ANTEK ECE863 Series Guide

Antriebstechnik GmbH
Technical Documentation EC863 and ECE3AP-00-01 Page 1 of 18
(02/99) R0047GB.DOC
Technical Documentation
for
6DWHOOLWHDQG5XEEHUEODQNHW
ZDVKLQJGULYH
1Q-Drive regulator ECE 3 AP-00-01
and
brushless direct current motor EC863

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Technical Documentation EC863 and ECE3AP-00-01 Page 2 of 18
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Contents: Page
1. SAFETY TIPS 3
2. TECHNICAL DATA 4
2.1 BRUSHLESS DIRECT CURRENT MOTOR EC 863... 4
2.2 CONTROL UNIT ECE3AP-01 4
2.4 DIMENSIONS 5
3. INSTALLATION 6
3.1 MECHANICAL INSTALLATION 6
3.2 ELECTRICAL INSTALLATION 6
3.3 INFORMATION ON EMC 7
3.4 CONNECTION 8
3.4.1 POWER AND MOTOR CONNECTION 8
3.4.2 CONTROL CONNECTIONS 9
3.4.3 ROTOR POSITION TRANSMITTER 11
4. SERVICE - INFORMATION 12
4.1 DISPLAYS 12
4.2 TRIMMER 13
4.3 CODING - PLUG BRIDGES 15
4.4 BLOCK CIRCUIT DIAGRAM 16
5. MANUFACTURER’S DECLARATION 17
-errors and revisions are reserved –
The text at hand is a translation which, before use, is to be examined by a professional
engineer of the company using it for its technical accuracy and agreement.

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1. Safety Tips
Electrical devices present a danger source.
In using in systems and controls with safety-technical requirements
and during installation, all appropriate laws
and regulations are to be observed.
The valid accident-prevention regulations are to be absolutely
observed during work on devices carrying electrical loads.
Repairs on the device or its components are only to be conducted
by the manufacturer for reasons of safety and the upkeep of
documented system data and functions.
No liability will be assumed for an unsuitable, incorrect manual or
automatic setting of the drive parameters.
Improper use can lead to personal injury and material damage.
The device operating manual must be carefully read before
installation by expert personal who are familiar with the electrical
drive equipment.
Before touching electrical contacts, be certain that the voltage
between them is less than 60 V.
The user is to ascertain, through independent monitoring units, that
in case of any fault in the drive unit, the drive unit is safely brought
to stop.
The user is responsible for the set-up an connection of the motor,
the converter an accessory devices in accordance with the
recognised technical regulations in the country of set-up
as well as any valid regional regulations. Here, the cable
dimensioning, shielding, grounding, switch off, separation,
and the overload protection are especially to be taken into
consideration.
The provisions according to DIN 57100, EN 60204 part 1 are valid.

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2. Technical Data
2.1 Brushless direct current motor EC 863...
Nominal voltage: UN230 V
Nominal current: IN1,8 A
Nominal speed: nN4500 r.p.m
Output power: P 300 W
Efficiency: η0,75
Rated torque MN0,64 Nm
Short-term torque: 3 Nm at 20% ED, cycle length 20 min
Design: according to VDE 0530, class of insulation E
Protection class: IP44 (except for the shaft outlet on the motor)
Bearings: Roller bearing with life lubrication
2.2 Control unit ECE3AP-01
Net input voltage: UN70 ... 270 VAC, 45 ... 64 Hz
Nominal input current: IN3 AAC
Internal fuse: 6,3 AT
Output voltage UM0 ... 90% UZK
max. output current: IMmax 6,5 A / Phase
Permanent output current: IM3 A / Phase
Nominal output power1:S
N0,7 kVA
Efficiency ηapprox. 95%
Power dissipation no load operation2PV0 approx. 18 W
Power dissipation full load PVapprox. 50 W
max. heat sink temperature ϑapprox. 80 °C
Control range 1 : 40
3Generally all metallic conducting parts which can be connected to a protective conductor,
such as cabinet frames, motor frames, foundation grounding, etc. are designated as a
ground.

