DynaDrive
INFORMATION MANUAL
3560-BRS
INDEX
Page
INTRODUCTION 2
ELECTRICAL CAUTIONS 2
SPECIFICATIONS 3
WIRING DIAGRAMS 4
OPERATIONAL MODES 5
TORQUE MODE - FACTORY POTENTIOMETER SETTINGS 5
TORQUE MODE - SETUP 6
MATCHING THE DYNADRIVE TO THE MOTOR 7
VELOCITY MODE – POTENTIOMETER SETTINGS 8
VELOCITY MODE - SETUP 9
CONNECTOR INFORMATION 10,11
ADJUSTMENTS 12
TEST POINT INFORMATION 12
TROUBLESHOOTING 13,14
MOUNTING DIMENSIONS 15
3560-BRS, 5/24/15
-1-
INTRODUCTION
This information manual provides the product specifications, wiring diagram, operational
modes (torque and velocity) and troubleshooting procedures for the brush DynaDrive
3560-BRS.
The DynaDrive 3560-BRS supplies 35 amps continuous current and 60 amps peak
current at 300 VDC for a total of 18000 watts of continuous power. The DynaDrive is a
current source type PWM amplifier.
The DynaDrive is a power duplicator of the command signal. A battery, a motion
controller, or a signal generator can be the source of the command signal input.
ELECTRICAL CAUTIONS
Make sure that all voltages and tests are made with battery powered or electrically
isolated instruments.
-2-
SPECIFICATIONS
DynaDrive 3560-BRS
Performance Characteristics
Peak Power 18 kW
Peak Output Voltage ± 300 vdc (shut off @ 450 vdc)
Peak Output Current ± 60 amps (1 sec.)
Max. Continuous Current ± 35 amps (50 °C)
Internal Shunt Regulator 110 W continuous, 5.3 kW peak for .02 seconds
(activates at 400 vdc)
Electrical Characteristics
Input Signal Voltage ± 10 vdc (typ.),
± 35 vdc (max.)
System Gain 0 to 6100 amps/volt – velocity mode
0 to 20 Amps/volt – torque mode
Input Impedance 40 k Ohms
Typical Input Drift 10 µV/°C
Bandwidth 2 kHz with 2.4 mHy Inductance
Dead Band Zero
Input Power Requirements
Input Voltage 50-260 VAC, single phase or three phase
Adjustments
Peak Current Limit 0 to 60 amps
RMS Current Limit 0 to 35 amps.
Signal Command Input Scaling
Balance Zero velocity/torque offset
Compensation System response
Tachometer Scaling
Diagnostics LED indication
Green LED 1 - RUN GREEN - AMPLIFIER OPERATIONAL
Red LED 2 - BUS OVER VOLTAGE
Red LED 3 – EXCESSIVE RMS CURRENT/ OVER TEMP
Red LED 4 - SURGE/GROUND FAULT
Physical Characteristics
Module Dimensions (L x W x H) 7.6 in. x 4.5 in. x 5.4 in.
Weight 4.8 lbs
Ambient Temperature – Operating 0 °C to 50 °C
Shutdown Temperature 80 C at heat sink
Relative Humidity 5 - 95% non-condensing
-3-
WIRING DIAGRAM
3560-BRS with Tachometer
J1 CONNECTOR
PIN 1 12 V, 5mA OUT
PIN 2 COMMON
PIN 3 12 V, 5mA OUT 150-260 VAC
PIN 4 COMMAND
PIN 5 COMMAND
PIN 6 TACH IN
PIN 7 ENC. TO TACH OUT
PIN 8 CURR. MONITOR OUT
PIN 9 INHIBIT/RESET
PIN 10 VOLTAGE OUT (+6V @15mA)
PIN 11 COMMON
PIN 12 NOT USE
PIN 13 NOT USE
PIN 14 NOT USE
PIN 15 COMMON
PIN 16 FAULT OUTPUT
J2 CONNECTOR TEST POINTS
PIN 1 MOTOR MOTOR
PIN 2 NOT USE
TP5 PEAK CURRENT LIMIT
TP6 TACH SIGNAL INPUT
PIN 3 MOTOR
TP4 COMPENSATION
PIN 4 DC BUS OUT
PIN 5 DC BUS OUT
TP1 COMMON
AC CONNECTOR
TP2 SIGNAL
TP3 TACH
PIN 1 L1
TP7 RMS
PIN 2 L2
PIN 3 L3
PIN 4 EARTH GND
1 10 11 12 13 14 16
SIGNAL
TACH PIN 1 PIN 16 PIN 1 PIN 5
COMPENSATION
RUN GREEN
RMS/OVER TEMP.
