TE300 Series User Manual issue 2 - Eurotherm by Schneider Electric
Contents
1. TE300 EUROTHERM L1 L2 L3 C1 C2 C3 RAA h gt lt 141 gt lt 186 gt 12 Control terminal block Power terminal block Safety earth terminal Figure 2 1 Dimensions of non fan cooled TE300 controllers Weight of non fan cooled TE300 controller 3 1kg TE300 User manual 2 3 Fan cooled controllers 50A and 63A rating TE300 controllers have permanent fan cooling Weight of fan cooled TE300 controller 3 5kg The overall dimensions of the fan cooled TE300 controller are given in Figure 2 2 Protective cover Power terminal block 40 gt lt 100 gt lt 57 gt Safety earth terminal Power Control terminal terminal block block lt 92 gt lt 92 gt Fan supply terminal block gt lt 141 gt lt 186 gt 12 Figure 2 2 Dimensions of fan cooled TE300 controller 50 and 63A rating 2 4 TE300 User manual MOUNTING DETAILS TE300 series controllers may be mounted On DIN rails code DIN On a bulkhead code BKD DIN rail mounting TE300 controllers are designed to be mounted on two DIN rails EN 50022 Upper DIN rail 125 0 5 mm Lower DIN rail Fixing clip Figure 2 3 DIN rail mounting for TE300 controller To mount the TE300 controller on DIN rails see Figure 2 3 1 Offer up the unit by first engaging the two lips on the upper part of2. PMAX Where represents the load power for full thyristor firing The length of the cycle in basic Burst firing is selected by the user from four values 1 8 16 and 128 which are the number of thyristor firing cycles at 50 power This value is configured at the factory when the controller is ordered TE300 User manual 5 3 The modulation time Burst firing mode is variable according to the power demand For example for 8 Burst firing At 50 power the typical value of the modulation time is 0 325 at 50Hz 8 firing and 8 non firing cycles For a setpoint less than 50 the firing time remains constant 8 cycles the non firing time increases and as a consequence the modulation time increases For a setpoint greater than 50 the non firing time remains constant 8 cycles the firing time increases and as a consequence the modulation time increases The control system adjusts the basic Burst firing modulation time in order to retain optimum accuracy irrespective of the power demand As a result of this type of modulation TE300 offers precision control which adapts to each particular setpoint zone Modulation time Twr 160 ms distribution 100 Figure 5 2 Modulation time as a function of power example 8 cycle Burst firing 5 4 TE300 User manual Single cyde mode 1 cyde Burst firing This Burst firing mode has a single firing
3. TE300 User manual 3 13 POWER WIRING Connection The power terminal blocks mains and load are cage terminal blocks The control terminal block has a plug in screw connector The safety earth is connected to an M8 screw and bolt The terminal capacities and tightening torques to be observed are given in Table 3 1 Parameter Power amp load Safety earth Control supply Terminal capacity mm2 10 to 25 10 to 25 1 5 Tightening torque Nm 2 12 5 0 7 Table 3 1 TE300 controller connection details The cross section of the conductors to be used must comply with Standard IEC 943 Power wiring diagrams The TE300 power wiring diagram depends on the load configuration The following three power and safety earth wiring diagrams are given below to illustrate different types of load configuration 3 14 TE300 User manual Chapter 4 CONFIGURATION Contents CONFIGURATION SAFETY 4 2 DRIVER BOARD CONFIGURATION 4 3 GENERALINTRODUCTION 4 3 LOCATION OF COFFEE BEANS SOLDER PADS 4 4 CONFIGURING FORTHE TYPE OF LOAD CONNECTION 4 5 CONTROLSIGNAL CONFIGURATION 4 6 THYRISTOR FIRING MODE CONFIGURATION 4 6 TE300 User manual 4 1 Chapter 4 CONFIGURATION CONFIGURATION SAFETY The controller is configured by soldered coffee beans located on the driver board Important The controller is supplied
4. 1 8 Chapter 2 INSTALLATION 52 7 a ao e 2 2 INSTALLATION SAFETY lt lt E ERRARE 2 2 DIMENSIONAL DETAILS 2 3 MOUNTING 6 2 5 Chapter 3 WIRING EE 3 2 WIRIN SAFETY Ga Gye 3 2 POWER RI 3 3 USER TERMINAL BLOCKS sss e ERR 3 7 ii TE300 User manual Chapter 4 CONFIGURATION Rv tos Ice xe 4 2 CONFIGURATION SAFETY 4 2 DRIVER BOARD CONFIGURATION 4 3 Chapter5 OPERATIONS reri eec ede gale 5 2 THYRISTOR FIRING MODES 5 2 CONTROLOPERATION 5 8 Chapter 6 COMMISSIONING 6 2 COMMISSIONING PROCEDURE SAFETY 6 2 CHECKING THE CHARACTERISTICS 6 3 POWERING UP THE CONTROLLER 6 4 Chapter 7 VRAC A 7 2 FUSES dd gu d ac 7 2 SERVICING erras dot beu 7 4 TOOLS ou uw av mex E RE au EE 7 4 TE300 User manual EUROPEAN DIRECTIVES CE MARKING AND SAFETY TE300 products carry the CE mark in compliance with the essential requirements of the European Low Voltage Directi