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2.4 Dimensions
210 195
95 55
27,5
* Option cover plate
60*

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3. Installation
3.1 Mechanical Installation
♦Mount the transverter on the assembly cooling corner in a vertical or horizontal position.
♦Maintain an installation clearance of 50 mm above and below the drive regulator
♦Ensure the unobstructed inflow and outflow of the exhaust air
♦When the cooling air is contaminated by (dust, slubs, aggressive gases, and greases),
which could impair the functioning of the drive regulator, sufficient countermeasures
must be taken, e.g. separate air ducts, installation of filters, regular cleaning etc.
♦Do not exceed the permitted range of the operating surrounding temperature.
♦If the drive regulator is exposed to vibrations or tremors, vibration damping is required.
3.2 Electrical Installation
♦The transverter contains components subject to electrostatics. Before installation and
service work in the terminal clamp area the staff must free itself of electrostatic electricity.
The discharging can be achieved by touching a grounded metal surface beforehand.
♦Due to the discharge currents of the Servo regulator (>3,5 mA) via the protective
conductor (PE) the input diameter of the protective conductor must be at least 10 mm²
Cu according to DIN VDE 0160, or a second protective conductor must be laid
electrically parallel. With greater connection powers the minimum diameter of the
protective conductor must correspond accordingly to the diameter of the external
conductors.
(see DIN 57100 Part 540)
♦The regulations for the minimum diameter of PE conductors must be observed. The
diameter of the PE conductors must be as large as the diameter of the conductor
connections at the least.
♦Conduct a safety disconnection of the drive regulator only via a network protection in the
input.
♦To protect the power supply cables the recommended cable protection fuse is required
♦We recommended conducting the temperature monitoring of the motor via a thermal
protection switch and the monitor switching which is integrated in the transverter.
♦Control wiring and power cables must always be laid spatially separated from each other.
♦Set value inputs, analog control inputs, and measurement outputs, must be laid in
shielded wiring.
♦Conductor diameters for power supply and motor wiring at least 1,5 mm²!
♦Observe the current local safety regulations.

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3.3 Information on EMC
In order to guarantee electromagnetic compatibility (EMC) in your switch cabinets in an
electrically raw environment, the following EMC rules are to be observed during construction
and set-up:
♦All metallic parts of the switch cabinet are to be connected flatly and in a well-conducting
manner (not lacquer on lacquer!). If necessary, use contact or scraper wafers. The
cabinet door is to be connected with as short a circuit as possible via the metal powder
tapes (upper, middle, lower).
♦Signal lines and power cables are to be laid separate from each other in order to avoid
coupling intervals. Minimum distance: 20 cm:
♦Signal lines should be led to the cabinet from only one level, if possible.
Unshielded lines from the same electrical circuit (outgoing and return circuit) are to be
transposed, if possible.
♦Contactors, relays and magnetic valves in the switch cabinet, if necessary in the adjacent
cabinets, are to be wired with quench combinations, e.g. with RC elements, varistors,
diodes.
♦The screens from signal lines are to be laid two-way (source and target), large-area and
well-conducting to a ground3. In case of poor potential equalisation between shielded
connections, an additional balancing network of at least 10 mm² must be laid parallel to
the screen to reduce the screen current.
♦Wiring is not to be laid freely in the cabinet, but should rather lead as tightly as possible
to the cabinet frame or to installation plates. This also applies to reserve cables. At least
one end of them must lie grounded, but preferably both (additional shield effect).
♦Unnecessary wire lengths are to be avoided. Coupling capacities and coupling
inductances are thereby kept small.
♦The screen from leads, such as resolver or incremental director cables, must be laid to
the frame grounding. Approximately 2 cm of the insulation is to be removed in the area
where the cable is to be led into the frame in order to expose the braided cable. The
braided cable may not be damaged while removing the insulation. The cable is to be led
at the position where the insulation has been removed by grounded terminals or taut
supports.
cable taut support

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3.4 Connection
3.4.1 Power and motor connection
♦min. wiring diameter for power and motor development connections 1,5 mm²
♦Power wiring to the plug-in connecting terminals X1
Connect N, L1, PE
(Starting torque: 0,5 - 0,6 Nm)
♦Motor wiring to the connecting terminals X3
Connect PE, W, V, U
(Starting torque: 0,5 - 0,6 Nm)
♦Rotor position transmitter to the connecting terminals X4
Connect VCC, GND, SA, SB, SC
Sensor wiring must be shielded.
♦Shield must be correctly mounted according to EMC - compatible wiring (see chapter
3.3)
♦It is recommendable to monitor the motor temperature via the thermal circuit breaker.
If a thermal circuit breaker is not installed in the motor, the input X4-1 must be bridged
to HIGH - Potential e.g. +15V X4-2.
6
5
4
3
2
1
2
3
4
5
1
2
3
6
7
8
9
X4
X3
X1
X2
L1
N
PE
Power connection
70 ... 270 VAC,
45 ... 64 Hz
floating
signal contact
120 VAC; 0,5 A
GND
right
left
Speed set value
EC 863
K1
1
M2
3
1
2
4
5
6
7
8
9
1
2
3
4
W
V
U
+15V
GND
S2
S3
S1
ϑ
ECE3AP-01
0 ... 10 V or n1,n2
Si
6,3AT
Connection of the brushless motor EC863 to drive regulator ECE3AP-01

