Unitek Classic P3 Series User manual

Manual
Classic P3
1 Quadrant
Thyristor Drive
Part 1 Thyristor Drive P3x/x-240...840A
Part 2 Analogue Control Electronics REG4
P3 240-840
Edition
0910

Classic P3 x/x - 240-840A
2
Contents Page
1. Basic Information
Safety advice 3
Standards and guidelines 3
General information 4
Features 5
Technical da 6, 7
Specification 8
2. Mechanical installation 9
Dimensions 10, 11
3. Electrical installation
Connections 12
Connection diagram 13
CE advice 14
Power supply 15, 16
Option - synchronization 17
Motor connection 19
Field connections 20
Actual value connection 21
Components 22
Adjustments 22
Circuit diagram 23
Current control loop 24
Signals 25
Measurements 25
4. Commissioning + REG4 26, 27
5. Faults 28, 29
6. Guarantee 30
7. Protocol 31, 32
8. Drawings
Dimensions (P3 240-360A) 33
Dimensions (P3 480-840A) 34
Note: For the commissioning and the error diagnosis please
refer to the manuals Q..., P...!
Observe any cross-references!
Contents

1 Basic - Information
P3 240-840A 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.
Safety advice - Standards and guidelines
ATTENTION - High voltage
500V ~ ac, 650V=dc

Classic P3 x/x - 240-840A
4
Attention
This manual P3 only describes the basic control unit.
P3
This device description must be read in conjunction with the
manual for
- an analogue control REG xx
- an internal field control Q3-F
- an external field control F2
- options Multi
General information
Series Classic P3
General information

1 Basic - Information
P3 240-840A 5
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).
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
- precision potentiometers for fine adjustments
- plug-in jumpers for the system set-up
Characteristics
* Series Klassik P3
* Thyristor drive for dc motors
* Power range 108kW to 378kW
* Drive in 1 quadrant
* Energy recovery
* Intrinsically safe power section
* Fast analogue current control
* Temperature watchdog - power section
* Controlled or uncontrolled field rectifier
* 26-pin interface
* Features of the control electronics:
see Manual REGxx or third-party product documentation
* Optional units
Features

Classic P3 x/x - 240-840A
6
P3 400/450-x
Power connection
Auxiliary voltage connection
Output voltage
Cooling
360 ... 440V~
360 ... 440V~ or 200...250V~
max. +450V=
ventilation fan
P3 400/450- 240 360
Input current A~ 192 288
Output current peak 5 s.
continuous
A=
A=
480
240
720
360
El. power kW 108 162
Fuses - input 3 pcs.
- field
ff installed installed
AFF 250 315
AF 10 10
Power chokes Type
mH
1x KD5-250
0.12
3x K 170-400
0.08
Armature chokes
Armature choeks are necessary only for special
applications.
Type
mH
Ul180B250
2.2
Ul210C400
1.8
Dimensions w x h x d mm 305x510x240 305x510x240
Wieght kg 23 23
P3 500/550-x
Power connection
Auxiliary voltage
Output voltage connection
Cooling
450 ... 550V~
360 ... 440V~ or 200 ... 250V~
max. +550V=
ventilation fan
P3 500/550- 240 360
Input current A~ 192 288
Output current - peak
- continuous
A=
A=
480
240
720
360
El. power kW 132 198
Fuses - input 3pcs.
- field
ff installed installed
AFF 250 315
AF 10 10
Power chokes Type
mH
1x KD5-250
0.12
3x K 170-400
0.08
Armature chokes
Armature chokes are necessary only for special
applications.
Type
mH
Ul180B250
2.2
Ul210C400
1.8
Dimensions w x h x d mm 305x510x240 305x510x240
Weight kg 23 23
Technisccal data

