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| www..com DataShee .com Mini-Series Amplifiers for Brush Type motors Instruction Manual for Models DC-35L and DC-45L Rockwell Automation/Electro-Craft 6950 Washington Avenue South Eden Prairie, MN 55344 .com THE RIGHT COMPANY. THE RIGHT SOLUTION. DataSheet 4 U .com www..com t4U.com DataShee .com (c) 1998 Rockwell International Corporation. All rights reserved. Printed in the United States of America. Information contained in this manual is subject to change without notice. Electro-Craft is a trademark of Rockwell Automation. UL and cUL are registered trademarks of Underwriters Laboratories. .com P/N 0013-1018-001 Rev E DataSheet 4 U .com www..com Contents IntroContents Contents List of Figures List of Tables Preface CHAPTER 1 Intro-3 Intro-5 Intro-7 Intro-9 Product Information Electro-Craft Amplifiers . Standard Features . . . Adjustment Controls . Design Elements . . . Amplifier Fan . . . . . . . Model DC-35L . . . . . . Model DC-45L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1 1-1 1-2 1-4 1-5 1-6 CHAPTER 2 Installation Mounting . . . . . . . . . . . . . . . . . . . . . . AC Input . . . . . . . . . . . . . . . . . . . . . . Multiple Axis Power Wiring . . . . . . . . . . . Tachometer Wiring . . . . . . . . . . . . . . . Analog Command Signal (VCS) . . . . . . . . Operational Modes. . . . . .com . ........... Switch Functions . . . . . . . . . . . . . . . . Voltage Mode . . . . . . . . . . . . . . . . . . IR Compensation Mode. . . . . . . . . . . . . Current (Torque) Loop Mode . . . . . . . . . Velocity Mode . . . . . . . . . . . . . . . . . . Startup Procedures. . . . . . . . . . . . . . . . . Current (Torque) Loop Mode . . . . . . . . . Velocity Mode . . . . . . . . . . . . . . . . . . Cautionary Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2-1 2-1 2-2 2-2 2-2 2-2 2-2 2-3 2-3 2-3 2-4 2-4 2-5 2-6 t4U.com DataShee CHAPTER 3 Warranty Defective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Return Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Troubleshooting CE Compliance Index of Topics Documentation Improvement Product Support .com Help-1 Help-3 Help-5 Help-7 Help-9 Instruction Manual for Models DC-35L and DC-45L DataSheet 4 U .com www..com Intro-4 Contents t4U.com DataShee .com .com P/N 0013-1018-001 Rev E DataSheet 4 U .com www..com List of Figures IntroList of Figures CHAPTER 1 Product Information Amplifier Schematic . . . . . . . . . . . . . . . . . . . . . Fan Schematic . . . . . . . . . . . . . . . . . . . . . . . . . DC-35L Amplifier Output Current Derating Curve DC-45L Amplifier Output Current Derating Curve . . . . . . . . . . . . . . . . . . . . . . (M743) . . . . . . . . . . . . . . . . . . . . . . (730A) . . . . . . . . . . . . . . . . . . . . . . (OP1) . . . . . . . . . . . . . . . . . . . . . . (OP2) 1-2 1-4 1-5 1-6 CHAPTER 2 Installation Typical Power/Motor Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (M692E) 2-1 CHAPTER 3 Warranty t4U.com DataShee .com .com Instruction Manual for Models DC-35L and DC-45L DataSheet 4 U .com www..com Intro-6 List of Figures t4U.com DataShee .com .com P/N 0013-1018-001 Rev E DataSheet 4 U .com www..com List of Tables IntroList of Tables CHAPTER 1 Product Information Amplifier Parameters . . . . . . . . Potentiometer Function . . . . . . . DIP Switch . . . . . . . . . . . . . . . Pin Function . . . . . . . . . . . . . . Fan Parameters . . . . . . . . . . . . DC-35L Parameters. . . . . . . . . . DC-35L Accessories . . . . . . . . . DC-45L Parameters. . . . . . . . . . DC-45L Accessories / Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 CHAPTER 2 Installation Warranty CHAPTER 3 t4U.com DataShee .com .com Instruction Manual for Models DC-35L and DC-45L DataSheet 4 U .com www..com Intro-8 List of Tables t4U.com DataShee .com .com P/N 0013-1018-001 Rev E DataSheet 4 U .com www..com Preface IntroPreface Mini-Series amplifiers are used to drive brush type DC motors. They can also interface with digital controllers or can be used as stand-alone amplifiers. A single red/green LED indicates the operating status (red or green). All models are fully protected against overvoltage, overcurrent, overheating and against short circuits across motor, ground and power leads. The DC-35L and DC-45L amplifiers operate directly from 120 VAC power. Potentiometer (pot) controls allow you to adjust Loop Gain, Current Limit, VCS Gain and IR Compensation (Test/Offset). The Test/Offset pot can also be used as an on-board input signal for test purposes. Typical Applications x x x x