Unitek Classic Q3 15-150A 4 Quadrant User manual

M A N U A L
Classic Q3 15-150A
4 Quadrant
Thyristor Drive
Part 1 Thyristor Drive Q3x/x-15-150A
Part 2 Analogue Control Electronics REGxx
Industrie Elektronik
G m b H
Hans-Paul-Kaysser-Straße 1
71397 Leutenbach –Nellmersbach
Ausgabe /
Version
Tel.: 07195 / 92 83 –0
Fax: 07195 / 92 83 –129
[e-mail]
www.unitek-online.de
10/2018
V
01

Basic - Information
1
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Q3 15-150A
1Inhaltsverzeichnis
2Basic - Information ........................................................................................................... 2
2.1 Safety advice ...................................................................................................................... 2
2.2 Standards and guidelines: .................................................................................................. 2
2.3 General and features.......................................................................................................... 4
2.4 Technical Data.................................................................................................................... 6
2.5 Specifiation......................................................................................................................... 8
2.6 Interface ............................................................................................................................. 8
3Mechanical installation .................................................................................................... 9
3.1 Mounting............................................................................................................................ 9
3.2 Dimensions Q3 15-60A..................................................................................................... 10
3.3 Dimensions Q3 120-150A................................................................................................. 11
3.4 Three-phase power-choke ............................................................................................... 12
4Electrical installation ...................................................................................................... 13
4.1 Connections...................................................................................................................... 13
4.2 Connection diagram ......................................................................................................... 14
4.3 CE-Advice.......................................................................................................................... 15
4.4 Connection advice............................................................................................................ 16
4.5 Power connection ............................................................................................................ 17
4.6 Option –external synchronization................................................................................... 18
4.7 Motor-connection ............................................................................................................ 19
4.8 Field-connection............................................................................................................... 20
4.9 Actual value...................................................................................................................... 22
5Adjustments .................................................................................................................. 23
5.1 Components ..................................................................................................................... 23
5.2 Circuit diagram ................................................................................................................. 24
5.3 Current controller............................................................................................................. 25
5.4 Displays............................................................................................................................. 27
6Commissioning.............................................................................................................. 28
6.1 Commissioning Q3 x/x-x with REG4 ................................................................................. 28
6.2 Protocol Q3 x/x-x with REGxx........................................................................................... 30
7Fauls .............................................................................................................................. 32
7.1 Fauls ................................................................................................................................. 32
7.2 Error diagnosis.................................................................................................................. 33
8Warranty ....................................................................................................................... 34
8.1 Warranty .......................................................................................................................... 34

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Safety advice
2Basic - Information
2.1 Safety advice
Electronic equipment is not fault proof.
Attention –High voltage
360-550V~, 450-550V=
Shock hazard / Danger of life!!
Before installation or commissioning begins, this manual must be thoroughly read and
understood by the technical staff involved.
The devices are electrical equipment (EB) to the power electronics for the control of power flow
in electrical power systems.
Protection rating IP00.
Control and power connections can
voltage lead, works without the drive!
Measured before disassembly voltage!
2.2 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:
2004/108/EG, 2006/95/EG, 2006/42/EG
EN 60204-1, EN292, EN50178, EN60439-1,
EN61800-3, ECE-R100
ISO 6469, ISO 26262, ISO 16750, ISO 20653, ISO12100
IEC/UL:
IEC 61508, IEC364, IEC664, UL508C, UL840
VDE Regulations:
VDE100, VDE110, VDE160
Trade body guidelines:
VGB4

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Standards and guidelines:
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 be ensured that the machines, equipment or vehicles are
fitted with device independent monitoring and safety feature.
Non-earthed systems (e.g. vehicles) need to be secured isolation
monitors.
There must be no danger to persons and property arising!
Assembly
- should only be carried out when all voltages have been removed and the units are secured
- should only be carried out by suitably trained personnel
Installation
- should only be carried out when all voltages have been removed and the units are sucured
- should only be carried out by suitably trained personnel for electrics
- should only be carried in accordance with health and safety guidelines
Adjustments and programming
- should only be carried out by suitable trained personnel with knowledge in electronic drives
and their software
- should only be carried out in accordance with the programming advice
- should only be carried in accordance with health and safety guidelines
CE
When mounting the units into machines and installations the proper operating of the units may
not be started until it is ensured that the machine, the installation, or the vehicle comply with the
regulations of the EC machinery directive 2006/42/EG and the EMC guideline 2004/108/EG.
On the installation and test conditions described in the chapter CE-advice it is adhered to the EC
guideline 2004/108/EG including the EMC standards EN61000-2 and EN61000-4.
A manufacturer’s declaration can be requested.
The manufacturer of the machine or installation is responsible for observing the threshold values
demanded by the EMC laws.
QS
The devices are archived with serial number and the test data from the manufacturer for 5 years.
The inspection reports may be requested.

