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TC1028 series Thyristor units Control of single

1. Figure 3 13 Wiring for retransmission signals The current measurement signal with or without the RMS option is displayed by the bargraph on the front panel of the controller This bargraph has 10 segments each segment represents 10 of the nominal current of the thyristor unit 3 18 TC 1028 User manual WIRING SINGLE PHASE LOAD WIRING DIAGRAM Below is the wiring diagram for the power safety earth and reference voltage for the control of a single phase load in the TC1028 series of controllers L1 Neutral orL2 Wire protection and mains circuit breaker installed by users Safety men earth nterna use or EN thyristor protection se tine TC1028 5 PLF relay lt contact output paa Control signal Figure 3 14 Wiring of a TC1028 controller with a single phase load TC1028 User manual 3 19 WIRING THREE PHASE LOAD WIRING DIAGRAMS Although TC1028 series controllers are single phase units they may be used in combination to control three phase loads In three phase use the power and reference voltage wiring is determined by the load configuration The most economical three phase application is to use the TC1028 controller as the Master with TC1027 series solid state relays acting as Slaves The Slave logic signal output is provided on the TC1028 control terminal block The TC1027 solid state relay inputs must be configured for a 10
2. 1 IDENTIFYING THE THYRISTOR UNITS 1 1 GENERAL INTRODUCTION TO THE TC1028 SERIES 1 2 TECHNICAL SPECIFICATION 1 7 PRODUCT CODE FOR TC1028 SERIES 1 10 EXAMPLE OF PRODUCT CODE 1 11 SERIAL NUMBER LABELS 1 12 CHAPTER 2 INSTALLATION PEE TE e se 2 1 INSTALLATION SAFETY 2 2 DIMENSIONAL DETAILS 2 3 MECHANICAL MOUNTING 2 5 INSTALLATION 8 2 6 CHAPTER 3 WIRING ages eee Yn We erre 3 1 WIRING SAFETY 522222499208 dee 3 2 CONNECTING THE POWER CABLES 3 3 REFERENCE VOLTAGE CONNECTION 3 6 CONTROL CABLES ck EN dx 3 7 CONTROL TERMINAL BLOCK 3 9 INPUT SIGNALS eie uv I ver nas 3 11 SINGLE PHASE LOAD WIRING DIAGRAM 3 19 THREE PHASE LOAD WIRING DIAGRAMS 3 20 PLE ALARM 3 24 ii 1028 User manual IDENTIFYING THE THYRISTO R UNITS CHAPTER 4 CONFIGURATION 4 1 CONFIGURATION SAFETY 4 2 POWER BOARD y rese 4 3 DRIVER BOARD m 9 ek RR ES 4 4 CHAPTERS
3. Warning The voltage given in the table above must be greater than or equal to the line to line supply voltage As shipped from the factory the voltage is configured according to the product code on the identification label of the controller TC 1028 User manual 4 3 CONFIGURATION DRIVER BOARD The jumpers on the driver board are used to configure the thyristor firing mode the input signals the rms option and the frequency of the supply used Y Potentiometer board User terminal block 277 Zan aaa ea 2 iene amine Configuration of contact type PLF Input configuration Firing mode configuration Frequency configuration Firing mode configuration Links if rms board not present O Location of rms board option Figure 4 2 Location of configuration jumpers on driver board 4 4 TC 1028 User manual CONFIGURATION Input signal Control signal type The specifications for control signals are given in Table 4 2 Control signal Input Lower threshold Upper threshold impedance 0 100 0 2V 4 2N 1 16V 4 36V 0 4V 8 4V Table 4 2 Control signal specifications Input configuration The input signal may be configured with a selection of four voltage levels and two current levels Jumpers K5 to K10 are u
4. 5 1 THYRISTOR FIRING MODES 5 2 CONTROL OPERATION re ye 5 7 555555 ER breta 5 10 PARTIAL LOAD FAILURE DETECTION 5 12 RETRANSMISSION i e ehe tmm 5 13 ENABLE INHIBIT 5 14 MASTER SLAVE OPERATION 5 14 CHAPTER 6 COMMISSIONING PROCEDURE 6 1 COMMISSIONING PROCEDURE SAFETY 6 2 CHECKING THE CHARACTERISTICS 6 3 DIAGNOSTIC ii aide apache O 6 5 PRELIMINARY ADJUSTMENTS 6 8 PARTIAL LOAD FAILURE DETECTION ADJUSTMENT 6 12 CURRENT LIMIT 5 6 13 44 lt 6 15 CHAPTER 7 MAINTENANCE 7 1 THYRISTOR PROTECTION 7 2 THYRISTOR PROTECTION FUSE 7 3 FUSE BLOWN INDICATION MICROSWITCH 7 4 PROTECTION FUSES FOR REFERENCE VOLTAGE CONNECTION em thane ERE 7 5 SERVICING eret 7 6 TOOLS avere pe RUE EG wale SERE 7 1 1028 User manual iii IDENTIFYING THE THYRISTO R UNITS RELEVANT EUROPEAN DIRECTIVES CE MARKING AND SAFETY TC1028 products carry the CE mark in compliance with the essential requirements of the European Low Voltage Directive 73 23
5. 6 9 RESISTIVE LOAD WITH SMALL RESISTANCE VARIATION neh igne en 6 10 RESISTIVE LOAD WITH LARGE RESISTANCE VARIATION dite se o e 6 10 NON SATURABLE INDUCTIVE LOAD 6 11 SATURABLE INDUCTIVE LOAD 6 11 PARTIAL LOAD FAILURE DETECTION ADJUSTMENT 6 12 CURRENT LIMIT ADJUSTMENT 6 13 LINEAR CIMEF cig reu bs kek EP 6 13 THRESHOLD LIMIT oi ca ca RR ee ee 6 14 TROUBLESHOOTING nm em eret emet 6 15 TC 1028 User manual 6 1 COMMISSIO NING Chapter 6 COMMISSIONING PROCEDURE Read this chapter carefully before commissioning the controller COMMISSIONING PROCEDURE SAFETY AN Warning Eurotherm cannot be held responsible for any damage to persons or property or any financial loss or costs arising from incorrect use of the product or failure to observe the instructions contained in this manual It is therefore the user s responsibility to ensure before commissioning the unit that all the nominal ratings of the power unit are compatible with the conditions of use and the installation Danger Live parts may be exposed when the door is open Only personnel qualified and trained to work with low voltage electrical equipment in an industrial environment should have access to the interior of the unit Access to internal components of the
6. CS174291U1A0 CP174293 63x15 x52 Table 7 2 Recommended protection fuse for reference voltage connection For the Fuse isolator assembly order the fuse and fuseholder isolator separately using their respective part numbers TC 1028 User manual 7 5 MAINTENANCE SERVICING TC1028 controllers must be mounted with the heatsink positioned vertically with no obstructions above or below which could inhibit or impede airflow Warning AN If several units are mounted in the same cabinet they must be arranged in such a way that air expelled from one cannot be drawn into the unit located above it In order to ensure correct cooling of the unit it is advisable to clean the heatsink and the protective fan guard regularly depending on the degree of environmental pollution Danger Every six months check that the screws of the power safety earth cables are correctly tightened see Wiring page 3 3 7 6 TC 1028 User manual MAINTENANCE TOOLS Flat blade Hex key Electrical apparatus screwdriver wrench mm Mounting Depending on M8 screw head style chosen O pening closing of front door 4mm HEX socket for M5 screw Safety earth connection HEX 19 M12 Power connection HEX 17 M10 supply side and thyristor fuse change Load connection HEX 19 M12 Cable clamp tightening Control and reference voltage connection Board
7. In Burst firing mode the power delivered to the load depends on firing cycles and non firing cycles The load power is proportional to the firing rate t and is defined by the ratio of the thyristor firing cycle and the modulation period The firing rate or duty cycle is expressed by the following ratio TF The load power can be expressed by P t Pmax where Py Ax represents the load power during thyristor firing Load voltage Figure 5 2 Periods of a Burst firing cycle Single cyde mode The Burst firing mode with a single cycle of firing or non firing is called Single cycle 1028 User manual 5 3 O PERATIO N Modulation period The modulation period in Burst firing mode is variable according to the output power demanded by the feedback As a result of this type of control function the TC1028 offers precision adjustment which adapts to each particular setpoint zone e At 50 power the typical value of the modulation period is 0 85 for fast cycle burst firing and 8s for slow cycle e Fora zone less than 50 of the maximum setpoint the firing cycle is decreased and the modulation period increased Fora power zone greater than 50 the non firing cycle is decreased with the increase in the modulation period For example in fast cycle burst firing e For 5 power 0 25 s TM 5s For 90 power Tp 2 255
8. 1028 User manual 6 15 COMMISSIO NING Symptom Action 2 In Burst firing mode 2 1 Check that load cabling is correct transient overcurrent is 2 2 Check the level of the oscillator input signal too great when starting position 15 of the diagnostic unit is 6 4 V peak to measure an inductive load use an oscilloscope 2 3 Check the adjustment of the Delay Retard potentiometer on the controller front panel if necessary turn the potentiometer anti clockwise See under heading Preliminary adjustments page 6 11 If the fault persists after all of these checks please contact your nearest EUROTHERM office where qualified staff will be able to advise or assist you 6 16 TC 1028 User manual MAINTENANCE Chapter 7 MAINTENANCE Contents Page THYRISTOR PROTECTION 7 2 THYRISTOR PROTECTION FUSE 7 3 FUSE BLOWN INDICATION MICROSWITCH 7 4 PROTECTION FUSES FOR REFERENCE VOLTAGE CONNECTION esas uet ca dna tad asd Un Rc ce deos 7 5 SERVICING o eeRSTEeRE RS TIAM 7 6 TOOLS t dence mo o bana dep dress 7 7 TC 1028 User manual 7 1 MAINTENANCE Chapter 7 MAINTENANCE Danger The unit must be maintained by qualified personnel THYRISTOR PROTECTION Thyristors in the TC1028 series of controllers are protected in the following way an internal high speed fuse against overcurrents an RC snubber and MOV varis
9. 3 18 SINGLE PHASE LOAD WIRING DIAGRAM 3 19 THREE PHASE LOAD WIRING DIAGRAMS 3 20 LOAD IN STAR WITH 3 21 LOAD IN OPEN DELTA 3 22 LOAD IN STAR WITHOUT NEUTRAL OR IN CLOSED DELTA TWO PHASE CONTROL 3 23 PEP ALARM eb bte Eds 3 24 1028 User manual 3 1 WIRING Chapter 3 WIRING WIRING SAFETY Danger Wiring must only be carried out by personnel who are qualified to work in a low voltage industrial environment It is the user s responsibility to wire and protect the installation in accordance with current professional Standards A suitable device ensuring electrical isolation between the equipment and the supply must be installed upstream of the unit in order to permit safe maintenance TC1028 series units have two protective covers upper and lower In order to make wiring easier the upper cover should be removed After connection and before powering up replace the upper protective cover to ensure the specified degree of protection Danger Before any connection or disconnection ensure that power and control cables or leads isolated from voltage sources For safety reasons the safety earth cable must be connected before any other connection is made during wiring and it must be the last cable to be disconnected The safety earth is connected to the screw located on the strip p
