Magnetek DSD 412 User manual

DSD 412 DC Elevator Drive
Technical Manual
CS00407 rev 06

2
Warranty
Standard products manufactured by the Company are warranted to be free from defects in
workmanship and material for a period of one year from the date of shipment, and any
products, which are defective in workmanship or material, will be repaired or replaced, at the
Company’s option, at no charge to the Buyer. Final determination as to whether a product is
actually defective rests with the Company. The obligation of the Company hereunder shall be
limited solely to repair or replace, at the Company’s discretion, products that fall within the
foregoing limitations, and shall be conditioned upon receipt by the Company of written notice of
any alleged defects or deficiency promptly after discovery and within the warranty period, and
in the case of components or units purchased by the Company, the obligation of the Company
shall not exceed the settlement that the Company is able to obtain from the supplier thereof.
No products shall be returned to the Company without its prior consent. Products, which the
company consents to have returned, shall be shipped prepaid f.o.b. the Company factory. The
Company cannot assume responsibility or accept invoices for unauthorized repairs to its
components, even though defective. The life of the products the Company depends, to a large
extent, upon type of usage thereof and THE COMPANY MAKES NO WARRANTY AS TO
FITNESS OF ITS PRODUCTS FOR THE SPECIFIC APPLICATIONS BY THE BUYER NOR
AS TO PERIOD OF SERVICE UNLESS THE COMPANY SPECIFICALLY AGREES
OTHERWISE IN WRITING AFTER PROPOSED USAGE HAS BEEN MADE KNOWN TO IT.
This warranty does not apply to experimental products for which no warranty is made or given
and Buyer waives any claim thereto.
THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER
WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING, BUT LIMITED TO, ANY
WARRANTY OF MECHANTIBILITY OR OF FITNESS FOR A PARTICULAR PURPOSE AND
BUYER HEREBY WAIVES ANY AND ALL CLAIMS THEREFORE.
Limitations Of Liability
IN NO EVENT SHALL MAGNETEK BE LIABLE FOR LOSS OF PROFIT, INDIRECT,
CONSEQUENTIAL OR INCIDENTAL DAMAGES WHETHER ARISING OUT OF WARRANTY,
BREACH OF CONTRACT OR TORT.
DSD 412 is a trademark of Magnetek, Inc.
All rights reserved. No part of this publication may be reproduced or used in any form or by any means - graphic, electronic, or
mechanical including photocopying, recording, taping, or information storage and retrieval systems - without written permission of
the publisher.
2004 Magnetek, Inc.

3
Table of Contents
Warranty 2
Introduction 15
Drive Description 15
The Standard Control Display Unit (SCDU) 15
The Portable Control Display Unit (PCDU) 15
Drive Ratings and Specifications 15
Basic Drive Specifications 15
Service Conditions 15
Protective Features 15
Power Conversion Unit 20
Description 20
Hardware Descriptions 20
DSD 412 Power Supply PCB (A4) 20
Armature Interface PCB (A2) 20
SCR's 21
Field Interface PCB (A3) 21
Cell snubber PCB (A5) 21
Drive Control PCB (A1) 21
Precautionary Statements 23
How To Contact Magnetek 23
Pre-Installation Considerations 24
Receipt of Shipment 24
Unpacking Instructions 24
Packing Instructions for Reshipment or Storage 24
Physical Installation 24
Selecting, Mounting and Wiring of the Digital Encoder 24
Electrical Hook up 26
Power Connections 26
Signal Connections 26
Grounding 26
Pre-power Check 26
Drive Start up 27
Drive power-up sequence 27
Abnormal Display Conditions 27
Fan Check 27
Verify Parameters 27
Standard Control/Display Unit Operation 35
General 35
Start-Up Operation 35
After Power-Up 36
Changing Parameter Functions 36
Viewing Monitor Functions 37
Error Reporting 38
Fault Display/Clear 40
Error Display 40
Non-Volatile Ram Access 41
Load Default Function 42
Self Tune Function 42
Power Conversion Diagnostics 44
Drive Setup & Adjustments 46

