Operating Instructions Publikation No. DNG 71149 E Contents 32 33 34 35 36 37 General Special Features Technical Information | Installation Dimensional Drawings Connection Terminal Allocations Mains Conditions Maing Connection Connecting Wiring Connection Example Fuse Protection Directives BBC BROWN BOVERI Noone Axodyn® Speed regulators Types 05 LE 07/08/10/11/20/30.... Three phase, single quadrant operation 86 751961 ‘Axodyn® speed regulator type 05 LE 10. 4, Setting to Work 4.1. Preparatory Work 42. Switching ON and OFF 43 Releasing 44 Current Limitation 4.5 Dynamic Peak Current 48 Torque Reduction 47 Tachogenerator Connection 48 Speed Matching 49 Speed Regulator Optimisation, ‘4.10Speed Limitation 4.11 Supplementary Speed Regulator 5. Other Modes of Operation 5.1 Armature Voltage Control with IR Compensation . 6. Fault Analysis 61 Control Measurements 62 Causes of Faults. 7. As Fitted Components 10 210 110 210 10 210 12 12 13 18 13 14 14 41. General © Fast reaction to drive requirement by dynamic current ‘Axodyn! three phase speed regulators, series O5LE..., @ Release input are motor drive units suitable for motors in a power Torque Retuction range 0.3 to 3 KW. They are for single quadrant @ Tacho control or Armature Voltage Regulation with ‘operation only ~ i.e. driving in one direction only. IR Compensation © Supplementary Speed Regulator Input. 141 Special Features © Three phase transformer input ke Integrated smoothing choke See © Foverreqaton ving Pulse Duraten Mediation cone tecnica data can be ound inthe Genera Information on Series 05 LE Speed Regulators, © Digital current limitation I d © Short circuit proof output ee Table 1 Summary of devices ‘Axoayn® speed 2. supply max rr regulator voltage total power eee Type regulating | power | dissipation | rated® | rated® | dynamic® | power | dynamic and contiol| section | atnormal | dc ac peak | rating —_| peak power section rating voltage | current __| current ve = w ve z a ew raw osieor... zo | 1000/5 30 708 50 72 06 12 os1e 08 zor | 1000/3 60 705 75 = o7 = oie 1 zor | a0/a 120 90 148 20 13 18 wen. zaor~ | a0~ 140 20 178 - 18 = ose 20 zor | _140ra~ 110 170 138 2 23 3a os LE 30 zor | _r20/3— 180 140 250 0 38 56 © permissible tolerances +10 %; ~16 %; 48 Hz..63 Hz ® control range of output voltage: 0..100 % © ambient temperature: 0.+45°C ‘operable: ~10.-+60°C, but power reduction at ambient temp. >+45°C by 2 %/K, {orm factor at rated current $1.05 @ fora duration of up to tia = O8 S at a maximum duty cycle of 5% ~ ‘able 2 Axodyn® speed regulating system for single quadrant operation ‘Axom* motor ‘Axodyn® speed regulator ‘Three-phase mains transformers Type Rated torque | Type OrderNo. | Type OrderNo. | Size Voltages GuRS. avi primisec* Nem WA, vam MATIN 120 OsLE07... | r08000R1 | DTKosa 03101 Re | 063 380/80 MAITH 160 OSLEO7... | t08000R1 | DTKO5a eos ooaRe | 075 360/100, MAIO | 18460 05 LE 08 yorecont | DTK Osa 0300 R2 | 075 380/100, Mig 320 O5LE 10... | t06400R1 | OTK 10a eos00sR2 | 1.90 380/80 Mi9® 3609 Os LETT 106400R2 | DTK 10a ‘08 0052 | 1.90 380/80 es ear 05 LE 20 tostoont | DTK 20a aoso09R2 | 350 380/140 M26 960 0SLE30... | 110000R1 | OTKS0a aoso1R2 | 525 380/120 © applies only for restricted operating cycle; the mean time value must not exceed the rated torque of 160 Nem. ® applies only for restricted operating cycle; the mean time value must not exceed the rated torque of $20 Nem. @ with potential separation to mains (voltage test 2.25 KV~). © available also with other primary voltages 220 V, 440 V, 600 V.c 2. Installation The speed regulators are designed for wall-mounting Ensure that the connection terminals (1 to 16) are positioned only at the top or bottom. ‘The device is secured by means of four holes provided inthe base plate. The minimum length ofthe fixing screws (M4) should be 15 mm. A clearance of at least '50 mm should be allowed above and below the device in order to provide adequate ar circulation (see Fig. 1). IF the permissible ambient temperature of 45°C is not exceeded, forced ventilation by an additional fan is not necessary 2.1 Dimensional drawings and dimensions of the ‘system components The basic format and the fixing holes are the same for models 05 LE 07/08/10/11... Higher powered devices 05 LE 20/30... are a little longer, but the basic format and fixing holes are the same for both. All dimensions are shown in Figs. 2 & 3 and tables 3 & 4. Dimensions in mm LLLLLLLLLLLLL, 3} | " qk Table 9 Speed regulators 05 LE... Dien: ok 5 a osLeO7.. 