var-p r/rr drive · r 115 error overload threshold for motor protection r 117 rampa up ramp up r...

MIPRO s.r.l.

VAR-P R/RR DRIVE

instruction manual

Via del Lavoro, 14 20030 Bovisio Masciago (MI) Italy - Tel. 039/362/57.11.33 - Fax 039/362/57.11.35 Web site http:// www.miprosyn.com - Indirizzo e-mail: [email protected]

MIPRO s.r.l.

SINGLE-PHASE FULLY-CONTROLLED THYRISTOR TYPE ELECTRONIC SPEED VARIATORS FOR CONSTANT TORQUE CONTROL

OF SEPARATED FIELD D.C. MOTORS

V A R P

TECHNICAL FEATURES AND DIRECTIONS FOR THE TECHNICIAN

SUMMARY 1 General characteristics page 01 1.1 Technical features page 02

2 Control systems of the motor page 03 2.1 Speed control page 03 2.2 Speed control ratio page 03 2.3 Stability page 03 2.4 Feedbacks page 03

3 Drive systems of the motor page 04 3.1 Led signallings page 04 3.1.1 VAR P/R signallings page 04 3.1.2 VAR P/R signallings page 04 3.2 VAR P Protections page 05 3.3 Dip-Switches setting page 05 3.3.1 VAR-P/R dip switches setting page 05 3.3.2. VAR-P/RR dip switches setting page 06 3.4 Calibration page 06 3.4.1 VAR P/R adjustment page 06 3.4.2 VAR P/RR adjustment page 07

4 Power and control groups description page 08 4.1 Power section page 08 4.2 Control section page 08

5 Installation page 09

6 Direction for troubleshooting page 10

7 Terminal blocks description page 13 7.1 Power terminal block description page 13 7.2 VAR P/R control terminal block description page 13 7.3 VAR P/RR control terminal block description page 14

8 interconnections drawings page 15 (A-B-C-D) WARNING: We recommend you reading of our manual for “EMC” rules before installing the equipment. ED. 01/2003

Instruction manual Var P R/RR Series

MIPRO s.r.l.

1. GENERAL CHARACTERISTICS VAR P series is available in two different versions (R or RR) depending on the mechanical needs of the machine to be worked:

VAR P/R Unidirectional Regenerative The power group of this version consists of a fully-controlled single phase bridge energy converter. It allows: • the unidirectional control of the motor; • the forced rotation from the outside of the motor in the opposite sense of the selected one

admitted, (for instance: decoiler); • the quick torque and speed reversal by remote control switches allowing to recovery to the line

inertial energy during braking. The braking in this system are at constant torque.

VAR P/RR Bi-directional The power group of this series consists of two fully controlled single phase bridge energy converters (bridges in anti-parallel configuration). The motion sense can be reversed statically (without any contactor's help) maintaining the involved speeding and braking torques within fixed values.

Independent ramp circuits allow the strict realization of predefined work diagrams (translations, positioning, and so on) During the phases of deceleration, reversal or stop, the inertial energy of the whole mechanical system is reconverted and sent to the line, without any heat conversion and with an energy saving as more important as higher is the time constant of the machine.

These devices have a large of uses in frequent movement reversals with controlled braking and acceleration, when high speed of reaction is required, when the motor must keep its speed constant even if pulled (decoiler, pull-groups, and so on).

Instruction manual 1 Var P R/RR Series

MIPRO s.r.l.

1.1 Technical features

TYPE OUTPUT CURRENT MECHANICAL POWER Nominal Max Line 240V Line 400V VAR P 11/R-RR 11 A 16 A 1,6 Kw 2,7 Kw VAR P 13/R-RR 13 A 21 A 1,9 Kw 3,2 Kw VAR P 16/R-RR 16 A 26 A 2,3 Kw 3,9 Kw VAR P 24/R-RR 24 A 32 A 3,5 Kw 5,8 Kw VAR P 32/R-RR 32 A 40 A 4,7 Kw 7,8 Kw Dimensions and weight: 320x185x160 mm (wxhxd), 2.8 Kg. Supply-line:

• Singlephase 240V ± 10%, 400V ± 10%, 50/60 Hz • For other voltages, please contact our technical office.