1 Basic - Information
P3 240-840A 7
P3 400/450-x
Power connection'
Auxiliary volrtage connection
Output connection
cooling
360 ... 440V~
360 ... 440V~ or 200...250V~
max. +450V=
ventilation fan
Gerät P3 400/450- 480 840
Input current A~ 384 672
Output current - peak
- continuous
A=
A=
960
480
1680
840
El. power kW 216 378
Fuses - input 3 pcs.
- field
ff installed installed
AFF 400 500
AF 10 10
Power chokes Typ
mH
3x KU150-600
0.06
3x KU150-800
0.04
Armature chokes
Armature chokes are necessary only for special
applications.
Typ
mH
Ul240C500
1.6
Ul240-700
1.2
Dimensions w x h x d mm 405x560x240 486.5x560x240
Weight kg 36 40.8
P3 500/550-x
Power connections
Auxiliary voltage connections
Output voltage
Cooling
450 ... 550V~
360 ... 440V~ or 200...250V~
max. +550V=
ventilation fan
P3 500/550- 480 840
Input current A~ 384 672
Output current - peak
- continuous
A=
A=
960
480
1680
840
El. power kW 264 462
Fuses - input 3pcs.
- field
ff installed installed
AFF 400 500
AF 10 10
Power chokes Type
mH
3x KU150-600
0.06
3x KU150-800
0.04
Armature chokes
armature chokes are necessary only for special
applications.
Type
mH
Ul240C500
1.6
Ul240-700
1.2
Dimensions w x h x d mm 405x560x240 486.5x560x240
Weight kg 36 40.8
Technical data

Classic P3 x/x - 240-840A
8
Specification
Mains frequency 50 or 60Hz ±5%
Protection rating IP 00
Format VDE 0100 group C,
VDE 0160
Humidity rating class F acc. to DIN 40040
Site of installation < 1000m above sea level
Operating temperature range 0 ... 45°C
Extended operating temp. Range up to 60°C reduced by 2%/°C
Storage temperature range -30°C to + 80°C
Current control loop circuit
Amplification
- input signal 0 to ±10V=
- output 0 to ±200% type current
Over-current limiting 10s 200% type current
Control precision ±2%
Control range 1:50
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
Function Connector 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
Device GND 0 X3: 9, 10, 11, 12, 13, 14
I command value (GND) 0 X3: 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 U
A
±10V= X3: 23
Option U
A
0-10V= X3: 24
Drive ready BTB +10V= X3: 25
+5V X3: 26
Technical data

2 Mechanical Installation
P3 240-840A 9
Mounting
Air flow direction
Ambient temperature 0 bis <45°C (reduced, up to 60°C)
max. Cooling unit temperature 80°C (internal watchdog)
Air-mass throughput 240A 680m³h
360A 680m³h
480A 820m³h
840A 820m³h
Dissipation loss with max. power
Unit P3-x/x- Unit W Mains choke W
240A- 1000 260
360A- 1440 330
480A- 1890 400
840A- 3060 780

Classsic P3 x/x - 240-840A
10
RVI1
RVI2
Enable
Phase
BTB
Field current
S2
S1
min. field current
triggering point
max. field current
Dimensions
Three-phase power choke single -phase mains choke
up to 250A from 360A
Features
U N 400V~50/60Hz
U K 4%
Protection rating IP00
isol. Class T40/E
vertical angle bracket
Unit
P3-Type Choke L
mH
PV
W
Dimensions
a b c d e
Weight
kg
Screw
M
240A KD5-250 0.12 260 300 170 270 200 100 31.5 8
360A K170-400 0.08 330 142 170 230 106 88 14 8
480A KU150-60
00.06 400 210 260 275 100 108 29 8
660A KU150-60
00.06 610 210 260 275 100 108 29 8
840A KU150-80
00.04 780 210 270 275 100 108 31 8
with filter: KDF xx
P3 240/360A

2 Mechanical Installation
P3 240-840A 11
Dimensions
Dimensions P3 240-840A
Unit
P3-x/x- Width mm Heigth mm Depth mm Drill hole mm Weight kg
240A 305 510 240 275 x 490 23
360A 305 510 240 275 x 490 23
480A 405 560 240 375 x 540 36
660A 405 560 240 375 x 540 36
840A 486.5 673 240 375 x 540 40.8
Fixing screw M8
P3 840A

Classic P3 x/x - 240-840A
12
Connections
X1:4
X5:11 X5:12
-K2
-L1
X10:14 X10:15 X10:16
P3-2x
-K3
REGx
K1
-F1.1 -F1.2 -F1.3
L1
L2
L3
N
PE
Super fast
acting
Push-button operated
Switch operated
Off
On/off
(Delayed opening) (Delayed opening)
10s. 10s
On
Switching-on Switching-off
Enable K3
Control voltage K2
Power voltage K1
Command value
* Switch-off delay
stand still 0.3s
10s*

