08/08 "98 SO 11:03 FAX +41 41 445 2108 SERVICE 01 RELIANCE ELECTRIC #0 MAXITRON S-6/S-6R 8000 Single-/four-quadrant Three-phase Power Converter Instruction manual 49 N97 e 05, ae p08/08 "98 SO 11:03 FAX +41 41 445 2108 SERVICE 49'1197 & RELIANCE ELECTRIC - ‘TABLE OF CONTENTS Page GUNBRAL NOTES ...++ DESCRIPTION WITH SCHEMATIC DIAGRAM Yel Features ceeeeeseeereeeeeeeees 2 112 Configuration +++ssssseeeesere 3 1.3 Funotiona of the controller «+++ 5 1.4 Functions of the power unit - 6 2. TECHNICAL DATA 2.1 Voltages +++++ sects we 1 2.2 Armature current, Piold current ...++++ 8 2:3 Diasipation seseteceessseeseee 8 2-4 Line impedance « 8 2.5 Ambient conditions - 9 2.6 Controller data 9 2.7 Wonitoring functions - 13 3. MODIFICATIONS, COMPLETION 3-1 Standard equipaent seseeeeeeeeeeeeeeees seeeeeees 14 3.2 Possibilities for controller adaptation .. te 15 4. MOUNTING AND cONNBCTION 4.4 Mounting, dimensions ..-.++sseeeeeeeeeeee sess 22 4:2 Cooling s+seeseerereeeee seseea tissesee 22 4:3 Connection plan ..+ tees setae 22 5. START UP INSTRUCTIONS 5.1 General SreereeEeeetesy ceetesseeseseeeeeereeeees Bt 5.2 General checks without line voltage applied ...sseeeeeececeseesseeeeeees St 5.3 General checks with line voltage applied «+... : te 32 5-4 Current regulator adjustment «+++. tesaseeeeneeeeesenenees 52 5.5 Voltage regulator adjustment . Tee 54 5.6 Speed rogulator adjustnent ...+s++eeeeeeeeres Hicteneeeeeeeese 3 5.7 Reference integrator LVTU adjustment ...seeeeeeeees fitteeeeeeeees 35) 6. ‘TROUBLESHOOTING 6.1 Safety precautions «.+- teeeeeeeeeeeeeee 36 6.2 Trouble shooting suggestions - te ne 56 6.5 Spare parts teseeeeneeeeeeeeeeenees cceneereeeee 40 6-4 Replacement of components Pee 42° 6.5 Accessories ....+ seedesseeeesesesseeseeeesegeeeeeenee 4408/08 "98 SO 11:04 FAX +41 41 445 2108 SERVICE 003 49/1197 © SAFETY INSTRUCTIONS DANGER, WARNING, and CAUTION point out potential trouble areas. 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 of a condition which could result in 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: Before installing and/or operating this device, this manual must be understood by the qualified electrical maintenance person who is familiar with this type of equipment and the hazards involved. Failure to observe this precaution could result in bodily injury. vo inhibit uncontrolled machine operation in case of the malfunction of the drive, the user must provide an external emergency stop circuit, which ensures disconnection of the power source from the motor. This safety 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) must be accessible to the operator. Failure to observe this precaution could result in bodily injury or loss of life. WARNING: The function of this electronic device, if not mounted in a metal contrel cabinet, can be disturbed by electromagnetic A radiation of nearby radio tranceivers (walkie-talkies). WARNING: Earth fault detection devices must not be used on this converter as the sole protection measure against unintentional touching. The DC-component in the earth fault current may inhibit the correct function of the fault detector. CAUTION: Electronic converters cause disturbances to the supply network. The basic version of the MAXTTRON does not include any radio interference- or harmonic filters, to fulfil the limits in the recommendations, because they are dependent on the supply network impedance.08/08 "98 SO 11:04 FAX +41 41 445 2108 4g'119T & 1. DESCRIPOTON tat Features Reliance power convertors of the MAXITRON S-6 8000 or S-6R 8000 series may be used for the stepless regulation of De-notors. ‘They are available in two variants: For single-quadrant operation: Eine St eco Controlled rectifier bridge with two directions. Clockwise rotation (I. cow motoring For four-quadrant operation: HaaTRO S-oF 8000 Taie convertor works as rectifier and inverter and allows operation in both directions of rotation in motoring and regenerative mode (driving and braking) - Quadrant) or rotation (III. Quadrant) AC-line reactors, super fast acting fuses and fault indicators are not inoluded in the device and have to be mounted separately. = Regulator and application specific components are assembled on separate FO-boards. This allows interchanging PC-boards without re-adJusting the controller. All important controller signals ere connected to a diagnostic socket (see Fig. 1-3 and 1-5). Extension poseibilities by additional printed circuits, e.g. potential-free controller inputs, position or tension regulator, comparators. ow ow Regenerative Motoring mM |r a tr [iv cow cow Motoring Regenerative SERVICE 004 RELIANCE ELECTRIC FE 1.141 Protective measures A balanced protective concept ensures @ high degreo of reliability On single-quadrant arives fast acting fuses must be provided on the mains eupply side to protect the thyristors against short circuits. On four- quadrant drives fuses are also Fequired in the armature circuit. Instantaneous electronic trip (IB?) Protects the device against over- current and overvoltage peaks. RC-networke Limit the voltage at the thyristors. Convertors with cooling fan are protected against excessive tenpera- tures from overload or fan loss by thermostats on the heatsink. ‘The controller is electrically isolated fron the power unit. Regulator blocking on phase sequence error, undervoltage or phase loss. LED indicator @isplay and fault monitor output through potential free relay contact.08/08 "98 SO 11:05 FAX +41 41 445 2108 SERVICE Boos 49°1197 ¢ RELIANCE ELECTRIC F 1.2 Configuration ‘Terminals: Themostat Control transformer Control voltage AC 24V Field rectifier -————- Ae-ine input Motor connection Field supply fuses #1/P2 Power atack Control transforser Interface Card ‘IKA/B or TGA/B Phase protecting fuses P4/P5/F6 Fuses: = FI Control voltage AC 24v ~ 72/83 Signal voltages Regulator Card DRA/B Variable Components Card VoB Fig. 1-2: Configuration of the power unit with controller hingel downBoos SERVICE 08/08 "98 SO 11:05 FAX +41 41 445 2108 RELIANCE ELECTRIC - 4g"197 4¥m ToxZUCD paw oyvTNFex oy Jo UBATETP OTIBMOYIG 26-4 “FTE08/08 “99 So 11:05 FAX +41 41 445 2108 49'1197 & SERVICE RELIANCE ELECTRIC £ Controller unit functions (Figure 1-3) Symbols identification: A ®@ 4.3.1 Reference inputs Wrap-pin Solder point Variable jumper-plug ‘Test point with selector awiten position - for 15 Vor 10 V = direct input through filter reference integrator (iVTU) with potentioneters for ACC-rate and DEC-rate 1.3.2 Speed or voltage regulator Pl-regulator (N-RB) ~ Speed regulator with active feedback Voltage regulator with passive feedback Voltage regulation mode is not used on 4-quadrant drives Current Limit IMAK POS motoring (1-quadrant mode) regenerative (4-quadrant mode) IWAK WEG Resistor feedback network for matching the to the tacho voltage Feedback signal for actual speed indication 1.3.3 Current regulator PI-regulator (1-RE¢) = with active feedback and fixed regulator time constant = Resistor network for matching the feedback burden resistance 1.3.4 Summing amplifier, firing angle liniting = Resistor network for matching the firing angle linit to the mains voltag Selector switch 441. ~ Adaptation of the rear firing angle Limitation to line impedance 1.3.5 not used 1.3.6 Control inputs (figure 1-4) = Applying control voltage to VeB-terminals 8-11 enables the controller. The potential free relay contact K1 signals the armature or AC- contactor = Additional functions on the ZFA~card (rofer to 1/M 49'1077) Fig. 1-4: Control inputs49°1197 @ RELIANCE ELECTRIC - 1.4 Power Unit dX et _ ! ! Le Fig. 1-5: Schematic diagram of power unit 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. ZL 0m 1500 A unit use external field rectifier or field controller QZ See technical data 2.1.2/2.1.3 On 1500 A units only blower supply on 380 V to terminals 187, 188, 189 WARNING The output voltage of the convertor (MAXITRON S-6/S-6R 8000 without field weakening) is not linited. In case of @ fault the output voltage (armature voltage) may reach the following value: Ug = 1.35 . Uy (observe the line voltage tolerance)08/08 "98 SO 11:06 FAX +41 41 445 2106 SERVICE 49'1197 e RELIANCE ELECTRIC cE 2: SBOHNITCAT DATA 2.1 Voltages 2.441 Convertor input voltages = Three-phase line input voltage (terminals 181, 182, 183) two variants: type 30 ~ 800'A type 1500 A + Line voltage tolerance for the controller «++ for naximan armature voliage acconting to Table 2-2 50 He or 60 Hs 22 He ++ 380/415 ¥ and 460/500 ¥ 11 380-500 ¥ and 660 7 . 