DC3R Isolation Option Board User Guide
Contents
1. Dimensions CONMECHONS wurst oe Bee da eS Beda SSW eet 5 Isolation option board connections 2 000 0c eee eee eee 5 Installation 5 Input voltage select switch 2 000 6 Speed adjust potentiometer connections 00 000005 7 Polarity reversal switch connections 2 00002 000ee 8 Calibration 10 Voltage input signal calibration 0000 c eee ees 11 Calibration procedure 0c eee ees 11 Current input signal calibration o ooooooooooooooooo 13 Calibration procedure 0 000 cece eee 13 Troubleshooting 15 Before troubleshooting eee ees 15 Illustrations Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Isolation Option Board Dimensions 2 005 3 Isolation Option Board Mounted on a Regenerative Drive 4 Isolation Option Board Connections 0000005 5 Input Voltage Select Switch 2 222222 6 Speed Adjust Potentiometer Connections 7 Polarity Reversal Switch Connection 0055 8 Open Collector PNP Transistor 00000 cece eeees 9 Polarity Reversal Using NPN Transistor Used as a Polarity Reversal Switch 9 Calibration Trimpot and DIP Switch Layout 10 vi Introduction The isolation option board allows regenerative drives to accept a grounded or floating D2. PNP transistor may also be used to reverse the output voltage polarity Figure 7 Another alternative is to use an NPN transistor as shown in Figure 11 to reverse the output voltage polarity IMPORTANT If using an NPN transistor additional components must be installed Install a 39K ohm resistor in series between Terminal 11 and the transistor collector and a 10K ohm resistor between Terminal 6 and the transistor collector as shown in Figure 8 TP POLREV COM T o M 10 11 12 POLARITY REVERSE SWITCH Figure 6 Polarity Reversal Switch Connection Installation 9 15 15 COM INPUT 1 INPUT2 TP POL REV COM 5 6 7 8 9 10 11 12 Zu Ns TRANSISTOR Figure 7 Open Collector PNP Transistor Used as a Polarity Reversal Switch L2 15 15 COM INPUT1 INPUT2 TP POL REV COM Anh WU ti ar U I U 1 1 fl 4 5 6 7 8 9 10 11 12 ADD 39K AND 10K OHM RESISTORS 19 39K AS SHOWN L o Cc 8 NPN F a TRANSISTOR Figure 8 Polarity Reversal Using NPN Transistor 10 Calibration ATTENTION The following adjustments are made with power on Exercise extreme caution as hazardous voltage exists Failure to observe this precaution could result in severe bodily injury or loss of life ATTENTION T
3. at terminals 3 and 4 L1 and L2 If there is no voltage then check the connections to the regenerative drive that it is connected to 3 Check that the isolation option board board is receiving a voltage or current input signal 4 Check to see that the signal input ADJ trimmer potentiometer P501 is not set to the full CCW position If the unit is running at full speed 1 Check that the voltage output signal across terminals 1 and 2 OUT1 and OUT2 changes when the voltage or current input signal changes 2 Check the wiring to the isolation option board board to the regenerative drive If the unit runs too slow or too fast 1 Check SW501 positions 2 Check MIN SPD and MAX SPD trimpot calibrations If unit does not reverse Check POL REV and COM connections Reach us now at www rockwellautomation com Wherever you need us Rockwell Automation brings together leading brands in industrial automation including Allen Bradley controls Reliance Electric power transmission products Dodge mechanical power transmission components and Rockwell Software Rockwell Automation s unique flexible approach to helping customers achieve a competitive advantage is supported by thousands of authorized partners distributors and system integrators around the world Americas Headquarters 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Rockwell European Headquarters SA NV avenue Herrmann Debr
4. line voltage and voltage input signal 5 Set the voltage input signal to Vj min 6 Adjust the MIN OUT trimmer potentiometer P503 so that the output voltage is Vomin 12 Calibration 7 Set the voltage input signal to Vimax 8 Calculate the test point voltage Vip Vimax m Vip p 2 where Vomax Vomin m Vimax Vimin 9 Adjust the SIGNAL INPUT ADJ trimmer potentiometer P501 so that the voltage from COM to TP terminal 7 to 10 is Vip 10 Adjust the MAX OUT trimmer potentiometer P502 so that the voltage output signal is Vomax 11 Repeat steps 4 5 6 7 9 and 10 Use the same voltage values that you previously calculated Calibration 13 Current input signal calibration The following minimum and maximum values should be known Vomax Maximum voltage output signal Vomin Minimum voltage input signal Lmax Maximum current input signal Lmin Minimum current input signal Limin and imax 15 the current applied through terminals 8 and 9 COM and INPUT 1 Vomin and Vomax is the voltage applied across terminals 1 and 2 OUT and OUT Calibration procedure 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 of loss of life ATTENT
