DC3R Regenerative DC Drive User Guide 1/4 to 2 HP, 115/230 VAC

DC3R Regenerative DC Drive
User Guide
1/4 to 2 HP, 115/230 VAC
Instruction Manual D2-3453
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:
m
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.
m
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.
Corcom is a trademark of CII Technologies.
Reliance s a trademark of Rockwell International Corporation.
©1999 Rockwell International Corporation.
iii
m
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.
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.
iv
Contents
Specifications
1
Dimensions
3
Installation
6
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Shielding guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Input isolation transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Mounting chassis drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Mounting enclosed drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Heat sinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Field output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Cage-clamp terminal block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Tachogenerator feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Chassis drive connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Enclosed drive connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Speed adjust potentiometer installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Speed adjust potentiometer connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Line Fusing for DC3R Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
+15 and –15 terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Voltage follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Operation
19
Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Selector switch settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Chassis drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Enclosed drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Starting and Stopping Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Line starting and line stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Automatic restart upon power restoration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Regenerative deceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Regenerative braking using the INHIBIT circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Coast to a stop using the INHIBIT circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Decelerate to minimum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Calibration
MAX SPD .
MIN SPD . .
IR COMP . .
REV TQ . . .
FWD TQ . . .
FWD ACC .
REV ACC .
DB (Range)
TACH . . . . .
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28
.29
.29
.30
.30
.30
.31
.31
.31
.32
Application Notes
34
Optional speed adjust potentiometer connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
FWD-REV switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
FWD-STOP-REV switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Independent adjustable speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Independent forward and reverse speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Independent Forward and Reverse Speeds with a Forward-Stop-Reverse Switch . . . . . . . . .38
v
Contents (cont.)
Troubleshooting
39
Prewired Connections for Enclosed Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Regenerative Drives
43
Exhibit “A”: Line Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
CE Compliance
44
vi
Illustrations
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
DC3R Chassis Drive Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
DC3R NEMA 4X Drive Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
DC3R Heat SInk Drive Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Cage-Clamp Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Chassis Drive Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Enclosed Drive Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Speed Adjust Potentiometer Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Voltage Follower Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Selector Switch Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Regenerative Deceleration Switch Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Inhibit Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
INHIBIT-RUN Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Run/Decelerate to Minimum Speed Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Calibration Trimpot Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Typical FWD TQ, REV TQ, and IR COMP Settings . . . . . . . . . . . . . . . . . . . . . . . . .33
Deadband Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Forward-Reverse Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Forward-Stop-Reverse Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Independent Adjustable Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Independent Forward and Reverse Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Independent Forward and Reverse Speeds with a Forward-Stop-Reverse Switch . .38
Prewired Connections to L1, L2(115) and L2(230) . . . . . . . . . . . . . . . . . . . . . . . . . .42
Prewired Speed Adjust Potentiometer Connections for Enclosed Drives . . . . . . . . .42
Four Quadrant Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
vii
Tables
Table 1. Field Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Table 2. Fuse Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Table 3. Corcom® Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
viii
1
Specifications
Model
Max.
Armature
Current
(Amps DC)
HP Range
with 115 VAC
Applied
HP Range
with 230 VAC
Applied
DC3R
10.0 †
1/4–1 †
1/2–2 †
† Maximum armature current and horsepower range apply when drive is attached to additional heat sink:
Reliance Electric part number DC3R-HS-00. Use heat sink when armature current is above 7 ADC. Heat
sinks are pre-mounted on DC3R enclosed drives.