10% Line frequency 1.2 Field rectifier input voltage: Single-phase line voltage (terminals 281, 282) ssssssereesseeseeeeerees maxe 415 V Fused by Fl, #2 +++ steve 30-830 A s+s12 ARP 800 A ...20 APF 1500 A unit’ with external field supply a) 2.1.3 Fan supply voltage and power consumption type 120-800 A (terminals 188, 189) « s+ AC 220, 50/60 Hz, 0,2 & type 1500 A (terminals 187, 188, 189) - ‘AG 380 ¥/50 Hz or 60 Ha, 1 A ‘thermal/magn- protection by external circuit breaker 164 Armature voltage: Standard voltages Uz ngn (according to DIN 40030) at inductive voltage drop of Ux <4% per phase according to Table 2-1. = Maxinun permissible amature voltages Ug max at inductive voltage drop of Ux <4% per phase and max. 5% line undervoltage according to Table 2-1. ‘Table 2-1: Amature voltages for different line voltages 8-6 motoring only 5-6R motoring/inverting operation Tine ‘raature ‘Reaature ine ‘Armature ‘pasture voltage voltage voltage voltage voltage voltage tH Us now Ua max oN Us nom Ua_max 380-7 460 V 460 V 380 V 400 ¥ 400 V 415 1 460. V 500_¥. | 415 v 490 ¥ 430 V 460 520 V 550 V 460 -V 460 480 V 500 ¥ 600 V 600 V 500 V 520 ¥ 520 ¥ OV ‘300-¥ B00_¥ om To0-¥ FOO = Haxinun permissible armature voltages at inductive voltage drop of Ux > 4% per phase and max. 54 line undervoltage, according to Table 2-2. Besides the armature voltage derating the rear firing pulse limitation ¢,4q must be displaced. This is done by adapting resistor R(45AV) on the VCB-board, according to Table 2-2. Table 2-2: Max. armature voltage at Ux > 4% or undervoltage > 5% UK andor maz. aruature ola RCABAY) voltage voltage ato 7h <5 8 0.95 + Uy max 152° TAT 1 to 12% <5% 0190 | Ug max 147" B25 <4k 5-10 % 0.95 . Up max 158° - <4% 10-15 0.90 « 158" -08/08 "98 SO 11:06 FAX +41 41 445 2106 SERVICE 49'1197 @ RELIANCE ELECTRIC cE 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 amature current current Pield current Tenon lad Tanax | Transformer Ratio Ie i 8-6/S-6R 8005 25 BOA 37.5 AI e734 ea 8-6/5-6R 8006 soa 60K OB 855: 2 BA 8-6/S~6R 8012 100A 120A 150 B55: 1 BA 8-6/8-6R 8129 2404 290A 360 Al 2000: 1 8A 3-6/S-6R 8145 BEOA 430A 540 5000 : 1 BA 8-6/8-6R 8260 666A 800A 1000 AI 525031 194 5-6/s~6R 6315 | 12504 15004 1875 A 10500 : 1 - Ignon # Permanent rated current with 50% overload during one minute every 10 minutes. q+ Pomnanont Limiting current without overioad (Zag = 142+ Tnnoa) Tamax ? Meximua current during one minute after 9 minutes with Tenom Clamax * 165 + Tanom) Current transformer ratio ii = _ Motor current Burden current Controller heat dissipation in watts my be expreased by the following formula: Dissipation Py*K +3. Tenom where 100 for units Type 8003, 8006 and 8012 200 for units Type 8129 and 8143 400 for unite Type 8280 800 for unite Type 8315 RAR Line impedance considerations So that the maximum permissible short cirouit current capacity of the convertor is not exceeded, minimum aupply network inductance is a mandatory requirenent. ‘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 and 6-6. ‘the short eirouit current at the field rectifier input (terminals 261, 282) must be limited to 25 kA. Exception: No reactor is required when a matched transformer is provided in the input to the convertor. -8-08/08 "98 SO 11:07 FAX +41 41 445 2108 SERVICE 49°1197 & RELIANCE ELECTRIC cE 2.5 Service Conditions 2.5e1 Ambient temperature : °C up to +55°C . = Operation cond.: For temperatures higher than 45°C the max. currents must be derated ty 1-5% per “Cy = Storage: 2570 to +55°C . = Transportation: 725°C to +70°C (+70°C during 24 hours max.) 2.5.2 Ambient humidity + ‘The relative humidity shall not exceed the following values: 50% at 40° Cand 90$ at 20° C and less (Class F, DIN 40040) NOTE: Condensing not allowed! 2.5.3 Air pollution The anbient air may contain some ary dust but aust aot contain excessive dirt, chemical fuses, oil vapor, etc. 2.5.4 Installation altitude: Max. 1000 a above sea level. Aoove, derate nax. current by 1% for every 100 a. 2.5.5 Degree of protection : P00 2.6 Controtler data 2.61 Control supply transformer = Line voltages, single-phase «.. 110/220/240 V, #108, 50/60 iz = Fuses (externally mounted) for cross section 1,52 Control voltage secondary at terminals 51/52 protected by fuse Fi on IKA/B-IGA/B-card -.++++ Switehing-on sequence for control supply end power unit, optional Switching-off sequence: power unit first max. 10 AP titers AC 24.0 + 200 mA 2.6.2 Controller power supply Stabilised output voltage -++eeseeeeeeeeeee sere IS 20.05 ¥ £300 mA Loading +eess++e Admissible, additional external supply loading at VOB-output terminals 96-57 (+15 V) and 97-57 (-15 V) veesesees maze 10 mA at VOB-wrap pins CF63, CK63 and CH63 ...++ ‘otal max. 200 mA = Input fuses F2/F5 vesseeeeeeee . seers TAD 2.6.3 Control input = Voltage at VCB-terminals 8/11 ...+ ~ Current consumption « NOTE: with DC +24 V Plus at terminal 8 Minus at terminal 11 serees optional AC 110/220 ¥, AC/DC 24 ¥ seeeeeeeees SppPOE. 76 mA 2.64 Control outputs = Contact loading of relays Ki, K2 at terminals 12/14 (K1) and 15/16 (x2) ss DC 50 /A0 220 ¥, 44 60 W /1000 VA approx. 250 ma = Drop out delay of Ki +++ -~9-08/08 99 SO 11:07 FAX +41 41 445 2108 SERVICE 49°1197 © RELIANCE ELECTRIC cE 2.6.5 2.6.6 2.6.7 2.6.8 2.6.9 + 10Vor 15 ¥ Reference voltages, optional ..+ Regulator zero (term. 57) shall not be connected to ground. An external reference eirouit with ground connection, aust be avoided or aust be isolated. If this is not possible, consult with RELIANCE. not included Speed reference integrator (LVTU) = Integration tine, standard adjustable - = Input impedance 15 V input « 10 7 input <2: Speed regulator = Rated gunning current s+++s+0+ +5065 mA = Regulator tine constant, standara HIT INL 015 s 2 qransition frequency of open loop regulator v.ceseee+ IIs raa/a @ Break point froquency sessssveseesseeereeeesccesceeces TB rad/s 2 proportional gain adjustable ty HSTAB, standard v.ssce+ Beets 357 = Adjustable current linit, IMAK POS motoring (1- and 4-quadr. drives)....10 - 1008 Tenax IMAK WEG regenerative (4-quadrant drives only)..+-10 - 100% Tenax Voltage regulator = Summing point, rated current ... = Reguletor frequency, standard = Transition frequency, standard = Proportional gain, standard ..+. 2 = IR-drop componaation adjustable by potmeter IRCOMP to max. .....++ 15% Ianax (on t-guadzant drives only) 2.6.10 Current reference integrator - Current rate, standard ... 2.6.11 Current regulator cette Ost ok Aeeeeeeeeees 15 ms 1416 ms - Summing point, rated current at Ianog ++e++++ = Mine constant in continuous condition in discontinuous condition +. - Adjustment of the transition frequency (without field) to « 225 rad/s ~ Regulator gain adjustable with ISTAB, standard ...++s.