MAXITRON frre orerer es — S-6/S-6R 8500 Instruction manual Betriebsanileitung Instructions de service Istruzioni di servizio Manual de instrucciones RELIANCE, 491208 english 08 —_pw-s0.00.7 ELECTRIC#U40'1208 Safety Instructions DANGER, WARNING, and CAUTION point out potential trouble areas. * A DANGER alerts a person that high voltage is present which could result in severe bodily injury or loss of life. © A WARNING alerts a person to potential bodily injury if procedures are not followed. * A CAUTION alerts a person that, if procedures are not followed, damage to, or destruction of equipment could result. DANGER: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards A 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 bodily injury. WARNING: Earth fault detection devices must not be used on this converter as the sole protection measure against unintentional touching. A The DC-component in the earth fault current may inhibit the correct function of the fault detector. WARNING: The function of this electronic device, if not mounted in a metal control cabinet, can be disturbed by electromagnetic LA Bettacssr oF nearby radio tranceivers (waikie-taikies): CAUTION: Electronic power converters cause disturbances to the supply network. The basic version of this converter does not include A any harmonic filters and may not fulfil the limits of the national recommendations. The harmonic voltage disturbances produced by the converter are dependent on the supply network impedance. Machinery Directive CAUTION: This converter device is a component intended for implementation in machines or systems for the capital goods A industry. The start-up of the converter in the European market is not. permitted until it has been confirmed that the machine into which -the .converters .are-. built -is in .conformance with the regulations of the Council Directive Machinery 89/392/EWG. WARNING: To inhibit uncontrolled machine operation in case of the malfunction of the drive, the user must provide an external A emergency stop circuit, which ensures disconnection of the power source from the motor. This circuit must be hardwired with electro-mechanic components and shall not depend on electronic logic or software. The stopping device (e.g. mushroom head pushbutton with lock) must be accessible to the operator. Failure to observe this precaution could result in bodily injury or loss of life.401208 e Electromagnetic Compatibility (EMC-Directive) CAUTION : The operating of power converters in the European market is only permitted if the Council Directive Electromagnetic A Compatibility 89/336/EWG has been observed. It is the responsibility of the manufacturer of the machine or system to observe the immunity and emission limits, requested by the Council Directive EMC in the European market. Guidelines for the installation according EMC-regulations - for shielding, grounding, filter arrangement as well as wiring instructions — are summarized in Appendix A, ‘CE-Conformance’ of this Instruction manual. II49'1208 TABLE OF CONTENTS Page GENERAL NOTES « 1. DESCRIPTION WITH SCHEMATIC DIAGRAM 1 Features ...+ 2 Configuration +3 Functions of the controller ssssssseeereeee 4 Functions of the power unit .. 1 1 1 1 2. TECHNICAL DATA 2s1 Voltages -eseeesseeseees senees eeseceseestee 2.2 Armature current, Field current ssssesseeseeee 2.3 Dissipation .. 2.4 Line impedance - 2.5 Ambient conditions «+.+++++ 2.6 Controller data 2.7 Monitoring functions - Gwoooar 3. MODIFICATIONS, COMPLETION +44 3.1 Standard equipment ....++ 3.2 Possibilities for controller adaptation « 4. MOUNTING AND CONNECTION + 22 4.1 Mounting, dimensions . 4.2 Cooling «+ 4.3 Connection plan -+..++ a preerd soeeeeee + 22 5. START UP INSTRUCTIONS 5e1 General seseeeeeeeeeee serene: seeeeeeeeees ol 5.2 General checks without line voltage applied .. teceee BT 5.3 Checks with line voltage applied +.+.+. 5.4 Current regulator adjustaent « 5.5 Voltage regulator adjustuent ... 5.6 Speed regulator adjustment . 5.7 Reference integrator LVTU adjustment ...++++ ieeersereee 32 Peeeeerceees | 52. feeeeeeee 34 + 8 + 6. TROUBLESHOOTING 6-1 Safety precautions « 7 se eeeeee 36 6-2 Trouble shooting suggestions .. seeeeeee 36 614 Replacement of components ss.scsssssseceees 4g 7. ACCESSORIES .. eee 46 APPENDIX A CE CONFORMITY . secerecrer 5949'1208 1 DESCRIPTION i+1 Features Reliance power convertors of the MAKITRON S-6 or S~6R series may be used for the stepless regulation of De-motors. ‘They are available in two variants: For single-quadrant operation: maxTTaon Se = Controlled rectifier bridge with two directions. Clockwise rotation (I. Quadrant) or cow rotation (III. Quadrant) motoring For four-quadrant operation: MAXTTRON S-6R = This convertor works as rectifier and inverter and allows operation in both directions of rotation in motoring and regenerative mode (driving and braking). A-line reactors, super fast acting fuses and fault indicators are not included in the device and have to be mounted separately (see chapter 6.5). ~ Regulator and application specific components are assembled on separate PC-boards. This allows interchanging PC-boards without re-adjusting the controller. = ALL important controller signals are connected to a diagnostic socket (see Fig. 1-3 and 1-5). +n ow ow Regenerative Motoring Bid ar|r + 1v cow Motoring cow Regenerative 2 1.1.1 Protective measures A balanced protective concept ensures a high degree of reliability: On single-quadrant drives fast acting fuses must be provided on the mains supply side to protect the thyristors against short circuits. On four- quadrant drives fuses are also required in the armature circuit. Instantaneous electronic trip (IT) protects the device against over current and overvoltage peaks. ‘ Summing RC-networks limit the voltage at the thyristors. Convertors with cooling fan are protected against excessive tempera tures from overload or fan loss by thermostats on the heatsink. The controller is electrically isolated from the power unit. Regulator blocking on undervoltage or phase loss. Phage sequence optional. LED indicator display and fault monitor output through potential free relay contact. Automatic adaptation to line frequency 50 He or 60 Ha. 1.1.2 Extensions With the additional functions card ZEL/RFL several systen drive functions (e.g. controlled deceleration, fast rate) may be incorporated. Refer to I/M 49'10% or 4911099. With the Section Controller Card Sch connected the analog speei regulator is converted into a digital speed regulator with digital major loop and data interface. Refer to I/M 49'109649°1208 1.2 Configuration ovens Bowen Fig. Regulator Card DRL/DRM Variable Components Card VCL Socket for Diagnostic Unit (Tester) Fuses 0.1 A for output AC 24 V on DRL/DRM Firing pulse card ZPL (on 4-quadr. units only) Fused terminals for field supply (the fuses are externally mounted on CSA approved units) Motor connections Line input connections Control terminals Socket for additional functions card Power stack Cooling fan 1-2: Configuration of the power unit with controller hinged down se49"1208 yyun Torzt0o puw royBTMBer oy Jo weAFETP oTeUOYOS t¢-| “FTE + £3-+—_4 sano® soo!4911208 e 1 3 Controller unit functions (Figure 1-3) Symbols identification: [ee)orn a PL: Wrap-pin Solder point Variable jumper-plug Test point with selector switch position @ 3.1 Reference inputs for 15 Vor 10 ¥ direct input through filter reference integrator (LVIU) with potentiometers for ACC-rate and DEG-rate 3.2 Speed or voltage regulator '-regulator (N-REG) Speed regulator with active feedback Voltage regulator with passive feedback Voltage regulation mode is not used on 4-quadrant drives Current Limit IMAX+ motoring (i-quadrant mode) IMAK- regenerative (4-quadzant mode) Add. limit in parallel to standard current limit LIM+ motoring LIM- regenerative (The lower limiting value of the standard- or parallel limit is active) Resistor network for matching the feedback to the tacho voltage Feedback signal for actual speed indication (SPEED FB) 1.3.3 Current regulator PI-zegulator (I-REG) = With active feedback. ‘The regulator time constant is adapted in 4 steps according to the discontin- uous conducting ratio of the armature current. - Resistor network for matching the feedback burden resistance 1.3.4 Summing anplifier, firing angle limiting + Resistor network for matching the firing angle limit to the mains voltage. Selector switch ACt4. ~ Adaptation of the rear firing angle limitation to line frequency 1.3.5 Control inputs = Applying control voltage to VOL~terminals 8-11 enables the controller. The potential free relay contact K1 signals the armature or AC- contactor- = Additional functions with ZFL-card (refer or Bfl-card {refer or SCi-card (refer to I/M 49'1094) to I/M 49'1099) to I/M 49'1096 and I/M 49'1222) Ver ac/oc+26v Fig. 1-4: Control inputs 449'1208 1:4 Power Unit Pig Far “Pisr Bae Piso Pio car Pras Pa a] | = ap fe 4 ; | a] tiers = pa | Nr Ill oe fe ee) | See] (ee zy | ime —@| laces ||] er = | =o He 8 | | | Hy a = | / is Jl | on | | tees loa 7.0), ee 1 a | Fig. 1-5: Schematic diagram of power unit S-6R with regulator supply - The power unit for single-quadrant Units of 120 A and above have one or two operation consists of a fully ‘thermostats, the connections of which controlled, three-phase bridge are brought out at terminals 101 and 29. rectifier, the four-quadrant variant In addition, these units have a cooling comprising two antiparallel connected fan. bridges. ~ Uncontrolled motor field supply- Zi On 1500 A unit use external field rectifier or field controller See technical data 2.1.2/2.1.3 interface card IM{ (the ZPL-card is not mounted) Z 23, On 1500 A units the firing pulse transformers are located on the Z4 On 1500 A units only external blower supply on 380 V to terminals 187, 188, 189 ‘WARNING The output voltage of the convertor (MAXITRON S-6/S-6R without field weakening) is not limited. In case of a fault the output voltage (armature voltage) may reach the following value: Ua = 1635. Uy (observe the line voltage tolerance)49°1208 2. TECHNICAL DATA 2.1 Voltages 2.141 Convertor input voltages: = Three-phase line input voltage (terminals 181, 182, 183) two variantes: type 30-290 A and 800 A . type 450 4 + 220-415 V and 220-500 V seeees 220-500 V type 1500 A seseseees 220-500 V and 220-660 V ~ Line voltage tolerance for the controller «++++ sesee 810% for maximum armature voltage according to Table 2-2 seeeee 50 He or 60 He £2 He - Line frequency - 2.1.2 Field rectifier input voltage: ~ Single-phase line voltage (terminals 281, 282) ~ Fused ty Fl, F2 ... + 50-430 A. = 1500 A unit with external field supply . max. 415 V 10 AFF 800 A ...20 AFF 2.1.5 Fan supply voltage and power consumption type 120-800 A internal .sssscesseeeeeeeeesenseesses AC 220 V, 50/60 Hz, 0,2 A type 1500 A external on 187, 188, 189 A ...... AC 380 V/ 50 Hz or 60 Ha, 1 A ‘Thermal/magnetic protection by external circuit breaker 2.1.4 Armature voltage ="Standard voltages Up nom (according to DIN 40030) at inductive voltage drop of Ux & 42 per phase according to Table 2-1. = Maximum permissible armature voltages Ug nax at inductive voltage drop of Uy < 4% por phase and nax. 5% line undervoltage according to Table 2-1. Table 2-1: Armature voltages for different line voltages 8-6 (motoring only) 8-6R (motoring and inverting) Tine ‘Remature ‘Armature Tine Kraature ‘Araature voltage voltage voltage voltage voltage voltage ow Va nom Va max UN Ue nom Ua max 380 V 460 V 460 V 380 V 400 T 400 V 415 V 460 V 500 V 45 V. 400 V 450_V 460 V 5200 550 V 460 V 460-7 ‘480 V 500 V 600 V 600 v 500 ¥ 520 V 520 ¥ 660-0 00-¥ 800-V 660_V 700-¥ "T00-V - Maximum permissible armature voltages at inductive voltage drop of Ux >4% per phase and max. 5% line undervoltage, according to Table 2~ Begides the armature voltage derating the rear firing pulse limitation @1im must be displaced. This is done by adapting resistor R501 on the VCL-board, according to Table 2-2. Table 2-2: Max. armature voltage at Ux > 4% or undervoltage > 5% UK under- max. armature lim R501 voltage voltage 4to 72 <58 0.95 « Ug max 152° 147 7 to 12% 54 0.90 . Ug max 147 82k5 <4% 5-10 6 0.95 . Up max 158° - <48 10-15 % 0.90 . Ug max 158° - 749"1208 2.2 Armature current, field current The current ratings stated in Table 2-3 are valid for service conditions as per 2.5 concerning ambient tenperature (45°C) and installation altitude (1000 m). On deviations the derating factors must be taken into account. Table 2-3: Armature current, current transformers, field current ‘Type armature current current Field current danon aa Tamax Transformer Ratio Ip 8-6/S~6R 8503 2A WA 35 A B33 4 BA S=6/S-6R 8506 or Ne 85522 BA $-6/S~6R 8512 1004 120A 150A 3:1 BA S-6/S~6R 8529 240A 2904 360A 2000 : 1 8A $~6/S-6R 8543 3EOA 450A 540 3000 : 1 BA 8-6/8-6R 8580 6664 800A 1000 & 5230: 1 1b A 8-6/S-6R 8515 1250 A 1500 A 1875. A 10500 : 1 - Ignom t Permanent rated current with 50% overload during one minute every 10 minutes. s Permanent Liniting current without overload (Iga * 1-2 + Zenon) Ignax ! Yaximun current during one minute after 9 minutes with Ianom (lamax * 1+5 + Tanom) Current transformer ratio i= Motor current : Burden current 2.3 Controller heat dissipation Controller heat dissipation in watts may be expressed by the following formula: Dissipation Py-K +3. Ipnom where 100 for -units Type 8503, 8506 and 8512 200 for units Type 8529 and 8543 400 for units Type 8560 800 for units Type 8515 Line impedance considerations So that the maximum permissible short circuit current capacity of the convertor is not exceeded, minimum supply network inductance is a mandatory requirement. Therefore a three phase iron core reactor should be incorporated in the mains supply to terminals 181, 182, 183. For selection see Table 6-5. ‘The short circuit current at the field rectifier input (terminals 281, 262) must be limited to 25 kA. Exception: No reactor: is required when a matched transformer is provided in the input to the convertor. -8-49°1208 2.564 2.5.2 2.563 2.5.4 2.5.5 5 Service Conditions Ambient temperature : 0°C up to +55°C - Operation cond.: For temperatures higher than 45°C the max. currents must be derated by 1.5% per °C. ~ Storage: =25°C to 455°C - Transportation: 25°C to +70°C (+70°C during 24 hours max.) Ambient humidity max. 50% at 40 degree C unlimited max. 90% at 20 degree C during max. 30 days/year 75% average (Class F, DIN 40 040) Nowe: Condensing not allowed! Air pollution ‘The ambient air may contain some dry dust but must not contain excessive dirt, chemical fumes, oil vapor, etc. Installation altitude: Max. 1000 m above sea level. Above, derate max. current by 1% for every 100 m Degree of protection : IP00 2.6 Controller data 2.6.4 2.642 2.6.5 2.664 Control supply transformer ceeeseee 110/220/240 ¥, 210%, 50/60 Ka ++ max. 10 AT AC 24.0 + 200 mA Line voltages, single-phase «+++s++e Fuses (externally mounted) for cross section 1.5 «++ Control voltage secondary at terminals 51/52 ..++. protected by fuse Fl on DRl~card ... Switching-on sequence for control supply and power unit, optional Switching-off sequence: power unit first or optional, if terminals 8-11 are voltagefree since at least 200 ms 1 Controller power supply = Stabilised output voltage ~ Loading « = Admissible, additional external supply loading at VCL-output terminals 96-57 (#15 V) and 97-57 (-15 V) s+++s++s+ maxe 10 mA at VCL-wrap pins and add. cards « ee seseeeeeees total max. 200 mi ~ Input fuses F2/P3 ...+- sescseseseses 1 AT Control input seeeeeees AC/DO_24 ¥ sesees approx. 76 mA = Voltage at VCL-terminals 8/11 ..- = Current consumption .+++++ NOTE: with DC +24 V Plus at terminal 8 Minus at terminal 11 Control outputs = Contact loading of relays K1, K2 at terminals 12/14 (K1) and 15/16 (K2) sseceeseeeeees DO 50 V /AC 220 V, 4 A 60 W /1000 VA seeseee approx. 250 ms = Drop out delay of K1 seseeseeeseceeeeeeeseeeeeeenee -9-4911208 & 2.6.5 2.6.6 2.667 2.6.8 2.6.9 Reference voltages, optional «++. steers 10 Vor 15° ¥ Regulator zero (term. 57) shall not be connected to ground. An external reference circuit with ground connection, must be avoided or must be isolated. If this is not possible, consult with RELIANCE. not included Speed reference integrator (LVTU) = Integration time, standard adjustable ...++++++ : ves 1552 8 = Input impedance 15 V input sevseseeseeee soeeee oe 1467 kObm 10 V input « eee soe seeee 10 kOhm = Buffered output +++ seevscees S10V, 25mA Speed regulator = Rated summing current ..++++e+++ seeteereeeees O05 mA = Regulator time constant, standard .++++++++++ 0.3 8 = Transition frequency of open loop regulator « 15 rad/s = Break point frequency «sssesssssssasesceeeesssenees ++ 3 rad/s Proportional gain adjustable by NSB, standard .+++se+eeeree “37 Adjustable current limit, IMaAX + motoring (1+ and 4-quadr. drives)....10 - 100% Iamax IMAX - regenerative (4-quadrant drives only) 10 = 100% Tamax LIM+, LIM- see. see 0 = 100% Iamax Voltage regulator Summing point, rated current ..+sss++ Regulator frequency, standard .....++ ‘Transition frequency, standard .--.+++++ Proportional gain, standard ...... IR-drop compensation adjustable by potmeter IRCP to max. (on 1-quadrant drives only) teeeeeeeseeseeeees O05 MA ++ 18 rad/s 38 rad/s ++ 28 33% see 158 Tomax 2.6.10 Current reference integrator - Current rate, standard . 2.6.11 Current regulator aA = Summing point, rated current at Ignom «+++ = Mime Constant in continuous condition, 1. stage seeseeeeees 15, m8 in discontinuous condition, 2. stage ++ sees 116 m8 3. stage sense 0.66 ms 4s stage seveseseeee 0.43 ms = Adjustment of the transition frequency (without field) to -+.++++. 225 rad/s = Regulator gain adjustable with ISB, standard ...... tenes OotBat ed = Response level of the I = § comparator « seeees 1.5% Ianom Rear firing pulse limitation, standard Current reversing dead time +++.+++ seeeee 158° see min, 1.35 ms 2.6.12 Firing pulse train = Length «+++ ~ Frequency teeeeeeeeeeeeeeees 400 ps = 1.67 ms ceases cas 40 kite49'1208 2.6.13 Data of the regulator card DRL/DRM current FDB current Signal name Short | 1-Quadrant | 4-Quadrant Value Tester Design | Range Range position| Reference MREF 1 “50 15 V 4 Maximum 1 input HOV 10 V speed Comparator compour }-1 V... +1 V v output Integrator rsua | £0.15 mA 20.15 mA summing Reference REP 2. | 0 V...#10 V+} -10 V...+0 | 10 V5 Maximum 2 output speed Speed ref. rer 3 | 0 V...+10 ¥ | -10 V...#10 Vo | 15 Vo Maximum input 1 M50 [AS Weed V speed (standard) Speed reference |wREF 4 | 0 V...#10 V |-10 V...+10 V | 10 V% Maximum input 2 speed Speed regulator |NREF 5 | O Veeette1 V[-1,1 Veeette1 V] 1.1 VoMaximun summing speed Speed regulator |MREF 0 WeeestO V | -10 Ve..t10 ¥ | -10 VeMeximun 3 output current Speed reg-integr. NIR 10 Ve..+10 0 time const. Speed regulator | NSB 0 Veee-10 V | -10 V.-.#10 ¥ proport. gain Actual SPEEDFB | 0 V...+10 V |-10 V...+10 V | +10 VeMaximum | 14 speed speed Armature |-UAFB O Veee5e2 V| 542 Veoot5e2 V] -UAFB = 1% Ug 15 voltage FDB Arua ture IAPB OV 5V OV. 3V | 3V Maximum | 16 =e49'1208 & 2.6.13 Data of the regulator card DRL/DRM - continued Signal Name short | 1-Quadrant | 4-Quadrant Value Tester Design | Range Range position] Current AREF [0 V...-10.V | -10 V...+10 V] -10. V 2 Maximual reference current| (150% Tanom) Current regu- | IAREF3 | -10 V...0 V | -10 ¥...0¥ “10. V2 Maximunl 4 lator input current Current regu- | TaREGOUT|O Vv... 10 V | OV... 10 V * at decreasing 5 lator output (-10 v)* (-10 v)* current only Firing pulse 19 | 4 Thyr. 1 et] FI7 L/t H& Firing pulse a Tayr. 2 we] r2/i2 L/a H4 Firing pulse 22 Thyr. 3 BS | FS/13 L/H Hs Firing pulse B Tyr. 4 Fa | P4a/t4 L/t He Firing pulse 24 ‘thyr. 5 Ff FS/15 L/a H& Firing pulse 5 Tayr. 6 F6 | 6/16 L/H H & Firing pulse 26 Supply 45 450 +15 -V 20.05 ¥ 19 “5 “5 15 V 10.05 V 20 ond 0) 2.6.14 Potentiometer functions on the VCL-card NMIN Minimum speed WAX Maximum speed UMAX Maximum armature voltage ACCS Acceleration ramp DECS Deceleration ramp IRCP IR-drop compensation NSB Speed regulator stability ISB Current regulator stability IMAX+ Maximum pos. armature current IWAX- Maximum neg. armature current OVLD Static thermal overload -12-49"1208 2.7 Monitoring functions Three-phase undezvoltage response level (5PE) +++. overcurrent response level (OCH) «+ 15 V undervoltage response level Regulator enabling - pulse blocking switch off response delay (PBL) - 2.71 LeD-indicator functions + 30% undervoltage teee 2x Tomax Giga) TITY naxs13.3% undervol tage ses approx. 