FXM5
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1. Figure 4 7 Location of jumper LK1 FXM5 User Guide 21 Issue Number 5 www controltechniques com 4 6 Setting the armature voltage range Analog control mode Digital control mode 4 6 1 Procedure OO Figure 4 8 Location of jumper LK2 Set jumper LK2 as follows Maximum armature voltage Setting 0 470V lt 470 gt 470V gt 470 4 7 Setting the maximum and minimum field current Analog control mode External control of the field current Internal control of the field current During the following procedures you will be required to apply AC power to the AN FXM5 controller and the motor Before applying AC power ensure the following The controller is correctly connected The controller cover is securely fitted 22 FXM5 User Guide www controltechniques com Issue Number 5 l max TEST I min I max CO O O SET SET SET MAX MAX MIN FIELD ARM V FIELD Figure 4 9 Locations of the controls and indicators on the front panel 4 7 1 Maximum current Apply AC power to the FXM5 controller Do not start the motor running Monitor the LED bar indicator and adjust the SET MAX FIELD potentiometer to set the current at the required proportion of I max Check that the Ikmax LED is lit Note that the LED bar indicator relates to the absolute maximum current that can be produced by the controller as determined by the setting of jumper LK1 and the number o2. Because the Drive FXM5 controller and motor operate in a closed loop the armature voltage remains constant when the speed is varied above base speed but the field current is reduced in inverse proportion to increases in speed For example to allow the motor speed to reach double the base speed the field current must be halved FXM5 User Guide 15 Issue Number 5 www controltechniques com 4 2 4 2 1 16 Control circuit description Figure 4 2 Main elements of the control circuit Refer to Figure 4 2 The control circuit comprises four main elements as follows Armature voltage monitor N1 N2 Field current limiter N3 e Field current amplifier N4 Thyristor bridge driver N5 The elements that are used depend on the system control mode that is in operation Main elements The armature voltage is applied to amplifier N1 The output is compared with a voltage reference N2 Preset potentiometer RV1 MAX ARM V and jumper LK2 are used to adjust the threshold level When a Mentor II Drive is used parameter 6 07 sets the threshold When the threshold level is not reached the resulting signal causes the field current limiter N4 and thyristor bridge driver N5 to apply full voltage to the field winding of the motor When
3. l max or pmax Ne Np ND oO When the FXM5 controller is used with a Mentor II Drive parameter 6 11 must be set at the value stated in the table The FXM5 controller is supplied having two turns through the DCCT The number of turns is defined by the number of times the wire passes through the hole in the DCCT Procedure Set the value of Ipmax at the nearest value above the maximum required field current At a later stage you can set the maximum field current at the required value using the SET MAX FIELD potentiometer or parameter 6 08 www controltechniques com FXM5 User Guide Issue Number 5 Mie Oooo Figure 4 6 Location of the DCCT and wire loop 4 5 Changing the DCCT primary winding turns Use the following procedure to change the number of turns 1 Or OV Pi OO Disconnect the loop of wire from the spade connectors on the printed circuit board and remove the wire from the DCCT Use insulated wire of sufficient length for the required number of turns and ensure the wire is of the correct size for the maximum field current Refer to Cables and fuses on page 5 Loop the wire through the DCCT in the same direction as the original wire Fit a 6 25mm 0 276in spade receptacle to each end of the wire Connect the wire to the spade connectors on the board Set jumper LK1 at the setting given in the table de 20 Np rj 7 15 Np
4. supply is connected If the FXM5 is faulty it must be returned to an authorized Control Techniques distributor for repair Electric shock risk If the FXM5 controller has been energized the supply must be isolated for at least five minutes This allows the internal capacitors to discharge fully before work may continue Refer to Safety information on the inside front cover of this user guide Fault Possible cause Action The AC supply isolator does not close The field current is low causing the field failure relay to be de energized Remove the cover and check all the fuses LED bar indicator indicates zero Faulty field winding connections The SET MIN FIELD potentiometer is set at the fully anti clockwise position Check the field winding connections Check and if necessary adjust the SET MIN FIELD potentiometer LED bar indicator indicates maximum No armature voltage signal applied to the FXM5 controller Check fuses FS1 and FS2 The motor does not attain maximum speed The SET MAX ARM V potentiometer is set too high or 6 07 is not set Adjust the potentiometer RV1 or parameter 6 07 The motor lacks torque and or The field failure relay trips when the motor is at high speed The SET MAX ARM V potentiometer is set too low or 6 07 is too low or The SET MAX FIELD potentiometer or parameter 6 08 is too low Adjust the potentiometer RV1 or set parameter 6
