td200 ac drive installation and operation manual version 1 · 2-4 td200 ac drive installation and...

Instruction Manual

TD200 AC DriveInstallation and Operation ManualVersion 1.0

0.3 to 20V RMS, 3-Phase Output63 A (Maximum Continuous Motor Amps)

D2-3462

©2000 Rockwell International Corporation

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:

Important: Identifies information that is critical for successful application and understanding of the product.

!ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss.

Reliance is a trademark of Rockwell Automation.

!ATTENTION: Only personnel familiar with the drive and associated machinery should plan or implement the installation, start-up and subsequent maintenance of the system. Failure to comply may result in bodily injury and/or damage to the equipment.

Contents I

CONTENTS

Chapter 1 Introduction to the Drive1.1 Drive Description ............................................................................................. 1-11.2 Identifying the Drive by Model Number ........................................................... 1-11.3 Getting Assistance from Reliance Electric....................................................... 1-1

Chapter 2 Setting the Drive Jumpers2.1 Removing the Drive Cover .............................................................................. 2-12.2 Setting the Speed Reference Jumper (J1) ...................................................... 2-22.3 Setting the Maximum Speed Jumpers (J2 through J8) ................................... 2-22.4 Setting the V/Hz Curve Jumpers (J9 through J12) .......................................... 2-32.5 Setting the Current Rating Jumpers (J13 through J16) ................................... 2-42.6 Setting the External Speed Control Jumpers (J17 through J19) ..................... 2-52.7 Reattaching the Cover..................................................................................... 2.6

Chapter 3 Mounting the Drive3.1 Planning the Installation .................................................................................. 3-13.2 Mounting the Drive .......................................................................................... 3-1

Chapter 4 Wiring the Drive4.1 Wiring the External Control Inputs and Outputs .............................................. 4-24.2 Wiring the Output Power to the Motor ............................................................. 4-24.3 Wiring Input Power to the Drive....................................................................... 4-3

Chapter 5 Checking the Installation5.1 Checking the Installation with the Power Off ................................................... 5-15.2 Checking the Direction of Motor Rotation........................................................ 5-15.3 Testing the Drive under Load .......................................................................... 5-2

Chapter 6 Operating the Drive ................................................................................................ 6-1

Chapter 7 Diagnostics and Troubleshooting7.1 Drive Faults and Corrective Actions ................................................................ 7-1

Appendix A Technical Specifications........................................................................................A-1

II TD200 AC Drive Installation and Operation

Contents III

LIst of Figures

Figure 1.1 – Identifying the Drive Model Number ..................................................... 1-1

Figure 2.1 – Location of Drive Jumpers.................................................................... 2-1Figure 2.2 – V/Hz Curve ........................................................................................... 2-3

Figure 3.1 – Drive Mounting Dimensions.................................................................. 3-1

Figure 4.1 – Drive External Wiring Diagram ............................................................. 4-1

IV TD200 AC Drive Installation and Operation

Contents V

List of Tables

Table 2.1 – Maximum Speed Jumper Settings......................................................... 2-2Table 2.2 – V/Hz Curve Jumper Settings ................................................................. 2-3Table 2.3 – Current Rating Jumper Settings ............................................................ 2-4Table 2.4 – External Speed Control Jumper Settings............................................... 2-5Table 2.5 – Output Frequencies for Input Voltage Reference

or External Resistance.......................................................................... 2-5

Table 4.1 – External Control Inputs and Ouputs....................................................... 4-2Table 4.2 – Output Power Connections.................................................................... 4-2Table 4.3 – Output Power Connections.................................................................... 4-3

Table 6.1 – Operating the Drive................................................................................ 6-1

Table 7.1 – Drive Status Indicators........................................................................... 7-1

VI TD200 AC Drive Installation and Operation

Introduction to the Drive 1-1

CHAPTER 1Introduction to the Drive

This chapter describes the drive and how to identify it using the model number matrix. It also provides an illustration of the drive showing the locations of major components.

1.1 Drive Description

The drive is powered by a nominal +28 VDC input, and provides a three-phase AC variable frequency and voltage output to control a 63 amp AC motor (maximum continuous amps).

1.2 Identifying the Drive by Model Number

Each 2 HP AC drive can be identified by its model number. See figure 1.1. This number appears on the shipping label and on the drive’s nameplate. The drive’s model number includes the Power Module and the regulator version.

1.3 Getting Assistance from Reliance Electric

If you have any questions or problems with the products described in this instruction manual, contact your local Reliance Electric sales office. For technical assistance, call 1-800-726-8112.

