Control Technologies PHANTOM IV User manual

CONTROL
TECHNOLOGY
PHANTOM IV
SINGLE PHASE TWO QUADRANT CONVERTOR
P O BOX 15019 31 CIRCUIT ROAD
WESTMEAD WESTMEAD
3608 3610
TEL: [phone] FAX: [phone]

PHANTOM IV
SINGLE PHASE TWO QUADRANT CONVERTOR
CONTENTS
PRODUCT OVERVIEW …………………………………………4
ELECTRICAL SPECIFICATIONS …………………………………………6
INSTALLATION INFORMATION ………………….…………...…………7
TERMINAL INFORMATION …………………………………………9
COMMISSIONING INFORMATION
a) Two quadrant DC braking controller
b) Simple field controller (current
control)
c) Field controller (spill over mode)
………………………………………..15
………………………………………..20
………………………………………..26
PROBLEM SOLVING INFORMATION ………………………………………..31
MECHANICAL DRAWINGS ……..…………………………………
BLOCK SCHEMATIC ……………………………………….
PC BOARD COMPONENT LAYOUT ………………………………………..

This equipment is guaranteed for twelve months from the date of delivery. The terms
of this guarantee are valid provided that CONTROL TECHNOLOGY is informed of
the fact within fourteen days of equipment malfunction and the equipment is returned
to the nearest agent with a factory accredited service department. The equipment
should be suitably packed and the transport prepaid.
WARNING
THIS EQUIPMENT MUST BE HANDLED WITH THE UTMOST CARE, AS
DANGEROUS ELECTRICAL POTENTIALS ARE PRESENT WHEN A SUPPLY
VOLTAGE IS APPLIED. WHEN PRINTED CIRCUIT BOARD REPAIR OR PART
REPLACEMENT IS REQUIRED ALWAYS ISOLATE ALL SUPPLY VOLTAGES
TO THE SYSTEM.

4
PRODUCT OVERVIEW
The PHANTOM IV is a dual purpose controller designed to operate either as a two
quadrant DC brake or for exciting DC motor fields. With regard to the latter, it is
possible to configure the controller to operate in the field spillover mode. When used
as a straight field exciter it will accept either a voltage or current reference.
One model caters for all the single phase ranges.
Two dual thyristors in isolated packages, configured as a DC bridge ensure chassis to
mains isolation. The speed of the DC motor, armature or field, is controlled using
linear closed loop circuitry with either armature\field voltage or tachogenerator
feedback. The armature\field voltage is isolated from the control circuit by a high
impedance buffer. An ACCT derived, current feedback signal, galvanically isolated
from the control circuitry, completes the current loop.

5
OTHER STANDARD FEATURES
TWO QUADRANT CONTROLLER
* 220 or 380 vac supply voltage link selectable.
* Field supply selectable for 220vac or 380vac.
* On board high speed fusing of field and armature.
* Torque reference input.
* Single board simplicity, bolts directly on SCR's.
FIELD REGULATOR
* Speed linearising curve. Corrects the exponential relationship between field
excitation and motor speed.
* Current reference input, eliminates speed variations due to temperature changes in
the motor.
* Field OK relay with a normally closed potential free contact.
* Field economy. In spill-over mode the field voltage is reduced to 50% if the
armature voltage is absent for 90 seconds.
* Full block firing. Allows for trouble free control of highly inductive loads.