x Medical Equipment Packaging Machinery Material Handling Textile Machinery Robotics t4U.com DataShee .com .com Instruction Manual for Models DC-35L and DC-45L DataSheet 4 U .com www..com Intro-10 Preface t4U.com DataShee .com .com P/N 0013-1018-001 Rev E DataSheet 4 U .com www..com CHAPTER 1: Product Information Electro-Craft Amplifiers Standard Features x x x x x x Intro Small size, low cost, ease of use Surface-mount board technology DIP switches that configure different modes of operation Four quadrant regenerative operation Short Circuit protection AC Power Cord for off-line operation WARNING Mini-Series Amplifiers are not capable of sourcing optical encoder power. ! Adjustment Controls t4U.com x x x I Limit adjusts both continuous and peak hand picked current limits by maintaining their ratio (50%). .com Offset/Test adjusts the zero velocity offset on board signal generator. VCS Gain adjusts ratio between input signal and output variables (voltage, current, and velocity). Loop Gain adjusts the system response. DataShee x TIP Output current must be derated when the heat sink and cooling fan are not used. .com Instruction Manual for Models DC-35L and DC-45L DataSheet 4 U .com www..com 1-2 Product Information Design Elements TABLE 1.1 Amplifier Parameters Item Part number Temperature (ambient) operating storage Relative humidity Current foldback Switching frequency Load inductance Input signal range Current output monitor (MCO) Value See Table 1.7 or Table 1.9 32 to 122 F (0 to 50 C) -40 to 176 F (-40 to 80 C) 5% to 95% non-condensing 50% automatic 22 kHz 200 mH minimum 10V (15 VDC maximum) Amps to Volts Intro t4U.com DataShee .com FIGURE 1.1 TABLE 1.2 Amplifier Schematic Potentiometer Function Potentiometer Loop Gain Function Loop gain, adjustment in voltage and velocity modes. Voltage-to-current scaling factor adjustment in current mode. Current limit. Adjusts both continuous and peak current limit by maintaining their ratio (I cont = 1/2 I peak). VCS gain. Adjusts the ratio between input signal and output variables (voltage, current and velocity). Test/offset. Used to adjust any imbalance in the input signal or in the amplifier. When SW4 (DIP switch) is ON, the sensitivity of this pot is greatly increased, so it can be used as an on-board signal source for test purposes. Turning CW Increases Loop Gain Increases Current Limit Increases VCS Input Gain Not applicable (M743) Current Limit VCS Gain Test/Offset .com P/N 0013-1018-001 Rev E DataSheet 4 U .com www..com Product Information TABLE 1.3 1-3 DIP Switch Switch Test/Offset Loop Compensation Loop Integrator Current Integrator Continuous Current Limit Current Limit Current Loop Integrator Current Loop Gain IR Compensation Volt Feedback Block Number 10 9 8 7 6 5 4 3 2 1 Mode OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON TABLE 1.4 Pin Function Pin 1 2 3 4 5 Function +10V @ 5mA SIGNAL GND -10V @ 5mA VCS+ VCSDescription For customer use. Reference ground only. For customer use. Differential Analog Reference Input. Negative voltage at VCS+ with respect to VCS- will cause clockwise rotation when facing motor shaft. Tachometer input. Signal is proportional to the actual current in the motor leads. Scaling is approximately 4A/V (2A/V when SW5=OFF) for the DC-35L; and 8A/V (4 A/V when SW5=OFF) for the DC-45L. Command signal to the internal current loop. .com The maximum peak current rating of the amplifier equals approximately 7.5V at this point. Not connected. Enables the amplifier when connected to SIGNAL GND. Disables CW rotation of the motor. To activate this input, remove connection to SIGNAL GND. Disables CCW rotation of the motor. To activate this input, remove connection to SIGNAL GND. TTL compatible output becomes high if output short-circuit, overvoltage, overheating, amplifier/disabled, or during power-up reset. Fault condition indicated by red LED. NOTE: Fault conditions are not latched. When a fault condition is removed, the amplifier will be enabled and can resume motion unexpectedly. 