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29

DC Permanent Magnet Motor Dynamic Braking Theory

In operation, a permanent magnet (PM) field DC motor has the
armature connected to its DC power supply. The interaction of the
magnetic field created by the field and the current flowing in the
armature winding causes the motor to run. A voltage called the
counter electromotive force (CEMF) is generated in the armature
conductors, when rotated in a magnetic field.

When the motor is running, the CEMF opposes the power supply
voltage and limits the armature current to a sufficient value to supply
adequate output shaft torque. Braking is accomplished by
disconnecting the armature from the DC power and shorting the
armature leads with a current limiting resistor. As soon as this is
done, the armature and its driven load will begin to stop.

Dynamic Braking

250-0021r5_readers.qxd  7/11/01  9:18 AM  Page 29

Summary of Contents for SL10U

Page 1: ...User s Manual SL10U Adjustable Speed Control for Hurst Permanent Magnet 90 VDC Motors 250 0021r5_readers qxd 7 11 01 9 18 AM Page i ...

Page 2: ...Corporation and its Divisions make no warranty of any kind with respect to this material including but not limited to the implied warranties of its merchantability and fitness for a given purpose Minarik Corporation and its Divisions assume no responsibility for any errors that may appear in this manual and make no commitment to update or to keep current the information in this manual Printed in t...

Page 3: ... and service this equipment Follow the National Electrical Code and all other applicable electrical and safety codes including the provisions of the Occupational Safety and Health Act OSHA when installing equipment Reduce the chance of an electrical fire shock or explosion by proper grounding over current protection thermal protection and enclosure Follow sound maintenance procedures i 250 0021r5_...

Page 4: ...tion Notes 14 Speed Adjustment 15 Adjustable Maximum Speed 16 Multiple Fixed Speeds 17 Adjustable Speeds in Two or More Non Overlapping Speed Ranges 18 Multiple Full Range Adjustable Speeds 19 Independent Forward and Reverse Speeds 20 External Signal Control 21 Simultaneous Speed Control of Multiple Systems 22 Run Stop Circuits 23 Run Stop Using Normally Closed Contacts 23 250 0021r5_readers qxd 7...

Page 5: ...namic Braking using a Toggle Switch 32 Run Stop Dynamic Braking using a Relay 33 Reversing with Dynamic Braking Circuits 35 Reversing with Dynamic Braking using a Rotary Switch 35 Reversing with Dynamic Braking using Relays 37 Limit Switch Circuits 39 Toggle Switch Reversing with Limit Switches 40 Relay Reversing with Dynamic Braking and Limit Switches 42 Troubleshooting 45 Parts List 49 Unconditi...

Page 6: ...eed Control of Multiple Systems 22 Figure 11 Run Stop Using Normally Closed Contacts 23 Figure 12 Run Stop Using Normally Open Contacts 24 Figure 13 Reversing with Toggle Switch 26 Figure 14 Reversing with Relays 28 Figure 15 Run Stop Dynamic Braking with Toggle Switch 32 Figure 16 Run Stop Dynamic Braking using a Relay 34 Figure 17 Rotary Switch Reversing with Dynamic Braking 36 Figure 18 Reversi...

Page 7: ...oke capacitor filtering to ensure quiet smooth and cool running In a typical application 2 base speed regulation is provided with the help of temperature line voltage and IR compensation The control has a speed range of 15 1 also has adjustable IR compensation and a maximum speed adjustment to limit high speed operation 1 General Information 250 0021r5_readers qxd 7 11 01 9 18 AM Page 1 ...

Page 8: ...tering Temperature Compensation 2 Base Speed Regulation Typical Application Maximum Speed Adjustment Adjustable IR Compensation Line Starting and Stopping Line Voltage Compensation Full Wave Armature Supply 250 0021r5_readers qxd 7 11 01 9 18 AM Page 2 ...

Page 9: ... Maximum Input Current 0 12 Amperes Output Armature Voltage 0 90 VDC Output Armature Current 0 07 Amperes Horsepower Range 1 250 1 50 Weight 8 0 Ounces Ambient Temperature Range 10 40 C Specifications 250 0021r5_readers qxd 7 11 01 9 18 AM Page 3 ...

