INSTRUCTION SHEET
INSTRUCTION DWG
A70-8706 0109
INSTRUCTION SHEET For Type GH515ED20 Brake Rectifier Controller DESCRIPTION OF OPERATION The GH515ED20 brake rectifier is designed for use with a type GH505 heavy-duty DC magnetic shoe brake on cranes or other machinery with 230V AC power source. The rectifier also utilizes a coil forcing circuit to obtain the published int. torque ratings on a continuous basis. The rectifier is designed to energize the coil (release brake) at full voltage and economize the coil through a dropping resistor. The economy circuit insures the applied power will not exceed the allowable wattage rating of the brake coil. PROCEDURE FOR INSTALLATION AND OPERATION 1. Verify correct coil is installed in brake to insure compatibility with rectifier controller being installed. See Table 1. 2. Verify correct resistance of 1RES resistor at 6 and 21 terminal of 2BR contactor. See Table 2. 3. Verify 230VAC verify the proper line voltage is present at the L1 & L2 terminal. 4. Temporarily set timer to maximum time 30 seconds. Energize rectifier and verify 208VDC output at + & terminals of bridge rectifier (RECT) or wire 24 at FU3 and wire 25 at FU4 before timer drops out 2BR contactor. If unable to read voltage before timer drops out 2BR contactor, install a temporary jumper across terminals 55 & 56 of 1BR timer. REMOVE temporary jumper after test. 5. De-energize rectifier control. 6. Energize rectifier control and observe brake release time. Will be between .22 and .50 seconds depending on brake size. 7. De-energize rectifier control and observe brake set time. Will be between .15 and .32 seconds. 8. Set 1BR timer to normal recommended setting of .5 to 1 second. 9. Energize rectifier control and verify drop out of 2BR contactor. Check DC voltage at brake coil terminals 1B1 and 1B2. Will be approximately 24 to 30 VDC depending on ambient and temperature of coil.
TABLE 1 Brake Size 8” 10” 13” 16’ 19” 23”
MADE IN U.S.A
Brake Coil P/N 9-872-18 9-871-7 9-875-7 9-890-1 9-888-3 9-889-1
Coil Ohms 44.4 44.6 29.1 24.5 9.34 11.0
Coil Current (Single Coil) 4.69 P.U. / .53 Seal 4.67 P.U. / .53 Seal 7.15 P.U. / .82 Seal 8.48 P.U. / .84 Seal 22.3 P.U. / 1.9 Seal 18.9 P.U. / 1.88 Seal
Maximum Coil Watts 310 385 550 710 1025 1400
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INSTRUCTION DWG
A70-8706
TABLE 2 Brake Size 8”
10” 13” 16’ 19” 23”
No Of Brakes 1 2 4 1 2 4 1 2 1 2 1 1
230VAC Rectifier Controller GH515ED20-1 GH515ED20-2 GH515ED20-3 GH515ED20-1 GH515ED20-2 GH515ED20-3 GH515ED20-4 GH515ED20-5 GH515ED20-4 GH515ED20-5 GH515ED20-6 GH515ED20-6
Diagram Number 284994D2 284995D2 284996D2 284994D2 284995D2 284996D2 284997D2 284998D2 284997D2 284998D2 284999D2 284999D2
1RES Value (Ohms) 351 189 81 351 189 81 224 108 224 108 108 224
Dimension Drawing Reference 39-46309 ITM 1 39-46309 ITM 2 39-46309 ITM 3 39-46309 ITM 1 39-46309 ITM 2 39-46309 ITM 3 39-46309 ITM 4 39-46309 ITM 5 39-46309 ITM 4 39-46309 ITM 5 39-46309 ITM 5 39-46309 ITM 5
NOTES:
MADE IN U.S.A
PAGE 2
INSTRUCTION DWG
A70-8706
RENEWAL PARTS
6
2
1
5
4
3
TABLE 3
MADE IN U.S.A
Item
Qty
1
2
2 3
1 1
4
2
5 6
1 1
Description
Publication
Size 1 Contactor Coil Only Timer Rectifier Module 10 Amp Control Fuse Fuse Block Terminal Board Resistor
22177 23337
Complete Part Number CN15DN3BB 9-2703-2 C320TP1 35-98-2 44-861 44-2534 80-4026-4 See Table 4, Pg 4
