Yaskawa DSD 406 User Manual

DSD 406 / DSD 412 Technical Manual

MagneTek

3/21/96

All rights reserved. No part of this publication may be reproduced or used in any form by any means – graphic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval systems – without written permission of the publisher.

MicroTrac, DSD, PAC and MagneTek are trademarks of MagneTek, Inc.

The following table shows all pages that have been revised since the first issue of this manual.

Revision Affected Pages

Date

4/15/94 Initial 3/21/96 Overall revision

Revision

History

Documents List

The following publications provide additional information on the DSD 406 / 412 drives. Each is available from MagneTek.

● PCDU Guide TM 6305

Additional copies of this manual can also be ordered by specifying the DSD 406 / 412 Product Guide (TM 6107).

Warranty

3/21/96

Warranty

Standard products manufactured by MagneTek are warranted to be free from defects in workmanship and material for a period of one year from date of shipment and any products which are defective in workmanship or material will be repaired or replaced, at MagneTek's option, at no charge to the Buyer. Final determination as to whether a product is actually defective rests with MagneTek. The obligation of MagneTek hereunder shall be limited solely to repair or replace, at MagneTek's discretion, products that fall within the foregoing limitations, and shall be conditioned upon receipt by MagneTek of written notice of any alleged defects or deficiency promptly after discovery and within the warranty period, and in the case of components or units purchased by MagneTek, the obligations of MagneTek shall not exceed the settlement that MagneTek is able to obtain from the supplier thereof. No products shall be returned to MagneTek without its prior consent. Products which MagneTek consents to have returned shall be shipped prepaid f.o.b. MagneTek's factory . MagneTek cannot assume responsibility or accept invoices for unauthorized repairs to its components, even though defective. The life of the products of MagneTek depends, to a large extent, upon the usage thereof, and MAGNETEK MAKES NO WARRANTY AS TO FITNESS OF ITS PRODUCTS FOR THE SPECIFIC APPLICATIONS BY THE BUYER NOR AS TO PERIOD OF SERVICE UNLESS MAGNETEK SPECIFICALLY AGREES OTHERWISE IN WRITING AFTER THE PROPOSED USAGE HAS BEEN MADE KNOWN TO IT.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE AND BUYER HEREBY WAIVES ANY AND ALL CLAIMS THEREFORE.

IN NO EVENT SHALL MAGNETEK BE LIABLE FOR LOSS OF PROFIT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL DAMAGES WHETHER ARISING OUT OF WARRANTY, BREACH OF CONTRACT OR TOR T.

Limitation

of Liability

Manual Contents

3/21/96

Table of

Contents

Page

Introduction ........................................................................................................ 1

How To Use This Manual ............................................................................. 1

Controls and Indicators ................................................................................. 1

Safety Statements .......................................................................................... 2

How To Contact MagneTek .......................................................................... 2

DSD Drive Description ................................................................................. 3

System Considerations .................................................................................. 5

Installation and Start-Up .................................................................................. 9

Pre-Installation Considerations ..................................................................... 9

Physical Installation ...................................................................................... 9

Electrical Hook-Up ..................................................................................... 14

Use of An Analog Tachometer ................................................................... 20

Pre-Power Check ......................................................................................... 20

Drive Start-Up ............................................................................................. 21

Operation .......................................................................................................... 23

Controls and Indicators ............................................................................... 23

Start-Up Operation ...................................................................................... 25

General Operation........................................................................................ 26

Parameter Functions .................................................................................... 28

Monitor Functions ....................................................................................... 30

Upload/Download of Program/Parameters ................................................. 31

Upload/Download Introduction and Definitions......................................... 31

General Upload/Download Procedures....................................................... 33

Error Handling/Reporting ........................................................................... 45

Non-Volatile “Ram”-Access ....................................................................... 51

Load Defaults Function ............................................................................... 53

Self-Tune (PCU Parameter Measurement) ................................................. 54

Maintenance ..................................................................................................... 57

Preventive Maintenance .............................................................................. 57

Power Conversion Unit Diagnostics............................................................ 58

Troubleshooting Guide................................................................................. 61

Replacing Fuse(s)......................................................................................... 77

Replacing DSD Drive Control PCB............................................................ 79

Replacing the Fan......................................................................................... 81

Replacing the Power Supply........................................................................ 85

Replacing the DSD Armature Interface PCB.............................................. 87

Spare Parts List ............................................................................................... 89

Glossary ............................................................................................................ 95

Index .............................................................................................................. 104

List of Tables

Table

Number Title Page

1 Drive Ratings and Specifications.................................................... 5

2 # Function Code Descriptions........................................................ 27

3 Troubleshooting Guide .................................................................. 61

4 Connectors on Drive Control PCB................................................. 79

5 230 Volt Drives Spare Parts............................................................ 89

6 460 Volt Drives Spare Parts ........................................................... 91

7 Burden Resistor .............................................................................. 93

8 Power Range Resistor..................................................................... 94

Manual Contents

iii

List of Illustrations

3/21/96

List of

Illustrations

Figure Number Title Page

1 Typical MicroTrac DSD System Diagram..................................... 7

2 Dimensions and Mounting Holes

DSD 406/412 1-60 Hp Versions..................................................... 10

3 Dimensions and Mounting Holes

DSD 406/412 75-125 Hp Versions................................................. 11

3.1 Dimensions and Mounting Holes

DSD 412 150-200 Hp Versions...................................................... 13

