TECHNICAL INFORMATION Issue 1.01 FOR TRANSISTOR-FOUR-QUADRANT- SERVO-AMPLIFIER TYPE MTR 2800 MTR 5000

Transcription

1 TECHNICAL INFORMATION Issue 1.01 FOR TRANSISTOR-FOUR-QUADRANT- SERVO-AMPLIFIER TYPE MTR 2800 MTR 5000 MATTKE AG Leinenweberstraße 12 D Freiburg Germany Telefon: +49 (0) Telefax: +49 (0)

2 MTR 2800 / Dear customer, We always try to guarantee for an optimum of security measures and to inform ourselves about the latest developments in technical research. However, it is necessary that we pass on the following further information to you as the user of our components: The appliances are supply parts meant for processing by industry, trade or other factories specialised in electronics. Safety precaution!! Attention - do not touch! The appliances have unprotected live parts. The voltage may be highly dangerous. We also have to inform you that, for your own security, only an expert should work on the appliances. In order to comply with the safety precautions, open connections must be protected against contact with cases, coverings or anything similar. Even after the appliance had been disconnected, there may still be a dangerous voltage (discharges of the capacitors). Due to an error in handling or unfavourable conditions, the electrolytic capacitors may explode. If you have to work on the open appliance, do protect your body (hands!) and your face! Make sure that there is enough ventilation because of the fire risk in case of overheating.

3 MTR 2800 / CONTENTS Page 1. General Information Technical Data Survey of Available Models Power Supply Common Data of all Devices Installation and Operation of all Devices Connection Transformer Selection Storage Coils and Protective Coils...6 Table of Transformers and Inductance Coils Ballast Circuit Commutation Current Limitation Installation of End Position Switch and Dynamic Brake DB Connecting the Devices Initial Operation External Poti for Current Limitation Optimisation of the Controller Optimisation via solderable Components Service Component Tables Calculation Aids for Deviating Operating Trouble Shooting Appendix Component Lay-Out Basic Circuit Diagram Circuit Diagram of Pre-Amplifier Device Dimensions - Series Device Dimensions - Series Table of Storage Coils Dimensions of Ballast Circuit and of Dynamic Brake circuit... 30

4 MTR 2800 / GENERAL INFORMATION Transistor servo amplifiers of the 2800 and 5000 series are pulse duration modulated amplifiers mainly intended to control fast servo motors within four quadrant operation. It thereby makes no difference whether disk rotor motors, drag-cup motors or iron armature motors are used. Motors driven by these devices have a completely quit run, high dynamics and a good efficiency. The amplifiers are therefore mainly intended for numerically controlled precision drives and have settings for all possible operation parameters. The devices contain electronic protective gear for protection against all possible over load situations e.g. peak current limitations (static and speed dependant), I 2 t (actual) current limitation as well as safety circuit for overcurrent, overvoltage, overheating and undervoltage. Also built-in is a rectifier which allows direct operation at a three-phase transformer without additional power supply. Also due to the energy saving operation of the outputstage, in most applications the transformer can be seized much smaller than the result of nominal voltage would suggest. Although the devices are small in size, they are nevertheless easy to service due to a totally pluggable board for the electronics and due their simple construction. If necessary, it is possible to mount upto 3 devices next to each other in a 19" rack. 2. TECHNICAL DATA 2.1 Survey of Available Models Device Designation Output- Voltage Nominal Current (1Q- Operation) Effective Current (4Q- Operation) Short Time Peak Current (max. 1 sec.) V 6A 10 A 18 A V 6 A 10 A 18 A A 6 A 10 A 18 A V 17 A 20 A 42 A V 17 A 20 A 42 A A 17 A 20 A 42 A V 25 A 30 A 80 A V 25 A 30 A 80 A V 25 A 30 A 80 A V 40 A 40 A 120 A V 40 A 40 A 120 A V 40 A 40 A 120 A Series 2800 Series 5000

5 MTR 2800 / Power Supply a) Auxiliary voltage 230 V (approx. 40 VA) single phase from network or from additional winding on main transformer. b) Main supply (for output stage) from appropriate three-phase transformer. With 6 A devices, single phase supply is also possible. For exact data refer to transformer table and inductance coil table. 2.3 Common Data of all Devices Voltage range of control inputs ± 10 V maximum input drift ± 15 :V / /C Operating frequency of the pulse duration modulator 7.4 khz IxR-regulation (without tacho) by changing a jumper. Additional input for output stage disable, jumper programmable for closing or opening end position switches. Additional Outputs: a) Auxiliary voltages ± 15 V, 100 ma b) Armature current monitor (Ri = 2.2 KS) ± 10 V = ± full peak current c) Control contacts for dynamic brake and motor contactor d) Alarm contact for servo interference (Closing during operation) Temperature ranges: a) Storage temperature -10 /C /C b) Operating temperature with 100 % load 0 /C /C c) Operating temperature with 80 % load +45/C /C Cooling: Forced air cooling via attached fan Fan monitoring by temperature switch on the heat sinks Electrical connection: Mechanical assembly: Screw terminals Screwed mounting with 4 screws on plane surface Dimensions (length x width x hight) and weight: Series 2800: Series 5000: 260 x 145 x 145 mm, 4.2 kp 320 x 145 x 180 mm, 6.5 kp

