PNPIld 4A9Vsd] SoNDIUYIG! 10.19U09 Spectrum 5 HP to 250 HP Adjustable Voltage DC Drive 9 EMERSON. Industrial AutomationSECTION 44 42 43 44 45 48 47 a7A 472 TABLE OF CONTENTS TLE PAGE PERFORMANCE FEATURES. Identification Ratings and Dimensions Specifications Service Conditions Performance Spectications ‘Adjustment Rangos (Typical) Protection and Performance Features . - Gonoral Description Modification Kit... Options. FUNCTIONAL DESCRIPTION Basic Functional Deseription Basic Circuit Analysis INSTALLATION AND START-UP INSTRUCTIONS | Safety Warnings Initial Checks... Installation Location of Control Wiring. Power Wiring Relay Control Wiring Signal Wiring Field Connections Programming Jumpers... Line Frequency ... Feedback Source Selections Feedback Range Jumper. Input Vottago Select... Fiold Loss Defeat Other Jumpers, Shunt Resistor Cooling Fan Select... Contact Suppression Start-up Procedures . Power-Off Checks. Power-On Chocks Adjustments enon IR Compensation MAINTENANCE AND ‘TROUBLESHOOTING. Normal Maintenance General Troubleshooting ‘Symptoms and Causes... Spectrum | SCR Replacement Spectrum II SCR Replacement ‘Spectrum ill SCR Roplacement... ‘Spactrum IV SCR Replatement......22 Heat Sink Assembly (On Bench) Removal of SCR ... Re-Instalation of SCR. SECTION A TABLE ADDENDUM TLE PAGE Recommended Spare Parts .nnn28 LIST OF TABLES TITLE PAGE Recommended Lugs for Spectrum Drivas. o Full Load AC and DC. ‘Amp Ratings... 25 Allowable Ampacities of Insulated Copper Conductors. 26LIST OF FIGURES FIGURE Te PAGE FIGURE Tme PAGE 1 Outline and Mounting Dimentsions 11 Spectrum IV interconnect Diagram Spectrum | - IV, 2200-3108, Sheet 1..27 2200-1004... 7 2 uline and Mounting Dimensions 42 Spectrum IV Option Interconnect and Spoctrum |- IV, 2200-3108, Sheet 2..28 Gustomer Comneton Diagram, 2200-10405 3 Ouline and Mounting Dimensions ‘Spectrum | IV, 2200-3106, Sheet $..29 18 Spectrum Interconnect Diagram Option Kits, 2200-1750 arn: 4 Typical Connections .-30 14 Schematic Diagram - Main Control 5 Spectrum Interconnect Diagram .....91 Board, 2200-1000, Sheet 1 40 6 ‘Spectrum | Option Interconnect and 18 Schematic Diagram - Main Control Customer Connection Diagram, Voard, 2200-1000, Sheet 2... at 2200-1011-1. 22 16 Schematic Diagram for Field 7 Spectrum I irterconnect Diagram Economy Delay PC Boa’d onnnoe-A2. 2200-1006-I son 8 ‘Spactrum Il Option Interconnect and Customer Connecton Diagram 2200-1021-1 ean 9 ‘Spectrum Ill Interconnect Diagram 2200-1003-1 10 Spectrum tll Option Interconnect and Customer Connection Dasran, 2200-1030-1 36Section 1 PERFORMANCE FEATURES 1.4 IDENTIFICATION tis important that the control unit be identified accurately and completely. The drive model and serial numbers should be recorded bbolow for reference when consulting the EMERSON factory or Sales Representative, 5a [aac noe. [escare oo noe : ay 1 Gael 2 8 eco ee Pree i] L > Came) “Ee se Cem) “he joo Came] “ed ve ae Se Cae ae I" - 3 eC] a | h_ ce *e] i ==— =e = = Sei ad | eee aoe) beer area CONTROL NAMEPLATE This identtication tag may be found on the lft side ofthe drive chassis. If this drive is integrated into an EMERSON system, the system number should also be recorded, 1.2 RATINGS AND DIMENSIONS: The Spectrum series of D.C. Drive Controls introduces a new concept in D.C. Motor Control. There are four standard Spactrum models covering a range from 5 to 250 HP. Each covers its range with no need for spacial modifications, ‘The four Spectrum Drives are identified in the ratings table below. ‘REPOWER ‘DEPOWER FELD, WERT LOSS HORSEPOWER (KW) RATINGS inpur’ ‘ourpur. oureur DAVE Zoe] 418860 a aK Ta | aR VATTS MODEL zioaiso | 40060 seoaeo | _vours | aups| votts_|awes | vors [anes | “Yerunn ‘Spectunt | &-10HP | 5-206 | —(a78-r3xW) | 20060 | 28 | avon | aa | vsoa00 | a 37-400 Speorum | 18-30HP | 28-6 qe-saKw) | zs0e0 | 4 | 2aasoo | yoo | isoaoo | 8 | sar-iose Seecuumit | 40-soHp | 7-700HP (o-seKw) | z2000 | 199 | Zeno | te0 | isoaoo | is | 380-1678 Seecnmniv | 60° 320 | 125-250? (a2-resiemy | 2301060 | ssa | Zeas00 | 42¢ | tsoaoo | is | ste0- eer RATINGS TABLE DIMENSIONS (SIZES IN INCHES) SPECTRUM ‘SPECTRUM [SPECTRUM I SPECTRUM u [oo | w 4 o a [oo [wT lo (CHASSIS CONTROL wp pe | cn «| 2 | © [a] | DIMENSION TABLE1.3. SPECIFICATIONS: 1.3.1 Service Conditions * Rated Voltage input (208) 230 vats (0, 10%) AC. phase (416) 460 vot (-10, 10%) AG. 8 phase 5380 ots (10, 10%) AG. phase + Freque 5060 He (£2 He) + Ambient Temperature O to a0" G(a2"- 104" F) + nttuse Soa Level 02200 Feet + Efcioney at Rated Output: Power unt 86% or batter depending on selected rating Dive Sysiom 82% or beter depending on seactd ang * Power Facorconected A. Lines Dive instalation on power facor corrected AC. Lines should 9 evalvatod by ehorhe cal sles oo or Manvfactora's Field Sewice Department pir to startup 1.3.2 Performance Specifications * Adjustable, Linoar Timed AcceVDece!: 2-30 Seconds, * Controlled Speed Range: 20:4 + Current Limit: 0-150% * Speed Regulation: (lor a 95% Load Change) Voltage Regulated - 2-5% of maximum top speed, Speed Regulated - 0.5% of maximum top speed (A.C. oF D.C, Tachometer) Modified - 0 0.1/0.15% of top speed * For All Other Variables: Voltage Regulated - Changes of up to 15% of top speed can result from temperature variations, voltage and frequency variations and drift. Speed Regulated - A.C. tachometer - 2% ‘Speed Regulated - D.C. tachometer - 1% * Minimum Spoad Adjustment: 0.30% Rated Speed * Maximum Spood Adjustment: 70-120% Rated Speed * Overload Capacity: 150% of Rated Current for 1 * Service Factor: 1.0 1.3.3 Adjustment Ranges (Typical) Minimum Speed 0 t0.30% rated speod Maximum Speed 70 to 120% rated speed ‘Acceleration Speed 2 t0 30 seconds (linear) Decoleration Time 2 t0 30 saconds (linear) Jog Speed 0 t0 30% rated speed IR Compensation Oto 22% rated voltage Current Limit to 180% current 1.4 PROTECTION AND PERFORMANCE FEATURES ‘Six SCR Full Wave Power Bridge Provides improved orm factor for greater efficiency of operation. Inner Loop Current Regulator Inherent high band-wicth capability for fast response. ‘SCR Trigger Circuits Pulse Transformer isolated to withstand 2,400 volts, hard tring high frequency “burst” type pulse train output from individually gatedoscillaors insure SCR conduction regardless ofthe effects Of line notching on incoming A.C. power lites. SCR heating during turn-on is also minimized, A.C. Line Connections Control is insensitive to phase sequencing, Reactors, Snubber Networks Prevents interaction and SCR DV/DT failures, due to Ine “Spikes and Transients". Provides DUDT protection during SCR turn-on and aids in SCR turn-off during SCR commutation, minimizing the effects of A.C. power line notching, D.C. Overload (Armature) 188s overcurrent with inverse time trip. A.C. Line Filter and Transient Voltage Suppressor Network Eliminates interaction between the Spectrum Drive, and other drives or A.C. equipment Heat Sink Thermal Switch Prevents long term thermal damage to SCRs due to loss of ‘cooling or overheating. (Except Spectrum I) High Speed Current Limiting SCR Semiconductor Fuses, Provides protection of the SCRs and motor with positive ereut, Clearing for both A.C. or D.C. faults, Field Loss Protection ‘Sequences the drive in he event of loss of motor lled current. ‘Standard Fiold Adjustments ‘Maximum speed, minimum speed, jog speed, soparate acco!