Schneider Electric Reversing variable speed controllers User Guide

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R ®

série 44

Variateurs de vitesse réversibles pour moteurs

à courant continu

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

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

Maintenance

Eléments séparés et de rechange

Câblage interne contrôle

Schéma synoptique

Contents

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

Connections

Layout

Initial setting up

Maintenance

Spare parts and accessories

Internal control wiring

Block diagram

33 to 34

36 to 37

44 to 46

47 to 51

52 to 57

58 to 60

Pages

3-4

6-7

14 à 16

17 à 21

22 à 27

28 à 30

Presentation

RTV-44 Reversing 4 quadrants

Characteristics

The RTV- 44 speed controllers are designed to control separately excited d.c. motors, or permanent magnet motors, from a single phase a.c. mains supply.

Reversing, with fully controlled bridge, they operate in all four torque/speed quadrants.

Total power/control isolation.

Ratings :

Mains voltage

Speed range

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

10 % 50/60 Hz

2 Hz

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

1 to 200 with tachogenerator

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

Composition

The RTV- 44 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-44 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

- reversing logic

- 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 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 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 = 1,6.

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 0,68.

General

Functional block diagram

IXI

L.INV

I. exc.

: single phase Graëtz bridge

: motor current measurement

: motor speed measurement

R : field winding supply

L.INV : reversing logic

Selection guide

Selecting the speed controller rating

The table on page 7 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 = 1,5 during 8s maximum (operating with

2 states limitation on overcurrent) with cyclic operation

Td/Tn

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

- Id must be

≤

maximum continuous current of the speed controller.

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.

1,75

Compensated motor

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

Id/In = 2.I maximum speed controller

≥

2 In motor.

1,5

1,25

Non-compensated motor

Operating modes

1,25 1,5 1,75 2

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.

Id/In

0 t1

T t2 t

For the Rectivar 4 series 44, the following time limits must be observed : t2

≥

7 t1, t1

≤

8s.

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

I maximum continuous 6

Io 4

Ip 9

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.

240V

50/60 8

380V

50/60 16

415V

50/60 16

Single phase Continuous Motor supply current

Voltage line d.c. side

Maximum motor RecomExcitation

power (

= 0,85) mended Rectifying

Maximum Peak standard 2 state armature voltage

current continuous

U rms I rms Im Ip

limitation (2) limitation( 2) voltage full half wave wave

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

In P Pn (4) Pc (3) UA

RECTIVAR (1)

Current Reference Weight

I ex.

220V

50/60 8

10 kW kW kW

0,6

1,25

0,5

1,15

2,3

150

190

100

2 kg

RTV-44U60M 3,600

RTV-44D12Q 3,600

20 2,55 2 4,6

36 4,6 3,7 8,4

5 0,65 0,55 1,2

150 190

160 205

100 2

110 2

RTV-44D24Q 6,000

RTV-44D44Q 6,000

RTV-44U60M 3,600

1,35

2,4

1,1

36 4,9 4

1,9

2,45

20 2,7 2,2 4,9

10 2,2 1,8 4

20 4,4 3,5 8

4,3

20 4,8 3,8 8,6

160

260

280

205

330

6,4 14,6 260 330

360

280 360

36 8,6 6,9 15,7 280 360

110 2

170

185

185 2

RTV-44D12Q 3,600

RTV-44D24Q 6,000

RTV-44D44Q 6,000

RTV-44D12Q 3,600

RTV-44D24Q 6,000

RTV-44D44Q 3,600

RTV-44D12Q 3,600

RTV-44D24Q 6,000

RTV-44D44Q 6,000

Form factor = 1,6.

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

To use them at 220/240V, follow the instructions on page 52.

The RTV-44U60M product is supplied for 220/240V exclusively.

(2) See "adjustement of current limitation" on page 54.

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

(4) Pn : rated power.

Characteristics

Mains supply, voltage and frequency

Recommended armature voltage depending on mains voltage

Excitation mains voltage

Maximum excitation current

Armature current limitation

Speed range

• Control by back emf

Accuracy :

• Control by tachogenerato

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

Reversing

Speed feedback

• by armature voltage

• by tachogenerator

Acceleration and deceleration ramp

Output relays

Electrical characteristics of contacts

Voltage and current available on the speed controller

(cumulative current values).

