ERC Statohm IV (Introduction & Table of Contents)

INTRODUCTION
Before installation and operation of the ERC Statohm IV, DC drive, read this instruction
manual carefully. Installation should only be done by a fully qualified licensed electrician. The
ERC Statohm IV, DC drive is only a portion of a complete drive system. Refer to the instruction
manuals of the other components in the drive system for details about auxiliary equipment and
the DC motor. This user’s manual does not purport to cover all details or variations of DC drive
installation, operation or maintenance.

CAUTION
Before MEGGER or DIELECTRIC testing the DC motor.
Disconnect the DC motor from the Statohm IV control. Megger or
dielectric testing will damage the semiconductors in the control.

Table of Contents
Pg. 3 Section 1) Receiving & Storage
Pg. 3 Section 1.1) Model Number Scheme
Pg. 3 Section 2) Installation Location
Pg. 3 Section 2.1) Operating Environment
Pg. 5 Section 3) Jumper Settings
Pg. 4 Jumper Setting Diagram
Pg. 5 Section 3.1) Field Current Jumpers
Pg. 5 Section 3.2) Armature Current Jumpers
Pg. 5 Section 3.3) Motor Feedback Jumper
Pg. 5 Section 3.4) DC Tach Voltage Jumpers
Pg. 5 Section 3.5) Field Regulation Jumpers
Pg. 5 Section 3.6) Acceleration and Deceleration Time Range Jumpers
Pg. 7 Section 4) Wiring
Pg. 6 Wire Size Tables
Pg. 6 Elementary Power Connection Diagram
Pg. 7 Section 4) Power and Control Circuit Wiring Introduction
Pg. 7 Section 4.1) AC Power Connections
Pg. 7 Section 4.2) Grounding
Pg. 7 Section 4.3) Phase Sequence Test
Pg. 7 Section 4.3A) Fuse Replacement
Pg. 7 Section 4.4) Armature Connections
Pg. 8 Section 4.5) Field Connections
Pg. 8 Section 4.5A) Field Disable
Pg. 9 Section 4.6) PC, Pre-Operational Conditions (i.e. Enable Drive)
Pg. 9 Section 4.7) Speed Reference & Reverse
Pg. 10 Section 4.8) Jog
Pg. 10 Section 4.9) Start & Stop (i.e. Run & Stop)
Pg. 10 Section 4.10) Emergency Stop (E.Stop)
Pg. 10 Section 4.11) DC Tach generator Feedback
Pg. 11 Section 4.12) Meter Dimensions
Pg. 12 Section 4.13) Speed Meter Wiring and Calibration
Pg. 13 Section 4.14) Armature Ammeter Wiring and Calibration
Pg. 14 Section 4.15) Field Ammeter Wiring and Calibration

Page 1
ERC Statohm IV (Table of Contents)
Pg. 15 Section 5) Operation and Adjustment
Pg. 15 Section 5.1) Check prior to operation
Pg. 15 Section 5.2) Pre-Operation Voltage Checks
Pg. 15 Section 5.3) Test Run
Pg. 15 Section 5.4) Jog Speed & Ramp Adjustment
Pg. 16 Section 5.5) Emergency Stop (E. Stop)
Pg. 16 Section 5.6) ZD, Zero motor rotation Detection relay and signal light adjustment
Pg. 16 Section 5.7) Zero Speed Adjust (12 SCR Regenerative Drives Only)
Pg. 17 Section 5.8) Zero Speed Hysteresis Adjustment (12 SCR Regenerative Drives Only)
Pg. 17 Section 5.9) Maximum Speed Adjustment for Armature Feedback
Pg. 17 Section 10) Maximum Speed Adjustment for DC Tach Feedback
Pg. 18 Section 5.11) Field Amperage Adjustment
Pg. 18 Section 5.11A) Field Weakening Adjustment (Tach Feedback Only)
Pg. 18 Section 5.11B) Field Economy
Pg. 18 Section 5.11C) Field Disable
Pg. 18 Section 5.11E) Field Loss
Pg. 18 Section 5.11F) Field Voltage Regulation
Pg. 19 Section 5.12) Armature Current Calibration
Pg. 19 Section 5.12A) Current Limit Adjustment
Pg. 19 Section 5.12B) Forward and Reverse Current Limit Adjustment
Pg. 19 Section 5.12C) One Minute Timed Overload Shut-off Adjustment
Pg. 19 Section 5.12D) Instantaneous Overload Current Shut-off Adjustment
Pg. 20 Section 5.13) Acceleration & Declaration Time Adjustment
Pg. 20 Section 5.14) Speed Overshoot and Stability Adjustment Overview
Pg. 20 Section 5.14A) Speed Overshoot Adjustment (i.e. Speed Response)
Pg. 20 Section 5.14B) Speed Stability Adjustment (i.e. Speed Gain)
Pg. 21 Section 5.15) ASR Feedback Loop Adjustment ( i.e. Speed PID )
Pg. 21 Section 5.16) Current Gain Loop Adjustment ( i.e. Current PID )
Pg. 22 Section 5.17) Master Slave Operation
Pg. 25 Section 6) Troubleshooting
Pg. 25 Section 6.1) Phase Load Balancing
Pg. 27 Section 6.2) Motor won’t start but non of the signal lights are on.
Pg. 27 Section 6.3) Motor Speed Runaway
Pg. 28 Section 6.4) Fuses blow immediately after start and the “OC signal lights
Pg. 29 Section 6.5) Unstable Speed
Pg. 30 Section 6.6) Motor will not go to full speed
Pg. 30 Section 6.7) Excessive overshoot and undershoot
Pg. 30 Section 6.8) Overload fault “OL” signal light
Pg. 31 Section 6.9) The ES, OH, VL signal lights are on and can not be reset
Pg. 31 Section 6.10) Signal lights R and PC are on F,AP, ZD flash and relays buzz.
Pg. 31 Section 6.11) Field loss is detected.
Pg. 32 Section 6.12A) Armature current is too high at low speed and normal load.
Pg. 32 Section 6.12B) During acceleration or heavy load the field is too low.
Pg. 33 Section 6.13) PH Light is on
Pg. 33 Section 6.14) The F light is dimly lite but field loss is not detected
Pg. 33A Section 6.15) Regulator card connections
Pg. 33A Section 6.16) Utilty company transfer switch problems (PH light disable)
ATTACHMENTS
Pg. 34 “S” Model Physical Diagram
Pg. 35 “M2” Model Physical Diagram
Pg. 36 “M3” Model Physical Diagram
Pg. 37 “L1” Model Physical Diagram
Pg. 37A “L2” Model Physical Diagram
Pg. 38 IFC 1084 Card
Pg. 38 41FS Auxiliary Field Supply
Pg. 39 Synchronization Card 1058C
Pg. 40 Oscilloscopes
Pg. 42 Regulator Card Control Block Diagram #9044
Pg. 43 Regulator Card Block Diagram # 9042-1
Pg. 44 Regulator Card Block Diagram # 9042-2
Pg. 45 Regulator Card Block Diagram # 9042-3
Pg. 46 Elementary Circuit Diagrams
Pg. 47 Terminal Table (for Regulator Card)
Pg. 48 Regulator Card 1059A Physical Diagram
Pg. 49 Regulator Card Tables (for Pots, Jumpers, Signal Lights and Test Points)
Pg. 50 Common Specifications
Pg. 51 Alphabetical Index

Page 2
ERC Statohm IV Manual; Section 1&2 (Receiving & Storage and Installation Location)

Section 1 Receiving & Storage

When you receive the ERC Statohm IV DC drive, avoid shock or vibration when unloading and
transporting the unit. This can damage the semiconductors or other components. Immediately
upon receipt, inspect the unit for the following;
y Check to be certain the unit is clean of packing materials.
y Check for damage incurred during shipment, dents, scratches, ect.

y Inspect mechanical the parts, loose screws, terminals, hinges, ect.

y Inspect the circuit cards, damaged, loose or shorted electronic components or connections.

y If you find damage do not connect power to it. The unit must be replaced or repaired. Connecting power could
result in fire or further damage and void the warranty.
y Promptly report damage or problems you found during inspection to Electric Regulator Corp., Telephone (760)
438-7873, Fax (760) 438-0437
y Store the ERC Statohm IV control in a clean dry place, in the package it was shipped. Avoid storing the unit in
a location with high temperatures, humidity, dust or corrosive gases. Outdoor storage is not recommended.
Section 1.1) Model Number Scheme DC42NS3-4
Input Voltage: 2=208~240V, 4=440~480V, 5=575~600V
Power Rating Number
Chassi Size.
N = 6 SCR, R = 12 SCR
Model Number

Model Ampere and Horsepower Ratings

42NM2-*

42NM3-*
42RM2-*

42RM3-*

42NL1-*

42NL2-*

42NL4-*

42NL5-*

42NL7-*
42NS1-*

42NS2-*

42NS3-*

42NS4-*

42RL1-*

42RL2-*
42RS1-*

42RS2-*

42RS3-*

42RS4-*

Model Number

Max., Current 37A 70A 110A 180A 400A 550A 720A 910A 1100A 1400A 1800A
Input 208~240V, Arm 240V 7 HP 15 HP 25 HP 45 HP 100 HP 125 HP 200 HP 250 HP 300 HP --- ---
Input 440~480V, Arm 500V 14 HP 30 HP 50 HP 90 HP 200 HP 250 HP 400 HP 500 HP 600 HP 750 HP 1,000 HP
Input 575~600V, Arm 600V --- 36 HP 60 HP 108 HP 240 HP 300 HP 480 HP 600 HP 720 HP 900 HP 1,200 HP

Section 2 Installation Location

Section 2.1 Operating Environment
The ERC Statohm IV control should be located in a operating environment that meets the
following conditions.
y Ambient Temperature between 14o to 104o Fahrenheit (-10o to 40o Celsius).

y Relative Humidity Avoid locations exceeding RH 90%.

y Condensation Do not locate the unit where condensation occurs.

y Corrosion Avoid locations with corrosive gases or liquids; example: ocean air.

y Contamination Avoid locations subject to dust or iron particles.

y Hazardous Gases & Liquids Do not locate the unit were it is subject to combustible or flammable gases or
liquids.
y Ventilation Mount the unit in a lengthwise vertical position to ensure proper cooling ventilation. Provide not
less than 5 inches (125 mm) of clear space on all sides of the unit. If the unit is in a sealed enclosure, provide
adequate ventilation for air flow from top to bottom.
y Shock & Vibration Avoid mounting the unit in a location subject to shock or vibration.

Page 3
REGULATOR CARD 1059D and earlier depicted
REGULATOR CARD 1059F eliminated jumpers 2,3,6, FV, FI and added jumpers 11 and 12

P3
/10
P6
/10
P2
/10
P5

CA
/10
P1
+V -15 +15 /10
P4
/10

TL
LV
COM TG
IMX HS /10
/10 /10
9 OC
COM
USER SELECT'S OL
A-1
A-2
A-3
A-4

ARMATURE CURRENT
FU
EXTRA JUMPERS
LV
USER SELECT'S
F-1
F-2
F-3
F-4
F-5

FIELD CURRENT PH

EF
FL
FV
10

FI
8

OH

ES

FL
AP
7

P
IF FM ZERO
IFR ZD
/10 /10 /10
IG FL RL SR SG DG PI OP
/10 /10 /10 /10 /10 /10 /10 /10
TG
50H

RESET

9
5A 5
/10 8
CROS
AP

7
/10 6
FE

COM
M3 M4
1 2 4 6 10
SF
VF

+B
5
4

T-4
T-3
T-2
T-1

3
2
S-1
S-2
S-3
S-4

MAX JOG ACC DEC FT -R NA AM IA

/10 /10 /10 /10 /10 /10 /10 /10 /10
RUN
JOG

R5
PC

R
1

R2

TERMINALS 1 TO 40

JUMPER JUMPER
ON OFF Armature Feedback Jumper Settings
User Selects JUMPERS ON: AP, CA, FE, FI, IFR, TG, VF, 1, 2, 4, 6, 8
Regulator card 1059F does not require jumpers 2 and 6 for armature feedback
Page 4
Section 3 Jumper Setting Tables
The jumper settings must be made prior to applying power. Complete the blanks below to determine the jumper
settings for your application. Consult the jumper tables below or “Master Jumper Table” to the left.
y Armature Voltage VDC y Armature Current Limit A.
y Field Current A. y Acceleration Time Sec.
y Feedback (Arm or Tach) y Deceleration Time Sec.
y Field Regulation (constant current, field weakening, permanent magnet) (Field Economy enabled or disabled)

Jumper Tables
3.1 Field Current
“S2, S3 & S4”
“S1” Model “M2 & M3” Models M4 Model “L1 & L2” Models
Models Current Jumper Settings
Current Range Current Range Current Range Current Range
Range
F1 - On
4.3 ~ 7.1 6A ~ 10A 10A ~ 17A NA 15A ~ 25A
F2, F3, F4, F5 - Off
F2 - On
2.1 ~ 4.3 3A ~ 6A 5A ~ 10A NA 7.5A ~ 15A
F1, F3, F4, F5 - Off
F3 - On
1.4 ~ 2.1 2A ~ 3A 3.3A ~ 5A NA 5A ~ 7.5A
F1, F2, F4, F5 - Off
F4 - On
0.7 ~ 1.4 1A ~ 2A 1.7A ~ 3.3A NA 2A ~ 2.5A
F1, F2, F3, F5 - Off
F5 - On
0.6 ~ 1.2 0.8A ~ 1A 1.3A ~ 1.7A NA 1.3A ~ 2A
F1, F2, F3, F4 - Off