4 Shield Sheath Termination ............................................................ 16

5 Basic Connections for DSD Power Cube –

Ratings up to 206 Amps................................................................. 17

6 Connections to TB3 and TB1 DSD Power Cube –

Ratings up to 206 Amps................................................................. 18

7 Grounding of Multiple Units.......................................................... 19

8 Operator Controls and Indicators................................................... 23

9 DSD 406/412 to IBM PC Compatible Comp. Inter. Diagram...... 31

10 DSD Drive Fuse Replacement....................................................... 76

11 DSD Drive Control PCB................................................................ 78

12 Replacing DSD Fan........................................................................ 66

13 DSD Power Supply Replacement.................................................. 84

14 DSD Armature Interface PCB Replacement ................................. 86

Introduction

How To Use This Manual

3/21/96

MagneTek has made this product guide an easy to use reference. To help you use this manual, we have provided the following guides:

● The top of each page has an identification of the section. For example, notice

that at the top of this page appears. This identifies the page as part of Section 1, Introduction. There are four sections in this

manual: Introduction, Installation and Start-Up, Operation and Maintenance.

● Each section is organized into one or more major subject headings. These are

the main topics covered in that section. You will recognize major subject headings by their distinctive appearances. The next line illustrates an example:

This is an example of a major subject heading from Section 3. Each major subject heading may have one or more minor topics that are

covered. The next line illustrates an example: This is a minor topic covered under “Controls and Indicators.” Each minor topic may have one or more descriptive headings. These identify

items covered within the minor topic. The next line illustrates an example: This is a descriptive heading covered under “Status LEDs.” At the bottom of each page is the name of the first major subject heading

covered on that page. The page number and revision date are also included. For example, at the bottom of this page, the information indicates that “How to Use This Manual” is the first major subject heading. The revision date indicates the last date the page was changed in any way .

Using the information on the top of the page to find the section, the bottom of the page to find the major subject heading and the left margin to find the minor topics and descriptive headings, you can easily page through the manual to find the information you need.

A table of contents and index are also included. The Table of Contents can be used to locate sections and major topics. The Index is helpful in locating specific terms or topics. A glossary is provided to define terms which may be unfamiliar.

How To Use

This Manual

Controls and

Indicators

Status LEDs

Ready

Introduction

Safety Statements

3/21/96

Safety

Statements

How To Contact

MagneTek

In addition to notes, the following types of precautionary statements appear in this manual.

IMPORTANT

A statement of conditions which should be observed during drive setup or operation to ensure dependable service.

CAUTION

A statement of conditions which must be observed to prevent undesired equipment faults or degraded drive system performance.

WARNING

A statement of conditions which MUST BE OBSERVED to prevent personal injury or serious equipment damage.

For additional information, contact any MagneTek Representative, or Authorized Distributor, or contact the DSD Technical Support Staff at:

MagneTek, Inc. 16555 West Ryerson Road New Berlin, WI 53151

(800) 541-0939 (414) 782-0200

FAX: (414) 782-1283

Introduction

DSD Drive Description

3/21/96

DSD Drive

Description

Regeneration

Capability

Flexibility

Control

Accuracy

The MicroTrac®DSD is a complete digital system drive which provides individual drive and system control in one compact package. This manual describes two basic configurations, the DSD 406 (6SCR) Nonregenerative and the DSD 412 (12SCR) Regenerative. All descriptions pertain to both configurations unless specifically noted.

The nature of an electric motor is such that, if more torque is applied to the motor by the load than is applied to the load by the motor, the motor will act as an electrical generator, producing an electrical current. This phenomenon, called regeneration, occurs anytime the speed of the motor is above the reference (or preset) speed, sometimes referred to as an “overhauling load” condition. A regenerative drive, such as the DSD 412, has the capability to feed the electrical power generated by the motor back into the supply mains. Also referred to as four-quadrant operation, it is this capability which requires that the DSD 412 contain a total of 12 SCRs, rather than the six included in the two-quadrant, Nonregenerative DSD 406.

The drive uses two microprocessors, one for the Power Conversion Unit circuitry , one for the Drive Control Unit circuitry, and is totally software configurable to the application through a high level language. This provides complete flexibility without having to make hardware adjustments. Interface to other equipment is provided with Local Input/Output (I/O) or a high speed Local Area Network. Use of the MicroTrac Local Area Network (LAN) means that a single coaxial cable eliminates multiple conductor cables and provides high noise immunity .

Extensive diagnostics and setup capability are provided through two Control/Display Units. The Standard Control/Display Unit (SCDU) is mounted on the Drive Control PCB and consists of a 4-1/2 digit numeric LED display , four push buttons and LEDs. The SCDU can be used for all setup functions and many diagnostics. The Portable Control/Display Unit (PCDU) is an optional hand-held device that can be plugged into any DSD drive and used for all the same functions as the SCDU plus some advanced diagnostics. The PCDU has two lines of sixteen alphanumeric characters and a thirty-key keypad.

The distributed control architecture of the DSD systems means that each drive performs its own regulation calculations synchronized to a common high accuracy crystal master. Thus even minute crystal drift will not affect multiple drive tracking. This allows a DSD system to maintain the drift between sections at 0.00% steady state. The fully digital nature of the regulation means that an individual drive can maintain a 0.00% average difference between set and actual speed from no-load to full-load when using digital tachometer speed feedback. Digital setup and performance assure exact process line and finished product duplication shift to shift and month to month.