2 298 28% os LE08 2 295 28 GiEt.. 7 295 281 olen... 7 295 284 E20 7 345 331 051 90 100 348 31 | Lis I al eel = st a 0c yp oS im. | Fig. 1 Mounting clearances es 0 Fig. 2 Dimensional drawing 05 LE 07/08/10/11/20/30.‘Table 4 Three phase mains transformers Type Order No. size Dimensions in mm. Total weight kVA approx. kg ato fe fe fe [t][oln OTK 04a (GIV 1 803 101 R. 0.88) a0 | 160 | 190 | 93 | 80 | aa | 49 | 9 | 11 OTK 5a (GV 1 808 004 F, 07s | 240 | 211 | 250 | 4 | 78 | 77 | s2 | 1 | 16 OTK 10a (GUY 1 809 005 Fi x90 | 2a | 260 | 25 | 193 | wor | oe | o | 1 | 39 ork 20a (GUY 1 809 008 F, aso | 205 | 269 | 205 | tea | 197 | 107 | e2 | 1 | 48 OTK 308 (GUV 1 808 010 R, 525 | 360 | 200 | 360 | tae | 112 | 100] 75 | 11 | 86 3. Connection All the connecting terminals are located in a row at the front of the unit. The connections are made by screw terminals, Pe LE Fig. 3 Dimensional drawing of three phase mains transformers 3.1 Terminal allocations All the devices have the same terminal allocations. The allocations can be seen in Fig. 4 3.2 Mains Conditions ‘Axodyn speed regulators remain fully operable with mains voltage fluctuations of +10 % and —15 %, This applies both to the voltage supply to the regulating and control section and to the power section. ‘The mains frequency is of secondary importance since the voltages in the power section and regulating and control section are rectified internally. In order to counteract brief peak voltages and voltage reductions such as occur in industrial supplies, interference ‘elimination elements are integrated which are adequately effective in normal cases. ‘Axodyn® 05 LE speed regulator 4 islis {ree speed control input ‘actual value input Set point value input electronic earth ower supply (transformer) ‘motor connection: Fig. 4 Terminal connections for Axodyn® 05 LE 07/08/10/11/20/90.. single quadrant speed regulators 4 —VH 220 a.c/32. mA releasing torque reduction +¥H — electronic earth© 3.3 Mains connection ‘Axodyn® speed regulator should be connected to the mains supply as shown in Fig. 5. The regulating and control section must be connected to a 220Va.c. supply, i.e. to one phase and neutral (erminats 15 and 16). Power matching from the mains to the Axodyn® speed regulators is via a threephase mains transformer. ‘The mains transformers listed in table 2 are recommen- ded for this purpose. These transformers wil provide ‘optimum matching of the regulators to the mains supply. Mains transformers are also available for other primary voltages. Figs. 6 & 7 show examples for connection to three-phase supplies of 220 V, 440 V and 500 V. Wiring The dimensions for the power wiring should corres- Pond to the particular current requirement of the devices (see VDE 0100 and tables 1 and 2). The connecting terminals on the Axodyn® speed regulators are designed for single wires of cross-section up to 4 sq mm and multi-cored wires of 2.5 sq mm (except 05 LE 30...: terminals 8 and 9, motor connec- tion, 10 sq mm resp. 6 sq mm). Details for wiring the control leads can be found in table 5 and sections 43 and 46. 3.5 Connection Examples Fig. 8 shows an example of connection for speed contro! by tachogenerator. Speed control other than tacho control is described in section 6. ue } reve =H |?) Example of connection to three phase a. c. mains supply 220 V Fig. 6 Example of connection to three phase a. c. mains supply $80 V Example of connection to three phase a. c. mains supply ‘440 0F 600 VTable § Control leads “Twisted wires upto Inputs/Outputs _| Terminals| Wing 500 mm 7 2s Setpoint speed | S01 Releasing 2 | wth tnaths over potentiometer Shielded cable wth S00 mm screened cable. Sie eer vw twisted intra conductor ecreen on rorque reduction | 1019 | conductors one side of electronic eee ™ ‘Actual speed 24 | carey Use svtchgear wit ow tachogenerator contact reitance (ed Lay leads separately relay, gold point contact) from the mains Free speed 14 | connections Bectronicearth | 4 | Donoteaaht conto input 10 + osteen ‘elesag) Fie. 8 Example of connection for speed regulation with Axodyn® (05 LE O7/o8vt0rtW20/20.