Operating Instructions
TBL99_24-GB1299
Part-No. 00158692-GB
1 / 23
Dcontrol
Type PKDT
Controllers for voltage-regulated
3-phase motors
Applications:
•
Speed controls for fans in refrigeration, air-conditioning
and clean-room engineering
•
Pressure / temperature controllers for refrigeration engineering
Seller:
Big Dutchman International GmbH
P.O. Box 1163
D-49377 Vechta
Phone: +49 (0) 44 47 / 801-0
Fax: +49 (0) 44 47 / 801-237
e-mail:
big@bigdutchman.de
internet: http://www.bigdutchman.de
Serial no:
from Software D1059A00 (PKDT5) D1085A00 (PKDT12)
Year of construction: 1998 onwards
Operating Instructions
Date 12/99
Controllers for voltage-regulated 3-phase motors, type PKDT
TBL99_24-GB1299
Part-No. 00158692-GB
2 / 23
Contents
1. General ..............................................................................................................................................4
1.1 Copyright .............................................................................................................................................................. 4
1.2 Basis for device construction................................................................................................................................ 4
1.3 Directions for use ................................................................................................................................................. 4
1.4 Transport and storage .......................................................................................................................................... 5
1.5 Obligations of owner............................................................................................................................................. 5
2. Safety measures ...............................................................................................................................5
2.1 Symbols and information...................................................................................................................................... 5
2.2 Electrical/electronic equipment............................................................................................................................. 6
2.3 Testing in accordance with accident prevention directives .................................................................................. 6
2.4 Accessories, spare parts ...................................................................................................................................... 6
2.5 Manufacturer address, service address ............................................................................................................... 7
3. General description / Programming of functions...........................................................................7
3.1 Scope of applications ........................................................................................................................................... 7
3.2 Programming the desired function (speed regulating rheostat / controller) ......................................................... 7
3.3 Technical data ...................................................................................................................................................... 8
3.4 Controls ................................................................................................................................................................ 9
4. Installation ......................................................................................................................................11
4.1 Wall-mounting .................................................................................................................................................... 11
4.2 Outdoor installation of devices in housing version (IP54) .................................................................................. 11
4.3 Installation in a switching cabinet ....................................................................................................................... 11
4.4 Installing the temperature sensor TF..(KTY10-6)............................................................................................... 12
4.5 Installing the DSF pressure sensor (refrigeration engineering, output 4-20 mA) ............................................... 12
4.6 Temperature influences during commissioning ................................................................................................. 12
4.7 Systems with current-operated circuit-breaker................................................................................................... 12
4.8 Potential of control voltage connections............................................................................................................. 12
4.9 Radiating interference / cable installation........................................................................................................... 12
4.10 Electrical installations ....................................................................................................................................... 13
5. Electrical connections (refer also to the connection plan in section 9.1) ..................................13
5.1 Mains connection ............................................................................................................................................... 13
5.2 Motor connection................................................................................................................................................ 13
5.3 Motor noise......................................................................................................................................................... 14
5.4 Motor protection ................................................................................................................................................. 14
5.5 Remote control / remote lockout (only type PKDT12) ........................................................................................ 14
5.6 External speed setting (operation as a speed regulating rheostat) .................................................................... 14
5.7 Sensor Connection (operation as a controller)................................................................................................... 15
5.8 Operation and fault indications........................................................................................................................... 15
5.9 Voltage supply for external equipment ............................................................................................................... 15
5.10 Output voltage( 0 )- 10 V (needed only as required) ........................................................................................ 15
Operating Instructions
Date 12/99
Controllers for voltage-regulated 3-phase motors, type PKDT
TBL99_24-GB1299
Part-No. 00158692-GB
3 / 23
6. Settings for operation as speed regulating rheostat ...................................................................16
6.1 Adjusting the minimum output voltage “n-min” (basic speed) ............................................................................ 16
6.2 Adjusting the maximum output voltage “n-max“ (speed limiter)......................................................................... 16
6.3 Setting the speed by the internal potentiometer “SET” ...................................................................................... 17
6.4 Setting the speed setting by an external signal or an external potentiometer.................................................... 17
6.5 Operation with two variable output voltages (2 steps)........................................................................................ 17
7. Settings for operation as a controller (standard factory setting) ...............................................17
7.1 Adjusting the minimum output voltage “n-min” (basic speed) ............................................................................ 17
7.2 Adjusting the maximum output voltage “n-max“ (speed limiter)......................................................................... 18
7.3 Adjusting the control range “Pband” (response rate) ......................................................................................... 18
7.4 Adjusting the nominal value “Set”....................................................................................................................... 19
7.5 Minimum airflow rate .......................................................................................................................................... 19
7.6 Reversed heating / cooling action (special function) .......................................................................................... 19
8. Faults and rectification of these....................................................................................................20
8.1 Mains fault .......................................................................................................................................................... 20
8.2 Temperature fault ............................................................................................................................................... 20
8.3 Motor faults......................................................................................................................................................... 20
8.4 Sensor-signal faults............................................................................................................................................ 21
8.5 Selection speed regulating rheostat / controller doesn´t work............................................................................ 21
9. Enclosure ........................................................................................................................................22
9.1 Connection diagram ........................................................................................................................................... 22
9.2 Connection suggestion for several motors with motor protection unit type STDT ............................................. 22
9.3 Dimensions sheet............................................................................................................................................... 23
Operating Instructions
Date 12/99
Controllers for voltage-regulated 3-phase motors, type PKDT
TBL99_24-GB1299
Part-No. 00158692-GB
4 / 23
1. General
1.1 Copyright
The copyright for these operating instructions remains with
ZIEHL-ABEGG GmbH & Co. KG, Künzelsau
These operating instructions are intended for assembly, operation, monitoring, and maintenance personnel. They
contain technical descriptions, directives, and drawings which shall be neither completely nor partially duplicated or
distributed. They shall not be used without authorisation for competition purposes or passed on to third parties.
