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Reliance electric HR2000 Series, Installation, Operation And Maintenance Instructions

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Reliance electric HR2000 Series Installation, Operation And Maintenance Instructions Download Page 4

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Wire the Drive

3:13

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Check Input Power Requirements

3:13

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Provide Appropriate Grounding

3:15

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Make Power Wiring Connections

3:15

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Make Control and Signal Wiring Connections

3:16

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Set Regulator Dip Switches

3:21

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4:

Start and Adjust the Controller

4:1

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Gather Necessary Test Equipment

4:1

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Check the Installation

4:1

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Check the Wiring

4:1

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Initialize the Regulator

4:2

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Review the Controller Regulator Jumpers

4:5

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Notch Filter 1J

4:5

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Accel/Decel Ramp 2J

4:5

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Factory Setup 3J

4:5

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Review the Regulator Pots

4:5

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Start the Controller

4:7

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Perform Startup Procedure 1 with Motor Uncoupled

4:7

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Perform Startup Procedure 2 with Motor Coupled

4:10

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Perform Startup in Speed Regulator Mode

4:10

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Perform Startup in Torque Regulator Mode

4:13

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Perform Startup in Position Regulator Mode

4:14

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5:

Understand How the Controller Operates

5:1

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Fundamentals of the HR2000 Controller and the Motor

5:1

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Fundamentals of Controller’s Operator Controls

5:2

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Start/Stop Control

5:2

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Speed Setting Control

5:2

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Forward/Reverse Control

5:2

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Motor, Controller, Encoder Compatibility

5:2

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6:

Service the Motor

6:1

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Establish Regular Motor Maintenance Program

6:1

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Troubleshoot the Motor

6:1

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Perform Initial Motor Checks

6:1

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Disassemble the Motor

6:1

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Reassemble the Motor

6:2

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7:

Service the Controller

7:1

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Know Function of Service Aids

7:1

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Understand Controller LED Indicators

7:1

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Understand Controller Status Indicators

7:3

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Understand Controller Test Points

7:3

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Gather Necessary Test Equipment

7:3

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Perform General Troubleshooting Procedures

7:3

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Identify Fault Symptoms and Correct Using Flow Charts

7:4

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Power Unit Checks

7:10

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Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Summary of Contents for HR2000 Series

Page 1: ...service in house repair center WE BUY USED EQUIPMENT Sell your excess underutilized and idle used equipment We also offer credit for buy backs and trade ins www artisantg com WeBuyEquipment REMOTE IN...

Page 2: ...E THREE PHASE INPUT HR2000t HIGH PERFORMANCE CONTROLLER AND MOTOR 208 230 VAC 60 Hz Input 71 2 and 15 HP Instruction Manual D5 3031 4 December 1993 Artisan Technology Group Quality Instrumentation Gua...

Page 3: ...or Features 2 3 Standard Features 2 3 Drive Specifications 2 4 Ratings 2 4 Fuse Data 2 4 Torque and Inertia Data 2 4 Service Conditions 2 4 Application Data 2 4 Adjustments 2 4 Product Publications 2...

Page 4: ...tup in Position Regulator Mode 4 14 5 Understand How the Controller Operates 5 1 Fundamentals of the HR2000 Controller and the Motor 5 1 Fundamentals of Controller s Operator Controls 5 2 Start Stop C...

Page 5: ...e 3 13 2CN Connector Pin Configuration 3 18 Figure 3 14 3CN and Encoder Motor MS Connector Pin Configurations 3 20 Figure 4 1 INIT0 1SW DIP Switch Settings 4 3 Figure 4 2 INIT2 1SW DIP Switch Settings...

Page 6: ...Switch Descriptions 3 21 Table 4 1 Default Values of EEPROM Version J or Later 4 2 Table 4 2 Motor Encoder Characteristics for Initialization 4 2 Table 7 1 Red LED Functions and Possible Causes for F...

Page 7: ...The sales order number uniquely describes the controller manufactured to customer specifications The model number describes the controller as follows 3RA 2 0 HR2000 High Performance Controller Input...

Page 8: ...he Carrier guarantees safe delivery If considerable damage has been incurred and the situation is urgent contact the nearest Reliance Electric Sales Office for assistance File a Return Request 1 To re...

Page 9: ...injury if procedures are not followed A caution alerts a person that if procedures are not followed damage to or destruction of equipment could result Drive Components The drive consists of an HR2000...

Page 10: ...ut in test mode ACC Acceleration rate QF Notch filter Q factor Controller Regulator Switches TST Test mode SI Speed loop integral OP Accel Decel rate DIR Direction in Position mode DV Pulse divider MD...

Page 11: ...ine to line and line to ground output short circuit protection Line transient protection to minimize effects of power line transients Single board microprocessor based regulator for increased reliabil...

