Schneider Electric Non-reversing variable speed controllers User Guide

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R ®

série 04

Variateurs de vitesse unidirectionnels pour moteurs

à courant continu non-reversing variable speed controllers for d.c. motors

Guide d'exploitation

User's manual

ATTENTION

NOTE

Le variateur comporte des dispositifs de sécurité qui peuvent, en cas de défauts, commander l'arrêt du variateur et par là-même, l'arrêt du moteur. Ce moteur peut lui-même subir un arrêt par blocage mécanique. Enfin, des variations de tension, et en particulier des coupures d'alimentation, peuvent

également être à l'origine d'arrêts.

La disparition des causes d'arrêt risque de provoquer un redémarrage entraînant un danger pour certaines machines ou installations, en particulier pour celles qui doivent être conformes aux décrets du

15 Juillet 1980 relatifs à la sécurité.

Il importe donc que, dans ces cas-là, l'utilisateur se prémunisse contre ces possibilités de redémarrage notamment par l'emploi d'un détecteur de vitesse basse, provoquant, en cas d'arrêt non programmé du moteur, la coupure de l'alimentation du variateur.

La conception des équipements doit être conforme aux prescriptions de la norme NF C 15-100.

D'une façon générale toute intervention, tant sur la partie électrique que sur la partie mécanique de l'installation ou de la machine doit être précédée de la coupure de l'alimentation du variateur.

CAUTION

NOTE

The speed controller includes safety devices which can shut down the speed controller, and consequently the motor, in the event of a fault. The motor may itself be stopped by mechanical faults. Finally, voltage variations and, in particular, mains failures can result in stoppages.

Disappearance of the cause of a stoppage may cause restarting of the motor, which can be dangerous for certain machines or installations, particularly those which must conform to specific safety regulations.

Therefore, in such cases, the user should take appropriate steps to prevent restarting, by the use of an underspeed detector for example, which causes disconnection of the speed controller power supply in the event of a non-programmed motor stoppage.

The design of control systems must conform to the appropriate standards.

As a general rule, the power supply to the speed controller must always be switched off before carrying out any intervention on either the electrical or the mechanical parts of the machine or installation.

Sommaire - Contents

Français

Présentation

Généralités

Guide de choix

Caractéristiques

Définition du Rectivar - Borniers de raccordement

Pont puissance 24/44A

Carte d'interface puissance 24/44A

Carte puissance 6/12A

Carte contrôle

Installation

Vérifications préliminaires

Précautions de montage

Montage en coffret métallique protégé

Encombrements

Raccordements

Schéma développé conseillé 2 sens de marche 6 à 44A

Nomenclature du matériel nécessaire

Raccordements

Implantations

Mise en service

Eléments séparés et de rechange

Maintenance

Câblage interne contrôle

Schéma synoptique

English

Presentation

General

Selection guide

Characteristics

Rectivar terminal referencing

Power bridge 24/44A

Power interface board 24/44A

Power board 6/12A

Control board

Installation

Preliminary checks

Mounting precautions

Mounting in a general purpose enclosure

Dimensions

Connections

Recommended circuit diagram for 6 to 44A reversing drives

Nomenclature of required material

Layout

Connections

Initial setting up

Spare parts and accessories

Maintenance

Internal control wiring

Block diagram

31-32

34-35

42 to 44

45 to 47

48 to 51

53 to 56

14 à 16

17 à 19

20 à 23

25 à 28

Pages

3-4

6-7

Presentation

RTV-04 Non-reversing 1 quadrant

Characteristics

The RTV- 04 speed controllers are designed to control separately excited d.c. motors, or permanent magnet motors, from a single phase a.c. mains supply.Non-reversing, with half controlled bridge, they operate in the first torque/speed quadrants. By using an appropriate sequence, it is possible for them to function in the first and third torque/speed quadrants.

Ratings :

Mains voltage

6, 12, 24, 44A up to 415V (1)

10 % 50/60 Hz

2 Hz

(1) except 6A rating : U = 220/240V

Speed range 1 to 200 with tachogenerator

1 to 20 by U-RI feedback; the accuracy, however, depends on the motor

Composition

The RTV- 04 range comprises 4 ratings from 6 to 44A, with compact technology.

Inside a metal enclosure with protective cover are housed :

- for ratings from 6 to 12A :

. the control board

. the power board

- for ratings from 24 to 44A :

. the control board

. the power interface board

. the power section.

• Control board

This is common to the complete range of RTV-04 and has the following characteristics :

- 4 point clip-on fixing,

- plug-in connectors for the external connections in the lower part of the board,

- principal adjustments arranged within the same zone.

It comprises the following functions :

- proportional and integral speed regulation,

- current regulation,

- 2 level current limitation,

- pulse train gate circuit,

- safety when switching on and off,

- ramp with independent adjustment of acceleration and deceleration times,

- LED and signalling relay.

• Power board (ratings 6 and 12A)

It comprises :

- the supply transformer,

- the power bridge,

- the power semi-conductor firing and protection circuits,

- the isolated armature current reading circuit,

- the excitation current rectifying diodes,

- the excitation current rectification type selection link :

. half wave

. full wave

For the 12A rating, a link enables selection of the transformer tap corresponding to the mains voltage.

