INSTRUCTION MANUAL Converters EYPACE TPy3...2B Converters for single and two quadrant operation Pages 393-456 PR 82 E (10/86) KContents 2. Tata ea ws G92 fal compen tr emu stage reJton 2 Technical dat = eprom gee = 2 = 6.33. raed moe tae, ome wedetn 2 a = 638 Spm sonang 5 28 rae ey = a7 Ott comm wae opdot a 289 Rover scion = ee ordiel pinta ‘0 27 — Regulation 400 64. Turing 430 2 re at Cone oir is 29 — Weights and power losses 401 €.4.2 Speed roguistor 433 5. spect tenures o 6. lag or comection of for quant 4, Fitting and electrical connections: 402 field converter 435 12 Bonen comectos oe 9. Bus canestion X tor the connection 42 Reet = Sencar Xe C 4.2.3 Two quadrant operation 408 10. ‘Test points avaitable 437 5. Converter circuits 410 10.2 Regulator supply Sy3 439 5.1 Internal power supply a0 103 Card ROy 439, 8.2.2 Enable ramp function generator 4i1 ‘11.1. Regulator card RyS2 440 Ese] sara sosee eget i ees fs Sa Roerence wee ret es {21a card ce ] 5.4.1. Operation with ramp function generator as ey a 54.3 Minimum speed a7 oom Ree 3 Sa neopnuer cop aes a suger “s 55 Current limitation 418 he) “3 5.5.2 External current limitation 418 4 Micro switches “ 5.5.4 Negative direction of torque with TPy3.. 2B +e 419 142 Regulator supply Sy 445 5.6 Speed regulator 420 143 Flold supply Fy90 445 88 Tor amen iss 15 Bridges, caration elements us tio ued ome @ {St Romunercare m0 is 6. commslrng atuctons wo {82 Fad ep 60 “ 82 Chasing eau voter te 18 senameve end evel agra i PR g2K 994 110185),Mostieton 24 General ‘The power section of the TPy3...28 consists of two fully-controlled three-phase bridges for the armature supply of d.c. shunt-wound motors of medium and high ratings. An uncontrolled Graetz bridge (82) with protective circuit and field current relay is available for the field supply. ‘The various cards of the regulator section are divided according to functions. They are connected to each other and to the power section via a ribbontype cable. —Ry32(+e) ESE 1609 Regulator, actuating logic, LED displays, calibration components, modula- (front card) tor and synchronization — Roy ESE 1639 Only on TPy3...28(+6) 38 ESE 1592 Regulator supply and voltage stabilization —PTya2 ESE 1610 Trigger circuits with pulse transmitters —Py320 ESE 1636 Summation - TSE - circuit Pys2-1 ESE 1611 Fuse monitoring for the power section Pys22 «ESE 1634 —Fy. ESE 1616 Field rectifier with protective circuit and ESE 1638 | field current relay. ‘The two ranges, TPy3-415/480....2B and TPy3-500/600...28 differ in the voltage stability of their power sec- tions. The regulator sections are identical. Converters up to a rated current of 500A are buitt as compact units. The power section is a separate unit, and is connected to the regulator section via plug-in connectors. Units from 110A rated current upward, are fancooled. See 2.8 for dimensions. Devices with type suffix «+e» have a combined armature field current converter. Mains connection Series TPy3...28 converters can be connected directly to the following mains systems: Tye Mains system 50160 Hz 7Pya-416/400...28 | 3x2G0V —1036.. 200V + 10% 3x380V 4 1006 = Standard Sxa15V #1096 1Py@-500/600.....28 | As above, addiionally: 3xcA4QV —10%6. 460V +1036 3x.400V —10%6... S0OV +1096 + Standara ‘The converters are matched to the mains voltage via the switches SW-U, SW-V and SW-W on the Sy3 card, Only one voltage range may be selected at any ane time; the positions of the three switches must agree. The position of the switch SW6-1...3 on the Ry82 card depends on the mains frequency. ‘ swer..3 SoHe cb OFF = Standard Gore 4406 on. Power and regulating sections may be energized at the same time, ‘As supplied, the power units are interconnected via the bridges, CV-U, CV-V and CV-W on the Py32... card, Itis recommended however, that the power and regulator sections are fed separately, so that the information provided by the LED and any possible fault indication via the relay is maintained, even ifthe motor is not swit- ched on. In this case, CV-U, CV-V and CV-W on the Py32.... should be removed. The regulator is then supplied via the terminals, 1U, 1V, 1W on Py32- PR 82K.905 ‘i186‘Common incoming supply ‘Separate incoming supply Fig. 21.4 Py 32 Regulator Power supply secton I Fig. 212 ‘The phase rotation must be the same as for he power section. The direction of the rotating field is as required 2.2 Rated d.c. voltage ‘The magnitude of the rated dc. voltage depends on the mains supply voltage ULN and the operating mode. (1Q = single quadrant operation, 20 = two quadrant operation), Uy verter a 10° zr, aare] Somers sxzzov | 260v 250 151480. -25( +8) sxaeov | 280V 2s0v axasov | save | 400 axarsy | 400y cov _ sxaeov | St0v ‘a6ov | TPy8-5001/600- .