Introduction

DSD Drive Description

3/21/96

Useability

Characteristics

Speeds, tensions, ratios, draws, limits, ranges, alarms, and other control parameters can be set as percentages or exact numerical values. Parameters are entered and displayed in common understandable units. The drive can be completely setup prior to actual running and changes can be made during operation. Keypad entry of changed parameters, protected memory , and factory default values allow the operator to modify data with minimum risk to the process.

The DSD is available for general use as a complete panel mounted enclosed drive (NEMA 1 or NEMA 12).

Authorized system integrators can also purchase the drive as a power cube. The power cube is designed for mounting in a cabinet; space allowances for air circulation, additional components, outgoing terminals, and wire bends must be provided.

The enclosed drive consists of the DSD power cube mounted on a panel with a skirted NEMA 1 or NEMA 12 enclosure, with added fused control transformer for 115V supply, armature loop contactor, and field wiring terminals. An input circuit breaker with through-the-door operator is available as an option.

The DSD drive is designed to be connected to a three wire ungrounded power system, or a four wire grounded or ungrounded power system.

All DSD drives are programmed using MagneTek's PAC language. The drive programming consists of two portions; the standard control programs shared by all DSD drives and the application specific programming which defines how the drive operates in the particular application. The latter portion of DSD drive programs are developed based on the PAC language, wherein different drive functions are represented by interconnected graphical symbols, called PAC blocks, much like an electronic schematic. This provides the ability to quickly modify programs, along with an assurance of program repeatability and stability .

PAC Language

Programming

Ratings Protective Features

● 3.3 - 206 Amps

● 3 Phase, 48-62 Hz

● 1.0 Service Factor

● 150% full load current for one

minute

● 200% full load current for 10

seconds

Basic Drive Specifications

● Full-wave six-pulse SCR control

● Regulation (of set speed) to

0.00% with digital tachometer speed feedback

● Current regulated shunt field

● Capable of constant HP

operation (requires tachometer)

● Self-adapting to incoming line

power of 230 or 460 VAC.

Service Conditions

● Line voltage 230 or 460 Vac, 3

phase, ±10% of nominal setting

● 115 volt, 1 phase control power

from separate source

● Frequency 48-62 Hz

● Incoming line impedance range

2%-10% of rated

● Operating Temperature 0-45° C

(55° C max at DSD chassis)

● Altitude to 3300 feet above sea

level

● Relative Humidity 95%

(noncondensing)

Introduction

System Considerations

3/21/96

System

Considerations

In order to operate in a system application, the DSD drive may be used with other MagneTek devices with which it will communicate by means of the MicroTrac Local Area Network (LAN). Refer to Figure 1 for a typical DSD System.

Each of the following remote devices (board or assembly) is described in detail in a separate User Reference Sheet.

● Remote Display Controller LAN Node PCB (RDC) – This board provides

a means for the DSD system to have system operating parameters displayed

● Programmed memory protection

● Self-protected control power

supply

● Fast phase-back of current

before loop contactor opens

● Contact interlock for E-Stop

● I

t motor overload protection

● AC line current limiting fuses

● DC bus fuse (DSD 412 only)

● Instantaneous over-current

protection

● Phase loss protection

● Input line monitoring

● Phase sequence insensitive

● dv/dt protection (snubbers)

● 1400 Peak Reverse Voltage

thyristors

● Field current economizer and

loss protection

● Tachometer monitoring and loss

protection

● Heat sink thermostat

● Automatic test of power circuit

upon power-up

● Control power supply loss

detection

● Isolated I/O and grounded

electronics

Table 1. Drive Ratings and Specifications

Introduction

3/21/96

System Considerations

at locations remote from the DSD drive. The RDC communicates with the drive through the LAN. A single RDC can support up to 31 Remote Display Units (RDUs). By means of a Portable Control/Display Unit (PCDU), the RDC allows the selected display for each RDU to be changed at anytime.

● Remote Display Unit (RDU) – Designed for mounting in a panel cutout, the

RDU provides a two-line LED display (16 character alphanumeric, and 5-1/2 digit numeric). It constitutes a terminal with the information on its display transmitted to it by a Remote Display Controller LAN Node PCB (RDC).

● Remote Keyboard Assembly – Designed for mounting on a panel with or

near a Remote Display Unit (RDU), the Remote Keyboard allows initiation of RDU display changes without the need for a Portable Control/Display Unit (PCDU) plugged into the Remote Display Controller LAN Node PCB (RDC).

● Remote I/O [Input/Output] Controller LAN Node PCB (RIO) – This

board provides a means for the DSD system to have inputs or outputs at locations remote from the DSD drive. The RIO communicates with the drive through the LAN. A single RIO can support up to 6 Remote I/O boards, using any combination of the following three available types.

● Remote Logic I/O PCB (LOGIO) – This board provides isolated and non

isolated remote logic signal input/output capability for the DSD system. It is connected to a Remote I/O Controller LAN Node PCB (RIO) for communication with the DSD drive.

● Remote Analog I/O PCB (ANIO) – This board provides isolated and non

isolated remote analog signal input/output capability for the DSD system. It is connected to a Remote I/O Controller LAN Node PCB (RIO) for communication with the DSD drive.

● Remote Thumbwheel Switch I/O PCB (TWIO) – This board provides

remote thumbwheel switch input/output capability for the DSD system. It can support up to 9 Thumbwheel Switch Assemblies. This board is connected to a Remote I/O Controller LAN Node PCB (RIO) for communication with the DSD drive.