3.2 Armature Current (see section 5.12 for Armature Current Calibration)
“S1” Model “S2” Model “S3” & “S4 ” Model “M2” &“M3” Model “L1 & L2” Model
Jumper Settings
Current Range Current Range Current Range Current Range Current Range
A1, A2, A3, A4 -
14 ~ 23 48A ~ 81A 183A ~ 300A 366A ~ 600A 730A ~ 1,200A
On
A1, A2, A3 - On
12 ~ 20 35A ~ 58A 161A ~ 269A 322A ~ 538A 640A ~ 1,100A
A4 - Off
A1, A3 - On
8.6 ~ 14 25A ~ 42A 115A ~ 192A 230A ~ 384A 460A ~ 770A
A2, A4 - Off
A1 - On
6 ~ 10 18A ~ 30A 83A ~ 139A 166A ~ 277A 330A ~ 560A
A2, A3, A4 - Off
A2 - On
4.5 ~ 7.5 14A ~ 23A 60A ~ 100A 120A ~ 200A 240A ~ 400A
A1, A3, A4 - Off
A3 - On
3.5 ~ 5.9 11A ~ 19A 46A ~ 78A 93A ~ 150A 190A ~ 300A
A1, A2, A4 - Off
A4 - On
2.8 ~ 4.7A 7A ~ 12A 38A ~ 62.5A 75A ~ 125A 150A ~ 250A
A1, A2, A3 - Off
3.3 Motor Feedback 3.5 Field Regulation
Feedback Jumper Settings Field Operation Jumper Settings
VF, TG - On Constant Field J8 - On
Armature SF, TL - Off (default) J7 - Off
DC Tachometer Generator
SF, TG, TL - On Field Weakening J7, J8 - On
VF - Off (Tach Feedback Only)
Enable: FE - Off (default)
Field Economy Disable: FE - On
3.4 DC Tach Generator Voltage
Example: DC tach is 50VDC/1000 rpm and DC motor’s maximum FL- On
speed is 2150 rpm 2.15 x 50 = 107.5 Volts select voltage range Disabling Field Don’t connect
88v~127V., jumpers S2- On / S1, S3, S4 - Off power to F+ and F-
Standard Setting Special Setting
(R2 & R5 are (R2 & R5 are zero Jumper Settings
220k resistors) ohm jumpers) 3.6 Acceleration & Deceleration Time Range
S1, S2, S3, S4 - Time Range Jumper Setting
41V ~ 60V 27V ~ 41V
Off
S1 - On T1 - On
60V ~ 88V 41V ~ 60V S2, S3, S4 - Off 0.7 ~ 6 Sec.
T2, T3, T4 - Off
S2 - On T2 - On
88V ~ 127V 60V ~ 88V S1, S3, S4 - Off 3 ~ 20 Sec. (default)
T1, T3, T4 - Off
S3 - On T3 - On
127V ~ 172V 88V ~ 127V S1, S2, S4 - Off 7 ~ 60 Sec.
T1, T2, T4 - Off
S4 - On T3, T4 - On
172V ~ 250V 127V ~ 172V S1, S2, S3 - Off 14 ~ 120 Sec.
T1, T2 - Off

Page 5
 Wire Size Tables
230 VAC 3 Phase 60 Hz Input 460 VAC 3 Phase 60 Hz Input
Full Load Minimum Wire Size Circuit Breaker Full Load Minimum Wire Size Circuit Breaker
HP HP
AC Amps for 40 ft length AC Amps at 250VAC AC Amps for 40 ft length AC Amps at 600VAC
5 17 12 AWG 25 5 8.6 14 AWG 10
7.5 25 10 AWG 30 7.5 11 14 AWG 15
10 32 8 AWG 40 10 13.5 12 AWG 20
15 49 6 AWG 70 15 21 10 AWG 30
20 63 4 AWG 90 20 27 8 AWG 35
25 79 3 AWG 100 25 34 8 AWG 40
30 93 1 AWG 125 30 40 6 AWG 50
40 124 00 AWG 175 40 54 4 AWG 70
50 156 000 AWG 200 50 67 4 AWG 90
60 184 0000 AWG 225 60 80 3 AWG 100
75 229 300 MCM 300 75 99 1 AWG 125
100 300 500 MCM 400 100 133 00 AWG 175
125 380 (2) 250 MCM 500 125 167 0000 AWG 225
150 450 (2) 350 MCM 600 150 202 250 MCM 300
200 266 (2) 000 AWG 400
250 375 (2) 250 MCM 500
240 VDC Armature 500 VDC Armature
Full Load Minimum Wire Size DC Fuse Amps Full Load Minimum Wire Size DC Fuse Amps
HP HP
DC Amps for 40 ft length (if used) DC Amps for 40 ft length (if used)
5 19 10 AWG 25 5 10 12 AWG 15
7.5 28 8 AWG 40 7.5 12 12 AWG 20
10 36 6 AWG 50 10 15 10 AWG 25
15 54 4 AWG 70 15 23 8 AWG 35
20 70 2 AWG 100 20 30 8 AWG 45
25 87 1 AWG 150 25 38 6 AWG 60
30 105 0 AWG 150 30 45 4 AWG 70
40 139 0000 AWG 200 40 60 3 AWG 100
50 173 250 MCM 250 50 75 2 AWG 150
60 205 300 MCM 300 60 90 1 AWG 150
75 254 500 MCM 400 75 110 00 AWG 200
100 337 (2) 250 MCM 600 100 148 0000 AWG 250
125 325 (2) 350 MCM 600 125 185 300 MCM 300
150 504 (2) 500 MCM 800 150 218 (2) 000 AWG 400
150 VDC Field 200 295 (2) 250 MCM 600
Wire Size for 40 ft Length 250 408 (2) 350 MCM 600
5 - 75 H.P. : 14 AWG 300 VDC Field
100 - 200 H.P. : 12 AWG Wire Size for 40 ft Length
5 - 75 H.P. : 14 AWG
100 - 200 H.P. : 14 AWG

Elementary Power Connection Diagram

DC Motor
A-
DC Drive
A
A+
ABC
L1F L2F L1C L2C L1S L2S L3S F+ F- L1C and L2C are alternately marked 115V.

FIELD 3A
fuse
L1 L2 L3

115V L1 L2 L3

Page 6
ERC Statohm IV Manual, Section 4 (Power & Control Circuit Wiring)

Section 4 Power & Control Circuit Wiring Introduction

The ERC Statohm IV is only one part of an entire drive system. The drive system
engineer should supply a wire diagram and/or wire connection net list ( i.e. net list ) for the drive
system’s control panel, switch panel, DC motor and other auxiliary equipment.
For easier installation we recommend the power circuit should be installed first and the
control circuitry second.

WARNING
Separate over current protection is required by the national electric code. The user is
responsible for conforming with the national electric codes and all applicable local codes
which govern such practices such as wiring protection, grounding, disconnects and other
current protection.

Power Circuit Wiring

NOTICE
Make all power circuit connections in accordance with the drive system engineer’s wire
diagram or the elementary wire diagrams provided in this manual. The power circuit
includes terminals L1, L2, L3, L1F, L2F, L1S, L2S, L3S, A+, A-, F+, F- and 115V.

4.1 AC Power Connections

y See on the Wire Size Tables on page 6 and Elementary Wiring Diagram below.
y Connect the three phase AC power to the buss terminals marked: L1, L2, L3 and to terminals
L1S, L2S, L3S that supply the SYNC card and to L1F, L2F that supply the field.
y Connect the single phase 110 ~ 120 VAC power to terminal block positions “115V”
(alternately marked L1C and L2C).

4.2 Ground in accordance with national and local electrical codes and regulations.

4.3 Phase Sequence Test

The Statohm IV PH signal light indicates if the phase of L1, L2 and L3 are in the same
sequence as L1S, L2S and L3S.
Turn on the AC power, if the PH light is off the phase sequence is correct. If the PH light
is on, the phase sequence is wrong. To correct the phase sequence. Turn off the power. Check
with an Ohm meter the sequence of L1, L2 and L3 are in the same sequence as L1S, L2S and
L3S and power test again. If this fails, change the sequence of L1 and L2 and test again. If this
fails, check the plugs connections from L1S, L2S and L3S to the synchronization card (i.e.
SYNC card and test again. Additional phase sequence tests are covered in section 6.13 Problem:
PH Light is on.

4.3A Fuse Replacement

When replacing fuses on the “M3” and “L” model drives, keep the fuse relay # G310000
MS3V 2-5 attached to the side of the fuse. The replacement fuse doesn’t include the fuse relay.
The fuse relay can be used again. Note: “S” models and the “M2” model don’t have fuse relays.
If you can not get replacement fuses from your local electrical supply. Replacement fuses
are available from Electric Regulator.

Page 7
ERC Statohm IV Manual, Section 4 (Power & Control Circuit Wiring)
4.4 Armature Connections
y See the motor data plate for the armature’s amp rating. Then select the wire size from the Wire Size
Table at the beginning of section 4.
y Connect the motor’s armature to the power busses marked A+ and A- .
y Current Range is selected from jumper the table below.
y For instructions bout adjusting the Current Limit, see section 5.12
“S1” Model “S2” Model “S3 & S4 ” Model “M2 & M3” Model “L1 & L2” Model
Jumper Settings
Current Range Current Range Current Range Current Range Current Range
14 ~ 23 48A ~ 81A 183A ~ 300A 366A ~ 600A 730A ~ 1,200A A1, A2, A3, A4 - On
A1, A2, A3 - On
12 ~ 20 35A ~ 58A 161A ~ 269A 322A ~ 538A 640A ~ 1,100A
A4 - Off
A1, A3 - On
8.6 ~ 14 25A ~ 42A 115A ~ 192A 230A ~ 384A 460A ~ 770A
A2, A4 - Off
A1 - On
6 ~ 10 18A ~ 30A 83A ~ 139A 166A ~ 277A 330A ~ 560A
A2, A3, A4 - Off
A2 - On
4.5 ~ 7.5 14A ~ 23A 60A ~ 100A 120A ~ 200A 240A ~ 400A
A1, A3, A4 - Off
A3 - On
3.5 ~ 5.9 11A ~ 19A 46A ~ 78A 93A ~ 150A 190A ~ 300A
A1, A2, A4 - Off
A4 - On
2.8 ~ 4.7A 7A ~ 12A 38A ~ 62.5A 75A ~ 125A 150A ~ 250A
A1, A2, A3 - Off

4.5 Field Connections

y See the motor’s data plate for the field’s amp rating. Then select the wire size from the Wire Size
Table at the beginning of section 4. We also strongly recommend reading page 41.
y The polarity of the field determines the motor’s direction of rotation. Connect the motor field wires
F1 and F2 to the terminal strip points F+ and F- according to the required direction of rotation. Note:
The American industry standard for determining if a motor’s rotation is clockwise or
counterclockwise is to view the motor from the commutator end. The commutator end of a standard
DC motor is the opposite end from the drive shaft.
y The field current is selected by setting the appropriate jumper in the table below.
See motor’s name plate for the motor’s field current. Note: The field current is limited by the input
voltage. The field voltage will not 71% of the input voltage. Example: With 460V connected to L1F
and L2F, the field voltage will not exceed 327 volts.
“S1” Model “S2 & S4” Models “M2 & M3” Models “L1 & L2” Models
Jumper Settings
Current Range Current Range Current Range Current Range
F1 - On
4.3 ~ 7.1 6A ~ 10A 10A ~ 17A 15A ~ 25A
F2, F3, F4, F5 - Off
F2 - On
2.1 ~ 4.3 3A ~ 6A 5A ~ 10A 7.5A ~ 15A
F1, F3, F4, F5 - Off
F3 - On
1.4 ~ 2.1 2A ~ 3A 3.3A ~ 5A 5A ~ 7.5A
F1, F2, F4, F5 - Off
F4 - On
0.7 ~ 1.4 1A ~ 2A 1.7A ~ 3.3A 2A ~ 2.5A
F1, F2, F3, F5 - Off
F5 - On
0.6 ~ 1.2 0.8A ~ 1A 1.3A ~ 1.7A 1.3A ~ 2A
F1, F2, F3, F4 - Off

4.5A Field Disable

The field is disabled when the motor has a permanent magnet field or series field and armature. To disable
the field loss detection circuit, put the jumper FL on and don’t connect power to L1F and L2F. Note: The
yellow “F” light will remain on when the field is disabled.
Field Weakening See Section 5.11A

Page 8
ERC Statohm IV Manual, Section 4 (Power & Control Circuit Wiring)

Control Circuit Wiring

Elementary Control Circuit Functions

y Start/Run (terminal 34) y Jog, if used (terminal 33)
y Emergency Stop (terminal 40) y PC, Enable Drive (terminal 36)
y Speed Reference (terminals 7,8 and 9) y DC Tach Feedback, if used (terminals 1 and 2)
y Reverse has two options (12 SCR drives only)
Option 1) Terminal 37.
Option 2) Speed Reference Voltage Polarity

NOTICE
Make all control circuit connections in accordance with the drive system engineer’s wire
diagram or the elementary wire diagrams provided in this manual if applicable. The
control circuit terminals 1 though 40 are located on the regulator card.

WARNING
Electrical noise pickup on the control circuit wiring can cause erratic operation.
y Never use solid wire.
y Use shielded wires or twisted wires for the control circuit. Connect shielding to common
terminal of each circuit.
y Run the control circuit wires in a separate duct or conduit. Maintain a space of 2 inches
(50 mm) or more from the general power circuit.

4.6 PC (Enable Drive)

The PC terminal number 36, enables the drive before start. This is a safety to detect when
external Pre-operational Conditions (PC) are engaged before the DC drive is able to start.
Example: A safety door has a micro switch connected to terminals 36 (PC) and 35 (COM). When
the door is open the micro switch is open. When the door is closed PC is engaged. PC must
remain closed during motor operation. PC should not be used to start and stop the motor.
If your application doesn’t require PC, connect a jumper wire from 35 to 36.

4.7 Speed Reference & Reverse

Speed Reference has two options.
Option 1) The factory default setting is 0 to 8 volts with the power supplied by the regulator
card. A potentiometer (typically a 500 pot) is connected to terminals 7, 8 and 9. The pot’s
wiper is connected to terminal 8 (Speed Reference). If you have a 12 SCR drive, Reverse is
activated by connecting terminal 37 (Reverse) to 35 (Com). This changes the polarity of the
speed reference voltage (terminals 7 and 9) and the motor changes direction.
Option 2) If an external speed reference power supply is used. You have the choice of ! 8V or
! 10V by setting jumper JP-1, see the jumper table below. Connect the speed reference signal to
terminals 8 and 9. The motor is reversed by changing the polarity of the speed reference voltage.