5. acceptable see section 3 2 Environment on page 4 The maximum permissible ambient temperature is not exceeded The EMC requirements are met The electrical installation meets safety requirements Motor cable In order to meet the EMC emissions requirements it is preferable that one of the following conditions applies for the motor cable Ifthe cable is to be entirely enclosed in grounded metal ducting the cable does not need to be shielded or armoured Ifthe FXM is to be mounted in a machine that has a grounded metal case and the motor cable is to be contained inside the case the cable does not need to be shielded or armoured Ifthe cable is to be exposed it should be armoured or shielded Alternatively unshielded cable could be used if an RFI filter is included in the output circuit of the FXM5 Ifthe length of the motor cable does not exceed 50 metres very little radiation should be produced In this case unshielded cable may be used on condition that the EMC emissions requirements of the installation are considered RFI filter An RFI filter type P2E 025 M7 must be connected as shown in the AC supply circuit to the FXM5 Mount the RFI filter beneath the FXM5 with a clearance of 300mm 12in Use the same type of filter if an RFI filter is to be included in the output circuit of the FXM5 The filter must be used in conjunction with a suitable RFI filter for the armature supply The filter input must obtain its su
6. the threshold is reached the field current limiter N4 and thyristor bridge driver N5 cause the field winding voltage to be reduced A direct current current transducer DCCT in the field winding circuit monitors the field current The output of the DCCT is applied to a negative feedback loop so that by varying the field winding voltage the FXM5 controller is in control of the field current The setting of jumper LK1 and the number of primary winding turns through the DCCT define the absolute maximum current max that can be produced by the controller FXM5 User Guide www controltechniques com Issue Number 5 4 3 4 3 1 see section 4 5 Changing the DCCT primary winding turns on page 21 This value should be set at the nearest value above the required maximum field current Preset potentiometer RV2 SET MAX FIELD is used to set the required maximum field current as a proportion of Ikmax This current level occurs when the armature voltage is below the preset threshold LED2 indicates when the field current is at the maximum level set using RV2 When a Mentor II Drive is used the required maximum current can be set using parameter 6 08 Preset potentiometer RV3 SET MIN FIELD and switch SW1 are used to adjust the minimum level of field current as a proportion of the current set using RV2 When SW1 is pressed the LED bar indicator indicates proportion of the maximum current set using RV2 The minimum level should be set for maximum re
7. 07 Adjust RV2 or set parameter 6 08 The Drive trips on current over load when the motor is normally loaded The maximum field current is set too low Adjust the SET MAX FIELD potentiometer RV2 or parameter 6 08 The field failure relay trips when the motor is under rapid acceleration The minimum field current is set too low Adjust the SET MIN FIELD potentiometer RV3 or parameter 6 10 FXM5 User Guide Issue Number 5 www controltechniques com 25
8. Drive when required use the following e 3 core and 4 core pvc insulated cable with copper conductors having a temperature rating not less than 60 75 C and laid in accordance with defined conditions Refer to EMC recommendations later in this chapter for shielding requirements The wiring must conform to local regulations and codes of practice Refer to the following table for the size of the AC supply and field winding cables In the event of conflicting data local regulations prevail FXM5 User Guide 5 Issue Number 5 www controltechniques com 3 5 Cable size Maximum current and fuse rating Fuses fitted to the FXM5 controller printed circuit board are as follows Fuse Rating Type Protects ST Partnumber Control circuits power supply 3537 3251 Thyristor bridge and field 3537 3252 weakening Access to the power and signal connectors Remove the four corner screws and the front cover The connectors are mounted on the printed circuit board which is now exposed C unl o B D Bov a FS3 FS4 wd ne BE pi A1 A2 Figure 3 2 Locations of the ground power and signal connectors fuses and jumpers FXM5 User Guide www controltechniques com Issue Number 5 3 6 Power connections Terminal Function A1 Positive Armature voltage input A2 Negative With forward rotation F1 Positive F2 Negative Field winding output AC supply See AC
