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28 

 

Recommended Amount of Grease (Oz.) 

Table 6-3 

 

Model No. 

Output 

Standard Ball 

Bearing 

Output 

Spherical 

Bearing 

DCD-132 

1.4 

N/A 

DCD-160 

2.0 

N/A 

DCD-180 

2.7 

N/A 

 

Insulation Testing 

After long time storage and once each year, for preventive 

maintenance, insulation resistance of the motor stator, 

clutch coil and brake coil (if used) should be tested and 

data recorded. Decreasing megohm readings indicate 

that insulation has become wet or is starting to fail. Use 

the recorded readings as a reference for the latest 

reading. Use a 500-volt hand cranked megger, cranking 

at full speed, until a good, stable reading is obtained. 

Follow the instructions supplied with the megger. 

A minimum reading of 2 megohms is acceptable for 

motors with input of 575 volts or less, and 200,000 ohms 

for clutch and brake coils. Whenever lower megohm 

readings are found, an authorized service shop or the 

Field Service Department at Sturtevant, Wisconsin should 

be consulted. 

 

Motors and coils that have become wet due to water spray 

or condensation should be dried out before applying 

power or subjected to an insulation test.  Consult the 

factory or one of the authorized service shops for 

assistance to dry out a unit. 

 

Troubleshooting 

The possibility of a component failure or other problem 

always exists. This section of the manual is intended to 

provide assistance in finding the fault. Check the obvious 

first; then follow the Troubleshooting Guide, Table 6-4. 

 

 

Troubleshooting Guide 

Table 6-4 

PROBLEM 

POSSIBLE FAULT 

Motor does not start. 

1. Lost power or phase -- blown fuse. 

2. Wiring loose, incorrect, grounded or shorted. 

3. Open or defective switch, circuit breaker or motor starter. 

4. Open or defective overload or safety interlock. 

5. Defective start/stop buttons or control circuit wiring. 

6. Motor winding grounded, shorted or otherwise defective. 

7. Mechanical defect inside motor or clutch. 

Motor does not run properly; 

noisy, erratic, imbalanced 

currents etc. 

1. Lost Phase -- blown fuse. 

2. Incorrect voltage or frequency. 

3. Intermittent problem as described above for failure to start. 

4. Overload or problem with driven equipment. 

5. Motor winding grounded, shorted or otherwise defective. 

6. Mechanical defect inside motor or clutch. 

Motor runs too hot. 

1. Overload. 

2. Frequent starts or reversals. 

3. Lost phase -- blown fuse. 

4. Incorrect voltage or frequency. 

5. Inadequate ventilation. 

6. Dirt in motor. 

7. Electrical or mechanical defect inside motor. 

Motor runs, but no output. 

1. No coil voltage, check controller. 

2. Loose or incorrect wiring. 

3. Open safety interlock. 

4. Open or defective clutch coil. 

5. Brake not releasing. 

6. Machine jammed. 

CAUTION

: Make sure the AC power to the motor is 

turned OFF and locked out before attempting to make 

the test. Disconnect the motor and coils and be sure 

that control circuits and other electronic devices are 

disconnected, as they will be damaged by the high 

voltage. Tachometer generator and other auxiliary 

devices must not be checked with a megger. Use an 

ohmmeter for these devices. 

CAUTION

: Turn AC power to the unit and controller 

OFF before making tests. When a voltage 

measurement is necessary, only qualified personnel, 

fully acquainted with safety  procedures and making 

power ON tests, should be allowed to service this 

equipment. 

Содержание DCD-132

Страница 1: ...ROUGH 160 EDDY CURRENT DRIVES INSTRUCTION MANUAL Revised 2021 DRIVE SOURCE INTERNATIONAL INC 7900 Durand Avenue bldg 3 Sturtevant WI USA 53177 Toll Free 800 548 2169 Phone 262 554 7977 Fax 262 554 7041 Email sales dynamatic com ...

Страница 2: ... Factory recommended test procedures included in the instruction manual should be followed Always disconnect electrical power before working on the unit REFER TO OSHA RULES AND REGULAT IONS PARAGRAPH 1910 219 FOR GUARDS ON MECHANICAL POWER TRANSMISSION APPARAT US Note Since Improvements are continually being made to available equipment the enclosed data is subject to change without notice All draw...

