Teil 1Thyristor DriveQ3 x/x- 1000 to 2000A
Teil 2Analoque Control ElectronicREG4
Edition
1108
Classic Q3 1000-2000A
Contents
ContentsPage
Basic Information
Safety advice3
Standards and guidelines3
General information4
Features5
Technical data 6, 7
Specification8
Mechanical installation9
Dimensions10, 11
Electrical installation
Connections12
Connection diagram13
CE advice14
Auxiliary voltage connection15
Transformer power connection16
Option - synchronization17
Motor connection19
Field connection20
Actual value connection21
Components22
Adjustments22
Circuit diagram23
Current control loop24
Signals25
Measurements25
Before installation or commissioning begins, this manual must be thoroughly
read and understood by the technical staff involved.
If any uncertainty arises, the manufacturer or dealer should be contacted.
Q3 devices are power electric parts used for regulating energy flow.
Protection rating IP00.
Standards and guidelines
The device and its associated components can only be installed and switched on
where the local regulations and technical standards have been strictly adhered
to:
EU Guidelines89/392/EWG, 84/528/EWG, 86/663/EWG,
72/23/EWG
- loss of regulation or control
the axis will be safely de-activated.
It must also be ensured that the machine or equipment are fitted with device in
dependent monitoring and safety features.
Setting adjustments
- should only be carried out by suitably trained personnel
- should only be carried out in accordance with health and safety guidelines
Assembly
- should only be carried out when all voltages have been removed.
QS
Test results are archived with the device serial number by the manufacturer.
-
CEThe device adheres to the following: Guideline EU 89/336/EWG. EMC stan
Q3 1000-2000A3
-
Classic Q3 1000-2000A
General information
Attention:
This manual Q3 only describes the basic control unit.
Manual Q3
This device description must be read in conjunction with the manual for
- an analogue controlREG xx
- an external field controlF2 xx
- optionsMulti xx
General information
Series Classic Q3
4
1 Basic information
Build
- switch cabinet mounting
- according to the VDE, DIN and EU regulations
- standard control electronics REG
-
intrinsically safe power section with current control loop
- controlled or uncontrolled field supply unit
- optional units
Galvanic isolation between
- the power section and the housing
- the power section and the control electronics
The distance of air gaps and leakage paths adhere to the VDE standards
(>8mm).
Features
Components
- only components customary in trade and industrially standardised are used
- high-quality bases for the IC with external connections
- LED displays
- precision potentiometers for fine adjustments
- plug-in jumpers for the system set-up
Characteristics
*Series Classic Q3
*Thyristor drive for dc motors
*Power range 6.75kW to 1.1MW
*Drive and brake in all 4 quadrants'
*Energy recovery
*Intrinsically safe power section
*Fast analogue current control
*Temperature watchdog - power section
*Circular current-free dual bridge circuit
*Controlled or uncontrolled field rectifier
*26-pin interface
*Features of the control electronics:
see Manual REGxx or third-party product documentation
*Optional units
Q3 1000-2000A5
Classic Q3 1000-2000A
Technical data
Q3 400/450-1000-2000
Power connection360 ... 440V~
Auxiliary voltage connection360 ... 440V~, 200 … 250V~ oder Option
Output voltagemax. ± 450V=
Coolingventilation fan
Field supply - externalField current controller F2.1 400/340-20
Q3 400/450-100015002000
Input currentA~80012001600
Output current- peak 5s