Presentation

• Power interface board (24 and 44A ratings)

It comprises :

- the supply transformer,

- the power semi-conductor firing and protection circuits,

- the excitation current rectifying diodes,

- the selection link for transformer supply voltage, depending on mains voltage,

- the excitation current rectification type selection link :

. half wave

. full wave

Dialogue by LED and relays

2 LEDs : 1 green and 1 yellow, visible from the front.

2 relays.

Data supplied by the LEDs :

- ON : speed controller validated

→ green LED on.

- I A > : speed controller in current limit

→ yellow LED on.

Data supplied by the relays :

• Relay K1 :

- speed controller validated

→

K1 energised, contact closed

• Relay K2 assignable via a 2 position link :

- either speed controller outside current limit

→

K2 energised, contact closed

- or speed not zero (N > 0,02 rated N)

→

K2 energised, contact closed.

Choice of motor

The motor should be designed and rated for supply by pulsed current, with speed and torque variation corresponding to the application.

Form factor = 1,5.

The motor must be separately excited or permanent magnet type. Do not use a series or compound excited motor.

Excitation voltage 0,45 or 0,86 times mains voltage, depending on whether the supply voltage is half or full wave rectified (choice via link F).

Recommended armature voltage

≤

mains voltage x 0,73.

General

Functional block diagram

TC i exc.

M B

–

: single phase Graëtz bridge

: motor current measurement

: motor speed measurement

: field winding supply

–

Selection guide

Selecting the speed controller rating

The table on page 35 enables the speed controller rating to be determined for :

- either continuous duty opération, with starting torque 1,2 times the rated motor torque,

- or an overcurrent of Id/In = 1,3 during 6s maximum (operating with

Td/Tn

2 states limitation on overcurrent) with cyclic operation.

D.C. motor

If the required starting torque is greater than1,2 Tn, use the maximum current taken by the motor Id determine the speed controller rating :

- Id must be

≤

maximum continuous current of the speed controller.

1,75

Compensated motor

To determine the maximum motor current Id depending on the starting torque, consult the machine curves or, if if these are not available, the curve on the left.

1,5

1,25

Non-compensated motor

Exemple : Td/Tn = 1,6 non compensaded motor. The curves give

Id/In = 2.I maximum speed controller

≥

2 In motor.

1,25 1,5 1,75 2

Operating modes

Id/In

Continuous duty

The speed controller has a maximum continuous current (I max.) which cannot be exeeded.

Normal duty cycle

Operation can be definited by two current values : Io and Ip.

- Io : continuous duty current

- Ip : peak current.

0 t1

T t2 t

For the Rectivar 4 series 04, the following time limits must be observed : t2

≥

7 t1, t1

≤

6s.

For Io et Ip, the maximum values for the different ratings are as follows (in A) :

I maximum continuous 6

Io 4

Ip 8

Special duty cycle

For a given known specific operating cycle, Imte, the equivalent mean thermal current must be calculated :

Imte =

I 2

+ I 2

+ ... I 2 n

avec T = t

+ t

+ ... t n

Operating conditions are satisfied for :

• Imte

≤

0,8 I maximum continuous of the speed controller,

• Ip motor

≤

Ip speed controller, defined in the table below.

Example of the Imte definition :

0 t1 t2

T t3 t4 t5 t

Imte =

I 2

+ I 2

Selection guide

Speed controller-motor combination

The speed controller's reference, shown on the delivery note and on the rating plate located on the left hand side of the controller, must be quoted in any correspondance with our departments.

The values given correspond to an ambient air temperature of 40

C. For operation between 40

C and 60

C, apply a current derating factor of 1,2% for each additional degree C.

Single phase Continuous Motor supply current d.c. side

Voltage line Maxi

Maximum motor RecomExcitation

power (

= 0,85) mended Rectifying

Peak standard 2 state armature voltage current continuous limitation(2) limitation(2) voltage wave

Td/Tn = 1,2 Id/In = 1,5 full wave

U eff.

I eff.

Im Ip In P Pn (4) Pc (3) UA

RECTIVAR (1)

Current Reference Masse half

I ex.

220V

50/60 7,5

10 kW kW kW

0,65

1,3

0,65

1,3

1,05

2,1

160

190

100

2 kg

RTV-04U60M 2,900

RTV-04D12Q 3,600

240V

50/60 7,5

380V

50/60 15

10 1,5 1,4 2,3

2,7

0,75 0,7 1,2

5,5

2,4

4,7

2,6

4,8

2,8

5,2

2,3

4,6

4,2

7,8

4,6

8,5

3,7

7,4

160

175

280

190

205

330

100

110

170

RTV-04D24Q 6,000

RTV-04D44Q 6,000

RTV-04U60M 3,600

RTV-04D12Q 3,600

RTV-04D24Q 6,000

RTV-04D44Q 6,000

RTV-04D12Q 3,600

RTV-04D24Q 6,000

415V

50/60 15

36 8,7 8,3 13,5 280 330

10 2,5 2,5 4 300 360

20 5 5

36 9,3 9

14,7

300

360

170 2

185 2

RTV-04D44Q 3,600

RTV-04D12Q 3,600

RTV-04D24Q 6,000

RTV-04D44Q 6,000

Form factor = 1,5.

