POWER CONTROLLER RPL1 TYPE USER`S MANUAL
Contents
1. A Po y fi Nof Non Nott Xin tt 3 X max X max Fig 5 3 Runs of characteristic quantities for the pulse control 5 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 5 4 xk Continuous X max input signal t WA A A N f WA A Supplying gt ma VVU VVU VVV load circuit current M A N A A a ZR a YY VY X o a Fig 5 4 Phase control runs of occurring signals 16 5 4 Control of the input line amplification The Span potentiometer serves to set the amplification of the input line in the control range from 50 up to 100 of the input control signal Xwe The gain control takes into account the phase shift between current and voltage in the control of receivers with a resistive inductive RL or inductive L character Fig 5 5 The relationship of the control signal from the nature of the load 1 5 X max 5 5 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 The setting of the potentiometer on minimum means the turn of the current lim2. glazing installations and devices for drying in infrared and ultraviolet radiation ladles for glass melt and heating of feeding devices chemical and petroleum industries facing heaters of tube installations preheating installations BASIC REQUIREMENTS 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 RPL1 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 5 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 RPL1 power controller 1 pc user s manual quick start card 1 pc warranty card 1 pc When unpacking the power controller please check the delivery complete ness and whether the type and version co
3. Prodaja in zastopa Materm d o o Morje morska cesta 6 2313 Fram tel 02 608 90 10 www materm si POWER CONTROLLER RPL1 TYPE O control O cas USER S MANUAL CONTENTS R ON APPLICATION mo iii 5 BASIC REQUIREMEMNTS OPERATIONAL SAFETY 5 POWER CONTROLLER SED wci LO aska 6 INSTALLATION X M Enn uka banani 6 4 1 Overall and assembly dimensions eee eeeeaaaaaa aa aaa eee aaa aaaaaaana ae 6 4 2 Electrical connections aaa A EE EA EAC Ek 8 4 3 Choice of the control type asa aoi siepe etant rra O AGGA 8 4 4 Connection or control Signals ausis A AG a EG RE ee 9 4 5 Connection of supply and HOA ucc onini noe RARE 11 DESCRIPTION OF CONTROL TYPES eeeeeeeeerme 14 S le Control of ON OFF YPE m EEG rani Eiaa eea vsi 14 ee UNS COMM ON E E A ET 15 30 Phase CONMO NT TT 16 5 4 Control of the input line amplification onore tts 17 5 5 Limitation of the load COIS s aneirrtrr exerit t tbe mE Pea Gothica dO T 3 0 Overload OF ORS COIN suisse teatro Yir da ossa Eu AE PRE Eae SEN pau casa ERE AEGEE SEE SEE 17 Dr DO Start UOCNOM ie etes AN AEGEE OE EEG 17 5 8 Signalling of maximal radiator temperature exceeding 17 CONTROLLER OPERATION menn 18 4 EGHNICAL DATA OM 19 7 1 Electrical parameters of the high
4. V eu m Em Uers supply 2 280V RPL1 power controller Fig 4 9 Connection diagramm of load in single phase system 4 5 2 Load connection in three phase system The power control is possible in the three wire three phase system using two power controllers only for RPL1 2xx version EUER d Control 0 5 10 V m Lz2 mini Power controller RPL1 PE Master RN useen mnv T eee LZ Load l Power controller RPL1 i Slave ui uz gd Fig 4 10 Connection diagram of a load in three phase system 13 5 DESCRIPTION OF CONTROL TYPES 5 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 lt 0 p 1 se max for X X nax Where P delivered power to the load X value of the input control signal The feed of the voltage signal on the control input causes the turn of the load current on The turn on follows immediately or at the nearest actual supply volta ge value transition across zero Runs of signals describing the power controller operation for the control of on off type are shown on the fig 5 1 U Voltage supplying the load circuit t Xwe i ka ana signal ucc turn the across zero voltage on Current in the load circuit Fig 5 1 Control of on off type runs of occurring si
5. commended to use shielded leads and a separate control and high current installation to connect control signals to the LZ2 terminal strip Relays outputs o D on o 5 Z 2 e o 5 9 5 o a N N o Y x a 5 5 o O Y Y EXETEIETETNE 000 858 Description of the LZ2 terminal strip SI MIS LETT M S output He b FETTE 2000098 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 10k9 Fig 4 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 only for control of relay type 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 Auxiliary inputs outputs Stop l 77 Output M S ND Fig 4 6 Analog outputs a triggering stoppage STOP One can carry out the triggering stoppage short circuiting 5 V and STOP terminals on the terminal strip The STOP input is active in the 4 8 V voltage range 10 b Output M S only for pulse relay control The output of Master Slave type is used when the power controller works as a master device Output load carrying capac