-25(+6) sxagov | 530v 480v sxaaov | 560v ‘s00v axsoqv | _600v 520 + a40V at mains votage fuctuaions to 1086 ULN. Type suffix «es “Type sux «+e in conjunction with 40 Feld converters TPey.. 0 should be tured fully anticlockwise 2. Following prior regulator blocking, (no voltage at terminal 21) During braking, the current set on the current limiter flows. Braking is not speed-contralled. The absolute value stage must be bypassed (SW4:2 OFF, SW4-3 ON). There are two types of two quadrant drive: 41. Operation in quadrants 1 and 4 or 3 and 2 (converter connected as in Fig. 4.2.3); the relevant torque direc- tion is maintained and the motor is driven by the load in the opposite direction to its inherent direction of rotation (e.g. decoiling machine). Actuation is dependent on the overall system control because operation in the quadrants mentioned above is not possible with a single motor. Please note the remarks above, concerning de-energization conditions. 2. Operation in quadrants 1 and 2 or 3 and 4 (connection as in Fig. 4.2.4 and 4.2.5); the motor's direction of rotation is maintained and the torque direction is reversed by switching in the armature or field circuit (For example to brake large centrifugal masses when switching of). During switch-over the regulator has to be blocked, and is not enabled until after switch-over. In the event Of field reversal, @ protective circuit for the field rectifier has to be provided. PR 824-408 ‘core.HO. LYS NO Eom HO. Z9MS it | PA g2K.407 ‘raPA mK. (60788).PR 82K 408 ‘coreMoatieaon 6. Converter circuits 5.1. Internal power supply The power supply is on the Sy8 card. The mains supply unit consists of three single-phase transformers of 14 VA each. The primary windings are delta-connected, and are matched to mains voltage by means of swt ches SW-U, SW-V and SW-W (see 2.1). One of the three secondary windings at a time supplies the synchroni zation voltage for the modulator (55V a.c), the other two suppiying two theree-phase bridges for generation Of the regulator supply voltages. For fusing, see 2.5.1 £10V 5% Highly stabilized, short-circuit proot Maximum residual ripple: 3 mVpp ‘Thermal stability: <100 ppm/°C ‘Symmetry tolerance: <196 In the event of a short-circuit, LED “RSH” £15V 44% Stabilized, short-circuit proof Maximum residual ripple: § mVpp In the event of an overload, LED “AR” lights up +24V Unstabilized Maximum residual ripple: 80 mVpp Tolerance +19...+28 V, depending on mains voltage and load lights up Votage Termination ‘Add, load capacty (OV = Reference Terminals 2, 8, OV potential Busx 8 10 Bus J 4st ‘Sov Terminas 3,317 | Sma =10v Terminals 4,22" | S0mA + Terminal 415 200 mA = Lap Bus x 16 Bus J a 18 Termin —15: 200 mA — Ioap Bux 9 Buy 20 Terminas 19, +24 | 200A — Iyeg— Noro ‘Bus x 1 Bus J 10 + With TPy..28+6 With F217 = Bridge oo With F218 = Bridge The load capacity as stated in the table relates to unloaded output terminals of the converter, and a mains undervoltage of 10% in relation to the rated value of the converter supply voltage. 52 Enable Enablement is through application of a voltage of +15 ...