Infringement shall result in the obligation to pay damages.
All rights reserved, especially if patents are granted or other forms of registration are submitted.
Subject to technical modifications.
Please note that these operating instructions refer to the device only and do
not apply to the entire system!
ZIEHL-ABEGG GmbH & Co. KG, Künzelsau
1.2 Basis for device construction
The device is constructed in accordance with:
The stipulations specified in the contract, e.g. design, choice of device components, and accessory selection.
The current state of technology and the recognised safety regulations.
Nevertheless, use of the device is associated with dangers which may cause death or injury to users or third
parties as well as damage to the system and other objects.
¡
The device is intended exclusively for the tasks listed in the order confirmation. Any other or extraordinary uses
of the device (unless previously agreed by contract) are considered contrary to regulations. The manufacturer
is not liable for damages resulting from incorrect use. The operating company alone bears the risk.
Observance of the procedures described in these operating instructions for assembly,
operation, and maintenance is also required for compliance with the specified use
.
1.3 Directions for use
¡
To allow for future developments, construction methods and technical data given are subject to alteration.
¡
We do not accept any liability for possible errors or omissions in the information contained in data, illustrations
or drawings provided.
¡
Before commissioning the device, ensure that you first read the information concerning assembly, adjustment,
operation, and maintenance.
¡
Apart from the operating instructions and the obligatory regulations to be followed by users relating to accident
prevention, the recognised technical regulations must also be observed (safety and branch-related work as per
UVV, VBG, VDE, etc.).
Operating Instructions
Date 12/99
Controllers for voltage-regulated 3-phase motors, type PKDT
TBL99_24-GB1299
Part-No. 00158692-GB
5 / 23
¡
Apart from these operating instructions, the information supplied by the manufacturer concerning components
(e.g. sensors) must also be observed.
¡
These devices are potentially dangerous if they are used incorrectly by untrained personnel or are not
implemented according to their specified use.
Work at/using the devices may only be performed by personnel who are authorised to
do so owing to adequate training and qualification. In addition, personnel must also be
specifically commissioned to do so by the owner!
1.4 Transport and storage
¡
Ziehl-Abegg controllers are packed ex factory to suit the previously agreed transport method.
¡
Always use the original packaging materials when transporting the controller.
¡
When transporting by hand, ensure that personnel possess the strength required to lift and carry the device.
¡
Avoid shocks and impacts to the device.
¡
Check the packaging and controller for damage.
¡
Store the controller in its original packaging in a dry and weather-proof room.
¡
The device must not be exposed to extreme heat and low temperatures.
1.5 Obligations of owner
The owner is obliged to ensure that the devices are operated in perfect working order
only. It is the owner's responsibility to safeguard hazardous areas located between
ZIEHL-ABEGG devices and customer equipment
!
2. Safety measures
2.1 Symbols and information
The symbols and information below warn of danger and indicate certain safety measures that must be taken.
Pay attention to this information and pass it on to other users!
Attention! Hazardous area!
Danger owing to electric current or voltage!
Important information!
Operating Instructions
Date 12/99
Controllers for voltage-regulated 3-phase motors, type PKDT
TBL99_24-GB1299
Part-No. 00158692-GB
6 / 23
2.2 Electrical/electronic equipment
Work on electric components/modules may only be carried out by trained electricians in
accordance with electro-technical regulations (e.g. EN 60204, DIN VDE 0100/0113/0160).
The contractor or owner must also ensure that the electric systems and equipment are
operated and maintained in accordance with electro-technical regulations.
¡
It is forbidden to carry out work on electrically live parts. The rating given in the enclosure for the device when
open is IP00! It is possible to inadvertently touch components carrying hazardous voltages!
¡
During operation, the device must be closed or installed in a control cabinet.
¡
Fuses may only be replaced by new ones and must not be repaired or bypassed.
¡
Use only fuses specified in schematic diagrams.
¡
The safe isolation from the supply must be checked using a two-pole voltage detector.
Any faults detected in the electric system/modules/operating equipment must be
corrected immediately. If these faults are not corrected, the device/system is potentially
very dangerous. The device/system must therefore not be operated when it is faulty.
2.3 Testing in accordance with accident prevention directives
Repair and maintenance work is often carried out by external personnel who are not aware of the special
circumstances and the resulting dangers associated with the equipment.
¡
Provide this personnel with detailed information concerning the dangers that they may face during the course of
their work
¡
Check that they are employing correct working procedures and intervene immediately if this is not the case
As the principal supervisor, it is your responsibility to ensure the safety of external
personnel!
2.4 Accessories, spare parts
For your own safety, use only parts, sensors, and supplementary equipment which have
been approved or recommended by ZIEHL-ABEGG. In the case of third-party products
that have not been released or recommended, or other modifications not carried out by
ZIEHL-ABEGG, it is impossible to assess whether a safety risk will arise in connection
with ZIEHL-ABEGG devices. Original ZIEHL-ABEGG parts, supplementary equipment,
and other products approved or recommended by ZIEHL-ABEGG as well as pertaining
expert consultation can be obtained from the ZIEHL-ABEGG customer service
department, tel. 07940/16-0. In your and our own interest, we once again ask you to
observe the information and directions given above:
OPERATIONAL SAFETY IS OF PRIME IMPORTANCE!
Operating Instructions
Date 12/99
Controllers for voltage-regulated 3-phase motors, type PKDT
TBL99_24-GB1299
Part-No. 00158692-GB
7 / 23
2.5 Manufacturer address, service address
If you have any questions concerning the use of our products or if you intend to use our products for special
applications, please contact us:
ZIEHL-ABEGG GmbH & Co. KG
Heinz-Ziehl-Straße
D-74653 Künzelsau
Phone +49 (0) 79 40/16-0
Fax +49 (0) 79 40/16-2 00
e-mail info@ziehl-abegg.de
Internet http://www.ziehl-abegg.de
3. General description / Programming of functions
3.1 Scope of applications
The controlling device as described is intended for infinitely variable speed settings in voltage-regulated 3-phase
motors for driving fans and pumps.