AC Line Voltage
115/230 VAC, ±10%, 50/60 Hz, single phase
Maximum Allowable Symmetrical AC Line Current
5000 A
Maximum AC Line Distribution kVA
with 115 VAC Input
25 kVA
with 230 VAC Input
50 kVA
Armature Voltage (115 VAC Input)
0–90 VDC
Armature Voltage (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)
Field Voltage (230 VAC Input)
100 VDC (F1 to L1); 200 VDC (F1 to F2)
Max. Field Current
1 ADC
Maximum Speed Trimpot Adjustment Range (% of rated voltage)
0 - 90%
Minimum Speed Trimpot Adjustment Range (% of rated voltage)
0 - 25%
Forward Torque Maximum Adjustment (% of rated current)
200%
Reverse Torque Maximum Adjustment (% of rated current)
200%
Accel. Time Range (with no load)
0.5 – 6 seconds
Decel. Time Range (with no load)
0.5 – 6 seconds
Analog Input Voltage Range (isolated; S1 to S2)
-10 VDC to +10 VDC
IR Drop Compensation (% of rated armature voltage)
0 to 15%
Input Impedance (S0 to S2)
32K ohms
Maximum Load
150% for 1 minute
Service Factor
1
Speed Range
60:1
Speed Regulation (with 95% load change)
with Armature Feedback
1% of base speed or better
with Tachogenerator Feedback
0.1% of base speed
Environmental Conditions
Ambient Temp. Range (chassis drive)
10°C–55°C
Ambient Temp. Range (enclosed drive)
10°C–40°C
Vibration
0.5g max (0 – 50 Hz)
Elevation
3300 ft (1000m) max without derating*
0.1g max (above 50 Hz)
Atmosphere (non-condensing relative humidity)
0% to 95%
* Derate the current by 1% for every 300-ft. elevation change, up to 10,000 ft (3000m)
Safety Certification
UL Listed Component
cUL Listed Component
CE Approved Component
2
Specifications
Drive Rating
Motor HP Rated AC
Line Amps
1/4
4.2
4.2
1/3
5.5
5.5
1/2
7.5
3.8
3.8
3/4
10.9
5.9
5.1
1
12.1
6.7
6.7
1 1/2
-9.8
9.8
2
-11.7
11.7
Input
KVA
--
--
DC Amature DC Armature Field
Field
Voltage
Current
Voltage Current
90
2.7
50
1
100
2.7
100
1
90
3.5
50
1
100
3.5
100
1
90
5
50
1
180
2.5
100
1
180
2.5
200
1
90
7.6
50
1
180
3.8
100
1
180
3.8
200
1
90
10
50
1
180
5
100
1
180
5
200
1
--180
7
100
1
180
7
200
1
--180
9.2
100
1
180
9.2
200
1
3
Dimensions
Figure 1. DC3R Chassis Drive Dimensions
4
Dimensions
Figure 2. DC3R NEMA 4X Drive Dimensions
Dimensions
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 3. DC3R Heat Sink Dimensions
5
6
Installation
Only qualified technical personnel, familiar with the
m ATTENTION:
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.
Wiring
The control circuit is at line potential when the drive is
m ATTENTION:
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, or cause severe injury or loss of
life.
ATTENTION: Installation of a master power switch in the input line is
required. This is 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.
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.
Installation
7
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
Electric recommends shielding all logic-level leads. If
m Reliance
shielding is not practical, use twisted pair control wiring to minimize
ATTENTION: If it is not practical to shield power conductors,
induced electrical noise.
ATTENTION: Under no circumstances should unshielded 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:
• 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 sconcerns
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.
*Reliance Electric considers this an unfavorable condition and does not
recommend bundling of power and logic leads for any length.
8
Installation
Optional isolation transformer
Distribution system capacity above the maximum
m ATTENTION:
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.
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.
Installation
Mounting chassis drives
parts and assemblies. Static control precautions are required
m sensitive
when installing, testing, servicing, or repairing this assembly. Failure
ATTENTION: This drive contains ESD (Electric Static Discharge)
to observe these precautions could result in damage to, or destruction
of, the equipment.
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. Six
0.188 inch (4.8 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 for noise suppression. To ground the
chassis, connect earth ground to the GND terminal on terminal block 501
(TB501).
9
10
Installation
Mounting enclosed drives
NEMA 4X enclosed drives come with three 0.88 inch (22 mm) conduit
knockout holes at the bottom of the enclosure. 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 enclosure. The right side of the
cover is hinged to the enclosure. Lift or pull the slotted screw to open
the enclosure.
3. Carefully remove the conduit knockouts by tapping them into the
enclosure 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 enclosure.
6. Turn the slotted screw clockwise until tight to secure the front cover.
7. Set the POWER switch to the “0” or OFF position before applying the
AC line voltage.
Heat sinking
Chassis DC3R models require an additional heat sink when the continuous
armature current is above 7 ADC. Use Reliance® part number
DC3R-HS-00. All enclosed drives have sufficient heat sinking in their
basic configurations. Use a thermally conductive heat sink compound
(such as Dow Corning® 340 Heat Sink compound) between the drive
chassis and the heat sink surface for optimum heat transfer.
Installation
11
Cage-clamp terminal block
Connections to the DC3R drive are made to a cage-clamp terminal block
(Figure 4). To insert a wire into the terminal block, press down on the
lever arm using a small screwdriver. Insert stripped wire into the large
opening in front of the terminal block. Release the lever arm to clamp the
wire.
Lever Arm
Figure 4. Cage-Clamp Terminal Block
Field output
The field output is for shunt wound motors only. Do not make any
connections to F1 and F2 when using a permanent magnet motor.
Use 18 AWG wire to connect the field output to a shunt wound motor.
Table 1 lists the field output connections.
Table 1. Field Output Connections
Line Voltage
Approximate
(VAC)
Field Voltage (VDC)
115
50
115
100
230
100
230
200
Connect Motor
Field To
F1 and L1
F1 and F2
F1 and L1
F1 and F2
12
Installation
Tachogenerator feedback
Applying the incorrect polarity to the tachogenerator
m ATTENTION:
can cause an overspeed condition. Make sure the positive (+) wire is
connected to terminal T1 and the negative (-) wire is connect to
terminal T2 when the motor is running in the forward direction. Failure
to observe this precaution could result in bodily injury.
