Rockwell Automation DC3E User Manual
DC3E Non-Regenerative DC Drive
User Guide
1/4 to 2 HP, 115/230 VAC
Instruction Manual D2-3452-1
M/N DC3N-12D-00-010-AI
M/N DC3N-12D-4X-010-AI
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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:
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.
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Trademarks not belonging to Rockwell Automation are property
of their respective companies.
©2001 Rockwell International Corporation All rights reserved
i
ATTENTION: Only qualified personnel familiar with the
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: The user is responsible for conforming
with all applicable local and national codes. 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. Failure to observe these
precautions could result in severe bodily injury or loss of
life.
ATTENTION: It is possible for a drive to run at full
speed as a result of a component failure. Please
ensure that a master switch has been placed in the AC
line to stop the drive in an emergency.
ATTENTION: Reduce the chance of an electrical fire,
shock, or explosion by proper grounding, over-current
protection, thermal protection and enclosure. Follow
sound maintenance procedures.
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ii Safety Warnings
ATTENTION: Starting and stopping with the start/stop
terminals does not disconnect AC power in the stop
position. A hardwired AC power disconnection switch
must be mounted between the AC source and terminals
L I and L2. This is required, as the DC 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. 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: This Drive contains ESD (Electric Static
Discharge) sensitive parts and assemblies, Static control
precautions are required when installing, testing,
servicing, or repairing this assembly. Failure to observe
these precautions could result in damage to, or
destruction of, the equipment.
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Specifications 1
Dimensions and Layout 4
Installation 7
Wiring ...............................................8
Shielding guidelines ..................................8
Chassis drive ........................................10
Mounting ..........................................10
Isolation transformer ..................................11
Heat sinking .......................................12
Fusing ............................................12
Line fusing . . ....................................13
Speed adjust potentiometer ............................14
Alternate speed adjust potentiometer connections .........15
Cage-clamp terminals ...............................16
Connections ........................................17
Motor ...........................................18
Power input . . ....................................19
Field output . . ....................................20
START/STOP pushbuttons ...........................21
Tachometer feedback ...............................22
Voltage or current follower ...........................24
Enclosed drive .......................................25
Mounting ..........................................25
Heat sinking .......................................26
Line fusing .........................................26
Connections ........................................27
Motor ...........................................28
Power input . . ....................................29
Contents
iii
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Field output . . ....................................29
Tachometer feedback ...............................30
Voltage or current follower ...........................32
Slide switches ........................................33
LINE VOLTAGE (SW501 and SW502) ....................33
MOTOR (SW503) ...................................33
SIGNAL (SW504) ...................................34
FEEDBACK (SW505) .................................34
Operation 36
Before applying power (all models) .........................37
Drive operation .......................................38
Chassis drive operation ...............................38
POWER ON start .................................38
Pushbutton start/stop ...............................39
Alternate Starting and Stopping Methods ..................41
Minimum speed ...................................42
Dynamic braking ..................................43
Dynamic brake resistor value ........................43
Enclosed drive operating modes .........................45
Manual mode ....................................45
Auto mode . . ....................................46
Enclosed drive operation ..............................46
To run the motor ...................................47
To stop the motor .................................47
Calibration 48
Drive Calibration Procedure .............................50
MINSPD ..........................................51
MAXSPD .........................................52
CURRENT LIMIT ....................................53
IRCOMP .........................................54
Approximate IR COMP calibration: ....................55
ACCEL ...........................................55
iv Table of Contents
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DECEL ...........................................56
TACHVOLTS.......................................57
Application Notes 60
Multiple fixed speeds ...................................60
Adjustable speeds using potentiometers in series .............61
Independent adjustable speeds ...........................62
Reversing ...........................................63
RUN/JOG switch . . ....................................65
Before troubleshooting .................................67
Troubleshooting 67
Diagnostic LEDs . . ....................................68
Block Diagram ........................................75
Terminal descriptions ..................................76
Chassis drive terminals ...............................76
Enclosed drive terminals ..............................77
CE Compliance 78
Exhibit “A” ...........................................79
Armature Filters . . ....................................80
Notes 82
vTable of Contents
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Figure 1. DC3N-12D-00-010-AI Dimensions ..................4
Figure 2. DC3N-12D-4X-010-AI Dimensions ..................5
Figure 3. PC Board Layout ...............................6
Figure 4. Speed Adjust Potentiometer ......................14
Figure 5. Cage-Clamp Terminal ...........................16
Figure 6. Chassis Drive Connections .......................23
Figure 7. Chassis Drive Signal Follower Connection ...........24
Figure 8. Enclosed Drive Connections ......................31
Figure 9. Slide Switches ................................35
Figure 10. Run/Decelerate to Minimum Speed Switch ...........42
Figure 11. Dynamic Brake Connection .......................44
Figure 12. Calibration Trimpot Layout .......................49
Figure 13. Typical CURRENT LIMIT and IR COMP Settings ......59
Figure 14. Multiple Fixed Speeds ..........................60
Figure 15. Adjustable Fixed Speeds Using Potentiometers in Series 61
Figure 16. Independent Adjustable Speeds ...................62
Figure 17. Reversing Circuit Connection .....................64
Figure 18. RUN/JOG Switch Connection to Speed Adjust
Potentiometer ...............................66
Figure 19. Diagnostic LED Locations ........................68
Figure 20. DC3N Block Diagram ...........................75
vi
Illustrations
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Specifications
Max.