3.2 Programming the desired function (speed regulating rheostat / controller)
It is possible to use the device as a speed regulating rheostat or as a controller.
Selection of the function must first be made by setting the internal connectors (
F
F Chap. 3.4).
Operation as a speed regulating rheostat
For operation as a speed regulating rheostat, the output voltage is set manually by adjusting the built-in
potentiometer, by an external potentiometer or external signal (0-10 V).
Operation as a controller, pressure controller (factory setting for the sensor with a 4-20 mA signal).
For operation as a controller, the actual value measured by the sensor is compared with the nominal value that
has been set. The output voltage and hence the rotational speed of the connected motor automatically change as
a function of the parameter settings.
Connector positions for PKDT5
Function
Connector
J1
Connector
J2
Connector
J3
Connector
J4
Connector
J5
Connector
J6
Speed regulating
rheostat
No function
Type of control
For speed regulating rheostat
No
function
Up: Internal potentiometer
Down: External pot./0-10V
Up
Not
inserted
Not
inserted
Controller
Minimum air
shutdown
No function
Depending on type of sensor
*Control
function
Temperature (0-60 °C)
TF sensor..(KTY10-6)
Up: OFF
Down: ON
Down
Up
Up
Up: H
Down: C
Pressure, input 4-20 mA
DSF sensor..
Up: OFF
Down: ON
Down
Down
Down
Up: H
Down: C
Pressure, input 0-10 V
Up: OFF
Down: ON
Down
not
inserted
Not
inserted
Up: H
Down: C
Operating Instructions
Date 12/99
Controllers for voltage-regulated 3-phase motors, type PKDT
TBL99_24-GB1299
Part-No. 00158692-GB
8 / 23
Connector and switch positions for PKDT12
Function
Switch S1
2
Switch S1
3
Switch S1
4
Connector
J4
Connector
J5
Switch S1
1
Speed regulating
rheostat
No function
Type of control
For speed regulating rheostat
No
function
on: internal potentiometer
off: external pot./0-10V
on
not
inserted
not
inserted
Controller
Minimum air
shutdown
No function
Depending on type of sensor
*Control
function
Temperature (0-60 °C)
TF sensor..(KTY10-6)
on: OFF
off: ON
off
up
up
on: H
off: C
Pressure, input 4-20 mA
DSF sensor..
on: OFF
off: ON
off
down
down
on: H
off: C
Pressure, input 0-10 V
on: OFF
off: ON
Down
not
inserted
Not
inserted
on: H
off: C
XXXXXXX = Connector position set at the factory
*Control function
C = Cooling function: Increasing output voltage for increasing actual value (factory setting)
H = Heating function: Increasing output voltage for decreasing actual value
3.3 Technical data
Type
Art.-No.
Nominal
voltage
[V]
Permissible
supply
voltage
[V]
Nom.
current
[A]
Max. line
fuse
{1}
[A]
Semi-
conductor
fuse
(Art.-No.)
{2}
Heat
dissipation
[W]
Housing
protection
PKDT5
304547
3~ 230 V,
50/60 Hz
*) 3~ 230 V,
-15% to +10%
5
10
FF20 A
6x32mm
(00089798)
approx. 40
IP54
PKDT5
304545
3~ 400 V,
50/60 Hz
3~ 400 V
-15% to +10%
5
10
FF20 A
6x32mm
(00089798)
approx. 40
IP54
PKDT5
(mobile
application)
304546
3~ 400 V,
50/60 Hz
3~ 400 V
-15% bis +10%
5
10
FF20 A
6x32mm
(00089798)
approx. 40
IP54
PKDT12
304549
3~ 230 V,
50/60 Hz
*) 3~ 230 V
-15% to +10%
12
16
FF30 A
10x38mm
(00155987)
approx. 55
IP54
PKDT12
304550
3~ 400 V,
50/60 Hz
3~ 400 V
-15% to +10%
12
16
FF30 A
10x38mm
(00155987)
approx. 55
IP54
¡
Output voltage approx. 0-100 % (line voltage)
¡
Minimum motor current 0.2 A
¡
Input resistance for sensor or signal set for the rotational speed:
- For 0-10 V input: Ri
>
100 k
Ω
- For 4-20 mA input: Ri = 100
Ω
¡
Voltage supply e.g. for sensors +24 V ±20 %, I
max
70 mA
Operating Instructions
Date 12/99
Controllers for voltage-regulated 3-phase motors, type PKDT
TBL99_24-GB1299
Part-No. 00158692-GB
9 / 23
¡
Output (0-)10 V, I
max
10 mA (short-circuit-proof)
- For function as speed regulating rheostat: Fixed voltage 10V for external potentiometer
- For function as a controller: 0-10 V proportional to the regulated output voltage
¡
Max. permissible ambient temperature 40 °C
¡
Permissible rel. humidity 85 %, no condensation
¡
Radiating interference in accordance with EN 50081-1
¡
Interference immunity in accordance with EN 50082-2
¡
Weight:
PKDT5
approx. 2.2 kg
PKDT12
approx. 3.9 kg
¡
Settings
−
“n-min“ = Min. output voltage 0 to approx. 100 % of line voltage
−
“n-max“ = Max. output voltage 100 % (line voltage) up to “n-min”
Operation as a speed regulating rheostat
−
Output voltage 0-100% (100 % approx. = line voltage) at the unit or from an external signal
Operation as a controller
−
Setpoint value
For temperature control 0-60 °C
For pressure control 0-100 %
measuring range of the pressure sensor
−
Control range (P-component)
For temperature control 4-24 K
For pressure control 5-30 %
measuring range of the pressure sensor
−
Operation at minimum rate of airflow ON / OFF
−
Selection of control response:
Increasing output voltage for increasing actual value /
Increasing output voltage for decreasing actual value
{1}
Max. construction side line fuse
{2}
Internal semiconductor fuse (no line protection)
*
It is possible to operate the unit from a line voltage of 3~ 200 V, 60 Hz if the power supply integrated in
the unit is not loaded by external devices e.g. sensors (terminals +24 V, GND).
