dc thyristors drive mp series instruction manual

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DC THYRISTORS DRIVE MP SERIES

IAG ELETTRONICA EVOLUTION S.R.L. NOVARA – ITALY

DC THYRISTORS DRIVE

MP SERIES

INSTRUCTION MANUAL

IS042A

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INDEX

1. INTRODUCTION ................................................................................................................................. 4

2. CONVERTOR TYPES ......................................................................................................................... 5 2.1. TRIPHASE BIDIRECTIONAL CONVERTORS. ................................................................................................ 5 2.2. TRIPHASE UNIDIRECTIONAL CONVERTORS. .............................................................................................. 6

3. ELECTRICAL SPECIFICATIONS ..................................................................................................... 7 3.1. REGULATION SUPPLY VOLTAGE............................................................................................................... 7 3.2. POWER SUPPLY VOLTAGE. ...................................................................................................................... 7 3.3. FREQUENCY. ......................................................................................................................................... 7 3.4. DIRECTION OF PHASE CYCLE. .................................................................................................................. 7 3.5. GROUNDING. ......................................................................................................................................... 7 3.6. OVERLOADING....................................................................................................................................... 8

4. ENVIRONMENTAL CONDITIONS ................................................................................................... 9 4.1. OPERATING TEMPERATURE RANGE. ......................................................................................................... 9 4.2. RELATIVE HUMIDITY. ............................................................................................................................. 9 4.3. PROTECTION AGAINST OVER HEATING. ................................................................................................... 9 4.4. STORAGE TEMPERATURE. ....................................................................................................................... 9

5. MECHANICAL CHARACTERISTICS ............................................................................................. 10

6. OPERATIVE THEORY ..................................................................................................................... 11 6.1. POWER SECTION: UNIDIRECTIONAL CONVERTOR................................................................................... 11 6.2. POWER SECTION. BIDIRECTIONAL DRIVE............................................................................................... 13 6.3. FIRING ANGLE...................................................................................................................................... 13

7. CONNECTIONS ................................................................................................................................. 15 7.1. POWER CONNECTIONS. ........................................................................................................................ 16 7.2. REGULATION CONNECTIONS. ................................................................................................................ 16 7.3. LAYOUT OF JUMPERS. ........................................................................................................................... 18

8. ELECTRICAL CHARACTERISTICS............................................................................................... 20 8.1. RL1 "ALARM" RELAY ". ..................................................................................................................... 20 8.2. RL2 "DRIVE READY" RELAY ". ......................................................................................................... 20 8.3. LOGICAL INPUTS. ................................................................................................................................. 20 8.4. ANALOG INPUTS. ................................................................................................................................. 21 8.5. ANALOG OUTPUTS. .............................................................................................................................. 21

9. SIGNALLING DISPLAY.................................................................................................................... 23 9.1. RESETTING THE ALARMS. ..................................................................................................................... 28

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10. DESCRIPTION OF THE CARDS .................................................................................................... 29 10.1. SF210B MOTHER BOARD. .................................................................................................................. 29 10.2. SF209B CARD.................................................................................................................................... 32 10.3. SF208A CARD (FILTERS R-C).......................................................................................................... 32 10.4. SF192A CARD (PERSONALISATION). ............................................................................................ 33

11. START UP ......................................................................................................................................... 34 11.1. NOISE IMMUNITY. .............................................................................................................................. 34 11.2. ENABLING AND BLOCKING THE DRIVE. ................................................................................................ 34 11.3. OVER CURRENT PROTECTION (GPS). .................................................................................................. 35 11.4. SETTING THE CURRENT LOOP (GCC). ................................................................................................. 35 11.5. SETTING THE SPEED LOOP (GSC)....................................................................................................... 36 11.6. SETTING UP LOAD OVERHEAT (SIMULATED HEAT MOTOR). ............................................................. 38

12. TROUBLESHOOTING .................................................................................................................... 39

13. MAINTENANCE AND REPAIRS .................................................................................................... 41 13.1. REMOVAL OF THE SF210B CARD......................................................................................................... 41 13.2. REMOVAL OF SF209B CARD. .............................................................................................................. 41 13.3. REMOVAL OF SF208A CARD. .............................................................................................................. 42 13.4. REMOVAL OF SCR MODULES (NOT VALID FOR 650FV). ........................................................................ 42 13.5. REPLACEMENT OF SCR MODULES (NOT VALID FOR 650FV). ................................................................. 42 13.6. REPLACEMENT OF POWER FUSE. .......................................................................................................... 42

1. SPARE PARTS .................................................................................................................................... 43

1. OPTIONALS. ...................................................................................................................................... 45 1.1. OPTIONAL CARD SF227A. .................................................................................................................... 45

1.1.1. Presentation................................................................................................................................ 45 1.1.2. Electrical specifications. ............................................................................................................. 45 1.1.3. Layout of jumpers. ...................................................................................................................... 46 1.1.4. Example of external current limit use: ........................................................................................ 47 1.1.5. Example of zero speed detector use: ........................................................................................... 48