Field power supply The field power supply of the motor is directly derived from the power supply of the equipments:

• Max field voltage: 200V (240V line)

340V (400V line)

• Max field current: 2,5 A Maximum starting current: From 1,3 to 1,5 times the nominal one (see table). Mechanical powers: The mechanical powers shown in the table take into account a motor efficiency of about 80%. Ambient conditions:

• Ambient relative humidity < 90% without condensation • Operating temperature 0 ÷ 45°C up to a maximum of 55°C with a reduction of

1,25% per C° increasing above 45°C. • Storing temperature -15 ÷ +65°C; • Climate variable tropical (according to DIN40 046 sheet 5)


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2. CONTROL SYSTEMS OF THE MOTOR 2.1 Speed control:

• Double current speed feedback loop;

• Speed control at constant torque by means of armature voltage control;

• Torque control. 2.2 Speed control ratio:

• With tacho feedback: 1:100 typical

• With armature feedback : 1:20 with R*I compensation 1:10 without R*I compensation

2.3 Stability:

• With tacho feedback: ± 0,01% ref. to max speed with 1÷100% load variation;

± 0,05% ref. to max speed with ±10% line voltage variation (with max gain); ± 0,01% ref. to max speed per °C of ambient temperature variation (tacho stability not included)

• With armature feedback ± 0,1% ref. to max speed per °C of ambient temperature variation (motor speed stability not included).

2.4 Feedbacks

• Speed: -d.c. tacho generator; -armature voltage with R*I compensation and galvanic separation between power and control circuit by means of optoisolator;

• Current: -by means of internal current transducer.


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3 DRIVE SYSTEMS OF THE MOTOR

• Dip-switches to facilitate setting and start-up; • Inversion times very short by means of block logic; • Tacho-generator breakage control; • Tacho-generator polarity inversion control; • Separately adjustable up/down ramps and maximum torques (for both directions); • Possibility of cascade control of n. motors, having one motor as MASTER and the others as

SLAVES; • Output contact signalling min. speed reached (adj. thresh); • Output contact signalling max. speed reached (adj. thresh); • Output contact signalling possible faults on the equipment; • Adjustable max. time of overload (motor thermal protection); • Armature voltage and current signals for panel meters; • Torque control input.

3.1 Led signallings

3.1.1 VAR P/R signallings

SIC. DIN tacho protections excluded SIC. ARMAT. armature protections excluded VH KO motor overload / thermal protection activated DIN. INV. tacho polarity reversed DIN. KO tacho breakage SOPP. IMP SCR firing pulses blocked RELE’ MAX max. speed reached RELE’ ZERO zero speed reached RELE’ OK all is OK EMERG. one or more fault present LINEA power line present CARICO output current higher than the nominal SOVRACC. converter thermal protection activated

3.1.2 VAR P/RR signallings

SIC. DIN tacho protections excluded SIC. ARMAT. armature protections excluded VH KO motor overload / thermal protection activated DIN. INV. tacho polarity reversed DIN. KO tacho breakage SOPP. IMP SCR firing pulses blocked RELE’ MAX max. speed reached RELE’ ZERO zero speed reached RELE’ OK all is OK FAIL one or more fault present LINEA power line present SOVRACC. converter thermal protection activated


MIPRO s.r.l.

