The DC Drive

In the beginning
 6 Basic Adjustments

• Speed Reference
• Minimum Speed
• Maximum Speed
• Acceleration
• Deceleration
• Current Limit
Typical DC Drive
Adjustments
 Adjustments - Speed Reference

• Speed Reference
• Typically it is a potentiometer that an operator
turns to adjust the speed of the machine.
 Adjustments – Min. Speed

• Minimum Speed
• How fast the machine will operate with the Speed
Reference turned all the way DOWN.
 Adjustments – Max. Speed

• Maximum Speed
• How fast the machine will operate with the Speed
Reference turned all the way UP.
 Adjustments - Acceleration

• Acceleration Rate
• How much time it will take to go from stop to full
speed.
 Adjustments - Deceleration

• Deceleration Rate
• How much time it will take to go from full speed to
stop.
 Adjustments - Current Limit

• Current Limit
• This limits the amount of current coming out of the
drive. It’s based on the motors Full Load Amps.
 Basic DC Drive Operations

• Speed Reference - How fast you want the

machine to go.
• Can be analog 0 - 10vdc or 4 - 20mA signal
from a controller.
• Can also be a adjustment via parameter,
network data or keypad input
• Signal is modified by Min. and Max. Speed
Adjustments
• Goes to the Ramp Circuits
 Basic DC Drives Operations

• Ramp (Rate) circuits get the speed reference

and ramps the signal up over a period of
time.
• The time periods are adjustable via a pot,
parameter or network data.
• Output goes to a summing junction.
Basic DC Drive Operations
 Basic DC Drive Operations

• Summing Junction
• Takes the signal from the Ramp circuits and adds
them together with some sort of feedback.
• Feedbacks can be speed,voltage or current.
• The result out of the summing junction is an error
signal indicating the difference between the speed
reference and the feedback. Another way to look
at it is “ difference between how fast I want it to go
verses how fast it is actually going”
• Output goes to the Major Loop (Speed or Voltage
Loop)
Basic DC Drive Operations
 Basic DC Drive Operations

• Major Loop Operational Amplifier (Loop 2)

• The speed error signal from the summing junction
is the input. This amplifies the error signal.
• There is a feedback loop around the amplifier.
This loop has a resister and capacitor (digital
drive’s would be integrator and proportional
response)
• Tuning these values of the feedback loop will
affect the overall response (stability) of the drive.
Basics DC Drive Operations
Basic DC Drive Operations
Stability
 Basic DC Drive Operations

• Second Summing Junction

• The input to this junction is the amplified error
signal out of the Major Loop (Loop 2) operational
amplifier. The signal is now called Current
Reference.
• Current Reference is “Summed” together with the
current feedback signal.
• The output signal goes to the Current Minor Loop
(Loop 1) Operational Amplifier.
Basic DC Drive Operations
 Basic DC Drive Operations

• Current Minor Loop (Loop 1)

• The current error signal from the summing
junction is the input. This amplifies the error
signal.
• There is a feedback loop around the amplifier
which is a resistor and capacitor. (Digital
drive’s is Integrator & Proportional response)
• Tuning these values will affect overall
response (stability) of the drive.
Basic DC Drive Operations
 Basic DC Drives Operations

• Gate Pulse Driver Circuits

• These circuits provide the pulse to the gate inputs
on all the SCR’s. Input from CML.
• Everything in the drive up to this point is there to
tell these circuits when to fire.
Gate Pulse Timing
Basic DC Drive Operations
 Basic DC Drive Operations

• Power Module
• This is where the SCR’s live.
• The Power Module has AC power connected to it
which is what gets switched (through the SCR’s)
to the motor armature circuit as DC.
Basic DC Drive Operations
SCR Construction
Typical DC Drive - SCR’s
Power Module (SCR’s)
Non-Regen
Power Module (SCR’s)
Regen
 Basic DC Drive Operations

• Motor
• The interaction of 2 magnetic fields causes
rotation (armature & field).
• Typically the Field coils have a constant voltage
applied and we vary the voltage in the armature to
get variable speed (up to Base speed)
• To go above base speed we have constant
maximum voltage in the armature and then we
weaken the field voltage.
Speed Regulator
Voltage Regulator
Current Regulator
Position Regulator
 Force Transducer
Tension Regulator Basic
Contactor Reversing
 3 Basic Types of Braking

• Coast to Rest
• Dynamic Braking
• Regenerative Braking
 Braking Methods

• Coast to Rest
• The application coasts to a stop. Time to rest is
determined by Friction, Windage and Inertia of the
load.
• Dynamic Braking
• Inertia contained in a load causes the load to
continue rotating generating a voltage and current
in the armature circuit opposite in direction of
motoring and being dropped across a high
wattage resistor.
 Braking Methods