BUS OVER VOLTAGE
SURGE/GROUND FAULT
POTS
PEAK CURR. LIMIT
BALANCE
RMS CONN. J2
CONN. J1 CONN. J4
TORQUE MODE
JUMPER J3
LEDs BUILT IN
POWER SUPPLY
WITH SHUNT
REGULATOR
TP8
DynaDrive
F1 SHUNT REGULATOR MDA 3A FUSE
F2 MDA 25A BUS VOLTAGE FUSE
-4-
OPERATIONAL MODES
The DynaDrive can operate in a Torque or Velocity mode.
In the Torque mode, the DynaDrive only closes the torque loop. The velocity loop is
closed in the motion controller.
In the Velocity mode, the DynaDrive itself closes both the torque and velocity loop.
Unless otherwise specified, the DynaDrive 3560-BRS is preset from the factory in the
Velocity mode.
TORQUE MODE - FACTORY POTENTIOMETER SETTINGS
The DynaDrive 3560-BRS is set in the torque mode by installing the torque mode
jumper at J3 and presetting the potentiometers for the torque mode. The factory
potentiometer settings for the torque mode are as follows: (See ADJUSTMENTS
section for a more complete description of the potentiometer functions)
Table 1
Potentiometer Potentiometer Potentiometer
Description Setting Test Point
N/A N/A TP1 – COMMON
SIGNAL 5.20 k Ohms TP2 – SIGNAL
TACH Full CCW TP3 – TACH
COMPENSATION Full CW TP4 – COMPENSATION
PEAK CURR LIMIT 2.32 k Ohms (60 Amps) TP5 – PEAK CURR LIMIT
BALANCE No Preset None
RMS 9.40 k Ohms (35 Amps) TP7 – RMS
Note: All Measurements are with respect to TP1 (Common) with J1 removed.
-5-
TORQUE MODE - SETUP
The factory preset potentiometer settings are adjusted for the torque mode operation.
To set up and run the DynaDrive 3560-BRS in the torque mode, perform the following:
1. Turn power off.
2. Remove J1.
3. Check all wiring connections. Verify that J3 jumper is installed.
4. Set the RMS, PEAK CURRENT LIMIT and SIGNAL pots to match the motor
as indicated in Table 2. For preliminary testing under no load, use the
factory preset pot settings.
5. Check that the TACHOMETER pot is full counterclockwise (CCW).
6. Check that the COMPENSATION pot is full clockwise (CW).
7. Replace J1.
8. Inhibit the DynaDrive by leaving pin 9 of J1 open or by pulling it to common.
9. Turn power on.
10. Insure that the voltage at COMMAND + and COMMAND – is zero.
11. Enable the Dynadrive by pulling pin 9 of J1 to + 5 VDC.
12. The green LED should be the only LED on. No other LEDs should be on at
this point. If any other situation exists, check the TROUBLESHOOTING
section of this manual.
13. Adjust the BALANCE pot to give zero volts at CURRENT MONITOR OUT,
J1 pin 8.
14. Apply a voltage (0 to +/- 10 Vdc) at COMMAND + and COMMAND -. The
motor shaft should turn CW when COMMAND + is positive and should turn
CCW when COMMAND + is negative. At low COMMAND voltage, holding
the shaft can stall the motor. At higher COMMAND voltage, the torque is
much greater and it should be difficult to stall the motor.
-6-
MATCHING THE DYNADRIVE TO THE MOTOR
The factory preset potentiometer settings of the DynaDrive 3560-BRS may need to be
adjusted to match the continuous current rating of your motor. To accomplish this, find
the continuous current rating of the motor to be used and adjust the RMS, PEAK CURR
LIMIT and SIGNAL pot per Table 2 below. If the continuous current rating is between
the values shown in the table, you may set to the lower value or use linear interpolation
for each pot value. The signal pot settings are based on +/- 10 vdc input command
signal.
Table 2
Continuous RMS PEAK CURRENT LIMIT SIGNAL
Current Rating of Pot Setting Pot Setting Pot Setting
Motor TP7 TP5 TP2
(Amps) K Ohms (Amps) K Ohms (Amps) K Ohms
10 2.56 k (10 Amps) .49 k (22 Amps) 1.86 k
15 5.78 k (15 Amps) 1.21 k (42 Amps) 3.50 k
23 7.89 k (23 Amps) 2.00. k (50 Amps) 4.40 k
30 9.20 k (30 Amps) 2.40 k (60 Amps) 5.20 k
35 9.47 K (35 Amps) 2.40 K (60 Amps) 5.20 k
Note: All Measurements are with respect to TP1 (Common) with J1 removed.
