List of Contents Introduction Specification Converter Connections Typical External Circuits Mains Input Voltage Phase Sequence Motor Connections Starting a Drive Adjustments 10 Outline of Operation 11 Fault Finding 12 Replacing Components on Converter Module 13 Maintenance and Fautt Finding Chart CoOrVHTawWNn| Issue 2 SEPT 1992 1 Introduction ‘The KTK Series 6P4Q. converters an extremely versatile and compact yet very accessible unit designed for speed control of DC motors by armature voltage variation in applications where static reversing and regeneration are required, ‘The unit features two 3 phase fully controled bridge rectifiers connected in inverse parallel ‘complete with DVIDT and transient overvoltage Suppression, for conversion of the incoming AC supply into an infinitely variable bidirectional OC ‘output voltage. ‘The unit, which is constructed for ease of maintenance, is assembled on a single extruded aluminium finned heatsink which is also the unit Chassis. This type of construction is made possible by the use of electricaliy isolated thyristor modules in which a pair of thyristors are mounted in a common fusing which has conductive metal base through which the intemaly generated heat is transferred to the heatsink on which itis mounted but from which the actual semiconductor elements are electrically isolated. On a level above this and supported by extruded aluminium side pieces are two printed Gircuit boards (PCBs) THY1R and EX1 which between them camy all the components at mains potential, Above these boards and also su from the unit's side is the main control PCB FAC 1R, eich sotto hinged fo easy access to the PCBS low. In addition to the usual contro faites, such as linear acceleration ramps, speed amplifier, current amplifier, and crossover loge, the unit also has many other specal features. Thynstors are protected by an electronic instantaneous overtoad, LED's indicate presence of fring pulses and monitor drive operation and dive response is optimised by adaptive contro. ‘Aiso provided is a drive ready relay, inverse time Current overtoad trip. tacho loss trip and an on board reset switch, To aid maintenance and fault diagnosis, a digital system monitor with ten postion selector switch is included. A fused motor field supply is also built in as standard Page 12:1 Standard Electrical Specification Supply Voltage 3 Phase, 3 Wire 50/60 Hz 380/440V + 6% nominal. Maximum Armature Voltage 40Q/460V OC depending on supply voltage Maximum Field Voltage 3401370V maximum depending on supply voltage Operating Temperature Range o-60"C Storage Temperature Range Minus 40°C to 70°C Maximum Altitude Without Derating 1000 metres Maximum Relative Humidity 85% Armature Converter 3 Phase fully controlled inverse-parallel 12 thyristor bridge. Electrical Isolation Main electronic control PCB FAC-1R is completely isolated from mains and earth, Preset Controls Ramp time, current limit 1, current limit 2, stabilty, minimum speed, inch speed, maximum speed Contact Ratings ‘Speed sensitive relay RL1 and drive ready retay RL2, ‘each contain a single set of changeover contacts, rated as follows: Switching Voltage VAC approx24—250 VDE approx 12—50 ‘Switching Curent A approx : ‘Switching Load VA approx 1000 W approx 100 22 Standard Performance Specification Type No and Rating 6403.75 3.75KWSHP 6P4Q7.5 7.5KW/10HP_ 6P4015 15KW/20HP_ 6P4030 © 30KW/40HP 6P4Q.37.5 37.5KWISOHP fan cooled 6P4055 55KW/75HP fan cooled ‘Speed Range 100: 1 with tacho generator feedback. Speed Holding Accuracy Regulation —+0.1% of maximum rated speed, steady state, for 100% load change. ‘Stabilisation — against +6% supply voltage variation and 10°C temperature change. — 285% with ‘achogenerator feedback Overload capacity 150% full load current/torque for 30 seconds and repeating with a duty cycle within the RMS rating, Instantaneous Sub Cycle Trip Operates at 250% fl load curent Crossover Delay Drive to brake or brake to drive set at 3.3MS. Torque Reversal Time Full load torque drive to full load torque brake typically 10MS. Current/Torque Limit Control Variation Bi-directionally independently adjustable (By current limit 1 and current limit 2 preset controls) between. 0% and 150% of full load values. ‘Acceleration and Deceleration Rates Mutually adjustable on a single preset control up to a maximum of 30 seconds. Speed Reference Input +12 —0— -12V or altematively, +10V —0.— -10V corresponds to ‘maximum forward — zero — maximum reverse motor speed. Motor stop Regenerative or coast stop selectable Page 23 Converter iS SALBRSSBBYBRRBS The following isa list of converter terminals, their function and their location on the converter unit. Line1 tine |] vente ars Ac the Located on THY-1R PCB Motor armature connection ] AA positive for positive Hon | ‘reference voltage Motor armature connecti of terminal 29 ‘Aux Line 1 —supplyforelectronics Aux Line 2— supply for electronics and motor field Aux Line 3— supply for motor field Located on EX 1 PCB +VEMotorfield connection —VE Motor field connection Electronics common Current feedback signal =24/28V unstabiised power supply =15V Power supply +24/28V unstabiised power supply Tachogenerator feedback (negative for positive reference) Inch reference pot (top) Electronics common +15V Power Supply Zero speed relay (RL) inhibit (connect to common to inhibit) Noconact Zero speed relay RL Common Contact NO Contact NCContact Drive ready relay RL2 Common Contact Minimum speed reference Inch reference Currentampiiferinput =12V stabilised reference Speedamplfier output Sidermax. speed pot External amp potentiometer common 4+12V stabilised reference Extemalramp down potentiometer Extemalramp up potentiometer Inverted speed demand output Direct ramp input Switched ramp input via AS1 AS! select Electronics common ‘Clamp release input Reference input via AS4 ‘Speed amplifier direct input ASA select Ramp output Page 3