+24V to the appropriate terminals. The inputs are protected against polarity reversal. Negative voltage, OV and missing signal are interpreted as “blocking” PR B2k-410 \io58)Moditoaton 5.2.1 Regulator enable 1% a Ti ah Fig, 82.4 oles +2v BLS. Fig. 6242 Kt ~Yaav Bt Fig, 8213 ° aus Pc Converter ov! oy Fig. 8214 5.2.2 Enable ramp function generator sws-2 gt Reguitor Connection: Terminal 21 (BLG) If the regulator is blocked, the LED “BLG” lights up. There are several enable possibilities: 1. Bridge between +24V (terminal 19) and terminal 21 (see Fig. 5.2.1.2). Thisis possible only i voltage is applied simultaneously to the power and regulator section, The regulator is enabled approx- rately 200 ms after switching on, thus allowing the supply vol tages to build up. 2, Enable via contact (see Fig. 6.2.1.3) Reguiator enable without delay by closing the contact of K1 The contacts must not be closed before voltage is applied to the power section (terminals U, V and W). The regulator is blocked when the contacts are opened. 3. Enable with programmable controller (see Fig. 5.2.1.4) Avoltage of +15V... +24V applied to terminal 21 enables the regulator. OV of PC and the converter are interconnected. Ena- ble conditions are the same as in 2 It the internal reference value generator is Used, it must be enabled via terminal 27, (BAG), When the ramp function generator is blocked, the LED "BAG" lights up. ‘As supplied, the ramp function generator enable is coupled to the regulator enable (GW9-2 = ON), i., generator enable on- ly with voltage at terminal 21 and 27 (see Fig. 5.2.2.1) If an independent generator enable is re- quired, the SW9-2 should be switched to the OFF position. Pa Enable facies as under 5.2.4 BAG Famp function enable generator erable L = block H = enable PR g2k 234 (ior 0)Moat With voltage applied to terminal 26 (ZAG) the speed refe- _ en a xe Enable facilities as under 5.2.1 os — eee ‘Abosite vale 2-2 amt t cen Sp Ra a Since the values are closely related to the specific application, they must be established at the commissioning (10986)53.1 53.2 The behaviour of the actual value circuil depends on the position of the switches SW4-2 and SW4-3, 1. SW4-2 ON, SW4-3 OFF = Standard on TPY3...28 ‘The actual value input behaves in the manner of a rectifier. The voltage at the test point Y1-16 is always negative. A.C. tachometers can also be connected: 2. SWA-2 OFF, SW4-3 ON = Standard on TPy3...28 +e The votage at Y1-16 has the same polarty as at terminal 1. This switch position is essential with two quadrant drives, because in this application, the tachometer voltage or the E.M.F. have the effect of a reference value during braking operation and must have postive polarity. ‘Tachometer regulation — Connection in accordance with Fig. 5.3.1.1 — Matching to tachometer voltage in accordance with table under 14.1 — Single quadrant operation: d.c. and acc. tachometers can be used as actual value transmitters — Two quadrant operation: only d.c. tachameters (For connection see Figs. 4.2.3 and 4.2.5) Fig. 83.1.1 Armature voltage regulation with high-impedance decoupling ! ! Pys- se [Ry az il sw7- Pa D> f Fig. 8321 — Connection as in Fig. 53.2.1 ‘SW3-1..8 in the ON position — Matching to the mains voltage with SW7 in accordance with the table overieat ‘The armature voltage is fed back to the actual value input via high-impedance resistors and a differential ampi- fier. By this means, the regulator sections can be de-coupled without the need for d.c.{d.c. transformers or mult-couplers. Alter the signal has been filtered and decoupled, the actual value signal is avallable asa voltage of approxima- tely 10V maximum (terminal 25). This signal ang the actual value input are connected via an external bridge between terminals 25 and 1 During armature voltage regulation, the motor speed at a constant armature voltage decreases as the load increases. This load-dependent decrease of the speed can be reduced by means ofthe builtin Rxl compensa- tion (potentiometer Rx). PR seK419 (0188)Moatieton 533 Matching of the decoupling amplifier: Un Oey = 10 Vet Un zaozenv AC | SWw74 rv DC sev ac | swre 423v DC. asv ac | swra 4e7V DC. saoreov ac | swr 508v DC ac | swrs sav DC 4801500 v * Rxl compensation not taken into account The position of the SW7 depends on the mains voltage UL\y. Only one micro-switch of SW7 may be closed The amplifier may also be matched to other mains voltages (for example from an ancillary transformer). In this case SW7-1...5 should be switched to the OFF postion, and R90 fitted Rating: Reo ULN = Voltage at terminals