ac wave 2 supply ( analog device ) «SPECIFIC PRODUCT SECTION» Instruction and user s manual Release 2.1 00/05 REEL S.r.l. Electronic Power Drives Via Riviera Berica, 42 36024 Ponte di Nanto - Vicenza - ITALY Tel. +39 0444 730003 - Fax +39 0444 638213 internet: www.reel.it - e-mail: reel@reel.it
CONTENTS 1 1. GENERAL REMARKS 1.1 Standard supply module 1.1.1 Control electronics supply 1.1.2 Power electronics supply 1.2 Technical features 2 2. INSTALLATION 2.1 Power connections 2.2 Signal and control connections 2.2.1 Signal connector (P5) 2.2.2 Interconnecting connector (P2) 3 3. COMMISSIONING 3.1 General remarks 3.2 Alarm configuration jumper 3.3 Configuration Dip Switch SW1 mains voltage selection 3.4 Product version 4 4. OPTIONALS 4.1 Optional braking module (integrated) 4.2 Additional braking module 4.3 Control and braking protection board 4.3.1 Working principle 4.3.2 Board setting 4.3.3 Setting of overload ratio trimmer RV1 4.3.4 Setting of maximum overload trimmer RV2 4.3.5 Default setting 4.4 Integrated programming keyboard 5 contents - ac wave 2 analogic aupply
5. ANOMALY SOLUTION GUIDE 5.1 Luminous signals 5.2 Machine state and alarms 6 6. ENCLOSURES 6.1 Standard supply module sizes 6.2 Overall dimensions 6.3 Block diagram of standard supply module 6.4 Application scheme 6.5 Electrical power connections contents -
1. GENERAL REMARKS 1.1 Standard supply module 1 The converters of the wave range have one single supply for more modules, even if these are heterogeneous. The standard supply module consists of two distinct sections: signals and power. The supply functions are described below. 1.1.1 Supply of control electronics Through an internal switching supply the module gets from the power dc (+/-dc bus), the 24Vdc needed to supply the whole control electronics of the tunnel and also possible external loads (such as encoder). It also gets +5Vdc for the programming keyboard supply and +/-10Vdc for the external potentiometers. KEYBOARD SERIAL CABLE COLOURED FLAT CABLE SUPPLY TO THE POWER MODULES TO THE FAN MODULES ELECTRICAL CABINET 1.1.2 Supply of power electronics It rectifies the ac mains and builds a continuous voltage that, after being filtered by the capacitor modules, supplies the power modules sections. MAINS 1. supply module: rectifies the ac mains 2. capacitor module: filters the supply s voltage 3. and 4. Power module: handles the motor directly and changes its speed. 1.2 Technical features
1 Nominal supply voltage Three-phase 380/440V +/-15% Nominal input frequency 45 65Hz Output voltage Voltage rectified through Graetz bridge Available auxiliary voltages Overload Type of capacitor pre-loading Mains dips +10Vdc IMAX 50mA - 10Vdc IMAX 50mA +24Vdc IMAX according to modules number (see tunnel dimensioning section) 150% for 1 minute every 10 minutes 200% for 10 seconds every 10 minutes Constant time of two seconds Automatic insertion through SCR diodes Different working solutions available Dynamic braking LED signals With optional circuit to be assembled on the supply module (dissipation resistors available on demand), or with additional circuit (for size 01) Bar of 10 LEDs showing machine state and anomalies
2. INSTALLATION 2.1 Power connections The modules have different sizes, different for deliverable nominal current. The fixing of power cables changes according to sizes: sizes 01 02 connection on bolt terminal M6 sizes 03 04 connection through double bolt terminal M6 size 05 connection through bolt M6 on aluminium bar 2 See enclosures Electrical power connections to find map, overall dimensions and connection diagram. 2.2 Signal and control connections The module versions 010 and 011 have two terminal boards for signal connections, one of which is dedicated to connections external to the tunnel, the other one for interconnecting with board 5324 in case of double tunnels (a single supply module with two tunnel parts: see general section). It has also a 20 way- flat connector for interconnecting of the power modules. Versions 012 and 212 have only one terminal board for signal connecting and two 20- way flat connectors for interconnecting of the power modules.