- ‘ration and deceleration time, stabilty, current limit, and IR ‘compensation, Dual Frequency Operation Basic controls are capable of operating from standard 50/60 Hz power suppliss, Function Indicators For A.C. power, D.C. output power, current limit, faut rip, and individual SCR indicators. Fault Indicating Lights and Protective Circuitry Provides LED indicators and positive drive shut down for heat sink over temperature, fisld loss, D.C. overload and instantane- ‘ous overcurrent, Test/Reset Pushbutton Provides check of fault detection circuitry and LED indicator with button depressed and resets control faultcondition is corrected. Static Adjustable Current Limit Allows static setting of desired current limit value without apply- Ing A.C. power and without aconnectedoutputload. Currontiit indicting ight is also supplied to provide visual indication when present current imit value is reached,1.8 GENERAL DESCRIPTION Main Circuit Board Indicators Light emitting diodes (LEDs) on the main citcuit board indicate the following: ‘AG. power on D.C. power on Current limit D.C. overload Fault trip In addition to these indicators, there are six LED indicators (one for each SCR) to indicate that each firing circuit is producing pulses. Fault Trip ‘The Spectrum series control board contains an instantaneous ‘fault trp protection circuit designad to shut the drive down any of the folowing conditions occur 1. Fiold loss (detoatable) 2. Heat sink overtemperature (excapt Spectrum I) 3, Instantaneous overcurrent (300% of rated). 4, Inverse D.C. overload (indicated by the D.C. overload LED). Test Reset tfany one! thepreviously stated faut conditions occur, the drive ‘can be reset by depressing the reset button on the main circu board. ‘The fault light will not reset if the fault condition is stil present. Control Circuit Board ‘The Spacttum series drives share a common circuit board. The Spectrum Illand iVcircuit boards have an extra one inch margin fon the lat and right sides but al are electrically Identical. The bboardis hingod and swings tothe lat for easy accesso the othor drive components. Isolated Control Circuitry Resistor isolation of the control circuitry from the power buss Provides added safety for maintenance personnel, as well as protection for tho control incase of agroundtautt. The ammator, speed potentiometer and tachometer are not at line potential WARNING ‘THE SECONDARIES OF THE TRANSFORMERS ARE AT LINE POTENTIAL AS WELL AS THE POWER SUPPLY TRANSFORMERS AND ALL CONTROL LOGIC CONNECTIONS ON TB1. THE REMAINING CONTROL CIRCUITRY IS RESISTANCE ISOLATED ONLY AND IS ALSO A SHOCK HAZARD! Current Feedback Isolation Currenttransformers on each ofthe three A.C. inputlines provide isolated armature current information to the main circult boar, Field Loss Isolation The fia current detection signal is isolated with the use of an opto isolator. Field Economy Terminals are provided on the main PC board for use with an externally timed contact for field economy contral (provided on Rev. "F"or later boards). On Spectrum | torminals aro identified as FESA & FESB. On Spectrum II, Ili and IV, terminals are identified as FE1 & FE2. When field economy is not used, termi- nals should be jumpered, Static Adjustable Current Limit Current limits adjustable without power applied to the system, ‘The current limit potentiometer is calibrated from 0 to 150% of rated armature current. A. Inputs - Phasing-Frequency ‘The Spectrum series of D.C. Motor Drives are insensitive to AC. line phase sequencing, The drives may be operated on 50 oF 60 Hz (selected by six Jumper wires on oldermodels; newer models uilize one jumper) Power Suppli ‘Spectrum drive controls contain internal 115 VAC, +24 VDC and regulated +15 VDC, -15 VDC and +10 VDC power supplies. The +10 VDC reference supply is separately regulated to prevent damage to the remaining supplies in case of a speed pol ‘grounding fault. NOTE Only the +10 VDC reference power supply is for cus- tomer use, and is intended for use with a 2K ohm (minimum)'Speed Potentiometer only. Cooling ‘The Spectrum | Drive is designed for adequate heat dissipation throughout its rated horsepower range (assuming that venation is not restricted) without the need for cooling fans. The Spectrum I, Il, and {V are supplied with cooling fans. In addition, each of these models have thermal switches mounted fon the SCR haat sink assombly programmed to sequence tho drive off in the event of heat sink overtemperature due to fan failure or air flow restriction. 1.6 MODIFICATION KITS WARNING THE FOLLOWING MODIFICATIONS KITS ARE DESIGNED FOR USE ONLY WITH THE SPECTRUM. ‘SERIES DRIVE CONTROLS, ANY APPLICATION OF ‘THESE KITS OTHER THAN AS STATED BY MANU- FAGTURER VOIDS ALL RESPONSIBILITY AND WARRANTIES, STATED OR IMPLIED. ‘Additional lexibilty is incorporated into the Spectrum serias with the availabilty of Modification Kits, These kits come supplied with all hardware, connection wires and instructions, Available Kits Include: NEMA Cabinets NEMA Type 1 -General purpose indoor enclosures available for all four Spactrum models. TENY Type - For indoor industrial use. Drip tight and dust tight for use with Spectrum | and Il only, Pre-Drilled Mounting Panels NEMA 12 construction pre-dilled and tapped for mounting the Spectrum Drive unit and options.1.6.1 Options 150 VA, 115 VAC Control Transformer PIN 2200-9120 Provides 50 VA of 115 VAC power for powering optional mocif- cation kits and 100 VATer customer use. Programmable 230/460 VAG input dual primary windings witha fused secondary Armature Contactor (PIN - Consult the Emerson Drves Catalog) For use as required by National and Local electrical codes, Fused AC Motor Starter (PIN - Consult the Emerson Drives Catalog) This option provides afused AC motor across-the-line starter, All ‘Spactrum models use NEMA size 00 starters and are suppiiod with adjustable thermal overload heaters, The 150VA, 115 VAC. Control Transformer (P/N2200-9102)is required when using this option, Dynamic Braking Resistors {PIN- Consult the Emerson Drives Catalog) ‘These high power resistors are designed to oloctrioally dissipate the inertial energy of the motor fora quick stop. Kits supplied for Spectrum | & Il are panel mountable with hook-up cable provided. Spectrum Ill & IV units ere supplied with cages for outside cabinet mounting. AC. Line Disconnect Switch (Non-Automatic) (PIN - Consult the Emerson Drives Catalog) WARNING ‘THIS CIRCUIT BREAKERISINTENDED FORUSE AS: A DISCONNECT SWITCH AND IS NOT DESIGNED FOR OVERLOAD PROTECTION. OVERLOAD PRO- ‘TECTIONISINCORPORATED INTO THE SPECTRUM. DRIVE UNIT ITSELF. Ammeter (PIN (Consult the Emerson Drives Catalog) Monitors armature current feedback. Dual range selector switch {or high or low current calibration Test Meter PIN 2200-9001 Dosigned to provide the user with a quick and easy means of ‘measuring the following functions: |. Line to line voltage L1-L2. Line to line voltage L2-L3. Line to line voltage L3-Lt 115 VAC control voltage. +15 VDC supply voltage. +15 VDC supply voltag ‘Armature voltage. Velocity error signal, Current error amplifier output 10. Percent armature current. 