TLV1000 Series User Manual
Contents
1. Alternating Red Green Self test DeviceNet Connector This connector provides DeviceNet connectivity Pin Signal Description 1 V Negative bus supply voltage 2 CAN_L CAN low bus line 3 SHIELD Cable shield 4 CAN_H CAN high bus line 5 V Positive bus supply voltage a DeviceNet bus power For more information see D 48 Technical Specification Anybus CompactCom DeviceNet Doc Rev 2 10 Doc ld HMSI 168 51 About the Anybus CC PROFIBUS DP V1 5 1 3 Front View Item 1 Operation Mode 2 Status 3 PROFIBUS Connector 4 M12 Female Connector 5 M12 Male Connector Operation Mode State Indication Comments Off Not online No power Green Data exchange Flashing Green Clear Flashing Red 1 flash Parametrization error See Parametrization Data Handling on page 15 Flashing Red 2 flashes PROFIBUS Configuration error 8 See Configuration Data Handling on page 16 Status State Indication Comments Off Not initialized Anybus state SETUP or NW INIT Green Initialized Anybus module has left the NW INIT state Flashing Green Initialized diagnostic event s present Extended diagnostic bit is set Red Exception error Anybus state EXCEPTION Anybus CompactCom PROFIBUS DP V1 Doc Rev 2 20 Doc HMSI2. 2 Slide the ears on the top and bottom covers into the slots in the stack sides 3 Clip the bottom ears of the front cover into the slots in the side of the stack so that the front cover traps the bottom cover against the crossbar 4 Clip the top ears of the front cover over the top cover and into the slots in the side of the stack Press home on top to secure 5 Fit the M5 front cover retaining screws Wiring Recommended Power Cable Sizes The following is a guide only as installation conditions will vary A maximum control cabinet internal temperature of 45 C has been assumed with cables routed in free air in the immediate vicinity of the stack and passing into trunking in groups of three The cable protective fuse or circuit breaker rating has been assumed to be equal to the stack current rating A cable suitable for operating at 90 C has been assumed A high temperature cable is required because the semiconductor fuses and the thyristors run hot and contribute to the heating of the cable Use of cable of smaller cross section may result in overheating of the cable fuses STACK RATING CABLE X SECTION 80A 25mm 125A 50mm 160A 70mm 200A 120mm 250A 120mm Temperature rating 120 C Power Connections and Auxiliary Line Connection Use the guide in the previous paragraph when determining cable type and cross section Cables should be connected using heavy duty tube type ring crimp terminals The stud diameter is 8mm
3. Control Board Connector Assignments Page 8 Commissioning and Operation Page 8 Configuration Jumpers ee ppieeehiaachteeid wis cht PANAGURI Page 8 Operation of Jumpers 3A to 3C in Setup Mode Communications Network Address and Baud Rate Km mada sae hohe aware eos Page 9 Preset Potentiometers Adjusting the Response Speed and Voltage Span Page 9 COMO SEIOOMMS EECHER Page 10 Controlled Parameters Page 10 Communications Data Nasaan KA els Bota KABA EN Page 10 LED Indicators nA KGG dt tre aka Ng nator moe Gio wad del ae Khan nab na Page 12 Maintenance manang ts ocala ghd wit a GR LAN PAANAN LTE tact pth nine BOR Se Page 12 Semiconductor Fuse Types 00 000 ccc ccc cece eee eee teens Page 12 Ordering Ru en Lu WEE EE EE Page 13 Caledon Controls Ltd Page 3 User Manual CONTACTING US TLV1000 Series Thyristor Stacks 80A to 250A Please feel free to contact us by telephone e mail or fax if you require further information or advice on the application installation or maintenance of these units Contact details are on the front of this manual IMPORTANT SAFETY INFORMATION WARNING SERIOUS DANGER OF ELECRIC SHOCK These thyristor stacks must be earthed The earthing arrangements must be able to carry the fault current associated with a short circuit of the main load circuit to the metalwork of the stack until the protection device opens Thyristor stacks must never be used as a means of supply isolation as
