DC3R Regenerative DC Drive User Guide 1/4 to 2 HP, 115/230 VAC Instruction Manual D2-3453
The information in this manual is subject to change without notice. Throughout this manual, the following notes are used to alert you to safety considerations: m ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. IMPORTANT: Identifies information that is critical for successful application and understanding of the product. m ATTENTION: The control circuit is at line potential when the drive is energized.
iii m ATTENTION: Starting and Stopping with the inhibit terminal pins does not disconnect AC power in the stop position; a hardwired AC power disconnection switch must be mounted in close proximity to the operator’s start/stop controls. This is required, as the DC3 drive does not have an armature loop contactor. A single fault like a power device short may cause motor rotation when in the stop mode.
iv Contents Specifications 1 Dimensions 3 Installation 6 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Shielding guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Input isolation transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Mounting chassis drives . . . . .
v Contents (cont.) Troubleshooting 39 Prewired Connections for Enclosed Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Regenerative Drives 43 Exhibit “A”: Line Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
vi Illustrations Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. DC3R Chassis Drive Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 DC3R NEMA 4X Drive Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
vii Tables Table 1. Field Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Table 2. Fuse Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Table 3. Corcom® Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
viii
1 Specifications Model Max. Armature Current (Amps DC) HP Range with 115 VAC Applied HP Range with 230 VAC Applied DC3R 10.0 † 1/4–1 † 1/2–2 † † Maximum armature current and horsepower range apply when drive is attached to additional heat sink: Reliance Electric part number DC3R-HS-00. Use heat sink when armature current is above 7 ADC. Heat sinks are pre-mounted on DC3R enclosed drives.
2 Specifications Drive Rating Motor HP Rated AC Line Amps 1/4 4.2 4.2 1/3 5.5 5.5 1/2 7.5 3.8 3.8 3/4 10.9 5.9 5.1 1 12.1 6.7 6.7 1 1/2 -9.8 9.8 2 -11.7 11.7 Input KVA -- -- DC Amature DC Armature Field Field Voltage Current Voltage Current 90 2.7 50 1 100 2.7 100 1 90 3.5 50 1 100 3.5 100 1 90 5 50 1 180 2.5 100 1 180 2.5 200 1 90 7.6 50 1 180 3.8 100 1 180 3.8 200 1 90 10 50 1 180 5 100 1 180 5 200 1 --180 7 100 1 180 7 200 1 --180 9.2 100 1 180 9.
3 Dimensions Figure 1.
4 Dimensions Figure 2.
Dimensions ALL DIMENSIONS IN INCHES [MILLIMETERS] Figure 3.
6 Installation Only qualified technical personnel, familiar with the m ATTENTION: construction and operation of this equipment and the hazards involved, should install, adjust, operate and/or service this equipment. Read and understand this instruction manual in its entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life. ATTENTION: This equipment is at line voltage when AC power is connected.
Installation 7 Use 18-24 AWG wire for speed adjust potentiometer wiring. Use 14–16 AWG wire for AC line (L1, L2) and motor (A1 and A2) wiring. Shielding guidelines Electric recommends shielding all logic-level leads. If m Reliance shielding is not practical, use twisted pair control wiring to minimize ATTENTION: If it is not practical to shield power conductors, induced electrical noise. ATTENTION: Under no circumstances should unshielded power and logic leads be bundled together.
8 Installation Optional isolation transformer Distribution system capacity above the maximum m ATTENTION: recommended system KVA requires the use of an isolation transformer, a line reactor, or other means of adding similar impedance to the drive power input. Failure to observe these precautions could result in damage to, or destruction of, the equipment. Input isolation transformers might be needed to help eliminate the following: · Damaging line voltage transients from reaching the drive.
Installation Mounting chassis drives parts and assemblies. Static control precautions are required m sensitive when installing, testing, servicing, or repairing this assembly. Failure ATTENTION: This drive contains ESD (Electric Static Discharge) to observe these precautions could result in damage to, or destruction of, the equipment. Protect the drive from dirt, moisture, and accidental contact. Provide sufficient room for access to the terminal block and calibration trimpots.
10 Installation Mounting enclosed drives NEMA 4X enclosed drives come with three 0.88 inch (22 mm) conduit knockout holes at the bottom of the enclosure. The units may be vertically wall mounted using the four 0.25 inch (6 mm) slotted holes on the attached heat sink. For motor loads less than 5 ADC, the drive may be bench mounted horizontally, or operated without mounting. 1. Install the mounting screws. 2.