15 16 NC NON-ISO GND Not Connected Connected to power ground and can be used as ground with P1-8, 9. NA I/O O GND O I I 6 7 8 -TACH +TACH (GND) CURRENT MONITOR I 0 t4U.com 9 CURRENT REF. (Volts) 10 11 12 NC ENABLE FORWARD AMPLIFIER CLAMP REVERSE AMPLIFIER CLAMP FAULT (Red LED) DataShee O NA I I 13 I 14 O .com Instruction Manual for Models DC-35L and DC-45L DataSheet 4 U .com www..com 1-4 Product Information Amplifier Fan TABLE 1.5 Fan Parameters Item Part number Air flow Speed Operating temperature Power input Voltage Housing Impeller Rotation Value 9090-0237 35.9 CFM @ 120 VAC, 60 Hz 3150 RPM -10C to +70C 10.5 Watts 115V, 50/60 Hz metal metal clockwise, looking at rotor Intro t4U.com FIGURE 1.2 DataShee Fan Schematic .com (730A) .com P/N 0013-1018-001 Rev E DataSheet 4 U .com www..com Product Information 1-5 Model DC-35L TABLE 1.6 DC-35L Parameters Item Part number Weight Power input auxiliary Output current, 1O continuous peak Value See Table 1.7 4 lbs, 2.5 oz. (1.9 Kg) 25-130 VAC 10 VDC (2) 5 mAmps max 8A 16A Intro t4U.com DataShee .com FIGURE 1.3 TABLE 1.7 DC-35L Amplifier Output Current Derating Curve DC-35L Accessories Part Number Description Stall Torque (lb-in) Max Speed (RPM) Power Supply (VAC) (OP1) 9077-0647 9077-0646 9106-0063 0721-34-001 0721-32-010 0721-31-041 0642-31-001 0643-33-004 0644-36-012 Amplifier, with heat sink Amplifier, without heat sink Connector kit, included with amplifier Motor, recommended for DC-35L Motor, recommended for DC-35L Motor, recommended for DC-35L Motor, recommended for DC-35L Motor, recommended for DC-35L Motor, recommended for DC-35L Not applicable 10 17 23 6 8 12 2750 2750 2750 4800 4800 1850 120 120 120 120 120 120 .com Instruction Manual for Models DC-35L and DC-45L DataSheet 4 U .com www..com 1-6 Product Information Model DC-45L TABLE 1.8 DC-45L Parameters Item Part number Weight Power input shunt Output current, 1O continuous peak Value See Table 1.9 4 lbs, 5.0 oz. (2.0 Kg) 25-130 VAC up to 30 W continuous (fused) 15A 30A Intro t4U.com DataShee .com FIGURE 1.4 TABLE 1.9 DC-45L Amplifier Output Current Derating Curve DC-45L Accessories / Repair Parts Part Number Description Stall Torque (lb-in) Max Speed (RPM) Power Supply (VAC) (OP2) 9077-0649 9077-0648 9106-0063 0721-34-001 0721-32-010 0721-31-041 0727-32-010 0728-39-003 0642-31-011 Amplifier, with heat sink Amplifier, without heat sink Connector kit, included with amplifier Motor, recommended for DC-45L Motor, recommended for DC-45L Motor, recommended for DC-45L Motor, recommended for DC-45L Motor, recommended for DC-45L Motor, recommended for DC-45L Not applicable 10 17 23 28 35 6 2750 2750 2750 2750 2750 4800 120 120 120 120 120 120 .com P/N 0013-1018-001 Rev E DataSheet 4 U .com www..com Product Information TABLE 1.9 1-7 DC-45L Accessories / Repair Parts (continued) Part Number Description Stall Torque (lb-in) 8 12 Not applicable Max Speed (RPM) 4800 1850 Power Supply (VAC) 120 120 0643-33-004 0644-36-012 Bussman P/N MDL3 Motor, recommended for DC-45L Motor, recommended for DC-45L Shunt Fuse, 3 A motor delay t4U.com DataShee .com .com Instruction Manual for Models DC-35L and DC-45L DataSheet 4 U .com www..com 1-8 Product Information t4U.com DataShee .com .com P/N 0013-1018-001 Rev E DataSheet 4 U .com www..com CHAPTER 2: Installation Mounting The amplifier must be mounted in the vertical position away from other heat producing devices. In multiple axis applications, a minimum of 1.0" separation between each chassis is recommended. AC Input The amplifier may be powered with a 25-130 VAC source, or directly off the 120 VAC power line. To avoid shock hazard, connect the power cord to a power receptacle with earth ground. WARNING A shock hazard potentially exists from improper or unguarded electrical equipment. Install a #16 or #18 green ground wire from the amplifier and motor cases to earth ground. Cable shield termination should also be grounded as shown in Figure 2.1. ! Multiple Axis Power Wiring The AC or line power can be common to more than one amplifier. Power leads from each amplifier should terminate at the power supply source. t4U.com Intro DataShee .com FIGURE 2.1 Typical Power/Motor Wiring (M692E) .com Instruction Manual for Models DC-35L and DC-45L DataSheet 4 U .com www..com 2-2 Installation Tachometer Wiring Use of twisted shielded pair wires for the tachometer is recommended. Ground the shield termination at only one end to the amplifiers P1 (+TACH/GND 7) input. Analog Command Signal (VCS) Use twisted shielded pair wires for the VCS input. If the VCS source can float (remain ungrounded), connect the cable shield to both the VCS source common and the amplifier signal ground. It is recommended that the input be connected directly to the amplifier differential input (if applicable). Connect the VCS source (+) to VCS+ and the VCS source(-) or common to VCS-. If the VCS source and amplifier power ground are grounded to the master chassis ground, leave the source end of the shield unconnected. The servo amplifiers input circuit will attenuate the common mode voltage between signal source and amplifier power