The minimum power supply may fall to 10 % below 3~ 200 V.
3.4 Controls
Pband
set
n-min
n-max
J4
A
B
C
J5
0
100
%
5
30
%
0
100
%
0
100
%
Off
On
4 3 2 1
S1
green
yellow
red
J1
J2
A
B
C
J3
J6
PKDT5
PKDT12
LEDs
Operating Instructions
Date 12/99
Controllers for voltage-regulated 3-phase motors, type PKDT
TBL99_24-GB1299
Part-No. 00158692-GB
10 / 23
Operation as a speed regulating rheostat
Setting
Potentiometer
Output voltage 0-100 % (Connector J2 in “up” position / switch S1-3 in
“on” position)
(Control by internal potentiometer)
“SET“
No function
“Pband“
Minimum output voltage 0-100 % (basic speed)
“n-min“
Maximum output voltage 0-100 % (speed limiter)
“n-max“
Operation as a controller (standard factory setting)
Setting
Potentiometer
Set value 0-100%
For temperature control 0-60 °C
For pressure control 0-100 %
measuring range of pressure sensor
“SET“
Control range 5-30 % (P-component)
For temperature control 4-24 K
For pressure control 5-30 %
measuring range of pressure sensor
“Pband“
Minimum output voltage 0-100 % (basic speed)
“n-min“
Maximum output voltage 0-100 % (speed limiter)
“n-max“
LED indications
Meaning
LED
Normal operation without any faults
Green
Motor fault (interruption at TK terminals)
Red
Line fault (failure by a line phase)
Yellow + red
Interruption / short circuit in sensor line, or sensor actual values outside
the measuring range
Yellow + green
Device overheating (measured at internal heat sink)
Red blinking
Line interruption to heat-sink sensor
green + red + yellow blinking
Only type PKDT12:
RS-RS terminals (remote lockout) are not brigded
green blinking
Operating Instructions
Date 12/99
Controllers for voltage-regulated 3-phase motors, type PKDT
TBL99_24-GB1299
Part-No. 00158692-GB
11 / 23
4. Installation
4.1 Wall-mounting
Please pay attention to the following points:
¡
Assemble the device on a clean and stable base. Do not distort during assembly!
¡
Use the appropriate fixing equipment.
The plastic washers must be installed between the screw heads and the housing for models with mounting
holes on the inside of the housing!
¡
Install the device away from transport routes. However, ensure however that the device is still easily accessible!
¡
Cable ducts must remain freely accessible!
¡
Protect the device from direct exposure to sunlight!
¡
Assembly of several control devices by stacking on top of one another is not permitted in order to avoid mutual
heating effects.
¡
Installation location (for applications in agriculture)
In order to avoid damage caused by ammonia vapours (NH
3
), the controller shall not
be installed in the stable, but rather in an outhouse wherever possible.
4.2 Outdoor installation of devices in housing version (IP54)
Outdoor installation is possible under the following conditions:
¡
Do not switch the controller to off at temperatures below 0
°°
C so that the losses from
the heat dissipated in the unit can prevent condensation. In other words, do not
switch off the leads supplying the power. The internal transformer for generating the
control voltage thus remains switched on. This generates sufficient heat.
¡
The outside temperature may not fall below -20
°°
C.
Installation must be protected from the effects of weather as much as possible,
including protection from direct sunlight (the maximum permissible ambient
temperature is 40
°°
C).
4.3 Installation in a switching cabinet
¡
Use the appropriate mounting devices for proper installation of the unit!
¡
A minimum distance of 5 cm between units shall be maintained when installing several units in one switching
cabinet.
¡
Assembly of several control devices by stacking on top of one another is not permitted in order to avoid mutual
heating effects.
Be sure to observe proper heat dissipation (
F
F 3.3: Technical data, “Power dissipation
requirements”).
Operating Instructions
Date 12/99
Controllers for voltage-regulated 3-phase motors, type PKDT
TBL99_24-GB1299
Part-No. 00158692-GB
12 / 23
4.4 Installing the temperature sensor TF..(KTY10-6)
¡
Depending on the application and the model in question, the temperature sensor must be installed at a location
suitable for the control task.
¡
Heat conductive pastes may be used for example, so as to keep the transfer resistance as low as possible for
immersion and contact sensors.
4.5 Installing the DSF pressure sensor (refrigeration engineering, output 4-20 mA)
¡
The connection on the coolant circuit is made at a suitable location using a Schrader valve.
¡
Please observe the operating instructions included with the sensor for this.
4.6 Temperature influences during commissioning
Avoid condensation in the controller and hence functional faults attributable to condensation by storing the
controller at room temperature!
4.7 Systems with current-operated circuit-breaker
Owing to possible leakage currents occurring when the device is switched on, it is
advisable to use time-delayed current-operated circuit-breakers. This prevents any
triggering by mistake.
4.8 Potential of control voltage connections
As a result of the ex factory connection between a “GND” terminal and the “PE”
connection (terminal
), the control voltage connections are, for safety reasons,
applied to the protective-conductor potential. If, in exceptional cases, disconnection of
the potential is necessary, then this connection can be removed.