Armature HP Range HP Range
Current with115 VAC with 230 VAC
Model (Amps DC) Applied Applied
DC3N-12D-00-010-AI 10A 1/4–1 1/2–2
DC3N-12D-4X-010-AI 10A 1/4–1 1/2–2
Model Style
DC3N-12D-00-010-AI Open chassis
DC3N-12D-4X-010-AI NEMA 4X/12
AC Line Voltage 115 VAC or 230 V AC, 50 or 60 Hz, 1 Phase
Maximum Allowable Symmetrical AC Line Current 5000 amps
Maximum AC Line Distribution kVA
with 115 VAC Input 25 kVA
with 230 VAC Input 50 kVA
Armature Voltage
With 115 VAC Input 0–90 VDC
With 230 VAC Input 0 – 180 VDC
Field Voltage
115 VAC Input 50 VDC (F1 to L1); 100 VDC (F1 to F2)
230 VAC Input 100 VDC (F1 to L1); 200 VDC (F1 to F2)
Maximum Field Current 1 ADC
Adjustments and Application Data
Form Factor 1.37 at base speed
Service Factor 1
Maximum Speed Trimpot Range (% of rated voltage) 0to90%
1
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Minimum Speed Trimpot Range (% of rated voltage) 0to50%
Torque Trimpot Maximum Setting (% of maximum current) 200%
IR Drop Compensation (% of rated armature voltage) 0to15%
Acceleration Time Range 0.5 – 10 seconds
Deceleration Time Range 0.5 – 10 seconds
Analog Input Signal Range (S1 to S2) 0 – 10 VDC or 4 – 20 mADC
Input Impedance (S1 to S2) >100 KOHMS
Speed Regulation (% of base speed with 95% load change)
With Armature Feedback 1% or better
With Tachometer Feedback 0.1%
Speed Range 60:1
Tachometer Feedback Voltage Range
7 – 50 VDC per 1000 RPM
Maximum Current Load 150% for 1 minute
Safety Certification UL Listed Component
cUL Listed Component
CE Approved Component
Weight 2.1 lbs (953g)
Service Conditions
Maximum Allowable Elevation
3300 ft (1000 m) max without derating*
Vibration 0.5G max. (0–50 Hz); 0.1G max. (>50 Hz)
Ambient Temperature Range
Chassis Drives 10°C – 55°C
Enclosed Drives 10ºC – 45ºC
Non-condensing Relative Humidity 0% to 95%
* Derate the current by 1% for every 300 ft (90m) above 3300 ft., up to 10,000 ft.
(3000m)
2 Specifications
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Drive Ratings
DC Motor Motor
Rated DC Armature Field Field
Motor AC Line Input Armature Current Voltage Current
HP Amps KVA Voltage (Amps) (Amps)
1/4 4.5 0.5 90 2.7 50 1
4.5 0.5 90 2.7 100 1
1/3 5.9 0.7 90 3.5 50 1
5.9 0.7 90 3.5 100 1
1/2 7.8 0.9 90 5 50 1
3.7 0.8 180 2.5 100 1
3.7 0.8 180 2.5 200 1
3/4 10.6 1.2 90 7.6 50 1
5.6 1.3 180 3.8 100 1
5.6 1.3 180 3.8 200 1
1 13 1.5 90 10 50 1
7 1.6 180 5 100 1
7 1.6 180 5 200 1
1.5 -- -- -- -- -- --
10.1 2.3 180 7 100 1
10.1 2.3 180 7 200 1
2------ ------
12 2.8 180 9.2 100 1
12 2.8 180 9.2 200 1
Efficiency (at maximum horsepower output) 92%
3Specifications
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4
Dimensions and Layout
Figure 1. DC3N-12D-00-010-AI Dimensions
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5Dimensions
THREE 0.88 [22] KNOCKOUTS
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 2. DC3N-12D-4X-010-AI Dimensions
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6 Dimensions and Layout
Figure 3. PC Board Layout
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7
Installation
ATTENTION: Only qualified technical personnel,
familiar with the 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. Disconnect and lockout all
ungrounded conductors of the AC power line before
working on the unit. Failure to observe this precaution
could result in severe bodily injury or loss of life.
