Rockwell Automation RELIANCE ELECTRIC DC3N Series User Manual Download Page 75

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Before troubleshooting

Perform the following steps before starting any procedure in
this section:

•

Disconnect AC line voltage from the drive.

•

Check the drive closely for damaged components.

•

Check that no conductive or other foreign material has
become lodged on the printed circuit board.

•

Verify that every connection is correct and in good
condition.

•

Verify that there are no short circuits or grounded
connections.

•

Check that the voltage selection switch settings match
the AC line and output voltages.

•

Check that the drive’s rated armature and field outputs
are consistent with the motor ratings.

•

Check that the line fuses are properly sized and not
blown.

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.



Troubleshooting

Summary of Contents for RELIANCE ELECTRIC DC3N Series

Page 1: ...DC3N Non Regenerative DC Drive User Guide 1 4 to 2 HP 115 230 VAC Instruction Manual D2 3452 4 M N DC3N 12D 00 010 AI M N DC3N 12D 4X 010 AI ...

Page 2: ...al is subject to change without notice Throughout this manual the following notes are used to alert you to safety considerations 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 ...

Page 3: ... 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 ATTENTION It is possible for a drive to run at full speed as a ...

Page 4: ...rt 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 i...

Page 5: ... Line fusing 13 Speed adjust potentiometer 14 Alternate speed adjust potentiometer connections 15 Cage clamp terminals 16 Connections 17 Motor 18 Power input 19 Field output 20 START STOP pushbuttons 21 Tachometer feedback 22 Voltage or current follower 24 Enclosed drive 25 Mounting 25 Heat sinking 26 Line fusing 26 Connections 27 Motor 28 Power input 29 Contents iii ...

Page 6: ...ration 38 POWER ON start 38 Pushbutton start stop 39 Alternate Starting and Stopping Methods 41 Minimum speed 42 Dynamic braking 43 Dynamic brake resistor value 43 Enclosed drive operating modes 45 Manual mode 45 Auto mode 46 Enclosed drive operation 46 To run the motor 47 To stop the motor 47 Calibration 48 Drive Calibration Procedure 50 MIN SPD 51 MAX SPD 52 CURRENT LIMIT 53 IR COMP 54 Approxima...

Page 7: ...LEDs 68 Block Diagram 75 Terminal descriptions 76 Chassis drive terminals 76 Enclosed drive terminals 77 CE Compliance 78 Exhibit A 79 Armature Filters 80 v Table of Contents Tables Table 1 Recommended Line Fuse Sizes 13 Table 2 Field Output Connections 20 Table 3 Field Output Connections 29 Table 4 Minimum Recommended Dynamic Brake Resistor Values 44 Table 5 Corcom Filters www corcom com 79 Table...

Page 8: ...Run Decelerate to Minimum Speed Switch 42 Figure 11 Dynamic Brake Connection 44 Figure 12 Calibration Trimpot Layout 49 Figure 13 Typical CURRENT LIMIT and IR COMP Settings for DC3N drive actual settings may vary with each application 59 Figure 14 Multiple Fixed Speeds 60 Figure 15 Adjustable Fixed Speeds Using Potentiometers in Series 61 Figure 16 Independent Adjustable Speeds 62 Figure 17 Revers...

Page 9: ... 1 Phase Maximum Allowable Symmetrical AC Line Current 5000 amps Maximum AC Line Distribution kVA with 115 VAC Input 25 kVA with 230 VAC Input 50 kVA Armature Voltage With 115 VAC Input 0 90 VDC With 230 VAC Input 0 180 VDC Field Voltage 115 VAC Input 50 VDC F1 to L1 100 VDC F1 to F2 230 VAC Input 100 VDC F1 to L1 200 VDC F1 to F2 Maximum Field Current 1 ADC Adjustments and Application Data Form F...