4. category Ill for supply voltages up to 300V line to earth 80A 125A 160A 200A 250A 50HZ 8 or 60HZ 8 24V DC 20 Without fan 80A model 150mA With fan 125A to 200A 1 150mA With fan 250A model 1 650mA All current ratings have the same dimensions Height excluding mounting clamps 290mm Width 136mm Depth 265mm M8 studs Supply at top load at bottom earth at bottom Plug and socket connections accepting wire size up to 1 5mm 0 50 degrees C 0 5V 1 5V 0 10V 0 20mA 4 20mA potentiometer jumper selectable Analogue input 1 Control input Analogue input 2 Current control current limit Activated by link contact closure or 5 to 24V Digital Input 1 Enable stack disables within 20ms when disabled Digital Input 2 Not set phase angle set soft start burst fire control Various Fieldbus types supported in data exchange mode only using HMS Anybus CompactCom plug in modules Caledon Controls Ltd Page 4 User Manual TLV1000 Series Thyristor Stacks 80A to 250A DIMENSIONS im ak 53 B Po om CH oor SR R Bpo BE Depth 265 mm Distance from E E E Bottom fixing centers E E to base of stack R S e 15mm Gi Si O H l 53 S sg Po om CH oor 05 eal INSTALLATION General Installation Requirements The following notes are a guide to ensuring sound system design and compliance with the requirements of the European Low Voltage Dir
5. 168 66 1 3 Front View About the Anybus CompactCom PROFINET IO 5 item 1 Network Status LED 2 Module Status LED 3 Link Activity LED 4 Ethernet Interface Network Status LED Note A test sequence is performed on this LED during startup LED State Description Comments Off Offline No power No connection with IO Controller Green Online RUN Connection with IO Controller established IO Controller in RUN state Green flashing Online STOP Connection with IO Controller established IO Controller in STOP state Module Status LED Note A test sequence is performed on this LED during startup LED State Description Comments Off Not Initialized No power or Module in SETUP or NW_INIT state Green Normal Operation Module has shifted from the NW_INIT state Green 1 flash Diagnostic Event s Diagnostic event s present Green 2 flashes Blink Used by engineering tools to identify the node on the network Red Exception Error Module in state EXCEPTION Red 1 flash Configuration Error Expected Identification differs from Real Identification Red 2 flashes IP Address Error IP address not set Red 3 flashes Station Name Error Station Name not set Red 4 flashes Internal Error Module ha
6. The terminal marked LINE is connected to the supply via a suitable fuse or circuit breaker see section on General Requirements The terminal marked LOAD is connected to one end of the load The other end of the load may be connected depending on the voltage rating of the thyristor stack either to a second supply line via a fuse circuit breaker or to the supply neutral A connection must be made from this end of the load to the terminal on the top of the control card marked Aux Line This connection is required to enable the controller to synchronise to the supply frequency and to measure the line and load voltages This connection should be wired with cable of 1mm or 1 5mm cross section If this connection is to a supply line rather than neutral the cable should be protected at source against short circuit by a fuse or circuit breaker of 6A rating A protective earth connection of suitable cross section should be made to the stud at the top of the unit More information is provided under Installation General Requirements Note that all studs are fitted with a plain and spring washer The recommended tightening torque is 12Nm Signal Wiring Signal cables should as far as possible be segregated from power cables and long runs parallel to power cables should be avoided Care should be taken to avoid signal flow and return paths which form loops enclosing a large area The flow and return paths should run parallel to ea
7. bits 8 and 9 Bits 7 to 10 are not Bit 8 Bit 9 implemented in the first 0 0 Setpoint 2 controlled parameter V software versions Setpoint 2 always 1 0 Setpoint 2 controlled parameter Power controls current 0 1 Setpoint 2 controlled parameter Volts 1 1 Setpoint 2 controlled parameter I Bit 10 Toggle high to reset energy counter 2 Setpoint 1 Active if Bit 3 in SR2 is set Range 0 0 to 100 0 3 Setpoint 2 Active if Bit 4 in SR2 is set Range 0 0 to 100 0 4 User Value A value entered in this register is returned in Production Register 15 After the stack has reset the energy counter it will ignore this bit for 1 minute After the energy counter is observed to have been reset this bit must be reset by the user otherwise the energy counter will be continually reset Caledon Controls Ltd Page 11 User Manual TLV1000 Series Thyristor Stacks 80A to 250A LED Indicators Four green LED indicators see diagram on page 8 show the operating status of the controller For information on the LED indicators on the CompactCom fieldbus communications module see the information appended at the end of the manual If no LEDs are illuminated the 24V power supply to the driver PCB is not present the board is unpowered Status LED 1 second slow flash The board is powered but is not enabled For the controller to enable there must be no alarms the hardware enable input must be activated and if comms read writ
