OPERATING INSTRUCTIONS FOR
TK5 – CONTROL UNIT
(Installation set)
S-TK5001
1 of 20
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TK 5
OPERATING INSTRUCTIONS FOR
TK5 – CONTROL UNIT
(Installation set)
S-TK5001
2 of 20
22.12/03/Siew
1 ELECTRICAL SAFETY
THE TK5-CONTROL UNIT CONDUCTS DANGEROUS VOLTAGE
WHEN CONNECTED TO THE MAINS POWER SUPPLY.
WHEN IN OPERATION, THE TK5-CONTROL UNIT MUST BE
EARTHED VIA A GROUND CONDUCTOR CONNECTED TO THE
PE MASS TERMINAL.
THE TK5-CONTROL UNIT CAN STILL BE UNDER OUTSIDE
VOLTAGE EVEN WHEN IT IS SWITCHED OFF.
BEFORE STARTING WORK, CHECK THAT THE TK5-CONTROL
UNIT IS NOT UNDER VOLTAGE BY MEASURING THE MAINS
POWER CONNECTION TERMINALS WITH A VOLTMETER.
THE ELECTRICAL INSTALLATION MAY
ONLY BE PERFORMED BY AN
APPROVED ELECTRICIAN.
Warning symbols
For your own safety, please pay particular attention to the
instructions marked with the symbols below:
Dangerous voltage
General warning
!
OPERATING INSTRUCTIONS FOR
TK5 – CONTROL UNIT
(Installation set)
S-TK5001
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2 NOTES ON THE EMVG ACT
The CE-mark which has been applied refers to the German EMVG Act of
9/11/1992 concerning electro-magnetic compatibility (EMC).
The TK5-control unit must be installed by personnel trained in the requirements
of EMC.
The TK5-control unit is compliant to the following standards / normed documents:
1. EN 50081-1
2. EN 50082-2
Providing the precautions detailed below are taken, the TK5control unit may be deployed:
- in the home, businesses, trade premises and in small firms
- in industrial applications
Precautions to be taken:
(as detailed in the circuit diagram in the Annex)
• All control lines must be screened and laid on one side of the
control unit.
• The line which connects the TK5-control unit and the drive must
be screened and laid double-sided.
OPERATING INSTRUCTIONS FOR
TK5 – CONTROL UNIT
(Installation set)
S-TK5001
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3 TABLE OF CONTENTS
1 ELECTRICAL SAFETY
2 NOTES ON THE EMVG ACT ...................................................................................................................3
3 TABLE OF CONTENTS .............................................................................................................................4
4 FOREWORD ................................................................................................................................................5
5 INTENDED USE ..........................................................................................................................................6
6 METHOD OF WORKING..........................................................................................................................6
7 INSTALLATION .........................................................................................................................................7
7.1 DESIGN ....................................................................................................................................................7
7.2 NOTES ON INSTALLATION .................................................................................................................7
7.3 CABLING .................................................................................................................................................8
7.4 CONNECTIONS .......................................................................................................................................8
7.5 PARTICULARITIES ................................................................................................................................9
7.5.1 Controller release...............................................................................................................................9
7.5.2 Output-side switching ........................................................................................................................9
7.5.3 Switching the target value signal .....................................................................................................9
7.5.4 Coarse/fine current applications ......................................................................................................9
7.5.5 Manual/automatic application...........................................................................................................9
7.5.6 Applications with multiple drives ....................................................................................................10
.....................................................................................................................2
8 COMMISSIONING ...................................................................................................................................10
8.1 CHECKS BEFORE TURNING ON THE MAINS VOLTAGE .............................................................10
8.2 TURNING ON THE MAINS VOLTAGE .............................................................................................. 10
9 ADJUSTMENT / RECONFIGURATION ...............................................................................................12
9.1 POSITION OF ADJUSTING ELEMENTS AND COMPONENTS.......................................................12
9.2 EXPLANTION OF ADJUSTING ELEMENTS .....................................................................................12
9.3 ADAPTING THE TARGET VALUE SOURCE ....................................................................................13
9.4 ADAPTING TO THE MAINS VOLTAGE ............................................................................................ 13
9.5 CALIBRATING THE CONTROL UNIT ...............................................................................................14
10 MAINTENENCE........................................................................................................................................14
11 NOTIFYING DEFECTS............................................................................................................................14
12 AUXILIARY DEVICES ............................................................................................................................16
13 ANNEX........................................................................................................................................................ 17
13.1 TECHNICAL DATA ..............................................................................................................................17
13.2 TYPE CODE ...........................................................................................................................................18
13.3 SCOPE OF SUPPLY ...............................................................................................................................19
13.4 FUSE .......................................................................................................................................................19
13.5 DIMENSIONS.........................................................................................................................................19
13.6 CIRCUIT DIAGRAM .............................................................................................................................20
OPERATING INSTRUCTIONS FOR
TK5 – CONTROL UNIT
(Installation set)
S-TK5001
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4 FOREWORD
These instructions apply solely to TK5-control units.
