Unitek C1 Series User manual

MANUAL
Thyristor Drive
Classic
C1 230/180 - 4(f)
Industrie Elektronik
Tel.: [phone]
Fax [phone]
email [e-mail]
Ht tp:// www.unitek-online.de
Version 0109

Classic C1 230/180 - 4 (f)
2
Contents
Page
1. Basic Information
Safety advice 3
Standards and guidelines 3
Features 4
Technical data 5
2. Mechanical Installation
Dimensions 6
3. Electrical Installation
Connections 7
Circuit diagram 8
4. Adjustments
Adjustment functions 9
Command value, Actual value 10
Armature voltage control 11
Current/speed control loop 12
Adjustment without measurement equipment 13
CE advice 14
5. Commissioning 15, 16
6. Guarantee 17

1 Basic Information
C1, C1f 3
Electronic equipment is not fault proof. This fact should be borne in mind for all
possible operating conditions.
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.
P3 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 Guidelines 89/392/EWG, 84/528/EWG, 86/663/EWG, 72/23/EWG
EN60204, EN50178, EN60439-1, EN60146, EN61800-3
IEC/UL IEC364, IEC 664, UL508C, UL840
VDE Regulations VDE100, VDE110, VDE160
TÜV Regulations
Trade body guidelines VGB4
The user must ensure that in the event of:
- device failure
- incorrect operation
- 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
independent 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.
CE
The device adheres to the following: Guideline EU 89/336/EWG. EMC standards
EN61000-2 and EN61000-4.
ATTENTION - High voltage
AC 230V~, DC 320V=

Classic C1 230/180 - 4 (f)
4
Thyristor Drive
- for inductive and ohmic consumer loads’
Applications
- speed control of dc motors
- 1-quadrant operation, driving
- power: up to 720W
- tacho control
- armature voltage control with IxR compensation
- torque control
- cascade control speed/current
- rectangular current/speed characteristic curve
- switch on and switch off logic
- mains connection can directly be switched
Compact single-board device
- European format
- pluggable terminal connection (-W)
- C1: galvanic connection
- C1-4f: galvanic isolation of the control and the power section
- fully insulated power semi-conductor
- field rectifier
Note for C1 devices:
Direct mains connection
- zero connection >> on thyristor negative electrode potential
- all control connections >> on mains potential
- switches and poti >> isolation voltage > 1500V
Connection via an isolating transformer
- zero connection >> with potential isolation
- control connections >> to be earthed and shielded
Note for C1-4f devices:
Tacho control
- device >> with potential isolation
Armature voltage control
- control unit >> with a high impedance mains connection
- zero connection (terminal no. 5) must not be earthed
Build
- switch cabinet mounting according to the VDE, DIN and EU regulations
- standard control electronics REG
- intrinsically safe power section with current control loop
- 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).
Components
- fully insulated thyristor modules, comfortably over-dimensioned
- only components customary in trade and industrially standardised are used
- high-quality bases for the IC with external connections
- LED displays
- DIP switches for the P-I adjustment of the current control loop
- precision potentiometers for fine adjustments
- plug-in jumpers for the system set-up

Characteristics
*Series Classic C1
* Thyristor drive for dc motors
* Power range 6.75kW to 22kW
* Drive in the first quadrant
* Energy recovery
* Intrinsically safe power section
* Completely controlled three-phase bridge circuit as output stage
* Fast analogue current control
* 26-pin interface
* Features of the control electronics:
see Manual REG or third-party product documentation
* Optional units
C1, C1f 5
1 Basic Information
Technical data C1 230/180 - 4 C1 230/180 - 4f
Limits
Power connection 230~ +10% / -15% 230~ +10% / -15%
Output voltage max. 180V= 180V=
Type current max. 4A= 4A=
Input current max. 4.8A~ 4.8A~
El. power max. 720W 720W
Field voltage 200V= 200V=
Control range (dc tacho) 1:300 1:300
Precision (Without act value error) 0.1% 0.1%
Control range (Armature voltage) 1:50 1:50
Precision 3% 3%
Control range (Torque control) 1:50 1:50
Precision 3% 3%
Command value supply 12V=, 10mA 12V=, 10mA
External command value max. 12V= 12V
Actual value max. -180V= -180V=
Switch-on logic enable time
(save entry)
100ms 100ms
Installed fuse F1 3.15AT 3.15AT
Accessories
Mains chokes K60-6 (F) K60-6 (F)
Isolating Transformer TE 12/1 (F) TE 12/1 (F)

Classsic C1 230/180 - 4 (f)
6
Dimensions C1 x/x-4-W
Dimensions C1 x/x-4f-W
Enable Enable
Enable