© 3.6 Fuse Protection ‘The regulating and control section is internally fused ‘with a 5 @ x 20 mm, 32 mA slow-blow fuse. The power section of the speed regulator is protected by digital current limitation contained in the device. ‘The Input end of the mains transformer can be fused according to table 6. 3.7 Directives In addition to the basic regulations concerning the installation of switchgear, distributors and control gear (VDE 0100/5:78 and VDE 0110), VDE O160 Part 1 and Table 6 Input fusing for three-phase mains transformers Part 2 combined with VDE 0860 Part 5 also apply for ‘combinations of switching devices with electronic ‘components. For control equipment for machining and processing machinery, VDE O113 must also be observed. The user must ensure that the device and its associated ‘components are installed in accordance with these regulations; e.g. installation in a control cabinet. 4. Setting to Work ‘The functions of the components which are referred to in the following chapters can be seen in the simplified circuit diagram, Fig. 9, while Fig. 10 shows the position of ‘the components on the peb. DTKO3a 4A a 2A ~ 2A 2A DIKOSa 4A 2A : 2A 2A Z SCs CEES Ie 4S 44 Té Fig. 9 Simplified cirouit diagram: Axodyn® 05 LE 07/08/10/11/20/90... single quadrant speed regulators. (0s LE oa/tt.-2 no dynamic regulator, 05 LE 08... no IR compensation)Tee jou | | | 8) component layout 05 LE 07. ) component layout 05 LE 08. Fig. 10 ‘Component layout information ‘©) component layout 05 LE 10/t.. ; 84.1 Preparatory work. The following must be checked in a no-volt condition: © Is the three-phase transformer output connected correctly to terminals 6, 6, 7 (see section 3.3)? © Does the output voltage from the three-phase transformer correspond to the connected voltage of the power section of the regulator (see table 1)? © Is the regulating and control section correctly connected to terminals 15 and 16 (see section 3.3)? ‘Are the polarities of the motor and tachogenerator correct (see Fig. 8 and section 4.7)? 4.2 Switching ON and OFF ‘The power supplies to the regulating and section and the power section must be switched on and off together. Switching examples are illustrated in Figs. 5, 6,7 and 8. For the mains contactor a BBC B 1021 (Order No. GH B102 1106V0) may be used, + Releasing Releasing means that the motor remains without current and voltage and can therefore develop no torque. The device is released by connecting terminals 14 and 12 together. This is illustrated in Fig. tta. Fig. 1b shows variation which has the advantage that in the event of bad contact or wire breakage the device goes into the safe, ie, released condition. The conditions specified in table 5 apply for the wiring of the release input. the lead between the switching element and the regulator is longer than 0.5 m, a screened cable with twisted core conductors should be used as shown in Fig. 11 4.4 Current limitation current limit is set at the works to the value of the rated current of the device (see identification plate). If itis required to lower the current an external resistor can be connected (see section 4.6). 4.5 Dynamic peak current ‘The dynamic peak current, which is considerably higher than the rated current, provides the disc armature ‘motor with a greater acceleration torque and thereby shortens the starting time. ‘The settings for both peak current time (max. 0.5 s) and maximum duty cycle (~ § %) of the peak current are permanently fixed. If no dynamic peak current is required, it can be de-activated by removing wire link 1011. Regulators 05 LE 08... and 05 LE 11... do not have dynamic peak current. 