Unitek Classic P3 Series User manual

MANUAL
Classic P3
1 Quadrant Thyristor Drive
15 to 40 A
P3 15 - 40A
Edition
0308-1

2
Classic P3 x/x -15-40A
Contents
Contents Page
1. Basic Information
Safety advice 3
Standards and guidelines 3
General information 4
Features 5
Technical data 6, 7
2. Mechanical Installation
Dimensions P3 15-25A 8
Dimensions P3 40A 9
3. Electrical Installation
Connection advice 10
Mains connection 11, 12
Motor connection 13
Field connection 14
CE advice 15
Actual value connection 16
4. Adjustments
Current control loop 17
Displays 18
5. Commissioning 19, 20
6. Guarantee 21
7. Protocol 22, 23
8. Drawings
Connections 24
Circuit diagram 25

1 Basic - Information
P3 15-40 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 guidelinese
ATTENTION
High voltage
360/550V AC, 450/550V DC

4
Classic P3 x/x -15-40A
General information
Attention
This device description MANUAL P3 only describes the basic control unit and it
must be read in conjunction with a control manual (e.g. REG).
The following control units for 1 quadrant control are available:
analogue control REG
General information
In conjunction with a control board (e.g. REG) the Classic P3 range of thyristor
drives act as current controllers (moment of inertia controllers).
A 26-pin connector, common to all boards, is used to connect the power section
and the control electronics. Using this interface it is possible for any external
control arrangement including third party equipment to drive the power section.
P3 drives are used to control the speed, the voltage or the moment of inertia of dc
motors.

1 Basic - Information
P3 15-40 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
- 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 P3
* 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
Features

6
Classic P3 x/x -15-40A
Technical data
P3 400/450-x
Power connection 360-440V~
Auxiliary voltage connection 360-440V~, 200-250V~
Output voltage max. +450V=
Cooling self cooling
P3 400/450- 15 25 40
Input current A~ 12 20 32
Output current peak
continuous
A=
A=
30
15 50 25 80 40
El. power kW 6,75 11,25 18
Input fuses (fast acting)
Input
AFF 20 30 50
Mains chokes T
yp
mH
KD2-16
0.9
KD2,5-25
0.7
KD2,5-50
0.4
Armature chokes
Typ
mH
EI135A-16
33
EI135B-24
16
EI150B-35
8
Dimensions h x w x d mm 200x160x110 200x160x127 240x160x127
P3 500/550-x
Power connection 500-550V~
Auxiliary connection 360-440V~, 200-250V~
Output voltage max. + 550V=
Cooling self cooling
P3 500/550- 15 25 40
Input current A~ 12 20 32
Output current peak
continuous
A=
A=
30
15 50 25 80 40
El. power kW 8,25 13,5 22
Input fuses (fast acting)
Input
AFF 20 30 50
Mains chokes
Typ
mH
KD2-16
1,2 KD2,5-25 0,7 KD2,5-50 0,5
Armature chokes
Typ
mH
EI135A-16
33
EI135B-24
16
EI150B-35
8
Dimensions h x w x d mm
200x160x112 200x160x12
7240x160x127

1 Basic - Information
P3 15-40 7
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
Amplification
- input signal 0 to ±10V=
- output 0 to ±200% type current
Enable +10V
Current control loop circuit
- control precision ±2%
- control range 1:50
Speed control loop circuit with REG
- control precision
(without actual value error) ±0.1%
- control range 1:300
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 X3: 9, 10, 11, 12, 13, 14I
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 +10V= X3: 21
Over-current power section n/a X3: 22
Trigger angle1 +10V= X3: 23
Trigger angle 2 +10V= X3: 24
Drive ready BTB +10V= X3: 25
not assigned n/a X3: 26
Technical data

8
Classic P3 x/x - 15-40A
Dimensions P3 15-25A
Enable
Enable ignition

P3 15-40 9
2 Mechanical Installation
Dimensions P3 40A
Enable
Enable ignition

10
Classic P3 x/x - 15-40A
Connection advice
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, 84/528/EWG, 86/663/EWG
- VDE and TÜV regulations and Trade body guidelines
- CE advice, EMC
Connection
Conductor minimal cross-section
Type current A 15 25 40
ac power supply mm² 1.5 2.5 4
Motor line mm² 1.5 2.5 4
Auxiliary voltage mm² 0.5 0.5 0.5