11, Field voltage. ‘Spood Metor Interface Board PIN 2200-9003 Designed for use with the speed meter option. interfaces the armature or tachometer voltage to the meter movement, Pro- vidos resistive isolation, Speed Meter PIN 2200-9074 For use with the speed meter interface board, Indicates motor or line speed ona Oto 100 % scale, Three ranges and acalibration potentiometer are included. Disconnect Door Interlock (PIN Consult the Emerson Drives Catalog) ‘Spectrum Drives with cabinet and circuit breaker canbe supplied with his through-the-door circuit breaker operating deviee. twill prevent the cabinet door from being opened when the circu reaker is closed, Process Signal Follower PIN 2200-9064 Accepts a 410 40 millamp signal o produce a Oto 10 vol drive reference signal. The Control Transformer option is required. Voltage Signal Isolator PIN 2200-9065 ‘Accepts an external voltage signalto produce a Oto 10 volt drive reference signal. Requires the Control Transformer option Field Range Regulator PIN 2200-9066 Regulates motor field current and is designed for use as a field weakening unit for wide range speed control Master Reference Kit (PIN Consult the Emerson Drives Catalog) ‘Accepts a single spoed potentiometer command to provide 10 isolated reference outputs, Requires the Control Transformer Ramp Stop/Zero Speed Detector PIN 2200-9068, Allows the Spectrum Drive to ramp to a controlled stop. Also detects (by relay contact closure) zero speed. Raaquires the Control Transformer option. Reverse By Selector Switch (PIN Consult the Emerson Drives Catalog) Reverses motor direction with the use of a switch. Revorsible only at zero speed. Requires the Control Transformer option. Ammeter Shunt Kit (PIN Consult the Emerson Drives Catalog) ‘These kits (total of 12) ware developed for use with standard 50 mV meters available off the shoSection 2 FUNCTIONAL DESCRIPTION 2.1. BASIC FUNCTIONAL DESCRIPTION ‘The Spectrum control series integrates an inner currentservo oop with ahigh gain outer velocity servo loop. An advantage of this system 168 astable current loop is realized, it willimit the currentto the D.C. motor. This wll protect the motor, power bridge, and uses ent of abnormal transient loading conditions (sudden changes), BASIC BLOCK DIAGRAM Inner Current Loop Thinner currentloop employs armature current feedback. The armature currants sensed by three current transformers (one for each of three phases) inductively coupled to the incoming lin ‘The current ioop reference (command) is the output ofthe velocity error amplifier. This command causes an armature current (result) propontional to the command, Outer Vetocity Loop The outer velocity loop employs voltage (proportional to speed) feedback suppliedby atachometerorby sampling thearmature voltage itself, The afore-mentioned current loop is contained within the velocity loop andis aslavotoit. A referance voltage tothe velociy error ampiier causes the current loop to function within its limits until the velocity feedback signal is sutfcient to nul the reference signal, Power Converter Line veltage conversion from A.C. to D.C. is accomplished with a six olament, three phase full wave silicon controlled rectifier (SCR) powerbridge. The SCRis an electronic switch (thyristor) which is switched on (triggered) at specific phase angles af the incoming AC. line, thereby controlling the average D.C. output votage to the motor armature, The inner current loop is in fotal control of this SCF bridge,BLOCK DIAGRAM A dotailed block éiagram of Spectrum D.C. motor driveis located below. The generalflow is explained inthe following crcult description. 406 Vv AY YY vevocity ERfod AMP i YE - errors ERROR AMP ‘ADS. a * Sa 4 MAX z Sef uit, (Se COMPARATOR x osc te { Lapp -1Vve 100% 1 44] pave [rt [SAB INHIB VS As SYNC ue FEY Traneoren — RAYP SHAC ‘SPECTRUM BLOCK DIAGRAM 2.2 BASIC CIRCUIT ANALYSIS ‘Acoel/Decel When érive run is initiated, an adjustable 0 to +10 Vis applied to the acco/deca circuit (L4A and L4B) from the speed potentiometer, ‘The output ofthis circuit rises linearly to the amplitude of the input (TB1 terminal). The rate of change of the output being determined by the acceleration adjustment setting when the input swings more positive, and the deceleration adjustment when the Input swings less positive. The output (TBI terminal 12) ofthis creuit is the velocity reference voltage (the polarity being inverted). Clockwise potentiometer rotation increases the acceleration or deceleration ime, EXTERNAL SPEED cRR Pot . 2K,2W ear EXTERNAL pecen JUMPER TE Ps SPEED om ACCELDECEL CIRCUIT 6VELOCITY ERROR AMPLIFIER ‘The negative reference voltage outputof the accel/dece! circuits applied tothe high gain velocity error amplifier L3A (inputtothe velocty ertor ampitior appears on TBI terminal 12). The feedback signal from either armature voltage or the tachometer voltage is algebrai- cally added to this reference voltage producing a velocity error signal at the output of the velocity error amplifier (TBI terminal 18) Potentiomater PS is the velocity stablty adjustment. Itis used to match the outer speed loop tothe inertial loading of the motor being Controlled. Potantiometer P4 isthe jog sped adjustment (note that the Jog Input Isto the error amplfiar which bypasses the accel! doce! circuit and isa "step" input). Potentiometer P8 isthe IR. compensation potentiometer (which compensates for armature resistive losses) and, as such, is a positive feedback signal, which if over compensated, can cause unstable operation. This adjustment is nor ‘mally factory set (CCW) and should be left counterclockwise for tachometer faedback (refer to set-up procedure, Section 3). The output of the velocity error ampiiar is a positive voltage. Feodback is scaled and ampltied by L7B and the max speed pot. L7Ais a differential amplilier that provides resistive isolation ofthe control circuit from the armature. Jumpers JP2 can be cut for maximum isolation when tach feedback is usedor can belt in atalltimes, -JP2 jumpars must be in for armature feedback. act Low, u MED. ty te =] [] [F (Oe STABILITY Cee NEGATIVE CURRENT. ‘eeDback pertnence cry to Tociovoe) 18 cour y00 re PEED VELOCITY ERROR AMPLIFIER 7CURRENT ERROR AMPLIFIER ‘Tho current error amplifier (L3B) receives a positive voltage trom the velocty error ampli (TB! terminal 19) and a negative current foodback voltage from the current transformers. The ouiput (L3B pin 7)s a negative voltage with sufficient amplitude to gate the SCR fring circuits on at the required phase angl Current limiting is achioved at the input to this amplifier. Potentiomenter P7 (current adjust limit) forms a voltage divider which limits the amplitude of the velocity error signal (limiting the current command reference) reaching the current error amplifier, ‘A cutrent limit condition is signaled by a yellow light emitting diode (LED). When the output of the velocity error amplifier reaches approximately 12 volts, DZ2, a 10 volt zener diode begins to conduct, ighting the LED. (CURRENT PULSES ARMATURE VOLTAGE. CURRENT FEEDBACK WAVEFORMS EXTERNAL ER positive _ VELociTY ERROR SIGNAL, NEGATIVE TRIGGER SIGNAL, -1V@ 100% ‘CURRENT CURRENT EXTERNAL, ‘TRANSFORMER>— SHUNT wwpuT RESISTOR > © venores ta AuMeTER 0 EE C) oenores ros conneevions CURRENT ERROR AMPLIFIER,TIMING RAMP CIRCUITS ‘An A.C. line syne signal is applied to the Q1-L1B switching amplifier arrangement. The output of L1B is an open collector configuration ‘Which removes any charge that may be present on C2, and allows ito charge only while the A.C. line sync signal to Q1 is a positive voltage. This arrangement produces a 60 Hz timing ramp. Tho slope of this timing ramp is determined by P1, R3 and RN1-9. Phase balance adjustment and 50 Hz compensation is accomplished by adjusting the charge rate of capacitor C2, There are six timing ramp Circuits followed by six comparator-oscllator circults (one for each SCR). +15v Iyer BEMOYE rni-o{ | lupr