efesotomasyon.

com - Control Techniques,emerson,saftronics -ac drive-servo motor

www.saftronics.com

DC6
DC Motor Drives

P/N X010004 REV:2

 efesotomasyon.com - Control Techniques,emerson,saftronics -ac drive-servo motor

DC6 SERIES
INSTRUCTION MANUAL CONTENTS
1. Description
1.1 General ......................................................................................................... 1
1.2 Standard Features ........................................................................................ 1
1.3 Optional Features ......................................................................................... 1
1.4 Power Bridge ................................................................................................ 1
2. Installation
2.1 General ......................................................................................................... 3
2.2 External Cabling ........................................................................................... 3
3. Startup
3.1 Adjustments prior to Operation ...................................................................... 5
3.2 Initial Operation of the Drive Unit .................................................................. 5
3.3 Maximum Speed Adjustment ........................................................................ 6
3.4 Minimum Speed Adjustment ......................................................................... 6
3.5 Tach Loss Protection Check ......................................................................... 7
3.6 Speed Stability Adjustment ........................................................................... 7
3.7 Normal Current Limit Adjustment .................................................................. 7
3.8 Two-stage Current Limit Adjustment ............................................................. 7
3.9 IR Compensation .......................................................................................... 8
3.10 Acceleration/Deceleration Adjustment ........................................................ 8
3.11 Jog Speed Adjustment ................................................................................ 8
3.12 General ....................................................................................................... 8
4. General
4.1 Block Diagram .............................................................................................. 9
4.2 Typical Wiring Diagram .............................................................................. 10
4.3 AA650MB Schematic .................................................................................. 11
4.4 A650 Control Schematic ............................................................................. 12
5. Burden Resistor
.......................................................................................................................... 14
6. Troubleshooting
.......................................................................................................................... 15
7. Spare Parts
.......................................................................................................................... 17
8. Warranty
.......................................................................................................................... 18
 efesotomasyon.com - Control Techniques,emerson,saftronics -ac drive-servo motor

SAFTRONICS
1. DESCRIPTION
1.1 General SAFTRONICS type DC6 SCR converters are intended to power DC motors ranging
from 5HP to 2000 HP.

The basic converter unit consists of:

a) A 6SCR power bridge.
b) A single control card type AA650 mounted on the power bridge assembly.
The entire control circuit is accommodated on this card.
c) Synchronizing transformer assembly, upon which is mounted a relay logic
PC board type A650-MB-2. This board is connected to the control card via a
flat ribbon cable.

1.2 Standard Features • Impedance-isolated armature feedback for a speed regulation of better than
5%.
• Isolated current feedback using current transformers.
• Visual indication of all important control points within the control card (light
emitting diodes - LED’s).
• Single control card for quick replacement.
• Phase rotation protection with run interlocking and indication.
• Instantaneous protection against excessive current overload (ICT Current
fault trip).
• Automatic resetting of ICT circuit when operating the normal STOP/START
circuit.
• Stall-protection where power to the motor will cease after a stall period of
longer than 12 seconds under current limit conditions.
• Adjustable maximum voltage with armature feedback.
• Adjustable maximum speed with tachometer feedback.
• Adjustable minimum speed.
• Adjustable acceleration (1-60 seconds).
• Adjustable deceleration (1-60 seconds).
• Adjustable current limit to the motor.
• Adjustable IR compensation.
• Adjustable velocity and current loop stabilities.
• Tachometer feedback loss protection i.e. the control will automatically revert
to impedance-isolated armature feedback if the tachometer fails.
• Jogging facility with independent speed adjustment.
• 2-stage current limit for high initial starting torque requirement .
• Tachometer feedback for a speed regulation of better than 1.0%.

1.3 Optional Features • Parallel 12-pulse operation.

• Multi-drive systems with accurate load sharing better than 3%.
• Input programming for follower drive applications.
• Constant kW/HP operation with a field current regulator.
• Constant current field regulator.
• Remote control station(s).
• Digital speed control for better than 0.1% regulation.

1.4 Power Bridge Standard Protective Features

• Fast acting fuses.