It is essential that these instructions have been read and understood
before starting installation and commissioning work.
The limit values stipulated in the technical data must be complied
with when the control unit is deployed.
The guarantee given for the manufacturer's drives/machines does
not include defects which are caused by misuse or false operation of
this control unit.
The instructions are sub-divided into different chapters as detailed in
the table of contents.
Please read chapter 1 "Electrical safety“ and chapter 2 "Notes on
the EMVG Act“ before starting work with the TK5-control unit.
It is essential that the operator is familiar with the contents of these
instructions before using the drive/machine or before making worksspecific adjustments and settings.
In case you have any questions concerning the TK5-control unit,
please contact the manufacturer directly.
The manufacturer reserves the right to make changes to products
without giving prior notice.
OPERATING INSTRUCTIONS FOR
TK5 – CONTROL UNIT
(Installation set)
S-TK5001
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5 INTENDED USE
The TK5-control unit is designed for operating oscillation equipment
with the manufacturer's magnetic drives of type JD connected to an
AC power system.
The TK5-control unit allows the amplitude of such equipment to be
infinitely adjusted - virtually from 0 to the maximum.
6 METHOD OF WORKING
Using the supplied potentiometer or an external 0/ - 20 mA or a
voltage signal 0 – 10 V DC as the source of the target value, the
amplitude can be infinitely adjusted, and thus also the conveying
performance of magnetic oscillation equipment within determined
limits (minimum and maximum values).
The target value signal which has been set arrives at a smooth startup and linearisation stage and is subsequently compared to the
actual value signal. The actual value signal here is the voltage
output by the control unit to the drive. The differential signal (control
deviation) is passed to a controller, thereby generating the actuating
signal for controlling the phase angle. The actuating signal
determines the point in time at which the thyristor triggers.
For the purpose of galvanic separation, the triggering pulses are fed
to the thyristor via an optocoupler. Triggering takes place within the
positive sinusoidal half-wave. The phase angle in the sinusoidal halfwave controls the electrical power made up of voltage and current
which is fed to the oscillation system.
Fluctuations of ± 10 % in the mains voltage are thus compensated to
approx. ± 2 % whilst the amplitude remains more or less constant.
OPERATING INSTRUCTIONS FOR
TK5 – CONTROL UNIT
(Installation set)
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7 INSTALLATION
7.1 DESIGN
The main components of the TK5-control unit are shown below:
1 Plexi-glass cover
2 Connecting terminals for mains power/drive/control signals
(removable)
3 Semi-conductor fuse
4 Thyristor with cooling element
5 Rating plate
6 Mounting holes
7.2 NOTES ON INSTALLATION
Cooling
The TK5-control unit is
cooled by natural
convection. In order to
ensure a sufficient flow
of air, the unit should be
installed in the vertical
position allowing for the
minimum spacings
stated in the figure
opposite. The cooling
air should be as clean
as possible and not
contain aggressive
substances. If the
cooling air contains
dust, the cooling surfaces must be cleaned regularly.
:
15 mm
TK5-
Cont rolunit
10 mm
Fastening:
The TK5-control unit can be fastened to a normal profile rail using a
rapid-fastening rail clip.
OPERATING INSTRUCTIONS FOR
TK5 – CONTROL UNIT
(Installation set)
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7.3 CABLING
Dimensions of power and drive cables:
A cable length of 150 m between the control unit and the drive has
been foreseen. If the distance is greater, the cable cross section
must be increased accordingly.
Type of
control unit
TK 5 /... 10 1.5
1)
Observe the local regulations for earthing and cables.
NOTE: The German EMVG Act states that the cable between
the control unit and the drive must be screened
sheath must have a large area on both sides and be laid
short to protective conductor potential.
Control cables:
The control cables must be screened. We recommend sheathed,
multi-strand, flexible cables with a conductor cross-section of 0.5 /
0.75 mm² for the control lines.
NOTE: Connect the cable sheath one-sided on the TK5-control
unit to the protective conductor potential .