FoR soHz 10 [OPERATION REMAINING <—_[-— 5 POTS, R3 BALANCE ‘ba 1a1,L1-8) eT sync InpuT SyNcHRONzED RAMP OUTPUT. PHASE SHIFT ce ee NETWORK, T 171 TIMING RAMP CIRCUITS FILTER AND: ‘TRIGGER PULSES. ‘TYPICAL TIMING CIRCUIT WAVEFORMS. COMPARATOR AND GATED OSCILLATOR CIRCUITS L1Cis voltage comparator whose threshold voltage levels controled by the negative trigger signalof the currenterror amplifier. When «a condition exists such that the voltage level ofthe timing ramp exceeds the threshold voltage lavel ofthis comparator gate, the output of L1C toggles to OV causing L1A to toggle positive. This signal enables the gated oscillator L2. The gated pulse train output of L2 is then routed to the SCRs through the isolator pulse transformer, TS. Each of the sbx trigger circuits recelves a 60° displaced synchronizing signal. This results in six current pulses to the motor par line cycle, TRIGGER SIGNAL (INVERTED) TIMING RAMP TRIGGER PULSES COMPARATOR TIMING WAVEFORMS EXPANDED VIEW OF THE TRIGGER PULSES 8+8v cm a me, pseu wane me Eee covion COMPARATOR AND GATED OSCILLATOR CIRCUITS Fault Trip ‘The Spectrum faut trip circuit is designed to protect equipment inthe event of 1. Field loss, 2. Heat sink overtamperature (except Spectrum 1). 3, Instantaneous overcurrent (300% of rated). 4: Inverse time D.C. overioad. 5. Phase loss or current imbalance. {nthe event that any of these conditions occur, Q6 is turned off, de-energizing control relay CRFT. This sequences the drive control off, Inthis condition, the lockout inputs to the gate circuits are pulled low, preventing SCR fring. Field loss, heat sink overtemperaturo, and instantaneous overcurrent protection are achieved by turning Q8 off, which is normally Biased on, triggering SCR 2 ‘The D.C, overload circuit consists of two operational amplifiers, one being an integrator (LSA), the other (LSB) a comparator. When ‘the armature current exceeds rated current (or a current feedback voltage greater than 1 volt), the integrator wlllegin to ramp poskive {the rato of rise being proportional to the amount of overcurrent). When the integrator ramps to approximately +10 volts, the compara. ‘or will swing positive and trigger SCR 1. This circuit allows the control to be in 150% current limi for approximately one minute, then ‘sequences the drive off. The reset willbe disabled for approximately one minute (a graphical representation of overload current vs, time ean be found on the following page). NOTE iald oss protection may be disabled by jumpering terminals “O" and "N’ at TBS. Relerto startup procedures, Phase lose is detected by QS, and L6 which s also a current balance monitor. Severe current pulse imbalance will shut the drive down. i so (uiren | Maran Fi = "EE | rowers 10Control Logic ‘To sequence the drive on andoff,115 VAC push-button switches (momentary contact) are used. The 115 VAC control voltage is convertadto 48 volts or 24 volts D.C. to oporate thecontrolrelays. Atypical run sequence follows: ‘Tho run pushbutton is depressed making a momentary closure between terminals #8 and #6 of TB1. This energizas CRA andis 150% interlocked "ON" via one of its normally open (NO) contacts. At the same time, another "NO" contact of CRR closes and supplies 190%, 115 VAC tothe coil of armature contactor control relay MC. This inturn will cause a "NO" contact of MC to clase and is tobe used soot the customer to energize an external DG loop contactor. A 10" contact o his contactors then returnadto terminals #2 and, 20% #3 of TBI, that, when closed, (when the DC loop contactor is closed) energizes control relay CRP. CRP then releases the clamp on the velocity and current eiror amplifiers. CRP also 0% ‘enables the field loss detection circuit. typical jog sequence wouldbe the samo asthe run sequence exceptthatamomntary RATED. 7 * mips) closureis made betweentorminals #4 and #60f TBI andthat CRU is not interlocked “ON" (CRJ Is de-energized when closure bbotween #2 and #3is opened). Itshould also ba noted that inthe run mode, jog cannotbe energized (although a run command wil override a jog cond se toa INVERSE TIME TRIP OVERLOAD CHARACTERISTICS t = aan O venores reau~ IMAL CONNECTION wadeet BRS on rel. —'-—, \ NO FRTT H8ERoswiten So w contactor CONTROL cincUIT Spectrum Main Control Board CONTROL LoGic ‘TWO WIRE OPERATION NOTE: TWO WIRE OPERATION: When two wire ‘operation is used, the "No Fault” Contact provided by NFLT Relay and the Motor Thermal switch should be wired into the system providing the Fun Contact so that resotting the faut in the drive cannot cause a Drive Start. Likewise, the Motor Thermal should be wired into the system providing the Run Contact so that motor ‘cooling will not cause a Restart. Drive Starts should be initiated only by the machine operator when possible "12Section 3 INSTALLATION AND START-UP INSTRUCTIONS. 3.1 SAFETY WARNINGS Improper installation or operation of this drive control may cause injury to personnel or equipment — read operating instructions, ‘The drive must be installed and grounded in accordance with local and national electrical codes. To reduce potentialof electric shock, disconnect all power sources before initiating any main- tenance or repairs. Keep fingers and foreign objects away from ventilation and other openings. Keep air passages clear. Poten- tial lethal voltages exist within the control unit and connections, Use extrome caution during installation and start-up. 3.2 INITIAL CHECKS Before installing the drive control, check the unt for physical damage sustained during shipment. Remove all shipping re- straints and padding, 3.3 INSTALLATION LOCATION OF CONTROL Spectrum control units are suitable for most factory areas whore industrial equipment is installed. The control and operator's ‘control station should be installed in a woll ventilated area. Lo- cations subject to steam vapors or excessive moisture, oil vapors, flammable or combustible vapors, chemical fumes, cor rosive gases or liquids, excessive dit, dust or lint should be avoided unless an appropriate enclosure has baen supplied or a ‘lean ai supply s provided othe enclosura. The location should ‘bodry and the ambient temperature should not exceed 131° F for chassis mount or 104 °F for an enclosed unit. i the mounting location is subject to vibration, the enclosure should be shock mounted. I the enciosure has a ventilating fan, avoid, wherever possible, an environmenthaving a high foreign:matter content; otherwise, the fiters will have to be changed more frequanty or micron-fi- tors must bo installed, ‘Should a control enclosure require cleaning on the inside, a low- pressure vacuum cleaner is recommended. Do not use an air hose because of high pressure and tha possible introduction of oil vapors in the compressed ait. 3.4 WIRING 3.4.1 Power Wiring The Spectrum will operate trom typical AC power ines. The line shouldbe monitored with an oscilloscope toinsure that transients, do not exceed limitations as listed below: 1. Repetitive line spikes of less than 10 microseconds must not ‘exceed the following magnitude, 240 Volts - 400 Volt Peak 380 Volts - 622 Volt Peak 4480 Volts - 800 Volt Peak 2, Non-repetitive transients must not excead 25 watt seconds of energy. Transients of excessive magnitude or time duration ‘can damage dvict networks or surge suppressors 3, Line notches must not exceed 300 microseconds in duration. 