ATTENTION: The user is responsible for conforming
with all applicable local and national codes. Failure to
observe this precaution could result in severe bodily
injury or loss of life.
250-0287-rev2.qxd 3/12/01 10:27 AM Page 7
Wiring
8 Installation
ATTENTION: Circuit potentials are at 115 or 230
VAC above ground. To prevent the risk of injury or
fatality, avoid direct contact with the printed circuit
board or with circuit elements. Use a non-metallic
screwdriver for the calibration trimpots.
ATTENTION: Do not disconnect any of the motor
leads from the drive unless power is removed or the
drive is disabled. Opening any one motor lead may
destroy the drive.
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
ATTENTION: If it is not practical to shield power
conductors, Reliance Electric recommends shielding all
logic-level leads. If shielding logic leads is not
practical, use twisted-pair control wiring to minimize
induced electrical noise.
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9Installation
*Reliance Electric considers this an unfavorable condition and does not
recommend bundling power and logic leads for any length.
ATTENTION: Under no circumstances should power
and logic leads be bundled together. Induced voltage
can cause unpredictable behavior any electronic device,
including motor controls.
As a general rule, Reliance Electric recommends shielding
of all conductors if:
1) wire lengths exceed 4 inches and power and logic leads
must be bundled together*; or
2) radiated and/or conducted noise must be minimized due
to concerns about immunity or general compliance (CE,
FCC, etc.)
It may be necessary to earth ground the shielded cable. If
noise is produced by devices other than the drive, ground
the shield at the drive end. If noise is generated by a
device on the drive, ground the shield at the end away from
the drive. Do not ground both ends of the shield.
If the device continues to pick up noise after grounding the
shield, it may be necessary to add AC line filtering devices,
or to mount the drive in a less noisy environment.
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10 Installation
Mounting
Protect the drive from dirt, moisture, and accidental
contact. Provide sufficient room for access to the terminal
block and calibration trimpots.
Mount the drive away from other heat sources. Operate the
drive within the specified ambient operating temperature
range.
Prevent loose connections by avoiding excessive vibration
of the drive.
Mount the drive with its board in either a horizontal or
vertical plane. Four 0.19 inch (5 mm) wide slots in the
chassis accept #8 pan head screws.
ATTENTION: This drive contains ESD (Electric Static
Discharge) sensitive parts and assemblies. Static control
precautions are required when installing, testing,
servicing, or repairing this assembly. Failure to observe
these precautions could result in damage to, or
destruction of, the equipment.
Chassis drive
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The chassis units do not have to be earth grounded. If you
choose to ground the chassis, use a star washer beneath the
head of at least one of the mounting screws to penetrate the
anodized chassis surface and to reach bare metal.
Isolation transformer
11Installation
ATTENTION: Distribution system capacity above the
maximum 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.
· Line noise from the drive back to the incoming power
source.
· Damaging currents that could develop if a point inside
the drive becomes grounded.
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12 Installation
ATTENTION: Most code requires that upstream
branch protection be provided to protect input power
wiring. Failure to observe this precaution could result in
severe bodily injury or loss of life.
Observe the following guidelines when installing an
isolation transformer:
· A power disconnecting device must be installed between
the power line and primary of the transformer.
· If the power disconnecting device is a circuit breaker, the
circuit breaker trip rating must be coordinated with the
in-rush current (10-12 times full load current) of the
transformer.
Heat sinking
This DC3 drive model contains sufficient heat sinking in
its original configuration. No additional heat sinking is
necessary when installed in accordance with the guidelines
specified in this instruction manual. The chassis plate acts
as the thermal heatsink.
Fusing
Install the required, user-supplied branch circuit protection
fuses according to the applicable local, national, and
international codes (e.g., NEC/CEQ).