10. 5 10 1028 User manual O Threshold current limit This type of limit is used to limit the load current to a desired value independent of the input signal and the linear current limit The Threshold limit input terminal 5 on the control terminal block may be controlled using an external potentiometer e byaOto 10 external DC voltage Warning AN When the threshold limit by potentiometer or by voltage is not used terminal 5 on the driver board user terminal block must be directly connected to the 10V user voltage terminal 2 This limits the current to 110 of nominal Otherwise the threshold current limit is at zero and the controller cannot deliver current Without current limit Without current limit 12 100 80 limit threshold Resulting limit 60 limit threshold Linear limit je 5096 0 50 100 0 50 100 Setpoint b Setpoint Figure 5 8 a Threshold current limit only b Threshold and linear current limit 1028 User manual 5 11 O PERATIO N PARTIAL LOAD FAILURE DETECTION The partial load failure PLF alarm detects an increase in the load impedance due for example to the failure of heating elements The sensitivity of the PLF circuit enables the user to detect a 20 increase in load impedance This will detect the failure of one in five identical elements connected in parallel
11. cycle burst firing modes composed of whole cycles start at zero voltage for loads which are purely resistive For an inductive load firing at zero voltage creates transient overcurrents Figure 5 5 a which could in certain cases cause saturation of a magnetic circuit and a blow out of the high speed thyristor protection fuse Non saturable inductive load for example an inductor To avoid overcurrent the initial firing of the thyristors can be delayed with reference to the zero crossing Figure 5 5 b The delay angle should be adjusted using the Delay Retard potentiometer on the front panel see Commissioning section for optimum load conditions Saturable inductive load for example transformer primary To avoid overcurrents use the Phase angle firing mode or Burst firing with slow start Overcurrent a ot gt b ot gt 0 Delay angle Figure 5 5 Inductive load switching at zero voltage a and with delay angle b 5 6 TC 1028 User manual O CONTROL OPERATION Feedback function TC1028 series thyristor units include an internal control loop The output power of the controller is linear between 0 and 100 of maximum voltage for an input signal vary ing between 4 and 84 of full scale y2 100 50 0 4 50 84 100 Setpoint Figure 5 6 Controlled parameter as a function of setpoint The square of the RMS
12. TC1028 series Thyristor units Control of single phase resistive or inductive loads User manual 300A to 500A rated units Copyright Eurotherm Automation 1998 All rights reserved All reproduction or transmission in any form or using any procedure electronic or mechanical including photocopying or recording without written authorisation from EUROTHERM AUTOMATION is strictly prohibited EUROTHERM AUTOMATION has made every effort to ensure that the specification given in this manual is as accurate and up to the minute as possible However in order to maintain our leading edge it may be necessary to make certain changes or omissions to our specification We cannot be held responsible for any damage to persons or property or for any financial loss or costs arising from this TC 1028 User Manual Ref HA174804ENG Issue 2 0 09 98 IDENTIFYING THE THYRISTO R UNITS TC1028 USER MANUAL SCOPE OF MANUAL This TC1028 User Manual Ref HA 174804 ENG is intended for 300A to 500A rated units in the TC1028 series carrying the CE mark manufactured from December 1995 The TC1028 Manual Ref HA 172963 is valid for units manufactured before this date The TC1028 Addendum Ref HA 174804 ENG 001 is intended for 750A to 1200A rated units CONTENTS EUROPEAN DIRECTIVES iv CE MARKING AND SAFETY iv ELECTROMAGNETIC COMPATIBILITY EMC iv PRECAUTIONS 254559 x y enu teet e
13. Contacts N C Controller enable Contacts open inhibited Driver board o 5 s 2 gt 0121 1 2 0 gt si Shela 2 gt lt lt S 399 Figure 3 11 Wiring of external voltage for threshold current limit 3 16 TC 1028 User manual WIRING 2 Adjustment by potentiometer For threshold current limit it is possible to use an external potentiometer A 4 7kW to 10kW potentiometer is connected between terminals 1 OV and 2 10V its wiper is connected to terminal 5 I Limit 4 7kQ to 10kQ potentiometer 100 current 0 current Contacts N C Controller enable Contacts open inhibited Driver board ELS 5 E 25 5 gt 9 gt Fla gt 3 gt 515512245 z 3 294 Figure 3 12 Wiring of external potentiometer for threshold current limit 3 Fixed external limit A fixed current limit of 110 of the nominal controller current is provided by connecting the I Limit terminal 5 to 10V terminal 2 1 Warning If the external current limit is not
14. TM 2 55 TM Modulation 65 Time 0 2596 50 75 100 Power Setpoint Figure 5 3 Modulation period as a function of power fast cycle burst firing 5 4 TC 1028 User manual O Soft start end Soft operation start or start amp end may be configured in both the slow and fast cycle burst firing modes The duration of the soft start is the time taken for the output power of the thyristor to change from 0 to 100 by varying the thyristor firing angle from 0 to full firing The duration of the soft end Tg is the time taken for the output power of the thyristor to change from 100 to 0 by varying the thyristor firing angle from full firing to 0 Soft start increasing Soft end by decreasing the firing angle the firing angle y D Full firing 4 se gt lt T gt Lr 1 F Figure 5 4 Soft start and end burst firing mode The soft end time is not included in the firing cycle but all the power delivered to the load is taken into account in the feedback After soft starting by varying the thyristor firing angle the unit remains in full conduction during the firing time Note For soft starts of loads with very large resistance variation for example Kanthal Super use the TC1028 Special 603 1028 User manual 5 5 O PERATIO N Overcurrent elimination for inductive loads Fast and slow
15. As an option RMS option board the 0 10 V retransmission signal is proportional to the RMS load current The value of this signal is 10 V for the nominal controller current Retransmission of the RMS load current values is correct only for Phase angle Single cycle and the various Fast cycle firing modes Load voltage measurement The Load voltage retransmission output is available between terminals Load V O P and 1 OV on the driver board user terminal output In the standard version and in the RMS option this output is a full wave rectified signal 5V rms 4 3V mean representative of the load voltage in full conduction produced using the auxiliary power supply Bargraph display The 10 segment bargraph on the front panel displays the load current with a resolution of 10 of the nominal load current as follows instandard version instantaneous load current e in RMS option RMS value of load current in Phase angle Single cycle and Fast cycle firing modes with or without soft start end TC 1028 User manual 5 13 O PERATIO N ENABLE INHIBIT TC1028 thyristors have active ENABLE for allowing operation requiring a 10V DC to be applied to terminal 9 If the enable voltage is absent operation is inhibited which means that the thyristors are unable to fire irrespective of the input signal The thyristor is enabled when a 10V DC voltage is applie
16. EEC amended by the Directive 93 68 EEC Dedaration of CE conformity For safety reasons Eurotherm certifies that TC1028 products installed and used in compliance with this User Manual meet the essential requirements of the European Low Voltage Directive mentioned above A declaration of CE conformity is available on request Validation by Competent Body Eurotherm has validated the compliance of TC1028 products with the European Low Voltage Directive and with the EMC test standards listed below through product design and laboratory testing These are described in a Technical Construction File validated by a Recognised Competent Body the LCIE Central Laboratory for the Electrical Industries ELECTROMAGNETIC COMPATIBILITY EMC The electromagnetic compatibility of TC1028 products has been designed specially for an industrial environment they must not be used in domestic environments Statement of EMC conformity Eurotherm certifies that TC1028 products installed and used in compliance with this User Manual meet the following EMC test standards and enable the system which incorporates them to comply with the EMC Directive as far as the TC1028 products are concerned EMC tests EMC test standards Immunity Electrostatic discharge EN 61000 4 2 06 1995 Fast transients bursts EN 61000 4 4 01 1995 RF electomagnetic fields prEN 61000 4 3 1984 Emission Radiated EN 55011 1991 EN50081 2 Class Conducted EN 55011 1991
17. IEC 1800 3 for 2nd environment 1028 User manual IDENTIFYING THE THYRISTO R UNITS PRECAUTIONS Safety symbols Important safety precautions and special information are indicated in the text of the manual by two symbols This symbol means that failure to take note of the information given in this manual may have serious consequences for the safety of personnel and may DANGER even result in electrocution This symbol means that failure to take note of the information may AN have serious consequences for the installation or WARNING lead to the incorrect operation of the unit These symbols must be observed for particular points However the whole of the manual remains applicable Personnel The installation configuration commissioning and maintenance of the unit must only be carried out by personnel qualified and trained to work with low voltage electrical equipment in an industrial environment EMC Guide In order to help you reduce the effects of electromagnetic interference depending on the product installation Eurotherm can supply you with the Electromagnetic Compatibility Installation Guide Ref HA 025464 This guide lists the rules generally applicable for EMC Independent alarm Given the safety regulations concerning personnel and property and the value of the equipment controlled by TC1028 products we recommend the use of an independent safety device alarm which must b
18. The alarm is indicated e indicator light mounted on the front panel and labelled Load fail illuminates when a partial load failure is detected the alarm relay contacts contact output is available on terminals 51 and 52 on the user terminal block at the bottom left hand side of the unit The alarm relay is energised when not in the alarm state if the unit is powered In the standard version the alarm contacts breaking capacity 0 25A at 250 Vac or 30 Vdc are open in the alarm state or in the event of a supply failure In the IPF option The contacts are closed in the alarm state The PLF alarm relay contact output is suitable for controlling an alarm unit The PLF alarm relay is reset either by switching off or by returning to the nominal current 5 12 1028 User manual O RETRANSMISSION TC1028 thyristors are able to retransmit load current and voltage measurements which are available on the control terminal block Also there is a a bargraph display of current on the front panel Retransmission signal Load current measurement The Load current retransmission is available between terminals 4 Load I and 1 OV It can be used for tests or external measurement In the standard version the full wave rectified output signal is directly proportional to the instantaneous load current 4 8V mean for the nominal controller current in full conduction