-7-
VELOCITY MODE – POTENTIOMETER SETTINGS
To set the DynaDrive in the Velocity Mode, remove the cover to expose the Torque
Mode Jumper at J3. Remove the Torque Mode Jumper at J3 that is located right
behind the Tach pot. The pot settings must be adjusted for Velocity mode per Table 3
below. The Velocity mode requires a tachometer feedback signal from the motor or
motion control system.
To match the motor to the DynaDrive 3560-BRS, set the RMS and SIGNAL pots per
Table 2. Set the PEAK CURR LIMIT pot to full CCW. Set the remaining pots per Table
3 below. Now perform the Velocity Mode Setup procedure on the next page.
Table 3
Potentiometer Potentiometer Potentiometer
Description Setting Test Point
N/A N/A TP1 – Common
SIGNAL See Table 2 TP2 – SIGNAL
TACH 2.4 k Ohms TP3 – TACH
COMPENSATION Full CCW TP4 – COMPENSATION
PEAK CURR LIMIT Full CCW TP5 – PEAK CURR LIMIT
BALANCE No Preset None
RMS See Table 2 TP7 – RMS
Note: All Measurements are with respect to TP1 (Common) with J1 removed.
-8-
VELOCITY MODE - SETUP
To set up and run the DynaDrive 3560-BRS in the Velocity mode, perform the following:
1. Turn power off.
2. Remove J1.
3. Check all wiring connections. Verify that J3 jumper is removed.
4. Check that the pots are set per Table 3.
5. Inhibit the DynaDrive by leaving pin 9 of J1 open or by pulling it to common.
6. Replace J1.
7. Turn power on.
8. Insure that the voltage at COMMAND + and COMMAND – is zero.
9. Enable the DynaDrive by pulling pin 9 of J1 to + 5 VDC.
10. The green LED should be the only LED on. No other LEDs should be on
at this point. If any other situation exists, check the TROUBLESHOOTING
section of this manual.
11. Slowly turn the PEAK CURR LIMIT pot CW. If the motor runs away, turn the
power off, reverse the velocity feedback leads and repeat above. If the
motor does not run away, turn power off and wait for the green LED to go
out, disconnect J1. Set the PEAK CURR LIMIT pot to the value given
in Table 2. Re-install J1, turn power on and continue.
12. Turn the COMPENSATION pot CW until the motor starts buzzing. Now turn
the pot CCW until the motor stops buzzing and then turn another 1 ½ turns
CCW.
13. The motor shaft should not be rotating at this point. If it is slowly rotating,
adjust the BALANCE pot until rotation is stopped.
14. With zero voltage at COMMAND + and COMMAND –, the motor shaft should
be stiff and difficult to turn. A low voltage at COMMAND + will cause the
motor to turn at a slow speed with high torque and the motor should be
difficult to stall. The motor speed should be proportional to the COMMAND
voltage.
-9-
CONNECTOR INFORMATION
DynaDrive 3560-BRS
J1
Pin Label Description
1 + 12V, 5mA OUT Auxiliary voltage that has 1K ohm
resistor in series with this output.
2 COMMON Connected to other commons and
connected to the metalwork of the
amplifier mounting plate.
3 - 12V, 5mA OUT Auxiliary voltage that has 1K ohm
resistor in series with this output,
4 COMMAND - Differential input. This pin can also
be used as a single ended input.
Use J1, pin 2 as common.
5 COMMAND + Differential input
6 TACH IN Single ended input that has
additional tach filtering and
conditioning.
7 ENCODER to TACH OUT (option) Jumper to Pin 6 if Encoder to tach
option is being used.
8 CURR MONITOR OUT Current monitor output. +/- 10 Vdc
out equals approx. +/- 60 amps.
9 INHIBIT/RESET Connect to + 5Vdc to enable
amplifier. Remove +5Vdc to inhibit
and reset amplifier.
10 HALL VOLTAGE OUT + 5Vdc can be use for Inhibit/reset
(200 mA max)
11 COMMON See pin 2 above
12 HALL 1 Not use on Brush Drive
13 HALL 2 Not use on Brush Drive
14 HALL 3 Not use on Brush Drive
15 COMMON See pin 2 above.
16 FAULT OUTPUT Uncommitted collector output that is
high (off) during normal operation
and low (on) if a fault occurs.
Note: Use an external pull up
resistor to 5 - 24 Vdc at 10 mA max.