Using tachogenerator feedback improves speed regulation from
approximately 1% of motor base speed to approximately 0.1% of motor
base speed. Use tachogenerators rated from 7 VDC per 1000 RPM to
50 VDC per 1000 RPM.
Connect the tachogenerator to terminals T1 and T2 of terminal block 502
(TB502). The polarity is + for T1 and – for T2 when the motor running in
the forward direction. The polarity is reversed when the motor is running
in the reverse direction.
Installation
Connections
Chassis drive connections
NOTE: TERMINAL 1 IS THE HOT
CONNECTION. TERMINALS 2 AND
3 ARE NEUTRAL CONNECTIONS.
Figure 5. Chassis Drive Connections
13
14
Installation
Enclosed drive connections
NOTE: TERMINAL 1 IS THE HOT
CONNECTION. TERMINALS 2 AND
3 ARE NEUTRAL CONNECTIONS.
Figure 6. Enclosed Drive Connections
Installation
15
Speed adjust potentiometer installation
Because the reference potentiometer is connected
m ATTENTION:
through the regulator to the armature power circuit, its terminals are at
line potential. Use a potentiometer that has a insulating shaft to insulate
the operator knob from this power circuit and that is capable of
withstanding Hi-pot tests at 2000 Volts DC for one minute. Failure to
observe this precaution could result in severe bodily injury or loss of
life.
ATTENTION: Be sure that the potentiometer tabs do not make contact
with the potentiometer enclosure. Grounding the input will cause
damage to the drive.
On chassis drives, install the circular insulating disk between the panel and
the 10 Kohm speed adjust potentiometer. Mount the speed adjust
potentiometer through a 0.38 in. (0.96 cm) hole with the hardware
provided (see Figure 7). Twist the speed adjust potentiometer wire to avoid
picking up unwanted electrical noise. If potentiometer leads are longer
than 18 in. (46 cm), use shielded cable. Speed adjust potentiometers are
installed on all enclosed drives.
Figure 7. Speed Adjust Potentiometer
16
Installation
Speed adjust potentiometer connections
ATTENTION: At very low input levels, noise or drift could cause
m analog
input polarity to change. This could cause the motor to rotate in
the opposite direction. Proper precautions should be taken as this could
result in damage to, or destruction of, the equipment.
The motor can operate in one direction (unidirectional) or in two directions
(bidirectional) depending on how the speed adjust potentiometer is
connected to the drive.
Connect the speed adjust potentiometer as shown in Figure 8(a) for speed
control in one direction.
Connect the speed adjust potentiometer as shown in Figure 8(b) for speed
control in two directions. The motor does not rotate when the wiper is in
the center position. Turning the wiper CW from the center position causes
the motor to rotate in one direction, while turning the wiper CCW from the
center position causes the motor to rotate in the opposite direction.
Refer to the Application Notes section for additional speed adjust
potentiometer connections.
(a)
(b)
Figure 8. Speed Adjust Potentiometer Connections for (a)
Unidirectional Operation, and (b) Bidirectional Operation
Installation
17
+15 and –15 terminals
The equipment is at line voltage when AC power is
m ATTENTION:
connected. Disconnect and lockout all ungrounded conductors of the
AC power line. Failure to observe this precaution could result in severe
bodily injury or loss of life.
DC3R drives can supply a regulated +15 and –15 VDC signal (each
sourcing 25 mA maximum) to isolated, external devices. These voltage
supply terminals are located on terminal block 502 (TB502).
IMPORTANT: Do not short +15 and –15 terminals for any reason!
Shorting these terminals may damage the drive.
Line Fusing for DC3R Drives
Most code requires that upstream branch protection be
m ATTENTION:
provided to protect input power wiring. Failure to observe this
precaution could result in severe bodily injury or loss of life.
DC3R drives require fuses for protection. Use fast acting fuses rated for
250 VAC or higher, and approximately 150% of the maximum armature
current. Fuse both L1 and L2 when the line voltage is 230 VAC.
Table 2 lists the recommended line fuse sizes.
Table 2. Fuse Chart
90 VDC Motor
Horsepower
1/20
1/15
1/8
1/6
1/4
1/3
1/2
3/4
1
180 VDC Max. DC Armature AC Line Fuse
Horsepower Current (amps)
Size (amps)
1/10
0.5
3
1/8
0.8
3
1/4
1.5
5
1/3
1.7
5
1/2
2.6
8
3/4
3.5
8
1
5.0
10
1 1/2
7.6
15
2
10
20
Install the required, user-supplied branch circuit protection fuses according
to the applicable local, national, and international codes (e.g., NEC/CEQ.
The fuses must be installed in the line before the drive input terminals.
