cm 27cm 19cm 43cm 30cm 27cm 17 10 5 7 5 17 12 10 5 TRU 080 DCI 43cm 27cm 22cm 43cm 30cm 27cm 17 10 5 8 17 12 10 5 TRU 125 DCI 53cm 27cm 24cm 53cm 30cm 27cm 21 10 5 8 5 21 12 10 5 TRU 200 DCI 28cm 33cm 27cm 61cm 61cm 30cm 11 13 10 5 24 24 12 TRU 300 DCI 42cm 37cm 28cm 76cm 61cm 30cm 16 5 14 5 11 30 24 12 TRU 500 DCI 45cm 42cm 36cm 76cm 61cm 30cm 17 5 16 ...

Page 11: ...rity 2 5 1 4 Install SCR so that roll pins engage dimples on both sides of the SCR 2 5 1 5 Tighten clamp bolts evenly until finger tight 2 5 1 6 Tighten each bolt according to table below based on number of spring bars and size of bars Note SMALL clamps are 4 25 inches 10 5 cm and LARGE clamps are 5 inches 12 5 cm CLAMP SIZE SPRING BARS BOLT TURNS PAST FINGER TIGHT SMALL 1 0 8 SMALL 2 1 LARGE 3 1 ...

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Page 13: ...NDICATIONS LED NAME COLOUR DESCRIPTION LD 1 DC INJCT RED On when unit is braking LD 2 PWR GREEN Must be On when 115 VAC is applied LD 3 IOC RED Instantaneous Over Current fault indication when illuminated NE1 PHASE OK ORANGE Phase loss indication when neon not glowing PAGE 9 C H ...

Page 14: ...decreased to 30 of the line voltage HI Braking action starts when motor starter has opened and the motor terminal voltage has decreased to 80 of the line voltage See important notes below HI setting is only used when the stopping time is critical and must be around 1 2 seconds For this application 300 DC current is not adequate Consult factory before using this jumper position When the DC Injectio...

Page 15: ...t exists 6 Normally open DCI relay auxiliary contact 7 Normally closed DCI relay auxiliary contact R7 1 2 Burden resistor terminals for calibration of DC injection current See table in Section 4 4 3 4 2 TERMINALS FOR INTERNAL USE TERMINAL NO DESCRIPTION J1 24V COM This terminal is used by C H as a 24V input to provide battery back up for DC injection in case of power loss J3 1 2 CURRENT FBK From c...

Page 16: ...vent the use of the starter The faults are explained below 3 5 1 PHASE LOSS If the single phase power 200 600V to L1 and L2 terminals is not present NE1 will be off and the DCI relay de energized When this condition is corrected the unit will allow the starter to be energized 3 5 2 INSTANTANEOUS OVER CURRENT IOC If the current feedback exceeds 1000 of the current setup by the burden resistor Rb th...

Page 17: ... result in damage to disconnecting device and or bodily injury The electrical code requires all equipment starter motor operator station brake etc to be grounded properly An incoming circuit breaker or disconnect switch must be locked open before wiring and servicing this electrical brake motor or other related equipment This equipment must be installed and serviced only by qualified personnel fam...

Page 18: ...ons are properly tightened The most important connection is the interlock between the DC Injection unit and the starter 4 5 1 2 Ensure that the burden resistor is equal or larger than the value listed in the following table or calculated by the following equation Rb Effective Current Transformer Ratio Motor Nameplate Amps 4 5 1 3 Set JP1 link to LO 4 5 1 4 Adjust RV2 braking torque and RV1 braking...

Page 19: ...nd the starter off If the motor reaches zero speed from the DC injection cycle close the switch to the Disable Input to disable the braking 4 5 2 2 Re adjust the braking torque pot RV2 if the actual braking time has to be increased or decreased to bring the motor to zero speed 4 5 2 3 Once the braking torque is set then adjust RV1 to match the DC injection time with the actual stopping time of the...

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Page 21: ...5 TYPICAL CONNECTIONS 5 1 STAND ALONE DC INJECTION UNIT WITH ZERO SPEED DISABLE PAGE 17 ...

Page 22: ...5 2 TRU START STARTER WITH DC INJECTION PAGE 18 ...

Page 23: ...5 3 REVERSING TRU START STARTER WITH DC INJECTION 125 AMPS AND BELOW PAGE 19 ...

Page 24: ...5 4 REVERSING TRU START STARTER WITH DC INJECTION 200 AMPS AND ABOVE PAGE 20 ...

Page 25: ...0SP03 CA524 CA398 3 TRU 040 DCI 1500 1 T261123 N10SP06 CA524 CA398 3 TRU 080 DCI 2500 1 T262230 N10SP16 CA524 CA398 3 TRU 125 DCI 2500 1 T262230 N20SP06 CA524 CA398 3 TRU 200 DCI 2500 1 T262230 N728452 CA232 CA398 3 TRU 300 DCI 5000 1 T265320 N718602 CA232 CA398 3 TRU 500 DCI 8500 1 T268320 N718133 CA232 CA398 3 PAGE 21 ...

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Page 27: ...78 for engineering services call 1 800 498 2678 or visit www cutler hammer ca Eaton Corporation is a global 7 3 billion diversified industrial manufacturer that is a leader in fluid power systems electrical power quality distribution and control automotive engine air management and fuel economy and intelligent truck systems for fuel economyand safety Eaton has 48 000 employees and sells products i...

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