13 ‘An abnormal ine condition can reflact tse as an intermittent ower unit fault. High amplitude spikes or excessive notch conditions in the appliad power could result in a power unit failure. ‘The Spectrum drive control is insensitive to A.C. line phase ssoquencing, Connect power ines as outlined by local and national elect ccalcodesto the drive control. Throaded studs are supplied for line and armature connections. Charis of racammended lug ‘and wire sizos can be located in the addendum ofthis manual WARNING AN ARMATURE CONTACTORIS MANDATORY. USE OF THIS CONTROL WITHOUT AN ARMATURE CON- ‘TACTOR VOIDS ALL WARRANTY AND RESPONSI. BILITY OF MANUFACTURER STATED OR IMPLIED. IF A CUSTOMER SUPPLIED ARMATURE CONTAC- ‘TOR IS USED, IT IS IMPORTANT THAT ITS AUXIL- IARY CONTACTS MAKE AFTER ITS POWER CON- TACTS, AND BREAK BEFORE ITS POWER CON- TACTS, When wiring the armature contactor fo the MC (Main Contactor Control Relay), use the CONTACTS LABELED NORMALLY OPEN, 3.4.2 Relay Control Wiring ‘The first sight terminals of TB1 are dedicated to contol logic wiring. Refer to the wiring diagram found in the addendum for typical connections. 3.4.3: Signal Wiring Terminals 9 through 22 of TB1 accept all signal wiring connec- tions. tis recommended that shielded wire be usedfor reference (speed potentiometer) and tachometer connections (optional ammeter connections should also incorporate shielded wire. Belden #83994 (two conductor) and Belden #33395 (threo ‘conductor shielded cable or equivalent) is recommended. The shields should be taped off at the remote end and connected 10 ‘common, TB1 terminal 20, at the drive control. Additional con- sideration is recommended to route this wiring away from high current lines (.6., A.C. line and armature wiring), ‘CAUTION ‘Atno point should any connection be made to earth ground unless specifically shown on EMERSON system diagrams, 3.4.4 Field Connections Field connections should be made with due consideration to proper polarity (Ft to F),‘The Spectrum field supply supplies 150 VDC when wired to2230 VAC line or 300 VDC when wired to a 480 VAC line. Field connections are made to a separate terminal strip located near the line fuses. Field economy requires a sequencing contact yited othe FEN/2 terminals, Wnt used these terminals must 30 jumper NOTE The connections shown in this manual will cause the motor to rotate counter-clockwise (when facing the commutator end). To reverse motor rotation, reverse the armature connections (A1 and A2) at the motor. Do ‘ot reverse the serias or shunt fold polar 3.5 PROGRAMMING JUMPERS NOTE if tha Spectrum unitis part of an EMERSON system, all program jumpers should be correct. Use discretion before changing any jumper. All Spectrum controls are shipped programmed for: ‘60 Hz -460 VAC ‘Armature Feedback description ot umpers follows. Be sure allprogram jumpersare ‘correct for your instalation. WARNING EQUIPMENT DAMAGE AND/OR PERSONALINJURY MAY RESULT IF ANY JUMPER PROGRAMMING IS. ATTEMPTED WHILE THE SPECTRUM IS OPERA- TIONAL. LOCK OUT POWER AT THE DISCONNECT BEFORE CHANGING ANY JUMPER POSITIONS. 3.5.1 Line Frequency JP1- There may be one or sixof these jumpers depending onthe revision lavelof the PC Board, Older rev. boards had sixjumpers located approximately 1-1/2" tothe lef the six pulse transform. ‘rs on the main circutt board, On a PC Board with Rev. °F" or highar etched in follon the rear ofthe board, a single jumper JP! Is located on the right hand side of the board, near the “IR comp potentiometer. Cut this jumper or jumpers for 50 Hz operation. 3.5.2 Feedback Source Selects Located on TBS. Selects armature or tachometer feedback. Jumper "F* to "G" for tachometer feedback. For Armature eedback jumper “G" to "H” (on older units) or jumper H1-H2 on. PC Boards with Rev. "F*or higher etched infollon the rear ofthe board. 3.5.3 Feedback Range Jumper Selects the acceptable range of feedback voltage levels. Lo- cated on TBS ‘TACHOMETER FEEDBACK REV." ORLATER UMPER | REV."©° OR EARLIER "TacH VOLTAGE” | CCNNECTION AIMAK SPEED, 3010 160 Toa we 100 VDE jowmev es 0 140 VDC. 0" 250 Hoh 20; 181 VOC, 14 NOTE AG tachometer generators are commonly nameplated in VAC (RMS)/1000 RPM. This AC voltage must be converted to a DC value, This requires a diode bridge and iter network whichis included inthe drive regulator Circuitry. Since the output wave form of an ACtachome- ter varies somewhat due to nonsinusidual charactaris- tics, the following table should be used to calculate the DC voltage produced in the drive regulator circutry. Nameplate: ‘KC Tachometer | VACT100 RPM | VOCT000 RPM | 3111 Type 45/90 e226 ‘AN Type, 45/90 50/100 RE Type 4590 ‘50/100 ARMATURE FEEDBACK “ARMATURE VOLTAGE JUMPER, ‘AT MAX SPEED CONNECTION 197 10 847 V Low 32610 376 V Mea 443 to 593 V High NOTE ‘Those tables are presented as guidelines. I'this control Lunit will not drive the motor to its maximum speed, the foodback range jumper may need to be set for a high feedback voltage. The table above applies to Rev. °E” fr earliar boards. On Rev. 'F” or higher boards, the ranging jumpers have no effect. Armature feedoack range is controlled by the maximum speed pot alone. ‘The armature feedback range is 150-600 V @ 10 V ret input NOTE Itafield weakening unitis used with the Spectrum drive, tachometer feedback is necessary. To determine the tachometer voltage at maximum speed, use the follow ing formula: MAXMUM TACHOMETER SPEED RPM) X VOLTS PER 1000 “00 RPMI TACH RATING MAXIMUM TACHOMETER VOLTAGE 3.5.4 Input Voltage Select Located at TB2. Jumper “B to "CO" and °C” to "D" for 460 VAC ‘operation or “A to °B" and "D" to “E" for 230 VAC operation, 3.5.5 Field Loss Defeat Field loss protection may be disabled by jumpering terminals "0" ‘and "N" at TBS (install this jumper only fan external field supply is used) 3.5.6 Other Jumpers TBI terminal numbers 12 to 13 interconnects the accel/decel Circuitto the velocity error amplifier. TBt terminal numbers 1810 49 interconnect the velocity error ampltiar to the current error ampltier. These jumpers allow additional lexiblity to the Spec- trum series and should be in place whan using the control as a standard speed control.3.6 SHUNT RESISTOR Itis necessary totailor the Spectrum drive to agiven motor. Use the charts below to determine the part number of the required ‘shunt. Install this resistor between terminals"O" and "M¢ at TBS. 230 VAC UNIT HP, PART NUMBER Spectrum | 5. 2200-003 75 2200-004 10 2200-007 Spectrum I 15 2200-008 20 2200-008 25 2200-005 30 2200-007 Spectrum Ill 40 2200-004 50 2200-007 ‘Spoctrum IV 60 2200-008 75 2200-002 100 2200-008 125 2200-007 460 VAC UNIT HP PART NUMBER ‘Specteum | 8 Not Required 7s 2200-001 40 2200-003 15 2200-004 20 2200-007 Spectrum Il 25 2200-009 30 2200-003, 40 2000-008 50 2200-005 60 2200-007 Spectrum tll 75 2200-004 100 2200-007 Spectrum IV 125 2200-003 150 2200-002 200 2200-008 250 220.007 NOTE ‘These resistors are supplied with the Spectrum drive control unit. 3.7 COOLING FAN VOLTAGE SELECT (Excludes Spectrum 1) Located at the bottom of the chassis on the interconnect board (TBa), For 290VAC Operation dumper "A" to “Br *Crto"D" For 460VAC Operation “B10 °C" 15 The Spectrum IV model is equipped with a 115VAC fan and a 230/460 VAG primary 115VAC secondary stepdown trans: formar (T!), Feet i L ly Fact, ‘SPECTRUM IV COOLING FAN TRANSFORMER 3.8 CONTACT SUPPRESSION ‘All relays or electrical solenoids with witing in close proximity to the Spectrum control wiring should be properly suppressed. This reduces the possibilty of electrical noise interference. Noto, however, that itis generally not