Eietemeca ique STATOIAR 4. series 64 4 quadrant variable speed controllers for asynchronous slip ring motors catalogue / user's manualWARNING “The speed controlar includes safety devices which, in the evant of @ fauit, can trigger the stopping of the contrlior, and ‘hence the motor. The motor itself can also be subject to stoppage by mechanical jamming. Finally, voltage fluctuations and ‘power supply fallures in particular, can also cause tha motor to stop. “The disappearance of the taut causing the stoppage can initiate a restart involving a hazard tor certain types of machines or Installations, especially those which must conform ‘o specific safety regulations. {tie Important that In euch cases the user should take appropriate steps to prevent such restarting possiblities. For example, by the use of an underspeed detector, causing the disconnection of the speed controller supply in the event af a non- programmed motor stoppage. “The design of the control system must conform to standard NFG 15-100. ‘As @ general rule the speed controller supply must always be switched off before carrying out any operation on either the ‘electical or the mechenical paris of the installation or the machine. ‘Asthe technological elements of he STATOVAR range derive from the REGTIVAR range, some functions and terminals on the controller must not, under any circumstances, be used or connected. “This is why, in this document, the phrase “do not use" appears each time thie is the case.Contents Presentation 238 a General 46 See Characteristics 6 Description ofthe commolprocsss Description af the control process 7 eee ‘Selection guide 89 SET Tae Associated componants, 10.14 et ‘Accessories and spare parts 12.13 = STATOVAR terminal referencing Powar bridge, ratings 40 to 530 A 4 Power interface board, ratings 40 to 530 A 14 Power bridge, ratings 650 to 2500 A 8 Power interface board, ratings 650 to 2500 A 15 Control board 16 ‘Spocial applications 7 ae Installation eee Mounting, wiring precautions 18 ‘Speed controller dimensions 191022 Fuse dimensions 23 —st—‘isSS——‘(—‘—‘—‘—C PB ‘Connections ee Power connections 24.25 Electromechanical circuit diagram (all ratings) 26 too Interconnections vertical movement board - complemontary moduis an xtemal control on power board 921038 cane Layouts eee Power bridgos 39 t0 22 Power interlace board, ratings 40 to $30 A, 4 fring gate board a Power intortace board, ratings 650 to 2500 A 44 Contzol board 45 ‘Adjustment board 46-47 Vertical movement board 48 ‘Complementary STATOVAR module: * hypersynehronous control logic board 49 ‘rotor step change board 50 eee Initial sting up 511057 Block diagram 58-59 ‘Cur company's policy is one of continuous development and improvemant and we roserve the sight to supply Products which may afer in cet rom those decors and Fisted above.Presentation of STATOVAR 4 series 64 variable speed controllers for asynchronous siip ring motors ‘The 4 quacrant STATOVAR is a variable speed controller for three phase asynchronous motors, ring {ts sold state variable speed controler using phase displacement. From the mains supply ft Produces a variable rms value AC vokage at fixed frequency, via a thyristor ascombly. ‘The closed loop control necessitates the use ofa speed sensor or a tachogenerator, mounted onthe ‘motor shat Reversal of phase rotation direction is sold state, and braking i by controlled countercurrent, thus ‘enabling motor operation in the 4 quadrants of the torque-speed range. ‘The transient acceleration/deceleration modes are controlled by ramp. Furthermore, @ current limitation function enables reduction of the motor current peaks. A brake logic board (voriical movement board) is incorporated in the speed controller, ‘The 4 quadrant STATOVAR 4 is therefore particulary wall suited to handling applications. “Complementary STATOVAR" MODULE VW3-ARD104 ‘This comprises: 117 A hypereynohronous control logic board, with the following functions : peed feedback adaptation circuit, *@ cirouft enabling the motor to run in hypersynchronous mode, Ia deving torque is created by an overhauling load (2.9. : high speed towering of a hoiet}, the countercurrent braking phase of operation can be extended. This cicult detects the moment when ‘the motor reachos is rated speed, and validates the thyristor assembly enabling hypersynchronous braking operation to be ebtained. 2/ Arolor step change board associated with the above, enabling the rotor resistance to be adapted 10 maintain the motor in the required operating zone.Presentation of STATOVAR 4 series 64 variable ‘speed controllers for asynchronous slip ring motors Functions Dialogue via LEDs, ~via relays, Via solid stato outputs (faults), via analogue outputs (current, spesd).. ee ‘Satoty toaturas presence and level of the mains supply. Ce ‘Speed references via potentiometer connected to the internal supply, ~via extemal analogue signals on: 2voltage inputs 70 10V, 2 current inputs :0 20 mA, 4 1020 mA. eee Reversing digit signal, via speed input polarity : 10 V. eee Spood feedback via sensor, ~via tachogenerator. ee Ramps ~ independent adjustments for accoleration and deceleration, ~remoto'y adjustable, ~Tast reset eee (Currant imitation Independent adjustments for motor and brake operation, remotely adjusiabie, eS ‘Stop logic at zero spead. ‘Speed limitation with adjustable threshold, eee ee Regulation loops: ~ access to functions : “ramp, + speed amplifier output, ‘current ampitior input, + Supplementary speed input, + remote cancellation of intogration. eee Hypersynchronous logic. ee Fotor stgp change. Brake control fog. ee Optional sotting up and debugging unitGeneral Characteristics ‘The STV-64 variable speed controliors are designed for the control of asynchronous allp ring