+++ + 015-164 ~ Response level of the I = J comparator «++es+sseeeeee 1.5% Tanom ~ Rear firing pulse limitation, standard « seeene 158" mine 1.4 ms = Current reversing dead time +...+++sseee 2.6-12 Firing pulse train ~ Length = Frequency -10-08/08 "98 SO 11:08 FAX +41 41 445 2108 SERVICE 49'1197 e RELIANCE ELECTRIC E 3 Date of the regulator card DRA/DRS eT Cand Signal nane | short | t-Quadrant | 4-Quadrant | Value Design. | Range Range Test pt, r ver, Reference weer 1 | 0 V5] -15 Veeetts v | 15 V a Maximus input mov | 10 vic10v | 10V speea | acto ves Comparator compoun |-1 Vie 1 | -1 Veer 1 ¥ output aET vos Integrator rwrsun | £0.15 ma 20-15 mA sunning 39 voB Reference meer 2 | 0v...#10¥ | -10 V...e10V [10 V @ Maximua output speed | BI9 vex Speed reference | mREPF 3 | 0 V...#10V | -10 V...#0V | 15 V5 Maxinun input 1 Higv | AS villet5 Vv speed | act VCE Speed reference | NREF 4 HOV | 10 ve..H0.¥ | 10 V @ Maximum input 2 speed | AC23 ves Speed regulator | sux | 0 Veeettel ¥ 1e1V 4 Maxiaun sunning speed | A026 vos Speed regulator | MREF 1ov | -10 ve.tt0 v0 [10.9 4 Maximum output current | 4029 Speed regulator | TR OVee.-10 0 | -10 Veett0-V ves integration tine constant A032 veB Speed regulator | NSTAB 10 Yeee10¥ proport. gain acta vee Actual spuepes | 0 V...+10 ¥ | -10 Ve..10 ¥ | #10 Va Maxinun speed speed | anio ves Armature wuaye | 0 V...-5.2 V] 5.2 Veee05.2 V] -UAPB = 12 Up voltage FDS act. ves Avnature TAB Ore 3V¥ | Ove 5V [50 a Maximum current ZDB current | AE32 =e08/08 “99 So 49°1197 e 11:08 FAX +41 41 445 2108 SERVICE RELIANCE ELECTRIC FF 13, Date of the regulator card DRA/DRB - continued Signal Wane | Short | 1-Quadrant | 4-Quadrant | Value Design. | Range Range current rarer = ov.eectov | 10 v...#10¥ | -10.¥ & Maximun reference current| ACt6 (150% Tanom) vee current regu-| raRzP3 | -10¥-..0¥ | -t0¥...0V | -10¥ # Maxima lator input carrent| AB25 DRA/B Current regu- | TARBCOUT # at decreasing lator output current only | BV73 Firing pulse DRA/B Thys. 1 w/t La Firing pulse aP7g Tyr. 2 Lit L @ Firing pulse Ag62 Taye. 3 /t La Firing pulse 4060 Tayr. 4 L/ 1 4 Firing pulse A056 Taye. 5 wt La Firing pulse Are3 Thyr. 6 Lt L @ Firing pulse 8058 ves Supply 45 “5 +15 ¥ 10.2 ¥ 0763 “50 “5 15 V 30.2 7 Hes en Kes 2.6.14 Potentiometer functions on the VCB-card MIN max Umax. ACO=RATE DBC-RATE IRCOMP NSTAB ISTAB INAXPOS IMAXNES Minimum speed Maximum speed Maximum arnature voltage Acceleration raap Deceleration ramp IR-drop compensation Speed regulator stability Current regulator stability Maxinum pos. armature current Maximum neg. arnature current = 12 - ors08/08 "98 SO 11:08 FAX +41 41 445 2108 SERVICE 5 49'1197 © RELIANCE ELECTRIC - Monitoring functions = Three-phase undervoltage response level (SPB) «+++++++ 30% undervoltage T overcurrent response level (OCH) +++-+++ : + 2 x Tenax - Single-phase undervoltage response level (1PE) sssversrerereseoes 35% undervoltage Rocalater enabling ssrss+ressssecseeseseseeeeesece @PPFOK: 500 ms after supply on Pulse blocking switch-on response delay (PBL) -.+.-++ + approx. { ms - pulse blocking switch off response delay (PBL) -++++++++eeeeeeeeees SPPFOK: 100 ms 2.7.1 LBD-indicator functions Location} Function | Colour | ugD tights, if LED remains dark, if Designat. DRA/B ose a —_| Current regul-stebility constant (uring adjustment only) SOK gn | Controller supply o-ks PSE rea No phase sequence error oce red No Over Current Error ore red Ho Line undervol tage AP gn _| Positive current flows ran ge _| negative current flows = 13 -08/08 "98 SO 11:09 FAX +41 41 445 2108 SERVICE 4g"1197 e 3. MODIFICATIONS, COMPLETT ON 3.1 Standard equipment as shipped fro stock rant-unit as voltage regulator with IR compensation =~ ine voltage 380 V / 50 He = Control voltage : 220 VAC = Regulation mode : Voltage regulator with IR-drop compensation = Armature voltage : 380 V to 460 V = Reference voltage: 15 V through LVTU ~ Burdon resiator : For lowest current 4 speed regulator Line voltage + 380 V / 50 He Control voltage : 220 VAC Regulation mode +: Speed regulator Tacho voltage —: 60 V to 76 V RELIANCE ELECTRIC £ Reference voltage: 15 V through LVIU Burden resistor : For lowest current Symbol identification: M Jumper plug inserted, (- open connection) Table 3-1: Standard equipment of the VCB-card Cireutt Standard function Solderpoint Value Coordinate Reference Speed reference (15 V) through LVTU (ix) 15y 00 input (isa) 10V- (180) n Discharge of LVTU by PET-switch (188) - with signal NEL R (27AV) - R (3OAY) : c (i5aa) - Reference Integration time 1s to 32s © (319) - integrator | adjustable by ACC and DEC RATE potnoters (ten) a Voltage/ Metwork for aneature voltage regulation (25u) wR Speed with TR-drop compensation (250) WR = Regulator Voltage feedback for amature (11s) 380-4607 7 voltages Ugnon 380 ¥ to 460 (140) var adjustable by potenoter UNAK R (12av) - (11m) 60> TeV = (ax) 76-97 = (ip) 97-126 - (119) 124-159. - Gr) 159-200 = (in) oan = R (6av) - ® (15a¥) - ¢ (st) - - 14 -08/08 "98 SO 11:09 FAX +41 41 445 2108 SERVICE our 49'1197 & RELIANCE ELECTRIC E 3.2 Possibilities for controller adaptations 3.2.2 Additional components on the VCB-card = Use resistors 0.5 or 0.25 Watt/1% and The basic controller my be extended non polarized capacitors. with further functions by the plug-on card ZFA nore: WARNING Waen soldering components on the For each intervention, the unit must VoB-card, verify that the electrical be separated fron mains! connection to active parts of the controller has been opened. Otherwise the C-NOS components may be damaged. Table 3-2: Possibilities for controller adaptation Modification Calculation forma / Selection table Resistore in kOhm, capacitors in uF = Speed reference 10 V Insert jumper (188) in (18) through LVTU = IVTU-output open Remove jumper (182) = Spoed reference 10 V through| Insert jumper (18?) in (18%) filter without LDU ~ Increasing of filter time T= 5. (C(13AG) + 0.22) ms constant 7 (ms) = Quick discharge of LVTU external contact on wrap-pin BO7-BG11 = Integration time taay extended O(BL9) = 0.25-tmax-8 (uP) Adjustment by ACC DEC RATE potneters = Network for speed Insert jumper (25%) in (25M) regulation Remove jumper (181) = Adapting voltage feedback Inaert jumper (118) in (111) + solder in R(124V) to armature voltage RC2AV) = 0602 «Ug ~ 5-8. (KOhw) if 380 V >U, > 460 ¥ for UMAX in position 5 = Adapting speed feedback a) Insert jumper (118) in (11M). to tacho voltage b) Ingort jumper (118) in (11M). and reduce voltage at terminal 267 to value a) 60 = Up = 200 ¥ below 200 V through external voltage divider. >) Up > 200 V fo) Insort juaper (118) in (11L) + solder in R(6AV) ©) 60 > Up R(GAV) = 0.3 Up - 3 (Kohn) Fine adjustment by NMAX for NMAX in position 6.3 ~ Forcing Tasert R(15AV), C(51¥) -15-08/08 “98 SO 11:10 FAX +41 41 445 2108 SERVICE 4g'igT e able 3-1: Standard equipment of the YoB-card (continued) RELIANCE ELECTRIC £F circuit Standard function Solderpoint Value Coordinate R (258G) - Voltage Stability cirouit for ¢ (25aG) - Regulator ‘Tm’ 2 0,04, Ra 20.05, ki > 1, cc (22a¢) (0,1uR = Tm <= 6s) Re Mechanical tine constant : Tq (s) wb Armature tine constant (ns) ty Armature inductivity (mH) Rated armature current : Iq (A) Line voltage + Uy (V) Motor inertia +3 (kgs?) Notor power 2B (Ww Motor rated speed rn (minmt) Speed Network for speed regulation (258) VR - Regulator or (5m) Rn Voltage — Regulator (118) 380-460v - (yg), WAR = R (2a) 2 Speed feedback for (4m) 60. 