3 POWER CONTROLLER RP1 type USER`S MANUAL
Contents
1. Fig 14 Control of on off type runs of occurring signals for resistive load 6 2 Pulse control Pulse control consists on the change of the pulse duty factor and the frequency of power Po delivered to the load in function of the analog control signal at the same time the output current is turned on synchronously with the transition of the supply voltage across zero Runs of signals are presented on the fig 15 Continuous input X4 see eut VNA V AVI IE nn AAN Fig 15 Pulse control with a variable pulse freguency runs of occurring signals 17 The power value in the pulse period according to the formula 2 is defined by the dependence 3 T T Na t Noo 2 No x E P p j dai No Nos Pe X in max where T_ period of the supply voltage N number of turned periods on No number of periods off The RP1 power controller has following kinds of pulse control e Quick cycle in which for X 1 2 X X No Nog 10 however f 2 5 Hz e Slow cycle in which for X 1 2 X X No Nog 100 however f 0 25 Hz 1 max Where X value of the analog control signal lja maximal pulse freguency Runs of characteristic guantities for the pulse control are presented on the fig 16 Y fo2. All our instruments have CE mark For more information please write to or phone our Export Department RP1 07 17 05 2010 LUMEL Lubuskie Zaktady Aparat w Elektrycznych LUMEL S A ul Sulechowska 1 65 022 Zielona G ra Poland Export Department Tel 48 68 329 51 00 exchange Tel 48 68 329 53 02 or 53 04 Fax 48 68 329 51 01 Fax 48 68 325 40 91 e mail lumel lumel com pl e mail export lumel com pl http www lumel com pl
3. Non Noff The filling factor y is described by i N the following dependence sli _fo Noff N 4 y Non ii Nos Xin R gt X max X max Fig 16 Runs of characteristic guantities for the pulse control with variable pulse freguency 18 6 3 Phase control At phase control a continuous change of delivered power to the load occurs it is realised by the change of the load current turn on angle in the function of the analog control signal Runs of signals for this kind of control for a resistive load are presented on the fig 17 Continuous xa input x signal MAX Ah mega szene TEE N EOS lee arzt zz ze AMA Y I I Supplying voltage of gt VA A EN load circuit I I current Ich in the the load circuit NM Fig 17 Phase control runs of occurring signals 6 4 Limitation of the load current If the current value in the load circuit exceeds the boundary value set by means of the Limit potentiometer then the current limitation operates regardless of the control signal value It is possible to assign it from an external potentiometer p 4 4 3 The setting of the potentiometer on minimum means the turn of the current limi tation operation off The maximal value of the current flowing in the load circuit can be set in the full range of the power controller rated value The current limitation does not operate for the impulse control or on o
4. Prodaja in zastopa Materm d o o Morje morska cesta 6 2313 Fram tel 02 608 90 10 www materm si POWER CONTROLLER RP1 type A RES O USER S MANUAL CE POWER CONTROLLER RP1 type USER S MANUAL CONTENTS 1 APPLICATION ria 5 2 BASIC REQUIREMEMNTS OPERATIONAL SAFETY 5 3 POWER CONTROLLER SET 6 4 INSTALLATION een 6 4 1 Overall and assembly dimensions 6 4 2 Electrical Connections MN A A u area 8 4 3 Choice of the control type een nee 8 4 4 Connection of control SIGNA S nenne aaa 9 4 5 Connection Of supply and lad 12 5 POWER CONTROL SERVICE una easa adapa 15 6 DESCRIPTION OF CONTROL TYPES 16 6 1 Control of ON OFF Tye za a en zanese 16 8 2 Pulse COMO nee ed rd 17 6 3 Phase Control ceneno noo EVE TAT MA RAVNI A 19 6 4 Limitation of the load current ua 19 6 5 Triggering delay of soft start type 19 6 6 Control of the initial triggering angle value 20 6 7 Control of the input line amplification 20 6 8 Check and current signalling in the load circuit 20 6 9 Signalling of supply correctness una 20 6 10 Signalling of maximal radiator temperature exceeding 21 6 11 Error signaling aaa se ae 21 6 12 Overload protection a a eko ao ie alla 21 7 SPECIFICATIONS oxicorte ceda ei 22 7 1 Electrical parameters of the high current circu