motors {rom a three phase AC mains. Reversing soli stato controters with 10 thyristors, they enable operation in the 4 quadrants of the torque speed range, and are specially adapted for holsting and handling applications. TECHNOLOGY + wide range from 40 to 2500 A, + spoed range: 1 10 20 with tachogenerator, + three voltage rangos : trom 220 V to 440 V, 600 V, and 660 V with ratings 650 A to 2500 A, + 80 oF 60 Hz frequency selzated by link, + total galvanic isolation between power and control, + customization and contigucation terminal blocks. SIMPLIFIED (NITIAL SETTING UP “= plugcin terminats, + supply connection indifferent to phase rotation direction, direct access from the front to: function display, ~ test and adjustment points, carried out by links and potentiometers arranged on a plug-in board, ‘which saves a back up copy of the adjustments. REDUCED MAINTENANCE ‘Tho homogeneous structure of the components limits the number of spare parts : + control board with adjustment board Identical throughout the range, + power interface boards common to the RECTIVAR 4 range, * power assemblios consisting of 10 thyristor solid state controllers, technology which derives from ‘the range RECTIVAR 4, + Kdentical complementary module for the whole range. ‘GREAT FLEXIBILITY OF UTILISATION ‘Speed referances via vottage and current signals, + ramp with separately adjustable acceleration and deceleration, + Current imitation separately adjustable in motor and brake operation, = Speed foodback by tachogenerator, + low speed function, ‘remote adjustment of ramp and current limitation, + large number of digtal controls, + option terminal boards enabling ~ separation by cabiing of the adjustment loops and the ramp, extemal tocking of the speed controller, addressing of the output relay functioné, output of the various signals, OPERATION SAFETY DEVICES. +maing voltage safety, + prosence of control supply, + brake logic. DIALOGUE ‘via LEDs, + Via the gold stato outputs, + via the currant and speed analogue outputs, + via the output relays with addressabie functions, + via the setting up and debugging unitGeneral Composition phe STATOVAR STV-64 range compris 10 ratings from 40 to 2500 A, Fresontation in @rebust metal enclosure, in two technologies {he contol section includes the power interface board, the conto! boar ‘canying an “adjustment* Plug-in daughter board with cieplay of the speed controler eeeter functions, and the verticat ‘movement board withthe brake logic function, ‘noth tochnologies, complementary STATOVAR modue ie aesocated with the ‘speed controler, a6 seescss ‘© POWER INTERFACE BOARD compares i igh cxrent contol cuits and tage vohages higher than 24, with a © omPlemontary fring gatedaughtr boar, solely or ratings 40IoSo0 A aswallas the folowing ‘adaptation and dlalogue functions » Parente nat module (ring 4010590 A}, or he connector (ratings 650 to 2500 A), which ‘adap the board to the speed controller rang, Common fo the ent range, this caries: {he electronic contol, aglustment and dlatogue functions, © + the vertical movement board, © =the plug-in agjusiment board, which enables: 7 the sioraga of the adjustments carried out by : @® ~links, ® —potentiometers, «the display by : @ © 3 LEDs, visibie with cover on, which light up when: Unlocked speed controtior Current limitation Feutt ON I> FAULT YWS-RRD104 MODULE This module comprises : ‘® + The hypersynchronous control logic board. OOOO ‘Tre atier comprises an ON or OFF tink forthe hypersyrichranaue control function, a8 wo 8 a spepd foodback adjustment potentiometer. [-—~® +The rotor stop change board, res omprises 1 application selection ink (horizontal or vertical movement) and 4 ‘speed ‘reshold adjustment potentiometers which authorisa the closing ofthe rol eereeneCharacteristics ‘Three phaso ——volage ‘Maximum 600 V + 10%, and 600 V 4 10 % for ralings 650 to 2500 A. mains supply —frequency 60/80 Hz +2 Hz. ‘Speed range 11020. ‘Current imitation ‘Adjustable on the spoed controller from 0,2 | peak to! peak. ‘Siowdown speed ‘Adjustable on the adjustment board, rom 10 % to 100 % af rated speed. 1 adjustment only for both directions. Precision * 1 % of the rated speed according to the accumulated variations = ~ of resistive torque : 0,2 Tn to Tn, =f the mains voliago “#10 %, ‘of the ambient air temperature : 20°C +20°C. * Excapt when operating at high speed, where the motor/resistance slip decidss the speed {(hypersynchronous operation}. ‘Speed references: ‘Two voltage inputs £ 10 V. va potentiometer 1 fo 10 kA connected to the intomal source 04 10 Vor 0-10 V. via analogue signal 0010 V supplied by an external source, input impedance 32 KO, Via curtent signal to 20 mA, input impodance 205 0, 4t0.20mA, input impadance 254.9. ‘The + 10 V inputs and tha 0 ta 20 mA input are summing and isolated from the mains, ‘Speed feodback by sensor 6 adjustment positions : 10-22-46-80-160-600. ‘or tachogenerator Acesleration and deceleration Acceleration and decelaraton times seperately adjustable irom 0,5 to 60 s in 2 ranges, ramp Possility of increasing the ime (see page 34). Reversing '8y external command on digtal inputs, of by reversing the speed reference. Reversing : dead band 50 ms. Operation in the 4 quadrants of the torque-speed range. Voltages and currents available +15 V (P16) or—1S V (N15) maximum 30 mA, forall he inputs (conto, validation, display, ‘on the speed controler ‘ogulatlon), the option boards, and all the extemal functions. {cumulative currents) +24 (PL) maximum 50 mA or 80 mA ite current taken from the +18 V. Output relays : 220.V AC for auxiliary contactor: inrush 300 VA, sealed 30 VA, or 30 V DC, maximum 0.5 A. ‘maximum electrical ‘Minium switching capacity 24 V-20 mA, AC or DC. characteristics of the contacts