9. Heat generated in the thyristors is dissipated to the air by a finned heatsink Ingress protection conforms to IP10 Controls and indicators Recessed preset potentiometers and LED indicators on the front panel of the module are used for setting up and monitoring the FXM5 controller Protection Change over relay contacts are operated when the field current reduces to the minimum field current set by the user The relay contacts can be used to disconnect the motor to prevent run away in the event of loss of field current FXM5 User Guide www controltechniques com Issue Number 5 A Data The voltages present in the FXM5 controller are capable of inflicting a severe electric shock and may be lethal The Stop function of the Drive does not remove dangerous voltages from the FXM5 controller or the driven machine AC supplies to the FXM5 controller must be disconnected at least 5 minutes before any cover is removed or servicing work is performed Permissible AC supply voltage for the controller power supply 220 254V 10 380 440V 10 AC supply frequency 48Hz 62Hz Permissible AC supply voltage for the thyristor bridge 0 480V 10 Number of AC supply phases 1 or across 2 phases Range of control of the field winding voltage depending on AC supply voltage OV 430V Field current 20A maximum Armature voltage 220V 600VDC Field failure relay contact ratings 250V 3 5A DC m
10. SAN OY BEJ ONTROL TECHNIQUES User Guide FXM5 Part Number 0410 0011 05 Issue Number 5 www controltechniques com Safety Information Persons supervising and performing the electrical installation or maintenance of a Drive and or its external Option Unit must be suitably qualified and competent in these duties They should be given the opportunity to study and if necessary to dis cuss this User Guide before work is started The voltages present in the Drive and external Option Units are capable of inflicting a severe electric shock and may be lethal The Stop function of the Drive does not remove dangerous voltages from the termi nals of the Drive and external Option Unit Mains supplies should be removed before any servicing work is performed The installation instructions should be adhered to Any questions or doubt should be referred to the supplier of the equipment It is the responsibility of the owner or user to ensure that the installation of the Drive and external Option Unit and the way in which they are operated and maintained complies with the requirements of the Health and Safety at Work Act in the United Kingdom and applicable legislation and regulations and codes of practice in the UK or elsewhere The Drive software may incorporate an optional Auto start facility In order to pre vent the risk of injury to personnel working on or near the motor or its driven equip ment and to prevent potential damage to equipm
11. XM5 field current controller System control modes Main features Data Installation Hazardous areas Environment Mounting instructions Cables and fuses Access to the power and signal connectors Power connections Armature connections and fuses EMC recommendations Signal connections Setting Up Control system description Control circuit description Setting the thyristor control mode Setting the value of IFmax Changing the DCCT primary winding turns Setting the armature voltage range Setting the maximum and minimum field current Adjusting the armature voltage threshold Fault Finding www controltechniques com OOANOOOA AHR BR Q _ a a a ua i onoono O1 D D D ND A D D N O1 Declaration of Conformity Control Techniques The Gro Newtown Powys UK SY16 3BE The AC variable speed drive product FXM5 current range 2A to 20A has been designed and manufactured in accordance with the following European harmonised national and international standards EN60249 Base materials for printed circuits IEC326 1 Printed boards general information for the specification writer 1EC326 5 Printed boards specification for single and double sided printed boards with plated through holes IEC326 6 Printed boards specification for multilayer printed boards Insulation co ordination for equipment within low voltage systems principles requirements and tests EN60529 Degrees of protection prov