necessary to suppress non- inductive loads such as resistive heater elamonts, ‘Such suppression, as shown in the following figures, also ro- duces contact arching and, therefore, increases contact life, 47a 122uf na06 SW h nove Pa (3) wv () For AC RolayiContactor For DC Relay/Contactor ‘SUPPRESSION TECHNIQUES3.9 STARTUP PROCEDURES. To insure maximum offciency with a minimum amount of delay Inproduction, factory star-up assistance by afactory engineer is available. Contact your nearest Manufacturer's Sales Olfice for further information. Requests for factory start-up assistance ‘should be made by contacting the Manager Fiald Engineering at least two weeks prior to the required date. CAUTION ‘The following startup instructions are Intended only asa gulde, and should be clearly understood by the responsible installation personnel before proceed- ing with them. 3.9.1 Power Off Checks Before applying power, make a detailed visual inspection of the system, checking for: + Loose electrical connections, + Pinched wires at the control, motor, or operator's station. + Loose mechanical connections, especially the tachometer coupling + Mechanical binding. + Incorrect power transformer connections, + Metalic chips within the drive caused by driling into the enclosure, + Correct jumper programming, ‘Check the resistance to ground from the armature, the field, and the system common (TB! terminal #20), Ifa resistance (of 1 megaohm or loss is measured, clear the shor or partial short before applying power. 16 3.9.2 Power On Checks Apply AC power and make the following chec + Check or airflow from the blower fan (iso equipped) + Check AC and DC supply voltages (test points available al J3. Roferto the following diagram or use the optional test meter.) + Note the level of the current limit setting Turn min, speed adjustment fully counter-clockwise. With the speed potentiometer fully counter-clockwise, press the start button. “The drive DC power light should come on; the motor ‘should not rotate. Press the stop bution; the DC power indicator should go out. Press the start button again and slowly increase the speed potentiometer to maximum, observing that the motor ‘speed increases smoothly to maximurn, WARNING IF THE MOTOR RUNS AWAY, STOP THE DRIVE IM- MEDIATELY. CHECK THE TACHOMETER FEED- BACK CONNECTIONS, POLARITY, AND PROGRAM JUMPERS,CONNECTION READING ez LEAD. a 1 2 3 4 5 8 7 8 E Line to Line Voltage L1-L3 Line to Line Voltage 3-2 +415 Volts DC Output Velocity Exror Ampliier (0-12V) Signal Common Signal Common Line to Lino Votage L1-12 ‘Shunt Voltage (-1V @ 100% current) Control Voltage, 115 VAC Loaded, 150 VAC Unloaded Output Current Error Ampitier (0 10 -11.5 V) “18 VDC “ht Sectors noma wed Sects pons mt, TEST POINTS AT J3 73.10 ADJUSTMENTS Max Speed The maximum speed should be adjusted with the operator controlied speed potentiometer fully clockwise. (Clockwi increases spoed). Tho maximum spood is typically adjusted ‘maximum rate armature vollage output to the motor. Min Speed ‘The minimum speed of the drive is adjusted with the operator's speed potentiometer fully counter-clockwise. When the mini- mum desired spood is zero, the minimum speed should be agjusted fully counterclockwise. The minimum speed agjust- ‘ment does not affect maximum speed, Stability ‘Amid postion setting will give optimum results for most machine load applications. Clockwise rotation wil increase response. Counter-ciockwise rotation will dampen the response. STABILITY EFFECTS OF THE VELOCITY PROFILE, Jog If the jog pushbutton is wired in, the Jog adjustment sets the preset slow speed. The jog speed is a"stepped” input reference from 0 to 30% of maximum speed. Current Limit ‘This adjustment is made using the scaled potentiometer dial indicator. A normal recommended sting is 125%, Adjusting this potentiometer clockwise increases allowable armature cur- rent ‘Accel Time ‘Clockwise adjustment increases the time that the drive takes to accelerate to the set speed. This rate of change is linear (or constant) throughout the speed range (the maximum accelera- tion rate may be limited by the curtent limit setting). Doce! Time Clockwise adjustment causes the drive to decelerate more slowly. (The drive cannot decelerate the motor more quickly than the coast rate). Phase Balance Adjustments NOTE ‘The phase adjustments are factory set and normally wll not need any further adjusting. 18 Procedure (Prior to Rev. “F") 1. Tum the minimum speed adjustment, the speed potentiome- tor, and all sixphase balance adjustments flly counter-clock- 2. With the drive control A.C. power on, turn each phase balance ‘adjustment clockwise unti its trigger circuit LED begins to light. Turn it counter-clockwise until the LED goes out. New Procedure (Board marked Rev. “F” oF higher in fol, at rear of board) 41. Note currant limit setting and rotate pot fully counter-clock- 2. With drive in run mode, adjust each phase balance LED until ittights. 3. Reset current limit pot to original setting and check phase balance under load. Advance adjustment only to balance a low pulse, so that LEDs wil remain on as Steps 1 and 2 3.10.1 IR Compensation |R Compensation increases the drive speed reference signal as armature current increases. The effactof the increase in current isan increased voltage drop, due to the internal resistance ofthe motor. This increased voltage drop causes a decrease in motor ‘speed. IR COMP can be used to compensate for this decrease in motor speed during loaded conditions, theretore improving speed regulation without speed feedback, This adjustment Is only used it armature feedback is used (sot fully counter-clock- Wise for tachometer feedback). Procedure 1. Run motor at maximum speed with no load 2, Record the motor RPM (hand tachometer required). 3. Load the motor 4, Again measure the motor RPM. Match this loaded! spoodto tne unladed speed of Step | using the IR comp potentome 5. Repeat Steps 1 through 4, NOTE Excossive IR compensation can cause the Drive Con- trol to become unstable,Section 4 MAINTENANCE AND TROUBLE SHOOTING 4.1 NORMAL MAINTENANCE ‘No adjustments or ‘tuneups" should be necessary on the Spec- trum drive. Only common sense maintenance procedures need to be followed. Keep It Clean. The control should be kept relatively free of dust, dit, oll caustic almosphere, and excessive moisture, External cabinet filters should be checked and cleaned periodically. Do not use high Pressure air to blow the control or cabinet clean — use a small brush and vacuum cleaner to limit dust being stirred up during cleaning, Keep It Coot Air filters should not block the passage of cooling ait to the Control. the control should be located away from, as best as possible, machines having a high ambient temperature, Airflow ‘across heat sinks must not be rastrictad by other equipment within the enclosure. Keep Connections Tight The equipment should be kept away from high vibration areas that could loosen connections or cause chating of wires. Also, al interconnections should be re-tightened at the time of intial Startup and at least every six months Follow Motor Maintenance Instructions The brushes and commutator shouldbe inspected for excossive wear or arcing. Tha wiring tothe motor should be inspected for Wear and tha connections should be checked for tighinoss. Consult the instructions supplied with the motor for more detal 4.2 GENERAL TROUBLESHOOTING ‘The most frequent causes of drive failure are: + Interconnect wiring discontinuity, caused by a broken wire or loose connection. * Circuit grounding within the interconnections or the power wiring. + Mechanical failure at the motor, or tachometer. DoNOTmaks adjustments or replace components beforecheck- ing all wiring. Also monitor al indicator lignts before proceeding with troubleshooting checks, I should be noted that modern solid state electronic circuitry is highly reliable. Often probloms which appear to be electrical are infact mechanical. itis advised that motor maintenance be kept Up and checked in the event of any driva problems. Refer to ‘motor owners manual for maintenance and repair procedures. WARNING TEST EQUIPMENT USED SHOULD NOT HAVE ITS CHASSIS GROUNDED BY THE THIRD PRONG OF THE POWER PLUG OR INCIDENTAL CONTACT OF ITS CHASSIS TO A GROUNDED OBJECT. WITH ‘TESTEQUIPMENTNOT GROUNDED, THE CHASSIS MAY BE AT HIGH VOLTAGE. EXTREME CARE SHOULD BE TAKEN WHEN OPERATING THIS EQUIPMENT TO AVOID SERIOUS ELECTRICAL SHOCK. 