10 Contact shown sotreioased fa 1) epentoesease Fig. 11 Alternative connection of release input 46 Torque Reduction The current limit of the regulator can be reduced externally by using terminal 13. This is equivalent to reducing the maximum possible torque of the motor, since with the Axem disc-armature motor the torque of the motor is proportional to the current supplied to the motor. The current limit can be set at will in the range 1:1 to approx. 0: : 1 fa 100 kQ resistor is connected between terminals 13, and 10 the range is 1: 1, and if shorted together the range is O11 It should be ensured that the correlation between the reduced current and the resistance is non-linear. Fig. 12 shows a typical correlation between the resistance and the ratio. The reduction in torque can be achieved both by means of a fixed resistor or a potentiometer (see Figs. 13 & 14). CC 0,2 0,30,40,5 0,81 Fig. 12 Relationship between reduction ratio and resistance 2,0 3,04,05,0 8,010 20 30 40 50 Bo loo Reed. KS f Steck a fa. ‘Torque reduction with a fixed resistor to 4,7 Tachogenerator Connections If the polarities of the motor and tachogenerator are known, they are connected according to the connection example Fig. 8. Ifthe polarities are not known, there are two methods of determining them. The first method is only possible if the motor has not yet been securely builtin and the motor shaft is stil accessible. A d. c. voltage measuring instrument is connected to the tachogenerator and the ‘motor shaft is rotated a few revolutions by hand until the ‘measuring instrument registers a deflection. The polarity of the tachogenerator is determined according to the polarity of the instrument. The polarity of the motor must bbe ascertained by the same principle. The second method can be employed with the motor built in. The motor is connected to the regulator, ‘capacitor C1008 short-circuited and the proportional ‘gain turned to a minimum (see layout plan. Fig. 10, potentiometer R21). The rated voltage must now be A too k s reduced to zero and the connections from the tachogenerator disconnected from the regulator and linked to a d, c. voltage measuring instrument. If the unit is now switched on and the set point voltage ‘gradually increased, the motor wil start to rotate in one direction. If this is the wrong direction it can be changed Fig. 14 ‘Torque reduction with a var ‘Contact shown sotredieed ble resistance by reversing the connections to the motor. The rotary motion of the motor induces a voltage in the tacho- ‘generator which causes a deflection on the measuring instrument. The polarity of the tachogenerator is determined according to the polarity of the measuring instrument. The positive connection should now be made to terminal 4 (or 10), the negative connection to terminal 2. After this has been carried out the original regulating parameters should be reset. 14.8 Speed Matching The regulators supplied with the components listed in table 2 (three-phase mains transformer, motor with tachogenerator F127) are ready for operation without modification. fa tachogenerator is used which has different voltages from the F12T, the actual speed input of the regulator must be matched with this voltage. For this purpose resistors R1008 and R1006 must be Cchanged and the new values are calculated as follows: © Determine the voltage of the tachogenerator (V) at maximum speed (S rated speed of motor). © The total matching resistance (R) can be calculated by the following equation: R= (Vx 24) ko © Divide the calculated resistance between the two resistors R1005 and R1006: 1005 ~ R106 ~ ¥% R The resistors which correspond most closely to the rated values should be soldered onto the insertion Points 1005 and 1006 (see layout plan Fig. 10). ‘Table 7 shows the values of the resistors R1005 and 11006 for various tachogenerator voltages. Table 7 Actual speed matching 1005 1008 ka ka 18 220 220 30 33 39 6 68 82 90 100 120 120 150 150 150 180 180 180 220 220 all resistors: 0.25 W as fitted 2 4.9 Speed Regulator Optimisation On detivery of the regulator, the