grounds. Intro WARNING ! During deceleration of the motor, the capacitor can be charged to potentially dangerous voltages. Electro-Craft uses a Shunt Power resistor (50 Watts) connected to the power supply to absorb the energy surge. Avoid touching connections to the Amplifier until the capacitor has drained to at least 30 Volts. Warning: Energy Surges Operational Modes Switch Functions Front panel DIP switches are used to set up different operational modes Switch 1 2 3 4 5 6 7 8 9 10 Function Supplies back EMF voltage feedback when ON. Supplies current feedback for IR compensation when ON. Reduces current loop gain when ON Increases the value of the current loop integrator capacitor when ON. Reduces both peak and continuous current limit by 50% when OFF. Reduces continuous current limit by 50% when ON. Shorts out (disables) the current loop integrator capacitor when ON. Shorts out (disables) the velocity loop integrator capacitor when ON. Increases the value of the velocity loop integrator capacitor when ON. Function on Pot 4 - test input when ON, offset adjustment when OFF. t4U.com DataShee .com Voltage Mode In voltage mode, the VCS input voltage commands a proportional motor voltage regardless of power supply voltage variations. This mode is recommended for velocity control when velocity feedback is unavailable. S1 ON S2 OFF S3 ON S4 OFF S5 ON S6 OFF S7 OFF S8 OFF S9 OFF S10 OFF .com P/N 0013-1018-001 Rev E DataSheet 4 U .com www..com Installation 2-3 IR Compensation Mode If there is a load torque variation when running in voltage mode, the motor current will vary, since torque is proportional to motor current. Since the motor windings have resistance, the actual motor voltage is reduced by the product of motor current and resistance. Therefore, motor speed which is proportional to motor voltage (terminal voltage minus IR drop) varies with the load torque. S1 ON S2 ON S3 ON S4 OFF S5 ON S6 OFF S7 OFF S8 OFF S9 OFF S10 OFF To compensate for the internal motor voltage drop, a voltage proportional to motor current can be added to the IR compensation level. If the feed back voltage is high enough to cause a rise in motor voltage with increased motor current, instability occurs. This is due to the fact increased voltage increases motor speed and load current which in turn, increases motor voltage. If a great deal of motor torque change is anticipated, it may be necessary to add a tachometer to the motor. To adjust IR feedback, start with a very high (or open) IR feedback resistor (R8) with an unloaded motor shaft. Command a low motor speed (about 20-200 RPM). Note that the motor shaft can be stalled easily without any IR feedback. Decreasing the IR feedback resistor increases motor torque at lower speeds. Too much IR feedback, for examples, too low of a resistor value, will cause motor run-away when torque is applied to the motor shaft. Current (Torque) Loop Mode Current mode produces a torque output from the motor proportional to the VCS voltage input. Motor output torque is proportional to the motor current. Current mode is particularly important if the servo amplifier is used with a digital position controller. Under this condition, a movement of the motor shaft from the desired position causes a large correcting torque, or "stiffness". Therefore, this mode may produce a "run away" condition if operated without a .com controller. S1 OFF S2 OFF S3 ON S4 OFF S5 ON S6 OFF S7 OFF S8 ON S9 OFF S10 OFF t4U.com DataShee Velocity Mode The addition of a tachometer to the motor shaft produces a voltage proportional to speed. The tachometer output voltage replaces the motor terminal voltage as the controlled variable. Since this voltage is proportional to the motor speed, the operating mode is velocity mode. S1 OFF S2 OFF S3 ON S4 OFF S5 ON S6 OFF S7 OFF S8 OFF S9 OFF S10 OFF Note that the speed is dependent on terminal voltage and motor current. The motor current is, in turn, dependent on the load torque which includes both constant friction torque and the torque to accelerate or decelerate the load. Velocity mode is more complex than voltage mode, but also results in the best performance among all the operating modes. Performance in the velocity mode is dependent on the load inertia and characteristics, and should be verified with the motor connected to the actual load. .com Instruction Manual for Models DC-35L and DC-45L DataSheet 4 U .com www..com 2-4 Installation Startup Procedures Current (Torque) Loop Mode Motor Leads 1. Connect the motor leads to P2. Pin 1 is MOTOR+ and Pin 2 is MOTOR-. To