500 ms after supply on ++ approx. 100 as Location | Function | Colour] LED lights, if LED remains dark, if Designat. DaL/M ost green | Current regul.stability constant (during adjustment only) 80K green | Controller supply o-k. TRE red | Thermal overload released ov red | Motor current in the range of thera. overload oce red No Overcurrent Error 3PB red No Line undervoltage 15E rea No #15 V undervoltage TAP green | Positive current flows IAN green | negative current flows -13-49'1208 3. MODIFICATIONS, COMPLETION 3.1 Standard equipment as shipped from stock Quadrant - Line voltage - Control voltage nit as voltage regulator with IR-drop compensation : 380 V / 50 He - 24 = - Regulation mode : Voltage regulator - with IR-drop compens. = Armature voltage : 380 V to 460 V - - Reference voltage: 15 V through LVTU - - Burden resistor +: For lowest current = - Symbol identification: ‘Table 3-1: Standard equipment of the VCL-card 4 Quadrant-unit as speed regulator Line voltage + 380 V / 50 Ka Control voltage : 24 Regulation mode : Speed regulator acho voltage : 59 V to 74 ¥ Reference voltage: 15 V through LVTU Burden resistor : For lowest current 1 Jumper plug inserted, (- open connection) Cirouit Standard function Solderpoint Value Coordinate Reference Speed reference 15 V through LVTU RRI5 (BUT4) 15.¥ 7 input RRO (BW74) 10 Vo - R222 (12486) - NER2 (BM74) n NRF! (BP74) 2 R220 (12886) - c2at (128) R223 (12086) Reference Integration time 1 s to 32 8 224 (55R) a integrator adjustable by ACCS and DECS potneters IROP (3964) n Voltage/ Network for armature voltage regulation UARG (BU64) n Speed with IR-drop compensation wRG1 (Bw64) - Regulator 1-Quadrant Voltage feedback for armature 380-460V 380-4607 7 voltages Uanom 380 V to 460 V var (BY48) . adjustable by potentiometer UMAX Ratt (49¢¢) - 59+4+.74V (BL48) ~ Thee e953 (BNA) - 93.2119 (BQ48) - 119...154 (BS48)- 154...200 (BU48) = NVAR (BJ48) NVAR R205 (58CC) . R206 (96CA) - C207 (85BU) - = 14 -49'1208 Possibilities for controller adaptations 3.2.1 Additional components on the VCL-card ~ Use resistors 0.5 or 0.25 Watt/1% and non polarized capacitors. = The basic controller my be extended with further functions ty additional plug-on cards. NOTE: When soldering components on the VeL-card, verify that the electrical connection to active parts of the controller has been opened. Otherwise the C-MOS components may be damaged. ‘WARNING: For each intervention, the unit must be separated from mains! Possibilities for controller adaptation Modification Calculation formula / Selection table Resistors in kOhm, capacitors in uF ~ Speed reference 10 V ‘through LVTU = LVTU-output open = Speed reference 10 V through| filter without LVTU ~ Increasing of filter time constant T (ms) Iasert jumper RF15 in RFIO Remove jumper NRF2 Insert jumper NRF2 in NRF1 and solder in 20 kOhm resistor in R222 T = 6.67 kOhm (0.22 uF + C221) = Integration time taax extended Adjustment by ACCS and DECS potentioneters 224 = +22 UA + tmax - 8 uP Network for speed regulation Insert jumper UARG in NRG1 and Insert jumper IRCP in (PARC) = Adapting voltage feedback to armature voltage if 380 V>U, >460 V Insert jumper (380-460) in (UVAR), solder in R211 R2i1 = 0.02 . Ug - 5-8 (kOhm) for UMAX in position 5 = Adapting speed feedback to tacho voltage a) 60.5 Up 5 2000 b) 60 > Up °) Up > 200 V Fine adjustment by NMAX a) ») °) Insert jumper 380-460 in corresponding volt.range| Insert jumper 380-460 in NVAR + solder in R205 R205 = 0.726 Up - 7-26 (kOhm) for NMAX in pos.6.3 Insert jumper 154-200 and reduce voltage at terminal 267 to value below 200 V through external voltage divider. = Foreing Insert R206, C207 -15-49°1208 Table 3-1: Standard equipment of the VCL-card (continued) Circuit Standard function Solderpoint Vaud Coordinate Voltage Stability cireuit for e210 (x122) . Regulator Ta" > 0.04, Ra >0.05, ki > 1, R210 (Y122) - : yy - Rasta~ laste ae vg (9) Ras Se Te. Uy Mechanical time constant : T (s) ww = U8 Armature time constant + 1 (ms) Ty Amature resistance: Rg (Ohm) Rated armature current : Iq (A) Line voltage 2 Uy (WV) Motor inertia : J (kgm?) Motor power :P (Ww) Motor rated speed sn (RPM) Speed Network for speed regulation UARG (BU64) - Regulator NRG1 (BH64) A 4-Quadrant Speed feedback for tachogenerator voltages 59-74 V 3E0-460V 580-4600 - UVAR (BY48) Ratt (49¢C) a +TAV (BL48) +93 (BN4S) 119 (BQ48) 119.4154 (BS48) 154.+.200 (BU48) NVAR (BI48) R205 (58Cc) R206 (SECA) = C207 (85BU) -49"1208 Possibilities for controller adaptation (continued) Modification Calculation formula / Selection table Resistors in kOhm, capacitors in uF Fine adjustment by NMAX = Adapting regulation gain | a) T™' > 0.04, Ra < 0.05 : R210 = 562. kc if oki <1 Te or Tu'<0.04 | b) Tm’ > 0.04, Ra >0.05 : R210 = 28. kek or Ba <0.05 ~Fa0.05 1 e) Tm’ < 0.04, Ra < 0.05 : R210 = Tn" +ki.562 If ki >t set i= 1 ~0.04=Ta" KL a) Tm’ < 0.04, Ra > 0.05 : R210 = Tm’ ki.562 TYE.0.8-Ta ki = Adapting filter C210 c2t0 = O.tur(1-ki) in addition if ki <1 rt ~ For ™ > 80 ms C210 = 0.1 pF = Network for armature Insert jumper NRG1 in UARG and voltage regul. 380 - 460 V Insert jumper IRCP in (PARC) (zR-drop compensation on 1-Quadr. drives only) - Adapting voltage feedback Insert jumper (59-74) in (UVAR) + solder in R211 to amature voltage R211 = 0.02. Ua - 5.8 (Ohm) if 380 V >U, > 460 ¥ for UMAX in position 5 - Adapting speed feedback a) Insert jumper (59-74) in corresponding voltage to tacho voltage range b) Insert jumper (59-74) in NVAR + solder in R205 a) 60.< Up < 2007 R205 = 0.726 Up - 7-26 (kOhm) for NMAX in pos.6.5 ) 60> Up ©) Insert jumper 152-200 and reduce voltage at °) Up > 200 ¥ terminal 267 to value below 200 V through external voltage divider. = Forcing Insert R206, C207 -1T-49°1208 Table 3-1: Standard equipment of the V0l-card (continued) Circuit Standard function Solder point value Coordinate Speed Stability circuit for R204 (108BG) = regulator R(V12BH) 681 ks = Tm = 0.4 to 2 (s) 1 Li 0203 (BV94) - C(100BA) 0-047pF adjustable on NSB potneter Maximum speed with reduced field: Naax Base speed: Snon Mechanical time constant: Tm (s) R202 (86AW) - (adequates acceleration time to R(82AM) «221k base speed at rated current) 201 (96AW) - Speed ratio Naax/"non! F Overload ratio Tamax/Tanom? Lit Low pass filter constant Tay = 3-2 ms Regulator time constant Tg = 0.33 R301 (11686) - Carrent reference rate T= 16 ms current (from zero up to Iamax) R102 (W30) : reference for amature ckt with LIM la = 0.6 to t.5ms] R(S31) 22k! integrator, | Ia = La - Ianog/Uy (ma) La = armature inductivity (mH) measured at disconnected field TIM = Iamax/Tanom Speed regulator torque reference MRF (BM64) n Current Armature current feedback: R103 (A950) - regulator Burden resistor selected for lowest x (awa2) 7 armature current of the controller A (AY42) n B (BA42) = c (Bc42) 2 D (BE42) . -18-491208 & Possibilities for controller adaptation (continued) Modification Calculation formula / Selection table Resistors in kOhm, capacitors in uF ~ Adapting regulator gain and | For NSB in position 6.7 low pass filter constant Tar to 5-2 ns, if 0.4 > ks >2 ke _| r2o4| r(112BH)| 203 | c(100BA) O-1-0.4 | 22kt | 68kt [O.1uF [0.047uF ks 0-4-2 - | 6eki | - |0.047ur tr 2-8 | 332k] remove |0.01_ | remove >8 | 825k| remove |0.0033| remove ~ Extending regulator time constant Ty. a) without field weakening for ks = 8: TR(s) | R(82AM) |R202_| C201 Ty = ks. 0.041 s 0.35 | 2atk | - |- b) with field weakening 0.38 221k - |0.22uF for ke <8: 0.44] 22te | - |o.47 Tg = F . 0.338 0.51 | 221k | - |o.68 for ks 28: 0.55 | 22k | - | 1 Tg =F. ke . 0.041 8 0.66 | 22k | - [1.5 0-80 |remove | 267K |1.5 For Tg > 1.18 provide add. 0.90 |remove | 301k |1.5 external capacitor through 1,00 |remove | 352k |1.5 weap-ping NRt, NR2 1.18 |remove | 392k |1.5 ct = TR(s) - 3 yr > 1418 | remove 392k [1-5 ext. ct 392k ~ Current limit adjustable R301 Ks 24 kOhm 5 K = permitted percent. speed with parallel limiter TOO; drop of Muay at current limit (DIM+ and LIH-) with R301 inserted, neg. voltage must be applied to wrap-pine HF2 (LIM+) and HF3 (LIM-) cee a) ») = Adapting current rate to TR.Ta(ms) [r(as) | ato2 | a(s51) | R102 | 2(s31) 0-3-0.6| 8 m1 | 22k | 100k | remove a) TI . Ta for motors O.6-1.5] 16 | “- | 22kt | 100k | remove without field weakening 1.5-2.5| 25 | 47 | remove | 100k | remove >) Fix standard value f. motors| > 2.5| 25 | 68kt | remove | 100k | remove with field weakening MREF and IAREF externally to spare terminals Remove jumper MRF and connect Wrap-pin IRt Burden resistor for approx. 2-V voltage drop at rated armature current assuming that Insert jumper A in position B, C or De If Ig is out-of the current ranges, insert jumper A in pos. X and solder R103. Tenax * 1+5 Tanom RIOS = 2. i. 0.85 Ohm Tanom Tr S503 506 512 HAT HAS B5HGO HIS x 15k SOA 59A 145A 214A 371A 140K B 18 5 n 170255441 880 ce a 42 84 202 S525 1050 D 25 50100240 560_625 1250 7 BI5:4 _OF522 F521 2000zT _5000e1 5av08T 1050037 -19-49"1208 Table 3-1: Standard equipment of the VCL-card (continued) awitch-over for single quadrant only 4Q (2x) Circuit Standard function Solder point Value Coordinate Current Stability circuit for adjustable | R101 (9609) . regulator Ta - LIM = 1.4 to 8 as on ISB R(Q2CR) 392 Ta = ba Tanon/ty (ns) UM: Tamax / Tanom ig (mit): Armature induetivity with disconnected field Ianom ? Rated armature current Uy? Line voltage ALPHA- Rear firing angle limitation 501 (4830) - Summing lim to 158° for Ug 4% per phase Noni toring For line voltage 380 V act4 (1) 380 V circuit and (2) 415 Vv Firing angle (3) 460 ¥ follow-up (4) 500 Vv and Line frequency 50 Ha R503 (18AW) - R502 (22AW) = Fault Relay K2 remains dropped out PARC (BK64) n indication = after line voltage dips longer ERL (BH64) - ‘than 500 us. = undervoltage at regulator supply. Drive must be restarted. Standby = Standby controlled via PARC (BK74) . input terminals 8-11 EXST (BH74) n 4 Standard equipment on the IMM-card (on 1500 units only) Polarity - Current reference polarity 1Q (2x) n 20g49"1208 Possibilites for controller adaptation (continued) Modification Calculation formula / Selection table Resistors in kOhm, capacitors in uF = Adapting regulator gain, if 1.4>Ta . TI >8 ns For ISB