Страница 3: ...tronic failure Be sure to consider this factor in selecting gear ratios and safety devices Always Wear Safety Glasses Safety glasses should be worn by all personnel involved in installing or maintaining the equipment This applies equally to all electrical and mechanical workers Other safety clothing should be selected as appropriate to the task and work environment Copyright Drive Source Internati...

Страница 4: ...eparation 17 Unit Preparation 17 Sizing Sheaves and Sprockets Overhung Load 18 Installing Sheaves Sprocket or Couplings 18 Initial Mounting 19 Alignment 19 Direct Coupled Shafts 19 Parallel Connected Shafts 20 Belt Tension 20 Final Mounting 21 Lubrication 21 Shaft and Belt Guards 21 Electrical Wiring 21 Transformer Winding Applies to Models DCD 132 through DCD 225 ONLY 21 AC Motor Leads 22 Clutch ...

Страница 5: ...hooting 28 Dis Assembly Instructions 30 Assembly Instructions 31 Drive Feet Mounting Procedure 33 Section 7 34 Service Renewal Parts 34 Field Service 34 Repair Service 34 Return Instructions 34 Repair Instructions 34 Renewal Parts 34 ...

Страница 6: ...ment Check Figure 3 2 20 Angular Alignment Check Figure 3 3 20 Parallel Shaft Alignment Figure 3 4 21 Perpendicular Shaft Alignment Figure 3 5 21 Precision Tension Check Figure 3 6 22 Belt Modulus Factors Mf Table 3 4 22 Typical Wiring Connections Figure 3 7 23 Tach Generator Leads Table 3 5 23 Maintenance Check List Table 6 1 27 Typical Assembly Drawing of DCD Drive Figure 6 1 28 Recommended Grea...

Страница 7: ...ructions and procedures Heed any hazard labels on the equipment and be sure to instruct others in their meaning and importance The various types of labels used to alert personnel of hazards and their degree of hazard potential are as follows DANGER Used to call attention to an immediate hazard where failure to follow instructions could be fatal WARNING Identifies hazards having possibilities for i...

Страница 8: ... warranty failure occurs contact your local DSI Dynamatic sales office or the factory s Service Department directly for instructions on how to obtain the required repair All repair arrangements must be approved by DSI Dynamatic in advance of returning any products to the factory Note that freight charges both ways are your responsibility For additional information refer to Section 7 Service and Re...

Страница 9: ...e shaft to stop in a different position each time The bearing chambers of grease lubricated machines are packed with grease at assembly and should not require additional grease unless unusually severe environmental conditions exist Refer to Section 6 for grease specifications and procedure to follow if periodic greasing is necessary Consult the Service Department at the factory whenever a question...

Страница 10: ...dard motors by matching the torque ratings of the motors to the clutch ratings taking into consideration starting torque overload torque speed range and thermal limits The resulting motor and clutch combinations comprise the adjustable speed drive product line Standard horsepower and speed range selections specifications application engineering data and outline drawings can be found elsewhere in t...

Страница 11: ...e increases Similarly torque is increased by increasing field coil current This torque versus slip with various current relationships is shown in Figure 2 3 Because some slip must occur to produce the required torque no torque is produced at zero rpm For this reason maximum output speed is always less than motor speed Since the eddy current clutch is a torque transmitter it has no inherent speed s...

Страница 12: ...ameplate of each unit is stamped to show the minimum operating speed at full load The minimum speed can be reduced when the load is also reduced Tables found elsewhere in this section list the horsepower capacities and speed ranges of standard drives For other ratings consult the factory The formula shown below is used to calculate the minimum continuous operating speed for a given load torque and...

Страница 13: ...he two model types covered by this manual The two model types differ in speed range and torque capability as indicated by the rating tables listed on the following pages Both model types are equivalent in the following respects 1 Weights and dimensions when motors and output bearings are equivalent 2 Clutch coil data current and resistance for 45V coil 3 Overhung load capacity when furnished with ...