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INSTRUCTION DWG
A70-8706
TABLE 4 Individual Resistor Element Resistor Value Element Part Qty (Ohms) Number 81 57-8770-22 4 27 57-8770-18 1
Brake Size
No Of Brakes
230VAC Rectifier Controller
1RES Value (Ohms)
Complete Resistor Assembly P/N
8”, 10”
1
GH515ED20-1
351
57-8714
8”, 10”
2
GH515ED20-2
189
57-8714-2
2 1
81 27
57-8770-22 57-8770-18
8”, 10”
4
GH515ED20-3
81
57-8714-3
3
27
57-8770-18
13”, 16”
1
GH515ED20-4
224
57-8714-4
2 1
81 62
57-8770-22 57-8770-21
13”, 16”
2
GH515ED20-5
108
57-8714-5
4
27
57-8770-18
19”, 23”
1
GH515ED20-6
108
57-8714-5
4
27
57-8770-18
MADE IN U.S.A
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INSTRUCTION DWG
MADE IN U.S.A
A70-8706
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INSTRUCTION DWG
MADE IN U.S.A
A70-8706
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INSTRUCTION DWG
MADE IN U.S.A
A70-8706
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INSTRUCTION DWG
MADE IN U.S.A
A70-8706
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INSTRUCTION DWG
MADE IN U.S.A
A70-8706
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INSTRUCTION DWG
MADE IN U.S.A
A70-8706
PAGE 10
INSTRUCTION DWG
TITLE Rev 1
New
GH515 BRAKE RECTIFIER INSTRUCTIONS Description Date Approved Drawn 1/19/09 G. Arneson Checked Approved
A
MADE IN U.S.A
Engineer G. Arneson G. Arneson J.Sanders
A70-8706
Date 1/19/09 1/19/09 1/19/09
70-8706
PAGE 11
A70-8706 0109
INSTRUCTION SHEET For Type GH515ED20 Brake Rectifier Controller DESCRIPTION OF OPERATION The GH515ED20 brake rectifier is designed for use with a type GH505 heavy-duty DC magnetic shoe brake on cranes or other machinery with 230V AC power source. The rectifier also utilizes a coil forcing circuit to obtain the published int. torque ratings on a continuous basis. The rectifier is designed to energize the coil (release brake) at full voltage and economize the coil through a dropping resistor. The economy circuit insures the applied power will not exceed the allowable wattage rating of the brake coil. PROCEDURE FOR INSTALLATION AND OPERATION 1. Verify correct coil is installed in brake to insure compatibility with rectifier controller being installed. See Table 1. 2. Verify correct resistance of 1RES resistor at 6 and 21 terminal of 2BR contactor. See Table 2. 3. Verify 230VAC verify the proper line voltage is present at the L1 & L2 terminal. 4. Temporarily set timer to maximum time 30 seconds. Energize rectifier and verify 208VDC output at + & terminals of bridge rectifier (RECT) or wire 24 at FU3 and wire 25 at FU4 before timer drops out 2BR contactor. If unable to read voltage before timer drops out 2BR contactor, install a temporary jumper across terminals 55 & 56 of 1BR timer. REMOVE temporary jumper after test. 5. De-energize rectifier control. 6. Energize rectifier control and observe brake release time. Will be between .22 and .50 seconds depending on brake size. 7. De-energize rectifier control and observe brake set time. Will be between .15 and .32 seconds. 8. Set 1BR timer to normal recommended setting of .5 to 1 second. 9. Energize rectifier control and verify drop out of 2BR contactor. Check DC voltage at brake coil terminals 1B1 and 1B2. Will be approximately 24 to 30 VDC depending on ambient and temperature of coil.