76-9 ‘achogenerator voltages 60-76 V Gin) 1697 - (1p) 97-124 = (419) 124-159 = (11R) 159-200 ~ (1b) waR = B (6AV) - R (154V) - ¢ (st) 2 = 16 - ors08/08 “98 SO 11:10 FAX +41 41 445 2108 SERVICE or 491197 & RELIANCE ELECTRIC FF Table 3-2: Possibilities for controller adaptation (continued) Modification Calculation foraula / Selection table Reaistors in kOha, capacitors in uF = Adapting regulation gain | a) Ta" > 0-04, Ra < 0.05 + R(25AG) = 562. ic" afk <1 T= kb or Tm'< 0.04 |b) Tm'> 0.04, Ra > 0.05 : R(25AG) = 28» keh - or Ha <0.05 -05.KE c) Ta’ < 0.04, Ra < 0.05 + R(25AG) = Ba" ki .562 if kh >t set ki = 1 _ 0.04" ct 4) tm’ < 0.04, Ra > 0.05 : R(25AG) = Ta’ .ici.562 .0.6-Te = Adapting filter 0(254G) (25aG) = Ont ue (inket) inadd. if ki 80 mo (2580) = 0.1 uP = Network for armature Insert jumper (118) and (254) in (25%) voltage regul. 380 - 460 V Junper (1ab) must be removed = Adapting voltage feedback Insert juaper (118) in (117) + solder in R(124V) ‘to armature vol tage RC2AV) = 0.02 « Ug ~ 5-8 (komm) Lf 380 V > Ug > 460 V for UAX in position 5 ~ Adapting speed feedback | a) Insert jumper (11S) in (11K).-+(11R) to tacho voltage ) Insert junper (118) in (11M)... (11R) and reduce voltage at terminal 267 to value a) 60< Up < 2000 below 200 V through external voltage divider. ») Up > 200 e) Insert jumper (118) in (11) + solder in R(6AV) e) 60 > Up R(GAV) = 0.5 Up ~ 3 (icohm) Fine adjustment by NAT for NMAX in position 6.3 ~ Foreing Insert R(15AV), 6(51W) -17-08/08 “99 So 49'1197 11:10 FAX +41 41 445 2108 SERVICE RELIANCE ELECTRIC EF ‘Table 3-1: Standard equipment of the VCB-card (continued) Gareuit Standard function Solder point value Coordinate Speed Stebility cirouit for R33) = regulator < x G5ax) — 66ie2 ks = Im = 0,4 to 2 (s) Fat © (19ac) c (168) adjustable on NSTAB potueter Maximum spood with reduced field: Taax Base speed: Nnom Wechanical time constant: tm (s) R (36AY) = (edequates acceleration time to R (36AK) 221k dase apeed at rated current) _ cus) = Speed ratio Mnay/“Nnon? o (aac) 1.5 we Overload ratio Tanex/Tenoa! it Low pass filter constant Tyr = 3-2 m9 Regulator tine constant Tk = 0.35 8 R(SIAY) = RGaav) = Current reference rate 7 = 16 mo Current (from zero_up to Tamax) R (4Bav) - reference for amature ckt with DIN La = 0.6 to 1.5ms| R (4BAX) 2x1 integrator | Tn = La + Tanog/ly_ (ne) Le * amature Inductivity (nit) "measured at disconnected field THM + Tenax/Tenon Speed regulator torque reference (250) 1 Current ‘Amature current feedback: B (42ac) - regulator Burden resistor selected for lovest Ge) or - amature current of the controller Ga) ok on Ger) Bo Ges) ce Gar) D - -18- ozo08/08 “98 SO 11:11 FAX +41 41 445 2106 4g*1i97 SERVICE RELIANCE ELECTRIC £F Table 5-21 Posoibilities for controller adaptation (continued) Modification Caleulation formula / Selection table Resistors in kOhm, capacitors in uP = Adapting regulator gain and low pass filter constant Thr to 5.2 ms, if For NSTAB in position 6.7 with field weakening 0.4 > ka > 2 ks __ [a(33av)|R(55ax) [o(1 98g) |o(1 6a) Dsi=Or4] Bakr | GBT | O-tF [0.087HF ks = 2a o.4-2 = | 6sxt | "- |o.oe7ur it 2-8 | 352e | rewove| 0.01 |renove > 825k | remove! 0.0033! remove = Extending regulator time constant Tr a) without field weakening for ks 28: a(a)|_n(s6ax)| R(36a¥)] o(31AG) Ty = ka - 0.041 8 0635; Bie] = |= b) with field weakening o.33| aie | = | 0.22 for ke <8: o.d4| 221k | = | 0.47 ‘tg F + 0.33 8 ost} 2a | = | 0.68 for ke >8 0.35} 22tk | =| 4 Tg =F. ka . 0.061 9 0.66) 22k | = 165 0.80 | renove | 267k [1-5 Por ty > 1-18 provide ada. 290 | remove | Z0tk [1:5 external capacitor through 1100 | remove | 352k |1.5 vray;ping 4029-032, 1118 | remove | 392k |1.5 TR(s) 3 uP >iltal venove | 392K 11:5 ext. ct Bek - Current limit adjustable Inert R(51AV) and R(54AV) externally Connect AB26 and AB29 to spare terminals —— a) ») + Adapting current rate to ‘BEM. Ta(ms)| 7(ms)| R(48av)] R(4SAX) | R(4BAV)| R(ABAX) _—_ 03-06] 38 | m | 22k! | 100k [remove a) DM . Ta for notors o.6-1.5] 16 | 2 | 2axt | 100k | remove ithout field weakening 125-2.5| 25 | 47k | renove | 100k | remove >) Pix standard value f. sotor >215|>25 | 6akt | remove | 100k | renove ~ MREF and IAREF externally Ronows Juapes (252) and connect Wrap=pins (AB26) (AB29) to spare terminals - Burden resistor for 2 ¥ voltage drop at rated armature current assuming that Insert jumper (329) in position 2, C or D. If Ty 48 out of the current ranges, insert jumper 32Q in pos. X and solder R(42AC). Tanax " '+3 Zenon R(4280) 2 jis 0.85 Onn Type BOOS [BO SET | Sa] BHO TBH x 15 A] 30k vasa] ie A 3TT A740 K 5 18 | 55 170} 255 | 441 850 ¢ at 4 202 | 505 | 525 | 1050 D 25 50 240 360. 625, 1250. EL | B35rd 18332 Lassit [Boor [Fooori|ses0e7 [ro50oeT -19-08/08 “98 SO 11:11 FAX +41 41 445 2106 SERVICE 4g9'1197 & Table 3-1: Standard equipment of the Vo3-card (continued) RELIANCE ELECTRIC cE Circuit Standard function Solder point Value ‘than 500 us. = undervoltage at regulator supply. Drive must be restarted. Coordinate Current ility circuit for adjustable R (21AV) = vegulator TIM = 1-4 to 8 as om TSTKB | (21AX) —39K2 Ta = ba + Yanon/ty (ns) Tamax / Tenom Ammetcre inducttvity with disconnected field Ratod amature current Line voltage ALPHA Rear firing gngle Limitation R(45AY) = Suaming © iin to 158" (45AK)—47%5 for Ux <4% per phase Monitoring For line voltage 380 V (44L) (1) circuit and 2 413 x Firing angle 5) 460 ¥ follow-up (4) 500 ¥ R (39a¥) - Razay) For line frequency 50 He n Gan) n (32M) 60 He - Control For control voltage AC 220 V 1m (2eBH) 220 V0 eireuit (20B3) 110 ¥ ~ tesnk) 24 Fault Relay K2 reuains dropped out o 25R n indication | - after Line voltage dips longer Boze08/08 “98 SO 11:12 FAX +41 41 445 2106 49°1197 SERVICE RELIANCE ELECTRIC - Table 3-2: Possibilites for controller adaptation (continued) Modification Calculation formule / Selection table Resistors in kOha, capacitors in yF = Adapting regulator gain, if 1.420a . TH 28 ns For ISTAB adjustment refer to section 5. for ISTAB in Pos. 6.7 = Adapting firing angle linitation to different line impedances Ux at the connecting point see (2.1.4, Table 2-2) @ lim < 158" R(45AV) = 5.85 .@2im (Ohm) 158 = @ lin ~ Adapting to different Standard line voltages = Adapting to special Line voltages Uy min * 220 ~ Slider switch (44b) to position (2), (3) or (4) = Open switch and insert resitors RUS9AY) and RC42AY)- R(S9AV) = 7800 - 4.75 (Ohm) for 50 He Uy R(S9AV) = 8700 - 4.75 (kOhm) for 60 Hz Thy n R(42A¥) = 0.25 » Uy -10 (kone) = Adapting to 60 Hz Line frequency Insert jumper (32L) in (32K) = Adapting control input to different voltages Insert jumper (288M) in (2833) or (288K) = Drive atarts auto- matically after restoration of line voltage or rogulator supply uadervoltage Remove jumper (258) - 208/08 “98 SO 11:12 FAX +41 41 445 2106 4g"1197 INSTALLATION AND CONNECTION 4:1 Assen! Always observe the following requirenents wien installing the MAXITRON in control cabinets: = Comply with mandatory protection standarda to prevent contact with live components (covera) and ahock when a fault ocoura (safe GND), eg. as per TRO-204 or YDE 100; Therefore the installation should be done ty instructed and qualified electrical personnel only. = Provide studs according to drilling plan Figure 4-1. = Leave space vacant to allow for controller to be hinged down for servicing (see Figure 4-2) ~ Leave space for mounting the fan unit (on types 8012, see Figure 4-2a) - Fix the unit in the position represented in Figure 4-2 and leave a gap of at least 100 mm for the free ciroulation 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 tenperatur) under maximum permissible continuous current loading. Basing calculations of the cooling air flow on an increase in temperature of AT = 10" the supply of cooling air (e.g. from the cabinet environnent) must not exceed a temperature of 35°C. If these temperature limits cannot bo maintained, a reduction in pover of the MAXITRON mjot be taken into account. (1.5% per °C above 45°C) SERVICE WORE! Waxiaun permissible ambient oper ating temperature of the MAXITROW of 55°C mst 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. 