Installation & Operating Procedures
DG2
Series
SINGLE PHASE CONVERTERS
18 Neville Street, Unit C
New Hamburg, ON N3A 4G7
Tel: 519-662-6489
Fax: 1-866-280-5247
1/4HP - 7.5HP 120/240/277 VOLTS 50/60HZ
www.safdrives.com
email: answers@safdrives.com
(Replies given within 24 hours)
TABLE OF CONTENTS
1.0
DESCRIPTION .................................................... Pg. 1
2.0
INSTALLATION AND START-UP ...................... Pg. 3
3.0
DRAWING INDEX .............................................. Pg. 7
1.0
DESCRIPTION
1.1
GENERAL
DG2 Series thyristor controllers are designed to control the speed of wound field or permanent
magnet DC motors from ¼ HP to 7.5 HP.
The controllers are available as complete, totally enclosed units suitable for wall-mounting, or as
kits suitable for custom applications.
When supplied as self-contained units, the converters are provided with transparent, high-impact
resistant polycarbonate covers, in a totally-enclosed, non-ventilated format.
The following controls are mounted on this cover:
- ON/OFF switch or circuit breaker
- Speed control pot
- STOP/START pushbutton or spring-loaded rocker switch
The transparent cover allows visual indication of "POWER ON" and "RUN" LED's.
1.2
FEATURES
-
-
-
NEMA 1 enclosure (polycarbonate transparent)
ON/OFF switch, AC line fuses (½ through 2 HP)
ON/OFF 2 pole AC circuit breaker (3 HP and above)
START/STOP pushbutton or spring-loaded rocker switch
Speed pot
2 Amp field supply
Adjustments:
- Min speed
- Max speed
- Current limit
- IR compensation
- Speed stability
- Current stability
LED indication:
- Power "ON"
- Run relay "ON"
Tachometer or armature feedback
Full wave bridge
2 isolated pulse transformer outputs to allow the use of different SCR bridge
configurations.
Page - 1
1.3
SPECIFICATIONS
DIMENSIONS - Inches (mm)
Model
Volts
Max.
50/60 Hz HP
L
NEMA 1
W
D
L
CHASSIS
W
AC
D
DC
Current Current
DG2-7.5-1
120
3/4
12 (305)
8.5 (216)
7 (178) 7.5 (191)
5 (127)
5 (127)
11A
7.5A
DG2-7.5-2
240
1.5
12 (305)
8.5 (216)
7 (178) 7.5 (191)
6 (152)
5 (127)
11A
7.5A
DG2-10-2
DG2-15-2
240
240
2
2
12 (305)
8.5 (216)
7 (178) 7.5 (191)
6 (152)
5 (127)
12 (305)
8.5 (216)
7 (178)
12 (305) 8.5 (216) 6 (152)
14A
21A
10A
15A
DG2-25-2
240
3
12 (305)
8.5 (216)
7 (178)
12 (305) 8.5 (216) 6 (152)
34A
25A
DG2-30-2.7
277
5
12 (305)
8.5 (216)
7 (178)
12 (305) 8.5 (216) 6 (152)
42A
30A
TABLE 1
1.3.1 Operating Temperature Range
10oC to +40oC (50oF to 104oF)
1.3.2 Short-Circuit Protection
For 240V models: HRC line fuses for chassis models, circuit breaker for Nema 1 models.
1.3.3 Speed Control Range
10:1 with armature voltage feedback
30:1 with tachogenerator voltage feedback
Page - 2
2.0
INSTALLATION AND START-UP
WARNING!
Equipment is at line voltage when AC
power is connected to the converter. All
phases must be disconnected before it is
safe to touch any internal parts.
2.1
INSTALL THE CONVERTER AND DC MOTOR IN AN AREA WHERE THE
FOLLOWING CONDITIONS EXIST:
a)
b)
c)
d)
2.2
Ambient temperature does not exceed 40oC. (104oF)
Ambient temperature is not less than 10oC. (50oF)
Altitude above sea level is below 2,000 meters (6500 ft.)
Ambient air is clean and dry. It must be free of flammable or combustible vapors,
steam or corrosive gases.
CONSIDERATIONS FOR EXTERNAL CABLING OF THE CONVERTER
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 voltages and/or currents are not available,
a matching transformer will be necessary.
All external connections must be made according to the Engineering Drawing supplied.
All power cabling and control cabling ratings should be referred to Cable Current Rating, TABLE
1. Rate incoming AC line and armature cabling for AC current rating. Field cabling should be
15A rated.
2.3
START-UP
Your DG2 converter has been factory adjusted to perform optimally with the DC motor supplied.
Just connect the unit as per relevant drawing and switch "ON". In the event that the unit must be
readjusted, use the following procedure.