Numiber of operations : 10°. Degree of protection P00, ‘Ambiont air temperature: = for operation ‘°C to 40°C (operation possible up to 60°C by deraling the current by 1,2 % for each addtional °C}. for storage =25°C to + 70°C. Dorating depending on Dorato the current by 0,7 % par 100 m above 1000 m. ‘the altitude Vibrations and shocks Tests carried out conforming to IEC publication 68-2-6-FC.Description of the control process Principle Torque-speed characteristics A throo phase cold stato controller wth thyristors is connected into the stator supply circuit, “The variation of the conduction angle enables modification of the stator voage value. ‘Motor torque is proportional fo the square of this vohage. ‘The diagram on the left represents the torqua- speed characteristic atthe rated mains voltage Un, and for a given value A of rotor resistance, This curve is altered for voltages : U250mm, 02100 mn, + provide ventilation louvres, a + make sure thatthe vertlation is adequate, itmo, fia cooting fan with itr, for STV-64033+ to M25, the air should “flow rom bottom to tap. Power dissipated by the epeed controler and air How of fans D ‘STV-64040-: 200 W ‘STV-64C53+: 2000 W— 1300 myn mn ‘STV-64055":270 W ‘STV-84085-: 2400 W = 2600 m°/h ‘STV-64016+;600 W- 860 m?/h ‘STV.64N410-: 3700 W- 2600 m®/n ‘STV-64022+;050 W-360 msn STV-64M14+: 5900 W - 2600 fh . ‘STV-64093-: 1200 W - 1300 m'7h ‘STV-64M25-: 8000 W - 8600 m*/h a = Wiring “Insulation precautions Apar trom the special earth terminal marked = no other conductors connected to terminal blocks ‘should be connected to aarth or the protective earth of the installation, + External circuits for speed setting, and feedback using a tachogenorator, must be wired using {wisted pairs (pitch s 5 om). Keep the control and power cables as separated as possible, Nis imperative thatthe signals tothe following terminals be connected as below, “It terminat block on the control board ey ov 1 terminal block on the powar interface board BNA RNB. + The other signals which are accessible on the customer termina) locks must be wired using twisted pairs (pitch < 8 om) and screened {withthe screening connected to the controller oarth). ‘The maximum longth ofthe interconnection is § m. For greater distances, use an interface ciroult. 18Installation Dimensions STATOVAR 40 to 150 A with module sheath 4 0.7 m " Vw2-RRD104 & STATOVAR 220 A with module sheath L~0,7 m VWS-RRD104, & Kn ar ‘Cooling spacers for controllers mounted on fat surfaces (¥Y1-FZD102 assembly to be ordered soparately).Installation Dimensions STATOVAR 330 and 530 A with module ' VW3-RRD104 sxor & wp? shea -0,7m ff 9 | =p - - 3 8 lal i ! 4 | Li a7 0 35 Power terminal b protective shrouds . a PA I A z ¢ Las-F703 taseroar7ea bb Relernce [a |b © | 4 | Speed conrter user [2s | aa | er | ve | statovanaowisoa usm [a | a | a4 | 90 | starovanmaoa LAS-F703- 35 58 45 We STATOVAR 330 t0 1400 A ~] 20Installation Dimensions Cortespondance tabie The STATOVAR 850 1.2500 A are modular wth separate Power and contra, Each of these two paris has ts own reference, STATOVAR Power part Control module Relorance Raterence Reterence STV-sacasasy VZ8-DROESC/SY VWw3 RADIO STV-64Mt00;S/Y Vze-DRMI0QSY VW3-RAD102 Sa RNOCISY VSR STVeamiaaey VZ8 DRMMOSY__vwa-ADio2 sTVeawesasy VZ6-DRMBSGISN__VWesADIo2 Control module Seat t.07m Ww3-RRD102 3 with module Vw3-RRD104 5) 3 STATOVAR 650 to 1400 A Power part sxo9 S53 S==si 17 S55 /S=Sai eS 5 u sheath teeny arInstallation Dimensions STATOVAR 2500 A power part oxoInstallation Dimensions Fuses Association with controler : soe page 12, Reference _L__ —_ Mounting in Relerence a bc d @ DFB.NFZ5002 51 51 67 92 51 DFBFFO6002 58 22 _DK1-FB26 isolator DF3-FF10001 5822 _DK1-GB2# isolator t 255 2 DFS.NFSOOO2 $1 51 67 92 51 DFSNF50002 51 51 67 92 51 DFS-QF80002 75 75 79 116 51 2 For each fuse, use: —a canter (see below), =a mierooontact, reference VZ1-PO01. 265 255 375. a 8 @ 12 Fuse carriers ‘on connection bars). WARNING: respect the craqpage distances between fuses. ‘Single pole carriers for DF3-NF25002 to DFS-CFB0002 fuses {for usa I the fuses are not installed a reteroce_Fese 2 bo OFSNzOT _orOAFOG is? sO 4 OFS Nz0{_oroNFaooe2 16? 398 Le OFS Nz0i_OFS-NFECOO2 167” 99 8 ! orsazor_ore-arennca tot ioe ie A TTI was es vt ope: 8Connections Power connections STATOVAR 40 to 150 A STATOVAR 220 A 5. 48 aie REE 29, 2 1. STATOVAR 330 and 530 A eo— aca fo-Connections Power connections STATOVAR, 650 to 1400 A STATOVAR 2500 AConnections All ratings Recommended electromechanical circuit diagram A a2 81 Fi tors. FIt-F3t Kat Kaz aa. Kaa. Kats Kaze Kaz3 Azo KAS KA61 to Kass Es Tho diagram below shows the power ckoutts with contactors and the logic relay assembly. It ‘corresponds to normal operation tor a hoisting sequence. speed controler Kio ‘motor ventiation contactor if necessary) complementary STATOVAR module kav20 speed contaller ventilation contactor achogererator ai main isolator or circuit breaker thyristor protection uses @ ‘At olcuft breaker ‘maximum current relay {It necessary) 3-020 speed contrallor ventilation circut broaker ‘mastor relay a0 Drake clecut breaker ‘irection 2 contol relay aig motor ventilation cuit breaker ( cacessary) diraction 3 control relay R ‘olor resistance movement celay RO1toRG3 brake RC ‘nd of travel reached relay st ‘muttipie control unt limit ewitch 2 relay sun reference potentiometer Jimi switch 83 relay sz slop limit switch, direction 2 firing gate validated relay ‘$3 ‘stop limit switch, direction 3 ultemate atop caemory relay 38 “runt pushbution| folor contactor control relays 80 "stop" pushbution slowdown relay siz slowdown iit switch, draction 2 maine fault relay sia siowrdown limit switch, rection 3 line contactor n ‘speed controller ventilation trancformor brake contactor (itnocassary, depending on the mains) rotor contactors y brake Note: from rating 650A upwards the quick acting fuses are incorporated into the spaed con ‘roller. Q1 is determined according to the ‘speed controller operating saquence and the power of the motor with which itis combined, Where several motors are in parallel, protect each motor with 2 maximum current relays.Connections All ratings Recommended electromechanical circuit diagram sO > « a7 $ nf 10 ay ow won oO Co ay ing tana ameiomeon “B i (207 atT T 36 oF ~ 5 o 408 . 