3.2 VAR P protections All devices from VAR P series are equipped with protection against overvoltage, spikes, wrong working, overheating and so on. They can work both with direct speed control (by tacho-generator) and indirect control (by armature feedback) with galvanic separation of the control circuits towards ground and line. Types 11 and 13 do not have ventilation (air convection cooling only) whilst types 16, 24 and 32 have it (forced air cooling). CAUTION: the equipment must be protected by the user with two line fuses, “ultra-rapid” type of suitable value:

VAR P TYPE 11 13 16 24 32

EXTERN. FUSES 20 A 25 A 30 A 35 A 50 A

The protection fuses for the control circuit and field voltage are incorporated in the equipment. 3.3 Dip-Switches setting

3.3.1 VAR P/R dip-switches setting

S1

1 2

ON OFF ON OFF

tacho protection active tacho protection excluded armature protection active armature protection excluded

S2

1 2

OFF ON OFF ON

internal torque control external torque control internal torque control external torque control

S3

1 2 3 4

ON OFF ON OFF ON OFF ON OFF

increase derivative action decrease derivative action decrease voltage gain increase voltage gain insertion of armature filter exclusion of armature filter insertion of armature filter exclusion of armature filter

S7

1 2

ON OFF ON OFF

increase current integration decrease current integration increase voltage integration decrease voltage integration

S8

1 2 3 4

ON OFF ON ON ON

armature feedback tacho feedback different speed laying different speed laying different speed laying


MIPRO s.r.l.

3.3.2 VAR P/RR dip-switches setting

S1

1 2 3 4

ON OFF ON ON ON

armature feedback tacho feedback different speed laying different speed laying different speed laying

S2

1 2

ON ON ON

stability compensation (if necessary) stability improvement

S3

1 2

ON OFF ON OFF

armature feedback tacho feedback armature feedback tacho feedback

S4

1 2 3 4

OFF ON ON OFF ON OFF OFF ON

internal torque control external torque control internal torque control external torque control internal torque control external torque control internal torque control external torque control

S6

1 2

ON OFF ON OFF

increase current integration decrease current integration decrease voltage gain increase voltage gain

S7

1 2

ON OFF ON OFF

tacho protection active tacho protection excluded armature protection active armature protection excluded

3.4 Calibration

3.4.1 VAR P/R adjustment

TRIMMER DESCRIPTION

NUMBER NAME R 10 V.MIN min speed R 12 COPPIA torque R 13 STABILITA’ stability R 14 V. MAX maximum speed R 34 REAZIONE speed feedback R 24 RL. MIN. zero speed relay excitation R 25 RL. MAX. max speed relay excitation R 111 V. ARM armature voltage out signal R 35 I. ARM armature current out signal R 113 R.I R*I compensation R 114 DELAY time constant for motor protection R 115 ERROR overload threshold for motor protection R 117 RAMPA UP ramp up

R 118 RAMPA DW ramp down

Remark all other calibration trimmers inside the equipment are sealed during factory test and the

operator is not allowed to touch them.


MIPRO s.r.l.

3.4.2 VAR P/RR adjustment

TRIMMER DESCRIPTION

NUMBER NAME R 107 COPP. AV forward torque R 129 COPP. IN backward torque R 65 STABILITA’ stability R 25 V. MAX max. speed R 178 R. MIN zero speed relay excitation R 177 R. MAX max. speed relay excitation R 24 V. ARM armature voltage out signal R 44 I. ARM armature current out signal R 26 REAZ. speed feedback R 121 RI IN. backward R*I compensation R 122 RI AV. forward R*I compensation R 174 DELAY time constant for motor protection R 175 DVH overload threshold for motor protection

R 127 RAMPA AV UP forward ramp up

R 125 RAMPA AV DW forward ramp down

R 126 RAMPA IN DW backward ramp down

R 113 RAMPA IN UP backward ramp up

Remark all other calibration trimmers inside the equipment are sealed during factory test and the

operator is not allowed to touch them.


MIPRO s.r.l.

4. POWER AND CONTROL GROUPS DESCRIPTION The VAR P equipment can be subdivided into two main sections: 4.1 Power section This section includes:

• the interface with power line and motor; • Graetz bridge converter fully controlled (R version) or double Graetz bridge converters fully

controlled (RR version); • current transducers, filters, case temperature sensor and ventilation.