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3.4.2 Control connections
3.4.2.1 Auxiliary voltages
+10V (X2-9) max. load 3 mA
+15V (X2-4) max. load 50 mA
GND (X2-7)
3.4.2.2 Connection of digital signals
n1 / n2 (X2-8) The function fixed speeds can be selected with the plug bridge
STB3 „Set value source„ (see chapter 4.3).
HIGH = Selection fixed speed n2
LOW = Selection fixed speed n1
Left (X2-6) HIGH = Selection of direction of rotation by connecting the
corresponding
Right (X2-5) control voltage. If both direction of rotation inputs are selected, the
power amplifier remains cut-off..
LOW = power amplifier cut-off
M2 (X4-1) Connection for the thermal circuit breaker (Break contact)
HIGH = Motor temperature in the work area, the LED „M2„ is lit up
to visualise the input.
LOW = Motor on excess temperature, stand-by signal contact is
tripped (see chapter 0).
Note: If the motor does not have temperature monitoring via a thermal
circuit breaker, the connecting terminal X4-1 must be installed to
HIGH-Potential e.g. +15 V X4-2.
X2
Drive regulator
+15V
+10V
3
2
1
6
5
4
9
8
7GND
X2
Drive regulator
n1
/
n2
Left
+15V
1
0
n
k
1
0
k
µ
1
k
Digital-
input 1
100k
Circuit diagram
Pegeldefinition
HIGH = +12 ... +35 VDC
LOW = 0 ... +2 VDC or open
Reference potential GND
Input resistance
Take attention to equivalent reference
potential if you connect signal inputs and
outputs of control unit with periphere units.
3
2
1
6
5
4
9
8
7
Right
ϑ
X4
4
5
6
1
2
3
M2
+15V

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3.4.2.3Connection of the analog speed set value
Speed (X2-8) Unipolar input for the manual speed set value specification. This
function can be selected with the plug bridge STB3 „set value
source„ (see chapter 0).
Input voltage: 0 ... +10 VDC
Input resistance: Ri = 100 kΩ
Reference potential: GND
3.4.2.4 Signal output
(X2-1/2) The signal output connects several functions
to each other and trips when a failure occurs.
The connection is clearly shown in the circuit
diagram.
Monitoring functions:
- Temperature monitoring via
Thermal circuit breaker in the motor
- internal stand-by signal monitors
a) the intermediary circuit voltage
(95V < UZK <420) and
b) the heat sink temperature < 80°C
- Optionally the function set value actual value
monitoring can be connected with plug bridge
STB2.
If the regulator is cut-off when the stand-by
signal is tripped, it must be connected
externally!
floating relay contact
max. load capacity
35 VAC; 0,5A
HIGH-Potential
internal Stand-by
signal
Thermal circuit
breaker
STB2
Set-actual
monitoring
X2-2
X2-1
K1
circuit diagram
10nk
µ1k
810k
Circuit diagram
Analogue set-value wiring must be
shielded.
Drehzahl
100k
-
+
12V
X2
Drive regulator
Rotation speed
+10V
3
2
1
6
5
4
9
8
7GND