6. current circuit 19 7 2 Electrical parameters of the supply and control circuit 20 7 3 Other parameters macki O Fo AEG open be panna k data AE E ESA 20 1 2 Satety TEQUMINGINISMUES ara Tan a ek aaa 20 1 5 Electromagnetic compatibility otn Poden ria ntn 21 ORDERING CODES eski didis Ed EEEE ORZEC 22 MAINTENANCE AND WARRANTY seeeeeaaaaaaaaaaa aa ea nennen 23 1 APPLICATION The RPL1 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 RPL1 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
7. de 4 2 Electrical connections One must carry out electrical connections by means of following leads a to LZ1 and LZ2 terminal strips fig 4 3 leads with cross section from 0 35 up to 2 5 mm b to high current terminals RPL1 x1xxx version leads with 6 mm cross section RPL1 x2xxx version leads with 10mm cross section RPL1 x3xxx version leads with 16 mm cross section RPL1 x4xxx 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 Switch according to the table 1 One must choose the kind of control at turned supply off Table 1 DIP switch section Phase control ver RPL1 1xxx EORECHECN E NR Input control signal oma oo Lo LOC mna Start off ntrol Contro type Soft Starton sid Start on Input control signal puse quickcyde 1 Control type pulse slow cycle _ O KE 0 open switch in position down OFF 1 close switch in position up ON PE State resulting from other settings 4 4 Connection of control signals 4 4 1 Connection of control to the LZ2 terminal strip It is re
8. de on the data plate correspond to the order 4 INSTALLATION 4 1 Overall and assembly dimensions The RP1 power controller is destined 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 4 1 174 204 of protective cover Dimensions in parenthesis concern the version with a fun Version RPL1 x4xxx 125 A Fig 4 1 Overall dimensions and fixing way of the RPL1 power controller In case of mounting in a control cabinet it is recommended to apply a forced air cycle RPL1 power controllers can be situated side by side preserving minimal spacing according to the fig 4 2 LZ1 LZ2 Fig 4 3 View of the frontal plate Servicing elements are disposed on the power controller frontal plate Fig 4 3 Signalling diodes e Control green diode 1 power controller readiness to work e Load green diode 2 triggering e Stop red diode 3 external triggering stoppage e Over Temp red diode 4 exceeding of the allowable temperature e Fuse fail red diode 5 fuse burnout Potentiometers and switch e Limit potentiometer 6 limitation of the load current only for phase control e Span potentiometer 7 control of the input line amplification only for phase control e DIP Switch DIP SWITCH 8 to configure analog inputs and the control mo
9. e RPL1 power controller fulfils requirements of the EN 60947 4 3 standard NOTE In case of phase control the power controller fulfils requirements of the electromagnetic compatibility in relation to the interference emission only when working near the of the supply voltage through zero 21 8 ORDERING CODES Control phase pulse on off Current range maximal output current 25 A maximal output current 40 A maximal output Current 70 A maximal output current 125 A Load voltage supply voltage supply voltage supply voltage Version standard custom made Acceptance tests without additional guality inspection reguirements with an extra guality inspection certificate other reguirements the version RPL1 x4xx has a fixed fan after agreeing with the manufacturer Ordering example The code RPL1 1 1 2 00 E O means RP1 power controller of RPL1 type 1 phase control 1 output current maximal 25 A 2 supply voltage 340 400 440 V a c 00 standard version E English 0 without additional quality inspection requirements 22 9 MAINTENANCE AND WARRANTY The RPL1 power controller does not require any special periodical maintenance In case of replacement of the damaged fuse you must disconnect the power supply of the power controller from power clamp and LZ1 terminal remove the cover fig 4 10 replace fuse B1 type according to the table 2 In case of some inco
10. gnals for resistive load 14 5 2 Pulse control Pulse control consists on the change of the pulse duty factor and the frequency of power Pj 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 5 2 The power value in the pulse period T according to the formula 2 is defined by the dependence 3 M 1 NA u No N X Es bos r E ndi ao SSP us X n Non TN Nos in max where T period of the supply voltage Y pulse duty factors N number of turned periods on on N number of periods off X value of analog control signal 2 3 sere ODIN reso NA Fig 5 2 Pulse control with a variable pulse frequency runs of occurring signals 15 The RPL1 power controller has following kinds of pulse control e Quick cycle in which for X 1 2 Xmax Xmin Non Now 25 however f ax 1 Hz e Slow cycle in which for X 1 2 Xmax Xmin Non Nog 100 however f a 0 25 Hz Where f az maximal pulse frequency Runs of characteristic quantities for the pulse control are presented on the fig 5 3