¡
If this connection is removed, it must be ensured that the maximum external voltage
at the control voltage connections does not exceed 20 V (between the “GND”
terminals and the “PE” protective conductor).
¡
An insulated power cable must be used for the sensor cable.
4.9 Radiating interference / cable installation
Motor feeder cable
The applicable standard for radiating interference is EN 50081.
A screened motor feeder cable is required for compliance with the standard for domestic household
applications (EN 50081-1). The screen must be connected to the protective conductor at both ends, i.e. at the
control unit as well as at the motor (as short and of as low an inductance as possible!). For motor lines up to about
2 m long, the standard for the household area is fulfilled in normal cases with or without shielded lines.
It is not necessary to used screened motor feeder cables for compliance with the standard for industrial
applications (EN 50081-2).
Sensor cable
Screened control cables must be used to prevent parasitics when the cable length is longer than 20 m or when
routed in the immediate vicinity of other cables (e.g. installed in a cable duct). When using a screened cable, the
screen must be connected to the protective conductor at one end, i.e. only at the control unit (as short and of as
low an inductance as possible!).
Operating Instructions
Date 12/99
Controllers for voltage-regulated 3-phase motors, type PKDT
TBL99_24-GB1299
Part-No. 00158692-GB
13 / 23
4.10 Electrical installations
¡
Electrical installations may only be carried out by trained specialists in accordance
with general and locally applicable regulations!
¡
Dangerous electric voltages are exposed when the controller is opened. Behave
accordingly when installing the device and ensure that employees without
appropriate training cannot enter the hazardous area!
The relevant connections can be found in the circuit diagram enclosed in the enclosure
appended to these operating instructions (
F
F Chap. 9.1)!
When using “WAGO” terminal strips, insert only one conductor with max. 2.5
¨.
Cable sleeves must be used for stranded leads !
The housing must be correctly screwed into position before final
commissioning is performed and any cable ducts openings not used
(depending on the housing model) must be sealed using the supplied stoppers!
5. Electrical connections (refer also to the connection plan in section 9.1)
5.1 Mains connection
Power from the mains is connected to terminals: PE, L1, L2, L3, and N. Here, it must be strictly observed that the
mains voltage lies within the allowable tolerance specifications (
F 3.3, Technical data) of the nominal voltage as
indicated on the device (
F nameplate affixed to the side).
The neutral conductor connection “N” is only for noise-interference suppression. It is of no significance for the
function of the device. The connection is not applicable for power supply networks without a neutral conductor.
Since higher leakage currents may arise by this across the protective-cable connection “PE”, unwanted triggering
by mistake may occur in systems with FI protection circuits.
5.2 Motor connection
The motor leads are connected to the terminals: PE, U, V, W. Several fans can be connected to the controller-the
maximum total current of all motors (maximum current for electronic control of the voltage) must not exceed the
current rating for the controller. If the maximum control current for the electronic voltage control is not known, then
allowance for an increase in the motor nominal current must be made. This is approximately 15 % for 2 and 4-pin
motors, and approximately 5 % for 6-pin motors. No increase is necessary for motors with more than 8 pins. For
the control of motors made by other manufacturers (not Ziehl-Abegg), the control characteristics and the
maximum current for electronic regulation of the voltage should be enquired from the manufacturer.
It is recommended that a separate motor protection unit be foreseen for each fan.
For motors with thermistors:
e.g. type TÜS 230 KIL
For motors with thermal contacts:
e.g. type STDT 16 (E) or AWE-SK
(
F
F Chap. 9.2 Circuit suggestion for several motors with motor protection unit
type STDT)
Operating Instructions
Date 12/99
Controllers for voltage-regulated 3-phase motors, type PKDT
TBL99_24-GB1299
Part-No. 00158692-GB
14 / 23
5.3 Motor noise
Motor noise can occur when fans are controlled using electronic voltage controllers (Phase cutting = series “P...”).
Such noise can be perceived as a disturbance. This noise is relatively low for fast-running fans where the noise
from the air is high. The noise from motors in slower-running fans where the noise from the air is less, can be
dominated by resonance in the lower speed ranges.
5.4 Motor protection
The motor can be protected by connecting the thermal contacts. The connection eastablished at the factory must
be disconnected for this (terminals “TK“).
¡
An outside voltage may never be connected to the terminals “TK” !
¡
The internal motor protection does not function if a bypass circuit has been realised.
In this case and as well as other precautions, an additional thermal contact
protective device is necessary.
¡
When several motors are connected ensure that the thermal contacts are always
connected in series.
¡
It shall be observed for motors with built-in PTC thermistors that these cannot be
connected to the “TK” terminals. A separate triggering unit (e.g. type TÜS 230KIL) is
required in this case for the PTC thermistor.
The unit switches off when a connected thermal contact has tripped the circuit (interruption between both TK
terminals). The unit then remains switched off. The fault-indicating relay opens (terminals 11-12 bridged) the red
LED for motor fault illuminates, the green LED for operating goes off. The unit starts up again once the drive has
cooled down (i.e. connection established again between the two “TK” terminals) by switching the mains voltage off
and then on again.
Only type PKDT12: It is possible to switch on the unit by briefly interruption of terminals “RS” (remote lockout).
5.5 Remote control / remote lockout (only type PKDT12)
The controller can be switched “on” or “off” by an external remote switch (“RS” terminals). The jumper installed at
the factory must removed for this.
Electronic switch off, none potential separation.
5.6 External speed setting (operation as a speed regulating rheostat)
The external signal for selecting the speed is connected to the terminals “E” and “GND”; be sure to observe
correct polarity. The maximum length of the connecting cable shall be 50 m (screened).
0-20 mA or 4-20 mA input signal:
Control by a 0-20 mA signal is possible by connecting in an external resistor (499
Ω
/ 0.25 W) in parallel between
the terminals “E” and “GND”. For control by a 4-20 mA signal, the connectors J4 and J5 must be in the “Down“
position“.