12. above any heat generating equipment such as a Drive Mounting instructions Refer to section 3 8 EMC recommendations on page 9 Install the FXM5 controller on a vertical surface enclosure back plate with the heatsink fins vertical Use the fixing holes in the mounting brackets Allow at least 100mm 3 937in clearance above and below the FXM5 controller to allow free air flow through the heatsink Allow at least 3mm 0 118in clearance each side of the FXM5 controller FXM5 User Guide www controltechniques com Issue Number 5 26mm 1 024in 150mm 5 906in 187mm 7 362in 176mm 6 929in 225mm 8 858in Figure 3 1 Mounting details 3 4 Cables and fuses The AC supply inputs in the FXM5 controller are fitted with fuses for protection l against overload and short circuits in the FXM5 controller and field winding of the motor These fuses will not protect the supply cables to the FXM5 controller The table shows recommended cable sizes and fuse ratings for a number of current levels Failure to observe this recommendation will cause a risk of fire Wiring must be in accordance with local regulations and codes of practice The table shows typical cable sizes for power input and output wiring In the event of a conflict local regulations prevail For the following power connections e AC supply to the isolator and fuses Isolator and fuses to the Drive Drive to the motor External braking resistor to the
13. aximum 1000VA 200W maximum Environmental Ingress protection IP10 in accordance with IEC539 Operating temperature range OC 50 C 32F 122 F Storage temperature range 40C 70 C 40F 128 F Humidity 85 maximum non condensing Derating for altitude Maximum altitude without derating is 1000m 3200ft De rate maximum field current by 1 for each additional I00m 320ft up to a maximum of 4000m Heat dissipation 75W maximum Electromagnetic compatibility EMC emissions When all the following conditions are met the installation can meet the requirements for conducted emissions of EN50081 2 The specified RFI filter or ferrite absorber ring and capacitor network is used The recommendations for the wiring arrangements are as follows Overall dimensions when installed Steatite P2E 025 M7 Width 250mm 9 843in Height 187mm 7 362in Depth 112mm 4 409in Weight FXM5 User Guide Issue Number 5 2 5 kg 6 lb www controltechniques com 3 3 Installation The equipment enclosure is rated at IP10 in accordance with IEC539 It is designed for installation within a protective enclosure which prevents unauthorised access except for trained service personnel and prevents contamination with conductive dust and condensation electric shock and may be lethal The Stop function of the Drive does not remove dangerous voltages from the FXM5 controller
14. d current more rapidly towards zero at each half cycle This increases the amplitude of the ripple current but gives faster control of the field current level Use full control under the following conditions When very rapid field weakening is required Motors that have an unusually long electrical time constant 18 FXM5 User Guide www controltechniques com Issue Number 5 4 3 3 Procedure OO 4 4 4 4 1 gt mz LK3 Figure 4 5 Location of jumper LK3 Set the required thyristor control mode using jumper LK3 Key to symbols Half control position Full control position Setting the value of Ipmax All system control modes Description The maximum field current Ipmax that can be delivered by the FXM5 controller depends on the following e Number of primary winding turns through the DCCT Setting of jumper LK1 Refer to the following table FXM5 User Guide 19 Issue Number 5 www controltechniques com 4 4 2 20 Maximum field Number of primary current turns LK1 setting 15 Np 20 Np Setting of parameter 6 11 10 4 10 4 oa 4 CO N of A oj N o CO N oF A oj N ASAS NEANS oO D wo A oa oo N o a a pol pol pol pol ol Al oo The maximum field current is derived as follows 20 15
15. ed under these conditions above base speed power output from the motor remains constant since the available torque reduces in inverse proportion to increases in speed The motor is normally controlled in a closed loop system by a variable speed drive such as a Control Techniques Mentor II Drive System control modes The FXM5 controller can be used in the following system control modes Analog control The motor speed is controlled by a variable speed drive which varies the armature voltage The FXM5 controller monitors the armature voltage When this has reached a preset level usually the level for base speed the controller reduces the field current This gives automatic field weakening resulting in constant power above base speed A suitable speed feedback device must be fitted to the motor shaft and used by the Drive Digital control The motor speed is controlled by a Control Techniques Mentor II Drive which varies the armature voltage and controls the field current using the FXM5 controller Basic PI loop gain adjustments can be made in the Mentor II Drive Highly precise control of motor speed above base speed can be obtained The FXM5 controller can be controlled by the Mentor II Drive to give automatic field weakening see Analog control above or to reduce the field current to a preset level when a specified speed has been reached A suitable speed feedback device must be fitted to the motor shaft and used by the Drive Exte