4.2 Control section This section directly refers to a single extractable board (upper side located) and includes:

• the interface with field signals/commands; • signalling LEDs and adjustable trimmers for the user; • the stabilized d.c. power supply for all the equipment; • all the converter controls and the protection circuits; • the power/control galvanic isolation circuit.


MIPRO s.r.l.

5 INSTALLATION Before proceeding with the installation, check the packaging and make sure that the equipment has not been damaged during the transport. The installer must closely follow the enclosed scheme to realize the outside connections, taking care of the polarities where specified. The conductors section to be used for the power circuit, motor line and armature, have to be in compliance to rating-plate current of the motor itself. The shown shields, particularly those of the speed potentiometer, must be used for lengths greater than one meter or in the cases in which these conductors run near other ones which can cause interferences. The screen must be connected ground at only one end, while the other one must be insulated. It is advisable to set up the equipment as near as possible to the driven motor, avoiding however polluted, aggressive and dusty environments.

Because of the used components any isolation/dielectric rigidity test (motor included), must be done with the equipment completely disconnected. Before connecting equipment to line, it is necessary to verify that the line voltage is the scheduled one, that all the connections have been made exactly according to the scheme, that the terminal blocks are well tight and that there are no isolation defects either between conductors or between these ones and ground. When you have accomplished all the above mentioned, place the speed potentiometer at position zero and connect the line voltage. If malfunctioning appears, please refer to paragraph "DIRECTION FOR TROUBLESHOOTING". MAINTENANCE Being a static machine, the VAR-P does not require any particular care. However, a minimum prior maintenance ensures the equipment a longer life. It is therefore recommended to effect periodical cleaning by low pressure air jet and to check the right tightness of the terminal board.


MIPRO s.r.l.

6 DIRECTIONS FOR TROUBLESHOOTING 6.1 External power fuse burns out

Probable cause: Short circuit or isolation lack between the power leads or between these ones and the ground;

Remedy: In order to find out the damaged component to be changed, disconnect all the motor wires from the power terminal block (but do not disconnect the line wires), replace the fuses and give power to the device. - if the fuses are not involved, the cause must be looked for in the

outside system, including the motor; - if they burn out it means that the converter has one or several

damaged SCR (short circuit). 6.2 Varistor VDR out of order

(probable burnt out of internal fuses F1 and F2)

Probable cause: Connection on line at a too high voltage; Too high line transients (spikes).

Remedy: Replace VDR. The device can work even without protections, however it is advisable to have them operating in order to avoid more serious damages. The break down of this component is made evident by the superficial burnout.

6.3 Auxiliary fuses F1 and F2 burnt out (green line LED off)

Probable cause: Short circuit or isolation lack between the motor field leads or between these ones and the ground; TR transformer in short circuit.

Remedy: Disconnect the excitation circuit leads from the terminal block, replace the fuse and give power to the device.

If the fuses are no more involved and: - there is voltage between the terminals -J and +K: the cause must be

looked for in the outside system, including the motor. - there is no voltage between the terminals –J and +K: it is necessary to

replace the broken diodes of the field bridge.

If the fuses are again involved: - it is necessary to replace the diode(s) of the field bridge or the TR

transformer. 6.4 The machine, when loaded, is not stable at the planned speed.

Probable cause: Speed potentiometer dirty or damaged.

Remedy: Replace the potentiometer. Probable cause: The time constants are not suitable to the specific mechanical load;

Excessive instability of the dandy roll for such system; There are abrupt variations of load during working.

Remedy: Operate the stability trimmer. If the operation is not successful, it is necessary to check the correct dimensioning of the system.


MIPRO s.r.l.

6.5 The machine does not start

(field voltage present, green line and OK LEDs lighted).

Probable cause: The speed potentiometer is disconnected or broken; Short circuit between inputs 10A or 10B and 0V, or between 10V output and 0V.