Page 10: ...Feedback 1 or better With Tachometer Feedback 0 1 Speed Range 60 1 Tachometer Feedback Voltage Range 7 50 VDC per 1000 RPM Maximum Current Load 150 for 1 minute Safety Certification UL Listed Component cUL Listed Component CE Approved Component Weight 2 1 lbs 953g Service Conditions Maximum Allowable Elevation 3300 ft 1000 m max without derating Vibration 0 5G max 0 50 Hz 0 1G max 50 Hz Ambient Te...

Page 11: ...1 1 3 5 9 0 7 90 3 5 50 1 5 9 0 7 90 3 5 100 1 1 2 7 8 0 9 90 5 50 1 3 7 0 8 180 2 5 100 1 3 7 0 8 180 2 5 200 1 3 4 10 6 1 2 90 7 6 50 1 5 6 1 3 180 3 8 100 1 5 6 1 3 180 3 8 200 1 1 13 1 5 90 10 50 1 7 1 6 180 5 100 1 7 1 6 180 5 200 1 1 5 10 1 2 3 180 7 100 1 10 1 2 3 180 7 200 1 2 12 2 8 180 9 2 100 1 12 2 8 180 9 2 200 1 Efficiency at maximum horsepower output 92 3 Specifications ...

Page 12: ...nsions and Layout 4 46 113 1 80 46 6 90 175 6 30 160 3 00 76 0 76 19 0 98 25 0 77 19 SIX 6 MOUNTING SLOTS 0 19 5 WIDE x 0 30 8 DEEP ALL DIMENSIONS IN INCHES MILLIMETERS Figure 1 DC3N 12D 00 010 AI Dimensions ...

Page 13: ... 22 6 6 90 175 6 30 160 9 80 249 10 22 260 1 45 37 1 50 38 1 50 38 1 40 36 7 00 178 0 12 3 2 31 59 4 78 121 5 51 140 THREE 0 88 22 KNOCKOUTS ALL DIMENSIONS IN INCHES MILLIMETERS Figure 2 DC3N 12D 4X 010 AI Dimensions ...

Page 14: ... SWITCHES CURRENT LIMIT LED IL501 POWER LED IL502 AC LINE VOLTAGE TERMINAL BLOCKS FIELD TERMINAL BLOCKS ARMATURE TERMINAL BLOCKS ARMATURE VOLTAGE SELECTOR SWITCH CURRENT VOLTAGE SIGNAL SELECTOR SWITCH 10 TURN MAXIMUM AND MINIMUM SPEED TRIMMER POTENTIOMETERS SPEED ADJUST POTENTIOMETER TERMINAL BLOCKS START STOP TERMINAL BLOCKS TACHOGENERATOR TERMINAL BLOCKS TACHOGENERATOR VOLTAGE TRIMMER POTENTIOME...

Page 15: ...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 ...

Page 16: ...or leads from the drive unless power is removed or the drive is disabled Opening any one motor lead may destroy the drive Use 18 24 AWG wire for speed adjust potentiometer wiring Use 14 16 AWG wire for AC line L1 L2 and motor A1 and A2 wiring Shielding guidelines ATTENTION If it is not practical to shield power conductors Reliance Electric recommends shielding all logic level leads If shielding lo...

Page 17: ...inches and power and logic leads must be bundled together or 2 radiated and or conducted noise must be minimized due to concerns about immunity or general compliance CE FCC etc It may be necessary to earth ground the shielded cable If noise is produced by devices other than the drive ground the shield at the drive end If noise is generated by a device on the drive ground the shield at the end away...

Page 18: ... connections by avoiding excessive vibration of the drive Mount the drive with its board in either a horizontal or vertical plane Four 0 19 inch 5 mm wide slots in the chassis accept 8 pan head screws 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...

Page 19: ... 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...

Page 20: ...er 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 Heat sinking This DC3 drive model contains sufficient heat sinking in its original configuration No additional heat sinking is necessary when installed in accordance with the guidelines specified in this instruction manual The ch...