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General and features
2.3 General and features
This manual describes the basic unit and
is only in connection with the manual of the control electronics
(e.g. REGxx) valid.
Manual use in connection with:
- an analogue control REGxx
- field regulation internal QS-F
- field regulation external F2xx
- options Multi-xx
Build
- switch cabinet mounting a
- 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 standardized 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

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General and features
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

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Technical Data
2.4 Technical Data
Q3 400/450-x
Power connection:
360 … 440V~
Auxiliary voltage connection:
360 … 440V~, 200 … 250V~ or option
Output voltage:
max. ± 450V=
Cooling:
self cooling
Q3 400/450 -
15
25
40
Input current
A~
12
20
32
Output current
-peak 5s
-continous
A=
A=
30
15
50
25
80
40
Elec. power
kW
6,75
11,25
18
Fuses
-input 3 St
-output 2 St
-field
ff
Aff
Aff
Af
20
25
10
30
50
10
50
63
10
Power chokes
Type
KD2-16
KD2,5-25
KD2,5-50
mH
0,9
0,7
0,4
Armature chokes
Type
EI135A-16
EI135B-24
EI150B-35
mH
33
16
8
Dimensions W x H x D
mm
290x230x190
290x230x190
290x230x190
Weight
kg
7,7
7,7
7,7
Q3 500/550-x
Power connection:
450 … 550V~
Auxiliary voltage connection:
360 … 440V~, 200 … 250V~ or option
Output voltage:
max. ± 550V=
Cooling:
self cooling
Q3 500/550 -
15
25
40
Input current
A~
12
20
32
Output current
- peak 5s
- continous
A=
A=
30
15
50
25
80
40
Elec. power
kW
8,25
13,75
22
Fuses
-input 3 St
-output 2 St
-field
ff
Aff
Aff
Af
20
25
10
30
50
10
50
63
10
Power chokes
Type
KD2-16
KD2,5-25
KD2,5-50
mH
0,9
0,7
0,4
Armature chokes
Type
EI135A-16
EI135B-24
EI150B-35
mH
33
16
8
Dimensions W x H x D
mm
290x230x190
290x230x190
290x230x190
Weight
kg

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Technical Data
Q3 400/450-x
Power connection:
360 … 440V~
Auxiliary voltage connection:
360 … 440V~, 200 … 250V~ or option
Output voltage:
max. ± 450V=
Cooling:
self cooling / 120-150A: ventilation fan
Q3 400/450 -
60
120
150
Input current
A~
48
96
120
Output current
-peak 5s
-continous
A=
A=
120
60
240
120
300
150
Elec. power
kW
27
54
67,5
Fuses
-input 3 St
-output 2 St
-field
ff
Aff
Aff
Af
80
100
10
120
150
10
150
200
10
Power chokes
Type
KD3-75
KD4-100
KD4-150
mH
0,3
0,25
0,16
Armature chokes
Type
El150A-50
UI50B-100
UI180B-150
mH
4
2,2
4,2
Dimensions W x H x D
mm
290x230x230
290x270x230
290x270x230
Weight
kg
7,7
8,6
13,5
Q3 500/550-x
Power connection:
450 … 550V~
Auxiliary voltage connection:
360 … 440V~, 200 … 250V~ or option
Output voltage:
max. ± 550V=
Cooling:
self cooling / 120-150A: ventilation fan
Q3 500/550 -
60
120
150
Input current
A~
48
96
120
Output current
- peak 5s
- continous
A=
A=
120
60
240
120
300
150
Elec. power
kW
33
66
82,5
Fuses
-input 3 St
-output 2 St
- field
ff
Aff
Aff
Af
80
100
10
120
150
10
150
200
10
Power chokes
Type
KD3-75
KD4-100
KD4-150
mH
0,3
0,25
0,16
Armature chokes
Type
EI150A-50
UI150B-100
UI180B-150
mH
4
2,2
4,2
Dimensions
mm
290x230x230
290x270x230
290x270x230
Weight
kg
7,7
8,6
13,5

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Specifiation
2.5 Specifiation
Specification
Mains frequency
50 or 60Hz ±5%
Protection rating
IP 00
Format
VDE 0100 Group C / VDE 0160
Humidity rating
class F nach DIN 40040
Site of installation
< 1000m above sea level
Operating temperature range
0 ... 45°C
Extended operating temp. range
up to 60°C red. 2%/°C
Storage temperature range
-30°C to + 80°C
Amplification
Input-Signal
0… ± 10V=
Output
0… ± 200% Type current
Enable
> + 10 Volt
Current control loop circuit
Control precision
± 2%
Control range
1:50
Over-current limiting
10 Sec. 200 % Type current
Speed control loop (see MANUAL REG)
Control precision (without actual value error)
± 0.1%
Control range
> 1:300
2.6 Interface
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 UA
±10V=
X3: 23
Option UA
0 - +10V=
X3: 24
Drive ready BTB
+10V=
X3: 25
+5V
X3: 26