8. Manual Issue Number R3 Date May 2013 GW11L1R3 JALITY MANAGEMENT USER MANUAL TLV1000 SERIES THYRISTOR STACKS PBB Bo Er ig a Fax 44 0 1555 772212 AN Caledon Controls Ltd Na ojia raas Unit 2 Block 4 Castlehill Ind Est Carluke Lanarkshire Scotland ML8 5UF Website www caledoncontrols co uk Email info caledoncontrols co uk User Manual REVISION HISTORY R1 First issue June 2012 R2 June 2012 R3 May 2013 Caledon Controls Ltd TLV1000 Series Thyristor Stacks 80A to 250A Preliminary information may be subject to change Added information on toggling comms established bit and other minor changes Added information on Profinet and other fieldbus networks and revised information regarding config parameters set by jumpers 3A to 3C Page 2 User Manual TLV1000 Series Thyristor Stacks 80A to 250A Table of Contents Revision MISON SEET Page 2 Ier RT EE Page 4 Important Safety Information Page 4 General Description Page 4 SPECINICANONS KAL abo ns DORR sd Hebe Rid eens Dba Ei Page 4 Kloe OT in EE Page 5 Installation NA INANG NG Airdate eed a Ba Ee EE ana Page 5 General Installation Requirements Page 5 MOUNUNG aaa KA ot EE Page 6 Cover Removal and Replacement Page 6 LL PAA EEN Page 7 Recommended Power Cable Sizes a Page 7 Power Connections and Auxiliary Line Connection 05 Page 7 Signal Winnog a ses saa aaa ens ik tent Bt nang a baga ee EE Page 7
9. applications We recommend a minimum gap between units of 15mm The mounting arrangement is shown in figure 2 Screw the upper and lower mounting brackets 1 and 2 to the mounting plate using M6 x 16mm screws or similar and plain washers but do not fully tighten Suitable holes should be drilled and tapped in the mounting plate dimensions on page 5 Hook the stack over the lower mounting bracket and raise the upper mounting bracket to the limit allowed by the slotted holes so that the stack may be installed against the mounting plate and the bracket hooked down over it Tighten up first the screws on the top bracket and then the lower bracket Cover Removal and Replacement A 3 part clear polycarbonate cover is provided The top and bottom cable entry covers are held in place by the front cover Caledon Controls Ltd Page 6 User Manual TLV1000 Series Thyristor Stacks 80A to 250A To remove the covers 1 Remove the M5 screws which fasten the front cover to pillars which extend from the printed circuit board 2 Grip the front cover at the top centre and pull forward The cover will unclip 3 The top and bottom cover plates are now free to be lifted off To replace the covers 1 Line and load cables must be fed through the slots provided in the top and bottom covers The top cover is provided with an additional slot for the auxiliary line cable The bottom cover has two slots for the control cables and a slot for the earth cable
10. ard for the relevant fieldbus COMMISSIONING AND OPERATION Configuration Jumpers The position of various configuration jumpers etc is shown in the PCB layout drawing below P13 P Aux Lina S JMP3 P2 PW P11 Dig UP 2 kes P1 Dig VP 1 LED i Status LED O JMP1 IMP2 c C B B A A Set the jumpers for analogue inputs as required according to the following tables Note that if inputs with offset are required 1 5V 4 20mA then both analogue inputs must have offsets Analogue Input 1 Jumper 1A Jumper 1B Jumper 1C Jumper 3A 0 5V on 0 10V on 0 20mA on on 1 5V on on 4 20mA on on on 10k ohm Potentiometer Input Caledon Controls Ltd Page 8 User Manual TLV1000 Series Thyristor Stacks 80A to 250A Analogue Input 2 Jumper 2A Jumper 2B Jumper 2C Jumper 3A 0 5V on 0 10V on 0 20mA on on 1 5V on on 4 20mA on on on 10k ohm Potentiometer Input Jumper 3B Communications Read Write if not fitted Read only if fitted Jumper 3C Controlled parameter for setpoint 1 V if not fitted Power if fitted If comms are in read write mode then this jumper is ignored and parameter must be set in status register 2 Jumper 4 Activate setup mode In setup mode jumpers 3A to 3C enable setting of additional parameters by counting flashes of the Status LED see section below 3A Set communications address 3B Set communic