Page 21: ...r recommended replacement line fuse sizes for specific application ratings Table 1 Recommended Line Fuse Sizes 90 VDC Motor 180 VDC Motor Max DC Armature AC Line Fuse Horsepower Horsepower Current amps Size amps 1 20 1 10 0 5 3 1 15 1 8 0 8 3 1 8 1 4 1 5 5 1 6 1 3 1 7 5 1 4 1 2 2 6 8 1 3 3 4 3 5 8 1 2 1 5 0 10 3 4 1 1 2 7 6 15 1 2 10 15 Reliance Electric offers a 0 5A pico fuse part number 050 007...

Page 22: ...iometer Install the circular insulating disk between the mounting panel and the 10K ohm speed adjust potentiometer see Figure 4 Mount the speed adjust potentiometer through a 0 38 inch 10 mm hole with the hardware provided Twist the speed adjust potentiometer wire to avoid picking up unwanted electrical noise If potentiometer leads are longer than 18 inches 46 cm use shielded cable ...

Page 23: ...otentiometer connections may be found in the Application Notes section of this user guide IMPORTANT The user may choose to install a 5K ohm speed adjust potentiometer however the MIN SPD and MAX SPD trimpots must be recalibrated if the 5K ohm potentiometer is used Installation ...

Page 24: ...made to cage clamp terminals To insert a wire into the cage clamp terminal Press down on the lever arm using a small screwdriver Insert wire into the wire clamp 1 2 Release the lever arm to clamp the wire 3 Figure 5 Cage Clamp Terminal Installation ...

Page 25: ...ntactor 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 To provide the motor with overload protection local national and international co...

Page 26: ...n 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 drive s output terminals IMPORTANT Reliance Electric drives supply motor voltage from A1and A2 terminals It is assumed throughout this manual that when A1 is positive w...

Page 27: ...t 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 Connect the AC line power leads to terminals L1 and L2 as shown in Figure 6 page 23 Install a master power switch in the voltage input line as shown in Figure 6 The...

Page 28: ...t magnet motor The field output is for shunt wound motors only See Table 2 for field output connections Table 2 Field Output Connections Line Voltage Approximate Connect Motor VAC Field Voltage VDC Field To 115 50 F1 and L1 115 100 F1 and F2 230 100 F1 and L1 230 200 F1 and F2 Field output ...

Page 29: ...circuit The drive will then operate in a power up start mode See Figure 6 page 23 for these switch connections ATTENTION Starting and stopping with the start stop terminals does not disconnect AC power in the stop position A hardwired AC power disconnection switch must be mounted between the AC source and terminals L I and L2 This is required as the DC3 drive does not have an armature loop contact...

Page 30: ...ure 6 for tachometer connections IMPORTANT The TACH trimpot must be adjusted prior to operating with tachometer feedback Refer to the Calibration section pg 48 for instructions on calibrating the TACH trimpot ATTENTION Applying the incorrect polarity to the tachometer can cause an overspeed condition Make sure the positive wire is connected to terminal T1 and the negative wire is connect to termin...

Page 31: ...H ARM SW505 T1 T2 P507 VOLTS TACH C506 FB IC505 IC504 C505 T501 CURRENT IL501 LIMIT SCR502 T502 CL IL502 IR COMP PWR 115V AC LINE VOLTAGE 230 VAC LINE VOLTAGE CW SPEED ADJUST POTENTIOMETER 10K OHMS N O S TART N C STOP NOTE IF PUSHBUTTONS ARE NOT USED CONNECT B1 TO B3 MOTOR TACHOGENERATOR OPTIONAL FIELD OUTPUT SHUNT WOUND MOTORSO NLY SEE NOTE 4 NOTES 1 L1 IS THE HOT TERMINAL 2 L2 115 IS THE NEUTRAL...

Page 32: ... of using a speed adjust potentiometer these DC3N model drives may be wired to follow an external input signal see Figure 7 for connections This input signal can be in the form of voltage 0 10 VDC or current 4 20 mA Because these drives have built in isolation the input signal can be either grounded or ungrounded The signal slide switch must be set for current or voltage input depending on the inp...