5. 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 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 Corcom is a trademark of Cll Technologies Reliance is a trademark of Rockwell International Corporation 1999 Rockwell International Corporation iii ATTENTION Starting and stopping with the inhibit terminal pins does not disconnect AC power in the stop position A hardwired AC power disconnection switch must be mounted in close proximity to the operator s start stop controls 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 visual alarms or other devices Failure to observe these precautions could result in bodily injury iv Contents Introduction 1 Specifications
6. C voltage or current signal This manual contains specifications installation procedures connections and calibration procedures for the isolation option board Refer to your regenerative drive user s manual for additional installation operation and troubleshooting procedures 2 Specifications Power Requirements Line input 115VAC 230 VAC 50 60 Hz single phase Input Signal Ranges Voltage signal narrow range 25 to 25 VDC Voltage signal wide range 250 to 250 VDC Current signal 1 5 mADC 4 20 mADC 10 50 mADC Input Impedance Voltage signal gt 25K ohms Current signal 1 5 mADC 1K ohms Current signal 4 20 mADC 235 ohms Current signal 10 50 mADC 100 ohms Output Voltage range max 10 to 10 VDC Linearity 0 01 Safety Certification UL Listed Component cUL Listed Component CE Approved Component Dimensions ALL DIMENSIONS IN INCHES MILLIMETERS Figure 1 Isolation Option Board Dimensions Dimensions oo Woo j 1 N Figure 2 Isolation Option Board Mounted on a Regenerative Drive Installation ATTENTION Only qualified personnel familiar with the constuction 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 bod
7. ION The DC3 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 operating personnel by providing suitable guards audio or visual alarms or other devices Failure to observe these precautions could result in bodily injury Use a voltmeter and ammeter for voltage and current measurements respectively 1 Switch only one of the SW501 DIP switches to the ON position Figure 9 pg 12 DIP switch 1 ON for 1 5 mA DIP switch 2 ON for 4 20 mA or DIP switch 3 ON for 10 50 mA 2 Connect but do not power the current input signal as follows a Connect the signal negative to COM terminal 7 b Connect the signal positive to INPUT 1 terminal 8 3 Adjust the regenerative drive s MIN SPD trimpot full CCW and the MAX SPD trimpot full CW 4 Apply both the AC line voltage and the current input signal 5 Set the current input signal to limin 6 Adjust the MIN OUT trimmer potentiometer P503 so that the output voltage is Vomin 7 Set the current input signal to limax 8 Calculate the test point voltage Vip 14 Calibration imax m Vip 2 where Vomax Vomin m limax 7 limin 9 Adjust the SIGNAL INPUT ADJ trimmer potentiometer P501 so that the voltage from COM to TP terminal 7 to terminal 10 is Vip 10 Adjust the MAX OUT trimmer potentiometer P502 so that the output voltage is Voma
8. RELIANCE ELECTRIC MLI DC3R Isolation Option Board User Guide Instruction Manual D2 3454 Rockwell 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 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 of loss of life ATTENTION It is possible for a drive to run at full speed as a
9. SW502 u INPUT VOLTAGE SELECT 115 gt 230 OUT1 OUT2 L1 L2 15 t Figure 4 Input Voltage Select Switch Installation 7 Speed adjust potentiometer connections ATTENTION Because the reference potentiometer is connected through the regulator to the armature power circuit its terminals are at line potential Use a potentiometer that has a insulating shaft to insulate the operator knob from this power circuit and that is capable of withstanding Hi pot tests at 2000 Volts DC for one minute Failure to observe this precaution could result in severe bodily injury or loss of life The isolation option board can be hooked up to speed adjust potentiometer instead of following an external current or voltage signal To control a motor in one direction hook up the speed adjust potentiometer as shown in Figure 5 a for bidirectional control use the connection in Figure 5 b a b Figure 5 Speed Adjust Potentiometer Connections for a Unidirectional Control and b Bidirectional Control 8 Installation Polarity reversal switch connections To reverse the output voltage polarity without changing the input voltage or current polarity connect POL REV to COM terminal 11 to terminal 12 A single pole single throw switch can be used as a polarity reversal switch Figure 6 Close the switch to reverse polarity Open the switch to return the output voltage back to its original polarity An open collector