U, V, W of the power section of the converter. ‘Speed signalling ‘The switching threshold for the speed signal can be infinitely adjusted using potentiometer “n=O”. There are two alternatives: 1. SW8-2 = ON setting range 0.3...10% nmax 2, SWB2 = OFF setting range 3..100% nmax Signal: — Via a potentialtree contact (220 V ac., 3A) between terminals 33 and 34 — Via a static signal OV/+24V, 10 mA at terminal 32 — Via the LED “RV” on card Ry32 Below the switching point — the contact is open — the static signal is O — the LED “RV” lights up ‘Above the switching point the contact is closed — the static signal is approximately +24V — the LED “RV” does not light up. Note: When using speed regulator matching, the position of the potentiometer shold for recognition of nact (see 5.6). ‘The speed signal decay is delayed, the delay time + being determined by the resistor R180. 'n=0" determines the thre rims} R180 [ko] Standard: R180 = 47 ko 7 = 65ms PR goKat4 idais6)Moxteation 5.3.4 Speed indication A signal, directly proportional to the actual value, is available at terminal 14 of the converter for connec- tion of a speed indicator. The polarity of terminal 14 corresponds to that of terminal 1 re ‘SW4-8 ON : Voltage signal rol T Sot © Ov epprotmatsly 4 10V maximum ee Pt as on terminal 14, load capacity: 3 mA i ar ‘SW4-8 OFF: Connection of an mA meter with 1: mA _ 4 at full-scale deflection. The deflection of the pointer at nmax can be calibrated Bey using potentiometer DTN. * Scale in rpm, mis. 9. 54 Reference value circuit ‘The magnitude of the reference value vata determines the speed of the motor under control “tape bo | Speed regulator Rterence value Pig. 54.3 soo 5.4.1 Operation with ramp function generator on ——— on 3 _ Be ‘Bac | ALG] sa See 522 Kt = Regulator onabio 2 = Ramp function generator enatle K3 = Reerence value enable Fig. 84.1.1 Spoed reference valve potertometer Reference value for 2.540 ul motor regulators PR BDK.Ai8. ‘sae8)The ramp function generator is used to delay changes in the reference value voltage and thus to achieve run- up and run-down processes of predetermined duration. Wiring is in accordance with Fig. 5.4.1.1 Input: Terminal 28 10 V maximum, 0. mA maximum Output : Terminal 30 £10 V maximum, 4 mA maximum (+ internal reference value input via SW8-1), On the converter as supplied, the ramp function generator output is connected to the input of the speed requ: lator via SW8-1 The run-up time is determined by resistors R142A, R142B, R142C and the position of the potentiometer“ +a" the run-down time by R141A, F141B, R141C and the position of "—a" STANDARD No STANOARD pine igia® |qi=2 os..53_|7 3.208 15.1508 rata = arma] ce |e = | isa armo) | oe | | peeve) ee | riz = awa) Se | ate = 0a] ee ae Rize = 22010] “> Fo 84.12 Ifthe run-up time is to be set externally, the supplementary card AGy should be used. This is fitted inside the unit, at the back of the Ry32 regulator card. Enable Mode of votage on | Function operation ‘ermal Fun 21, 26, 27 | Motor runs up tothe required speed i the ramp time set on potentiometer "+a! ‘operation Contraied 21, 27 | Motor runs down to zero speed inthe rap time set on potentometer run-down Pre-requste: The set run-down times anger the run-down ime without ramp function generator Uncortoted = The motor runs Gown. The tine s determined by centifugal mass, fcton and the run-down speed al the mament of switching of For enable facilis, see 5.2. During transition processes (speed changes), on coiling machines and the like, a voltage signal is available at terminal 29 for the actuation of the inertia compensation. Motor accelerates -* approximately —-10V; load capacity: 4 mA maximum Motor decelerates + approximately + 10V: load capacity: 4 mA maximum 5.4.2 Operation without ramp function generator — Connection as in Fig. 5.4.2.1 — SW8-1 in the OFF postion — Reference value input: +10 Vmaximum, 0.65 mA speed regulator maximum (terminal 5) ov ‘The motor speed follows the setting on the potentio- a meter. Transition times from one speed to another during re elena wus phantom ference value changes are determined by the set oa currentlimitation and the motor load. Terminal 6 is et available for reference and correction values from ex ternal source (see 5.4.5), PR goKai6 ‘dora5.4.3 Minimum speed If the circuit is connected as shown in Fig. 5.4.3.1 and the reference value potentiometer is turned anti- clockwise to its fullest extent, a basic speed can be set, using the potentiometer “nymin'* on card Ry32 The maximum value of this will depend on the resi- stance of the selected reference value potentiometer. 