Rockwell Automation RELIANCE ELECTRIC DC3N Series User manual

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

Corcom is a trademark of CII Technologies.
Reliance is a trademark of Rockwell Automation.
© 2004 Rockwell International Corporation All rights reserved
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:
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.

i
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: 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 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.


ii Safety Warnings
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 DC 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.


Specifications 1
Dimensions and Layout 4
Installation 7
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Shielding guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Chassis drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Isolation transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Heat sinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
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

Field output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Tachometer feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Voltage or current follower . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Slide switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
LINE VOLTAGE (SW501 and SW502) . . . . . . . . . . . . . . . . . . . .33
MOTOR (SW503) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
SIGNAL (SW504) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
FEEDBACK (SW505) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Operation 36
Before applying power (all models) . . . . . . . . . . . . . . . . . . . . . . . . .37
Drive operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Chassis drive operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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
Approximate IR COMP calibration: . . . . . . . . . . . . . . . . . . . .55
ACCEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
iv Table of Contents

DECEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
TACH VOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Application Notes 60
Multiple fixed speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Adjustable speeds using potentiometers in series . . . . . . . . . . . . .61
Independent adjustable speeds . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
RUN/JOG switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Troubleshooting 67
Before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Diagnostic 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
vTable 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 6. Armature Filters www.minarikcorp.com . . . . . . . . . . . . . .80

Figure 1. DC3N-12D-00-010-AI Dimensions . . . . . . . . . . . . . . . . . . . .4
Figure 2. DC3N-12D-4X-010-AI Dimensions . . . . . . . . . . . . . . . . . . . .5
Figure 3. PC Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Figure 4. Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . . . . .14
Figure 5. Cage-Clamp Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Figure 6. DC3N-12D-00-010-AI Drive Connections . . . . . . . . . . . . . .23
Figure 7. DC3N-12D-00-010-AI Drive
Signal Follower Connection . . . . . . . . . . . . . . . . . . . . . . . .24
Figure 8. DC3N-12D-4X-010-AI Drive Connections . . . . . . . . . . . . . .31
Figure 9. Slide Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Figure 10. 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. Reversing Circuit Connection . . . . . . . . . . . . . . . . . . . . . .64
Figure 18. RUN/JOG Switch Connection to
Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . . . .66
Figure 19. Diagnostic LED Locations . . . . . . . . . . . . . . . . . . . . . . . . .68
Figure 20. DC3N Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
vi
Illustrations

Specifications
Max.
Armature HP Range HP Range
Current with115 VAC with 230 VAC
Model (Amps DC) Applied Applied
DC3N-12D-00-010-AI 10A 1/4 – 1 1/2 – 2
DC3N-12D-4X-010-AI 10A 1/4 – 1 1/2 – 2
Model Style
DC3N-12D-00-010-AI Open chassis
DC3N-12D-4X-010-AI NEMA 4X/12
AC Line Voltage 115 VAC or 230 V AC, 50 or 60 Hz, 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 Factor 1.37 at base speed
Service Factor 1
Maximum Speed Trimpot Range (% of rated input voltage) 0 to 90%
1

Minimum Speed Trimpot Range (% of rated input voltage) 0 to 50%
Torque Trimpot Maximum Setting (% of maximum current) 200%
IR Drop Compensation (% of rated armature voltage) 0 to 15%
Acceleration Time Range 0.5 – 10 seconds
Deceleration Time Range 0.5 – 10 seconds
Analog Input Signal Range (S1 to S2) 0 – 10 VDC or 4 – 20 mADC
Input Impedance (S1 to S2) >100 KOHMS
Speed Regulation (% of base speed with 95% load change)
With Armature 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 Elevation3300 ft (1000 m) max without derating*
Vibration 0.5G max. (0–50 Hz); 0.1G max. (>50 Hz)
Ambient Temperature Range
Chassis Drives 10°C – 55°C
Enclosed Drives 10ºC – 45ºC
Non-condensing Relative Humidity 0% to 95%
* Derate the current by 1% for every 300 ft (90m) above 3300 ft., up to 10,000 ft. (3000m)
2 Specifications