Note : (1) Products are delivered set to 380/415V.

To use them at 220/240V, follow the instructions on page 48.

The RTV-04U60M product is supplied for 220/240V exclusively.

(2) See "adjustement of current limitation" on page 50.

(3) Pp : peak power on overload (Id/In = 1,5).

(4) Pn : rated power.

Characteristics

Mains supply, voltage and frequency

220/240 V and 380/415 V

10 %

(except 6A rating : 220/240 V only, 50/60 Hz

2 Hz)

Recommended armature voltage U armature

≤

U mains x 0,73 depending on mains voltage

Excitation mains voltage

Maximum excitation current

Armature current limitation

Maximum voltage : 415 V, and U excitation : 0,45 or 0,86 U mains (see table on page 35)

Current limitation adjustable by potentiometer from

0,4 to 1,3 times the max. continuous current

Speed range

• Control by back emf

Accuracy :

• Control by tachogenerator

Accuracy with variations :

• of resistive torque 0,2 Tn

to Tn

• of mains voltage

10%

• of ambient air temperature

Speed references

• two voltage inputs :

- by potentiometer

- by analogue signal

1 to 20 (by U-RI feedback)

Depends on motor characteristics

1 to 200

– 0,24 % of the set speed

– 0,07 % of the maximum speed

0,22 % of the set speed

2,2 % of the set speed

0,1 % of the maximum speed

Galvanically isolated from power circuits

0 to + 10 V (*) input impedance 23 k

Ω

2,2 to 10 k

Ω

connected to the internal supply : 0 to + 10 V

0 to + 10 V, supplied by an external supply

(*) The 2 inputs + 10 V are summing; their sum must never exceed 10 V

Speed feedback

• by armature voltage

• by tachogenerator

Acceleration and deceleration ramp

Output relays

Electrical characteristics of contacts

Degree of protection

Ambient air temperature

• for operation

• for storage

Derating according to altitude

Vibrations and shocks

Link H in position U. Use the galvanic isolation board

5 adjustment positions : 10 - 30 - 60 - 120 - 240 V

Independently adjustable acceleration and deceleration times : 2 to 20 s

Possibility of increasing time up to 120 s, or of cancelling ramp

For auxiliary contactor : 250 V ~, inrush 300 VA max., sealed 30 VA max. ; 30 V 0,5 A max.

Number of operations : 10 6

Minimum switching capacity : 24 V/20 mA, a.c. and d.c.

IP 00

C to 40

C (operation possible up to 60

C by derating the current by 1,2 % per additional

– 25

C to + 70

Current derating by 0,7 % for each 100 m above 1000 m

Tests carried out conforming to the recommendations of IEC publication 68-2-6/FC

RECTIVAR terminal referencing

Power bridge 24/44A

Marking

AL1

AL2

Function

Power bridge mains supply up to 415V 50/60Hz

Earth (ground)

M2 -

M1 +

Motor armature

Power interface board 24/44A

AL11

AL21

CL1

CL2

FL1

FL2

F1 +

F2 -

Power board 6/12A

10-1

10-2

10-3

10-4

10-5

10-6

10-7

10-8

Mains voltage pick-off AL1-AL2

Control supply : 220/240V or 380/415V (see page 45)

Single phase supply to the excitation bridge

Positive output of the excitation bridge

Negative output of the excitation bridge

M2 -

M1 +

AL1

AL2

AL11

AL21

CL1

CL2

FL1

FL2

F1 +

F2 -

Control board

RNA

RNB

1 J1

2 J1

3 J1

4 J1

3-1

3-2

4-1

4-2

5-1

5-2

5-3

5-4

5-5

5-6

5-7

5-8

Motor armature

Power bridge mains supply up to 415V 50/60 Hz

(except 6A : 220V/240V)

Mains voltage pick-off AL1-AL2

Control supply : 220/240V or 380/415V (see page 46)

Single phase supply to the excitation bridge

Positive output of the excitation bridge

Negative output of the excitation bridge

Speed sensor input

SAO

P10

0E1

CAI

0VD

RUN

INR

IRT

K1A (2)

K1B

K2A (2)

K2B

(1)

(2)

13 J2

14 J2

15 J2

16 J2

17 J3

18 J3

19 J3

20 J3

5 J2

6 J2

7 J2

8 J2

9 J2

10 J2

11 J2

12 J2

Assignable terminal, second reference input (1)

(Speed amplifier output) Speed loop input I max

≤

5mA

Reference potentiometer supply + 10V

0,6V

Speed reference input to + 10V (23K Ω )

0V of E1 input

(Current amplifier input)current loop input (68K

Ω

)

0V of input INR

0V of input RUN

Validation of the controller (gate circuits, loops, ramp)

Cancellation of ramp

Increase of ramp time by external voltage, see page 43

Voltage free contact of relay K1 (interlock) closed when the controller is validated

Voltage free contact of relay K2 (current limitation) closed when the controller is outside limitation.