6.6 The machine accelerates too slowly

Probable cause: The set of maximum torque trimmer has been altered.

Remedy: Reset the max. trimmer.

Probable cause: The time of starting ramp is too long.

Remedy: Reduce time by means of the appropriate ramp trimmer.

Probable cause: The machine has a too high dynamical moment of inertia.

Remedy: Recalculate the power taking into account the necessary starting overloads.

6.7 The machine accelerates too quickly

Probable cause: Input 10B (without ramp) is used; The time of the starting ramp is too short.

Remedy: Use input 10A (with ramp). Increase time by means of the appropriate Ramp trimmer.

6.8 The motor becomes overheated

Probable cause: Insufficient dimensioning.

Remedy: Replace the motor or apply forced ventilation. Probable cause: Mechanical seizure;

Ambient temperature is too high.

Remedy: Remove the mechanical obstacle; Fan the motor with cold air coming from outside. 6.9 The motor brush sparking is excessive

Probable cause: Brushes are worn out or they do not slide freely in their slots.

Remedy: Replace the brushes or check their smoothness in the slots. Probable cause: The collector is dirty, worn out or ovalized;

The brush holder is not in a neutral zone.

Remedy: Consult the constructor of the motor or a specialized shop.


MIPRO s.r.l.

6.10 The machine does not reach the nominal speed

(with input signal at 10V and max speed trimmer at max.)

Probable cause: -Mechanical seizure.

Remedy: Verify the armature voltage and increase it using the MAX VEL. trimmer if it is too low.

Probable cause: A controlled diode is not switched on (the motor is overheated and

becomes very noisy)

Remedy: Make sure, using the oscilloscope, that between the terminals +A and –H a half wave is missing; consequently replace the damaged controlled diode.

6.11 The machine quickly reaches the maximum speed

(even when the speed potentiometer is at intermediate position).

Probable cause: The speed potentiometer is disconnected toward 0V.


MIPRO s.r.l.

7 TERMINAL BLOCK DESCRIPTION 7.1 Power terminal block description

RL-SL Power line input +A -H Motor armature output voltage -J +K Motor field output voltage

7.2 VAR P/R control terminal block description

RELE’ MAX (n.o. contact) max speed reached V.ARM. Armature voltage out. signal (0-8V max) I.ARM. Armature current out. signal (0-8V max) 0 V. 0 Volt ref. for our. signals RELE’ ZERO (n.o. contact) zero speed reached REL E’ OK (n.o. contact) all is OK

10 A Speed input signal with ramps (0, -10V) 10 B Speed input signal without ramps (0, -10V) V. OUT Speed output signal for cascade control of other drives. 8A -10 -10V (10mA max stabilized output) 2A +10 +10V (10mA max) stabilized output B SCRs firing pulses block

To enable the drive, connect terminal B with 0 Volt D Torque input signal (0, +10V) 7 A Speed input 0 Volt ref. when minimum speed function has to be

used -GT Negative feedback input from tacho

(standard tacho constant 60V/1000 rpm) +GT Positive feedback input from tacho 0 VOLT 0 Volt ref. for input signals

The MAX, ZERO and OK relay functions can be inverted (output contact from n.o. to n.c.) by means of the bridge located by the side of every relay.


MIPRO s.r.l.

7.3 VAR P/RR control terminal block description

RELE’ MAX n.o. contact max speed reached V ARM. Armature voltage out. signal (0-8V max)

I ARM. Armature current out. signal (0-8V max). 0 VOLT 0 Volt ref. for out. signals RELE’ ZERO (n.o. contact) zero speed reached RELE’ OK (n.o. contact) all is OK 10 A Speed input signal with ramps (0, -10V forward, 0, +10V backward) 10 B Speed input signal without ramps (0, -10V forward, 0, +10V backward) 10 OUT Speed output signal for cascade control of other drives 8A -10 -10V (10mA max stabilized output) 2A +10 +10V (10mA max) stabilized output B SCRs firing pulses block

To enable the drive, connect terminal B with 0 Volt COPP.A Forward torque input signal (0, +10V) COPP.I Backward torque input signal (0, -10V) -DIN.TAC. Negative feedback input from tacho

(standard tacho constant 60V/1000 rpm) +DIN.TAC. Positive feedback input from tacho 0 VOLT 0 Volt ref. for input signals


MIPRO s.r.l.