0~8V or ! 8V speed reference voltage

Jumper ON (default) ! 8V requires external power supply
Jumper: JP-1
0~10V or ! 10V speed reference voltage
Jumper OFF, External 10V or ! 10V power supply required

Page 9
ERC Statohm IV Manual, Section 4 (Power & Control Circuit Wiring)

4.8 Jog
Jog will run up to 20% of full speed. The FT pot adjusts Jog’s acceleration time equal to or faster
than ACC setting. Important note: FT also adjusts E. Stop’s deceleration time. See section 4.10
option 2. The user must decided the priority when making this setting. The control circuit should
be designed so that Jog and Start (Run) are not on simultaneously. They should only be on
alternately.
4.9 Start/Run and Stop
To start the drive close terminals 34 (Run) to 35 (Com). For normal stop with deceleration time
controlled by the Deceleration pot, open terminals 34 and 35.
Note: Don’t open PC to stop the motor, see section 4.6
4.10 Emergency Stop (E.Stop)
Emergency Stop has two options.
Option 1) Freewheeling stop is the factory default setting. The motor is allowed to coast to a
stop and the regulator card power is switched off.
Option 2) Controlled deceleration stop To enable controlled E Stop, set the EF jumper ON and
make jumper connections from terminals 21 to 35 and 23 to 36. The E. Stop deceleration time
can be set to equal to or less than the DEC pot setting. The “FT” pot adjusts the E. Stop
deceleration time. Note: FT also equally adjusts Jog’s acceleration time. (See section 4.8) Proper
adjustment of the OP pot is required for a complete stop (see section 5.5A). The OP pot sets the
point when the regulator card power is switched off. Setting the OP pot too low will cause the
ZD relay to buzz
REGULATOR CARD

Emergency Stop mode Jumper Setting

Power Off
EF - Off
Uncontrolled Coast to Stop
Jumper EF - On EF - Jumper ON

and OP Pot

Controlled ZD relay terminals

Deceleration Stop are connected FT Pot

21 to 35 and 23 to 36. FT Relay

See diagram to the right

1 2 3 ---------------------21 22 23 ----------35 36 --- 40

4.11 DC Tach generator Feedback

The factory default setting is armature feedback (i.e.. Voltage Feedback, VF). If tach feedback
(i.e.. Speed Feedback, SF) is used. Move the jumper on VF to SF. Next calculate the maximum
tach voltage. Example, the tach is 50V per 1000 rpm and the base speed of the motor is 1750
rpm. The maximum voltage will be 87.5V (1.75 x 50). The table shows jumper S1 (60~88V)
would be appropriate. The speed will not to exceed 88 volts or 1760 RPM. If field weakening is
used and 2200 rpm is required. Then calculate 2.2 x 50=110, jumper S2 (88~127V) is in this
range. This range will permit the speed to go up to but not exceed 2540 RPM ((127/50)1000=2540).
DC Tach Generator Jumper
R2 and R5 are 220k ohms (standard setting) R2 and R5 are zero ohm jumpers. (special setting) Settings
41V ~ 60V 27V ~ 41V S1, S2, S3, S4 - Off
S1 - On
60V ~ 88V 41V ~ 60V
S2, S3, S4 - Off
S2 - On
88V ~ 127V 60V ~ 88V
S1, S3, S4 - Off
S3 - On
127V ~ 172V 88V ~ 127V
S1, S2, S4 - Off
S4 - On
172V ~ 250V 127V ~ 172V
S1, S2, S3 - Off

Page 10
ERC Statohm IV Manual, Section 4 (Power & Control Circuit Wiring)

Section 4.12 Meter Dimensions

4.33" 0.79" 0.63"

110mm 20mm 16mm
3.55" 0.218" 3.15"
90mm 5.5mm 80mm

3.86"
98mm
0.60"
15mm

M5 x 0.8

Meter Dimentions

Meters are an optional accessories available from Electric Regulator.

Meters are stocked in the following scales.
Scale of face plate Input
0 to 50 Amps 0 to 2 volts
0 to 100 Amps 0 to 2 volts
0 to 200 Amps 0 to 2 volts
0 to 400 Amps 0 to 2 volts
-100, 0, +100 Amps, Center Zero 0 to 2 volts
-200, 0, +200 Amps, Center Zero 0 to 2 volts
0 to 100% 0 to 2 volts
0 to 150% 0 to 2 volts
-150%, 0, +150%, Center Zero 0 to 2 volts
0 to 2000 RPM 0 to 1 mA
0 to 100% 0 to 1 mA
-100%, 0, +100%, Center Zero 0 to 1 mA
0 to 600 Volts 0 to 1 mA
0 to 300 Volts 0 to 1 mA

The Statohm IV has meter outputs for Armature current, Field current and Motor Speed.

+
See page 13 17 ARMATURE AMMETER
for instructions 18 -
A INPUT: 0 TO 2V

+
See page 12 19 SPEED METER
for instructions 18 - N INPUT: 0 TO 1mA

+
See page 14 20 FIELD AMMETER
for instructions 18 - F INPUT: 0 TO 2V

Page 11
ERC Statohm IV Manual, Section 4 (Power & Control Circuit Wiring)

Section 4.13) Speed Meter Wiring and Calibration

Selecting a meter
y The speed meter is an ammeter with a 0 to 1 mA input (meters are available from ERC).
y The application determines the units and the scale of the meter’s face plate.
For example, units RPM, scale 2000. For one direction rotation, left is zero and full
clockwise is 2000 RPM. If you are reversing the motor, a meter with a center zero with right
and left scales is required.
Jumper and Potentiometer Settings
Before calibrating the ammeter make all final jumper settings and pot adjustments.
y Make final settings to jumpers A1, A2, A3 and A4.
y Set Jumpers, SF-on, VF-off and user selects JP-7.
y Make final adjustments to potentiometers (pots), MAX and CROS.
y If any of these settings are changed after calibrating the speed meter, recalibration of the
speed meter is required.
How to calibrate the speed meter.
y An independent speed measurement for reference is required to calibrate the speed meter.
You can improvise by using an voltmeter to measure the armature voltage or DC tach
voltage. Then use the voltage to calculate the speed.
y The NA pot calibrates the speed meter
y Run the motor at a level speed and adjust the NA pot until the speed meter equals the
independent speed measurement.
The speed meter circuit is a current regulator circuit, the NA pot sets the current limit.
Example: The meter has a 0 to 2000 RPM face plate, the input is 1 mA = 2000 RPM (100%).
The motor’s base speed is 1750 RPM. The speed meter is calibrated by running the motor at base
speed and adjusting the NA pot until the meter reads 1750 RPM. The current limit is set to 0.875
mA (1750 RPM = 0.875 mA). If changes are made to extend the speed of the motor to 1900
RPM by using field weakening. If the speed meter is not recalibrated. The speed meter will read
1750 RPM when the motor is actually running 1900 RPM. Creating a 8.5% error over the entire
meter’s range. The speed meter must be recalibrated by adjusting the NA pot to read 1900 RPM
at full speed (1900RPM = 0.95 mA).

REGULATOR CARD

JP-7

CROS

SF VF
NA pot

S1--S4
MAX

SPEED METER

1 2 3 - - - - - - - - - - 18 19 - - - - - - - - - - - - - - - 39 40
POS + INPUT NEG
0 to 1 mA

Page 12
ERC Statohm IV Manual, Section 4 (Power & Control Circuit Wiring)

Section 4.14) Armature Ammeter Wiring and Calibration

Selecting a meter.
y The armature ammeter is a voltmeter with a 0 to 2 volt input (meters are available from ERC).
y The motor’s rating and application determines the scale of the meter’s face plate.
For example, a 0 to 2 volt meter with 100 Amp scale face plate. For one direction operation,
left is zero and full clockwise is 100A. If you are reversing the motor, a center zero with left
and right scales is required.
Jumper and Potentiometer Settings
Before calibrating the ammeter make all final jumper settings and pot adjustments.
y Make final setting of jumpers A1, A2, A3 and A4.
y Set JP2 - on, JP3 - off.
y Make final adjustment of potentiometer (pot), IMX.
y If any of these settings are changed after calibrating the ammeter, recalibration of the
ammeter is required.
How to calibrate the ammeter.
y An independent ammeter for reference is required to calibrate the ammeter.
y The AM pot calibrates the ammeter
y Run the motor at a level speed and load and adjust the AM pot until the ammeter equals the
reference ammeter.

Note: The IMX pot sets the current limit circuit’s internal reference point. The AM pot sets the
output voltage scale. For example: If a motor’s rating is 50 amps, the IMX pot calibrates the
current limit circuit’s internal reference point to 50 amps. The meter has 0 to 2 volt input with
100 amp scale face plate. Next with the motor running under a 50 amp load and using an external
ammeter for reference. The AM pot is adjusted until the ammeter reads equal to the reference
meter, 50 amps. This sets the scale to 1 volt equals 50 amps. If after the ammeter is calibrated,
the IMX pot is changed to 70 amps. This changes the scale to 70 amps equals 1 volt. If the
ammeter is not recalibrated, the ammeter will read 50 amps when the armature current is actually
70 amps. The ammeter always must be recalibrated after the IMX pot is adjusted.

REGULATOR CARD

IMX

A1--A4
JP-2
JP-3
AM pot

ARMATURE
AMMETER

1 2 3 - - - - - - - - - - 17 18 - - - - - - - - - - - - - - - 39 40
NEG INPUT POS +
0 to 2V

Page 13
ERC Statohm IV Manual, Section 4 (Power & Control Circuit Wiring)

Section 4.15) Field Ammeter Wiring and Calibration

Selecting a meter.
y The ammeter is a voltmeter with a 0 to 2 volt range input (meters are available from ERC).
y The motor’s field current rating determines the scale of the meter’s face plate.
For example, 0 to 2 volt meter with 10 Amp scale face plate.

Jumper and Potentiometer Settings

Before calibrating the ammeter make all final jumper settings and pot adjustments.
y Make final settings to jumpers F1, F2, F3, F4 and F5
y Set jumper FI - on and FV - off.
y Make final adjustments to potentiometer (pot), IF
y If any of these settings are changed after calibrating the field ammeter, recalibration of the
field ammeter is required.

How to calibrate the ammeter.

y An independent ammeter is required as a reference to calibrate the field ammeter.
y The FM pot calibrates the ammeter
y Energize the field and adjust the FM pot until the ammeter equals the reference ammeter.

The IF pot sets the field regulation circuits’ internal reference point. The FM pot sets the scale of
the field ammeter circuits’ output voltage scale. For example: If the motor’s field is 6 amps and
the meter has a 0 to 2 volt input with a face plate scale of 0 to 10 amps. With the field energized,
the FM pot is adjusted until the field ammeter equals the reference ammeter, 6 amps. This sets
the output voltage to 1.2 volts at 6 amps. After the field ammeter is calibrated, if the IF pot or F
jumpers are changed so that the field is 4 amps. This changes the scale to 4 amps equals 1.2
volts. If the field ammeter is not recalibrated, the ammeter will read 6 amps when the field
current is actually 4 amps. The field ammeter always must be recalibrated after the IF pot is
adjusted.

REGULATOR CARD

F1----F5
FV
FI
FM Pot
IF Pot

FIELD AMMETER

1 2 3 - - - - - - - - - - -18 19 20 - - - - - - - - - - - - - 39 40
POS + INPUT NEG-
0 to 2V

Page 14
ERC Statohm IV Section 5 (Operation & Adjustment)

Section 5 Operation and Adjustment

5.1 Check prior to operation

Check all of the following before applying power.
y Check for any loose connections on any of the control circuit terminals, power circuit
terminals and fuses.
y Verify all connectors are correctly inserted in the regulator card’s terminals. Carefully
inspect for frayed braids of wire. Frayed wires that are and not inserted in the terminal, can
cause short circuits or intermittent shorts.
y Use an Ohm meter to check the wiring continuity and the isolation between the wiring and
control panel.

5.2 Pre Operation Voltage Checks

Never measure voltage test points when the motor is running.
Item Measuring Location Voltage
AC Input Power Buss
3 Phase AC Input Power Within !10% of Rated Voltage
(L1-L2-L3 or R,S,T)
Field AC Input Power Terminal Block (L1S, and L2S) (L1F and L2F) Within !10% of Rated Voltage
Single Phase Input Power Terminal Block ( L1C and L2C) 110 VAC to 120 VAC
Signal Relay Power Test Points on Regulator Card (+V to Com ) +19.5 VDC !1V
Positive and Negative Test Points on Regulator Card
(+15 VDC !0.5V) (-15 VDC !0.5V)
Power Supplies (+15 to Com ) (-15 to Com)

5.3 Test Run

The primary adjustments have been made at the factory prior to shipping. The jumper settings
were covered in section 3 . Fine adjustments should be made in the following sequence prior to
full operation.
y Confirm the operation of emergency stop sequence.
y Set the JOG pot to an intermediate position.
y Start the motor using the jog control. If the motor rapidly accelerates past 20% of the motor’s
base speed. Stop and check if the tach feedback wires are connected properly and if the tach
voltage jumper is correct (see section 3.4). If the motor runs in the wrong direction, for
armature feedback check the polarity terminals F1, F2. For tach feedback check the polarity
of the tach wires to terminals 1 and 2.
y When the motor operates properly, continue.

5.4 Jog Speed & Acceleration and Deceleration Adjustment

y Start the motor using the jog control.
Note: Jog operates only when the Run not activated.
y Adjust the JOG pot until motor runs at desired speed.
y Jog acceleration and deceleration time are adjusted by the “FT” pot. Clockwise is slower,
Counter Clockwise is faster. The scale of the FT pot is with in the range of the setting of the
DEC pot.
y Note: Jog’s deceleration time is the same as Emergency Stop’s (E-Stop) deceleration time.
The user must decided witch function has priority when setting this adjustment. See section 5.5

Page 15
ERC Statohm IV Section 5 (Operation & Adjustment)

5.5 Emergency Stop (E. Stop)

The Statohm IV has two options for emergency stop ( i.e. E. STOP).
Option 1) Power Off E. Stop (uncontrolled coast to stop) (default setting). Local regulations
may require emergency stop to shut off the drive and let the motor to coast to a stop. When EF
jumper is off, the motor will coast to stop and FT relay will switch.
Option 2) Controlled Deceleration E. Stop with power switch off at zero speed. Set the FE
jumper on and make connections from terminals 21 to 35 and 23 to 36 (see diagram). The E.
Stop deceleration time can be set to equal to or less than the DEC pot deceleration time setting.
The “FT” pot adjusts the E Stop deceleration time. Proper adjustment of the OP pot is required
for a complete stop (see section 5.6). The OP pot sets the point when the drive switches off.
REGULATOR CARD

Emergency Stop mode Jumper Setting

Power Off
EF - Off
Uncontrolled Coast to Stop
EF - Jumper ON
Jumper EF - On
Controlled and OP Pot

Deceleration Stop with ZD relay terminals

FT Pot
Power Switched Off at Zero are connected
Speed 21 to 35 and 23 to 36. ZD Relay

See diagram to the right 1 2 3 ---------------------21 22 23 ----------35 36 --- 40

5.6 Zero motor rotation Detection relay and signal light adjustment
The regulator card has a motor rotation detection circuit (i.e. Zero Detection, ZD). The ZD
circuit has a SPDT relay on terminals: 21 center pole, 22 normally closed, 23 normally open and
a signal light marked ZDL. The switch point of the ZD circuit is set by the OP pot. The switch
point adjustable over a range of 0 to 25% of full speed.
y While the motor is stopping adjust the OP pot to the desired switching point. The ZDL signal
light will switch on.
y Note: Adjusting the OP pot too low can cause the ZD relay to buzz when the motor is
stopped.

5.7 Zero Speed Adjust (12 SCR Regenerative Drives Only)

Regenerative drives that start and stop with a small load, may require special adjustment to make
smooth starts, stops and remain stationary when stopped. This problem is common with tach
feedback systems. To obtain best results, we recommend using an oscilloscope to view the signal
across A+ and A-.
y Turn the acceleration and deceleration pots full clockwise.
y Set the speed reference to zero volts and engage E. Stop and PC. If the motor turns, adjust
the ZERO pot until the motor is at a standstill.
y Regenerative drives with tach feedback sometimes exhibit instability is at low speeds and
during start and stop. Removing the AP jumper will stabilize the problem by placing a
capacitor in parallel with the speed feedback opamp resistor.
y If problems persists, see section: 5.8, Zero Speed Hysteresis Adjustment.