Second speed input connected either to the ramp, or to the speed amplifier.

Maximum characteristics of contacts :

- voltage 250V ~, inrush 300 VA max., sealed 30 VA maxi ; 30V d.c. : 0,5 A maxi

- number of operations : 10 6 , minimum switching capacity : 24 V/20 mA a.c. or d.c.

Installation

Preliminary checks

Remove the Rectivar from its packaging and check that it has not been damaged during transport.

Make sure that the reference on the speed controller label is the same as that on the delivery note, corresponding to the order form.

Mounting precautions

Mount the speed controller in the vertical position, so that the air circulates from the bottom to the top of the heat sink fins.

Do not install near heat radiating elements.

Mounting in a general purpose metal enclosure

IP23 degree of protection.

➤

1234567890123456789012345678

1234567890123456789012345678 In order to ensure adequate air flow inside the controller :

- leave sufficient space around the unit :

. d

≥

50 mm,

. D

≥

100 mm,

- provide ventilation louvres,

- make sure that the ventilation is adequate; if not, fit a cooling fan with filter.

θ ≤

➤

θ ≤

➤

1234

1234 d

M d

123456789012345678901234567

1234

Wiring precautions

Apart from the special earth terminal marked , no other conductors connected to terminal blocks should be connected to earth or to the protective earth of the installation.

The external speed setting and feedback circuits (when using a tachogenerator) must be wired using twisted pairs (pitch

≤

5 cm).

As far as possible, separate the control wires from the power cables.

The signals to the following terminals must be connected as described above.

Terminal block J2 control board Terminal block J2 control board

P10

0E1

RNA

RNB

The other signals accessible at the customer terminal block (except K1A-K1B, and K2A-K2B), must be cabled using twisted pairs (pitch

≤

5 cm) and screened (with the screening connected to the controller earth). The maximum length of the interconnection is 5 m. For greater distances, use an interface circuit.

Group mounting of two or more speed controllers : where necessary, fit line inductances.

Where necessary, fit interference suppression circuits on the sequence contactors.

Installation

Dimensions

Rectivar

Fixings: 4 x ø 6,5

H b

Reference

RTV-04U60M

RTV-04D12Q

RTV-04D24Q

RTV-04D44Q

159

162

Line inductances

Association with controllers (page 52) b

220

264

264 c

115

163

190

230

G a

120

G a

H c

Reference

VZ1-L008 U860

VZ1-L016 U860

VZ1-L032 U800

VZ1-L060 U400 a

108

Fuses

Association with controllers (page 41) b

105

135

145

L c

110

120

135

5,5

Weight (kg)

0,500

0,850

2,100

3,450

Reference

DF2-CF02001

DF2-CF02501

DF3-EF04001

DF3-FF10001

Connections

Non-reversing

Supply : 220/240V or 380/415V, 50/60 Hz

6 to 44A speed controllers

Recommanded circuit diagram

1 x

T1 x

Q1 x

S1 KM1

KM1

1 x

3 x

AL1

M1+

AL2

M2+

FL1 F1+

FL2

F2-

AL11 RNA

CL1 RNB

AL21

P10

CL2 E1

K1A

K1B

0E1

0VD

K2A RUN

K2B

0VD

INR

1 2 3 4 5 6

Exitation voltage

Mains supply

220/240V 380/440V

190/205V

100/110V

330/360V

170/185V

Exitation

Links

I T

Limitation

Special Standard

Note :

* "general interlock" relay outpout (open contact = interlock)

** assignable relay (speed controller ouside limitation or speed not zero)

LAD

Connections

Non-reversing

Supply : 220/240V or 380/415V, 50/60 Hz

6 to 44A speed controllers

Nomenclature of the required equipement

Item

KM1

LAD

S1-S2

Description Voltage Voltage Reference Reference Reference

Mains Armature Maximum power with Td/Tn = 1,2

220/240V 150/160V 0,65 kW 1,3 kW 2,7 kW

Reference

5 kW

Motor

Speed controller

380/415V 260/280V –

RTV-04U60M

2,4 kW 4,7 kW 8,7 kW

RTV-04D12Q RTV-04D24Q RTV-04D44Q

Thermal overload relay (1)

+ terminal block

Line contactor

Line inductance is required

Smoothing choke if required

Isolator

+ 2 power fuses

Circuit breaker

+ contact block

Circuit breaker

Potentiometer

Control

Signalling

Transformer

(secondary 220V)

LR2-D13••

LA7-D1064

LR2-D••••

LA7-D••••

LC1-D0910M7 LC1-D1210M7 LC1-D2510M7 LC1-D5011M•

- Where several speed controllers are connected in parallel(P52)

- Essential for motor with flat rotor.

- Strongly recommended for torque motor.

(Consult our local sales office).