3 Electrical Installation
C1, C1f 7
Mains connection
Connection directly to the mains power supply wall mounting
Phase L terminal X1:8
Zero N terminal X1:16
Mains chok K60-6 (F)
Note:
C1: Zero connection on mains potential!
C1f: Zero connection has no connection to the mains potential!
Connection via an isolating transformer
Secondary voltages 230V~, special voltages 42V~, 115V~
Transformer type TE 12/1 (F)
Transformer fuse 6AT
Motor connection
Motor armature wall mounting
positive terminal X1:10
negative terminal X1:14
Motor field positive terminal X1:12
negative terminal X1:14
Smoothing choke type EI 78A-4

Classic C1 230/180 - 4 (f)
8

4 Adjustment
C1, C1f 9
Adjustment potentiometers
No. Short symbol Function Range
P1 IxR Speed compensation
with armature voltage control
0 ... 10%
P2 nmax Exact adjustment - max. speed 80 ... 120%
P5 INT Integration time - slope limiting device 0.08 ... 5s
P4 nmin Min. speed -0.2 ... +2V
P6 Imax Current limit 0 ... 100%
P7 XPAmplification 3 ...
Adjustment switches
No. Contact Function Range
Current control loop
S1 1, 2 Integral term xx
S1 3, 4 Proportional amplification xx
Speed control loop
S2 1, 2 Integral term xx
S2 3, 4 Proportional amplification xx
S3 1 ... 4 Coarse tacho adjustment xx
Basic set-up
Tacho control
Switch in position ‘ON’: S1-1, S1-4, S2-1, S2-3, S3-1 to S3-4
Armature voltage control 180V=
Switch in position ‘ON’: S1-1, S1-4, S2-1, S2-3, S3-1 to S3-4
Torque control
Switch in position ‘ON’: S1-1, S1-4
Jumper: S9 plugged
All other contacts in position ‘OFF’ (open)!

Classic C1 230/180 - 4 (f)
10
Command value/actual value
Command value
Command value voltage
Command value potentiometer Resistance >1k (2.5 ... 10kOhm)
Input resistance 50kOhm
Input voltage 0 ... max. +12V
Command value from current source
External terminating resistance 12V/20mA = 0.6kOhm
Note for C1x/x-4-W:
The command value input is connected to the mains potential!
Integrator
Adjustment Range
Potentiometer INT P5 0.08 to 5s
longer time >>> turn potentiometer clockwise
Actual value
Tacho control
- DC tacho
- AC or three-phase tacho with rectification
- Tacho voltage max. - 180V=
- IxR potentiometer P1 full left scale!
Coarse tacho adjustment
Tacho voltage S3-1 S3-2 S3-3 S3-4
90 ... 180V ON ON ON ON
60 ... 140V ON OFF ON OFF
20 ... 60V OFF ON OFF ON
11 ... 20V OFF OFF OFF OFF
Exact speed adjustment
Adjustment Range
Potentiometer nmin P4 -0.2 ... 2V command value
Potentiometer nmax P2 50% of the
coars
adjustment
higher speed >> turn potentiometer clockwise
Attention: First adjust nmin and then nmax.

4 Adjustment
C1, C1f 11
Armature voltage control
Adjustment switch S3
Armature voltage S3-1 S3-2 S3-3 S3-3
90 ... 180V ON ON ON ON
60 ... 140V ON OFF ON OFF
20 ... 60V OFF ON OFF ON
11 ... 20V OFF OFF OFF OFF
Exact speed adjustment
Adjustment Range
Potentiometer nmin P4 -0.2 ... 2V command value
Potentiometer nmax P2 50% of the coarse adjustment
higher speed >>> turn potentiometer clockwise
Attention: First adjust nmin and then nmax.
Note for C1:
With armature voltage control the zero connection is connected to
the mains potential!
IxR compensation
- Voltage drop across the internal resistance of the motor
- Compensation by means of a current proportional increase of the speed
Adjustment Range
Potentiometer IxR P1 0 ... 10%
higher compensation >>> turn potentiometer clockwise
- at 10% speed
- increase load up to 100%
- increase compensation
- load speed >>> idle speed
Torque control
- Speed controller loop circuit with -1 amplification
- Jumper S9 closed; XPwithout function
- All contacts of switch S2 in ‘OFF’ position
- No tacho; no armature voltage feedback

Classic C1 230/180 - 4 (f)
12
Current
Current limit
Adjustment Range
Potentiometer P6 Imax 0 ... 100%
Higher current limit >>> turn potentiometer clockwise
Current measiring >>> amperemeter in thearmature circuit
PI loop circuit - current controller
Adjustment by means of DIP switch S1
P-values amplification S1-3 S1-4
150 K xx OFF OFF
60 Kxx OFF ON
35 Kxx ON OFF
26 Kxx ON ON
I-values S1-1 S1-2
0.22 F OFF OFF
0.69F ON OFF
1.22F OFF ON
1.69FON ON
Integral time constant = I-value xP-value x4
PI loop circuit - current controller
Adjustment by means of DIP switch S2
P-values amplification S2-3 S2-4
330 K xx OFF OFF
165 Kxx ON OFF
110 Kxx ON ON
I-values S2-1 S2-2
0.22 F OFF OFF
0.69FON OFF
1.22F OFF ON
1.69F ON ON
Integral time contant = I-value xP-value x4
Adjustment amplification Range
Potentiometer XPP7 3 ... 
Low amplification >>> turn potentiometer clockwise