4
Software Operating Features 46
Motor Field Current Control 46
Analog Velocity Follower 47
Internal Preset Speed & Profile Generator 47
Serial Link Follower 47
Maintainance mode - Armature Voltage Feedback 47
Pre-Torque 47
Current Ramp-Down 47
Electronic Motor Over-Load 48
External/Auto Fault Reset 48
Over-Speed Test 48
Anti-Rollback (ARB) 48
Drive Standby Power Reduction (DSPR) 48
Brake Control Logic 48
Adjustment Function Descriptions 49
Drive Set-Up 67
Field Regulator Set-Up 67
AC Input Voltage Requirement & Adjustment 67
Speed Regulator Adjustment 67
Drive Faults 88
Function Error Code Listing 88
Troubleshooting 89
Input – Output Signal Verification 99
Maintenance 100
Preventive Maintenance 100
Repair and Replacement Procedures 100
Printed Circuit Boards 100
Drive Control PCB Replacement. 106
IC Replacement 106
Testing and Replacement of Power Components. 106
Testing and Replacement of Power Semiconductors and Snubber Components. 107
Testing and Replacement of the Motor Field Control Module and PCB 107
Repair of the 195Amp Assembly 108
Repair of 300Amp Assembly 110
Spare Parts 113

5
List Of Tables
Table 1: Drive Parameters 11
Table 2: Monitor Functions 12
Table 3: Misc Commands 12
Table 4: Fault References 14
Table 5: Binary Preset Speed Select 58
Table 6: Progressive Preset Speed Operation 58
Table 7: Programmable Output Selections 63
Table 8: Notch Period steps 63
Table 9: Cube I.D. Number 66
Table 10: Field Current Range 66
Table 11: Binary Input Control 76
Table 12: Progressive Input Control 76
Table 13: Fault Code Descriptions 97
Table 14: Connector Definitions 101
Table 15: Test Point Definitions 105
Table 16: SCR Gate Resistance Testing 108
Table 17: Spare Parts 114
List Of Figures
Figure 1: DSD 412 Block Diagram A 16
Figure 2: DSD 412 Block Diagram B 17
Figure 3: Component Layout Front View 18
Figure 4: Component Layout Right Side View 19
Figure 5: Common Problems in Encoder Mounting 25
Figure 6: Typical Power Wiring 29
Figure 7: Typical Analog Signal Wiring 30
Figure 8: Typical Serial Signal Wiring 31
Figure 9: Power/ Signal Wiring Notes 32
Figure 10: Drive Brake Control Feature 33
Figure 11: Speed Select Logic Input Wiring 34
Figure 12: S-Curve Accel/Decel Cycle 61
Figure 13: S-Curve Accel with min %S 61
Figure 14: S-Curve with 100% S 61
Figure 15: E-REG Tracking Profiles (1) 70
Figure 16: E-REG Tracking Profiles (2) 70
Figure 17: E-REG Tracking Profiles (3) 71
Figure 18: Motor Overload 72
Figure 19: Elevator Start - Stop Timing 74
Figure 20: Analog Signal Ground Noise 79
Figure 21: Serial Link Connections 79
Figure 22: Other Faulting Conditions 98
Figure 23: I/O Monitor Function 99
Figure 24: Connector and E-prom Locations 102
Figure 25: Test Point Locations 103
Figure 26: Drive Chassis Outline, DSD 412, 100 Amp 115
Figure 27: Drive Chassis Outline, DSD 412, 195 Amp 116
Figure 28: Drive Chasis Outline, DSD 412, 300 Amp 117
Figure 29: Layout, DSD 412, 100 Amp 118
Figure 30: Layout, DSD 412, 195 Amp 119
Figure 31: Layout, DSD 412, 300 Amp 120

6

QUICK REFERENCE FOR SET-UP PARAMETERS
7
FNCT.# DESCRIPTION UNIT RANGE DEFAULT
SITE
SETTING SITE SETTING
1 CURRENT LIMIT. % 0 - 300 250
2 USE SELF- TUNE
VALUES
LOGIC 0 - 1 0=OFF
3 RTD. ARMATURE AMPS ADC 2.0 -
1250.0
50.0
4 ARMATURE OHMS OHMS 0.001 -
5.000
0.100
6 ARMATURE
INDUCTANCE
HNY 0.0010 -
1.000
0.0100
7 RTD. ARMATURE VOLTS VDC 150 - 550 240
8 I REG CROSSOVER RAD 100 - 1000 500
9 NOMINAL AC INPUT VAC 150 - 525 230
10 ENCODER PPR P/R 600 -
19999
1024
11 RATED MOTOR RPM RPM 50.0 -
1999.0
1150.0
12 OVERSPEED % % 0.0 - 150.0 110.0
14 V SENSE % % 0.0 - 100.0 25.0
15 T SENSE % % 0.0 - 100.0 5.0
16 ENCDR / MTR RATIO - 1.000 -
19.000
1.000
17 RATED CAR SPEED - 1.0 -
1900.0
400.0
21 EXT ACCEL LIMIT n/S^2 2.00 -
10.00
4.20
22 ERROR LIST RESET LOGIC 0 - 1 0=OFF
32 FULL FIELD DETECT % 30 - 90 80
38 ARM VLT RESPONSE RAD 1.0 - 4.0 2.0
39 HI SPEED BANDWIDTH RAD 1 - 15 6.0
40 LO SPEED BANDWIDTH RAD 1 - 15 6.0
41 PER-UNIT INERTIA SEC 0.10 - 9.99 2.00