LS1-D2531A65 LS1-D2531A65 GK1-EK DK1-GB2

DF2-CF02001 DF2-CF02501 DF3-EF04001 DF3-FF10001

GV1-M07

GV1-A01

GV1-M07

GV1-A01

GV1-M07

GV1-A01

GV1-M07

GV1-A01

GV1-M05

GB2-CB05

SZ1-RV1202 SZ1-RV1202 SZ1-RV1202 SZ1-RV1202

Either XB2-M or XB2-B or complete control stations.

100 VA

LR2-D13••

LA7-D1064

GV1-M05

GB2-CB05

100 VA

LR2-D••••

LA7-D••••

GV1-M05

GB2-CB05

100 VA

GV1-M07

GB2-CB06

250 VA

(1) To be suitably rated for the motor, taking the form factor into account.

Connections

RECTIVAR 6/12A

RECTIVAR 24/44A

35 45

16 16

Ø6,5

Control terminals

Power interface terminals

Power terminals 15

Ø6,5

Control terminals

Power interface terminals

100

130

Connections

Function of the speed reference inputs

The circuit enables two voltage references to be used varying between 0V and + 10V.

The first is applied to the ramp function input, via terminal E1.

The second must be applied to the AT terminal. A two position link enables the reference to be directed to :

- either the ramp function

- or the speed amplifier.

Warning : the sum of the voltages applied SIMULTANEOUSLY to the two inputs must never exceed 10V.

Ramp

Acceleration time (ACC) and deceleration time (DEC) can be adjusted independently. They can be adjusted independently using a potentiometer, from 2 to 20 seconds. A link device enables suppression of the ramp function where necessary.

V+

DEC. ext.

2,2k

Ω

The ramp time can be modified using the

IRT (J2-16) input, connecting two 2,2 k

Ω potentiometers and two diodes as shown in the diagram on the left.

IRT (J2-16)

0VD (J2-12)

ACC. ext.

2,2k

Ω

V-

V (IRT)

1,5

4 t(s)

1 2 3 4 5 6 7 8 9 10

The operating range is from 1,5 to 10V. Reducing this voltage enables the times, which can be adjusted using the ACC and DEC potentiometers, to be increased by a factor varying from 1 to 6.

When the INR input is connected to 0V, the speed ramp is validated. To reset the ramp to zero, the INR-0VD link must be opened.

Connections

Function of the speed reference inputs

External current limitation

It is possible to modify the speed controller's current limitation externally (decrease of current value only) in two separate ways :

• by fitting potentiometers

J2-7

SAO

2,2 k

Ω

J2-11

CAI

Set link E to position 0 (separate speed and current loops), the link thus takes place through the external potentiometer divider.

J2-10

0E1

Adjustement from 0 to 100% of the limitation current.

WARNING : this arrangement causes increased gain in the speed loop. Instability can appear if the level

applied to CAI becomes too low.

• by fitting a rheostat

470 k

Ω

J2-7

SAO

J2-11

CAI

Set link E to position 0 (separate speed and current loops), the link thus takes place through the externalrheostat mounted potentiometer .

Do not exceed the maximum value of 470

Ω

The limitation current's adjustement range becomes 0,15 < I lilitation < 1.

Validation

J2-14

RUN

J2-13

0VD

The speed controller is validated via the RUN command input (J2 - 14).

When this input is connected to the 0VD input

(J2 - 13), the speed controller is validated.

When the link is no longer active, the speed loop, current loop, firing gate and ramp functions are interlocked :

- time delay for validation : 250 ms,

- time delay for interlock : 15 ms.

When the control supply (CL1-CL2) is connected upstream of the line contactor KM1, the closure of the contact on RUN must never precede the closure of the line contactor (risk of damage).

Layouts

Power bridge 24/44A

RTV-04D24Q RTV-04D44Q

AL1 AL2 AL1 AL2

M2M1+ M2M1+

1 Thyristor module

Power interface board 24/44A

2 Diode module

J9 J12

220

380

J11

3 Current feedback board

Link U

Link F

J10

J11

: control supply transformer

: selection of control transformer tap

: selection of excitation voltage

: galvanic isolation option board

: motor output

: power supply

: speed feedback, galvanic

isolation adaptation (optional)

: customer connection,

control and excitation supply

: U feedback, reading not isolated

J10 J4

Layouts

6/12A power board

P11

J11

J3 J4

J10 J3 J4

J10

P11 : factory preset, adjustment of Hall effect current

reading to zero

T : control supply transformer

Link U : selection of control transformer tap

(strap soldered in the 220V position for the 6A

version)

Link F : selection of excitation voltage

A : galvanic isolation option board

J3 : motor output

J4 : power supply

J7 : speed feedback, galvanic isolation adaptation

(optional)

J10 : customer connection, control and excitation

supply

J11 : U feedback, reading not isolated

Current feedback board (ratings 24/44A)

P11

LC

12345678

LC : Hall effect current reading

P11 : factory preset, adjustment of reading to

zero

Layouts

Control board (common to all RTV-04 speed controllers)