adjustment refer to section 5. Tg = Las Ianom (ms) Un Ta.tTt R(92CR) 0.5=164 3K2 _ 144-8 392 R101 18.35 . TA.DIN-10 8 -30 renove for ISB in Pos. 6.7 = Adapting firing angle Limitation to different line impedances Uy at the connecting point see (2.1.4, Table 2-2) alin <158° R501 = 5.85 .alim (k0hm) 158 = at - Adapting to different standard line voltages ~ Adapting to special line voltages or line frequency 60 He Uy min = 220 - Slider switch AC14 to position (2), (3) or (4) ~ Open switch and insert resitors R503 and R502. R503 = 7800 - 4.75 (kOhm) for 50 Hz Oy R503. = 8700 - 4.75 (kOhm) for 60 Ha Uy i R503 = 0.25 « Uy -10 (kOhm) - Drive starts auto- matically after restoration of line voltage or regulator supply undervoltage Insert jumper PARC in position ERD = On drives with 2FL/REL or SCL-card extension Insert jumper BXST in position PARC ladaptation on the IMM-card Polarity awitch-over Change jumpers 1Q to position 4Q -a-49'1208 e 4. INSTALLATION AND CONNECTION 4.1 Assembly Always observe the following requirements when installing the MAXITRON in control cabinets: = Comply with mandatory protection standards to prevent contact with live components (covers) and shock when a fault occurs (safe GND), e-g- as per TEC-204 or VDE 100; Therefore the installation should be done by instructed and qualified electrical personnel only. - Provide studs according to drilling plan Figure 4-1. = Leave space for mounting the regulator unit (see Figure 4-2a) - Pix the unit in the position represented in Figure 4-2 and leave a gap of at least 100 am for the free circulation of cooling air and to eliminate the possibility of internal hot spots. 4.2 Ventilation Cabinet ventilation must be designed so that the air entry temperature in the heatsink does not exceed 45°C (nominal operating temperature) under maximum permissible continuous current loading. Basing caloulations of the cooling air flow on gn increase in temperature of A= 10° the supply of cooling air (e.g. from the cabinet environment) must not exceed a temperature of 35°C. If these temperature linits cannot be maintained, a reduction in power of the MAXITRON must be taken into account. (1.5% per °C above 45°C) NOTE Maximum permissible ambient operating temperature of the MAXITRON of 55°C must never be exceeded. = resulting heat dissipated must be exhausted by suitably dimensioned fans. Power dissipation values depending on controller output current can be calculated according to chapter 2.3. Refer to the following interconnection diagrans Figures 4-3, 4-4 and 4-5. 4.3.1 General signal wire instructions: = Keep signal wire connections as short as possible. = Separate signal wires from current carrying wires (I >0.1 A) as far as possible. Use separate conduit. = Signal wires should not be run near electro-magnetic fields of high energy (motors, transformers) = Cross signal with non signal conductors at angle of between 45° and 90°. = To avoid ground loops, connect only one end of the screen to ground. (earth bus in the cabinet). ~ Use steel shielded, twisted cables with at least 15 twists per meter. 4.342 Transient suppression of contactor and relay coils: Switching of contactor and relay coils (also valves, fan motors etc.) causes transient voltages of high frequency (bursts), which can disturb electronic circuits. NOTE A proved measure, to avoid potential problens, is to provide suppression networks on all contactor and relay coils of the drive equipment: AC-coils with RC-units, D0-coils with diodes in non conducting direction. In any case such coils, which contacts are connected to the drive, or which are actuated by contacts from the drive, must be suppressed. If cabinet blowers or power unit fans are switched, the RC-unit (215'02-00) must ve connected across the contact. -2-49°1208 [L aati Unit B HE L Le Ww x a Z kg Weight kg 1) BOS scoo minal Op sence rss Gee 2oomea = 215 | 6-9(1-), See 8506 225 185350 8 ORS oe eee 7.904-Q), 8.8(4- 1) With additional card ZFL/RFL or SCL: H = 225 Pig. 4-1a: Dimensions, weight and drilling plan for Types 8503/8506 -23-49°1208 e ee Figs 4-1b: Dimensions, weight and drilling plan for Type 8512 Unit B 7 cw Toe Weight 1 Sie _| 225 21 45080 SBT ia ke 1) With additional card ZFL/RFL or SCL: H = 251 Connection Unit fo | T-Quadr. [182183 teT aT FQuadr. | 45 18218116347 fonnection designations = 24 =49°1208 Fig. 4-1c: Dimensions, weight and drilling plan for Types 8529/8543 Space requirement for controller in hinged down position Pig. 4-20:491208 e ceworr 89 K9 WEOT 183 UBS 60 i 208 Pigs 4-1d: Dimensions, weight and drilling plan for Type 8580 ANSICHT A 66 50,50, Fig. 4-24: Space requirement for controller in hinged down position - 2% -491208 © cewent. 1956 wath = 08s GH q 1 u 3 3 GH 7 [ i | _u © & £0. 455 8 sif sa a7, DETAIL A 8 Fig. 4-1e: Dimensions, weight and drilling plan for type 8515, Fig. 4-2e: Space requirement for controller in hinged down position -2-49°1208 AC/OC+26v Peer a fa REF 1— ov 1%} sy i, @ -15V - - ie : a +487 IF \) n-REG ms | \ \ Fig. 4-3: Regulator connections standard wiring diagram for Speed control, basic version Vel-Terminals Function Remark 96, 57 = DC +15 V supply for reference supply 91, 57 = DC -15 V supply only (max. 10 mA) 167, 60 = Reference input 15 Vor 10¥ 261, 57 = Speed feedback Voltage adaptation with/without n min adjustm. 57 - Speed indication (if connected) "1 = Regulator standby Control voltage AC/DC 24 ¥ 14 = Output contact CONTACTOR OFF (K1) 16 = Output contact ERROR (K2) 3PE, OCE, TRE, 158 +905 = Available inputs/outputs49°1208 u w 1 + a a | cee Saavik | “fl | ao ToT af i | | : I '29 ior {a7 lee 0 {reo fou | her fier feo fear free ey ee ese Ae nt DRL/M x lA | n-REG I-REG | Y wu CHCl: y | rE sy | i : A len eo t a ae : Li 7 Ts Pe F4o! Z1 On 1500 A unit use external field 7 | rectifier or field controller Re : 22 0n 1500 A unit all pulse firing transformers bw © are placed on the interface card IMM a ce ieee PR) re (2PL is not used) 271505.00 | sett Ls Z3 0m 1500 A only external blower supply on terminals 187, 188, 189 ZA, On CSA approved units 30 A, 60 A and 120 A the fuses are not provided On CSA approved unite all short circuit and overcurrent protecting devices in the line input to the power convertor must be in accordance with CEC part 1. Fig. 4-4: Power unit standard wiring diagram Connector Function Remark 181, 182, 185 = Convertor AC-line supply input For supply voltages see: PE ~ Protecting earth connection 2A 281, 282 - Field rectifier supply input 22 45, 47 - Convertor output 35, 37 - Field rectifier output 0-110/220/240 = Control transformer supply 2.6.1 187, 188, 189 = Cooling fan supply (1500 A unit) 2.1.3 29," 101 ~ Thermal contact output on type 120 A and above 51, 52 ~ Output 24 V for control input 2.6.1 ror49'1208 MOTOR READY START FIELD ON MAIN CONTACTOR | xa\ «2 ra Hb Te 7 438 2 wi : OFA xs ca Kz ws was m8 Fig. 4-5: Control circuit standard wiring diagran, basic version "S" = Relay supression against overvoltage peaks by RC units (see chapter 4.3.2) Functions: a) De-notor cirouit protection by = 722 Thermistor motor protection - Q2 Motor blower circuit breaker ») Convertor protection by = K2 Error output contact (undervoltage, overcurrent, thernal overload) = F3 Cooling fan protection through thermal switch on heatsink (on units > 120 A) c) START/STOP relay (K25) actuated by pushbuttons 4) Motor shunt field ow (K29) e) Main contactor (K38) = For extended life time of the contacts, the contactor K38 is held in by K1, until the armature current has dropped to zero Amps.49°1208 5. START-UP PROCEDURE 3 General Procedure of chapters 3 and 4 must be completed and checked before the drive is ready for start-up. We also recommend a study of chapter 1 and 2 to become more familiar with the operation of the drive. If the additional functions card ZFL/RFL has been added to the controller the start-up instructions of this card (Wo. 49°1094 or 49'1099) must be followed also. As the convertors are delivered fully tested, problems during start-up are caused in most cases by faults outside the controller (see chapter 6). WARNING This equipment should only be in- stalled, adjusted and serviced by qualified personnel familiar with the drive funtions and operation and the hazards involved. Wrong handling may cause damage to the machine or injury to personnel. ‘WARNING Before it is safe to touch any internal parts, all phases of the AG-power line must be disconnected from the power unit. Test instruments: = see chapter 6.2.1 NOTE: For measuring voltage and current in the amature circuit different meters are required. = a) Mean values (Ia ~ M, Ua ~ EMF¢RI) og. digital meter FLUKE 60223 b) BMS values (Ia rms) thermal looding of cables: real RMS-neter 5.2 General pre-operation checks with power off ~ Visual check of electronic circuits and of motor for mechanical defects. Check of external connections according to interconnection diagran (cross sections, earth fault). - Check of the externally mounted semiconductor protection fuses according to Table 6.5, 6.6 = Check of the motor protection relay in the armature circuit for setting to 1.05 x rated motor current or 0.85 x Iy if the relay is connected to the line input. This thermal overload aay be fully replaced by the built-in electronic overcurrent tripping circuitry. - Check of the basic adjustments of all potmeters on the VCL card. MMIN, WMAX, UMAX, IMAX+, IMAK~, OVL IRCP: on the left end stop NsB, NOFS, ISB, ACCS, DBCS: in the middle position - Check voltage regulation circuit 5-2-1 On speed regulators Preparation of the tacho polarity check (not used on voltage regulation). For this the tacho feedback aust be disconnected and voltage regulation mode selected by changing VCL-jumper (59-74 V) to (380-460 V) and NRG! to URAG. + Turn reference potentiometer to position zero (cow). + Connect voltmeter to terminals 267 and 57. =e49'1208 e 5.3 General checks with mains voltage applied NOTE: For each intervention, the unit must be separated from mains! 5.3.1 Check of sense of rotation = De-notor blower - Power unit fan if mounted 5.3.2 Checking of controller supply = Switch on regulator supply and check if the LED indicator SOK is on. During about 250 ms error indicator LED's 3PE, 15, TRE, IAP, IAN and OCB will be lit (lamp test). 