Logic inputs

Degree of protection

Ambient air temperature

• for operation

• for storage

Derating according to altitude

Vibrations and shocks

220/240 V and 380/415 V

10 % (except 6A rating : 220/240only)

50/60 Hz

2 Hz

U armature

≤

U mains x 0,68

Maximum voltage : 415 V, and U excitation : 0,45 or 0,86 U mains (see table on page 37)

Current limitation adjustable by potentiometer from

0,4 to 1,5 times the max. continuous current

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 39 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

0-20 mA and 4-20 mA with reversing by logic signal (optional)

(*) The 2 inputs

10 V are summing; their sum must never exceed

10 V

By speed reference polarity or by logic signal (optional)

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 : 0 to 20 s in two ranges.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.

+15 V (P15): 50 mA. -15 V (N15): 50 mA. For all the inputs, optional boards and external functions.

+24 V (PL): 30 mA (80 mA if no load on the +15 V).

+10V (P10): 5mA. -10 V (N10): 5mA.

RUN: 10mA consumption at 24 V, 10 V minimum switching

INR, ISI: 10mA consumption at 24 V, 7,5 V maximum switching.

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 Function

AL1

AL2

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

Earth (ground)

M2 -

M1 +

Motor armature

Power interface board 24/44A

Mains voltage pick-off AL1-AL2

AL11

AL21

CL1

CL2

FL1

FL2

F1 +

F2 -

Control supply : 220/240V or 380/415V (see page 50)

Single phase supply to the excitation bridge

Positive output of the excitation bridge

Negative output of the excitation bridge

Power board 6/12A

M2 -

M1 +

AL1

AL2

AL11

AL21

CL1

CL2

FL1

FL2

F1 +

F2 -

Control board

CAI

ECL

DCC

RUN

INR

ISI

P10

RNA

RNB

AT (1)

IRT

SAO

N10

P15

N15

K1A (2)

K1B

K2A (2)

K2B

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 48)

Single phase supply to the excitation bridge

Positive output of the excitation bridge

Negative output of the excitation bridge

Speed sensor input

Assignable terminal, second reference input (39 k

Ω

)

Speed reference input 0 to

10V (39 k

Ω

)

Speed signal [0

8 V for the maximum set speed (3 mA max)]

Increase of ramp time by external voltage (page 45)

Speed loop output. I output

≤

3mA

Speed loop input (68 k

Ω

)

Current limitation input 0/-10 V

Current signal. I output

≤

3 mA (1,5V for set I, average value)

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

Logic input supply (24 V), RUN, option1 and option 2

Validation of the ramp by 0V

Inhibition of the speed amplifier integration by 0V

Reference potentiometer supply + 10V

0,2V (5 mA)

Potentiometer supply -10 V

Supply +15 V

0,2 V (5 mA)

0,6 V. I max. = 50 mA

Supply -15 V

0,6 V. I max. = 50 mA

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

Voltage free contact of relay K2 with function configurable by link : a) Current limitation. Closed when the controller is

outside limitation b) Speed not zero. Closed when the speed is higher

than 0,02 times the rated speed

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

(2) 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

, 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.

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 ≤

40 °

C

➤

θ ≤

40 °

C

➤

1234

1234567890123456789012345

1234567890123456789012345 d

M d

1234

1234567890123456789012345

Wiring precautions

To carry out the external wiring, remove the cover and use a suitable screwdriver. 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.

Control board terminals Control board terminals

P10

N10

0V

E1

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-44U60M

RTV-44D12Q

RTV-44D24Q

RTV-44D44Q

Overall

159

162

Line inductances

Association with controllers (see pages 43 and 62) b

264

264 c

130

177

G a

Fixings

230

120

G a

H c

Overall Fixings

Référence

VZ1-L008 U860

VZ1-L016 U860

VZ1-L032 U800

VZ1-L060 U400 a

108 b

105

135

145 c

105

115

130

Fuses

Association with controllers (pages 43 and 61)

ø

L

Reference

DF2-CF02001

DF2-CF02501

DF3-EF04001

DF3-FF10001

5,5

Weight (kg)