1 0

RAMP SAI

ACC

+

DEC

+

HSP

+

SPG

IA>

+

– U

10V

30V

60V

120V

240V

+ 15V

– 15V

+

0 1

I T

1 0

OSP

+

IA>

RUN

K1 K2

J1 J2 J3

J1 : tachogenerator feedback

J3 : K1 and K2 relay outputs

J6 - J7 : test sockets for diagnosis

Links

J2 : reference connections, interlocks

J4 - J5 : outputs to power board

: separates the speed amplifier (

) from the current amplifier (open in position 0)

: enables the reference applied to terminal AT to be directed, either to the ramp (position

RAMP) or to the speed amplifier (position SAI)

R : operation with or without ramp

I T : selection of the type of limitation

1 : ramp on

0 : ramp off

0 : standard

1 : with 2 states

: selection of level of speed image voltage feedback

Potentiometers

ACC : adjustment of acceleration time

DEC : adjustment of deceleration time

HSP : adjustment of maximum speed (high speed)

SPG : adjustment of speed loop gain (speed gain)

RI : adjustment of RI compensation (U – RI operation)

IA > : adjustment of limitation current

+15V : adjustment of +15V supply

–15V : adjustment of –15V supply

OSP : adjustment of the speed amplifier offset

factory preset

LEDs

RUN : (green LED) validated state of the speed controller

I A > : (yellow LED) operating state in current limitation

Electromagnetic relays

: relay indicating validation state

: relay indicating operation in current limitation

Initial setting up

Preliminary checks

OUR PRODUCTS ARE PRESET FOR TACHOGENERATOR FEEDBACK

With the supply disconnected

Check the rating plates and the labels on the equipment to ensure that the speed controller, the motor and the mains supply are compatible.

Make sure that the wiring corresponds to the circuit diagram.

Check that all terminals are tight, and that the speed controller connectors are fully plugged in and latched.

When a voltage speed reference is being used, check the connections of the speed reference potentiometer and measure its resistance using a multimeter :

- suggested value : 2200

Ω

(0E1 and P10 terminals)

- recommended value : 2,2 k

Ω ≤

≤

10 k

Ω

When the AT additional input is being used, check that : max. U ref. = V (E1) + V (AT) = 10 V.

Check the position of the links. Make sure that they are in the positions shown on pages 47 to 49. The control board must be turned round in order to check the links on the power board.

Adaptation to the mains supply

Ratings 12, 24 and 44 A are dual-voltage products. They are delivered suitable for 380/415 V.

To use them with a 220/240 V mains, modify the position of link U on the power board.

Also check that the position of link F on the power board corresponds to the excitation voltage.

Mains voltage

50 / 60 Hz

Excitation

according to link F

220 V

240 V

380 V

415 V

100 V

110 V

170 V

185 V

190 V

205 V

330 V

360 V

Mounting of the options

Operation with isolated U

Galvanic isolation board : reference VW2-RZD2071.

The board is not supplied with the controller. If required, mount this option onto the power board using the 3 rapid fixing insulating separators, then connect the connecting ribbon n

1 to the J7 connector and the connecting ribbon n

4 to the J11 connector on the power board. Set the H link on the control board in position U.

NOTE : connecting ribbons and separators are supplied with the board. For further details, please refer to the documentation enclosed with the option board.

Operation with non-isolated U-RI

The controller is supplied with a separate connector (J7) enabling the armature voltage readed on the M1

- M2 terminals to be directed to the control board. It should be fitted into place on the J7 connector of the power board ONLY with this operating mode.

Set the H link on the control board in position U.

In this case, the electronic control is no longer isolated from the mains supply.

Initial setting up

Equipment required

– A multimeter, preferably 20000 ohms/volt.

– A two channel oscilloscope, if required.

The apparatus must be isolated from the mains supply. Do not connect the oscilloscope to another

earth of the installation.

– A moving scale ammeter, if required, with shunt if necessary.

Static adjustments

IA >

Maximum motor current adjustment

• Mains supply disconnected

– Open the Q2 circuit breaker (for motors with permanent excitation, mechanically jam the motor shaft,

if it is possible to do so).

– On the control board, position the I T at 0 (I max. = constant) and check that the ACC and DEC

potentiometers are in the fully anti-clockwise position (ramp at minimum) and the R link in

position 0.

– Connect an ammeter (position ) to the motor armature.

• Switch on the speed controller

– Set maximum speed using the reference potentiometer : the motor should not rotate.

– Turn P8 clockwise in order to obtain the required limitation value, taking Td/Tn into account.

• Safety measures

– Do not stay in current limitation too long, as the motor and the commutator segments may overheat.

– Never exceed I maximum shown on the speed controller rating plate.

– Remember to derate the speed controller by 1,2 % for each

C, for ambient temperatures between

40 and 60

• Example :

Take an RTV-04D24Q operating in an ambient temperature of 55

Derating is equal to 1,2 x (55-40) = 18 % giving a derated operating current of :

(100-18)

24 x 20 A

100

For a motor operating with Td/Tn of 1,2 and

= 0,85, the maximum power available from the motor becomes :

I max x U armature x

20 x 280 x 0,85

Td / Tn 1,2

= 3.900 W

Note : for motors which cannot be blocked mechanically, the limitation will be adjusted with the

motor running during the dynamic tests.