5.3.3 Check field current according to motor name plate as well as polarity NOTE: In the cold state, the field current may be approx. 20-50% higher than the nominal field current. 5.3.4 On speed regulators checking of tachometer polarity Reliance circuit diagrams are drawn for clockwise operation of the motors (rotates clockwise when looking from the drive side). = Apply low positive reference ~ Terminal 267 should be negative with respect to 57 = Switch off - Delete all measures of chapter 5.2.1 and set the VCL in the previous condition. = Insert jumpers for speed regulation UARG to NRG1 and (380-460 V) appropriate tacho voltage. = Turn reference potentioneter fully cow (low reference). 5.4+ Current regulator adjustment = Connect voltmeter to Vl-wrap-pin IR4 (current feedback signal) and terminal GND (0 V) or tester in position 16 = Disconnect field supply = Switch on and enable the regulator - Verify that the motor does not turn due to the remanence (block the motor if necessary) 5.4.1 Electronic overcurrent trip ~ If the overcurrent tripping device is not used (external thermal overload), pot. OVLD stays in the left end stop. = OVLD-Adjustment is accomplished together with the maximum current setting. At first set the armature current to 106% with pot. IMAXr. Then turn pot. OVLD cw until the LED OVLD is lit. 5.4.2 Current limit Depending on the specified duty class the armature current must be limited to 100% for continuous duty or 150% for short time overload (1 minute). = Apply max. positive reference = Adjust with potmeter IMAK+ 150% resp. 100% armature current (IAFB = 3 V resp. 2V) -~32-49'1208 e If with potmeter IMAK in the right end position ca. 3 V cannot be reached check burden resistor according to Table 3-1. We recommend for checking the armature current either measuring through shunt in the armature circuit or by current transformer in the line input (eae iy) NOTH: With stalled motor max. armature current is allowed for a short time only, otherwise the collector may be damaged. On 4-quadrant drives in addition: - Apply max. negative reference = Adjust with potmeter IMAK- 150% resp. 100% armature current 5.4-3 Standard current regulator stab. adjustment for motors without series field winding - With the LED indicator OST on at max. current, turn potentiometer ISB counter clockwise until the CS? LED starts to flicker, than turn clockwise until the LED lights permanently. Should the LBD never extinguish the current regulator gain has to be reduced (R101, according to Table 3-1). Should the LED never light, the gain has to be increased by removing R(92CR)- During operation the LED CST is of no importance. = Switch OFF = Re-connect field supply. 5-4-4 Check of current reference rate Firat the values of the appropriate variable components on the VCL-card should be checked according to Table 3-1. On drives with field weakening R102 must be 100 kOhm and R531 removed. - Connect scope to pin IR4 (IAFB) Range: 20 ms/div, 1 V/div By-pass LVTU by changing jumper plug NRE2 to NRFt NOTE! The motor load mst be disconnected ~ Apply 100% speed reference - Switch on and give RUN order. Pulses of current feedback signal IAFB should reach Iamax and show an image like Figure 5-1. REMARK: If Iamax is not reached, overshooting] up to 3 V (Iamax) is permitted. For optimum dynamic resistor R102 must be determined so that just no overshooting is obtained. = Switch OFF. = Re-insert jumper plug NRF1 to NRF2 + UiRG av Fig. 5-1: Diagram of current rate as491208 & 5-4-5 Current regulator stab. adjustment 5.5 Voltage regulator adjustment for high dynamic performance or not uséd on speed regulation) motors with 9 field winding 5.5.1 Check armature voltage regulation On motors operating in 4-quadrants, a cireuit series field winding is normally not Jumper to (380-460) and UARG provided. 5.5.2 Offset, n min and n max adjustment Field supply on Comnect voltmeter to V0L-wrap pin NRIS Connect scope to Tester in Pos. 5 or (Signal -UAPB) DRL/M-pin (GQ86) (signal TAREGOUT) Range: 20 ms/div, 1 V/div Switch ON and give RUN command Apply positive speed reference voltage = Switch on and apply 100% speed reference. Turn pot. ACCS, DECS Set reference to zero and adjust motor fully clockwise. speed to zero by turning pot. NOFS Give RUN order and adjust with potentiometer ISB the current ripple of signal IAREGOUT to 1.52 V during Adjust minimum speed by pot. NMIN Set reference to +100% and adjust" acceleration of the motor with maximum maximun speed with potentiometer UMAK current. 5-5.3 Check speed stability If the drive oscillates, the voltage regulator stability components must be determined according to Table 3-1. 5.4 Adjustment of the IR-drop compensation - This control should only be used with voltage regulator systems, never with speed regulators. TR-dvop compensation cannot be used on 4-quadrant regulators since this signal is not inverted. Insert jumper-plug PARC in pos. IRCP Fig. 5-2: Current ripple during Initially set the potentiometer IRCP acceleration fully cow (IR-Comp. = 0%). Start drive and run unloaded at desired speed. Load the drive to full load current. Adjust the IRCP potentioneter clockwise until the desired speed is achieved ty compensation. Do not adjust for a speed higher than the unloaded speed. Setting the IR-comp. too high may cause instabilit Adjust potentiometer IRCP cow if this occurs.49°1208 5.6 Speed regulator adjustment (not used on voltage regulation) 5.6.1 Check speed regulation circuit Set jumpers on NRG! and for the appropriate tacho voltage. 5.6.2 Offset, n min and n max adjustment ~ Connect voltmeter to VCL wrap pin NRIO (actual speed signal SPEEDFB) ~ Switch ON and give RUN command - Apply positive reference voltage = Set reference to sero and adjust motor speed to zero ty turning potentiometer NOFS = Adjust minimum speed by potentioneter NNN - Set reference to +100 % and adjust maximum speed with potentioneter NMAX. Signal NFB should read approx. -10 V. On 4-quadrant drives in addition: - Apply negative reference voltage = Set reference to -100% speed. The voltmeter connected to NRIO should read the same but inverse voltage as with positive reference. 5.6.5 Check speed stability If the drive oscillates, the speed regulator stability components must be determined according to Table 3-1. 5.6.4 Optimize speed regulator stability On drives with high dynamic performance we recommend, checking the speed stability ty the use of an oscilloscope. = Connect scope to VCL pin NRIO (speed feedback) - Switch on and give RUN order - When applying max. speed reference, the tacho voltage should show an image like the one illustrated in Figure 5-3 - Adjust potentiometer NSB until the curve Figure 5-3 is obtained. If the regulator overshoots or oscillates permanently, the gain must be readjusted. If the adjustment cannot be reached with the NSB potentioneter, the stability components aust be determined again according to ‘Table 3-1. Ur ven Fig. 5-3: Diagram of speed stability — Speed regulator optimally adjusted —-= Speed regulator gain too high or too low 5.7 Adjustment of the reference 2-1 ptemetor (TUS = The acceleration and deceleration times are adjustable with potentiometers ACCS and DECS in the range 1-32 s. If the acceleration time or deceleration time is above 32 s, an addition capacitor C224 has to be soldered according to Table 3-1 - Switch OFF. -35-49"1208 6. TROUBLE SHOOTING 6.1 Safety precautions WARNING: Trouble shooting should be done by instructed and qualified electrical personnel] only. Before touching any internal parts, disconnect all] input powers. Verify the absence of hazardous voltages by the use of a voltmeter. NOTE: Static sensitive PC boards. Handle without touching components, connectors or leads. When soldering variable| components on the VCL-card; disconnect the sensitive PC boards first. 6.2 Trouble shooting 6.21 Test instruments The following meters or their equivalent are reconmended: a) An analog multimeter having a sensitivity of 100 kOhm/Volt, or a digital multimeter with a 10 megohn input impedance on all ranges (FLUKE). >) The optional diagnostic tester PN 836'57-00 in lieu of the above device. For trouble shooting inside the controller a megger and an oscilloscope (KO) will be required. NOTE: The KO used mst not be grounded. It should (if possible) be connected to mains by means of an| isolation transformer. Voltage measurenents on the power| unit must be differential. For checking the controller care must be taken, that the housing of the KO is connected to zero tential of the controller Ceorminal 157)- 6-2.2 Fault causes As the MAXITRON is delivered fully tested, problens during start-up are caused in most cases by faults outside the controller such as = Engineering errors = Wrong connections - Operating faults = Wrong regulator adaptations. 6.2.3 Trouble shooting steps + Determine operation condition where the fault occurs * Determine fault symptom With this information consult the following Table 6-1 of trouble shooting suggestions and locate the fault with the aid of connection plan. If this procedure should not be successful, trouble shooting aust be continued systematically in or against the direction of signal flow in the power unit, control - or regulator circuits. 6-2-4 Power stack and reference circuit function check - Remove armature current connections from ‘the unit (45 and 47) and connect instead lamps of the same maxinun voltage or a resistor of approx. 