2.2.1 Signal connector (P5) PIN DENOMINATION NOTES TECHNICAL FEATURES 2 01 +10 Stabilised supply +10Vdc +10Vdc Max. current = 50mA 02/03 SG Signal- ground of stabilised supplies +/-10V 0Vdc 04-10 Stabilised supply -10Vdc -10Vdc Max. current = 50mA 05 IG Input ground for serial input protection 0V input impedance 10 06/07 +P Stabilised supply +24Vdc +25,5Vdc maximum current 5,.5A for version 010 and 011 1,5A for version 012 and 212 derating depending on module number (see chapter Product version ) 08/09 PG Stabilised power ground +24Vdc 0Vdc reference for +P 10 -C Common optoinsulator input for drive enablement 11 RST Optoinsulated input for general reset (enabled for all drives at the same time) 0Vdc Optoinsulated OFF=<3Vdc ON=15 28Vdc Impedance 1,6K 12 EN General enablement Optoinsulated OFF=<3Vdc ON=15 28Vdc Impedance 1,6K 13 +C input for dc voltage to take to static outputs UAL and msr (common input for optoinsulators) 14 msr Output for rotating motors (enabled output means 1 or more motors rotating) 15 UAL General output for run enablement (enabled output means: no anomaly occurring) 5 30Vdc max. Optoinsulated max. current = 50mA Optoinsulated max. current = 50mA
2.2.2 Interconnecting connector (P2) PIN DENOMINATION NOTES TECHNICAL FEAUTURES 1 +S Serial line RS485 Line driver 0 5Vdc 2 -S Serial line RS485 Line driver 0 5Vdc 2 03/04 0P Stabilised power ground +24Vdc 0Vdc Max. current 5,5A 5 msr Input for the sum of minimum speed relays 6 ALARM Input for the sum of alarms (1 = alarm) 0 24Vdc Impedance 3,3K 0 24Vdc Impedance 2,2K 7 /RESFE General reset output Buffered 0 24Vdc IMAX = 350mA 8 DRENFE General enablement output Buffered 0 24Vdc IMAX = 350mA 9 HV Output for the dc link s measure V/V converter 10 ST Input for the sum of thermal sensors 0 10Vdc IMAX = 1mA Impedance 4,7 0 24Vdc Impedance 2,2K 11 HOLD Mains failure warning Buffered 0 24Vdc IMAX = 350mA 12/13 +24 Stabilised supply 24Vdc +25,5Vdc Current depending on installed modules (MAX 5,5A) 14/15 0P Stabilised power ground 24Vdc 0Vdc IMAX = 5,5A Note: Do not ground the supplies zero (PG, SG or 0P)
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3. COMMISSIONING 3.1 General remarks The general section describes all measures and precautions to be taken before putting the device under voltage. That section should be carefully read before feeding the drive. 3.2 Alarm configuration jumper A jumper on the supply module s board allows to choose the tunnel s working in case of an alarm generated by a single power module. The jumper is shown in the map below: 3 SERIAL LINE RS485 Board configuration 010 and 011 version SERIAL LINE RS485 Board configuration 012 and 212 version Note: See also chapter Product versions
Jumper 1-2 In case of alarm all inverters belonging to the tunnel are desabled as well as the enabling (standard configuration). Jumper 2-3 In case of alarm only the inverter involved is desabled as well as the enabling output. Such configuration is to be preferred when the machine requires the stopping of the other motors with controlled deceleration. 3.3 Configuration Dip Switch SW1 mains voltage selection Version 012 and 212 (see chapter Product versions have a dip switch called SW2 allowing to select different mains voltage values as planned for the AC WAVE series. 3 DIP SWITCH NO. FUNCTION DEFAULT 1 not used OFF 2 not used OFF 3 mains voltage selection ON 4 mains voltage selection ON The selection logic of dip switch 3 and 4 is the following: DIP 3 DIP 4 MAINS VOLTAGE ON ON 380-400V ON OFF 415V OFF ON 440-460V OFF OFF not used Dip switches can be seen on map below: SERIAL LINE RS485
3.4 Product version The different product versions which are to be considered in case of order or spare part enquiry are listed below: 010 TF Analog supply module with T= built-in keypad F= built-in dynamic braking module 011TF Analog supply module with built-in FAN 00 module and T= built-in programming keypad F= built-in dynamic braking module 012 TF Analog multi-voltage supply module with: T= built-in keypad F= built-in dynamic braking module 3 212 TF Analog multi-voltage supply module - small size with T= built-in keypad F= built-in dynamic braking module