Страница 14: ...FC Motor Frame Size 3 1630 0 DCD 132030 4141 145TC 5 1500 0 DCD 132050 4141 145TC 5 3300 0 DCD 132050 4121 182TC 7 5 3300 50 DCD 132075 4121 184TC 7 5 1660 350 1680 50 DCD 132075 4141 DCD 160075 4141 213TC 213TC 10 3250 0 1580 0 DCD 132100 4121 DCD 160100 4141 215TC 215TC 15 3300 0 1550 340 DCD 160150 4121 DCD 160150 4141 254TC 254TC 20 3250 0 1615 145 DCD 160200 4121 DCD 160200 4141 256TC 256TC 2...

Страница 15: ... on right or left side Totally enclosed covers are available for several models Alternate flanges are available for basic and freestanding models see page 54 Weight is approximate and includes motor Dimension includes flange see page 54 DIMENSIONS ARE IN INCHES Model Hp Frame AC LE AA 2E 2F KK 3 182TC 8 8 13 65 75 DCD 132 5 7 5 184TC 213TC 8 8 10 25 14 50 15 00 75 1 00 10 215TC 10 25 16 25 1 00 7 ...

Страница 16: ...16 Alternate Flange Outline Dimensions Model C LA LF M N P T NW SS DCD 132 4 84 74 7 4 6 10 8 46 9 84 16 2 75 6 DCD 160 7 87 63 8 74 10 43 9 06 14 0 16 3 375 6 DIMENSIONS ARE IN INCHES ...

Страница 17: ...vertical model that is specifically designed for vertical mounting and operation Other models must be mounted horizontally unless certified drawings or other documentation furnished for equipment supplied for a specific customer order indicates that the equipment is designed for vertical mounting and operation Operation in ambient above 104ºF 40ºC requires the HP dissipation to be de rated 10 for ...

Страница 18: ... load ratings listed in Section 2 are for units with a standard length output shaft and either standard output ball bearing or optional standard output spherical roller bearing as indicated in the tables Units with an external brake have a longer shaft Separate overhung load rating tables are provided for units with a brake For non standard models contact DSI Dynamatic to obtain the overhung load ...

Страница 19: ...ignment Offset Alignment Check Figure 3 2 Note Dial indicators used for alignment must be non magnetic due to possible magnetism of the unit s shaft If possible rotate both shafts when required in procedure If one shaft cannot be turned alignment can still be checked by rotating the other shaft with indicator attached to it 1 Clamp base of indicator to hub of unit s shaft and position its indicato...

Страница 20: ...f the horizontal shaft as shown in the front view a line perpendicular to the vertical shaft at the center of its sheave must pass a distance Y below the center of the horizontal shaft Belt Tension Belt and chain drives are tensioned by sliding the unit sideways after loosening the hold down bolts It is very important to establish the proper tension which is one just above the point of slippage Be...

Страница 21: ...ting shafts couplings belts and chain devices Refer to OSHA rules and regulation paragraph 1910 219 for requirements covering guards on mechanical power transmission apparatus Be sure machine is safe to operate and all safety devices have been installed checked out and made operable CAUTION When designing belt and shaft guards remember that bearings must be lubricated periodically Grease fittings ...

Страница 22: ...tions furnished with the eddy current controller Tachometer Generator Leads The tachometer generator leads are connected to the same terminal block as the clutch and brake leads described above Three tachometer generator leads are brought out to the conduit box in a shielded insulated cable Two of these leads are connected to terminals G1 and G2 according to maximum output speed as shown in Table ...

Страница 23: ...ycle requires frequent overloads or frequent motor stops starts or reversals the application should be reviewed and specific limits determined Consult the factory Under normal speed control the controller is constantly regulating clutch coil current to maintain set speed Motor current and clutch coil excitation will vary in proportion to the amount of regulation required This is normal do not expe...

Страница 24: ...ation through the grille on clutch housing If the direction is not correct turn AC power OFF lock out the disconnect switch and reverse any two of the three incoming power leads then repeat the test to ensure proper rotation 5 Start the AC motor and observe its operation Listen for any abnormal noise or vibration Using a clamp on ammeter check motor current All three phases should be balanced If a...