18
Installation
Voltage follower
The drive may be wired to follow a floating (isolated) 0 to ±10V signal
that is isolated from earth ground instead of using a speed adjust
potentiometer. Connect the signal input to S2, and the signal common to
S0 (see Figure 9).
Figure 9. Voltage Follower Connections
19
Operation
Only qualified technical personnel, familiar with the
m ATTENTION:
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.
20
Operation
Before applying power
Change voltage switch settings only when the drive is
m ATTENTION:
disconnected from AC line voltage. Make sure both switches are set to
their correct position. If the switches are improperly set to a lower
voltage position, the motor will not run at full voltage and may cause
damage to the transformer. If the switches are improperly set to a
higher voltage position, the motor will overspeed, which may cause
motor damage or severe bodily injury or loss of life.
1. Check connections before applying AC line voltage to the drive.
2. Check that no conductive material is present on the printed circuit
board.
3. Verify that all selector switches are set correctly (see the following
section for selector switch settings). See Figure 10 for all switch
locations.
Selector switch settings
Change slide switch settings only when the drive is
m ATTENTION:
disconnected from the AC line voltage. Make sure both line voltage
and motor switches are set to their correct position. If the switches are
improperly set to a lower voltage position, the motor will not run at full
voltage and may cause transformer damage. If the switches are
improperly set to a higher voltage position, the motor will overspeed,
which may cause motor damage or severe bodily injury or loss of life.
1. Set the line voltage selector switches (SW501 and SW502) to 115 if
using 115 VAC line voltage, or to 230 if using 230 VAC line voltage.
2. Set the armature voltage selector switch (SW503) to 90 if using a 90
VDC motor, or to 180 if using a 180 VDC motor.
3. Set the feedback selector switch (SW504) to TACH if using a
tachogenerator; otherwise set it to ARM for armature feedback.
IMPORTANT: You may be required to derate a 90 VDC motor when
230 VAC is applied to the drive. Contact the factory for details.
Operation
Feedback
Selector Switch
Armature Voltage
Selector Switch
Line Voltage
Selector
Switches
Figure 10. Selector Switch Locations
21
22
Operation
Startup
Chassis drive
1. Set the speed adjust potentiometer for zero speed.
2. Apply AC line voltage.
3. Slowly advance the speed adjust potentiometer clockwise (CW). The
motor slowly accelerates as the potentiometer is turned CW. Continue
until the desired speed is reached.
4. Remove AC line voltage from the drive to coast the motor to a stop.
Enclosed drive
1. Set the FORWARD/BRAKE/REVERSE switch to the BRAKE position.
2. Set the speed adjust potentiometer to “0” (full CCW).
3. Apply AC line voltage.
4. Set the POWER switch to the ON position.
5. Set the FORWARD/BRAKE/REVERSE switch to the desired direction
of rotation.
7. Slowly advance the speed adjust potentiometer clockwise (CW). The
motor slowly accelerates as the potentiometer is turned CW. Continue
until the desired speed is reached.
8. To brake the motor, set the FORWARD/BRAKE/REVERSE switch to
the BRAKE position. To coast the motor to a stop, set the POWER
switch to the OFF position.
9. To reverse direction:
a. Set the FORWARD/BRAKE/REVERSE switch to the BRAKE
position.
b. After the motor comes to a complete stop, set the
FORWARD/BRAKE/REVERSE switch to the desired direction of
rotation.
10. Set the POWER switch to OFF to remove power from the drive.
Operation
23
Starting and Stopping Methods
For frequent starts and stops, use regenerative
m ATTENTION:
deceleration (shorting RB1 and RB2), regenerative braking (shorting
INHIBIT terminals to each other), coasting to a stop (shorting
INHIBIT–RUN terminals 1 and 2), or decelerating to minimum speed
(shorting S2 to S0). Do not use any of these methods for emergency
stopping. They may not stop a drive that is malfunctioning. Removing
AC line power (both L1 and L2) is the only acceptable method for
emergency stopping.
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.
Failure to observe these precautions could result in bodily injury.
Line starting and line stopping
Line starting and line stopping (applying and removing AC line voltage) is
recommended for infrequent starting and stopping of a drive only. When
AC line voltage is applied to the drive, the motor accelerates to the speed
set by the speed adjust potentiometer. When AC line voltage is removed,
the motor coasts to a stop.
Automatic restart upon power restoration
All drives automatically run to set speed when power is applied. Wiring a
latching relay into the AC line is one way to prevent automatic restarting
following a power outage.
24
Operation
Regenerative deceleration
Starting and stopping with the inhibit terminal pins does
m ATTENTION:
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.
Failure to observe these precautions could result in bodily injury.
ATTENTION: At very low input levels, noise or drift could cause
analog input polarity to change. This could cause the motor to rotate in
the opposite direction. Proper precautions should be taken as this could
result in damage to, or destruction of, the equipment.