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1. INTRODUCTION The TIRIBLOC-MP series is made up of drives for dc motors up to 650 Adc and using MICROPROCESSORS technique. PARTICULAR PERFORMANCE CHARACTERISTICS PERMITTED BY USE OF THE MICROPROCESSOR The introduction of a microprocessor has allowed a more compact version to be produced, the number of electronic components has been reduced and greater reliability thus ensured. Maintenance and the location of faults has also been made easier as the microprocessor displays selfdiagnoses on an LCD display. It also allows "ON LINE" control over the most important points on the regulation loop. Software effects an arcocoseno between the pulse generator input and the firing angle. The self-synchronisation of the phases is allowed by the convertors in TIRIBLOC-MP products. It is not necessary to search out the correspondence of phases between two triphase feeds, which can sometimes be difficult. OTHER CHARACTERISTICS The control section is electrically insulated from the power section. The insertion of an internal voltage loop into the regulation and commutation system maximises operation during the bridges commutation phase (reversible convertors) ; unlike other products on the market, it does not, however, require the current loop to accelerate to a point which does not allow natural shut- off of the bridge previously in operation. The high stability of this regulator is such that the best overall response times allowed by the motors are obtained without going over current loop response time. The current loop can thus be set to totally safe values for bridge commutation. The drive contains a ramp function generator, gate pulse suppression, overload electronics The SCR are fired by a train of pulses; this eliminates the problem that SCR with very inductive loads can fail to fire. Personalisation card with all setting potentiometers (it is not necessary to repeat the setting if the cards or the entire drive have to be replaced). In the TRM (4Q) version, two quadrants may be excluded in order to get a unidirectional braking drive (2Q).

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2. CONVERTOR TYPES

2.1. TRIPHASE BIDIRECTIONAL CONVERTORS. Type Idc (A) Ventilation Fuses

TRM 30 30A Natural External 35A


TRM 50F 55A Natural 63A





TRM 250FV 250A Fan 220Vac (40W) 250A

TRM 300FV 310A Fan 220Vac (0.85A) 315A

TRM 400FV 410A Fan 220Vac (0.85A) 350A

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2.2. TRIPHASE UNIDIRECTIONAL CONVERTORS. Type Idc (A) Ventilation Fuses

TTM 30 30A Natural External 35A


TTM 50F 55A Natural 63A





TTM 250FV 250A Fan 220Vac (40W) 250A

TTM 300FV 310A Fan 220Vac (0.85A) 315A

TTM 400FV 410A Fan 220Vac (0.85A) 350A

TTM 500FV 530A Fan 220Vac (0.85A)) 550A

TTM 650FV 650A Fan 220Vac (120W) 650A

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3. ELECTRICAL SPECIFICATIONS

3.1. REGULATION SUPPLY VOLTAGE. Terminals 39-40 : 110 Vac +/- 10% 12 VA (protected internally by 1A fuse).

3.2. POWER SUPPLY VOLTAGE. Between 10 Vac and 480 Vac. If voltages of between 10 Vac and 110 Vac are used (e.g. annealing or galvanic ), the BT variation of the model is required e.g. TTMxxxxBT. If voltage greater then 380V are used the AT variation of the model is required e.g. TTMxxxAT.

3.3. FREQUENCY. 50 or 60 Hz +/- 5%, selected by the JP21 jumpers on the SF210B card and the J jumper on the SF209B card.

3.4. DIRECTION OF PHASE CYCLE. The drive operates correctly whatever the direction of the sequence of phases. The sequence is given as a reference on the display (RST or RTS). The triphase control voltage is not designed to be separate from that supplied to the power as it is derived from this power supply through a multitension circuit included.

3.5. GROUNDING. The drive must be grounded through the terminal indicated.

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3.6. OVERLOADING. Maximum peak current is 200% of the rated current for the model (protection intervention threshold). The drive can supply 150% of the rated current for up to 30 seconds, as shown in the graph below.

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4. ENVIRONMENTAL CONDITIONS

4.1. OPERATING TEMPERATURE RANGE. From 0 to 45 C at nominal current. From 45 to 70 C reduce rated current 2% at C.

4.2. RELATIVE HUMIDITY. Maximum 95% non condensing

4.3. PROTECTION AGAINST OVER HEATING.

The thermostat on the heat sink is already connected to terminals 35 and 36 on the SF210B card. Contact : normally open.

4.4. STORAGE TEMPERATURE. From -20 to +70 degrees C.

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5. MECHANICAL CHARACTERISTICS

TTM & TRM L (mm) H (mm) H* (mm) Depth (mm) L1 (mm)

H1 (mm) W (Kg)

30 250 300 235 230 220 8.5

50/130F 250 300 235 230 220 12

190F 250 320 270 230 240 15

250FV 250 410 270 230 240 17

300FV 250 490 270 230 240 20

400FV 250 490 270 230 240 25

TTM500FV 250 490 270 230 240 26

TTM650FV 500 510 320 472 305 50

For safety reasons, the heat sink must be grounded through the appropriate terminal. Some of the models in the TIRIBLOC-MP series are cooled by natural convection, others by forced air. In order to maximise cooling, however, all models are recommended to be mounted leaving a clear space of at least 100 mm above and below the drive. For the same reason, the space between two drives should not be of less than 30 mm. N.B. The TIRIBLOC-MP series drives are designed to be mounted on boards containing the appropriate protections.

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6. OPERATIVE THEORY

6.1. POWER SECTION: UNIDIRECTIONAL CONVERTOR..

The power section is composed of a GRAETZ bridge (see fig. 1).