1
 efesotomasyon.com - Control Techniques,emerson,saftronics -ac drive-servo motor

SAFTRONICS
1.4 Power Bridge cont'd • Instantaneous protection against excessive current overload (Electronic pro-
tection - ICT).
• SCR protection against excessive dv/dt and over-voltage by means of indi-
vidual R-C circuitry.
• Power bridge overtemperature protection to cut-out when stack temperature
exceeds 85 degrees C (+/- 5o).

Optional Protective Features

Blower for cooling the DC motor, supplied via a contactor with thermal overload and
using protection interlocked with the run control circuitry.

Power Bridge Rating Data

The DC6 series covers the power range of 5HP to 2000HP. The control circuit, howev-
er, remains basically the same for the full range up to 2000HP. The different bridge as-
semblies are listed in Table 1.
Table 1
BASIC MAXIMUM HP ARMATURE MAX DC
MODEL 240V 480V 600V VOLTAGE AMPS

DC6-61 15 30 30 240/500 60
DC6-126 30 60 60 240/500 100
DC6-251 75 150 150 240/500 175
DC6-350 100 200 250 240/500/700 350
DC6-500 150 300 400 240/500/700 500
DC6-800 250 500 700 500/700 800
DC6-1000 300 600 800 500/700 1000
DC6-1250 400 800 1100 500/700 1250
DC6-2000 800 1750 2000 500/700 2000

Derating Data
Table 1 lists the maximum continuous DC output current at a maximum ambient tem-
perature of 40o C (104o F) and an altitude of 5,000 feet (2,000 meters). For ambient
temperatures in excess of this value all powerstack assemblies must be derated by
1.5% per degree C. (.75oF). For altitudes in excess of 5,000 feet (2,000 meters) above
sea level, all power stack assemblies must be derated by 1% for every 250 ft. (100
meters) above 5,000 ft. (2,000 meters).

Field Excitation Supply

Constant field excitation is supplied from a bridge rectifier having the voltage and cur-
rent ratings listed in Table 2.

Table 2

AC SUPPLY DC FIELD SUPPLY VOLTAGE MAXIMUM DC

VOLTAGE Standard Optional CURRENT

240V 3 Phase 150V 220V 10A

480V 3 Phase 300V 440V 10A
600V 3 Phase 300V 440V 10A

2
 efesotomasyon.com - Control Techniques,emerson,saftronics -ac drive-servo motor

SAFTRONICS
2. INSTALLATION
2.1 General Unless the unit has been specifically designed for poor environmental conditions, it
must be installed in an area where the following conditions exist:
a) Ambient temperature does not exceed 40°C (104°F)
b) Ambient temperature is not less than 10°C (50°F)
c) Altitude above sea level in excess of 5,000 ft. (2,000 meters) must be taken
into account as in Derating Data,Section 1.4.
d) Ambient air is reasonably clean and dry. It must be free of flammable or com-
bustible vapors, steam or corrosive gases.
e) The clearance around the cabinet must be sufficiently large to:
i) Provide full accessibility to the front.
ii) Provide a non-restricted airflow (with a minimum of 1" clearance) from
the intake and exhaust ventilation louvers.

2.2 External Cabling It is most important that the AC supply to the unit is of the correct voltage and current
rating. It should be kept in mind that where the specified drive unit voltages and/or cur-
rents are not available, an interstage transformer will be necessary. All external con-
nections must be made according to the Engineering drawing supplied. All power and
control cable ratings should be referred to the National Electrical Code Handbook.

Cable Current Ratings

Table 3 lists the maximum continuous current which the AC and DC cables must car-
ry for the various drive types. If the system uses a transformer, then the AC ratings
are for the transformer secondary. Primary ratings must be determined by the trans-
former rating.

Table 3

MAXIMUM ARMATURE 3 PHASE SUPPLY

DRIVE TYPE
AMPS (AVG) AMPS (RMS)
DC6-61 60 49
DC6-126 125 103
DC6-251 251 204
DC6-350 350 286
DC6-500 500 408
DC6-800 800 653
DC6-1000 1000 816
DC6-1250 1250 1020
DC6-2000 2000 1632

Motor Field Cable Current Ratings

Motor field cable current ratings are determined by the motor being used. This can
normally be ascertained by referring to the motor nameplate. A cable rating of 20
amps should be adequate for the full range up to 1500HP. The cable insulation rating
should not be less than 600V.