Page 12: ...ge A C line frequency 50 60 Hz 2 Hz Application Data Current Control Method Sinusoidal Service Factor 1 0 Displacement Power Factor 0 96 Maximum Load 150 for 20 seconds 200 for 10 seconds Speed Range...

Page 13: ...04 Foot C Face w Foot Foot C Face w Foot Torque in lbs Base Speed RPM lb in S2 270 540 1750 1750 0 0895 0 1641 See Figure 2 3 for 2500 RPM and 3000 RPM Curves See Figure 2 4 for 10 HP Torque and Inert...

Page 14: ...lb Base Speed RPM lb in S2 156 384 3000 2500 0 090 0 164 7 5 HP NOM RATING 840 384 0 CONTINUOUS OPERATING RANGE 2500 3200 NOM RATING SPEED IN RPM 3600 24 48 312 200 768 200 Inertia lb Ft2 234 44 Figur...

Page 15: ...RA2015 3RA2015 lb in 175 250 317 421 Nm 19 8 28 2 35 8 47 6 2000 2000 2000 2000 21 0 30 0 56 0 83 0 2 4 3 4 6 3 9 4 lb in A 7 0 7 9 7 6 8 2 Nm A 0 79 0 89 0 86 0 92 96 108 104 112 0 24 0 19 0 13 0 10...

Page 16: ...5 Phase to Phase 3RA2008 S 6200 3RA2015 S 8350 3RA2015 S 6300 3RA2015 S 8500 Figure 2 5 Servo Motor Torque Data Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg...

Page 17: ...sis controllers and 0oC to 40oC 32oF to 104oF for enclosed controllers 5 Check that relative humidity is between 5 and 95 noncondensing 6 Do not install above 3300 feet 1000 meters without derating Fo...

Page 18: ...3 2 Figure 3 1 Chassis Controller Dimensions and Weights Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Page 19: ...step up or step down input voltage and can be either autotransformers or isolation transformers Isolation transformers help eliminate Damaging A C line voltage transients from reaching the controller...

Page 20: ...BS 71 2 25 56 12 69 7 69 11 25 235 10 26 56 13 69 8 69 12 25 255 15 27 56 14 69 9 69 13 25 265 WT HP C B BS 2F LBS 71 2 25 31 12 69 7 69 11 25 235 10 26 31 13 69 8 69 12 25 255 15 27 31 14 69 9 69 13...

Page 21: ...3 5 Figure 3 2a S 6200 and S 6300 Motor Dimesions Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Page 22: ...3 6 Figure 3 2b S 8350 and S 8500 Motor Dimesions Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Page 23: ...2CN 32 OVI This power supply must source 40 mA maximum at 12 VDC Analog Input Signals Speed Torque Reference The controller accepts analog reference signals when operating as a speed or torque regulat...

Page 24: ...based on the motor encoder selection on 1SW 3 and 1SW 4 When using 2000 RPM motors with 2500 PPR encoders the signal will be 4 8 VDC at 2000 RPM at the OA output The polarity of the signal is either...

Page 25: ...for momentary run input It is similiar to a seal in contact but is not a physical contact See the Start Stop circuits shown in Figure 3 12 INHIBIT REFERENCE 16 This input FHC prevents the controller...

Page 26: ...lue determined by the PG pot POSITION Indicates that positioning is complete WARNING THIS DRIVE IS CAPABLE OF OPERATING AT AND MAINTAINING ZERO SPEED THE USER IS RE SPONSIBLE FOR ASSUR ING SAFE CONDIT...

Page 27: ...8 Refer to Figure 3 8 for single channel input signals When using either single or dual channel signal the pulse magnitude should be 3 5 to 8 0 volts and the input frequency should not exceed 750 KHz...

Page 28: ...32 V typ with a maximum of 50 volts at 20 mA load These signals are not isolated from signal common Channels A and B can be divided by 1 2 or 4 by using 2SW 7 and 2SW 8 switches See Figure 3 9 for a...

Page 29: ...el up on the hinge and swinging the panel to the right Locate the internal three position power terminal block in the non hinged part of the controller and reconnect the RED wire 230 VAC factory set J...

Page 30: ...3 14 Figure 3 11 Location of Typical Control Wiring and Startup Components Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Page 31: ...n damage to or destruction of this equipment 1 Size and select input and output power wire according to all applicable codes so that it is adequate for the voltages and currents to which it will be su...

Page 32: ...5 250 VAC THERMAL MAGNETIC C B MAGNETIC ONLY C B TRIP POS Westinghouse reference number is shown in 7 5 35 Amp 40 Amp 40 Amp 50 Amp A HMCP050G2 15 60 Amp 60 Amp 60 Amp 100 Amp A HMCP100L3 Make Control...