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3.4.3 Rotor position transmitter
The signals of the rotor position transmitters (3x120° staggered commutation sensors) are
used for the commutation control of the motor phases. The actual speed is also recorded
with the rotor position transmitter signals. With standard equipment a control range of 1:40
can be achieved.
The commutation sensors must be connected to the drive regulator according to the
following diagram. The sensor wiring must be shielded.
+15V (X4-2) Sensor power supply (Standard 15VDC)
GND (X4-3) Reference potential
S2 (X4-4) Rotor position transmitter with internal
S3 (X4-5) Pull-up resistances 1 kΩ, 6 V Reference voltage
S1 (X4-6) HIGH at input signal > 4 V
LOW at input signal < 1 V
Motor connection see chap. 3.4.1
Speed gauging via rotor position transmitter
The speed is proportional to the signal frequency of the commutation sensors installed in
the motor. If the frequency is gauged at a sensor input, the following applies:
f ... Signal frequency [Hz]
p ... number of pole pairs
n ... Synchronous speed [r.p.m.]
p60f
n ×
=
X4
4
3
1
6
5
Drive regulator
VCC
GND
S2
S1
S3
NEC
motor N
S
S
0 60 120 180 240 300 360 420 480 540
S2
S3
S1
IU
V
W
I
I
electrical angle 600 660 720
2

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4. Service - Information
4.1 Displays
Error (RD) Excess current or inadmissible rotor position sensor condition
n2 (YE) Fixed speed n2 was selected
SET-ACTUAL (YE) The difference between set to actual speed is smaller than 20% of
the currently specified set value speed. In the lower speed range (<
0,25 n-max.) this threshold increases.
The monitoring function is time-delayed.
With deviation 1% above/below threshold approx. 10 sec.
With deviation 100% above/below threshold approx. 0,5 sec.
Stand-by (GN) ON = Control device ready for operation
OFF= Control device collective failure
- Intermediate circuit voltage > 420 V
- Intermediate circuit voltage < 95 V
- Heat sink temperature > 80°C
If there is a failure the power amplifier is immediately cut-off. The
failure remains filed until it is acknowledged. The acknowledgement
of the failure signal is conducted by removing the regulator release.
M2 (GN) Input thermal circuit breaker motor is on High-Potential.
F1
1
2
3
4
5
6
7
8
9
1
5
4
3
2
4
3
2
1
1
2
3
X3
X4
X1
R40
C37
OFFSET
n-max
PI
n2 n1
tH tR
Set value source (STB3
)
Relay function (STB2) Brake (STB1) Error
Set - actual
n2
Stand-by TM
I-max
Rotor position transmitter
Motor winding connections
Power supply
Control connections
6
X2

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4.2 Trimmer
All of the trimmers required for the adjustment of the drive regulator to the respective
application are located on the unit boards. All of the trimmers are pre-set to the standard
parameters and/or the customer commissions so that the customer normally does not have
to re-adjust the trimmers.
n-max Setting of the maximum speed
1. Specify maximum set value voltage (10V).
2. Set the desired max. speed on the trimmer „n-max„
(see diagram at trimmer OFFSET and
Chapter 0 Rotor position)
Setting range: 4-pol. Motor 2000 to 5200 r.p.m.
Works setting: 5000 r.p.m.
OFFSET Speed offset adjustment
Adjust set value input to „0„.
Release drive regulator,
this means set „Right „ or „Left„ to HIGH-Potential. Set the motor to
standstill with trimmer „OFFSET„.
n
n-max
Set value 10V
0V
I-max Works setting must not be changed!
6
7
8
9
C37
OFFSET
n-max
PI
n2
n1
tH tR
Set value source
(STB3
)
Rela
y
fun
c
tion (STB2)
Brake
(STB1)
Error Set value
n2
Stand-by
TM
b
a
X2

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tH Run-up time of the set value integrator
tR Reverse running time of the set value integrator
Setting the set value slope
Specify set value jump (0 →10 V) at the set value input and set the
desired speed slope with trimmer „tH„ and/or „tR„.
Setting range: 100 ms ... 2 s
Works setting: 2 s
internal
Set value
10V
100ms
Signal after set value jump
tH tR
2s
0V
t
100ms
2s
PI Setting of the speed control behaviour. When necessary adjust to
the respective application. Clockwise rotation increases the
proportional amplification.
Incorrectly set control behaviour leads to vibrations of the drive
which can destroy the motor or other components connected
downstream (gears etc.).
The manufacturer is not liable for damages which are caused by
incorrect parametrisation.
Works setting Middle
n1, n2 Fixed speeds n1 and n2. This function can be selected with the plug
bridge STB3 „set value source„ (see chapter 0).
Works setting: n1 = 4538 r.p.m.
n2 = 1396 r.p.m