0,400

0,750

1,850

3,100

Connections

Reversing with regenerative braking

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

6 to 44A speed controllers

Recommanded circuit diagram

3 4

KM1

3 4

S1 KA1

KA1

0,2s

KM1

3 4

AL1

AL2

M1+

M2-

F1+

F2-

FL1

FL2

RNA

AL11 RNB

CL1

AL21

N10

P10

CL2 E1

K1A

K1B

K2A

* *

K2B

RUN

INR

1 2 3 4 5 6

LAD

KA1

Exitation voltage

Mains supply

220/240V 380/440V

190/205V 330/360V

100/110V 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)

Connections

Reversing with regenerative braking

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

6 to 44A speed controllers

Nomenclature of the required equipement

Item

KA1

KM1

LAD

S1-S2

-S3

Description Voltage

Mains

Voltage Reference Reference Reference

Armature Maximum power with Td/Tn = 1,2

Reference

Motor

Speed controller

220/240V 150/160V 0,65 kW

380/415V 260/280V –

RTV-44U60M

1,3 kW

2,4 kW

2,7 kW

4,8 kW

8,5 kW

RTV-44D12Q RTV-44D24Q RTV-44D44Q

Thermal overload relay (1)

+ terminal block

Control relay

Timer

LR2-D13••

LA7-D1064

LR2-D13•• LR2-D••••

LA7-D1064 LA7-D••••

LR2-D••••

LA7-D••••

CA2-DN40M7 CA2-DN40M7 CA2-DN40M7 CA2-DN40M7

LA3-DR0 LA3-DR0 LA3-DR0 LA3-DR0

Line contactor

Line inductance

Smoothing choke if required

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

VZ1-L008U860 VZ1-L016U860VZ1-L032U800VZ1-L060U400

-Essential for motor with flat rotor.

-Strongly recommended for torque motor.

(Consult our local sales service)

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

Isolator

+ 2 power fuses

Circuit breaker

+ contact block

Circuit breaker

Circuit breakerr

Potentiometer

Control

Signalling

Transformer

(secondary 220V)

GV1-M05

GB2-CB05

SZ1-RV1202

GV1-M05

GB2-CB05

SZ1-RV1202

GV1-M05

GB2-CB05

SZ1-RV1202

GV1-M07

GB2-CB06

SZ1-RV1202

Au choix, éléments XB2-M ou XB2-B ou boîtes complètes

100 VA 100 VA 100 VA 250 VA

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

Connections

RECTIVAR 6/12A

BORNIER CONTROLE

BORNIER INTERFACE

PUISSANCE

BORNIER PUISSANCE

RECTIVAR 24/44A

AL1 AL2

ø 6.5

BORNIER CONTROLE

ø 6.5

BORNIER INTERFACE

PUISSANCE

102

135

Connections

Function of the speed reference inputs

Speed reference

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 or -10V.

The direction command is given by the reference polarity.

P10

2,2 k

Ω

N10

2,2 k

Ω

P10

N10

Ramp

Acceleration time (ACC) and deceleration time (DEC) can be adjusted independently. They can be adjusted in 2 ways : internallly

- by a switch with 2 positions, defining 2 ranges : 0 to 1s and 0,5 to 20s.

- by a potentiometer which enables time adjustment within each range externally the ramp time can be modified using the IRT input, connecting the two 2,2 k

Ω

potentiometers and two diodes as shown in the diagram on the left, or by using a programmable controller analogue output.

1,5

V (IRT)

P15

2,2 k

Ω

IRT

0V 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.

+ 24V

2,2 k

Ω

& &

INR

15 k

Ω

0 V

10 V

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)

N15

2,2 k

Ω

1 k

Ω

ECL

I = 0 for ECL = - 10V

I = I lim for ECL = 0V

0 to 100 % adjustment of the current limitation

Integration short-circuit

+24V

SLIM

2,2k

0

& & &

15k

10V

ISI

1 0V

RUN

OSP

In order to cancel the integral term of the speed loop, link terminal ISI to zero by connecting terminal

ISI to the 0V terminal on the control board.

ISI

It is also possible to cancel the integral term for N

≤

0,02 times rated N by setting the ISI link in the

1 position, if the link is in position 0 the term can only be cancelled by terminal ISI on the customer connector.

Validation

RUN

The speed controller is validated via the RUN command input.