P3 15-40 11
3 Elektrical Installation
Connection advice
This connection advice is a general information and non-obligatory.
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 15
Short conductor length to be used between the input filter and the device
Operation with 60Hz: switch S3 contact 1 in position ON
Auxiliary voltage connection
Connection terminal X5:11, X5:12
Power supply 230V~ or 400V~ (Pls. observe the type plate)
Input current 0.1A
Phase position regardless
Internal fuses 2.5Af
Power supply
X5: 11 12 18 19 20

12
Classic P3 x/x - 15-40
Direct power connection
Connection
Phase L1 terminal X10:16
Phase L2 (N) terminal X10:15
Phase L3 terminal X10:14
Input fuses
Super fast acting fuses
Power choke
Inductance >200mH
Power connection with a transformer
Transformer performance
1.1 x continuous motor power
Secondary voltage
0.9 x motor power
Transformer fuses
Slow acting
Input fuses
Super fast acting fuses
Attention:
If the secondary voltages produced by the
transformer are inferior to 60% of the rated device
voltage, the voltage watchdog has to be adapted. These modifications may only
be effected in the factory and thus, the transformer secondary voltage has to be
indicated on order.
Internal watchdog for fuse failures
Power connection

P3 15-40 13
3 Elektrical Installation
Motor connection
Connection
Motor- bolt X10:10
Motor+ bolt X10:13
Armature choke
Inductance: -L 4 [ mH ] = U/I
A
x 0.8
Armature chokes are only necessary for
special applications, e.g. low-noise motor
operation (stagecraft).
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
in parallel to the motor armature
without separation from the device
Attention:
Power lines have to be shielded and routed separately from
control lines!
For electro-magnetic interferences please refer to the CE advice (page 15).
Motor connection
X10: 10 13

14
Classic P3 x/x - 15-40
Field connection
Field connection
Connection Plug-in terminal connectors
Input X5:11, X5:18
Field negative X5:20
Field positive X5:19
Field voltage
Power supply Field supply
230V~ 210V=
400V~ 360V=
400V~ with N 210V=
Field current max. 1.5A
Fuses 2.5Af
Watchdog omitted
11 12 18 19 20
L1 N
230V~
Field
210V=
11 12 18 19 20
L1 L2
400V~
Field
210V=
11 12 18 19 20
L1 L2
400V~
Field
360V=
N

P3 15-40 15
3 Elektrical Installation
CE 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:
- The device, the power choke, and the 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.
Connection:
Power choke type: see technical details
Filter capacitors: 3 x 0.5 m F/600V ~ 3 x 1 m F (x) + 1 x 0.5 m F (y)
Conductor length between the device and the power choke <250mm
CE- Advice

16
Classic P3 x/x - 15-40
Actual value connection
Actual value connection
Tacho
Suitable actual value encoders:
- DC tacho generator
- Brushless tacho generator with evaluation electronics
- Incremental encoders with evaluation electronics
- AC or three-phase tacho with rectification
Connection
Control electronics (see Manual REG)
In case of a positive command value
Tacho positive X 1:8b
Tacho negative X 1:9
Shield X 1:8
Armature voltage
Ground referenced actual value
Fuses 2x 0.1A/500V directly in the armature circuit
For armature voltage >180V= additional resistors are required
Use unit UNITEK EXZU-UA1
(including 2 fuses and 2 resistors in an insulated housing)
REGxx
* only for

P3 15-40 17
4 Adustment
Adjustments – Current controller
Current controller - PI loop circuit
Adjustments with the DIP switch S2
Optimization of the current controller
- Connect an oscilloscope across the current actual value X3:21
- Current command value step-change 1V X3:16
- Increase the current command value by 1V steps to 10V
- Alter the P-amplification by means of the DIP switches S2:1 and S2:2
- Optimal adjustment see fig. 1
- Not permissible adjustment see fig. 2
- Alter the integral part by means of the DIP switches S2:3 and S2:4
Oscilloscope - Current adjustment
Fig. 1 Fig. 2 Fig. 3
Optimal adjustment Amplification too high P-amplification too low
Adjustment
47K
150K
100K
2
1
4
3
0,68µF
0,33µF
0,22µF
RVI
100K
P - component
I - component
S2
Imax