4 Adjustment
C1, C1f 13
Adjustment without measurement equipment
Connect the motor,
command value = 10%
XP= 50%
Switch S2-3 = position ON
Switch S2-4 = position OFF
Enable the drive,
Turn the potentiometer XPanti-clockwise until the axis begins to oscillate.
LED RVU flickers.
If no oscillation is achieved,
- set switch S2-3 to position OFF
- adjust to oscillations with potentiometer XP
- LED RVU flickers
- turn the potentiometer XPclockwise until the oscillations disappear
- LED RVU lights constantly
- turn the potentiometer XPanother 2 clicks clockwise
Adjust the switches S2-1 and S2-2 such that after a command value change of
50% the drive runs smoothly after approx. two oscillations
Drive behaviour
Amplification too low Amplification too high
Long-wave oscillations 1 to 0.1Hz Short oscillations 30 to 200Hz
Large overshoots Vibrates during acceleration

Classic C1 230/180 - 4 (f)
14
EMC Advice
The devices adhere to the EU guidelines 89/336/EWG and the technical
standards EN 61000-2 and 61000-4 provided that the following conditions are
observed:
Tacho control
- The device, the transformer or the motor choke, and the armature choke are
mounted on a 500x500x2 mm mounting plate.
- The motor is shielded through the use of collector condensers.
- 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 terminal no. 5 must be connected to ground using a 2.5mm² wire.
Connection using a mains choke
Mains choke with filter type K60-6F
Conductor length choke - device: 200mm
Armature choke type EI78A-4
Conductor length choke - device: 200mm
Connection using a isolating transformer
Transformer with filter type TE12/1F
Conductor length transformer - device: 200mm
Armature choke type EI78A-4
Conductor length choke - device: 200mm
Connection of the control conductors:
All control conductors must be twisted, <1.5m. No shield.
Note for C1-x/x-4-W:
Direct mains connection
Zero connection >>> on the negative electrode potential of
the thyristor
All control conductors >>> on the mains potential
Switches and poti >>> isolation voltage >1500V
Connection using an isolating transformer
Zero connection >>> isolated from the potential
Control connections >>> to be earthed and shielded

5 Commissioning
C1, C1f 15
Commissioning
Enable open, command value zero
Switch on mains supply
The motor must be at a torque-free standstill.
Close the drive enable switch
The LED ‘enable’ must light.
Turn the command value potentiometer slowly up.
The motor must accelerate according to the command value voltage.
(If the motor immediately accelerates to full speed or if full voltage is
immediately applying, the actual value connection across terminal 6-7
must be swapped).
Speed adjustment
Adjust the coarse actual value using the switch S3 (rf. to page 10).
When the command value is 1.2V adjust the speed to 10% by means of
the potentiometer nmax (P2).
Adjust the min. speed by means of the potentiometer nmin (P4).
Increase the command value to 12V and adjust the max. speed by
means of the potentiometer nmax (P2).
Current adjustment
Connect an ammeter to the armature circuit.
Set the potentiometer Imax to left full scale.
Disable the motor (disconnect the field).
Adjust the permissible motor current by turning the potentiometer Imax
(P6) clockwise.
Amplification speed controller
Basic set-up: P-amplification S2-3 = ON, S2-4 = OFF
I-term S2-1 = ON, S2-2 = OFF
For large centrifugal masses switch S2-2 must be closed and switch S2-3 can
be opened.
If friction loads are predominant the switches S2-2 and S2-4 can be closed
and the switches S2-1 and S2-2 can be opened.
Exact adjustment by means of the potentiometer XP(P7).
Turn the potentiometer anti-clockwise until the LED RVU flickers.
Then turn it clockwise until the LED either lights constantly or is dark.
The brightness of the LED indicates the current demand of the drive.

Classic C1 230/180 -4 (f)
16
Amplification current controller
If the armature circuit inductivity is high, all contacts of the switch S1 are
in ‘OFF’ position.
If the inductivity is low, all contacts are in ‘ON’ position.
The adjusted values can be exactly measured by displaying the motor
current on an oscilloscope.
Preset the command value step-change.
The first current half-wave must not exceed 1.5A.
(Adjustment by means of S1-3, S1-4).
The current should rise to 4A via 5 half-waves.
(Adjustment by means of S1-1, S1-2)
IxR compensation (only for armature voltage control)
Adjust the speed to 10%.
Change the load between idle running and full load.
Compensate for the speed loss at full load by turning the potentiometer
IxR (P1) clockwise.

6 Guarantee
C1, C1f 17
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
attributes. 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 components
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.

Classic C1 230/180 -4 (f)
18 UniTek Industrie Elektronik GmbH, Hans-Paul-Kaysser-Str.1 D-71397 Leutenbach-Nellm. (b.Stuttgart)