6
ELECTRICAL SPECIFICATIONS
MODEL SUPPLY
VOLTAGE INPUT CURRENT OUTPUT VOLTAGE OUTPUT CURRENT HEAT DISS.
0.1 – 7.5
KW 220-380 VAC .1-38 AAC 200-340 VDC .1-30 ADC 10-432W
ALL MODELS:
FIELD VOLTS: .9 X SUPPLY VOLTAGE.
FIELD CURRENT: 2 AMPS.
MAXIMUM OVERLOAD ON UNIT: 150% FOR 15 SECONDS.
MAXIMUM FORM FACTOR: 1.5.
I SQ.T FUSING REQUIREMENT: 300 AMPS SQ. PER SEC.
SUPPLY FREQUENCY: 50 HZ.
ENCLOSURE: IP00
OPERATING TEMPERATURE: -10 TO 40 DEG.C
HUMIDITY: 85% R.H. AT 40 DEG. C
NON CONDENSING.
ALTITUDE: ABOVE 1000M DERATE 1%
PER 100M
SPEED CONTROL
ARMATURE FEEDBACK
SPEED REGULATION: 3% TYPICAL
TORQUE/SPEED RANGE: 20:1
TACHOGENERATOR FEEDBACK
SPEED REGULATION: 1% TYPICAL
TORQUE/SPEED RANGE: 100:1
CONTROL FUNCTION:
CLOSED LOOP PROPORTIONAL PLUS INTEGRAL CONTROL WITH
ADJUSTABLE STABILITY.
TORQUE CONTROL
ACCURACY: 2% TYPICAL
CONTROL FUNCTION:
CLOSED LOOP PROPORTIONAL PLUS INTEGRAL

7
INSTALLATION INFORMATION
Before commissioning it is essential to ensure the following installation information
has been complied with.
1. A good air flow is essential for maximum cooling. When fitting in an enclosure
allow 100 mm clearance on all sides. If a smaller enclosure is used it may be
necessary to fit a cooling fan. When fitting in a system with cable trunking ensure
a 50 mm clearance top and bottom and 25 mm side clearance.
2. Operating temperature range 0 - 40 deg. C.
3. Avoid vibration. Excessive vibration can cause general deterioration of
connections and component damage.
4. Ensure that the motor is correctly mounted and aligned as per the manufacturer's
specifications.
5. Ensure that motor cooling accessories and
louvers are functional.
6. Check dynamic mechanical integrity of all bushes, bearings and brushgear by
manually rotating the motor.
7. Check that pulleys are correctly aligned.
DISCONNECT PHANTOM POWER WIRING TO DRIVE!

8
8. Measure the resistance of the windings for
correct terminal allocation.
a) Low impedance across armature.
b) High impedance across shunt field.
c) Low impedance across series field.
(NOTE Shunt field should be left unconnected in a regenerative system.)
d) More than 2 mega ohm from any terminal to ground.
9. All control cabling should be 0.75 sq.mm. minimum. A noisy environment could
necessitate screening of the reference and feedback control signals. Care should be
taken in the grounding of the screen conductor so as to avoid earth loops.
CONNECT SCREEN TO EARTH ONLY AT CONTROLLER END.
10. Power cable to be minimum 600 vac rated at 1.5 X armature\field current.
11. High speed rated, are protection unit which fuses or circuit breakers, suitably
recommended for incoming supply on all versions except the 2.2 KW is internally
fused.
2.2 KW 20A
3.7 KW 25A
5.5 KW 30A
7.5 KW 40A
12. Ensure good quality earth bonding.

9
TERMINAL INFORMATION
CONTROL TERMINALS
1. 0 volt Common : Tachogenerator + input
reference.
2. 0 volt Common : Tachogenerator + input
reference.
3. 0 volt Common : Tachogenerator + input
reference.
4. Tachogenerator :Tachogenerator feedback.
5. Speed indication :0 - 5 vdc for 0 to 100%, short
output circuit protected. Maximum load
10 ma.
6. Speed reference :0 - 12 vdc for 0 - 100%.
input Ramp rate adjustable on P2
7. Current reference :0 -12 vdc for 0 - 100%
input. current control.
8. Stop :- 22 vdc supply for internal start
relay. Connect to stop button
when internal latch required.
Connect to term.16 via a potential
free contact for remote starting.
9. Common stop/start :Connected to common of
stop/start circuitry when latch
required.
10 Start :Internal relay coil. Connect to
start button when internal latch
required. Connect to terminal 8
via a potential free contact for
remote starting.

