POWER CONTROLLER RP1 type USER'S MANUAL
Contents
1. z 1 11 N sifs2 __ irl GND In U __ LZ1 LZ2 K RP1 power Dk controller U1 U2 PE B 5 L1 N PE b Load supply Uloaa 400 V Ucts supply 230 V Control 0 5 10 V Li n si s2 __ menom LZ1 LZ2 RP1 power controller U1 U2 PE 3 3 L2 L1 N PE Fig 12 Connection diagram of load in single phase system 14 4 5 3 Load connection in three phase system The power control is possible in the three wire three phase system using two power controllers The presented way of control concerns the on off control type in the zero cross of the supplying voltage or the pulse control with the turned soft start and current limitation off Control 0 5 10 V Kt1 _ _ MS GND In GND In U 5v _ _ GND RP1 power controller Master L1 N S1 S2 u1 K Tms eno m eno inu sv Jenn controller Fig 13 Connection diagram of a load in three phase system 5 POWER CONTROLLER SERVICE S Start and Limit potentiometers must be set on minimum and omax and Span potentiometers on maximum In such settings corresponding functions to them are inactive One must carry out successively following operations a install the power controller according to p 4 1 b carry out electrical connections a2. The power value in the pulse period according to the formula 2 is defined by the dependence 3 T Ts Non Norr 2 Non Xin Ps Poe FE 3 o o max Non re Nor Po max Xima where T period of the supply voltage Non number of turned periods on Nor number of periods off The RP1 power controller has following kinds of pulse control e Quick cycle in which for X 1 2 Xmax Xmin Non No 10 however fi max 2 5 HZ e Slow cycle in which for X 1 2 Xmax Xmin Non Nor 100 however fi max 0 25 Hz Where X value of the analog control signal fimax maximal pulse frequency Runs of characteristic quantities for the pulse control are presented on the fig 16 A Y fo Non Noff The filling factor y is described by the following dependence Noff _ fo Noff 4 y Non Non Nor Xin E mo 3X max X max Fig 16 Runs of characteristic quantities for the pulse control with variable pulse frequency 18 6 3 Phase control At phase control a continuous change of delivered power to the load occurs it is realised by the change of the load current turn on angle in the function of the analog control signal Runs of signals for this kind of control for a resistive load are presented on the fig 17 Continuous input x XA EA AO AA AAA LARIOS VOTRE AAN signal max ci T H H gt i N t Supplying U il y win YN N NA A AANA load circuit N GE ENEN Woy Fe TE ZU EEE MAD
3. V v Yi MY Y Si MY Y V current lo ty in the the m HAN AN load circuit fo E A ry I Fig 17 Phase control runs of occurring signals 6 4 Limitation of the load current If the current value in the load circuit exceeds the boundary value set by means of the Limit potentiometer then the current limitation operates regardless of the control signal value It is possible to assign it from an external potentiometer p 4 4 3 The setting of the potentiometer on minimum means the turn of the current limitation operation off The maximal value of the current flowing in the load circuit can be set in the full range of the power controller rated value The current limitation does not operate for the on off control type in the turn on configuration at across zero voltage In case of exceeding of the current boun dary value the Load diode is alight in red 6 5 Triggering delay of soft start type The soft start function enables a soft accretion of the voltage from zero up to the rated value or value resulting from the current limitation action in the time set by means of the S Start potentiometer In the case of phase control or on off control type in the configuration of imme diate turn on the soft start time t s is controlled in the range from O up to 10 s 19 In case of the pulse control this time is equal to 4 tss e 7 5 4 fi max The function is not active in case of the on off