Page 10: ...4 Dimensional Data Figure 1 Dimensions ALL DIMENSIONS IN INCHES MILLIMETERS 250 0021r5_readers qxd 7 11 01 9 18 AM Page 4 ...

Page 11: ...5 Figure 2 SL10U Connections PL1 CW 250 0021r5_readers qxd 7 11 01 9 18 AM Page 5 ...

Page 12: ...he locknut Mount the chassis to appropriate subplates using the four threaded 6 32 mounting stand offs refer to figure 1 on page 4 for mounting dimensions The chassis has adequate heat sinking to properly dissipate the load generated heat and can be either vertically or horizontally mounted Installation The SL10U is not isolated from earth ground Unless an isolation transformer is used circuit com...

Page 13: ...wires These 3 wires should NOT be bundled with the motor and power line leads because induced voltages could cause erratic operation If the speed adjust pot requires wiring longer than 18 inches 0 5m a shielded cable must be used Do not ground both ends of the shield 2 Connect the motor to its appropriate wires If the motor rotates in the wrong direction remove line voltage and reverse the motor a...

Page 14: ...ing is desired see Dynamic Braking on page 29 Minarik strongly recommends the installation of an emergency stop switch as shown in Figure 2 page 5 The switch must be rated at a minimum of 250 VAC and 150 of the maximum motor armature rating Alternative Wiring By utilizing additional components the SL10U may be operated by external signal control have multiple preset speeds dynamic braking limit sw...

Page 15: ... Dangerous voltages exist on the printed circuit board Contact with components and or printed circuitry could cause serious injury or fatality Please refer to the Safety Warnings on page i Warning Maximum Speed and Regulation IR COMP Adjustment Two potentiometers located on the control PC board are provided for adjustment of the maximum motor speed and regulation of the motor s speed Calibration 2...

Page 16: ...etween 85 to 115 of motor name plate rated speed when the speed adjust knob is set at maximum REGULATION IR COMPENSATION Regulation is obtained by circuitry which raises the armature voltage to maintain speed when increased loading tends to slow the motor down 250 0021r5_readers qxd 7 11 01 9 18 AM Page 10 ...

Page 17: ...f the control has been repaired or if you want to make any changes then follow the procedure listed below 1 Disconnect the power line 2 Set the speed adjust knob to 0 full CCW 3 Set the MAXIMUM SPEED trim pot to full CCW refer to Figure 3 on page 13 4 Set the REGULATION trim pot to full CCW refer to Figure 3 on page 13 5 Read and follow the SAFETY WARNING on page i 6 With no load on the motor appl...

Page 18: ...7 Adjust the MAXIMUM SPEED trim pot for motor base speed at no load 8 Load the motor to full load and adjust the REGULATION trimpot to obtain the same speed as at no load 250 0021r5_readers qxd 7 11 01 9 18 AM Page 12 ...

Page 19: ...13 Calibration Figure 3 Maximum Speed and Regulation Trimpot Locations MAXIMUM SPEED REGULATION IR COMP 250 0021r5_readers qxd 7 11 01 9 18 AM Page 13 ...

Page 20: ...or the use of any circuitry described and makes no representation that they are free from patent infringement Application Notes The components shown in the following circuitry should only be connected by qualified electrical personnel familiar with the construction operation and hazards of all the components used Personal injury and or equipment damage may occur if components are improperly connec...

Page 21: ... path must be maintained between the gray and violet leads b Any replacement resistors or potentiometers must be capable of carrying 10 milliamps c The three speed adjust circuit leads brown gray and violet should NOT be bundled with the motor or power line leads d If the length of the three speed adjust circuit leads exceeds 18 inches 0 5m then a shielded cable must be used Do not ground both end...

Page 22: ...usly variable or a fixed maximum speed see Figure 4 below This is useful in applications where a fast return to the home position is desired after certain operations have been accomplished at slower adjustable speeds Adjustable Maximum Speed Figure 4 Adjustable Fixed Speeds 250 0021r5_readers qxd 7 11 01 9 18 AM Page 16 ...

Page 23: ...rect number of positions for the desired number of fixed speeds and the same number of resistors with a total series resistance of 10K Ohms to replace speed adjust pot P1 See Figure 5 below Multiple Fixed Speeds Figure 5 Multiple Fixed Speeds 250 0021r5_readers qxd 7 11 01 9 18 AM Page 17 ...

