Unitek TV3.230 Series User manual

MANUAL
Servo Drive
TV3.230-xx-
for DC-Servomotors
with DC-Tachometer
TV3.230
Edition
0109

Transistor-Servo-Drive TV3.230
2
Content Page
Safety Advice 3
General Information 4
Application 5
Construction 6
Characteristics 6
Technical Data 7
Dimensions Compact Device 8
Dimensions Transformer and Chokes 8
Dimensions Multi-Axes Combination 9
Connection Overview - Flat Version 10
Connection Overview 11
Connection Plans 12
EMC-Advice 13
Connection with Isolation Transformer 14
Motor Power Connection 15
Connection 16
Speed Nominal Value 17
Current 18
Signals - Ready for Operation Signal BTB 19
Analogue Measuring Outputs 19
Pin assignment. 20
Component Overview 21
Block Diagram 22
Adjustment Functions 23
Adjustment Advice 24
Speed Actual Value 25
Nominal value - Integrator 27
Current Limitation 28
Speed Controller Switching 29
Adjustment without Measuring Instruments 29
Basic Setup 30
Getting Started 31
Faults 32
Signals 34
Protocol 35
Quarantee 36
Content

1 Basic Information
TV3.2 3
Electronic devices always involve the risk of failure.
Thi
s
ma
nu
al
ha
s to be read carefully and must be understood
by experts before installing or starting the device.
If there are any doubts call your trader or the manufacturer.
The TV3-230 series is designed to regulate electrical currents;
protection standard IP00.
Standards and Guidelines:
The device and it’s associated components can only be installed and switched on where
the local laws 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
- Regulations of Professional and Occupational bodies: VGB4
The user has to assure that:
after
- a failure of the device
- an incorrect handling
- a failure of the control unit etc.
the drive has to be brought to a secure operating condition.
Machines and installations are to be provided with supervisory and safety equipment,
that is indepentent of the device.
Adjustment
-only by qualified personnel
- adher to safety regulations
Installation work
-only when disconnected from all power lines.
QS
The devices are archived by the manufacturer with serial number and their test
specifications.
CE
The EU-guide line 89/336/EWG with the Regulations EN61000-2 and EN61000-4 are
observed.
Caution High Voltage
AC 255V~, DC 400V=
Safety Advice

Transistor-Servo-Drive TV3.230
4
General Information
The transistor servo amplifier SERVO-TV3.2 forms together with the direct current
servomotor a propulsion unit distinguished by its high regulating quality
The physical characteristics correspond to those of the direct current motors, that is, the
current is proportional to the torque and the voltage is proportional to the speed. Current
and speed can be measured precisely,
The tachometer actual value is generated from the sensor unit.
(incremental encoder with rotor position track or resolver.)
The analogue regulation circuits of the servo amplifier are designed simply.
In the speed controller (P-I-controller) of the servo-amplifier the nominal value and the
actual value are processed. The result is the current nominal value.
As occurs in all DC-servo-amplifiers which are supplied by the dc-bus ,
the feed-back of the energy must be observed when braking in the dc-bus (especially
where stroke or eccentric cycles are concerned). The ballast circuit is designed for 3%
on-period, higher cyclic durations can be reached by adding external resistors. (option)
Information:
Further servo-amplifiers for DC-servo-motors
for low power SERVO -DC TV3&TV6 24 ... 120V, 6 ... 12A
for midrange power SERVO -DC TVQ6 up to 250V, 10 ... 25A
for high power Classic Q2, Q6 up to 250V, 15 ..60A
Motor governor for DC-shunt motors
from midrange upto
higher power Classic Q1, Q3 up to 550V, 15 ... 2000A
3-Phase-servo-amplifier analog for AC-synchro-servo motors
for low power SERVO -AC TVD3-2 24 ... 115V, 5 ...10A
SERVO-AC TVD3-230 230V, 5...10A
for midrange power SERVO - AC TVD6-2 200V , 400V, 5 ... 25/40A
for high power SERVO-AC AS250/275, AS450/475
3-Phase-servo-amplifier digital for AC-synchro-servo motors
for low power upto
higher power Digital-AC-SERVO DS 2xx 230V, 5...10A
Digital-AC-SERVO DS 4xx 400V, 5...50A
Battery Drive BAMO C 24V, 10...40A
BAMO A1,A2,A3 24..200V, 10...500A
BAMO D3 (digital) 24..200V, 10...500A
General Information