11. as read only or read write by jumper 3B In read only mode jumper 3B fitted the stack does not care whether or not communications are established All operating parameters are determined by the hardware The user may read parameters such as load voltage etc to determine the operating state In read write mode jumper 3B not fitted the operation of the stack can also be controlled by the user eg sending setpoints In this mode the stack will not operate unless Status Register 2 bits 1 and 2 are activated by the user Bit 1 is an additional enable This performs a similar function to the hardware enable and if it is not set the stack will be disabled but will not alarm Bit 2 comms established must be toggled approximately once per second If it is not toggled the stack will disable and alarm The purpose of this is to ensure that if communications are lost the stack will disable rather than continuing to operate with the same setpoint as when communication was lost The toggle function may be performed by the user s own timer or alternatively the heartbeat bit 9 in Status Register 1 may be read by the user and reflected back to status register 2 bit 2 In addition the user may write values eg an incrementing number into Consumption Register 4 which will be returned in Production Register 15 enabling the operation of the communication loop to be ascertained The function of the communications registers is defined in the table
12. ations baud rate 3C Set burst fire cycle time default value 10s 50 duty cycle Operation of Jumpers 3A to 3C in Setup Mode Communications Network Address and Baud Rate When jumper 4 is removed jumpers 3A to 3C take on their setup roles Before removing jumper 4 jumpers should be removed from 3A to 3C Then when jumper 4 is removed initially there will be no change to the parameters which are adjustable by 3A to 3C When the stack is first shipped these parameters will have default values The stack is now waiting for one of the jumpers 3A to 3C to be fitted When it is fitted the Status LED will start flashing and the number of flashes counted determines the value of the parameter When the required number of flashes has been observed the jumper is removed The new values are stored when the jumper 4 is replaced and the stack reverts to normal operating mode As shown in the table below for addresses the first flash represents zero the second flash represents 1 etc for burst fire cycle time the first flash represents 5s the second flash represents 6s etc Depending on the fieldbus fitted the address and or baud rate jumper may have no function 3A Counts address from 0 to 63 3B Changes baud rate Baud rate 1 baud rate 2 baud rate 3 increasing 3C Counts burst fire cycle time in seconds from 5 to 30 seconds While undertaking the above procedure normally only one of the jumpers 3A to 3C should be fitted at any one time If the co
13. be used Consult us before using other fuse types 2 DIN43 653 80 000 Stack Current Rating Nominal Fuse Current Fuse It ae Fuse Type Rating Approx A s B588 Chang Centres 80mm fixina centres B ssmanh E330100C M330038 Siba 110A 6 800 170M1485 170M1317 20 559 20 110 20 282 20 125 Ferraz F330055C N330039 Bussmann 160A 15 400 170M1469 170M1319 Siba 20 559 20 160 20 282 20 160 Ferraz H330057 Q330041 Bussmann 250A 44 000 170M1487 170M1321 Siba 20 559 20 250 20 282 20 250 Ferraz J330058C R330042 Bussmann 315A 77 000 170M1488 170M1322 Siba 20 559 20 300 20 282 20 315 250A Bussmann e 170M2670 Siba 350A DIN 00 size 110 000 DH 20 189 20 350 125A rating The line terminal fuse support pillar has alternative mounting points on the heatsink to cater for the different pitch of Caledon Controls Ltd Page 12 User Manual TLV1000 Series Thyristor Stacks 80A to 250A alternative fuses If necessary unscrew the pillar from the heatsink and re fit in the alternative position Note that a serrated lockwasher is fitted behind the fuse on the line stud It is most important that this is not omitted otherwise excessive torque may be transmitted to the stud when the fuse cable retaining nut is tightened The recommended tightening torque for these nuts is 12Nm ORDERING INFORMATION Select the desired options from the following table the nominal supply voltage range is for information only Typical example TLV1000 125A 480V 24V De