5. Digital Power Controllers TE300 Series Three phase load control User Manual Copyright Eurotherm Automation 1996 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 omissions to our specification We cannot be held responsible for any damage to persons or property or for any financial loss or costs arising TE300 User manual HA175437ENG Issue 2 0 09 2000 00 USER MANUAL CONTENTS EURO PEAN DIRECTIVES iv CE MARKING AND SAFETY iv ELECTRO MAGNETIC COMPATIBILITY iv DECLARATION PRECAUTIONS 2 net toe Chapter 1 IDENTIFYING THE CONTROLLERS 1 2 GENERAL INTRODUCTION TO THE TE300 SERIES 1 2 TECHNICAL SPECIFICATION 1 5 PRODUCT CODE 2 eine 1 7 EXAMPLE OF PRODUCT 1 8 SERIAL NUMBER LABELS
6. 1 Chapter 6 COMMISSIONING PROCEDURE Read this chapter carefully before commissioning the controller COMMISSIONING PROCEDURE SAFETY AN Important 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 A thyristor is not an isolating device Touching a load terminal even with a zero load current is as dangerous as touching mains live 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 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 controller is operational The heatsink remains hot for around 15mins after the unit has been switched off 6 2 TE300 User manual CHECKING THE CHARACTERISTICS Load current The maximum load current must be less than or equal to the value of the nominal current of the controller taking int
7. 63A 51730870063 FU3258 50A 00 140 x108 x90 63A 80A 51732460080 FU3760 63A 00 150x114 107 JN Table 7 2 Recommended high speed fuses for thyristor protection Maximum operating voltage for fuses 500V line to line Attention For resistive loads except short wave infrared applications the use of any fuses other than those recommended for thyristor protection will invalidate the controller s guarantee TE300 User manual 7 3 SERVICING TE300 controllers must be mounted with the heatsink positioned vertically with no obstructions above or below which could inhibit or impede airflow AN Attention If several units are mounted in the same cabinet they should 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 users are advised depending on the degree of environmental pollution to regularly clean the heatsink and for 63A rating units the protective fan guard DANGER Cleaning should only be carried out when the controller supply is disconnected and at least 15 minutes after it has ceased operating Every six months check that the screws of the power and safety earth cables are correctly tightened see Wiring page 3 3 TOOLS Operation Flat blade screwdriver Hex key Safety earth wiring HEX13 M8 Power wiring 0 5 x4 Load wiring 0 5 x4 Control fan 50A 63A ratin
8. European Low Voltage Directive and EMC test standards through product design and laboratory testing The tests carried out on TE300 products are listed in a Technical Construction File validated by the LCIE Central Laboratory for the Electrical Industries a Recognised Competent Body 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 TE300 User manual 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 even result in electrocution DANGER This symbol means that failure to take note of the information may have serious consequences for the installation or lead to the incorrect operation of the power unit ATTENTION 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 power unit should only be carried out by personnel qualified and trained to work with low voltage electrical equipment in an industrial environment Independent alarm Given the value of the equipment controlled by TE300 products it