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4. OPTIONALS 4.1 Optional braking module For particular applications, where the working cycles are very charged and decelerations extremely quick, it might be necessary to add a braking unit, in order to limit the unavoidable voltage increase on the dc link during the energy recovering phase. The resistance value to be applied to the braking unit has to be chosen according to the max. urrent the unit itself can endure. NB: The braking circuit checks voltage on the dc link but not current and temperature of the recovery resistor. It is therefore recommended to insert a thermal protection circuit for the resistor itself that will disable the drives when necessary. The power of the dissipation resistor and the braking module s size have to be chosen according to the working cycle. The chart below shows the minimum resistance values to be applied according to the supply module s size. SIZE DELIVERABLE POWER MINIMUM OHM VALUE 01 0 40 kva ---------- (braking outside the module) 4 02 0 100/120 kva 15 03 0 160 kva 5 04 0 240 kva 3 05 0 480 kva 3 NOTE: The optional braking module must be ordered together with the supply module, as the braking board cannot be connected after the supply module assembling. On demand, the dissipation resistors can also be supplied by Reel.
4.2 Additional braking module An additional braking module was developed only for size 01 (deliverable power 60kVA) that is not integrated in the supply module. This very compact module already has the dynamic braking resistor built inside. In order to increase the radiating surface, it would be better to choose a panel fixing. The modules has only four bolt terminals: +600 for direct connection to the tunnel power bus -600 (dc link) +P for direct connection to the 24Vdc connector s output signal OP connection (pin 08/09 and 06/07 of P5) The Multi-Voltage version gives the possibility of selectig the mains supply through the dip switch shown on the drawing below, according to the indicated chart. 4 JUMPER RETE ac ON 400 415 OFF 440-460 Overall dimensions and map are shown below: L= 260 H = 90 P = 85 The integrated resistor has nominal value 36 450W (2,2kW for 5 seconds)
4.3 Control board and braking protection In order to protect the dynamic braking resistor from a thermal point a view (which is often installed to achieve stop in shortest time, also in case of strong inertial mass), Reel has developed a circuit able to check the power being dissipated. It is a board to be installed in the electrical cabinet, with a parallel connection to the resistor (to measure insertion times) and an interface with the electric devices. It shows the maximum braking alarm through a double contact relay and is therefore very versatile in application. There is a single 24Vdc supply that can be also taken from the supply module directly (terminals 8/9 and 6/7 of terminal board for connection signals). The message regarding the occurred alarm stays and can be reset with a 24Vdc impulse on the related input. Connector P2 for power connection PIN DENOMINATION NOTES TECHNICAL FEATURES 1 +R Connection to positive terminal of the braking resistor (terminal B2 supply module) 2 -R Connection to negative terminal of the braking resistor (terminal B1 supply module) 0 +850Vdc Impedance = 500K 0Vdc Impedance = 500K 4 Connector P1 for signal connection PIN DENOMINATION NOTES TECHNICAL FEATURES 01/02 +24 Positive supply input 20 28Vdc 3 0V Negative supply input 0Vdc 4 RST Alarm reset Impulse giving towards positive supply: normally not connected NC 28Vdc Reset = 10 28Vdc Impedance = 4K 5 C2 Common enabling contact NA2 Contact closed (pin 5-6 in short circuit ) 6 NA2 Enabling contact NA2 for run enablement 7 C1 Common enabling contact NA1 Contact closed (pin 7-8 in short circuit) 8 NA1 Enabling contact NA1 for run enablement 4.3.1 Working principle
The board reads the voltage applied to the braking resistor s ends constantly and increases the timer slowly or quickly, according to the power measured at each moment. While the resistor is resting, the timer is decreased. As soon as the timer reaches its limit value, an alarm memory is activated. The circuit has two LEDS indicating the state: L1 green on: start enablement L1 green off: occurred alarm L2 yellow blinking: timer increasing Only two trimmers set the features of the resistor to be protected: Trimmer RV1: setting the overload ratio Trimmer RV2: setting the maximum overload 4 4.3.2 Board setting Foreword The dynamic braking circuit dissipates on the resistor the exceeding energy during the temporary recovery due to the braking through the driving force mass. Energy is dissipated with high instant power peaks, while the effective value is considerably lower. The control tasks are: instant power measuring and comparison with the nominal power (rated value of the resistor used); calculating the overload as sum of instant powers; activating an alarm at the set value.