1 = 2kD = min <20% Mmax RI = SKQ : Amin S 9% max Rt = reference value potoniometer 2.5K Fig. 8485 5.4.4 Independent creep speed +0 500.0 (Creep speed Fig. 84.41 Ifthe circuit is connected as shown in Fig. 5.4.4.1, a creep speed can be set, using potentiometer “nmin ‘on card Ry32. The possible range depends on the rating of R217. The load capacity of the + 10V power sup. ply has to be taken into consideration (see 5.1) Umax * 5002 Rei = Te soon | (114 Watt) ig = Creep speed when potentiometer “nmin is turned clockwise to its fullest extent Standard: R217 = 4,70 -* ng = 0..9,5% max 5.4.5 External reference and correction values x6. Fo. 6451 PR 82417 ‘i88)Modteaon ‘The influence of the voltage on terminal 6 is determined by R21, which as supplied, has a resistance of 22 k@. This corresponds to a maximum external input reference value of 10V. In all other applications R21 has to be exchanged and rated in accordance with the formulae below. Please note: When using terminal 6 and the required speed regulator matching, R149 must be rated ac cordingly (see 5.6). Maximum load of the external voltage source: 0.65 mA. 1. External reference values Ug must be a postive voltage. Input matching is via R21 Rating (1/4 Wat) 2. Correction values Rating depends on the degree to which the correction value is to influence the reference value. The correc: tion figure, as a percentage of the speed, is to be inserted in the following formula: U 100% oma TE 27 Ko (14 Watt) Rat 0,2 mA - ...% 3. Ifthe reference or correction value comes from an internal supplementary card, itis switched to the speed regulator input via internal bus connection to terminal 6, No external connection is necessary to terminal 6. 55 Current limitation The current limitation is set exworks to the rated current of the device (IN). This value may be reduced (see ‘also 2.3). When the current as set on the current limitation potentiometers is reached, the LED “Igy” lights up. 5.5.1 Internal current limitation Ly J ower is 7 Fg. 55.1. SW4-7 ON = Standard — Current limitation is set with the potentiometer “—ign’” on card Ry32 (see 6.3.1), 55.2 External current limitation Fig. 852. PR 2K 418 (coreg)— Switch $W4-7 to the OFF position — Connect circuit as in Fig. 5.5.2.1 — The setting of the intemal potentiometers "Ign" determines the current when the external potentiometer “Imax” is turned fully clockwise. 553 Current indi ‘A signal which is proportional to the actual value of the current is available at terminal 13 of the converter, for connection of an ammeter (positive voltage). We recommend the use of a mA-meter registering 1 mA at full scale deflection, the scale being appro- priately calibrated. The deflection of the pointer can be set with the potentiometer "Ian" on card Ry32 Fo. 553: i (see 6.3.1) 55.4 Negative direction of torque with TPy3...2B+e When operating TPy...28 +e units in conjunction with four quadrant field current converters, the current limi: tation for the negative torque direction can be set separately on card ROy. 2) itera current imiaton | nyazee roy | ] | | dq Fig. 85.41 — SW11-1 on card ROy = ON -* standard — Setting of the current limitation with potentiometer *+Ign!" on card ROy ') External current limitation | ny aase 4 | | | Lo L _) 4 Fig, 85.42 — Switch SW1-11 on card ROy to the OFF postion — For connection see Fig. 5.5.4.2 — The position of the internal potentiometer “+IgN" determines the current when the external potentiometer "+lmax” is turned fully clockwise. PR ADKA1o dais)56 Speed regulator ‘The speed regulator can be operated as PI or P regulator as required. A voltage of + 15V 21 (see 5.2.1) will enable the regulator. Measuring point Y1-1 + OV = component enabled + +15V = component blocked LED "BLG" lights up —> regulator blocked LED “BLG” does not light up, LED "+ 15” lights up ~ regulator enabled +24V at terminal Forces em, 837 ia/etoe bas ' 27 1 = bis oe pd vg | ie | Pr | 3 | Fi. 56.1 Speed regulator PR eK 420 (10158.1, Plcharacteristic = standard version ‘SW4-1 OFF — V8 = bridge — Calibration of P-ampification with potentiometer “pn” on card Ry32 — Calibration of amplification with potentiometer "iq" on card Ry32. 