● Remote Programmable Logic Controller (PLC) Interface – Available for

PLCs from many major manufacturers. It allows bi-directional communication via the MicroTrac LAN between DSD drives and the PLC. Both logic and numeric data can be transferred.

● Remote Power Supply – The Remote Power Supply produces control level

voltages for use by a Remote LAN Node PCB or a Remote Display Unit.

● Remote Serial Communication Controller LAN Node PCB (RSC) – This

board provides a means for the DSD system to have input from or output to other equipment that uses RS-232 serial communication. The RSC communicates with the DSD drive through the LAN.

Introduction

3/21/96

System Considerations

Figure 1. Typical MicroTrac DSD System Diagram

MicroTrac

Drive

DRIVE

CONTROL

UNIT

93 Ohm Terminator

INPUT/OUTPUT

REMOTE

CONTROLLER

PCB (RIO)

MicroTrac

Drive

DRIVE

CONTROL

LOCAL

I/O

PROGRAMMABLE

LOGIC

CONTROLLER (PLC)

UNIT

REMOTE

PLC

INTERFACE

LOCAL

I/O

RG 62/U Coaxial Cable

2.5 million bits/second

REMOTE

COMMUNICATIONS

CONTROLLER

PCB (RSC)

MicroTrac

CONTROL

RS-232

Drive

DRIVE

UNIT

LOCAL

I/O

REMOTE DISPLAY

CONTROLLER

PCB (RDC)

RS-485

PCDU

DISPLAY #1

8 ISOLATED LOGIC

REMOTE

LOGIC

INPUT/OUTPUT

PCB

(LOGIO)

REMOTE ANALOG

INPUT/OUTPUT

PCB

(ANIO)

REMOTE

THUMBWHEEL

INPUT/OUTPUT

PCB

(TWIO)

UP TO 6 REMOTE INPUT/OUTPUT PCBS

I/O MODULES 7 NON-ISOLATED

LOGIC OUTPUTS 16 NON-ISOLATED

LOGIC INPUTS

2 NON-ISOLATED ANALOG OUTPUTS

4 ISOLATED ANALOG I/O MODULES

4 NON-ISOLATED ANALOG OUTPUTS

4 NON-ISOLATED ANALOG INPUTS

PERSONAL

COMPUTER

UP TO 9 BANKS OF

6 DIGITS

+188888

8 8 8 8 8 8

+188888

THUMB

WHEELS

UP TO 31 REMOTE

DISPLAY UNITS

REMOTE DISPLAY

UNIT (RDU)

DISPLAY #2

MESSAGE

DISPLAY #3

DISPLAY #4

KEYBOARD

123DC 456DN 7

•

KEYBOARD

SELECT

ENABLE

LA-8

Installation and Start-Up

3/21/96

Pre-Installation Considerations

Pre-Installation

Considerations

Receipt of

Shipment

Unpacking

Re-Packing

Physical

Installation

The “Installation and Start-Up” section describes and illustrates the following:

● How to select the site to install your DSD drive.

● How to mount your DSD drive.

● How to connect your DSD drive to incoming power and the motor .

● How to start-up the system after it is installed.

The DSD drive is air cooled. The lowest HP rated units are cooled by convection; all other units are equipped with a fan to ensure adequate air flow . Select a site for installing the drive which is clean and well ventilated. Maintenance will be minimized if the drive is located in a clean atmosphere. The standard drive is designed for vertical mounting.

All equipment is fully tested at the factory . Any damage or shortages evident when the equipment is received must be reported immediately to the commercial carrier who transported the equipment. Assistance, if required, is available from your MagneTek representative. Always refer to the order number, equipment description, and serial number when contacting MagneTek.

For long periods of storage, equipment should be covered to prevent corrosion and should be placed in a clean, dry location. If possible, equipment should be stored in its original crating. Periodic inspection should be made to ensure that the equipment is dry and that no condensation has accumulated. The equipment warranty does not cover damage due to improper storage.

Remove the protective shipping material from around the equipment. Remove all packing material. Unbolt the equipment from its crate. Inspect for loose wiring. Make sure that all contact wedges and other shipping devices have been removed.

The drive should be bolted in a crate which provides at least 2 inches clearance. The drive should then be wrapped in polyethylene and covered with wax impregnated double walled # 350 corrugation and crated. Assistance, if required, is available from your MagneTek representative.

Attach the drive to a cabinet panel or other vertical structure using the mounting holes provided at the back of the drive (refer to Figure 2, 3 or 3.1 for dimensions and mounting hole locations). Allow six inches top and bottom and two inches at sides for free air circulation. For either style, hinged door swing-out clearance is the same as the width dimension. Ensure that the unit is level.

Storage

CAUTION

The DSD Drive Control PCB has electrostatic sensitive components. You must follow Electrostatic Discharge (ESD) procedures to protect the components.

4/15/94

Installation and Start-Up

Physical Installation

Figure 2. Dimensions and Mounting Holes

DSD 406/412

1-60 Hp Versions

MIN. DOOR SWING CLEARANCE

2.00

(APPROX. 6.75" ABOVE MTG. SURFACE)

9.75

0.50

0.31

12.25

11.25

ARM. NEG.

GND.

NEG GND L1 L2 L3 POS

ARM. POS.