The adjustment having been made :

– Switch off the supply.

– Reclose Q2 or release the motor shaft.

– Disconnect the ammeter.

– Reset the speed reference potentiometer to zero.

Initial setting up

0,9

0,8

0,7

0,6

0,5

1,3

1,2

1,1

1,0

Dynamic adjustments

Adjustment of speed data feedback

Adaptation of voltage feedback is carried out using link H, as shown in the table below , with, or without the galvanic isolation option board.

10V

–U

Mode

Feedback

Link H

Armature

Position Voltage voltage

(1) use the board

V W 2 - R Z D 2 0 7 1

(p48).

30V

60V

D.T.

0 - 10 V

0 - 30 V

0 - 60 V

0 - 120 V

0 - 240 V

0 - 10 V

10 - 30 V

30 - 60 V

60 - 120 V

120 - 240 V

(2) use the connector

J7 (p48).

isolated U-RI (1) 0 - U 0 - 10 V 150 à 300 V

120V

Non-isolated

U-RI (2)

0 - U 0 - 10 V 150 à 300 V

240V

Dynamic adjustments

Adjustment of rated speed

Adjusted by HSP potentiometer, as follows :

– Switch off the speed controller.

– Set a low reference value :

– If the motor runs away : - switch off,

- check the continuity of the 2 tacho feedback wires,

- if not, reverse the 2 wires.

HSP

– If the motor rotates the wrong way :

- switch off

- then reverse :

• either the field winding,

• or the armature (for motors with permanent magnets),

- switch the supply back on.

– If the motor is rotating slowly, but in the right direction :

- set the maximum reference

- adjust the rated speed, using (HSP)

- switch off.

t1 t2

Id/In = 1,3

→ t1

≠

6 s

Id/In = 1,1

→ t2

≠

10 s

≤

→ t =

∞

Adjustment of current limitation

This has 2 possible uses :

– I T link at 0 : called "standard" use, does not authorise any overload; the current is adjustable to a value

≤

the maximum continuous current of the controller.

– I T link in 1: called "2 state limitation" utilisation, which authorises, as with the motor, temporary overloads.

In this case, it is possible to exceed the set current value by up to 1,3 times, during a certain time limit, automatically followed by a reduction to 0,8 times the set value.

The time of overload operation depends on the overload value.

For 30 % (1,3 times the adjusted value) the time is around 6 seconds.

See the curve on the left.

Initial setting up

Dynamic adjustments, Special applications

Compensation for RI drop (only with U-RI coupling) P10

– Check whether the speed drops according to motor load.

P10

– Correct the drop by turning P10 in the clockwise direction, to raise the compensation, until the speed remains perceptibly the same, whatever the motor load, from no-load operating, to operation at rated torque.

– Check that the compensation is operating satisfactorily throughout the speed range, and make sure that it does not exceed the level above which oscillations can occur; if this should happen,reduce the compensations until the oscillations are eliminated.

Note : having adjusted the RI drop, it may be necessary to reset the high speed value.

SPG

Ramp time

P7 gain

P7 has been factory preset in mid-position.

To get the best performance from the speed controller, the gain must be increased to the limit of stability.

Stability must be monitored at the normal operating level (without variation of either the set speed or the resistive torque) as in transitory mode (when a change in speed or resistive torque occurs).

In order to obtain maximum accuracy and speed, the current limitation must be as high as possible with respect to normal operating current (without exceeding, as before, the maximum continuous current of the speed controller in use).

On the other hand, the higher the current limitation, the more frequently transitory mode speed limits will be exceeded.

Usually, the speed controller is delivered with the ramp function non-operational.

In order to validate the ramp function, set the R link to position 1.

ACC

DEC

Acceleration and deceleration ramp times are individually adjustable, using the control board's ACC and DEC potentiometers.

The adjustment range for these potentiometers is from 2 s (fully anti-clockwise position) to 20 s (fully clockwise position).

NOTE : when the ramp is off, this in fact corresponds to a very short ramp time, which nevertheless remains adjustable, from approximately 20 ms to 300 ms, using the potentiometer.

Spare parts and accessories

Description For RECTIVAR Characteristics Reference

Fuses

Line (1) inductances

Diodes (2)

Thyristors (2)