Page 16
ERC Statohm IV Section 5 (Operation & Adjustment)

5.8 Zero Speed Hysteresis Adjustment ( 4 Quadrant, 12 SCR, Regenerative Drives Only)
The regulator card switches the motor from forward to reverse by changing the polarity of the
speed amplifier output. The output of the speed amplifier includes ripple form the tach or arm
feedback. To minimize the effect of ripple from this feedback. A Hysteresis circuit adjusts the
input sensitivity of the to the reverse switch logic. The “HS” pot is usually set on or about
2.5 /10 scale. If the motor is frequently reversed with light load, adjust the “HS” pot clockwise.
The Hysteresis circuit is an imprecise adjustment. Set the pot and wait for the drive to stabilize
before making another adjustment. Avoid making an excessive number of adjustments.

5.9 Maximum Speed Adjustment for Armature Feedback

See the motor’s data plate to confirm the maximum armature voltage. The drive is preset at the
factory for the typical motor. See section 3 for the parameters of your motor and drive. If the
drive requires adjustment follow the procedure below.
y When the motor is stopped. Adjust the “CROS” pot full counter clockwise (0/10) and the
“MAX” pot to full clockwise (10/10).
y Start the motor, adjust the speed reference to maximum speed and observe the armature
voltage. When the motor’s speed has stabilized at maximum speed proceed to the next step.
y Adjust the “CROS” pot to the maximum permissible armature voltage. This calibrates the
range of the “MAX” pot. The “MAX” pot will not exceed the setting of the “CROS” pot
calibration setting. Another way of describing this is. When the “MAX” pot is full clockwise
(10/10). It is equal to the setting of “CROS” pot. If a maximum speed below the maximum
permissible armature voltage is required. Adjust the “MAX” pot to required speed.
y Note: If a speed above base speed (above the maximum armature voltage is required).
Motor’s with tach generator feedback have the option of field weakening. See Sections: 3.5
Field Regulation and 5.11A Field Weakening Adjustment.

5.9A) Armature Ammeter Wiring and Calibration, See section 4.14

5.10 Maximum Speed Adjustment for DC Tach Generator Feedback

See the motor’s data plate to confirm the maximum armature voltage, base speed and maximum
mechanical speed. See the DC tach generator’s data plate to confirm the volts per 1000 RPM.
Check the tables below to confirm jumpers are set for DC tach feedback and the correct voltage
range for the maximum tach generator voltage. Example: If you have a 50VDC/1000 RPM Tach
and your application requires 2,250 RPM. Multiply 2.25 X 50 = 112.5VDC. Select the voltage
range of 88V ~ 127V.

Motor Feedback Jumper Settings DC Tach Generator Voltage Jumper

R2 and R5 are 220k ohms R2 and R5 are zero ohm
VF - On Settings
Armature ( Standard Set Up ) jumper ( Special Set Up)
SF, TL - Off 41V ~ 60V 27V ~ 41V S1, S2, S3, S4 - Off
SF, TL - On S1 - On
DC Tach Generator 60V ~ 88V 41V ~ 60V
VF - Off S2, S3, S4 - Off
S2 - On
88V ~ 127V 60V ~ 88V S1, S3, S4 - Off
S3 - On
127V ~ 172V 88V ~ 127V S1, S2, S4 - Off
S4 - On
172V ~ 250V 127V ~ 172V S1, S2, S3 - Off

5.10A) Speed Meter Wiring & Calibration, See section 4.13

Page 17
ERC Statohm IV Section 5 (Operation & Adjustment)

5.11 Field Amperage Adjustment

Warning, never disconnect the field power while the motor is running. We strongly
recommend reading page 41 before continuing. Instructions for connecting the field power and
jumper settings are on page 8, section 4.5,.
Temporally disable field economy by putting on jumper FE. The IF pot adjusts the field
amperage within the jumper settings range. We recommend using a ammeter, if one is not
available, then calculate the motor’s cold field voltage and quickly adjust the field while the field
is cold. Important note: Note: the field voltage will not exceed 71% of the input voltage
connected to terminals L1F and L2F.
5.11A) Field Weakening Adjustment ( DC Tach Feedback Only )
Field weakening offers both constant power and extended speed. Field weakening is only
available for motors with tach generator feedback. To enable field weakening, jumpers J7 and J8
must be on. If the field weakening is below half (½) of full field, put jumper CA on. The field
weakening minimum is 1/3 of full field. The optional 1059A-11 regulator card permits field
weakening to about 1/4 to 1/6 of full field.
y Adjust the ACC and DEC pots full clockwise (slow).
y Adjust the speed reference to maximum speed and observe the armature and tach generator
voltages. When the armature and tach voltages stabilize at maximum, proceed to the next
step.
y Adjust the CROS pot to the desired maximum armature voltage.
y Adjust the MAX pot to the desired maximum speed. Warning, do not exceed the motor’s
maximum speed listed on the motor’s data plate. Note: the motor speed will not exceed the
DC tach jumper setting, see page 5, section 3.4,.
5.11B) Field Economy
When the motor is not running, full field power is not necessary. Field economy reduces the field
power, when the motor is stopped and the PC light has been off approximately six to eight
seconds. When the motor is started full field power is automatically reapplied. If you want to
disable field economy put the jumper FE on.
5.11C) Field Disable
The field is disabled when the motor has a permanent magnet field or series field and armature.
To disable the field loss detection circuit, put the jumper FL on and don’t connect power to L1F
and L2F. Note: The yellow “F” light will remain on when the field is disabled.
5.11D) Field Ammeter Wiring and Calibration, See section 4.15
5.11E) Field Loss
The 1059A regulator card has field loss protection circuit that shuts off the motor if the field
goes below 1/6 of full field.
5.11F) Field Voltage Regulation
If the application requires field voltage regulation to interface with your equipment. The optional
IFC 1084 card is available.

Page 18
ERC Statohm IV Section 5 (Operation & Adjustment)

5.12 Armature Voltage and Current Calibration

The CROS pot serves two functions, when field weakening is not used. The CROS pot sets the
maximum armature voltage. When you set the armature current jumpers in section 3.2 only the
current range was determined. Now you must calibrate the regulator card to the motor’s rated
current by adjusting the IMX pot. We strongly recommend the use of an ammeter when making
these settings.
y Turn the IMAX pot full counter clockwise. Set the FL and RL pots to 4/10 scale.
y Run the motor at full load. (If running under full load is not possible. See estimating IMX
adjustment below.
y When the motor is running with a load adjust the IMX pot to the motor’s rated current.
y All the following percentages are based on the calibrated current set by the IMX pot.
y Estimating adjusting IMAX by determining the ratio of the current range. Example: The
42NS4-4 armature jumper is set A-4, the IMX pot will set the current range from a minimum
of 38 amps to a maximum of 62 amps. If the motor is rated at 50 amps, (62-38=24 and
38+12=50, half of 24) set the IMX pot at 5/10 (midrange).
5.12B) Current Limit Adjustment The FL (Forward Current Limit) and RL (Reverse Current
Limit, 12 SCR, Regenerative drives only) pots are preset at the factory. It is recommended to
leave these pots set at the factory settings. If a current limit other than the motor’s rated current
is required. See the table below. The scale on the table below is approximate. Fine adjustment
should be made with an ammeter.
Potentiometer 100% 150% 200%
FL 4 /10 scale 6 /10 scale 8 /10 scale
RL (12 SCR only) 4 /10 scale 6 /10 scale 8 /10 scale
The above settings are only approximate

5.12C) Forward and Reverse Current Limits (Reverse, 4 Quadrant, 12 SCR, Regenerative Drives Only)
Four pots are used in the adjustment of current limit: IMX, FL, RL and IA.
y The IMX pot sets the motor’s rated current.
y The FL pot sets the forward current limit.
y The RL pot sets the reverse current limit.
y The IA pot sets the one minute timed current overload shut off.
Example: The motor’s rated current is 10 amps. Regenerative drive applications set the forward current limit to the motor’s
rating of 10 amps. The reverse current limit is often set higher, in this example 13 amps for extra braking power. Short time
periods of over current for regenerative braking should not damage the motor. Make sure the FL and RL pot are set at 100% (see
Section 5.9B 4/10 scale). Run the motor in forward with load and adjust the IMX pot to 10 amps. If you want the reverse current
limit to be 13 amps for extra braking power. Run the motor in reverse and adjust the RL pot to 13 amps.
If for example you should want the forward current limit to be 6 amps. Run the motor in forward and adjust the FL pot to 6
amps. Now you have a forward current limit of 6 amps and a reverse current limit of 13 amps. Setting the IMX pot to 10 amps
calibrates the regulator card’s protection circuits. If the motor should suddenly exceed 25 amps the instantaneous shut off circ uit
will activate based on 250% of motor’s rating of 10 amps. Not at 32.5 amps (250% of RL) and not 15 amps (250% of FL).
5.12C) One Minute Timed Current Overload Shut Off Adjustment
The overload current can be set up to of current limit for a fixed period of one minute.
y When the power is on and the motor is not running. Adjust IA according to table below.

Potentiometer 150% 1 Minute 200% 1 Minute

IA 7/10 scale 9/10 scale
5.12D) Instantaneous Current Overload Shut-Off
When the motor exceeds 250% of it’s rated current (calibrated with the IMX pot). The regulator
will instantaneously shut-off the motor. This circuit is not adjustable and cannot be overridden.
5.12E) Armature Ammeter Wiring and Calibration, See section 4.14
Page 19
ERC Statohm IV Section 5 (Operation & Adjustment)

5.13 Acceleration & Deceleration Time Adjustment

The jumper settings for accelerate and decelerate time ranges were covered in section 3.6.
y Adjust ACC and DEC pots full clockwise (slowest).
y Start the motor and set the master speed control to desired speed. Adjust the ACC pot slowly
counter clockwise until desired acceleration is achieved.
After the motor has reached full desired speed set the master speed control to zero speed. Adjust
the DEC pot slowly counter clockwise until desired deceleration is achieved.
5.14 Speed Overshoot and Stability Adjustment
Overshoot and stability are adjusted at the factory but operating conditions at the site may
require additional adjustment.
5.14A) Speed Overshoot Adjustment (i.e. Speed Response)
To view the motor’s overshoot and stability attach an oscilloscope to test points 10 and com or to
the tach feedback wires.
y Adjust the ACC and DEC pots for fast operation (turn the pots counter clockwise).
y Set the JOG pot full clockwise. If jog is not available set the master speed control to 20% of
full speed.
y Start the motor while the motor is rapidly accelerating observe the oscilloscope and compare
to the drawings in Fig. 5-12.
y Optimum is one overshoot peak as in figure in 5-12 (B). To adjust overshoot use the SR pot.

fig.
5-12 (A) (B) (C)
Stable but slow Stable and fast Fast but unstable

5.14B) Speed Stability Adjustment (i.e. Speed Gain)

y After the SR pot has been adjusted. Return the ACCEL, DECEL and JOG pots to their
normal positions.
y Start the motor and observe the oscilloscope. After overshoot has occurred, observe the
stability of the motor.
y To adjust stability use the SG pot.

Page 20
ERC Statohm IV Section 5 (Operation & Adjustment)

5.15 Speed Feedback Loop Adjustment (i.e. Speed PID)

The ASR feedback loop is adjusted at the factory. If adjustment of the SR and SG pot does not
produce satisfactory results. Adjustment of the PI pot may be necessary.
y Record the factory setting of the PI pot /10.
y To increase overshoot adjust the PI pot clockwise.
y To decrease overshoot adjust the PI pot counterclockwise.

5.16 Current Gain Loop Adjustment (i.e. Current PID)

The regulator card has two control loops. The main voltage feedback loop (speed feedback loop)
and a secondary minor current feedback loop. The current feedback loop is adjusted by the “IG”
pot (i.e. Current Gain). The IG pot is adjusted at the factory but if the current response and
stability is poor, adjust the IG pot according to the following instructions.
y Connect a jumper to M3 and M4. Remember to remove jumper afterwards.
y Write down the settings of FL, RL, DEC, ACC and JOG for readjustment after completion of
IG adjustment. Adjust FL and RL to 3/10 scale, adjust DEC and ACC to full counter
clockwise and adjust JOG to full clockwise. If jog is not available set the master speed
control to 20% of full speed.
y Remove all the jumpers from T1, T2, T3, T4 this sets acceleration time to 0.6 seconds.
y Observe the wave form of the armature by connecting an oscilloscope to TP10 and COM.
Compare the wave form to figures (a) and (b).
y If the wave form is unstable, make small counter clockwise adjustments to the IG pot.
y If the current response is too slow, make small clockwise adjustments to the IG pot.

Page 21
 ERC Statohm IV Section 5 (Operation & Adjustment)

Section 5.17) Master Slave Operation

The Statohm IV can be configured for Master Slave operation with or without Master speed
gain.

y Terminal 3 is the master speed reference output.

y Terminal 14 is the slave speed reference input.
y Terminal 13 is the commons for both master and slave.

Master Slave with-out Master speed gain

MASTER SLAVE
DC drive DC drive

3 789 13 13 14

Master Speed Gain permits the speed overshoot, stability to be controlled by the master drive.
See sections 5.14 and 5.14B for more details.
y Terminal 10 is the master speed gain output.
y Terminal 6 is the slave speed gain input.

Master Slave with Master speed gain

MASTER SLAVE
DC drive DC drive

3 7 8 9 10 13 6 13 14

Page 22
ERC Statohm IV Section 5 (Operation & Adjustments)
Section 5.18) AC contactor
Not all applications required contactors, below is a elementary diagram of AC contactor circuit.

Elementary Power Connection Diagram with AC Contactor

DC Motor
A-
DC Drive
A
A+
L1F L2F L1C L2C L1S L2S L3S F+ F-
ABC

FIELD 3A
fuse
L1 L2 L3

115V

AC Contactor
Connect L1S, L2S and L3S befor the contactor to prevent the LV light switching on
Close the AC contactor befor activating Run (terminal 34), not simultaneously

L1 L2 L3

Section 5.19) DC contactor

Warning, don’t use a DC contactor with a 12 SCR, 4 quadrant, regenerative drive.

DC contactor can be used with a 6 SCR, 2 quadrant drive. A freewheeling rectifier is strongly
advised.

Note: Electric Regulator prefers AC contactors, DC contactors can lead to a variety of problems.