QUICK REFERENCE FOR SET-UP PARAMETERS
8
FNCT.# DESCRIPTION UNIT RANGE DEFAULT
SITE
SETTING SITE SETTING
42 STIFFNESS - 0.2 - 9.9 1.0
49 WEAK FIELD CURRENT ADC 0.2 - 40.0 40.0
50 FULL FIELD CURRENT ADC 0.20 -
40.00
1.90
51 MOTOR FIELD L/R SEC 0.10 -
10.00
0.54
52 RTD. FIELD VOLTS DC VDC 50 - 525 240
53 STANDBY FIELD AMPS % 10 - 100 25
54 FIELD RESPONSE RAD 1.0 - 10.0 5.0
55 FIELD CONTROL AC
SOURCE VOLTS
VAC 0 - 525 0
63 U/D PICK-UP % 0.01 -
100.0
0.10
64 LOW SPEED
THRESHOLD
% 0.1 - 100.0 2.0
80 OVER SPEED TEST LOGIC 0 - 1 0=OFF
81 OVER SPEED MULT - 1.00 - 1.50 1.00
82 REFERENCE MULT - 0.500 -
2.000
1.000
83 MOTOR OVERLD TIME SEC 2.0 - 500.0 48.0
84 MOTOR OVERLD LEVEL PU 0.5 - 2 1.15
85 I DECAY RAMP SEC 0.01 - 2.50 0.20
86 ANALOG SPD REF
ZERO
PU -0.02 - 0.02 0.0000
87 PRE-TORQUE MULT - 0.25 - 2.00 1.00
88 DSPR DELAY TIME MIN 0 - 60 0 (OFF)
89 BRAKE PICK TIMER SEC 0.5 - 5.0 1.0
90 BRAKE DROP TIMER SEC 0.5 - 5.0 1.5
91 MUST STOP TIMER SEC 0.1 - 5.0 2.0

QUICK REFERENCE FOR SET-UP PARAMETERS
9
FNCT.# DESCRIPTION UNIT RANGE DEFAULT
SITE
SETTING SITE SETTING
92 BRAKE AUTO STOP ON LOGIC 0 - 1 0=OFF
93 ANALOG OUT 0 BIAS - -1 - +1 0.0
94 ANALOG OUT 1 BIAS - -1 - +1 0.0
95 ANALOG OUT 0 SELECT
TB1(45)
NUM 0 - 8 1
96 ANALOG OUT 1 SELECT
TB1(46)
NUM 0 - 8 3
97 ANALOG OUT 0 MULT - 00.10 -
10.00
0.80
98 ANALOG OUT 1 MULT - 00.10 -
10.00
0.80
99 SPEED ERROR TRIP
TIME
SEC 0.20 - 5.00 5.00
100 SPEED ERROR TRIP
LEVEL
% 0.0 - 100.0 100.0
101 AUTO FAULT RESET ON LOGIC 0 - 1 0=OFF
102 3S LOOP FLT LOGIC 0 - 1 0=OFF
104 SERIAL GAIN SWITCH LOGIC 0 - 1 0=OFF
105 GAIN SWITCH SPEED PU 0.00 - 1.10 1.10
107 TACH RATE GAIN % 0.0 - 30.0 0.0
110 REFERENCE MODE
SELECT
NUM 1 – 4 2
111 ARCH TRAV DISABLE LOGIC 0 - 1 1=ON
112 FEEDBACK SELECT NUM 0 - 1 1 =
ENCODER
113 ARM VOLTS @ MAX
SPEED
VDC 650 - 0 100
114 PRE-TORQUE ENABLE LOGIC 0 - 1 0=OFF
115 RNUP RNDN ENABLE LOGIC 0 - 1 0=OFF
116 DECEL RATE LATCH LOGIC 0 - 1 0=OFF
120 SPEED ERROR DETECT
TIME
SEC 0.0 - 5.0 0.5