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13Installation
Line fusing
This DC3 drive model has 15-amp line fuses preinstalled
on fuse holders 501 and 502 (FU501 and FU502). When
replacing the line fuses, use fast acting fuses rated for 250
VAC or higher. See Figure 3, page 6, for fuse holder
location, and Table 1 for recommended replacement line
fuse sizes for specific application ratings.
Table 1. Recommended Line Fuse Sizes
90 VDC Motor 180 VDC Motor Max. DC Armature AC Line Fuse
Horsepower Horsepower Current (amps) Size (amps)
1/20 1/10 0.5 3
1/15 1/8 0.8 3
1/8 1/4 1.5 5
1/6 1/3 1.7 5
1/4 1/2 2.6 8
1/3 3/4 3.5 8
1/2 1 5.0 10
3/4 1 1/2 7.6 15
1 2 10 15
Reliance Electric offers a 0.5A pico fuse (part number 050–0074) which protects the control board power supply
transformer and logic.
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14
Figure 4. Speed Adjust Potentiometer
Installation
Speed adjust potentiometer
Install the circular insulating disk between the mounting
panel and the 10K ohm speed adjust potentiometer (see
Figure 4). Mount the speed adjust potentiometer through a
0.38 inch (10 mm) hole with the hardware provided. Twist
the speed adjust potentiometer wire to avoid picking up
unwanted electrical noise. If potentiometer leads are longer
than 18 inches (46 cm), use shielded cable.
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15
Alternate speed adjust potentiometer connections
Alternate speed adjust potentiometer connections may be
found in the Application Notes section of this user guide.
IMPORTANT: The user may choose to install a 5K ohm
speed adjust potentiometer; however, the MIN SPD and
MAX SPD trimpots must be recalibrated if the 5K ohm
potentiometer is used.
Installation
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16
Cage-clamp terminals
Logic connections are made to cage-clamp terminals. To
insert a wire into the cage-clamp terminal:
Figure 5. Cage-Clamp Terminal
Installation
1. Press down on the lever arm using a
small screwdriver.
2. Insert wire into the wire clamp.
3. Release the lever arm to clamp wire.
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17Installation
ATTENTION: Do not connect this equipment with
power applied. Failure to follow this directive may
result in fire or serious injury.
ATTENTION: Starting and stopping with the start/stop
terminals does not disconnect AC power in the stop
position. A hardwired AC power disconnection switch
must be mounted between the AC source and terminals
L I and L2. 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. 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: To provide the motor with overload
protection, local, national, and international codes
(e.g.,NEC/CEC) require that a motor thermostat,
internal to the motor, be installed or an electronic
thermal motor overload relay, sized to protect the
motor, be installed between the motor and the drives
output terminals.
Connections
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18 Installation
ATTENTION: Installation of a master power switch in
the input line is required. This is the only way to
disconnect power from the motor. 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.
Motor
ATTENTION: To provide the motor with overload
protection, local, national, and international codes (e.g.,
NEC/CEC) require that a motor thermostat, internal to
the motor, be installed or an electronic thermal motor
overload relay, sized to protect the motor, be installed
between the motor and the drive’s output terminals.
IMPORTANT: Reliance Electric drives supply motor
voltage from A1and A2 terminals. It is assumed throughout
this manual that, when A1 is positive with respect to A2,
the motor will rotate clockwise (CW) while looking at the
output shaft protruding from the front of the motor. If this
is opposite of the desired rotation, simply reverse the
wiring of A1 and A2 with each other.
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19Installation
Connect a motor to terminals A1 and A2 as shown in
Figure 6 (page 23). Ensure that the motor voltage rating is
consistent with the drive’s output voltage.
Power input
ATTENTION: Installation of a master power switch in
the input line is required. This is the only way to
disconnect power from the motor. 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.
Connect the AC line power leads to terminals L1 and L2 as
shown in Figure 6 (page 23). Install a master power switch
in the voltage input line, as shown in Figure 6. The switch
contacts should be rated at a minimum of 250 volts and
200% of maximum drive current.
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20 Installation
ATTENTION: Do not make any connections to F1 and
F2 when using a permanent magnet motor. The field
output is for shunt wound motors only. See Table 2 for
field output connections.
Table 2. Field Output Connections
Line Voltage Approximate Connect Motor
(VAC) Field Voltage (VDC) Field To
115 50 F1 and L1
115 100 F1 and F2
230 100 F1 and L1
230 200 F1 and F2
Field output
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