- continuous
El. powerkW450675900
Fusesff
Power chokes
Armature chokesArmature chokes are necessary only for special applications
Dimensions w x h x dmm550x800x520550x800x520550x800x520
A=
A=
AFF
Type
mH0,050,030,02
2000
1000
installed
6x1000
3x
KU240-1000
3000
1500
installed
12x1000
3x
KU240-1500
4000
2000
installed
12x1000
3x
KU240-2000
Q3 500/550-1000 bis 2000
Power connection450 ... 550V~
Auxiliary voltage connection360 ... 440V~, 200 … 250V~ oder Option
Output voltagemax. ± 550V=
Coolingventilation fan
Field supply - externalField current controller Unitek F2.1 400/340-20
Q3 500/550-100015002000
Input currentA~80012001600
Output current- peak 5s
- continuous
El. powerkW5508251100
Fuses
Power chokes
Armature chokeArmature chokes are necessary only for special applications
Dimensions w x h x dmm
A=
A=
ff
AFF
Type
mH0,050,030,02
2000
1000
Installed
6x1000
3x
KU240-10003xKU240-15003xKU240-2000
550x800x520550x800x520550x800x52
3000
1500
Installed
12x1000
4000
2000
Installed
12x1000
0
6
1 Basic information
Specification
Mains frequency50 or 60Hz ±5%
Protection ratingIP 00
FormatVDE 0100 group C,
VDE 0160
Humidity ratingclass F acc. to DIN 40040
Site of installation< 1000m above sea level
Operating temperature range0 ... 45°C
Extended operating temp. rangeup to 60°C reduced by 2%/°C
Storage temperature range-30°C to + 80°C
Current control loop circuit
Amplification
- input signal0 to ±10V=
- output0 to ±200% type current
Over-current limiting10s 200% type current
Control precision±2%
Control range1:50
Enable>+10V
Speed control loop circuit (with manual REG)
Control precision
(without actual value error)<±0.1%
Control range>1:1000
Interface control electronics X3
FunctionConnector no.
+ 24V±10%X3: 1 and 2
+ 15V±2%X3: 3 and 4
- 24V±10%X3: 5 and 6
- 15V±2%X3: 7 and 8
DeviceGND0X3: 9, 10, 11, 12, 13, 14
I command value (GND)0X3: 15
I command value (signal)+10V=X3: 16
Current controller enable+10V=X3: 17
Drive disable1+10V=X3: 18
Drive disable 2+10V=X3: 19
N (speed) actual+10V=X3: 20
I (current) actual+5V=X3: 21
Over-current power section+10V=X3: 22
Option UA±10V=X3: 23
Option UA0-10V=X3: 24
Drive ready BTB+10VX3: 25
+5VX3: 26
Techniscal data
Q3 1000-2000A7
Classsic Q3 1000-2000A
Air flowdirection
Mounting
Ambient temperature0 to <45°C(reduced, up to 60°C)
max. cooling unit temperature80°C(internal watchdog)
Air-mass throughput1000-2000A2500m³h
Dissipation loss with max. power
Unit Q3-x/xUnit WMains choke W
100037001000
150054001300
200072001600
8
2 Mechanical installation
1-phase mains choke
Faetures
UN400V~50/60Hz
UK4%
Protection ratingIP00
Isolation classT40/E
Vertical angle bracket
Dimensions
Units
Q3-x/x
1000
1500
2000
Choke
type
KU240-10
00
KU240-15
00
KU240-20
00
with filter: KDFxx
L
mHPVW
0,051000320 270470250 1909810
0,031300320 270470250 1909810
0,021500320 270470250 1909810
Dimensions
abcde
Weight
kg
Screw
M
Q3 1000-2000A9
Classsic Q3 1000-2000A
Dimensions
10
3Electrical installation
Dimensions
Q3 1000-2000A11
Q3 1000-2000A
Une protection
Pusch button operated
Switch operated
ON/OFF
10s
10s
OFF
(Delayed opening)
(Delayded opening)
ON
Switching on
Switching off
Enable K3
Control voltage
Power voltage
Command value
10s*
* switching-off delay
stand-still 0.3s
Connections
12
3Electrical installation
Connections
Q3 1000-2000A13
Q3 1000-2000A
CE-Advice
CE Advice
The devices adhere to the EU guidelines 89/336/EWG and the technical stan
dards EN 61000-2 and 61000-4 provided that the following conditions are ob
served:
- The device, the transformer, and filter capacitors are mounted on a 500x500x2
mm mounting plate.