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Mounting
3Mechanical installation
3.1 Mounting
Q3-Montage-V616
Ambient temperature 0 to <45°C (reduced, up to 60°C)
Max. cooling unit-temperature 80°C
Air-mass throughput 15-60A natural convection
120A 360m³h
150A 360m³h
Dissipation loss with max. power
Unit Q3-x/X
Unit W
Fuse
Mains choke W
15
65
32
30
25
95
42
40
40
140
65
60
60
200
100
75
120
380
140
125
150
470
160
185

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Dimensions Q3 15-60A
3.2 Dimensions Q3 15-60A
Q3-M656-15-40
(Feld = field / Feldstrom = field voltage / Freigabe = release / Ablösepunkt = take off point)

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Dimensions Q3 120-150A
3.3 Dimensions Q3 120-150A
E-Q3-M657-Maßbild840
Dimensions
Unit Q3-x/x
Width
Height
Depth
Drill hole
Weight
mm
mm
mm
mm
15A
286
225
190
270x175
7.7
25
286
225
190
270x175
7.7
40
286
225
190
270x175
7.7
60
286
225
230
270x175
10.5
120
286
270
230
270x220
13.5
150
286
270
230
270x220
13.5

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Three-phase power-choke
3.4 Three-phase power-choke
Features
UN
400V~50/60Hz
UK
4%
Protection
rating
IP00
Isolation class
T40/E
Vertical angle bracket
Q3-V257-UID-Trafo und Q3-V256-UI-Trafo
Q3-x/x-
Choke type
LmH
PVW
Dimension
Weight
Screw
a
b
c
d
e
kg
M
15
KD2-16
1.7
30
100
55
115
56
44
2
4
25
KD2.5-25
1.0
40
150
75
150
90
55
3.5
5
40
KD2.5-50
0.6
75
150
90
150
90
70
5.1
5
60
KD3-75
0.4
110
185
135
170
122
85
7
6
120
KD4-100
0.3
125
240
130
225
140
85
14.5
6
150
KD4-150
0.2
185
240
150
225
140
105
15.5
6
with filter: KDFxx

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Connections
4Electrical installation
4.1 Connections
Q3-Relais-1V647
E-Q3-Schaltfolge-1-V647
E-Q3-647

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Connection diagram
4.2 Connection diagram
E-Q3A019

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CE-Advice
4.3 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, transformer and filter capacitors are mounted on a 800x800x2mm 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, I = 50mm.
Three-phase connection:
Power choke type: see technical details
Filter capacitors: 0.5mF/600V~ 3 x 1µF (x) + 1 x 1µF (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
E-Q3-A639

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Connection advice
4.4 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
- 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
Short conductor length to be used between the input filter and the device
Auxiliary voltage connection
Connection terminal X5:17, X5:18
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
Q3-Hilfsspannung1-V647
Note: Observe the respective type plate. Control voltage XXX

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Power connection
4.5 Power connection
Direct power 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 Q3 x/x-
Power choke
Fuses A
Type current
KD-three-phase current
Superfast acting
K-Phase choke
installed
240
KD5-250
6 x 250 A FF
360
K170-400
6 x 315 A FF
480
KU150-600
6 x 400 A FF
840
KU150-800
6 x 500 A FF
Power connection with an auto-transformer
1.1 x continuous motor power
Secondary voltage
0.9 x Motor voltage
Transformer fuses
Slow acting
Observe the switch –on current!
Nput fuses F1, F2, F3
Rf. to the table above
Q3-V747-with filter
Attention:
If the secondary voltages produced by the transformer are inferior to 60% the voltage watchdog
has to be adapted. These modifikations may only be effected in the factory and thus, the
voltages have to be indicated on order.
Watchdog connection
LED BTB inactive >>> missing phase
>>> wrong rotating field
Line protection
Power choke
Transformer
guard

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Option –external synchronization
4.6 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
Q3-M656-ext-synch-15-40
Q3-ext-synch-anschluss-v647
The wiring has to be short-circuit proof or protected means of a line protection.
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
Attention:
If incorrectly connected at X18 –the device can be destroyed

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Motor-connection
4.7 Motor-connection
Positive command value
Q3-Motor-V647-1
Motor –
Motor +
bolt
bolt
X10:13
X10:10
Attention:
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*
Fuses A
Min. conductor
Type current
Direct current
super fast
cross-section (mm²)
actin F4
15
EI135A-16
2 x 25
1.5
25
EI35B-24
2 x 35
2.5
40
EI150B-35
2 x 63
4
60
EI150A-50
2 x 100
10
120
UI150B-100
2 x 150
25
150
UI180B-150
2 x 200
35
*choke are necessary only for special applications
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
Braking effect only with an excited field!
Attention:
Power lines have to be shielded and routed separately from control lines!
For electro-magnetic interferences please refer to the CE advice.