Page 33: ...ews 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 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 k...

Page 34: ...the guidelines specified in this manual Line fusing Installation ATTENTION Most code requires that upstream branch protection be provided to protect input power wiring Failure to observe this precaution could result in severe bodily injury or loss of life This DC3N model has 15 amp line fuses preinstalled on fuse holders 501 and 502 FU501 and FU502 When replacing the line fuses use fast acting fus...

Page 35: ...e 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 ATTENTION Do not connect this equipment ...

Page 36: ...rminals IMPORTANT Reliance Electric drives supply motor voltage from A1and A2 terminals It is assumed throughout this manual that when A1 is positive with respect to A2 the motor will rotate clockwise CW while looking at the output shaft protruding from the front of the motor If this is opposite of the desired rotation simply reverse the wiring of A1 and A2 with each other Connect a motor to termi...

Page 37: ... ATTENTION Do not make any connections to F1 and F2 when using a permanent magnet motor The field output is for shunt wound motors only See Table 3 for field output connections Table 3 Field Output Connections Line Voltage Approximate Connect Motor Terminal VAC Field Voltage VDC Field To Numbers 115 50 F1 and L1 4 and 1 115 100 F1 and F2 4 and 5 230 100 F1 and L1 4 and 1 230 200 F1 and F2 4 and 5 ...

Page 38: ... page 23 for tachometer connections IMPORTANT The TACH trimpot must be adjusted prior to operating with tachometer feedback Refer to the Calibration section page 48 for instructions on calibrating the TACH trimpot ATTENTION Applying the incorrect polarity to the tachometer can cause an overspeed condition Make sure the positive wire is connected to terminal T1 and the negative wire is connect to t...

Page 39: ...LD CONNECTIONS SHOWN REFER TO TABLE 2 PAGE 29 5 REMOVE THE 510 OHM INTERNAL RESISTOR CONNECTED BETWEEN TERMINALS 8 9 IF YOU ARE USING A 0 10V REMOTE INPUT SIGNAL 230 VAC 115 VAC 115 230 VAC LINE VOLTAGE INPUT MOTOR ARMATURE FIELD COIL SEE NOTES 1 2 AND 3 SEE NOTE 4 COM REF 0 10 VDC OR 4 20 mADC INPUT SIGNAL EARTH GROUND GREEN SCREW 1 L 2 L 0 3 2 2 L 5 1 1 1 F 2 F 1 A 2 A M O C F E R 1 2 3 4 5 6 7 ...

Page 40: ... an external input signal see Figure 8 on page 31 for connections This input signal can be in the form of voltage 0 10 VDC or current 4 20 mA Because these drives have built in isolation the input signal can be either grounded or ungrounded The signal slide switch SW504 must be set for voltage input see Slide switches section on page 33 ...

Page 41: ...C If the AC line voltage is 230 VAC the typical maximum output voltage is 180 VDC ATTENTION Change slide switch settings only when the drive is 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...

Page 42: ...sonnel by providing suitable guards audio or visual alarms or other devices Failure to observe these precautions could result in bodily injury Select the appropriate feedback option ARMATURE for armature feedback or TACH for tachometer feedback SIGNAL SW504 This switch should be left in the VOLT mode NOTE If the input signal is 0 10 VDC the resistor must be removed If the input signal is a 4 20 mA...

Page 43: ...502 FU501 R502 TB501 L2 115 L2 230 L1 ACCEL C504 SPD P503 S2 B3 S1 TB502 B2 B1 P502 IC502 C502 IC501 K501 SW504 SIG IC503 P501 SPD MAX C503 RC501 F1 F2 A1 R501 A2 180V MOTOR SW503 FU503 S3 P504 DECEL C507 C508 C510 C509 VOLTAGE SELECT SWITCHES SW501 SW502 FEEDBACK SELECT SWITCH SW505 ARMATURE A VOLTAGE SELECT SW503 SIGNAL SOURCE SELECT SW504 Installation Figure 9 Slide Switches ...