6 MTR 2800 / INSTALLATION AND OPERATION OF THE DEVICES 3.1 Connection Transformer Selection Because of the low-loss operation of the devices, in many applications it is possible to size the transformer smaller than first thought. Contrary to thyristor drives, the device only takes active power from the supplying transformer and not reactive power. Since the transformer itself only produces very low stray compared to the nominal power, the consumed power at constant torque is nearly proportional to the speed! This effect is explained by the fact that with small output voltages, the large motor current preferably circulates as reactive power in the inductive coils and charged electrolytic capacitors, and only the hereby generated losses as well as the provedid electrical power must be supplied by the mains. Thus, in all applications where the motor is preferably operated at small or medium speeds, and where high speeds with power-output only occurs for short periods, the size of the transformer can be reduced by 50 %. The transformer may also be dimensioned much smaller with dynamic four quadrant operation only (with triangular speed characteristics), since even with continuous increase and decrease of speed, the average speed cannot exceed a value of 50 %. It is therefore only necessary to have a full size transformer for main drives, where the motor is driven at full nominal power over longer periods (over 5 minutes) e.g. cutting large work pieces at high speed. A complete table of required transformers is contained in the following section. The defined current values refer to full power (100 %) and can be reduced depending on the application Storage Coils and Protective Coils Each device requires an inductance which should not be lower than a certain minimum load inductance without impairing the function. Since many servo motors (e.g. disk rotors) have a negligibly low inductance, suitable selfs are available for these devices to provide the necessary continuity to the output current. When employing selfs, it is recommended to include a coil with half of the desired total inductance into the lines between the motor and the device since in doing so a very good protection against short-to-ground or short-circuits at the motor is achieved.

7 MTR 2800 / For the same reason one should include special protective coils when connecting iron armature motors even if the motor already has sufficient self-inductance. The effect of the protective coils is to limit the speed inrease in case of a short circuit so that sufficient time remains for the overcurrent protective circuit to switch off the output stage. Minimum values of load inductances in mh I nom. / A U Anom. / Volt Table of Transformers and Inductances Coils Device Designation Main Transformer Storage Ind. Coil Protective Ind. Coil Voltage Current Designation Type Designation Type V 5 A D EJ 60/21 BV 10 EJ 60/ V 5 A D EJ 66a BV 10 EJ 60/ V 5 A D EJ 66b BV 10 EJ 60/ V 14 A D EJ 66b BV 20 EJ 60/ V 14 A D EJ 84a BV 20 EJ 60/ V 14 A D EJ 84b BV 20 EJ 60/ V 20 A D EJ 78 BV 30 EJ 60/ V 20 A D EJ 84b BV 30 EJ 60/ V 20 A D EJ 96b BV 30 EJ 60/ V 33 A D EJ 84b BV 40 EJ 60/ V 33 A D EJ 96b BV 40 EJ 60/ V 33 A D EJ 120a BV 40 EJ 60/21 All current values are provided for 100 % transformer utilisation and three-phase connection. For the devices 60-6 to single-phase supply is also possible; the nominal current of the transformer must then be approx. 10 A.

8 MTR 2800 / Ballast Circuit The necessity of this externally connected option is restricted to the 2800 series devices and mainly to devices above 100 Volt nominal voltage; with 60 Volt device it is normally not necessary. This circuit is mainly used when the motor has a good efficiency and also if the total moment of inertia is large. In this combination, when braking, a particularly large portion of the rotational energy is reconverted into electrical energy which can be perceived as excessive operating voltage. The ballast circuitry converts this energy into heat and thereby prevents the attached devices to be switched off due to overvoltage. If several devices of same voltage are installed on one machine, then it is practical to switch the D.C. terminals (terminals 26, 27) in parallel (pos. Pole, terminal 26, only over fuses!) And to connect all of them together onto one ballast circuit (fig. 1). As long as at least one device of the 5000 series with the same nominal voltage is present, a separate ballast circuitry for additional devices of the 2800 series is not required at all, since the ballast circuitry already installed in the large device also works for the other devices. When it is switched in parallel, the load resistor of the circuit has such a low resistance, that only in very extreme cases the voltage limiting effect will fail. In multi-axle systems with different nominal voltages, a ballast circuit must be provided for each voltage group. In this case, only the negative terminals (terminal 27) are connected to each other by cables with large cross sections (fig. 2). When installing the external ballast circuit, be sure that the heat produced by the power resistor (80 Watt) is well conducted. For this reason it is recommended to assemble the unit within the outgoing air device (on the terminal side). Fig. 1: Ballast circuit with tree device of the same voltage Fig. 2: Ballast circuit with devices of different voltage