5. and within the period stated in the warranty card One should return the power controller to the Manufacturer s Quality Inspec tion Dept If the device has been used in compliance with the instructions the Manufacturer warrants to repair it free of charge The disassembling of the housing causes the cancellation of the granted warranty After the warranty period One should send the device to repair it in an authorized service workshop Spare parts are available for the period of five years from the date of purcha se Our policy is one of continuous improvement and we reserve the right to make changes in design and specifications of any products as engineering advances or necessity requires and revise the above specifications without notice 25 26 27 SALES PROGRAM MEASUREMENT CONTROL DIGITAL and BARGRAPH PANEL METERS RECORDING MEASURING TRANSDUCERS ANALOG PANEL METERS DIN INSTRUMENTS ANALOG and DIGITAL CLAMP ON METERS INDUSTRIAL and HOUSEHOLD CONTROLLERS CHART AND PAPERLESS RECORDERS POWER CONTROL UNITS and INVERTERS AUTOMOTIVE DASHBOARD INDICATORS ACCESSORIES FOR MEASURING INSTRUMENTS MEASURING SYSTEMS ENERGY HEAT CONTROL CUSTOM MADE PRODUCTS WE ALSO OFFER OUR SERVICES IN THE PRODUCTION OF m ALUMINIUM ALLOY PRESSURE CASTINGS Nm PRECISION ENGINEERING AND THERMOPLASTICS PARTS NM PRESSURE CASTING DIES AND OTHER TOOLS QUALITY PROCEDURES According to ISO 9001 and ISO 14001 international requirements
6. ccessible after removing the protective cover fig 10 The protective cover is closed by two lateral fasteners fig 1 12 Cover Fig 10 View of the high current power controller circuit 4 5 1 Connection of the supply and synchronisation circuit to the LZ1 terminal strip GTS supply Synchronisation 115V 60Hz or 230V 50 Hz 24 440V 50 60Hz Fig 11 Description of the LZ1 terminal strip One must connect the Gate Triggering System GTS to the LZ1 terminal strip depending on the power controller version 115 V 60 Hz or 230 V 50 Hz S1 and S2 terminals of the synchronisation system should be connected to the load supply circuit 13 4 5 2 Load connection in single phase system a Load supply U lt 230 V U supply 230 V Control 0 4 20mA La n stjs2 Inm eND Imu LZ1 LZ2 x RP1 power DK controller U1 U2 PE TO oj s L1 N PE b Load supply U saa 400 V Urs supply 230 V Control 0 5 10 V LI N s1 s2 __ m eno inu izi LZ2 RP1 power controller U1 U2 PE Fig 12 Connection diagram of load in single phase system 14 4 5 3 Load connection in three phase system The power control is possible in the three wire three phase system using two power controllers The presented way of control concerns th
7. e on off control type in the zero cross of the supplying voltage or the pulse control with the turned soft start and current limitation off VA Control 0 5 10 V RP1 power controller Master y AS L2 L3 KJ M S GNDJ In GND m U 5v END 122 Load RP1 power controller fo Slave LZ1 L1 N s1 s2 Ut U2 L1 In io A o IS EEN PE Fig 13 Connection diagram of a load in three phase system 5 POWER CONTROLLER SERVICE S Start and Limit potentiometers must be set on minimum and amax and Span potentiometers on maximum In such settings corresponding functions to them are inactive One must carry out successively following operations a install the power controller according to p 4 1 b carry out electrical connections according to p 4 2 p 4 4 and p 4 5 c set the controll type and the input control signal according to p 4 3 19 d turn on the supply voltage of the load circuit and of the gate triggering system according p 4 5 e set the current limitation according to p 6 4 set the Limit potentiometer on maximum Observing indication of the meter measuring the load current at the maximal value of the input control signal set the reguired current value decreasing the setting on the Limit potentiometer f set the triggering delay according to p 6 5 g set the initial
8. ed to be mounted on a wall by means of holders Power controller overall dimensions spacing of assembly holes and the fixing way are presented on the fig 1 174 204 Snap fastener of protective cover Dimensions in parenthesis concern the version with a fun Version RP1 4 x x 125 A Fig 1 Overall dimensions and fixing way of the RP1 power controller In case of mounting in a control cabinet it is recommended to apply a forced air cycle RP1 power controllers can be situated side by side preserving minimal spacing according to the fig 2 Lal LZ2 7 1 8 2 9 10 3 11 6 Fig 3 View ofthe frontal plate Servicing elements are disposed on the power controller frontal plate Fig 3 Signalling diodes e Control two colour diode 1 supply correctness and power controller readiness to work e Load two colour diode 2 passage of current through the load when Ijoad gt 5 In of the controller e Stop red diode 3 external triggering stoppage e Error red diode 4 error related to the power controller work e Over Temp red diode 5 exceeding of the allowable temperature e Fuse fail red diode 6 fuse burnout Potentiometers and switch e S Start potentiometer 7 control of the soft start function duration e Limit potentiometer 8 limitation of the load current e max potentiometer 9 control of the