9. Input and 7 45V EUER Contacts for example relay output of 2216 controller User 5V Control signal connector P View of TE300 LOAD controller from below 7 8 9 rx eee ae Figure 3 7 Contact wiring for logic operation TE300 User manual 3 9 Power supply separate from electronics option TE300 controllers can be used with non standard mains If a TE300 series controller is used with a mains supply the voltage of which is not shown in the voltage codes the control electronics must be fed separately from the power by 115V or 230V supply The separate power supply must be connected between terminals 10 and 12 terminal 11 is not used The auxiliary power supply must be in phase with the power voltage between phases 1 amp 2 power terminals L1 amp L2 Line protection and mains circuit breaker installed by user Non standard mains Thyristor protection high speed fuses except for short wave infrared 0 5 fuses application Must be in phase with L1 L2 View of controller from above 10 11 12 Figure 3 8 Connection of power supply separate from electronics option Attention Each auxiliary power supply feed wire connected to a supply phase mu
10. TE300 products comply with Electromagnetic Compatibility test standards see page iv Analogue in Burst firing and Single cycle modes voltage 0 to 5V or 0 to 10V current 4 to 20mA Logic ON OFF mode nominal levels voltage 5V or 10V current 20mA On state gt 50 and off state lt 25 of the nominal level Voltage input gt 100 current input 2500 Coffee beans on driver board 10kQ potentiometer supplied by the user voltage Dry contact for logic operation Input configured as 0 to 5V TE300 User manual 1 5 Thyristor firing Firing modes Switching Indication Control performance Control type Linearity Stability Options Auxiliary power supply Environment Operating temperature Storage temperature Thyristor protection Protection External wiring Operating atmosphere Humidity Pollution ON OFF Logic Burst firing mode Number of firing cycles at 50 of configurable power 1 8 16 or 128 cycles Advanced Single cycle load in star with neutral or open delta Firing by complete cycles separated by half cycles of non firing without DC component One cycle of firing and one cycle of non firing at 50 power Conduction starts and ends at zero voltage Thyristor firing is signalled by a green LED The power controlled in the load simulated by voltage squared is proportional to the setpoint Better than 2 of the full scale With variations Of the supply voltag
11. is the responsibility of the user and it is highly recommended that an independent safety device alarm should be installed This alarm must be tested regularly Eurotherm can supply suitable equipment vi TE300 User manual Chapter 1 IDENTIFYING THE CONTROLLERS Contents GENERAL INTRODUCTION TO THE TE300 SERIES 1 2 TECHNICAL SPECIFICATION 1 5 PRODUCT CODE 9 X OR D S 1 7 EXAMPLE OF PRO DUCT 1 8 SERIAL NUMBER LABELS 1 8 TE300 User manual 1 1 Chapter 1 IDENTIFYING THE CONTROLLERS GENERAL INTRODUCTION TO THE TE300 SERIES The TE300 series of controllers are thyristor units designed to control the electrical power of industrial three phase loads A TE300 series controller is made up of three channels each comprising a pair of thyristors connected in anti parallel The TE300 series is designed to control three phase resistive loads elements with a low temperature coefficient short wave infrared elements Three phase loads can be connected in star with or without neutral in open or closed delta The wiring of the controller is indifferent to the order of the supply phase rotation The nominal line to line voltage can be selected from 230V to 500V The nominal currents of the TE300 series controllers are between 16A and 63A per phase defined at an ambient temperature of 45 C 4 63 A fan
12. 0 thyristor firing takes place as in the standard Single cycle mode see page 5 5 For a setpoint greater than 50 in advanced Single cycle mode The non firing time is constant at one half cycle Firing takes place over whole cycles The use of half cycles for the non firing time accounts for the reduced cycle time when compared to the standard Single cycle mode In a short wave infrared application advanced Single cycle firing mode reduces the brightness of the infrared elements and thus minimises annoying visual flickering The advanced Single cycle firing mode is available for 4 and 6 wire configurations 5 6 TE300 User manual Logic mode The logic thyristor firing mode ON OFF controls power in the load proportionally according to the firing time set by the logic control signal This firing mode is activated by a signal greater than 50 of full scale It is deactivated when the signal falls below 25 of full scale 100 96 Load voltage 50 Input signal 0 25 50 75 100 Figure 5 5 Voltage Logic signal diagram Important In order to reduce the emission of electrical interference and electromagnetic radiation thyristor switching takes place at zero voltage for resistive loads irrespective of the beginning and end of the logic control signal Logic control signal Load voltage A K t gt Zero voltage switching