9 MTR 2800 / Commutation Current Limitation This plug-module is mainly required when traditional iron armature motors are used. Such motors only stand large short time peak currents at low speeds whilst at high speeds and large currents normally very strong commutator sparking occurs, which, in extreme cases, can spark over to the next commutator segment and immediately damage the amplifier. Also, the life time of the graphite brush as well as the commutator is extremely reduced. Therefore, when selecting a motor, it is necessary to regard is commutation limitation characteristics. The plug-module monitors these limits in all operational statuses, whereby is characteristic curve should never exceed the pulse limit characteristics for acceleration and braking defined by the manufacturer The motor characteristics are normally defined as n = f (M) (speed as the function of the produced torque) and must be converted with torque constants and voltage constants as well as considering the ohmic drop to U A = f (I A ) before a direct comparison with the above mentioned current limitation characteristics is possible. Looking at the problem in a simpler way, it is also permitted to determine the limit current at the highest possible speed only, since this is normally the most critical point. When considering it this way, assume that the amplifier is replaced by a constant voltage source which at the time has nominal voltage. Required is the motor current which approaches the commutation limit characteristics. The characteristic curves illustrated on the left all refer to the nominal voltage of the device an to the specified short time peak currents and are not influenced in their principal form by potentiometers within the device. Restrictive influences are only performed by the potentiometers for short time peak current (P6) and for effective current (P7), this is nevertheless not speed dependant, but rather done according to two symmetrical lines which lie parallel to the n-axis and which cross each other. With this, the motor only runs within the limits of the characteristic curves. Fig. 3: Characteristic curves of the commutation current limitation

10 MTR 2800 / Installation of End Position Switch and Dynamic Brake (DB 3) Lots of machines with limited working lift must be protected against accidentally overshooting the working range. For this purpose, an interrupting end position switch must be installed at each end of the working range and a dynamic brake (option DB 3) must be installed at the device. In addition, jumper Stbr. 2 must be changed to ext (change jumper only on currentless device). The method of operation for this arrangement, is that when the end position switch is activated first of all the output stage of the devices disabled. After a safety pause of approx. 1 ms has expired, a contact closes (terminal 17-18) and ignites the thyristor of the dynamic brake. Thereupon, the thyristor short-circuits the motor via a low resistant protective resistor which allows the motor to brake quickly. Since after activating the brake circuit the thyristor only deletes when the motor has come to a stillstand, the device contains a pause circuit which enables the output stage 1 sec. After the disable command has expired. This prevents the output stage to be short circuited by the still ignited thyristor (e.g. in the case that the end position switch in only activated for a short time). The dynamic brake also works with a currentless device but not when the servo interference is activated, (e.g. due to overvoltage). If activation is also required in such a case, then the alarm contact for servo interference (Terminal 19-20) must be included in the end position switch (fig.5). Fig. 4: Connection of the dynamic brake DB 3 (Activation by pressing end position switch and by power outage) Fig. 5: Connection of the dynamic brake (Activation by pressing end position switch, by power outage and by servo interferences)

11 MTR 2800 / Connecting the devices To prevent reactions or mutual interferences but also for protecting the drive and control one must consider a few important points when connecting pulse duration modulated servo amplifiers. a) Cable routing and Grounding Assure, that power cables (power supply, motor cables, inductance cables) are routed as far away as possible from the control lines (speed set value, tacho, ext. Current limitation, end position switch). The two types of cables should be routed in separate bunches and in separate cable channels. Note, that for grounding cables, the largest possible cross section and the shortest possible length is used. Routing should not be together with other cables, rather on their own since, in most cases, this allows shorter cables to be used. The storage coil should be mounted as close to the associated device as possible and the cores should be grounded there. With multi-axle operation, all devices should be mounted on a common mounting plate and grounded via a grounding terminal located directly next to the device. The normal way of routing grounding cables to a central point is not efficient due to the interferences caused by long cable lengths. The grounding of the motor housing and of the controller must also be attached to the prior mentioned mounting plate, but over dedicated cables; connection to other parts of the machine may be a danger for the device and for the controller in case of a short-to-ground due to possible coats of paint. b) connecting the control cables the two poles of the tacho generator may only be attached to the associated terminals at the servo amplifier (terminals 5+6). If the tacho signal is also required in the controller, then, with lower precision requirements, this can be taken from terminal 6; reference zero is in this case ground. If the ground coupling with the output stage causes interferences, then a differential amplifier must be provided in the controller. The inputs of the amplifier can then be attached in the desired polarity parallel to the tacho generator. The input control lines must always be lead to the controller as bipolar lines, otherwise, with reference to 0 V at the devices (terminal 7), reaction are nearly inevitable. Hence, the cold end of the control inputs must not be zero, but at the reference potential of the controller. An electronic ground which is routed through the entire machine is in comparison not advantageous. The reference potential of the controller should be attached to ground within the controller and the ground connection again directly to the ground connection of the servo amplifier (mounting plate). The shielding of the tacho cable is attached to the device. The shielding of the control cables can be attached either to the controller or to the device, but not to both. If active components (operational amplifiers) are present at the output of the controller, then connection of the shielding to the controller is more advantageous (in this case the controller, as well as the device, must be grounded). If nevertheless only passive