Page 44: ...d which may cause motor damage or result in bodily injury or loss of life ATTENTION Only qualified technical personnel familiar with the construction and operation of this equipment and the hazards involved should install adjust operate and or service this equipment Read and understand this instruction manual in its entirety before proceeding Failure to observe this precaution could result in seve...

Page 45: ...T switch SW503 to either 90V or 180V to match the maximum armature voltage Set SIGNAL SELECT switch SW504 to CURR if using a 4 20 mADC current signal set it to VOLT if using a 0 10 VDC voltage signal or the speed adjust potentiometer Verify that no conductive material is present on the printed circuit board If using a 90 VDC or 130 VDC motor with 230 VAC line voltage derate the nameplate motor spe...

Page 46: ... 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 or analog input signal When AC line voltage is removed the motor coasts to a stop 1 Turn the speed adjust potentiometer full counterclockwise CCW or set the external ...

Page 47: ... stop position A hardwired AC power disconnection switch must be mounted between the AC source and terminals L I and L2 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 vi...

Page 48: ...reference signal and press the START pushbutton The motor accelerates as the potentiometer is turned CW or the external speed reference is increased Continue until the desired speed is reached 4 Press STOP pushbutton to coast motor to a stop 40 Operation ...

Page 49: ...ry ATTENTION For frequent starts and stops use coasting to a stop with a STOP pushbutton decelerating to minimum speed shorting S2 and S1 to each other or dynamic braking 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 Frequent starts and stop...

Page 50: ...sing the switch between S1 and S2 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 S1 and S2 is closed The DECEL trimpot setting determines the rate at which the drive decelerates By opening the switch the motor accelerates to set speed at a rate deter...

Page 51: ...otor voltage and braking time Use a lower value higher wattage dynamic brake resistor to stop a motor more rapidly Refer to Table 4 page 44 for recommended dynamic brake resistor sizes Dynamic braking ATTENTION Wait for the motor to completely stop before switching it back to RUN This will prevent high armature currents from damaging the motor ATTENTION Armature output can drift full ON with the s...

Page 52: ...igure 11 Dynamic Brake Connection Table 4 Minimum Recommended Dynamic Brake Resistor Values Motor Armature Minimum Minimum Current Rating Dynamic Brake Dynamic Brake Wattage Resistor Value Resistor Less than 2 ADC 1 ohm 1W 2 3 ADC 5 ohm 5W 3 5 ADC 10 ohm 20W 5 10 ADC 20 ohm 40W ...

Page 53: ... is controlled by the speed adjust knob located on the drive cover Setting the speed adjust knob to zero causes the motor to run at the minimum speed dictated by the MIN SPD trimpot setting Refer to the Calibration section page 48 for information on calibrating the MIN SPD trimpot Set SIGNAL SELECT switch SW504 to VOLT when in manual mode ATTENTION If you run the drive in AUTO mode you must recali...

Page 54: ... an external current signal you must recalibrate the MIN SPD trimpot to offset any motor drift caused by the input signal IMPORTANT When switching between MANUAL and AUTO 0 10 VDC modes you must balance the MIN SPD trimpot setting for both operating modes Set the mode selector switch to AUTO if you wish to follow an external signal independent of the speed adjust knob setting In AUTO mode the driv...

Page 55: ...speed adjust potentiometer or external reference signal Continue until the desired speed is reached To stop the motor 1 Rotate the speed adjust potentiomter to zero full CCW or set the external reference signal to zero The motor will slowly decelerate until minimum speed is reached 2 Set the POWER switch on the front panel to OFF ATTENTION Frequent starting and stopping can produce high torque Thi...

Page 56: ...Refer to Figure 12 for trimpot locations Calibration ATTENTION Dangerous voltages exist on the drive when it is powered and up to 30 seconds after power is removed and the motor stops When possible disconnect the voltage input from the drive before adjusting the trimpots If the trimpots must be adjusted with power applied use insulated tools and the appropriate personal protection equipment BE ALE...