19 4.3 SYMPTOMS AND CAUSES ‘or other fuses blown = Armature contactor not energized or defective + Faulty control logic wiring, switch or rolay + Motor or machine jammed + Defective spood potentiomater or witing + Control in fault trip = Open armature or field circuit + Incorrect jumper programming (refer to Section Il) = Open motor thermal = Blower motor not energized Drive Runs To Top Speod + Drive in currant limit, + Motor baing driven ey external forces + Low line voage + Stray pick-up in signal wiring (eefer to Section Il) + Dotoctive tachometer of coupling = Worn motor brushes + Incorrect IR comp or stability adjustment (referto Section Il) + Incorrect shunt resistor (rafer to Section Il) Drive Trips Out = Intermittent open in control wiring logie + Fault tip condition exists 1. D.C. overload Field loss, ‘Abnormal motor loading Faully motor Poor drive control ventilation (except Spectrum I) ‘Aczal rate too quick (refer to Section ill) Defective SCR Incorrect shunt resistor (fer to Section Il} PNonsen ‘Motor Will Not Reach Top Speed ~ Incorrect speed potentiometer (use only a2K ohms, 2 watts potentiometer) + Incorrect field current or witing (noted by current limit LED) > Motor overloaded (noted by current limit LED) + Incorrect current mit setting (refer to Section Il) + Incorrect max speed adjustment (rofer to Section Il) + Incorrect shunt resistor (rofar to Section Il) + Low line voltage + Biow ine fuses Line Fuses Blown + Shorted armature ~ Ground fault Shorted SCR = Dofective control circuit board 4.4 SPECTRUM I SCR REPLACEMENT Tools ~ 5/16" Nut Driver + 76" Nut Drivar = Modium Screwdriver ~ Torque Wrench ead all instructions carafully before beginning. Referto Spec- trum | chassis diagram.Procedure 1 ‘Mechanically disconnectthe MCrrlay by removing the single hold down screw. Do not remove the electrical connections, Remove the armature fuse (4FU). Also remove the two nuts ‘rom the stud thatthe top end of this fuse rests on, Remove the hardware from the A stud, Remove all six SCR hold down screws, ‘Swing the circuit board out of the chassis. Replace defective SCRs wire for wire, ‘Apply (very sparingly) the silicon thermal compound (EMER- ‘SON part number 3484-001) to the bottom of the new SCR (EMERSON part number 4014-040-12). Replace the circuit board. Torque SCR hold down screws to 19:inch-pounds. Roplace other hardware, ‘SCR PACKAGES. ‘THE INTERCONNECT BOARD MC RELAY ‘THE DUAL PACKAGE SCR 4.5 SPECTRUM Il SCR REPLACEMENT Tools = 9/8 * Nut Driver ‘Screwdriver (medium) + Torque Wrench Read instructions completoly before beginning. Refer to the ‘Spectrum Il chassis diagram. Procedure 1, Mechanically disconnect the MC relay by removing the single hold-down screw. Do rit remove the electrical connections. 2, Remove both buss bars by unbotting the three connecting bolts on each, 3. Mechanically disconnectthe SCR module, tobe replaced, by removing the two hold-down botts (one each at the top and bottom). Remove only the AC line elactricaleonneetions from the SCR at this time. ‘4. Apply (very sparingly) the silicon thermal compound (EMER ‘SON part number 3463-001) to the bottom of the new SCR (EMERSON part number 4014-070-12) 5. Bolt the new SCR in place keeping the gate connections (Gt ‘and G2) closer to the interconnect board, Torque the holé- down bolts to 19 inch-pounds, 6. Transfer electrical connections from the used SCR to the new ‘SCR one at a time to prevent connection errors. 7. Install buss bars. 8. Mount MC relay.‘THE SCR IN LOCATION ‘THE DUAL PACKAGE SCR nee Meta Harare MC RELAY ai 4.6 SPECTRUM Ill SCR REPLACEMENT Tools ~ 7/16" Socket Wranch ~ 1-1/4" Grows Foot (startype, available from Snap-On Corp.) = ‘Small Screwdriver = Torque Wrench Road instructions completely before starting. Refer to the Spectrum lll chassis diagram. Procedure 1. SORs 3, 5 and 6. Romove the detective SCR, noting wire locations. Apply silicon thermal compound (EMERSON part ‘number 3463-001) very sparingly to tha bottom of the new ‘SCR (EMERSON part number 4054-S23x12). Torque SCR to 250 inch-pounds. 2. SCR4. Remove armature use and its lower spacer. Replace SCR as in Step 1, above. 3. SCR2, Remove the six iter board hold-down screws. Swing the right-hand side of the board up. Replace SCR asin Stop 1, above, 4. SOR1. Remove the tine connection to SOR 4 and the ferrite ‘cores from this spacer. Replace SCR as in Step 1, above, ‘THE ‘STUD MOUNT’ SCRTHE SCR IN LOCATION ‘THE ‘CROWS FOOT’ WRENCH 4.7 SPECTRUM IV SCR REPLACEMENT INSTRUCTIONS Tools = T/N6, 1/2" Socket Wrench + Medium-large Philips Sorewdriver + Flat Screwdriver (modium) Read instructions completely before beginning. Refer to the Spectrum IV chassis diagram, Procedure 1. Remove the armature connections (A+ and A+) 2, Remove the lower front and extreme top of the main housing cabinet, 3, Remove the six SCR fuses, 4, Disconnect the three buss bars, 5. Separate connectors J4 and J from the interconnect board. "bars. Remove the wires rom the three right- bars. Tum bars away from the interconnect 6, Loosenaltsi hand side board. 7. Remove the six ets of SCR gate leads (red and white wires). ‘8, Remove the two bolts and two nuts (7/16") that hold down the interconnect board, 22 8, Remove the two nuts (7/16") that hold down the red fiberglass standoff (near A+ and A- connection). 10. Lift interconnect board from studs. 11. Carefully lft the heat sink unit off its two mounting studs and ‘carefully pull out from the top ofthe cabinet. 