209 : . = ar 12 or 92 ° on - my es soe us Tr > O. > o % 3 toetza ws maon BE woe wnams : Ss & (Cao Tao Taf [42 Ta [aa | 45] 46 [a7 [ae [ag [50 | 51 [sa [Sa] 52] SB] 6 aT) 27Connections All ratings Recommended electromechanical circuit diagram _ ~ > mm | asaraise | a) ia sous i ! [al] van. ea eas io a2 = v0 sao i & mas ssaracse ad ” " 2 2 a i a o a o a a > KAzo KM M18 (iF nator ‘KN20 (depends of ‘KMO ~ ie ie venssi) ‘38 “mana ‘ar is 3 s 88 (sa [59 | 60 | 61 | 62 [63 | 64 | 65 | 66 | 67 | 68 [69 | 70 | 71 | 72 [73 [74 [75 1 76 pa sia 8 SUR Si7 EE ra 27 120 i ibe [7a 73 [30 [ai | 22 [03 | 84 [05 | 06 [a7 68 [85 | 80 | 91 | 92 1 85 T 94 | 95 |Connections All ratings Recommended electromechanical circuit diagram > — > a se ey sy v = las se ye we sway 8 vost wo rato? 8 yes 2 1 1 1 2 eye eo po a > KAQ2 KARa KA70 KAST was ~ ee oe 17 8 i 38 tes ft ie ire A OO i071 jos tos Tig Lit Liz 11g 4 a eH 1 a eo as ANA ANB PLAS RUN FW ase cet Mio po & ees aa ao in noes + fem Sy eae, ot w90\ sano seats) BY B92 4 4 Li oat) ry gral te 20 @ 2 Lard g (iss Lire Lair Tite [119 1920 Liat 182 aes [tea 178 Tae Ley Lie Lee Fa Ta: 733. 20Connections All ratings Recommended electromechanical circuit diagram Vertical movenents [x] se 2 ss 0 ‘gs fp — ca i fas) > KABI eat (34 Ti3s 1136 T8717 4 44g [144 V4. 447 Horizontal movernents A ee KABI ‘AG KASS. kas ‘ x se 2 ee e e % fas) age) aaa s ba i a fa 2 1 4 2 fa ePiprpipe Papigds 4 wast WAGER wit kwe aga 88 188 60 0 8 18 8 763 [154 T7 15; 63 1164 [16 ‘167 14 7GConnections Interconnections vertical movement board - complementary module \vws-ARD104 MODULE ‘STV-64 SPEED CONTROLLER hypersynchronous board terminale ‘control board JS connector 16 14 8 12 " RELSSS BF fil SERBLESRSVSLRSRAREBBsseaRa wid 2RBRAS nil RBRRBIWS black braided sheath L=700 mm approximately 43 47 46 movement cst 10 ar 1st wa2 1 SRC ‘Affor the factory fests, the controlar is detiverod with the JB connector in this configuration. aConnections External controls Function of the speed reference inputs Utilisation of the control and speed feference inputs ‘The circuit enables two voltage rolerences, or wo Oto 20mA, 4 to 20mA current referencas tobe used. The voltage referance values and the current reference value can be entered simultaneously, provided that the precautions mentioned below are followed. ‘A peak jimiting circuit enablas the sum of these various reference values to be limited to about 10V. ‘The circuit alsa ensures the low speed tunction which is a modification of the peak limiting voltage. Output (SCR) s the algebraic sum of £1, E2 and EC1 up to amaximum ot 10V or less ithe low speed function is active (input LS. not connect. Voltage control Control of the direction of rotation via FW and RV. St closed : forward ‘82 closed : reverse ~ Bhp 2 Inthis case, do not use the RV input. Control of the direction of rotation by the vottage polarty on Et (or E2).. [ro] st 22Ka ont Reverse rotation via S1 and $2 whon $3 is closed. OE Reverse rotation via the potantiomater when $3 is closed. Direction of rotation controlled by 4,7 kA potentiometer with mid-point. 32Connections Extemal controls 010.20 ma current contro! ‘The input impedance is 205 0.20 mA gives approximately 10 V (10,2 V) on J6.3 (SRC), signa | ow2ma } [ == z : ' Nottage control on £1 and E2 can be activated simultaneously. ‘The direction of rotation is determined by operating $1 or S2. 410.20 mA cureent control ln this case link terminals E1, £2 and O€, ithe voltage inputs are not used. 'nput impedanco: 254.9, giving 10 V for 20 mA and OV for 4 mA on J8.3 (SAC). poo a 4 ‘The 4 to 20 mA control can be used with other cortrol signals, provided that 1 kf 0 § KEL maximum Potentiometers are used on the EY and E2 inputs, connected across P10 and OV. Reterence value peak limiting circuit ‘When the PL-LS link is removed, his elreuit enables the reference values to be limited to the value sat on the LSP potentiometer and to obtain low speed. This crcuit enables 2 operaling speeds to bo ‘obtained, HSP (high speed) and LSP (low speed). Low speed adjustment limits : trom 10 % to 100-9 of rated spasd. ‘Adjustment by LSP emote adjustment (LSP at minimum} Los ee} arteConnections External controls ‘The acceleration (ACC) and deceleration (DEC) times are adjusted independently, They can be adjusted in two ways : by 22 position link which defines the 2 ranges : 0,5 to 6 5 and 6 to 60, ~~ by @ potentiometer which enables the time to be adjusted within each range. ‘Tho ramp time can be modified by using input IRT (1.24) by connecting a2,2 k0 potentiometer as ‘shown in the cleat clagram on the left or by an analogue elgnal trom a programmable controler. VIR) 10 Ree aareo ‘The operating rangeis from 110 10V. Red Using potentiometers ACC and DEC to be ing this voltage onabies the times which canbe adjusted increased by a factor K varying trom 1 to 10. ‘The speed ramp is validated when RZR is not connected. To reset the ramp to zero, an 0 V signal ‘must be applied to this input or it must be connected to the O V terminal ofthe control board. [= “y "The Vertical movement board resets the ramp to zero when the AT terminalis not validated,Connections External controls External current limitation ISI input