DMC-500 TM. DC Motor Drive Control. Operation / Installation Manual Manual Part Number: S8M5003 Date: August 11, Computer Weld Technology, Inc.

Transcription

1 omputer Weld Technology, Inc. 070 Old ammel N Houston Rd. Houston, TX Telephone: (7) 46-8 Fax: (7) DM-500 TM D Motor Drive ontrol Operation / Installation Manual Manual Part Number: S8M500 Date: ugust, 998

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3 TLE OF ONTENT SETION - OVERVIEW....0 Functional Description.... Remote I/O ontrol.... Motor Output.... Operational Status... SETION - INSTLLTION....0 Enclosure Installation.... D Motor onnector Pin-Out...4. Optional Encoder onnections...4. Enable Optional Encoder Motor onnection Remote I/O onnector Pin-Out...6 SETION - OPERTION Theory of Operation...8. ontrol alibration...8 SETION 4 DRWINGS ND PRTS LISTS System onfiguration System Schematic Diagram DM-500 Enclosure Details...

4 SETION - OVERVIEW.0 Functional Description The DM-500 D Motor ontroller is a SR motor speed controller using an embedded micro controller to provide motor speed regulation and torque compensation. The controller can be used to control permanent magnet (PM) or shunt wound field motors up to ¼ hp and is designed to be used with the WS-000 Weld Sequence ontroller or user supplied controllers. The DM-500 is used to control linear D drive motors for wire feed and or travel speed functions. The DM-500 provides speed and torque regulation using an optical encoder or phase sampled ack EMF. The embedded controller provides precise motor braking and anti-plugging features to extend motor life.. Remote I/O ontrol. Motor Output The DM-500 provides remote speed control using a 0-0 VD input signal. Two 4 VD inputs provide remote direction control. The control provides an optional isolated encoder output signal. remote I/O connector located on the rear of the enclosure provides all user control connections. The DM-500 can be used with 90 VD permanent magnet or shunt field wound motors up to ¼ H.P. motor connector located on the rear of the enclosure provides all user motor connections. The control can be used with or without an optical tachometer. The control uses a 60-line optical tach input and can provide a 5 VD or 5 VD output for the tachometer. The Tachometer input mode is enabled by an internal jumper connection.. Operational Status The operational status of the DM-500 is displayed using 4 LED s located on the front panel. The POWER +4V LED indicates that power is applied to the controller. The RKE LED indicates when the motor is at rest or is braking to a stop condition. The DRIVE ON led indicates when the drive is active. The REVERSE LED indicates when the motor is operating in the reverse direction. Note: When the motor is active in the forward direction the DRIVE ON LED will illuminate. When the motor is active in the reverse direction, the DRIVE ON and REVERSE LED will illuminate.

5 .4 ontrol Specification The following are the electrical specifications for the DM-500 : Power Input 0 vac ± 5amps rmature urrent amps rmature Voltage vdc Field Voltage - 0 vdc nominal Field urrent -.0 amps maximum Encoder Input - 5 or 5 vdc 60 lines/rpm max frequency.0khz Encoder output - 4 vdc pulse Forward Input 4 0ma (ctive High) Reverse Input 4 0 ma (ctive High) Speed Reference Input ma The following are the mechanical specifications for the DM-500 control: Dimensions.0 H x 8.5 W x L (5mm x 65mm x 80mm) Mounting Dimensions 7.5 W x 8.5 L (4 ea 0- tapped hole) Weight 5 lbs (.7 kg) Operating Temperature - -0 F to +40 F (- to +60 )

6 SETION - INSTLLTION.0 Enclosure Installation Locate the DM-500 enclosure in a convent location. The enclosure can be installed using the four 0- mounting holes located on the bottom of the enclosure. Refer to Figure - for mounting dimensions: FRONT VIEW OTTOM VIEW Fig - DM-500 Enclosure Mounting dimension onnect power cable SW504 to suitable 5 V power outlet. onnect motor control cable to MOTOR connector on rear of enclosure. onnect remote I/O cable (SW5058) to REMOTE I/O connector on rear of enclosure.

