Rockwell Automation DC3N User Manual

DC3N DC Drive User Guide 1/4 to 2 HP, 115/230 VAC

Instruction Manual D2-3451

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 of loss of life.

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: 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.

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. The user is responsible for assuring safe conditions for operating personnel by providing suitable guards, audio or visual alarms, or other devices.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss.

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:

IMPORTANT: Identifies information that is critical for successful application and understanding of the product.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

iii

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.

Specifications 1 Dimensions 3 Installation 7

Chassis drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Heat sinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Line fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Speed adjust potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Alternate speed adjust potentiometer connections . . . . . . . . . . . . . .10

Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Power, fuse and motor connections . . . . . . . . . . . . . . . . . . . . . . . . .11

Voltage follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Enclosed drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Mounting (NEMA 1 enclosure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Mounting (NEMA 4X enclosure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Heat sinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Line fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Operation 17

Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Drive Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

DC3N Chassis Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

DC3N Enclosed Drives (NEMA 1 and NEMA 4X) . . . . . . . . . . . . . . . .19

Starting and stopping methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Line starting and line stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Starting and stopping using inhibit terminals . . . . . . . . . . . . . . . . . . . . .20

Configuring the inhibit response . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Decelerating to minimum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Dynamic braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Dynamic brake resistor value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Power supply header block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Calibration 26

MIN SPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

MAX SPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

ACCEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

DECEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

IR COMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Application Notes 31

Multiple fixed speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Adjustable speeds using potentiometers in series . . . . . . . . . . . . . . . . . .31

Independent adjustable speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

RUN/JOG switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Contents

Troubleshooting 35

Before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Functional Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

CE Compliance 41

External filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Line filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Armature filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Figure 1. DC3N-12D-00-010-AN Dimensions . . . . . . . . . . . . . . . . . . . . . . . .3

Figure 2. DC3N-12D-01-010-AN Dimensions . . . . . . . . . . . . . . . . . . . . . . . .4

Figure 3. DC3N-12D-4X-010-AN Dimensions . . . . . . . . . . . . . . . . . . . . . . . .5

Figure 4. Heat Sink Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Figure 5. Speed Adjust Potentiometer Installation . . . . . . . . . . . . . . . . . . . .10

Figure 6. DC3N Chassis Drive Connections . . . . . . . . . . . . . . . . . . . . . . . .12

Figure 7. Voltage Follower Connections . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Figure 8. Enclosed Drive Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Figure 9. Voltage Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Figure 10. INHIBIT Terminals and Jumper Location . . . . . . . . . . . . . . . . . .20

Figure 11. Inhibit Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Figure 12. Run/Decelerate to Minimum Speed Switch . . . . . . . . . . . . . . . .22

Figure 13. Dynamic Brake Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Figure 14. Power Supply Header Block . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Figure 15. Calibration Trimpot Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Figure 16. Recommended Torque and IR COMP Settings . . . . . . . . . . . . .30

Figure 17. Multiple Fixed Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Figure 18. Adjustable Fixed Speeds Using Potentiometers in Series . . . . . .31

Figure 19. Independent Adjustable Speeds . . . . . . . . . . . . . . . . . . . . . . . .32

Figure 20. RUN/JOG Switch Connection to Inhibit Plug . . . . . . . . . . . . . . .33

Figure 21. RUN/JOG Switch Connection to Speed Adjust Potentiometer . .33

Figure 22. Reversing Circuit Connection . . . . . . . . . . . . . . . . . . . . . . . . . .34

Figure 23. Diagnostic LED Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Figure 24. DC3N Series Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Figure 25. Terminal Block Connections for DC3N Enclosed Drives . . . . . . .40

Illustrations

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Table 1. Recommended Line Fuse Sizes . . . . . . . . . . . . . . . . . . . . . . . . . .9

Table 2. Recommended Dynamic Brake Resistor Sizes . . . . . . . . . . . . . . .23

Table 3. Corcom® Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Table 4. Reliance Electric® Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Tables

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Specifications

Max.

Armature HP Range HP Range

Current with 115 VAC with 230 VAC

Model (Amps DC) Applied Applied Style

DC3N-12D-00-010-AN† 10.0 1/8–1 1/4–2 Chassis DC3N-12D-01-010-AN‡ 10.0 1/8–1 1/4–2 NEMA 1 DC3N-12D-4X-010-AN‡‡ 10.0 1/8–1 1/4–2 NEMA12/4/4X

† Double maximum armature current and horsepower when drive is mounted on heat sink

part number DC3N-HS-00.

‡ Double maximum armature current and horsepower when drive is mounted on heat sink

part number DC3N-HS-01.