on the contro! board Mains fault (SF) te ee L-0%wih ECL =-10¥ adhstmant 016100 % of th current imitation Ua This input is validated intamally by a resistance of 15 KO connected to + 15 V. ‘When terminal ISI is not connected, the speed loop integration is validated. wena i| * ‘To canoe! the ettact ofthis integration, a OV signal should be appiied to the Input by linking terminals |S! and OV on the control board. ‘Transistor output. in the evant of a fault, relay K opens. Tmax = 20 mA with a voltage of 24 V.Connections External controls Validation logic ‘The RUN, FW, FV and_LS digital inputs are validated by PL or an extemal vokage supply of between HIZV=0% and +24 V4 10%, UM > 2a a > 2aKe Function of the RUN terminal = Validation ofthe firing gates, the ramp, the current ampitier and the reversing logic. ‘Safety precautions to take when using the RUN terminal : {case : common control and power supply (ratings 40 to 530 A: inks CAL at 0). “The RUN command can precede or foliow the switching on of the speed controller, however it must be switched off before the speed controller is switched off (ime delay 0,2 5}. 2 case : control and power eupplied separately (ratings 40 to 630 A:links CAL at 1). ‘The control is supplied upstream of the ine contactor. Follow the time-way diagram below: Mt t AUN —— + fs Where tt 20 and 1220.25 ® In this case, the RUN command must not precede switching on of the speed controller, and its cancollation must be carried out at least 0,2 s before switching off the speed controller. Note ‘The speed controlteris validated by the simuitanaous presence cf the RUN and IHL signals. Keither ‘of these signals falls to zara, the controller locks.Connections External controls Momorization of the start signal is initiated ; ~ either by the FW RV signal, or by the reterence detector which is connected to SM (SM-SMA link on connector JS, see page 17), and supplies a start signal when the reference signal is prosent. “The prosence ofa start signal is indicated by the green LED (AF). ‘The memory is reset to zara when the 2 following conditions are futfiled = — absonce of start signal by removal of signal FW or RV, ~ 2210 spoed, Le, lass than 2 % of maximum speed. ‘The operation ofthis sequance Is shown In the diagram below : | opm — t 37Connections External controls ‘Application exampto using the digital Inputs ‘Whore two speed operation is required (HS-LS), signals FW (or RV) and LS can be used without an extemal reference potentiometer. Closing 1 oF $2 selects the direction of operation. ‘The maximum speed is set on potentiometer HSP. Low speed is obtained by opening $3 and is aduustable using potentiometer LSP. ‘This enables a handling cycle to be contlled. ‘The speed controller locks when zero speed Is reached (at approximately 1 % of N max). le t g ) + --- |eLayouts Power bridge 40 to 220 A 4010 150A 220A © Current transformer ‘© Thermocontaet for 150 and 220 A ratings only ‘© 2 thyristor module (5 por controler) © Control supply transformer @ Resistance for 150 and 220 A ratings only ‘Mains 220/240 V : bypass the resistance with a shunt across pins § and 10 of the J11 connector Con the power interface board (aaa page 49) 35,Layouts Power bridge 330 and 530 A q p q ° ° [fo offamto of { | ° 0 [ole o o ; \ { ° mo} io] Co] fo oO 4 a | il a 6 4 © Current transformer © Thermocontzet © 2 thyristor modulo (6 por contri) © Control supply transformerLayouts Power bridge 650 to 1400 A © Current tanstormer @2 thyristor rack (5 per controler) © Utra-rapia tuse (2 por contol) 4aLayouts Power bridge 2500 ALayouts STATOVAR, ‘Aapation of cuter reading 40 10 530A Bonording to rating {customizing i trod. power interface ule, see page 13) board Choice of type of controtier, settovA ‘Adaptation ofthe conv supply trantormer to wut tho meine Set ato, must bo sot in poston tt eoparate the contol supply from the powar supply . Relay closed whan te speod conor outieaitaen or at ‘zero speed or under brake conve Relay closed when the peed contre veldatd 43 _sthermocontact ‘J4U5 : output to thyristor gate / cathode J" Leunenttanatonner resding tak JB: power votage ako ot J9_ ZR connection fo thyristor torminle Jie supply and ouput tothe contol vansfomer 311 :fan supply * B12 Sposa tosdback A ang gato board * 160 and 220 A ratings wth 229/240 V supply: fa shunt (upped with he conto aoroas pins Band 10 4 firing gate board e st all ratings ° ooo oon °o — =< coe J1 : output fo thyristor gate/oathods V22, V28 +J2 : output to thyristor gateyeathode V21, V25Layouts STATOVAR 650 to 2500 A power interface Current transformer ‘Outputs to power bridge board roading tink impulse ranstornors al=lelala[es 7° 0 _ __Chniee of ype o conto, o. a 77 ‘set to ST : ne cat gt ei Tr AT AT eM on tiot used forthe starovan—{ fH] eraser vd Se ne Adaptation of ne conto is ‘supply transformer to suit the 3 : Not used forthe STATOVAR, malas oe positions immatorial [ae * i >. ” Customizing comector __I}}« " according t rating U, a Kei KI pe? ' reat a ‘2 fl 3 % not used forthe STATOVAR 53,8 10": expply and output to he conto transformer Jn ‘not used for the STATOVAR S12: speed feedback JS) pot used forthe STATOVAR 20 t0 23 = outputs to power bridge impulse transtormers 24 + power briggo current transformer reading ink Y25 not used for the STATOVAR For STATOVAR | J4 connector ‘Shunts across pins erating to 530 A | VZ6-DR531 56 | 10-18 STV.c4ce5- | vz6-DRESO 13] 56 | 718 STV-64M10> | VZ6-DR1000 44] 56 | e138 stvsamie- | vzp-0R1400 13, 56] 948 sTv.s4Mas- | vz6-R2590 42 | 56 JieLayouts Control board ‘Selector switches for the choice of controller, sat as shown below saa? & er] aa Ey ‘SPO: amplifer offset adjustment (factory preset)Layouts Adjustment board mm nitiat position ol links 2 aocaloration time adjustment range . deceleration tne ajstmertrange _} O8%680r6t0 608 mains frequency selection (50 or 60 Hz) + selection according to voltage of tachogonerator feadback + epeed feedback derlvative (selection ofthe time constant) (see page 47) + speed feedback fiter (selection of cut of frequency) (eee page 47) RSI__ current loop adaptation (must stay in positon 1/3) ‘SPP: adjustment rango ofthe state gan ofthe speed loop ‘SPD _ speed loop derivative action (OV: donot use (for interchangeabilty of eld boards) Potentiometers ACG: acceleration time adjustment DEC _: deceleration ime adjustment FID: inactive (do not use) LSP: low spoad adjustment (see page 55) HSP high speed adjusimont (see page 55) 1> adjustment of currant limitation value (see page $4) Bi braking current adjustment (269 page 55) RS!