ANAP

F

R S T

Fig.1

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Fig.2 Fasi RST Canale=FOR Angolo=75

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Figs. 1 and 2 illustrate the concepts set out below. Initially, Thyristors 1 and 6 are blocked. When t=15, a pulse is simultaneously applied to 5 and 6; both start to conduct and a channel is closed for the current from T and P through the load, as far as N and S. In this way the voltage TS is applied to the load. After 60, i.e. at t=75, pulses are applied to Thyristors 1 and 6, 1 fires and the load current commutes from 5 to 1 since the voltage on line RS is greater than TS at this moment. After another 60, 2 and 1 fire and a further commutation occurs. If the load is strongly inductive, the ac will reach operational level after several cycles and every thyristor will conduct for 120 at each cycle. Fig. 2 illustrates drive phase displacement for =75. Note that 'a' is measured from the point at which the voltage between the anode and cathode of the thyristors being examined becomes positive. For this reason, when =0, the thyristors are like diodes. It can be seen from the output voltage waves that tha average Ed value is in proportion to angle a, reaches its maximum when =0, zero and has negative values when =180. The transfer can be effected by integrating the waves. The following formula results : Ed Ed 0 *cos

in which output saturation voltage Ed Eu0 3 2 * *

where Eu is the actual value of the linked line voltage. Since the current to the load cannot be inverted, the power will change direction together with the voltage. When operating as a rectifier (a<90) it supplies power to the load while when functioning as an invertor (a>90) it requires power from the load. The circuit described above supplies a voltage to both polarities but supplies a current in one direction only. If inverted current is required, an antiparallel connection between two bridges must be made.

6.2. POWER SECTION. BIDIRECTIONAL DRIVE. The operative theory for the BIDIRECTIONAL drive is exactly the same as that set out for the UNIDIRECTIONAL drive. The above paragraph therefore also describes the bidirectional drive but this also includes a second GRAETZ bridge with polarities opposite to those in the model described above.

6.3. FIRING ANGLE.

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Fig. 3 below illustrates the sinusoidal curve of the power voltage input phases set against the graphs representing firing and shutdown times for each Thyristor according to its firing angle. 'Firing angle' means the angle measured as an advance as regards 40 and a delay as regards the appearance of a voltage in the resistive load. As can be seen, a Thyristor is commanded by a series of pulses of a fixed duration of 120 from a firing angle of 53 to the maximum firing value. For firing angles of less than 53, however, the series of pulses is interrupted about 13 before the voltage of the phase of the following thyristor exceeds the voltage of the phase relevant to the thyristor to which the train of pulses is being applied.

Fig.3

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7. CONNECTIONS

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7.1. POWER CONNECTIONS.

GR Ground Connection.

R/S/T Supply (from 110 Vac to 480 Vac).

P Motor armature positive terminal.

N Motor armature negative terminal. flexible section wire with F kink according to which type is being used.

7.2. REGULATION CONNECTIONS.

1 0/10 v input reference (+ for unidirectional, + or - for bidirectional)

2 Non inverting 0/10 V differential input

3 Logic input enabling drive to run

4 Ramp function generator logical input

5 0/10 V inverting differential input

6 0/10 V reference input

7 Common OV (GND)

8 Speed regulator output

9 Common OV (GND)

10 0/10 V ramp function generator input

11 Ramp function generator output

12 Differential amplifier output

13 Delayed armature current signal output

14 Common OV (GND)

15 -15 V, 10 mA output

16 +15 V, 10 mA output

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17 0/10 V reference input

18 Tacho generator (10V) feedback input

19 Tacho generator (0.02V /rev) feedback input

20 Tacho generator (0.06V/rev) feedback input

21 Current regulator output

22 Common OV (GND)

23 Speed transducer (F/T etc.) feedback input

24 Common RL1 alarm relay output

25 RL1 alarm relay contact, normally closed (opens in state of alarm)

26 RL1 alarm relay contact, normally open (closes in state of alarm)

27 Current feedback signal

28 Voltage feedback signal

29 DAC ouput (for particular uses)

30 DAC input (for particular uses)

31 RL2 drive ready relay common output

32 RL2 relay contact, normally closed (opens at drive ready)

33 RL2 relay contact, normally open (closes at drive ready)

34 Remote voltage feedback

35 Heatsink thermostat

36 GND heatsink thermostat

37 TX

38 RX

39 Regulation supply voltage (110V)

40 Regulation supply voltage (110V)

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Wire of up to 1.5 mm in diameter may be used to connect the regulation terminals. If strong electrical noise is present, users are advised to fit shielded wires; the shield should be fitted to one "GND" only from the drive side.

7.3. LAYOUT OF JUMPERS. For the insertion of jumpers, see the figure following paragraph 10.1 SF 210B MOTHER BOARD. Setting type of regulation. If the drive is used to control the speed of a motor fitted with a tacho generator, encoder or resolver with a frequency- voltage transducer, the jumpers must follow the layout given in the following table:

TTM (1Q) TRM (4Q) JP1 (1Q) JP2 (W-X) JP2 (W-X) JP3 (A-B) JP3 (A-B) JP4 (I-L)

YES JP4 (I-L) JP9 (M-P) JP9 (M-P) JP10 (REV) JP13 (FOR) JP13 (FOR) JP15 (F-E) JP3 (A-C) JP1 (1Q) JP5 (F-R) JP3 (A-C) JP7 (G-H) JP5 (F-R)

NO JP10(REV) JP7 (G-H) JP14 (G-H) JP14 (G-H) JP16 (2Q+) JP16 (2Q+) JP17 (2Q-) JP17 (2Q-) JP21 (60Hz) JP21 (60Hz)

If the JP13 jumper is removed from a TRM (bidirectional 4Q) drive, positive speed reference is no longer given; this is equivalent to removing the GATES JP25 command connector. If the JP10 (REV) jumper is removed from a TRM (bidirectional 4Q) drive, negative speed reference is no longer given; this is equivalent to removing the GATES JP28 command connector. Jumper JP15 (F-E) only must be mounted on the unidirectional TTM drives and improves the response of the speed loop during speed reductions.