Arrange control cables so that there is at least 0.5m
spacing to the drive cable to prevent interference.
7.4 CONNECTIONS
1,5mm² is the cable cross-section able to be connected to both
terminal strips.
Please refer to the circuit diagram in the Annex or to the note
packed in with the control unit for the connection assignment of the
power, drive and control cables.
Pre-fuse
[A,
delayed
action]
Cross-section of
power and drive
cables 1) [mm²]
. The
NOTE: If the target value potentiometer is used, please ensure
that the connections are made in the correct sequence.
OPERATING INSTRUCTIONS FOR
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(Installation set)
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7.5 PARTICULARITIES
7.5.1 Controller release
The TK5-control unit is equipped with an input for releasing the
controller (control terminals 14/15).
The controller is blocked when the terminals are open. The drive is
at standstill.
The controller is released when the terminals are bridged. The drive
vibrates.
If the drive is switched off via controller release, the
mains power is not cut off to connection terminals 3/4.
If the technical process requires the
drive to be switched on and off frequently, then "controller release“
should be used instead of line-side switching. The control unit
remains connected to the mains voltage in this case.
7.5.2 Output-side switching
Switching in the output is only admissible when the control unit is
switched off (line-side or via controller release). Switches or fuses
with the corresponding maximum loading then need to be deployed.
The V-fuse unit
switching between the control unit and the drive. It must remain on
the drive when the control unit is switched off.
7.5.3 Switching the target value signal
If switching is to take place in the target value lines, then relays with
gold contacts or hermetically encapsulated relays should be used
due to the low switching voltage (U ≤ 10V=, I ≤ 20mA). In the case of
mA signals, ensure that the load resistor is built into the TK5-control
unit.
7.5.4 Coarse/fine current applications
A target value specification for coarse/fine current can be enabled
for dosing and weighing applications. If a potentiometer is used for
specifying the target value, a second potentiometer is required (->
order separately). The first potentiometer then specifies the target
value for coarse current and the second specifies the target value for
fine current. An example circuit is shown in the circuit diagram in the
Annex. Terminals 26/27 then serve solely as support terminals for
the sliders, and are thus not used on the control unit.
An external target value signal (mA or V) can likewise be used for
the aforesaid applications. For example, a signal of 2V corresponds
to the fine current value and 8V to the coarse current value.
(see chapter "Auxiliary devices“) must be used when
7.5.5 Manual/automatic application
Manual/automatic application is understood to mean that the actual
target value (->automatic) comes from an external source (controller
/ PLC as mA or V). A target value can be supplied from a manual
potentiometer instead of the automatic target value from the control
unit by switching over (-> manual). An example circuit is shown in
the Annex "circuit diagram".
OPERATING INSTRUCTIONS FOR
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(Installation set)
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The S3 selector switch (target value source) must then be set to the
automatic target value signal.
7.5.6 Applications with multiple drives
If more than one drive is to be connected to the control unit, this is
possible in the majority of cases by simply switching the drives in
parallel. The admissible nominal current for the control unit may then
not be overshot. In certain applications it is necessary to run the
individual drives via separating diodes
Please consult the manufacturer.
8 COMMISSIONING
8.1 CHECKS BEFORE TURNING ON THE MAINS VOLTAGE
The TK5-control unit is set in the manufacturer's works to the
oscillation equipment supplied and can therefore be deployed
without needing any further adjustments. An exception to this is if
the notice plate on the control unit refers to a resetting.
(see chapter "Auxiliary devices“).
The setting trimmer Umin / Umax and the S1 selector
switch in the TK5-control unit may not be altered.
!
Should it be necessary to make settings other than those delivered,
please read the chapter "Adjustment/reconfiguration".
Check the following points before switching on the mains power
supply:
1. The control unit must be connected to the associated
oscillation equipment.
2. The specifications made on the control unit's rating plate must
agree with those for the drive. It is especially important that
the control unit's output frequency agrees with the oscillation
frequency of the drive.
3. The nominal mains power voltage must lie within the voltage
range stated on the rating plate (entered under "V" on the
rating plate).
4. The control unit must be earthed via the PE terminal.
5. Action must be taken to comply with the EMVG Act (see
chapter 2)
6. The mains power cable must be connected to terminals
1/2/PE.
7. The drive cable must be connected to terminals 3/4/PE.
8. The appropriate target value transmitter must be connected
(see the type designation on the rating plate and the
explanation of the type code in the Annex)
9. Set the target value transmitter to minimum ( 0/4 mA, 0V, /
target value potentiometer to 0)
10. Terminals 14/15 must be bridged if an external Controller
release is not connected.