When this input is connected to the PL input, the speed controller is validated.

When this link is no longer closed, the speed loop, current loop, firing gate and ramp functions are locked :

When the control supply (CL1-CL2) is connected on the incoming side of the line contactor KM1, the closure of the contact on RUN must never precede the closure of the line contactor (risk of damage). When the controller is switched on, the RUN contact must always open 0,2 seconds minimum before the line contactor (risk of damage).

Layouts

RTV-44U60M / RTV-44D12Q

OPTION

BOARD

CONTROL

BOARD

GALVANIC ISOLATION

BOARD

SUPPLY

TRANSFORMER

POWER BOARD

CURRENT

TRANSORMER

SUPPLY

TRANSFORMER

THYRISTOR

MODULES

RTV-44D24Q / RTV-44D44Q

AL1 AL2

M2M1+

GALVANIC ISOLATION

BOARD (OPTIONAL)

OPTION BOARD

POWER INTERFACE

BOARD

CONTROL BOARD

J11 10

J7 16

Layouts

24/44A power interface board

Galvanic isolation board

(optional)

PD1

380V

J5 J8

220V

J11

J10

Layouts

Control board (common to all the speed controllers)

Clip-in board

J5 J1

RAMP

0,5-20s 0-1s

ACC

DEC

HSP

SPP

SPI

J2 option board, if fitted

OSP

SAI RAMP

10V

30V

60V

120V

240V

60Hz 50Hz

RZI

I T

K1 K2

ISI

AK2

OSP

RUN

Layout

Potentiometers

LEDs

Control board

Links

: 50 or 60 Hz

: separates the speed amplifier (w) 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)

RAMP : operation of the reference ramp : 0 - 1 s or 0,5 - 20 s.

ISI

I T

AK2

: cancellation of the integral gain : 0 : standard. 1 : for N

≤

2 %

: selection of the type of limitation

0 : standard

1 : with 2 states

: selection of level of speed image voltage feedback

: assignment of relay K2 : - IA : closed outside current limitation

- OSP : closed when speed

≥

2 %

Potentiometers

ACC : adjustment of acceleration time

DEC : adjustment of deceleration time

HSP : adjustment of maximum speed (high speed)

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

IA > : adjustment of limitation current

SPP : proportional speed adjustment

SPI : integral speed adjustment

OSP : adjustment of the speed amplifier offset, factory preset

LEDs

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

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

RZI

: (green LED) bridge 1 validated

: (green LED) bridge 2 validated

: (yellow LED) current loop reset

Electromagnetic relay

: relay indicating validation state

: assignable relay

Power board

Links

: excitation voltage selection

: control transformer supply voltage selection, except 6A rating, supplied for 220V only.

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

(terminals 0V, P10, N10)

- recommended value : 2,2 k

Ω ≤

≤

10 k

Ω

- power : P

≥

3W.

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 48 to 51.

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

220 V

240 V

380 V

415 V

Exitation voltage

according to link F

100 V

110 V

170 V

185 V

190 V

205 V

330 V

360 V

NOTE : the 6A rating (RTV-44U60M) is only

supplied for 220 / 240V.

Initial setting up

Preliminary checks

Mounting of the options

(For further detail, refer to the documentation supplied with each option)

.

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 connecting ribbon n

5 to the power board J7 connector and connecting ribbon n

6 to the J11 connector on the power board. Set the H link on the control board in position U. Check the position of the galvanic isolation link according to the armature voltage

(see notice for the board)

NOTE : connection ribbons and separators are supplied with the board.

VW2-DF308L current reduction board

The board is not supplied with the controller.

Mount on connectors J2 and J3 on the control board without any other wiring.

VW2-RZD309 variable gain board

Also includes current reduction function.

The board is not supplied with the controller.

Mount on connectors J2 and J3 on the control board without any other wiring.

Adaptation modules

(see documentation supplied with each module)

.

- Adaptation of the VW3-RZE101 speed reference (current input, direction via logic signals…) .

- Excitation presence control. See RM2-JA••• relay

Initial setting up

Static adjustments

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.

– Initial setting up and control unit if necessary (page 61).

Static adjustments

Maximum motor current

This controller has 2 possible operating modes :

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

value

≤

max. continuous controller current.