7 . D Motor onnector Pin-Out Several cables are available from the factory, which and can be used for connecting a D drive motor to the DM-500. onsult the factory for available cable assemblies. The following is the pin-out for the DM-500 motor connector: PIN DESRIPTION +5 VD for optional encoder +5 VD for optional encoder Not used D Not used E Not used F hassis Ground G Encoder Pulse input ( TTL or 5 Volt Pulse) H Encoder ommon J Motor Field - K Motor rmature - L Motor Field + M Motor rmature + Figure - Motor onnector Pin-out. Optional Encoder onnections The DM-500 can use a 5-volt or 5-volt encoder. oth power outputs are provided on the connector. onnect the optional motor encoder to the correct voltage output. Use Pin for a 5-volt encoder or Pin for a 5-volt encoder. The DM-500 is designed for a 60-line encoder and can be used for motor speeds up to 000 rpm. For faster speeds, contact the factory. The following is a typical connection for a 5-volt TTL encoder: D E F G H J K L M EN +5VD EN PULSE EN OM 5 volt TTL Encoder Fig - 5-volt TTL encoder connection

8 The following is the connection diagram for a 5 VD encoder: EN +5VD D E F G H J K L M EN PULSE EN OM 5 volt Encoder Fig -4 5-volt TTL encoder connection. Enable Optional Encoder When using an optional encoder the DM-500 must be configured for encoder input. To select the Encoder mode remove the cover from the DM enclosure by removing the six (6) screws on the side of the cover. Locate the jumper labeled JP- TH and install a jumper. This enables the Tachometer mode of operation..4 Motor onnection Note: For non-tach applications the jumper on JP- TH must be removed. The DM-500 can be used with a permanent magnet, or shunt field motors with an armature rating of volt dc. The following is the connection diagram for a permanent magnet motor: D E F G H J K L M RM- RM- Fig -4 Permanent magnetic motor wiring

9 The following is the connection diagram for a shunt field motor: D E F G H J K L M Fig -5 FIELD- RM- RM+ FIELD+ Permanent magnetic motor wiring.5 Remote I/O onnector Pin-Out The DM-500 is controlled via the REMOTE I/O connector. The control has two () 4 VD inputs for motor direction control, a 0-0 vdc input for speed control and a 4 VD output. The following is the pin-out for the REMOTE I/O connector: PIN D E F G H FUNTIONL DESRIPTION +4 vdc 00ma 4 vdc common Speed Input signal common Speed input signal ( 0 0 vdc) Drive Forward command input (4 0 ma) Drive Reverse command input (4 0 ma) Motor Tachometer output (4 vdc) Frame ground (able Shield connection) Fig -6 Remote I/O connector pin-out

10 remote I/O cable SW5058 is available for interfacing the DM-500 to the WS- 000 controller or for direct interface to user supplied PL controller. The following is an example of using the DM-500 controller with a user supplied PL controller: D E F G H FWD REV SPEED SIGNL OM SPEED SIGNL (0 0 vdc) Fig -6 PL interface to DM-500

11 SETION - OPERTION.0 Theory of Operation The DM-500 is a direct off-line SR motor speed controller. The control uses a embedded micro-controller to provide line synchronization, phased back EMF sampling and direction control logic with anti-plug motor reversing. The phased EMF sample provides precise back EMF sample for improve motor speed regulation. The nti-plug feature prevents reversing the drive before the motor armature has stopped. This prevents excessive motor current and brush arcing in the motor. The Micro-ontroller synchronizes all input commands to the incoming line frequency and assures proper phase angle firing of the power SR devices. The nalog speed signal is coupled to a Voltage-to-Frequency convert and is electrically isolated from the off-line control. The remote direction control inputs are optically coupled to the controller. n isolated 4-vdc-power supply is provided for all remote input control functions. The user can use this supply to operate remote input relays or switches for direction control. The supply has a solid-state circuit breaker, which protects the 4-volt I/O control from external shorts. The circuit breaker will reset when the 5-vac power is cycled off. Optional optical tach input is provided which can be used with a 5 or 5 vdc 60-line encoder. The encoder input is also provided as an output on the remote I/O connector. This output is an isolated 4-vdc pulse representing the encoder input. When an encoder is installed on the motor shaft, the DM-500 can be set for encoder feedback by installing a jumper on JP. When the jumper is installed, the controller uses the tachometer to regulate motor speed. When the jumper is removed, the controller will use the motor back EMF for speed regulation.. ontrol alibration The DM-500 controller is factory calibrated to produce 00 rpm with an input of 0 volts. This is performed using a 60 line Tach and a permanent magnet /8 motor. No adjustment is required to operate different drive motors. However, there may be a need to check or recalibrate the DM-500 for use with a different motor or motor speed range. To calibrate the DM-500 perform the following steps: Warning - The DM-500 is a direct off-line controller. Due not used grounded instruments during calibration. 5 vac is exposed on the heat sinks used on the P oard. Only qualified personal should perform test or calibrations on the control. ) Remove the cover from the DM-500 controller. onnect a calibrated digital voltmeter to the speed reference signal on JP- (-) and JP-4 (+). ) If encoder is installed on the drive motor connect a frequency counter to the encoder output JP-7(+) and JP-(-). 60-line tachometer will produce a direct readout of motor RPM. If a tach is not installed, use a hand tach to measure actual motor RPM. ) onnect the DM-500 to a suitable 5vac source. Make sure that the motor is free to rotate then power up the DM control.