Installation 11 Cage-clamp terminal block Connections to the DC3R drive are made to a cage-clamp terminal block (Figure 4). To insert a wire into the terminal block, press down on the lever arm using a small screwdriver. Insert stripped wire into the large opening in front of the terminal block. Release the lever arm to clamp the wire. Lever Arm Figure 4. Cage-Clamp Terminal Block Field output The field output is for shunt wound motors only.
12 Installation Tachogenerator feedback Applying the incorrect polarity to the tachogenerator m ATTENTION: can cause an overspeed condition. Make sure the positive (+) wire is connected to terminal T1 and the negative (-) wire is connect to terminal T2 when the motor is running in the forward direction. Failure to observe this precaution could result in bodily injury. Using tachogenerator feedback improves speed regulation from approximately 1% of motor base speed to approximately 0.
Installation Connections Chassis drive connections NOTE: TERMINAL 1 IS THE HOT CONNECTION. TERMINALS 2 AND 3 ARE NEUTRAL CONNECTIONS. Figure 5.
14 Installation Enclosed drive connections NOTE: TERMINAL 1 IS THE HOT CONNECTION. TERMINALS 2 AND 3 ARE NEUTRAL CONNECTIONS. Figure 6.
Installation 15 Speed adjust potentiometer installation Because the reference potentiometer is connected m ATTENTION: through the regulator to the armature power circuit, its terminals are at line potential. Use a potentiometer that has a insulating shaft to insulate the operator knob from this power circuit and that is capable of withstanding Hi-pot tests at 2000 Volts DC for one minute. Failure to observe this precaution could result in severe bodily injury or loss of life.
16 Installation Speed adjust potentiometer connections ATTENTION: At very low input levels, noise or drift could cause m analog input polarity to change. This could cause the motor to rotate in the opposite direction. Proper precautions should be taken as this could result in damage to, or destruction of, the equipment. The motor can operate in one direction (unidirectional) or in two directions (bidirectional) depending on how the speed adjust potentiometer is connected to the drive.
Installation 17 +15 and –15 terminals The equipment is at line voltage when AC power is m ATTENTION: connected. Disconnect and lockout all ungrounded conductors of the AC power line. Failure to observe this precaution could result in severe bodily injury or loss of life. DC3R drives can supply a regulated +15 and –15 VDC signal (each sourcing 25 mA maximum) to isolated, external devices. These voltage supply terminals are located on terminal block 502 (TB502).
18 Installation Voltage follower The drive may be wired to follow a floating (isolated) 0 to ±10V signal that is isolated from earth ground instead of using a speed adjust potentiometer. Connect the signal input to S2, and the signal common to S0 (see Figure 9). Figure 9.
19 Operation Only qualified technical personnel, familiar with the m ATTENTION: construction and operation of this equipment and the hazards involved, should install, adjust, operate and/or service this equipment. Read and understand this instruction manual in its entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life. ATTENTION: This equipment is at line voltage when AC power is connected.
20 Operation Before applying power Change voltage switch settings only when the drive is m ATTENTION: disconnected from AC line voltage. Make sure both switches are set to their correct position. If the switches are improperly set to a lower voltage position, the motor will not run at full voltage and may cause damage to the transformer. If the switches are improperly set to a higher voltage position, the motor will overspeed, which may cause motor damage or severe bodily injury or loss of life. 1.
Operation Feedback Selector Switch Armature Voltage Selector Switch Line Voltage Selector Switches Figure 10.
22 Operation Startup Chassis drive 1. Set the speed adjust potentiometer for zero speed. 2. Apply AC line voltage. 3. Slowly advance the speed adjust potentiometer clockwise (CW). The motor slowly accelerates as the potentiometer is turned CW. Continue until the desired speed is reached. 4. Remove AC line voltage from the drive to coast the motor to a stop. Enclosed drive 1. Set the FORWARD/BRAKE/REVERSE switch to the BRAKE position. 2. Set the speed adjust potentiometer to “0” (full CCW). 3.
Operation 23 Starting and Stopping Methods For frequent starts and stops, use regenerative m ATTENTION: deceleration (shorting RB1 and RB2), regenerative braking (shorting INHIBIT terminals to each other), coasting to a stop (shorting INHIBIT–RUN terminals 1 and 2), or decelerating to minimum speed (shorting S2 to S0). Do not use any of these methods for emergency stopping. They may not stop a drive that is malfunctioning.
