Rockwell Automation DC3RD User Manual
DC3RD Digital Regenerative DC Drive
User Guide
1/4 to 2 HP, 115/230 VAC
Instruction Manual D2-3455
Important: Identifies information that is critical for successful
application and understanding of the product.
ATTENTION: Identifies information about practices or
circumstances that can lead to personal injury or death,
property damage, or economic loss.
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.
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:
Trademarks not belonging to Rockwell Automation are
property of their respective companies.
©1999 Rockwell International Corporation All rights reserved
i
ATTENTION: This drive is isolated from earth ground.
Circuit potentials are at 115VAC or 230VAC above earth
ground. Avoid direct contact with the printed circuit
board or with circuit elements to avoid the risk of serious
injury or fatality. Use a non-metallic screwdriver when
adjusting the calibration trimpots.
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: 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 5
Installation 6
Mounting . ............................................7
Wiring . . . ............................................8
Shielding guidelines .................................9
Heat sinking .........................................10
Line fusing ...........................................10
Cage-clamp terminals ..................................12
Connections ..........................................13
Field output ..........................................15
Limit switch connections (optional) ........................16
Remote pushbuttons (optional) ...........................16
Slide switches ........................................17
Mode select switches ..................................19
Operating modes . ...................................20
Operation 21
Before applying power .................................22
Startup .............................................22
Jogging the motor ...................................23
Limit switch operating modes ............................24
Mode 1 – Half cycle between forward and reverse limit switches 24
Mode 2 – Single cycle between forward and
reverse limit switches .............................25
Mode 3 – Continuous cycle between forward and
reverse limit switches .............................26
Mode 4 – Single cycle with one limit switch ................27
Contents
ii
Calibration 28
Power board trimpots ..................................29
MINSPD ..........................................29
MAXSPD .........................................29
FWDACC .........................................30
REVACC .........................................30
IRCOMP .........................................31
FWDTQ ..........................................32
REVTQ ...........................................33
DB 34
TACH (for use with tachogenerator feedback only) ...........36
Logic board trimpots ...................................38
FWDJOG .........................................38
REVJOG .........................................38
DWELL TIME . . ....................................39
Troubleshooting 41
Before applying power: .................................42
Block Diagram ........................................48
Prewired Connections ..................................49
Regenerative Drives 51
CE Compliance 53
AC Line Filters .......................................54
Armature Filters . . ....................................55
iiiContents
Figure 1. DC3RD Dimensions ...........................5
Figure 2. Cage-Clamp Terminal .........................12
Figure 3. Connections ................................14
Figure 4. Optional limit switch connections .................16
Figure 5. Optional remote pushbutton connections ...........16
Figure 6. Slide Switch Locations ........................18
Figure 7. Mode Select Switches .........................19
Figure 8. Recommended FWD TQ, REV TQ
and IR COMP Settings for DC3RD ...............40
Figure 9. Deadband Settings ...........................40
Figure 10. DC3RD Block Diagram ........................48
Figure 11. Prewired Connections to L1, L2 (115) and L2 (230) . . .49
Figure 12. Touch Panel, Logic Board and
Power Board Connections ......................50
Figure 13. Four Quadrant Operation ......................52
iv
Illustrations
Table 1. Recommended Line Fuse Sizes .................11
Table 2. Field Output Connections ......................15
Table 3. AC Line Filters ..............................54
Table 4. Armature Filters .............................55
v
Tables
vi
Max.