QUICK REFERENCE FOR SET-UP PARAMETERS
10
FNCT.# DESCRIPTION UNIT RANGE DEFAULT
SITE
SETTING SITE SETTING
121 SPEED ERROR
THRESHOLD
% 0.0 - 15.0 2.0
130 ARB MODE NUM 0 - 2 0 (OFF)
131 ARB BANDWIDTH RAD 1.0 - 15.0 6.0
132 ARB DAMPING - 0.01 -
20.00
2.00
133 ARB SPD
THRESHOLD
% 0.0 - 10.0 0.0
150 BINARY SELECT ON LOGIC 0 - 1 1=ON
151 PRESET SPEED #1 - 0.0 -
1900.0
0.0
152 PRESET SPEED #2 - 0.0 -
1900.0
0.0
153 PRESET SPEED #3 - 0.0 -
1900.0
0.0
154 PRESET SPEED #4 - 0.0 -
1900.0
0.0
155 PRESET SPEED #5 - 0.0 -
1900.0
0.0
156 PRESET SPEED #6 - 0.0 -
1900.0
0.0
157 PRESET SPEED #7 - 0.0 -
1900.0
0.0
170 ACCEL #1 TIME SEC 0.50 -
15.00
5.00
171 ACCEL #2 TIME SEC 0.50 -
15.00
5.00
172 DECEL #1 TIME SEC 0.50 -
15.00
5.00
173 DECEL #2 TIME SEC 0.50 -
15.00
5.00
174 ACCEL #1 % S % 0.1 -
100.0
25.0
175 ACCEL #2 % S % 0.1 -
100.0
25.0
176 DECEL #1 % S % 0.1 -
100.0
25.0
177 DECEL #2 % S % 0.1 -
100.0
25.0

QUICK REFERENCE FOR SET-UP PARAMETERS
11
FNCT.# DESCRIPTION UNIT RANGE DEFAULT
SITE
SETTING SITE SETTING
178 ACCEL #3 TIME SEC 0.50 -
15.00
5.00
179 DECEL #3 TIME SEC 0.50 -
5.00
5.00
180 ACCEL #3 % S % 0.1 -
100.0
25.0
181 DECEL #3 % S % 0.1 -
100.0
25.0
182 INVERT ALARM
RELAY
LOGIC 0 - 1 0=OFF
183 K3 LGC OUT SELCT NUM 1 - 4 1
184 K4 LGC OUT SELCT NUM 1 - 4 1
185 K5 LGC OUT SELCT NUM 1 - 4 1
186 K6 LGC OUT SELCT NUM 1 - 4 1
187 K7 LGC OUT SELCT NUM 1 - 4 1
190 NOTCH DEPTH - 0 - 10 0
191 NOTCH PERIOD - 0 - 10 7
192 F413 DETECTION LVL PU 0.05 -
0.50
0.05
Table 1: Drive Parameters

READ-OUT AND CONTROL FUNCTIONS
12
FNCT.# DESCRIPTION UNIT
600 CAR SPEED -
601 MOTOR RPM RPM
602 SPEED REF -
603 PRE-TORQ
SIGNL %
609 CEMF VOLTS VDC
610 MOTOR ARM V VDC
611 MOTOR ARM I ADC
612 MOTOR FIELD I ADC
613 MEASURED R OHM
614 MEASURED L HNY
615 MEAS. FIELD L/R SEC
616 MEASURED
SPEED ERROR %
617 LINE FREQ HZ
618 HEAT SINK TEMP DEG C
619 MEASURED AC
LINE VOLTS VAC
620 FIELD TRACKING PU
621 SERIAL COMM
ON LOGIC
688 CUBE I.D. -
689 FIELD RANGE -
FNCT.# DESCRIPTION UNIT
690 PCU - VERSION 404
691 PCU - RELEASE -
692 DAY -
693 MONTH -
695 YEAR -
696 BETA “P” -
697 VERSION “SA” 407
698 DCU -RELEASE -
699 CUSTOMER ID 9
Table 2: Monitor Functions
FNCT.# DESCRIPTION
22 CLEAR ERRORS LIST
000 VIEW FAULT LIST
800 VIEW ERROR LIST
801 FAULT/ERROR
ACTIONS
980 TRACE MONITOR
981 VERIFY I/O
993 CLEAR NV RAM
994 SAVE/RECALL
FUNCTION
995 LOAD DEFAULTS
997 SELF TUNE
998 PCU DIAGNOSTICS
Table 3: Misc Commands

