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2: Introduction to the Controller

Controller Configurations

The controller converts singlephase AC line power to adjustable DC

power for either speed or torque control of DC motors rated 1/4

through 2 HP. The controller is specifically performance matched to

Reliance DC Motors to provide a compact controller/motor package. It

will operate all Reliance 1/4 through 2 HP permanent magnet or wound

field DC motors with compatible armature and field voltages.
The controller is available in a wide array of applicationspecific

configurations, in flat plate chassis or open chassis designs as well as

NEMA 12 or NEMA 4/4X/12 enclosure designs. Tables 21 through

Table 23 list available configurations.

Note

: Oiltight and dusttight conduit hole plugs (part 197308A) are

standard on DC2 NEMA 12K designs. Conduit hubs are not supplied.

Note

: Watertight conduit hubs are standard on DC2 NEMA 4/4X/12

designs. Additional conduit hubs for NEMA 12 or NEMA 4/4X/12

designs can be ordered by referencing Reliance Part Number

6088262A.

Note

: Models DC295 and DC297 feature a special 10turn speed

potentiometer. Reference Reliance part number 60059414SFX for

replacement.

Note

: When the RE020 DC Tachometer is used, a controller isolation

transformer must be used. See Install a Disconnect in Section 3 of this

instruction manual for complete instructions.

Table 21. Open and Plate Style Chassis Controllers Listed

by Features and Configuration.

Controller Model Number by Configuration

Speed Control

Torque Control

Controller Features

DC240U

DC245U

DC250U

DC255U

DC243U

DC253U

Basic

DC242U

DC246U

DC252U

DC256U

DC244U

DC254U

Basic plus

Process

Control Interface

Special customer model.

Содержание DC2 VS series

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Страница 6: ...shipping container 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...

Страница 7: ...s service within ten days of receipt 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...

Страница 8: ...hole plugs part 197308A are standard on DC2 NEMA 12K designs Conduit hubs are not supplied Note Water tight conduit hubs are standard on DC2 NEMA 4 4X 12 designs Additional conduit hubs for NEMA 12 o...

Страница 9: ...roller Model Number by Configuration Speed Control Torque Control Controller Features Not Available Not Available Not Available Table 2 3 NEMA 4 4X 12 Enclosed Controllers Listed by Features and Confi...

Страница 10: ...Features Models DC2 40 42 45 46 50 52 55 56 60 62 65 66 70 71 72 80 82 90 91 92 95 97 99 D All features listed in Basic Controller Features All Models D Speed control by armature voltage regulation o...

Страница 11: ...rque Control Features Models DC2 43 44 53 54 63 64 73 74 83 84 93 94 D All features listed in Basic Controller Features All Models D Motor torque adjustment by potentiometer D Independently adjustable...

Страница 12: ...0_C 32_ to 104_F NEMA UL 4 4X 12 enclosed 0_ to 40_C 32_ to 104_F D Altitude 3300 feet 1000 meters maximum D Non Condensing Relative Humidity 5 to 95 D NEMA 12 enclosure is intended for indoor use It...

Страница 13: ...1 1 00 1 40 71 1 00 1 40 2 20 2 90 90 90 90 90 90 180 180 180 180 180 2 5 3 7 5 0 7 5 10 0 2 5 3 7 5 0 7 5 10 0 50 50 50 50 50 100 100 100 100 100 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 1 1 Includes...

Страница 14: ...djustable from 3 seconds to 3 5 seconds D Dynamic braking provided in Models DC2 71 78 91 and 98 only This capability is designed for applications requiring infrequent stops of loads in which the iner...

Страница 15: ...acteristics and IR drop compensation adjustment 4 Applicable to non reversing models only Armature Feedback Voltage Tachometer Feedback 0 1 0 1 1 20 1 30 1 1 0 1 5 5 12 0 5 2 5 3 Speed 4 Normal2 Table...

Страница 16: ...ing instructions thoroughly before proceeding Throughout the installation and wiring procedures use Figure 3 1 or Figure 3 1A to locate adjustment potentiometers terminal boards special selector jumpe...

Страница 17: ...lug located on the bottom right side See Figure 3 2 for dimension and mounting details 6 Seal the unused conduit entries of the NEMA 12 enclosed controller using the supplied plug part 197308A to ret...