Armature HP Range HP Range
Current with 115 VAC with 230 VAC
Model (Amps DC) Applied Applied
DC3R-12D-4X-010-DN 10.0 1/4–1 1/2–2
AC Line Voltage 115/230 VAC, ±10%, 50/60 Hz, single phase
Maximum Allowable Symmetrical AC Line Current 5000 amps
Maximum Line Distribution kVA
115 VAC Input 25 kVA
230 VAC Input 50 kVA
Motor Armature Voltage
115 VAC Input 0–90 VDC
230 VAC Input 0–180 VDC
Form Factor 1.37 at base speed
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
Acceleration Time Range (with no load) 0.5–15 seconds
Deceleration Time Range (with no load) 0.5–15 seconds
Analog Input Voltage Range (isolated; RB1 to S2) –10 to +10 VDC
Input Impedance (RB1 to S2) 32K ohms
Specifications
1
Load Regulation
with Armature Feedback 1% of base speed or better
with Tachogenerator Feedback 0.1% of base speed
Dwell Time 0.1 – 1 second (0.1 second increments)
Environmental Conditions
Vibration 0.5G max. (0–50 Hz)
0.1G max. (>50 Hz)
Ambient Temperature Range 10°C–40°C
Weight 8.3 lb
Safety Certification UL Listed Component
cUL Listed Component
CE Approved Component
2 Specifications
Drive Rating
Motor HP Rated AC Input DC Armature DC Armature Field Field
Line Amps kVA Voltage Current Voltage Current
1/4 4.2 0.48 90 2.7 50 1
4.2 0.97 180 2.7 100 1
1/3 5.5 0.63 90 3.5 50 1
5.5 1.27 180 3.5 100 1
1/2 7.5 0.86 90 5 50 1
3.8 0.87 180 2.5 100 1
3.8 0.87 180 2.5 200 1
3/4 10.9 1.25 90 7.6 50 1
5.9 1.36 180 3.8 100 1
5.1 1.17 180 3.8 200 1
1 12.1 1.39 90 10 50 1
6.7 1.54 180 5 100 1
6.7 1.54 180 5 200 1
1 1/2 -- -- -- -- -- --
9.8 1.25 180 7 100 1
9.8 2.25 180 7 200 1
2 ---- -- -- ----
11.7 2.69 180 9.2 100 1
11.7 2.69 180 9.2 200 1
3Specifications
4
5
Dimensions
Figure 1. DC3RD Dimensions
6
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.
Mounting
NEMA 4X enclosed drives come with three 0.88 inch (22
mm) conduit knockout holes at the bottom of the case. 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. For access to the terminal strip, turn the slotted screw on
the front cover counterclockwise until it is free from the
case. The right side of the cover is hinged to the case.
Lift or pull the slotted screw to open the case.
3. Carefully remove the conduit knockouts by tapping them
into the case and twisting them off with pliers.
4. Install conduit hardware through the 0.88 inch (22 mm)
conduit holes. Connect external wiring to the terminal
block.
5. Grasp the slotted screw and tilt the front cover back into
place. Avoid pinching any wires between the front cover
and the case.
6. Turn the slotted screw clockwise until tight to secure the
front cover.
7. Set the POWER switch to the OFF position before
applying the AC line voltage.
7Installation
8 Installation
Wiring
ATTENTION: This drive is isolated from earth
ground. 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
9Installation
As a general rule, Reliance Electric recommends shielding
of all conductors if:
• wire lengths exceed 4 inches and power and logic leads
must be bundled together*; or
• radiated and/or conducted noise must be minimized due
to concerns about immunity or general compliance (CE,
FCC, etc.)
* Reliance Electric considers this an unfavorable condition and does
not recommend bundling 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 noise.
ATTENTION: Under no circumstances should power
and logic leads be bundled together. Induced voltage
can cause unpredictable behavior any electronic device,
including motor controls.
The DC3RD drive has line fuses mounted on fuse holders
501 and 502 (FU501 and FU502). When replacing the line
fuses, use fast acting fuses rated for 250 VAC or higher,
and at least 200% of the armature current. See Table 1 for
recommended line fuse sizes.
10 Installation
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.
Heat sinking
The DC3RD contains sufficient heat sinking in its basic
configuration. No additional heat sinking is necessary.
Line fusing
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.
11Installation
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 20
12 Installation
Cage-clamp terminals
DC3RD Series drive connections are made to cage-clamp
terminals. To insert a wire into a terminal, see Figure 2.
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.
Figure 2. Cage-Clamp Terminal
13Installation
ATTENTION: Do not connect this equipment with
power applied. Failure to heed this directive may result
in fire or serious injury.
Connections
Connect the power input leads and a DC motor to the
drive’s terminal board as shown in Figure 3, page 14.
Ensure that the motor voltage rating is consistent with the
drive’s output voltage.
DC3RD drives supply motor voltage from A1 and 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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