DCD300-GB-O.

DC MOTOR DRIVE

Technical Features and

Installation Instructions

DCD 300

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REVISION
Code new version

DATE

OBSERVATIONS

Compilated

DCD300-GB-0.1

11/06/01

DCD 300
Reference manual

A. Giuriato

DCD300-GB-0.2

09/10/01

Trimmer for the offset compensation

A. Giuriato

DCD300-GB-0.3

03/12/01

Add size 75/150

A. Giuriato

DCD300-GB-0.4

05/06/03

Soft start circuit

A. Giuriato

Approvated

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WARNING!
The converters of the DCD 300 series are running at high voltages. Even after disconnecting the
converter, the capacitor circuits are still under voltage for a short period of time. Therefore it is
absolutely recommended to wait 5 minutes until operating on the inner part of the converter.
The converter is equipped with an inner recovery resistance working at high voltages and high
operating temperatures. Do not touch under no circumstances the recovery resistance also after
disconnecting the converter.

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SOMMARIO:
GENERALITY................................ ................................ ................................ .................... 4
OVERALL DIMENSIONS ................................ ................................ ................................ ..5
TECHNICAL FEATURES ................................ ................................ ................................ ..8
GENERAL CHARACTERISTICS................................ ................................ ....................... 9
FUNCTIONAL DIAGRAM ................................ ................................ ................................ ..11
BLOCK DIAGRAM OF THE REGULATION CARD................................ ............................ 12
CUSTOMISING CARD AND SETTINGS ................................ ................................ ...........13
DISPLAY SIGNALS................................ ................................ ................................ ...........14
TERMINAL CONNECTIONS ................................ ................................ ............................. 16
POWER CONNECTIONS ................................ ................................ ................................ .17
WARNING:................................ ................................ ................................ ........................ 18
EXAMPLES OF CONNECTIONS ................................ ................................ ...................... 19
RECOMMENDATIONS FOR THE INSTALLATION AND OPERATION ............................ 22
DIAGNOSTICS................................ ................................ ................................ .................. 24
RECOMMENDATION FOR INSTALLATION ACCORDING TO THE EMC
STANDARDS ................................ ................................ ................................ .................... 27

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GENERALITY
The four quadrant converters of the DCD 300 series
integrate both the power supply unit and the braking unit and
have been realised to exploit the most advanced technology,
in particular the final IGBT stage which operates with a PWM
switching frequency of 10 KHz.
The regulation is realised by the P.W.M. (Pulse Width
Modulation) using a particular technology with 2 different
signals (instead of the traditionally used single signal) with a
phase displacement of 180 for controlling the final power.
The combination of these signals allows to obtain a
switching cycle of the final power which reduces the current
ripple by 50 % combined with all advantages regarding
maintenance and life of the brushes and of the motor.
The converters of the DCD 300 series are developed for
controlling the speed of d.c. motors with permanent magnets
both with dynamo tachometric and armature feedback.

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OVERALL DIMENSIONS

DCD 300 10/20 20/40 30/60 40/80

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DCD 300 60/120

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Note: Observe a minimum free distance of 10 cm

between converter and surrounding components so
as not to hinder the ventilation of the converter.

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TECHNICAL FEATURES

Drive sizes

NOMINAL
CURRENT AT 40
###C

PEAK CURRENT
FOR 1.5 sec.

OUTPUT
VOLTAGE

10A

20A

30120 Vcc

10A

20A

DCD 300 / 10A

10A

20A

DCD 300 / 20A

20A

40A

30A

60A

40A

80A

60A

120A

75A

150A

TYPE
DCD 150 / 10M

DCD 300 / 10M

DCD 300 / 30A

DCD 300 / 40A
DCD 300 / 60A
DCD 300 / 60A

POWER SUPPLY
Single phase
2590 VAC
10% 50 - 60 Hz.
Single phase
90 190 VAC
10% 50 - 60 Hz.

Three-phase
90 190 VAC
10% 50 - 60 Hz.

120250 Vcc

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GENERAL CHARACTERISTICS
Supply voltage of the DCD
150M:

from single-phase autotransformer with a

secondary voltage of 25V 90VAC 10%

Supply voltage of the DCD

150:

from three-phase autotransformer with a

secondary voltage of 25V 90VAC 10%

Supply voltage of the DCD

300M:

from single-phase autotransformer with a

secondary voltage of 90V 190VAC 10%

Supply voltage of the DCD

300:

from three-phase autotransformer with a

secondary voltage of 90V 190VAC 10%

Mains frequency:

50/60 Hz.

Output voltage:

30 / 250 Vdc

Speed loop bandwidth:

> 100 Hz.