4.3.3 Setting of overload ratio trimmer RV1 The dc link s voltage values at which the braking resistor is inserted are the following: for mains 380 400 = 660Vdc for mains 400 440 = 780Vdc Once the resistor s ohm value is known, the instant power can be calculated with the following formula: V = value of intervention voltage R = resistor s ohm value V 2 = instant power R The overload ratio is calculated with formula: PI = overload ratio PN 4 PI = instant power PN = nominal power (rated value) Trimmer RV1 has to be set according to the calculated overload ratio: ratio 20 = trimmer in zero position ratio 3 = trimmer in 100%position intermediate trimmer positions determine ratio values between 3 and 20
4.3.4 Setting of maximum overload trimmer RV2 The maximum overload allowed by the resistor can be taken from the rated data or the resistor s technical sheet. The setting of trimmer RV2 can be seen on the chart below, that shows the intervention according to setting made on trimmer RV1. % SETTING TRIMMER RV2 4 INTERVENTION TIME (sec.) Example: rated data mains: 380Vac resistance: 18 900W 6.6Kw for 5 seconds RV1 setting NB: mains 380V corresponds to intervention voltage 660V instant power = V 2 = 660 2 = 24,2Kw R 18 overload ratio = PI = 24200 = 26,8 PN 900 position of trimmer RV1 = 0% ( ratio 20) RV2 setting
To consider: the resistor is rated 6,6Kw for 5 seconds; being the instant power 24,2Kw, it can be deduced that limit time at that power value is: 6,6 x 5 = 1,36 seconds 24,2 Setting of RV2 can be taken from the chart above: % SETTING TRIMMER RV2 4 INTERVENTION TIME (sec.) RV2 setting = 88% 4.3.5 Default setting Reel supplies the board with: trimmer RV1 = 0% trimmer RV2 = 100% The intervention limit time of the integrator at such setting is 1,6 seconds with mains 380Vac.