19. condensing Pollution degree 2 permissible defined by IEC 664 2000m maximum 570mm H x 133mm W x 268mm D Weight 10kg 570mm H x 248mm W x 268mm D Weight 19kg TC 1028 User manual 1 7 IDENTIFYING THE THYRISTO R UNITS Control Power supply Input type Range Input impedance Manual control Thyristor firing modes Delayed thyristor firing overcurrents Enable Inhibit Diagnostics Control type Wiring Connections Self supplied from power circuit 300A to 500A rated units with reference phase or neutral connection Consumption 20VA Analogue Voltage 0 5V 1 5V 0 10V or 2 10V Current 0 20mA 4 20mA Voltage gt 50 Current 2500 5kQ external potentiometer The following may be reconfigured by the user Phase angle Single cycle Burst firing with one firing or non firing cycle Fast cycle burst firing typical modulation time at 5096 power 0 8s Slow cycle burst firing typical modulation time at 5096 power 8s Fast cycle with adjustable soft start between 0 and 250ms with or without soft end Slow cycle with adjustable soft start between 0 and 250ms with or without soft end For inductive loads delayed firing in the first half cycle of burst firing without soft start eliminates transient Using external contacts or external voltage 10VDC to enable Response time enable 2s inhibit 25ms Connector for diagnostic unit permits adjustment and test
20. control signal which can be reconfigured by the user has four voltage levels 0 5V 0 10V 1 5V 2 10V and two current levels 0 20mA 4 20mA Manual control using an external potentiometer is possible The TC1028 series is equipped with the following functions electrical power control of inductive and resistive loads various thyristor firing modes current reduction by soft starting for loads with large temperature coefficient elimination of overcurrent when starting inductive loads current limit partial load failure detection logic output to control other power units Slave firing output selective pulse blocking circuit inhibit input available on user terminal block retransmission of load current and voltage bargraph current level display on front panel 1 2 1028 User manual IDENTIFYING THE THYRISTO R UNITS Upper protection cover Bargraph PLF detection indicator light D f Charge Current limit Adiust potentiometer Seuil O Test ma Mimit Limit Delay Retard 74 PLF adjustment PLF test pushbutton Delayed firing or starting ramp potentiometer EUROTH Access door to diagnostic connections Control cable clamp Lower protective cover i N PLF contact terminal block Reference voltage Cable gland for load cables terminal black Figure 1 1 Overview of TC 1028 series thyristor
21. controller is prohibited to users who are not authorised to work in an industrial low voltage electrical environment The temperature of the heatsink may exceed 100 C Avoid all contact even occasional with the heatsink when the unit is operational The heatsink remains hot for around 15mins after the unit has been switched off 6 2 1028 User manual COMMISSIO NING CHECKING THE CHARACTERISTICS Warning Before powering up the unit make sure that the identification code complies with the product code specified when ordering and that the characteristics are compatible with the installation Load current The maximum load current must be less than or equal to the value of the nominal current of the unit taking into account load and power supply variations In three phase operation if three identical loads are configured in closed delta the line current of the controller both Master amp Slave is V3 times greater than the current in each branch of the load Supply voltage The nominal value of the TC1028 voltage must be greater than or equal to the line to line voltage Danger Never use thyristor with a supply voltage greater than the nominal voltage specified in the product code If the line voltage is less than 80 of the nominal voltage the thyristor is inhibited The unit is re enabled automatically if the voltage returns to a value greater than or equal to 80
22. delay Apply a control signal corresponding to approximately 20 of the maximum setpoint Turn the Delay Retard potentiometer clockwise to obtain the minimum peak current displayed by bargraph without RMS option or the minimum overcurrent visible on the screen of an oscilloscope at the start of each burst Saturable inductive load When controlling a saturable inductive load transformer primary for example transient overcurrents are limited by reducing the thyristor firing angle Transformer primary with small temperature coefficient resistive load Use the Phase angle or Burst firing with soft start firing modes the Delay Retard potentiometer is adjusted as for loads with a large resistance variation see previous page Transformer primary with large temperature coefficient resistive load Use the Phase angle or Burst firing with soft start firing modes and the TC1028 Special 603 version the Delay Retard potentiometer is adjusted as for loads with a large resistance variation see previous page 1028 User manual 6 11 COMMISSIO NING PARTIAL LOAD FAILURE DETECTION ADJ USTMENT Partial load failure detection PLF is adjusted using the potentiometer marked Adjust Seuil on the front panel see Figure 6 2 The purpose of this is to adjust the PLF detection sensitivity to match the actual load of the thyristor unit To guarantee correct operation of the PL
23. fixing For M4 nut Commissioning and RMS ammeter or calibration clip on current probe Eurotherm type 260 diagnostic unit recommended Table 7 3 Tools TC 1028 User manual 7 7
24. load voltage represents the power dissipated in a purely resistive load the value of which is constant with temperature The accuracy of the power control function is guaranteed to 2 of the maximum voltage The feedback system automatically selects the greater of the two values V P For loads with a small resistance variation as a function of temperature iron alloys nickel chrome aluminium Inconel etc feedback by V is sufficient Feedback having automatic transfer between the two measured values is very important for loads with a large resistance variation as a function of temperature molybdenum molybdenum disilicide tungsten platinum etc For this type of load operation is as follows P feedback at start when cold e automatic changeover to V2 feedback when hot which gives optimum control and feedback at all temperatures 1028 User manual 5 7 O PERATIO N Compensation for supply voltage variations Compensation for variations in supply voltage acts in the range 10 to 15 of the nominal voltage This voltage is self supplied on the power and reference phases Without compensation for supply voltage variations a 10 increase or decrease in the supply voltage would lead to a 20 increase or decrease in the power supplied to the controller load For a constant resistive load feedback with compensation for supply variations enables the output power to be kept constant despite variations in the su
25. manual control the controller input should be configured to 0 10V see Product code 4 7 to 10kQ potentiometer Contacts N C Controller enable 1 l Contacts open inhibited 9 8 7 6 5 4 3 2 1 Driver board 10V SLAVE CONTROL AUTO INPUT MANUAL INPUT I LIMIT INPUT LOAD I OUTPUT LOAD V OUTPUT ENABLE Figure 3 10 Wiring of manual input for TC 1028 When manual control is used terminal 7 of the external input labelled Automatic input must be connected to 0V terminal 1 Warning If the input signal is not disconnected from terminal 7 the two signals external and manual are added together TC 1028 User manual 3 15 WIRING External current limit wiring TC1028 series thyristor units have two types of current limit see Chapter 5 Operation linear limit internal limit and threshold limit external limit External current limit is controlled by a voltage level or by an external potentiometer and may be used with automatic external control as well as with manual control External current limit may be adjusted in three different ways 1 Adjustment by external voltage To implement threshold limit a 0 10V external voltage should be connected between terminals 5 I Limit and 1 OV terminal 5 is positive External current limit voltage 0 to 10V
26. of the nominal value Warning It is essential that the nominal voltage of the controller should be as close as AN possible to the supply voltage given that inhibition occurs at 80 of nominal voltage TC1028 User manual 6 3 COMMISSIO NING Reference voltage The reference voltage for the electronics second phase or neutral depending on the supply wiring must correspond to the power voltage Selection of this voltage is made using the jumpers and by the choice of transformer on the power board Transformers for the electronics power supply are selected at the factory as specified by the voltage code see Configuration chapter page 4 3 Input signals Jumper settings on the driver board must be compatible with the signal chosen for control see page 4 5 Partial load failure detection The voltage used for the partial load failure detection circuit is that of the reference phase neutral Check that this voltage corresponds to the power voltage Check that the PLF alarm relay contacts are connected to a signalling or alarm circuit energised by 230V or less single phase or three phase 230V supply 6 4 TC 1028 User manual COMMISSIO NING DIAGNOSTIC UNIT To make adjustments and commissioning easier and to diagnose the state of the controller it is advisable to use the Eurotherm type 260 diagnostic unit Provided with a 20 way switch the diagnostic unit is used to view controller v
27. of thyristor unit Control of load voltage squared or load current squared Supply variation compensation Shielded cable connected to ground at both ends 0 5 mm 1 0 mm conductors Tightening torque 0 7Nm TC 1028 User manual IDENTIFYING THE THYRISTO R UNITS RMS option board Retransmissions Display Current limit Linear limit Threshold limit RMS load current DC signal 0 10V proportional to the actual load current Retransmission output on the user terminal block Display of RMS current using 10 segment bargraph Proportional load current limit from 20 to 100 of the nominal current Adjustment using potentiometer on front panel Maximum load current limit Adjustment using external potentiometer Partial load failure detection Alarm Test Signalling Bargraph Display Detection of 20 decrease in current Adjustment by potentiometer marked Adjust on front panel Using Test push button on front panel Load fail indicator light on front panel Alarm relay contacts open in alarm state in standard version Alarm relay contacts closed in alarm state IPF option Instantaneous current filtered mean value for the adjustment of initial firing of thyristors in the case of inductive loads basic version RMS value of load current in Phase angle and Fast cycle firing modes with or without soft start or end with RMS option board Warning AN In order to ma