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It is essential that jumpers JP1 (1Q) and JP13 (FOR) are inserted in unidirectional TTM drives, and that JP10 (REV) is not inserted. It is essential that jumpers JP13 (FOR) and JP10 (REV) are inserted in bidirectional TTM drives and that JP1 (1Q) is not inserted. Jumpers JP7 and JP14 (G - H) are inserted if armature voltage is to be regulated by the drive. This feedback can be useful during inspection and trouble-shooting with resistive load to check the firing of the phase set in action by the SCR. Jumper JP16 (2Q drives) is only used on TRM (4Q drives); if it is inserted, negative reference operation is no longer possilbe (the motor turns in one direction only), to allowe the possibility of braking (2 quadrant operation). Jumper JP17 (2Q) is only used on TRM (4Q) drives; if it is inserted, positive reference operation is no longer possible (the motor turns in one direction only), to allowe the possibility of braking (2 quadrant operation). Jumper JP21 must be inserted only for 60 Hz power supply. BE CAREFUL : when the frequency is 60 Hz, users must insert the four jumpers marked "J" on the SF209B card inside the drive. If the drive is used to control a motor, jumpers JP4 (I-L), JP3 (A-B) and JP2 (W-X) must be inserted. For special uses, alterations may be made to the position of these jumpers e.g. for annealing ovens, galvanic supplies. The jumpers listed below are used to adapt the current sensor mounted on the drive output bas (50A, 200A etc.) to the model being used to achieve always a signal of 5 volts at maximum current (terminal 27).

TTM650 insert JP28 TTM500 insert JP19 TRM400, TTM400 insert JP18 TRM300, TTM300 insert JP18 TRM250, TTM250 insert JP19 TRM190, TTM190 insert JP20 TRM130, TTM130 insert JP22 TRM 90, TTM 90 insert JP23 TRM 50, TTM 50 insert JP24 TRM 30, TTM 30 insert JP27

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8. ELECTRICAL CHARACTERISTICS

8.1. RL1 "ALARM" RELAY ". Normally non-activated. It activates if malfunction occurs (exchange contact). Connections:

24 Common

25 Normally closed (NC)

26 Normally open (NO) Contact 1A/110 Vac or 0.5A/220 vac resistive load.

8.2. RL2 "DRIVE READY" RELAY ". Normally activated. Disactivates if malfunction occurs (exchange contact). Connections:

31 Common

33 Normally open (NO)

32 Normally closed (NC)

Contact 1A/110 Vac or 0.5A/220 vac resistive load.

8.3. LOGICAL INPUTS. The logical inputs enable the drive to run. They may be activated by open-collector outputs or by relay contacts set at zero (GND). Internal pull-up resistance : 22 kohm to +24 Vdc Commutation input max. "Low" : +2 Vdc min. "High": +4 Vdc

Terminal 3: reset for internal regulators and pulse generator (microprocessor)

Terminal 4: ramp function generator reset

Terminal 35: heatsink protection alarm (thermostat)

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Terminal 38: serial communication input (reserved)

8.4. ANALOG INPUTS.

Terminals 1/6/17 : speed reference feedback (current). Impedance : 68 kohm 1%.

Terminal 18 : low value tacho generator feedback (about 10 volts).

Impedance : about 21 V.

Terminal 19 : medium value tacho generator feedback (0.02 Volts/rev).

Impedance : about 44 k.

Terminal 20 : high value tachymetric generator feedback (0.06 Votls/rev).

Impedance : about 110 K.

Terminal 23 : speed feedback frequency/voltage (for signals from encoder etc.).

Impedance : about 11 k.

Terminal 30 : DAC input for special uses (reserved). Input impedance : about 10 k.

Terminal 34 : voltage regulator feedback input (reserved).

Terminals 2/5 : differential amplifier inputs. Impedance : 68 kohm 1%.

Terminal 10 : ramp function generator input . The "RFG" trimmer can be used to adjust

the time from 0.5 to 50 seconds.

8.5. ANALOG OUTPUTS.

Terminal 16: +15 volts dc supply. Max. 10 mA.

Terminal 15: -15 volts dc supply. Max. 10 mA.

Terminals 7/9/14/22: signal and regulatiocommon Gnd

Terminal 12: differential amplifier output . Max. 5 mA.

Terminal 11: ramp function generator output. Max. 5 ma.

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Terminal 8: speed regulator ouput. The value given (from -10V to 10V) indicates the

current necessary for the motor to run at the required speed . If connected to terminal 6,

the drive perform current regulation. Max. 5 mA.

Terminal 21: current regulator output

Terminal 27: not delayed armature current signal. This accurately reproduces the waveform of the output current from the drive; it has a value of +/- 5V (average value) when the current is at the maximum permissible rated size Max. 5 mA.

Terminal 13: delayed armature current signal. Trimmer P4 on the SF210B card sets signal

to +/- 10V within current limit. Max. 5 mA.

Terminal 28: non delayed armature voltage signal. This signal, which accurately

reproduces the waveform of the voltage output from drive, has a value of +/- 10 V

(average value) when the drive is reaching saturation point (on resistive load, about 500V

with a 380 V ac power supply).

Terminal 29: DAC output (reserved for special uses). Max. 5 mA.

Terminal 37: serial output (reserved for special uses).

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9. SIGNALLING DISPLAY

A high contrast, backlit LED display is mounted on the SF210B card, on which information appears, sent by the microprocessor, concerning the operational state of the drive and any alarms. Should the display prove difficult to read, the P1 "Contrasto" trimmer can be used to adjust the contrast. A second P2 trimmer (DISPLAY READOUT) is used to change the messages visualised on the display. If this trimmer is moved fully ccw, blocking the drive and not connecting the power part on the display, the following message will appear :

In the following picture, only the power feed frequency has changed, rising from 50 Hz to 60 Hz. The three dashes ( - - - ) in the bottom left hand corner represent the three drive input phases and as the power supply is not connected, the exact sequence of phases cannot appear.