2 kOhm/100 W as a load. Connect oscilloscope to output terminals of the unit. = Jumper 0201 = Insert jumper in location TEST (DRL) = Connect’ to reference input terminal 167 a low positive reference signal, 0-3 ¥ = Switch unit on = Check polarity reference; voltage 47-45 should be positive and LED IAP lit. = Check with scope wave form of output voltage, 6 pulses per period. By varying the reference voltage, the Light intensity will be changed also. = Switch off = Reconnect armature circuit instead of lamps. = Remove jumper across C201 and jumper plug TEST on DRL. -36-49'1208 e Table 6-1: Faults and their possible causes Operating condition Symptons Possible causes Necessary test Elimination of fault + Regulator OW + No RUN order * LED "SOK" extinguished Short cireuit at 15 V supply output Check fine wire fuses ¥2/¥3 on DRL/DRM card and connections Bliminate short and replace fuses F2/F3 on DRL/DRM Ext. overload Check external connections| Reduce load * LED "3PE" on blocked at undervoltage) at 15 V supply | to terminals 96/97 to 10 mA + Regulator and Power circuit | Check input voltage at | Connect Power unit on insufficient | terminals 181/182/183 according to + RUN order supply voltage | (The regulator is section 4 No supply voltage to regulator unit Check phase fuses ¥4,F5, ¥6 on interface card Replace fuses Controller not adapted to supply voltage Check voltage adaptation according to section 3 Push VCL-slider switch in cor- rect position Faulty power stack Check if thyristors are short circuit. Replace thyristors * The motor Field supply Check voltage at terminals| does not turn nissing 281/262 and field supply fuses. If fuses are failing replace fuses repeatedly, a short cirouit may be the cause, or the field current may be too high. Interruption | Measure voltage at Close armature in armature terminals 45/47. circuit circuit Check interconnections. Interruption | Check wiring of reference | Establish in reference | potentiometer correct cireuit wiring * speed drop MREF- ripple | IMAX+ limitation Change 0210 with load at too high cuts ripple peaks Increase Volt-Regulation IMAK+ pot. -31-49'1208 e Table 6-1: Faults and their possible causes (continued) does not turn Faulty LVTU 14 or Tester pos. 2 Check jumpers + Operating condition | Possible Yecessary test Elimination * symptom causes of fault + Regulator and Controller With run function on vol- | Change power unit on not enabled tage should be applied control + RUN order to VCL-terminals 8/11 circuit * the motor Chock LVTU output on VoL Replace DRL/M Faulty speed regulator With Tester in pos. 3 Check speed regulator out- put VCL,NR1. Check jumpers and stability circuit according to 3. Replace DRL/M Faulty current regulator With Tester in pos. 5 Check current regulator output (DRL/M-GQ86) Check jumpers and stability cireuit according to 3. Replace DRL/# Firing pulse generator Check firing pulses (DRL/Mi 21.626) Replace DRL/M Pulse stage defective Replace DRL/M * The motor turns uncontrollably Ref-wiring has | Check reference voltage Replace loose contact | at mR9 potmeter or ref.potmeter slider has poor contact Ref. wiring Check setting of ref-pot-- | Close is interrupted | meter and voltage at NR9 | reference cirouit No tacho gene~ rator voltage at terminals Check tacho generator line for interruption and check tacho generator Replace tacho 157 and 267 Tacho gene— Polarity of terminal 267 | Change rator voltage | has to be negative with connections has reversed | respect to terminal 157. 267 - 157 polarity (at clockwise rotation and _pos. reference) Amature Check voltage at NR15 and | Insert jumper voltage feed~ back missing jumpers according to 3.49°1208 Table 6~ Faults and their possible causes (continued) ; Operating condition * syapton Possible causes Necessary test Elimination of fault Motor turns Speed regulator Check feedback resistors Select correct| too high (term. 45-47) feedback circuits according to 3. uncontrollable without tacho | and links feedback resi- feedback signal] according to 3. tor on VCL Wo field supply] Check field supply voltage | Connect field supply * overcurrent Current regu- | Check current regulator Adjust current monitor (IE?) lator loop is | overshooting. Check stability acc.| trips, unstable stability circuit elements | to 5.4.3./ according to 3. 5.405 Reset IB? LED "OCE” on Power stack Check if thyristors are Replace faulty short circuit. Check line | thyristors or input fuses. If failed, fuses check supply voltage for overvoltage peaks. * Speed is poorly Drive is Measure armature current | Re-adjust controlled, running at and set limitation with potmeter drive oscillates | current limit | pot. IMAX+/IMAX- on VCL. | IMAX+/IMAK~ Amature current must not exceed 1.5 times rated current or max. convertor output current. Speed regu- Check stab. ckt. elements | Re-adjust lator is not | according to 3. stability stabilized ace. to 5.6.4 Ripple of feed-| Check mounting of tacho Replace back voltage | generator. brushes signal too high| Check motor brushes. output voltage | Check field voltage and Adjust field voltage ‘The motor develops no torque Compare field current with indications on motor name plate. NOTE: Under cold running conditions the field current may exceed the rated current by approx. 20 % Adjust field current -39-491208 © 6.3 Spare parts Table 6-2: Urgent recommended spare parts for 1-Quadrant units, standard version Unit Without With Cover | Cover Thyristors | Cooling Fan P.Ce Fuses Type Part Nr. |Part Nr. Field rectif. | Board 10 each BOA 1 Modul 1 Rectifier | 1 DRL | - 2.5 at 380 v|837'34-00]837'34-10 | 135'02-00 124'07-00 | 803'92-00] F4,#5,76 500 v} 34-01 34-11 | 135°02-01 1 1SL 550"06-20 805'95-00 | - 0.2 aD 7] 60a 550'15-09 380 ¥]837'36-00| 837'36-10 | 135'04~00 500 v[ 36-01 36-11 | 135°04-01 - tar F2,F3 550'17-00 1208 1 Rectifier ~ field 380 V|857'38-00| 857'38-10 | 135°03-00 124"07-00 rect. fuse 500 v} 38-01 38-11 | 135'03-01 | 1 Fan 550'54-08 921 "22-01 = field 290 A 2 Thyrist.| rect. fuse 380 v|857'40-00/837'40-02 | 122'29-19 | 1 Rectifier | 1 DRL 12 AFF 500 v} 40-10) 40-12 | 122*06-11 124'07-00 | 803"92-00] —553"00-09 1 Fan 1 IGh 921'90-00 | 804'20~00| - further 430 A fuses 380/ same as 500 V|837"40-11|837'40-13 | 122'07-14 above =o 800 & 1 DRL F4,85,76 380 ¥|857°42-00]857'42-01 | 122"04~00 803'92-00] —550"56~04 500 v] 42-10] 42-41 | 122*04-02 1 IML | - field 804°21-00| rect. fuse 553°00-08 - fur.tuses same as above [1500 4/50 Ha 1 DRM | - 12 AFF 500 V|837'44~10/857"44-11 | 122°93-02 | 1 Fan 804'22-00] F4,F5,76 660 Vv] 44-20) 44-21 | 122°93-03 g21'91-00 | 1 Tim 553"00-09 803'66~00 | - no field rectifier 500 4760 Ha] T Yan - further 500 V|837'44-40|837'44-41 | 122'95-02 921 *91-10 fuses 660 v] 44-50] 44-51] 122'93~05 same as above Further recommended spare parts for Units Type 30 A to 1500 A: Variable Components Card YCL Regulator supply transformer 71 Suppression print SBA = 40 - 803 '93-00 254 123-00 803"56-00 (type 1500 A only)49'1208 & Table 6-3: Urgent recommended spare parts for standard version Unit without With Cover |, Cover ‘Thyristors | Cooling Fan P.Ce Fuses Type Part Ne. |Part Nre Field rectif.| Board 10 each 30 1 Modul | 1 Rectifier | 1 DRL | - 2.5 ar 380 V|837'35-00] 837'35-10] 135'02-00 124"07-00 | 805'92-00) P4,F5,F6 500 vj 35-01] 35-11 | 135*02-01 1 SL 550'06-20 805'95-00] - 0.2 ar Fi 604 5501509 380 V)837'37-00| 857'37-10] 135'04~00 1 PL 500 v| 37-01] 37-11] 135°04-o1 805'94-00] - 1 At ¥2, 73 550'17-00 1204 1 Rectifier - field 380 ¥|837'39-00] 837'39-10] 135'03-00 124'07-00 rect. fuse 500 v]- 39-01] 39-11 135'03-01 | 1 Fan 550'54-08 921 "22-01 ~ Held 290 A 2 Thyrist.| rectifier 380 v|857'41~00| 857'41-02| 122"29-19 | 1 Rectifier | 1 DRL fuses 124 500 V 41-10) 41-12] 122'06-11 124'07-00 | 803'92-00] | 553"00-09 1 Fan 1 IGh 921"90-00 | 804'20~00 430 8 12pL | = F1-F6 380/ 803'94-00] same as 500 v)es7'41-11]837'41-13] 122°07-14 above =o 800 & 1_DRL F4, 25,76 380 ¥|857'43-00| 857°43-01 | 122"04-00 805'92-00] 550"56-04 500 v] 43-10] 43-11] 122"04~02 1 mL | - fiela 804'21-00] rect. fuse 1 PL 553 "00-08 805'94~00| - Fi-F3 same as above l1500 4/50 Hz 1 pre | - 12 ARF 500 V|837"45-10| 857'45-11] 122'95-02 | 1 Fan 804'22-00] F4,75,F6 660 V} 45-20 45-21] 122°93-05 get'91-00 | 1 nor 555'00-09 803'66-00| - no field- rectifier 500 K760 Ha 7 Fan, - further 500 V|837'45-40| 857'45-41 | 122'93-02 921 "91-10 fuses 660 V} 45-50 45-51] 122"93-03 same as above Further recommended spare parts for Units Type 30 A to 1500 A: Variable Components Card VCL 803'95~00 Regulator supply transformer Tt 254'25-00 Suppression print SBA 803"56-00 (type 1500 A only) = 4149°1208 Table 6-4: Urgent recommended spare parts for 1-quadrant unite (SA approved Unit Without With Cover | Cover Tayristors | Cooling Fan Pee Fuses ype Part Nr. |Part Nr. Field rectif. | Board 10 each 30 A 1 Modul | 1 Rectifier | 1 DRL | - 2.5 a9 380 V|837'54-00]837'54-10| 135'02-10 124°07-00 | 803'92-00| 4, ¥5,F6 500 vy} 54-01] 54-11] 135'02-11 1 SL 550'06-20 803'95-00 | - 0.2 ar Fi 604 550'15~09 380 ¥|857'56-00] 857'56-10| 135'04-10 500 v) 56-01] 56-11] 135°04-11 -1ar ¥2,73 550'17-00 120.4 1 Rectifier - field 380 V|857'58-00] 837°58-10| 135'03-10 124'07-00 rect.fuse 500 v] 58-01] 58-11] 135°03-11 | 1 Fan 550'54-08 921'22-01 (extern) 290 A 2 Thyrist. = field 380 v|857'60-00]857'60-02 | 122'29-19 | 1 Rectifier | 1 DRL rectifier 500 V 60-10) 60-12 | 122°06-11 124'07-00 | 805'92-00] fuse 1 Fan 1 GL 553'00-09 921'90-00 | 804"20-00 430 & - further 380/ fuses 500 V|857'60-11/857"60-13 | 122'07-14 sane as above = 4 OF 800 A 1 DRL F4,55,76 380 v|857"62-00| 857'62-01 | 122'04-00 803'92-00 | 550"56-04 500 v) 62-10} 62-11 | 122"04-02 Vm | - field 804'21-00| rect. fuse 555'00-08 ~ fur-fuses sane as above [1500 4/50 Hz 1 DRM | - 12 AFF 500 v|857'64~10/857'64-11 | 122"93-02 | 1 Fan 804'22~00 | - F4,75,F6 660 Vv} 64-20} 64-21 | 122°93-05 gei'g2-00 | 1 rn 555'00-09 803"66-00 | - no field rectifier 500 A760 ia T Fan ~ further 500 V1837'64-40]837"64-41 | 122"93-02 921'92-10 fuses 660 V| 64-50] 64-51 | 122°95-05 same as above Further recommended spare parts for Units Type 30 A to 1500 A: Variable Components Card VCL 803 '93-00 Regulator supply transformer M1 254'50-00 (30-60 A) Suppression print SBA 254'31-00 (120-800 A) 254'32-00 (1500 A) 805'56-00 (type 1500 A only)49°1208 e Table 6-5: Urgent recommended spare parts for 4-quadrant units CSA approved Unit Without With Cover | Cover Tayristors | Cooling Fan Pace Fuses ‘Type Part Nr. | Part Nr. Field rectif. | Board 10 each 30 A 1 Modul | 1 Rectifier | 1 DRL | - 2.5 aT 380 v| 837'55-00| 857'55-10] 135'02-10 124'07-00 | 803'92-00| 4, 75,6 500 vy} 55-01] 55-11] 135°02-11 1 TSL 550'06-20 803'95-00 | - 0.2 at FI 608 550"15-09 380 v| 857'57-00| 657'S7-10| 135'04-10 1 2PL 500 v) 57-01] 57-11] 135%04-11 805'94-00| - 1 aT F2,25 550'17-00 1204 1 Rectifier ~ field 380 V} 837'59-00] 837'59-10| 135'03-10 124'07-00 rect.fuse 500 vj) 59-01) 59-11] 135°03-11 | 1 Fan 550'54-08 921 '22-01 (extern) 290 4 2 Mhyrist, - field 380 v|_857'61~00| 857'61-02| 122*29-19 | 1 Rectifier | 1 DRL rectifier 500 v]6t-t0] 61-12] 122"06-11 124'07-00 | 803'92-00| fuses 1 Fan 1 GL 553°00-09 921"90-00 | 804"20-00 450 4 12PL | - further 380/ 803'94-00] fuses 500 v|es7'61-11|a57'61-13| 122°07-14 sane as above = 4 AF 800 A 1 DRL F4,75,F6 380 V|.837'63-00] 857'65-10| 122'04~00 803'92-00| 550'56-04 500 v} 63-10] 63-11 122°04-02 1 1ML | - field 804'21-00| rect.fuse 1 2b 553'00-08 803"94-00 | - fur.fuses same as above 1500 4/50 Hs 1 prm | - 12 AFF 500 v|@37'65-10]857"65-11| 122"93-02 | 1 Fan 804'22-00| - F4,75,76 660 v} 65220] 65-21| 122°93-05 gaitg2-00 | 1 no 555'00-09 803'66-00| - no field rectifier 17500 A760 Ha 7 Fan, - further 500 Vv] 837'65-40|837'65-41 | 122"93-02 921 "92-10 fuses 660 v] 65-50] 65-51] 122'93-05 same as above Further recommended spare parts for Units Type Variable Components Card VCL Regulator supply transformer Tt Suppression print SBA are 30 A to 1500 Ar 803'93-00 254'30-00 (30-60 A) 254'31-00 (120-800 A) 254"32-00 (1500 A) 803"56-00 (type 1500 A only)49°1208 6-4 Replacement of components Use original spare parts only. Selection according to Table 6-2. The location of the parts is shown on the layout label inside the U-frane. 