13. 5 OPEN DELTA CONFIGURATION 3 6 USER TERMINAL 5 3 7 GENERAL INTRO DUCTION 3 7 EXTERN AL INPUT WIRING 3 8 CONTROL WIRING IN LOCALMODE 3 9 PO WER SUPPLY SEPARATE FROM ELECTRONICS OPTION 3 10 TE300 User manual 3 1 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 operation TE300 series units have a protective cover DANGER Before any connection or disconnection ensure that power and control cables or leads are isolated from voltage sources For safety reasons the safety earthing cable must be connected before any other connection is made during wiring and it should be the last cable to be disconnected The safety earth is connected to the screw located on the slot at the side of the controller and is denoted by the symbol Attention To ensure correct grounding of the TE300 unit make sure that it is mounted on the reference ground surface panel or bulkhea
14. NG THE CONTROLLER TE300 series controllers are ready to operate correctly immediately after installation and wiring in accordance with this user manual After checking that the nominal parameters of the controller voltages currents input signal and load configuration are compatible with those of the installation apply volts to the controller Check that the current in each phase of the controller is equal to 0 in the absence of the control signal Make sure that the r m s current in each phase does not exceed the nominal controller rating when the setpoint is at maximum 6 4 TE300 User manual Chapter 7 MAINTENANCE Contents EUSES aa ney 7 2 PROTECTION OF AUXILIARY VOLTAGE CONNECTION 7 2 THYRISTOR PROTECTION 7 3 SERVICING 5 5 eO 7 4 TOOLS ze wiser ty tat casa eek a tr IRIS 7 4 TE300 User manual 7 1 Chapter 7 MAINTENANCE DANGER The controller must be maintained by personnel qualified and trained to work with low voltage electrical equipment in an industrial environment The user s installation must be protected upstream non high speed fuses thermal or electromagnetic circuit breaker suitable fuse isolator and must comply with current standards FUSES Protection of auxiliary voltage connection Protection fuses for both the fan connection 63A nominal current unit and separat
15. Stop at end of cycle Figure 5 6 Logic firing mode TE300 User manual 5 7 CONTROL OPERATION TE300 controllers include an internal control loop The control algorithm of the TE300 series takes into account the value of the r m s load voltage squared The square of the r m s load voltage represents the power dissipated in a purely resistive load whose resistance remains constant with temperature The output power of the controller is linear between 0 and 100 of maximum power for an analogue input signal variation between 4 and 96 of full scale Nominal Output V2 96 voltage 100 75 50 25 Input of the maximum scale 0 20 40 60 80 100 Figure 5 7 Input Output response curve for an analogue signal Control precision is guaranteed to 2 of the power dissipated the load for constant resistance The output power of the controller is calibrated according to the nominal voltage specified when ordering 5 8 TE300 User manual Chapter 6 COMMISSIONING PROCEDURE Contents COMMISSIONING PROCEDURE SAFETY 6 2 CHECKING THE CHARACTERISTICS 6 3 LOAD CURRENT 6 3 LOAD CONFIGURATION 6 3 SUPPLY 6 3 AUXILIARY PO WER SUPPLY VOLTAGE OPTION 6 3 CONTROLSIGNALS 6 3 POWERING UPTHECONTROLLER 6 4 TE300 User manual 6
16. UPPLY SELF SUPPLIED INPUT 0 5V FAN POWER SUPPLY NONE FIRING ADVANCED SINGLE CYCLE WIRING STAR WITH NEUTRAL ANY NON SPECIFIED FUSE INVALIDATES GUARANTEE FERRAZ B093910 Figure 1 3 Example of identification tabet for a TE300 controiter The information corresponds to the product code example Attention Following any re configuration on the part of the user there is no guarantee that the controller will corespond to the label information AN 1 8 TE300 User manual TE300 series controllers may be mounted MOUNTING DETAILS Fan cooled controllers 63A rating TE300 controllers have permanent fan cooling Weight of fan cooled TE300 controller 3 5kg The overall dimensions of the fan cooled TE300 controller are given in Figure 2 2 Figure 2 2 Dimensions of fan cooled TE300 controller 63A rating TE300 User manual 1 9 Chapter 2 INSTALLATION Contents INSTALLATION 5 2 2 DIMENSIO NAL DETAILS 2 3 NON FAN COOLED CONTROLLERS 2 3 FAN COOLED CONTROLLERS 2 4 MOUNTING DETAILS 2 5 DIN RAILMOUNTING 2 5 BULKHEAD MOUNTING 2 6 00 User manual 2 1 Chapter 2 INSTALLATION INSTALLATION SAFETY DANGER TE300 units must be installed by personnel qualified and trained to work with low vo