9. eding devices chemical and petroleum industries facing heaters of tube installations preheating installations BASIC REGUIREMENTS OPERATIONAL SAFETY Power controllers are applied in high current installations in which devices under voltage can be a source of danger Considering the personnel safety one should observe following principles Devices can be installed serviced and maintained exclusively by a suitably qualified personnel having essential knowledge about equipment RP1 power controllers should be connected to the power network according to the present operative regulations and standards concerning electrical installations and concerning specially the protection against electric shocks During the start and operation of the device One must comply with recommendations included in this user s manual and specially to sections 4 5 and 6 Qualified personnel defines persons which are acquainted with the user s manual assembly starting and service of the product and have appropriate qualifications to carry out these activities 3 POWER CONTROLLER SET The set consists of RP1 power controller 1 pc user s manual 1 pc warranty card 1 pc Quick start card 1 pc When unpacking the power controller please check the delivery complete ness and whether the type and version code on the data plate correspond to the order 4 INSTALLATION 4 1 Overall and assembly dimensions The RP1 power controller is destin
10. ents of the EN 60947 4 3 standard NOTE In case of phase control the power controller fulfils reguirements of the electromagnetic compatibility in relation to the interferen ce emission only when working near the of the supply voltage through zero 23 8 ORDERING CODES Table 3 Power controller RP1 X X X Current range maximal output current 25A PREN 1 oad voltage maximal output current 40A 24 400Vac 2 maximal output current 70A 50 60 Hz 3 maximal output current 125 A 4 Gate triggering system system GTS supply voltage 85 115 135 V a c 1 supply voltage 195 230 253 V a c Acceptance tests without an additional quality inspection certificate 8 with an extra quality inspection certificate 7 other requirements coooooccccconccnnccnnncnononnnnanonanncannnnn namen nnnnnnnnnnannnnnnnannnnnn x The RP1 4xx version has a buil in fun ORDERING EXAMPLE The code RP1 3 2 0 means RP1 power controller of RP1 type 3 maximal output current 70 A for the range of voltages 24 400 V supplying the load circuit 2 voltage supplying the gate triggering system 230 V 8 without an additional guality inspection certificate 24 9 MAINTENANCE AND WARRANTY The RP1 power controller does not reguire any special periodical maintenance In case of some incorrect operations After the dispatch date
11. ff type in the turn on configuration at across zero voltage In case of exceeding of the current boundary value the Load diode is alight in red 6 5 Triggering delay of soft start type The soft start function enables a soft accretion of the voltage from zero up to the rated value or value resulting from the current limitation action in the time set by means of the S Starf potentiometer In the case of phase control or on off control type in the configuration of immediate turn on the soft start time t_ is controlled in the range from 0 up to 10 s 19 In case of the pulse control this time is equal to _ 1 tos 4 5 i max The function is not active in case of the on off control type in the turn on confi guration at zero voltage 6 6 Control of the initial triggering angle value During the power controller use for the rotational speed control of a single phase motor fan one can set the current value Ir necessary for the motor start by me ans of the amax potentiometer In this case the control is in the range from the set value Ir of the current up to the rated value In of the current The function does not operate in case of the on off control type in configuration turned on at zero voltage 0 7 ontrol signal Fig 18 Action of the amax function 6 7 Control of the input line amplification The Span potentiometer serves to set the amplification of the input line in the contro
12. initial triggering angle value e Span potentiometer 10 control of the input line amplification e Switch DIP SWITCH 11 to configure analog inputs and the control mode 4 2 Electrical connections One must carry out electrical connections by means of following leads a to LZ1 and LZ2 terminal strips leads with cross section from 0 35 up to 2 5 mm b to high current terminals RP1 1xxx version leads with 6 mm cross section RP1 2xxx version leads with 10mm cross section RP1 3xxx version leads with 16 mm cross section RP1 4xxx version leads with 35 mm cross section c to the protective terminal lead with a cross section at least the same as leads in high current circuits It is recommended to shield leads in the synchronisation circuit with the network voltage supplying the load and signalling leads on the LZ2 terminal strip 4 3 Choice of the control type Depending on the kind of control and the input control signal one must suitably set sections of the DIP according to the table 1 One must choose the kind of control at turned GTS supply off see p 4 5 1 Table 1 DIP switch section Input control signal Phase Pulse quick cycle Pulse slow cycle On Off switching at zero voltage On Off prompt switching Kind of control 0 Open switch 1 short circuited switch State resulting from other settings 4 4 Connection of control signals 4 4 1 Co