14. ch other Signal connections are made direct to the printed circuit board connectors Connectors are suitable for cable up to 1 5mm cross section Note that all connectors are unpluggable for ease of maintenance Caledon Controls Ltd Page 7 User Manual Control Board Connector Assignments TLV1000 Series Thyristor Stacks 80A to 250A Number Function Comment 1 3 3V Output Supply to energise a single 10k ohm potentiometer for use with an analogue input 2 Analogue input 1 3 Analogue input 2 4 Analogue inputs 0V 5 Digital input 1 Stack Enable Digital inputs are activated by applying a voltage of 5V to 24V 6 Digital input 2 Phase angle not activated DC between the input and the input common Voltage may be Soft start burst fire activated either polarity These terminals are galvanically isolated from all 7 Common for digital inputs other terminals 8 Alarm contact N C Volt free contacts Maximum rating 250V AC resistive 2A 30V 9 Alarm contact N O DC resistive 2A Isolation from 24V circuits meets requirements 10 Goninon tor alarm contacts for basic insulation overvoltage category II 11 24V Supply for control circuits and fan 24V supply should be protected with a 6A antisurge fuse or circuit breaker 12 OV Supply Fieldbus connections are made to the connector on the Anybus CompactCom grey module on the left of the control card and will follow the stand
15. e mode is selected the comms enable bit must be set consumption register 1 status register 2 Fast flicker The board is powered and enabled and is either operating in phase angle mode or is at zero setpoint Fast flicker full on The board is powered and enabled and is operating in burst fire mode The LED is full on in the on periods and fast flickers in the off periods Off Either the board is unpowered or the stack is in Setup mode jumper 4 off and awaiting action by the user Alarm LED This LED illuminates when there are no alarms The alarm relay will be energised The relay de energises in the alarm state Alarms which cause the LED to extinguish are Main power supply 50 60 Hz load power under voltage loss of phase lock heatsink temperature too high comms established bit in status register 2 not set comms read write mode only Dig In 1 Illuminates to indicate that digital input 1 hardware enable is activated Dig In 2 Illuminates to indicate that digital input 2 is activated the controller will operate in soft start burst fire mode MAINTENANCE Semiconductor Fuse Types Checking or changing of any fuse must not be attempted unless both main and driver supplies are isolated To do so is extremely dangerous and may also cause damage to the controller See Cover removal and Replacement for instructions on how to remove and replace the cover The semiconductor fuses listed in the table below may
16. ective and other international standards The stacks should be installed in a cabinet requiring a tool to gain access and access should be restricted to suitably trained and qualified personnel Provision should be made to exclude conductive pollution eg graphite dust from the cabinet and to avoid condensation Caledon thyristor stacks are designed with an impulse withstand voltage power circuits to earth of 4kV This meets the requirements of IEC and European standards for installation over voltage category 3 and supply voltage line to earth up to 300V AC RMS This corresponds to 520V line to line on most distribution systems in which the distribution transformer is star connected with earthed star point This does not preclude the use of the stacks in higher voltage systems provided the thyristor devices are suitably rated but the over voltage category will be reduced to 2 and precautions may be necessary eg surge arrestors to limit the expected impulse voltage level if systems compliance with the above standards is required All stacks in the TLV range incorporate an integral semiconductor fuse This is intended to provide short circuit protection for the thyristor devices by limiting the peak half cycle surge current and total energy let through It only provides limited protection against long term overload The stack ratings are co ordinated with standard HBC fuse values and the supply cables should be protected with gL gG fuse
17. even in the off state lethal leakage currents will flow An independent means of isolation complying with local standards must always be fitted The clear polycarbonate cover provides protection against accidental contact with live parts and must never be removed unless the main supply has been isolated elsewhere Busbars and circuitry on the printed circuit boards under this cover carry the full line voltage The stacks are intended for mounting in an enclosure which requires a tool to gain access Maintenance and installation work on these units should only be carried out by suitably qualified and trained personnel who have read and are familiar with the contents of this manual Additional information is provided under Installation General Requirements GENERAL DESCRIPTION A range of single phase thyristor stacks with digital communications facilities for use with transformer loads or other loads requiring phase angle control SPECIFICATIONS Voltage Rating Current Ratings at 50 C ambient Supply Frequency Main terminals Control Circuit Supply Voltage Control circuit supply current Dimensions High Current Connections Control Wiring Connections Operating Temperature Range Analogue Inputs Not isolated from 24V supply Digital Inputs Communications Up to 480V nominal supply voltage Isolation between the main supply and the 24V control circuits meets the requirements for reinforced insulation overvoltage