3
 efesotomasyon.com - Control Techniques,emerson,saftronics -ac drive-servo motor

SAFTRONICS

2.2 External Cabling Control Signal Cable Consideration

cont'd All control signal cables must have a current rating of at least 5 Amps and the insula-
tion rating should be 600V. TACH and SPEED CONTROL signal wiring should be inter-
connected by means of cables with individually shielded and twisted cables.

For extra protection against electro-magnetic interference and mechanical damage,

PVC covered shielded cables should be run completely in steel conduit, separately
from power and AC control cables. The shields of the individual cables should then
be terminated together at one point in the control cabinet at the control circuit common
NOTE: Shielded cables must be (where specified). It should be noted that the shields must be grounded at one point
continuous with no breaks in
the shield. only, preferably the control cabinet, to avoid unwanted ground current loops.

All control cables should be kept away, as far as possible from high power cables, pref-
erably run in a separate channel.

Motor Connections to DC6

CCW ROTATION CW ROTATION
(FACING DRIVE SHAFT) (FACING DRIVE SHAFT)

SERIES SERIES
S2 FIELD S2 FIELD
+ S1 + S1
20 20

A2 - A1 A1 - A2
21 21

SEE NOTE 1 SEE NOTE 1

SHUNT SHUNT
FIELD FIELD
F4 + F3 F4 + F3
22 22
300V 300V
SHUNT SHUNT SHUNT SHUNT
F1 - FIELD F2 FIELD F1 - FIELD F2 FIELD
23 23
SEE NOTE 2 SEE NOTE 2

P1
MOTOR
THERMAL
OVERTEMP
TO
START/STOP
LOGIC

P2
NOTE 1: FOR ARMATURE REVERSING DUTY, DO NOT CONNECT THE SERIES FIELD.
IF EXTRA STARTING TORQUE IS REQUIRED, CONNECT THE SERIES FIELD VIA
SEPARATE FULL-WAVE BRIDGE SUCH THAT (S1) IS ALWAYS THE SAME POLARITY AS (F1).

NOTE 2: 150V CONNECTION

SHUNT
+ FIELD
22
F1 F3
150V
SHUNT
FIELD
F2 F4
-
23

4
 efesotomasyon.com - Control Techniques,emerson,saftronics -ac drive-servo motor

SAFTRONICS
3. STARTUP
3.1 Adjustment Prior To When all cable connections have been thoroughly checked out according to the Engi-
Operation neering drawing, Power may be applied to the drive unit, but the Start circuit must not
be operated at this point.

The following adjustments should be made on the AA650 control card:

RV6 - MAXIMUM SPEED (tach feedback) -Fully counter-clockwise
RV3 - RATE I (Acceleration Rate) -Fully clockwise
RV4 - RATE II (Deceleration Rate) -Fully clockwise
RV5 - STABILITY (Speed) -Mid Position
RV9 - CURRENT LIMIT ¼ clockwise
RV7 - MINIMUM SPEED -Fully counter-clockwise
RV8 - IR COMPENSATION -Fully counter-clockwise
RV2 - AV (Max. Armature Voltage) -Fully counter-clockwise
RV1 - CS (Current Stability - Factory Set) -Mid position approx.

The state of the LED's on the AA650 control card should be as follows:
-V (-12 Volt Supply) -Glowing brightly
NOTE: If any of the LED’s do not R (Run indication) -Off
conform to the pre-start list , do DV (Speed Reference) -Off
not immediately suspect the VA (Speed Error Amplifier Output) -Off
AA650 card of being faulty. First
check out all external connec- CA (Current Error Amplifier Output) -Off
tions for short circuits and cross ST (Stall Sensing) -Glowing brightly
connections etc. The AA650 TR (Trip Circuit) -Off or On*
card has been thoroughly tested 2S (2-Stage Current Limit Circuit) -Off
at the factory and it will be un-
ΦPhase Rotation Indication -Glowing brightly
likely that this card would be at
fault. +V (+12 Volt Supply) -Glowing brightly
Φ1, Φ2, Φ3 (Comparator Output Indication) -Glowing dimly

*The TRIP LED should come on after the run command is applied to the drive.

Phase Rotation Correct Indication

If the phase rotation LED is not glowing, the supply should be disconnected and any
two phases of the supply reversed. When power is restored, this LED should glow
brightly. If this LED remains in the OFF condition, the supply to the drive should be
checked for the correct phase to phase voltage.