12 MTR 2800 / components are used for controlling (e.g. potentiometer and switches), then it is better to connect the shielding of the feed line to the device. Fig. 6: connection suggestion for two axes

13 MTR 2800 / Initial operation External Poti for current limitation For initial operation, a potentiometer (10 ks lin.) can be attached to the devices which allows the maximum short time peak current to be reduced to zero. Hereby, the risk of possibly connecting the machine incorrectly is reduced. The potentiometer reduces the armature current set value which is generated by the speed controller. For an analogous correct functioning (right stop = full current) the potentiometer must be connected, assuring that the left end is attached to terminal 7, the slider to terminal 8 and the right end to terminal 9. Before switching the device the first time on, the potentiometer is set to left stop position and is advanced during initial operation. After initial operation has been performed, the potentiometer is taken away and replaced by a jumper between terminal 8 and Optimisation of the controller If the requirements regarding the controlling features are not all that high, then a good alignment can be achieved with the standard circuitry even without using an oscilloscope. For such an alignment proceed according to the following scheme: a) Tacho adaption ( only with tacho regulation) 1.) Decouple motor of machines with limited run-time if possible. 2.) Potentiometer P5 (gain) in middle position. Potentiometers P1, P2 (inputs) and P6 (short time peak current) rightstop position. External potentiometer (current limitation) left-stop position 3.) Issue input voltage 0 V and switch in the device. 4.) Advance external potentiometer slowly and observe motor. When the motor accelerates, turn external potentiometer back left-stop and after motor stillstand change polarity of tacho lines. Then advance potentiometer again. The motor must stand a holding torque or should only drift slightly. 5.) Advance potentiometer approx. 1/3 and issue maximum input voltage (e.g. 10 V). Measure the speed of the motor and align to the desired nominal value (e.g RPM) using P3 (tacho alignment). b) Offset alignment (only with tacho regulation) Connect the controller as described, but switch off the position loop. Issue input voltage 0 V and remove drift with potentiometer P4. c) Alignment of the IxR compensation (only with IxR regulation) 1.) Change jumper Stbr 1 to position IxR. Potentiometer P10 to left-stop, P5 in middle position, P1, P2, P6 to rightstop. External Potentiometer to left-stop. 2.) Issue input voltage 0 V, switch device on.

14 MTR 2800 / Advance external potentiometer approx. 1/3 and roughly remove drift with P4. 3.) Turn motor manually and at the same time advance P10 slowly. Advance P10 only so far to allow the motor to rotate slowly. If P10 is turned too far, the motor reverses oscillates. 4.) Adjust drift with P4 again. d) Amplification alignment 1.) Load motor with smallest flywheel mass used in operation. Preset decided short time peak current at (distribution is linear between 19 % (at left-stop) and 100 % (at right-stop), whereby 100 % represents the specified short time peak current). Advance external potentiometer fully or insert jumper between terminals 8 and 9. 2.) Turn to P5 to the far right (motor must howl strongly) and then immediately back until the howling stops. Do not turn further to the right. 3.) Issue approx. 2/3 of the maximum imputed voltage. If strong vibrations can be heard (also by attaching oscilloscope to terminal 10, armature current monitor, check ripple: A.C. portion max 5 V pp ) then turn P5 even further to the left. e) alignment of the effective current limitation 1.) If selfs are provided with the required minimum inductance, then switch off the device, disconnect the motor and instead attach a moving iron amperemeter behind the inductance coils. If storage coils are not available, then simply switch the amperemeter in series to the motor and block the motor mechanically. Never short circuit the device output without an inductance coil! 2.) Provide square wave voltage (approx. ± 2 V, 1 Hz) and switch device on. After a short overcurrent period (approx sec., depending on position of potentiometer P6) the current will reduce itself to the device nominal value and the red LED D7 illuminates. 3.) Set the effective current by rapid step-by-step adjustment of P7. After each adjustment a certain time period elapses until the circuit has adapted itself to the new value. During this time, the current value is zero or it is equal to the set pulse value. f) Peak current limitation 1.) Connection and activation as described in e) except that a switch is used between terminals 8 and 9 instead of a jumper. First the switch is opened. 2.) Switch on the device and do not use for half a minute. 3.) Short-circuit switch and set desired pulse value at P6. Since the effective current limitation is activated after a short time, it is necessary to react quickly.