16. ent users and operators all necessary precautions must be taken if operating the Drive in this mode The Stop and Start inputs of the Drive should not be relied upon to ensure safety of personnel If a safety hazard could exist from unexpected starting of the Drive an interlock should be installed to prevent the motor being inadvertently started General Information The manufacturer accepts no liability for any consequences resulting from inappro priate negligent or incorrect installation or adjustment of the optional operating pa rameters of the equipment or from mismatching the Drive with the motor The contents of this User Guide are believed to be correct at the time of printing In the interests of a commitment to a policy of continuous development and improve ment the manufacturer reserves the right to change the specification of the product or its performance or the contents of the User Guide without notice All rights reserved No part of this User Guide may be reproduced or transmitted in any form or by any means electrical or mechanical including photocopying record ing or by any information storage or retrieval system without permission in writing from the publisher Copyright Septemaber 2002 Control Techniques Drives Ltd Issue Code 5 1 1 1 2 1 3 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 FXM5 User Guide Issue Number 5 Contents Introduction Purpose of the F
17. f primary winding turns in the DCCT The absolute maximum current is defined as I max The title p max on the LED above the SET MAX FIELD potentiometer relates to the maximum required current set using the potentiometer not the absolute maximum current of the FXM5 controller 4 7 2 Minimum current 1 Press the TEST switch continuously The LED bar indicator now shows the proportion of current set using the SET MAX FIELD potentiometer 2 Monitor the LED bar indicator and adjust the SET MIN FIELD potentiometer to set the current at the required proportion of the maximum level Check that the Ipmin LED is lit The value of minimum field current that can be set is between 0 1 and 0 9 of the maximum The minimum current should be set to either of the following To just below the field current required for the maximum speed e g for double the base speed set the SET MIN FIELD potentiometer for just below half the current set using the SET MAX FIELD potentiometer The field failure relay will be de energized when the field current reduces to the level set using the SET MIN FIELD potentiometer To define a level for the field failure relay to be de energized independently of the minimum required field current 3 Release the TEST switch 4 Remove AC power from the FXM65 controller and from the field winding of the motor 4 7 3 Fixed field current Use the procedure given above to set the maximum field current Set the minimum field curren
18. he back plate to the power Ai A2 F1 F2 Li L3 10 way ribbon cable to Mentor Drive only AC supply phases and ground cables must be parallel y ot 2 E LOAD RFI filter Alternative System isolator ground bus bar AC supply AC supply L1 distribution and fuses or MCBs Ground Power ground bus bar Bus bar does not need to be isolated from the enclosure Safety bond to enclosure Site ground if required and close together location of fuses or MCB AC supply to other FXM5 controllers Bond the armour or shield to the back plate If the enclosure construction permits you may instead bond the armour or shield to the enclosure at the cable entry point Refer to Radiated emissions in the EMC Data Sheet Back plate Enclosure Figure 3 5 EMC wiring recommendations To minimize radio frequency emissions it is necessary to install the FXM5 in a steel enclosure and pay attention to the arrangement of the wiring inside the enclosure Any number of FXM5 controllers may be installed in an enclosure FXM5 User Guide Issue Number 5 www controltechniques com 3 8 1 3 8 2 A 3 8 3 10 Figure 3 5 shows an example of wiring arrangements for minimum radio frequency emissions The actual arrangement used will have to be adapted to individual requirements The following conditions must be met The environment is