Page 23
Page 24
ERC Statohm IV Manual; Section 6 (Trouble Shooting)

Section 6 Trouble Shooting

Trouble shooting may require the following test equipment:
y Digital Multimeter
y DC Ammeter
y Oscilloscope with a isolation transformer and a 10X probe or higher.
When a problem occurs. Write detailed notes of the operating conditions when the problem
occurred. Check the Regulator card, if any of the red signal lights are on. Refer to the list below
and correct the problem. After the problem has been corrected it may be necessary to press the
reset button before operation.
“TG” Tach Generator Loss
Light’s when the regulator card is not receiving a signal voltage from the DC tach generator.
“OC” Instantaneous Over Current
When 250% of the motor’s rated current is exceeded. The instantaneous over current circuit will
shut off the motor.
“OL” One Minute Delay Over Current Shut Off
When 150% of the motor’s rated current is exceeded for more than one minute. The time delay
over current circuit will shut off the motor.
“FU” Fuse Blown
One or both of the AC input fuses have blown.
“LV” Low input Voltage
The AC input voltage is more than 10% below normal.
“PH” Phase Loss or Phase Sequence Error
Indicates the loss or low voltage of one of the three phases. Also indicates if L1, L2 and L3 are
not in correct sequence. See section 4 “Wiring”.
“FL” Field Loss
The field input current is below 13% of normal.
“OH” SCR Over Heat
A thermostat on the SCR heat sink trips at 185oF (85oC) shutting off the motor.
“ES” Emergency Stop
Signals when the emergency stop system is engaged.

Page 25
ERC Statohm IV Manual; Section 6 (Trouble Shooting)

6.1 Phase Load Balance

Phase load balance settings are made at the factory. If a phase load balance problem should
occur. Check the following two items before adjusting the phase balance.
y Insufficient gain of the ACR amplifier.
y Improper tach generator coupling.

6.1A Observing and Adjusting Phase Load Balance

To observe the phase load balance connect an oscilloscope to test points 10 and com.
y Run the motor at a steady speed and observe the wave from. Adjust the speed and load until
a stable wave form is displayed.
y If an unbalanced current wave form is displayed. Adjust pots PH1 to PH6 in the following
sequence. PH1, PH6 ... PH2, PH4 ... PH3, PH5
y If improvement is not sufficient adjust the IG pot slightly counter clockwise and repeat
adjusting the PH pots.

Unbalanced Balanced

Page 26
ERC Statohm Manual Section 6 (Trouble Shooting)
Section 6.2 Problem: Motor won't start but none of the red signal lights are on.
Check the following: Recommendations:
y AC input voltage: Check if the unit is receiving power.
Check if the other drive system components are working
properly.

y Control circuit relay sequence: Check if RN1, RN2, JOG and ES relays circuits are wired
properly.
When RN1, RN2, JOG and ES relays are open. Check if test
point +B is 25VDC

y Jumper JP-10 Jumper JP-10 must be off. The motor will not run when this
jumper is on.

y Measure the ramp reference signal at test Test point “4” is the acceleration and deceleration ramp signal.
point “4”. When starting the signal should ramp up to 8V or for reverse
-8V.

Section 6.3 Problem: Motor Runaway

Check the following: Recommendations:

y TG Jumper The TG jumper must be on for both Armature and Tachometer
feedback. TG - On

y Tach Generator circuit. Check if the tach generator circuit wiring is faulty.
Check if the polarity is correct.
See section 4.11 DC Tach Generator

y Tach feedback: Check voltage of test If no voltage is present at test point “1” Check wire
point “1”. The normal voltage range is connections. If wire connections are good. The regulator card
-0.02 to -8.5 V DC may need to be replaced.

y Armature feedback: Check voltage of test If no voltage is present at test point “2” Check wire
point “2”. The normal voltage range is connections. If wire connections are good. The regulator card
+0.02 to +8.5 VDC may need to be replaced.

y Armature feedback: Check the armature If this plug is not connected or reversed the motor will run
voltage plug connected to the bottom left away. The correct sequence is red wire right (H) and white
corner of the synchronization card. wire left (N). See bottom of page 39 for details.

y Measure the field current. If field current is insufficient. Check if jumpers F1-F5 are set
right and the continuity is good. See section: 3.1 Field Current
and 3.5 Field Regulation.

y Phase to the field is not correct. Line L1 and L2 must be connected respectively to L1F and
L2F. If these connections are not correct, the field voltage will
be too low, causing the motor to run fast.

y The motor’s field is not correctly See section 6.12B on page 32.
connected.

y Check jumper settings and continuity. Check if SF, TG, TL and S1-S4 are set right and the continuity
is good. See section: 3.1 Motor Feedback

Page 27
ERC Statohm Manual Section 6 (Trouble Shooting)
Section 6.4 Problem: Fuses blow immediately after start and the “OC” signal lights.

Check the following: Recommendations:

y The DC armature circuit is shorted. Check the DC power circuit.

y The load on the motor is stalled. Check the load on the machine.

y SCR failure (i.e. thyristor) Disconnect L1, L2, L3 and A+, A- and measure the
resistance between them. The typical resistance
between them should be about 100k . If the
resistance is low the SCR modules may need to be
replaced. Contact the factory for assistance.

y Improper setting of current limit or Check if jumpers A1-A4 are set right and the
current protection circuits. continuity is good. See sections: 3.2 Armature
Current and 5.12 Armature Current Calibration

y Measure voltages of If voltage is present when the motor is stopped the

test points “1” - “6”. regulator card may need to be replaced.

y Measure the resistance between The normal resistance is only a few ohms or less.
CT1R & CT1W and CT2R &
CT2W on the SYNC card.

y Rapid change of load or motor Check the machine load and motor commutator.
flash-over.

y Check for the presence of a surge If a surge is present. Connect a noise suppresser to
during the operation of the external the external contactor and relays.
contactor or relays.

Page 28
ERC Statohm Manual Section 6 (Trouble Shooting)
Section 6.5 Problem: Unstable Speed

Check the following: Recommendations:

y Measure test points “+” and “-” to The normal voltages are +15VDC and -15VDC
“com”. respectively. If they are not nominal the SYNC card
may need to be replaced.

y Measure the voltage of If there is any variation. Check the speed pot wiring.
test point “4”

y Unstable field voltage. If the regulator is set for field weakening with
armature feedback the speed will be unstable. Set
the regulator card for constant field.
See section: 3.3 Motor Feedback

y Improper installation of the tach Check the tach’s mounting, coupling and wiring.
generator. Check for noise pick up on the tach’s wiring.

y Armature feedback only: Check for instability of power supply input voltage.
If present correct the problem.

y Improper adjustment of “SR” or See sections: 5.14, 5.14A and 5.14B

“SG”.

y Excessive field weakening. Field weakening applications. The field should not
go below 1/3 to 1/6 of normal full field.
Example: Full field is 300VDC . Field weakening to
100VDC or less will cause unstable motor speed. A
special regulator card PN 1059A-11 is required.

y Current Limit The drive is repeatedly reaching current limit

(bouncing agianst current limit).

y Thyristor (SCR) has failed A thyristor has failed and must be replaced.

Page 29
ERC Statohm Manual Section 6 (Trouble Shooting)
Section 6.6 Problem: Motor will not go to full speed.

Check the following: Recommendations:

y Insufficient voltage. Readjust the “MAX” pot. (Do not exceed motor’s rating)

y Insufficient current. Refer to section 3.1 Armature Current

(Do not exceed motor’s rating)

y Measure voltage of test point “4” Normal is about 8 volts.

y Measure 3 phase input voltage. Should be within !10%

y Improper calibration of speed Check the speed with another calibrated meter for
meter comparison.

y Excessive field current. Check with calibrated ammeter and compare with
motor’s ratings.

y Load is greater than motor’s rating.

Section 6.7 Problem: Excessive overshoot and undershoot.

Check the following: Recommendations:

y The acceleration or deceleration is Adjust “ACC” or “DEC” pots.
too short despite the load’s large See Section 5.13 Acceleration and Deceleration
inertia. Adjustment

y Excessive overshoot, undershoot Improper adjustment of the speed regulation loop.

and unstable level speed. Adjust “SR”, “SG” and “PI” pots. See section 5.14,
5.14A, 5.14B and 5.15

Section 6.8 Problem: Overload fault “OL” signal light.

Check the following: Recommendations:

y Overload of motor. The “OL” signal light may turn on if an intermittent
load exceeds the square root mean value of 100%.
Check the intermittent load of the motor.

y Check field current. Low field current reduces the power of the motor.

y Improper setting of “IA” pot. See section 5.12C

Page 30
ERC Statohm Manual Section 6 (Trouble Shooting)
Section 6.9 Problem: The ES, OH, VL signal lights are on and can not be reset.

Check the following: Recommendations:

Plug CN1 on the Regulator card and Check CN1 is plugged on properly.
SYNC card maybe loose.

Check voltage from terminal board If 25VDC is not present the 115VAC transformer may
positions 35 & 38 to +B. The voltage be damaged, check the transformer. If the
should be 25VDC = !3VDC transformer output voltages are good. The SYNC
card should be replaced.

Section 6.10 Problem: Signal lights R and PC are on, the F, AP, ZD flash and the relays
buzz.

Check the following: Recommendations:

Check the armature connections. The armature circuit is bad or open. Trouble shoot
and correct the problem.

Section 6.11 Problem: Field loss is detected

Check the following: Recommendations:
Check the motor’s name plates’ field If the field current is too low and the voltage
specifications. Measure the field corresponds to the field resistance. The F jumper is
current and voltage to determine if set too low.
they are comply with the
If the field current and voltage are correct. The F
specifications.
jumper could be set too high.
Note: Remember to disable field
economy when making field Explanation: The field has a current regulation circuit, but the
field voltage will not exceed 70% !5% of the AC input voltage
measurements.
connected to terminals L1F and L2F. The current is limited to
the voltage available.
First example: The 42NS1-4 is connected to a motor with a 1
amp field and the F jumper is set for 7.1 amps (F1). The
voltage will go up to maximum available and the current will
be 1 amp. The field loss circuit will detect the current is too
low.
Second example: The 42NS1-4 is connected to a motor with a
1 amp field and the F jumper is set for 1.4 amps (F4). When
the motor has rapid load increase, the field will drop
momentarily and trigger the field loss detection circuit.
The best setting for a motor with 1 amp field would be 0.6 ~1.2
amps (F5).

If the field current is too low and the voltage is too

high for the field’s specified resistance. The field
possibly has bad connections or is beginning to fail.

Page 31
ERC Statohm Manual Section 6 (Trouble Shooting)

Section 6.12A) Problem: The armature current is too high at low speed and small load.
Check the following: Recommendations:
Read the field specifications on One of two problems are possible:
the motor’s name plate. Then 1) If the field input power is incorrectly connected. The
measure the field current and field power will be too low. The motor will draw too
voltage to determine if they much current during start and run too fast if the load is not
comply with the specifications. too large. Common mistakes are L3 is connected to L1F
Note: Remember to disable field or L2F or the single phase 110V ~ 120V is connected to
economy when measuring the L1F or L2F. The correct connections are shown below.
field. Field economy is disabled
by placing the FE jumper on. L1F L2F L1C L2C L1S L2S L3S F+ F-

115V

L1 L2 L3
R S T

2) The field isolation is deteriorating and beginning to

fail. The current is jumping from one winding to the next.
The is field controlled by an current regulation circuit.
The current is held at normal but not making enough
ampere turns. This results in the field being too weak,
replace the motor.

Section 6.12B) Problem: During acceleration or heavy load the field is too low.
Check the following: Diagram
Check the motor terminal box for Elementary Motor Connection Diagram
leads S1 and S2. Some motors
have leads S1 and S2, some
motors don’t. If S1 and S2 are
STABILIZING FIELD
present and not connected. See A2 S1 S2
A-
the diagram to the right for how
to connect them. The letter “S” A
stands for Stabilizing field. If the A1
motor doesn’t have S1 and S2, A+
then the stabilizing field is
connected internally. 300 VOLT FIELD
F4 F3 F2 F1
F- F+
L1F L2F L1C L2C L1S L2S L3S F+ F-
150 VOLT FIELD
F4 F3
F- F+
F2 F1

Page 32
Section 6.13 Problem: The PH light is on
Check the following: Diagram
Several problems are possible.
1) Lines L1, L2 and L3 should be
connected respectively to terminals
L1S, L2S and L3S.
Also check the plugs on the F2 F1 F4 F3

R51 R50 R74 R73 M6

synchronization card. L1S goes to R4

R10
R51A

(red wire) L2S goes to S4 (white wire) R50A

SYNCHRONIZATION CARD
SH-1058C-
R74A R73A

J3T
M5

J3T J3T

L3S goes to T4 (blue wire). See CN2

J4T J2T J4T J2T J4T J2T

diagram to the left. R2 R1

R4 R3 TR3 TR2 TR1

2) Possibly transformer TR1, TR2 or R6 R5

TR3 has failed. Disconnect leads to R8 R7

T4 S4 R4
terminals L1S, L2S and L3S and H A

BLUE WHITE RED

measure the resistance between these
terminals. The normal resistance should
be 1k , !10%. Also visually inspect the
legs on the transformers for breakage. L1F L2F L1C L2C L1S L2S L3S F+ F-

3) When the motor is running if the PH

light switches on. The phase load may
not be balanced. The most common
reason for this problem is unequal phase L1 L2 L3
R S T
voltage. This occurs when the voltage
of one phase is 25% below the others.
This problem is often caused by loose
power connections.
4) When the motor is running if the PH
light switches on. The SCR thyristors
may not be phase correctly. See sections
6.1 and 6.1A.

Section 6.14) The “F” light is dimly lite but field loss is not detected
Check the following:
An error was made connecting L1F L2F L1C L2C L1S L2S L3S F+ F-
power to the field. Line 3 (L3) is
connected to either L1F or L2F. 115V

The correct connections are

shown in the diagram to the right. L1 L2 L3
R S T

Page 33
Section 6.15 Regulator Card Connections
Warning ! Diagram
Incorrect connections will
irreparably damage the regulator
card, synchronization card and
REGULATOR CARD 1058 PULSE CARD 1057
pulse card. Carefully refer to the CN3

diagram to ensure correct CN24

connections.
CN3

SYBCHRONIZATION CARD 1058

CN24

CN1 CN8
CN1

Section 6.16 Utility Company Transfer Switch Problems (PH light disable)
Warning ! Diagram
Disabling the PH light will not
resolve incorrect input power
connections! Disabling the PH REGULATOR CARD 1058

light and running the drive with

improper phasing will eventually
damage the motor and the drive.

If the drive runs normally for

hours or days then suddenly
displays PH light fault and
resetting clears the PH light. C125

Then the drive runs normally JP-FL

until the same time the next day,

or until the same day and time
each week. This problem is RESET

typically the result of the utility

company transfer switch in areas
with old utility systems. As a last
resort, disabling the PH light
circuit can be done.

Bypass capacitor C125 by laying

it on its left side and solder a wire
across it’s leads.