Considerations before Running the Motor

Prior to running the DC motor, ensure that the motor is free to rotate at maximum
speed without damage to the machine to which it is coupled. It is preferable to de-cou-
ple the motor from the machine if possible, as this will ensure no possible damage to
the machine. Where compound motors are used, it is preferable to by-pass the series
field winding until the drive unit has been completely set up.

3.2 Initial Operation of the Before running the drive, it will be necessary to carry out the following:
Drive Unit a) Operator’s speed control set to its zero-position. Where motorized potenti-
ometers are used, this can be done by operating the Increase/Decease
speed buttons.

5
 efesotomasyon.com - Control Techniques,emerson,saftronics -ac drive-servo motor

SAFTRONICS
b) Where tachogenerator feedback is used, it will not initially be certain whether
the signal is of the correct polarity. It is, therefore, suggested that the tacho-
NOTE: In de-energized state,
generator be electrically disconnected temporarily. The drive will automati-
the field economy circuit will be
operation. The field voltage will cally revert to the correct polarity armature feedback, and the drive can be
be at 2/3 normal level until the set up initially on this feedback signal.
DC6 is started. c) Ensure that the Shunt Field voltage is at the correct maximum value.

Press the Start pushbutton and slowly adjust the Operator’s Speed control in a clock-
wise direction until the motor starts to turn and accelerate up to the set speed.

CAUTION: Dangerous voltage Check that the motor is turning in the correct direction. If the motor is not turning in the
will be present if power is not correct direction, switch off the power and reverse the connections to the motor’s
removed. shunt field.
NOTE: The Trip circuit may
operate at 12 second intervals Restore power to the drive, and run the motor once more. The motor should now turn
during this procedure and re- in the correct direction.
move power from the motor.
This is normal, and the Stop/ While the motor is running, check the polarity of the voltage generated by the tach.
Start circuit should be re-acti- When this polarity has been determined, switch off the drive unit and re-connect the
vated after such a trip. Once the
tach to the drive with the polarity indicated in this manual or in the Engineering Draw-
correct maximum motor current
and speed has been set up, the ing supplied if a standard non-modified DC6 was purchased.
Trip circuit will act correctly,
Restore power to the drive and run once more. The motor should be running under the
that is only remove power from
the motor if it has stalled for a influence of the tach, and the ST light should be glowing brightly.
period longer than 12 seconds
If the motor accelerates to the absolute maximum speed, regardless of speed setting,
under maximum current condi-
tions. this will indicate that the tach voltage polarity is incorrect, and should be rechecked.

3.3 Maximum Speed With Armature Feedback

Adjustment This adjustment should be carried out with the tach disconnected from the drive unit, if
this option is used.

Start the drive and set the operator’s speed control to maximum. Adjust the control
“AV” (RV2) on the control card for the correct maximum armature voltage indicated on
the motor nameplate. Once this adjustment has been carried out, the tach connec-
tions can be restored to the drive unit.

With Tach Feedback(Optional)

Set the operator’s Speed Control to maximum, and check the motor speed by holding
a hand tach to the motor shaft or by checking the tachogenerator voltage. The stan-
dard tach type 5PY used by Saftronics is rated at 50 Volts/1000RPM. This should,
Note: If the tachometer is 100V/ however, be confirmed by referring to the tach nameplate. It will also be noted that with
1000 rpm and the motor is 1750 the Speed Control set at maximum, the DV lamp on the AA650 card will glow brightly.
rpm, then put an 82K resistor in Adjust the Maximum speed control,RV6 on the AA650 card, for the required maxi-
series with the tach lead.
mum speed; usually 1750RPM, or 87.5 Volts on the 5PY tach.

3.4 Minimum Speed Set the operator’s Speed Control to zero while the drive unit is on, and adjust the Mini-
Adjustment mum speed control, RV7 on the AA650 card, for the correct minimum speed.

6
 efesotomasyon.com - Control Techniques,emerson,saftronics -ac drive-servo motor

SAFTRONICS
3.5 Tach Loss Protection When steps 2.3.5, 2.3.6, and 2.3.7 have been carried out, it will be possible to check
Check this feature as follows:
With the motor running at half speed, remove one of the tach connections from
the drive. The control should now revert to impedance-isolated armature volt-
age feedback and the motor speed should only change marginally (it can either
increase or decrease depending on the setting of “AV”, RV2, with respect to the
Maximum speed adjustment).