17. are configured as 3 wire L1 912 L3 Line protection and mains circuit breaker installed by user Thyristor protection high speed fuses except for short wave infrared application EUROTHERM L1 L2 L3 C1 C2 C3 TE300 Safety earth es A C1 C2 C3 Figure 3 1 Power and safety earth wiring for a load connected in star without neutral or in closed delta 3 wire configuration 0 5A fuse in each wire connected to a phase Control input 115 V or 230 V fan supply 50A amp 63A rating only 3 4 TE300 User manual Star with neutral configuration A three phase load connected in star with neutral is configured as 4 wire L1 L2 L3 N Line protection and mains circuit breaker installed by user Thyristor protection high speed fuses except for short wave infrared application EUROTHERM L1 L2 L3 C1 C2 C3 Control input Fuse in each wire connected to a phase Fan supply 50A amp 63A rating only 4 wire load Figure 3 2 Power and safety earth wiring for a load connected in star with neutral 4 wire configuration The cross section of the neutral cable must match the cross section of the phase cables TE300 User manual 3 5 Open delta configuration Important The load wiring given below must be observed Line protection and mains circuit breaker installed
18. by user Thyristor protection high speed fuses except for short wave infrared applications EUROTHERM L1 L2 L3 Control input 115 230 V Fuse in each wire connected to a phase Fan supply 50A amp 63A rating only 6 wire load Figure 3 3 Power and safety earth wiring for a load connected in open delta 6 wire configuration 3 6 TE300 User manual USER TERMINAL BLOCKS General introduction The user terminal blocks comprise A control terminal block A fan terminal block for the 50A and 63A rating An auxiliary power supply terminal block option The control terminal block is located below the controller on the left side The fan terminal block is located below the controller on the right side The auxiliary power supply terminal block is located above the controller on the right side option These connectors for the wires plug in Terminal numbers label Function 7 User output 5V for wiring manual contro potentiometer 8 Control input signal ve 9 Control ov I0 amp 12 Power supply separate from electronics option Not used 115V 0r230V Farrsupply 50 anc rating Table 3 2 Function of user terminals Front fascia of controller Control terminal block mano Lil cee Figure 3 4 Control terminal DIOCK view Controller trom below TE300 User manual 3 7 Ex
19. cooled 50 f cooled 20 25 30 35 40 45 50 55 60 70 Figure 1 1 Current derating per phase as function of ambient temperature dotted line current limit for recommended fuse Attention AN In order to allow for variations in load resistance the calculated current should not exceed 0 8 times the maximum rated current of the unit The load current is calculated from the supply voltage and the load power or resistance 1 2 TE300 User manual Heatsink Supply terminal block Bes 7 x vage Auxiliary power supply connector option SE or NASA Thyristor firing Control connector x Load terminal block Figure 1 2 Overview of the TE300 series controller TE300 User manual The unit is controlled by analogue or logic signals The input analogue signals have two possible voltage ranges 0 to 5V or 0 to 10V and a current range of 4 to 20mA The input logic signals have the following nominal values 5V 10V or 20mA Local control is possible via a potentiometer or external contacts The input must be configured as 0 to 5V code 0V5 The 5V 0 5mA user voltage output on terminal 7 and 9 is intended for this purpose The electronics of the TE300 controllers are self supplied from the power voltage and do not require external connections The control method of the TE300 series includes line voltage squared V2 compensatio