An external speed setting is possible by using a 1 k
Ω
potentiometer connected to the terminals “A“ (+10V) and
GND with pick-off at terminal “E”.
Operating Instructions
Date 12/99
Controllers for voltage-regulated 3-phase motors, type PKDT
TBL99_24-GB1299
Part-No. 00158692-GB
15 / 23
5.7 Sensor Connection (operation as a controller)
The signal from the sensor for detection of the actual value is connected to the terminals E” and “GND”, for sensor
in two-wire-technology (output 4-20mA) to terminals "E" and "24V". Be sure to observe correct polarity. The
maximum length of the connecting cable shall be 50 m (screened).
There is an integrated power supply (+24V) for e.g., a pressure sensor of the type DSF.
Sensors with the following standard signals may be connected depending on the programming of the controller: 0-
10 V, 4-20 mA, KTY10-6 (PTC temperature sensor).
5.8 Operation and fault indications
An external operational or fault indicator is available over the potential-free contacts of the built-in relay (contact
load-carrying capacity 5 A, 250 V AC).
The relay is energized if the controller is on mains supply and the control lockout (terminal “RS”) is bridged, i.e.
terminals “11” and “14” are bridged.
If there is a fault or a switch off via remote control the relay is de-energized, i.e. terminals “11” and “12” are
bridged.
A fault is indicated by:
A phase failure, blown semiconductor fuse, excessively high temperature at the unit, interruption / short circuit in
sensor conductors or actual sensor value being outside the measuring range (only for operation as a controller), a
defective controller-internal voltage supply, overheating by the motor (thermal contacts connected).
5.9 Voltage supply for external equipment
There is an integrated power supply e.g. for pressure sensors of the type DSF2-25
Terminals
+ 24 V
Output voltage tolerance +10 % / -20 %.
Max. on-load current 70 mA
The transformer built into this controller for the control voltage is, to a certain extent, “short-circuit-proof” because
of the integrated PTC thermistor. In the event of overheating by the transformer, e.g. because of overloading, the
control voltage cuts out and hence switches off the control unit. The controller can be switched on again once this
has cooled down again.
5.10 Output voltage( 0 )- 10 V (needed only as required)
For operation as a controller:
Output voltage 0-10V (terminals „A“/“GND“) is approximately proportional to the regulated output voltage. This can
be used for example, for a downstream speed regulating rheostat or for a valve-positioning motor.
For operation as a speed regulating rheostat:
Fixed 10-V voltage for maintaining the output voltage from an external potentiometer.
Operating Instructions
Date 12/99
Controllers for voltage-regulated 3-phase motors, type PKDT
TBL99_24-GB1299
Part-No. 00158692-GB
16 / 23
6. Settings for operation as speed regulating rheostat
6.1 Adjusting the minimum output voltage “n-min” (basic speed)
Needed only as required
1. PKDT5:
Connector J2 in the “UP“ position (control by internal potentiometer).
PKDT12:
Switch S1-3 in the “ON” position (control by internal potentiometer).
2. Turn the speed potentiometer “SET“ to its counter-clockwise limit.
3. Set minimum speed desired with the potentiometer "n-min".
Setting range:
From the counter-clockwise limit = “0“ (no “n-min“) to 15-100 % (
approximately the mains voltage applied).
The output voltage is switched off to “0” at the counter-clockwise potentiometer limit for a controller output less
than 15 % of approximately 15 % of the mains voltage that is applied.
This means control by an external signal of less than approx. 1.5 V or near to the counter-clockwise limit of the
potentiometer “SET“ for internal control.
For a controller output greater than 20 % (i.e. for an external control greater than approx. 2 V for the set signal),
the output voltage is switched on to approx. 20 % of the mains voltage applied, and in increasingly raised for
continuously increasing input signal.
6.2 Adjusting the maximum output voltage “n-max“ (speed limiter)
Cos
ϕϕ
adjustment of the output voltage
Needed only as required
1. PKDT5:
Connector J2 in the “UP“ position (control by internal potentiometer).
PKDT12:
Switch S1-3 in the “ON” position (control by internal potentiometer)
2. Turn the speed potentiometer “SET“ to its clockwise limit.
3. Set maximum speed desired using the potentiometer "n-max“.
Setting range:
From the clockwise limit (100 %) to 20 % (
approx. 100 % -20 % of the applied mains voltage).
For a given minimum output voltage to the setting “n-min“.
For cos
ϕ
adjustment, turn “n-max“ counter-clockwise such that the maximum output voltage will just be
measured.
This adjustment must be made for maximum output from the fans. All flaps must be opened when using
centrifugal fans.
Cos
ϕϕ
adjustment
The output voltage from the unit depends on the inductance of the motor (cos
ϕϕ
). By this,
the maximum output voltage can already be reached below the maximum input signal
(<10 V / 20 mA). A correction is possible by setting “n-max" (cos
ϕϕ
adjustment).
Operating Instructions
Date 12/99
Controllers for voltage-regulated 3-phase motors, type PKDT
TBL99_24-GB1299
Part-No. 00158692-GB
17 / 23
6.3 Setting the speed by the internal potentiometer “SET”
1. PKDT5:
Connector J2 in the “UP“ position (control by internal potentiometer).
PKDT12:
Switch S1-3 in the “ON” position (control by internal potentiometer).
2. Setting the output voltage by the potentiometer “SET“ from approx. 0-100 % of the applied mains voltage, or in
the range of the settings “n-min” to “n-max”.
6.4 Speed setting by an external signal or an external potentiometer
1. PKDT5:
Connector J2 in the “DOWN“ position (control by an external potentiometer).
PKDT12:
Switch S1-3 in the “ON” position (control by an external potentiometer).