reduce the effect of radiated electrical noise, the motor leads and the supply leads should be run as twisted pairs or as shielded cable. Keep the motor and power leads away from the signal leads. Do not connect any tachometer leads. Interface Connections 2. Install the required interface connections to P1 as outlined in Table 1.4. Initial Potentiometer Setting 3. Rotate loop gain potentiometer full CW (15 turns maximum). Rotate all other potentiometers to full CCW position. Apply Power 4. Apply power; verify that the LED indicator is red. Once the amplifier is enabled and no fault conditions are present, the LED will turn green. Current Limit 5. Set the current limit potentiometer to a suitable current level for the motor being used. Turns CW Percent of Rated Current 33% 66% 100% t4U.com 5 10 15 DataShee .com The current limit potentiometer adjusts both peak and continuous current at the same time. The amplifier will output peak current for 2 seconds before gradually reducing the current limit to 50% of the peak current setting. Test/Offset 6. Adjust the test/offset potentiometer until the motor shaft remains stationary. VCS Gain 7. Adjust the VCS gain potentiometer for the desired scaling of VCS Volts to motor torque. After adjusting, bring the VCS input to zero and readjust the test/offset potentiometer if necessary. .com P/N 0013-1018-001 Rev E DataSheet 4 U .com www..com Installation 2-5 Velocity Mode Motor Leads 1. Connect the motor leads to P2. Pin 1 is MOTOR+ and Pin 2 is MOTOR-. To reduce the effect of radiated electrical noise, the motor leads and the supply leads should be run as twisted pairs or as shielded cable. Keep the motor and power leads away from the signal leads. Tachometer Leads 2. Connect the tachometer leads to P1. Pin 7 is +TACH and Pin 6 is -TACH. Interface Connections 3. Install the required interface connections to P1 as outlined in Table 1.4. Initial Potentiometer Setting 4. Rotate all potentiometers at least 15 turns CCW (to full CCW position). Apply Power 5. Apply power; verify that the LED indicator is red. Once the amplifier is enabled and no fault conditions are present, the LED will turn green. Current Limit 6. Slowly turn the current limit potentiometer CW until the motor starts to rotate. If it accelerates toward full speed, remove power and reverse the tachometer leads. Apply power again and the motor should rotate slowly. t4U.com Test/Offset Control 7. Adjust the test/offset potentiometer until the motor shaft remains stationary. DataShee .com Current Limit Control 8. Set the current limit potentiometer to a suitable current level for the motor being used. Turns CW 5 10 15 Percent of Rated Current 33% 66% 100% The current limit potentiometer adjusts both peak and continuous current at the same time. The amplifier will output peak current for 2 seconds before gradually reducing the current limit to 50% of the peak current setting. Loop Gain Control 9. Turn the loop gain potentiometer CW until the motor shaft starts to oscillate, then turn back sufficiently to stop the oscillation. VCS Gain 10. After the desired system response is obtained by appropriate adjustment of the loop gain potentiometer, adjust the VCS gain potentiometer for the desired scaling of VCS Volts to motor RPM. After adjusting, bring the VCS input to zero and readjust the test/ offset potentiometer if necessary. .com Instruction Manual for Models DC-35L and DC-45L DataSheet 4 U .com www..com 2-6 Installation Cautionary Notes Do Not Reverse the Power Supply Leads Damage can result from reversing current flow through the amplifier. Always check the polarity of wire leads before connecting. ! Intro Use Sufficient Power Supply Capacitance Insufficient power supply capacitance problems occur particularly with high inductance motors. During braking much of the stored mechanical energy is fed back into the power supply which charges the output capacitor to a higher voltage. If the charge reaches the amplifier's overvoltage shutdown point, output current and braking will cease. At that time the energy stored due to the motor inductance continues to flow through diodes in the amplifier to further charge the power supply capacitor. The actual voltage rise depends upon the power supply capacitance, motor speed, and inductance. For example, a 2mH motor at 20 amperes can charge a 2000F capacitor up to 30V. ! Do Not Spin The Motor Without Power Intro ! t4U.com Intro The motor acts as a generator and will charge the power supply capacitors through the amplifier. Too high a speed may cause overvoltage