Only when an external controller release is connected:
Connect a make contact to terminals 14/15 and remove the
jumper
8.2 TURNING ON THE MAINS VOLTAGE
The points listed under 8.1 must have been performed before the
mains voltage is turned on.
The Mains voltage can now be switched on.
OPERATING INSTRUCTIONS FOR
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(Installation set)
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The TK5-control unit now conducts voltage which can
cause fatal injuries.
The green LED above terminal 27 should now be lit.
The oscillation equipment should now operate at minimum
amplitude.
The target value signal can now be slowly adjusted to maximum.
Once the maximum target value has been reached, the oscillation
equipment should operate at the amplitude stated in the technical
documentation for the machine.
When increasing the target value signal, pay attention
!
Once running smoothly, the target operating value can be set and
material fed to the conveyor.
If it is necessary to make subsequent adjustments to the control unit
to take account of the prevailing conditions, please refer to the
chapter "Adjustment/reconfiguration".
to the operating noise made by the oscillation
equipment. If knocking sounds can be heard, turn the
oscillation equipment off immediately. The equipment
can be switched back on once the error has been found
and rectified.
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(Installation set)
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9 ADJUSTMENT / RECONFIGURATION
9.1 POSITION OF ADJUSTING ELEMENTS AND COMPONENTS
Thyristor + heat sink
Choke
Fuse
Mains
transformer
Terminal strip
View with the plexi-glass cover removed.
LED: Green for "voltage “on
9.2 EXPLANTION OF ADJUSTING ELEMENTS
IMPORTANT NOTE:
!
Uncontrolled changes to the adjusting elements can
cause the control unit to malfunction.
Before settings are changed, it is essential to read the
following points through carefully.
Trimming potentiometers:
2 Trimming potentiometers are arranged on the control card.
Function of the trimming potentiometers:
Umax: Setting for the maximum output voltage *)
Umin: Setting for the minimum output voltage *)
*) Both trimmers are locked and may not
be altered without
consultation.
S3 selector switch (DIP switch):
There is a 4-way selector switch (S3) – a so-called DIP switch –
fitted to the control card.
Each of these switches is a slide switch which are number 1-4 from
left to right.
S1 slide switch:
SW 3
SW 3
SW 3
9.3 ADAPTING THE TARGET VALUE SOURCE
OPERATING INSTRUCTIONS FOR
TK5 – CONTROL UNIT
This switch serves to adapt the mains voltage and has two positions.
The switch position is locked. Changing this incorrectly can lead to
the destruction of the control unit! See 9.4
The S3 selector switch serves to adapt the control unit to the various
target value sources.
Do not touch the slide switches until the mains voltage
!
Position of SW 3 (1-3):
OFF
OFF
OFF
has been switched off. The plexi-glass cover must be
removed from the control unit to change their positions.
does not
1234
1234
1234
require the trimmers Umax/Umin to be reset.
(Installation set)
Target value 0...10 V via terminal 7/8
and/or target value potentiometer on
5/7
Target value 0...20 mA via terminal 7/8
Target value 4...20 mA via terminal 7/8
NOTE: Changing the setting of S3
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9.4 ADAPTING TO THE MAINS VOLTAGE
There is a slide switch (S1) on the control card to select the mains
voltage.
The power to the control unit must
before switch S1 is operated. Make sure there is no
voltage ! The plexi-glass cover must be removed from
!
NOTE: Changing the mains voltage requires the trimmers
the control unit.
Selecting a false mains voltage will destroy the control
unit.
The drive must be selected to suit the mains voltage.
Umax/Umin to be reset
manufacturer's service department.
. Should only be done by the
be switched off
9.5 CALIBRATING THE CONTROL UNIT
10 MAINTENENCE
OPERATING INSTRUCTIONS FOR
TK5 – CONTROL UNIT
(Installation set)
Switch position for mains voltage between 100V
and 120VAC.
Switch position for mains voltage between 200V
and 240VAC.
An amplitude measuring gauge and a TRMS voltmeter are required
to calibrate the control unit. Consult with the manufacturer's
service department.
The TK5-control unit generally does not require any maintenance.
However, in particularly dusty environments regular cleaning is
essential.
The drive's power draw should be measured at each service with a
TRMS ammeter (real-effective value). The maximum amplitude of
the oscillation equipment should also be checked (nominal values
are stated in the drive documentation).