PWM switching frequency:

10 KHz

Velocity input reference:

10 VDC (input impedance 100 Kohm)

Regulation:

Fine velocity tuning with trimmer P7 on the customising card

Offset compensation of the velocity signal with trimmer P1 on the

regulation card

Acceleration ramp gradient adjustable from 0 to 1 sec. with trimmer

P2 on the customising card

Deceleration ramp gradient adjustable from 0 to 1 sec. with trimmer

P1 on the customising card

Current limit with trimmer P4 on the regulation card

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Functions:

Diagnostics on DISPLAY

Torque programming from the outside by signal from 0 to +10V DC

Inner protections:

Against short-circuit between motor terminals

Against short-circuit between motor and towards earth

Against mains overvoltage

Against mains undervoltage

Against power overheat

Against excessive energy gain on inner clamp resistances

Against breakage or failure of dynamo tachometric connections

Optional:

Velocity regulation with armature feedback

Operation:

Temperature:

from 0 40 C

Humidity:

90% max. without condensation

Altitude:

1000 m.

Protection degree:

IP 20

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FUNCTIONAL DIAGRAM

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BLOCK DIAGRAM OF THE REGULATION CARD

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CUSTOMISING CARD AND SETTINGS

Description of the plug-out customising card and settings

Jumper closed
S6

S7

S8

Range

S9

Dynamo voltage
17.5VDC 28.5VDC
26VDC 42VDC

36VDC 60VDC

51VDC 84VDC
x

79VDC 130VDC

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DISPLAY SIGNALS

Segment

Indicates that the unit is supplied with power, however not

enabled for operation

One

Drive enabled for operation

Point

The point lights up when the motor absorbs current superior to

its nominal current. This is normal during the acceleration and
starting. When the point lights up for more than 23 seconds,
the IxT device activates and on the display will light up 7
instead of 1

Five

Alarm of the protection device against mains over- and under

voltage. Check the R.S.T. power supply. Until the abnormality
continues the drive is disabled. Automatic reset is done when
the normal operation conditions are achieved

Six

Fault alarm. Short-circuit between the motor connections or of

the power unit. Check the insulation of the motor terminals and
towards earth (motor housing) by measuring the resistance.
The measured value has to be inferior to 1 Mohm. During this
operation the drive is blocked and can be reset by tuning off
from the R.S.T. power supply for at least 5 seconds

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Seven

The IxT device is activated. This protection circuit limitates the

drive current to the fixed nominal current (which corresponds
normally to the nominal current of the motor). After 2 seconds
this function is disactivated and allows the maximum current
output of the motor size

Eight

Alarm of missing or inverted connections of terminal 7 and 8 of

the dynamo tachometric. During this operation the drive is
blocked and can be reset by tuning off from the R.S.T. power
supply for at least 5 seconds

Nine

Alarm of excessive gain and overheat of the inner braking

resistance. The machine cycle or the deceleration ramp timing
have to be increased. During this operation the drive is blocked
and can be reset by turning off the R.S.T. power supply for at
least 5 seconds

Zero

Overheat alarm of the power supply. Until the abnormality

continues, the drive is disabled. Automatic reset is done when
the normal operation temperature is achieved. Check the well
functioning of the ventilation. Observe the minimum free
distance of at least 10 cm. of the inferior part when installing
the drive

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TERMINAL CONNECTIONS

Table of available INPUT/OUTPUT of the plug-out connector:

Connector X1
TERMINAL

NAME

1
2
3
4

+REF
-REF
GND
DIR

RAMP

CONN.

7
8
9
10

+TACHO
-TACHO
GND
TORQUE

11

DRIVE OK

12

DRIVE OK

13

ENABLE

TYPE

DESCRIPTION

Non inverting input of the analogic reference signal

Inverting input of the analogic reference signal
0V of the regulation circuits, such as terminal 9
OUT Output of the differential input stage. It has to be
connected to terminal 6 CONN. when the inner ramp
circuit is not used. The terminal remains free when
the inner ACC/DEC ramps are used
OUT Output of the ramp circuit. It has to be connected to
terminal 6 CONN. when the inner ramp circuit is
used. The terminal remains free when the inner
ACC/DEC ramps are used
IN Connection terminal for the function mode. When
connected to terminal 4 (DIR),, the inner ACC/DEC
ramp circuits are excluded, when connected to
terminal 5 (RAMP) they are enclosed
IN Positive input signal of the dynamo tachometric
IN Negative input signal of the dynamo tachometric
0V of the regulation circuits, such as terminal 3
IN Input for the signal from 0 to +10V for the external
torque regulation (+10V correspond to the peak
current of the drive). Do not use this input and let
disconnected the terminal when running at the max.
available torque
Output with no voltage applied for the contact of the
inner protection relay. During faultless operation, the
contact is normally closed. When a protection device
is activated, the contact is open (max. 24V, 100 mA)
Output with no voltage applied for the contact of the
inner protection relay. During faultless operation, the
contact is normally closed. When a protection device
is activated, the contact is open (max. 24V, 100 mA)
IN Input for the 0V or 24VDC enable signal of the drive
(without no difference a 0V or a +24V signal can be
used)
IN
IN

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TERMINAL

NAME

14

MIN. SPEED

15
16
17
18

+10V
-10V
+24V
I. MOT.