breakdown in the power MOSFETs. An amplifier with an internal power converter operating from a high voltage supply will become operative. Do Not Short The Motor When the motor is shorted, its own generated voltage may produce a current flow as high as 10 times the amplifier peak current. The short itself should not damage .com the amplifier but may damage the motor. If the connection arcs or opens while the motor is spinning rapidly, this high current flows back into the amplifier (due to stored energy from the motor inductance) and may damage the amplifier. DataShee ! Protect Against Electrical Noise Intro ! The main source of amplifier noise is the high DV/DT (typically about 1V/nanosecond) of the amplifier's output power MOSFETs. Unfiltered motor outputs can introduce noise in digital encoder signal wires if they are routed in the same cable harness without shielding. .com P/N 0013-1018-001 Rev E DataSheet 4 U .com www..com CHAPTER 3: Warranty The following product warranty and returned goods information summarizes the product warranty and return policy of Electro-Craft. A copy of the formal "Returned Goods and Field Service Policy" is available upon request. Defective Equipment If you are unable to correct a problem, and the product is defective, you may return the unit to your Electro-Craft distributor for repair or replacement. There are no field serviceable parts in the drive. If the drive fails, the unit should be returned to the factory for repair or replacement. To save unnecessary work and repair charges, please verify that the drive unit is defective before returning it for repair. Limitations to warranty coverage are detailed in "Returned Goods and Field Service Policy." Products that have been modified by the customer, physically mishandled, or otherwise abused through incorrect wiring, inappropriate settings, and so on, are exempt from the warranty plan. Return Procedure t4U.com To ensure accurate processing and prompt return of any Rockwell Automation / Electro-Craft product, the following procedure must be followed: 1. Call your distributor to obtain a Return Material Authorization (RMA) number. Do not return the drive or any other equipment without a valid RMA number. Returns lacking .com a valid RMA number will not be accepted and will be returned to the sender. 2. Pack the drive in the original shipping carton. Rockwell Automation is not responsible or liable for damage resulting from improper packaging or shipment of returned products. 3. Include a detailed description of the problem and any relevant information. Repaired units are shipped via UPS Ground delivery. If another method of shipping is desired, please indicate this when requesting the RMA number and include this information with the returned unit. DataShee .com Instruction Manual for Models DC-35L and DC-45L DataSheet 4 U .com www..com 3-2 Warranty t4U.com DataShee .com .com P/N 0013-1018-001 Rev E DataSheet 4 U .com www..com Troubleshooting HelpTroubleshooting Things to Check Overload Fault 1. Verify that the motor shaft rotates freely with no power applied and while uncoupled from the load. 2. Verify that the minimum inductance requirement is met. Heat Sink Temperature 1. Verify that the heat sink temperature is less than 65C. Overvoltage Shutdown 1. Check the input power voltage. If the voltage is greater than the value listed in the specifications, check the AC power line connected to the power supply for the proper value. 2. Check the regenerative energy absorbed during deceleration. Use a voltmeter or oscilloscope to monitor the power supply voltage. If the supply voltage increases above the specified values, additional power supply capacitance is necessary. Additional capacitors must be electrolytic type and located within one foot of the amplifier. Undervoltage Shutdown 1. Verify that the power supply voltage is above the minimum listed in the specifications. Short Circuit Fault t4U.com 1. Check each motor lead for shorts with respect to motor housing and power ground. 2. Measure motor resistance between motor leads with the amplifier disconnected. .com Status 1. Check ALL INHIBIT inputs for the proper levels. Causes of Erratic Operation 1. Improper grounding. 2. Noisy command signal. Check for system ground loops. 