15 MTR 2800 / ) If the setting procedure could not be carried out in time, then open the switch again for about ½ minute and repeat point 3. g) Amplification of the armature current controller(p11) if the specified minimum load inductance is available, then this potentiometer must be set to left-stop position. Only with very much larger load inductances is it possible to improve the slightly impaired controlling dynamics (especially with relatively small short time peak currents) by advancing the potentiometer. The amplification limit is noticeable by oscillation within the frequency range of 1-4 khz during the acceleration pulses. h) Other potentiometers Depending on the type of device there are one to two additional locked potentiometers contained in the devices which for operational safety reasons are not allowed to be adjusted. They determine the switching thresholds of the overcurrent safety circuit and of the ballast circuit Optimisation via solderable components for certain applications, especially for those with high precision requirements and repetitive accuracy, the above mentioned alignment via potentiometers is not sufficient. The most important alignment determining components are therefore mounted on solder pins, designated appropriately and can be easily changed if necessary. With appropriate dimensioning, one can nearly do without potentiometers i.e. these are then set to stop position. With this method one achieves the best possible repetitive accuracy with least expense of work. The only inevitable exceptions are the potentiometers for offset-, tacho- and IxRalignment, since these parameters are submitted to tolerances either on behalf of the device or on behalf of the motor and have to be adjusted locally in any case. For the alignment of the other features, a storage oscilloscope and an amperemeter are necessary. Set potentiometers P1, P2 (set value inputs), P6 (short time peak current) and P7 (effective current) to right-stop position. Potentiometers P5 and P11 (amplification of speed controller and current controller) must be set to left-stop position. Determining the values of the components can be performed as follows. a) Tacho adaption, offset alignment and IxR compensation proceed as described in section b) Short time peak current limitation (R144) With fully advanced potentiometer P6 and missing resistor R144, the short time peak current Î max. is exactly 100 % of the specified value (refer to section 2.1). By installing R144 this value can arbitrarily be reduced. The interrelationship can be expressed as follows:

16 MTR 2800 / I$ R144 = 10 kohm $I ax I$ m. An influence on the effective and commutation current limitations does not exist. C) Effective current limitation (R145) With fully advanced potentiometer P7, the maximum permittable effective current for the 4-quadrant operation is just achieved with the standard circuitry. If currents are required, which deviate from these, then R145 can approximately be determined with the following equation: R145 = Ieff $I m ax. 11. I 2 2 eff 47 kohm The specified maximum short time peak current Î max. must also be employed if the actual peak current was reduced by P6 or R144. The accuracy of this equation is nevertheless limited, especially with current reductions to very small values. The calculated value must therefore be checked on its exactness and if necessary it must be corrected (refer to section e). The deviation is caused by the limited possibility to simulate the square characteristic curve with a network of Z-diodes. The repetitive accuracy from device to device is nevertheless higher which means, that a value found once can be upkept. d) Frequency response of the speed regulator To completely determine all components, to begin with, one must short circuit C4 and R22 and remove capacitor C5. The oscilloscope is attached to TP5 (armature current monitor) and the reaction of the device is examined when issuing startstop pulses (e.g.. 0 V / 1 V, 1 Hz). Every acceleration and brake procedure generates a pulse at test point 5. The variation in time of the pulse provides information regarding the dynamic reaction of the servo drive. The goal of the alignment is to make these pulses trapezoidal, whereby, as delimiting factors, the inductivity of the load, the torque stability of the tacho coupling or the ripple of the tacho voltage become effective. The edge steepness of the trapeze is approx. 500 as/10 V at minimum load inductance. R24 - A.C. amplification if the reverse edges of the pulses line-up into the zero line as an e-function, then this resistor has to be increased. If a triangular damping is recognized, then it must be