regulating action is set ‘0 that with loads on the motor of 1 to S-fold inertia moment and the system components listed in table 2, itis possible to achieve optimum performance without the need for adjustments. Only with mades of operation going beyond this might it become necessary to change the circuitry of the speed regulator and the following procedures should be adopted: Changing the proportional gain of the speed regulator: Short circuit C1003. ‘Tum potentiometer R21 (Vp) gradually towards maximum until the system oscillates. © Tum potentiometer R21 (Vp) back to half the former setting, © Remove short circuit from C1003, tan adequate degree of optimization is not achieved, ‘the value of C1003 must be changed. An oscilloscope is required for evaluating the new value, Note: make sure the oscilloscope is at zero potential (isolating transformer in the mains supply or battery operated). The oscilloscope is connected to terminals 2 and 4 (terminal 4 is the electronic earth), Fig. 15 shows different characteristic curves for the actual speed with a stepped set point course. In order to obtain the corresponding characteristic curves, a defined set point step must be applied at the input of the regulator (terminal 3) and the value of C1003 found by the following procedure. © Set the proportional gain as described above. © Connect a capacitor decade in place of C1003 and begin with a high capacitance e. g. 10 uF. © Reduce the capacitance until at a set point step the run of the actual speed curve on the oscillo- ‘scope corresponds to curve 2 in Fig. 16. Over- shooting from 10 to 15 % is permitted. © Solder the new value capacitor in the C1003 position. © R21 0p) too aoa 61003 00 sat ® mat) and.c1005 a optimum © 21.0») too small orc1003 00 grat Fig. 15 ‘Actual speed curvesC 4.10 Speed limitation When supplying the set point potentiometer with the positive auxiliary voltage, itis possible to set higher set Point voltages than required for the maximum speed. In devices 05 LE... c-E, a potentiometer (R61) is fitted in order that the upper speed limit can be set. This is carried out as follows: © Turn the potentiometer R61 to minimum, ‘Turn the set point potentiometer to maximum. @ Tum potentiometer R61 towards maximum until the rated speed of 3000 rpm or any desired lower speed is reached. With devices 05 LE... a-f and 05 LE... b-E, an external potentiometer must be used for speed limitation according to the suggested circuit in Fig, 16 The setting is as described above. Fig. 16 ‘Speed limiting 4.11 Supplementary Speed Regulator ‘An additional input to the speed regulator (terminal 1) with input filter R1012, R1013 and C1014 is. available for special uses. (This input is not available ‘on regulators 05 LE... a). This input can be used for ‘example, for introducing a simple facility for switching to a permanently set speed (rapid or creeping), which independent of the setting of the set point potentio- meter. Fig. 17 illustrates such a speed-change arrangement. ‘itch Lt} eiorz 1019 Fig. 17 Example of speed switching 5. Other Modes of Operation 5.1 Armature Voltage control with IR compensation Ifno high demands are made on the regulating range and regulating accuracy of the drive motor, a tacho- generator is not necessary and the voltage to the motor (armature voltage) can be used as the value for the actual speed. ‘The armature voltage is composed of inner EMF plus a voltage drop across the resistance of the armature winding resulting from the armature current. The arma- ture voltage is used as the value for the actual speed. for armature voltage regulation, but only the internal EMF of the motor is proportional to the speed. This results in a false value IR, dependent on the armature current, which is added to the speed regulation, and this can be balanced, With regulators 05 LE 07/08/10/11 ... the output voltage of the regulator (terminal 9) is fed back to the actual ‘speed input (terminal 2), ¢. terminals 9 and 2 are connected (see Fig. 18a). In addition, resistors R1005 and R106 must be changed in order to