20. cycle or a single non firing cycle and is called Single cycle or standard Single cycle firing mode Load voltage C e Ne 50 power Tp TNF lt gt n t gt 0 gt lt gt SEE mm gt 25 power TNF 3 lt gt lt T gt lt NE gt 75 power 3 TNF Figure 5 3 Single cycle firing mode At 50 power the modulation time in Single cycle mode is 40ms 1 firing cycle 20ms at 50Hz 1 non firing cycle 20ms at 50Hz For a setpoint less than 50 firing time remains constant 1 cycle The non firing time increases and as a consequence The modulation time increases For a setpoint greater than 50 non firing time remains constant 1 cycle firing time and the modulation time increase TE300 User manual 5 5 Advanced Single cyde mode In order to minimise power fluctuation during the modulation period the advanced Single cycle thyristor firing mode uses complete number of cycles for firing A complete number of half cycles for non firing Load voltage Standard Single Cycle 1 cycle Burst firing t 0 lt gt lt TNF gt lt TM gt A Load Advanced Single cycle voltage gt Figure 5 4 Comparison of Single cycle and advanced Single cycle firing modes 66 power TF 2 TNF At 50 power and for a setpoint less than 5
21. d Failing this it is necessary to add a ground connection at most 10cms long between the earth connection and the reference ground surface DANGER This connection which is intended to ensure good ground continuity can never be used to replace the safety earth connection 3 2 TE300 User manual POMEN SIRNA DETAILS controllers Fhe gewallidimengiened snenfagn eee RADR centeollano K 40A ratings are given Figure 2 1 i The control terminal block has a plug in screw connector The safety earth is connected to an M8 screw and bolt The terminal capacities and tightening torques to be observed are given in Table 3 1 Parameter Power amp load Safety earth Control supply Terminal capacity mm2 10 to 25 10 to 25 1 5 Tightening torque N m 2 12 5 0 7 Table 3 1 TE300 controller connection details The cross section of the conductors to be used must comply with Standard IEC 943 Power wiring diagrams The TE300 power wiring diagram depends on the load configuration The following three power and safety earth wiring diagrams are given below to illustrate different types of load configuration Figure 2 1 Dimensions of non fan cooled TE300 controllers Weight of non fan cooled TE300 controller 3 1kg TE300 User manual 3 3 Star without neutral and dosed delta configuration Three phase loads connected in star without neutral or in closed delta
22. d 128 cycles 128 Advanced Single cycle Mains voltage 4 or 6 wire configuration SCA line to line Code 230 volts 230V 240 volts 2407 Code 277 volts 277V Delta 3 wire 3D 380 volts 380V Star without neutral 3 wire 35 400 volts 400V Star with neutral 4 wire 45 415 volts 415V O pen delta 6 wire 6D 440 volts 440V 480 volts 480V 500 volts 500V Mounting Code Bulkhead BKD DIN rail DIN Fan supply Code Without fan cooling 16A to 40A 000 ManuaHanguage Code pM French FRA 115V 115V English ENG 230V 230v German GER Italian ITA Code 0 to 5 volts 0 5 0710 10 volts 0710 Options Code 4 to 20 milliamps 4mA20 Power supply separate from TE300 User manual 1 7 EXAMPLE OF PRODUCT CODE Controller and installation parameters Nominal load current 35 amps Nominal supply voltage 415 volts line to line Input signal 0 to 5 volts Firing mode Advanced Single cycle Load configuration Star with neutral DIN rail mounting DIN User manual In English Controller code TE300 40A 415V 000 5 SCA 45 DIN 00 SERIAL NUMBER LABELS An identification label provides all the information relating to the factory settings of the controller The identification label is located externally on the right side of the unit EI EUROTHERM 2 20 WORTHING ENGLAND 01903 268500 MODEL TE300 40A 415V 000 0V5 SCA 4S DIN ENG 00 SERIAL No INT100 002 001 03 99 0F222935 RANGE 40A 415V AUX POWER S
23. e 10 15 Of the temperature from 0 to 40 C stability is better than 2 of full scale Possibility of operation for non standard three phase mains by supplying the electronics separately from the power at 115V or 230V 0 C to 45 C at maximum altitude of 2000m 10 C to 70 C High speed external fuses except for short wave infrared application Internal MOVs varistors and RC snubbers IP20 on the front facia in compliance with Standard IEC529 To be carried out in compliance with standard IEC 364 Non explosive non corrosive non conductive RH 5 to 95 non condensing Pollution degree 2 permissible defined by TEC 664 In order to maintain 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 1 6 TE300 User manual PRODUCT CODE TE300 Current Voltage Cooling Signal Firing Configuration Mounting Language Options 00 Non standard mains use the coding for the voltage immediately above and choose option of power supply separated Bulkhead mounting TE300 controllers may be bulkhead mounted Nominal current Code Thyristor firing mode Code 16 amps I6A Logic ON OFF LGC 25 amps 25A Burst firing 40 amps 40A 1 cycle 50 amps 50 8 cycles FC8 63 amps 63A 16 cycles C16 Lx Fan coole