4. input 0 5 V 0 10 V Control from potentiometer 10 kQ Th In HI HHHEI Els Zlw5 El slela z slzlW15 DODDO DODO DODO Fig 5 Connection of control signals a by analog signal The control from a voltage or current control signal source or from the poten tiometer is possible In case of control from the potentiometer the voltage input should be set on the 0 5 V range b by pulse signal One must connect the control signal 4 32 V to terminals of the voltage input IN U set on the 0 5 V range 4 4 3 Limitation of the load current There is the possibility to limit the load current from the external potentiometer which should be connected according to the presented drawing One must set the Limit potentiometer on minimum 10 mo S SE SlelsiSlalelalz e O ls 8151 13 un 5 DODODODLDOODOODDODODODD Fig 6 Limitation of the load current In case of using the current limitation potentiometer on the power controller fron tal plate one must short circuit 5 V and Limit terminals fig 5 4 4 4 Triggering stoppage One can carry out the triggering stoppage short circuiting 5 Vand STOP termi nals on the terminal strip The STOP input is active in t
5. POWER CONTROLLER RP1 type USER S MANUAL CE POWER CONTROLLER RP1 type USER S MANUAL CONTENTS 1 APPLICATION iia 5 2 BASIC REQUIREMEMNTS OPERATIONAL SAFETY conccnccnccccnncnincnanoss 5 3 POWER CONTROLLER SET uusenssnsnnnennannnnnonnnnnonnnnnnnnnnnnonnnnnnnnannannnnnnnenn 6 4 INSTALLATION 22 aaa alas 6 4 1 Overall and assembly dimensions 4 440s sense 6 4 2 Electrical COMNECION S A 8 4 3 Choice of the Control type ooocoocccinoccconociconcccconncconancnononcnn na noma nnnnnncnnnnno 8 4 4 Connection of control Signals cc ccecceeeeeeeeeeeeeneeeeeeeeeeeeeseneeeteaees 9 4 5 Connection of supply and load c ceceeeceeeeeeeeeeeeeeeeeeeeeeeeeeteneeeees 12 5 POWER CONTROL SERVICE uunnusnnsnrsnnnnnnnnnnnnnnnnnannannnnnnnnnnnnnnnnnnnnannn 15 6 DESCRIPTION OF CONTROL TYPES nunsnnsnnsnnsnnnnnnnnnonnnnnonnnnnnnnnnnnannann 16 6 1 Control of ON OFF type cooocccccccccococccooncconocononnncnnn nn cnn nn naar ncnannn cnn ncnannns 16 6 2 PUISE COMO vic e area 17 632Phase controls otitis ea a E rad 19 6 4 Limitation of the load current eee ee cece te eceeeeeeeteeeteeeeeaeeeaeeaes 19 6 5 Triggering delay of soft start type ooooococnccccnnccconocccononcnnannnonanonanancnnnno 19 6 6 Control of the initial triggering angle value nenne 20 6 7 Control of the input line amplification 400mm 20 6 8 Check and current
6. RS INDUSTRIAL and HOUSEHOLD CONTROLLERS CHART AND PAPERLESS RECORDERS POWER CONTROL UNITS and INVERTERS AUTOMOTIVE DASHBOARD INDICATORS ACCESSORIES FOR MEASURING INSTRUMENTS MEASURING SYSTEMS ENERGY HEAT CONTROL CUSTOM MADE PRODUCTS WE ALSO OFFER OUR SERVICES IN THE PRODUCTION OF m ALUMINIUM ALLOY PRESSURE CASTINGS m PRECISION ENGINEERING AND THERMOPLASTICS PARTS m PRESSURE CASTING DIES AND OTHER TOOLS QUALITY PROCEDURES According to ISO 9001 and ISO 14001 international requirements All our instruments have CE mark For more information please write to or phone our Export Department May 2005 Lubuskie Zaktady Aparat w Elektrycznych LUMEL S A ul Sulechowska 1 65 022 Zielona G ra Poland iaa pei Tel 48 68 329 51 00 exchange Tel 48 68 329 53 02 or 53 04 Fax 48 68 329 51 01 Fax 48 68 325 40 91 e mail lumel lumel com pl e mail export lumel com pl http www lumel com pl
7. Slelel2ls BE HE BE DODDODODDDDDDO222 Fig 9 Relay outputs 4 5 Connection of supply and load U1 and U2 high current sockets to connect supplies of the load circuit the termi nal PE of the protection wire and the fuse B1 are accessible after removing the protective cover fig 10 The protective cover is closed by two lateral fasteners fig 1 12 Cover Fig 10 View of the high current power controller circuit 4 5 1 Connection of the supply and synchronisation circuit to the LZ1 terminal strip No o S1 GTS supply Synchronisation 24 440V 50 60Hz 115V 60Hz or 230V 50Hz L1 I S2 Ss Mi Sisal SIF Sn Fig 11 Description of the LZ1 terminal strip One must connect the Gate Triggering System GTS to the LZ1 terminal strip depending on the power controller version 115 V 60 Hz or 230 V 50 Hz 1 and S2 terminals of the synchronisation system should be connected to the load supply circuit 13 4 5 2 Load connection in single phase system a Load supply Ujoag 230 V Ugrs supply 230 V Control 0 4 20mA