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4.3 Coding - plug bridges
STB1 Linf plug Position a
Brake function A cut-off of the control voltage on connecting terminal 2-5 and/or X2-
6 causes the motor to come to a standstill. This is the normal
operation mode of the control device..
Link plug Position b with brake function for positioning
After the cut-off of the control voltage on connecting terminal X2-5
ad/or X2-6 the motor winding is short-circuited. The current
dependant of the braking energy and must not exceed 8 A because
otherwise the motor or the control device can be destroyed. If the
jumper is plugged in Position a, the manufacturer is not liable for
damages to the motor or the control device.
STB2 Link plug Position a
Relay function The function set-actual monitoring has an effect upon the stand-by
signal output, this means that function result is UND-coupled.
Link plug Position b
The function set-actual monitoring has no effect upon the stand-by
signal output.
STB3 Link plug Position a
Set value source The function fixed speeds is selected. Selection of the fixed speed
via connecting terminal X2-8.
HIGH = Selection fixed speed n2
LOW = Selection fixed speed n1
Plug bridge Position b
The function analog set value is selected.
Speed set value 0 ... 10 V to connecting terminal X2-8.
6
7
8
9
C37
OFFSET
n-max
PI
n2
n1
tH tR
Set value source
(STB3
)
Rela
y
fun
c
tion (STB2)
Brake
(STB1)
Error Set value
n2
Stand-by
TM
b
a
X2

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4.4 Block circuit diagram
Direction of rotation logistics
tRtH
fun-max
TM
&1
Set value integrator Speed control
Offset
PI
_
U
V
W
M
3~
Monitoring
heat sink temperature
-UZK
UZK
Circuit power internal voltage
supply unit
Regulator release left
Regulator release right
S
peed set value 0 - 10 V
o
r fixed speeds
Power
amplifier
U
W
V
Current
control
and PWM
L1
N
PE
TM
STB3
Fixed speeds
n1 n2 n2
floating
signal output
Set-actual value
monitoring
Set actual
>1 >1RLG
3
Impulse
transmitte
optional
+15V
GND
+10V
Stand-by
STB2
Set-actual
I-max Error
STB2
Brake

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5. Manufacturer’s declaration
The manufacturer, ANTEK Antriebstechnik GmbH, herewith declares that the drive regulator
ECE3AP must be used as a component of the control equipment for variable speed motors
to be installed in a machine or to be used for the construction of a machine together with
other components. The drive regulators are not machines as defined in the machine
guideline 89/392/EWG.
Notes and recommendations for the installation and proper operation are included in this
technical documentation.
The start-up of the machine is prohibited until it has been determined that the protection
and safety requirements of the machine guideline 89/392/EWG including revisions 68/EWG
are fulfilled.
In this technical documentation the measures are described with which the drive regulator
complies with the EMC-limiting values. The electromagnetic compatibility of the machine is
based on the method and thoroughness of the conducted installation. The user is
responsible for the compliance of the EMC guideline 89/336/EWG including the revisions
92/31/EWG during operation of the machine.
Norms and regulations taken into account
♦Installation of high-voltage current plants with electrical operating equipment: DIN VDE
0160
♦Regulations for the set-up of high-voltage current plants: DIN VDE 0100
♦IP-protection systems: EN 60529
♦Basis material for printed circuits: DIN IEC 249 Part 1
♦Printed circuits, circuits boards: DIN IEC 326 Part 1
♦Regulation of air and flow routes: DIN VDE 0110 Part 1-2
♦De-charging of statical electricity (ESD): EN 50082-2
♦Rapid transient interference factors (Burst): EN 50082-2
♦Radio shielding of electrical operating equipment and plants: EN 50081-2, EN 55011
ANTEK – Antriebstechnik GmbH
IM Köchersgrund 3
D – 71717 Beilstein
 ++49 – (0) 7062 / 9406 – 0
 ++49 – (0) 7062 / 23518
 [e-mail]

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Appendix:
Factory adjusment:
ECE3AP-00-01
MAN Com. Satellite washing drive
n-max: 5000 rpm(166,7Hz)
Offset: 0
PI: middle
tH: max
tR: max
STB3: a
STB2: a
STB1: a
n2: 1396 rpm (31Hz)
n1: 4538 rpm 00,8Hz)
I-max: 6,5A (0,44V)
ANTRIEBSTECHNIK GmbH
Im Köchersgrund 3
D - 71717 Beilstein
Tel. 07062 / 9406-0 Fax. 23518
ANTRIEBSTECHNIK GmbH
Im Köchersgrund 3
D - 71717 Beilstein
Tel. 07062 / 9406-0 Fax. 23518