_: austin ofthe current loop response time {raspone 1) SPP _:adjustmont of the proportional gain of the speed loop. ‘SPI: adjustment of the overall gain ofthe speed loop ‘Attar camying out the factory tests, Bis set to the fully clockwise position; ACC, DEC, LSP, HSP, >, RSI, SPP and SPI are set to the fully anticlockwise position. Test points OvM cov | :eurrant signal (+ 5 V average value with I> set value and ECL. disabled) CA external current loop output (0 to + 19 V) ‘SP: speed signal (4.8 V for the maximum spood set on HSP) SAO = speed loop output (+ 10 V)Layouts Links HO : speed feedback derivative (see page 68) of 5 8 2c Links HF: speed foodback fiter (for use when interferance on speed feedback) 0 c 5c 6c LEDs + 4rod LEDs — USF : mains supply undervoitage FF inot used for the STATOVAR ~FPHS: phase 3 faut (phase falure) Ft indicates that one of he 2 above fauls is present + 3 green LEDs — RUN : on when the RUN terminal is activated —RF zon when the direction of rotation has been selected —ON on when the controller has received the RUN and FF signals + A yollow LED —1> ron when the speed cantroltor is in current imitation LEDs F, ON and > can be soon by the operator when the speed controller cover is fitted. a7Layouts Vertical movement board 1019) BRAKE AEG THRESHOLD IMAP CURRENT OOO © lo lo lo lo lo io ao oo TSP CL, Potentiometers REG time delay equivalent to brake response time on opening (clockwise direction = time increase) THRESHOLD ——_: do not use; eatin the fully anti-clockwise position Wax SP +o not use; set inthe fully ant-clocieaiss position BRAKE CURRENT : current level adjustment for puleing betero the brake contactor signal (KM10) Test points ECL : (external current limit) currant limitation input: = Imax 10 V «zero exrront ‘TSP : ({hreshold speed) speed feedback simulation input; do not use ‘After carrying out the factory tas's, potentiometers REG, THRESHOLD and IMAX/ SP ars set to the fully anti-clockwise position, and BRAKE CURRENT Is eet to the fully clockwise position.Layouts Complementary STATOVAR module : hypersynchronous contral — {ogi board A To the 48 | ) epesa controller Link HYP: locking of hyporsynchrenous control in directions 2 and 3 when the link isin position N. Potentiometer P3: adaptation of the speed feedback voltage (adjustment of hypersyachronous contro! threshold) ‘Test point ‘TP1: speed feedback reading after adaptationLayouts Complementary STATOVAR module : olor stop change board _ a connection YL~4 ces oo 1 \ ea) . ON) «o Xd st tog semen itn: HOR; horizontal movament (handling) VERT: vertical movement (hoisting) Potentiometers, 4, P2, P3, PA: adjustment of the voltage threshold for the closing of the rotor contactors Test points ‘TP1, TP2, TP3, TP4: reading of the vollage threshold for the closing of the rotor contactorsInitial setting up Preliminary checks With the supply disconnected ‘Tho STATOVAR is factory proset and supped with he JS terminal iock pre-wired (sae page 17). ‘Check the rating plates andthe labets on the equipment to ensursthatthespeed controler, the motor ‘and the mains supply are compatible. Enure that the wiring corresponds to the circuit diagram, ‘Check thet all terminals are ight and that the speed controller connectors are fully phugged in and latched. STATOVAR STV-64... SPEED CONTROLLER (Check the position of tha jnks. Maka sure thal hey ara in the positions show on pages 43 10 48. The: ‘control board must be removed in order to check the jinks on the power intertace board. Power interlace boards * Vx-DM209M (from 40 to 530A) {tthe mains supply is other tnan 220/240 V, 980/415 V or 440 V, position the 3 links CAL to 1, and ‘connect an autotransformor batween the mains and CL, CL2, CLS to supply the control at 380 V. Placa link CAV 4 in position 980/418 V (oe8 page 43). Forthe STATOVAR STV.64611 and 022, with220/240 V supply, fita shunt (supplied with the speed Controller) across pins § and 10 of the J11 connector (see page 43). Ensure thal the J12 connector is filed into the power intertace board. I the power intertacs boards ‘replaced, the RT unt, adapted to the controller rating, should be reinserted (see pages 43 and 13). + VX5-RZ0102 {from 650 to 2500 A) Supply via CL1-CL2-CL3 taking care withthe phaos coordinetionbetwean controland power. Settho link according tothe supply voltage (see page 44). tthe power intartace board's replaced, te J4 connector, adapted tothe controler rating, should be reinserted (s9@ pages 44 and 13). Controt board Ensure that 3 switches are in position S (STATOVAR) and that 1 switch is In position 6 (s00 page. 45). ‘The VW2-RLD310 vertical movement board Is factory mounted on the control board. ‘Adjustment board _Engure that link FID is in postion 0, and that potentiometer Bl isin the fully clockwise position (soo adjustment board checks, pages 46 and 47). Vertical movernent board VW2-RLD319 Conform te the indications given on page 42. VWS-RRD104 COMPLEMENTARY MODULE ‘WWD I01 hypersynchronous control Yogic boare CGnoek that tha fink HYP la in position N (hypersynchronous contral disabled, see page 48). ‘Connect the ibbor connector inkingthe J5 connecior ofthe control board withthe hypersynchronous, ‘control fogie board, according to the references marked on the connectors. ‘WWI-RRD 100 rotor siep change board Check thatthe flat cable is corectly connected tothe hypereyachonous contol fogis boar, Position the link according to the application {see page 50). 