2. P-characteristic — SW4-1 ON — Potentiometer “in’” on card Ry32 fully clockwise — Calibration of ampitication with potentiomieter “pn” on card Ry32. 8, Phand P-characteristic — SW4-1 OFF — Remove CV3 bridge — No voltage at terminal 20 -> P-characteristio. — +16...+24V al terminal 20 + Pl-characteristic Please note: If the current as set on the current limiter flows, the speed regulator always has P-characteristic. P. and Leomponents can be calibrated separately, P-component. : The minimum amplification Kpmin is 2.4 as standard, and is determined by R37. Kp can be set between 1 and 9:3 Kpmin vie the potentiometer “pn”. if required, R37 can be exchanged. [— RS7 Kpmin = Standaré: AGT = 120 KO Prin = SOKO Leomponent ; The minimum time constant Trin is 60 ms and is determined by C10. Tj can be set between 1...10 Timin with the potentiometer ‘‘in”. The supplementary capacitors C10a can be fitted in order to Increase Tj. The following applies: [Timax = 120 (6 +C10a) | T (ms) C GF) Note: The output signal of the speed regulator is available on terminal 10. It should not be transmitted beyond short distances within the control panel. Wiring should be screened. I! lengthy connections are unavoidable, we recommend the use of an Ay:type P-amplifier for decoupling in order to avoid external influences on the relerence current value. Speed regulator matching is provided as standard, but as supplied, is switched off. The following speed regu- lator behaviour is achieved by switching in the individual matching components. SW5-4. ON + R27 is switched in parallel to the speed regulator feedback when nref = 0 and nagt turn potentiometer “p" and/or “lap” anti-clockwise or optimise regulator 28) Main contactor open ‘© Check energization criteria (motor protection, contra circuits, et.) a4) Main contactor closed, external fuses o.k. ‘= Is motor connected properiy? * LED "+ 15V" does not light up > no supply voltage, regulator fuse blown * LED “Ign” lights up —> interruption in the armature circuit, no field, motor mechanically braked, current limitation too low ‘Is regulator enabied? LED "BLG” must not light up * Are SW4-4 and SW7-6 ON? ‘© During operation without ramp function generator: is reference value present at terminal 5? © During operation with ramp function generator: is reference value present at the generator input (Ki and terminal 28) and is SW8-1 ON? (see 5.4.1) Are ramp function generator and reference value enabled? Is input voltage present? d b) Motor does not reach full s + Potentiometer “imax” is 4 incorrectly andlor SWS... is coded incorrectly * LED "ign" lights Up ~+ motor drawing maximum current, relieve load on motor or increase curcent limi tation (maximum lan) check field current + Are all sx thyristors of a bridge actuated? Six pulses must occur per mains cycle (20 ms at 60 Hz, 16,7 ms at 60 Hz) ©) Motor runs up too slowly * LED “lg” lights during acceleration ~ motor draws maximum current while accelerating, Relieve load fon motor or increase current limitation (maximum Ig), check field current # LED "Ign" does not ight up ~ ramping time too long, Try using the direct input o (terminal §) for the reference value 1e speed regulator 4) Motor can be regulated only in the upper speed range '* No OV connection to the reference value potentiometer ) Motor runs in fe tight direction, but cannot be regulated * No actual value input * Actual value has incorrect polarity (terminal 1). Note: Only when SW4-2 OFF and SW4-3 ON * Phase sequence between power and regulator section incorrect (see 2.1) * No OV connection to the reference value potentiometer Pa won cst ido)