28. provide all the information relating to the factory settings of the controller One identification label is located externally on the right hand side of the unit EUROTHERM 2 20 WORTHING ENGLAND 1903 268500 MODEL TC1028 300A 440V 000 0V10 SFC RMS EN G IPF FUMS 96 00 SERIAL No LC1111 001 001 11 97 RATING 1 PHASE 300A 440V 50Hz AUXILIARY PO WER SUPPLY SELF SUPPLIED MADE IN FRANCE Figure 1 3 Example of identification label for a TC 1028 controller The information corresponds to the product code example The second identification label and the configuration label are located inside the controller SERIAL No LC1111 001 001 11 97 TC1028 FACTO RY SETTINGS INPUT 0 10V DC FIRING FAST CYCLE BURST MO DE O PTION S FUSE BLOWN INDICATION SWITCH CONTACTS CLOSED IN ALARM STATE RMS BOARD ANY NON SPECIFIED FUSE INVALIDATES GUARANTEE SEE USER MANUAL HA174804ENG Figure 1 4 Example of configuration label for a TC 1028 controller Warning Following any re configuration on the part of the user there is no guarantee that the controller will correspond to the label information 1 12 TC 1028 User manual IN STALLATIO N Chapter 2 INSTALLATION Contents Page INSTALLATION SAFETY 2 2 DIMENSIONAL DETAILS 2 3 MECHANICAL MOUNTING 2 5 INSTALLATION DETAILS 2 6 1028 User manual 2
29. used terminals 5 and 2 must be connected 1028 User manual 3 17 WIRING Retransmission signal wiring Load current and voltage measurements are available on the control terminal block The voltage measurement is retransmitted as a full wave rectified signal proportional to the instantaneous value of the load voltage The value of this signal is 5V rms 4 3V mean for the nominal voltage The voltage measurement is available between terminals 3 Load V output and 1 OV Retransmission of the current measurement requires the RMS board option In the basic version without RMS option the signal available between terminals 4 Load I output and 1 OV is a full wave rectified signal proportional to the instantaneous value of the load current The value of the retransmitted signal is 5 RMS 4 3V mean for the nominal current of the power controller With the rms option the signal retransmitted between terminals 4 and 1 of the driver board is proportional to the true rms value of the load current The value of this signal is 10V for the nominal current of the controller Current Voltage measurement measurement Contacts N C Controller enable Contacts open inhibited B 9 8 7 6 5 4 3 2 1 Driver board MANUAL INPUT I LIMIT INPUT LOAD OUTPUT LOAD V OUTPUT 10V ov ENABLE SLAVE CONTROL AUTO INPUT
30. 1 IN STALLATIO N Chapter 2 INSTALLATION INSTALLATION SAFETY Danger TC1028 units must be installed by personnel trained to work with low voltage electrical equipment in an industrial environment Units must be installed in fan cooled electrical cabinets to ensure that condensation and pollution are excluded The cabinet must be closed and bonded to the safety earth in accordance with IEC 364 or current national Standards For installations which are fan cooled it is recommended that a fan failure detection device or a thermal safety cut out should be fitted in the cabinet The TC1028 series of units may be bulkhead mounted The units must be mounted with the heatsink positioned vertically with no obstructions above or below which could inhibit or impede airflow If several units are mounted in the same cabinet they must be arranged in such a way that air expelled from one cannot be drawn into the unit located above it N Warning The units are designed to be used at an ambient temperature less than or equal to 50 C 40 C for 500A nominal units Leave a minimum gap of 5cm between two units placed side by side Excessive overheating may lead to incorrect operation of the unit This may in turn cause damage to the components TC1028 series power units have permanent fan cooling 2 2 1028 User manual IN STALLATIO N DIMENSIONAL DETAILS Dimensions and weights of TC102
31. 1028 series of power controllers have the following thyristor firing modes Phase angle Single cycle Fast cycle burst firing modulation period at 50 power 0 8s Slow cycle burst firing modulation period at 50 power 8s Fast cycle burst firing with soft start and end adjustable between 0 and 250ms Slow cycle burst firing with soft start and end adjustable between 0 and 250ms They may be re configured by the user refer to Chapter 4 Configuration Phase angle mode In Phase angle mode the power transmitted to the load is controlled by firing the thyristors for a part of each half cycle of the supply voltage see Figure 5 1 The firing angle is varied in the same sense as the power demand by the control system The power delivered is not a linear function of the firing angle Resistive load voltage Supply voltage 6 Figure 5 1 Phase angle firing mode 5 2 1028 User manual O Burst firing mode Burst firing mode is a duty cycle mode which consists of supplying a series of complete mains voltage cycles to the load Thyristor firing and non firing are synchronised with the mains and are performed at zero voltage for a resistive load This type of firing eliminates steep rates of voltage applied to the load minimises interference to the supply network and above all avoids generating radio frequency interference RFI
32. 3 6V 8V peak 10ms Enable lt 10V Fast cycle burst firing and Single cycle Table 6 2 Description of positions on Eurotherm type 260 diagnostic unit TC 1028 User manual 6 7 COMMISSIO NING PRELIMINARY ADJ USTMENTS Preliminary adjustments are made to adapt the thyristor firing to suit the type of load first thyristor firing in Burst firing mode duration of the soft start ramp in Phase Angle firing mode e For resistive loads with low resistance variation thyristor firing is at zero voltage This prevents steep rates of change of voltage thus minimising the electromagnetic interference produced For resistive loads with high resistance variation and for saturable inductive loads the Burst firing with soft start operation reduces the current requirement and thus prevents fuse blowing or saturation of magnetic systems The duration of the start ramp may be adjusted between 0 and 250ms e For non saturable inductive loads delayed first firing eliminates transient overcurrents in Burst firing see Operation Chapter 5 This delay may be adjusted between 0 and 90 and only acts on the first half cycle of each burst Preliminary adjustments are made using the 12 turn potentiometer labelled Delay Retard on the front panel The effect of the Delay Retard potentiometer depends on the thyristor firing mode Thyristor firing mode Effect of adjustment potent
33. 8 controllers units rated between 300A and 500A are given inFigure 2 1 andin Table 2 1 Door fixing Upper protection cover Dat Charge Adjust Seul Une B jl EUROTHERM ONE NY Lower protection cover lt U gt lt gt lt D gt Door open Figure 2 1 Overall dimensions with upper protective cover TC 1028 User manual 2 3 IN STALLATIO N Dimensions Values Description 425mm Height without protective cover 570mm Height with cover 133mm Width up to 500V 248mm Width 690V Depth Width between fixing holes up to 500V Width between fixing holes 690V Height between fixing holes Depth with door open Height of side faces Distance between Earth busbar and panel Depth between LOAD terminal and panel Depth between LINE terminal and panel Up to 500V 690V Table 2 1 Dimensions and weights of TC1028 units 300A to 500A 2 4 1028 User manual IN STALLATIO N MECHANICAL MOUNTING TC1028 controllers have two protective covers upper and lower The controllers may be mounted with their protective covers in position However the upper protective cover must be removed to make electrical connections Having drilled the support panel to the dimensional values given above insert the f
34. F detection circuit the load current must not be less than 10 of the nominal current when using a bulb as a load in a thyristor test the load fail indicator will always be illuminated When commissioning it is essential to make the following adjustment e First make sure that the controller is connected correctly and that the thyristors are permanently on Turn the PLF detection adjustment potentiometer completely anti clockwise and check that the Load Fail indicator light on the front panel is off Turn the Adjust Seuil potentiometer slowly clockwise until the indicator light is on Turn the potentiometer slowly anti clockwise until the Load Fail light has just gone off Adjusted in this way the potentiometer is used to obtain maximum sensitivity in detecting partial load failure for a specific load The pushbutton on the front panel marked Test which simulates a current drop of 10 in the load is used to check that the PLF circuit is operating correctly without having to disconnect the load This button will put the thyristor unit into the alarm state if the adjust ment has been performed correctly Reminder The PLF detection circuit does not use the load voltage but the reference voltage 6 12 TC 1028 User manual COMMISSIO NING CURRENT LIMIT ADJ USTMENT Linear limit The linear current limit is adjusted by the I limit Limit potentiometer on the front panel Make su
35. NG INPUT SIGNALS The control wires are connected on the plug in user terminal block located on the driver board The user terminal block can be accessed with the front door open To open the door undo the front screw release the door from its notches by lifting it up then pull it towards you Danger Live parts be exposed when the door is open if the controller is powered up The units may be controlled by an external analogue signal from a temperature controller or another signal source or manually by an external potentiometer TC 1028 User manual 3 11 WIRING External analogue input The TC1028 may be configured for voltage input or current input signals Signal type Signal level Input impedance Voltage 0 5V 50kQ 1 5V 0 10V 2 10V Current 0 20mA 4 20mA Table 3 4 1C 1028 Input signals The external signal is applied to terminals 1 amp 7 of the control terminal block on terminal 7 Contacts N C 5 Controller enable Control signal Contacts open inhibited 1917 driver board 5 5 2 5 5 2 9 lt ul gt 0 0 gt 2558 99 Figure 3 7 Wiring of external control signal For normal operation of the TC1028 series controller also co