Page 24: ...total series resistance must be 10K Ohms and a multi position switch Illustrated is a connection diagram for two speed control with high and low speed adjust pots See Figure 6 below Adjustable Speeds in Two or More Non Overlapping Speed Ranges Figure 6 Two Non Overlapping Speed Ranges 250 0021r5_readers qxd 7 11 01 9 18 AM Page 18 ...

Page 25: ...adjust pot P1 with two or more potentiometers connected in parallel total parallel resistance must be 10K Ohms and a multi position switch Illustrated is a connection diagram for two full range adjustable speeds See Figure 7 Multiple Full Range Adjustable Speeds 250 0021r5_readers qxd 7 11 01 9 18 AM Page 19 ...

Page 26: ...h two 20K Ohm potentiometers connected in parallel equals 10 Ohms with a SPDT switch and a DPDT switch to select operating station See Figure 8 below Independent Forward and Reverse Speeds Figure 8 Independent Forward and Reverse Speeds 250 0021r5_readers qxd 7 11 01 9 18 AM Page 20 ...

Page 27: ...ccomplished by wiring a 1K ohm resistor in series with the speed adjust pot wiper and applying the DC voltage across the resistor Use the speed adjust pot to set the motor s minimum speed If only a grounded signal is available use a Minarik PCM4 Process Control Module to convert the signal to ungrounded floating External Signal Control 250 0021r5_readers qxd 7 11 01 9 18 AM Page 21 ...

Page 28: ...Systems Multiple drives can be controlled with a single speed adjust potentiometer using a PCM4 at the input of each drive to provide isolation Figure 10 Optional ratio potentiometers can be used to scale the PCM4 output voltage allowing independent control of each drive 250 0021r5_readers qxd 7 11 01 9 18 AM Page 22 ...

Page 29: ...oast to a stop This method is desirable when dynamic braking is not needed but frequent starts and stops are required This method also has the advantage of not having to switch the AC power line or the DC armature line See Figure 11 Run Stop Using Normally Closed Contacts Figure 11 Run Stop Using Normally Closed Contacts Run Stop Circuits 250 0021r5_readers qxd 7 11 01 9 18 AM Page 23 ...

Page 30: ... closed the motor will coast to a stop This method is desirable when dynamic braking is not needed but frequent starts and stops are required This method also has the advantage of not having to switch the AC power line or the DC armature line See Figure 12 Run Stop Using Normally Open Contacts Figure 12 Run Stop Using Normally Open Contacts 250 0021r5_readers qxd 7 11 01 9 18 AM Page 24 ...

Page 31: ...re reversing will cause excessively high currents to flow in the armature circuit which can damage the control and or motor and is not recommended If rapid reversing is required use one of the dynamic braking circuits listed in this manual Warning 250 0021r5_readers qxd 7 11 01 9 18 AM Page 25 ...

Page 32: ...pped When the switch is actuated in one direction the motor will run forward The motor will coast to a stop when the switch is placed in the STOP position When the switch is actuated in the other direction the motor will run in reverse See Figure 13 Reversing with a Toggle or Rotary Switch Figure 13 Reversing with Toggle Switch 250 0021r5_readers qxd 7 11 01 9 18 AM Page 26 ...

Page 33: ...to be located remotely from the control low voltage relay coils are used In operation power is applied to the SL10U control and the appropriate voltage to L1 and L2 When PB1 is actuated the motor will run forward When PB2 is actuated the motor will stop When PB3 is actuated the motor will run in reverse When the motor is running a change in direction is not possible without actuating PB2 STOP firs...

Page 34: ...28 Reversing Circuits Figure 14 Reversing with Relays PL1 250 0021r5_readers qxd 7 11 01 9 18 AM Page 28 ...

Page 35: ...ive force CEMF is generated in the armature conductors when rotated in a magnetic field When the motor is running the CEMF opposes the power supply voltage and limits the armature current to a sufficient value to supply adequate output shaft torque Braking is accomplished by disconnecting the armature from the DC power and shorting the armature leads with a current limiting resistor As soon as thi...

