Rockwell-automation DC3R Regenerative DC Drive User Guide 1/4 - 2 HP, User Manual

DC3R Regenerative DC DriveUser Guide1/4 to 2 HP, 115/230 VACInstruction Manual D2-3453

2SpecificationsDrive RatingMotor HP Rated AC Input DC Amature DC Armature Field FieldLine Amps KVA Voltage Current Voltage Current1/4 4.2 90 2.7 50 14

3DimensionsFigure 1. DC3R Chassis Drive Dimensions

4DimensionsFigure 2. DC3R NEMA 4X Drive Dimensions

5DimensionsFigure 3. DC3R Heat Sink DimensionsALL DIMENSIONS IN INCHES [MILLIMETERS]

6InstallationWiringATTENTION: The control circuit is at line potential when the drive isenergized. Use a non-metallic screwdriver when making adjustm

7InstallationAs a general rule, Reliance Electric recommends shielding of allconductors if:• wire lengths exceed 4 inches and power and logic leads m

8InstallationInput isolation transformers might be needed to help eliminate thefollowing:· Damaging line voltage transients from reaching the drive.·

9InstallationProtect the drive from dirt, moisture, and accidental contact. Providesufficient room for access to the terminal block and calibration tr

10InstallationMounting enclosed drivesNEMA 4X enclosed drives come with three 0.88 inch (22 mm) conduitknockout holes at the bottom of the enclosure.

11InstallationCage-clamp terminal blockConnections to the DC3R drive are made to a cage-clamp terminal block(Figure 4). To insert a wire into the term

ATTENTION: Identifies information about practices or circumstancesthat can lead to personal injury or death, property damage, or economicloss.The info

12InstallationTachogenerator feedback ATTENTION: Applying the incorrect polarity to the tachogeneratorcan cause an overspeed condition. Make sure the

13Chassis drive connectionsInstallationConnectionsFigure 5. Chassis Drive ConnectionsNOTE: TERMINAL 1 IS THE HOTCONNECTION. TERMINALS 2 AND3 ARE NEUT

14InstallationFigure 6. Enclosed Drive ConnectionsEnclosed drive connectionsNOTE: TERMINAL 1 IS THE HOTCONNECTION. TERMINALS 2 AND3 ARE NEUTRAL CONNE

15ATTENTION: Because the reference potentiometer is connectedthrough the regulator to the armature power circuit, its terminals are atline potential.

16InstallationSpeed adjust potentiometer connectionsFigure 8. Speed Adjust Potentiometer Connections for (a)Unidirectional Operation, and (b) Bidirect

17ATTENTION: The equipment is at line voltage when AC power isconnected. Disconnect and lockout all ungrounded conductors of theAC power line. Failure

18Voltage followerThe drive may be wired to follow a floating (isolated) 0 to ±10V signalthat is isolated from earth ground instead of using a speed a

19ATTENTION: Only qualified technical personnel, familiar with theconstruction and operation of this equipment and the hazards involved,should instal

201. Check connections before applying AC line voltage to the drive.2. Check that no conductive material is present on the printed circuitboard.3.

21OperationLine VoltageSelectorSwitchesArmature VoltageSelector SwitchFeedbackSelector SwitchFigure 10. Selector Switch Locations

ATTENTION: Starting and Stopping with the inhibit terminal pins doesnot disconnect AC power in the stop position; a hardwired AC powerdisconnection sw

22OperationStartupChassis drive1. Set the speed adjust potentiometer for zero speed.2. Apply AC line voltage.3. Slowly advance the speed adjust potent

23OperationLine starting and line stoppingLine starting and line stopping (applying and removing AC line voltage) isrecommended for infrequent startin

24OperationFigure 11. Regenerative Deceleration Switch ConnectionRegenerative deceleration Short terminals RB1 and RB2 to regeneratively decelerate a