36. V logic signal and connected in parallel Important In Master Slave three phase operation only burst firing modes Single cycle fast cycle and slow cycle without soft operation are possible 3 20 TC 1028 User manual WIRING Load type star with neutral Wire protection and mains circuit breaker installed by user Master slave connection Control signal Figure 3 15 Wiring of a TC1028 controller Master and two TC 1027 solid state relays Slaves for star with neutral load configuration for low temperature coefficient resistive loads only TC 1028 User manual 3 21 WIRING Load type open delta For open delta load configuration 6 wire configuration three TC1028 power controllers can be used with all the available firing modes The power wiring given in the diagram below should be followed Danger The controllers and reference voltage circuits are at line to line voltage Wire protection and mains circuit breaker installed by user Ph 1 O Ph 2 O Ph 3 O TC1028 Control signal Three phase load in open delta configuration Figure 3 16 Wiring diagram of three 1028 controllers in open delta do not use for three phase transformer primaries 3 22 TC 1028 User manual WIRING Load type star without neutral or in closed delta two phase control For three phase loads connected in st
37. alues and feedback parameters on a digital display The unit shows two decimal places to give a precise reading of the selected values The diagnostic unit has a ribbon cable which plugs into the 20 pin connector diagnostic connector provided on the front panel of the controller The signals from the diagnostic connector may also be viewed using an oscilloscope Delay Retard Diagnostic connector TC1028 Connection by ribbon cable Digital display EUROTHERM diagnostic unit Oscilloscope connection terminals isolated from power 9 V power supply Standard or rechargable battery Battery charger Figure 6 1 Connection of the EUROTHERM type 260 diagnostic unit to the thyristor unit The following tables give a description of each position of the diagnostic unit selector switch together with typical values of the measured signals mean DC values TC 1028 User manual COMMISSIO NING Position Function Current measurement nominal load Manual input if used PLF output In alarm Notin alarm External setpoint Example 0 10V 5V Threshold limit max approx 10V Current measurement for PLF 2 5V Load voltage measurement 2 25 Amplified setpoint 2 5V Slave output not used Firing demand 8 4V 10 referen
38. ar without neutral or in closed delta 3 wire configuration it is advisable to use two phase control One supply phase is direct not controlled In the two controlled phases a TC1028 controller which operates as a Master and a TC1027 operating as a Slave must be connected together The Slave control logic output terminal 8 is provided on the TC1028 driver board user terminal block Wire protection and mains circuit breaker installed by user Three phase load in star without neutral or closed delta Figure 3 17 Wiring of a controller and a solid state relay in two phase control do not use for three phase transformer primaries TC 1028 User manual 3 23 WIRING PLF ALARM The partial load failure PLF detection alarm relay contacts which signal the active state of the alarm are connected to the user terminal block located below the unit on the left hand side The contact output terminals are 51 amp 52 PLF alarm NES contact terminal block View of unit from below Figure 3 18 PLF alarm relay contact connection The PLF alarm relay is de energised in the alarm state and in the absence of the power supply voltage In the standard version the relay contacts between terminals 51 amp 52 are open in the alarm state In the IPF option the alarm relay contacts are closed in the alarm state The partial load failure detection alarm r
39. ated on the right hand side below the unit The maximum cross section of the conductors is 1 5 mm tightening torque of control terminals 0 7Nm To second phase or neutral depending on wiring of load Control cable Fusible clamp 1A LL a Not used View of unit Reference voltage from below connection ternminal block Figure 3 2 Reference voltage connection terminal block The reference voltage second phase or neutral must correspond to the load configuration voltage A 1A external fuse must be fitted to protect the reference voltage wiring 3 6 TC 1028 User manual WIRING CONTROL CABLES Warning Control connections should be made using shielded cables grounded at both ends in order to ensure satisfactory immunity against interference Separate the control cables from the power cables in the cable trays Mounting The control wires must be grouped together in a shielded cable passing through the cable clamp located below the unit Control cable clamp Tightening screw Lower cover CNN Stirrup View of unit comen from below Figure 3 3 Location of control cable clamp Important AN To facilitate earthing of the cable shield and to ensure maximum immunity from electromagnetic interference the metal cable clamp is bonded directly to the ground of the unit 1028 User manual 3 7 WIRING Connection of the shield to the ground To insert t
40. ble 6 5 Example of threshold current limit It is possible to use these two current limits simultaneously e to set an absolute current limit with the threshold limit and to adjust the linear current limit with the potentiometer on the front panel 6 14 TC 1028 User manual COMMISSIO NING TROUBLESHOOTING Symptom 1 Thyristor does not fire when demanded Action 11 1 2 13 1 4 1 5 1 6 1 7 1 8 Check that the Enable input terminal 9 on the driver fire board is connected properly to 10V terminal 2 Check that the control signal is reaching the user terminal block on the driver board e terminal 7 with external control e terminal manual control and that the polarity is correct Check that the input signal level and type are compatible with the level and type of signal configured Check the wiring of the thermal switches on the power board Check that thyristor firing pulses are present e 20 V pulses for Phase angle firing e 26 V pulses in Burst firing mode in position 13 of the diagnostic unit Check that the current limit is not at zero position 5 of the diagnostic unit and that the setpoint is present external input in position 4 or manual input in position 2 Check that the supply voltage is greater than or equal to 80 of the nominal Check that the electronics are correctly powered 15V 15 amp 10V voltages present
41. ce 10V 0 1V 24V full wave recified 20V Pulse output 15 power supply Oscillator input 20V no pulses 20V pulses 20V pulses 15V 0 15V 1 2V 6 4V peak 1 2V 6 4V peak 90 pulses 90 pulses 15V power supply 15 0 15 0 voltage crossing pulse 10 5V 12V peak 0 5ms OV OV Saw tooth generator 3 6V 8 4V peak 10ms Enable lt 10V Table 6 1 Description of positions on Eurotherm type 260 diagnostic unit Thyristor firing angle variation 6 6 TC 1028 User manual COMMISSIO NING Position Function Current measurement nominal load 0 50 setpoint setpoint Modulation 2 5V Manual input if used PLF output In alarm Notin alarm 2 5V 12 6V 13 5V External setpoint Example 0 5V OV 2 5V Threshold limit max approx 10V Current measurement for PLF Load voltage measurement Amplified setpoint Modulation 0 to 4 6V Modulation 0 to 4 3V 2 5V Slave output Modulation 0 13 5V Firing demand 6 25V 12 5V peak 10V reference 10V 0 1V 24V full wave recified 20V Pulse output 15 power supply 26V pulses 15V 0 15V Oscillator input 6 4V peak 1 2V 6 4V peak 15V power supply 15V 0 15V 0 voltage crossing pulse OV 10 5V 12V 0 5ms OV Saw tooth generator
42. check the design of the installation 1028 User manual 6 13 COMMISSIO NING Threshold limit Threshold current limit is independent of the control signal it is either 110 of the nominal current terminal 5 of the control terminal block directly connected to terminal 2 10V orcontrolled by an external potentiometer of approximately 5kQ connected between terminal 2 10V and terminal 1 OV the wiper is connected to terminal 5 orcontrolled by an external DC voltage 0 to 10 V The threshold I limit input impedance terminal 5 is greater than or equal to 150kQ To adjust the threshold current limit After adjusting the linear limit using the potentiometer on the front panel switch on the controller set the control to maximum Reduce the Threshold current limit setpoint gradually until the current begins to decrease Record the above current limit setpoint read from the diagnostic unit in position 5 then increase it by approximately 10 so that the limit acts only as a back up safety measure for the linear current limit Warning AN The threshold current limit can be pre adjusted when a controller is switched on but not firing The value of the RMS load current squared is proportional to the Threshold current limit setpoint displayed in position 5 of the diagnostic unit Current limit signal position 5 on diagnostic unit 10V 9 1V 4 1V Ta
43. d state relay in Master Slave operation Access to the user terminal block is by opening the front door Danger Live parts may be exposed when the door is open if the TC1028 controller is powered up 9 8 7 6 5 4 3 2 1 Driver board E 2 5 2g c Lr eiS gt 2 5 gt wO 2 a o gt Who gt 2 gt 2 51551221515 lao az 2 94 Figure 3 6 Labelling of TC1028 control terminals Control terminal block terminal capacity 0 22 to 1 5mm Control terminal tightening torque 0 7Nm The input is isolated from the power supply and from the load circuit TC 1028 User manual 3 9 WIRING Terminal Labelling Function OV Common 10V 10V user voltage LOAD V OUTPUT O utput for load voltage measurement retransmission LOAD OUTPUT O utput for load current measurement retransmission I LIMIT INPUT Input for threshold current limit MANUAL IN PUT Input for manual control signal AUTO INPUT Input for automatic control signal SLAVE FIRING OUTPUT EN ABLE INPUT Logic output to drive other units in Master Slave operation Enables thyristor operation Table 3 3 Terminal designation of TC1028 thyristor unit control terminal block 3 10 TC 1028 User manual WIRI
44. d to terminal 9 4V min 32V max with reference to terminal 1 see Figure 3 7 on page 3 12 To enable the controller a connection via normally closed contacts between the Enable terminal and the 10V user voltage terminal 2 may be used Opening these contacts will inhibit the controller MASTER SLAVE OPERATION A logic signal 10Vdc 10mA is available on the Slave output between terminals 8 Slave and 1 OV when the TC1028 controller is firing in slow cycle fast cycle or single cycle Firing modes The Slave output is used to control external solid state relays By using this logic signal output it is possible to implement Master Slave operation with a TC1028 Master controlling one or more TC1027 series solid state relays Slaves for both single phase and three phase loads see Chapter 3 Wiring 5 14 TC 1028 User manual COMMISSIO NING Chapter 6 COMMISSIONING PROCEDURE Contents Page COMMISSIONING PROCEDURE SAFETY 6 2 CHECKING THE CHARACTERISTICS 6 3 LOAD CURRENT mtm Rb Son 6 3 SUPPLY VOLTAGE el 6 3 REFERENCE VOLTAGE 6 4 INPUT SIGNALS e Rye ch eed 6 4 PARTIAL LOAD FAILURE DETECTION 6 4 DIAGNOSTIC UNIT RR URN Rs 6 5 PRELIMINARY ADJUSTMENTS 6 8 FACTORY SETTINGS esee Rm