12 4) Set the speed reference input to zero and activate the drive forward input command. djust R4 (MIN) for zero motor RPM. 5) Set the speed reference to 0.0 volts and adjust R (MX) for 00 (HZ or RPM) or desired motor speed. When using a Tachometer the maximum motor speed is 000 RPM. If the Tachometer input is disabled (Jumper on JP) the maximum armature voltage is 05 vdc. 6) djusting R may change the motor zero input. Repeat Steps 4 and 5 until desire results are obtained. 7) The motor current limit R6 is factory set and should not be changed. 8) Disable the forward direction input. Turn the power off and reinstall the DM cover.

13 SETION 4 DRWINGS ND PRTS LISTS 4. System onfiguration DM-500 ENLOSURE P/N: S5040 POWER LE P/N: SW504 REMOTE I/O LE P/N: SW5058 MOTOR LE SEE HRTS ELOW TO WR-000 ENLOSURE OR USERS PL MOTOR LE HRT PRT NUMER SW5059 SW5060 SW507 SW507 DESRIPTION MILLER D4 MOTOR LE STNDRD MOTOR WITHOUT TH LE LINOLN N5 MOTOR LE STNDRD MOTOR WITH TH LE

14 4. System Schematic Diagram HOT NEUTRL GROUND P LK 8 WG WHITE 8 WG GREEN 8 WG JP9 JP9 PT07--P POWER POWER IN F 5 MP G RROWHRT 600RE S LK 8 WG ROWN 8 WG WHITE 8 WG GRY 8 WG YELLOW 8 WG JP JP8 POWER OUT DM-500 SR P... SSEMLY P/N: S V +5V GROUND EN OM FIELD- RM- FIELD+ RM+ P D E F G H J K L M PT07-4-S MOTOR YELLOW WG RED WG GREEN WG WHITE WG LK WG LK 6 WG ROWN 6 WG YELLOW 6 WG RED 6 WG JP 4 JP JP ENODER JP7 MOTOR +4V OM SPEED- SPEED+ FWD+ FWD- EN GROUND P D E F G H ROWN WG LK WG LUE WG ORNGE WG VIOLET WG GRY WG GREEN/WHITE WG RED/WHITE WG JP JP PT07--8S I/O I/O

15 4. DM-500 Enclosure Details

16 ITEM QTY PRT NUMER DESRIPTION SE5044 OVER SE505 ENLOSURE SE5054 FRONT OVERLY 4 SE5055 RER OVERLY 5 S5508 DM-500 SR P SSEMLY 6 SW5054 POWER IN LE 7 SW5055 POWER OUT LE 8 SW5056 SR MOTOR LE 9 SW5057 INTERNL I/O LE 0 S5I50 DM-500 SR PROESSOR XS5078 ROKER SWITH X000 FUSE HOLDER X50 5 MP G FUSE 4 ¼ DIMETER X ½ LONG HET SHRINK TUING 5 4 X6Z507 ¼ HOLE DOME PLUG 6 9 #6- X /8 LONG PN HED SREW W/ INT LOK WSHER 7 6 #6- X ¼ LONG SOKET UTTON HED SREW 8 #6- HEX NUT