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

overloads.

In this case, it is possible to exceed the set current value by up to 1,5 times, during a certain time period, automatically followed by a reduction to 0,8 times the set value.

The time of overload operation depends on the overload value. For 50 % (1,5 times the set value) the time is around 8 seconds. See the curve below.

I D / I N

1,2

1,1

0,9

0,8

0,6

1,5

1,4

1,3

Without ramp

Ramp correct

Ramp too long a 8 s a 2 0 s

2 4 6 8 1 0 1 2 1 4 1 6 1 8 2 0

NOTE : 1 - the set value corresponds to 1,5V on terminal DCC (page 39), i.e. 2,3V for the overload value

2 - caution, in the event of a driving load, check that the 2 state current is adequate for braking.

Adjustment

(carry out without the 2 state function. If required, take into account the ratio I

= 1,5 set I).

• Mains supply disconnected

– Open the Q2 circuit breaker (for motors with permanent excitation, mechanically block 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 RAMP link in position 0.

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

• Switch on the speed controller

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

– Turn potentiometer I

> clockwise in order to obtain the required limitation value, taking Td/Tn into

account (see safety precutions on the next page).

Adaptation modules (see documentation supplied with each module).

Initial setting up

Dynamic adjustments

• 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-44D24Q operating in an ambient temperature of 55

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

(100-18)

100

= 0,85, the maximum power available at the motor shaft becomes :

I max x U armature x

Td / Tn

=

20 x 280 x 0,85

1,2

= 3900 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..

Adjustment of speed data feedback

Adaptation of voltage feedback is carried out using link H, as shown in the table below (with the galvanic isolation option board, essential if U

RI feedback).

–U

10V Mode

Feedback

Link H

Position Voltage

Armature voltage

H

30V

0 - 10 V 0 - 10 V

0 - 30 V 10 - 30 V

0 T.G.

0 - 60 V 30 - 60 V

60V

0 - 120 V 60 - 120 V

0 - 240 V 120 - 240 V

Isolated U

±

RI

120V

240V

0 - U 0 - 10 V 150 to 280 V

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 : for T.G. feedback

- switch off,

- check the continuity of the 2 tacho feedback wires,

- if not, reverse the 2 wires.

for U

- check the galvanic isolation board connections and the

position of its link

– 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.

HSP

Initial setting up

Dynamic adjustments

Special applications

Compensation for RI drop (only with U

RI coupling)

– Check whether the speed drops according to motor load.

– 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.

Speed loop adjustments

- set a reference of 100 %

- validate the product using RUN

- SPP and SPI are factory preset at the minimum (potentiometers against the stop in the anti-clock wise

direction)

- adjust SPI so that the stability limit is reached, then set SPP at the stability limit as well

- for a display of the speed increase, connect an oscilloscope between 0V (terminal 31) and Sp

(terminal 6)

SPI

SPP

SPI minimum

SPP minimum

SPI adjusted

SPP minimum

SPI adjusted

SPP adjusted

Initial setting up

Dynamic adjustments

Ramp time

The speed controller is delivered as standard with the ramp function in position 0 - 1 s.

+ +

DEC ACC

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 0 s (fully anti-clockwise position) to 20 s (fully clockwise position) in 2 ranges : 0 - 1 s and 0,5 - 20 s (RAMP link).

Option boards

For current reduction or variable gain, refer to the instructions supplied with the boards.

Maintenance

Systematic checks

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

– Check the voltage at the terminals (see terminals on page 39)

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

– Ensure that the 0V-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.

V voltmeter or multimeter.

Ω ohmmeter or "test lamp".

Use of the SD2MT2001 test unit, enabling display of the speed controller's internal signals, facilitates fault-finding and diagnostic.