COMMON FAULT REFERENCES
13
FAULT # DESCRIPTION
97 OVERSPEED TRIP
98 TACH/ENCODER
LOSS
99 REVERSE
TACH/ENCODER
117/118 SERIAL COM FAULT
400 MOTOR OVERLOAD
401 EXCESSIVE FIELD
CURRENT
402 CONTACTOR FAULT
403 5 MIN FULL FIELD
FAULT
404 OPEN ARMATURE
CIRCUIT FAULT
405 SAFETY CIRCUIT
FAULT
406 10% LOW LINE
ALARM
407 DCU CEMF ALARM
408 PCU CEMF FAULT
409 PCU RESET FAULT
410 SPEED ERROR TRIP
FAULT
411 MAXIMUM AUTO
RESETS FAULT
FAULT # DESCRIPTION
413 FIELD CURRENT
TRACKING FAULT
414 SOFTWARE
COMPATABILITY F
Prot CORRUPTED NV
RAM DATA
900 PCU LOOP FAULT
901 PCU IST FAULT
902 POWER SUPPLY
FAULT
903 LINE SYNC FAILURE
904 LOW LINE FAULT
905 FIELD LOSS
907 THERMISTOR FAULT
908 OVER
TEMPERATURE
909 EXCESSIVE RIPPLE
910 BLOWN FUSE
915 PARAMETER SETUP
917 REVERSE ARM. V.
FEEDBACK
919 RATED VAC.
SETTING ERROR

COMMON FAULT REFERENCES
14
FAULT # DESCRIPTION
920 RATED ARM. VOLT.
SETTING
921 BRIDGE RATING
FAULT
923 RATED ARM. I.
SETTING ERROR
924 RATED FIELD I.
SETTING ERROR
925 FIELD PCB SENSE
FAULT
926 PCU WATCHDOG
929
IFLD FB CANNOT BE
REDUCED TO ZERO
DURING SELFTUNE.
930 IFLD FB CANNOT
GET TO RATED
931
EXCESS OPEN
CIRCUIT VOLTAGE
DURING SELFTUNE.
932
ARMATURE CEMF
VOLTAGE IN XCESS
DURING SELFTUNE.
933
IARM DOES NOT
INCREASE TO NEAR
TEST AMPS DURING
SELFTUNE.
FAULT # DESCRIPTION
934
CALC ARML IS
UNDER RANGE
DURING SELFTUNE.
935
VOLTAGE
FEEDBACK AND
BUSS VOLTAGE
DOESN’T MATCH
DURING SELFTUNE
936
ESTOP CONTACT
WAS OPENED
DURING SELF TUNE
937
LOW READ BACK
VOLTAGE
FEEDBACK DURING
SELFTUNE
938
LOW READ BACK
FROM DC BUSS
CIRCUIT DURING
SELFTUNE
939
FAULTY HARDWARE
IN THE FIELD
INTERFACE CIRCUIT
940 FIELD A/D READING
IS SATURATED
941 MOTOR
THERMOSTAT OPEN
Table 4: Fault References

