https://www.youtube.com/watch?

v=FG3l29ySCF0&index=66&list=UUgnmHHsB-99_GrbhKDtq3
vA
https://www.youtube.com/watch?v=pL0HApSJiAo&index=68&list=UUgnmHHsB-99_GrbhKDtq3
vA motor control hum
Removing noise Optimum / Quantum machines with DC motors
(All information is supplied for information, without any responsibility for the
results of its use is accepted)
Introduction.
In this thread we will describe one of the ways that you can eliminate the treme
ndous electrical "noise" produced by DC motors, certain machine tools. This nois
e is caused by the absence of a filter at the output of the power board, which m
akes the engine will reach a pulsed power, with peaks of great value, which make
s the electric current through the motor windings to induce a pulsating flow in
the motor iron. Being built by this stacked plates, begin to vibrate, producing
sound waves in the audible spectrum.
The content of this text is aimed at machines with DC motors up to 500 watts. Fo
r example:
Millers Quantum BF16 and BF20 Optimum (motors up to 500 watts)
Optimum 180 * 300 Vario lathe.
But actually it is valid for any model from another manufacturer, provided that
the motor is DC, and much power not exceeding the limit indicated.
Beyond remove noise of the machine, the advantages of mounting a filter with an
inductor and a capacitor, are:
* It reduces harmonics and improves RMS current.
* Improves power factor.
* Limits the AC component superimposed on the continuous, improving DC moto
r commutation.
Internal electrical connection of machines.
The feed enters at around through the fuses, and passes through a switch with el
ectrical interlocking (so that if the power goes out, the auto-disconnect). Henc
e they are the network cables to the small plate. This is a control plate.
In the low voltage control plate (type 9V, 5V, etc.) for different uses, such as
feeding the system safety limit switches, or power the tachometer (if winch fit
ted) are obtained.
Since this control plate, in turn, leaving two network cables, to the power boar
d.
That is, the board reach 220V power from the control board.
The power board regulates the voltage that reaches it, and becomes continuous ad
justable pseudo-effective value, which is what we get to your departure. Hence t
wo wires leave toward the switch.
That pseudo-voltage reaching the switch can be reversed here, so that the motor
rotates in one direction or another.
Procedure to remove noise:
To eliminate the noise of these machines, it is necessary to mount an LC filter
between the plate and the switch that feeds the engine, so you have to buy a coi
l (L) and a capacitor (C) to appropriate values. Also some small mounting hardwa
re, tools, box, etc..

Justification of the solution. General explanations.

An LC filter for continuously rotating machine is not a system to be calculated
accurately for each case. In fact, there are some values ??that are the best, si
nce low values ??filter bit, but too high values ??distort transients starting,
acceleration and deceleration.
The LC filters strict calculation involves much mathematical apparatus. Is from
Bode, for underdamped second order system, typical of systems with low resistanc
e, which defines how much is to be the principal harmonic damping, etc..
Anyone who is curious, you can read a brief introduction to the subject here:
http://www.fisicarecreativa.com/informes/infor_em/rlc_serie_libre_beck2k2.pdf
As already hinted at in the document mathematical apparatus that accompanies the
se calculations corresponds to the second cycle of industrial engineering, altho
ugh the problem itself is simple to solve.
Made these calculations for several machines of this forum, is just adjusted to
suit each case.
When physically mount the LC filter, it is desirable to remember that the capaci
tors are connected in parallel to add their effects, and if electrolyte, the pol
arity must be respected, so join the (+) on the one hand, and (-) on the other.
The inductor and capacitor are called "dual component". This means that produce
exactly the same effect, when one is in series and one in parallel. Ie in the LC
filter add their effects.
Another very important function of L is to limit the starting current is require
d from the power board. Because C is very large, to connect the circuit and be d
ischarged, it behaves like a short circuit, in the sense that they require a lot
of power to the power board, to begin charging. This only lasts a moment, becau
se as of to be charged, the current demand will decline, but it is enough to bur
n the power board time.
To avoid this, the coil is mounted in series between the plate and C. As we know
, the coils are opposed to abrupt changes of current. Thus, although the C start
up requires high current, the coil will not allow this to grow much, leaving thi
s limited form of current that is required to power board. This prevents burning
power thyristors.
Therefore, we should not remove any of the two components.
Details of the LC filter mount.
These schemes are the most important in the whole thread:
Wiring diagrams of the machine, with and without LC filter:
Recommended values ??for the LC filter.
We recommend the following values:
* A coil of about 15 milli Henries and 2.5 or 3 Amps maximum current work.
* An electrolytic capacitor 1500 micro farads, and 400V maximum voltage.
As we see, we do not provide exact values??, because it is not necessary to rest
rict both. Yes it is important that their values ??are around which are indicate
d.