10
11. Field OK :Potential free n/o contact
4 amps 250 vac.
Energises when field current
exists. May be used to signal
field integrity.
Refer to terminal 12.
12. Field OK :Potential free n/o contact
4 amps 250 vac.
Energises when field current
exists. May be used to signal
field integrity.
Refer to terminal 11.
13. - 12 vdc :Negative power supply rail
maximum load 20 ma.
14. 0 volt Common :Tachogenerator + input
reference.
15. + 12 vdc :Positive power supply rail
maximum load 20 ma.

11
POWER TERMINALS
L1 and L2 Main supply terminals, if a live
and neutral supply is used
connect neutral to L2.
NOTE!
On board fusing may be retained
for up to 15 amps DC output
current. For greater output
currents the onboard fuses F1 and
F2 must be replaced with the
shorting bars supplied and
external fuses must be wired in.
A+ and A- DC output from controller to
motor armature\field. Polarity
will effect direction of rotation.
F+ and F- DC output to field winding. if
controller is used as a two
quadrant DC drive. Polarity will
effect direction of rotation.
N If selected by links a neutral may
be connected to to this terminal to
supply a 200 volt field if
required.
EARTH Connect to chassis in bottom left
hand corner with 5mm fixing
system.
TERM 16 + 17 Refer to layout for location.
These terminals are connected to
the armature of the master DC
drive when this controller is used
as a field weakener in spill-over
configuration.

12
COMMISSIONING INFORMATION
INTERNAL PRE-SET POTENTIOMETER INFORMATION
CW = Clockwise CCW = Counter clockwise
REFER TO PAGE 23 for component location.
ALL QUICKSET POSITIONS ARE GIVEN FOR TEST PURPOSES ONLY.
DAMAGE MAY OCCUR IF FULL COMMISSIONING PROCEDURE IS
NOT ADHERED TO.
P1 MAX. Sets the maximum speed of the
motor with 12 vdc speed reference.
Quickset position: 50%
P2 RAMP. Controls the rate of deceleration and acceleration of the motor. Fully
CW is equal to quickest acceleration.
Quickset position: 100% CW
P3 Minimum speed. Sets the minimum speed of the motor with zero speed
reference. CW from the 50% position will increase the speed from zero. CCW
from the 50% position is used to offset a 4 - 20 ma. speed reference input if
required. Adjusts the spillover point when used as a field weakener.
Quickset position: 50%
P4 PROP. Optimizes the speed loop. Rotate CCW for faster response. Excess
adjustment may cause instability. Further optimization may be obtained by
different values. for RBi and C22. (Altering the integral time)
Quickset position: 50%
P5 FIELD FAIL. When this controller is used as a field controller this
potentiometer sets the minimum current allowed before the field OK relay will
de-energize.
Quickset position: 1001. CCW

13
P6 I MIN. When this controller is used as a field controller this potentiometer sets
the minimum field current. When used as a two quadrant DC controller this
potentiometer must be left in the fully CCW position
Quickset position: 100% CCW
P7 I MAX. CCW for minimum current setting CW for maximum setting, must be
readjusted if motor is changed.
Quickset position: 50%
P8 ISTAB. Optimizes the current loop. Rotate CCW for faster response. Excess
adjustment may cause instability.
Quickset position: 50%
LINKING OPTIONS
LK.1 Selects terminal N and L1 to be connected to the on board field
rectifier. When a Neutral is connected to terminal N, a 200 vdc field
supply is available at terminals F+ and F-.
LK.2 The supply voltage connected to terminals L1 and L2 supply the on
board field rectifier.
IMPORTANT!!!! LK.1 and LK.2 must not be both connected.
220 vac Link :Insert for 220 vac main incoming
supply. Remove 380 vac link.
380 vac Link :Insert for 380 vac main incoming
supply. Remove 220 vac link.
LINK.1 + LINK.2 + LK 5 inserted for internal armature\ voltage feedback. Remove
LK 5 for tachogenerator feedback.
IMPORTANT!!!! Remove LINK.1 and LINK.2 when used as field controller.