TYPE

OUT
OUT
OUT
OUT

DESCRIPTION

Output for the 0V/+24V signal with electronic

threshold for minimum speed. A 0V signal indicates a
motor speed between 0 and 5 % of the maximum
fixed speed; a +24V signal indicates that the fixed
speed level has been exceeded
Auxiliary voltage of +10V (max. 2mA)
Auxiliary voltage of -10V ( max. 2mA)
Auxiliary voltage of +24V ( max. 50mA)
Output for the voltage signal between -2V and +2V
proportional to the effective current value of the
corresponding motor size (the sign depends on the
motor current polarity)

POWER CONNECTIONS
Connector X2
TERMINAL

NAME

###M

+M
R
S
T

Attention:

TYPE

DESCRIPTION

OUT Negative motor connection terminal

OUT Positive motor connection terminal
IN Phase 1 of the secondary of the
autotransformer for the power supply of
(190 VAC maximum)
IN Phase 2 of the secondary of the
autotransformer for the power supply of
(190 VAC maximum)
IN Phase 3 of the secondary of the
autotransformer for the power supply of
(190 VAC maximum)
Connection terminal for grounding

three-phase
the converter
three-phase
the converter
three-phase
the converter

Do not disconnect the motor when the converter is

supplied, even by converter disabled. Do not supply
the converter during controls and maintenance.

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WARNING:
.
If you use a more then 9KVA trasformer / autotransformer, will be necessary to use a soft start circuit
as reported in the following scheme:

Elenco componenti:

R1, R2, R3 da 20W min. 50W

T2 25/30 A power contact

Rispect the following procedures to start:

1. Insert T2 while mantaining T1 OFF
2. swith ON T1 after 2/3 seconds

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EXAMPLES OF CONNECTIONS
General connections

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Connection with potentiometer reference

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Connection with PLC or CNC reference

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RECOMMENDATIONS FOR THE INSTALLATION AND OPERATION

Unpack the DCD 300 and verify the integrity of all the single parts

Connect a potentiometer of 5 K### to the terminals 15 and 16.

Connect the cursor of the potentiometer to terminal 2 and terminal
1 to terminal 3. With the potentiometer in a central position, the
motor stands still; when turning it to the right or to the left, the motor
rotates in one or the other direction

Make a jumper between the terminals 5/6 or 4/6, depending if the

inner ramp circuit will be used or not

Prepare a jumper between terminal 13 and OS (terminal 9), or

alternatively with terminal 17 (+ 24V), however without connecting it

Connect the armature circuit of the motor to the +M and -M

terminals

Connect the dynamo tachimetric (with a screened cable) to the

terminals 7 and 8, and connect the screen to terminal 9

Connect the three-phase power supply inferior to 190 VAC to the

R.S.T. terminals

Supply the DCD 300 and check the flash-up of the segment on the
DISPLAY

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Close the jumper of terminal 13 towards OS or +24 V and supply

with a potentiometer a voltage of at least 100 mV on the reference
input. Now the number ONE lights up on the DISPLAY and the
motor will start rotating in one direction. If the number EIGHT lights
up, invert the connection of terminals 7 and 8

Tune the maximum velocity by setting the highest possible input

reference (highest value) and turn the P7 trimmer on the
customising card to the desired value

Check the well functioning of the drive and proceed the offset tuning
by applying a 0V reference voltage and turning the P1 trimmer (on
the regulation card) until the motor stops rotating

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DIAGNOSTICS
Trouble shooting guide
The DISPLAY does not light up
Check the power supply (within the allowed range) on the
R.S.T. terminals. If there is no voltage supplied, check the
fuses mounted before and after the power transformer.
If the terminals result under voltage but the DCD 300 is not
enabled, please contact the customer service of SCT
or the supplier o f the drive
The DISPLAY shows "1" however the motor stands still and has no torque
If the display signalizes that the drive is enabled but the
motor does not rotate or shows no resistance (the rotor
rotates freely), check that the terminal 10 is not occupied,
or if used, that there is a sufficient positive voltage towards
ground which allows to generate an adeguate torque (see
description of terminal 9 TORQUE)
The DISPLAY shows "5" and the motor rotates irregularly
When the display shows the alarm "5" (mains under- or
overvoltage) during the acceleration period of the motor,
probably one of the power supply phases for the DCD 300
fails. It is recommended to check the fuses before and/or
after the power transformer. If the fuses are in perfect
conditions and the three-phase power supply is present on
the R,S,T, terminals, please contact the customer service of
SCT or the supplier o f the DRIVE