• Regeneration
• Inertia contained in a load causes the load to
continue rotating generating a voltage and current
in the armature circuit opposite in direction of
motoring current. Using a second set of SCR’s
connected opposite than the first set, these are
fired so that current flow is allowed to flow in the
opposite direction back to the AC line supply.
4 Quadrant Operations
DC Dynamic Braking
Braking Force
Stopping Methods Compared
The AC drive

Then there was AC

 AC Drive Power Section

AC Line

Motor

Input Filter Inverter

rectifier
Drive Basics - PWM AC Operation

VLL @ Drive
500 Volts / Div.
+ DC Bus

- DC Bus

Phase Current
10 Amps / Div.

M2.00s Ch1 1.18V

PWM waveform is a series of repetitive Voltage pulses

 NEMA Enclosures For Drives

NEMA TYPE 1 - General Purpose Indoor, Nonvent &

Ventilated
Designed for use indoors
Intended for areas where no unusual service conditions exist (relatively
clean/dry)
Prevent accidental contact with the enclosed equipment
Panels are louvered and not sealed/gasketed
Provide good protection against falling dirt
 NEMA Enclosures For Drives

NEMA TYPE 1 - General Purpose Indoor, Nonvent &

Ventilated

FlexPak 3000 w/NEMA 1 Enclosure

5 HP SP500 w/Mains Filter
 NEMA Enclosures For Drives

NEMA TYPE 4 - Water-tight/Dust-tight, Indoor/Outdoor

Nonventilated
Intended for use indoors to protect against:
Splashing water
Falling or hose-directed water
Seepage of water
Severe external condensation
Must have conduit hubs for water-tight connection at conduit entrance
Mounting method must be external to equipment cavity
No louvers, no ventilated openings
 NEMA Enclosures For Drives

NEMA TYPE 4 - Water-tight/Dust-tight, Indoor/Outdoor

Nonventilated
Gaskets on doors
NEMA Type 4X are also corrosion-resistant

NEMA 4/12 1 HP MinPak Plus

SP500
 NEMA Enclosures For Drives

NEMA TYPE 12 - Dust-tight/Drip-tight, Indoor

Nonventilated
Suitable for indoor industrial applications
Designed to protect against:
Fibers wFlyings wLint
Dust wDirt wLight splashings
Seepage wDrippings
External condensation of noncorrosive liquids
All holes/conduit openings must have oil-tight gaskets and use oil-tight or dust-
tight mounting mechanisms
 NEMA Enclosures For Drives

NEMA TYPE 12 - Dust-tight/Drip-tight, Indoor

Nonventilated
Doors must have oil-resistant gaskets
Mounting method must be external to equipment cavity
Enclosures must have captive closing hardware and provision for locking
Reliance often times combines Type 4 with Type 12 to make a versatile NEMA
4/12 (water/dust) enclosure
 NEMA Enclosures For Drives

NEMA TYPE 12 - Dust-tight/Drip-tight, Indoor

Nonventilated

Type 4X/12
Type 4/4X/12 Type 12
Open Loop AC
Closed Loop AC
Vector
Open Loop SensorLess
3 Components of Vector
Control

Motor
Current
Torque
Current

Magnetizing
Current
 Optimizing Torque output

Motor
Current
Torque
Current

90 Degrees

Magnetizing Current
Torque is optimized by maintaining Magnetizing & Torque Current @ 90 degrees
 Magnetizing Current

• Identified during Auto-tuning

• Typically ranges from 30%- 50% of Motor FLA
• Fixed from 0% to 95% of Motor Base RPM
• Proportionally decreased in Field Weakening Range

Fixed @ 30% - 50% FLA

Motor Base RPM

95% Motor Magnetizing Current is decreased

Base RPM in the Field Weakened area
 Torque Current

• Represents the actual load at the motor shaft

• Current demand above Magnetizing is Torque

Torque Current varies from Magnetizing to Max FLA

95% Motor Base RPM Motor Base RPM

Magnetizing Current is fixed Mag. Current is decreased

 Motor Current

• The vector sum of Magnetizing and Torque Current

• Regulated by internal current feedback

Torque Current varies from Magnetizing to Max FLA Motor Current

is the sum of
Magnetizing
95% Motor Base RPM Motor Base RPM
and Torque

Magnetizing Current is fixed Mag. Current decreases

General Purpose Mode V/Hz
Vector Mode Torque Curve
Constant Torque Load
Variable Torque Loads
AC Snubber Braking
AC Regeneration
Transportation Application
Matrix
Metals Application
Matrix
Paper Application
Matrix
Consumer Application
Matrix
Gas/Oil/Mining Application
Matrix
• THE END
Notes
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