14
COMISSIONING INFORMATION.
TWO QUADRANT DC MOTOR BRAKING CONTROLLER
Although the following information is fairly general, it is assumed that the system
being commissioned is a simple braking controller and motor.
Before energising the controller for the first time choose the correct application
connections from the descriptions given in the application information section of this
manual.
CHECK :Main power supply voltage is correct.
:Motor current and voltage ratings are compatible with controller.
:The controller has not been mechanically damaged in transit.
:All power and control wiring fasteners are tightened adequately.
:The motor is free to rotate in either direction and no personnel or
machinery will be injured or damaged if the motor is rotated at
maximum speed.
STARTUP PROCEDURE
1. ISOLATE THE INCOMING MAINS SUPPLY.
2. Ensure correct linking for main supply
voltage.
3. Ensure correct LINKS are selected for armature or tacho. feedback.
SEE SECTION 11.
4. Turn pre-set potentiometers to the
positions listed below.
P1 100% CCW
P2 100% CW
P3 50%
P4 50%
P5 100% CW
P6 100% CCW
P7 100% CCW
P8 50%

15
5. TACHO scaling resistor R18 has been selected for 1750 RPM, 60 volts DC per
1000 RPM. If tacho feedback is used the correct value R18 for other motor\tacho
combinations must be calculated using the formula below.
If armature feedback is required ensure the correct value's for R6 + R7 are
inserted.
310 volt armature R6 + R7 = 3.3 Mega ohms
180 volt armature R6 + R7 = 2.2 Mega ohms
6. Select the correct settings for Dip switches
1 + 2
S1 1 OFF S2 1 OFF
S1 2 ON S2 2 ON
7. Ensure the fuses are correctly rated. Unscrew
the motor field DC supply terminal.
8 . CURRENT LIMIT ADJUSTMENT
This adjustment must be completed as swiftly as possible to prevent damage to the
motor armature.
Ensure instruction 7 is completed before the main isolator is switched on.
Select the ACCT terminating resistor as per the following formula.
Fit a DC ammeter in one leg of the armature circuit.
Switch on the mains isolator. Measure at the incoming mains supply terminals for
the correct voltage.
Set the speed reference to + 12 vdc.
Check that LED's L0,L2 + L4 (Power on, zero speed and field OK respectively)
are illuminated. Press the start button check that LED L3 (run) and, one second
later, L1 (enable) are illuminated. Turn the IMAX. (current limit) potentiometer
slowly clockwise until the DC ammeter indicates the armature current on the
motor nameplate.
Press the stop button.
Switch off main isolator. Reconnect the motor field.

16
9. MAXIMUN SPEED ADJUSTMENT
If the product being pulled off this braking motor is severed the motor will
accelerate to the speed set below.
The controller is factory set to accept a
60 vdc per 1000 RPM tachogenerator.
ensure that the output shaft can rotate in the opposite direction for unwinding.
With Tachogenerator feedback.
Ensure LK 5 has been removed.
Select the correct tachogenerator scaling resistor. SEE SECTION 5
Set the speed reference to +/-10%. Press the start button. If the motor accelerates
to full speed, correct the wiring as follows:
a. Direction correct :Reverse tacho
but motor runs away. polarity only.
b. Direction incorrect :Reverse field
and motor runs away. polarity only.
c. Direction incorrect :Reverse tacho
but in control. and field polarity.
Increase speed demand to + 12 vdc and check that the motor accelerates smoothly
and that the DC output level listed on the controller nameplate or the maximum
armature voltage, whichever is lower, is not exceeded.
Adjust on P1 (MAX SPD)
With armature feed back.
Ensure that LK 5 is inserted.
If armature feedback is used the motor will not run away. The direction of the
motor can be corrected by reversing the field or armature polarity.
Select the correct armature feedback scaling resistor.
310 volt armature R6 + R7 = 3.3 Mega ohms
180 volt armature R6 + R7 = 2.2 Mega ohms
Press the start button. Set the speed reference to + 12 vdc. Ensure that the motor
accelerates smoothly and that the DC output
level listed on the controller nameplate or the maximum armature voltage,
whichever is lower, is not exceeded.
Adjust on P1 (MAX SPD)