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11 NOTIFYING DEFECTS
Before notifying defects to our service department, please make a
note of the following data:
− Type designation of the control unit (see rating plate)
− No. of the control unit (see rating plate)
− Mains voltage (measured)
− Drive data
− Noticeable defects
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12 AUXILIARY DEVICES
The following auxiliary devices are available for the TK5-control unit:
− Fault warning unit "H“:
Current monitor to monitor the drive current. A fault warning
contact is made if a limit value is undershot because of a wire
break, for example
− Target voltage source "Q":
Provides a constant voltage of 10V= to feed target value
potentiometers
− Fuse unit "V":
Required to protect the drive if switching is made between the
control unit and the drive.
− Separating diodes "F":
If more than one drive is connected to the control unit, it can be
necessary to deploy this component in order to prevent mutual
electrical interference
− Protective device "N":
Required to limit the current for explosion-protected drives. It
must be connected between the control unit and the explosionprotected drive.
OPERATING INSTRUCTIONS FOR
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(Installation set)
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13 ANNEX
13.1 TECHNICAL DATA
Nominal mains voltage 115, 230 V AC
(1Ph+N), switchable
Mains voltage ranges 100 - 120 V AC
200 - 240 V AC
Admissible voltage fluctuations + 5 %, (ref. to nominal voltage)
- 10 %, (ref. to nominal voltage)
Nominal mains frequency 50/60 Hz; ± 1 %
Max. output current 5 A
Output frequency As nominal mains frequency
Power loss Pv (W) max. 6 W
Internal voltages ± 12V stabilised, short-circuit
proof
+10V stabilised, short-circuit
proof for max. 2 target value
potentiometers (5 KΩ)
Target value input 0/4 - 20 mA, load 250 Ω;
0 - 10 V;
selectable via DIP switch
Target value integrator Permanently set
Target value linearisation Permanently set
Warning lights 1 x LED; for operating voltage
Controller release Via potential-free external make
contact,
OTHER DATA
Approvals EN 50081-1, EN 50082-2
VBG4
Semi-conductor fuse 10 AFF (superflink), 5x20mm
Cooling method Air self-cooling
Max. installation altitude 1000 m (over 1000m consult
the manufacturer)
Admissible humidity DIN 40040 F
Protection system DIN 40050 IP 21
Operating temperature 0°C to + 45°C
13.2 TYPE CODE
OPERATING INSTRUCTIONS FOR
TK5 – CONTROL UNIT
Storage and transport temperature - 10°C to + 85°C
Installation position Vertical
Cont. admissible vibration level ≤ 0.5 G
Weight 700 g
Dimensions 110
112 x 197 mm (WxD) base area
The designation on the rating plate of the TK5-control unit is
composed as follows:
(Installation set)
40 mm high
Only for special models
yyy stands for 000 - 999
Additional connection
0 = No separating diodes
1 = Separating diode connection
Target value signal
1 = Potentiometer
2 = 0 - 10 V
3 = 0 - 20 mA
4 = 4 - 20 mA
5 = Special signal
6 = Universal device, 1 and 2 pre-set
Type of control unit
K = Voltage return
Output frequency = mains power
frequency 50, 60 Hz
Exxx = installation set
if installed always E000
Nominal mains power voltage
115, 230 V
Max. output current
5 = 5 A
Type of control unit
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13.3 SCOPE OF SUPPLY
The following items are supplied with the TK5-control unit:
1 x target value potentiometer with scale and rotary knob
1 x circuit diagram
1 x spare fuse 10A FF
13.4 FUSE
Turn off the mains power before changing the fuse
The pre-installed fuse (superflink)
serves to protect the thyristor in
case of a short circuit. Only use the same type when changing the
fuse.
Fuse: 10 A FF (superflink) 5 x 20 mm
13.5 DIMENSIONS
TK5-control unit:
198
110
Potentiometer 5 KΩ with scale and rotary knob:
O 28mm
a
b
c
M10
O 6mm
16
88
Scale : 64 x 64 mm
Centre hole: ∅ 11 mm
Rotary knob : ∅ 36 mm
Height : 20 mm
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(Installation set)
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CIRCUIT DIAGRAM
MAINS
The EMVG Act states that
screened lines, as shown, must
be deployed.
Target value
(see below)
Controller release
OPEN : STOP
DRIVE
TARGET VALUE CONNECTION
MANUAL-AUTO SWITCHOVER
INPUT
NOTES:
POTI R1: APART PROVISION WITH SCALE AND KNOB
ADMISSIBLE CABLE LENGTH 150 m
POTI R2: ORDER SEPARATELY
Fine
Coarse
Customer supply
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