45. e tested regularly Eurotherm can supply various types of alarm systems for this purpose Further information For any further information or if in doubt please contact Eurotherm Controls where qualified staff are available to advise or assist you with the commissioning of your installation 1028 User manual V IDENTIFYING THE THYRISTO R UNITS Chapter 1 IDENTIFYING THE THYRISTOR UNITS Contents Page GENERAL INTRODUCTION TO THE TC1028 SERIES 1 2 TECHNICAL SPECIFICATION 1 7 PRODUCT CODE eph rer ERR 1 10 EXAMPLE OF PRODUCT CODE 1 11 SERIAL NUMBER LABELS 1 12 1028 User manual 1 1 IDENTIFYING THE THYRISTO R UNITS Chapter 1 IDENTIFYING THE THYRISTOR UNITS GENERAL INTRODUCTION TO THE TC1028 SERIES The TC1028 series of thyristor units are designed for the control of industrial single phase loads The TC1028 series is designed to control inductive loads transformer primaries in particular or resistive loads with a large temperature coefficient A thyristor unit comprises a pair of thyristors connected in anti parallel and mounted on a heat sink together with control and alarm circuits The TC1028 series of thyristor units control currents up to 1650A This User Manual is valid for TC1028 units rated between 300A and 500A The nominal line to line voltage is between 100V and 690V depending on the product code The
46. ed on the lower part of the unit labelled LOAD see Figure 3 1 The power terminal capacities are given in Table 3 1 Tightening torques should not exceed the limits given in this table Terminal Wiring details Supply and load 185 to 2 x 150mm Earth cable 95 to 185mm Fuse stud Tightening torque M10 25Nm Load screw Tightening torque M12 43 5Nm Earth screw Tightening torque M12 43 5Nm Table 3 1 Power connection details 300A to 500A The cross section of the conductors to be used must comply with Standard IEC943 TC 1028 User manual 3 3 WIRING Thyristor protection fuse Safety earth connection Supply phase connection Load connection Figure 3 1 Fixing points for power cables 300A to 500A unit 3 4 TC 1028 User manual WIRING Distance between Dimensions Earth busbar and upper fixing hole Earth busbar and left fixing hole LOAD terminal and lower fixing hole LOAD terminal and left fixing hole LINE terminal and upper fixing hole Table 3 2 Details of power cabling Warning The power cables leading to a load pass through a cable gland aperture to 38mm which must be tightened carefully after wiring TC 1028 User manual 3 5 WIRING REFERENCE VOLTAGE CONNECTION The reference voltage second phase or neutral used by the electronics is connected to a plug in user terminal block loc
47. elay contacts are protected from interference by an RC snubber on the driver board Warning PLF alarm relay contacts must be only be connected to circuits energised by 230V or less single phase or three phase 230V supply 3 24 TC 1028 User manual CONFIGURATION Chapter 4 CONFIGURATION Contents Page CONFIGURATION SAFETY 4 2 POWER BOARD RE 4 3 SUPPLY VOLTAGE SELECTION 100V TO 500V 4 3 DRIVER BOARD Lev ds aie Ee 4 4 INPUT SIGNAL e ER 4 5 Control signal type 4 5 Input configuration 4 5 THYRISTOR FIRING MODE 4 6 RETRANSMISSION OF RMS CURRENT OPTION 4 7 FREQUENCY eL ERI NER Eq 4 8 ALARM RELAY CONTACT TYPE 4 8 1028 User manual 4 1 CONFIGURATION Chapter 4 CONFIGURATION CONFIGURATION SAFETY The thyristor unit is factory configured using moveable jumpers and soldered links It can be reconfigured on site by using these jumpers Important The controller is supplied fully configured in accordance with product code on the identification label This chapter is included in order to Check that the configuration is suitable for the application Modify if necessary certain characteristics of the unit on site Danger For safety reasons re configuration of the controller usi
48. ent retransmission and bargraph display use instantaneous values pins 11 amp 12 and pins 7 amp 8 must be short circuited using the jumpers provided see Figure 4 2 Figure 4 3 RMS option board With the RMS option jumper M1 on the RMS option board must be in position 1 2 as shown in Figure 4 3 1028 User manual 4 7 CONFIGURATION Frequency In the standard version the operating frequency of the TC1028 is 50Hz As an option code 60H the frequency is 60Hz The value of the frequency used is configured by means of jumper K10 on the driver board Frequency Position of K10 jumper 50Hz 1 60Hz option 0 Table 4 5 Frequency configuration for supply used PLF alarm relay contact type The PLF alarm relay is de energised in the alarm state and when the power supply is cut In the standard version the relay contacts provided between terminals 51 amp 52 are open in the alarm state In the IPF option the relay contacts are closed in the alarm state Configuration of the contact type is done at the factory depending on the product code ordered Soldered links LK11 amp LK12 on the driver board are used to configure the contact type The location of links LK11 amp LK12 is given in Figure 4 2 Contact type Configuration links LK11 LK12 O pen in alarm state standard Cut Soldered Closed in alarm state option Soldered Cut Table 4 6 C
49. ft start for large temperature coefficient resistive loads and the delayed firing angle in the first half cycle when controlling inductive loads minimise transient overcurrents Which otherwise can cause fuse blowing or trigger a protective circuit breaker The soft start and end time can be adjusted between 0 and 0 25s via the potentiometer on the front panel TC1028 units have two types of current limit linear limit adjusted by potentiometer on front panel threshold limit adjusted by external potentiometer The partial load failure detection circuit PLF detects 2596 increases in load impedance independent of supply voltage variations PLF detection is adjusted by a potentiometer on the front panel which is used to set the actual load current PLF alarm signalling is provided by the alarm relay contacts and by the Load Fail indi cator light on the front panel Thermal protection is provided by means of a thermal switch which senses fan failure or heatsink over temperature TC1028 units have active enable An external 10V signal 32V max or a switch connected to the user terminal block are used to enable operation Absence of the enable voltage or opening of the switch contacts causes inhibition of the controller 1 6 1028 User manual IDENTIFYING THE THYRISTO R UNITS TECHNICAL SPECIFICATION units rated between 300A and 500A The TC1028 is a power thyristor unit designed to control an i
50. he control cable and earth its shield Strip the shielded cable as shown in Figure 3 4a The control wires must be long enough for connection to be made to the user terminal blocks on the boards whilst the bare screen is grounded at the metal cable clamp when the door is open Wiring inside the unit should be as short as possible Control wires Shield Insulating sheath 1 5 to 2 cm 20 to 40 cm Control wires Insulating sheath Shield folded back b Figure 3 4 Control cable stripping Fold back the shield on to the insulating sheath Figure 3 4b Insert the cable into the metal cable clamp so that the shield is located in the stirrup and not inside the unit at least not beyond the lower cover Tighten the stirrup 4x1 flat bladed screwdriver tightening torque 0 7Nm Lower cover Ld EJERCER Tighening screw Cable clamp SES Shield folded back Cabe View from left side Figure 3 5 Cable tightening and shield grounding The possible diameter of the cables with the shield folded back is from 5mm to 10mm per cable clamp 3 8 TC 1028 User manual WIRING CONTROL TERMINAL BLOCK The following connections are made on the driver board user terminal block input signal external or manual enable for controller operation threshold current limit load current and voltage retransmission logic signal output to drive a soli
51. he guarantee TC1028 User manual 7 3 MAINTENANCE FUSE BLOWN INDICATION MICROSWITCH As an option the high speed fuse can be fitted with a fuse blown indication microswitch FUMS option with the reference for BUSSMANN fuses EUROTHERM DC172267 or FERRAZ P96015 or BUSSMANN 170H0069 for FERRAZ fuses EUROTHERM DC172997 or FERRAZ G310 000 To ensure better isolation between the wiring of the microswitch terminals the power and the cover TC1028 power controllers are supplied with flag type cable lugs with insulating sleeves Each external terminal on the fuse blown indication microswitch must be wired with a flag lug fitted with an insulating sleeve to comply with Figure 7 1 Line bar Sleeve Fuse Housing EDV Changeover microswitch Common Contacts shown in non blown condition Contacts N O Contacts N C Figure 7 1 Use of flag lugs and insulating sleeves to comply with electrical clearance distances 7 4 TC 1028 User manual MAINTENANCE PROTECTION FUSES FOR REFERENCE VOLTAGE CONNECTION These fuses must be installed in the connection wires of the reference voltage leading to the second phase if the controller is wired between two phases see Chapter Wiring Reference voltage max 1A fuse 6 3 x 32mm Fuse holder isolator Dimensions of fuse isolator assembly mm 500 V CS174289U1A0 CP174293 63x15 x52 690 V
52. intain its leading edge Eurotherm may have to make changes to its specifications without advance notice For any further information or if in doubt please contact Eurotherm Controls 1028 User manual 1 9 IDENTIFYING THE THYRISTO R UNITS PRODUCT CODE FOR TC1028 SERIES 1028 Nominal Nominal Fan Input Firing Manual O ptions current voltage supply signal mod Nominal current Code Input signal Code 300 amps 300A 0 5 V 0 5 400 amps 400A 1 5V 1V5 500 amps 500A 0 10 V 0V10 750 amps 750A 2 10 V 2V10 900 amps 900A 0 20 mA 0mA20 1200 amps 1200A 4 20 mA 4mA20 1650 amps 1650A Thyristor firing mode Code Nominal voltage Code Phase angle PA 100 volts 100V Single cycle SGL 110 volts 110V Fast cycle burst firing 0 85 FC 115 volts 115V Fast cycle burst firing with 120 volts 120V soft start SFC 200 volts 200V Fast cycle burst firing with 220 volts 220V soft start amp end SDF 230 volts 230V Slow cycle burst firing 8s SC 240 volts 240V Slow cycle burst firing with 277 volts 277V soft start SSC 380 volts 380V Slow cycle burst firing with 400 volts 400V soft start amp end SDS 415 volts 415V 440 volts 440V Manual language Code 480 volts 480V English ENG 500 volts 500V French FRA 690 volts 690V German GER Italian ITA Fan supply Code Dutch NED Self supplied Swedish SWE 300A to 500A ra
53. iometer Phase angle No effect Single cycle Fast cycle Burst firing Delay of first thyristor firing at the start of each Slow cycle Burst firing firing cycle 0 to 90 Burst firing with soft start Duration of soft start in thyristor firing angle variation 0 to 250ms Burst firing with soft start Duration of soft start and end in thyristor and end firing angle variation 0 to 250ms Table 6 3 Effect of Delay Retard potentiometer 6 8 1028 User manual COMMISSIO NING Bargraph PLE detection indicator lig Load Fail D f Charge Adjust Adjustment potentiometer for Seuil linear current limit PLF detection adjustment Test potentiometer Q 4 Limit 1 2 Delay WH Access door to diagnostic connector Adjustment potentiometer delayed firing or soft start duration ____ Access door to diagnostic connector Figure 6 2 Front panel of TC 1028 controller location of adjustment potentiometers Factory settings As shipped from the factory the controller is pre set with a firing mode configured Thyristor firing mode Position of Delay Retard potentiometer Fast cycle Burst firing Completely clockwise Slow cycle Burst firing Zero voltage switching Firing delay 0 Soft start or soft start and end Completely anti clockwise Maximum ramp 250ms Phase angle No effect Table 6 4 Fac