19. ided by enclosures IP code UL94 Flammability rating of plastic materials IEC664 1 This product complies with the Low Voltage Directive 73 23 EEC and the CE Marking Directive 93 68 EEC SEE W Drury Executive VP Technology Date 9 December 1996 This electronic drive product is intended to be used with an appropriate motor controller electrical protection components and other equipment to form a complete end product or system It must only be installed by a professional assembler who is familiar with requirements for safety and electromagnetic compatibility EMC The assembler is responsible for ensuring that the end product or system complies with all the relevant laws in the country where it is to be used Refer to the product manual or EMC data sheet for further information on ENC standards complied with by the product and guidelines for installation FXM5 User Guide www controltechniques com Issue Number 5 1 1 1 2 1 2 1 1 2 2 1 2 3 1 2 4 1 3 1 3 1 FXM5 User Guide Introduction Purpose of the FXM5 field current controller The FXM5 field current controller allows wound field DC motors to be run at speeds above base speed This is achieved by automatically reducing the field current which reduces the magnetic flux This in turn reduces the back emf in the armature windings The result is an increase in armature current and a consequent increase in speed When a motor is operat
20. nal connections to terminal block TB1 as follows Function Field economy contact Not used OV common Apply an external field current reference signal 0 Field current amplifier input to 10V Remove jumper LK4 Use to supply external devices e g external field current reference potentiometer 15V 10mA max output Use to supply external devices Field current output signal 0 10V represents 0 to Ip max 15V 10mA max output Armature voltage output signal Not used Common contact Field current failure relay Contact closed when field current is normal Contact open when field current is normal l The field current must not be allowed to become zero while the motor is running Cut the wire jumper LK4 since stages N1 N2 and N3 are not used and must not affect the system see section 4 2 Control circuit description on page 16 OO Figure 3 9 Location of wire jumper LK4 FXM5 User Guide 13 Issue Number 5 www controltechniques com 3 9 5 Internal control of the field current fixed level TB1 A1 A2 PL1 1 10 N pa anne Field Field failure economy relay Figure 3 10 Power and signal connections for internal control of the field current Make signal connections to terminal block TB1 as follows Function 1 Connect to terminal 2 for normal operation Open Field economy contact circuit for field economy 2 OV common 3 Field c
21. ntact closed when field current is normal Contact open when field current is normal Armature voltage output signal Field current failure relay Field Field failure economy relay To Mentor II Drive Figure 3 7 Power and signal connections for digital control FXM5 User Guide 11 Issue Number 5 www controltechniques com Digital control can be obtained only by connecting a Control Techniques Mentor II Drive to PL1 of the FXM5 controller using the 10 way ribbon cable supplied with the controller When the cable is connected the FXM5 control circuits are automatically disconnected from the thyristor bridge driver N5 The Mentor II Drive then controls the bridge driver directly Use Menu 6 parameters in the Mentor Il Drive to set up and control the FXM5 controller Remove the following jumpers from the power boards of the Mentor II Drive M25 to M210 LK1 and LK2 M350 to M1850 LK1 3 9 3 Connections to the Mentor Drive Mentor Power Board Connector Designation M25 M75 MDA75 M25R M75R MDA75R M105 M210 MDA210 M105R M210R MDA210R M350 M1850 MDA6 M350R M1850R MDA6 3 9 4 External control of the field current variable or fixed levels TB1 il 10 J22eeeeeeee Field failure relay Field current reference Figure 3 8 Power and signal connections for external control of the field current 12 FXM5 User Guide www controltechniques com Issue Number 5 Make sig
22. or the driven machine AC supplies to theFXM5 controller must be disconnected using an approved isolation device before any cover is removed or service work is performed Electric shock risk If the FXM5 controller has been energized the supply must be isolated for at least five minutes This allows the internal capacitors to discharge fully before work may continue Ground connections The ground connections should be inspected and tested at appropriate and The voltages present in the FXM5 controller are capable of inflicting a severe regular intervals Hazardous areas Approval and certification for hazardous areas should be obtained for the complete installation of the motor Drive and FXM5 controller Environment In accordance with the IP10 rating of the FXM5 the FXM5 must be located in an environment that is free from dust corrosive vapors gases and all liquids including condensation of atmospheric moisture i e pollution degree 2 as required by UL840 and IEC664 1 If condensation is likely to occur when the FXM65 is not in use install an anti condensation heater This heater must be switched off when the FXM5 is in use automatic switching is recommended Install the FXM5 vertically for best flow of cooling air When the FXM6 is installed in an enclosure install the FXM5 as low as possible without contravening EMC requirements Observe the requirements for ambient temperature if the FXM5 is to be mounted directly