INTRODUCTION
15
Introduction
Drive Description
The DSD 412 Drive is a complete digital
system drive that provides individual drive
and system control in one compact package.
It is of 12SCR Regenerative configuration.
The drive uses two microprocessors, one for
the Power Conversion Unit (PCU) circuitry,
one for the Drive Control Unit (DCU)
circuitry. Interface to other equipment is
provided with Local I/O [Input/Output], or
RS-232 & RS-422 serial communications.
Extensive diagnostics and setup capability
are provided through two Control/Display
Units.
The Standard Control Display Unit
(SCDU)
is mounted on the Drive Control PCB and
consists of a 4-1/2 digit numeric LED
display, four push buttons and
READ/WRITE colored LEDs. The SCDU
can be used for all setup functions and
many diagnostics.
The Portable Control Display Unit
(PCDU)
is an optional hand-held device that can be
plugged into any analog controlled DSD drive and
used for all the same functions as the SCDU plus
some advanced diagnostics. There exists a
version of this PCDU which will work with the
serial version DSD 412, contact Magnetek for
more information. The PCDU has two lines of
sixteen alphanumeric characters and a thirty-key
keypad. Parameters are entered and displayed
in common understandable units. The drive can
be completely setup prior to actual running and
changes can be made during operation. Keypad
entry of changed parameters, protected memory,
and factory default values allow the operator to
modify data with minimum risk to the process.
The DSD 412 is a power cube. Depending on
rating of the unit, the power cube is in one of four
chassis sizes. Refer to the outline dimension
drawings furnished in section 6. Each power
cube is designed for mounting inside a qualified
electrical enclosure. Space allowances for air
circulation, additional components, outgoing
terminals, and wire bends must be provided.
Hinged door swing-out clearance is the same as
the width dimension.
Drive Ratings and Specifications
The DSD 412 Elevator Drive is designed to be
connected to a three wire ungrounded power
system, or a four wire grounded or ungrounded
power system.
Basic Drive Specifications
• 10-300 Amps (Special order up to
1285Amps or 600VAC)
• 3 Phase, 48/62 Hz
• 1.0 Service Factor
• 150% full load current for one minute
• 250% full load current for 5 seconds
• Full-wave six-pulse SCR control
• Regulation (of set speed) to 0.05% with
digital encoder speed feedback
• Current regulated shunt field control
• Automatic Field weakening.
• Self-adapting to incoming line power
Service Conditions
• Line voltage 150-525 Vac, ±10%, 3 phase.
• 115 volt, ±10%, 1 phase control power
from a separate source.
• Frequency 48-62 Hz
• Operating Temperature 0-45° C (55° C
max at DSD chassis)
• Altitude to 3300 feet above sea level.
Derate 5% for each 1,000 ft above 3300 ft.
• Relative Humidity 95% (noncondensing)
Protective Features
• Programmed memory protection
• Self-protected Control V power supply
• Fast phase-back of loop current
• Contactor interlock for E-Stop
• I2t motor overload protection
• AC line current limiting fuses
• Automatic power up test.
• Control power supply loss detection
• Isolated and grounded electronics
• Encoder/Tachometer monitoring and loss
protection.
• Input line monitoring
• Phase sequence insensitive
• dv/dt protection (snubbers)
• 1400 PRV Thyristors
• Instantaneous over-current protection.
• Phase loss protection
• DC bus fuse
• Field current economizer and loss
protection

INTRODUCTION
16
Figure 1: DSD 412 Block Diagram A
ISOLATION
TRANSFORMER
50/60 Hz
UTILITY
POWER
CUSTOMER
DISCONNECT
F1
F2
F3
SNUBBER PCB
AND
COMPONENTS
L1
L2
L3
LPR
LOOP
PICK-UP
RELAY
K1
CONTACTOR
PILOT
RELAY
MOTOR &
TRANSFORMER
THERMOSTATS
E-STOP
SENSE
K1
SAFETY
CHAIN
LPR
ME
LOOP
CONTACTOR
CONTROL
POWER
XFMR
POWER
SUPPLY
PCB
HEAT SINK
COOLING FAN
CONTACTOR
CONTROL
SIGNAL
SENSING
LOW VOLTAGE
POWER
115 VAC
MOTOR FIELD
CONTROL
HOI ST
MOTOR
FIELD
+
FIELD CURR.
SIGNAL
FIELD CONTROL
SCR GATING

INTRODUCTION
17
SCR POWER BRIDGE
12 SCR REGEN
F4
CURRENT
SENSOR
RIPPLE FILTER
MOTOR
ARM.
ME
SCR
GATE
SIGNALS
RT1
ARMATURE
INTERFACE
PCB
DB
RESISTOR
CONTROL SIGNAL
WIRING
LOCAL CDU
STATUS
LEDS
+18888
UN PRO T
NV MEM
MEM PROT
SWITCH
RE-
SET
POWER CONVERSION UNIT
MICROPROCESSOR
DUAL PORT
MEMORY
RAM &
EPROMS
NV-RAM, RAM
& EPROMS
DRIVE CONTROL UNIT
MICROPROCESSOR
IN-OUT
DRIVERS
TB1 LOCAL CONTROL I / O
DRIVE CONTROL PCB
ME
ME
RS-232 OR RS-422
SERIAL PORT
OPTIONAL
PCDU
PROGRAMMER
OR
OPTIONAL
SERIAL LINK
TO CAR
CONTROLLER
Figure 2: DSD 412 Block Diagram B