18
Classic P3 x/x - 15-40A
Displays
Some important functions are indicated by LEDs:
Display LED
Drive ready BTB
Current controller enable enable
Triggering enabled enable triggering
Current command value direction RVI
The green LEDs indicate the active states!
BTB signal - Drive ready
BTB signal X3:25 >+10V
Error X3:25 <+2V
Error
Auxiliary voltage supply +24V, +15V, -15V
Power supply:
Fuse failure
Under-voltage
In case of errors or failure the power section is internally disabled without delay.
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%
Measured values
with a positive command value
Voltage: X10:10 negative, X10:13 positive
max. 1.15 x power supply
Current: ammeter in the motor circuit
Measured values across REG4
Speed X2:109 ± 5V for ± 100% speed
Current X2:111 ± 5V for ± 200% current
GND X2:104
Displays
BTB
RVI
Enable
Enable ignition

P3 15-40 19
5 Commissioning
Commissioning
1. Connection advice
Connect the drive in accordance with the P3 manual and the control electronics
manual (e.g. REG).
Please observe in particular:
- Check the power supply voltage with that specified on the type plate.
- Insert the correct fuses according to the technical data (rf. to page 6)
- Check the field voltage connection and the motor and tacho connections!
- For 60Hz applications set the switch S3, contact 1 to ON
2. Commissioning
Basic connections:
Mains supply, field, tacho, or armature feedback, drive enable, command value.
For armature voltage control the tacho watchdog must be switched off.
2.1 Drive enable switch open or drive enable voltage 0V
Command value 0V
Switch S9 adjust to tacho voltage
for armature voltage control adjust to 0
Switch S4 position 2
Switch S5 position 6
Potentiometer I max1 left full scale
Potentiometer I max2 adjust to approx. 10% of full scale
Potentiometer X P adjust to 50%
Potentiometer I D = 10
Potentiometer IxR = left full scale
Potentiometer n max = left full scale
Potentiometer INT = left full scale
2.2 Apply the voltage
T he LEDs L3 (BTB) and L7 (stationary) must light.
All other LEDs are off.
2.3 Close the switch ‘drive enable’ or apply a drive enable voltage of 10V
The LEDs L1 and L2 must also light
The drive must be at a standstill or turn slowly (offset).
If the drive accelerates in the correct direction, the polarity of the tacho voltage
and the armature voltage feedback must be changed.
If the drive accelerates in the wrong direction, the polarity of the armature or the
field must be changed.
2.4 Increase the command value voltage to approx. 10%
The drive must accelerate to approx. 10% of the speed.
If the rotation direction is wrong, change the polarity of the tacho and the field
or the polarity of the tacho and the armature.
Commissioning

20
Classic P3x/x - 15-40A
Commissioning
2.5 Current controller amplification
(Switch S2 on the power section)
The current amplification is adjusted to a low armature circuit inductance
(all switches On)
High inductance values can lead to motor oscillation which cannot be influenced
by means of the speed controller.
In this case, first set switch S2-2 to Off.
If the drive still does not run smoothly, set the switch S2-1 to Off.
The current response can be measured by means of an oscilloscope across the test
point X4:20 (see page 17).
2.6 Speed controller amplification
Adjust on the REG board.
Adjust the P-term to the lowest possible setting from 1 to 5 (switch S4).
Adjust the I-term to match the axis momentum (switch S5):
large axis momentum - high adjusted value
small axis momentum - low adjusted value
With the command value set to 10% speed, increase the amplification by turning
the potentiometer Xp clockwise. When the drive begins to oscillate, reduce the
amplification by turning the potentiometer anti-clockwise by approximately 10%.
For the fine adjustment of the amplification the control response should be
measured by means of an oscilloscope across the test point X4:15.
2.7 Further adjustments
such as speed, peak current, continuous current, etc.
(rf. to the manual REG and P3)
2.8 Switching Off
If the switch drive enable is opened, or the drive enable voltage is switched to
0V, LED L1 and L2 will extinguish and the drive will be disabled.
DIP switch DS1:K4 (REG4) in position OFF!
After approx. 2s the thyristor triggering circuit is disabled.
2.9 Commissioning adjustments
The adjustments should be documented in the protocol and the adjustment
potentiometers should be sealed with a suitable lacquer.