17
10 Set the minimum speed to the required level on P3 (MIN SPD).
11. Set the deceleration and acceleration of the motor on P2 (RAMP).
12 SPEED STABILITY ADJUSTMENT
Set the speed reference to the level where the motor is most unstable. Slowly
rotate P4 (PROPORTIONAL GAIN) until motor stabilizes.
13. CURRENT STABILITY ADJUSTMENT
Set the speed reference to the level where the motor is most unstable. Slowly
rotate P8 (ISTAB.) until motor stabilizes.
14. BRAKING TENSION SETTING
The braking tension input terminal (Term. 7) is scaled to accept a 0 - +12 vdc
reference input. Refer to the application connection diagram drawing.

18
COMISSIONING INFORMATION.
SIMPLE FIELD CONTROLLER (CURRENT CONTROL)
Although the following information is fairly general, it is necessary to choose whether
to make use of the speed linearising curve option described below.
Most DC motors are characterised by a non linear relationship between field current
and motor speed. If the signal being supplied to the external current limit input has
taken the above into account it will be necessary to choose OPTION 1 .
OPTION 1. Uncompensated 1:1 relationship between current reference and field
current.
Remove R102
Change R107 to 27K
OPTION 2. is a four break point analog curve converter, the values of which, have
been selected to generally improve the field voltage\motor speed exponential, taking
into account variations there of between motor size and manufacturer.
A standard controller is set up for option 2
R102 = 1K2
R107 = 150K
Before energising the controller for the first time choose the correct application
connections from the descriptions given in the application information section of this
manual.
CHECK :Main power supply voltage is correct.
:Motor current and voltage ratings are
compatible with controller.
:The controller has not been mechanically
damaged in transit.
:All power and control wiring fastners
are tightened adequately.
:The motor is free to rotate in either dir¬ection and no personnel or
machinery will be injured or damaged if the motor is rotated at
maximum speed.

19
STARTUP PROCEDURE
1. ISOLATE THE INCOMING MAINS SUPPLY.
2. Ensure correct linking for main supply voltage.
3. Remove LK 5.
4. Turn pre-set potentiometers to the
positions listed below.
P1 100% CCW
P2 100% CW
P3 100% CW
P4 100% CW
P5 100% CCW
P6 100% CCW
P7 100% CCW
P8 50%
5. Replace C22 with a 100K ¼ watt resistor.
6. Select the correct settings for Dip switches
1 + 2
Input reference options
0 vdc = Minimum field excitation.
12 vdc = Maximum field excitation.
S1 1 ON S2 1 ON
S1 2 OFF S2 2 OFF
0 vdc = Maximum field excitation.
12 vdc = Minimum field excitation.
S1 1 OFF S2 1 ON
S1 2 ON S2 2 OFF

20
7. Select the mode of operation.
OPTION 1. Uncompensated 1:1 relationship between current reference and field
current.
Remove R102
Change R107 to 27K
OPTION 2. is a four break point analog curve convertor, the values of which,
have been selected to generally improve the field voltage\motor speed
exponential, taking into account variations there of between motor size and
manufacturer.
A standard controller is set up for option 2
R102 = 1K2
R107 = 150K
8. CURRENT LIMIT ADJUSTMENT
Select the ACCT terminating resistor as per the following formula.
It is assumed that the Stop\Start buttons referred to below control the master DC
drive.
Fit a DC ammeter in one leg of the field circuit.
Switch on the mains isolator. Measure at the incoming mains supply terminals for
the correct voltage.
Set the field weaken reference at terminal 6 for maximum field strength.
0 vdc = Minimum field excitation.
12 vdc = Maximum field excitation.
S1 1 ON S2 1 ON
S1 2 OFF S2 2 OFF
0 vdc = Maximum field excitation.
12 vdc = Minimum field excitation.
S1 1 OFF S2 1 ON
S1 2 ON S2 2 OFF
Check that all the LED's are illuminated.
Turn P7 (IMAX.) potentiometer slowly clockwise until the DC ammeter indicates
the field current on the motor nameplate.