TABLE 1 Brake Size 8” 10” 13” 16’ 19” 23”
MADE IN U.S.A
Brake Coil P/N 9-872-18 9-871-7 9-875-7 9-890-1 9-888-3 9-889-1
Coil Ohms 44.4 44.6 29.1 24.5 9.34 11.0
Coil Current (Single Coil) 4.69 P.U. / .53 Seal 4.67 P.U. / .53 Seal 7.15 P.U. / .82 Seal 8.48 P.U. / .84 Seal 22.3 P.U. / 1.9 Seal 18.9 P.U. / 1.88 Seal
Maximum Coil Watts 310 385 550 710 1025 1400
PAGE 1
INSTRUCTION DWG
A70-8706
TABLE 2 Brake Size 8”
10” 13” 16’ 19” 23”
No Of Brakes 1 2 4 1 2 4 1 2 1 2 1 1
230VAC Rectifier Controller GH515ED20-1 GH515ED20-2 GH515ED20-3 GH515ED20-1 GH515ED20-2 GH515ED20-3 GH515ED20-4 GH515ED20-5 GH515ED20-4 GH515ED20-5 GH515ED20-6 GH515ED20-6
Diagram Number 284994D2 284995D2 284996D2 284994D2 284995D2 284996D2 284997D2 284998D2 284997D2 284998D2 284999D2 284999D2
1RES Value (Ohms) 351 189 81 351 189 81 224 108 224 108 108 224
Dimension Drawing Reference 39-46309 ITM 1 39-46309 ITM 2 39-46309 ITM 3 39-46309 ITM 1 39-46309 ITM 2 39-46309 ITM 3 39-46309 ITM 4 39-46309 ITM 5 39-46309 ITM 4 39-46309 ITM 5 39-46309 ITM 5 39-46309 ITM 5
NOTES:
MADE IN U.S.A
PAGE 2
INSTRUCTION DWG
A70-8706
RENEWAL PARTS
6
2
1
5
4
3
TABLE 3
MADE IN U.S.A
Item
Qty
1
2
2 3
1 1
4
2
5 6
1 1
Description
Publication
Size 1 Contactor Coil Only Timer Rectifier Module 10 Amp Control Fuse Fuse Block Terminal Board Resistor
22177 23337
Complete Part Number CN15DN3BB 9-2703-2 C320TP1 35-98-2 44-861 44-2534 80-4026-4 See Table 4, Pg 4
PAGE 3
INSTRUCTION DWG
A70-8706
TABLE 4 Individual Resistor Element Resistor Value Element Part Qty (Ohms) Number 81 57-8770-22 4 27 57-8770-18 1
Brake Size
No Of Brakes
230VAC Rectifier Controller
1RES Value (Ohms)
Complete Resistor Assembly P/N
8”, 10”
1
GH515ED20-1
351
57-8714
8”, 10”
2
GH515ED20-2
189
57-8714-2
2 1
81 27
57-8770-22 57-8770-18
8”, 10”
4
GH515ED20-3
81
57-8714-3
3
27
57-8770-18
13”, 16”
1
GH515ED20-4
224
57-8714-4
2 1
81 62
57-8770-22 57-8770-21
13”, 16”
2
GH515ED20-5
108
57-8714-5
4
27
57-8770-18
19”, 23”
1
GH515ED20-6
108
57-8714-5
4
27
57-8770-18
MADE IN U.S.A
PAGE 4
INSTRUCTION DWG
MADE IN U.S.A
A70-8706
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INSTRUCTION DWG
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INSTRUCTION DWG
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INSTRUCTION DWG
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INSTRUCTION DWG
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A70-8706
PAGE 9
INSTRUCTION DWG
MADE IN U.S.A
A70-8706
PAGE 10
INSTRUCTION DWG
TITLE Rev 1
New
GH515 BRAKE RECTIFIER INSTRUCTIONS Description Date Approved Drawn 1/19/09 G. Arneson Checked Approved
A
MADE IN U.S.A
Engineer G. Arneson G. Arneson J.Sanders
A70-8706
Date 1/19/09 1/19/09 1/19/09
70-8706
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