25OperationINHIBIT TERMINALSFigure 12. Inhibit TerminalsRegenerative braking using the INHIBIT circuitATTENTION: Starting and stopping with the inhib

26OperationFigure 13. INHIBIT-RUN TerminalsINHIBIT-RUNTERMINALSCoast to a stop using the INHIBIT circuitATTENTION: Starting and stopping with the inh

27The circuit shown in Figure 14 may be used to decelerate a motor to aminimum speed. Closing the switch between S2 and S0 decelerates themotor from s

28Figure 15. Calibration Trimpot LayoutEach drive is factory calibrated to its maximum horsepower rating.Readjust the calibration trimpot settings to

29CalibrationATTENTION: The DC3 Drive is intended to operate at apredetermined minimum speed. If the application requires zero speedoperation, the use

FWD TQREV TQ30CalibrationThe FWD TQ setting determines the maximum torque for accelerating anddriving the motor in the forward direction. It also sets

31CalibrationRecalibrate the IR COMP setting when using a lower horsepower motor.See Figure 19 for typical IR COMP settings, or recalibrate using thef

ivContentsSpecifications 1Dimensions 3Installation 6Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32Calibrate the TACH setting only when a tachogenerator is used. TheTACH setting, like the IR COMP setting, determines the degree to whichmotor speed

33CalibrationFigure 16. Typical FWD TQ, REV TQ, and IR COMP Settings(actual settings may vary with each application)Figure 17. Deadband Settings

34Application NotesFWD-REV switchUse a single-pole, two-position switch with a single speed adjustpotentiometer to plug reverse the motor (Figure 18).

35Use a single-pole, three-position switch with a single speed adjustpotentiometer to stop a motor between reversals (Figure 19). Set the switchto the

36Application NotesIndependent adjustable speedsConnect two speed adjust potentiometers with a single-pole two-positionswitch to select between two in

37Application NotesIndependent forward and reverse speedsFigure 21. Independent Forward and Reverse SpeedsATTENTION: At very low input levels, noise

38Application NotesIndependent Forward and Reverse Speeds with a Forward-Stop-Reverse SwitchFigure 22. Independent Forward and Reverse Speeds with aFo

39TroubleshootingATTENTION: This equipment is at line voltage when AC power isapplied. Disconnect and lockout all ungrounded conductors of the ACpow

40TroubleshootingLine fuse blows1. Disconnect AC line voltage from the drive.2. Check that the motor cable and armature is not shorted or grounded.a

41TroubleshootingMotor will not reach the desired speedATTENTION: The control circuit is at line potential when the drive isenergized. Use a non-metal

vTroubleshooting 39Prewired Connections for Enclosed Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42Regener

42TroubleshootingPrewired Connections for Enclosed DriveFigure 23. Prewired Connections to L1, L2(115) and L2(230)Figure 24. Prewired Speed Adjust Pot

43Regenerative DrivesFigure 25. Four Quadrant OperationMost non-regenerative, variable speed, DC drives control current flow to amotor in one directio

44CE ComplianceReliance Electric hereby certifies that its DC3 series drives have beenapproved to bear the “CE” mark provided the conditions of approv

45CE ComplianceTable 3. Corcom®FiltersNameplate Current ofMotor Wired to the Drive Corcom®Filter Part Number0 to 4 amps 6VV14.1 to 13 amps 20VV1The f

The OEM has this liberty because CE is a machinery directive. Whetheror not every component in the OEM’s machinery meets CE, the OEMmust still submit

U.S. Drives Technical Support Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: [email protected], Online: www.ab.com/support/abdrives

Figure 1. DC3R Chassis Drive Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3Figure 2. DC3R NEMA 4X Drive

viiTablesTable 1. Field Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11Table 2

viii

1SpecificationsMax. Armature HP Range HP RangeCurrent with 115 VAC with 230 VACModel (Amps DC) Applied AppliedDC3R 10.0 † 1/4–1 † 1/2–2 †† Maximum ar