3.6 Speed Stability When in operation, the drive unit regulator may be unstable. This becomes evident
Adjustment when the motor speed is unstable or erratic. The Stab control, RV5 on the AA650 con-
trol card, should be adjusted whenever necessary so that the motor speed is smooth
and stable, with very little under or overshoot with speed changes.

3.7 Normal Current Limit With the motor running normally, at maximum speed, adjust the Current Limit control
Adjustment towards minimum until the motor speed starts dropping. Stop the drive unit, and
switch off the AC supply. Disconnect the field supply from the motor, and jam the
shaft to prevent it from turning. Field loss relay protection, FLR must be bypassed in
the 120 vac control logic during this set up.
NOTE: The motor may stop com-
pletely, but this is quite normal. Restore power to the drive, set the speed control to minimum and press the Start
pushbutton. Slowly increase the speed control to maximum.The motor armature cur-
rent will rise to a low value, as indicated by an ammeter and the stall LED. ST will go
off, indicating that there is a 12-second period in which the current limit can be set be-
NOTE: Compound Motors gen-
erate considerable torque even fore the trip circuit comes into operation. Adjust the Current Limit (CL) control slowly
without SHUNT FIELD excita- toward motor nameplate full load current rating.
tion, so it is advisable to leave
NOTE: The TRIP circuit may frequently operate during this adjustment, but
the series field winding discon-
this is quite normal as it will depend on how long the adjustment takes to be
nected from the armature circuit
carried out.
as previously suggested (see
section 3.1).
The TRIP circuit prevents the motor from drawing high current for excessive periods,
while in the stall condition. The Start/Stop circuit should be re-activated to clear this
condition.

After set up disconnect power, remove the object jamming the shaft, and re-install
field cables and field loss protection circuit.
3.8 Two-stage Current With the two-stage current limit feature, it will be essential that the Burden Resistor be
Limit Adjustment sized to give the desired break away current. Standard drives are supplied with Bur-
(Optional) den Resistors sized for approximately 150% of full load current of the motor, with full
clockwise rotation of the current limit potentiometer.

The normal running current limit point can be set by inserting a resistor of a specified
value in place of the 0 ohm Resistor supplied with the standard card. This resistor is
R214 on the AA650 control card.

For a 200% break away current, the normal running current limit can be set by choos-
ing a resistor from the table below:

7
 efesotomasyon.com - Control Techniques,emerson,saftronics -ac drive-servo motor

SAFTRONICS

%
Resistance
Running
ohms
Current

200 0

150 330

130 560

120 680

100 1000

To set current limit with this option (two stage current limit) follow the proceedure laid
out in section 3.7 above.

After the current limit has been set to the break away current, the drive automatically
adjusts the current limit setting to the normal running limit after the 2S led has turned
on.

3.9 IR Compensation General

IR compensation must only be used with Armature Feedback control and should
never be used with Tach Feedback control.Therefore, where tach feedback is used,
this control must remain in the full counter-clockwise position. Furthermore, the motor
must be coupled to the machine before this adjustment is carried out.The purpose of
IR Compensation is to compensate for IR losses in the motor such that low speed
holding capability is improved with armature feedback control.

IR Compensation Adjustment
With the drive in operation at half speed, slowly adjust the IR compensation control
(RV8) clock-wise until there are signs of instability with quick speed changes from
25% to 75%. Slowly adjust the IR compensation control towards minimum again until
all signs of instability have disappeared. This will be the maximum amount of the IR
compensation that the machine will allow with good stability. It should be kept in mind
that where the machine is new or reconditioned, it may be “tight” initially, and it may be
found necessary to reduce the amount of IR compensation at a later stage to prevent
instability.

3.10 Acceleration/ The acceleration and deceleration control RATE I and RATE II respectively, can be ad-
Deceleration Adjustment justed for the required acceleration and deceleration to suit the application.

3.11 Jog Speed Where this feature is supplied, the Jog pushbutton must be pressed and the Jog
Adustment Speed control on the A650-MB-2 control board must be adjusted for the desired jog
speed.