54. ixing screws halfway into the bulkhead mounting plate holes Offer up the controller by first engaging the heads of the upper screws in the respective holes on the upper section Lower the unit making sure that it engages properly on the lower screws Then slide the unit down completely until it is in position Tighten the four screws correctly 1028 User manual 2 5 IN STALLATIO N INSTALLATION DETAILS TC1028 series units are designed to be mounted directly on to a panel using the fixing points located on the rear of the units Protection 4 drilling holes for M8 screws Figure 2 2 Mounting details 300A to 500A rated units 2 6 TC 1028 User manual WIRING Chapter 3 WIRING Contents Page WIRING SAFETY a I e eis 3 2 CONNECTING THE POWER CABLES 3 3 REFERENCE VOLTAGE CONNECTION 3 6 CONTROL CABLES Re EGG URN eee DN 3 7 MOUNTING eee eb Ies 3 7 CONTROL TERMINAL BLOCK 3 9 INPUT SIGNALS iae 3 EXTERNAL ANALOGUE INPUT 3 12 CONTROL OF MULTIPLE UNITS 3 13 Witing in parallel 5 25 ccs 95 4 3 13 Witing Series iius elicere ER ERE 6 3 14 MANUAL CONTROL WIRING 3 15 EXTERNAL CURRENT LIMIT WIRING 3 16 RETRANSMISSION SIGNAL WIRING
55. llel input wiring TC 1028 User manual 3 13 WIRING Wiring in series The inputs must be configured as current inputs Wiring in series is possible if all the controllers are configured for the same current signal 0 to 20mA for example For 0 to 20mA and 4 to 20mA inputs the impedance of an input is 250Q For each input 5 volts are required for a current of 20mA Control signal 0 20 mA 4 20 mA lt Contacts N C Controller enable Contacts open inhibited res sd 8 8 15 52 8 5 amp 2 5 5 5 5 5 gt 5212215 8 295 98 2025 5 21312 22 2 o 3 Ela 515 2 255 2 5 5 151212155 2122121919 lt 2 5 Dalz 131 Driver board 1 Driver board 2 Driver board 3 Figure 3 9 Series input wiring 3 14 TC 1028 User manual WIRING Manual control wiring The TC1028 can be controlled by an external potentiometer manual control A 4 7kO to 10kQ potentiometer should be connected between terminals 1 0 and 2 10V The wiper is connected to terminal 6 Manual input To use
56. nductive industrial load or a load with a high current requirement at start up Warning It is the user s responsibility to ensure before commissioning the controller that all the nominal ratings of the controller are compatible with the conditions of use and the installation Power Nominal current Nominal line to line voltage Supply frequency Dissipated power Fan Load Environment Operating temperature Storage temperature Protection Thyristor protection Wiring Atmosphere Humidity Pollution Altitude Dimensions Up to 500V 690V 300A 400A 500A 100Vac to 690Vac 10 15 Inhibition below 80 of nominal voltage response time lt 10ms automatic reset 2s after return to nominal 50Hz or 60Hz 2 7 1 3W per amp Allow 2W per amp to include fuse 6 5W consumption 24Vdc fan Self supplied by power circuit for 300A to 500A rated units External supply for other ratings see addendum HA17804ENG001 Resistive with large temperature coefficient or inductive transformer primary or inductor 0 C to 50 C in vertical position 40 C for 500A nominal at 50 C derate to 450A 10 to 70 C Two covers provide IP20 protection on the front panel Internal high speed fuse with fuse blown indication microswitch option MOV varistor and RC snubber To be carried out in compliance with Standard 364 Non explosive non corrosive amp non conductive RH 5 to 95 non
57. ng jumpers must be carried out with the unit switched off and by qualified personnel only Before starting the re configuration procedure check that the unit is isolated and that any accidental power up is not possible After re configuring the unit amend the codes on the identification label to prevent any subsequent maintenance problems 4 2 TC 1028 User manual CONFIGURATION POWER BOARD There are two types of power board for the TC1028 series a board for operating voltages from 100V to 500V and two specific boards for the 690V operating voltage Selection of the supply voltage is only performed on the 500V power board Supply voltage selection 100V to 500V The nominal line to line voltage specified when ordering is configured by the position of jumpers JP1 to JP6 and by the type of auxiliary power supply transformers Three types of transformer are used see Table 4 1 below J3 GE 2 5 7 5 J1 JP2 JP1 JP6 JP5 JP4 5 Neutral 1 Ell Neutral 2 El os el Figure 4 1 Location of jumpers on power board 100V to 500V Line to line aes Transformer voltage absent 1 present reference number P2 P3 P5 JP6 100V 110V to 120V 127V 200V 220V to 240V 277V 380V to 415V 440V 174973 480V to 500V 174613 Table 4 1 Voltage configuration 100V to 500V 174973 174544 174613 174973 174544 174613 174544
58. nnect Enable input terminal 9 to the 10V user voltage terminal 2 Current limit input terminal 5 to the 10V user voltage Manual control input terminal 6 to terminal 1 OV 3 12 1028 User manual WIRING Control of multiple units The inputs of several controllers may be wired in parallel or in series For this type of wiring all the thyristor units must have the same mode of firing and the inputs must be configured for the same signal type Wiring in parallel The inputs must be configured as voltage inputs The input impedance per controller is 50 The current required for each controller is 0 2mA at full scale Control signal 0 5 V 1 5 V 0 10 V 2 10 V Contacts N C Controller enable Contacts open inhibited e al E o E El5 o 9 5 5 5 2 t 5 gt a t Pla 22 51212121512 lt gt 6 le Oz Ola 6 o 8 9 gt 25 2 9 gt 29 gt 2 Uo2tni a 31512 315135 5155255 5151512 515 219 alzi 2191 Driver board 1 Driver board 2 Driver board 3 Figure 3 8 Para
59. onfiguration of alarm relay contact type 4 8 1028 User manual Chapter 5 OPERATION Contents Page THYRISTOR FIRING MODES 5 2 GENERAL Hoses suet sai 5 2 PHASE ANGLE MODE 5 2 BURST FIRING MODE 2k b RES ee ek 5 3 SINGLE CYCLE MODE 5 3 MODULATION PERIOD 5 4 SOFT SPART ZEND nates 5 5 OVERCURRENT ELIMINATION FOR INDUCTIVE LOADS sce on 5 6 CONTROL OPERATION dus eere ohne 5 7 FEEDBACK FUNCTION e ew ns 5 7 COMPENSATION FOR SUPPLY VOLTAGE VARIATIONS COMER ORO Eb metre te RU 5 8 SELECTIVE BLOCKING OF TRIGGER PULSES 5 9 CURRENT LIMIT 5 savers s 5 10 LINEAR 5 10 THRESHOLD CURRENT LIMIT 5 11 PARTIAL LOAD FAILURE DETECTION 5 12 RETRANSMISSION RR ehe ress 5 13 RETRANSMISSION 5 5 13 LOAD CURRENT MEASUREMENT 5 13 LOAD VOLTAGE MEASUREMENT 5 13 BARGRAPH DISPLAY esee t heec ces 5 13 ENABLE 7 INHIBIT mne 5 14 MASTER SLAVE OPERATION 5 14 1028 User manual 5 1 O PERATIO N Chapter 5 OPERATION THYRISTOR FIRING MODES General The TC
60. pply voltage Range of variation Setpoint Power supplied in supply voltage With compensation Without compensation 0 to 10 100 100 to 121 5 to 10 90 81 to 109 10 to 10 80 65 to 97 15 to 10 70 50 to 85 Table 5 1 Control operation with compensation for supply voltage variation Table 5 1 demonstrates stabilisation of the output power on a constant resistance load as a function of supply variations If the voltage drops below 80 of its nominal value the controller will be inhibited A compensation circuit simultaneously adjusts thyristor firing time depending on supply variations This compensation action prevents power fluctuations without the intervention of the control loop enabling a faster response 5 8 TC 1028 User manual O Selective blocking of trigger pulses Thyristors in the TC1028 controller are triggered by a pulse train of 5ms maximum dura tion To reduce the cost of the electronics in most single phase applications it is possible to send trigger pulses every 10ms so that the thyristors are polarised in direct mode positive anode in relation to the cathode or in inverse mode negative anode Each thyristor will only fire when its voltage is positive when it is negative the anti parallel thyristor will fire In certain applications trigger pulses on the inverse polarised thyristor may lead to operating problems firing instability fuse blo
61. re the load is connected If using in conjunction with the threshold current limit potentiometer or external signal first make sure that the Threshold limit setpoint terminal 5 I Limit input on the control terminal block is set to its maximum value Turn the I limit Limit linear current limit potentiometer completely anti clockwise minimum current e Apply a OV signal to the input and connect the power voltage The RMS voltage at the load terminals should be zero e Increase the input signal to 100 The load voltage must represent approximately 1546 of the supply voltage e Turn the current limit potentiometer gradually clockwise and check that the load current slowly increases Adjust the I limit Limit potentiometer in order to obtain the maximum current permitted for the load Warning A N To adjust current limit use only a true RMS reading ammeter to measure load current This avoids the risk of errors which could reach 50 For a three phase installation using two or three TC1028 controllers take care to turn each of the current limit potentiometers gradually in succession in order to maintain the current balance in each of the phases Warning When controllers are configured in Star with neutral the neutral current for a large temperature coefficient load when starting from cold can be 1 7 times greater than the phase currents limited by the current limit As a consequence
62. rovided for this purpose in the upper part of the unit behind the phase terminal and labelled Danger To ensure correct grounding of TC1028 unit make sure that it is properly mounted on the reference ground surface panel or bulkhead Failing this it is necessary to add a ground connection at most 10cms long between the earth connection and the reference ground surface This connection which is intended to ensure good ground continuity can never be used to replace the safety earth connection 3 2 TC 1028 User manual WIRING CONNECTING THE POWER CABLES The supply power cable passes through an opening in the upper protective cover of the TC1028 unit In order to make connection of this cable easier the upper cover of the unit is removed To remove the cover open the access door by undoing the front screw located on the top left hand side of the door lift the door in order to release it from its slots open the door completely by pulling it towards you remove the upper cover by unscrewing the two fixing nuts by sliding it forwards to release the two catches located at the rear and then raising it The supply connection is made on the fuse stud on the upper part of the unit labelled LINE see Figure 3 1 The load power cable passes inside the unit through a cable gland located below the unit The aperture of this cable gland is up to 38mm The load connection is made on the screw locat