51Initial setting up Static adjustments Equipment required Precautions Checking the synchronisation Reference potentiometer Rotor step change board Horizontal movements: Vertical movements —Two mulimetors, preferably 20000 ohms / volt. —A two channel oscilloscope, if required. “The apparatus must bo isolated trom the mains supply. Do not connect the oscilloscope earth 10 another earth of the installation, —A moving scale ammeter. ‘Chock that the LS (C J1.80) - PL (C.J1.28) interconnection has bean mado. Do not select a direction of rotation via FW or RV (see page 32}. For hoisting applications (vertical movemert), carry out the following operations without the usoful toad, up to the adjustment ofthe brake logic function (sea page 64}. ‘Where separate control and power supplies are boing used on the VX1-DM208M power interface: board (links CAL sst to posttion 1), or the VXS-RZD102 power interface board, check the phase + eoordination between control and power. Q ‘Check its connections (see page 32). Measure ALT-CL1, O12, CL3. For the lowest vollage measured, connect the corresponding wite to CL1 Measure AL2-CL2,CL3. For the lowest voltage measured, cannect the corresponding wire to CL2. Connect the remaining wire to CL3. Single potentiometer: eoommended vaiue 2.2 KO, minimum power 8 W. Nid-point potentiometer: recommonded valua 4,7 kX, minimum power 6 W. Check its ohmic vatue on the multimeter, torminais disconnected. ‘With the potentiometer connected, check the voltages betwen OEt and E1 = cursor at zero: OV, cursor fully at maximum : + 10 V according to the operating direction. “Threshold voltages on the VW1-RRD 100 rolor atop change board. “These voltages are measured al test points TP, TP2, TPS, TP4, andadjustedby potentiometers P1, 2, P3, PA (sap page 50). “Tho voltage atthe toat point daterminos the speed at which the corresponding rotor contactor closes, knowing that ~ 8 V represonis the synchronism speed of th motor. Furthermore, al test point TP, the voltage's postive value corresponds to a speed during countercurrent braking. ‘The following table is for standardised starting resistances: Contactor Speed threshold (%4) Test point —-Potentiometer Adjustment voltage (V) roa -40 TP ane +33 Tre kus +68 1P3 iat +85, TPs KMi11 lowering +75 Pa KM raising $25 TP2 PI a2 Pe - 2,64 Pa -544 Pa -58 Pa =6 P2 -2 Inthe event of spaciat starting applications, the control system's own fle must spocily he anticipated ‘threshoid values. 82Initial setting up Static adjustments Verification of the direction of rotation ‘Setthe BRAKE CURRENT potertiomoter onthe vertical movement beard in the fully anti-clockwise position ‘Sot selection ink H on the adfustment board to position 500. Connect a voltmetor between terminals FINA and RNB on the power interface board {0 on RNB). Short out the integration by connecting terminal ISI on the control board 10 OV. Caution: the motor might run away without reguiation If the tachogenerator Is inverted of disconnec- ted. Include a stop in the sequence : normal stop, emergency stop. ‘As a precaution, input ECL (CJ1.10) can be used to limit the current and prevent the motor accolerating too quickly, Give the FW signal. The green LED RF end the green LED ON go on if the RUN signal is given. ‘Select a positive low speed reference (about 1/4). The motor starts to rotate. Check the polarity of the voltags teadback using the voltmeter. 1) Ifthe voltage poiarty is negative, the speed is regulated. ‘Checicthat the motor runs inthe required direction for the FW signal. not, tum off FW signal then ‘switch off the mains supply to the equipment, and change over the tachogenerater connections RNA and RINB on the power intertace board, and also two stator supply phases of tha motor. Flemove the FW signal. ‘Switch off he supply. ‘Sot the link H on the adjustment board according to the tachoganerator characteristics and ‘maximum motor speed. 2) i the voltage polarity is positive, the speed is not regulated. ‘Stop the sequence. Remove the directional signal FW. Revarsa the tachogenerator signal by lnwerting the wires connected to RNA and RNB on the power interface board. Restart the varification of the direction of rotation, 9) 1! the veltago is zero, stop the sequence and check the continuity of the tachogensrator cirout, Flomove the aitectional signal FW and rastart the test. ‘Note: the polarity of the tachegenerator voltage is valid in this test for a positive reference valve and a directional signal FW. ‘Switch off the supply. Remove the shorting link between OY and (St. Cancel the signal at the ECL input, it necessary. Retum the BRAKE CURRENT potentiometer to the tuly clockwise position.initial setting up Dynamic adjustments Factory settings Adjustment of the current limitation Adjustment of the brake | function ‘The speed controler is supplied with the response times sot tothe values given below. ‘The static gain i defined in agjustmant ranges by link SPP: position 0: 4 to 20; position 1:20 to 100, adjustment within each range by potentiometer SPP. ‘Adjustmant of the integration time constant by potentiometer SPI: range adjustable trom 20 to 900 ms. Precautions ~Do not remain too long in current limitation as the motor may overheat. —Bo not excaed the peak current of the speed