8. ccording to p 4 2 p 4 4 and p 4 5 c set the controll type and the input control signal according to p 4 3 15 d turn on the supply voltage of the load circuit and of the gate triggering system according p 4 5 e set the current limitation according to p 6 4 set the Limit potentiometer on maximum Observing indication of the meter measuring the load current at the maximal value of the input control signal set the required current value decreasing the setting on the Limit potentiometer f set the triggering delay according to p 6 5 g set the initial value of the triggering angle according to p 6 6 Increase the input control signal up to reach the current value lr necessary to the motor start next decrease gradually on the amax potentiometer up to turn off fig 5 In this case the control range depends on the set current Ir value to the rated load current In value h set the amplification of the imput line according to p 6 7 One can reach experimentally the obtainment of proper settings by means of potentiometers and this should be carried out by a suitably trained personnel 6 DESCRIPTION OF CONTROL TYPES 6 1 Control of ON OFF type At the on off control the delivered power to the load is described by the following dependence 0 for Xin 0 pie 1 Po max for Xin Xmax Where P delivered power to the load Xin value of the input control signal The power controller wor
9. control type in the turn on configu ration at zero voltage 6 6 Control of the initial triggering angle value During the power controller use for the rotational speed control of a single phase motor fan one can set the current value Ir necessary for the motor start by means of the amax potentiometer In this case the control is in the range from the set value Ir ofthe current up to the rated value In of the cur 1 rent The function does notope 100 rate in case of the on off control type in configuration turned on at zero voltage I gor Control signal Xin o ma Aine 5 100 Fig 18 Action of the amax function 6 7 Control of the input line amplification The Span potentiometer serves to set the amplification of the input line in the control range from 50 up to 100 of the input control signal 6 8 Check and current signalling in the load circuit The passage of current in the load circuit is signalled by means of a two colour Load diode During the normal work the diode is alight in green however in the moment of the current limitation action it is alight in red 6 9 Signalling of the supply correctness The two colour Control diode is alight in green during the normal work howe ver in the moment of lack of power controller readiness to work it is alight in red the power controller is locked 20 6 10 Signalling of maximal radiator temperature exceed The exceed of th
10. e 85 C radiator temperature causes the automatic triggering stoppage and display of signalling on the Over Temp diode and the PK2 relay turn on p 4 4 6b The restart of the power controller is possible after the radiator cooling below 60 C and the supply turn on to GTS again p 4 5 1 6 11 Error signalling The power controller submits the error in following cases a lack of synchronisation b the current flows through the load despite of lack of triggering pulses e g as the result of a thyristor module damage c Lack of current passage in the load circuit e g because of a break in the high current line the function begins to operate over 50 of the control signal In case of an error statement the automatic triggering stoppage and display of the Error diode follows and the PK2 relay turns on p 4 4 6b The restart of the power controller is possible after removing damage causes and the renewed supply turn on to GTS p 4 5 1 6 12 Overload protection The output circuit of the power controller is protected against its overload The protection is set on 125 of the power controller rated current The exceed of this value will cause the action of current limitation The function does not operate in case of on off control type in the configuration turned on at zero voltage 21 7 SPECIFICATIONS 7 1 Electrical parameters of the high current circuit Table 2 Supply Lost Fuse parameters Max voltage Max