Page 36: ...verse itself the speed will be rapidly reduced from the original direction As the speed decreases so does the CEMF When the motor reaches zero speed the CEMF is also zero and the motor has been dynamically braked to a stop The speed of braking is controlled by the braking current limiting resistor s resistance The lower the resistance the greater the current flow And since the reversing current or...

Page 37: ...namic braking is only for fast stopping and NOT for holding a load IMPORTANT For motors rated 1 17 horsepower and lower a brake resistor is not necessary since the armature resistance is high enough to stop the motor without demagnetization Replace the dynamic brake resistor with 12 gauge wire Dynamic Braking Circuit Cautions Gearmotor Caution 250 0021r5_readers qxd 7 11 01 9 18 AM Page 31 ...

Page 38: ...er is applied to the control When the toggle switch is set to RUN the motor starts running When the toggle switch is set to BRAKE the motor is dynamically braked to a stop See Figure 15 Run Stop with Dynamic Braking using a Toggle Switch Figure 15 Run Stop Dynamic Braking with Toggle Switch 250 0021r5_readers qxd 7 11 01 9 18 AM Page 32 ...

Page 39: ...d STOP pushbuttons are to be located remotely from the control a low voltage relay coil is used In operation power is applied to the SL15U control and the appropriate voltage to L1 and L2 When PB1 is actuated the motor will run and when PB2 is actuated the motor will dynamically brake to a stop See Figure 16 page 34 Run Stop Dynamic Braking using a Relay Dynamic Braking 250 0021r5_readers qxd 7 11...

Page 40: ...34 Figure 16 Run Stop Dynamic Braking using a Relay Dynamic Braking 250 0021r5_readers qxd 7 11 01 9 18 AM Page 34 ...

Page 41: ...ed to FORWARD the motor starts running in one direction When the rotary switch is switched to BRAKE the motor is dynamically braked to a stop When the rotary switch is switched to REVERSE the motor starts running in the opposite direction See Figure 17 page 36 Reversing with Dynamic Braking using a Rotary Switch Reversing with Dynamic Braking Circuits 250 0021r5_readers qxd 7 11 01 9 18 AM Page 35...

Page 42: ...36 Figure 17 Rotary Switch Reversing with Dynamic Braking Reversing with Dynamic Braking Circuits 250 0021r5_readers qxd 7 11 01 9 18 AM Page 36 ...

Page 43: ...ons are to be located remotely from the control low voltage relay coils are used In operation power is applied to the SL15U control and the appropriate voltage to L1 and L2 When PB2 is actuated the motor will dynamically brake to a stop When PB3 is actuated the motor will run in reverse When the motor is running a change in direction is not possible without actuating PB2 BRAKE first See Figure 18 ...

Page 44: ...38 Reversing with Dynamic Braking Circuits Figure 18 Reversing with Dynamic Braking using Relays 250 0021r5_readers qxd 7 11 01 9 18 AM Page 38 ...

Page 45: ...t switches or allow limit switches to deactivate Care must be taken when using dynamic braking with gearmotors connected to inertial type loads Forces can be developed which may be destructive to the gearing IMPORTANT Dynamic braking is only for fast stopping and NOT for holding a load Warning 250 0021r5_readers qxd 7 11 01 9 18 AM Page 39 ...

Page 46: ...sition the motor is STOPPED When the toggle switch is actuated in one direction the motor runs forward until the limit switch is actuated and the motor stops When the toggle switch is actuated in the other direction the motor will run in reverse until the limit switch is actuated and the motor stops See Figure 19 Toggle Switch Reversing with Limit Switches 250 0021r5_readers qxd 7 11 01 9 18 AM Pa...

Page 47: ...41 Figure 19 Toggle Switch Reversing with Limit Switches Limit Switch Circuits 250 0021r5_readers qxd 7 11 01 9 18 AM Page 41 ...

Page 48: ... two normally closed limit switches and a 12 AWG jumper wire in place of a dynamic braking resistor L1 and L2 supply power to the relay holding circuitry Normally if the FORWARD BRAKE and REVERSE pushbuttons are to be located remotely from the control low voltage relay coils are used Relay Reversing with Dynamic Braking and Limit Switches 250 0021r5_readers qxd 7 11 01 9 18 AM Page 42 ...