Short terminals RB1 and RB2 to regeneratively decelerate a motor to a
stop (Figure 11). Since terminal RB1 bypasses the MIN SPD circuit,
shorting RB1 and RB2 will decelerate a motor to a stop instead of
minimum speed. Calibrate the deceleration time by adjusting the oppositedirection acceleration trimpot.
Figure 11. Regenerative Deceleration Switch Connection
Operation
25
Regenerative braking using the INHIBIT circuit
Starting and stopping with the inhibit terminal pins does
m ATTENTION:
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.
Failure to observe these precautions could result in bodily injury.
Short the INHIBIT terminals to regeneratively brake the motor (see
Figure 12 for INHIBIT terminal location). Reopening the INHIBIT
terminals causes the motor to accelerate to set speed.
The INHIBIT terminals bypass both the MIN SPD circuit and the
deceleration circuit. This causes the motor to stop rapidly when the
INHIBIT terminals are shorted. Braking torque is determined by the
opposite-direction torque setting.
Twist inhibit wires and separate them from other power-carrying wires or
sources of electrical noise. Use shielded cable if the inhibit wires are
longer than 18 in. (46 cm). If shielded cable is used, ground only one end
of the shield to earth ground. Do not ground both ends of the shield.
INHIBIT TERMINALS
Figure 12. Inhibit Terminals
26
Operation
Coast to a stop using the INHIBIT circuit
Starting and stopping with the inhibit terminal pins does
m ATTENTION:
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.
Failure to observe these precautions could result in bodily injury.
To coast the motor to a stop without removing power to the drive, jumper
INHIBIT–RUN terminals 1 and 2 (Figure 13). To restart the motor, jumper
INHIBIT–RUN terminals 2 and 3. A single-throw, double-pole switch may
be used as a COAST/RUN switch.
IMPORTANT: Each drive is assembled with INHIBIT–RUN terminals 2
and 3 jumpered. These terminals must be connected for the motor to run.
Certain Reliance Electric drives (regenerative and non-regenerative) coast
to minimum speed when the inhibit terminals are shorted to each other.
IR COMP and CURRENT LIMIT (FWD TQ and REV TQ on regenerative
drives) are still active while the drive is in the inhibit mode.
Frequent regenerative deceleration, regenerative braking, coasting to a
stop, or decelerating to minimum speed produces high torque. This may
cause damage to motors, especially gearmotors that are not properly sized
for the application.
INHIBIT-RUN
TERMINALS
Figure 13. INHIBIT-RUN Terminals
Operation
27
Decelerate to minimum speed
Starting and stopping with the inhibit terminal pins does
m ATTENTION:
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.
Failure to observe these precautions could result in bodily injury.
The circuit shown in Figure 14 may be used to decelerate a motor to a
minimum speed. Closing the switch between S2 and S0 decelerates the
motor from set speed to a minimum speed determined by the MIN SPD
trimpot setting. If the MIN SPD trimpot is set full CCW, the motor
decelerates to zero speed when the switch between S2 and S0 is closed.
The DECEL trimpot setting determines the rate at which the drive
decelerates. Set the switch to the RUN position to accelerate the motor to
set speed at a rate determined by the ACCEL trimpot setting.
Figure 14. Run/Decelerate to Minimum Speed Switch
(shown with bidirectional speed adjust potentiometer connection)
28
Calibration
The following adjustments are made with power on.
m ATTENTION:
Exercise extreme caution as hazardous voltage exists. 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.
Each drive is factory calibrated to its maximum horsepower rating.
Readjust the calibration trimpot settings to accommodate lower
horsepower motors.
All adjustments increase with CW rotation, and decrease with CCW
rotation. Use a non-metallic screwdriver for calibration. Each trimpot is
identified on the printed circuit board.
MINIMUM
SPEED
REVERSE
TORQUE
FORWARD
TORQUE
MAXIMUM
SPEED
IR COMP
REVERSE
ACCELERATION
FORWARD
ACCELERATION
Figure 15. Calibration Trimpot Layout
TACH
DEAD
BAND
Calibration
29
MIN SPD
The DC3 Drive is intended to operate at a
m ATTENTION:
predetermined minimum speed. If the application requires zero speed
operation, 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: At very low input levels, noise or drift could cause
analog input polarity to change. This could cause the motor to rotate in
the opposite direction. Proper precautions should be taken as this could
result in damage to, or destruction of, the equipment.
The MIN SPD setting determines the minimum speed when the speed
adjust potentiometer is turned full CCW. It is factory set to zero speed.
IMPORTANT: The minimum speed feature applies only when the drive
is operating in unidirectional mode.
To calibrate, set the speed adjust potentiometer full CCW. Adjust the MIN
SPD trimpot until the motor turns at the desired minimum speed.