About the coils:

The coil 15 milli Henries must serially obtained by placing two reels in milli H
enries 7 or 8 each, or by purchasing a "choke" phase, and connecting two of the
windings in series.
I have chosen to put two coils in series 9 milli Henries. If I see that it takes
more, I can always add another ...
In the case of buying a "three-phase choke", the device has three coils with iro
n cores shared (as in the figure below). The correct connection would be as show
n below:
(Due to the type of construction of the core, the three coils share the magnetic
core.'s Why not just consider the corresponding terminals, it is necessary to t
ake into account the topology of the iron. With this type of construction, is im
possible to achieve all three streams join, so you can only use two coils (any),
but never three. With three connected, always have at least one coil whose flow
can see counteracted by the other. the result would much noise vibration plates
of the iron core).
Shock phase, connected to filter coil for dc
It is best that the magnetic circuit as short as possible, so that the dispersio
n is minimal flow by reducing the magnetic reluctance. Thus, the induction and m
agnetic coupling will be greater. Thus the central coil and any one of the side
is used.
About the condenser to be used:
We must also mention that the electrolytic capacitors have polarity, and if you
spend your polarity when connected, they explode.
Also need a resistor in parallel with it, so that you can download to turn off t
he machine (if you are way on the other hand ...) Keep in mind that we talk abou
t high voltages, 300-400 volts, and with these capabilities, we can give a big "
whiplash".
Acquire the necessary components.
An inevitable and sometimes almost insurmountable problem is knowing where to bu
y the necessary electronics.
You really can not buy all of them in one store, since the electronic components
do not sell as large coils and capacitors, so they have to buy them in a store
of industrial power supplies.
Another good option is to buy everything online. It's pretty expensive, but you
can solve everything in one morning .... So many of the options indicated refer
to shop online Inrtenet rs-call, or RS Components.
Buy the condenser:
Electrolytic capacitor 1500 micro farads, and 400V
http://es.rs-online.com/web/search/searchBrowseAction.html?method=getProduct&R=2
550046

Buy the coil L:

Coil about 15 milli Henries and 2.5 or 3 Amps
Serve any of these:
Phase Shock:
We can buy this (sometimes it is out of stock):

# header http://es.rs-online.com/web/search/searchBrowseAction.html?method=getPr
oduct&R=4576135
Or they (are what I used, they put two in series):
Mfr: PR2.5
http://www.polylux.com/familia/pr_inductancias_de_linea_monofasicas
There Polilux to call by phone to tell you a dealer in your city. You can also s
end them an email. Me too I responded to that method.
In Madrid the Dimel ordered in, but there are hundreds of distributors throughou
t Spain. (It took three weeks to get my hands on, because the manufacturer had n
o stock).
This small company also sells a valid coil. There you telephone them and see how
they order it.
Item No.: 002220RI0
http://www.tecnotrafo.es/RI-RT-R1.pdf
Plug connectors.
(For this, better go to a store electronic components and connectors for microph
ones questions, asking for three-way connectors, XLR type
Recessed in the box:
http://es.rs-online.com/web/search/searchBrowseAction.html?method=getProduct&R=0
405629
and this:
http://es.rs-online.com/web/search/searchBrowseAction.html?method=getProduct&R=0
405590 (is left)
for around:
You can embed a connector as above, or leave it to air.
If you leave the air, you will need:
A male and a female, type "aero" ie, that are in the air, without embedding.
Terminals for cables of this type (must be the size of the cables used in arrivi
ng at the plate):
http://es.rs-online.com/web/search/searchBrowseAction.html?method=browseSubRange
&Ne=4294954407&N=4294584945&productNum=6688980
Some points of these:
http://es.rs-online.com/web/search/searchBrowseAction.html?method=browseSubRange
&Ne=4294954407&N=4294612782&productNum=7187375
Heat-shrinkable tubing of different sizes, and red and black color (very cheap):
http://es.rs-online.com/web/search/searchBrowseAction.html?method=browseSubRange
&Ne=4294954407&N=4294547605&productNum=2088967
As I say, small is better for mounting buy them in a store, not online, because
they can advise you ....
Mounting the LC filter in the machine.
The way of working is:
Change original fuses, other extra-fast, 5 Amps. This will help protect the mach
ine if something goes wrong.
Turn the speed potentiometer to the minimum. In this way, we will work with low

output voltages, and we will protect us and the power board.