Page 57: ...01 W504 URR K501 IC501 C502 IC502 C503 P502 C504 ACCEL R502 FU501 F 1 FU502 F C501 2 TACH ARM SW505 VOLTS TACH C506 FB IC505 IC504 C505 T501 CURRENT IL501 LIMIT IL502 IR COMP IR COMP CURRENT LIMIT TACH VOLTS DECELERATION ACCELERATION MAXIMUM SPEED MINIMUM SPEED ...

Page 58: ... the enclosure The right side of the cover is hinged to the enclosure Pull the slotted screw to open the enclosure 3 Set all trimpots except CURRENT LIMIT and TACH VOLTS full counterclockwise CCW 4 Set the CURRENT LIMIT trimpot full clockwise CW 5 Make no adjustment to the TACH VOLTS trimpot unless tachometer feedback is used If you use tachometer feedback set the TACH VOLTS trimpot to the center ...

Page 59: ...tiometer full CCW or set the external reference signal for minimum voltage or current 2 Adjust the MIN SPD trimpot until the motor has stopped or is running at the desired minimum speed Calibration MIN SPD ATTENTION The DC3N Drive is intended to operate at a predetermined minimum speed If the application requires zero speed operation the user is responsible for assuring safe conditions for operati...

Page 60: ...l CCW 2 Turn the speed adjust potentiometer full CW or set the external reference signal for maximum speed 3 Adjust the MAX SPD trimpot until the desired maximum motor speed is reached IMPORTANT Check the MIN SPD and MAX SPD settings after recalibrating to verify that the motor runs at the desired minimum and maximum speeds IMPORTANT If operation requires switching between AUTO and MANUAL modes th...

Page 61: ...motor CURRENT LIMIT must be recalibrated for the motor To calibrate CURRENT LIMIT refer to Figure 13 on page 59 or use the following procedure 1 With the power disconnected from the drive connect a DC ammeter in series with the armature 2 Set the CURRENT LIMIT trimpot to minimum full CCW 3 Lock the motor armature shaft Be sure that the motor is firmly mounted in order to withstand torque generated...

Page 62: ...gulation for the highest motor horsepower To calibrate IR COMP refer to Figure 13 on page 59 or use the following procedure 1 Turn the IR COMP trimpot full CCW 2 Set the speed adjust potentiometer or external reference signal until the motor runs at midspeed without load for example 900 RPM for an 1800 RPM motor A hand held tachometer may be used to measure motor speed 3 Load the motor armature to...

Page 63: ...orque The ACCEL setting is factory set for its fastest acceleration time full CCW To calibrate ACCEL 1 Set the speed adjust potentiometer or external reference signal for minimum speed The motor should run at minimum speed 2 Set the speed adjust potentiometer or external reference signal to maximum speed and measure the time it takes the motor to go from minimum to maximum speed 3 If the time meas...

Page 64: ...ence signal for maximum speed The motor should run at maximum speed 2 Set the speed adjust potentiometer or external reference signal for minimum speed and measure the time it takes the motor to go from maximum to minimum speed 3 If the time measured in step 2 is not the desired deceleration time turn the DECEL trimpot CW for a slower deceleration time or CCW for a faster deceleration time Repeat ...

Page 65: ...S ATTENTION Applying the incorrect polarity to the tachometer 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 ATTENTION The control circuit is at line potential when the drive is energized Use a ...

Page 66: ...inimum speed 9 Set SW505 to TACH for tachometer feedback 10 Set the IR COMP trimpot full CCW 11 Set the TACH VOLTS trimpot full CW 12 Apply power to drive 13 Set the speed adjust potentiometer or external reference signal to maximum speed 14 Adjust the TACH VOLTS trimpot until the armature voltage is the same value as the voltage measured in step 6 Check that the TACH VOLTS trimpot is properly cal...