Page 33A
Blank Page

Page 33B
 A 12mm
6.4mm
1/4"
CARLSBAD, CA. USA 15/32"
Tel (760) 438-7873
Fax(760) 438-0437
[email protected]
"S" Model Ratings

"S" Model Physical Diagram

Model Max 230VAC 460VAC 575VAC
Number Amps Max HP Max HP Max HP
S1 31 7 14 17
S2 70 15 30 37
S3 110 25 50 62

19/32"
17/32"

1/2 "
420mm

447mm

470mm
S4 180 45 90 110

18

Page 34
17
16
30mm
1 3/16 "
L1 L2 L3 A+ A-
79mm 45mm 45mm 40mm 35mm
6.8mm DIA
3 1/8" 9/32" DIA 1 3/4" 1 3/4" 19/16" 1 3/8"
6.4mm
225mm
8 7/8 " 1/4"
210mm
8 1/4"
256mm
10 3/32"
 176mm 176mm
7" 7mm 7"
13mm 9/32"
A 1/2"
CARLSBAD, CA. USA
Tel (760) 438-7873
70mm
2 3/4 "

Fax (760) 438-0437

[email protected]

129mm
5 1/16 "
"M2" Model Ratings
A-
Model Max 230VAC 460VAC 575VAC
Number Amps Max HP Max HP Max HP
M2 400 100 200 250
50mm
2"
4 13/16 "
221mm
1/2 "

19/32"

17/32"
447mm
470mm
18

240mm

A+

Page 35
16
17

150mm
5 7/8 "

"M2" Model Physical Diagram

8 5/8 "
219mm

L1 L2 L3
2"
50mm
8mm DIA
5/16" DIA
104mm 50mm 50mm
4 3/32 " 2" 2" 7mm
9/32"
303mm 230mm
1115/16" 9 1/16"

256mm
10 3/32"
A
Carlsbad, CA. 92009 USA

160mm
6 5/16 "
13mm
1/2"

7mm
9/32"

256mm
10 3/32"

375mm
14 25/32 "
98mm
3 27/32"
Tel (760) 438-7873

5 1/8 "
130mm
Fax(760) 438-0437
[email protected]

204mm
8 1/32"

"M3" Model Physical Diagram

"M3" Model Ratings
Model Max 230VAC 460VAC 575VAC A-
Number Amps Max HP Max HP Max HP

Page 36
13/16 "
122mm
50mm
M3 550 125 250 312 2"

17/32"

1/16 "

7/16"
420mm

510mm

544mm

674mm
1/2"
A+

20

21
16

26
150mm
5 7/8 "

219mm
8 5/8 "
50mm
L1 L2 L3

2"
8mm DIA
5/16" DIA
104mm
50mm 50mm
4 3/32 " 2" 2" 7mm
9/32"
293 mm 230mm
111/2" 9 1/16"
256mm
10 3/32"
 375mm 132mm
14.75" 5.19"

A
Carlsbad, CA 92009 USA
Tel. (760) 438-7873
Fax (760) 438-0437
[email protected]

Model: L-1 67mm

Amps: 720 2.62" 136.5mm
0.65" (16.5mm) 5.37"
230VAC: 200HP
480VAC: 400HP

9.84"
575VAC: 500HP 1.48" (37.5mm)

250mm
A
32.26"
820mm

4.12"
105mm

Page 37
25.60"
650mm

A+
2.95"
75mm

0.42" DIA
7 places

11.81"
300mm

"L1" Model Physical Diagram

9.50"
241mm

L1 L2 L3
0.27" DIA
6 places
82.5mm 82.5mm
3.25" 3.25"
276mm
10.875" 303mm
295mm
2.00" (51mm) 11.93"
11.63"
317.5mm
12.50"
 10 1/4"
260mm
Carlsbad, CA. 92009 USA
Tel (760) 438-7873
Fax (760) 438-0437 570mm 260mm
[email protected] 22 7/16 " 101/4 "
472mm
160mm
18 19/32 "
6 5/16 "
5 1/8 "
130mm

2"
50mm
100mm
Model: L-2 4"
A+ A-

70mm
Amps: 910
2 3/4"
70mm

2 3/4"
60mm
240VAC: 250HP 2 3/8 "

480VAC: 500HP
575VAC: 625HP

Page 37A
39 3/8 "
1000mm

500mm
19 11/16 "

"L-2" Model Physical Diagram

9 27/32 "
250mm

4"

L1 L2 L3
100mm

50mm 60mm 60mm

2" 70mm 70mm
2 3/8" 2 3/4" 2 3/4" 2 3/8"
570mm
22 7/16 "
Page 37B
 IFC 1084 card connections

Regulator Card 1059C IFC 1084 Card

CN 9
123456 1
2
3 S-1 2 3 4
4
V3HG
5
CN10
6 V3 V2LG
1
7 GA
2
3 8
4 L
5 9 H
6

DC
MOTOR
F+ F- F1 F4

41FS Auxiliary Field Supply for High Current Fields

DC drive Auxiliary Field Supply

Model series # 41xxx-x Model series # 41FSx-x
L1 L2

CT1 CT1
CT4
CT4
F1K
F1K
F1G
F1G
F2K
F2K
F2G
F2G

FF2 FF1

D2 D1

F- F+

Page 38
The Synchronization Card 1058C (i.e. SYNC CARD 1059C) can be modified to work with
different model drives and input voltages by changing resistor values and jumpers.
Part Number Input Voltage Armature Voltage
1058C-01 200V ~ 240V 240V
1058C-02 380V ~ 480V 500V

Input Voltage 200V ~ 240V, 3&, Armature 240V

Resistors Resistors Transformers
Model Resistor
R1, R2, R3, R4, R50, R51, TR1, TR2, TR3
Regulator Card
Field Amps
Number R10 Field Jumper
R5, R6, R7, R8 R73, R74 Jumpers
F1 4.3 ~ 7.1
each each F2 2.1 ~ 4.3
66.5Ω J2T, J2S, J2R-ON
42NS1-2 237kΩ 47.5kΩ F3 1.4 ~ 2.1
½ Watt J3T, J3S, J3R-OFF
42RS1-2 ¼ Watt ½ Watt F4 0.7 ~ 1.4
tol +/- 2% J4T, J4S, J4R-OFF F5 0.6 ~ 1.7
tol +/- 1% tol +/- 5%
No Jumper 0.3 ~ 0.6
42NS2-2 F1 6 ~10
42NS3-2 each each F2 3~6
47.5Ω J2T, J2S, J2R-ON F3 2~3
42NS4-2 237kΩ 47.5kΩ F4 1~2
½ Watt J3T, J3S, J3R-OFF
42RS2-2 ¼ Watt ½ Watt F5 0.8 ~ 1.0
tol +/- 2% J4T, J4S, J4R-OFF
42RS3-2 tol +/- 1% tol +/- 5%
No Jumper 0.5 ~ 0.8
42RS4-2
F1 10 ~17
each each F2 5 ~ 10
28Ω J2T, J2S, J2R-ON
42NM2-2 237kΩ 47.5kΩ F3 3.3 ~ 5
½ Watt J3T, J3S, J3R-OFF F4 1.7 ~ 3.3
42RM2-2 ¼ Watt ½ Watt
tol +/- 2% J4T, J4S, J4R-OFF F5 1.3 ~ 1.7
tol +/- 1% tol +/- 5% No Jumper 0.8 ~ 1.3

Input Voltage 440V ~ 480V, 3&, Armature 500V

Resistors Resistors Transformers
Model Resistor
R1, R2, R3, R4, R50, R51, TR1, TR2, TR3
Regulator Card
Field Amps
Number R10 Field Jumper
R5, R6, R7, R8 R73, R74 Jumpers
F1 4.3 ~ 7.1
each each F2 2.1 ~ 4.3
66.5Ω J2T, J2S, J2R-OFF
42NS1-4 475kΩ 95kΩ F3 1.4 ~ 2.1
½ Watt J3T, J3S, J3R-OFF
42RS1-4 ¼ Watt ½ Watt F4 0.7 ~ 1.4
tol +/- 2% J4T, J4S, J4R-ON F5 0.6 ~ 1.7
tol +/- 1% tol +/- 5%
No Jumper 0.3 ~ 0.6
42NS2-4 F1 6 ~10
42NS3-4 each each F2 3~6
47.5Ω J2T, J2S, J2R-OFF F3 2~3
42NS4-4 475kΩ 95kΩ F4 1~2
½ Watt J3T, J3S, J3R-OFF
42RS2-4 ¼ Watt ½ Watt F5 0.8 ~ 1.0
tol +/- 2% J4T, J4S, J4R-ON
42RS3-4 tol +/- 1% tol +/- 5%
No Jumper 0.5 ~ 0.8
42RS4-4
F1 10 ~17
each each F2 5 ~ 10
28Ω J2T, J2S, J2R-OFF
42NM2-4 475kΩ 95kΩ F3 3.3 ~ 5
½ Watt J3T, J3S, J3R-OFF
42RM2-4 ¼ Watt ½ Watt F4 1.7 ~ 3.3
tol +/- 2% J4T, J4S, J4R-ON F5 1.3 ~ 1.7
tol +/- 1% tol +/- 5%
No Jumper 0.8 ~ 1.3
42NM3-4 F1 15 ~25
F2 7.5 ~ 15
42NL1-4 each
19Ω J2T, J2S, J2R-OFF F3 5 ~ 7.5
42NL2-4 475kΩ No Resistor F4 2.5 ~ 5
1 Watt J3T, J3S, J3R-OFF
42RM3-4 ¼ Watt Open Circuit F5 2 ~ 2.5
tol +/- 2% J4T, J4S, J4R-ON
42RL1-4 tol +/- 1% No Jumper 1.3 ~ 2
42RL2-4

F2 F1 F4 F3

R51 R50 R74 R73 M6

Note: When soldering R 10 be careful
R10

to keep the soldering iron away from

R51A
R50A R74A R73A
M5 near by capacitors.
SYNCHRONIZATION CARD
SH-1058C- J3T J3S J3R
J4T J2T J4S J2S J4R J2R
CN2

R2 R1

R4 R3 TR3 TR2 TR1

R6 R5

R8 R7
T4 S4 R4
H A

BLUE WHITE RED

WHITE RED

Page 39
 Oscilloscopes
Viewing the armature voltage with a oscilloscope requires special care. The oscilloscope can
not be grounded. The oscilloscopes power can not be grounded or connected to the neutral. The
oscilloscope and step down transformer can not rest on a grounded surface, such as the floor or
metal electrical enclosure. Resting the oscilloscope and transformer on a sheet of plywood or
thick card board often provides sufficient isolation from ground. A expensive oscilloscope is not
require, a inexpensive oscilloscope is recommended.

L1 L2
Don't rest the ocilloscope Don't Ground
or transformer on grounded Step Down
surface. Transformer
Neutral can not be used to
power the oscilloscope.
Don't Ground
Oscilloscope

L3
10X Probe
DC Drive
A+

Armature
A--

L1 L2 L3

Viewing the field voltage with an oscilloscope also requires the same special care plus
additional precautions. Before starting the motor, first view the field voltage to ensure the
oscilloscope is set up correctly. Take extra precautions so that the field can not be accidentally
grounded while the motor is running. If the field were accidentally grounded while the motor is
running will result in catastrophic damage to the motor and the drive, that would requiring
replacement of the drive and rewinding the motor.

Page 40
Supplemental Field Information

Field Power
The field power is vital to DC motors. Never disconnect the field power when the
motor is running. Also if the field does not have power, don’t apply power to the armature.
Why is the field vital? The field induces resistance in the armature, without the field the
armature has virtually no resistance.
Example: A 100 HP DC motor is running at full load; the armature is 500 volts, 150
amps. The armature has an effective resistance of 3.333 ohms. If the field power is disconnected
the armature resistance will drop to about 0.08 ohms (virtually zero) and the armature current
will immediately go up to 6,250 amps. Within mille seconds both the motor and drive will
incurred serious damage that is often irreparable.

Field Voltage
The field is a ampere circuit, the field voltage will vary with temperature.
Example: The 3212AT frame, 100 HP, DC motor field current is specified to be 3.5 amps. When
the motor is cold, 20oC (68oF) the field resistance is 66.8 ohms, the voltage would be 234 volts.
When the motor warms up to 40oC (104oF) the field resistance will increase to 85.7 ohms and the
field voltage would be 300 volts.

Stabilizing field winding

Modern DC motors have the stabilizing field connected internally. Older DC motors
sometimes have the field stabilizing terminals, giving the user a choice. Below is a diagram of
how to connect the stabilizing field winding.

Elementary Motor Connection Diagram

STABILIZING FIELD
many motors don't have
leads S1 and S2.
A2 S1 S2
A-

A
A1
A+

L1F L2F L1C L2C L1S L2S L3S F+ F-

300 VOLT FIELD
F4 F3 F2 F1
F- F+
150 VOLT FIELD
F4 F3
F- F+
F2 F1

Page 41
 F/R
CONTROL
LOGIC
+15V
M3 M4 M1 M2
SR
2.2µ 47K 1µ 47K
COM SG IG
200K
-15V LINEAR
1K 2.2K
TIME
ACC SPEED CURRENT
CONTROL CONTROL
4 6 THYRISTOR
RUN
TB8 ARMATURE
SPEED THYRISTOR
DRIVER
REFERANCE
+,-8V/ TB9
JOG
+,-100% N JOG DEC 10
CURRENT CURRENT
FEEDBACK TRANSFORMER
AMPLIFIER
0.7 to 6 Sec T-1

Regulator Card Control Block Diagram #9044

3 to 20 Sec T-2 5
CROS
7 to 60 Sec T-3 10
ARMATURE
14 to 120 Sec T-4 *1 FEEDBACK
CIRCUIT
MAX
1
TACH
ZERO FEEDBACK DM
APMLIFIER
TACH
TB6
GENERATOR
EXT. SM
CURRENT REF.