028 RELIANCE ELECTRIC ££ 4.3 Connection Refer to the following interconnection diagram Figure 4-5 with legend Table 4-1. It shows the necessary connections as well as layout and order of the terminals. 4.3.1 General aignal 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. (carth bus in the cabinet). - Use steel shielded, twisted cables with at least 15 twists per meter. 4.3.2 Transient suppression of contactor Switching of contactor and relay coils (also valves, fan motors etc.) causes transient voltages of high frequency (bursts), which can disturb electronic circuits. Nore A proved measure, to avoid potential problems, is to provide suppression networks on all contactor and relay coils of the drive equipment: AG-coils with RO-units, DC-coils with Aiodes 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 Dlowers or power unit fans are switched, the RO-unit (215°02-00) mat be connected across the contact. ~ 22+08/08 “98 SO 11:18 FAX +41 41 445 2106 49°1197 e EST bo i ;t+ | + Pi | rt i i | savor 8 1 | itt | ET BM. | | i oe | i+ iB P| | t i \ = SERVICE 25 RELIANCE ELECTRIC cE Fig. 4-1a: Dimensions, weight and drilling plan for Types 8005/8006/6012 { ) 4 a4 7 i Yan for ype 8012 c Fig. 4-2a: Space requirement for controller in hinged down position - 3 -08/08 “98 SO 11:18 FAX +41 41 445 2106 SERVICE 49'1197 e RELIANCE ELECTRIC EE Fig. 4-1b: Dimensions, weight and drilling plan for Types 6129/51 43 Fig. 4-2b: Space requirement for controller in hinged down position = 24 =08/08 “98 SO 11:14 FAX +41 41 445 2108 SERVICE wo27 4g'1197 & RELIANCE ELECTRIC #0 Pig. 4-1¢: Dimensions, weight and drilling plan for Type 6260 ANSIHT. A 38) Fig. 4-2c: Space requirement for controller in hinged down position = 25 -08/08 “98 SO 11:14 FAX +41 41 445 2108 SERVICE ozs RELIANCE ELECTRIC FF 49°97 & Pig. 4-1d: Dimensions, weight and drilling plan for type 8315 Pig. 4-24: Space requirenent for controller in hinged down position ~ 26 =08/08 "98 SO 11:15 FAX +41 41 445 2108 SERVICE Boze 4g'1197 & RELIANCE ELECTRIC E MOTOR READY START FIELD OW MAIN CONTACTOR > fey a wo F | er or a aw # = | OE-} 2s Fig. 4-3: Control cireult standard wiring diagran, basic version "S" = Relay supression against overvoltage peak by RC unite (see chapter 4.3.2) Fune tion: a) De-motor circuit protection by = F22 Thermistor motor protection = @ Motor blower circuit breaker = Pi Thermal overload relay ») Convertor protection by = "K2 Error output contact (undervoltage, overcurrent) = F3 Cooling fan protection through therwal switch on heatsink (on units 120 A) ©) START/STOP relay (k25) actuated by pushbuttons 4) Motor shunt field oN e) Main contactor (k38) ~ For extended live tine of the contacts, the contactor K38 is hold in ty Kt, until the armature current has dropped’ to sero Amps.08/08 “99 So 491197 & 11:15 FAX +41 41 445 2108 SERVICE RELIANCE ELECTRIC cE Fig. 4-4: Regulator connections standard wiring diagram for Speed control, basic version VoRTerminals © Fumetion Romark 96, 57 De +15 V supply for reference supply 91, 57 = Do -15 V supply only (max. 10 mA) 187, 60 Reference input 15.V or 10 267, 57 Speed feedback Voltage adaptation with/without n min adjustn. 904, 57 Spoed indication (f connected on VCB) 8,11 Regulator standby Control voltage adaptation 12, 14 Output contact CONTACTOR OFF (K1) 15, 16 Outpat contact BRROR (Ke) 3PB, O08, TRE, 152 901 905; Available inpute/outputs - 28 - 03008/08 "98 SO 11:16 FAX +41 41 445 2106 SERVICE os1 49'1197 e RELIANCE ELECTRIC - “ oa & ahhh 7 e—— ANd go xa8\-— xaa\-—} > f TT, sce | | rt orl | ~, _!29 hor_!187/188 p39 261 _ [282 a hate i a7 oe 0 DRA/B ~ = ~ m7 ae | A ww ¥ | Ve ¥ xan | ES - rT. 7~ ~ - 7 - ~ ‘7 as fa? (35 volt raf ew] “A. on 1500 A unkt uae exteraad fteld why, bed, Some peabrae ict eestenet oe OO ne A on 1500 A unit externa? blower supply on terminals 187, 188, 189 (3x380 V) Fig. 4-5: Power unit standard wiring diagran Connector Function Remark 181, 182, 185 = Convertor AG-1ine supply input For supply voltages see: PE = Protecting earth connection Balad 281, 262 = Field rectifier supply input Bate? 45, 47 = Convertor output 35, 37 = Field rectifier output 0-110/220/240 = Control transformer supply 2.641 187, 188, 189 = Cooling fan supply (1500 A) BAB 29, tot ‘Theraal contact output on type 120 A and above 51, 52 = Output 24 VAC for control input 2.6.108/08 "98 SO 11:16 FAX +41 41 445 2106 SERVICE ose 49°1197 RELIANCE ELECTRIC Ec = 30 -08/08 “99 So 11:16 FAX +41 41 445 2108 SERVICE 4g'1197 5. START-UP PROCEDURE 521 General Procedure of chaptera 3 and 4 must be completed and checked before the drive ig ready for start-up. We also recoamend a study of chapter 1 and 2 to become more familiar with the operation of the drive. If the additional functions card ZFA has been added to the controller the start-up instructione of this card (No. 49°1077) must be followed also. Ag 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 equipaent should only be in- atalled, adjusted and serviced by qualified personnel familiar with ‘the drive funtions and operation and the hazards involved. Wrong handling may cause danage to the machine or injury to personnel. WARNING Before it is safe to touch any internal parts, all phases of the AC-power line mst be disconnected from the power unit. ‘Test instrunonts = see chapter 6.2.1 NOTE: For measuring voltage and current in the araature cirouit different meters are required. _ a) Mean values (Ia ~M, Ua ~ m4reRt) eg: digital acter FLUKE 80228 >) RMS values (Ia rma) themal loading of cables: real RUS-neter 31 RELIANCE ELECTRIC cE 5:2 General pre-operation checks With power off Visuel check of electronic circuits and of motor for mechanical defects. Check of external connections according to interconnection diagram (cross sections, earth fault). Check of the externally mounted seniconductor protection fuses according to Table 6.5/6.6. Check of the motor protection relay in the araature circuit for setting to 1.05 x rated motor current or 0.85 x Iy if the relay is connected to the line input. Check of the basic adjustments of all potueters on the VOB card. MMIN, HKAK, UMAX, TA MAX POS/NEG, IR COMP: on the left eni stop NSTAB, OFFSET, ACC RATE, Dao RATE: in the middle position Check voltage regulation circuit 5.2.1 On apeed regulators Preparation of tho tacho polarity check (not used on voltage regulation). For thie the tacho feedback must be Aisconnectod and voltage regulation mode ected ty changing VOB-jumpers (11§) to (113) and NR to VR. Turn reference potentioneter to position sero (cow). Connect volteter to terninals 267 and 57. ‘Turn TAMA POS/NEG fully ccws08/08 "98 SO. 11:17 FAX +41 41 445 2106 49'119T & SERVICE 034 RELIANCE ELECTRIC £F 3 General checks with mains voltage applied NOTE: For each intervention, the unit must be separated fron mains! 5.5.1 Check of senae of rotation = De-notor blower ~ Porer unit fan if mounted 5.3.2 Checking of controller supply ~ Switch on regulator supply and check Af the LED indicator SOK is on. During about 500 ms error indicator LBD'e 3PE, PSB and OCE will be lit Ganp test). 5.3+3 Check field current according to notor name plate as well as polarity WOTE: In the cold state, the field current nay be approx. 20 higher than the nominal field current. 5.34 Checking phase sequence - Apply low positive reference veltage ~ Give RUN-order and verity the presence of line voltage with correot phase sequence (8D indicators PSE and 3PE renain dark). 