1 Basic Information
TV3.2 5
Application:
for all kinds of machines up to 1.8KW drive power especially as 4Q-servo-drive in travel
axes with
- high dynamic acceleration and deceleration cycles
- great regulation range
- high efficiency
- small motor size
- even and smooth travel
for speed or torque regulation or
combined speed-torque regulation with or without superposed position controller.drives
with constand speed as in conveyors, lead screw drives, pumps or divider units
For use in
component insertation machines, metall-sheet working machines
machine tools, plastic working machines, assembly machines,
knitting and sewing machines, textile working machines, grinding machines, wood and
stone working machines, food processing machines, robots and manipulators, storage
across machines, Extruder, Kalander, and many other machines and installations.
DC-drives are particularly known for their good true running and even torque.
Notice
when deceleration is mainly require.
For example
- winding machines, lifts, great centrifugal masses
the braking energy will be annihilated in the ballast circuit
or re-feded to the mains using an external dc-bus converter.
Application

Transistor-Servo-Drive TV3.230
6
Construction:
cubicle-mount or 3HE-plug-in unit
according to the VDE- DIN- and EU- regulations.
Standard analog regulation electronics.
Power electronics for 5A and 10A.
galvanic isolation between
power section and device-zero (GND)
There are used:
- fully isolated six-pack IGBT-power semiconductors,generous dimensioning.
- only industrial standard components are used
- SMD - basic insertion
- LED displays
- 4 digit binary switches for system setup
- precision potensiometers for fine adjustment
Characteristics:
* Power supply max. 230V~
* differential nominal value inputs
* Speed and torque regulation
* Static and dynamic current limit
* Current nominal value output
* Test connectors for current and speed
* Enable logic
* Quick stop
* Mains failure braking
* Temperature control for motor and device
Construction

1 Basic Information
TV3.2 7
Technical data
Power supply 24V~ bis 230V~ +10%
Auxiliary supply 20V~ +10%/-5%
24V= +10%/-5%
300mA pro device
Spezifications
Device TV3.230 5 10
Output - standstill current
continuous
peak
A=
A=
5
10
10
20
El. power max. W 900 1800
ZW-fuses quick mounted AF 12,5 - 16 12,5 - 16
Cooling 100% ED convect fan
Dim. plug in device
compact device
BxHB
HxWxD mm
12TE/3HE
132x67x205
12TE/3HE
132x82x205
Mains module TVD3-230
Power supply V~ 1x oder 3x 230V~ plus 1x 20V~
Output voltage V= max. 320
Output current A= max. 30
Ballast circuitry with V= 400
Ballast power W
WS
50
6000
Common spezifikationen
Enclosure protection IP 00
Norms EN 61800-3, EN 60204-1
EN 50178
Humidity stress Klasse F nach DIN 40040
Site altitude <1000m über NN
Ambient temperature 0 … 45°C
Extended operating range up to 60°C red. 2%/°C
storage temperature -30°C bis +80°C
Speed controller
control accuracy (with out actual value error) ±0,5%
Control range (Tacho) 1:1000
Technical Data

Transistor-Servo-Drive TV3.230
8
Dimensions Compact Device
Dimensions transformer, choke
Compact Device
Choke
Typ
rated
current A
Ind.
mH
Dimensions
a /b /c mm
Weight
kg
2M5-4 4 2.5 60x 85x 65 0.7
2M6-8 8 2.5 70x 90x 75 1.2
2M7-12 12 1.5 80x 105x 86 1.4
Trafo-
Typ
Trafo power
VA
Dimensions
a /b /c mm
Weight
kg
TE 8/2 100 85x 89x 82 2.0
TE 12/1 250 120x101x115 4.3
TE12/3 400 120x133x115 6.8
TE 15/1 500 108x132x122 8.2
TE 15/3 800 150x150x132 13.5
TE 74/2 1300 175x140x160 15.4
TE 74/3 1600 175x150x160 18.5

2 Mechanical Installation
TV3.2 9
Multi-Axes Combination

Transistor-Servo-Drive TV3.230
10
Regen circuit
Type TVD3-230-K 5A 10A
Internal resistor 100 Ohm 100 Ohm
Continuous power 50W
Pulsepower 6kW
Ext. resistor min. Ohm 80 42
Fuses F2 6,3 AF
The energy generated during braking is
refed to the DC-BUS. The Elkos
DC-Buses are able to store only a small
amount of energy. The excess energy
has to be converted into heat in the
regenerative resistor. The internal
resistor is designed for drives without
flyweights.
Always use external regenerative
resistors for flyweights or design
uncertainties.
External regen resistor
Dimensionierung
Maximalwert der Bremsleistung
Jg x D n x n
P
max
[W] = -----------------------------
91 x t
B
Jg = Motor- und reduziertes Lastmoment [kgm
2
]
n = maximum Speed [min
-1
]
n = Speed differenz [min
-1
]
t
B
= Brake time [ s ]
Power regen resistor
Pmax
P regen [W] = -------------------
K1 x K2