18. it is toggled once per second 2 Status Register 2 The same as Consumption Status Register 2 3 Line Voltage 4 Load Voltage In burst fire mode these values show the voltage and current in real time ie they 5 Load Current switch on and off 6 Load Power As a percentage of Span voltage x stack rated current 7 Firing Angle 0 180 degrees where 180 corresponds to fully conducting 8 Voltage Span In Volts The value set on the span potentiometer 9 Working Setpoint 10 Analogue setpoint 1 In Yo 11 Analogue setpoint 2 In Yo 12 Setpoint 1 comms In 13 Setpoint 2 comms In Yo 14 Energy Consumption Energy supplied to the load since last reset Maximum value before roll over is kWh 50 000 kWh 15 User Value This register returns the value entered in Consumption Register 4 Write Consumption Registers 6 registers are configured Number Name Additional Information 1 Status Register 2 Bit O Digital Input 2 Set Burst fire Not set Phase angle Bit 1 Comms enable Bit 2 Comms established Bit 3 Use comms for setpoint 1 analogue setpoint 1 not used Bit 4 Use comms for setpoint 2 analogue setpoint 2 not used When comms are in Bit 5 Bit 6 read write mode bits 5 0 0 Setpoint 1 controlled parameter V and 6 MUST be set as required 1 0 Setpoint 1 controlled parameter Power 0 1 Setpoint 1 controlled parameter Volts 1 1 Setpoint 1 controlled parameter I Bit 7 If not set setpoint 2 controls current If set setpoint 2 parameter is defined by
19. n will influence the temperature of the connection studs and the guide in the wiring section of this manual shows recommended cross sections Consideration must be given to fault conditions In particular a short circuited thyristor could result in loss of control of the load current If this could cause a dangerous temperature to arise in the controlled load then an independent means of monitoring and switching off the current should be provided This could take the form of an independent over temperature controller switching a contactor or under voltage release on a circuit breaker fitted in the main supply lines Contacts should be arranged to de energise in the alarm over temperature state European standard EN 60519 2 Safety in electroheat installations part 2 Particular requirements for resistance heating equipment para 13 3 requires independent protection of electronic heating controllers and frequently operated heating control contactors where temperature rise in the load could otherwise be excessive under fault conditions Independent provision for electrical isolation of the power and control circuit power supply must be provided Mounting The stack must be mounted vertically with the load terminal and fan if fitted at the bottom of the unit Allow a minimum of 100mm above and below the stack body to allow free airflow Do not mount stacks one above the other The stacks are designed to be mounted closely side by side in multi zone
20. ratings of cables and other switchgear within the cabinet Elevated temperatures also shorten the life of some electronic components notably electrolytic capacitors which dry out A major cause of elevated temperatures in a cabinet containing thyristor stacks is the power dissipated by the thyristor devices which may be approximated in watts as 1 5 x RMS current x Number of controlled lines The exhaust air temperature from the stack will be higher than ambient by up to 20 C It is not good practice to mount other items of control gear directly in the exhaust airflow In particular the current carrying capability of fuses or circuit breakers will be significantly reduced if this is done A tidy solution is to mount circuit breakers or fuses supplying the stack on a sub chassis mounted forward from the main chassis on which the stack is mounted The exhaust air then passes behind these components Alternatively they should be mounted to the side of the thyristor stack Thyristor stacks should not be mounted one above the other as this will significantly derate the upper unit which for rating purposes will be operating in an ambient equal to the exhaust air temperature of the lower unit Heat from the thyristors together with that dissipated by the semiconductor fuses will also raise the temperature of the stack busbars to which outgoing cables are connected and high temperature cables should be used The cross section of the cables and their ventilatio