3.12 General When all adjustments have been carried out, reconnect the series (compound) field
(see p4). It must be ensured that the series field is correctly connected such that it as-
sists the main shunt field of the motor and not oppose it.

8
 efesotomasyon.com - Control Techniques,emerson,saftronics -ac drive-servo motor

SAFTRONICS
4. DIAGRAMS
4.1 Block Diagram

9
 efesotomasyon.com - Control Techniques,emerson,saftronics -ac drive-servo motor

SAFTRONICS
4.2 Typical Wiring Diagram

10
 efesotomasyon.com - Control Techniques,emerson,saftronics -ac drive-servo motor

SAFTRONICS
4.3 AA650MB Schematic

11
 efesotomasyon.com - Control Techniques,emerson,saftronics -ac drive-servo motor

SAFTRONICS
4.4 A650 Control Schematic

12
 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

A +26V +26V

450 uSEC
0V 0V
100R 1/2W

R42
R43
D4 T1 D11
G1 G4
C7 D5 C2 D10
D3 C5 C6 D12
220R .022 10uF 220R

R44
R45

B .1 10uF .022 .1
X-COUPLE +V +V X-COUPLE
K1 OUTPUT 1 OUTPUT 7 K4

+V 100K
2 AT9

R6
R14
AT8 D16 7 100K D17 1K
1K
6
TP13 R22 4K7 2K2 2K2 4K7 QA6 R39 TP14
AT5 3
AT7 4 R25 R18 R13 R36 AT6 AT10
C -V D28 AT4
D18 AT3 AT2 D23

R12
22K

R24
R37
22K
15K D20 1K5 D9

R23
R38
15K

15K
D6 4K7 D21
X-COUPLE R11 X-COUPLE
INPUT 1 -V -V INPUT 7

R31

R30
15K 6
-V C3 15K -V
4.4 A650 Control Schematic cont'd

R8

R19

R10
1K5 7 4 47K .1 15K
+V -V
AT1 D22
D 9.1V L1 2 3 5K6 -V
+26V +V +26V
D2 C4 R34

D15 .22 +V
0V

R9
0V +V

R1
D14 10K 10K
1K5 6

R5
R17
0V 0V
E +V
2 -V R32
7
6
QA3 R7
3

R33
R35
4 1K5 D8 56K 56K +V
-V 2 7
10V -V -V 6
QA2
3
4 D7
F
-V 4.7V
10V

R2
68K 10R

R26
10K
0V D19

R29
R28
R27
22K

4K7
+12V -12V +26V
-V
-V
D24 D25 0V
-10V

G
INHIBIT RAMP REF CONTROL INHIBIT +12V -12V +26V 0V
SIGNAL 9.1V SYNCHRONIZING SIGNAL -10V SIGNAL
INPUT

TRIGGER CIRCUITS A, B, C AS ABOVE

H

UNLESS OTHERWISE SPECIFIED DIMENSIONS ENG BP 07 SEP 90

ARE IN INCHES & TOLERANCES ARE:
ANGLES DECIMALS DRAWN JM 07 SEP 90
+ = + .XX
- - = APP'D

- = - = .XXX
THE INFORMATION, DATA, AND DESIGNS
SAFTRONICS
SOLID STATE MOTOR CONTROLS
CONTAINED ON THIS DRAWING
MATERIAL SPECIFICATION ARE CONSIDERED
CUSTOMER

PROPRIETARY INFORMATION DC6

OF SAFTRONICS, INC.
DISCLOSURE, PUBLISHING, AND USE
CONTROL CARD
WITHOUT THE EXPRESS WRITTEN AUTO CAD # SHEET DRAWING/PART NUMBER
CONSENT OF SAFTRONICS, INC.

REVISIONS
IS PROHIBITED.
AA6502 2 OF 3 AA650
efesotomasyon.com - Control Techniques,emerson,saftronics -ac drive-servo motor