Page 42
-/+4V / 100% IA TB13 TB19
FL DG
N SPEED METER
TB12 TB18 1mA / 100%
FORWARD AM
CURRENT LIMIT AMMETER
A 1mA / +/-150%
+4V / 100% IA TB13 TB17
RL 2 V / +/-150%
TB11
FIELD FIELD
REVERSE FUNCTION CURRENT
CURRENT LIMIT GENERATOR CONTROL THYRISTOR
-4V / 100% IA TB13 JP 7
FIELD F+
*1 THYRISTOR
DRIVER
FIELD WEAKENING FIELD
ENABLE - ON F-
DISABLE - OFF
1F
7
ARMATURE
FEEDBACK
A
CIRCUIT
Carlsbad, CA. 92009 USA
DC42 REGULATOR CONTROL BLOCK DIAGRAM DWG 9044
Regulator Block Diagram (DWG 9042-1)
Page 43
Regulator Block Diagram (DWG 9042-2)
Page 44
Regulator Block Diagram (DWG 9042-3)
Page 45
 2 QUADRANT, 6 SCR
BOL
MAIN BM
ELEMENTARY MCB MCB BM DC MOTOR
BM
CONTROL L1
BOL
L1
CIRCUIT L2
L2 BM
L3
ES RESET L3
FT BM TS SHT
ES ES DC DRIVE
A+ A+
ES
L1
STOP START L2
ES L3
A
RUN RUN

L1F A- A-
RUN
F+ F1
JOG

FIELD
RUN L2F
JOG JOG
F- F2

+
L1S 1
L2S _ TG
RUN L3S 2
PC PC 30 17 ARMATURE TS
A AMMETER
JOG 31 ST
18 INPUT: 0 to 2V P1 P2

115VAC 19
ZD PC 115V N SPEED METER
1 PHASE INPUT: 0 to 1mA
18
7 8V
SPEED 20 FIELD
REFERENCE 8 REF F AMMETER
Note: All relays are showen when INPUT: 0 to 2V
9 COM 18
the power is off. Exsample: When the
power is on the ES contact will close. JOG 21
33 JOG
RUN 22 ROTATION SIGNAL
34 RUN ZD SPDT RELAY (AC 250V 0.5A)
23
35 COM
PC (Enable) 24
36 PC
25 FAULT
38 COM FT SPDT RELAY (AC 250V 0.5A)
ES 26
40 E. STOP
27
28 FIELD LOSS
FL SPDT RELAY (AC 250V 0.5A)
29

4 QUADRANT, 12 SCR, REVERSING & REGENERATIVE BRAKING

BOL
MAIN BM
ELEMENTARY MCB MCB BM DC MOTOR
BM
CONTROL BOL
L1
L1
CIRCUIT L2
L2 BM
L3
ES RESET L3
FT BM TS SHT
ES ES DC DRIVE
A+ A+
ES
L1
L2
ES REV
L3 A
REV REV
A- A-
L1F
FOR
F+ F1
STOP START
FIELD

L2F
RUN RUN
F- F2
RUN +
L1S 1
JOG L2S _ TG
RUN L3S 2
JOG JOG 30 TS
17 ARMATURE
31 ST A AMMETER
18 INPUT: 0 to 2V P1 P2

115VAC 19
115V N SPEED METER
1 PHASE
RUN 18 INPUT: 0 to 1mA
PC PC 7 8V
SPEED 20 FIELD
JOG 8 REF F AMMETER
REFERENCE
9 COM 18 INPUT: 0 to 2V
ZD PC JOG 21
33 JOG
RUN 22 ROTATION SIGNAL
34 RUN ZD
23 SPDT RELAY (AC 250V 0.5A)
35 COM
Note: All relays are showen when PC (Enable) 24
36 PC
the power is off. Exsample: When the REV 25 FAULT
37 REV FT
power is on the ES contact will close. 26
SPDT RELAY (AC 250V 0.5A)
38 COM
ES
40 E. STOP 27
28 FIELD LOSS
FL SPDT RELAY (AC 250V 0.5A)
29

Elementary Circuit Diagrams

Page 46
 Regulator Terminal Table
TERMINAL DESCRIPTION
1 (+) Input: DC Tach Generator Feedback
2 ( - ) Input: DC Tach Generator Feedback
3 Master Speed Reference output (!8 Volts / 100% N )
4 Auxiliary Speed Feedback input (!8 Volts / 100% N )
5 Common for 4
6 Slave Speed Gain input ( !4V / 100% IA )
7 +8V Speed Reference Power Supply
8 Speed Reference Input
9 Common for Speed Reference Power Supply
10 Master Speed Gain Output (!4V / 100% IA )
11 Auxiliary Reverse Current Limit Reference Input (-4V / 100% IA) (12 SCR Only)
12 Auxiliary Forward Current Limit Reference Input (+4V / 100% IA)
13 Master, Slave and Auxiliary Common for Terminals 3, 6, 11, 12, 14 and 15.
14 Slave Speed Reference Input (!8 Volts / 100% N )
15 Auxiliary Field Current Reference Input (!8 Volts / 100% N ).
16 Not Used
17 Armature Ammeter Output (0~2V / 100% IA)
18 Common for Terminals 17, 19 and 20.
19 Speed Meter Output (0~1mA / 100% N)
20 Field Ammeter Output (0~2V / 100% IF)
21 ZD SPDT Relay: Tc / Center Pole (Rating: 250VAC, 0.5 A)
22 ZD SPDT Relay: Tb / Normally Closed (Motor Rotation opens it)
23 ZD SPDT Relay: Ta / Normally Open (Motor Rotation closes it)
24 FT SPDT Relay: Tc / Center Pole (Rating: 250VAC, 0.5 A)
25 FT SPDT Relay: Tb / Normally Open when 115V power is on.
26 FT SPDT Relay: Ta / Normally Closed when 115V power is on.
27 FL SPDT Relay: Tc / Center Pole (Rating: 250VAC, 0.5 A)
28 FL SPDT Relay: Tb / Normally Closed when 115V power is on.
29 FL SPDT Relay: Ta / Normally Open when 115V power is on.
30 ST SPST Relay: Normally Open (Input Circuit Breaker Shunt Trip)
31 ST SPST Relay: Normally Open (Rating: 250VAC, 0.5 A)
32 Not Used
33 Jog Input
34 Run (i.e. Start) Input
35 Common for 33, 34 and 37
36 PC (Enable) Input
37 Reverse Input (Regenerative Only)
38 Common for 36, 39 and 40
39 Auxiliary Reset Input
40 Emergence Stop Input

Regulator Card Terminal Table

Page 47
 REGULATOR CARD 1059D and earlier depicted
REGULATOR CARD 1059F eliminated jumpers 2, 3, 6, FV, FI and added jumpers 11 and 12
P3
/10
P6
/10
P2
/10
P5

CA
/10
P1
+V -15 +15 /10
P4
/10

TL
LV
COM TG
IMX HS /10
/10 /10
OC
9

COM
OL
A-1
A-2
A-3
A-4

FU
EXTRA JUMPERS
LV
F-1
F-2
F-3
F-4
F-5

PH

EF
FL
FV
10

FI
8

OH

ES

FL
AP
7

P
IF FM ZERO
IFR ZD
/10 /10 /10
IG FL RL SR SG DG PI OP
/10 /10 /10 /10 /10 /10 /10 /10
TG
50H

RESET

9
5A 5
/10 8
AP

CROS 7
/10 FE
6

COM
M3 M4
1 2 4 6 10
SF
VF

+B
5
4

T-4
T-3
T-2
T-1

2
3
S-1
S-2
S-3
S-4

MAX JOG ACC DEC FT -R NA AM IA

/10 /10 /10 /10 /10 /10 /10 /10 /10
RUN
JOG

R5
PC

R
1

R2

CONNECTION TERMINALS 1 TO 40

Regulator Card Physical Diagram

Page 48
 POTENTIOMETER TABLE JUMPER TABLE
POT. DESCRIPTION Jumper Function
5A* Factory Reserve, Do not adjust. 50H 50 Hz Power-ON / 60 Hz Power-OFF
ACC Acceleration Time Adjustment (See Section 3.6) A1~A4 Armature Current Range Settings (See section 3-3)
AM Armature Ammeter Calibration (See Section 4.14) AP PC Terminal: Disable-ON / Enable - OFF
CROS Field weakening Crossover Point (See Section 5.9) CA Field Weakening Ratio: Below ½ -ON / Above ½ -OFF
DEC Deceleration Time Adjustment (See Section 3.6) EF E. Stop: Controlled Decel: Enable-ON / Disable-OFF
DG* PID Lead Compensation (i.e. ASR Lead Comp) F1~F5 Field Current Range (See section 3.5)
FL* Forward Current Limit (See Section 5.12) FE Field Economy: Enable-OFF/ Disable-ON
FT Jog and E. Stop Accel & Decel (See Sections 5.4 & 5.5) FI Field Ammeter: Enable-ON / Disable -OFF
FM Field Ammeter Calibration (See Section 4.15) FL Field Loss Signal: Enable-OFF / Disable -ON
HS Zero Speed Hysteresis (See Section 5.8) FV Aux. Field Voltmeter: Enable-ON / Disable -OFF
IA* Instantaneous Over Current Trip (See Sections 5.12A & 5.12B) IFR Internal Field Regulator: ON / External Field Regulator -OFF
IF Field Economy (See Section 5.11A) JP-1 Speed Reference Scale: 8V- ON / 10V- OFF
IG* Current Gain (See Section 5.16) JP-2 Armature Ammeter: Enable -ON / Disable -OFF
IMX Armature Current Reference Point (See Section 5.12) JP-3 IA internal reference: Enable - OFF / Disable - ON
JOG Jog Speed (See Section 5.4) JP-4 Jog Signal: Enable -ON / Disable -OFF
LV* Low Input Voltage Shut Off Level (set at factory) JP-5 Jog PID: Enable-ON / Disable -OFF
MAX Max. Speed (i.e. Max. Armature Voltage) (See Section 5.9) JP-6* PID: Enable-ON / Disable -OFF (i.e. ASR, Speed Gain)
NA Speed Meter Calibration (See Section 4.13) JP-7 Field Weakening: Enable-ON / Disable -OFF
OP ZD Relay Latch Point (See Section 5.6) JP-8 Field Current Limit: Enable-ON / Disable -OFF
PI* PID (See Section 5.15) JP-9 Driver Test: Enable-ON / Disable -OFF
-R For/Rev Speed Balancing (See Section 5.12) JP-10* Calibrate AM pot to zero: Enable-ON / Disable -OFF
RL Reverse Current Limit (Regenerative Drives Only) JP-11* 1059F card only, Manufacturer test equipment use only
SG Speed Gain (i.e. Speed Stability) (See Section 5.14B) JP-12* 1059F card only, Manufacturer test equipment use only
SR Speed Response (i.e. Speed Overshoot) (See Section 5.14A) S1~S4 DC Tach Generator Voltage (See section 3.2 and 4.11)
P1* 1F/1R SCR Phasing Balancing (See Section 6.1A) SF Tach Feedback: Enable-ON / Disable -OFF (i.e. Speed Feedback)
P2* 2F/2R SCR Phasing Balancing (See Section 6.1A) T1~T4 Accel and Decel Time Range (See Section 3.6)
P3* 3F/3R SCR Phasing Balancing (See Section 6.1A) TG Tach Feedback ASR: Enable-ON / Disable -OFF
P4* 4F/4R SCR Phasing Balancing (See Section 6.1A) TL Tach Loss: Enable-ON / Disable -OFF
P5* 5F/5R SCR Phasing Balancing (See Section 6.1A) VF Armature Feedback: Enable-ON / Disable -OFF
P6* 6F/6R SCR Phasing Balancing (See Section 6.1A) Note: * We strongly suggest the user not change the factory setting.
ZERO Zero Speed Adjustment
Note: * We strongly suggest the user not change the factory setting.

RED SIGNAL LIGHT TABLE TEST POINT TABLE

Light Description Test
ES Emergency Stop Description
Point
FL Field Loss (Lights when current is 13% or less) TP-1 Tach Feedback Reference Voltage (8VDC / Max. Speed)
FU Fuse Blown TP-2 Arm Feedback Reference Voltage (7.5VDC / Max. Speed)
LVL Low Voltage Level (Lights when voltage is 70% or less) TP-4 Accel & Decel Voltage Ramp (+8 VDC / Max.)
OC Instantaneous Over Current Shut Off (see IA pot) TP-5 ASR Voltage (+4 VDC / Rated Current)
OL 60 Sec Current Overload TP-6 ACR Voltage (-8 VDC / Max.)
PH Phase Loss & Phase Sequence Error TP-7 Field Current Reference Voltage (2VDC / Max. IF)
TGL Tach Generator Signal Loss TP-8 Field Current Reference (-7.9 ~ -1.3VDC )
TP-9 Reference Input for Fire Block Test (factory use only)
TP-10 Armature Current Oscilloscope Connection Point
YELLOW SIGNAL LIGHT TABLE 15 +15 Volt Power Supply ( !0.5 V)
Light Description -15 -15 Volt Power Supply ( !0.5 V)
AP Auto Precondition +V Internal Relay Power (19.5 VDC !1V)
F Forward +B External Relay Signal Voltage (20 VDC !1V)
JOG Jog in Operation
P PI Gain (for special applications only)
PC Pre-Condition (i.e. Enable System before start)
R Reverse (12 SCR, Regenerative Only)
RUN Run (i.e. Start)
ZD Zero Detect ( Detects Motor Rotation)

Regulator Card Tables

Page 49
Statohm IV DC Drive Common Specifications
3 Phase Input Voltage 230VAC or 380VAC or 460VAC or 600VAC, Nominal range ±10%
Input Power 1 Phase Input Voltage 115VAC or 230VAC
Input Frequency 50 Hz and 60 Hz
Armature Starting &
Adjustable up to 200% for up to one minute.
Starting Regenerating Current
Field 1 phase, SCR phase control, Current Regulation Circuit 0.8A ~ 30A.
Field Economy When stopped the field is reduced to 50%, this feature can be disabled.
Output Power Only for motors with DC tachometers.
The field can be reduce down to 1/3 of full field
Field Weakening Crossover voltage can be adjusted down to 3/5 of full armature voltage.
Notes: Field Weakening is used to extend speed and / or adjust torque.
The crossover voltage is the armature voltage when field weakening begins.
Armature feedback regulation ±2%, Ratio 1:100
Speed Regulation DC tachometer feedback regulation ±0.5%, Ratio 1:100
Motor DC tachometers from 18V/1000RPM up to 100V/1000RPM
Regulation Acceleration & Deceleration 0.7 to 120 seconds, each independently adjustable.
Features Braking (12 SCR drives only) Regenerates power to lines
Adjustable up to 150%.
Current Limit
12 SCR drives have independent forward and reverse current limits.
VREF 0 to 8V with internal voltage supply, RL(IN) 100k
Speed Reference VREF 0 to 10V, auxiliary voltage supply required, RL(IN) 100k
VREF ±8 and ±10V, auxiliary voltage supply required, RL(IN) 100k
Reverse Terminal
Reverse (12 SCR drives only) VREF Speed Reference Polarity, ±8V and ±10V, Aux Power Supply
Required
Jog 0 ~ 20% of maximum speed, independent acceleration adjustment
Control Emergency Stop (E. Stop) Controlled deceleration or coast to stop.
Input & Output Safety feature to detect Pre-operation Conditions are met before the
PC (i.e. Enable)
drive is enabled to start.
Features
Zero speed Detect relay ZD relay has adjustable trip voltage. SPDT 0.5A / 250VAC
Fault Trip relay FT relay, SPDT 0.5A / 250VAC
Field Loss relay FL relay, SPDT 0.5A / 250VAC
Armature Ammeter output 0 ~ 2V
Field Ammeter output 0 ~ 2V
Speed Meter output 0 ~ 1mA
One master drive and one slave drive
Master Slave operation
One master drive and one slave drive with master speed gain
ST overload relay (i.e. Shunt Trip) is triggered at 250%,
Instantaneous Overload Trip (OC)
SPDT 0.5A / 250VAC
One Minute Delay Over Current 150% of the motors’ rating exceeded for more than one minute.
(OL)
Fault Diagnosis High / Low Input Voltage (LVL) ±15% of input voltage.
and Protection Phase Error (PH) Detects phase sequence error or phase lost.
Tachometer Generator Loss (TG) User has choice of stop or full speed when TG loss is detected.
Field Loss (FL) Detects when field current is 13% below normal.
SCR Thyristor Over Heat (OH) 85oC / 185oF thermostat switches off motor.
Fuse Blown (FU) Signal light indicates when AC input fuse has blown.
Storage Temperature -40O F to +140O F / -40O C to +60O C
Ambient Operating Temperature -14O F to +104O F / -10O C to +40O C
Relative Humidity 95% max., no condensation allowed
Environment
Atmosphere Avoid iron dust particles and corrosive gases , example: Ocean air.
Mount lengthwise vertical position, 5”/125 mm air space on all sides
Ventilation
and 2”/50 mm air space on front side in ventilated enclosure.