If, at this point, the drive is enabled to run, the following message will appear :

This means that the process of enabling the drive to run is being attempted but that one or more phases are missing. This can happen if one or more extrafast fuses at the input to the drive or similar elements have been burnt.

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If the power supply is correctly connected and the drive is enabled to run, the following message will appear:

"RTS" or "RST" may appear in the bottom left hand corner, indicating the exact sequence of the input phases. If trimmer P2 is now moved cw, the following further 7 messages will appear in the sequence given below : SECOND message :

GPG (gate pulse generator) input voltage signal, both digital and analogical, expressed in a percentage. The analogical value is represented by a black bar which moves from the left (minimum value) to the right (maximum value) on the second line of the screen. THIRD message :

Drive output voltage signal, both digital and analogical. This value is always expressed in the form of a percentage, from -100% to +100%. The analogical signal has a central zero so it can also give negative values, which are possible in bidirectional drives.

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FOURTH message :

% output current value versus max current of drive.

OVERLOAD condiction. FIFTH message :

PSP (+15V) This value is always given both digitally and analogically. SIXTH message :

PSN (-15V), always both digitally and analogically. N.B. if the voltage value of the two above messages varies by about 12%, the drive will block, the alarm relay will go off and the voltage which has caused the alarm will appear on the display.

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SEVENTH message :

voltage present at the current regulator input, expressed in the form of a percentage; this may vary between -100% and +100%. If the value is greater than +90% or less than -90%, the drive is probably in current limitation. EIGHTH message :

This is the last message. Trimmer P2 (DISPLAY READOUT) is turned fully cw. This gives the percentage value of the rated current of the motor compared to the maximum for the type of drive being used.The microprocessor calculates the heat profile of the motor armature. When this protection is activated, the following message appears on the screen:

For the setting of I nom, see paragraph headed START UP. Other than the messages described above, the microprocessor may enter into state of alarm or visualise an error :

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If protection against overcurrent is activated (peak current 200% compared to maximum convertor current, e.g. 180A for the TRM90) the following message will appear on the display :

If drive terminal 35 (heat button input) is shortcuircuited towards the ground, "THERMAL PROTECTION" will appear on the screen, indicating that the heat sink temperature is too high.

If the operation of the P U15 (TTR1) should be interrupted whilst the P U12 (TTR2) continues to operate, the following message will appear on the screen:

Obviously, if, for whatever reason, the drive enters alarm state, it will be blocked by the microprocessor which will also activate the RL1 alarm relay.

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9.1. RESETTING THE ALARMS. The alarms are reset in different ways depending on what activated them, particulary: Alarm activated because PSP or PSN are not present: the alarm goes off when the cause itself is eliminated. Alarm activated to suppress pulses GPS because of overcurrent: alarm goes off when the drive is disabled and normal visualisation is reset when the drive is once more enabled to run. Alarm activated by intervention of heat protection: the alarm goes off when the simulated heat capacity is discharged to below the Inom and normal visualisation is reset when the drive is once more enabled to run (if the alarm has receted). Alarm activated by intervention of thermostat on the heatsink: the alarm goes off when the cause is eliminated and normal visualisation is reset when the drive is once more enabled to run (if the alarm has receted).

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10. DESCRIPTION OF THE CARDS

10.1. SF210B MOTHER BOARD.

SF210B

SF192A

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8751 microprocessors and other elements are incorporated into this board. The principal components of this card serve the following purposes :

U1-Quadruple operational amplifier : acts as speed regulator, ramp function generator

and adaptor for the current signal from the HALL sensor.

U2-Quadruple comparator : supplies FOR or REV direction to the microprocessor , acts

as OVER CURRENT threshold and the WATCHDOG to keep the RL2 relay activated

during regular operation ("READY" drive).

U3-Integrated electronical switches used to reset the ramp and internal regulators.

U4- Voltage regulator for +5V microprocessor supply.

U5-U9- Voltage regulator for +/-15V operational amplifiers supply.

U6-Quadruple operational amplifier. Serves as current regulator, filter for 0/10 V current

signal available from terminal 13 and other internal circuits.

U7-Quadruple operational amplifier: serves as armature voltage regulator, differential

amplifier as required by user and performs other internal functions.

U8-Divider by 4 . Receives the 2MHz signal from the microprocessor and supplies a

500KHz clock for the ADC (U14).

U10-U16- Inverters with smith triggers. Used to square signals.

U11-DAC ( digital to analog converter for special uses).

U12-U15- 8751 microprocessors internally programmed to control + and - 15 V feeds, to

perform as protection against over current and as thermostat heat sink. They also receive

synchronisation references from the synchronism transformers to generate the series of

pulses which fire the power SCR. The series of pulses firing the scr depends on the

frequency of the network; for this reason the microprocessor generates them differently

following insertion of the "60 Hz" jumper. They also receive block signals from terminal 3

and, if there are no malfunctions, they enable the current speed regulators to run. In the

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event of fault or malfunction, they activate the "RL1" alarm relay whose contacts are

connected to terminals 24, 25 and 26. They also elaborate the messages visualised on the

display.

U13-Oneshoot timing circuit. When all three phases are present, the frequency of 150 Hz

resets this continually; if one phase is missing, the frequency of 50 Hz is sent to the

microprocessor as an alarm.

U14- 8 bit analog/digital converter (ADC). This converts the analog signal from the

regulators (in GPG) to an 8 bit binary number which is then elaborated by the

microprocessor. This integrated circuit also measures the following values : supply vol-

tages, armature current and voltage and the trimmer to select visualisation.

U17-U18- Integrated darlington transistors. These amplify the GATE pulses from the

microprocessor in order that they can be applied to the pulse transformers.

X1-12 MHz quartz oscillator.