controller (see page 8). = Remember to derate tha controller by 1,2 % per °C for ambion! temperatures between 40.and 60°C. Exampie: ‘Tako an STV-64C65O operating at an ambient temperature of 55°C. Derating is equal to : 1,2x (55 ~40) = 18%, siving a dorated operating current of 650 x £1907 18) _ 539 4 100 loss tho contactor KM1t (vertical mavamert) or KM14 (horizontal movement) by short-cireulting ‘the control relay contact (see diagram, page 30). ‘Switch off the supply 0 the brake. ithe latter s not suiciently powerfulto hold the motor at stant ‘lock the shaft mechanically, in addition to the brake. Check thet the BRAKE CURRENT potentiometer on the vertical movement board is in the fully ‘lockwise position, and the REG potertiometer in the fully anticlockwise position. Connect a moving scale ammater to one of the stator phases. ‘Switch on, and give the maximum speed signal to the reference potentometer, ‘Give the FW signal. The green LED AF and tha grean LED ON go on. ‘Tho motor is not rotating. The LED I> should be an. ‘On the adjustment board, tum the potentiometer I> in the ciockwise direction, 1o obtain the required limitation value, taking TW/Tn into account. Adjustmart limits : Ip 310 Ip, Unless indicated otherwise inthe control system fle, the starting currentis limited to 2,5 Isetor vertical ‘movements and 2,2 se for horizontal movernents, Check that the adjusted value isthe same tor both Girections, Remove the short-circuit of the KM or KM14 contactor control, Fleconnect the supply to the drake. This adjustment is made for vertical movement only. ‘Test with the usstul oad. ‘On the vetioal movement board, sel the REG potentiometer inthe fully clockwise positon. Select a tow speed reference in the “Halse” drection, and adjust he level ot he corresponding current tothe torque required fer maintaining the lad at stansti, using the BRAKE GUARENT potentiometer. Reset the REG potentiometeriothe full anti-clockwise position. Select alow speed reference inthe “False” direction. H the load swings wnen the brake is itted, tun the REG potentiometer in the clockwise direction fo cancel the swing.Initial setting up Dynamic adjustments Braking current Maximum speed adjustment Low speed adjustment Ramp times ‘Adjustmentby potentimeter Bl on the adjustment board. The maximum braking currents equal tothe limitation current iB is in the fuly clockwise direction. can be reduced by turning Bl inthe anti- ‘clockwise diraction, according to the requited current (Br is @ percentage, from 10 to 100 % of the limitation current set on! >). Vertical movement: leave 8! in the fully clockwise position, Horizontal movement : adjust while running, ‘This adjustmont, lie the foflowing one conceming the speed loop, must be made with the motoren nodoad. ‘Connect a voltmeter botween terminals RNA and RNB on the power interface board. (On the adjustment board, check that HSP is in the fully anticlockwise position. (Cancet hyperaynchronous operation using the ink HYP on the hypersyachronous contral logic board (position N). ‘Switch on. ‘Select RUN then FW or RV (for vertical movernant, choose the "Raise" direction). “The green LED ON should be on, and all the others off. Select a spsed reference; the motor should run. ‘Select reference OV. ifthe motor rotates, adjust potentiometer SPO (zero speed adjustment) on the ‘contrat board. ‘Select raference 10 V. Adjust the maximum speed of the motor using potentiometer HSP on the adjustment board, ‘measuring the voltage on ANA-RNB, until the multimeter reading stabilises. Chock the correct change of the rotor steps. ‘The motor thus rotates at a speed close to synchronism. ‘Turn the HSP potentiometer (adjustment board) slightly back in order to position pracisely on the threshold. eset the speed reference to z0ro, reverse the operating direction, select high speed and check itby tuming the HSP potentiometer vary slowly uri in the ragion of synchronism speed. this is necessary, LSP must be activated by removing the link between LS and PL on the termina block of the contro! board. ‘Adjust LSP to obtain the required value. Adjustment range 10 to 100 % of maximum speed, ‘Tho ramp times have two adjustment ranges and canbe eet using the potentiometers AGC and DEG 6s 6s 6s Bs 80s 60s 60s, 606 6 | fg [6Initial setting up Dynamic adjustments Action of the For vericai movement, cary ut the folowing adjustment with and without the uel load adjustment parameters ‘Aajusimert of the speed oop, it tho factory setting is nol suitablo: ~ select a low speed referonce (20 % for example), ~ validete tha controtier by FW and FUN, = begin by adjusting SPF upto tha limit of stabity, way to the limit of stabiliy, ‘diagrams below, then adjust SPP in the same. Connect an csciloscope between test points OV and SP onthe adjustment board. The curves below show the variation o! the spaad signal according to the settings of SPI and SPP. SPI minimum hoomea A SPP minimum ve SPD position 0 - P| tf SPI adjusted ‘nconea B SPP minimum SPD position o I SPI adjusted Corea C SPP adjusted SPD position 0 4, paving adjusted SPP and SPI. a type B curve persists, place link SPO in position 1, mova link HD (seepage 47) up toobtain sabiliy, Thon readjust SPiand SPP and then theramptimes, necessary,Adjustment of the hypersynchronous contro! threshold Initial setting up Dynamic adjustments Connect the mutimeter between OV and test point TP on the hypersynchronous control logic board Switch on the supply, and select a referonea of 10. Adjust the potentiometer P3, so as to obtain a voltage of 10,2 V on the multimeter. Return the reterence to 2010, ‘Switch off the supply. Revert to hyparsynchronous oparation by setting the link HYP in position O. 7Block diagram SLOPSALS 58biases wey mon Ween mee, 52