Maintenance

Fault-finding table

Before any intervention on the RTV-44, 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

The motor does not rotate smoothly – SPP and SPI gain

adjustement

The motor runs away

– Unlocking : when testing the OV-RUN and OV-INR interconnections, the LED

must be on

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

–

– The power bridge

– Position of link F

Ω

– The power bridge

Ω

Instability – SPP et SPI gain

– 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

–

– 0-10 V reference at terminal

0V 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 V from 0-10V to 0-240V H to H0-HU

– The TG feedback to – The voltage feedback – The excitation current A – The wiring terminals RNA et RNB V

– The TG-motor coupling – RI drop

compensation – That the motor is not of

the compound type

–That the cause is not

mechanical

–

– RI drop

compensation

–

–The value of raed

armature voltage

150 V for 220 V

260 V for 380 V

–

– –

– The wiring(short-

circuit or earthfault)

– The fuse rating

(see pages 41)

– the contro circuit wiringl

(see page 39)

–

Maintenance

Power bridge check

+ – +

With the speed controller switched off, disconnect AL1, AL2, M1 and M2 and test the bridge as shown below, bearing in mind that 2 cases can arise:

1 - Thyristor open circuit : check each thyristor.

2 - Thyristor in short-circuit : as the bridge is fully controlled, one of the bridges must be

removed before it is possible to determine whether a thyristor from bridge A or bridge B is involved.

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

– Test the power wiring.

– + –

– Replace the faulty part(s) (1).

(1) Note : for the 6 / 12 A ratings replace the power board.

–

THYRISTOR

gate

anode

– –

cathode

+ – +

–

+ –

off off on*

gate is disconnected.

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.

+ –

Spare parts and accessories

Description For RECTIVAR Characteristics Reference Weight (kg)

Fuses

RTV-44U60M A060URB020T13 DF2-CF02001 0,010

RTV-44D12Q A060URB025T13 DF2-CF02501 0,010

RTV-44D24Q 6,621CPURGB145140 DF3-EF04001 0,020

RTV-44D44Q 6,621CPURD2258100 DF3-FF10001 0,045

Line (1) inductances

RTV-44U60M 860

H 8 A VZ1-L008 U860 0,400

RTV-44D12Q 860

H 16 A VZ1-L016 U860 0,750

RTV-44D24Q 800

H 32 A VZ1-L032 U800 1,850

RTV-44D44Q 400

H 60 A VZ1-L060 U400 3,100

Thyristors (2)

RTV-44D24Q 26 A - 1200 V 1000 V/

µ s VZ3-TM2026M12 0,150

RTV-44D44Q 55 A - 1200 V 1000 V/

µ s VZ3-TM2055M12 0,180

Control board all ratings VX4-RDE101 0,340

Power board

RTV-44U60M 6 A VX5-RDE101 1,130

RTV-44D12Q 12 A VX5-RDE102 1,130

Power interface board

RTV-44D24Q, D44Q 24/44 A VX5-RDE103 0,470

Variable gain all ratings VW2-RZD309 0,100 option board

Current reduction all ratings VW2-DF308L 0,080 option board

Excitation presence all ratings see RM2-JA••• 0,250 module

Speed reference all ratings VW3-RZE101 0,220 adaptation module

Galvanic isolation board all ratings VW2-RZD2071 0,240

Reference potentiometer all ratings 2,2 k

Ω

3 W SZ1-RV1202 0,060

Control unit all ratings For setting up without VW3RDE105 0,900

external sequence

(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.

Internal control wiring

Speed controllers

AL1

AL2

V22

K22

V21

K21

G21 G22

V14

K24 K14

V24

V12

K12

V11

K13

V13 K23

K11

G13 G24 G23 G14

V23

G11 G12

M2M1+

RNA

RNB

RTU

P10

N10

CAI

SAO

IRT

DCC

(D)

RAMP

SAI

+10V

-10V

HSP 6 H

SPP

SPI

ISI1

SYN

1 1

# R

ACC-DEC

INR

+1.62

-2% +2%

IA>

+5 1

OSP

ECL ECL ISI INR RUN P15 N15 PL K1A K1B K2A K2B CL1 CL2 AL2 AL1 AL11 AL21

+ +

ALIM

+15V -15V +24V

0 T1

(E)

INR

RUN

AK2

OSP

ISI

ALIM

SYN

OSP

ISI1

220V

380V

F 0

I T

1.5

IN 0.8

FHZ

PA SPA

LCI

LSI

CAO

(A)

RZI

DVA1

DVA2

V12

V14

V21

V23

V11

V13

V22

V24

RZI A1 A2

M2 M1

RNA

SCHEMA SYNOPTIQUE RTV 44

RNB

F1+

F2-

FL1

FL2

44875 MARS 94

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