3. Mechanical backlash, dead-band, slippage, etc. 4. Excessive tachometer noise. DataShee .com Instruction Manual for Models DC-35L and DC-45L DataSheet 4 U .com www..com Help-2 Troubleshooting t4U.com DataShee .com .com P/N 0013-1018-001 Rev E DataSheet 4 U .com www..com CE Compliance HelpCE Compliance Although amplifiers are not considered "machinery" under directive 89/336/EEC, machine builders prefer to use components that can meet electromagnetic compatibility (EMC) standards when properly installed. EMC Wiring Requirements The DC-35L and DC-45L conform to the generic and basic standards of EN50081-1:1992 and EN50082-2:1995 when installed in accordance with the installation instructions below. Considerations General 1. Shielded cables must be used for all interconnect cables to the amplifier and the shield of the cable must be grounded at the closest ground point with the least amount of resistance. 2. The amplifiers metal enclosure must be grounded to the closest ground point with the least amount of resistance. 3. The amplifier must be mounted in such a manner that the connectors and exposed printed circuit board are not accessible to be touched by personnel when the product is in operation. If this is unavoidable there must be clear instructions that the amplifier is not to be touched during operation. This is to avoid possible malfunction due to electrostatic discharge from personnel. t4U.com Analog Input Amplifiers 4. A Fair Rite model 043167251 round suppression core must be fitted to the low level signal interconnect cables to prevent pickup from external RF fields. .com PWM Input Amplifiers 5. A Fair Rite model 043167251 round suppression core must be fitted to the PWM input cable to electromagnetic emissions. MOSFET Switching Amplifiers 6. A Fair Rite model 043167251 round suppression core must be fitted at the load cable connector to electromagnetic emissions. 7. An appropriately rated Schaffner 2080 series AC power filter in combination with a Fair Rite model 5977002701 torroid (placed on the supply end of the filter) must be fitted to the AC supply to any MOSFET amplifier system in order to reduce conducted emissions fed back into the supply network. Fitting of AC Power Filters 8. The above mentioned AC power filters should be mounted flat against the enclosure of the product using the two mounting lugs provided on the filter. Paint should be removed from the enclosure where the filter is fitted to ensure good metal to metal contact. The filter should be mounted as close to the point where the AC power enters the enclosure as possible. Also the AC power cable on the load end of the filter should be routed as far from the AC power cable on the supply end of the filter and all other cables and circuitry to minimize RF coupling. DataShee .com Instruction Manual for Models DC-35L and DC-45L DataSheet 4 U .com www..com Help-4 CE Compliance t4U.com DataShee .com .com P/N 0013-1018-001 Rev E DataSheet 4 U .com www..com Index of Topics HelpIndex of Topics DIP Switch A AC Input 2-1 Adjustments 1-1 Amplifier controls 1-1 current foldback 1-2 fan 1-4 features 1-1 humidity 1-2 load inductance 1-2 part number 1-2 signal range 1-2 switching frequency 1-2 temperature operating 1-2 storate 1-2 current integrator 1-3 current limit 1-3 feedback 1-3 IR compensation 1-3 loop compensation 1-3 loop gain 1-3 loop integrator 1-3 offset 1-3 test 1-3 E Electrical 1-2 Electromagnetic compatibility, see EMC EMC requirements Help-3 wiring Help-3 Analog Command Signal, see VCS Applications Intro-9 F Fan 1-4 Fault overload Help-1 short circuit Help-1 C Cautions 2-6 CE Compliance AC filters Help-3 analog Help-3 DC-35L Help-3 DC-45L Help-3 general Help-3 MOSFET Help-3 PWM Help-3 Controls 1-1 Current foldback 1-2 monitor 1-2 Current Loop mode 2-3 Features 1-1 I IR Compensation Mode 2-3 t4U.com DataShee .com L LED Intro-9 M Mode current loop 2-3 IR compensation 2-3 torque 2-3 velocity 2-3 voltage 2-2 D DC motors Intro-9 DC-35L AC input 2-1 accessories 1-5 EMC standards Help-3 mounting 2-1 overcurrent Intro-9 overheating Intro-9 overvoltage Intro-9 short circuits Intro-9 specifications 1-5 DC-45L AC input 2-1 accessories 1-6 EMC standards Help-3 mounting 2-1 overcurrent Intro-9 overheating Intro-9 overvoltage Intro-9 short circuits Intro-9 shunt power 1-6 specifications 1-6 Digital controllers Intro-9 Model DC-35L 1-5 DC-45L 1-6 Mounting 2-1 O Overcurrent Intro-9 Overheating heat sink Help-1 protection Intro-9 Overvoltage protection Intro-9 shutdown Help-1 .com Instruction Manual for Models DC-35L and DC-45L DataSheet 4 U .com www..com Help-6 Index of Topics P Pin AMPLIFIER CLAMP 1-3 CURRENT MONITOR 1-3 CURRENT REF 1-3 ENABLE 1-3 FAULT 1-3 NON-ISO GND 1-3 red LED 1-3 SIGNAL GND 1-3 TACH 1-3 VCS 1-3 V Velocity mode 2-3 Voltage mode 2-2 W Warning dangerous voltage 2-2 optical encoder power 1-1 