MICROPHASE DCD300 User manual

MICRO
PHASE
Service Manual
DCD300
Via Palladio, 23 – 36051 Creazzo (VI) - Italy
 [phone] - in [e-mail] – www.microphase.eu

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DCD300
White page

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DCD300
WARNING!
The converters of the DCD300 series are running at high voltages. Even after disconnecting the
converter, the capacitor circuits are still under voltage for a short period of time. Therefore it is
absolutely recommended to wait 5 minutes until operating on the inner part of the converter.
The converter is equipped with an inner recovery resistance working at high voltages and high
operating temperatures. Do not touch under no circumstances the recovery resistance also after
disconnecting the converter.

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DCD300
SOMMARIO:
GENERALITY 5
OVERALL DIMENSIONS 6
TECHNICAL FEATURES 9
GENERAL CHARACTERISTICS 10
FUNCTIONAL DIAGRAM 12
BLOCK DIAGRAM OF THE REGULATION CARD 13
CUSTOMISING CARD AND SETTINGS 14
DISPLAY SIGNALS 15
TERMINAL CONNECTIONS 18
POWER CONNECTIONS 19
WARNING: 20
EXAMPLES OF CONNECTIONS 21
RECOMMENDATIONS FOR THE INSTALLATION AND OPERATION 24
DIAGNOSTICS 26
RECOMMENDATION FOR INSTALLATION ACCORDING TO THE EMC STANDARDS 29

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DCD300
GENERALITY
The four quadrant converters of the DCD300 series
integrate both the power supply unit and the braking unit and
have been realised to exploit the most advanced technology,
in particular the final IGBT stage which operates with a PWM
switching frequency of 10 KHz.
The regulation is realised by the P.W.M. (Pulse Width
Modulation) using a particular technology with 2 different
signals (instead of the traditionally used single signal) with a
phase displacement of 180°for controlling the final power.
The combination of these signals allows to obtain a
switching cycle of the final power which reduces the current
ripple by 50 % combined with all advantages regarding
maintenance and life of the brushes and of the motor.
The converters of the DCD300 series are developed for
controlling the speed of d.c. motors with permanent magnets
both with dynamo tachometric and armature feedback.

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DCD300
OVERALL DIMENSIONS
DCD300 10/20 20/40 30/60 40/80

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DCD300
DCD300 60/120

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DCD300
Note: Observe a minimum free distance of 10 cm between converter
and surrounding components so as not to hinder the ventilation of the
converter.

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DCD300
TECHNICAL FEATURES
Drive sizes
TYPE POWER SUPPLY
NOMINAL
CURRENT AT
40###C
PEAK
CURRENT FOR
1.5 sec.
OUTPUT
VOLTAGE
DCD 150 / 10M
Single phase
25÷90 V AC
±10% 50 - 60 Hz.
10A 20A
30÷120 Vcc
DCD300 / 10M
Single phase
90 ÷240 V AC
±10% 50 - 60 Hz.
10A 20A
DCD300 / 10A
DCD300 / 20A
DCD300 / 30A
DCD300 / 40A
DCD300 / 60A
DCD300 / 60A
Three-phase
90 ÷240 V AC
±10% 50 - 60 Hz.
10A 20A
20A 40A
30A 60A
40A 80A
60A 120A
75A 150A
120÷280 Vcc

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DCD300
GENERAL CHARACTERISTICS
Supply voltage of the DCD
150M: from single-phase autotransformer with a
secondary voltage of 25V ÷90V AC ±10%
Supply voltage of the DCD
150: from three-phase autotransformer with a
secondary voltage of 25V ÷90V AC ±10%
Supply voltage of the
DCD300M: from single-phase autotransformer with a
secondary voltage of 90V ÷ 240V AC ±10%
Supply voltage of the DCD300:
from three-phase autotransformer with a
secondary voltage of 90V ÷240V AC ±10%
Mains frequency: 50/60 Hz.
Output voltage: 30 / 280 Vdc
Speed loop bandwidth: > 100 Hz.
PWM switching frequency: 10 KHz
Velocity input reference: ±10 V
DC (input impedance 100 Kohm)
Regulation:
• Fine velocity tuning with trimmer P7 on the customising card
• Offset compensation of the velocity signal with trimmer P1 on the regulation
card
• Acceleration ramp gradient adjustable from 0 to 1 sec. with trimmer P2 on
the customising card
• Deceleration ramp gradient adjustable from 0 to 1 sec. with trimmer P1 on
the customising card
• Current limit with trimmer P4 on the regulation card

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DCD300
Functions:
•Diagnostics on DISPLAY
• Torque programming from the outside by signal from 0 to +10V DC
Inner protections:
•Against short-circuit between motor terminals
•Against short-circuit between motor and towards earth
•Against mains overvoltage
•Against mains undervoltage
•Against power overheat
•Against excessive energy gain on inner clamp resistance’s
•Against breakage or failure of dynamo tachometric connections
Optional:
•Velocity regulation with armature feedback
Operation:
Temperature: from 0 ÷40°C
Humidity: 90% max. without condensation
Altitude: 1000 m.
Protection degree: IP 20

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DCD300
FUNCTIONAL DIAGRAM

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DCD300
BLOCK DIAGRAM OF THE REGULATION CARD

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DCD300
CUSTOMISING CARD AND SETTINGS
Description of the plug-out customising card and settings
Jumper closed Range
S6 S7 S8 S9 Dynamo voltage
17.5VDC
÷ 28.5VDC
x 26VDC
÷ 42VDC
x x 36VDC
÷ 60VDC
x x x 51VDC
÷ 84VDC
x x x x 79VDC
÷ 130VDC