3 Electrical Installation
TV3.2 11
Connection Overview

Transistor-Servo-Drive TV3.230
12
Compact Device
Connection Plan
Multi-axes Combination
230V~ 20V~
o. 24V=

3 Electrical Installation
TV3.2 13
EMC-Advice
The standards EN 50081-2 and prEN 50082-2 will be observed under the following
conditions:
device, mains choke and filter capacitor concuctive fixed on a 500x500x2 mm mounting
board.
mounting board connected to gnd with a 10mm² wire.
device ground X1:7 connected to mounting board with a 2.5mm² wire.
X10:1(-UB)connected to mounting board with a 50mm long 4mm² wire.
Rack-gnd-screw connected to mounting board with a 50mm long 4mm² wire.
Connection one-phase:
Trafo with filter type : TE8/2 F to TE17/3 F
linelength between device and mains filter <100mm
Connection three-phase:
Trafo with filter type : DT3/50 F to DT4/75 F
connection motor :
motor-line chokes type: 5A= MD66-5 10A= MD78-10
motor-line 1.5m long, 4wires shielded. Shield fixed to mounting plate
on device side and to gnd on motor side.
connection control lines:
all control lines shielded 1.5m. Shield fixed to gnd.
EMC

Transistor-Servo-Drive TV3.230
14
Caution:
The connection advice concerning the individual attachments of the connections to the
plug numbers or terminals are binding.
All further advices to this are not binding. The input and output lines can be altered or
completed in consideration of the electrical regulations.
Notice:
- connection advice and operation advice
- local technical regulations
- EU-machine regulation 89/392/EWG
Connection with isolation transformer
Notice:
- rate contactor contacts according to transfomer inrush current.
- delay-action fuses before transformer
- fuse value according to transformer current
- quick fuses after transformer
- fuse value for each power supply unitl max. 30AF
Isolation transformer
Transformer-nominal power [VA]= 1.42 x 115 x IM x GLF x nF
IM = Sum of motor currents (effective)
GLF = coincidence factor
nF = speed ratio factor
GLF = nF =
1 with 1 motor effective speed
0.5 - 0.7 with 2 motors maximum speed
0.4 - 0.6 with > 2 motors
Connection compact device X3
auxiliary voltage
clamp X3:6, X3:7
of isolation
transformer
or external 24V
supply
Connection Advice
LN LN
67
20V~
24V=

3 Electrical Installation
TV3.2 15
Connection at Power Supply X10
alternating voltage 3-phase voltage auxiliary voltage
1x 230 + aux.voltage 3x 230V +aux.voltage
3
0
Dimensions 5A-k 10A-k
Power
supply
10A
Power
supply
30A
Auxiliary
voltage
line cross section mm² 0.5 0.75 0.75 2.5 0.5
fuse protection
blow-out-fuse AF 6 10 10 25 0.5
automattion - B A 6 10 10 25
Motor-Power Connection
cable No. PE M1 M2 M3
connection PE-bolt X3:1 X3:3 M3:3
motor cable with 5A 10A thermo break
cross section 0.75 1.5 0.5 0.5
kable kind 2x motor line + PE shielded
+ (if required: 2x thermo + 2x break)
shielding
- with earth clamp
- directly at switch cabinet entry
- and connect with motor.
- earth manifold with long lines.
ferritte cores
- against HF-failures
motor chokes
- against NF-failures
- against high discharge curent
- for motor efficiency
- for motor operating life
Connection

Transistor-Servo-Drive TV3.230
16
The connecting advices are for general information and without
obligation
Notice:
- Connecting- and operating instructions
- Local regulations
- EU-machine regulation
connection-No. clamps-plugs
X1: 1 up to X1:7 and X2 : 8 up to X2 : 14
Signal lines
Shielded and seperated from power lines.
nominal values paired twisted and shielded.
Logical connections
relay with gold contacts or reed relays. Contact current 6mA.
Enable -internal logical voltage
- internal logical voltage X1:1 +15V/10mA
- contact chain between X1:1 and X1:2
Enable -external logical voltage
- enable voltage +10 ... +30V X1:2
- GND X1:7
Switch on enable
- nominal value and speed controller are enabled immediately.
Switch off enable
- quick stop
- nominal value >>> is switched internally immediately to 0
- after 2 seconds >>> speed controller is locked.
Mains failure- breaking
breaking function
-switch nomianl value in case of mains failure to 0V
-breaking time max. 150ms
generatoric rear feed into intermediate circuit
Connection