match the actual speed input of the speed regulator to the higher voltage. Table & lists the resistance values for matching with various motors. For IR compensation itis also necessary to solder in link 1010 (not possible with 05LE 08...) With regulators 05 LE 20/30... the inclusion of the link 41010 causes armature voltage to be connected to the speed regulator input (see Fig, 18b). The units are then matched to the corresponding motors (05 LE 20... to M23; 05 LE 30... to M26). The adjustment of the IR compensation uses potentio- meter R3 in the following manner: © Set R3 to minimum. Set rated speed when the motor is idling. When at rated speed, bring the motor under ‘maximum load torque and return it to rated speed by increasing R3. The maximum load torque should be less than the rated torque of the. motor. 13Me Bolemtomoter ‘Actual vai ajusiment Aico Rida wa edz met for types 05 LE 7/10/11 (OS LE 08... has no facility for IR compensation) Fig. 18 ‘Armature voltage control with IR compensation Table & Armature voltage regulation for 06 LE 07/08/10/11, Dise armature 1008, 1006, Motor, type ka ka MAIZN 82 a MAT7H 120 120 Mt9P 100 120 all esistors: 0.25 W © 1002 to be reduced to 0016 uF. 6. Fault Analysis The following paragraphs are intended as a guide to ) for types 05 LE 20/30. 6.1 Control Measurements When making control measurements the three-phase transformer must be disconnected from the mains. The voltage supply to the regulating and control section (terminals 15 and 16) must be connected to the 220 Va. c. supply. The voltages listed in Table 8 should be checked with a high impedance instrument. All measurements are related to the electronics earth (terminals 4 and 10) of the regulator. 6.2 Causes of Faults Table 10 shows a list of some faults and their possible 7. As Fitted Components assist the users to analyse simple faults. See Table 1. Table 9 Measurement point ‘Applicable for devices 05 LE. Functions o7/08rtort 20130 Vottages to be measured | Voltages to be measured +140... 160 +110...4180V | positive auxiliary voltage Terminal 12 140... 160 =110..-130V__| negative auxiliary voitage Terminal 3 0..2v 0... HOV speed set point (dependent on sider position of the set point potentiometer) Point of reference: Terminal 4 and 10 4‘Table 10 Couses of faults Fault Possible cause ‘Motor does not turn; no output voltage No mains voltage No set point Release facility has been activated (see section 4.3) Motor under load does not start with rated current Note: turn off the device; overloading of motor Rated speed cannot be reached Motor tums above rated speed; no speed regulation possible Load torque too great Motor shaft blocked Incorrect actual speed matching (see section 4) Load torque too great (current limit reached) Current limitation not matched to the motor (Gee section 4.4) Torque reduced (see section 4.6) No actual speed value incorrectly matched actual speed (see section 4.8) Incorrect actual speed polarity (see section 4.7) Set point potentiometer or supply leads defective ‘Speod fluctuates after change in load Motor reaches speed, but drops again after approx 05 secs, No dynamic peak current No d. . voltage at terminals 11 and 12 Fuse on the pcb defective Components sled athe eran polis ‘Component Value | Function Insertion point R105 ka 22 ‘Actual speed F1008_ka 22 ‘matching R1012 ka | not occupied | Matching of additional 1013 ka. | not occupied | sPeed regulator input ©1002 uF 0.047 | Smoothing actual speed C1003 yr on Integral part speed regulator 1014 uF | not occupied | Smoothing additional speed Fegulator input 1010 not occupied | 1x R compensation 1011 wire tink | dyn. peak current all esistors: 0.25 W_ all capacitors: 160 V ‘Speed regulator not optimized (see section 49) Rated torque exceeded (the required torque Is reached short-term as a result of the dynamic peak current) The drive motor is at the current limit Interval too short Wire link 1011 missing (see section 4.5) Fuse on the peb defective No a,c. voltage (220 V~) to terminals sSand 16 ‘A.C. voltage too high at terminals 1S and 16 8