- The mounting plate must be connected to ground using a 10mm² wire.
- The motor housing must be connected to ground using a 10mm² wire.
- The device ground X1:8 must be connected to the mounting plate using a
2.5mm² wire.
- Device PE screw must be connected to the mounting plate using a 4mm² wire,
l = 50mm.
Three-phase connection:
Power choke type:see technical details
Filter capacitors:0.5mF/600V~3 x 1mF (x) + 1 x 1mF (y)
Conductor length between the device and the power choke <250mm
-
-
Motor connection:
Motor conductorsl = 1.5m, shielded
Tacho and all control linesl = 1.5m, shielded
Shielding connected to PE
Connections diagram
14
3Electrical installation
Attention:
The order of the connections to the connector numbers or screw terminals is obli
gatory. All further advice is non-obligatory.
The input and output conductors may be altered or supplemented in accordance
with the electrical standards.
Note:
- Connection and operating instructions
- Local regulations
- EU guideline 89/392/EWG
- VDE and TÜV regulations and Trade body guidelines
Switch onthe auxiliary voltage and the supply voltage simultaneously.
Switch offthe supply voltage after the auxiliary voltage
-
Power connection
Input filter
see CE advice, page 14
Short conductor length to be used between the input filter and the device
Auxiliary voltage connection
Connectionterminal X5:17, X5:18
Power supply400V~ ±15%
Special voltages24V~, 110V~, 230V~, 500V~
Input currentmax. 300mA
Phase position
Internal fusesFE1, FE2 0.8AT
regardless
- Min. line cross-section 0.5mm²
- External fuse
- Min. line protection 6A
Note:
Observe the respective type plate.
Control voltage XXX
Note:
L1,L2,L3 - clockwise rotating field
Protecting earth - PE connection
To work without PE connection is for
bidden !!!
Q3 x/xcurrent type
1000KU240 -10006 x 1000 A FF
1500KU240 -150012 x 1000 A FF
2000KU240 - 200012 x 1000 A FF
Power choke
KD- three phasecurrent
K - phase choke
-
Fuses A
Super fast acting installed
Power connection with an auto-transformer
Transformer performance
1.1 x continuous motor power
Secondary voltage
0.9 x motor power
Transformer fuses
Slow acting
Observe the switch-on current!!!
Input fuses F1, F2, F3
rf. to the table above
Attention:
If the secondary voltages produced by the transformer are inferior to 60% the
voltage watchdog has to be adapted. These modifications may only be effected
in the factory and thus, the voltages have to be indicated on order.
Watchdog power connection
BTB inactivedark LED>>> missing phase
>>> wrong rotating field
16
3Electrical installation
R15
R34
R40
35
X18
R15
36
37
LEDD7
red
Line protection
Short-circuit proof wiring
Option - External synchronization
For special applications it might be necessary to tap the synchronization before
the power commutating choke, e.g
- when operating via field triggering circuit
- in case of an instable power supply
When changing to external synchronization, the 3 resistors 0W (R15, R34, and
R40) on the board ‘Q3 - Ein3’ have to be removed.
Option
Connection across the terminals X18:35, 36, 37
Observe the phase position!
- L3 across X10:14 (via power choke) and directly across terminal X18:36
- L2 across X10:15 (via power choke) and directly across terminal X18:37
- L1 across X10:16 (via power choke) and directly across terminal X18:35
The wiring has to be short-circuit proof or protected by means of a line protecti
on.
The phase position function has
a watchdog and in case of
wrong connections the LED D7
on the board Q3-on3 will light
and the BTB signal on the con
troller extinguishes when the
controller is enabled.
LED D7 also lights if there is a
breakage of the installed fuses.
-
Q3 1000-2000A17
Q3 1000-2000A
Free
18
3Electrical installation
Connection
positive command value
Motor-bolt X10:13
Motor+bolt X10:10
Note:
Armature choke only for a few applications
Inductance:L [mH] = UA/IAx 0.8
Standard version without a choke
Motor lines have to be shielded.