Figure 1.1 – Identifying the Drive Model Number

1 TD 20 002

Catalog Number

TD = Universal

Input Voltage 20 = +28 VDC

Horsepower Rating 002 = 2 HP

1-2 TD200 AC Drive Installation and Operation

Setting the Drive Jumpers 2-1

CHAPTER 2Setting the Drive Jumpers

Before the drive can be mounted and wired, you must set the drive jumpers to match your drive application.

2.1 Removing the Drive Cover

You must remove the drive cover to provide access to the drive jumpers.

Step 1. Place the drive with the six cover screws facing up.

Step 2. Remove the six M4 machine screws that hold the cover in place.

Step 3. Remove the cover.

Important: Note that the gasket inside the cover is glued to the inside of the cover. Do not disturb the gasket.

!ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. Failure to observe this precaution could result in damage to the equipment.

Figure 2.1 – Location of Drive Jumpers

J5

0

1S1

J1 J3J2 J4

S2

J7J6 J8 J9 J11

J10

J12

J13

0

1

J18

J16

J14

J15

J17

J19

S3


2.2 Setting the Speed Reference Jumper (J1)

Jumper J1 is used to select between the external speed reference or the internal speed jumpers. When this jumper is set (J1 = 1), the motor speed can be externally adjusted from the POT1 and POT2 terminals (see section 2.6). When J1 is reset (J1 = 0), the internal speed jumpers (J2 through J8 ) are used to set the maximum speed. In either configuration, the "HI/LO" external input is active (see section 4.1). Note that if the drive input power drops below a nominal 25 VDC, the speed will drop to 3/4 of HI speed.

2.3 Setting the Maximum Speed Jumpers (J2 through J8)

Jumpers J2 through J8 set the maximum speed when jumper J1 (Speed Reference Jumper) is in the "Speed Jumpers" position (J1 = 1). The range of values for output frequency is 0 to 127 Hz in 1 Hz steps (see table 2.1). The speed selected by totalling the values of these jumper settings is the nominal speed. The actual output frequency will be within -0.5 to +1.3 Hz tolerance. Actual motor speed will depend on load and associated slip.

Table 2.1 – Maximum Speed Jumper Settings

Jumper Position Maximum Speed Level

J2 1 Adds 0 Hz to speed reference

0 Adds 64 Hz to speed reference


0 Adds 32Hz to speed reference












2.4 Setting the V/Hz Curve Jumpers (J9 through J12)

Jumpers J9 through J12 set the frequency break point for the V/Hz Curve . The breakpoint is the frequency at which the output voltage reaches the maximum voltage. Below this point the output voltage and frequency increase together. This feature is required to allow the drive to work with motors rated at various frequencies. Figure 2.2 shows a general V/Hz curve.

Figure 2.2 – V/Hz Curve

Table 2.2 – V/Hz Curve Jumper Settings

Jumpers

Frequency at Maximum VoltsJ9 J10 J11 J12

1 1 1 1 42 Hz

0 1 1 1 46 Hz

1 0 1 1 50 Hz

0 0 1 1 53 Hz

1 1 0 1 56 Hz

0 1 0 1 60 Hz

1 0 0 1 63 Hz

0 0 0 1 66 Hz

1 1 1 0 70 Hz

0 1 1 0 74 Hz

1 0 1 0 77 Hz

0 0 1 0 81 Hz

1 1 0 0 85 Hz

0 1 0 0 88 Hz

1 0 0 0 92 Hz

0 0 0 0 95 Hz

Boost

F (Hz)

V

Vmax


2.5 Setting the Current Rating Jumpers (J13 through J16)

Jumpers J13 through J16 set the maximum continuous current rating and the associated current limit level of the drive’s output current. The four jumpers are binary weighted and scaled so that the current limit level is adjustable from 30 to 70 amps RMS in approximate 3 amp RMS steps. Table 2.3.6 shows the nominal current limit level for each possible jumper setting.

Table 2.3 – Current Rating Jumper Settings

Jumpers

Rated Continuous

Current Current Limit Threshold1

1Eventual drive shutdown if sustained

Current Limit(A RMS)(1 minute

Instantaneous Overcurrent Trip

J13 J14 J15 J16 (A RMS) (A RMS) allowable) (A Peak)

0 0 0 0 30 >30 39 68

0 0 0 1 33 >33 42 75

0 0 1 0 35 >35 46 80

0 0 1 1 38 >38 49 86

0 1 0 0 41 >41 53 93

0 1 0 1 43 >43 56 98

0 1 1 0 46 >46 59 105

0 1 1 1 49 >49 63 112

1 0 0 0 51 >51 66 116

1 0 0 1 54 >54 70 123

1 0 1 0 57 >57 73 130

1 0 1 1 59 >59 76 134

1 1 0 0 62 >62 80 141

1 1 0 1 632

2The user must verify that the application does not exceed the maximum continous rating of 63 A RMS. Exceeding this rating could cause overtemperature protection to shut down the drive. For maximum system protection, it is recommended that the current limit jumpers be set to a value not greater than the application demands.