4.4 Integrated programming keyboard The supply module can integrate the keyboard described in he general section, under Parameter input. The keyboard is fixed on the supply module s front side and completes the tunnel by giving the user programming support as well as alarm diagnostics. NOTE: The keyboard communicates with the modules through serial line RS 485 (9 pole connector sub D of the supply module). It can be therefore installed in case the user should use the serial line. See general section for any information on the device. 4
5. ANOMALY SOLUTION GUIDE 5.1 Luminous warnings The supply module has a little bar with 10 warning LEDS, whose function is marked. The warnings are very helpful for the running state or anomaly diagnostics. PWR msr RUN TS EN OK HLD RST +/- RSI PWR power: when on, it indicates that 24Vdc is given OK ready to start: f off, it means that an anomaly is occurring msr minimum speed relay: if on, it means that at least one of the motors is rotating HLD hold: if on, it means failure of at least one of the power phases 5 RUN run: if on, it means that the power modules have been enabled RST reset: gets on only when alarms are reset TS thermal sensor: if on, it indicates the intervention of one of the thermal sensors placed on the power radiator +/- +10V -10V supplies: if on, it indicates that power supplies +/-10V are given EN enable: if on, it means that enabling input is on RSI input reset: if on, it means that reset input is on The LEDS can be seen on the map below:
STATE SIGNALLING LEDS SERIAL LINE RS485 5
5.2 Machine state and alarms Indication on machine state: tunnel is on, but not enabled; following LEDS are on: PWR; OK; +/- tunnel enabled, while motors stand still, following LEDS are on: PWR; OK; RUN; +/-; EN If one motor is rotating msr goes also on Anomaly state Note: Any kind of alarm switches OK off. LED ST, when going on, means: lacking ventilation check w orking of radiator' s fan Thermal sensor intervention of thermal sensor placed on pow er dissipator w eak heat exchange check cooling air and control board temperature 5 too heavy w orking cycle check average current of w orking cycle to be correct according to set parameters if LEDS PWR or +/- are off or weak, they mean overload of the supplies +/-10V o 24Vdc when LEDS are blinking, they warn on a short circuit or an overload on one of the supplies. In this case disconnect the loads in order to find the short circuit, following the steps below: 1. Disconnect the supply s output terminal board 2. Remove programming keyboard 3. Disconnect he coloured flat cable from the modules Once the short circuit cause has been found out, remove it. If no power module shows an alarm state and only the OK LED is off, that means that a minimum or maximum voltage alarm is occurring:
Mimimum voltage DC pow er voltage decreasing excessively supply voltage decreasing drive supplied in monophase check supply not to go below 15% of the nominal value reset missing phase braking resistor not connected reset w iring too abrupt braking increase deceleration ramp 5 Maximum voltage DC pow er voltage too high too high inertial load increase deceleration ramp or add braking resistors (see related chapter) w rong supply voltage reset nominal value of ac voltage
6. ENCLOSURES 6.1 Sizes of standard supply modules SUPPLY MODULE BRAKING DIMENSIONS TYPE SIZE DELIVERABLE POWER MINIMUM OHM VALUE L H P 00 ADDITIONAL SUPPLY 260 120 230 MODULE 01 0-40 KVA ----- 260 120 230 02 0-100 KVA 15 ohm 260 120 230 03 0-160 KVA 5 ohm 260 200 230 04 0-240 KVA 3 ohm 260 320 230 05 0-480 KVA 3 ohm 260 640 230 6.2 Overall dimensions SUPPLY T.01 (40KVA) L= 260 H= 120 P= 230 SUPPLY T.02 (100KVA) L= 260 H= 120 P= 230 SUPPLY T.02 (120KVA) L= 260 H= 160 P= 230 SUPPLY T.03 (160KVA) L= 260 H= 200 P= 230 SUPPLY T.04 (240KVA) L= 260 H= 320 P= 230 6 R - S - T = LINE INPUT B1 - B2 = BRAKING RESISTOR SUPPLY T.05 (480KVA) L= 260 H= 640 P= 230
6.3 Block diagram of standard supply module INTERNAL BUS (COLOURED FLAT CABLE) PICK VOLTAGE INHIBITOR CONNECTOR RS48 5 ALARM JUMPER CONFIG. ALARM CONTROL MinV / MaxV / HOLD CONTROL TRANSLATOR V/V MEASURING DYNAMIC BRAKING RESISTOR PRELOADING CONTROL 6 THERMAL SENSOR SUPPLY MODULE SUPPLY LINE SWITCHING CIRCUIT
6.4 Application scheme 6
6.5 Electrical power connections WARNING: PLEASE PROVIDE GROUNDING L INE INPUT ALUMINIUM OR COPPER BARS NOTE: PLEASE ASSEMBLE FILTER WITHIN 50CM FROM THE SUPPLY MODULE E.M.I. FILTER 6 THERMAL PROTECTION CIRCUIT (BOARD 9966) NOTE: For dimensioning of ultra-quick break fuses and input inductance see the manual s general section.