17 MTR 2800 / reduced. Once a value has been found which determines the desired behaviour, one must check whether the ripple of the tacho voltage is small enough at high speeds. The A.C. portion at TP5 should not exceed 5 V pp, otherwise the motor doesn`t run so quiet and the current form factor is not very good. If the A.C. portion exceeds this value, then either the control bandwidth or the total A.C. amplification must be reduced. Depending on the type of interference frequency either the one or the other proceeding is of more significance. A further complication which may arise during this alignment is also the occurrence of torsional resonances especially with disk rotor arrangements. This feature can be recognized by obstinate buzzing the frequency of which can hardly be influenced even by changing R24. In this case, the control band width must also be reduced. One should always try to achieve a high value for R24, since this is positively perceptible especially when interrelating with the integration capacitor C4. C5 - Limitation of the control bandwidth Without capacitor C5 the control bandwidth is 1 khz. With torsional resonances, excessive inductive phase angle rotation or too high tacho voltage ripple, a reduction of the bandwidth may be advantageous. The capacitor (C5) to be built-in should remain as small as possible since it amplifies the overshoot feature. After employing C5, one can nevertheless also increase resistor R24 which again has a positive effect on the control behaviour. To determine the correct value for C5, a resistor and capacitor decade should be connected instead of R24 and C5 to exactly determine the required combination in which R24 has the largest value without torsional resonances or without excessive overshoot occurring. Determining the right combination requires a certain amount of experience. C4 - Integral - behaviour On principle, one can say that the smaller C4 is, the higher the torque stability of the motor shaft is when loaded. At the same time, the settling time decreases according to a pulsewise load, whilst the size of the overshoot increases slightly. For operation of the device as a non-guided speed controller, C4 should be chosen so that the current curve approaches the zero line as fast as possible after a single overshoot. If the device nevertheless lies within a position loop, then C4 should be increased so far, that a speed-overshoot is just prevented when approaching the set position. If the value for C4 are too small, then over-shoot continues. On the other hand, if the value is too large, then line-up in the exact final position is delayed unnecessary. R22 - amplification when operating the device as speed controller, this resistor must be short circuited, since it causes a limberness when the motor shaft is loaded and thereby reduces the speed control ratio. If the device is nevertheless used as a servo component (controller) in a superposed position loop, then this feature is desired. Whereas, with short-circuited R22, the motor shaft, after short excursion, is pulled into zero position again. This is done with full force after a sudden load has assured. The shaft then makes the same kind of movement in the other direction when it is suddenly released. With increasing R22 a certain static stability is defined, i.e. by how many degrees (per Newtonmeter load) the shaft limbers. From a certain value of R22 on, there is no more

18 MTR 2800 / overshooting over the zero position in case of a sudden relief. R22 also helps to achieve a line-up into a new set position without overshoot. The value required for this purpose also depends on the size of the A.C. amplification (R24). With increasing R24, R22 can become smaller without overshooting appearing. 4. SERVICE 4.1 Component Tables The control electronic of the devices as well as of the ballast circuit contains some components which are mounted on soldering pins. These components together with other units within the basic device define the operating data and limit values. The control modules of all device types only differ by these components and therefore can be converted for other types of devices in emergency cases. A conversion within a device group (same measuring resistors within basic device) is also possible, whereby only a reduction is permitted, since, in other case, the device would be loaded in a range in which it was not tested. Table of components of the ballast circuit Nominal Voltage R1 R4 R5 R12 R13 R17 R18 Output stage transistor 60 V 3,9 K 100 K 100 K 3,3 K 330 Ohm 3,9 K 3,9 Ohm BUL V 6,8 K 100 K 150 K 4,7 K 470 Ohm 6,8 K 3,9 Ohm BUL V 12 K 180 K 220 K 6,8 K 680 Ohm 8,2 K 5,6 Ohm BUL 5025 Type Tolerance KH % SBB % SBB % LH % KH % SBC % HL-80 5 %