63. sed for this configuration Jumper position K1 K2 K3 External Table 4 3 TC1028 unit input configuration TC1028 User manual 4 5 CONFIGURATION Thyristor firing mode The firing modes available for the power controllers may be configured using jumpers K5 to K9 and K11 to K13 located on the driver board Thyristor firing mode Jumper position K11 K12 Phase angle 0 Single cycle Fast cycle burst firing Fast cycle burst firing with soft start 0 0 0 0 0 0 0 Fast cycle burst firing with soft start and end Slow cycle burst firing Slow cycle burst firing with soft start Slow cycle burst firing with soft start and end Table 4 4 Thyristor firing mode configuration Note Jumpers K11 to K13 are used to select filter characteristics for the RMS current measurement RMS option in Table 4 4 indicates that operation is indifferent to position of jumpers don t care 4 6 1028 User manual CONFIGURATION Retransmission of RMS current option Retransmission of the load current RMS value is achieved except for slow cycle burst firing mode by installing the RMS option board on the driver board at the factory see Figure 4 2 This board is installed using three groups of pins labelled 1 to 12 If the RMS option board has not been fitted thus the curr
64. tart duration diagnostics connector bargraph showing the mean or RMS current optional potentiometer for partial load failure detection adjustment Test pushbutton to test the PLF alarm adjustment indicator light to display PLF detection 1 4 1028 User manual IDENTIFYING THE THYRISTO R UNITS Safety Power supply connection screw Filter Internal thyristor protection fuse Power board Load Flat connection connection cable PLF contact terminal block Filter board Ground bonding link Reference voltage Control terminal block Potentiometer board Driver board RMS option board Figure 1 2 Circuit boards for the TC 1028 series thyristor unit 500 version TC 1028 User manual 1 5 IDENTIFYING THE THYRISTO R UNITS TC1028 thyristors have the following thyristor firing modes Phase angle variation in the thyristor firing angle Burst firing modulation of burst firing duty cycle from 0 to 100 Burst mode firing is characterised by various modes Single cycle one cycle of firing or non firing slow cycle burst firing modulation time 8s at 50 setpoint fast cycle burst firing modulation time 0 85 at 50 setpoint burst firing fast or slow cycle with phase angle soft start burst firing fast or slow cycle with phase angle soft start and end The so
65. ted units 000 External voltage Options Code ratings gt 750A RMS current 115 volts 115V retransmission and display RMS 230 volts 230V 60Hz frequency 60H PLF alarm contacts closed Input signal Code in alarm state IPF 0 5 V 0V5 Fuse blown indicator 1 5V 1V5 microswitch FUMS 0 10 V 0V10 No internal fuse NOFUSE 2 10 V 2V10 Separate MC control unit 0 20 mA 0mA20 for gt 750A rated units 4 20 mA 4mA20 not available for 690V MC See addendum HA174804ENG 001 1 10 1028 User manual IDENTIFYING THE THYRISTO R UNITS Example of product code TC1028 controller and installation parameters Nominal load current 250 amps Nominal supply voltage 440 volts line to line Analogue input signal 0 to 10 volts Firing mode Fast cycle burst firing with soft start Options RMS current display and retransmission Partial load failure detection alarm relay contacts closed in alarm state Fuse blown indication microswitch Controller code 1028 300A 440V 000 10 SFC ENG RMS IPF FUMS 96 00 Warning The nominal voltage of the TC1028 controller must correspond to the supply voltage used in order to eliminate problems of the controller not operating below 80 of the nominal voltage TC 1028 User manual 1 11 IDENTIFYING THE THYRISTO R UNITS SERIAL NUMBER LABELS Two identification labels which include the controller product code and one configuration label
66. tor which protect against excessive rate of change of voltage and transient overvoltages when the thyristors are not conducting athermal switch if the heatsink overheats the thermal switch opens causing the thyristors to cease firing 7 2 1028 User manual MAINTENANCE THYRISTOR PROTECTION FUSE The standard version of the TC1028 series of power controllers is supplied with a high speed fuse mounted on the line busbar Warning A N A high speed fuse is used only for the internal protection of thyristors against large amplitude overloads Under no circumstances must this fuse be used to protect the installation Danger The user s installation must be protected upstream with non high speed fuses thermal or electromagnetic circuit breaker suitable fuse isolator and must comply with current standards Table 7 1 contains all the references for the original internal fuses as shipped from the factory and the recommended replacement fuses which can be used during maintenance Maximum line to line voltage 690 V Nominal current Reference Controller Fuse EUROTHERM FERRAZ BUSSMAN A A 300 400 LA172486U400 H300065 170M5458 400 500 LA172468U500 K300067 170M5460 500 630 141724680630 300069 170 5462 Table 7 1 Recommended high speed fuses for thyristor protection Warning A N The use of any fuses other than those recommended for thyristor protection invalidates t
67. tory settings 1028 User manual 6 9 COMMISSIO NING Resistive load with low resistance variation with temperature For loads with a low temperature coefficient use Single cycle or Burst firing modes This type of load does not require either delayed firing or soft start Turn the Delay Retard potentiometer on the front panel completely clockwise the ramp duration is zero Power up the controller On the external input Auto Input terminal 7 on the control terminal block apply a signal corresponding to 0 Using an RMS ammeter check that there is no load current On the external input Auto Input terminal 7 or manual input Manual input terminal 6 apply a signal corresponding to 10046 of the control signal Using an RMS ammeter check that the current is equal to the nominal load current and that it does not exceed the nominal thyristor unit current Resistive load with high resistance variation with temperature For loads with a high temperature coefficient use the following firing modes e Phase angle with current limit or e Burst firing with soft start The soft start or start and end ramp may be adjusted from 0 to 250ms Make sure that the Delay Retard potentiometer on the front panel is turned completely anti clockwise the ramp duration is maximum Power up the controller On the external input Auto Input terminal 7 on the con
68. trol terminal block apply a signal corresponding to 0 Using an RMS ammeter check that there is no load current On the external input Auto Input terminal 7 or manual input Manual input terminal 6 apply a signal corresponding to 100 of the control signal Using an oscilloscope or the bargraph on the front panel check that the overcurrent at the start does not exceed the values permitted by the load and the thyristor unit When controlling a load with a very large temperature coefficient Kanthal Super for example in Burst firing with soft start mode use the TC1028 in Special 603 mode on request 6 10 TC 1028 User manual COMMISSIO NING Non saturable inductive load When the load includes a non saturable inductive component inductor for example firing at zero voltage in Burst mode produces a transient overcurrent at the start of each burst see Chapter 5 Operation Transient overcurrents may cause safety systems to trip and in some cases high speed thyristor protection fuses to blow To prevent these overcurrents at the start of each burst the first thyristor firing must be delayed relative to the corresponding zero voltage Depending on the load the optimum delay angle for thyristor firing must be adjusted by the Delay Retard adjustment potentiometer For this adjustment Make sure that the Delay Retard potentiometer is turned completely anti clockwise 90
69. unit 500V version 1028 User manual 1 3 IDENTIFYING THE THYRISTO R UNITS The standard basic version of the TC1028 series of controllers is fitted with e thyristor firing board power board which generates thyristor firing pulses and provides current and voltage measurement a driver board which produces signals to control thyristor firing potentiometer board to allow adjustment of delayed firing inductive loads and soft start time a filter board to protect thyristor unit operation from transient interference As an option the TC1028 may be fitted with a board which plugs into the driver board and which converts the instantaneous current into an rms current measurement RMS option board The RMS value of the load current is displayed on a bargraph and is retransmitted via a signal available on the user terminal block The control system uses analogue feedback of load voltage squared V2 or load current squared 12 the highest value being automatically selected TC1028 units compensate for supply variations in the range 10 to 15 of the nominal voltage TC1028 series thyristor units are used for control of electrical loads such as loads with large resistance variations as a function of temperature transformer primaries inductors The following features are found on the front panel potentiometer to adjust the initial firing delay on inductive loads or soft s
70. wing It is therefore very important to eliminate trigger pulses when the thyristor is inverse polarised This function is performed by the selective trigger pulse blocking circuit available for TC1028 units Selective blocking of trigger pulses is essential for configurations in which multiple controllers are distributed between the phases of a three phase supply and have an elec trical configuration which could induce a voltage phase shift For example control of heating electrodes in transformer secondary immersed in the same pool of molten glass e loadin star with neutral with the central point of the star connected to the supply neutral by a conductor of significant resistance compared with that of the load 1028 User manual 5 9 O PERATIO N CURRENT LIMIT TC1028 thyristor units have two types of current limit using the load current measurement alinear current limit and athreshold current limit These two limits are independent Linear current limit This function limits the RMS load current squared P In current limit the relationship between the load current and the input signal is adjusted using the potentiometer labelled I Limit Limit on the front panel 2 Without current limit 100 75 limit 50 50 limit 0 50 100 Setpoint Figure 5 7 Linear current limit Power feedback in V and current limit in P provide best performance in all the feedback zones

TC1028 series Thyristor units Control of single

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