6.461 Replacement of a thyristor or thyristor module on power unit ‘Type 30 = 600 A 1 = loosen and swing out regulator card { - Remove bus bars above the thyristors - Remove gate leads of the thyristor concerned T =e - Unscrew fastening screws and remove f : 3 thyristor = Before mounting the new thyristor, coat the side which is in contact with the heat sink with a thin layer of nee heat conducting paste For units 290 A - 800 Ar = Insert thyristor into box-clamp and put the package on the centering dolt on the heatsink - Fasten the four hexagon bolts by hand until all slack is taken out and take 5 care that the clamp housing stays parallel to the heatsink = Mghten each bolt by half a revolution at one time with hexagonal socket spanner 8 mm (10 mm), diagonally - Repeat the procedure until the clamp is held down firmly to the heatsink on each side - Re-connect gate leads = Screw on bus bars. Pos. 1 Screws NOTE: Before replacing a thyristor 2 Steel plate the gate and cathode faston 3 Housing connectors must be checked 4 Plate springs for conductivity. 5 Stamp 6 Semiconductor 1 Centering bolt 8 Heatsink49°1208 e 6.4.2 Replacenent of a thyristor on power unit ‘Type 1500 A ~ Write protocol about the following procedure = Open controller and protection unit by tilting forwards. Layout of thyristor assembly is visible now on side wall. = Remove bus bars on front heat sink ~ Unscrew the upper cooling air deflector. Unscrew the hexagon screws for the bus bar mounting = Unserew the lover cooling air deflecto = loosen the two screws (15 mm) on the clamp by quarter turns. (Caution: the centre clamp screw 24 mm must not be turned) = Withdraw clamp and heat sink = Clean heat sink from thermoconductive paste - Coat both sides of the new thyristor with an extrenely thin filn of thermoconductive paste /a. ~ Mount the thyristor on the centering pin in the rear heatsink Observe correct polarity of cathode and anode according to layout. = Insert clamp in front heatsink and attach to thyristor with centering pin Nore /b = Mighten the two clamp screws (13 mm) alternately by one quater turn until the control ring under the centre clamp nut can be turned through 360° by hand. Keep clearance to a minimun. = Proceed installation in the reverse order of removal. -45-49/1208 e 7. Accessories Table 7-1: Power independent accessories Part Description Part No. Instruction Manual Diagnostic unit with cable 836"59-00 4971256 Supplementary Board 2FL 803 96-.. 49° 1094 Supplementary Board RFL 804'62-.. 49/1099 Kit Supplementary Board TBN 839 33-00 Installation with Mounting set (for CE-Conformity only, see APPENDIX A) Component Kit for vCL~card 486" 00-00 Power Input Protecting Devices Protecting fuses in the AC-line input of the converter and field circuit and in case of four-quadrant operation in the motor armature circuit are to be selected from the following table 7-2. Chokes in the AC-line input of the converter and field rectifier are to be selected from the table 7-3. The fuses and chokes are externally mounted and not supplied with the power module. Table 7-2: Power Input Protecting Fuses Motor Armature (4-Quad) ‘AC-Line input Drive [Fuse Fuse Fuse Trip |Fuse Fuse Fuse type |Rating [Part No. |Indicator|Holder |Rating | Part No. (2 piec.) | (2 piec.) | (2 piec.) (3 piec.) 553,28, 04 [553.29.00 |511.23.00 32a__|553.28.02 60a, 0a [553.28.07|553.29.00|$11.23.00 63a [553.28.06 goa __|553.28.07|553.29.00|511.23.00 63a_|553.28.06 120K 125A _[553.28.09]553.29.00]511.23.00] 100A |553.28.08 160A _| 553.30. 04 |553.26.29 |511.24.00 200A _[S53.30.05 | 553.26.29 | 51.24.00 izsa_|553.28.09 T60n [5535.30.04 290A 315A |553.31.13]553.26.29]511.24.00] 250a | 553.30.06 350A__|553.31.14|553.26.29|511.24.00| 315a_|553.31.13, 430A 450A [553.32.16|553.26.29|511.24.00| 350A |553.31.14 S50A_|553.32.18|553.26.29|511.24.00| _450a_|553.32.16 ‘B00R G00 [53.33.21] 553.26.29|511.24.00] 630A [553.33.19 1000 _|553.33.22 |553.26.29|511.24.00| _800a_|553.33.21 500A 1250A__|853.33.23|553.26.29|511.26.01| 1000A |553.33.22 soov |2 // 800A/553.33.21|553.26.29|511.26.01] 1250 |553.33.23 2 // 900A} 553.33.24 | 553.26.29|511.26.01]2 // 800A} 553.33.21 15008, 2 700A] 553.34.35 | 553.26.30|511.26.01]2 77 630A7553.34.34 esov [2 // 800A/553.34.36|553.26.30|511.26.01]2 // 700A|553.34.35 2 // 00a] 553.34.36|553.26.30]511.26.01]2 // 700A] 553.34.35 Fuse Holder for external field rectifier fuses on CSA-types 30 -120 A 511.00.00 NOTE: | If MAXTTRON CSA approved are used, all short circuit and overcurrent protecting devices in the line input to the power converter must be in accordance with CEC, part 1. - 46 -49'1208 Table 7-3: Iron Core Choke Selection The AC-line input chokes 252.40.xx produce 2% voltage drop at 400 Vv and rated current. The AC-line input chokes 252.44.xx produce 2% voltage drop at 690 V and rated current. Note, that for applications with radio frequency interference filters (RFI) chokes for 2% voltage drop at rated input voltage up-to 500 Vv and 4% voltage drop at 690 V are mandatory. If on applications with RFI filters the drive is connected to a supply with nominal voltage >400V < 690V two 2% chokes 252.40.xx in series will be required (for nom. voltage 690 V two 2% chokes 252.44.xx). = Line Input. hase Drive | Rating | Choke Type Tron _|Part No. 30K 25A__[252.40.01| 6a | 252.42.05 GOR 40a [252.40.02| 6A |252.42.05 e2a_|252.40.03 i208 5A [252.40.04 uisa_|252.40.05| 6a__|252.42.05 160A | 252.40.06 2908 210a |252.40.07| 6a —|252.42.05 290a__|252.40.08 430A 392n__|252.40.09| 6a | 252.42.05 ‘3008 530A [252.40.10| 12a |252.42.06 660A |252.40.11 500A 50a | 252.40.12 = = 500v ai00a_ | 252.40.13 1300a | 2582.40.14 TS00A ‘50a [252.44.12 = = es0v aoa | 252.44.13 1300a | 252.44.14 AC Line us PE www Converter Input Line Reactor Wiring Diagram Btu49/1208 e we wi v2v1u2Ut @ (2) A Protection earth connection stud Tine PB | Fis. Reactor | a] a | c] vo |e] er | c | w feel om Part No. 252-40-01| 190 | 150| 190] 170| 75 | 45 | 67 | 60 | 4.7] 50 | 2 252-40-02| 185 | 150| 190] 170| 75 | 60 | 72 | @5 | 6.5| 60 | a 252-40-03| 210 | 180 | 240 | 210| 90 | 52 | 72 | 90 | 7.8| 70 | a 252-40-04| 160 | 180 | 240 | 210| 90 | 52 | 72 | 95 | 7.8] 20 | 2 252-40-05 | 160 | 180 | 240 | 210 | 120| 72 | 93 [115] 11] 90 | 2 252-40-06 | 240 | 260 | 260| -- | 240| 75 | 97 [170] 18] 130] 2 252-40-07 | 240 | 260 | 260| -- | 240| 75 | 96 [170] 26] 150] 2 252-40-08 | 240 | 290 | 260| -- | 240 [100] 116|190| 26]170| 2 252-40-09 | 290 | 320 | 320| -- | 300| e0 [116 | 220] 35| 225| 2 252-40-10 | 280 | 270 | 320 | 300 tos | 123 [180] so| ses] 2 252-40-11| 310 | 320 | 320] -- | 200| 93 [120] 220] 40] 370] 2 252-40-12 | 330 | 350 | 350] -- | 240 [110] 140| 250] 55| 590] 2 252-40-13| 475 | -- | 390] -- | 355| 95 | 135 | 250| 70| so] 2 252-40-14| 535 | -- | 390] -- | 355| 95 [iss [250] e0|7e5| 2 Figur 7-2: Line Reactor Dimensions (mm),~Power Losses (W) and Weight (kg): = 48 =49'1208 e Radio Frequency Interference Filter General Description Power converters in general cause line disturbances over a wide frequency range. Through the correct connection of the adapted Radio Frequency Interference Filter the emissions in the frequency range 150 kHz to 30 MHz can be kept below the recommended limits. NOTE: On all Maxitron 9000 drives a line input reactor must be connected between filter output and converter input. This line reactor should be rated for minimum 2% voltage drop on drives up to 500 V and 4% for 690 V drives (selection according to Table 7-9). Also the drives AC-line input semiconductor protection fuses as per Table 7-7 must be mounted between filter output and line reactor. Otherwise the filter inrush current may damage the fuses. For installation instructions refer to Appendix A RFI Filter Selection The RFI-Filters can be selected from Tab. 7-10 according to the permitted filter current and the maximum operating voltage. The permitted filter current is dependent on the application specific maximum continuous DC-current I,q of the drive, the DC-current form factor (FF) and the ambient temperature T. ‘The ambient temperature T is the max. temperature around the filter (typical 50°C inside cabinets for a standard max. cooling air temperature of 40°C). ‘Typical DC-current form factor FF = 1.05 For cabinet mounting with T = 50°C and FF = 1.05: Filter current = maximum continuous DC-current Tas For other ambient temperatures (T) and form factors (FF) the continuous current of the filter can be calculated as follows: ae _ 2 aC ay JAC = 2 crea tyy x | AOC Linetoms) “35°C —T E Plea sco Table 7-10: RFI Filter Selection Tere RFI Filter Filter 380 - 440 450 ~ 500 V 690 v Current | Part No. | see Page | Part No. | see Page | Part No. | see Page 25a [839.7205] 50 Jon request 36 839.72.06 50 on request 50A 839.72.07 50 on request 80a 8839.72.09 51 on request rooa = a39.71.53| 52 — |e39.71.53 52 1soa 1839.70.20] 53 180A 8839.74.22 54 on request 250A 839.73.25 57 on request 270A 8839.70.66 55 839.70.66 55 280A 839.72.67 54 839.72.67 54 340A 8839.71.68 