Page 33: ...res 3 13 and 3 14 to identify connector pin locations and Tables 3 2 and 3 3 for connector pin functions Note If optional motor encoder circuit box is provided use color code information shown in Tabl...

Page 34: ...3 18 Figure 3 13 2CN Connector Pin Configuration Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Page 35: ...ce 18 ZHC Inhibits Torque reference in Torque mode Locks motor shaft in Position Speed mode 19 25 0V Common for 12 V supply on pins 1 and 2 26 32 0VI Common for isolated 12 to 24 V supply on pin 10 33...

Page 36: ...tput PGZ 7 N Shield SH 8 H Channel U output PU 9 J Channel U output PU 10 K Channel V output PV 11 L Channel V output PV 12 M Channel W output PW 13 T Channel W output PW 14 P Spare Wire SP 15 E Sense...

Page 37: ...ng OFF PI 1SW 7 BBK 3 Disables the base driver and prevents the output transistors from firing use only during troubleshooting Enabling this switch will cause the BBK LED to illuminate ON DISABLE OFF...

Page 38: ...e the input disconnect is in the OFF position power OFF 2 Verify that motor nameplate data corresponds to the controller output ratings 3 Make sure that any motor thermal switch or overload device if...

Page 39: ...ed of 1750 RPM INIT selections are still valid The preferred INIT selections for 4 6 and 8 pole motors are listed in Table 4 1 If you are unsure of the motor s design either obtain the data from the n...

Page 40: ...re 4 1 INIT0 1SW DIP Switch Settings 3 3 Turn power ON for 10 seconds 3 4 Turn power OFF INIT0 procedure is now complete 3 5 Refer to Table 3 4 to set 1SW switches per your application requirements 3...

Page 41: ...for 6 pole motors only 5 1 Turn power OFF 5 2 Set 1SW DIP switches for INIT3 as shown in Figure 4 3 Figure 4 3 INIT3 1SW DIP Switch Settings 5 3 Turn power ON for 10 seconds 5 4 Turn power OFF INIT3...

Page 42: ...ymbol CL Function Maximum instantaneous current output Range See Figure 4 5B Factory Setting 3 8 V 200 of motor rating Symbol SG Function Speed loop gain Range 6 8 to 35 Factory Setting 6 8 Symbol SZ...

Page 43: ...Figure 4 4 Typical Notch Filter Wave Form 3500 4000 4500 1500 Figure 4 5 Curves Showing Ranges of Regulator Pots Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg...

Page 44: ...Follow all of the Check the Installation procedures if not already performed 2 Make sure all power is OFF The D C bus capacitors remain charged for at least one minute after power is removed Do not wo...

Page 45: ...4 8 Figure 4 6 Controller Switch and Pot Settings for Procedure 1 and Speed Mode Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Page 46: ...t 13 Check motor shaft rotation If the motor is not rotating slowly increase the Speed reference until the motor rotates If shaft rotation is correct proceed to Step 14 If shaft rotation is incorrect...

Page 47: ...The POWER ON and the RDY LEDs should illuminate 6 Place a digital voltmeter 20 VDC scale on 2CN pin connectors 8 and 23 COM Note This analog D C signal is proportional to speed 7 Adjust the SZ pot un...

Page 48: ...THE MO TOR TO ROTATE IN BOTH THE FORWARD AND RE VERSE DIRECTIONS MAKE SURE MECHANICAL EQUIP MENT IS CAPABLE OF SUCH OPERATION FAILURE TO OBSERVE THIS PRECAU TION COULD RESULT IN BODILY INJURY 20 Conne...

Page 49: ...4 12 Figure 4 7 Speed Feedback Signals Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Page 50: ...AUSE THE DRIVE TO OVERSPEED AT THE INITIAL STARTUP BE PREPARED TO STOP THE DRIVE IMMEDIATELY IF UN CONTROLLED ACCELERA TION SHOULD OCCUR FAILURE TO OBSERVE THIS PRECAUTION COULD RE SULT IN BODILY INJU...

Page 51: ...eters and any other instrumentation connected during startup 16 Close and secure the controller enclosure door if applicable Perform Startup in Position Regulator Mode WARNING THIS DRIVE IS CAPABLE OF...

Page 52: ...83 3 KHz input corresponds to 2000 RPM on this motor encoder combination 15 Give the controller a Start command 16 With the reference pulse frequency at 0 Hz quickly increase the reference to maximum...

Page 53: ...r J2 The output of the LVTU circuit feeds a summing amplifier which is also fed by a Test mode reference The tester pot is enabled when a dip switch accessed through the hinged panel faceplate is swit...

Page 54: ...motor rotation is determined by a reference polarity when the regulator is set for Speed or Torque modes When the controller is in Position mode motor rotation is determined by the logic level state o...