3 Electrical Installation
TV3.2 17
Nominal Value-Speed
voltage source for nominal values ±10V,10mA
+10V X1:3
-10V X1:5
GND X1:7
Nominal value input
- nominal value input maximum ±10V=
-differential input
- input resistance 50 kW
- relay contacts: gold- or reed contacts
Caution
Nominal value lines paired twisted and shielded. Screen connection one-sided.
Connection :
Nominal value voltage with internal supply
nominal value X1:4 (signal)
X1:7 (GND)
bridge X1:6 — X1:7
External nominal value voltage SPS/CNC
nominal value X1:4 (signal)
X1:6 (GND)
External nominal value current SPS/CNC
resistance for nominal value current 0 ... ± 20mA >>> R-nominal = 500 W
nominal value current X1:4 (signal)
X1:6 (GND)
Caution:
to not use nominal value current between 4 and 20mA
Nominal Value

Transistor-Servo-Drive TV3.230
18
External current limitation
voltage source for external current limit
+10V/10mA X1:13
GND X1:7
Range
0...+ 5V >>> 0 up to 100% device rated current
0...+10V >>> 0 up to 200% device rated current
internal overcurrent control >>> max. 5sec.
Current limit- input
maximum input voltagel +10V
input resistance 10 kW
Internal attenuation with potentiometer I max1
relay contacts: gold- or reed contacts
switch S1, contact 2 = OFF
Connection
current limit X2:13 (signal)
X1:7 (GND)
Caution:
in case of internal current limit adjustment
switch S1 >>> Contact 2 = ON
Current

3 Electrical Installation
TV3.2 19
Ready for operation signal BTB
Relay RL1
signal contact X2:12 - X2:13
contact values max. 48V, 0.5A
The ready for operation signal (BTB) shows the CNC/SPS
that the drive is ready for operation.
switch BTB- signals of several axes in one row.
delay after switching on mains >>> max. 1sec.
Indication
ready for operation LED green bright contact closed
error LED red bright contact open
BTB turns off with
overtemperature controller, motor stored
overvoltage stored
short-circuit, line-to-earth-fault stored
voltage error not stored
intermediate circuit error not stored
To reset store switch off/on enable
Caution:
Use BTB-contact always with CNC/SPS - control
or with emergency-stop circuit !
Self-starting possible!
fault memory
- is not effective with all faults!
Signal blocked
current demand normal overload
output X2:14 >+12V <+2V
Analogue measuring outputs
function motor current indication speed- indication
connection X2:9 - X1:7 X2:8 - X1:7
measuring value 2.5V = type current tacho voltage
5.0V = peak current before divider
unipolar positive bipolar
output resistance 1 kW4.7 kW
Signals

Transistor-Servo-Drive TV3.230
20
Control connections
Function clamp No.
+ 15 Volt (for enable) X1: 1
enable - input(+10 ... +30 Volt) X1: 2
+ 10 Volt (for nominal value) X1: 3
nominal value + input X1: 4
- 10 Volt (for nominal value) X1: 5
nominal value- input X1: 6
GND X1: 7
speed- actual value- output X2: 8
current- actual value- output X2: 9
current nominal value- output X2: 10
BTB contact X2: 11
BTB contact X2: 12
external current limit input X2: 13
blocked-output X1: 14
Power connections compact device
function clamp No.
motor 1 X3: 1
free X3: 2
motor 3 X3: 3
power X3: 4
voltage X3: 5
auxiliary- X3: 6
voltage X3: 7
Power connections plug-in unit
Function plug-in connector clamp-No.
intermediate circuit - (UB-) X5: 30, 32 ace X3: PE
motor 1 X5: 26, 28 acc X3: 1
free X3:2
motor 3 X5: 18, 20 ace X3: 3
intermediate circuit (UB+) X5: 14, 16 ace
24V~ X5: 8 ace
24V~ X5: 6 ace
Power supply unit plug-in unit
Function plug-in connector clamp-No.
intermediate circuit- PE(UB-) X5: 30,32 ace X10: 1
power U X5: 26,28 acc X10: 2
power V X5: 22,24 ace X10: 3
power W X5: 18,20 ace X10: 4
intermediate circuit+ (UB+) X5: 14,16 ace X10: 5
auxiliary- X5: 8 ace X10: 6
voltage X5: 6 ace X10: 7
Plug-Clamp-No.