56 839.71.68 56 soo, |839.73.31| 57 on request 600A - - 839.73.92 58 8839.73.92 58 1000A 8839.73.35 57 839.73.95 58 8639.73.95 58 iso0a__|839.73.38| 57 _|839.73.98 58___|839.73.98 - 49 -49/1208 e Radio Interference Filters 25, 36 and 50 A, 440 V Me 150 65 Ae EwRu LINE | aE i 8 ! a | 8 a et . I | ! | ae LOAD eu 2 ur : oct le 2 120 435 Filter Part No.: 839.72-05 —-839.72-06 839.72-07 Rated Current 25.8 368 SOA Power loss: aw ow uw Weight: 3 kg 3.1 kg 3.5 kg Figure 7-3: 25, 36 and 50 A, 440 V Filter Dimensions (mm) - 50 -49/1208 @ Radio Interference Filter 80 A, 440 Vv 450 90 65 70 la tols 130 Filter Part No.: 839.72-09 Power loss: 23 Weight: 9.5 xg Figure 7-4: 80 A, 440 V Filter Dimensions (mm) esr49'1208 e Radio Interference Filter 100 A, 500 V 275 i [——— axme Saale aly | 785 a1 i | | | | LOAD Cie tes + ee 2 Leta pars Filter Part No.: 839.71-53 Power loss: 75.0 Weight: 9.5 kg Figure 7-5: 100 A, 500 V Filter Dimensions - 52 - 80 7a] —}—- (mm) 3 T hoe49/1208 e Radio Interference Filter 150 A, 460 V __194 a 160 LZ 25, 55 5525, i! Mio) : d ah ju a2 a3{ a =| 180 ke 95 | al 8 Loap PE AL1 112 113 > iol|el-| >) EEE = |o+]-o| i) 55 Filter Part No.: 839.70-20 Power loss: Weight: 14 kg Figure 7-6: 150 A, 460 V Filter Dimensions (mm) ~ 53 -49'1208 e Radio Interference Filter 180 a, 440 Vv and 280 A, 500 V A|F T [Filter P, | Terminal, tal|part no. | a |B |c |e |r {ele| a ||P |e |exgi| cw) | max. mot 180 |839.74-22|537|360| 88 [132/470] 25|2e[180|156|510|77| 13 [49| 95 280 | 839.72-67| 742|530| 103] 153] 660| 31] 59|260|220| 700] 82] 28 | 70] 150 Figure 7-7: 180 A, 440 V and 280 A, 500 V RFI-Filter Dimensions (mm) oe49/1208 e Radio Interference Filter 270 A, 440/500 V 350 pe ‘_R L2 5.1 eet atat 320 Filter Part No.: 839.70-66 Power loss: 28 W Weight: 48 kg Figure 7-8: 270 A, 500 V RFI-Filter Dimensions (mm) - 55 -49/1208 e Radio Interference Filter 340 A, 440/500 V 110 Tl # 000 000 000 000 797 = — S = S S = S = — — — S Filter Part No.: Power loss: Weight: Figure 7-9: 360 839.71-68 50 W 22 kg 340 A, 440/500 V RFI-Filter - 56 - be DF Dimensions (mm)49/1208 e Radio Interference Filter 250, 500, 1000 and 1600 A, 440 V : 3 ee | | oe i Ke Loan PE uns’ L2| Et SE ' : {ul I |Filter tay [part no. | a | B | c|o|ese]ri{¢ |x] xi{uis 250 [839.73-25| 460 | 350 | 230 | 149 | 260 | 200 | 285 | 120 | 100 |79.5] 24 500 |839.73-31| 590 | 500 | 250 | 154 | 280 | 280 | 305 | 150 | 93 |59.5] 24 1000| 839.73-35| 840 | 650.|.400 | 204 | 440 |.320 | 465] 262] 127| 79 | 34 1600| 839. 73-38] 870 | 680 | 400 | 204 [ 440 | 340 | 465 | 262 | 127| 79 | 34 I Ground | W | Py [Aj Peace s r Bolt |tkg]| (WI 250| - | 24 [30] o10.s{e10.5| mio | 16 | 18 500} 15 | 30 | 30} 11 |912 M12 49 | 45 1000| 20] 50 | 40| gia [oi2 m2_ | 90 | 90 1600| 20 | 50 | 40 [2x 14 [o12 miz__| 130 | 144 Figure 7-10 250, 500, 1000 and 1600 A, 440 V RFI-Filter Dimensions (mm) - 57 -49/1208 e Radio Interference Filte: 600 ,1000 and 1600 a, 500/690 v ° Pe uma a ig eu ve s [= ate Al Bi F e z a Pe uns | L K I |Filter talfpare no. | a | 3 | c | o |e | e|e¢lsu| «||» 600| 839.73-92| 590 | 500 | 250 | 154 | 280 | 280 | 305 | 150 |94.5/61.5| 26 1000} 839.73-95| 610 | 500 |-250-| 198 | 280 |-280 |-305 |-172 | 90 51 26 1600] 839.73-98| 844 | 650 | 400 | 210 | 440 | 320 | 465 | 192 | 92 56 28 T Ground |W | mil{eloelr| s | 2 | pote [rail mm soo] 15 | 20 | 30| 11 [our | mio | a9 | as 1000} 20 | 40 | 30 @11 |@12 M10 65 | 120 z600| 20 | 40 [40 [2x oa |oi2 | m2 | 180 | 220 Figure 7-11 - 58 - 600, 1000 and 1600 A, 500/690 V RFI-Filter Dimensions (mm)49'1208 e APPENDIX A CE Conformity (EMC Directive) This converter device is a component intended for implementation in machines or systems for the capital goods industry. They have been tested to meet Council Directive 89/336 Electromagnetic Compatibility (EMC) and all applicable standards (listed in the technical construction file). With the specified RFI-filters and the measures as described in this guidelines the Maxitron 8500 can be operated in the Industrial environment according to EN 50081-2 for Emission and EN 50082-2 for Immunity (performance criteria A). The cable length is thereby limited to 75m. [cAUTION: The conformity of the drive and filter to any standard does not guarantee that the entire installation will conform. Many other| factors can influence the total installation and only direct measurements can verify total conformity. It is therefore the responsibility of the machine manufacturer, to ensure, that the EC-conformity is met. Essential Requirements for Conforming Installation The following items are required for CE conformance: 1. Connection of RFI-Filter as specified in Chapter 7, Accessories. 2. Because converter and RFI-filter have protection class IP00 they must be built in a cabinet. Both units must be mounted on a blank (not painted) panel with good conductivity. 3. Correct grounding of the equipment and the cable screens as shown in example Figure A-1 4. Output power wiring (drive to motor) must be screened cable or run in a separate steel conduit. 5. All control (I/O) and signal wiring must be screened cable. 6. The braid of screened cables must be connected to the terminal box of the motor by the use of suitable, EMC-tested cable glands. 7. To ensure the immunity of the analog and control signal inputs of the cards VCL, ZFL/RFL against high frequency interference, the supplemen- tary card TBN containing suppression capacitors must be installed in front of these inputs. &. For all DC-converters a minimum line reactor of 2% voltage drop will be required. The line reactors must be linked between RFI-filter (Output) and D¢-Converter (Input). For line reactor selection refer to Table 7-3. Mounting Instructions (Refer to Figure A-1) * The filters must be screwed directly to the panel with the largest possible contact area. * The support panel for the converters and filters must be a conducting steel sheet, with a common ground busbar at the bottom. This ground busbar, mounted in front of the terminals, must be solidly connected to the panel, ensuring good conductivity. * All cable screens, entering the cabinet, must be connected to the control cabinets ground busbar. To ensure that the screen of the individual cable is connected solidly and with good conductivity to the ground busbar, galvanised cable brackets as shown in Figure A-1 are recommended. This applies also for coaxial cable, at which only the outer insulation should be removed. a 55S49/1208 e APPENDIX A 181,182,183 N MAXITRON ZFL VCL 48,47 35,37| 267 57 & min teee eer eeerereeiare renee Cabinet Panel AC-line reactor REI Filter Card with suppressor capacitors (Set part No. 839/33-00) AC-Input contactor AC-Input fuses Terminals for 4-wire AC-Input cable (L1,L2,L3, PE) Cabinet protection ground Cable bracket Screen Screened 3-wire motor armature cable motor field cable Shielded signal conductor cable (feedback, reference) oO ® @ @ shietded 2-wire © © EMC-tested armoured cable gland at terminal box Figure A-1: Example for control cabinet configuration - 60 -49/1208 APPENDIX A Wiring Instruction Motor Cable © The cables between cabinet / armature output and Dc-motor armature shall be 3-wire screened cable (+, - and earth conductor green/yellow) as specified in Figure A-2. * The cables between field supply output and Dc-motor field shall be 2-wire screened cable. * The screen must be tinned copper braid or tinned steel braid. It must be solidly connected to the control cabinet ground busbar or ground stud of the converter with large connection area and good conductivity. © The screen on the motor side must be solidly connected to the motor housing providing large connection area with good conductivity. * If screened cables are not available (limited by the obtainable cross sections) the individual conductors and protective conductors must be run in steel conduits or enclosed metal cable ducts also connected to ground at both ends. * All leads shall have the same cross section (earth conductors with cross section. >16° : min. 16° or 50% of armature lead) * The connections between filter and converter should be as short as possible!! These conductors must be bound together (with tie wrap) forming a triangle in cross section. Power and signal leads inside the cabinet must be distanced. Analog Signals (e.g. reference, feedback) and Control Signals (Relays) These signal leads must be screened cable as specified in Figure A-2. The individual conductors must be stranded, but twisted pairs are not required. The screen must be grounded at both ends. CAUTION: To ensure the immunity of the analog and control signal inputs of the cards JCL, NFL/RFD against high frequency interference, the supplemen- tary card TAN containing suppression capacitors must be installed in front of these inputs. The capacitors are rated for max. 24 V, with the exception of those on terminals X1:1/X2:1 and X1:2/X2:2 (400 V capacitors), which are reserved for the tach signal. (e.g. at JCL 267 and 57). f-—— Stranded copper wire Plastic insulation 4 Inner plastic sheath Si compact screen of galvanised (tinned) copper or steel braid outer plastic jacket Figure A-2: Specification for screened cable Cable Glands * Use suitable EMC-tested cable glands only * The conductivity of the screen ground connection is ensured by laying the braid over a plastic cone which will press it to the inner side of the gland when mounted. It is important that the connection area is 360 degree around the cone. The cable glands provide pull-relief through the cable jacket. -61-Reach us now at www.rockwollautomation.com Wherever you need us, Rockwell Automation beings together leading bran in indus automation incudng Ale Sradey convo, » Reiance Electric power ansmission products, Dodge mechanical power i” transmission components, and Rockwel Software. Rockwall Automatons <~ ‘unique, flexible approach to helping customers achieve a competitive 2 ‘advantage is supported by thousands of authorized partners, dstibulos| and eystom integrators around the werd iH, 2 Sot Gon Sat Man, 24, UA Te 41420 Fae 44 2.4L Rockwell Caropen agurs SA Ser aera bse ig Ts 20800 a 8008) Y ‘iPectebentqnter 2 oop Ge. Bi Rot, cane ay ging Tas aera ess © FLUE OUNATIOET Copyright Rockwell International Corporation