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DCD300
DISPLAY SIGNALS
Segment Indicates that the unit is supplied with power, however not
enabled for operation
One Drive enabled for operation
Point The point lights up when the motor absorbs current superior to
its nominal current. This is normal during the acceleration and
starting. When the point lights up for more than 2÷3 seconds,
the IxT device activates and on the display will light up 7instead
of 1
Five Alarm of the protection device against mains over- and under
voltage. Check the R.S.T. power supply. Until the abnormality
continues the drive is disabled. Automatic reset is done when
the normal operation conditions are achieved

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DCD300
Six Fault alarm. Short-circuit between the motor connections or of
the power unit. Check the insulation of the motor terminals and
towards earth (motor housing) by measuring the resistance.
The measured value has to be superior to 1 Mohm. During this
operation the drive is blocked and can be reset by tuning off
from the R.S.T. power supply for at least 5 seconds
Seven The IxT device is activated. This protection circuit limitates the
drive current to the fixed nominal current (which corresponds
normally to the nominal current of the motor). After 2 seconds
this function is disactivated and allows the maximum current
output of the motor size
Eight Alarm of missing or inverted connections of terminal 7 and 8 of
the dynamo tachometric. During this operation the drive is
blocked and can be reset by tuning off from the R.S.T. power
supply for at least 5 seconds

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DCD300
Nine Alarm of excessive gain and overheat of the inner braking
resistance. The machine cycle or the deceleration ramp timing
have to be increased. During this operation the drive is blocked
and can be reset by turning off the R.S.T. power supply for at
least 5 seconds
Zero Overheat alarm of the power supply. Until the abnormality
continues, the drive is disabled. Automatic reset is done when
the normal operation temperature is achieved. Check the well
functioning of the ventilation. Observe the minimum free
distance of at least 10 cm. of the inferior part when installing the
drive

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DCD300
TERMINAL CONNECTIONS
Table of available INPUT/OUTPUT of the plug-out connector:
Connector X1
TERMINAL NAME TYPE DESCRIPTION
1 +REF IN Non inverting input of the analogic reference signal
2 -REF IN Inverting input of the analogic reference signal
3 GND 0V of the regulation circuits, such as terminal 9
4 DIR OUT
Output of the differential input stage. It has to be
connected to terminal 6 CONN. when the inner ramp
circuit is not used. The terminal remains free when
the inner ACC/DEC ramps are used
5 RAMP OUT
Output of the ramp circuit. It has to be connected to
terminal 6 CONN. when the inner ramp circuit is used.
The terminal remains free when the inner ACC/DEC
ramps are used
6 CONN. IN Connection terminal for the function mode. When
connected to terminal 4 (DIR),, the inner ACC/DEC
ramp circuits are excluded, when connected to
terminal 5 (RAMP) they are enclosed
7 +TACHO IN Positive input signal of the dynamo tachometric
8 -TACHO IN Negative input signal of the dynamo tachometric
9 GND 0V of the regulation circuits, such as terminal 3
10 TORQUE IN Input for the signal from 0 to +10V for the external
torque regulation (+10V correspond to the peak
current of the drive). Do not use this input and let
disconnected the terminal when running at the max.
available torque
11 DRIVE OK Output with no voltage applied for the contact of the
inner protection relay. During faultless operation, the
contact is normally closed. When a protection device
is activated, the contact is open (max. 24V, 100 mA)
12 DRIVE OK Output with no voltage applied for the contact of the
inner protection relay. During faultless operation, the
contact is normally closed. When a protection device
is activated, the contact is open (max. 24V, 100 mA)
13 ENABLE IN Input for the
0V or 24VDC enable signal of the drive
(without no difference a 0V or a +24V signal can be
used)

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DCD300
TERMINAL NAME TYPE DESCRIPTION
14 MIN. SPEED Output for the 0V/+24V signal with electronic
threshold for minimum speed. A 0V signal indicates a
motor speed between 0 and 5 % of the maximum
fixed speed; a +24V signal indicates that the fixed
speed level has been exceeded
15 +10V OUT
Auxiliary voltage of +10V (max. 2mA)
16 -10V OUT
Auxiliary voltage of -10V ( max. 2mA)
17 +24V OUT
Auxiliary voltage of +24V ( max. 50mA)
18 I. MOT. OUT
Output for the voltage signal between -2V and +2V
proportional to the effective current value of the
corresponding motor size (the sign depends on the
motor current polarity)
POWER CONNECTIONS
Connector X2
TERMINAL NAME TYPE DESCRIPTION
###M OUT Negative motor connection terminal
+M OUT Positive motor connection terminal
R IN Phase 1 of the secondary of the three-phase
autotransformer for the power supply of the converter
(190 VAC maximum)
S IN Phase 2 of the secondary of the three-phase
autotransformer for the power supply of the converter
(190 VAC maximum)
T IN Phase 3 of the secondary of the three-phase
autotransformer for the power supply of the converter
(190 VAC maximum)
Connection terminal for grounding
Attention: Do not disconnect the motor when the converter is
supplied, even by converter disabled. Do not supply
the converter during controls and maintenance.

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DCD300
WARNING:
.
If you use a more then 9KVAtrasformer / autotransformer, will be necessary to use a soft start circuit
as reported in the following scheme:
Bill of components:
 R1, R2, R3 da 20Ωmin. 50W
T2 25/30 A power contact
Rispect the following procedures to start:
1. Insert T2 while mantaining T1 OFF
2. swith ON T1 after 2/3 seconds