11. ine For resistance load the Spam potentiometer must be set on maximum In case of inductive load the phase shift between current and voltage must be taken into consideration decresing the amplifiaction in such a way as to obtain current control on the receiver to the full extent of the control signal f set the current limitation At the maximal value of the input control signal set the required current value increasing the seting on the Limit potentiometer Getting the right tune using potentiometers shall be achieved experimentally and should be performed by appropriately trained employee 18 7 TECHNICAL DATA ZVHH3H 091 88 S8 000 aun 69 uueussng 334007 _ V 002 09L ZNAdJA 001 88 Sd 000 aun 6 9 uuewssng 44001 V 001 ZvdH3J 08 88 Sd 000 auf 6 9 uuewssng 340GS vos ZNHH3d 0v 88 sa 000 gHO 6 9 uueussng 349 Op SE 91nj2ejnueui pue uoneufisag siajawesed asnj c SI EL 7 1 Electrical parameters of the high current circuit Szy 0096 Szy 009 SzV Oby Szy O8C A GLb ye p z ma zz ae rz Sl0 SIJAU ul Jamod 1S0 XEINI ZH OS 00S ZH OS A 00v ZH 08 A OEZ ZH OS A 00S ZH 08 A 00r ZH 0G A 082 ZH OS 00S ZH 08 A 00v ZH 08 A O 2 ZH OS 00S ZH 08 00r ZH 08 A 0 amp 2 yn3119 peo au jo afieyjon Ajddns yuana indjno Xe 19 Leakage current lt 20 mA Kind of load resistance or resistance inductance load 0 2
12. itation operation off 5 6 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 5 7 Soft Start function In the case of large surge currents toroidal transformers furnaces with graphite lined heaters etc you must enable Soft Start function which enables a smooth access to the setpoint value of the output current with a delay up to a maximum of 2 s reaction to the change swept the control signal Function is active in the entire range of adjustment 5 8 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 Note The driver will automatically go into operating mode after cooling the heater below 60 C therefore immediately after the alarm disconnect the power supply of the device Applies only to control the phase 2 17 6 CONTROLLER OPERATION In the order please follow these steps a install the power controller b carry out electrical connecitons c set the control type and the input control signal d turn on the supply voltage of the load circuit and of the gate triggering system in the case of phase control in addition e set the amplification of the input l
13. ity max 5 mA 4 4 4 Relay outputs In 60 mA 230 V a c d c Ron 35 Q Uisoi 1500 Vnus PK1 and PK2 are voltageless outputs MOFSET with optoisola tion they are not protected against overloads or shortings Fig 4 7 Relay outputs a Output PK1 Signalling of damaged fuse b Output PK2 Signalling of an incorrect working state active signal of triggering stoppage STOP exceed of allowable radiator temperature fuse damage 4 5 Connection of supply and load U1 and U2 high current sockets to connect supplies of the load circuit the termi nal PE of the protection wire and the fuse B1 are accessible after removing the protective cover fig 4 8 The protective cover is closed by two lateral fasteners 11 Cover Fig 4 8 View of the high current power controller circuit 4 5 1 Load connection in single phase system For terminals L1 and N of the LZ1 terminal strip nalezy podtaczy zasilanie 230 V 50 Hz In the case of phase control lecture RPL1 1xx the S1 and S2 terminals of the synchronisation system should be connected to the load supply circuit Depending on the controler version 230 V a c version RPL1 xx1xx Connection only for hase control 400 V a c version RPL1 xx2xx sm 500 V a c version RPL1 xx3xx sina RPL1 power controller a Load supply Ujoad 230 V Ucrs supply 230 V 12 b Load supply Uload 400
14. lt cos lt 1 in compliance with the application category AC 51 EN 60947 4 3 7 2 Electrical parameters of the supply and control circuit GTS supply voltage 195 230 253 V a c supply voltage frequency 50 Hz power consumption lt 4 5 VA synchronizing input 230 V a c ver RPL1 xx1xx 400 V a c ver RPL1 xx2xx 500 V a c ver RPL1 xx3xx voltage control input 0 5 V R 20 kQ 0 10 V R 40 kQ current control input 0 4 20 mA R 7125 Q pulse control input 0 4 32 V R 20 kO STOP signal input 4 8V R 1kQ M S signal output 6 12 V labil load carrying capacity of 5 V output 25 mA load carrying capacity of relay outputs 60 mA 350 V R 35 Q U 1500 VRys 7 3 Other parameters working temperature 0 40 C storage temperature 25 55 C humidity lt 90 without condensation working position vertical dimensions 135 x 201 x 199 mm 135 x 231 x 199 mm ver RPL1 x4xx version with a fan weight 4 5 kg 5 0 kg ver RPL1 x4xx version with a fan 7 4 Safety requirements maximal phase to earth working voltage 320 V for power and supply circuits 50 V for other circuits 20 pollution degree 2 installation category III 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 Th
15. rrect operations After the dispatch date 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 purchase 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 23 LUMEL S A ul Stubicka 1 65 127 Zielona Gora Poland Tel 48 68 45 75 100 Fax 48 68 45 75 508 e mail lumelQlumel com pl http www lumel com pl Export Department Tel 48 68 45 75 302 Fax 48 68 32 54 091 e mail export lumel com pl P41 09
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