INTRODUCTION
18
Figure 3: Component Layout Front View
Q7, FIELD
SCR
SCR'S
A2TB5
SNUBBER
PCB
AC INPUT
FOR FIELD
SUPPLY
DC
OUTPUT
FIELD
SUPPLY
ARMATURE
CURRENT
TRANSDUCE
R
DC
ARMATURE
FUSE F4
AC LINES
FUSES
F1-3
INPUT
POWER
LUGS
GROUND
LUG
ARMATURE
INTERFACE
PCB
BRIDGE
THERMISTOR
CUBE I.D.
PCB

INTRODUCTION
19
Figure 4: Component Layout Right Side View
POWER
SUPPLY
COVER
A4
POWER
SUPPLY
A4 TB3
A1 MAIN
CONTROL
PCB

INTRODUCTION
20
Power Conversion Unit
Description
The Power Conversion Unit circuitry has
three major functions;
1. It converts three phase AC input power
to variable DC voltage for application to
a motor armature.
2. It converts motor generated DC power
to three-phase power to feed back to the
line.
3. It converts single phase AC input power
to a variable DC voltage for application
to a motor field.
Two sources of power are required. A three-
phase power isolation transformer adjusts
the utility mains voltage to that required to
operate DSD 412 efficiently with the needs
of the DC hoist motor. 115VAC control
power from a separate source is used to
power the low voltage power supply, cooling
fans, relay and contactor logic.
Three phase input power is applied through
the AC line fuses to twin 6-SCR power
bridges for forward and reverse control. The
PCU microprocessor controls armature
current based on a reference received from
the Drive Control Unit microprocessor.
Output from the PCU microprocessor is sent
to the Armature Interface PCB, which
produces the gating signals for power SCRs.
The SCR bridge output is an adjustable DC
voltage, which is applied to the motor
armature circuit. Power circuit AC and DC
measurement signals are routed to voltage
dividers on the Armature Interface PCB, and
scaled values are sent to the PCU
microprocessor. Armature current is also
measured and the feedback signal is routed
through the Armature Interface PCB to the
PCU microprocessor. An over current trip
function monitors this signal to initiate an
instantaneous static trip (IST) in the event of
excessive output current.
Single-phase power is also applied through
the AC line fuses to the Field Rectifier
Module. SCR gating signals from the PCU
microprocessor control the field rectifier
SCRs. A separate current measuring device
is used to monitor the DC current flowing to
the motor field. Additional connections allow
for a separate step-up or step-down
transformer to be used to power the motor
field rectifier from voltage mains different
from that for the motor armature.
If optional dynamic braking resistors (DBR)
are present they are applied across the
motor armature to dissipate rotational
energy whenever the loop contactor is
dropped out. This helps to bring the motor
to a stop even when utility power is lost.
The largest component of the PCU is the
SCR bridge (Heat Sink Assembly). The heat
sink is an extruded aluminum structure that
dissipates the heat generated by the SCRs
mounted on the front surface (or between
heat sink sections, in large size power
cubes). The SCRs control the current to the
motor armature and in turn are controlled by
the Armature Interface PCB mounted in front
of the SCRs. Three input power line fuses
are provided. A DC Bus fuse protects the
motor armature circuit. A thermistor (and
thermostat on some ratings) senses heat
sink temperature and gives an over-
temperature warning if an over-temperature
occurs.
Access to the SCR Bridge is obtained by
opening the hinged door containing the
Drive Control PCB A1.
WARNING
Opening the hinged door with power applied
to the drive exposes dangerous voltage
levels. The hinged door should only be
opened by a qualified service technician,
and only when the power to the drive is
turned off.
Hardware Descriptions
DSD 412 Power Supply PCB (A4)
Provides +5V, +15V, -15V, and +24V to the
control circuits and has fold-back current
limit protection. It also provides 115VAC
connections for the main contactor, motor
thermostat and fans.
Armature Interface PCB (A2)
Provides the interface circuitry between the
digital firing pulses generated by the Drive
Control PCB and the high current SCR
gating pulses controlling the armature
current. It also provides feedback signals