13
SAFTRONICS
 efesotomasyon.com - Control Techniques,emerson,saftronics -ac drive-servo motor

SAFTRONICS
5. BURDEN RESISTORS

240 VAC 480 VAC

Burden O/L Heater or Burden O/L Heater or
Current resistor Setting Current resistor Setting
HP F/B CT ohms O/L CT F/B CT ohms O/L CT
5 1500:1 120 - FH46 1500:1 270 - FH38
7.5 1500:1 82 - FH50 1500:1 180 - FH43
10 1500:1 56 - FH54 1500:1 125 - FH46
15 1500:1 40 - FH83 1500:1 82 - FH49
20 1500:1 30 - FH86 1500:1 68 - FH53
25 1500:1 25 - FH89 1500:1 50 - FH55
30 1500:1 20 - FH90 1500:1 47 - FH82
40 2500:1 27 250:5 2.3 1500:1 33 - FH85
50 2500:1 22 250:5 2.9 1500:1 27 - FH88
60 2500:1 18 250:5 3.3 1500:1 22 - FH89
75 2500:1 15 250:5 4.2 1500:1 18 - FH92
100 2500:1 12 500:5 2.8 2500:1 22 250:5 2.6
125 5000:1 18 500:5 3.5 2500:1 18 250:5 3.3
150 5000:1 15 500:5 4.1 2500:1 15 250:5 3.9
200 - - - - 2500:1 12 500:5 2.6
250 - - - - 5000:1 18 500:5 3.2
300 - - - - 5000:1 15 500:5 3.9
400 - - - - 8500:1 20 1000:5 2.6
500 - - - - 8500:1 15 1000:5 3.3
600 - - - - 8500:1 12 1000:5 4.0
700 - - - - 8500:1 10 1000:5 4.7
800 - - - - 8500:1 10 1500:5 3.6

Burden resistor calculation:

R=1.53 x CT / FLA
Where R = burden resistor in ohms,
CT = Current F/B ratio
FLA = Motor full load amps
Example: FLA = 100, CT = 1500:1, then
R= 1.53 X 1500 / 100 = 23 ohms, use 22 ohm, 3 watts.

14
 efesotomasyon.com - Control Techniques,emerson,saftronics -ac drive-servo motor

SAFTRONICS
6. TROUBLESHOOTING
The three most frequent causes of a drive system or major component malfunction
are:
1. Fuse failure.
2. Discontinuity in a circuit, caused by a broken or loose connection of the wir-
ing.
3. Circuit grounding, caused by faulty or damaged insulation or wiring or a loose
component coming in contact with ground.

If a drive or major component, that has been operating properly, suddenly malfunc-
tions, do not make any adjustments or replace any components without first check-
ing:
1. For blown fuses.
2. All connections for tightness.
3. All wiring for breaks.
4. All wires for faulty or damaged insulation.

If, after making the above checks, trouble is still encountered, refer to the following
trouble shooting table.

SYMPTOM PROBABLE CAUSES

1. Overload relay tripped.

2. No control power. Check for 120 vac supply.
Contactor will not
3. Faulty or improper wiring between drive cabinet and operator's control station.
energize when Star t
4. Field loss relay contact open.
button is pressed
5. Open contactor coil.
6. Safety circuit open.

Output voltage does 1. Improper or defective wiring between cabinet and speed pot.
not increase as speed 2. Defective speed pot.
pot is turned up. 3. Defective AA650 card.

1. IR drop compensation set too high.

2. Motor series field connected backwards.
Drive unstable.
3. Defective AA650 card.
4. Stability pot needs adjustment.

1. Current limit set too low.

Speed drift or poor 2. Motor overloaded.
regulation 3. Defective AA650 card.
4. Defective A650MB-2 assembly.

1. Current limit set too low.

2. Motor overloaded.
3. Max speed pot not adjusted properly.
Low maximum speed
4. Defective wiring between AA650 card and A650MB-2 assembly.
5. Open scr gate.
6. Low reference voltage

15
 efesotomasyon.com - Control Techniques,emerson,saftronics -ac drive-servo motor

SAFTRONICS

SYMPTOM PROBABLE CAUSES

1. Current limit set too high.

2. Ground in motor armature or field.
Circuit breaker trip 3. Defective SCR.
4. Defective AA650 card.
5. Defective A650MB-2 assembly.

1. Shor ted or grounded DC output wiring.

AC line fuse/fuses 2. Grounded motor armature or field.
blown 3. Shor ted motor field.
4. Defective SCR.

Control circuit fuse 1. Defective wiring or component contacting ground or other circuits.
blown 2. Shor ted relay or contactor coil.