Page 55: ...3023 2 for encoder alignment Also a two channel oscilloscope can be used during slow turns of the motor shaft with the drive not in Run mode the power turned ON and the encoder connected Note The enc...

Page 56: ...5 4 SBD FBK Figure 5 3 Typical Functional Block Diagram Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Page 57: ...f the insulation When these measurements indicate a wide variation determine the cause 5 Recondition the motor if it has been subjected to excessive moisture rewind or reinsulate as necessary High hor...

Page 58: ...ition on the frame so it can be easily replaced 9 Remove any bearing clamp screws 10 Remove the end shield through bolts 11 Pull the end shields Remove and Replace Ball Bearings 12 Thoroughly clean an...

Page 59: ...itiating an appropriate and orderly drive shutdown The other two red LEDs BBK and SZ indicate a status condition The controller will not operate when the BBK LED is illuminated though will operate wit...

Page 60: ...Over load Output motor current exceeded allowable overload as adjusted by OL pot Motor s RMS load greater than continuous motor rating UV Undervoltage D C snubber resistor shorted Input voltage less t...

Page 61: ...onnector 2CN pin 45 V and any unused connector 2CN pin from 26 32 0VI Understand Controller Test Points 1 The controller has 6 test points and a common on the regulator that are accessible through the...

Page 62: ...or enclosed controllers 10 Check that all pots dip switches and jumpers are in the correct position for the application 11 Check that external sequencing logic is wired properly to the controller thro...

Page 63: ...7 5 Figure 7 1 Motor Will Not Run Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Page 64: ...7 6 Figure 7 2 Motor Runs at Uncontrolled Speed Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Page 65: ...7 7 Figure 7 3 Motor Rotation is Unstable Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Page 66: ...7 8 Figure 7 4 Acceleration Deceleration is Not Smooth Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Page 67: ...7 9 Figure 7 5 Heavy Vibration Results When Motor Stops Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Page 68: ...tter using the terminals defined in Table 7 2 4 Connect the positive lead determined in Step 2 to the terminal indicated in Table 7 2 Connect the negative lead to the terminal indicated in Table 7 2 R...

Page 69: ...KS ARE MADE WITH INPUT VOLTAGE APPLIED TO THE CONTROLLER EXERCISE EXTREME CARE BECAUSE HAZARDOUS VOLTAGE EX ISTS FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE...

Page 70: ...R 11R 1 2 63481 75QFW 50 Ohm 63481 75QDJ 25 Ohm Precharge Relay 7 1 2 15 HP 1 705310 51B D C Bus Resistor 2R 12R 7 1 2 HP 15 HP 2 2 63481 31T 2500 Ohm 63481 31S 1750 Ohm Cooling Fan 7 1 2 15 HP 1 6973...

Page 71: ...4RC033 4RC053 4RC103 4RC151 4RC251 4RC501 4RC001 4RC152 4RC252 4RC502 4RC002 D5 3026 D5 3026 D5 3026 D5 3026 D5 3026 D5 3026 D5 3024 D5 3024 D5 3024 D5 3024 D5 3024 D5 3024 D5 3024 D5 3024 Circuit Br...

Page 72: ...7 14 Figure 7 9 Typical Wiring Diagram Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Page 73: ...7 15 SBD FBK Figure 7 10 Typical Functional Block Diagram Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Page 74: ...7 16 100C 18R 33 2K Figure 7 11 Typical Regulator Board Component Layout Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Page 75: ...LEDs 7 1 Controller Regulator Jumpers 2 2 Pots 2 2 Switches 2 2 Controller Regulator Adjustments 3 21 4 1 to 4 6 Jumpers 4 5 Pots 4 5 to 4 6 Switches 3 21 Controller Status Indicators 7 3 Fault Conta...

Page 76: ...ontroller 3 1 to 3 3 Drive 3 1 to 3 21 Input Disconnect 3 3 Motor 3 3 Transformer 3 3 LED Functions 7 2 Logic Input Signals 3 9 Logic Output Signals 3 10 Maintenance Regular Program 6 1 Model Number C...

Page 77: ...7 to 4 9 Startup Procedure 2 with Motor Coupled 4 10 Perform Startup in Position Regulator Mode 4 14 to 4 15 Perform Startup in Speed Regulator Mode 4 10 to 4 12 Perform Startup in Torque Regulator Mo...

Page 78: ...Reliance Electric 24701 Euclid Avenue Cleveland Ohio 44117 216 266 7000 D5 3031 4 Printed in U S A 1293 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Page 79: ...service in house repair center WE BUY USED EQUIPMENT Sell your excess underutilized and idle used equipment We also offer credit for buy backs and trade ins www artisantg com WeBuyEquipment REMOTE IN...

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