23. pply from the input of the armature filter and line chokes otherwise it may be over heated and possibly damaged by the armature voltage notching Ground connections The ground stud on the heatsink of the FXM5 must be connected to the power ground bus bar This bus bar must be connected to the enclosure ground by a safety ground connection It is essential that these connections are permanently installed and cannot be inadvertently disconnected The size of external grounding terminals should be appropriate to the size of the grounding cables Ground loop impedance must conform to the requirements of local industrial safety regulations Do not connect the signal OV common connections to ground at the FXM5 Connect them to ground at the isolated OV bus bar FXM5 User Guide www controltechniques com Issue Number 5 3 9 Signal connections 3 9 1 Analog control Field Field failure Armature economy relay voltage Figure 3 6 Power and signal connections for analog control Make signal connections to terminal block TB1 as follows Function Connect to terminal 2 for normal Field economy contact operation Disconnect for field economy OV common Field current amplifier input Do not connect 15V 10mA max output Use to supply external devices 15V 10mA max output Use to supply external devices Field current output signal 0 to 10V represents 0 to IF max 0 to 10V represents 0 to 600V armature voltage Common contact Co
24. quired motor speed When a Mentor Il Drive is used the required minimum current can be set using parameter 6 10 LED3 indicates when the field current is at or below the minimum level set using RV3 The field current feedback signal is monitored by an LED bar indicator LED1 and N6 The LED bar indicates proportion of absolute maximum current Ipmax in steps of 0 1 10 When the FXM5 controller is operating normally field failure relay RL1 is energized by N6 When the field current is detected by N6 to be below the setting of RV2 or the minimum current set by a Mentor II Drive the relay is de energized The contacts can be used to break the AC supply to the armature Setting the thyristor control mode All system control modes Description The thyristors are arranged as a full wave bridge rectifier The thyristors can be controlled so that the bridge gives half control or full control In both cases full wave rectification is obtained The results are as follows Half control Figure 4 3 Waveforms resulting from half control FXM5 User Guide 17 Issue Number 5 www controltechniques com Full control Figure 4 4 Waveforms resulting from full control 4 3 2 Recommendations Half control Normally use half control since this generally produces a lower amplitude of current ripple This results in lower torque ripple in the motor Full control Full control causes the thyristor bridge to force the fiel
25. rnal control of the field current An external source can be used for either of the following Field weakening by applying a variable field current reference signal e g from a system controller such as a PLC A suitable speed feedback device must be fitted to the motor shaft and used by the system controller Fixed level of field current e g using an external preset potentiometer Internal control of the field current The field current is set at a fixed level using a preset potentiometer in the FXM5 controller The motor can then be run with a reduced field current at fixed or varying speed Main features AC supply requirements The FXM5 controller operates on a single phase AC supply The AC supply is rectified and controlled by thyristors which can be used to give half control or full control as required Issue Number 5 www controltechniques com 1 3 2 1 3 3 1 3 4 1 3 5 The AC supply to the FXM5 controller must be isolated externally Field economy Control of the field current can be over ridden to a field economy level using an external switch This can be used for the following purposes Over ride the normal field current when the motor is stationary in order to prevent over heating of the motor By keeping the motor warm prevent atmospheric condensation in the motor when it is not in use Mounting arrangement The FXM5 controller is contained in a module which must be mounted on a vertical surface
