Unitek Classic Q3 Series User manual

Manual
Classic Q3 1000-2000A
4 Quadrant
Thyristor Drive
Q3-1000 - 2000A
Edition
1108
Teil 1 Thyristor Drive Q3 x/x- 1000 to 2000A
Teil 2 Analoque Control Electronic REG4

Classic Q3 1000-2000A
2
Contents Page
Basic Information
Safety advice 3
Standards and guidelines 3
General information 4
Features 5
Technical data 6, 7
Specification 8
Mechanical installation 9
Dimensions 10, 11
Electrical installation
Connections 12
Connection diagram 13
CE advice 14
Auxiliary voltage connection 15
Transformer power connection 16
Option - synchronization 17
Motor connection 19
Field connection 20
Actual value connection 21
Components 22
Adjustments 22
Circuit diagram 23
Current control loop 24
Signals 25
Measurements25
Commissioning + REG4 26, 27
Fault 28, 29
Guarantee 30
Protocol 31, 32
Contents

1 Basic information
Q3 1000-2000A 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.
Q3 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 in-
dependent 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 stan-
Safety advice - Standards and guidelines
ATTENTION - High voltageAC 500V~, DC 650V=
500V ~ ac, 650V=dc

Classic Q3 1000-2000A
4
Attention:
This manual Q3 only describes the basic control unit.
Manual Q3
This device description must be read in conjunction with the manual for
- an analogue control REG xx
- an external field control F2 xx
- options Multi xx
General information
Series Classic Q3
General information

1 Basic information
Q3 1000-2000A 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
- 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 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
Features

Classic Q3 1000-2000A
6
Q3 400/450-1000-2000
Power connection 360 ... 440V~
Auxiliary voltage connection 360 ... 440V~, 200 … 250V~ oder Option
Output voltage max. ± 450V=
Cooling ventilation fan
Field supply - external Field current controller F2.1 400/340-20
Q3 400/450- 1000 1500 2000
Input current A~ 800 1200 1600
Output current - peak 5s
- continuous
A=
A=
2000
1000
3000
1500
4000
2000
El. power kW 450 675 900
Fuses ff
AFF
installed
6x1000
installed
12x1000
installed
12x1000
Power chokes Type 3x
KU240-1000
3x
KU240-1500
3x
KU240-2000
mH 0,05 0,03 0,02
Armature chokes Armature chokes are necessary only for special applications
Dimensions w xhxd mm 550x800x520 550x800x520 550x800x520
Q3 500/550-1000 bis 2000
Power connection 450 ... 550V~
Auxiliary voltage connection 360 ... 440V~, 200 … 250V~ oder Option
Output voltage max. ± 550V=
Cooling ventilation fan
Field supply - external Field current controller Unitek F2.1 400/340-20
Q3 500/550-1000 1500 2000
Input current A~ 800 1200 1600
Output current - peak 5s
- continuous
A=
A=
2000
1000
3000
1500
4000
2000
El. power kW 550 825 1100
Fuses ff
AFF
Installed
6x1000
Installed
12x1000
Installed
12x1000
Power chokes Type 3x
KU240-1000
3x
KU240-1500
3x
KU240-2000
mH 0,05 0,03 0,02
Armature choke Armature chokes are necessary only for special applications
Dimensions w xhxd mm 550x800x52
0
550x800x52
0
550x800x52
0
Technical data

1 Basic information
Q3 1000-2000A 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
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 UA±10V= X3: 23
Option UA0-10V= X3: 24
Drive ready BTB +10V X3: 25
+5V X3: 26
Techniscal data

Classsic Q3 1000-2000A
8
Mounting
Air flow direction
Ambient temperature 0 to <45°C (reduced, up to 60°C)
max. cooling unit temperature 80°C (internal watchdog)
Air-mass throughput 1000-2000A 2500m³h
Dissipation loss with max. power
Unit Q3-x/x Unit W Mains choke W
1000 3700 1000
1500 5400 1300
2000 7200 1600

2 Mechanical installation
Q3 1000-2000A 9
Dimensions
1-phase mains choke
Faetures
UN 400V~50/60Hz
UK 4%
Protection rating IP00
Isolation class T40/E
Vertical angle bracket
Units
Q3-x/x
Choke
type
L
mH
PV
W
Dimensions
a b c d e
Weight
kg
Screw
M
1000 KU240-10
00 0,05 1000 320 270 470 250 190 98 10
1500 KU240-15
00 0,03 1300 320 270 470 250 190 98 10
2000 KU240-20
00 0,02 1500 320 270 470 250 190 98 10
with filter: KDFxx

Classsic Q3 1000-2000A
10
Dimensions

3 Electrical installation
Q3 1000-2000A 11
Dimensions

Q3 1000-2000A
12
Connections
Une protection
Pusch button operated Switch operated
ON/OFF
10s
10s
OFF
(Delayed opening) (Delayded opening)
ON
Switching on Switching off
Enable K3
Control voltage
Power voltage
Command value
10s*
* switching-off delay
stand-still 0.3s

3 Electrical installation
Q3 1000-2000A 13
Connections

Q3 1000-2000A
14
CE Advice
The devices adhere to the EU guidelines 89/336/EWG and the technical stan-
dards EN 61000-2 and 61000-4 provided that the following conditions are ob-
served:
- 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: 0.5mF/600V~ 3 x 1mF (x) + 1 x 1mF (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
Connections diagram
CE-Advice

3 Electrical installation
Q3 1000-2000A 15
Attention:
The order of the connections to the connector numbers or screw terminals is obli-
gatory. 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 X5:17, 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
Note:
Observe the respective type plate.
Control voltage XXX
Power connection

Q3 1000-2000A
16
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
To work without PE connection is for-
bidden !!!
Q3 x/x-
current type
Power choke
KD- three phasecurrent
K - phase choke
Fuses A
Super fast acting installed
1000 KU240 -1000 6 x 1000 A FF
1500 KU240 -1500 12 x 1000 A FF
2000 KU240 - 2000 12 x 1000 A FF
Power connection
Line protection
Mains choke
with filter
Transformer protection
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

3 Electrical installation
Q3 1000-2000A 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 - Ein3’ have to be removed.
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 protecti-
on.
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 con-
troller extinguishes when the
controller is enabled.
LED D7 also lights if there is a
breakage of the installed fuses.
R15 R34 R40
35
X18
R15
36 37
LED D7
red
Line protection
Short-circuit proof wiring

Q3 1000-2000A
18
Free

3 Electrical installation
Q3 1000-2000A 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 Q3 x/x- Power choke* Min. conductor
cross-section (mm²)
Type current Direct current
1000 auf Anfrage 2x 240
1500 auf Anfrage 2x 240
2000 auf Anfrage 2x 240
* Chokes 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
Attention:
Power lines have to be shielded and routed separately from control lines!
For electro-magnetic interferences please refer to the CE advice.

Q3 1000-2000A
20
Field regulator is not installed.
External field current regulator F2.1 xx
Field connection