- 10 -
J4
Pin Label Description
1 N. C. No Connection
2 Enc. (B) Encoder B Input for Enc. To Tach.
3 N. C. No Connection
4 Enc. (A) Encoder A Input for Enc. To Tach.
5 Enc. Common Encoder Ground for the Enc. To Tach.
J2
Pin Label Description
1 MOTOR (U) Output power to motor
2 MOTOR (V) Not use on Brush Dirve
3 MOTOR (W) Output power to motor
4 - DC BUS OUT Output Bus Voltage Return
5 + DC BUS OUT Output Bus Voltage High Side
- 11 -
ADJUSTMENTS
The following is a description of the function of each pot. The pot settings can be
measured at test points TP1 thru TP7.
SIGNAL The signal potentiometer is used for scaling the command signal.
Turning the potentiometer CW increases the amount of command
signal to the front end of the amplifier.
TACH The tachometer potentiometer is used for scaling the various
tachometer voltage gradients. This input has to be used because
of special signal conditioning. Turning the pot CW increases the
amount of tach-feedback into the amplifier.
COMPENSATION The Compensation potentiometer is used to increase or decrease
the response (bandwidth) of the amplifier. Turning the
potentiometer CW increases the response of the amplifier.
PEAK CURR LIMIT The peak current limit potentiometer is used to increase or
decrease the peak output current of the amplifier. Turning the
potentiometer CW increases the output current of the amplifier from
zero amps to maximum peak amps.
BALANCE The balance potentiometer is used to stop motor rotation when no
input signal exists. The function of this pot is such that for zero
input volts the output current should be at zero amps.
RMS The RMS potentiometer is for changing the level of the RMS
current. The amplifier is capable of providing maximum RMS
current when fully CW. The minimum current is approximately 0
amps when fully CCW.
TEST POINTS INFORMATION
DynaDrive 3560-BRS
TP1 - COMMON
TP2 - SIGNAL input pot wiper
TP3 - TACH input pot wiper
TP4 - COMPENSATION pot wiper
TP5 - PEAK CURR LIMIT pot wiper
TP6 - TACH IN signal directly connected to J1, pin 6 thru a 10K resistor
TP7 - RMS current setting pot wiper
TP8 - Front-end opamp output (J3, pin 2)
- 12 -
TROUBLESHOOTING
The DynaDrive 35560-BRS has four diagnostic LEDs:
1) RUN GREEN
2) BUS OVER VOLTAGE
3) RMS/ OVER TEMP
4) SURGE/ GROUND FAULT
GREEN LED:
RUN GREEN - Indicates the amplifier is working properly. When the green LED goes
off and there are no red LEDs on, the following may have occurred:
1. Loss of power to the amplifier.
2. Bus Voltage less than 100 VDC.
3. Amplifier has been inhibited by J1, Pin 9.
RED LEDs:
Note: When a red LED is on, the amplifier has been inhibited and remains inhibited
until reset. To reset, toggle J1 pin 9 momentarily to Common.
BUS OVER VOLTAGE - Indicates that the bus voltage has exceeded 450 VDC. This
condition may be caused by rapid deceleration or back driving of the motor. A shunt
regulator is required to dissipate the motor energy. If a shunt regulator is present in the
system check its fuses.
RMS/OVER TEMP
Excess RMS - The amplifier delivered current beyond its continuous capability. This
condition can exist if a machine is asked to perform a task greater than its design
capabilities. This would include a motor that is mechanically stalled or binding or a
motor with shorted stator (armature) wires.
Over temperature - The heat sink has exceeded 80 C. An over temperature condition
may exist for the following reasons:
a) Insufficient airflow across the heat sink.
b) Ambient cabinet temperature too high.
SURGE/GROUND FAULT
Surge - Indicates an excessive amount of current through the power transistors in the
output power bridge. This condition may be due to a damaged output power device or
shorted output leads to the motor.
Ground fault - One of the output wires to the motor is shorted to ground. This condition
may be due to faulty or pinched wiring or the motor is arcing to the case ground.
- 13 -
OTHER CONDITIONS:
MOTOR OR MACHINE RUNS AWAY:
1.Check the tachometer voltage to the amplifier by testing TP3 with respect to TP1.
Then look at TP6 with respect to TP1 with a voltmeter.
2.Ensure the tachometer signal is phased correctly.
3.Check to see if the position loop phasing (CNC command) is correct relative to the
position encoder feedback device.
MOTOR PRODUCES VERY LOW TORQUE IN VARIOUS SHAFT POSITIONS:
1. Check you pot settings the PEAK CURENT LIMIT may be to low
- 14 -
MOUNTING DIMENSIONS W/OUT FINS
DynaDrive 3560-BRS
5.400
- 15 -