Страница 25: ... Erratic speed control or abnormal response will usually affect the product being manufactured When the clutch does not seem to control the way it should the problem can be either electrical or mechanical When investigating check for loose belts loose setscrews overloading and other mechanical problems It is not always the fault of the controller Motor current should be monitored it can indicate m...

Страница 26: ...ictated by the environment of the unit The more severe dirty or hot the conditions are the more often these tasks must be performed Before doing any work turn AC power OFF and lock out disconnect switch Clean accumulated dust and dirt from the unit and immediate area Pay special attention to air intake areas under end bracket Dirt allowed to accumulate there can easily obstruct airflow or be drawn...

Страница 27: ...ed at the factory Recommended amounts of grease for the bearings are listed in Table 6 3 Any equivalent and compatible grease may be used Special greases may be specified at the time of order entry Consult your order papers if a special grease has been specified When lubrication is required use the following procedure to grease the bearings 1 Stop the motor and clutch and allow both to coast to a ...

Страница 28: ...rt 1 Lost power or phase blown fuse 2 Wiring loose incorrect grounded or shorted 3 Open or defective switch circuit breaker or motor starter 4 Open or defective overload or safety interlock 5 Defective start stop buttons or control circuit wiring 6 Motor winding grounded shorted or otherwise defective 7 Mechanical defect inside motor or clutch Motor does not run properly noisy erratic imbalanced c...

Страница 29: ...nd rotor 7 Bent shaft Unit overheats 1 Overload 2 Operating below minimum speed 3 Air passage blocked 4 Recirculating cooling air or ambient temperature 5 Brake not releasing Bearing overheats 1 Bearing failing 2 Excessive thrust or overhung load 3 Lack of excessive or wrong lubricant 4 Unit misaligned 5 Bent shaft Erratic operation 1 Controller malfunction check controller 2 Cyclic or shock loadi...

Страница 30: ...To separate the coil and tach wires cut the waxed string and carefully slide the rubber tube off If the tach is being replaced a string or small wire tied to the old tach wires before removing can be used to assist in pulling in the new wires Note Broken wires tach should be 220 ohms a bad tach will cause the drive to run at full speed when the controller is energized 6 Remove the tach cover plate...

Страница 31: ...Mount the front bearing retaining ring onto the shaft Insert the shaft assembly into the output assembly from the front side by pressing on the inner and outer front bearings while supporting the rear bearing 4 Mount the star tolerance ring and tach armature onto the shaft Feed the tach wires through the hole in the output assembly and slide the tach stator plate over the shaft and bolt to the out...

Страница 32: ...0HP 95012 02 STD COIL FOR 4 3HP 4 4HP 2 5HP 2 7 5HP 95013 03 HP COIL FOR 4 5HP 2 10HP 95013 04 HP COIL FOR 4 3HP 4 4HP 2 5HP 2 7 5HP 95002 02 95002 01 TORQUE TUBE ROTOR ASSY 4 POLE 95004 01 95004 02 BLADED POLE WHEEL STD 95004 01 95004 02 BLADED POLE WHEEL REDUCED 95002 02 95002 01 TORQUE TUBE ROTOR ASSY 2 POLE 95004 01 95004 02 BLADED POLE WHEEL REDUCED C W AXIAL BLADES 95002 02 95002 01 TORQUE T...

Страница 33: ...en bolts 5 Re check alignment and change shims as required 6 Push slotted shims under AC Motor mounting feet and moderately tighten the bolts Note The decision to mount bolt the motor feet should be based on the application dynamics i e vibration support It is not always necessary to mount the motor feet and is specifically motor size related Note When Drives are purchased with a base the base mus...

Страница 34: ...m Contact your local Sales Office for the form and return authorization Provide all the information requested on the form and return it with the equipment and your purchase order Those items not manufactured by DSI Dynamatic such as instruments meters and digital counters are repaired by the vendor Returning them to the factory will only delay the repair Contact the Repair Service Department at th...

Страница 35: ...DRIVE SOURCE INTERNATIONAL INC 7900 Durand Avenue Bldg 3 Sturtevant WI USA 53177 Toll Free 800 548 2169 Phone 262 554 7977 Fax 262 554 7041 Email sales dynamatic com IM 160000 2019 ...

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