Page 67: ... COMP CURRENT LIMIT IR COMP 1 HP 90 VDC 1750 RPM 10 ADC 1 2 HP 90 VDC 1750 RPM 5 ADC 1 4 HP 90 VDC 1750 RPM 1 4 ADC 1 HP 180 VDC 1740 RPM 5 ADC 1 2 HP 180 VDC 1750 RPM 2 5 ADC 1 4 HP 90 VDC 1750 RPM 1 2 ADC Figure 13 Typical CURRENT LIMIT and IR COMP Settings for DC3N drive actual settings may vary with each application ...

Page 68: ...ition switch with the correct number of positions for the desired number of fixed speeds Application Notes S3 S2 S1 R1 R2 R4 TOTAL SERIES RESISTANCE 10K OHMS R3 Figure 14 Multiple Fixed Speeds ATTENTION The equipment is at line voltage when AC power is connected Disconnect and lockout all ungrounded conductors of the AC power line Failure to observe this precaution could result in severe bodily in...

Page 69: ...entiometers in series Replace the speed adjust potentiometer with a single pole multi position switch and two or more potentiometers in series with a total series resistance of 10K ohms Figure 15 shows a connection for fixed high and low speed adjust potentiometers CW S3 S2 S1 CW 5K OHM 5K OHM HIGH SPEED LOW SPEED ...

Page 70: ...ition switch and two or more potentiometers in parallel with a total parallel resistance of 10K ohms Figure 16 shows the connection of two independent speed adjust potentiometers that can be mounted at two separate operating stations S3 S2 S1 SPEED 1 SPEED 2 20K OHM CW CW 20K OHM Figure 16 Independent Adjustable Speeds ...

Page 71: ...ms or other devices Failure to observe these precautions could result in bodily injury Reversing A dynamic brake may be used when reversing the motor direction Figure 17 page 64 Use a three pole three position switch rated for at least the maximum DC armature voltage and maximum braking current Wait for the motor to stop completely before switching it to either the forward or reverse direction See...

Page 72: ...64 Application Notes Figure 17 Reversing Circuit Connection A2 A1 B1 B2 B2 FWD REV BRAKE MOTOR DYNAMIC BRAKE RESISTOR ...

Page 73: ...peed trimpot setting Press the JOG pushbutton to jog the motor Return the RUN JOG switch to RUN for normal operation ATTENTION Starting and stopping with the start stop terminals does not disconnect AC power in the stop position A hardwired AC power disconnection switch must be mounted between the AC source and terminals L I and L2 This is required as the DC3 drive does not have an armature loop c...

Page 74: ...66 Application Notes S3 S2 S1 10K OHM SPEED ADJUST POTENTIOMETER JOG RUN JOG PUSHBUTTON CW Figure 18 RUN JOG Switch Connection to Speed Adjust Potentiometer ...

Page 75: ...there are no short circuits or grounded connections Check that the voltage selection switch settings match the AC line and output voltages Check that the drive s rated armature and field outputs are consistent with the motor ratings Check that the line fuses are properly sized and not blown ATTENTION This equipment is at line voltage when AC power is connected Disconnect and lockout all ungrounded...

Page 76: ...ever the drives reaches current limit and stays off whenever the drive is not in current limit normal operation The green POWER LED turns on whenever AC line voltage is applied to the drive and stays off whenever there is no AC line voltage applied to the drive DECEL CCEL 2 TACH ARM SW505 VOLTS TACH C506 FB IC505 IC504 C505 T501 CURRENT IL501 LIMIT SCR502 IL502 IR COMP POWER LED CURRENT LIMIT LED ...

Page 77: ...ing caused by a combination of ambient conditions and high current spikes i e reversing 4 Field circuit is open shunt wound motors only 1 Check that line fuses are correct for motor size page 13 2 Check motor cable and armature for shorts 3 Add a blower to cool the drive components or decrease the duty cycle of the system 4 Send drive to Reliance Electric repair department ...