0.31

FAN (WHEN SUPPLIED)

AIR FLOW

TB3

MOTOR FIELD CONNECTIONS

8 7 6 5 4 3 2 1

TB3

8 7 6 5 4 3 2 1

17.12

19.87

TB1

TB4

2.44

TB1

TB4

F2(–)

FAN (WHEN SUPPLIED)

11.25

3" MINIMUM CLEARANCE REQUIRED

0.50

LA-4

Installation and Start-Up

Physical Installation

3/21/96

Figure 3. Dimensions and Mounting Holes

DSD 406/412

75 - 125 Hp Versions

0.31

GND

TB3

MIN. DOOR SWING

WITH MATING DB9

CONNECTOR IN J1

8 7 6 5 4 3 2 1

21.06

GND

2.69

0.38

0.94

18.06

F1 F2 F3 F4

12.00

11.25

ARM (–) L1 L2 L3

GND

TB3

8 7 6 5 4 3 2 1

11.00

13.06

0.44

ARM (+)

FAN

AIR FLOW

13.88

TB1

TB4

FAN

MOTOR FIELD

CONNECTIONS

0.31

0.38

4.00

ALLOW APPROX. 4" BELOW FAN FOR SERVICING OF FAN, AND UNRESTRICTED AIR INTAKE.

AC1

0.38

1.25 LA-4A

Installation and Start-Up

Physical Installation

3/21/96

Installation and Start-Up

Physical Installation

3/21/96

Figure 3.1. Dimensions and Mounting Holes

DSD 412

150-200 Hp Versions

4.00 MINIMUM CLEARANCE

REQUIRED

AIR FLOW

1.94

2.13

FAN

3.50

1.69

23.49

19.50

0.50

A4 TB3

17.09

10.75

0.505

0.83

12.50 MIN.

WIRE BEND

ALLOWANCE

1.94

0.58

2.38 MIN.

DOOR SWING

0.438

12.93

GND

ARM (–)

GND

UNPLUG TB3 FROM HEADER WHILE INSTALLING WIRES.

LA-100

TB1

8 7 6 5 4 3 2 1

(TERMINAL BLOCK QTY PER DRIVE SPECIFICATION)

L1 F1 L2 F2 L3 F3

ARM(+)

MOTOR

FIELD

CONNECTIONS

GND

Installation and Start-Up

Electrical Hook-Up

3/21/96

Ensure that wire size and disconnect devices conform to the installation contractor’s drawings and to all applicable codes.

● Although the three phase input power line is fuse protected internal to the

drive, it is recommended to provide branch circuit protection by means of a circuit breaker in accordance with the National Electrical Code, local codes and with a rating of not less than 5,000 rms Symmetrical Amperes and 600 Volts for 2 to 25 Hp rated drives or 10,000 rms Symmetrical Amperes and 600 volts for 30 to 60 Hp rated drives.

● Electronic overload protection is provided as part of the standard DSD

product. It si electronically timed and will shut down the drive along a time/output current curve which provides shutdown at 60 seconds at 150% or 10 seconds at 200% of rated output current. An overload relay may be added external to the drive in accordance with the National Electrical Code and local codes for additional protection.

● Main Circuit Input/Output Wire Sizing:

L1-3

: Using 600V vinyl-sheathed wire per the following table.

Electrical

Hook-Up

Recommended Wire Gauge (Copper Only)

Torque

Drive Hp

60°C 75°C

(in-lbs)

214 1435 314 1435 514 1435

7 8 10 40 - 35 * 10 8 10 40 - 35 * 15 6 8 45 - 40 * 20 6 8 45 - 40 * 25 4 4 45 30 4 4 45 40 1 150 50 1 150 60 1/0 180 75 3/0 250

100 3/0 250 125 250 MCM 325 150 600 MCM 375 200 600 MCM 375

* Torque per wire gauge.

Installation and Start-Up

Electrical Hook-Up

3/21/96

ARM (–): Using 600V vinyl-sheathed wire per the following table.

ARM (+): Using 600V vinyl-sheathed wire per the following table.

● Field Current Wire Sizing: The recommended conductor for field current

ratings between 10.0 Ampere and 16.0 Ampere is 12 AWG. The recommended conductor for field current ratings below 10.0 AMpere is 14 AWG. use 600 V vinyl-sheathed 105°C wire or equivalent. The recommended torques on the field lugs for 14-10 AWG is 25 in-lbs.

Recommended Wire Gauge (Copper Only)

Torque

Drive Hp

60°C 75°C 90°C

(in-lbs)

214 14 35 314 14 35 514 14 35

7 6 8 45 - 40 * 10 6 8 45 - 40 * 15 4 4 45 20 4 4 45 25 3 50 30 3 50 40 1/0 50 50 1/0 50 60 3/0 50 75 250 MCM 325

100 250 MCM 325 125 350 MCM 325 150 500 MCM 375 200 750 MCM 375

* Torque per wire gauge.

Recommended Wire Gauge (Copper Only)

Torque

Drive Hp

60°C 75°C 90°C

(in-lbs)

214 14 35

314 14 35

514 14 35

7 6 8 45 - 40 * 10 6 8 45 - 40 * 15 4 4 45 20 4 4 45 25 3 50 30 3 50 40 1/0 180 50 1/0 180 60 3/0 250 75 250 MCM 325

100 250 MCM 325 125 350 MCM 325 150 500 MCM 375 200 700 MCM 375

* Torque per wire gauge.

Installation and Start-Up

Electrical Hook-Up

3/21/96

● If the DSD drive is being used in a system application, use a BNC "T"

connector to connect LAN (Local Area Network) coaxial cable to J3 on the DSD Drive Control PCB.