MAX SPD
The MAX SPD setting determines the maximum motor speed when the
speed adjust potentiometer is turned full CW. It is factory set for maximum
rated motor speed.
To calibrate, set the speed adjust potentiometer full CW. Adjust the MAX
SPD trimpot until the motor turns at the desired maximum speed.
30
Calibration
FWD TQ
Although FWD TQ is set to exceed the motor
m ATTENTION:
nameplate current rating, continuous operation beyond that rating may
damage the motor.
The FWD TQ setting determines the maximum torque for accelerating and
driving the motor in the forward direction. It also sets the maximum torque
for decelerating the motor in the reverse direction. FWD TQ is factory set
at 120% of rated motor current.
If the time it takes to accelerate a load is too long due to the forward
torque setting, increase the forward torque setting to 130% of rated motor
current. The decision to change the forward torque setting must be made
after considering the gearbox and drivetrain ratings, duty cycle, and motor
characteristics. See Figure 16 for typical FWD TQ settings.
REV TQ
Although REV TQ is set to exceed the motor
m ATTENTION:
nameplate current rating, continuous operation beyond that rating may
damage the motor.
The REV TQ setting determines the maximum torque for accelerating and
driving the motor in the reverse direction. It also sets the maximum torque
for decelerating in the forward direction. REV TQ is factory set at 120%
of rated motor current.
If the time it takes to accelerate a load is too long due to the reverse torque
setting, increase the reverse torque setting to 130% of rated motor current.
The decision to change the reverse torque setting must be made after
considering the gearbox and drivetrain ratings, duty cycle, and motor
characteristics. See Figure 16 for typical REV TQ settings.
IR COMP
The IR COMP setting determines the degree to which motor speed is held
constant as the motor load changes. It is factory set for optimum motor
regulation.
Calibration
31
Recalibrate the IR COMP setting when using a lower horsepower motor.
See Figure 19 for typical IR COMP settings, or recalibrate using the
following procedure:
If the motor does not maintain set speed as the load changes, gradually
rotate the IR COMP trimpot CW. If the motor oscillates
(overcompensation), the IR COMP trimpot may be set too high (CW).
Turn the IR COMP trimpot CCW until the drive stabilizes.
FWD ACC
The FWD ACC setting determines the time the motor takes to ramp to
either a higher speed in the forward direction or a lower speed in the
reverse direction, within the limits of available torque. The FWD ACC
setting is factory set for its fastest forward acceleration time.
Turn the FWD ACC trimpot CW to increase the forward acceleration time,
and CCW to decrease the forward acceleration time.
REV ACC
The REV ACC setting determines the time the motor takes to ramp to
either a higher speed in the reverse direction or a lower speed in the
forward direction, within the limits of available torque. The REV ACC
setting is factory set for its fastest reverse acceleration time.
Turn the REV ACC trimpot CW to increase the reverse acceleration time,
and CCW to decrease the reverse acceleration time.
DB (Range)
The deadband trimmer potentiometer determines the time that will elapse
between the application of current in one direction before current is
applied in the opposite direction.
The deadband trimmer potentiometer affects the resistance that a motor has
to changes in shaft position at zero speed. It does this by applying AC
voltage to the motor armature.
Deadband is factory calibrated to approximately the 3 o’clock position for
60 Hz AC line operation. Recalibrate the deadband to the 9 o’clock
position for 50 Hz AC line operation. See Figure 17 for recommended
deadband settings.
32
Calibration
TACH
Applying the incorrect polarity to the tachogenerator
m ATTENTION:
can cause an overspeed condition. Make sure the positive (+) wire is
connected to terminal T1 and the negative (-) wire is connect to
terminal T2 when the motor is running in the forward direction. Failure
to observe this precaution could result in bodily injury.
Calibrate the TACH setting only when a tachogenerator is used. The
TACH setting, like the IR COMP setting, determines the degree to which
motor speed is held constant as the motor load changes.
To calibrate the TACH trimpot:
1. Disconnect power from drive.
2. Connect the tachogenerator to T1 and T2. The polarity is + for T1 and
– for T2 when the motor running in the forward direction.
3. Set switch 504 (SW504) to ARM for armature feedback.
4. Apply power to drive.
5. Set the speed adjust potentiometer full CW. Measure the armature
voltage across A1 and A2 using a voltmeter.
6. Set the speed adjust potentiometer to 0 (zero speed).
7. Disconnect power from drive.
8. Set SW504 to TACH for tachogenerator feedback.
9. Set the IR COMP trimpot full CCW.
10. Set the TACH trimpot full CW.
11. Apply power to drive.
12. Set the speed adjust potentiometer full CW.
13. Adjust the TACH trimpot until the armature voltage is the same value
as the voltage measured in step 5.
Check that the tachogenerator is properly calibrated. The motor should run
at the same set speed when SW504 is set to either armature or
tachogenerator feedback.