Control board

Power board

RTV-04U60M

RTV-04D12Q

RTV-04D24Q

RTV-04D44Q

RTV-04U60M

RTV-04D12Q

RTV-04D24Q

RTV-04D44Q

RTV-04D24Q

RTV-04D44Q

RTV-04D24Q

RTV-04D44Q all ratings

RTV-04U60M

RTV-04D12Q

RTV-04D24Q, D44Q

A060URB020T13

A060URB025T13

6,621CPURGB145140

6,621CPURD2258100

860

H 8 A

860

H 16 A

800

H 32 A

400

H 60 A

45A - 1200 V

70A - 1200 V

26 A - 1200 V 1000 V/

µ s

55 A - 1200 V 1000 V/

µ s

6 A

12 A

24/44 A

DF2-CF02001

DF2-CF02501

DF3-EF04001

DF3-FF10001

VZ1-L008 U860

VZ1-L016 U860

VZ1-L032 U800

VZ1-L060 U400

VZ3-DM2045M12

VZ3-DM2070M12

VZ3-TM2026M12

VZ3-TM2055M12

VX4-RAE101

VX5-RAE101

VX5-RAE102

VX5-RAE103 Power interface board

Current feedback board

Galvanic isolation board

Reference potentiometer

RTV-04D24Q, D44Q all ratings all ratings

24/44 A

2,2 k

Ω

3 W

VX5-RAE106

VW2-RZD2071

SZ1-RV1202

(1) Mounting of two or more speed controllers together.

(2) These characteristics are given purely as a guide, and are not the only ones to be considered when

selecting a component.

When carrying out an exchange, it is possible to replace a board by one with the same index (the same version) or higher (later version).

Never fit a board with a lower index (earlier version).

Maintenance

Systematic checks

A loose contact, or faulty connection can result in faulty operation.

– Check the voltage at the terminals (see terminals on page 37)

– Ensure that the 0VD-RUN link is properly connected (speed controller unlocking).

– Ensure that the 0VD-INR link is properly connected (ramp unlocking).

Problems coveredin the fault findingtables

– The motor is not rotating smoothly.

– Poor regulation: drop in speed as the load increases.

– Instability.

– Motor runs away.

– Speed adjustment not operating.

– Blown fuses.

– The motor is not rotating.

For each operation, the use of a measuring, or test device is recommended.

A moving scale ammeter.

Ω voltmeter or multimeter.

ohmmeter or "test lamp".

Maintenance

Fault-finding table

Before any intervention on the RTV-04, check all the peripherals.

Faults observed Check on the speed controller

control board power section

The motor does not rotate – The current limitation adjustement A

– Mains supply voltage

– Isolator fuses – Unlocking : when testing the 0VD-RUN and 0VD-INR interconnections, the LED

must be on

– Reference 0-10 V on terminal 0E1 et E1 V

The motor does not rotate smoothly – SPG gain adjustement (P7) – The power bridge

Ω

The motor runs away

–

– Position of link F

– The power bridge

Ω

Instability – SPG gain (P7)

– Position of link H

–

Poor regulation, speed drops as the load increases

Speed regulation impossible

Fuses blown

– Current limitation adjustement

(set too low)

LED I > (yellow) goes on

–

– Reference 0-10 V on

terminal 0E1 and E1

– The power bridge

Ω

–

– The wiring(short circuit or

earth fault)

– The power bridge

Ω

Maintenance

Fault-finding table

Check the speed feed back Check

by tachogenerator.

by U- RI on the motor

– –

The exitation current and

voltage on terminals

F1+ et F2–

A V

Check on the other items

–The wiring and

connections

– That the motor is not

blocked mechanically

– Brush wear

– – RI drop compensation – Motor and tachogenerator – That there is no earth fault

brush wear V

– The position of the link H – The position of the link – The exitation voltage from 0-10V to 0-240V H to H0-HU – The excitation current A

– The TG feedback to – The voltage feedback – The Wiring terminals RNA et RNB V

– The wiring

– The TG-motor coupling – RI drop compen-

sation

– That the motor is not of

the compound type

–That the cause is not

mechanical

–

– RI drop

compensation

–

–The value of raed

armature voltage

160 V for 220 V

280 V for 380 V

–

– –

– The wiring(short-

circuit or earthfault)

– The fuse rating

(see page 41)

– the contro circuit wiringl

(see page 38)

Maintenance

Power bridge check

With the speed controller switched off, disconnect AL1, AL2, M1 and M2 and check the bridge according to the table below :

AL1

AL2

–

Polarities of the

test lamp

+ –

–

AL1

AL2

Component tested

AL1

AL2

–

V1 (TH)

V2 (TH)

V1 (TH)

V3 (D)

V4 (D)

V3 (D)

In the event of a fault, disconnect the components' cathodes and :

– Test the power wiring.

– Test each component : result (see below).

– Replace the faulty part(s) (1).

Lamp off

Normal

Faulty

Normal

Lamp on

Faulty

Normal

Faulty

Normal

Faulty

–

anode

DIODE

gate

cathode

THYRISTOR

gate

anode cathode

–

+ – +

–

off on off off on*

(*) Note : the lamp goes on when the gate and the anode are connected, and stays on

–

+ –

Excitation circuit check

– The circuit is located on the power board.

– Remove the control board.

– Disconnect F1 and F2.

– Test the following four bridge diodes : D1 - D2 - D3 - D4.

– In the event of a fault, replace the power board.

+ –

Internal control wiring

Speed controllers 24/44A

J9

1 4

J12

1 4

V1

V2

G1 G2

V3

V4

1 12

J4

Tightening torques : - fixing : 4,5 N.m

15 %

- connections : 2,5 N.m

15 %

Schéma synoptique - Block diagram

44995 JUILLET 1994

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