Page 78: ... signal or current external reference signal set to zero speed 2 Speed adjust potentiometer voltage or current external reference signal not connected to drive input properly connections are open 3 S2 is shorted to S1 1 Increase the speed adjust potentiometer voltage or current setting 2 Check connections to input Verify that connections are not open 3 Remove short ...

Page 79: ...voltage 6 Motor is not connected 7 B1 not connected to B3 if START STOP pushbuttons are not used 8 Motor is stalled because of incorrect field connections shunt wound motors only 4 Verify that motor is not jammed Increase CURRENT LIMIT setting if it is set too low 5 Apply AC line voltage to L1 and L2 6 Connect motor to A1 and A2 7 Connect B1 to B3 8 Verfiy proper field connections ...

Page 80: ...X SPD settings are too high 2 Motor field connections are loose shunt wound motors only 3 Motor is demagnetized 4 Tachometer leads are reversed 1 Recalibrate MIN SPD and MAX SPD 2 Check motor field connections 3 Check for proper braking technique and method by which power is cycled 4 Check tachometer connections ...

Page 81: ...PD not calibrated 3 Motor field not properly connected shunt wound motors only 4 TACH VOLTS trimpot not calibrated properly 5 Motor is demagnetized 1 Verify all switch settings 2 Calibrate MIN SPD and MAX SPD 3 Verify motor field connections 4 Recalibrate TACH VOLTS trimpot 5 Check for proper braking technique and method by which power is cycled ...

Page 82: ... COMP setting is too low 3 Motor is overloaded 1 IR COMP is set too high 2 Motor bouncing in and out of torque limit 1 Increase MAX SPD setting 2 Increase the IR COMP setting 3 Check motor load Resize the motor if necessary 1 Adjust the IR COMP setting slightly CCW until the motor speed stabilizes 2 Make sure motor is not undersized for load adjust CURRENT LIMIT trimpot ...

Page 83: ...75 Troubleshooting Figure 20 DC3N Block Diagram Block Diagram ...

Page 84: ...tage L2 230 TB501 Neutral terminal for 230 VAC line voltage F1 F2 TB501 Field coil connections shunt wound motors only Field voltage is 100 200 VDC A1 A2 TB501 Connections to motor B1 B2 B3 TB502 Connections for START STOP pushbuttons S1 S2 S3 TB502 Connections for speed adjust potentiometer or external reference signal 76 Troubleshooting ...

Page 85: ...for 115 VAC line voltage L2 230 terminal 3 Neutral terminal for 230 VAC line voltage F1 F2 terminals 4 and 5 Field coil connections shunt wound motors only Field voltage is 100 200 VDC A1 A2 terminals 6 and 7 Connections to motor COM terminal 8 Circuit common for external reference signal REF terminal 9 Signal lead for external reference signal 77 Troubleshooting ...

Page 86: ...st specifications EN55011 1991 emissions EN50082 1 1992 immunity Compliance allows Reliance Electric s DC3N 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 componen...

Page 87: ...oFarads X 0 0055 microFarads Y R 330Kohms Rated current 1 4 times maximum DC motor current Filter type Balanced 2 section Table 5 Corcom Filters www corcom com Nameplate Current of Motor Wired Corcom Filter to the Drive Part Number 0 to 4 amps 6VV1 4 1 to 13 amps 20VV1 IMPORTANT The filters in Table 5 must be wired to the AC output of the drive as close to the drive as possible The ground connecti...

Page 88: ...MM filter must be deployed on the output XX is the rated current on the filter The CE20MM 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 6 Armature Filters www minarikcorp com Nameplate Current of Motor Wired Minarik Filter to the Drive Part Number...

Page 89: ... 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 mach...

Page 90: ...NOTES 82 ...

Page 91: ...NOTES 83 ...

Page 92: ...l International Corporation All rights reserved Printed in USA This document as well as more information about Reliance Electric products can be found at www reliance com drives C M Y CM MY CY CMY K 92 pdf 8 5 04 3 16 57 PM 92 pdf 8 5 04 3 16 57 PM ...

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