21. s below Each register is 16 bits wide Numerical parameters are expressed as 16 bit binary values representing the parameter value in engineering units multiplied by 10 except energy consumption which is in kWh not multiplied by 10 Setpoints must be supplied in percent 0 0 100 0 multiplied by 10 whatever the controlled parameter Voltage setpoint 100 corresponds to stack voltage span Current setpoint 100 corresponds to stack rated current Power setpoint 100 corresponds to Voltage span x rated current Voltage setpoint 100 corresponds to voltage span but operation is non linear so that voltage output voltage span x V setpoint 100 Current setpoint 100 corresponds to current rating but operation is non linear so that current output current rating x V setpoint 100 Caledon Controls Ltd Page 10 User Manual TLV1000 Series Thyristor Stacks 80A to 250A Read Only Production Registers 19 registers are configured Number Name Additional Information 1 Status Register 1 Operating status Bit 0 Line present Bit 1 Phase lock achieved Bit 2 Heatsink temperature OK Bit 3 Phase angle burst fire mode burst fire when set Bit 4 Hardware enable Bit 5 Stack enabled Bit 6 Alarm Bit 7 Setpoint 1 Controlling not set default setpoint 2 controlling set Bit 8 Setup mode not set Run mode set Bit 9 Heartbeat This b
22. s encountered a major internal error LINK Activity LED LED State Description Comments Off No Link No link no communication present Green Link Ethernet link established no communication present Green flickering Activity Ethernet link established communication present Ethernet Interface The Ethernet interface operates at 100 Mbit full duplex with autonegotiation enabled as default IMPORTANT For information on how to connect the PROFINET cable see Protective Earth PE Requirements on page 150 Anybus CompactCom PROFINET IO Doc Rev 2 15 Doc ld HMSI 168 74
23. s or circuit breakers of current rating the same as or lower than the stack All the stacks with fan cooling also incorporate automatically resetting thermal cut outs which monitor the temperature of the heatsink and ensure that it does not rise to an unsafe level The stacks must be fitted with a protective earth conductor and the earth connection must be capable of carrying the prospective fault current for the main load circuit until the protective fuse blows An important reason for this is to protect against short circuit to ground which might occur in one of the semiconductor modules should the internal structure rupture under severe fault conditions Provided the correct semiconductor fuses are fitted which limit the maximum energy let through under short circuit conditions a short cable of 6mm cross section connecting between the stack earth stud and the chassis Caledon Controls Ltd Page 5 User Manual TLV1000 Series Thyristor Stacks 80A to 250A plate will provide an adequate local earth Care must be taken to ensure that the panel in which the stack is installed is adequately earthed with an earth loop impedance less than 0 0392 400 230V 800A system and taking account of local regulations The stacks are rated for a maximum ambient operating temperature of 50 C This refers to the ambient air temperature entering the heatsink at the base of the stack The design of an installation must however take into account the
24. t all otherwise the calibration will be compromised and difficult to reinstate Caledon Controls Ltd Page 9 User Manual TLV1000 Series Thyristor Stacks 80A to 250A P4 upper Adjusts the response speed phase angle ramp speed for setpoints 1 and 2 when controlling in phase angle mode Response is fastest when the potentiometer is fully anticlockwise This potentiometer can be adjusted while the stack is operational It does not affect the soft start ramp time in burst fire mode which is preset at approximately 10 cycles of the supply It does affect the speed of response of current limit controlled by setpoint 2 when in burst fire mode P3 lower Is used to set the voltage span of the controller to the supply voltage Adjustable over the range 300V to 600V on 480V model There are two possibilities for setting this 1 If communications are established the span voltage may be read in production register 8 and observed while adjusting the potentiometer 2 If communications are not available then the simplest way to span the stack is to run it in phase angle mode controlling V with a setpoint of 100 The potentiometer is adjusted until the voltage measured across the load is the desired span voltage Note that this value is best approached from below and that the supply voltage must be greater than or equal to the desired voltage If the supply voltage is low then a lower setpoint may be chosen For example with a setpoint of 80