Unit Q3 x/x-Power choke*
Type currentDirect current
1000auf Anfrage2x 240
1500auf Anfrage2x 240
2000auf Anfrage2x 240
Min. conductor
cross-section (mm²)
* Chokes are necessary only for special applications
Switching in the armature circuit
- dc circuit current-free
- disable inactive
Motor connection
Warning:
Faulty switching will create arcing across the switch contacts.
Power supply failure - brake resistor
Break contact of the mains contactor K1
Rating: Resistor RNB = max. armature voltage/2 x type current
Attention:
Power lines have to be shielded and routed separately from control lines!
For electro-magnetic interferences please refer to the CE advice.
Q3 1000-2000A19
Q3 1000-2000A
Field connection
Field regulator is not installed.
External field current regulator F2.1 xx
20
5 Adjustments
13
10
*Only by U > 180V
Actual value connection
Tacho
Suitable actual value encoders:
- DC tacho generator
- Brushless tacho generator with evaluation electronics
- Incremental encoders with evaluation electronics
Note: AC or three-phase tachos with rectification are not suitable
Connection
Control electronics (see Manual REG)
In case of a positive command value
Tacho positiveX 1:8b
Tacho negativeX 1:9
ShieldX 1:8
Actual value
Armature voltage
Ground referenced actual value
Fuses2x 0.1A >>> directly in the armature circuit
For armature voltage>180V= >>> additional resistors are required
Use unit UNITEK EXZU-UA1
(two resistors and two fuses in insul. case)
Note:Observe Manual REG
Option:In case of internal potential-free armature voltage
control please indicate on order.
Q3 1000-2000A21
Q3 1000-2000A
Components
Adjustments
Variable elementsFunctionRange
R14P-amplification
R33P-amplification
R75Exact adjustment current limit100kW to 470kW
R101Trigger angle control240kW to 560kW
R125Field current
current controller 118kW to 470kW
current controller 218kW to 470kW
C80Integral term - current controller 10.1mF to 2.2mF
C81Integral term - current controller 20.1mF to 2.2mF
D25ACurrent control loop RVI-1control active
D25BCurrent control loop RVI-2control active
D25CEnable current controller/triggeringenabled
D25DPhase errorerror
D25EBTB readyoperational
D25FField currentuminous intensity =field
current
(only for a controlled field)
D25GCurrent flow direction S2active
D25HCurrent flow direction S1active
22
5 Adjustments
Circuit diagram
Q3 1000-2000A23
Q3 1000-2000A
18K
1
18K
1
Bridge 1
Bridge 2
Current controller
Current controller - PI loop circuit
Bridge 1Bridge 2
for a positive command value
Bridge 1negative R14, C80
Bridge 2positiveR33, C81
Basic set-up
Amplification ~0.4Integration time ~18m
Changing the amplification
Bridge1Bridge 2
18kW x R14
18kW + R14
Xp=
43kW
Changing the integration time
t[ms]-
18kW x R14
18kW + R14
x 1µF+C81
Brid
ge 1Bridge 2
Xp=
t[ms]-
18kW x R33
18kW + R33
43kW
18kW x R33
18kW + R33
x 1µF+C80
24
Optimization of the current controller
- Connect an oscilloscope across the current actual valueX3:21
In case of errors or failure the power section is immediately internally disabled
without delay.
To clear the saved error re-enable the drive (switch off/on or reset key)
Measurements
Measurement advice
Measuring instruments:multimeters for current and voltage
shunt or clamp-on ammeter
Measuring faults:mean value > actual value
acc. to the form factor
approx. 1 to 5%
Displays
Measured values
with a positive command value
Voltage:X10:10 positiveX10:13 negative
max 1.15 x power supply
For 400V~>>460V=
Current: ammeter in the motor circuit
5s 200%, continuously 110% type current
Measured values across REG4 (selectable, see Manual REG4)
SpeedX2:109±5V or ±10Vfor ±100% speed
CurrentX2:111±5V or ±10Vfor ±200% current
GNDX2:104
Q3 1000-2000A25
Q3 1000-2000A
Commissioning
Commissioning Q3 x/x-x with REG4
Check the following connections before commissioning
Observe the type plate!