5.3.5 On speed regulators checking of tachoneter polarity Reliance circuit diagrams ere drayn for Clockwise operation of the motors (rotates clockwise when looking from the drive side). = Apply low positive reference ~ Terminel 267 should be negative with respect to 57 = Switeh off = Delete all measures of chapter 5.2.1 and set the VOB in the previous condition. = Ingert jumpers for speed regulation R(25L) to NR(25M) and 119 to the appropriate tacho voltage. ~ Turn reference potentiometer fully cew (low reference). 5.4. Current regulator adjustment = Connect Voltmeter to wrap-pin AB32 (current feedback signal) and terminal 57 (OV) or tester in position 22 ~ Disconnect field supply = Verity that the motor does not turn due to the remanence (block the motor if necessary = Switch on and enable the regulator 5-4-1 Current limit adjustment 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 potweter IA MAK POS 150% resp. 100% arnature current (ZARB = 3 V reap. 2V) If with potueter TA MAX in the right end position ca. 3 V cannot be reached check burden resistor according to Table 3-2. We reconsend for checking the armature current either measuring through shunt in the armature circuit or by current transformer in the line Input Cg = 1618 « Ty) NOTS: With stalled notor max. armature current is allowed for a short tine only, otherwise the collector may be damaged. On d-quedrant drives in addition: = Apply max. negative reference = Adjust with potmeter TAIAK NET 1508 resp. 100% armature current - 3208/08 "98 SO. 11:17 FAX +41 41 445 2106 SERVICE oss 49°97 e RELIANCE ELECTRIC £ 5.4.2 Standard current regulator 5.4.3 Check of current reference rate stab. adjustment for motors without 8 field winding ~ With the LED indicator CST on at maz. current, turn potentioneter ISTAB counter clockwise until the CST LED starts to flicker, than turn clockwise until the LED lights pernanently- Should the LED never extinguish, the current regulator gain has to be reduced (R(21AV) according to Table 5-2). Should the LED never light, the gain has to be increased by renoving R(24AK). During operation the LED CST is of no importance. = Switon OFF = Re-connect field supply. Firet the values of the appropriate variable components on the VCB-card should be checked according to ‘Table 3-2. On drives with field weakening R(48AV) must be 100 kOhm and R(4BAX) removed. = Connect scope to pin AE32 (TAFB) Range: 20 ms/div, 1 V/div By-pass LVTU by changing jumper plug (18P) to (18H) NOTE! The motor load mst be Gigconnected Apply 100% speed reference Switch on and give RUN order Pulses of current feodback signal TAFE ghowld reach Tamax and show an image like Figure 5-1. REMARK: Tf Tanax ig not reached, overshooting up to 3 V (Ianax) is pemitted. For optimun dynanic resistor R(48AV) must be determined 90 that just no overshooting ie obtained. Switch OFF. Re-insert jumper plug (18N) to (18?) Uae 32 Pig. 5-1: Diagraa of current rate ~~08/08 "98 SO 11:18 FAX +41 41 445 2108 49'1197 e SERVICE 036 RELIANCE ELECTRIC - 5.4.4 Current regulator stab. adjustaent for high dynamic performance or motors with series field winding on motors operating in 4-quadrants, @ series field winding is normally not provided. = Field supply on = Connect scope to Tester in Pos. 6 or ‘DRA/B-pin BV7S (signal IARBGOUT) Range: 20 as/div, 1 V/div = Switch on and apply 100% apsed reference. Turn pot. ACC-RATE, DEC-RATE fully clockwise. = Give RUN order and adjust with potentionetor ISTAB the current ripple of signal IAREGOUT to 1.52 V during acceleration of the motor with maxinun current. Pig. 5-2: Current ripple during acceleration 5.5 Voltage regulator adjustment mot used on speed regulation) 5.5.1 Check armature voltage regulation eirouit = Jumper to 118 and VR(25L) 5.5.2 Offset, n min and n max adjustment Connect voltaeter to VOB-wrap pin ACI3 (Signal -UArB) ‘Switch ON and give RUN command Apply positive epeed reference voltage Set reference to zero and adjust motor gpeed to zero by turning potentionster N OFFSET Adjust minimum speed by potentiometer aH Set reference to +100% and adjust maximum speed with potentioneter UMAX 5.5-3 Check speed stability = If the drive oscillates, the voltage regulator stability components must be determined according to Table 3-2. 54-4 Adjustment of the IR-drop compensation = This control should only be used with voltage regulator aystens, never with speed regulators. WOUE? fi-drop compensation cannot be used on 4-quadrant regulators since this signal is not inverted. = Initially set the potentioneter IRCOMP fully cow (IR-Comp. = Of). = Start drive and run unloaded at desired speed. = Load the drive to full load current. = Adjuot the IRCOMP potentioneter clockwise until the desired speed is achieved ty compensation. Do not adjust for a speed higher than the unloaded speed. Setting the [R-comp. too high may cause instability. Adjust potentionetert IRCOMP cow if this -u-08/08 “99 So 11:18 PAX +41 41 445 2108 49'1197 & 5.6 Speed regulator adjustment 2 EE ised on voltage Tegilation) 5.6.1 Check speed regulation circuit = Set jumpers on WR(25") and 115 for the appropriate tacho voltage. 5.6.2 Offset, n min and n max adjustment Connect voltmeter to VOB wrap pin AEIO or ZPA BO10, if used (actual speed signal NFB) Switch ON and give RUN command = Apply positive reference voltage Set reference to zero and adjust motor speed to zero by turning potentioneter NT OFFSET Adjust minimum speed by potentiometer min Set reference to +100 % and adjust naxinum apeed 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 AE10 should read the saze but inverse voltage as with positive reference. 5-6-3 Check speed stability If the drive oscillates, the voltage regulator stability conponents must be determined according to Table 3-2. SERVICE RELIANCE ELECTRIC cE 5.6+4 Speed regulator stability On deives with high dynamic performance we recommend, checking the speed stability by the use of an oscilloscope. = Connect scope to VOB pin ABIO (speed feodback NFB) or 2FA BOIO, if used ~ Switch on and give RUN order = When applying max. speed reference, the tacho voltage should show an inage like the one illustrated in Figure 5-5 = Adjuat potentionster NSTAB until the curve Figure 5-5 is obtained. If the regulator overshoots or oscillates peraanontly, the gain must be decreased (turn NSTAB CCW). Tg the adjustment cannot be reached with the NSTAB potentionster, the stab{lity components must be determined again according to Table 3-2. Ur DQ Fig. 5-3: Diagram of apeed stability Speed regulator optimally adjusted —Speed regulator gain too high or ‘too low 5.7 adjustment of the reference cL intepator GN) = The acceleration and deceleration tines are adjustable with potentioneters ACC RATE and DEC RATE in the range 1-32 s. If the acceleration tine or deceleration time ie above 32 8, an addition capacitor 6(BL9) has to be soldered according to Table 3-2. = Switch OPF. -35-08/08 "98 SO 11:18 FAX +41 41 445 2108 49"1197 6. TROUBLE SHOOTING 6.1 Safety precautions WARNING: Trouble shooting should be done by instructed and qualified electrical peraonnel| only. Before touching any interasl parts, disconnect all input powers. Verify the absence of hazardous voltages vy the use of a voltnete: WOTE: Static sensitive PC boarda. Handle without touching components, connectors or leads. When soldering variablo| components on the YOB-card, Gisconnect the sensitive PC boards first. 