CC1-Voltage elevator to illuminate display

Q1, Q2, Q4- Low power NPN type transistors

Q3-PNP medium power transistor. Supplies 24V to 20 kHz chopper voltage for the pulse

transformers.

TF1-12 VA feed transformer

RL1-Relay (alarm). Normally non-activated, it is commanded by the microprocessor if

there is a malfunction and activates protection in the event of Over Current, +15V and -15V

outside tolerance, or the lack of a phase (burnt power fuses etc.) RL2-Relay (ready). Timeset relay preventing the SCR from firing for the time necessary for the microprocessor to start up. It remains nonactivated (state of malfucntion) if the WATCH-DOG circuit, made up of a U2 drive, does not receive pulses from U12 and U15 indicating regular operation.

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10.2. SF209B CARD. This card interfaces between the SF210B regulation card and the drive power section. Its principal elements are the following :

TS, TT, TR- Synchronisation transformers. These are connected in a triangle on the

three power phases. Their primary winding is dimensioned for the maximum voltage

allowable for the drive (480 Vac). If the power voltage is equal to or less than 110 Vac

(TTMxxxBT and TRMxxxBT type convertors) the primary winding of these transformers is

110 Vac.

IC1 - IC2- Quadruple drives. These obtain two square waves from the synchronisation

transformers as a reference for the micro processor (see fig....., sinusoids etc.) and the 150

Hz signal (when all three phases are present) for the circuit of the missingphase. If any

phase is missing, the frequency drops to 50 Hz.

IC3- operational amplifier which receives the signal from the optoisolator and obtains a

peak 10 volt sinusoidal wave.

T1 ..T6- Pulse transformers for the "REV" channel SCR (only mounted on TRMxxx type

drives).

J- Four jumpers to be inserted for 60 Hz frequency power supply.

10.3. SF208A CARD (FILTERS R-C). R-C filters for the ac/dc side and the two power resistances for the armature voltage reaction are mounted on this card. Resistance R6, through the JR6 bridge, must be shortcircuited for a power voltage equal to or less than 220V ac.

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10.4. SF192A CARD (PERSONALISATION). All adjustments which are normally carried out directly onto the plant are contained in this card. If the drive or the SF210B card have to be replaced, the SF192A card may be remounted on the "new" drive without having to repeat the setting. The trimmer is as follows :

GCC-Stability of current regulator. When turning CW, the current loop response time

increases.

GSC-Stability of speed regulator. When turning CW , the speed loop response

timeincreases.

SPEED-Setting the tacho generator feedback. When turning CW, the motor speed

increases.

BIAS-Offset of speed regulator. Set to keep the motor still when there are no references.

LC-Current limit. This sets maximum motor current (the nominal current of the armature

is given on the motor data plate). When turning cw, the current increases up to about

110% of the maximum current for the size being used. Setting up is carried out as follows:

disconnect the motor field (excitation) mechanically block the motor arm, supply the drive,

give terminal 1 a positive voltage reference (taken from terminal 16, for example), enable

the drive to run by connecting terminal 3 to terminal 9 and use the "LC" to set the current

required (normally that given on the motor data plate).

RFG-This sets the ramp function generator time. Turned fully CCW, the ramp time is

about 0.5 seconds. Turned fully CW it is about 50 seconds.

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11. START UP

11.1. NOISE IMMUNITY. To ensure the drive operates properly, bear the following points in mind : All relays and contactors mounted on the same board as the drive must be fitted with a R-C in parallel with the reel/coil, or, if supplied by dc, must have a discharge diode. The recommended R-C value is:

R=100 Ohm-0.5W C=0.47uF-220Vac The same R-C is applied to the electric valves command.

11.2. ENABLING AND BLOCKING THE DRIVE. When the drive is enabled to run (terminal 3 closed down at common grounding) , it continually checks the presence of the three power phases ; if one or more of these is missing, it activatetes the "alarm" relay (terminals 24,25 and 26) and the message "MISSING POWER" appears, which is normally a part of the machine's stop sequence. For this reason, the drive must never be enabled to run before the power voltage has been supplied and must remain enabled to run after the power voltage has been removed, otherwise a nonexistent supply fault may be indicated. Normally the drive is enabled to run by means of an auxiliary contact on the power relay switch; a command connection could be of the type illustrated in the figure.

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BE CAREFUL! The message "POWER MISSING" only appears if the P2 trimmer is turned fully CCW.

11.3. OVER CURRENT PROTECTION (GPS). Over Current protection serves to protect the SCR from current peaks. It cannot be set, and is 200% of the maximum current tolerated by the drive (for example, fo the TRM130, it is 260 Ampere). When the protection is activated, the generation of GATE pulses is blocked and the "alarm" relay is activated. "OVER CURRENT" appears on the display. This alarm situation is memorised until the drive is blocked, upon which the alarm disactivates. The message "OVER CURRENT" on the display, however, remains until the drive is once again enabled to run.

11.4. SETTING THE CURRENT LOOP (GCC). Normally, the GCC trimmer is kept half-turned. In this state, the typical response of the current regulator (on a motor with a typical inductive value) is of about 80 ms. In order that this time may be measured, an oscilloscope with a 10 ms/div delay time must be applied to the Test-Point "Ia". Disactivate motor field, mechanically block the motor arm and supply a step (- 15V/+15V) to a reference input (e.g. terminal 1) with a switch.The following wave form appears on the oscilloscope:

10.0 mS/div

If the user requires a particularly fast response from the drive, a rise of about 20 ms can be obtained by turning the GCC trimmer fully cw. See the figure overleaf.

300mV/div.

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10mS/div.

As already stated in chp.1 of the introduction, there is little use in requiring lower response times than the standardones from TIRIBLOC-MP.