24. e electronics supply Auxiliary power supply option must be installed in each conductor connected to a supply phase Auxiliary 0 5A fuse 6 3 x 32 mm Fuse holder voltage max isolator Fuse isolator assembly dimensions mm Table 7 1 Recommended fuse for auxiliary voltage connection 7 2 TE300 User manual Thyristor protection The thyristors in the TE300 series controllers are protected in the following way external high speed fuses against overcurrents except for short wave infrared applications RC snubbers and MOVs varistors protect against over fast voltage variations and transient overvoltages when the thyristors are not conducting DANGER IN High speed fuses are used only for the protection of thyristors against large amplitude overloads Under no circumstances should these high speed fuses be used to protect the installation Attention For the use of high speed fuses in short wave infrared applications please contact Eurotherm Controls To protect the thyristors in the TE300 series 3 fuses and a tri polar fuse holder must be used Details of these are given in the following table Nominal current Eurotherm reference Dimensions Controller Fuse Fuse Fuse fuse holder assembly H 16A 20A CH 260024 FU3038 16A 00 81x52 5 x 68 25A 30A 260034 FU 3038 25A 00 81 x52 5 x 68 40A 50A CH 330054 FU3451 40A 00 95 x79 x 86 50A
25. fully configured in accordance with the product code on the identification label and is ready for operation after wiring This chapter is included with a view to Checking that the configuration is suitable for the application Modifying if necessary certain characteristics of the controller on site DANGER For safety reasons re configuration of the controller using the coffee beans must be carried out with the unit switched off and by personnel qualified and trained to work with electrical equipment in a low voltage industrial environment Before starting the re configuration procedure ensure that the controller is isolated and that any accidental power up is not possible After re configuring the controller amend the codes on the identification label to prevent any later maintenance problems 4 2 TE300 User manual DRIVER BOARD CONFIGURATION General introduction The coffee beans located on the driver board are used to configure The type of load connection The type and level of the control signal The thyristor firing mode The Elimination of DC component option The functions of the coffee beans on the driver board are summarised in the following table Function Coffee beans Type of load configuration GS7 GS6 Thyristor firing mode GS1 GS2 GS3 GS4 Type and level of control signal GE1 GE2 Table 4 1 Function of coffee beans on driver b
26. g and auxiliary power supply option wiring 0 5 x 2 5 Table 7 3 Tools 7 4 TE300 User manual
27. hen ordering the controller 1 4 TE300 User manual TECHNICAL SPECIFICATION The TE300 series of controllers is intended for thyristor regulation and control of an industrial three phase load Power Nominal current per phase Line to line voltage Supply frequency Dissipated power Insulation 1 min test Cooling Fan power supply 63 amp unit Load Supply phases Load configuration CE Marking Electrical safety 16A 25A 40A 50A or 63A at 45 C 230V to 500V 10 15 50Hz and 60Hz 2Hz automatic selection 1 3W approx per amp per phase Fuses are external to TE300 and will produce 0 7W approx per amp per phase 2000Vac between power and earth and 3600Vac between power and control Natural convection for 16A 25A 40A ratings Permanent fan cooling for 50A and 63A rating 115V or 230V to be specified 13VA Resistive three phase load with a low temperature coefficient or short wave infrared elements Wiring independent of the phase rotation order Closed delta 3 wire or open 6 wire Star without neutral 3 wire or with neutral 4 wire Load configuration set by coffee beans TE300 controllers carry the CE mark in compliance with the essential requirements of the European Low Voltage Directive 73 23 EC amended by the Directive 93 68 EC Electromagnetic compatibility Immunity and Emissions Control External control signal Input impedance Configuration Local control