Calibration
Figure 16. Typical FWD TQ, REV TQ, and IR COMP Settings
(actual settings may vary with each application)
Figure 17. Deadband Settings
33
34
Application Notes
The equipment is at line voltage when AC power is
m ATTENTION:
connected. Disconnect and lockout all ungrounded conductors of the
AC power line. Failure to observe this precaution could result in severe
bodily injury or loss of life.
Optional speed adjust potentiometer connections
At very low input levels, noise or drift could cause
m ATTENTION:
analog input polarity to change. This could cause the motor to rotate in
the opposite direction. Proper precautions should be taken as this could
result in damage to, or destruction of, the equipment.
FWD-REV switch
Use a single-pole, two-position switch with a single speed adjust
potentiometer to plug reverse the motor (Figure 18). The MIN SPD setting
is in effect for either direction.
Figure 18. Forward-Reverse Switch
Application Notes
35
FWD-STOP-REV switch
Starting and stopping with the inhibit terminal pins
m ATTENTION:
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.
Failure to observe these precautions could result in bodily injury.
Use a single-pole, three-position switch with a single speed adjust
potentiometer to stop a motor between reversals (Figure 19). Set the switch
to the center position to decelerate the motor to a stop.
Figure 19. Forward-Stop-Reverse Switch
36
Application Notes
Independent adjustable speeds
Connect two speed adjust potentiometers with a single-pole two-position
switch to select between two independent speeds shown in the forward
direction ( Figure 20). The speed adjust potentiometers can be mounted at
two separate operating stations.
Figure 20. Independent Adjustable Speeds
(Forward Direction)
Application Notes
37
Independent forward and reverse speeds
At very low input levels, noise or drift could cause
m ATTENTION:
analog input polarity to change. This could cause the motor to rotate in
the opposite direction. Proper precautions should be taken as this could
result in damage to, or destruction of, the equipment.
Connect two speed adjust potentiometers as shown in
Figure 21 to select between independent forward and reverse speeds.
Figure 21. Independent Forward and Reverse Speeds
38
Application Notes
Independent Forward and Reverse Speeds with a
Forward-Stop-Reverse Switch
Starting and stopping with the inhibit terminal pins
m ATTENTION:
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.
Failure to observe these precautions could result in bodily injury.
Use a single-pole, three-position switch to stop the motor when the switch
is in the center position ( Figure 22).
Figure 22. Independent Forward and Reverse Speeds with a
Forward-Stop-Reverse Switch
39
Troubleshooting
This equipment is at line voltage when AC power is
m ATTENTION:
applied. Disconnect and lockout all ungrounded conductors of the AC
power line before working on the unit, Failure to observe this
precaution may result in severe bodily injury or loss of life.
Check the following before proceeding:
• The AC line voltage must match the voltage on the drive nameplate.
• On dual voltage drives, check that the voltage switches are set to the
correct position.
• The deadband (DB) must be set approximately at the
3 o’clock position for 60 Hz AC line frequency or at
9 o’clock for 50 Hz AC line frequency.
• The motor must be rated for the drive’s rated armature
(all motors) and field outputs (shunt wound motors only).
• Do not make any connections to F1 and F2 if using a permanent magnet
motor.
• Terminal block connections should be consistent with the connections
shown in this manual.
• Check that line fuse FU501 (and FU502 for 230 VAC line voltage) is
properly sized and not blown.
40
Troubleshooting
Line fuse blows
1. Disconnect AC line voltage from the drive.
2. Check that the motor cable and armature is not shorted or grounded.
a. Armature resistance should measure approximately 1 to 100 ohms,
depending on motor horsepower.
b. A resistance reading from the motor frame to either armature side
should show open when an ohmmeter is used on its high resistance
scale.
3. Check that the field circuit is not open.
4. A combination of ambient conditions and frequent
high-current spikes (i.e. reversing) causes fuse to “nuisance trip”.
Consider using a slow-blow fuse, or over-rating the fuse 120%
Motor pulsates or surges under load
Readjust the IR COMP setting slightly CCW until the motor speed is
stabilized.
Line fuse does not blow, but the motor does not run
1. Verify that the speed adjust potentiometer is not set to its zero speed
position.
2. Check the speed adjust potentiometer for continuity.
3. Verify that the inhibit pins are not shorted together.
4. Check that INHIBIT–RUN terminals 2 and 3 are connected.
5. Verify that the drive is receiving AC line voltage.
6. Check that the drive is not in current limit. If the drive is in current
limit, verify that the motor is not jammed. It may be necessary to
increase the FWD TQ or REV TQ setting if it is set lower than the
current rating of the motor.
7. Check that the speed adjust potentiometer connections to the terminal
block are correct and not open.
Motor runs too fast at the maximum speed setting
1. Check that the MIN SPD and MAX SPD setting is not set too high.
2. Check that the field output connections are secure if you are using a
shunt wound motor.
