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.

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

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

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

Tables

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

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

Dimensions

Figure 1. DC3RD Dimensions

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.

+ 47 hidden pages