3 Electrical Installation
P3 240-840A 13
Connection diagram

Classic P3 x/x - 240-840A
14
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:
- 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: 3 x 0.5mF/600V~3 x 1mF (x) + 1 x 0.5mF (y)
Conductor length between the device and the power choke <250mm
Motor connection:
Motor conductors l = 1.5m, shielded
Tacho and all control lines l = 1.5m, shielded
Shielding connected to PE
Earthing diagram
CE Advice

3 Electrical installation
P3 240-840A 15
Attention:
The order of the connections to the connector numbers or screw terminals is
obligatory. 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 on the auxiliary voltage and the supply voltage simultaneously.
Switch off the supply voltage after the auxiliary voltage
Input filter
see CE advice, page 14
Short conductor length to be used between the input filter and the device
Auxiliary voltage connection
Connection terminal X5:11, X5:12
Power supply 400V~ ±15%
Special voltages 24V~, 110V~, 230V~, 500V~
Input current max. 300mA
Phase position regardless
Internal fuses FE1, FE2 0.8AT
- Min. line cross-section 0.5mm²
- External fuse
- Min. line protection 6A
Note: Observe the respective type plate.
Control voltage XXX
Power supply

Classic P3 x/x - 240-840A
16
Direct power connection
Connection
Phase L1 bolt X10:16
Phase L2 bolt X10:15
Phase L3 bolt X10:14
Note: L1, L2, L3 - clockwise rotating
field
Protecting earth - PE connection
Unit P3
Type current
Power choke
KD-three-phase current
K-phase choke
Fuses A
super fast acting
installed
240 KD 5-250 3x250 A FF
360 K 170-400 3x315 A FF
480 KU 150-600 3x400 A FF
840 KU 150-800 3x500 A FF
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 inactive dark LED >>> missing phase
>>> wrong rotating field
Power supply
Transformer guard
with filter

3 Electrical Installation
P3 240-840A 17
Option
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 - on3’ have to be removed.
Connections
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 protection.
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 controller extinguishes when
the controller is enabled.
LED D7 also lights if there is a
breakage of the installed fuses.
R40 R34 R15
35
X18
36
37
LED D7 red

Classic P3 x/x - 240-840A
18
Free

3 Electrical Installation
P3 240-840A 19
Motor connection
Connection
positive command value
Motor- bolt X10:13
Motor+ bolt X10:10
Note:
Armature choke only for a few applications
Inductance: L [mH] = U
A
/I
A
x 0.8
Standard version without a choke
Motor lines have to be shielded.
Unit P3 x/x-
Type current
Choke *
Direct current
Min. Conductor
cross-section (mm²)
240 UI180B250 70
360 UI210C400 150
480 UI240C500 240
840 UI240-7000 500
* Chokes are necessary only for special applications, e.g. quiet motor operation
(stage technique)
Switching in the armature circuit
- dc circuit current-free
- disable inactive
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.
Motor connection

Classic P3 x/x - 240-840A
20
Constant field
Connection Plug-in terminal connectors
Input X5:17, X5:18
Field negative X5:19
Field positive X5:20
Signal contact X5:21, X5:22
Field voltage
Power supply Field supply
230V~ 210V=
400V~ 360V=
Variable 0.9 x transformer secondary voltage
with auto-transformer
Field current max. 10A=
Internal fuses 2 x 10AF
Cross-section -connecting line min. 0.5mm²
External protection line protection, min. 10A
Field current watchdog
Operating current 700mA
Signal contact 48V/0.5A
Connection X5:21, X5:22
Error open contact
Controlled field
Optional field current controller P3-F
Observe Manual P3-F
Field current control
Field voltage max. 320V=
Control range 200mA to 10A
Combination of field/armature control
Field triggering circuit
Internal potential-free armature voltage measuring
Field voltage max. 320V=
Control range 200mA to 10A
Triggering pointU
A
max. 450V=
Adjustments min./max. field current
control parameter
EMC: for a controlled field >>> use shielded field lines
Field current
signal contact
field
Field connection