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The DISPLAY shows "6" when starting or during normal operation

If this alarm occurs, cut off immediately the power supply of
the DCD 300 unit or better of the complete electrical
installation and check the motor connections. If the
connections result correct, check the condition of the
brushes and if the motor is clean and free of carbon
residues. (Take note that dirt or carbon dust as a sign of
wear of the brushes might cause an insufficient insulation
of the motor armature circuit towards ground). In case of
malfunction of the motor collector and the brushes, a motor
inspection is recommended. If the alarm continues after
having carried out the controls without having noticed any
abnormality, please contact the customer service of
SCT or the supplier of the DRIVE
The DISPLAY shows"7" and the motor lose speed
This alarm occurs always after the lighting up of the point
on the DISPLAY. It signalizes that the motor has absorbed
a current superior to its nominal current for more than 3
seconds. When the IxT protection is activated, the current
output of the drive is reduced by a value inferior to 50 % in
consequence of which the current output of the drive
decreases. This abnormality can be caused by a hardening
of the mechanical motor connections or by a wrong motor
dimensioning
The DISPLAY shows "8" and the drive is blocked
This alarm occurs only if the dynamo tachimetric circuit is
interrupted or if the dynamo tachimetric has been wrongly
connected when installing the unit. In any case, the motor
will not be out of control; check the dynamo tachimetric and
the corresponding connections
This alarm might also occur if the dynamo connection
towards the motor is lose or broken
NOTE: A lose dynamo tachimetric connection might cause
an irregularly motor rotation varying according to the
rotation speed

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The DISPLAY shows "9" and the drive is blocked

This alarm protects against excessive gain on the braking
circuit. This condition can cause the breakage of the inner
recovery resistances of the DRIVE. For a faultless
operation, reduce the motor velocity or increase the
deceleration ramp period
The DISPLAY shows "0" and the drive is blocked
This alarm protects against overheat of the drive dissipator.
Verify that the inner working temperature is inferior to 40 C,
that the air shafts of the installation are free and that the
ventilation of the DRIVE is not hindered due to dirt or that
the minimum free distance is not observed and therefore a
well ventilation is not guaranteed. Verify also the faultless
operation of the inner DRIVE fans (if mounted) by
controlling if there is an air outflow on the top side and that
the fans are not hindered by some small objects which
were fallen into. If the alarm continues after having carried
out all the controls without having noticed any abnormality,
please contact the customer service of SCT-Servosystems or
the supplier of the DRIVE.

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RECOMMENDATION FOR INSTALLATION ACCORDING TO THE EMC

STANDARDS
The application standards illustrated here below aim to reduce the interference
coming either from the converter or those referred to it.
For the use of trine converter in EMC environments, it is necessary to use the
mains filter, which reduces the converter emission. The filter must be connected
observing the connection diagram indicated. (Fig. 1)
For the power supply of the converter a transformer insucessory, the wirings must
be performed with screened cables accordign to the connection diagram (see Fig.1).
The filter, suitably chosen accordion to the converter size, must be located as near
as possible to the converter, but in such a way not to obstruct the ventilation of the
same.
The filter connection to the converter must be performed with a no longer than
40Cm three-phase screened cable.
As for the cable upstream the filter, i.e. from the filter to the transformer and from it
to the mains, it is not necessary for them to be performed in a screened cable.
Three conductors plus a ground connection also perform the converter connection
to the motor in a screened cable. For the cable related to the motor feedback is
necessary to use a three separated screened couple, in order to guarantee a low
noise on the motor, even in presence of longs tracts.
Pay attention to the connection related to the cable to cont rol converter as for the
speed a torque. They have to be screened.
The remaining control signal e.g. unlocks and signalling does not require the use of
a screened cable: it is sufficient that the path is as much as possible separated from
the power cables. Here below, it is shown a generically diagram for the connection of
a converter, with the indication on the connection of the masses and heaths of the
screened cables in use.

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200510

Figure 1

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Note:

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The information contained in this document is subject to modification without warning by SCT
You are kindly requested to notify us of errors of any kind that you happen to observe in this manual so
that we may make the necessary modifications and thereby improve the servicing assistance that
SCT offers its clients.

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