11.5. SETTING THE SPEED LOOP (GSC).

Sudden reference variation may cause speed overshoot in the motor.This can be seen if an oscilloscope is applied to the motor tacho generator.If overshoot occurs the generator voltage react as illustrated below:

0.5 S/div.

300mV/div.

20V/div.

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This fault may be eliminated by turning the "GSC" trimmer CW to get a reaction such as that illustrated below:

0.5S/div

If, however, motor speed oscillates (is unstable), the "GSC" trimmer may be turned too far and signal given by the generator will be:

0.5S/div.

It so, stabilise the motor by turning the "GSC" trimmer CCW. If it proves impossible to stabilise the motor, the current loop may be at fault (see paragraph above); to correct it, turn the "GSC" trimmer CCW.

20V/div.

20V/div.

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11.6. SETTING UP LOAD OVERHEAT (SIMULATED HEAT MOTOR).

I2t operation are carried out within the microprocessor in order to give a heat profile of the motor (simulated of a heat relay on the motor armature current).The protection intervention time correspond to that required by the most important manifacturers of the dc. motors. The intervention time versus current ratio is illustrated in the graph below:

Multiple of Inom

The setting operation is carried out using the P3 trimmer and them setting value can be visualised on the display when the P2 trimmer is turned fully CW.The "I nom" setting is made with the P3 trimmer and must always be adjusted to the rated current dc. motor .It is expressed as percentage of the max current of the type of drive. For example, if the motor absorbs 40A and the drive is a TRM90, the following setting must be made with the P3 (keeping the P2 trimmer turned CW):

P In3 7090

100 78( om) * %

Heat protection on the drive allows the current limit to be set at a value higher than the rated current of the dc. motor if this should be necessary.

Tempo In Secondi

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12. TROUBLESHOOTING

Symptom. Probable Difficult Test or replace

Irregular speed control. Motor at max speed whatever the reference value.

No speed feedback present or tachogenerator inverted.

Check the tacho signal. Check its inter-connection; it should have polarity opposite to the reference polarity

Irregular speed control. The drive does not regulate the current correctly at the load outlets.

Load current limit requested. Line voltage drops with the load.

Test to see if the motor requires the current limit. Check the mechanical part. Check the main voltage does not drop to under 10% at the load outlets.

Irregular speed control. The motor cannot reach max speed .

It may be necessary to adjust the SPEED trimmer. Reference less than 10V. The motor is at current limit.

Increase the speed. Move the generator to an input with greater impedance: terminals 18/19/20. Change the mechanical load to the motor.

Irregular speed control.The motor speed is in overshoot.

It may be necessary to adjust the SPEED trimmer.

See star-up paragraph.

Irregular speed control. The motor oscillates.,

Speed or current loop

need to be regulated.

See start-up paragraph.

The motor does not turn. The display does not come on.,

No power supply to regulation cards.

No supply getting througth.

The motor does not turn. When the drive is blocked (turn P2 fully CCW) "MISSING POWER" appear on the display.

The microprocessor shows one or more power phases are not present.,

A power fuse inside or outside the drive has burnt. Or a contact has be broken in the contactor or a syncronisation trasformer protection fuse has burnt in FS and FT on the SF208 card).

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The motor does not turn. The display PSP and PSN off-gauge.

The +15 and -15 supplies are too high and too low.

Check to see if there is a short circuit on terminal 14,15,16. Check 110V Vac is present on terminals 38 and 40.

The motor does not turn. The power fuses burn,, or "OVER CURRENT" appears on the display.

The motor is grounded or in short circuit or an SCR has been burnt.

Test the drive power part with a dc. voltmeter. Replace any shortcicuited SCR. Look for the ground on the motor.

The motor does not turn. The ammeter shows maximum motor current.

Motor field not present. Check the field voltage with a dc. voltmeter. If there is no voltage present,, check the fuse and replace the diode bridge if necessary.

The motor does not turn. "LOAD OVERHEAT PROTECTION" appears on the display.

Motor heat protection has intervened. There may be an overload present or trimmer P3 on the SF210B card may not be set correctly.

Check a field voltage voltage is present,, that there is no excess mechanical load and the setting of P3 (see Start-up paragraph)

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13. MAINTENANCE AND REPAIRS

DANGER!! DISCONNECT THE MAIN POWER SUPPLY BEFORE MAINTENANCE AND

REPAIR WORKS.

13.1. REMOVAL OF THE SF210B CARD.

Unhook the protection cover from the upper part and turn it over.

Take out removable terminals. It is not necessary to disconnect the individual terminal

conductors since these are removable and the card can simply be pulled upwards.

Unhook the two flat cable connectors, JP25 and JP 26 (and also JP28 if TRM reversible

drive is being used)

Unhook the 4 pole CNH connector

Pull the four black plastic fasteners at the corners of the card and remove it. If it is

necessary to replace it, reuse the personalised SF192A card.

13.2. REMOVAL OF SF209B CARD.

Remove SF210B card as indicated above.

Disconnect the CNAC connector and the 6 2 pole connectors on the GATES (12 if a

TRM reversible drive is being used).

Quarterturn CCW the four plastic screws and carefully pull out the card.

When the card is remounted and connected, be careful that the GATES connectors are

connected accurately (they are in direct correspondence with the SCR modules).

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13.3. REMOVAL OF SF208A CARD. Remove the SF209B and SF210B cards as indicated above. Unhook the RST connector from the SF208A card and unscrew the M3 screws which link the printed circuit to the bars and, if necessary, the M4 screws which hold it to the dissipator. (only on TTM and TRM 30-50-90-130).