● The coaxial cable must ultimately be terminated at both ends by a 93 ohm

termination resistor. (MagneTek part number 05P00034-0586)

Figure 4. Shield Sheath Termination

● GND: Recommended conductor size, 2 AWG 600 V vinyl-sheathed for

COPPER wire, 1/0 AWG 600 V vinyl-sheathed for ALUMINUM OR COPPER CLAD ALUMINUM wire. Recommended torque on the GND lug is 50 in-lbs.

● Control Wire Sizing:

TB1

: Recommended conductor size, 22-18 AWG 300 V 105°C

vinyl-sheathed wire. Recommended torque is 3.4 in-lbs. TB3

: Recommended conductor size, < 12 AWG 300 V 105°C

vinyl-sheathed wire. Recommended torque is 5 in-lbs. TB1

: Recommended conductor size, 14 AWG 300 V 105°C

vinyl-sheathed wire. Recommended torque is 3.4 in-lbs.

Observe the following when wiring:

● Separate the leads used for speed reference, feedback, and other low level

signals from those used for the motor armature, field and AC power. Do not run these two groups in the same conduit or wire trough.

● Provide shielded and twisted leads as indicated on the Schematic and/or

Interconnection Diagrams. Connect all shields on shielded wire to system common (not ground) on one end only . Twisted shielded pair wire should be used for long runs. (Refer to Figure 4 for proper cable preparation.)

SHIELD SHEATH

OUTER JACKET

TO DSD

406/412

SIGNAL

TERMINALS

TO SHIELD

SHEATH

TERMINAL

CRIMP

CONNECTION

WRAP BOTH ENDS

OF SHEATH WITH

INSULATING TAPE

DO NOT

CONNECT

EXTERNAL

CIRCUIT

LA-9

Installation and Start-Up

Electrical Hook-Up

3/21/96

For a NEMA 1 or open panel mounted drive, refer to the equipment Interconnection Diagram for detailed wiring information.

If only a power cube was ordered, the following connections need to be made (refer to Figures 5 and 6 for location of terminating points on drives rated up to 330 Amps):

❏ On units rated at 206A armature current (206A Iarm) or less, connect the

three phases of the line from the load side of the isolation transformer or input circuit breaker to fuses F1, F2, and F3 (marked L1, L2, and L3). (Refer to Figure 5.) Phase rotation is not important.

Figure 5. Basic Connections for DSD Power Cube –

Ratings up to 206 Amps

WARNING

The external COAST STOP circuit shown on the Schematic Diagram MUST BE WIRED to the drive as a safety consideration in case of microprocessor failure.

3 PHASE 230-460 VAC INPUT POWER

FROM CIRCUIT BREAKER OR

ISOLATION TRANSFORMER.

PHASE ROTATION IS NOT IMPORTANT

GND

NEG

L1 L2 L3 POS

F2F1 F3

(DSD

412

ONLY)

DBR

MTR

ARM.

CONNECT TO

ONLY ONE TERMINAL

PER

APPLICATION

CONNECT HERE

FOR DSD412

ONLY

ARMATURE INTERFACE PCB (A2)

(MOUNTED ON SCR BUS BARS)

TB5 (PART OF E5

SCR BUS BAR)

FIELD INTERFACE PCB (A3)

L2A

L1A

F1(+)

TB4

F1 F2

(+) (–)

MOTOR FIELD

FRONT VIEW OF POWER CUBE INTERIOR WITH SWING DOOR OPEN

F2(-)

AC AC

2 1

–

(LOCATED UNDER FIELD INTERFACE

CONNECT

HERE FOR

DSD406

ONLY

FIELD

CONTROL

MODULE

PCB)

LA-2

Installation and Start-Up

Electrical Hook-Up

3/21/96

Figure 6. Connections to TB3 and TB1 DSD Power Cube –

Ratings up to 206 Amps

❏ On units rated at 206A or less, connect the motor field lead F1 (+) to

A3TB4(F1+), and motor field lead F2 (-) to Field Control Module (F2–). (Refer to Figure 5.)

❏ On units rated at 206A Iarm or less, connect armature voltage sensing lead

(A1) to Armature Interface PCB(A2) TB5-2(+), and connect armature voltage sensing lead (A2) to Armature Interface PCB TB5-1(–). (Refer to Figure 5.)

❏ On units rated 206A Iarm or less, connect the motor armature A1 lead

through contactor N.O. contact to fuse F4 (in a DSD 412) or terminal E5 (in a DSD 406). (Refer to Figure 5.)

❏ On units rated at 206A Iarm or less, connect the motor armature A2 lead

through armature contactor N.O. contact to terminal ‘NEG’. (Refer to Figure 5.)

115 VAC LO (NEUTRAL)

MOTOR THERMOSTAT

MOTOR LOOP CONTACTOR

COAST STOP

115 VAC HI (HOT)

DSD POWER SUPPLY PCB (A4)

TB3

8 7 6 5 4 3 2 1

DSD DRIVE CONTROL PCB (A1)

TBI

FRONT VIEW OF SWING OUT DOOR

4843

K1 AUX

42 84

LA-1

❏ Connect 115 VAC control power to the DSD Power Supply PCB(A4), TB3-

1 (Hot) and (A4)TB3-7 (Neutral). This source must be rated at 250 VA or greater. (Refer to Figure 6.)

❏ Connect the armature (motor loop) contactor coil to DSD Power Supply

PCB, (A4)TB3-4 and (A4)TB3-5. (Refer to Figure 6.)