24 Operation Regenerative deceleration Starting and stopping with the inhibit terminal pins does m ATTENTION: not disconnect AC power in the stop position. A hardwired AC power disconnection switch must be mounted in close proximity to the operator’s start/stop controls. This is required, as the DC3 drive does not have an armature loop contactor. A single fault like a power device short may cause motor rotation when in the stop mode.
Operation 25 Regenerative braking using the INHIBIT circuit Starting and stopping with the inhibit terminal pins does m ATTENTION: not disconnect AC power in the stop position. A hardwired AC power disconnection switch must be mounted in close proximity to the operator’s start/stop controls. This is required, as the DC3 drive does not have an armature loop contactor. A single fault like a power device short may cause motor rotation when in the stop mode.
26 Operation Coast to a stop using the INHIBIT circuit Starting and stopping with the inhibit terminal pins does m ATTENTION: not disconnect AC power in the stop position. A hardwired AC power disconnection switch must be mounted in close proximity to the operator’s start/stop controls. This is required, as the DC3 drive does not have an armature loop contactor. A single fault like a power device short may cause motor rotation when in the stop mode.
Operation 27 Decelerate to minimum speed Starting and stopping with the inhibit terminal pins does m ATTENTION: not disconnect AC power in the stop position. A hardwired AC power disconnection switch must be mounted in close proximity to the operator’s start/stop controls. This is required, as the DC3 drive does not have an armature loop contactor. A single fault like a power device short may cause motor rotation when in the stop mode.
28 Calibration The following adjustments are made with power on. m ATTENTION: Exercise extreme caution as hazardous voltage exists. Failure to observe this precaution could result in severe bodily injury or loss of life. ATTENTION: The control circuit is at line potential when the drive is energized. Use a non-metallic screwdriver when making adjustments to the circuit board potentiometers. Exercise extreme caution as hazardous voltage exists.
Calibration 29 MIN SPD The DC3 Drive is intended to operate at a m ATTENTION: predetermined minimum speed. If the application requires zero speed operation, the user is responsible for assuring safe conditions for operating personnel by providing suitable guards, audio or visual alarms, or other devices. Failure to observe these precautions could result in bodily injury. ATTENTION: At very low input levels, noise or drift could cause analog input polarity to change.
30 Calibration FWD TQ Although FWD TQ is set to exceed the motor m ATTENTION: nameplate current rating, continuous operation beyond that rating may damage the motor. The FWD TQ setting determines the maximum torque for accelerating and driving the motor in the forward direction. It also sets the maximum torque for decelerating the motor in the reverse direction. FWD TQ is factory set at 120% of rated motor current.
Calibration 31 Recalibrate the IR COMP setting when using a lower horsepower motor. See Figure 19 for typical IR COMP settings, or recalibrate using the following procedure: If the motor does not maintain set speed as the load changes, gradually rotate the IR COMP trimpot CW. If the motor oscillates (overcompensation), the IR COMP trimpot may be set too high (CW). Turn the IR COMP trimpot CCW until the drive stabilizes.
32 Calibration TACH Applying the incorrect polarity to the tachogenerator m ATTENTION: can cause an overspeed condition. Make sure the positive (+) wire is connected to terminal T1 and the negative (-) wire is connect to terminal T2 when the motor is running in the forward direction. Failure to observe this precaution could result in bodily injury. Calibrate the TACH setting only when a tachogenerator is used.
Calibration Figure 16. Typical FWD TQ, REV TQ, and IR COMP Settings (actual settings may vary with each application) Figure 17.
34 Application Notes The equipment is at line voltage when AC power is m ATTENTION: connected. Disconnect and lockout all ungrounded conductors of the AC power line. Failure to observe this precaution could result in severe bodily injury or loss of life. Optional speed adjust potentiometer connections At very low input levels, noise or drift could cause m ATTENTION: analog input polarity to change. This could cause the motor to rotate in the opposite direction.
Application Notes 35 FWD-STOP-REV switch Starting and stopping with the inhibit terminal pins m ATTENTION: does not disconnect AC power in the stop position. A hardwired AC power disconnection switch must be mounted in close proximity to the operator’s start/stop controls. This is required, as the DC3 drive does not have an armature loop contactor. A single fault like a power device short may cause motor rotation when in the stop mode.