25. the output voltage should be V0 8 x Voltage span Control Setpoints Two setpoints are active at any one time and may each control a different variable eg V and I A setpoint takes control if its controlled variable rises above the setpoint setting If communications are set as read only setpoints 1 and 2 will be derived from analogue inputs 1 and 2 If operation in current control mode is required analogue input 2 analogue input 1 must be tied high If operation is required in voltage or power mode analogue input 1 with current limit only at the stack rating then analogue input 2 must be tied high If communications are set as read write then each of the two setpoints may be sourced either from the analogue input or from a comms register as selected by bits in status register 2 in the write consumption registers If current limit at the stack rated current is required the current setpoint must be set to 100 Controlled Parameters Setpoint 2 always controls current initial versions of software and its primary function will be as a current limit setpoint If communications are configured as read only Setpoint 1 can be set to control either V or Power as determined by jumper 3C If communications are configured as read write the controlled parameter for setpoint 1 is determined by the comms using status register 2 and other parameters are available Jumper 3C is ignored Communications Data Communications may be configured
26. unt is allowed to exceed the above ranges the value will not be updated and the LED will stop flashing If two jumpers are fitted counting will stop and no value will be updated If all 3 jumpers are fitted together all parameters will revert to the default values when jumper 4 is replaced Note that while jumper 4 is removed the span adjustment potentiometer does not operate Table of Jumper 3A to 3C Count Values Default Values Fieldbus 3A Address S 2 Network Type Profinet Station Name 3B Baud Rate 3C Burst fire Cycle Time Range Default Range Default Range Default DeviceNet 0 to 63 63 EE BE 5 30s 10s N A Auto S Profibus 0 to 63 63 detect N A 5 30s 10s Thyristor 000 Profinet to Blank N A N A 5 30s 10s Thyristor 063 Modbus TCP N A 255 N A N A 5 30s 10s 9 600 19 200 Modbus RTU 0 to 63 63 57 600 9 600 5 30s 10s For Ethernet based networks the IP address and subnet mask cannot be set from the TLV1000 They must be set using the user s network configuration software or alternatively the Anybus IPconfig utility which is available from the downloads page of our website www caledoncontrols co uk or from the HMS website www hms se Preset Potentiometers Adjusting the Response Speed and Voltage Span Two potentiometers P3 and P4 are available for adjustment by the user These are accessible with the front cover fitted None of the other potentiometers should be adjusted a
27. viceNet Series Current Rating Load Supply Control Supply Voltage Communications Nominal load supply Voltage voltage range TLV1000 80A 690V 24V DC None 500V to 690V 125A 480V DeviceNet 380V to 480V 160A 230V Profibus DP 200V to 270V 200A 150V Profinet 115V to 150V 250A Modbus TCP Modbus RTU Other Please enquire Over voltage category 2 Caledon Controls Ltd Page 13 1 3 Front View About the Anybus CompactCom DeviceNet 5 ltem 1 Network Status LED 2 Module status LED 3 DeviceNet Connector 4 M12 Female Comnector 5 M12 Male Connector aa L Network Status State Indication Off Not online No power Green On line one or more connections are established Flashing Green 1 Hz On line no connections established Red Critical link failure Flashing Red 1 Hz One or more connections timed out Alternating Red Green Self test Module Status State Indication Off No power Green Operating in normal condition Flashing Green 1 Hz Missing or incomplete configuration device needs commissioning Red Unrecoverable Fault s Flashing Red 1 Hz Recoverable Fault s
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