10. he 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 All adjustments increase with CW rotation and decrease with CCW rotation Use a non metallic screwdriver for calibration Each trimpot is identified on the printed circuit board MIN MAX IN OUT B SIGN L l P502 P503 j INPUT ADJ l N on wn uo oe NAL e com 3 INPUT DIP SWITCHES 1 2 3 4 5 6 7 11 12 lt lt lt lt lt gt lt gt gt lt lt lt lt 38 38 38 38 P Foo eo TA ad Yoo 4 Y 4 0 tT 4 gt 01 2 3 ot 2 3 o 1 2 3 01 23 N ma un Fl 4 Ale SW501 SW501 SW501 SW501 SWITCHES SET SWITCHES SET SWITCHES SET SWITCHES SET FOR VOLTAGE FOR 1 5 MA FOR 4 20 MA FOR 10 50 MA INPUT CURRENT INPUT CURRENTINPUT CURRENT INPUT Figure 9 Calibration Trimpot and DIP Switch Layout Calibration 11 Voltage input signal calibration The following maximum and minimum voltages should be known Vimin Minimum voltage input signal Vomin Minimum voltage output signal Vimax Maximum voltage input signal Vomax Maximum voltage output signal Vimin and Vimax is the voltage appl
11. ied across terminals 7 and 8 COM and INPUT 1 if the voltage input signal range is 0 25 VDC or across terminals 7 and 9 COM and INPUT 2 if the voltage input signal range is 0 250 VDC Vomin and Vomax is the voltage across terminals 1 and 2 OUT1 AND OUT2 Calibration procedure 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 of loss of life ATTENTION The DC3 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 operating personnel by providing suitable guards audio or visual alarms or other devices Failure to observe these precautions could result in bodily injury Use a voltmeter for voltage measurements 1 Switch all three of the SW501 DIP switches OFF as shown in Figure 9 page 12 2 Connect the signal input as follows a Connect signal common to COM terminal 7 b For 0 25 VDC input signal connect the signal positive to INPUT 1 terminal 8 for 0 250 VDC input signal connect the signal positive to INPUT 2 terminal 9 3 Adjust the regenerative drive s MIN SPD trimpot full CCW and the MAX SPD trimpot full CW 4 Apply AC
12. ily injury and 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 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 Connections Isolation option board connections See Figure 3 for isolation option board connections Isolation option board terminals 1 through 4 are prewired on DC3R drives s2 so 0 25 VDC 1 5 mADC 0 250 VDC L1 4 20 mADC 10 50 mADC L2 Figure 3 Isolation Option Board Connections 6 Installation Input voltage select switch ATTENTION Change slide switch settings only when the drive is disconnected from the AC line voltage Make sure line voltage is set to its correct position If the switch is improperly set to a lower voltage position the motor will not run at full voltage and may cause transformer damage If the switch is improperly set to a higher voltage position the motor will overspeed which may cause motor damage Set the input voltage select switch to 115 or 230 to match the AC line voltage See Figure 4 for switch location 5 INPUT P gt VOLTAGE x SELEC E d SWITCH
13. oux 46 1160 Brussels Belgium Tel 32 2 663 06 00 Fax 32 2 663 06 40 Asia Pacific Headquarters 27 F Citicorp Centre 18 Whitfield Road Causeway Bay Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Automation Publication D2 3454 December 1999 1999 Rockwell International Corporation All rights reserved Printed in USA
14. x 11 Repeat steps 4 5 6 7 9 and 10 Use the same voltage and current values that you previously calculated 15 Troubleshooting ATTENTION Dangerous voltages exist on the isolation option board and regenerative drive when it is powered When possible disconnect the AC line voltage from the isolation option board and regenerative drive while troubleshooting Be alert High voltages can cause serious or fatal injury Before troubleshooting Perform the following steps before starting any procedure in this section e Disconnect AC line voltage from the isolation option board adder board and regenerative drive e Check the isolation option board and drive closely for damaged components e Check that no conductive or other foreign material has become lodged on the printed circuit board e Verify that every connection is correct and in good condition e Verify that there are no short circuits or grounded connections e Check that the input voltage select switch is set to either 115 or 230 to match the AC line voltage e Check that the regenerative drive s rated armature and field outputs are consistent with the motor ratings 16 Troubleshooting If there is no output 1 Measure the voltage output signal across terminals 1 and 2 OUT1 and OUT2 If there is a DC voltage present and there is no DC motor output then check the connections to the regenerative drive that it is connected to 2 Check the voltage
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