4.7.1 Heat Sink Assembly (On Bench) Removal Of SCR ‘A. With 1/2" wrench/socket, loosen only, SCR clamp nuts (donot remove from clamp). B. Holding gate leads of SCR, gently pull outer portion of heat sink away until SCR comes free from locating pins. Note po- sition of gate leads with respect to heat sink 4.72 Re-Istallation of SCR ‘A. Apply very sparingly the silicon thermal compound (EMER- SON part number 3463-001) to the contact surfaces of the new SCR (EMERSON part number 4060-S102X1.2), 8. Holding SOR by its gate leads, lower SCR into position (between heat sinks) onto locating pins. CAUTION Extrome care should be taken to ensure proper alignment of SCR onto pins. Ensure that the gate leads aro in the same position as when removed. C. Re-tighten clamp nuts (drawn down equally) unti!2000 pound pressure indicator reading on clamp gauge is reached.L"BARS ‘SCR BANKS ‘THE SPECTRUM IV CHASSIS SCR CLAMP GAUGE ‘THE HEAT SINK ASSEMBLY THE SCR CLAMP GAUGE THE PRESS PACK SCR 2a24ADDENDUM RECOMMENDED SPARE PARTS TABLE 1 RECOMMENDED LUGS FOR SPECTRUM DRIVES are parts can be order ur local EME} 08 Reprosantanes °° 72ered though yourlocal EMERSON Sales Fe — ag wie sud Bao SPECTROM a eo ‘Suaniity Description Pact Number Ear ors - 1 Main ConirolBoard | 2200-4000, slang he [zee sso 3 Line Fusas 3701-50400 i fae 8S |i Ee | one AS 4 Armature Fuse 3701-70500 2 [ssn ko | eee thas | seam ues 3 Field Diodes 4001-22015 4 a 3 Silicon Controlled Rectifier | 4014-055-12 o | zen ae tee | em tna 1 "M" Contactor Auxilary | 3513-030, & |e ie iso | ston thse Limit Switch arr ser =e es Se ae SPEOTRUMT es fe | [fm Ge|ee ae ‘Guan Desorintion Pact Number |e gee thse | esi thom 1 Main GontrolBoard | 2200-4000 = = Seren tken 3 Line Fuses 3701-51000 > srt nunibarerotar compraesbai 7 3 pllte Fuses 3701-810000 | The AMP. Ine. part numbers refer to compression iype connec tors and arepretarred. These connectors must be installed with 3 Fiold Fuses 3707-601000 | ean a Olea 3 Siicon Controlled Rectiter | 4014-090-12 3 Floid Diodes 4001-D220X15 | The Renn-Union Eletic part numbers refer to mochanicaltyoo SPECTRUM connectors. The wrtolugconnectionismada ightwithanallan wrench. These connectors ara not preferred, as the connection ‘Quantity. Description Part Number il bo 80 ater some time. 1 Main Conti Board | "2200-4005 wilbecome loose ater some time. 3 Line Fuses 3701-517500 TABLE2 3 Deane oa FULL LOAD AC AND DC AMP RATINGS - 7 use 2 ‘OPTIMAL iSOI 6 | Siteon Contalad Rect | 4064-S231K12 Menaate Ra oan Pe er swe NOS 3 Field Diodas 4002.0950X15 AC] OC BE] Be ‘SPECTRUM IV Hp | kva|ames|ames || Hp | Kva | aMPs|amps Searle | antes | Pathumbe tain Control Boar 8 Line Fuses 3701-53500 51754701] 08 1.8_| 26 | 141] 17 3 id Fuses 13707-60150 75| 1 [105] 13 |l75[ 11 | eto] os 2 Transiormer Fuses 3704-146 6 Slicon Controlled Rectifier | 4060-S102x12 10 | 8 | t40[ 7 |[v0| 15 | 2a0| a 3 Field Diodes 4002:D350X15 15 | 20 [210] @% |/is| 20 | aan | ot ‘SPECTRUM SPARE BOARD "B" KITS. 20 | 27 | 200 | a4 |] 20] 27 | $611 | 68 SPECTRUM1 PARTNUMBER 25 [34 [asa | 42 |[a5 | 94 | 700 | os 380,VAC 72200-9910 30 | 40 | ai] st |[ ao] a0 | eae | ice 2301480 VAC. 2200-9005, 208/816 VAC. 2200-9911 30 | 83 [704 | | ao || 408 | a7 ‘SPECTRUM PARTNUMBER [7] BAZ | TR BO 8S] aS] es 380 VAC 2200-9912 75 | 8 | Toe | Ter || 1 | 9a] 208 | Bee 230/480 VAC 2200-9906 208/416 VAC. 2200-9909 Too] 78 | 138 | 1659 ||700] sa | are | Se SPECTRUMIN PARTNUMBER TE | aE | Te | aie [os | Vas | Bae | war 380 VAC 72200-9978 TO] 175] 208 | 25a 230/480 VAC. 2200-9907 208/416 VAC 220.0914 200 | 220 | 278 | 339 ‘SPECTRUMIV PARTNUMBER 20 | 275 | 348 | 424 380 VAG 22009913, 230/480 VAC. 2200-9907 208/416 VAC 22009914 25ALLOWABLE AMPACITIES OF INSULATED TABLES. ‘COPPER CONDUCTORS* TEASED OW AUBIENT PERATURE OF 46.85) SIZE ‘TEMPERATURE RATING OF CONDUCTOR awe | coc | 7c | asc | soc | soc | r25°c | aso | 200°c Mem | (aor) | (67°F) | (185°) | (194°) | (230°) | (257°F) | (202"F) | (ae2°F) 14 15 15 25 25 30 30 | a0 30 12 20 20 30 80 35 4 | 40 40 10 30 30 40 40 45 50 50 55 8 40 45 50 50 60 65 65 70 6 55 65 70 70 80 as | 90 95 4 7 85 30 90 105 15 | 115 120 3 80 100 105 105 120 s30 | 135 145 2 95 115 120 120, 135 145 | 150 165 4 110 190 140 140 160 170 | 180 190 ° 125 150 185 155 190 200 | 210 225 00 145 175 195 185 215 230 | 240 250 000 165 200 210 210 245 265 | 275 285 0000 195 230 235, 235 275 310 | 825 340 250 215 255 270 270 315 335 300 240 285 300 300 345 380 350 260 310 325 325 380 420 400 280 335 360 360 420 450 500 320 380 405 405 470 500 600 355 420 455 455 525 545 700 385 460 490, 490 560 600 750 400 475 ‘500 500 580 620 800, 410 490 515 515. 800 640 900 435 520 555 555 1000) 455 845 585 585 680 730 1250 495 580 645, 645, 1500 520, 625 700 700 705 1750 545, 650 735 735 2000 560 665, 775 775 840 *Source - National Electrical Code, 1978 “*Reter to National Electrical Code for exceptions 26G on anes - - = = | ! A | c To J | : 1 | te fe —— } ——-ot + Dp ——_4 k- + gs 4 Figure + Outline and Mounting Dimensions Spectrum 1-4, 2200-3108, Shoot 1 ATs ]e¢].D | € | F [Goa] A [wiles PARTNO. srectRuM! | 1450 | 1163 | 1050 [1075 | 200 | aa | 201 | a00| 20 2200-84200 spectRUMI | 18.00 | 11.463 | 1400 | 10.75 | 200 | 44 | 261 | 600 | 26 2200-8480 ‘SPECTRUM | 22.00 | 1863 | 1275 | 1363 | 475 | 1.00] 312 | 900] 3B 2200-8810 ‘SPECTRUMW | 27.00 | 21.00 | 1925 [i925 | 98 | a | 500 | 100) es 22008825 27Hinge Snoves \! OPERATOR OPTION S | | —ciacurr sreaKen, ‘fanu OGoR P-MAMEPLATE Figure 3 Outline and Mounting Dimensions. ‘Spectrum 1-4, 2200-3106, Sheet 3 B_OPTION RESISTOR ENCLOSURE SPECTAUM Is -- A BOTTOM 29 NEMAT ATSB Te [0 [e | F | & [wns] caaneren | ware ene spectRUM! | 30.00 | 24.00 | 12.00 [31.50 [1800 | wa | wa | 61 | 2200-5050 | 075 (14GA) SPecTRUMI| | 36.00 | 24.00 | 12,00 | 37.50 [1800 | ves | WA | 73 | 2200-5051 | .075(14GA) spectauMil |’ 42.00 | 30.00 | 12.00 [4350 [2400 | YES | 7.00 | 104 | 2000-5052 | 075 (14GA) speoTRUMW |” 48.00 | 36.00 | 16.00 | 49.50 [90.00 | YES | 7.00 | 182] 2008053 | 075 (14GA) TENV ATe [evolve fn wries | _caBINeT PN. [ MATL THENS spectRUM! | 30.00 |24.00 | 12.00 | 31.50 | 18.00 | WA et 2 = spectrum ti | 60.00 [36.00 | 1200 | WA | NA | 6.00 210 2200-5085 |.075 (14 GA) SAME AS 220 50S0W GASKET KIT 1 200M CLEARANCE REGUIRED FOR EFFICENT VENTEATON TENV& NEMA | CABINET VENTILATION SLOTS BOTH SIDES AND,Wuonas BAIWO wnwLoaes Figure 4 Typleal Connections 80i (yoas/er) eon core ‘1 noee) 2008-022 9 £2200-1005-1, Rev. D Figures ‘Spectrum | Interconnect Diagram anNOTE: Tho kit # 2200-9008 connections shown aro forarmature voltage. Se instuctons supplied witht |# 2200-0074 for tachometer voltage connoctions Figure 6 Spectrum | Option Panel "A" Interconnect and Customer Connection Diagram, 12200-1011, Rev. D 932.Orrsag cere arapree 250-4501 dhl 22052250 ae counter gcse eoyu tro0-4002 on we ii = 8 iG igure Spectrum Il Interconnect Diagram £2200-1006-I, Rev. D 33A R Rye] ee Ke At €] } fh 4 Figure 8 Spectrum Il Option Interconnect and Customer Connection Diagram 2200-10214), Rev. E 34Figure 9 ‘Spectrum Ill Interconnect Diagram £2200-1003-I, Rev. C 35Figure 10 ‘Spectrum Ill Option interconnect and Customer Connection Dia £2200-1030-1, Rov. E 36Figure 11 ‘Spectrum IV Interconnect Diagram 2200-10041, Rev. Ggram Figure 12 ‘Spectrum IV Option Interconnect and Customer Connection Di 2200-1040-I, Rev. D 38Figure 13 Spectrum Interconnect Diagram ‘Option Kits 2200-1750-1, Rev. A 3940Figure 15 ‘Schematic Diagram - Main Control Board, 2200-1000, Sheet 2, Rev. M a1026-0022 “ON 41% No a3sn oa is “rowinas nun ont vos 4 Lie) uum pa wy as eset maes cena gS aa , “Q¥¥OR 24 NO Sova ¥30705 = @ o £2. i al026- 0082: TwnNWM aNIWsaNIoN® pet I ~§] ‘HOLIMGORY IHL 3] aa * roy ost 211aHm 01.) Fi 44081 27 NaH IH I Sy Sei ONDA (oasn) 2 a or (el j = _ Fo or [Sar So [6 108 ie a is wes REE OS - m 164 L di 108, ° conse ee El ey : W Figure 16 ‘Schematic Diagram for Field Econom) y Delay PC Bpard 12200-1850, Rev. CSpectrum II With Modification Kits ARMATURE CONTACTOR ‘AC LINE DISCONNECT PANEL ‘SWITCH DYNAMIC BRAKING RESISTOR ‘SPEED METER INTERFACE P/C BOARD 12200-9003 CABINET ‘SPECTRUM 24 EMERSON. Industrial Automation Control Techniques Legacy Product For information regarding parts, repairs and upgrade to current designs ~ Contact: Control Techniques Service Center 359 Lang Blvd Grand Island, NY 14072 Phone: 716-774-1193, 800-367-8067 Fax: 716-774-8327 Website: [Link]ES9-003) March 1993 EMERSON Industrial Controts Emerson Electric Co. Industrial Controls Division 3036 Alt Boulevard Grand Island, NY 14072 Phone: 716-773-2321 Fax 716-773-6264