State of LED's
When power is applied:
-V R DV VA CA ∅1 ∅2 ∅3 ST TR 2S ∅ +V

When the start pushbutton is pressed:

-V R DV VA CA ∅1 ∅2 ∅3 ST TR 2S ∅ +V

LED on

LED off

LED dim

16
 efesotomasyon.com - Control Techniques,emerson,saftronics -ac drive-servo motor

SAFTRONICS
7. SPARE PARTS

MODEL NUMBER
PART
DESCRIPTION
DC6-61 DC6-126 DC6-251 DC6-350 DC6-500 DC6-800

Control Card AA650 AA650 AA650 AA650 AA650 AA650

List Price $1500 $1500 $1500 $1500 $1500 $1500
Recommended Quantity 1 1 1 1 1 1

Mother Board
240V A340001 A340001 A340001 A340001 A340001 A340001
480V A340002 A340002 A340002 A340002 A340002 A340002
List Price $600 $600 $600 $600 $600 $600
Recommended Quantity 1 1 1 1 1 1

Suppression Card AA1094-2 AA1094-2 AA1094-2 AA1094-2 AA1094-2 AA1094-2

List Price $105 $105 $105 $105 $105 $105
Recommended Quantity 1 1 1 1 1 1

Ribbon Cable W2600-36 W2600-36 W2600-36 W2600-36 W2600-36 W2600-36

List Price $35 $35 $35 $35 $35 $35
Recommended Quantity 1 1 1 1 1 1

S523002-- S523002-- S523002-- S523002-- S523002-- S523002--

Stack Over temp Switch
03 03 03 03 03 03
List Price
$20 $20 $20 $20 $20 $20
Recommended Quantity
1 1 1 2 2 2

F602003-- F602003-- F602003-- F602003-- F602003-- F602003--

AC Line Fuse
09 11 20 20 23 25
List Price
$36 $54 $67 $67 $93 $168
Recommended Quantity
3 3 3 3 3 3

SCR N10SP06A N10SP06A N20SP10 N728452 N716452 N719122

List Price $150 $150 $285 $225 $240 $397
Recommended Quantity 3 3 3 6 6 6

Field Bridge D310002 D310002 D310002 D310002 D310002 D310002

List Price $33 $33 $33 $33 $33 $33
Recommended Quantity 1 1 1 1 1 1

FIELD LOSS RELAYS

RATING PART NUMBER LIST PRICE

0.25 - 1.0 Amps A450001 $115

1.0 - 4.0 Amps A450002 $115

4.0 - 10.0 Amps A450003 $115

2.0 - 6.0 Amps A450004 $115

17
 efesotomasyon.com - Control Techniques,emerson,saftronics -ac drive-servo motor

SAFTRONICS
8. WARRANTY
Saftronics warrants to buyer that products, and any services furnished hereunder will
be free from defects in material, workmanship and title, and will be of the kind and
quality specified in the quotation. The foregoing shall apply only to failures to meet
said warranties (excluding any defects in title) which appear within one year from the
date of shipment hereunder, provided, however, that if buyer, in the course of its regu-
lar and usual business, transfers title to or leases such products (including equipment
incorporating such products) to a third party, such period shall run until one year from
such transfer or lease or eighteen months from shipment by Saftronics whichever oc-
curs first. The warranties and remedies set forth herein are conditioned upon (a) prop-
er storage, installation, use and maintenance, and conformance with any applicable
recommendations of Saftronics and, (b) buyer promptly notifying Saftronics of any de-
fects and, if required, promptly making the product available for correction.

If any products or services fails to meet the foregoing warranties (except title),
Saftronics shall thereupon correct any such failure either, at its option, (i) by repairing
any defective or damaged part or parts of the products, or (ii) by making available
FOB Saftronics plant or other point of shipment, any necessary repaired or replace-
ment parts. The preceding paragraph sets forth the exclusive remedies for claims
(except as to title) based on defect in or failure of products or services, whether claim
in contract or tort (including negligence) and however instituted. Upon expiration of
the warranty period, all such liability shall terminate. The foregoing warranties are ex-
clusive and in lieu of all other warranties, whether written, oral, implied or statutory. No
implied statutory warranty of merchantability or fitness for particular purpose shall ap-
ply and Saftronics will not be liable for any consequential damage arising from any
product defect or failure to deliver on time. Saftronics does not warrant any products
or services of others which buyer has designated.

18