36 Application Notes Independent adjustable speeds Connect two speed adjust potentiometers with a single-pole two-position switch to select between two independent speeds shown in the forward direction ( Figure 20). The speed adjust potentiometers can be mounted at two separate operating stations. Figure 20.
Application Notes 37 Independent forward and reverse speeds At very low input levels, noise or drift could cause m ATTENTION: analog input polarity to change. This could cause the motor to rotate in the opposite direction. Proper precautions should be taken as this could result in damage to, or destruction of, the equipment. Connect two speed adjust potentiometers as shown in Figure 21 to select between independent forward and reverse speeds. Figure 21.
38 Application Notes Independent Forward and Reverse Speeds with a Forward-Stop-Reverse Switch Starting and stopping with the inhibit terminal pins m ATTENTION: does not disconnect AC power in the stop position. A hardwired AC power disconnection switch must be mounted in close proximity to the operator’s start/stop controls. This is required, as the DC3 drive does not have an armature loop contactor. A single fault like a power device short may cause motor rotation when in the stop mode.
39 Troubleshooting This equipment is at line voltage when AC power is m ATTENTION: applied. Disconnect and lockout all ungrounded conductors of the AC power line before working on the unit, Failure to observe this precaution may result in severe bodily injury or loss of life. Check the following before proceeding: • The AC line voltage must match the voltage on the drive nameplate. • On dual voltage drives, check that the voltage switches are set to the correct position.
40 Troubleshooting Line fuse blows 1. Disconnect AC line voltage from the drive. 2. Check that the motor cable and armature is not shorted or grounded. a. Armature resistance should measure approximately 1 to 100 ohms, depending on motor horsepower. b. A resistance reading from the motor frame to either armature side should show open when an ohmmeter is used on its high resistance scale. 3. Check that the field circuit is not open. 4.
Troubleshooting 41 Motor will not reach the desired speed The control circuit is at line potential when the drive is m ATTENTION: energized. Use a non-metallic screwdriver when making adjustments to the circuit board potentiometers. Exercise extreme caution as hazardous voltage exists. Failure to observe these precautions could result in severe bodily injury of loss of life. 1. Check the MAX SPD setting and increase if necessary. 2. Check that the IR COMP setting is not set too low. 3.
42 Troubleshooting Prewired Connections for Enclosed Drive Figure 23. Prewired Connections to L1, L2(115) and L2(230) Figure 24.
43 Regenerative Drives Most non-regenerative, variable speed, DC drives control current flow to a motor in one direction. The direction of torque is the same direction as the motor rotation. Non-regenerative drives operate in Quadrant 1, and also in Quadrant 3 if the drive is reversible (see Figure 25). Motors must stop before reversing direction. Unless dynamic braking is used, nonregenerative drives cannot oppose an overhauling load, and cannot decelerate a load faster than coasting to a lower speed.
44 CE Compliance Reliance Electric hereby certifies that its DC3 series drives have been approved to bear the “CE” mark provided the conditions of approval (listed in Exhibit “A”) have been met by the end user. The DC3 series has been tested to the following test specifications: EN55011:1991 (emissions), and EN50082-1:1992 (immunity) Compliance allows Reliance Electric’s DC3 series to bear the CE mark. The end user, as described herein, falls into one of two categories: 1.
CE Compliance 45 Table 3. Corcom® Filters Nameplate Current of Motor Wired to the Drive 0 to 4 amps 4.1 to 13 amps Corcom® Filter Part Number 6VV1 20VV1 The filters in Table 3 should be wired to the AC line within 0.25 meters of the drive. The ground connection from the filter must be wired to solid earth ground (resistance less than 500 ohms); not machine ground.
46 CE Compliance The OEM has this liberty because CE is a machinery directive. Whether or not every component in the OEM’s machinery meets CE, the OEM must still submit his machine for CE approval. Thus, no component must necessarily meet CE within the machine, as long as the OEM takes the necessary steps to guarantee the machine does meet CE. By the same token, even if every component in the OEM’s machine does meet CE, the machine will not necessarily meet CE as a machine.
U.S. Drives Technical Support Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: support@drives.ra.rockwell.com, Online: www.ab.com/support/abdrives Publication D2-3453-December 1999 Copyright © 1999 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.