13.4. REMOVAL OF SCR MODULES (NOT VALID FOR 650FV). Take off the copper bars by unscrewing any spacers and all screws holding them to the SCR blocks. It is not necessary to detach the wires connected to the bars. To remove the blocks from the dissipator, use a 5 mm hexagonal screwdriver.

13.5. REPLACEMENT OF SCR MODULES (NOT VALID FOR 650FV). Users are advised to apply a force of 5 Nm +/- 10% to fix the mounting screws into the heat sink block and a force of 3 Nm to fix the bars to the blocks. Siliconic wax is recommended.

13.6. REPLACEMENT OF POWER FUSE. If the drive is fitted with internal power fuses, they can be replaced as follows : remove the SF210B card as described in paragraph 13.1, remove the power terminal protections by pulling out the two black plastic screws. At this point, it is possible to gain access to the screws holding in the fuse. Only use "Extrarapid" fuses as indicated in the table in paragraphs 2.1 and 2.2

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1. SPARE PARTS Type TTM30 TTM30F TTM50 TTM50F TTM90 TTM90F TTM130F TTM190F TTM250FV TTM300FV TTM400FV TTM500FV TTM650FV

Card SF208A 1 1 1 1 1 1 1 1 1 1 1 1 1 Card SF209B 1 1 1 1 1 1 1 1 1 1 1 1 1 Card SF210B 1 1 1 1 1 1 1 1 1 1 1 1 1 Card SF192A 1 1 1 1 1 1 1 1 1 1 1 1 1 SCR IRKT 26-12 3 3 3 3 SCR IRKT 56-12 3 3 SCR IRKT 91-12 3 SCR IRKT 162-12 3 3 3 SCR IRKT 250-12 3 SCR MCC312-12i01 3 SCR ST330C12C 3 Fuses 35FE 3 Fuses 63FE 3 Fuses 100FE 3 Fuses 160FEE 3 Fuses 200FM 3 Fuses 250FM 3 Fuses 315FM 3 Fuses 350FM 3 Fuses 550FMM 3 Fuses 630FMM 3

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Type TRM30 TRM30F TRM50 TRM50F TRM90 TRM90F TRM130F TRM190F TRM250FV TRM300FV TRM400FV

Card SF208A 1 1 1 1 1 1 1 1 1 1 1 Card SF209B01 1 1 1 1 1 1 1 1 1 1 1 Card SF210B 1 1 1 1 1 1 1 1 1 1 1 Card SF192A 1 1 1 1 1 1 1 1 1 1 1 SCR IRKT 26-12 6 6 6 6 SCR IRKT 56-12 6 6 SCR IRKT 91-12 6 SCR IRKT 162-12 6 6 6 SCR IRKT 250-12 6 Fuses 35FE 3 Fuses 63FE 3 Fuses 100FE 3 Fuses 160FEE 3 Fuses 200FM 3 Fuses 250FM 3 Fuses 315FM 3 Fuses 350FM 3

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1. OPTIONALS.

1.1. OPTIONAL CARD SF227A.

1.1.1. PRESENTATION. The optional card SF227A complete some functions of MP series: Zero speed detector. Speed limitation in case of tacho breaking or reverse signal polarity. External current limit setting by means of voltage reference 0/10Vdc for REVERSE and FORWARD channels.

1.1.2. ELECTRICAL SPECIFICATIONS. Regulation supply voltage:+15Vdc -15Vdc 40mA from SF210B card by means of EDR connector. Terminal 41: output for function of external current limit adjustment. Load current 5mA max. If used connect to terminal 17 of SF210B card. Terminal 42: input reference 0/10Vdc for REVERSE channel current limit adjustment. The request polarity depend on position of JP4 jumpers. Input impedance about 110Kohm. Terminal 43: input reference 0/10Vdc for FORWARD channel current limit adjustment. The request polarity depend on position of JP1 jumpers ( JP2 for SF227A01 ). Input impedance about 110Kohm. Terminal 44: output open-collector transistor for zero speed detection. Transistor is "on" at zero speed. Output rating: 35Vdc 100mA max.

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1.1.3. LAYOUT OF JUMPERS.

Polarity selection of reference for current limit adjustment. SF227A SF227A01 POS. JP1 JP2 + Positive reference on terminal 43 ( REVERSE channel ) JP1 JP2 - Negative reference on terminal 43 ( REVERSE channel ) JP4 JP4 + Positive reference on terminal 42 ( FORWARD channel ) JP4 JP4 - Negative reference on terminal 42 ( FORWARD channel ) Enabling external reference for current limit adjustment. SF227A SF227A01 POS. Current limit depend on: JP3 JP1 A Reference signal to terminal 43 ( REVERSE ). JP3 JP1 B LC potentiometer ( REVERSE ). JP2 JP3 C Reference signal to terminal 42 ( FORWARD ). JP2 JP3 D LC potentiometer ( FORWARD ). Enabling speed limitation in case of tacho breaking or reverse signal polarity. In this case the armature voltage is limited to a value <=70Vdc. JP5 YES Enables NO Disabled

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1.1.4. EXAMPLE OF EXTERNAL CURRENT LIMIT USE:

TRM...

SU SF227A01

INSERIRE INSERT

JP2 +

JP4 +

JP1 A

JP3 C

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1.1.5. EXAMPLE OF ZERO SPEED DETECTOR USE:

Potentiometer P1 set intervention threshold . With tacho 0,06V/rev and 0/10Vdc reference, intervention threshold is from 20 to 90 rpm.

ATTENTION. I.A.G. Elettronica assumes no obbligation of notice to holders of this document with respect to changes subsequently made, and assumes no responsability for the accuracy, competeness, sufficiency, or usefulness of the information contained herein.

dc thyristors drive mp series instruction manual

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