2.3.1 Ensure that the wiring is according to the appropriate drawing.
2.3.2 Measure and confirm that the AC supply voltage is as per DG2 converter nameplate.
2.3.3 Confirm that the AC current supply is adequate, (see TABLE 1).
Page - 3
2.3
START-UP - Continued...
2.3.4 Switch power "ON" and confirm:
- that field voltage is correct
- that the power "ON" LED lights up
2.3.5 Switch power "OFF" and set all trim adjustments fully counter clockwise. Remove one field
wire, and physically clamp the motor shaft. Insert a DC ammeter in series with the motor
armature. Set the external speed control pot to 50% full speed.
2.3.6 Apply power. Connect an ungrounded oscilloscope across A+ and A-. Press the "START"
pushbutton. Confirm that the "RUN" LED goes ON. Slowly turn "I MAX" trimpot clockwise until the
armature current is 100% of motor nominal current. To ensure current stability, turn the "I STAB"
trimpot slightly clockwise.
2.3.7 Switch power "OFF". Disconnect the ammeter, and reconnect the field. Turn "SPEED
POT" to "0".
2.3.8 Switch power "ON", and press "START" pushbutton.
- Adjust the "MIN SPEED" trimpot until the motor turns at the desired minimum speed.
- Slowly turn the external speed pot to position 10 and watch out for instability. It is usually
necessary to adjust the "V STAB" trimpot slightly clockwise to achieve stable operation with good
response.
- At position 10, adjust the "MAX SPEED" pot until the motor's rated RPM is achieved.
Alternatively, connect a DC voltmeter across A+ and A- and adjust the "MAX SPEED" pot for
appropriate DC voltage as follows:
Input AC Volts
120V 90V
240V 180V
277V 240V
Max DC Output Volts
Page - 4
2.3.9 IR Compensation
This control is used to even out speed variations due to load changes. If your load is of a variable
nature, observe the motor RPM under light load and full load conditions at 25% full speed.
Slowly adjust the "IR COMP" trimpot until the speed changes disappear or are minimized.
WARNING!
Do not adjust this control beyond 30% of full
clockwise setting as this may
result in unstable drive operation.
2.3.10 Tachogenerator Feedback
Remove the "ARM" link. Connect the "TACH" link. Go through Start-up steps 2.3.1 through 2.3.4.
IMPORTANT
To prevent drive run away, be very careful to establish tachogenerator polarity with the motor
rotating in the desired direction. Then, connect tach + to terminal 12, and tach - to terminal 13.
When the tachogenerator is connected for the first time, do not start the drive unless the external
speed pot is set at "0", and the "MIN SPEED" pot is full counter clockwise. Set the "I MAX" pot
slightly clockwise.
Start the drive and slowly turn the speed pot clockwise. Confirm that the motor's speed increases
to a low speed, but does not run away. Switch the drive "OFF" and go through Start-up steps
2.3.5 through 2.3.7.
IMPORTANT
The "IR COMP" trimpot is not used with tachogenerator feedback and must remain fully counter
clockwise.
Page - 5
2.4
TERMINAL DESIGNATIONS
FIGURE 1
FIGURE 2
2
NOTES:
1.
For constant torque control, link
shown in Fig. 2 above.
4
to
5
and connect torque pot to terminals 3, 6 and 7 as
Page - 6
3.0
DRAWING INDEX
NUMBER
CA185-3
TITLE
Control Card Drawing
DG2-10-1
DG2 Converter ¼ - 1 HP,
120 VAC
DG2-10-2
DG2 Converter ¼ - 2 HP,
240 VAC
DG2-10-2.7
DG2 Converter ¼ - 2 HP,
277 VAC
DG2-15-2
DG2 Converter 3 HP, 240
VAC
DG2-25-2
DG2 Converter 5 HP, 240
VAC
DG2-30-2.7
DG2 Converter 7.5 HP,
277 VAC
CP71
Drawing Notes
Page - 7
CA185-3 CONTROL CARD DRAWING
Page - 8
DG2-10-1 CONVERTER 1/4 - 1HP, 120VAC
Page - 9
DG2-10-2 CONVERTER 1/4 - 1HP, 240VAC
Page - 10
DG2-15-2 CONVERTER 3HP, 240VAC
Page - 11
DG2-25-2 CONVERTER 5HP, 240VAC
Page - 12
DG2-30-2.7 CONVERTER 7.5HP, 277VAC
Page - 13
Installation & Operating Procedures
DG2
Series
SINGLE PHASE CONVERTERS
18 Neville Street, Unit C
New Hamburg, ON N3A 4G7
Tel: 519-662-6489
Fax: 1-866-280-5247
1/4HP - 7.5HP 120/240/277 VOLTS 50/60HZ
www.safdrives.com
email: answers@safdrives.com
(Replies given within 24 hours)