Страница 18: ...3 3 1 1 RATE 1 RRATE 2 1 Functional on 0 57210 31 Regulator Boards only Figure 3 1A Controller Terminal Board Locations 0 57210 31 and 0 57210 32 Regulator Boards Only...

Страница 19: ...Area 2 5 64 Dimensions shown in Inches Millimeters FRONT VIEW SIDE VIEW CHASSIS DESIGN DC2 Series 40 4 0 102 0 625 16 12 5 321 7 735 188 6 5 167 Restricted Area 5 0 128 7 0 179 FRONT VIEW FUSE Side Vi...

Страница 20: ...7 0 179 1 5 38 5 5 141 4 875 125 3 5 90 0 875 22 2 PLACES 4 875 125 10 125 260 Restricted Area NOTE OPERATOR S DEVICES SUPPLIED ONLY ON MODEL DC2 70 THROUGH DC2 79 AND DC2 90 THROUGH DC2 99 PRODUCTS...

Страница 21: ...ons have proper sheave belt alignment to minimize unnecessary motor loading Install a Disconnect DANGER THIS EQUIPMENT IS AT LINE VOLTAGE WHEN A C POWER IS CONNECTED DISCONNECT AND LOCKOUT ALL UNGROUN...

Страница 22: ...mer cannot be used since it will not provide isolation from ground WARNING WHEN THE START STOP SWITCH DOES NOT INCLUDE AN A C POWER DIS CONNECT FUNCTION IN THE STOP POSITION THE A C POWER DISCON NECT...

Страница 23: ...T CONNECT AN APPRO PRIATE EQUIPMENT GROUNDING CONDUCTOR UNBROKEN FROM THE CONTROLLER GROUND POINT THE MOTOR FRAME THE TRANSFORMER ENCLOSURE IF USED THE CONTROLLER ELECTRICAL ENCLOSURE THE WIRING CONDU...

Страница 24: ...9 minimum 12 maximum in lbs TB2 Thermostat 32 132 4 in lbs CAUTION If motors other than a straight shunt are used with the DC2 controller and an S1 and S2 winding is present on the motor additional mo...

Страница 25: ...e Reliance shunt wound D C motors are supplied with dual voltage reconnectable fields 50 100 volts or 100 200 volts Reference Table 2 4 Controller Ratings by Motor Horsepower in this manual and note t...

Страница 26: ...HESE TERMINALS FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY WARNING A MAINTAINED CLOSED CONTACT CAN CAUSE THE CONTROLLER TO AUTOMATICALLY RESTART IF LINE INPUT POWER IS REMOVED AND...

Страница 27: ...STOP POSITION THE A C POWER DISCON NECT SWITCH MUST BE MOUNTED IN CLOSE PROXIMITY TO THE OPERA TOR S START STOP CONTROLS THIS IS REQUIRED AS THE DC2 DRIVE DOES NOT HAVE AN ARMATURE LOOP CONTACTOR A S...

Страница 28: ...art Stop control wiring 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 3 Use 16 AWG cable...

Страница 29: ...GER BECAUSE THE TACHOMETER IS CONNECTED THROUGH THE REGULA TOR TO THE ARMATURE POWER CIRCUIT THE TACHOMETER TERMINALS ARE AT LINE POTENTIAL DISCONNECT ALL INPUT POWER TO THE DRIVE BEFORE SERVICING FAI...

Страница 30: ...ller from the A C power source ground Each such controller must have it s own isolation transformer NOTE Any DC2 controller used in a motor reversing application cannot employ a D C tachometer speed f...

Страница 31: ...3 16 419 519 TB2 Motor Mounted D C Tachometer Figure 3 8 D C Tachometer Connection...

Страница 32: ...o locate adjustment pots terminal boards special selector jumpers and pins Wiring diagrams are given in Figures 5 1 5 1A 5 2 and 5 3 Position the Controller Jumpers to Fit Application The controller c...

Страница 33: ...osition J5 for the current rating selected in Step 2 Table 4 1 Controller D C Output Current Rating Controller Output Current Rating by Input Voltage Rating 115 VAC 230 VAC Motor HP 1 4 1 3 1 2 3 4 1...

Страница 34: ...1 2 Turn MIN SPEED potentiometer fully counter clockwise to obtain zero minimum speed J202 S Curve Acceleration NOTE A 4 7 mFD Reliance part 69380 51PS capacitor is provided in a plastic bag shipped w...