❏ An auxiliary 10ma, 24VDC, low power, normally open (N.O.) contact from

the armature (motor loop) contactor must be connected to DSD Drive Control PCB, (A1)TB1-48 and (A1)TB1-7, for the drive to operate. (Refer to Figure 6.)

❏ The Coast Stop push button (maintained, 10ma, 24VDC, low power), MUST

BE CONNECTED to the DSD Power Supply PCB, (A4)TB3-3 and (A4) TB3-6. (Refer to Figure 6.)

❏ Connect a grounding wire from the ground pole to the ground terminal

provided. The ground terminal is marked GND, and is located near the power input and output terminals.

❏ Where several units are used side by side, all units should be grounded

directly to the ground pole. However, it is permissible to connect all the ground terminals in series and ground only one unit to the ground pole (refer to Figure 7). DO NOT FORM A LOOP WITH THE GROUND WIRES.

Installation and Start-Up

Electrical Hook-Up

3/21/96

❏ If dynamic braking resistors (DBR) are to be used, connect across motor

armature in series with loop contactor N.C. contact. (See Figure 5.)

Figure 7. Grounding of Multiple Units

CORRECT CORRECT NOT

ACCEPTABLE

GROUND

POLE

GROUND

POLE

GROUND

POLE

LA-10

Installation and Start-Up

Using of An Analog Tachometer

3/21/96

❏ Inspect all equipment for signs of damage, loose connections, or other

Drive Start-Up

3/21/96

Drive Start-Up

❏ Ensure that all electrical connections are secure. ❏ Ensure that all transformers are connected for proper voltage according to

the drive system Schematic Diagram.

❏ Attach a DVM across the 115 VAC control power , at transformer T1

secondary terminals X1 and X2.

❏ Apply the three phase power and verify that the control power is between

103 VAC and 126 VAC as read on the DVM. Then press the RESET push button on the front of the power cube, and observe the “Drive power-up sequence” as described below .

NOTE: The "Drive Power-Up Sequence" is also described in the Operation section of this manual under “Start-Up Operation”. If using upload/download capabilities, please refer to DSD 406/412 Upload/Download procedure in the Operation section.

❏ The “Drive Power-Up Sequence” can be observed by monitoring the

Standard Control/Display Unit (SCDU) on the front of the power cube.

❶ First, all of the segments on the digital LED display and all of the LEDs

will light for about one second.

❷ Then the LEDs and display extinguish and the drive will perform

internal checks.

❸ If the drive passes the self-test, then the READY LED will light and the

SCDU will display 'P-UP' to indicate a proper power-up.

Displays other than those mentioned above may occur. If abnormal display conditions occur, the following actions maybe necessary to correct the situation:

● If no digits or LEDs ever light up, check for proper voltage between the 115

VAC control power lines, or for blown 115 VAC control power fuses, or for a defective control voltage power supply in the power cube.

● If horizontal segment(s) of the SCDU display are lit, then one or more

phases of the three phase power are missing. Check the three phase power fuses. See Section 3, Start-Up Operation, for more detailed information about this test.

Installation and Start-Up

Drive Start-Up

3/21/96

Parameter

Verification

● If the FAULT LED lights and a fault code appears on the SCDU, then refer

to the Fault/Error Codes List in Section 4, Maintenance, to see what caused the fault and to find the correct solution. A fault code is the letter 'F' followed by a number representing the fault. See Section 3, Operation, for more detailed information about fault reporting and clearing.

● If the SCDU displays 'Prot', then the initial checks found that the protected

non-volatile RAM (NVRAM) has not been initialized. Move the NVRAM PROTECTION switch to "OFF" in order to allow the CPU to initialize the NVRAM with preprogrammed default values. Notice that the NVRAM UNPROTECTED LED is now lit to indicate the NVRAM PROTECTION switch position. Next, press the RESET push button. The

drive will go through its power up sequence again; however, this time it will initialize the protected NVRAM. After the power up sequence has finished, return the NVRAM PROTECTION switch to "ON" in order to assure protection of this memory area. Notice that the NVRAM UNPROTECTED LED is now turned off.

❏ On drives with fans, verify that the fans are working. When the READY LED on the SCDU is lit, all the selectable parameter data

should be verified for the proper values as follows. See the PCDU Guide for information on verifying and entering parameter values on a PCDU:

❏ VERIFY OR CHANGE EACH PARAMETER VALUE for the particular

application and motor involved.

❏ PCU DIAGNOSTICS (function # 998) should now be performed to verify

armature and field circuitry .

❏ SELF-TUNE (PCU Parameter Measurement) (function # 997) should be

performed before the drive is “RUN”. This gives the drive various motor parameters essential for optimal operation. NVRAM protection must be off to store parameters.

❏ SELF-TUNE SELECT (Function # *) should be turned on for optimal

operation. (* Check the PAC diagram for correct function number.)

❏ STORE PARAMETERS, (function # 994) so that power can be removed and

reapplied without losing the entered parameters. Remember that NVRAM protection must be OFF to store parameters.

❏ Operate drive, using external control signal inputs shown on the system

schematic.

Operation

3/21/96

Controls and Indicators

Controls and

Indicators

Pressing the reset button causes the drive to clear faults, or in some cases to reset the drive, depending on the context.

To the right of the RESET button is a vertical strip of six light emitting diodes (LEDs):

All status LEDs are under the control of the application specific software. However, the following descriptions indicate typical uses for the LEDs. The PAC diagram for this drive must be consulted to determine the actual meaning for each LED.