6.2 Trouble shooting 6.2.1 Test instruments ‘The following meters or their equivalent are recommended: a) An analog multimeter having a sensitivity of 100 k0hn/Volt, or 2 digital multimeter with a 10 negohn input impedance on all ranges (FLUKE) ) The optional diagnostic tester Pu 836'57-00 in lieu of the above device. For trouble shooting inside the controller a busser and an oscilloscope (KO) will be required. HORE: The KO woed quot nob bo grounded. It should (if possible) be connected to moins by means of aa GSointion transforaes. 12tage aeaasronsnts on the pover Unie must. be differential. For checking the controller care uot be taken, that the housing Ot the KO’ te coanested to: sere ontial of the controller Peemainal 157)» SERVICE 038 RELIANCE ELECTRIC EF 6.2.2 Fault causes As the MAXITRON is delivered fully tested, problems during start-up are caused in most cases by faults outside the controller such as = Engineering errors = Wrong connsetions Operating faults = Weong roguletor adaptations. 6.2.3 Trouble shooting steps + Determine operation condition where the fault ocours * Determine fault symptom With thie 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 must be continued systematically in or against the direction of signal flow in the power unit, control - or regulator cireuits. 6.2.4 Power stack and reference eirouit function check ~ Remove armature current connections from the unit (45 and 47) and connect instead lange of the same maximum voltage or a resistor of approx. 2 kOhm/100 W as a Joad. Connect oscilloscope to output terminals of the unit. = Jumper (5140) = Insert jumper in location TEST (DRA/B) = Connect to reference input terminal 167 a low positive reference signal, O35 = Switch unit on = Check polarity reference; voltage 47-45 should be positive and LED IAP lit. = Check with scope ave form of output voltage, 6 pulses per period. By varying the reference voltage, the Light intensity will be changed also. = Switoh off = Reconnect armature circuit instead of Lampe. = Renove jumper across C(31AG) and Jumper plug TEST on DRA/B. - 36 -08/08 “98 SO 11:19 FAX +41 41 445 2108 SERVICE 491197 e RELIANCE ELECTRIC F Table 6-1: Faults and their possible causes + Operating condition | Possible Yiecessary test Hlinination of * symptoms causes fault + Regulator Ov Snort cirouit | Check fine wire fuses | Eliminate short + No RUN order ati5v F2/F3 on IKA/B-IGA/B card | and replace suppiy output | and connections fuses F2/23 * LED "SOK" extinguished Beternal over- | Chock external connections Reduce load load at the to terminals 96/97 15° V supply = Regulator and Power circuit | Check input voltego at — | Connect Power unit on insufficient terminals 181/182/183 according to = RU order supply voltage | (The regulator is section 4 Blocked at undervol tage) * LED "3PE" on Wo supply Check phase fuses Replace fuses voltage to F4,75,¥6 on interface regulator unit Controller not | Check position of slider | Push slider adapted to switoh on VOB (421) ewiteh in cor supply voltage | according to section 3 | rect position Faulty Check if thyristors ere | Replace power stack short circuit. thyristors * LED "PSB" on Phase sequence | Check connections at Interchange any is incorrect | terminals 181/182/183 two AC-Line power connection * me aotor Field supply | Check voltage at terminal does not turn nissing 281/282 ani field supply fuses F1/P2. Eliminate short,| If fuses are failing replace fuses repeadedly, a short ciroult may be the cause, or the field current may be too high. Interruption | Measure voltage st Close armature in arnature terminals 45/47- cireult circuit Check interconnections. Interruption | Check wiring of reference | Eetablish in reference | potentiometer correct cdrouit wiring ~ aT08/08 “98 SO 11:19 FAX +41 41 445 2108 SERVICE ag'ligt e RELIANCE ELECTRIC - Table 6-1: Faults and their possible causes (continued) « Operating condition | Possible Necessary test Elimination * sympton causes, of fault + Regulator and Controller With run function on vol- | Change power unit on locked ‘tage should be applied control + RUN order to VOB-terminals 8/11 oirouit * the motor With eater in pos, 15, does not ture Faulty VEU Check LVTU output (B9) Replace DRA/B and_jumpers With Tester in pos. 11 Faulty speed | Check speed regulator out- | Replace DRA/3 regulator put (AC29). Check jumpers and stability circuit according to 3. With Tester in pos. 6 Faulty current | Check current regulator Replace DRA/B regulator output (DRA/B-BY75) - Check jumpers and stability edreuit according to 3. Firing pulse | Chook firing pulses Replace DRA/B generator (DRA/B~AP79, AG62, AG6O, defective AG56, AFO3, A058) Pulse stage Replace DRA/B defective * The motor turns Ref.wiring hes | Cheok reference voltage Replace uncontrollably loose contact | at VOB ACIO potneter or ref.potmeter slider has poor contact Ref. wiring | Chock setting of ref-pot.- | Close is interrupted | meter and voltage at ACIO | reference cirouit Ho tacho gene- | Check tacho generator line rator voltage | for interruption and check | Replace tacho at terninala | tacho generator 157 and 267 acho gane- ~~~ Polarity of tomainal 267 [Change ratoc voltage | hao to be nogative with | connections has reversed | respect to torainat 157. | 267 - 157 polarity (at clockwise rotation and __| pos. reference) Amature Check voltage st C13 and | Insert jumpor voltage feed | jumpers according to 3. back missing = 38 =08/08 "98 SO 11:20 FAX +41 41 445 2108 SERVICE 49'1197 RELIANCE ELECTRIC cE Table 6-1: Faults and their possible causes (continued) + Operating condition | Possible Necessary test Blimination * Symptom causes of fault * Motor turns Speed regulator | Check fecdback resistors | Select correct] uncontrollable without tacho | and links feedback resi-| feedback signal | according to 3. tor on VOB No field supply | Cheok field supply voltage | Connect field supply * overcurrent current regu- | Check current regulator Adjust current| nonitor (ET) lator loop is | overshooting. Check stability acc. trips, unstable atability circuit elements | to 5.4.2. according to 3+ Roast IST 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 sot limitation with potmeter arive oscilla! current limit | potmeter IAMAX POS on VOB. | TAMAK Armature current must not exceed 1-5 times rated current or max. convertor output current. Speed regu- Check stab. ckt. elements | Re-adjust lator ia not | according to 3. stability stabilized 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 too high feodback circuits field voltage (term. 45-47) | according to 3. The motor Compare field current with | Adjust develops no indications on motor nane | field current torque plate. NOTE: Under cold running conditions the field current may exceed the rated current by approx. 20 %. = 39 -08/08 "98 SO 11:20 FAX +41 41 445 2108 SERVICE ose 49'1197 e RELIANCE ELECTRIC cE 6.3 Spare parts for !-Quadrant units Table 6-2: Urgent recommended spare parts packages Convertor Spare ________ Bach package contains: vait parts ‘hysisters | Cooling Fan, | P.