To modify the wiring and include the LC filter, change the connections in the
first plate, and then follow the original cables to the switch.
The output cables of the plate are called DC1 and DC2, and those are the ones we
need to change by our filter. You have to do one at a time, that is to say firs
t DC1 change the cable at both ends, and then the DC2.
The time to get down to work, be ever present to you will work with peak voltage
up to 400V and current of a few amps (in the extreme case), so you will have to
be very careful. Not a game, you can just use a electric shocks let you trembli
ng all day, and scared to death.
Also think it is very easy carry you the power board if conexionas bad things, a
nd the replacement board is worth about 150 euros.
After making the connections, remount everything, and we started the machine.
If all went well, the motor begins to rotate smoothly. If we have some bad wirin
g, not spin, or even be a great short, and some flash connections .... especiall
y if much turn potentiometer, and provoke a sharp rise in the output voltage of
the plate.
In the end, if everything went as it should, I assure you that is very, very goo
d. Not a sound, beyond the spindle bearings. A blast.
And Filter Mounted:
Throughout the time we have been installing different versions of the filter, to
suit the needs of each machine, although essentially the same.
With three phase shock as filter coil.
(In the following two pictures there is a small error: They had three windings c
onnected in series, when in fact only connect two.)
With individual coils (Polilux mark).
In the particular case at hand, change the power components,
The procedure is as follows:
Detach the plate and look "very closely" the black surface of each thyristor or
diode. If anyone has a pore is matte blackened, etc.. that will be burned down.
Of the five components, three are diodes, thyristors and two, but outside are eq
ual. They have the same package, and nomenclature vary only in a letter .... Be
careful with that. Try to read the nomenclature that burned, not the next.
Power components that can be damaged by an error in assembly.

As the diodes and thyristors are not worth that much, I would buy all five.
At present (2010), the Optimum / Quantum manufacturer assembles these components
:
Thyristor (2 Eur):
http://uk.farnell.com/littelfuse/s6025l/thyristor-25a-600v-to-220/dp/1456980
Diode (2,8 Eur):
http://uk.farnell.com/littelfuse/d6025l/diode-rectifier-600v-25a-to220ab/dp/1827
589

The one that almost certainly has not done anything, is the component that is in
the middle of them all. A diode-called "free circulation" which does not belong
to the rectifier bridge itself.
More possibilities:
If you search the datasheets of these power components you will see that with th
e same code, changing only one letter, diodes, thyristors and triacs are encapsu
lated. Thyristors and triacs in this series are complemented, in the sense that
such a triac thyristor can replace this range, no problems. The converse is not,
of course.
So if you do not find the thyristor, triac you can put that same family:
Format triac (two antiparallel thyristors)
http://es.farnell.com/jsp/search/productdetail.jsp?sku=1456976
I also wanted to tell you that if a thyristor due to overload burns usually also
burns a diode, since they work in series, ie pairs.
Therefore, it is also possible that a diode is bad, but not something mathematic
al. Be careful with that.
If it's any consolation, some time ago, in my tests, also burned a bridge of the
se, and since then I have thyristors and diodes Extra specifically purchased for
leave reserve.
Tip / Trick:
When you go to desolder components, Do not risk the board: Cut the legs first of
a sewing kit with scissors to remove the body of the components. So already the
re just desolder the pins, which are now alone, and you can grab it with tweezer
s.
Thus, the process is very fast unsoldered, which avoid heating the plate tracks,
and these become detached from the base bakelite (or fiber, or what it is made)
. Employs a tinker about 30 watts.
if a track comes off, the pineapple is good fat. You can paste, etc.. but the fu
dge begin to take shape .....
It is true that cutting the legs causes the component unusable, and that one can
be healthy, but you do not really worth it for those prices, carry you to risk
the board itself.
he required equipment consists of:
30W tinker.
Tin of good quality.
Film desoldering to remove the existing solder tin. It only costs a few euros, a
nd it is necessary not to botch.
tweezers to pull the pins on the board, when applying to melt tin tinker.
Repair process.
With the tape desoldering and tinker eliminates all possible tin solder. To put
it the end of the ribbon above the weld, and applies the tinner. When the heat t
in case, will be absorbed by the film (which is a grid of tin).
If done with patience, and giving time to tinker good both hot tape as tin, it w
ill absorb all the tin, and the pins will practically loose.
With the pin cut and the component body already retired, we hold the first leg w
ith tweezers and apply the tinker.

When the tin is left to melt, the pin is removed by pulling the clips.
well with them all.
You can now install the newly purchased component and solder with new tin.