Indicates that the drive is ready to operate. DC loop contactor is closed and drive is controlling motor speed. Drive is demanding armature current at or above the preset current limits.

RESET Button

Status LEDs

Ready

Run

Torque Limit

Figure 8. Operator Controls and Indicators

The “Operation” Section describes and illustrates the following:

● Operator’s controls and indicators.

● Steps you need to follow to start-up your DSD drive.

● Types of parameters that can be entered after start-up.

● Types of monitor functions available after start-up.

● Upload/Download of Programs or Parameters procedure.

● How to access error and fault lists and clear them.

● How to access non-volatile “RAM”.

● How to reload the default functions.

● Self-tuning feature.

The upper right corner of the power cube cover contains the operator controls and indicators of the SCDU. Figure 8 identifies these operator components. Although accessible with the cover in place, all of these components are part of the DSD Drive Control PCB.

RESET BUTTON

RUN (green)

READY (green)

SCDU

MEM UNPROT

DOWN

NV RAM PROTECTION

ENTER

E-STOP (red)

FAULT (red)

OVERLOAD (yellow)

TORQUE LIMIT (yellow)

DATA/FCTN

LA-3

DATA LED

DATA PENDING

Operation

Controls and Indicators

3/21/96

Standard

Control/Display

Unit (SCDU)

Non-Volatile

“RAM” Protection

Current exceeded safe levels for too long and drive was stopped to protect the motor.

Drive contactor safety interlock is detected as open. Drive will not run when this light is on.

Indicates that a declared drive fault exists. The Fault/Error Code List defines what conditions the drive will recognize as faults.

IMPORTANT

Clearing a Fault from the Fault List is NOT THE SAME as resetting the fault. Some faults are transient in nature and require no further action after clearing the fault from the Fault List. Others require some additional positive action to allow the drive to continue to run. See the Fault/Error Code List for further details.

The major part of the SCDU is a 4-1/2 digit numeric LED display . Each of its four full digits can display the values of 0 to 9 plus limited alphabetic characters. The so-called half digit can display only the value “1” and a plus or minus sign. Below the numeric LED, is a single indicator and four push buttons. The four push buttons (DATA/FCTN, ⇑[UP], ⇓ [DOWN], and ENTER) are used to

operate the SCDU. Next to the numeric displays of the SCDU is a red LED labeled MEM

UNPROT. This LED is lit when the “protected” portion of the non-volatile random access memory (NVRAM) can be written to. Protection of the NVRAM is determined by the switch labeled NVRAM PROTECTION. When this switch is in the "ON" position, the MEM UNPROT LED is off and the protected portion of the NVRAM can not be written to. This prevents setup parameters and other important constants from being accidentally erased or changed. When these parameters need to be changed the switch can be moved to the "OFF" position, removing the write protection and causing the MEM

UNPROT LED to be lit.

Fault

CAUTION

The NVRAM PROTECTION switch should be left in the "ON" position to protect the NVRAM during the critical power-up and power-down periods.

Overload

E-Stop

The optional Portable Control/Display Unit (PCDU) plugs into a telephone-style jack at the bottom left of the DSD Drive Control PCB (accessible through a cutout at the bottom left of the front cover). If your unit is equipped with this option, refer to the PCDU guide provided with the unit for operating procedures.

Portable

Control/Display

Unit Connection

Operation

Start-Up Operation

3/21/96

Start-Up

Operation

❏ When power is first applied to the drive, all of the segments on the 4-1/2

digit display will turn on briefly in order to show that all are functioning:

❏ After this lamp test is completed, an internal check is made to determine if

the NVRAM chips have ever been used before, or if the EPROMs are the same as before power-down. If not, the drive software will attempt to load the defaults into the NVRAM chips. The SCDU displays the word ‘Prot’ if the NVRAM PROTECTION switch is in the “ON” position; this prevents NVRAM updates:

If the display shows ‘Prot’, it is necessary to move the NVRAM PROTECTION switch to the "OFF" position and press the RESET button in order to load defaults into NVRAM and restart the drive. Then set the NVRAM PROTECTION switch back to "ON". This message will only happen when the drive is powered up for the very first time or if the software in the drive or the NVRAM chips are changed.

❏ After the LED lamp test has completed, the drive software will now perform

a fuse test on each of the three line fuses. If any power conversion fuse is open, the SCDU will indicate this on its display as follows:

1.8.8.8.8.

prot

DATA

RED

Operation

General Operation

3/21/96

If two fuses are blown, the SCDU display will be:

The drive will not operate unless all three line fuses are functional. If the SCDU indicates a bad fuse, power must be removed from the drive, the fuse replaced and power reapplied.

❏ After the drive has performed all three tests (lamp test, “RAM” test, and fuse

test), the SCDU displays one of two final messages. If there are any faults present at this time, the SCDU will display a Fault code. The display will be similar to:

where the leading ‘F’ indicates a fault and the 3 digits following the ‘F’ indicate the fault number. If however, there are no faults present, the SCDU displays the normal power-up message:

General

Operation

This ‘P-UP’ display will remain on the SCDU until a key is pressed or a fault occurs.

After the drive has powered up and the SCDU display is showing ‘P-UP’ or a fault number, it can be used to enter new parameters, monitor drive operation, and/or perform certain drive diagnostics. Every operation that the SCDU can perform is called a ‘function’. There may be up to 1000 functions defined.

The function codes between # 000 and # 999 are grouped as follows:

- -

DATA

RED

OFF

DATA

f 102

OFF

DATA

p-up

+ 84 hidden pages