11. e RP1 4xx version has a buil in fun ORDERING EXAMPLE The code RP1 3 2 0 means RP1 power controller of RP1 type 3 maximal output current 70 A for the range of voltages 24 400 V supplying the load circuit 2 voltage supplying the gate triggering system 230 V 0 without an additional quality inspection certificate 24 9 MAINTENANCE AND WARRANTY The RP1 power controller does not require any special periodical maintenance In case of some incorrect operations After the dispatch date and within the period stated in the warranty card One should return the power controller to the Manufacturer s Quality Inspection Dept If the device has been used in compliance with the instructions the Manufacturer warrants to repair it free of charge The disassembling of the housing causes the cancellation of the granted warranty After the warranty period One should send the device to repair it in an authorized service workshop Spare parts are available for the period of five years from the date of purchase Our policy is one of continuous improvement and we reserve the right to make changes in design and specifications of any products as engineering advances or necessity requires and revise the above specifications without notice 25 26 27 SALES PROGRAM MEASUREMENT CONTROL DIGITAL and BARGRAPH PANEL METERS RECORDING MEASURING TRANSDUCERS ANALOG PANEL METERS DIN INSTRUMENTS ANALOG and DIGITAL CLAMP ON METE
12. eaters resistive inductance transformer loaded by a resistive load transformer loaded by a rectifier system The application area of RP1 power controllers includes 2 electrical furnaces and drying constructions particularly industrial tunnel and belt type furnaces furnaces for annealing and hard soldering crucible furnaces and furnaces for hardening in salt bath devices of mechanical engineering aggregates and extruding presses for plastics devices for winding and tempering of springs spot welding and seam welders production of glass and glazing installations and devices for drying in infrared and ultraviolet radiation ladles for glass melt and heating of feeding devices chemical and petroleum industries facing heaters of tube installations preheating installations BASIC REQUIREMENTS OPERATIONAL SAFETY Power controllers are applied in high current installations in which devices under voltage can be a source of danger Considering the personnel safety one should observe following principles Devices can be installed serviced and maintained exclusively by a suitably qualified personnel having essential knowledge about equipment RP1 power controllers should be connected to the power network according to the present operative regulations and standards concerning electrical installations and concerning specially the protection against electric shocks During the start and operation of the starting system One mu
13. ge supplying the load and signalling leads on the LZ2 terminal strip 4 3 Choice of the control type Depending on the kind of control and the input control signal one must suitably set sections of the DIP according to the table 1 One must choose the kind of control at turned GTS supply off see p 4 5 1 Table 1 DIP switch section 1 2 3 4 5 Input control signal Phase Pulse quick cycle Pulse slow cycle On Off switching at zero voltage On Off prompt switching Kind of control 0 Open switch 1 short circuited switch State resulting from other settings 4 4 Connection of control signals 4 4 1 Connection of control to the LZ2 terminal strip It is recommended to use shielded leads and a separate control and high current installation to connect control signals to the LZ2 terminal strip sa i oO E 3 Relays outputs s oO nn o D ad oO oO Q y 3 2 a 3 2 a E ol T E Z 2 E gt 3 5 Sl al 5 Fe al o a 8 a El 5 5 o Y 2 2 Zz 5 2 5 gt El 9 Y 2 a o OF 9 gt 9 ALF 6 o S lt a2 oo 2 a sl lsl 51515 15 315 5 220220082088222 Fig 4 Description of the LZ2 terminal strip 4 4 2 Input control signal Current input 0 20 mA 4 20 mA Voltage