>65 83 148

1 1 1 0 632 >67 87 153

1 1 1 1 632 >70 90 160


2.6 Setting the External Speed Control Jumpers (J17 through J19)

The motor speed can be manually adjusted between minimum speed and full speed with 0 to 4.5 volt voltage reference, or a 1000 ohm potentiometer. To make the external speed control inputs (POT1, POT2) active, jumper J1 (Speed Reference Jumper) must be in the Speed Ref position (J1 = 1), as described in section 2.2. Jumpers J17 through J19 configure the external speed control function for either an external 1 Kohm pot control or a 0 to 4.5 VDC voltage control (see table 2.4). Zero ohms and zero volts are minimum speed. For the voltage control, the positive input is into the POT1 terminal, the return being POT2. In either configuration, the "HI/LO" external input is active.

Table 2.5 shows what the output frequency is for a given input voltage reference or external resistance. When driving the input with an external voltage source, the source sees a 200 Kohm input impedance. When driving an external potentiometer, the drive input circuit sources 5 mA. When configured for external speed control (pot), an open circuit condition will cause the drive to default to 128 Hz. For the pot control selection, a resistor should be installed across the input if 128 Hz is beyond a safe operational speed. For voltage source control, an open circuit will cause the drive to default to 2 Hz.

Table 2.4 – External Speed Control Jumper Settings

Jumpers

External Speed Control Min/Max SpeedJ1 J17 J18 J19

1 0 0 0 External 1 Kohm pot 0 ohm / 1 kohm

1 1 1 1 External 0 to 4.5 V control 0 VDC / 4.5 VDC

Table 2.5 – Output Frequencies for Input Voltage Reference or External Resistance

Volt Reference (V)J17 J18 J19 = 1 1 1

Output Frequency (Hz)

External Resistance (Ω)J17 J18 J19 = 0 0 0

Output Frequency (Hz)

0 2 0 3

0.45 15 50 16

0.90 28 100 26

1.35 41 250 54

1.80 54 300 62

2.25 67 393 75

2.70 80 500 88

3.15 93 750 113

3.60 106 825 119

4.05 118 910 125

4.50 128 1000 128


2.7 Reattaching the Cover

Follow these steps to reattach the drive cover.

Step 1. Position the cover on the back of the drive.

Step 2. Reinstall the six M4 machine screws finger tight, beginning with the two middle screws, then the four corner screws.

Step 3. Beginning with the two middle screws, torque all of the screws to 4 to 6 lb-in ( .45 to .68 Nm). Do not overtighten.

Mounting the Drive 3-1

CHAPTER 3Mounting the Drive

3.1 Planning the Installation

The drive should be installed in a location where high airflow and low ambient temperatures are present. The jumpers must be configured before installation, because their access is from the bottom of the unit.

3.2 Mounting the Drive

Use the following steps to mount the drive.

Step 1. Prepare the mounting surface based on the dimensions shown in figure 3.1.

Step 2. Position the drive in the enclosure. Choose the mounting surface (horizontal or vertical) to provide maximum airflow through the fin area.

Step 3. Attach the drive to the mounting surface using four fasteners.

Figure 3.1 – Drive Mounting Dimensions

.334 Places

12.25

12.95

6.50

3.00

4.12

3.75

Dimensions in inches

Front ViewSide View

0.25

0.25

Wiring the Drive 4-1

CHAPTER 4Wiring the Drive

Figure 4.1 shows the wiring scheme for the drive’s external control inputs and outputs. Sections 4.1 through 4.3 provide information for wiring the drive circuits.

Figure 4.1 – Drive External Wiring Diagram

Drive

FAULT

ON/OFF

HI/LO

POT1 (+)*

POT2 (-)*

+28 V

GND

UVW

T1 T2 T3

20 VAC Motor 3

Drive

Lamp or Relay(500 mA max.)