Troubleshooting
41
Motor will not reach the desired speed
The control circuit is at line potential when the drive is
m ATTENTION:
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.
1. Check the MAX SPD setting and increase if necessary.
2. Check that the IR COMP setting is not set too low.
3. Check that the motor is not overloaded.
42
Troubleshooting
Prewired Connections for Enclosed Drive
Figure 23. Prewired Connections to L1, L2(115) and L2(230)
Figure 24. Prewired Speed Adjust Potentiometer
Connections for Enclosed Drives
43
Regenerative Drives
Most non-regenerative, variable speed, DC drives control current flow to a
motor in one direction. The direction of torque is the same direction as the
motor rotation. Non-regenerative drives operate in Quadrant 1, and also in
Quadrant 3 if the drive is reversible (see Figure 25). Motors must stop
before reversing direction. Unless dynamic braking is used, nonregenerative drives cannot oppose an overhauling load, and cannot
decelerate a load faster than coasting to a lower speed.
Regenerative drives operate in two additional quadrants: Quadrant 2 and
Quadrant 4. In these quadrants, motor torque is in the opposite direction of
motor rotation.
Regenerative drives can reverse a motor without contactors, switches,
brake resistors, and inhibit plugs. They can also control an overhauling
load and decelerate a load faster than it would take to coast to a lower
speed.
Figure 25. Four Quadrant Operation
44
CE Compliance
Reliance Electric hereby certifies that its DC3 series drives have been
approved to bear the “CE” mark provided the conditions of approval
(listed in Exhibit “A”) have been met by the end user.
The DC3 series has been tested to the following test specifications:
EN55011:1991 (emissions), and
EN50082-1:1992 (immunity)
Compliance allows Reliance Electric’s DC3 series to bear the CE mark.
The end user, as described herein, falls into one of two categories:
1. The Consumer will deploy a stand-alone unit as an integral, yet
external, portion of the machine he/she is operating.
2. The Original Equipment Manufacturer (OEM) will implement the
product as a component of the machine being manufactured.
Exhibit “A”: Line Filters
In addition to EMI/RFI safeguards inherent in the DC3 series’ design,
external filtering is required.
Reliance Electric requires the Corcom® filters listed in Table 3. If the
exact filter is not available, the specifications are as follows:
L = 1.8 milliHenries.
C = 0.01 microFarad (Line to Ground); 1.1 microFarads (Line to
Line).
Discharge Resistor = 330Kohms.
Rated current: 1.4 times maximum DC motor current.
Filter type: Balanced 2-section.
CE Compliance
45
Table 3. Corcom® Filters
Nameplate Current of
Motor Wired to the Drive
0 to 4 amps
4.1 to 13 amps
Corcom® Filter Part Number
6VV1
20VV1
The filters in Table 3 should be wired to the AC line within 0.25 meters of
the drive. The ground connection from the filter must be wired to solid
earth ground (resistance less than 500 ohms); not machine ground. This is
very important!
Armature Filters
If the end-user is using a CE-approved motor, the correct filter from Table
3 is all that is necessary to meet the EMC directives listed herein.
If the end-user is not using a CE-approved motor, a Reliance Electric
CEXXRG filter must be deployed on the output. XX is the rated current
on the filter
The CE20RG is a Real-Pole Balanced-Pi 3-pole filter. If the exact filter is
not available, the specifications are as follows:
L & L1 = 2 * (0.8) milliHenries.
C & C1 = 2 * (0.1) microFarads @ 400W VDC.
Rin = 0.1 ohm; Rout = 1.2 ohm.
Table 4. Armature Filters
Nameplate Current of
Motor Wired to the Drive
0 to 4 amps
4.1 to 13 amps
Reliance® Filter Part Number
CE4RG
CE20RG
The filters in Table 2 must be wired to the DC output of the drive, as close
to the drive as possible. The ground connection from the filter must be
wired to solid earth ground (resistance less than 500 ohms); not machine
ground. This is very important!
The end user must use the filtration listed in Exhibit A to comply with CE.
The OEM may choose to provide alternative filtering that encompasses the
Reliance drive and other electronics within the same panel.
46
CE Compliance
The OEM has this liberty because CE is a machinery directive. Whether
or not every component in the OEM’s machinery meets CE, the OEM
must still submit his machine for CE approval. Thus, no component must
necessarily meet CE within the machine, as long as the OEM takes the
necessary steps to guarantee the machine does meet CE. By the same
token, even if every component in the OEM’s machine does meet CE, the
machine will not necessarily meet CE as a machine.
Using CE-approved wiring practices (like proper shielding) and the filters
listed in Exhibit A guarantee the drive will meet EN55011 (1991 emissions
standard) and EN50082-1 (1992 immunity standard).
Publication D2-3453 - December 1999 ©1999 Rockwell International Corporation. All rights reserved. Printed in USA