14. he 4 32 V 5 mA voltage wu TE EE am Sl3 El3 218 8151 13 a a Fig 7 Triggering stoppage 4 4 5 Analog outputs a Output U f lo 0 5 V 5 mA output voltage proportional to the current value in the load circuit b Output M S The output of Master Slave type is used when the power controller works as a master device The slave power controller must be set in the turn on working mode at the zero across of the supply voltage Output load carrying capacity max 5 mA Example of connection is shown on the fig 13 Output M S GND Output lo GND NX 9 2 1 1291 gt El O wm T 2 sl l2l lt lz s SlulsiSlalelslzls Fr 5 DOOOOO22O2222222 Fig 8 Analog output 11 4 4 6 Relay outputs Semiconductor relays of MOSFET type a Output PK1 Signalling of damaged fuse b Output PK2 Signalling of an incorrect working state lack of supervision on the control ERROR active signal of triggering stoppage STOP lack of synchronisation fuse damage exceed of allowable radiator temperature IN 60 mA 350 V Ron 35 Q Uizol 1500 VRMS amp Peak value for sinusoidal voltage Y Outputs are not protected against overloading o o Ht gt JA e ei
15. ks in the semi conductor relay mode The feed of the voltage signal on the control input p 4 4 2b causes the turn of the load current on Depending on the setting configuration table 1 The turn on follows imme diately or at the nearest actual supply voltage value transition across zero Runs of signals describing the power controller operation for the control of on off type are shown on the fig 14 16 Voltage supplying UA the load circuit AAN gt Pulse input Xwe signal Y Turn the acros zero voltage on Current in the lo A load circuit T gt it P t nn Turn ae on Fig 14 Control of on off type runs of occurring signals for resistive load 6 2 Pulse control Pulse control consists on the change of the pulse duty factor and the frequency of power Po delivered to the load in function of the analog control signal at the same time the output current is turned on synchronously with the transition of the supply voltage across zero Runs of signals are presented on the fig 15 Continuous xk input y n i signal max oo TIT SPS pe ee nn Re U Athi RIA hy I MM N MIA Fern NUN Mm INN TT Delivered BA power to the load Fig 15 Pulse control with a variable pulse frequency runs of occurring signals 17
16. load powerin output oftheload power thyristors Designation and manufacturer current circuit A V kw 25 20 440 10 35FE Bussmann 50 60 Hz i 6 6 URS 17 35 FERRAZ 20 440 176 50FE Bussmann 50 60 Hz j 6 6 URS 17 50 FERRAZ 40 20 440 30 8 90FE Bussmann a 50 60 Hz f 6 6 URS 217 90 FERRAZ 20 440 55 0 160FEE Bussmann 50 60 Hz 6 6 URS 217 160 FERRAZ 125 Minimal input current 5 of In range of the power controller output current Leakage current lt 20 mA Kind of load resistance or resistance inductance load 0 5 lt cos fi lt 1 in compliance with the application category AC 51 EN 60947 4 3 Other applications after agreement with the manufacturer 7 2 Electrical parameters of the supply and control circuit GTS supply voltage 85 115 135 Va c 195 230 253 Va c supply voltage frequency 50 60 Hz power consumption lt 4 5 VA synchronizing input 20 440 Va c Rin 240 kQ voltage control input 0 5 V Rin 20 KQ 0 10 V Rin 40 KQ current control input 0 4 20 mA Rin 125 Q pulse control input 0 4 32 V Rin 20 KQ STOP signal input 4 32 V 5 mA 22 load carrying capacity of 5 V output load carrying capacity of lo output load carrying capacity of M S output load carrying capacity of relay outputs 7 3 Other parameters 25 mA 5 mA 5 V 5 mA 5 V 60 mA 350 V Ron 35 Q Uizo 1500 V rms wo
17. rking temperature 0 40 C storage temperature 25 55 C humidity lt 90 without condensation working position vertical dimensions version without fan 135 x 201 x 199 mm version with fan 135 x 231 x 199 mm weight 4 5 5 0 kg 7 4 Safety requirements maximal phase to earth working voltage 320 V for power and supply circuits 50 V for other circuits pollution degree 2 installation category lll protection degree from terminal side IP 10 acc to EN 60529 housing protection degree IP 20 acc to EN 60529 7 5 Electromagnetic compatibility immunity noise EN 60947 4 3 emission noise EN 60947 4 3 The RP1 power controller fulfils requirements of the EN 60947 4 3 standard NOTE In case of phase control the power controller fulfils requirements of the electromagnetic compatibility in relation to the interference emission only when working near the of the supply voltage through zero 23 8 ORDERING CODES Table 3 CAT E Current range maximal output current 25A e 1 oad voltage maximal output current 40A 24 400 Vac 2 maximal output current 70 50 60 Hz 3 maximal output current 125 A 4 Gate triggering system system GTS supply voltage 85 115 135 V a c supply voltage 195 230 253 V a c Na Acceptance tests without an additional quality inspection certificate with an extra quality inspection certificate otherrequirement ou Th