Open = OFFClosed = ON

Open = HIClosed = LO

3

2

1

1K Potentiometer orExternal Voltage Source1

28 Volt Battery+

–

1 When using 0 to 4.5 VDC external voltage source, POT1 is +.2 Fuse or circuit breaker, value dependent on application.3 Contact your local Reliance Electric sales office for motor availability.

2


4.1 Wiring the External Control Inputs and Outputs

Table 4.1 describes the external control circuits shown in figure 4.1. All control circuits should be wired as follows:

• use 12 to 18 AWG wire terminated with ring lugs sized for a #8 stud.

• torque all connections between 11 to 13 in-lb.

4.2 Wiring the Output Power to the Motor

Table 4.2 describes the drive output power connections shown in figure 4.1. All output power connections should be wired as follows:

• Minimum 6 AWG wire terminated with ring lugs sized for a 3/8” stud (drive end).


Table 4.1 – External Control Inputs and Ouputs

Terminal Label Function

ON/OFF ON = Closed to run motorOFF = Open to stop motor

There is an approximate delay of 1.0 second at startup.Peak input current = 0.2 A, approximate 0.02 A average continuous

HI/LO LO (speed) = Closed for 3/4 of maximum speed.HI (speed) = Open for maximum speed.

Nominal input current = 50 mA

POT1POT2

Analog speed reference input. POT1 is the signal and POT2 is the return.

The input signal range is 0 to 4.5 VDC.

May also be used with a 1000 ohm pot between POT1 and POT2 if appropriate jumpers are selected.

FAULT Output fault indication. The fault output will sink up to 500 mA when operating normally, and sink 0 A when the drive is faulted or not activated.

Table 4.2 – Output Power Connections


U Connect to motor terminal “U”

V Connect to motor terminal “V”

W Connect to motor terminal “W”

Wiring the Drive 4-3

4.3 Wiring Input Power to the Drive

Table 4.3 describes the input power connections to the drive as shown in figure 4.1. All input power connections should be wired as follows:

• Minimum 6 AWG wire terminated with ring lugs sized for a 3/8” stud (drive end).


!ATTENTION: The input power of this drive is not internally fused. The user is responsible for external fusing. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

ATTENTION: Applying reverse polarity at the drive input terminals will allow unlimited input current to flow. A user-supplied fast-acting fuse or circuit breaker should be installed in the drive input circuit to prevent damage to the drive. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

Table 4.3 – Output Power Connections


+28 V Connect to power source +28 VDC terminal

GND Connect to power source ground terminal

Checking the Installation 5-1

CHAPTER 5Checking the Installation

To ensure safe operation, check the installation with the power off before operating the unit. When power is first applied, the direction of rotation, operator speed reference, and operation under load should be tested.

5.1 Checking the Installation with the Power Off

Perform the following installation checks of the unit with the power off:

Step 1. Disconnect DC input power to the unit.

Step 2. Check that the wiring to the power terminals and to the external control inputs and outputs are correct (refer to figure 4.1 and sections 4.1 through 4.3).

Step 3. Check that incoming DC power is correctly rated.

Step 4. Where applicable, check that a properly sized ground wire is installed and that a suitable earth ground is used. Verify that all ground leads are run unbroken.

5.2 Checking the Direction of Motor Rotation

Important: If any problems occur while the drive is running, refer to chapter 7, Diagnostics and Troubleshooting.

After verifying that the drive installation is correct, check the direction of rotation of the motor using the following procedure:


Step 2. Uncouple the driven equipment from the motor, if possible.

Step 3. Connect input power to the unit.

Step 4. Start the drive.

!ATTENTION: Only qualified electrical 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 manual in its entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.

!ATTENTION: The following procedures require rotating parts and/or electrical circuits to be exposed. Stay clear if the motor must be running. Disconnect, lockout, and tag the power source if contact must be made. Failure to observe this precaution could result in severe bodily injury or loss of life.


Step 5. Visually check the direction of motor shaft rotation. If shaft rotation is correct, proceed to the next section, Testing the Drive under Load. If shaft rotation is incorrect, continue to step 7.


Step 7. Reverse any two of the three motor power leads (U, V, and W).

5.3 Testing the Drive under Load

Use the following procedure to test the drive under load:

Step 1. Turn off, lockout, and tag power to the drive.

Step 2. Couple the driven equipment to the motor.

Step 3. Turn power on and start the drive.

Step 4. Run the drive across the required speed range under load.

Step 5. If the drive does not operate the motor properly, refer to chapter 7, Diagnostics and Troubleshooting.

Operating the Drive 6-1

CHAPTER 6Operating the Drive

The following table describes how to start and stop the drive, and how to change the motor speed. This table assumes that the drive is wired as shown in figure 4.1.