Basic connection - power connections Q3
Power supplypowerbolts X10:14, X10:15, X10:16
Power supplyauxiliary voltageterminals X5:17, X5:18
Motor connectionA1/A2bolts X10:10, X10:13
Protecting earthPEearthing screws PE on the housing
Control connections
Enablecontact between X1:3 and X1:4
Command valuesignal X1:6, GND X1:8a
Actual valuesignal X1:9, GND X1:8b
ShieldsX1:8
Control electronics REG4
SwitchS4PI amplificationposition 4
SwitchS5I-termposition 4
SwitchS8D amplificationposition 8
SwitchS9actual valueposition 8
PotentiometerI1peak current10%
PotentiometerI2peak current10%
PotentiometerIDcontinuous current 100%
PotentiometerXPamplification50%
PotentiometerINTintegratoleft full scale
Potentiometernmaxspeedleft full scale
Potentiometeroffsetoffset50%
- Wrong polarity of the actual value
(tachoarmature voltage)
- Values of the tacho switch S9 too low
- Command value too high
For armature voltage control
- Field current too low
- Fuses, armature voltage feedback activated
Error diagnosis
Motor runs unsteadily
No motor torque
- Mechanical defect of the tacho
- Tacho malfunction
- Amplification of the speed controller too low
or too high
- Wrong PID parameter
- Command value errors
- Amplification of the current controller too
low or too high
- Current limits too low
- Field current too low
- Mechanical overload of the axis
Q3 1000-2000A29
Q3 1000-2000A
Quarantee
Guarantee
UNITEK guarantees that the device is free from material and production defects.
Test results are recorded and archived with the serial number.
The guarantee time begins from the time the device is shipped, and lasts one
year. Unitek undertakes no guarantee for devices which have been modified for
special applications.
During the warranty period, UNITEK will, at its option, either repair or replace
products that prove to be defective, this includes guaranteed functional attribu
tes. UNITEK specifically disclaims the implied warranties or merchantability and
fitness for a particular purpose. For warranty service or repair, this product must
be returned to a service facility designated by UNITEK.
For products returned to UNITEK for warranty service, the Buyer shall prepay
shipping charges to UNITEK and UNITEK shall pay shipping charges to return
the product to the Buyer.
However, the Buyer shall pay all shipping charges, duties, and taxes for products
returned to UNITEK from another country.
The foregoing warranty shall not apply to defects resulting from:
* improper or inadequate repairs effected by the Buyer or a third party,
* non-observance of the manual which is included in all consignments,
* non-observance of the electrical standards and regulations
* improper maintenance
* acts of nature
-
All further claims on transformation, diminution, and replacement of any kind of
damage, especially damage, which does not affect the UNITEK device, cannot be
considered. Follow-on damage within the machine or system, which may arise
due to malfunction or defect in the device cannot be claimed.
This limitation does not affect the product liability laws as applied in the place of
manufacture (i. e. Germany).
UNITEK reserves the right to change any information included in this MANUAL.
All connection circuitry described is meant for general information purposes and
is not mandatory.
The local legal regulations, and those of the Standards Authorities have to be
adhered to. UNITEK does not assume any liability, expressively or inherently,
for the information contained in this MANUAL, for the functioning of the device
or its suitability for any specific application.
All rights are reserved.
Copying, modifying and translations lie outside UNITEK’s liability and thus are
not prohibited. UNITEK’s products are not authorised for use as critical compo
nents in the life support devices or systems without express written approval.
The onus is on the reader to verify that the information here is current.