shock hazard 2-1 Potentiometer current limit 1-2 loop gain 1-2 offset 1-2 test 1-2 VCS gain 1-2 Warranty coverage 3-1 Wiring power 2-1 tachometer 2-2 Power AC input 2-1 shunt 1-6 wiring 2-1 Product support Help-9 R Return procedure 3-1 t4U.com S Short circuit fault Help-1 protection Intro-9 Specifications current foldback 1-2 humidity 1-2 load inductance 1-2 signal range 1-2 switching frequency 1-2 temperature 1-2 DataShee .com Support network Help-9 T Tachometer 2-2 Technical assistance Help-9 Temperature operating 1-2 storage 1-2 Torque Mode 2-3 Troubleshooting erratic operation Help-1 heat sink Help-1 overload Help-1 overvoltage Help-1 short circuit Help-1 status Help-1 undervoltage Help-1 .com P/N 0013-1018-001 Rev E DataSheet 4 U .com www..com Documentation Improvement HelpDocumentation Improvement Rockwell Automation/Electro-Craft Technical Communications Department 6950 Washington Avenue South Eden Prairie, MN 55344 Fax: 612-942-3636 DOCUMENTATION IMPROVEMENT FORM Manual Number: _________________________ Page Number: ___________________________ Comments: Please give page numbers and specific paragraphs that the change will affect. Include markups from the document or attach additional pages if necessary. ____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ t4U.com ____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ DataShee .com ____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ What improvements will this suggestion provide? ____________________________________________________________________________ ____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ Originator:_____________________________________ City: ___________________ State: _______ Zip: ____________________________ Company: _____________________________________ Phone: _______________________________________________________________ Address: ______________________________________ Date: ________________________________________________________________ Thank you for your comments. Technical Writing Internal Use: Follow-Up Action .com Instruction Manual for Models DC-35L and DC-45L DataSheet 4 U .com www..com t4U.com DataShee .com .com DataSheet 4 U .com www..com Product Support HelpProduct Support Electro-Craft product support is available over the phone. When you call, you should be at your computer and have the hardware and software manuals at hand. Be prepared to give the following information: x x x x The version numbers of the hardware and software products The type of hardware that you are using The fault indicators and the exact wording of any messages that appears on your screen How you have tried to solve the problem Distributor & Representative Network Electro-Craft has a wide network of distributors that are trained to support our products. If you encounter problems, call the distributor or representative where you purchased the product before contacting the factory. Applications Engineers and Field Service In the United States you can reach the Electro-Craft factory based support staff by phone between 7:30 AM and 5:00 PM (CST) Monday through Friday at 1-800-328-3983. The applications engineers can assist you with programming difficulties as well as ideas for how to approach your automation task. Should your problem require on-site assistance, field service is available. The applications engineers can also be reached via fax at 1-612-942-3636. The fax machine is open 24 hours 7 days a week. Faxes will be answered during regular business hours only. In Europe, support can be obtained through Electro-Craft Limited. The support staff may be reached by telephone between 8:30 and 17:30 local time, Monday through Friday at [44] 1270-580142, or via fax at [44] 1270-580141. t4U.com DataShee .com Bulletin Board Service (BBS) If you have a modem, you can reach the Electro-Craft BBS 24 hours a day, seven days a week at 1-612-942-3618. The following services are available through the BBS: x x x x Example application programs Technical bulletins, product update and errata information Leave messages and files for the application engineers Help with your application .com Instruction Manual for Models DC-35L and DC-45L DataSheet 4 U .com www..com t4U.com .com Rockwell Automation/Electro-Craft 6950 Washington Avenue South Eden Prairie, MN 55344 612.942.3600 - main 612.942.3636 - fax 800.328.3983 - technical support Mini-Series Amplifiers for Brush Type motots Instruction Manual for Models DC-35L and DC-45L .com P/N 0013-1018-001 Rev E DataSheet 4 U .com |
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