19 MTR 2800 / Table of Components for the basic device including control electronics Device Designati on R40 R41 R60 R61 R125 R145 R148 R149 R154 R155 R189 Overvoltage D27 D28 Unde r- volt. D29 Limiter Ballastcircuit Shunt within Output Stage Charging Elec.Capac. Driving transistor Output stage Transistor K 60.4 K 6.8 K 22 K 47 K 15 S 100 K V 33 V 105 V 0.1 S 2500 :F/100 V --- 4x BUL K 100 K 12 K 22 K 68 K 1.2 K 150 K 75 V 75 V 47 V 135 V 0.1 S 1850 :F/150 V --- 4x BUL K 169 K 22 K 22 K 120 K 6.8 K 270 K 100 V 120 V 100 V 205 V 0.1 S 1000 :F/200 V --- 4x BUL K 6.8 K 15 K 47 K 15 S 100 K V 33 V 105 V 0.02 S 2500 :F/100 V 4x BUL x BUL K 12 K 15 K 68 K 1.2 K 150 K 75 V 75 V 47 V 135 V 0.02 S 1850 :F/150 V 4x BUL x BUL K 22 K 15 K 120 K 6.8 K 270 K 100 V 120 V 100 V 205 V 0.02 S 1000 :F/200 V 4x BUL x BUL K 6.8 K 12 K 47 K 15 S 100 K V 33 V 105 V 0.01 S 4100 :F/100 V 4x BUL x BUL K 12 K 12 K 68 K 1.2 K 150 K 75 V 75 V 47 V 135 V 0.01 S 2600 :F/150 V 4x BUL x BUL K 22 K 12 K 120 K 6.8 K 270 K 100 V 120 V 100 V 205 V 0.01 S 1500 :F/200 V 4x BUL x BUL K 60.4 K 6.8 K 8.2 K 47 K 15 S 100 K V 33 V 105 V 0.01 S 4100 :F/100 V 4x BUL x BUL K 100 K 12 K 8.2 K 68 K 1.2 K 150 K 75 V 75 V 47 V 135 V 0.01 S 2600 :F/150 V 4x BUL x BUL K 169 K 22 K 8.2 K 120 K 6.8 K 270 K 100 V 120 V 100 V 205 V 0.01 S 1500 :F/200 V 4x BUL x BUL 5025 Type LH Tolerance 5 % 1 % 5 % 5 % 5 % 10 % 5 % 5 % 5 % 5 % 1 % Additional exchangeable components, identical within all devices: R22: 330 S C4: 0.1 :F C5: 4.7 nf R24: 150 ks

20 MTR 2800 / Calculation Aids for Deviating Operating Data Some applications require device output data which are not available as standard. Since especially the maximum output voltages only limited by the size of the applied operating voltage, it may be necessary to adapt the devices to an altered operating voltage. Only reduction is hereby allowed. The tolerance range for a reduction of the nominal voltage without alterations to the device is 20 %. An increase of the operating voltage over the common network overvoltage of +5 % is not permitted and mainly danger the ballast circuit. Hence, if the nominal voltage is to be reduced by more than 20 %, then other components must be used than the ones installed as standard. The data can be calculated with the following equations. a) Transformer voltage Device internal voltage drop approx. 10 V const.; the required transformer voltage is then: UTeff = 071. ( UANom + 10V ) but max 125 V eff b) Transformer nominal current Essential for this is the electrical continuous power which is provided to the motor by the device (compare section 3.1.1). For the unlimited continuous operation at full output voltage the following equation is relevant: I T = IANom (I ANom is the continuous output current of the device) c) Voltage standardization of the control electronics 10 K R60 = R61 = UANenn 1 kohm 10V d) Switching threshold of the overvoltage safety circuit This threshold must not only conform to the voltage stability of the installed electrolytic capacitors, transistors or to the ballast circuit, but must also be changed of other components (especially in the driver circuit) are changed due to the new operating points. The size of the cutoff voltage is determined by the Z-diodes. D27 and D28. UD27 + UD28 = UANom+ 50V e) Undervoltage switching threshold When dimensioning this threshold, one must consider network voltage fluctuations (-10 %) as well as voltage drops which are caused by loading by loading the transformer. The lower limit lies at 33 Volt. For even lower voltages one must reduce'ce resistors built in the driver circuit. The switching threshold is determined by Z-diode D29. UD29 = UANomn 50V but min. 33 V

21 MTR 2800 / Switching threshold of the ballast circuit This threshold conforms to the size and accuracy of the overvoltage switching threshold of the devices. It should be dimensioned so that the switching point of the ballast circuit lies approx. 4 Volt under the lower tolerance limit of the Z-diodes for overvoltage. With switching thresholds below these, there is the danger that even with slight network overvoltages, the ballast circuit doesn`t switch off anymore. The resistor burns within seconds. UBallast = UD27 + D28 15V (Upper switching point) f) Peak current standardization An alteration should not be performed since all device features, involved with the output current e.g. peak current, effective current, commutation current limitation etc. Apart from the switching threshold for the overcurrent safety circuit, depend upon it. An alteration of these parameters should always be carried out at the appropriate potentiometers or fixed resistors, and not at the total standardization. 10 K R40 = R41 = I$ RS 100 Ohm 10V (R S = Shunt in basic device) g) other components R 125 UANom = 8 ma R R U = R = U = R = V 15, ma ANenn 80V 15 ma ANom R 189 UANom 5V = 064. ma