13. it 22 7 2 Electrical parameters of the supply and control circuit 22 7 3 Other parameters ae aaa dia 23 7 4 Safety requirements hen ee 23 7 5 Electromagnetic compatibility cora en 23 9 ORDERING CODES zao ina tieisiai a eaaa aaa aa iaa 24 9 MAINTENANCE AND WARRANTY nee 25 1 APPLICATION The RP1 power controller is destined to control the load power in function of the input control signal for following types of loads resistive wit a positive temperature coefficient of resistance heaters made of alloys on the base of molybdenum Mo platinum Pt tantalum Ta tungsten W iron Fe resistive with a negative temperature coefficient resistance heaters made of sintered carbide graphitical heaters resistive inductance transformer loaded by a resistive load transformer loaded by a rectifier system The application area of RP1 power controllers includes 2 electrical furnaces and drying constructions particularly industrial tunnel and belt type furnaces furnaces for annealing and hard soldering crucible furnaces and furnaces for hardening in salt bath devices of mechanical engineering aggregates and extruding presses for plastics devices for winding and tempering of springs spot welding and seam welders production of glass and glazing installations and devices for drying in infrared and ultraviolet radiation ladles for glass melt and heating of fe
14. it terminals fig 5 4 4 4 Triggering stoppage One can carry out the triggering stoppage short circuiting 5 V and STOP termi nals on the terminal strip The STOP input is active in the 4 32 V 5 mA voltage range Fig 7 Triggering stoppage 4 4 5 Analog outputs a Output U z f lo 0 5 V 5 mA output voltage proportional to the current value in the load circuit b Output M S The output of Master Slave type is used when the power controller works as a master device The slave power controller must be set in the turn on working mode at the zero across of the supply voltage Output load carrying capacity max 5 mA Example of connection is shown on the fig 13 V 2 a o Bla 315 5 zZ O OJO Fig 8 Analog output 11 4 4 6 Relay outputs Semiconductor relays of MOSFET type a Output PKT Signalling of damaged fuse b Output PK2 Signalling of an incorrect working state lack of supervision on the control ERROR active signal of triggering stoppage STOP lack of synchronisation fuse damage exceed of allowable radiator temperature In lt 60 mA 230 V a c d c Ron lt 35 Q Uiso 1500 Vrms Voltageless outputs they are not bi protected against overloads or x x shortings Fig 9 Relay outputs 4 5 Connection of supply and load U1 and U2 high current sockets to connect supplies of the load circuit the ter minal PE of the protection wire and the fuse B1 are a
15. l range from 50 up to 100 of the input control signal 6 8 Check and current signalling in the load circuit The passage of current in the load circuit is signalled by means of a two colour Load diode During the normal work the diode is alight in green however in the moment of the current limitation action it is alight in red 6 9 Signalling of the supply correctness The two colour Control diode is alight in green during the normal work however in the moment of lack of power controller readiness to work it is alight in red the power controller is locked 20 6 10 Signalling of maximal radiator temperature exceed The exceed of the 85 C radiator temperature causes the automatic triggering stoppage and display of signalling on the Over Temp diode and the PK2 relay turn on p 4 4 6b The restart of the power controller is possible after the radiator cooling below 60 C and the supply turn on to GTS again p 4 5 1 6 11 Error signalling The power controller submits the error in following cases a lack of synchronisation b the current flows through the load despite of lack of triggering pulses e g as the result of a thyristor module damage c Lack of current passage in the load circuit e g because of a break in the high current line the function begins to operate over 50 of the control signal In case of an error statement the automatic triggering stoppage and display of the Error diode fo