Model Ampere and Power Ratings

42NM2-*

42NM3-*
42RM2-*

42RM3-*

42XXNL5-*
42XXNL4-*

42XXNL7-*
42NL1-*

42NL2-*
42NS1-*

42NS2-*

42NS3-*

42NS4-*

42RL1-*

42RL2-*
42RS1-*

42RS2-*

42RS3-*

42RS4-*

Above 1000 HP inquire

Model Number

Max., Current 37A 70A 110A 180A 400A 550A 720A 910A 1,100A 1,400A 1,800A
Input 208~240V, Arm 240V 7 HP 15 HP 25 HP 45 HP 100 HP 125 HP 200 HP 250 HP 300 HP --- ---
Input 380~410V, Arm 440V 3 kW 20 kW 32 kW 58 kW 130 kW 165 kW 233 kW 375 kW --- --- ---
Input 440~480V, Arm 500V 14 HP 30 HP 50 HP 90 HP 200 HP 250 HP 400 HP 500 HP 600 HP 750 HP 1,000 HP
Input 575~600V, Arm 600V --- 36 HP 60 HP 108 HP 240 HP 300 HP 480 HP 600 HP 720 HP 900 HP 1,200 HP

Page 50
 Alphabetical Index
1 Jumper (JP-1) Pg. 9 Section 4.7
10 Jumper (JP-10) Pg. 49 Jumper Table
1058C Synchronization Card Pg. 39
1059A Regulator Card Physical Diagram Pg. 48
2 Jumper (JP-2) Pg. 13, Sec 4.14 and Pg. 49
2 Quadrant, 6 SCR Elementary Diagram Pg. 54
3 Jumper (JP-3) Pg. 13, Sec 4.14 and Pg. 49
4 Jumper (JP-4) Pg. 49 Jumper Table
4 Quadrant, 12 SCR Elementary Diagram Pg. 54
5 Jumper (JP-5) Pg. 49 Jumper Table
50H Jumper Pg. 49 Jumper Table
6 Jumper (JP-6) Pg. 49 Jumper Table
7 Jumper (JP-7) Pg. 5, Sec 3.5 and Pg. 18, Sec 5.11A
8 Jumper (JP-8) Pg. 5, Sec 3.5 and Pg. 18, Sec 5.11A
9 Jumper (JP-9) Pg. 49 Jumper Table
9042-1 Regulator Card Block Diagram Pg. 43
9042-2 Regulator Card Block Diagram Pg. 44
9042-3 Regulator Card Block Diagram Pg. 45
9044 Regulator Card Control Block Diagram Pg. 42
A1~A4 Jumpers Pg. 5, Sec 3.2 and Pg. 8, Sec 4.4
AC contactor Pg 23 Section 5.18
AC Power Connections Pg. 7 Section 4.1
ACC Potentiometer Pg. 20 Section 5.13
Acceleration and Deceleration Time Range Jumpers Pg. 5 Section 3.6
AM Potentiometer Pg. 13 Section 4.14
AP Jumper Pg. 49 Jumper Table
Armature Ammeter Wiring and Calibration Pg. 13 Section 4.14
Armature and Field in series (see field disable) Pg. 18 Section 5.11C
Armature Connections Pg. 7 Section 4.4
Armature Current Calibration Pg. 19 Section 5.12
Armature Current is too high at low speed and normal load. Pg. 32 Section 6.12
Armature Current Jumpers Pg. 5 Section 3.2
Armature Current Limit Adjustment Pg. 19 Section 5.12A
Armature Feedback Jumper Settings Pg. 5
Armature Feedback Jumper Settings Pg. 4
Armature Voltage Adjustment Pg. 19 Section 5.12
ASR Feedback Loop Adjustment ( i.e. Speed PID ) Pg. 21 Section 5.15
Balancing Phase Load Pg. 25 Section 6.1
CA Jumper Pg. 18 Sections 5.11A
Check prior to operation Pg. 15 Section 5.1
CROS Potentiometer Pg. 18, Sec 5.11A & Pg. 19, Sec 5.12
Current Gain Loop Adjustment ( i.e. Current PID ) Pg. 21 Section 5.16
Current Limit Adjustment Pg. 19 Section 5.12A
DC Contactor Pg. 23 Section 5.19
DC Tach Generator Feedback Pg. 10 Section 4.11
DC Tach Voltage Jumpers Pg. 5 Section 3.4
DEC Potentiometer Pg. 20 Section 5.13
Deceleration and Acceleration Time Range Jumpers Pg. 5 Section 3.6
DG Potentiometer Pg. 49 Potentiometer Table
EF Jumper Pg. 16 Section 5.5
Elementary Circuit Diagrams Pg. 54
Elementary Diagram of DC Drive Power Connections Pg. 6
Emergency Stop (E.Stop) Pg. 10 Section 4.10
Emergency Stop (E. Stop) Pg. 16 Section 5.5
Environment, Operation Pg. 3 Section 2.1
ES light (Emergency Stop) Pg 25 and Pg. 49, Section 5.11B

Page 51
 Alphabetical Index Continued
Field Ammeter Wiring and Calibration Pg. 14 Section 4.15
Field Amperage Adjustment Pg. 18 Section 5.11
Field and Armature in Series (see field disable) Pg. 18 Section 5.11C
Field Connections Pg. 8 Section 4.5
Field Current Jumpers Pg. 5 Section 3.1
Field Disable Pg. 18 Section 5.11C
Field Economy Pg. 18 Section 5.11B
Field Loss Pg. 18 Section 5.11E
Field Loss is Detected. Pg. 31 Section 6.11
Field Overview Pg. 18 Section 5.11
Field Regulation Jumpers Pg. 5 Section 3.5
Field Weakening Adjustment (Tach Feedback Only) Pg. 18 Section 5.11A
FL Jumper Pg. 18 Sections 5.11C & 5.11E
FL light Pg 25, Pg. 33 Section 6.14 and Pg. 49
FL Potentiometer Pg. 19 Section 5.12A
FM Potentiometer Pg. 14 Section 4.15
Forward and Reverse Current Limit Adjustment Pg. 19 Section 5.12B
FT Potentiometer Pg. 15, Sec 5.4 and Pg. 16, Sec 5.5
FU light Pg 25 and Pg. 49
Fuse Replacement Pg. 7 Section 4.3A
Fuses blow immediately after start and the “OC signal lights Pg. 28 Section 6.4
FV Jumper Pg. 14 Section 4.15
Grounding Pg. 7 Section 4.2
Horsepower Rating Pg. 3 Section 1.1
HS Potentiometer Pg. 17 Section 5.8
IA Potentiometer Pg. 19 Section 5.12C
IF Potentiometer Pg. 18 Sec 5.11A and Pg. 14 Sec 4.15
IFC 1084 card Pg. 38
IFR Jumper Pg. 49 Jumper Table
IG Potentiometer Pg. 21 Section 5.16
IMX Potentiometer Pg. 19 Sections 5.12, 5.12A, 5.12B
Installation Location Pg. 3 Section 2
Instantaneous Overload Current Shut-off Adjustment Pg. 19 Section 5.12D
Jog Pg. 10 Section 4.8
JOG Potentiometer Pg. 15 Section 5.4
Jog Speed & Acceleration Adjustment Pg. 15 Section 5.4
Jumper Setting Diagram Pg. 4
Jumper Settings Pg. 5 Section 3
Jumper Table Pg. 5 and Pg. 49
L1 Model Physical Diagram Pg. 37
L2 Model Physical Diagram Pg. 37A
Location, Installation Pg. 3 Section 2
LV light (i.e. LVL) Pg. 25 and Pg. 49
M2 Model Physical Diagram Pg. 35
M3 Model Physical Diagram Pg. 36
Master Slave Operation Pg. 22 Section 5.17
MAX Potentiometer Pg. 18, Sec 5.11A and Pg. 17, Sec 5.9
Maximum Speed for Armature Feedback Adjustment Pg. 17 Section 5.9
Maximum Speed for DC Tach Feedback Adjustment Pg. 17 Section 10
Meter Dimensions Pg. 11 Section 4.12
Model Number Scheme Pg. 3 Section 1.1
Motor Data and Elementary Motor Connection Diagram Pg. 41
Motor Feedback Jumpers Pg. 5 Section 3.3
Motor Rotation Detection Relay and Signal Light Adjustment (i.e. ZD) Pg. 16 Section 5.6
Motor Speed Runaway Pg. 27 Section 6.3
Motor will not go to full speed Pg. 30 Section 6.6

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 Alphabetical Index Continued
Motor information Pg. 41
Motor connections Pg. 41
NA Potentiometer Pg. 12 Section 4.13
OC light Pg 25 and Pg. 49
OH light Pg 25 and Pg. 49
OL light Pg 25 and Pg. 49
One Minute Timed Overload Shut-off Adjustment Pg. 19 Section 5.12C
OP Potentiometer Pg. 16 Section 5.5
Operating Environment Pg. 3 Section 2.1
Operation and Adjustment Pg. 15 Section 5
Oscilloscope Pg. 40
Overload “OL” signal light Pg. 30 Section 6.8
Overshoot and Undershoot Pg. 30 Section 6.7
Overshoot and Undershoot Pg. 20 and Pg.30
P1 ~ P6 Potentiometer Pg. 26 Section 6.1A
PC, Pre-Operational Conditions (i.e. Enable Drive) Pg. 9 Section 4.6
Permanent Magnet Field Pg. 8 Section 4.5A
Permanent Magnet Field (see field disable) Pg. 18 Section 5.11C
PH light (Phase loss or phase sequence error) Pg 25 , Pg. 33, Pg 33A and Pg. 49
Phase Load Balancing Pg. 25 Section 6.1
Phase Sequence Test Pg. 7 Section 4.3
PI Potentiometer Pg. 21 Section 5.15
PID Current Regulation (i.e. Current Gain Loop Adjustment) Pg. 21 Section 5.16
PID Speed Regulation (See ASR Feedback Loop Adjustment) Pg. 21 Section 5.15
Potentiometer Table Pg. 49
Power and Control Circuit Wiring Introduction Pg. 7 Section 4
Pre-Operation Voltage Checks Pg. 15 Section 5.2
-R Potentiometer Pg. 49 Potentiometer Table
Receiving & Storage Pg. 3 Section 1
Regenerative 12 SCR Elementary Diagram Pg. 54
Regulator Card Block Diagram # 9042-1 Pg. 43
Regulator Card Block Diagram # 9042-2 Pg. 44
Regulator Card Block Diagram # 9042-3 Pg. 45
Regulator Card Control Block Diagram # 9044 Pg. 42
Regulator Card Physical Diagram Pg. 48
Regulator Card Tables (for Pots, Jumpers, Signal Lights and Test Points) Pg. 49
Reverse Current Limit Adjustment Pg. 19 Section 5.12B
Reversing 12 SCR Elementary Diagram Pg. 54
RL Potentiometer Pg. 19 Section 5.12A
S Model Physical Diagram Pg. 34
S1 and S2 motor leads Pg 41
S1~S4 Jumpers Pg. 5, Sec 3.4 and Pg. 10, Sec 4.11
Series Field and Armature Motors (see field disable) Pg. 18 Section 5.11C
SF Jumper Pg. 5, Sec 3.3 and Pg. 17, Sec 5.10
SG Potentiometer Pg. 20 Section 5.14A
Signal Light Table Pg. 49
Signal lights R and PC are on F,AP, ZD flash and relays buzz. Pg. 31 Section 6.10
Slave Master Operation Pg. 22 Section 5.17
Speed Meter Wiring and Calibration Pg. 12 Section 4.13
Speed Overshoot Adjustment (i.e. Speed Response) Pg. 20 Section 5.14A
Speed Overshoot and Stability Adjustment Overview Pg. 20 Section 5.14
Speed Reference & Reverse Pg. 9 Section 4.7
Speed Stability Adjustment (i.e. Speed Gain) Pg. 20 Section 5.14B
SR Potentiometer Pg. 20 Section 5.14A

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 Alphabetical Index Continued
Stabilizing field winding Pg. 32 Section 6.12B and Pg 41
Start & Stop (i.e. Run & Stop) Pg. 10 Section 4.9
Synchronization Card 1058C Pg. 39
T1~T4 Jumpers Pg. 5, Sec 3.6 and Pg. 10, Sec 4.11
Tach Feedback Jumper Settings Pg. 5 Section 3.3
Terminal Table (for Regulator Card) Pg. 47
Test Point Table Pg. 49
Test Run Pg. 15 Section 5.3
TG Jumper Pg. 5 Section 3.3
TG light (i.e. TGL) Pg. 25 and Pg. 49
TG Voltage Jumpers Pg. 4 Section 3.4
The ES, OH, VL signal lights are on and can not be reset Pg. 31 Section 6.9
TL Jumper Pg. 5, Sec 3.3 and Pg. 18, Sec 5.11C
Troubleshooting Pg. 25 Section 6
Undershoot and Overshoot Pg. 30 Section 6.7
Unstable Speed Pg. 29 Section 6.5
VF Jumper Pg. 5 Section 3.3
Wire Size Tables Pg. 6
Wiring Pg. 7 Section 4
ZD, Zero motor rotation Detection relay and signal light Adjustment Pg. 16 Section 5.6
ZERO Potentiometer Pg. 16 Section 5.7
Zero Speed Hysteresis Adjustment (12 SCR Regenerative Drives Only) Pg. 17 Section 5.8
Zero Speed Adjust (12 SCR Regenerative Drives Only) Pg. 16 Section 5.7

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