-C. Fuses type Part Ho. | package Pield rectifier | Boards | 10 each 304 4 Modut | 1 Rectitier | 1 DRA |- 2.5 a? 380 ¥_937'22-03_| 4a6"51-00_| 135'02-00 124'07-00 | 803'64-00] ¥4,75,26 500V 22-15 =10 02-04 1 KA 550'06-20 _ | 803"60-00 | - 0.2 at ¥ 60.8 550'15-09 3o0V____ 22-08 <0 04-00 500 VTE sti 04-01 - tan ¥2,55 —— 550'17-00 120 1 Rectifier > Piela BOY 22005 x02 | 05-00 124*07-00 rect.fuse 500 VBE iz O01 | 1 Fan 993°54-08 921 '22-01 — Fie 290 A 2 thyriet. rect. fuse OV 24-02 -03_| s22'20-19 || 1 Rectifier | 1 DRA 12 APP 500 V24-t2 “5 06-17 2407-00 | a05"64-00| 553°00-09 _ 1 Fan 1 TGA g2t'go-00 | 803'62-00|- further 450.4 fuses 380/ sone as 500 V0 24-13 “4 o7r-14 above 7 oF, 800 A 4 pRa F4 75,76 380 ¥___ 26-01 05 94-00 803'64-00| 550°56-04 $00 V 36-11 ‘08-02 Vrca | - tte1a 803'58-00| rect. fuse 553'00-08 fur-fuses _L above = 12 ARP 1500 a/50Rs P4,75,76 S00 v 2-11 | 120"93-06 | 122"95-02 | 1 Fan 1 DRA 553'00~09 660. ¥——28-2 =e =O5 g2itg1-00 | 805"64-00| - no fiela- | _| 1 THA rectifier 803'71-00 | - further 1500 A/60H= 1 Fan fuses 500v_ 26-41 | -02 | 122"95-02 191-10 sane as 60-V 28-54 +05 =o Further recommended apare parts for Units Type 30 A to 1500 Ar Variable Components Card VCE 805'67-00 Regulator supply transformer Tt 251 99-00 Suppression print SBA 803'56-00 (type 1500 A only) - 40 -08/08 “99 So 11:21 PAX +41 41 445 2108 49'1197 & 6.5.1 Spare parts, Table 6-2: Urgent SERVICE for 4-Quadrant units oss RELIANCE ELECTRIC ££ recomended spare parts packages Convertor Spare Each package contains: Unit parts Thyristors | Cooling Fan, | P.C. Fuses ‘Type Part No. | package Field rectifier| Boards | 10 each BOA 4 Modul 1 Rectifier | 1 DRB |- 2.5 AT 380 ¥_837'23-03 | 4631-00 _| 135'02-00 124"07-00 | 805°65-00} F4, 75,76 500-V 235-13 =10 ‘02-01 1 1KB 550°06-20 805'61-00 | - 0.2 aT FI 604 550"15-09 380 ¥ 25-04 01 04-00 500-0 Bag ait ‘04-01 - ar 2,53 580"17-00 120 A 1 Rectifier ~ field 80 V 23205, 02 03-00 124"07-00 rect. fuse 500-V 25-15 ra ‘O5-OF 1 Fan. 553'54~08 921 "22-01 + field 290 & 2 Thyrist. rectifier 380 ¥ 25-02 05 | 122'29-19 | 1 Rectifier | 1 DRE fuses 12a 500 V 2-12 a3 06-11 124'07-00 | 803'65-00] 553'00=09 1 Fan 11GB 921'90-c0 | 805"63-00 430 & ~ 6 380/ same as 500 v 25-13 “4 or-14 above ar 800 A 1_DRB. 4,85, 76 380 ¥ 27-01 05, 04-00 803'65-00| 550°56-04 500 V Brit = O4-O2 110B | - fiela 803'59-00| rect. fuse 553°00~08 ~ FI-PS above - 12 AFF 1500 4/50He 4,79 ,76 500 V 29011 06 _| 122"93-02 | 1 Fan 1 _DRB 550°00-09 660-V 29-21 =16 +03 921 "91-00 | 805"65-00 | - no field~ — 1 NB rectifier 500 K76ORE T Fan 803'72-00 | - further 500 ¥ 29041 122'95-02 921'91-10 fuses 660-¥ 29-51 705 sane as above Further recommended spare parte for Units Type Variable Components Card VCB Regulator supply transformer ™ Suppression print SBA 803"67-00 251'99-00 30 A to 1500 As 803'56-00 (type 1500 A only) ae08/08 "98 SO 11:21 FAX +41 41 445 2106 SERVICE 49'1197 e RELIANCE ELECTRIC E 6.4 Replacement of compor Use original spare parts only- Selection according to Table 6-2. ‘The location of the parts ia shown on the layout label inside the U-fram 6.4.1 Replacement of a thyristor or thyristor module on power unit Type 30 — 800 A = Loosen and swing out regulator card I . = Remove bua bars above the thyristors = Renove gate leads of the thyristor 2 concerned = Uaserew fastening screws and ronove cr thyristor - Before mounting the new thyristor, coat the side which is in contact with the heat sink with a thin layer of heat conducting paste For units 290 A - 800 Az = Insert thyristor into box-clamp and put the package on the centering bolt on the heatsink = Fasten the four hexagon bolts by hand until all slack is taken out and take care that the clamp housing stays parallel to the heatsink . = Tighten each bolt by half a revolution at one tine with hexagonal socket 6 spanner 8 am (10 ma), diagonally 7 = Repeat the procedure until the clasp 8 is held down firnly to the heatsink on each side i ~ Re-connect gate leade 8 = Screw on bus bars Pos. 1 Screws 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 7 Centering bolt 8 Heatsink08/08 "98 SO 11:21 FAX +41 41 445 2106 SERVICE 49'1197 & RELIANCE ELECTRIC FE 6.4.2 Replacement 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 agsenbly is visible now on side wall. = Renove bus bars on front heat sink = Unserew the upper cooling air deflector. Ungerew the hexagon screws for the bus bar nounting = Unserew the lower cooling air deflector ~ Loosen the two screws (13 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 toth sides of the now thyristor with an extrenely thin film of thermoconductive paste /s. = Mount the thyristor on the centering pin in the rear heatsink Observe correct polarity of cathode and anode according to layout. = Insert cleap in front heatsink and attach to thyristor with centering pin the two clamp screws (13 mm) alternately by one quater turn until ‘the control ring under the contre clamp nut can be turned through 360° by hand. Keep clearance to a minimum. = Proceed installation in the reverse order of removal. = 43 -08/08 “98 SO 11:22 FAX +41 41 445 2106 SERVICE Boss 49°1197 @ RELIANCE ELECTRIC £ 6.5 Accessor’ ‘In Tables 6-4 and 6-5 sone of the most important accessories aro listed. ‘Table 6-4: Power independent accessories Part Description Diagnostic unit with cable Supplementary Board ZPA (with 5 Spacers) Component kit for VCB card Reference Potentioneter 30W/2k5 | 481 ‘00-01 (with knob and dial) Power dependent accessories (to be externally mounted) unit | Fuse Fuse Trip | line input | Armature | Fuse 3-Phase Iron Core| Current | Indicator | Fuse Fuse Holder Reactor 4-Quadr. Tn soa] 32.4 | 553'29-00 | 553'28-02 5123-00 | 25.4 252'40~01 4oa | 555'29-00 553'28-04 | 511*25-00 60a] 63.4 | 555'29-00 | 555'28-06 51112500 | 40 A 02 80.4 | 553'29-00 553'28-07 | 511"25-00 | 62 A 03 100 a | 953'29-00 | 553'28-08 511'23=00 | 85 A 04 120a| 125 4 | 553'29-00 | 553'28-09 511 23-00 |115 A 05) 160A | 553'26-29 553°30-04 | 511'24-00 2904} 315 a | $53'26-29 | 595'51-13 511 "24-00 |160 a 06 210 4 07 350 4 | 555°26-29 553°31-14 | 511"24-00 |290 & 08 4g0.a| 450.4 | 953'26-29 | 555'52-16 511'24~00 |392 A 09 550 a | 555°26-29 5553218 | 511°24-00 630 4 | 553'26-29 | 553°35-19 511'24~00 |550 A 10 goo a| 800 a | 555'26-29 | 553'33-21 5125-00 | 660 A “1 1000 a | 553'26-29 953'33-22 | 511°25-00 Le —-L. = 4408/08 “99 So 4g°1197 41:22 PAX +41 41 445 2108 SERVICE Table 6-6: Power dependent accessories (to be externally mounted) Type: 8315 - 1500 A < 500 ¥ oar RELIANCE ELECTRIC cE unit Fuse Fuse Trip | Line input | Armature | Puse 3-Phase Iron Current | Indicator | Fuse Fuse Holder Core Reactor 4-Quadr. Ta 1000 A. 1000 a | 593'26-29 511126-01 | 850 A 252°40-12 1250 4 | 553°26-29 595°33-23] 511°26-01 1200 & 1250 a | 993'26-29 | 553°33-23 514'26-01 | 1100 A 252*40-13 2x800 A | 553'26-29 953°33-21 | 511'26-01 parallel 1500 A 2x800 A | 553'26-29 | 553'33-21 511*26-01 | 1300 A 252"40-14 parallel. 2x900 A} 553'26-29 955'33-24| 511°26-01 parallel. ‘Type: 8315 - 1500 A < 660 V 1000 A 2x630. A | 553'26-29 | 553'34-34 511 "26-03 parallel 850 A 252"44-12 2x700 4 | 5552629 553°34-35 | 511'26-03 parallel] 1200 & 2x700 A | 553'26-29 | 553'34-35 511°26-03 | 1100 A 252"44~15 parallel: 2x800 A | 555'26-29 553'34-36 | 511°26-03 parallel 1500 A 2x800 A | 555'26-29 | 553°34-36 511 "26-05 )1300 A 252°44=14 parallel] 2x900 A | 553'26-29 593°34-37 | 511°26-03 parallel = 4508/08 "98 SO 11:28 FAX +41 41 445 2108 SERVICE EUROPE senice Contacts : ee @® @Oeo @ eurasonaionemet — Fediwelsugetin al. apy automation AG Seren igen Foca scons oy Sant oe Sees azz ne Felson Sen OS ae 2022 Feo graze) Ea ETE fate WER 2 & oe CR ‘Rockwell Automation: Rockwell Automation: ‘Rockwell Automation: -Industriering Ost 81 ‘Disselbergerstrasse 15 ‘Herstedostervej 27-29 Buea! Berea? Se ase ethan BES Kneer Ls aogo Taco’ Mbinuscozve ‘elon 4e4gae 6000 Taro BEEBE, cate" thes Fa Ee : _ ce a - Rockwell Automation SA Rockwell Automation. Rockwell Automation S.r. | CfDoctor Trueta 113-119 | 36, Avenue de Europe Viale'De Gasper, 126 | E-08005 Barcelona, F-78140 Velizy-Villacoublay £20017 Mazo di Rho (Milano) Telefon 34-93-285 90 00 Telefon 33-1-3067 73 60 Telefon 39-2-9397 21 Fax. 34-03-295 90 01 Fax. 33-1-30 67 73 70 Fax 39-2-93 97 201 oe aD ‘Rockwell Autornation Rockwell Automation Rockwell Automation B.V. Hortonwood 30 Pitfield, Kiln Farm 30 ‘Amsterdamseweg 15. GB-Telford/Shropshire TF1 4ET. ‘GB-Milion Keynes MK11 30R. 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