18. signalling in the load circuit 20 6 9 Signalling of supply correctness een 20 6 10 Signalling of maximal radiator temperature exceeding 21 6 11 Erro signalling era E aa rarai 21 6 12 Overload protection 2004244044nnsennnnnnnnnonnnnnnnnnnnnnnnnnnnnnnennnn nen 21 7 SPECIFICATIONS uusussnesnsesnensonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnunnunnnnnnnnnnnnnen 22 7 1 Electrical parameters of the high current Circuit 22 7 2 Electrical parameters of the supply and control circuit 22 7 3 Other parameter ita unsere ei 23 7 4 Safety requirements ccccccceececeeeeeeeeceeseneeeeeeeeseeeeseaeeesaeeeseeenteaes 23 7 5 Electromagnetic compatibility ooonoocconncccnnccnnnnccnnccccnnccnninacananancnnnon 23 8 ORDERING CODES uusasrsnsannonnannonnonnonnnnnunnnnnnnnnnnnnnnannnnnnnennennannnnnnanns 24 9 MAINTENANCE AND WARRANTY uusnnssnssnnnnnonnnnnennnnnnnnnnnnnnnnnnnnnnnannannanne 25 1 APPLICATION The RP1 power controller is destined to control the load power in function of the input control signal for following types of loads resistive wit a positive temperature coefficient of resistance heaters made of alloys on the base of molybdenum Mo platinum Pt tantalum Ta tungsten W iron Fe resistive with a negative temperature coefficient resistance heaters made of sintered carbide graphitical h
19. st comply with recommendations included in this user s manual and specially to sections 4 5 and 6 Qualified personnel defines persons which are acquainted with the user s manual assembly starting and service of the product and have appropriate qualifications to carry out these activities 3 POWER CONTROLLER SET The set consists of RP1 power controller 1 pc User s manual 1 pc warranty card 1 pc Quick start card 1 pc When unpacking the power controller please check the delivery complete ness and whether the type and version code on the data plate correspond to the order 4 INSTALLATION 4 1 Overall and assembly dimensions The RP1 power controller is destined to be mounted on a wall by means of holders Power controller overall dimensions spacing of assembly holes and the fixing way are presented on the fig 1 of protective cover pj e F P Dimensions in parenthesis concern the version with a fun Version RP1 4 x x 125 A Fig 1 Overall dimensions and fixing way of the RP1 power controller In case of mounting in a control cabinet it is recommended to apply a forced air cycle RP1 power controllers can be situated side by side preserving minimal spacing according to the fig 2 150 LZ1 LZ2 08090999980928 Fig 3 View of the frontal plate Servicing elements are disposed on the power con
20. troller frontal plate Fig 3 Signalling diodes e Control two colour diode 1 supply correctness and power controller readiness to work e Load two colour diode 2 passage of current through the load e Stop red diode 3 external triggering stoppage e Error red diode 4 error related to the power controller work e Over Temp red diode 5 exceeding of the allowable temperature e Fuse fail red diode 6 fuse burnout Potentiometers and switch e S Start potentiometer 7 control of the soft start function duration e Limit potentiometer 8 limitation of the load current e max potentiometer 9 control of the initial triggering angle value e Span potentiometer 10 control of the input line amplification e Switch DIP SWITCH 11 to configure analog inputs and the control mode 4 2 Electrical connections One must carry out electrical connections by means of following leads a to LZ1 and LZ2 terminal strips leads with cross section from 0 35 up to 2 5 mm b to high current terminals RP1 1xxx version leads with 6 mm cross section RP1 2xxx version leads with 10mm cross section RP1 3xxx version leads with 16 mm cross section RP1 4xxx version leads with 35 mm cross section c to the protective terminal lead with a cross section at least the same as leads in high current circuits It is recommended to shield leads in the synchronisation circuit with the network volta
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