Page 49: ...ill run in reverse until the other limit switch is actuated and the motor dynamically brakes to a stop When PB2 is actuated the motor will dynamically brake to a stop When the motor is running a change in direction is not possible without actuating PB2 BRAKE first If dynamic braking is not desired eliminate the jumper wire Refer to Figure 20 page 44 for an illustration of relay reversing with dyna...

Page 50: ...44 Limit Switch Circuits Figure 20 Relay Reversing Braking with Limit Switches 250 0021r5_readers qxd 7 11 01 9 18 AM Page 44 ...

Page 51: ...line is the same voltage as that listed on the control nameplate Check to see that the line fuse is of the same value as shown on the control nameplate I Read and follow the SAFETY WARNING on page i Troubleshooting 250 0021r5_readers qxd 7 11 01 9 18 AM Page 45 ...

Page 52: ...ollowing A Transient suppressor DAS may be shorted B One or more of the diodes D2 D3 D4 or D5 may be shorted 1 Disconnect the motor from the control 2 Across each of the diodes resistance should read high in one direction and low in the opposite direction C Motor cable may be shorted or grounded 250 0021r5_readers qxd 7 11 01 9 18 AM Page 46 ...

Page 53: ...he motor c Apply power Motor should run at full speed without blowing the fuse 2 Motor armature may be shorted or grounded Disconnect the motor cable An ohmmeter reading on the motor cable armature connections should read approximately 380 ohms A reading from either side of the armature connections to the motor frame should show open use high ohm scale 3 The filter capacitor C4 may be shorted Trou...

Page 54: ...will not run 1 The speed control potentiometer P1 may be open 2 The rectifier SCR may be defective 3 A Transistor Q1 Q2 or Q3 may be defective 4 The filter choke X1 may be open 5 The zener diode Z1 may be shorted IV If the motor runs at high speed regardless of the speed control potentiometer setting A The rectifier SCR may be shorted B A transistor Q2 or Q3 may be shorted 250 0021r5_readers qxd 7...

Page 55: ... AMP 600 VDC SILICON DIODE D3 D5 071 0007 3 AMP 600 VDC SILICON DIODE DAS 075 0002 TRANSIENT SUPPRESSOR P1 120 0006 10K OHM 5 WATT POT P2 121 0023 25K OHM 1 4 WATT POT P3 121 0002 100 OHM 1 4 WATT POT PL1 164 0056 11 TERMINAL CONNECTOR FEMALE Q1 070 0009 D5E44 OR 2N5354 Q2 070 0010 2N3638 OR 2N5354 Q3 070 0011 2N2923 Parts List Troubleshooting 250 0021r5_readers qxd 7 11 01 9 18 AM Page 49 ...

Page 56: ...2 WATT R8 R9 031 0047 33K OHM 1 2 WATT R10 R11 031 0032 820 OHM 1 2 WATT R12 031 0046 27K OHM 1 2 WATT R13 031 0012 47 OHM 1 2 WATT R14 032 0020 10 OHM 5 WATT SO1 164 0054 9 TERMINAL CONNECTOR MALE SCR 072 0024 8 AMP 400 VOLT SCR TH 033 0002 3K OHM THEMISTOR X1 240 0004 MINARIK CHOKE Z1 071 0002 1N4747 ZENER DIODE Troubleshooting 250 0021r5_readers qxd 7 11 01 9 18 AM Page 50 ...

Page 57: ...NOTES 250 0021r5_readers qxd 7 11 01 9 18 AM Page 51 ...

Page 58: ...Notes 250 0021r5_readers qxd 7 11 01 9 18 AM Page 52 ...

Page 59: ...lity In the event of any claim for breach of any of the Corporation s obligations whether express or implied and particularly of any other claim or breech of warranty contained in Paragraph A or of any other warranties express or implied or claim of liability that might despite Paragraph B be decided against the Corporation by lawful authority the Corporation shall under no circumstances be liable...

Page 60: ...91201 2011 Tel 800 MINARIK or 800 646 2745 Fax 800 394 6334 www minarikcorp com Document Number 250 0021 Revision 5 Printed in the U S A 6 01 North America 10 00 Outside North America 11 00 250 0021r5_readers qxd 7 11 01 9 18 AM Page 54 ...

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