Instruction manual 15-A Var P R/RR Series

8 CONNECTIONS TO TERMINAL STRIP

MIPRO s.r.l.

Instruction manual 15-B Var P R/RR Series

8 CONNECTIONS TO TERMINAL STRIP

MIPRO s.r.l.

NOTES:

instruction manual Var P R/RR Series

SANDRO

15-C

MIPRO s.r.l.

MIPRO s.r.l.

ELETTROQUADRI

LINEA DI PRODUZIONE PRODUCTS RANGE GAMME DE PRODUCTION PRODUKTIONSREIHE

REGOLATORI DI VELOCITÀ SERVODRIVES REGULATEURS DE VITESSE GESCHWINDIGKEITSREGLER a S.C.R., transistors o IGBT per motori c.a., c.c. e brushless; inverters.

S.C.R., transistors or IGBT types for a.c., d.c. and brushless motors, inverters.

à S.C.R., transistor ou IGBT pour moteurs en c.a., c.c. et brushless; inverseurs.

mit S.C.R., Transistor oder IBGT für Wechselstrom-, Gleichstrom- und Brushlessmotoren; Wechselrichter.

MOTORI MOTORS MOTEURS MOTOREN c.a., c.c., a magneti permanenti e brushless con relativi accessori.

a.c., d.c., permanent magnet and brushless motors, including the accessories.

en c.a., c.c., à aimants permanents et brushless avec accessoires.

Gleichstrom-, Wechselstrom-, Dauermagnet- und Brushlessmotoren mit Zubehör.

SISTEMI COMPLETI PLANT MOTION CONTROL SYSTEMS

SYSTEMES COMPLETES VOLLSTÄNDIGE SYSTEME

per l’automazione industriale. tailor-made for industrial automation.

pour l’automatisation industrielle.

Komplette Antriebs-Systeme für die Industrieautomatisierung.

FILTRI FILTERS FILTRES FILTER monofase e trifase a doppia cella conformi alle normative EMC.

single-phase and three-phase filters at double cell in compliance with EMC regulations.

monophasés et triphasés à double chambre conformes aux normes EMC.

einphasige und dreiphasige Filter mit doppelter Zelle gemäß der EMC-Vorschriften.

QUADRISTICA PANELS TABLEAUX SCHALTTAFELN progettazione e realizzazione quadristica di comando e di controllo, anche per la distribuzione industriale.

design and realization of control panels, also for the industrial distribution.

projet et réalisation de tableaux de commande et de contrôle, aussi pour la distribution industrielle.

Entwurf und Herstellung von Steuerschalttafeln, auch für die Industrieverteilung.

IMPIANTI INDUSTRIALI INDUSTRIAL PLANTS INSTALLATIONS INDUSTRIELLES INDUSTRIEANLAGEN CABLAGGI A BORDO MACCHINA. WIRING ON MACHINES CABLAGES DES MACHINES MASCHINENVERDRAHTUNGE

N

MIPRO S.r.l.

Tel. 0039/362/57.11.33 r.a. Fax 0039/362/57.11.35 – Indirizzo e-mail: [email protected]

ELETTROQUADRI GUIZZO

Tel. 0039/362/55.99.29 – Fax 0039/362/59.07.42 – Indirizzo e-mail: [email protected]

Via del Lavoro, 14 – 20030 BOVISIO MASCIAGO (Milano) - ITALY

Instruction manual Var P R/RR Series

var-p r/rr drive · r 115 error overload threshold for motor protection r 117 rampa up ramp up r...

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