Table 6.1 – Operating the Drive

Function Process

Start the drive Apply 28 VDC to the ON/OFF terminal.

Stop the drive Remove 28 VDC to the ON/OFF terminal.

Adjust motor speed Motor speed can be controlled by:

• jumper settings (see section 2.3).

• speed potentiometer (see section 2.6).

• external voltage control (see section 2.6).

• application of 28 VDC to HI/LO terminal. This will reduce motor speed by 75%.

Diagnostics and Troubleshooting 7-1

CHAPTER 7Diagnostics and Troubleshooting

7.1 Drive Faults and Corrective Actions

The drive has two status LEDs that can be used to diagnose drive faults. Table 7.1 lists some possible drive faults and their corrective actions.

To reset a fault, toggle the ON/OFF switch to OFF. When the switch is returned to the ON position, the drive will attempt to restart.

Table 7.1 – Drive Status Indicators

Status

Motor LED (M)

Drive LED (D) Possible Cause Corrective Action

Drive is running

ON ON Drive is running (normal status).

Drive runs, but not at

commanded speed

ON ON Internal speed reference set improperly

External peed reference not present

HI/LO input has voltage applied

Current limit set too low

V/Hz jumpers set improperly

Excessive load

Input voltage too low (< 25 VDC, nominal)

Power source not delivering enough current

Check jumper settings (J1 - J8).

Check speed reference jumpers (J1, J17 - J19), POT1 and POT2.

Remove input voltage.

Increase J13 - J16 settings.

Set J9 - J12 to proper motor setting.

Reduce load.

Increase input voltage.

Supply appropriate input current.

Drive is stopped

ON ON Overtemperature - result of inadequate air flow, excessive ambient temperature, and/or excessive load current

Overvoltage - voltage exceeds 32 VDC

Let drive cool down, then cycle ON/OFF input.

Unit will automatically restart when voltage returns to normal input levels.

ON OFF Internal Drive Fault Cycle power. If fault repeats, replace drive.

OFF ON Overcurrent - sustained overload exceeding limits in table 2.3.

Instantaneous Overcurrent (IOC) - short circuit or other fault applied to the output

Ground Fault

Reduce current load.

Check output circuitry; reduce current load.

Check motor and motor wiring.

OFF OFF Input power is too low or ON/OFF input is low (OFF).

A-1

APPENDIX ATechnical Specifications

Drive Dimensions

Height: 12.95 inches

Width: 6.50 inches

Depth: 4.12 inches

Weight: 7.88 pounds

Input Voltage

Nominal: +28 VDC

Operating Range: +20 to +32 VDC

Maximum Non-operating Transient: +60 V peak., 0.1 seconds

Source: battery, battery & alternator, stand-alone alternator, or DC power supply

Note: Negative voltage should not be applied to the drive.

Input Current

Nominal: +65 A DC (@ 28 VDC input and rated HP)

Output Voltage

Nominal: 0.3 to 20 V RMS, 3-phase (@ 28 VDC input)

Output Current (per phase)

Maximum Continuous: 63 A RMS, (jumper-selectable range from 30 A to 63 A)

Instantaneous Overcurrent Trip (IOC Trip):160 A peak @ 63 A jumper setting (any phase). This value is proportional to jumper setting.

Horsepower Rating

Maximum motor size: 2 HP. Maximum continuous output current must not be exceeded.

Efficiency

Minimum: 93% (@ 28 V input and maximum continuous output current)

Humidity and Water Splash

The drive is suitable for wash down. The drive is not submersible.

A-2 TD200 AC Drive Installation and Operation

Shock and Vibration

Will withstand 3-axis sinusoidal vibration from 20 to 200 Hz @ 2 g.Will withstand 3-axis, 10 g shock pulse with a duration of 8 msec.

Cooling Air Requirements

Minimum air velocity: 1000 linear ft/min (LFM) referenced to standard conditions of 25° C and 760 mm Hg, directed through base areas of the unit’s cooling fins.

Electromagnetic Interference (EMI)

This product has been tested for immunity to electrostatic discharges, radiated interference, and electrical fast transients. The IEC1000-4- 2, 3, 4 standards were used to establish compliance.

U.S. Drives Technical Support Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: [email protected], Online: www.ab.com/support/abdrives

Trademarks not belonging to Rockwell Automation are property of their respective companies. Publication D2-3462- October 2000 Copyright © 2000 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.

td200 ac drive installation and operation manual version 1 · 2-4 td200 ac drive installation and...

Documents