16. llows and the PK2 relay turns on p 4 4 6b The restart of the power controller is possible after removing damage causes and the renewed supply turn on to GTS p 4 5 1 6 12 Overload protection The output circuit of the power controller is protected against its overload The protection is set on 125 of the power controller rated current The exceed of this value will cause the action of current limitation The function does not operate in case of on off control type in the configuration turned on at zero voltage 7 SPECIFICATIONS 7 1 Electrical parameters of the high current circuit Table 2 Max Supply Lost Fuse parameters output Voltage Max oag powerin fizdt current of the load power tyr circuit yristors at 415 V 20 440 V 2 35 40 A 35FE Bussmann 50 60 Hz 1 0 kW ee 6 9 gRB 000 BS 88 40 FERRAZ 20 440 V 50A 50FE Bussmann As 50A 50 60 Hz eki une 6 9 gRB 000 BS 88 50 FERRAZ Designation and manufacture 20 MOV 39 3 kw 3600 Azs 100A 100FE Bussmann 50 60 Hz 6 9 URB 000 BS 88 100 FERRAZ 20 440 V 160 200 A 200FEE Bussmann 2 50 60 Hz 55 0 kW 9600 A s 6 9 URB 000 BS 88 160 FERRAZ 21 Minimal input current Leakage current Kind of load 5 of In range of the power controller output current lt 20 mA resistance or resistance inductance load 0 5 lt cos fi lt 1 in compliance with the application category AC 51 EN 60947 4 3 Other applicati
17. nnection of control to the LZ2 terminal strip It is recommended to use shielded leads and a separate control and high current installation to connect control signals to the LZ2 terminal strip Relays outputs f lo Limitation of the load current Triggering stoppage Output U PK2 o o PK2 M S output GND i Current input GND Voltage input 5V Fig 4 Description ofthe LZ2 terminal strip 4 4 2 Input control signal Current Voltage Control from input input potentiometer 0 20 mA 0 5 V 4 20 mA 0 10 V 10kQ Fig 5 Connection of control signals a by analog signal The control from a voltage or current control signal source or from the potentio meter is possible In case of control from the potentiometer the voltage input should be set on the 0 5 V range b by pulse signal One must connect the control signal 4 32 V to terminals of the voltage input IN U set on the 0 5 V range 4 4 3 Limitation of the load current There is the possibility to limit the load current from the external potentiometer which should be connected according to the presented drawing One must set the Limit potentiometer on minimum G Xx o SIMME II E 0502888885080 Fig 6 Limitation of the load current 10 In case of using the current limitation potentiometer on the power controller frontal plate one must short circuit 5 V and Lim
18. ons after agreement with the manufacturer 7 2 Electrical parameters of the supply and control circuit GTS supply voltage supply voltage freguency power consumption synchronizing input voltage control input current control input pulse control input 8n 115 135 Va c 195 230 253 Vasc 50 60 Hz lt 4 5 VA 20 440 Va c R 240k0 0 5 V R 20 kQ 0 10 V R 40 kQ 0 4 20 mA R 1250 0 4 32 V R 20 kQ STOP signal input 4 32 V 5 mA load carrying capacity of 5 V output 25 mA load carrying capacity of lo output 5 mA 5 V load carrying capacity of M S output 5 mA 5 V load carrying capacity of relay outputs 60 mA 350 V R 35 Q U 1500 V rms 7 3 Other parameters working temperature 0 40 C storage temperature 25 55 C humidity lt 90 without condensation working position vertical dimensions version without fan version with fan weight 22 135 x 201 x 199 mm 135 x 231 x 199 mm 4 5 5 0 kg 7 4 Safety reguirements maximal phase to earth working voltage 320 V for power and supply circuits 50 V for other circuits pollution degree 2 installation category Ill protection degree from terminal side IP 10 acc to EN 60529 housing protection degree IP 20 acc to EN 60529 7 5 Electromagnetic compatibility immunity noise EN 60947 4 3 emission noise EN 60947 4 3 The RP1 power controller fulfils reguirem
19. value of the triggering angle according to p 6 6 Increase the input control signal up to reach the current value Ir necessary to the motor start next decrease gradually on the amax potentiometer up to turn off fig 5 In this case the control range depends on the set current Ir value to the rated load current In value h set the amplification of the imput line according to p 6 7 One can reach experimentally the obtainment of proper settings by means of potentiometers and this should be carried out by a suitably trained personnel 6 DESCRIPTION OF CONTROL TYPES 6 1 Control of ON OFF type At the on off control the delivered power to the load is described by the following dependence 0 for X 0 P max for Xin X nax Where P delivered power to the load X value of the input control signal The power controller works in the semi conductor relay mode The feed of the voltage signal on the control input p 4 4 2b causes the turn of the load current on Depending on the setting configuration table 1 The turn on follows imme diately or at the nearest actual supply voltage value transition across zero Runs of signals describing the power controller operation for the control of on off type are shown on the fig 14 16 Voltage supplying U the load circuit t Pulse input Xwe signal t Turn the acros zero voltage on Current in the lo load circuit k 1 L gi l v Turn immediately on
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