26. supply connections Alternative AC supply See AC supply connections 3 6 1 AC supply connections Using an alternative AC supply The AC supply applied to terminals L1 and L3 supplies the following Field winding of the motor through the thyristor bridge Power supply for the control circuits The AC supply voltage must be in the range specified in Data on page 3 for the control circuits power supply If the voltage is less than 220V 10 the control circuits power supply must be supplied by an alternative AC supply having an acceptable voltage Use the following procedure 1 Remove fuses FS1 and FS2 from the printed circuit board in order to ensure isolation between the alternative AC supply and the field winding AC supply 2 Connect the alternative AC supply to terminals E1 and E3 Ensure that the alternative supply is connected so that the voltage applied to E1 is in phase with the voltage applied to L1 3 Ensure that both connections of the alternative supply are protected with 500mA fuses If the voltage rating of the field is much lower than the supply voltage it is advisable to use a transformer to reduce the supply voltage This maximises the resolution of the controller and prevents the possibility of excessive voltage being applied to the field winding 220V 480V Figure 3 3 Connecting an alternative AC supply in phase with the field winding supply FXM5 User Guide 7 Issue Number 5 www controltechniq
27. t at a level for the field failure relay to be de energized Set the MAX ARM V potentiometer at the fully clockwise position FXM5 User Guide 23 Issue Number 5 www controltechniques com 4 8 Adjusting the armature voltage threshold Analog control mode FXM5 controller and to run the motor Before applying AC power ensure the During the following procedure you will be required to apply AC power to the following The controller is correctly connected The controller cover is securely fitted The motor can be run safely Use the following procedure to adjust the FXM5 controller to begin field weakening at the required armature voltage 1 2 3 4 5 24 Set the SET MAX ARM V potentiometer at the fully clockwise position Apply AC power to the Drive and FXM5 controller Set the Drive to run the motor at base speed or at the required speed if field weakening is to start at a lower speed Slowly turn SET MAX ARM V potentiometer anti clockwise until the highest illuminated segment of the LED bar indicator becomes extinguished Stop the motor and remove AC power from the system FXM5 User Guide www controltechniques com Issue Number 5 5 gt Fault Finding Users must not attempt to repair the FXM5 if it is faulty nor carry out fault diagnosis other than through the use of the diagnostic features described in this section Under no circumstances must the casing of the FXM5 be opened when the AC
28. ues com Using a Mentor Il Drive When using the FXM5 controller with a Mentor Il Drive ensure that terminals L1 and L3 of the controller are connected to the same phases as L1 and L3 in the Drive 3 6 2 AC supply voltage 3 7 230V l M LK5 LK6 fo iw Figure 3 4 Locations of jumpers LK5 and LK6 Set jumpers LK5 and LK6 for the AC supply voltage This may be the voltage applied to terminals L1 and L3 or E1 and E3 see Using an alternative AC supply on page 7 Both jumpers must be set for the same voltage Armature connections and fuses Connections Make armature connections to terminals A1 and A2 as follows System control mode Analog control Connect Digital control External control of field current Internal control of field current Fuses Protect each armature connection with a 2ADC fuse FXM5 User Guide www controltechniques com Issue Number 5 3 8 EMC recommendations Fit a ferrite ring Single power cable Part No 3225 1004 Mls Twin AC power cable Key to symbols Safety ground terminal on heatsink Ground cable around the 10 way ribbon cable FXM5 field controller Output 3 Output 1 OV Ground Host controller E cables to Output 2 the FXM5 Control controllers Isolated OV bus bar Bus bar must be isolated from the enclosure Bond t
29. urrent amplifier input Do not connect 4 15V 10mA max output Use to supply external devices 5 15V 10mA max output Use to supply external devices 6 Field current output signal 0 10V represents 0 to lp max 7 Armature voltage output signal Not used 8 Common contact 9 Field current failure relay Contact closed when field current is normal oO Contact open when field current is normal 3 9 6 Field economy When the FXM5 controller is in normal use connect TB1 terminal 1 to terminal 2 This can be achieved using external contacts When field economy is required the contacts should be opened The field current is reduced to the minimum value set using RV2 When the FXM5 is being controlled from the Mentor using Menu 6 the field current can be reduced by controlling parameter 6 14 The field can be automatically reduced if the armature is disabled This function is controlled by parameter 6 12 6 15 14 FXM5 User Guide www controltechniques com Issue Number 5 4 Setting Up 4 1 Control system description Figure 4 1 Control of armature voltage and field current with varying motor speed Refer to Figure 4 1 The FXM65 controller maintains the field current IF at a fixed value until base speed n is reached detected by the armature voltage VA reaching a maximum value Attempts by the Drive to increase the speed by further increasing the armature voltage causes the controller to reduce the field current
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