22 MTR 2800 / Trouble Shooting a) Error message contact The isolated reed contact between terminals 19 and 20 is only closed if the device is ready for operation. This contact as soon as the safety circuit identifies an error or if one of the power supplies breaks down. The disable input (terminals 13, 14) is not influenced. b) LED D26 (red) - Overcurrent This LED can not be addressed during normal operation due to the fact, that the associated switching threshold lies a few percent above the maximum possible peak current (the setting for this, at potentiometer P12, is done during manufacturing). Only, if in the event of a connection error, motor error or device error a higher current flows, the overcurrent safety circuit is triggered, the output stage is switched off quickly and LED D26 is addressed. Although this circuit is provided, the devices are not totally short-circuit proof. If e.g. a short-toground occurs at the output during operation, then the switching off of the saturated output stage takes so long, that one can normally not prevent the output transistor from being damaged. On the other hand, the circuit operates very reliable if the error was already present when switching on the device. In this case, LED D26 illuminates immediately after applying the operating voltages. Nevertheless, this procedure should not be performed too often since extremely large current pulses flow through the transistors (upto 300 A at full operating voltage!) Which can lead to an ageing of the transistors. If, due to the illumination of D26, a defect output stage is suspected, then this can be examined in the following way. The device must first of all e disconnect at terminals and not used for at least 10 minutes to allow discharge. Then, the output stage can be tested using an ohmmeter (switch to low resistance range). Hereby, all of the below listed combinations must be checked in both polarities. In one direction one must always be able to measure the voltage drop of a silicium diode attached in conducting direction (needle deflection approx. 2/3), whilst when changing polarity of the ohmmeter, the needle deflection must nearly fall back to zero again after a short pulse. The pulse is initiated by reloading the charging electrolytic capacitor, whilst the rest deflection (approx. 1 kohm) is caused by the load of the electronics. The deflection itself must be the same with all four combinations left back left front 28 left top left bottom 29 right back right front 29 right top right bottom Measuring schema for series 2800 Measuring schema for series 5000 the locations defined in the tables refer to the appropriate transistors. The output stage transistors in the devices of the 2800 series are mounted on plug in sockets and can easily be exchanged without soldering. When exchanging the transistors one must assure that the pins fit well into the sockets which must be readjusted if necessary. In the large devices (5000 series), sockets can not be used due to the parallel switching of output-stage transistors. For repairing the outputstage the device must therefore be opened. Within a quadrant, only transistors with the same identification colour may be used. c) LED D32 (yellow) - Overvoltage

23 MTR 2800 / This diode can normally only be addressed with devices of the 2800 series if they run without ballast circuit. In this case, the operating voltage can reach values, which, when braking the motor, are so high, that operation has to be aborted otherwise the output-stage would be indanger. The installation of a ballast circuit helps to prevent such a case. d) Both LED's D26 + D32 - Undervoltage or overtemperature This indication occurs e.g. if the power supply for the output-stage is missing or if the size of the voltage is not sufficient. If there is an error in the power supply, (e.g. failure of one of the three phases), then this can be noticed by short-term flashing during run-up of the motor. An activation caused by overtemperature should normally not occur, since the ventilation is so sufficient, that the switch-off temperature (95/C at the heat sinks) is never reached under normal operating conditions. Although this limit value is high, one should assure a good ventilation of the switch cabinet so that this value is not reached, since semi-conductors thereby incline to age. e) LED D7 (red) - Effective current This diode signalizes when the load limit of the device is reached. The device is thereby not switched off, rather, it reduces the peak current itself, so far, that the effective value is not exceeded. If during initial operation (especially with drives calculated with small power tolerances), after a certain run-time, this diode illuminates now and then, one can normally help oneself by reducing the peak current a bit via potentiometer P6. Although slightly longer run-up and braking times are optained, the times for the total cycle with equal effective current are still better. One should therefore try to achieve a triangular speed-time diagram. f) LED D4 (green) - Ballast Circuit Diode D4 signalizes that the ballast circuit is in operation i.e. it is indicated when surplus energy is being derived. In general, this is produced by the rotating masses at the motor shaft whereby during braking, this rotational energy can not be returned into the network, it is transformed into heat within a special load resistor. D4 should therefore only illuminate when braking the motor from high speeds, possible also at the end of a run-up procedure (overswing) but never at standstill. This leads to the conclusion, that operating voltage is too high, which over-loads to the load resistor.

24 MTR 2800 /

25 MTR 2800 /

26 MTR 2800 /

27 MTR 2800 / Air Intake Device Dimensions Series 2800

28 MTR 2800 / Air Intake Control Electronics Ballast Circuit Device Dimensions Series 5000

29 MTR 2800 / Data sheet of selfs Inductance Coil Desigantion Inductance Coil Core Size a b c e f h D EJ 66 a D EJ 66 a D EJ 66 b D EJ 66 B D EJ 84 a D EJ 84 b D EJ D EJ 84 b D EJ 96 b D EJ 84 b D EJ 96 b D EJ120 a

30 MTR 2800 / Ballast Circuit Dynamic Brake DB 3