Страница 35: ...4 4 1 DO NOT USE 135 Figure 4 1 Controller Circuit Board Jumper Pin and Potentiometer Locations 0 57210 30 Regulator Boards only...

Страница 36: ...4 5 1 1 RATE 1 RRATE 2 1 Functional on 0 57210 31 Regulator Boards only Figure 4 1A Controller Circuit Board Jumper Pin and Potentiometers Locations 0 57210 31 and 0 57210 32 Regulator Boards only...

Страница 37: ...fully CCW With Torque Control models D MAX fully CCW D MIN fully CCW D IR DROP fully CCW D CURRENT LIMIT 50 of full scale D RATE 1 and RATE 2 75 of full scale D PI GAIN on Process Control models only...

Страница 38: ...ESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE 7 On controllers employing D C tachometer speed feedback the following steps may be used to determine the correct direction of rotation and the correct po...

Страница 39: ...s a drive that consistently and reliably establishes line speed D Load the motor with a reasonably constant load over the speed range Such a system may be a pre loaded dancer loop preceding a center d...

Страница 40: ...cation speed or 90 180 VDC on the armature D Return the Torque potentiometer fully CCW 10 Adjust the IR Comp With Speed Control models only If the torque demand on the drive motor is relatively unifor...

Страница 41: ...er 12 If you have a Process Control model proceed to Setup the Process Interface Setup for Process Interface On 0 57210 31 Regulator Boards only NOTE The process control input plus and minus is buffer...

Страница 42: ...minimum reference from your process control unit and adjust PI BIAS to the desired minimum operating speed or torque 6 Increase the process control reference signal to maximum and adjust PI GAIN to t...

Страница 43: ...tors and diodes in one power cube If you determine that there has been a failure in either of these replacement parts are available from Reliance Refer to Table 5 1 for specific DC2 parts Figures 5 1...

Страница 44: ...2 71 78 91 98 63481 49AM Toggle Switch Boots Controllers for NEMA 4 4X 12 4DC20000 Conduit Hole Plugs for NEMA 12 Controllers 197308A Conduit Hubs for NEMA 4 4X 12 Controllers 608826 2A Fuse Kits Cust...

Страница 45: ...all wiring within the mo tor conduit box Correct any faulty wiring Incoming line fuse blown and or upstream protection de vices open Investigate upstream equip ment for possible cause and correct Repl...

Страница 46: ...mper as required Current feedback jumper set lower than applied motor horsepower Recheck and reset as necessary Motor does not rotate Continued Drive will not go to zero speed or torque WARNING DO NOT...

Страница 47: ...at zero CCW Set IR drop compensation pot to zero CCW With Process Control models improperly set maximum speed pots Reset maximum speed pots With Process Control models reference signal producing less...

Страница 48: ...5 6 Figure 5 1 Wiring Diagram of Basic Speed Controller 0 57210 30...

Страница 49: ...5 7...

Страница 50: ...5 8 Figure 5 1A Wiring Diagram of Torque and Process Interface Controller 0 57210 31 and 57210 32 Regulator Boards only J4...

Страница 51: ...5 9 J4...

Страница 52: ...17A 49869 20 R DB 32 132 F 2 1 35 38 2 1 D B REV RUN JOG SWITCH CONNECTION START STOP SWITCH 49869 17 START STOP SWITCH 49869 17A 2 1 2 1 32 132 35 38 R DB F STANDARD DB REV SWITCH CONNECTION STANDAR...

Страница 53: ...5 11 DEVICE INTERCONNECTIONS BACK OF REVERSING SWITCH Figure 5 3 Operator Device Interconnections...

Страница 54: ...5 12 REAR SIDE OF SPEED POT REAR VIEW OF START STOP SWITCH Figure 5 3 Operator Device Interconnections Continued...

Страница 55: ...r you have completed this form please return it to Reliance Electric Technical Documentation 24800 Tungsten Road Cleveland Ohio 44117 Fax 216 266 7785 Thank you for your comments Publication Name Inst...

Страница 56: ...Reliance Electric 24701 Euclid Avenue Cleveland Ohio 44117 216 266 7000 Printed in U S A D2 3231 3 March 1994...

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