‡‡ Indoor use only

Motor HP Rated AC Input DC Amature DC Armature

Line Amps KVA Voltage Current

1/4 4.5 0.5 90 2.7

2.6 0.6 180 1.4

1/3 5.9 0.7 90 3.5

3.1 0.7 180 1.8

1/2 7.8 0.9 90 5

3.7 0.8 180 1.3

3/4 10.6 1.2 90 7.6*

5.6 1.3 180 3.8

1 13 1.5 90 10*

7 1.6 180 5

1 1/2 -- -- -- --

10.1 2.3 180 7*

2------ --

12 2.8 180 9.2* * Heatsink required for operation above 5 amps. Use DC3N-HS-00 for chassis drives and DC3N-HS-01 for NEMA 1 drives.

AC Line Voltage 115 VAC or 230 VAC ±10%, 50/60 Hz, single phase Maximum Allowable Symmetrical AC Line Current 5000 Amps Maximum AC Line Distribution kVA

115 VAC Input 25 kVA 230 VAC Input 50 kVA

Motor Armature Voltage

115 VAC Input 0–90 VDC 230 VACInput 0–180 VDC

Adjustments and Application Data

Form Factor 1.37 at base speed Service Factor 1 Maximum Current Load 150% for 1 minute Speed Regulation 1% with 95% load change

Adjustments and Application Data (cont.)

Specifications

Speed Range 60:1 Accel. Time Range

0–90 VDC Armature Voltage 0.5–17 seconds 0–180 VDC Armature Voltage 0.5–17 seconds

Decel. Time Range

0-90 VDC Armature Voltage 0.5–17 seconds

0–180 VDC Armature Voltage 0.5–17 seconds Current Limit Overload Range 150% Analog Input Voltage Range (must be isolated; S1 to S2)

for 0–90 VDC Armature Voltage 0–1.4 VDC

for 0–180 VDC Armature Voltage 0–2.8 VDC Torque 150% of rated current Input Impedance (S1 to S2) 100K ohms Speed adjust potentiometer rating 10k ohm, 5W (5k ohms acceptable) IR Drop Compensation (% of rated armature voltage) 0% to 15%

Service Conditions

Elevation 3300 ft (1000 m) max without derating** Vibration 0.5G max (0–50 Hz)

0.1G max (>50 Hz)

Ambient Temperature Range

Enclosed drive 10°C–40°C

Chassis drive 10°C–55°C Non-condensing Relative Humidity 0% to 95% ** Derate the current by 1% for every 300 ft (90m) above 3300 ft. (1000m), up to 10,000 ft (3000m)

Safety Certification

UL Listed Component

cUL Listed Component

CE Certificate of Compliance

Dimensions

Figure 1. DC3N-12D-00-010-AN Dimensions

ALL DIMENSIONS IN INCHES [MILLIMETERS]

Dimensions

TWO 0.88 [22] CONDUIT HOLES

Figure 2. DC3N-12D-01-010-AN Dimensions

ALL DIMENSIONS IN INCHES [MILLIMETERS]

Dimensions

FOUR MOUNTING SLOTS 0.19 INCHES [5 MILLIMETERS] WIDE

Figure 3. DC3N-12D-4X-010-AN Dimensions

ALL DIMENSIONS IN INCHES [MILLIMETERS]

TWO 0.88 [22] KNOCKOUTS

Dimensions

PART NO. DIM “A” DIM “B” DIM “C” DC3N-HS-00 4.40 [112] 3.00 [76] 0.7 [18] DC3N-HS-01 7.78 [198] 6.00 [152] 0.89 [23] Heat sinks sold separately.

Figure 4. Heat Sink Dimensions

ALL DIMENSIONS IN INCHES [MILLIMETERS]

Installation

Mounting

Mount drive with its board in either a horizontal or vertical plane. Six 0.19 inch

(5 mm) wide slots in the chassis accept #8 pan head screws. Fasten either the large

base or the narrow flange of the chassis to the subplate.

The chassis must be earth grounded. 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.

ATTENTION: Do not install, remove, or rewire this equipment with power applied. Doing so may cause fire or serious injury. Make sure you have read and understood the Attentions on page ii before attempting any of these procedures.

Chassis drive

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.

Wiring

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 of loss of life.

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.

• 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.

Installation

As a general rule, Reliance Electric recommends shielding of all conductors if:

• wire lengths exceed 4 inches and power and control wiring must be bundled

together*;

• 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 drive 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.

Isolation

*Reliance Electric considers this an unfavorable condition and does not recommend bundling of power and logic leads for any length.

ATTENTION: If it is not practical to shield power conductors, Reliance Electric recommends shielding all logic-level leads. If shielding is not practical, use twisted-pair control wiring to minimize induced electrical noise.

Shielding guidelines

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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