2. Setting the output voltage by the external signal or by an external potentiometer from approx. 0-100 % of the
applied mains voltage, or in the range of the settings “n-min” to “n-max.
6.5 Operation with two variable output voltages (2 steps)
Switchover between two variable output voltages for the operational mode of external control (PKDT5: connector
J2 in the “down” position / PKDT12: switch S1-3 in the “off” position) is possible by means of external potential-free
contact-making.
Step 1 (low speed)
When there is no input signal connected to the input terminal “E“, then the unit supplies the output voltage set by
“n-min”.
Step 2 (high speed)
When the terminal “A“ (+10V) is connected with the input terminal “E“, then the units supplies the output voltage
set by “n-max.”
7. Settings for operation as a controller (standard factory setting)
7.1 Adjusting the minimum output voltage “n-min” (basic speed)
Needed only as required
1. Turn the speed potentiometer “SET“ to its clockwise limit (for “cooling function”).
(For the “heating function, turn the speed potentiometer “SET“ to its counter-clockwise limit.)
2. Turn the potentiometer range “Pband“ to its clockwise limit.
3. Set the desired minimum speed using the potentiometer “n-min“.
Setting range:
From the counter-clockwise limit = “0“ (no “n-min“) to 15 to 100 % (
approximately the mains voltage applied).
At the counter-clockwise potentiometer limit, the output voltage is shut down to “0” from approximately 15 % of
the applied mains voltage when the set nominal value has almost been reached.
The output voltage switches on at approximately 20 % of the applied mains voltage for an increasing deviation
in the control and is increasingly raised for further deviations in the actual value.
The minimum-air shutdown function can be activated if the unit shall cut out when the nominal value is reached
during operation with a set “n-min“(
F7.5 Minimum airflow rate).
Operating Instructions
Date 12/99
Controllers for voltage-regulated 3-phase motors, type PKDT
TBL99_24-GB1299
Part-No. 00158692-GB
18 / 23
7.2 Adjusting the maximum output voltage “n-max“ (speed limiter)
Cos
ϕϕ
adjustment of the output voltage
Needed only as required
1. Turn the speed potentiometer “SET“ to its clockwise limit (for “cooling function”).
(For the “heating function, turn the speed potentiometer “SET“ to its clockwise limit.)
2. Turn potentiometer control range to the anti-clockwise limit.
3. Set maximum speed desired with the potentiometer “n-max“.
Setting range:
From the clockwise limit (100 %) to 20 % (
approx. 100 % -20 % of the applied mains voltage)
For a given minimum output voltage to the setting “n-min“.
For cos
ϕ
adjustment, turn “n-max“ counter-clockwise such that the maximum output voltage will just be
measured.
This adjustment must be made for maximum output from the fans. All flaps must be opened when using
centrifugal fans.
Cos
ϕϕ
adjustment
The output voltage from the unit depends on the inductance of the motor (cos
ϕϕ
). By this,
the maximum output voltage can be reached before the deviation in the control has reached
the set controlling range. A correction is possible by setting “n-max" (cos
ϕϕ
adjustment).
7.3 Adjusting the control range “Pband” (response rate)
Selection of the control range, i.e. the proportional section of the controller; The counter-clockwise potentiometer
limit gives greater amplification and hence shorter control times for a lower controller stability. The clockwise limit
gives lower amplification, i.e. longer control times and higher controller stability.
The control range can be adjusted from 5 % (counter-clockwise limit) to 30 % (clockwise limit). The percentage
given refers to the pressure control over the measuring range given by the pressure sensor, and for temperature
control to the measuring range of the controller 0-80 °C (cos
ϕ
dependency-see 7.2).
•
E.g., pressure control by the pressure sensor, type DSF 2-25 (range 2-25 bar
23 bar)
- E.g., adjustment of the control range 10%
2,3 bar
- E.g., adjustment of the control range 30 %
6,9 bar
•
E.g., temperature control by the temperature sensor, type TF..(KTY10-6)
- Adjustment of the control range 10 %
8K
- Adjustment of the control range 30 %
24K
Example for a cooling function (increasing speed for increasing actual value, PKDT5: connector J6 in the “down”
position / PKDT12: switch S1-3 in the “off” position):
For an actual value = nominal value, the fans run at their maximum speed (for operation at minimum airflow rate).
If the actual value then exceeds the nominal value, then the output voltage )fan speed) is increased proportionally.
If the deviation in the control then reaches the set control range, then the fans runs at the maximum speed.
E.g., temperature control:
Nominal value 50 %
30 °C, control range 10 %
8 K,
i.e. at 30 °C + 8 K = 38 °C, the fans runs at maximum speed.
Operating Instructions
Date 12/99
Controllers for voltage-regulated 3-phase motors, type PKDT
TBL99_24-GB1299
Part-No. 00158692-GB
19 / 23
7.4 Adjusting the nominal value “Set”
Set the desired nominal value at the setpoint potentiometer in the range from 0-100 %. For temperature control
from 0-100 %
0-60 °C, for pressure control from 0-100 %
measuring range of the sensor.
E.g., pressure control:
Pressure sensor, type DSF 2-25 (2-25 bar, measuring range 23 bar)
Setting 50 %
2 bar + 11.5 bar = 13.5 bar nominal value
E.g., temperature control:
Setting 50 %
30 °C as the nominal value.
7.5 Minimum airflow rate
Needed only as required
The minimum airflow rate can be switched "ON" or "OFF" using connector / switch.
PKDT5:
Connector J1 "DOWN": Without minimum airflow rate
Connector J1 "UP":
With minimum airflow rate (factory setting)
PKDT12:
Switch S1-2 “OFF”:
Without minimum airflow rate
Switch S1-2 “ON”:
With minimum airflow rate (factory setting)
Example of the function for control response for the cooling function (increasing speed for increasing actual value).
For operation at the minimum airflow rate (without minimum-air shutdown), the motor connected then also runs at
its minimum speed (setting “n-min“) if the actual value at the sensor falls below the nominal value that has been
set.
For operation without a minimum airflow rate (with minimum-air shutdown), the motor cuts out when the nominal
and actual values are approximately the same, i.e. from the setting “n-min“ to “0“ (OFF).
Hysteresis (ON / OFF) approx. 2.5 % of 100 % as the nominal value.
7.6 Reversed heating / cooling action (special function)
Needed only as required
The controller setting made at the factory is for the cooling function, i.e. increasing speed for increasing actual
value (temperature, pressure)
Switchover to the heating function is possible by means of the internal connector J6
PKDT5:
Connector J6 “UP”:
Heating function (increasing speed for decreasing actual value)
Connector J6 “DOWN”: Cooling function (increasing speed for increasing actual value)
PKDT12:
Switch S1-1 “ON”:
Heating function (increasing speed for decreasing actual value)
Switch S1-1 “OFF”:
Cooling function (increasing speed for increasing actual value)
Operating Instructions
Date 12/99
Controllers for voltage-regulated 3-phase motors, type PKDT
TBL99_24-GB1299
Part-No. 00158692-GB
20 / 23
8. Faults and rectification of these
8.1 Mains fault
Function only for a connected inductive load
The device is provided with a built-in phase-monitoring function for the mains supply.
In the event of a mains interruption (failure of a fuse or mains phase) the unit switches off after a delay. The unit
then switches on again automatically when the voltage has been restored.
Line fault (failure of a line phase)
Yellow + red
Remedy:
Check the mains supply and the internal semiconductor fuses.
8.2 Temperature fault
The unit is fitted with a built-in temperature monitoring device coupled to the internal heat sink. The unit cuts out at
a temperature of approximately 90 °C and cuts in automatically again when the unit has cooled down again to
about 65 °C.
An excessively high unit temperature is signalled by the internal LED’s.
Excessively high unit temperature (measured at the internal heat
sink)
Red blinking
Interruption in the leads to the heat-sink sensor
Green + red + yellow blinking
Remedy in the event of an excessively high unit temperature:
- Check whether the heat dissipation is adequate.
- Check for any overloading of the unit, i.e. whether the maximum control current occurring is above the
nominal current for the unit.
8.3 Motor faults
The unit cuts out and does not switch on again when the connected thermal contacts have tripped (interruption
between both terminals “TK” (
F Chapter 5.4 Motor protection).
Motor fault (interruption TK terminals)
Red
Operating Instructions
Date 12/99
Controllers for voltage-regulated 3-phase motors, type PKDT
TBL99_24-GB1299
Part-No. 00158692-GB
21 / 23
8.4 Sensor-signal faults
Function only for operation as a controller
The unit is fitted with a built-in monitoring device for the sensor signal. A fault is signalled over the internal LED’s
and the operational signalling relays in the event of a interruption or a short circuit in the sensor conductors, or
measured values that are outside of the measuring range for the unit.
Interruption / short circuit in the sensor leads or sensor values
measured that are outside of the measuring range
Yellow + green
Cause for the signal “Sensor fault” and the response by the controller
1. For a temperature-dependent control (input for temperature sensor, type TF..):
•
In the event of an interruption in the sensor leads.
The controller acts as in the case of an extremely high temperature, i.e. maximum output voltage.
(Control response for increasing speed for increasing actual value, see chap. 7.6)
•
In the event of a short circuit in the sensor leads.
The controller acts as in the case of a very low temperature, i.e. minimum output voltage.
(Control response for increasing speed for increasing actual value, see chap. 7.6)
•
In the case of temperatures at the sensor that are outside the measuring range of the controller,
i.e. at approx. 0 °C and as of approx. 80 °C.
The controller functions automatically again with the value measured at the temperature sensor after the fault has
been rectified or when the actual temperature returns to within the measuring range of the controller.
2. For a pressure-dependent control (input 0-10 V / 4-20 mA):
•
In the event of an interruption in the sensor leads or for a short circuit between the terminals “E“ and “GND“.
The controller acts as in the case of a very small measured value, i.e. minimum output voltage.
(Control response for increasing speed for increasing actual value, see chap. 7.6)
•
When the upper or lower limit of the measuring range for the sensor has been reached
-For a 4-20 mA input for a sensor signal of approx. 4 mA or approx. 20 mA
-For a 0-10 V input for a sensor signal of approx. 0 V or approx. 10 V
The controller functions automatically again with the value measured at the temperature sensor after the fault has
been rectified.
8.5 Selection speed regulating rheostat / controller doesn´t work
Selection of speed regulating rheostat / controller only if the device in not on mains supply.
If the device is on mains supply modifications will not be identified and realized.
It is forbidden to carry out work on electrically live parts. The enclosure rating of the device
when open is IP00! It is possible to inadvertently touch components carrying hazardous
voltages.
Operating Instructions
Date 12/99
Controllers for voltage-regulated 3-phase motors, type PKDT
TBL99_24-GB1299
Part-No. 00158692-GB
22 / 23
9. Enclosure
9.1 Connection diagram
9.2 Connection suggestion for several motors with motor protection unit type STDT
•
Total motor protection: Automatic cut-off by thermocontact actuation
motor overtemperature. Button for Reset after
malfunction.
•
Line protection: A thermal over current sensor and a magnetic short circuit releasing elements are the parts of the integral
line protection. Adjustment to the thermal overcurrent sensor to the max. permissible current of the connected cable.
•
No cut-off if the mains supply is interrupted.
Operating Instructions
Date 12/99
Controllers for voltage-regulated 3-phase motors, type PKDT
TBL99_24-GB1299
Part-No. 00158692-GB
23 / 23
9.3 Dimensions sheet
PKDT5
PKDT12
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