28. ltage electrical equipment in an industrial environment Units must be installed in electrical cabinets correctly fan cooled to ensure that condensation and pollution are excluded The cabinet must be closed and bonded to the safety earth in accordance with Standards NFC 15 100 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 TE300 units may be bulkhead or DIN rail 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 should be arranged in such a way that air expelled from one cannot be drawn into the unit located above it Attention The units are designed to be used at an ambient temperature less than or equal to 45 C Leave a minimum gap of 5cm between two units placed side by side Excessive overheating of the controller may lead to incorrect operation of the unit This may in turn cause damage to the components 2 2 TE300 User manual DIMENSIONAL DETAILS Non fan cooled controllers The overall dimensions of non fan cooled TE300 controllers 16A to 40A ratings are given in Figure 2 1 Protective cover Power terminal block lt 100 gt lt 57 gt 40
29. n for line variations in the range 10 to 15 of the nominal voltage of the controller TE300 series controllers have several thyristor firing modes Logic ON OFF Cycle time modulation Burst firing with four possible cycle times Advanced Single cycle firing by complete cycles separated by a complete number of half cycles of non firing Thyristor firing ensures the absence of any DC component in load currents when connected in open delta or in star with neutral configurations TE300 series controller is equipped with A driver board which generates thyristor firing pulses implements control and provides power for the electronics This board is also used for the signal and operating mode configurations A filter board to ensure Electromagnetic Compatibility in accordance with the test standard and to protect the controller from transient interference The filters which provide immunity against electromagnetic interference are located Between the power phases Between the phases and the safety earth connector The user terminal block below the controller is used for the control signal connection without having to open the front door of the unit A green LED indicating thyristor firing ON is located on the front facia TE300 power controllers are designed to be bulkhead or DIN rail mounted The 63A rated limit must be permanently fan cooled The fan power supply of either 115V or 230V should be specified w
30. o account the load and power supply variations If three identical loads are configured in closed delta the current of each phase of the controller is times greater than the current in each branch of the load For a given power P of a three phase load and with line to line voltage VL the current to be compared with the nominal current of the controller is x Vr For open delta the current to be compared with the nominal current of the controller is 3x VT Load configuration type Check that the type of connection used is correctly configured by the coffee beans GS6 and GS7 on the driver board Supply voltage The nominal value of the controller voltage must be greater than or equal to the line to line voltage of the supply used Attention In order for the control algorithm to function correctly the nominal unit voltage rating must be as close as possible to the supply voltage Auxiliary power supply voltage option In the case of operation with non standard three phase mains a separate power supply for the electronics must be provided at either 115V or 230V The auxiliary power supply voltage is set at the factory from the ordered product code Control signals Configuration of the coffee beans on the driver board must be compatible with the type and level of the control signals see page 4 6 TE300 User manual 6 3 POWERI
31. oard Coffee beans GR1 to GR4 are used for factory settings and are not intended to be re configured by the customer Important In the coffee bean configuration tables X denotes the corresponding solder link coffee bean NES denotes absence of open solder link TE300 User manual 4 3 Location of coffee beans Dy GR3 gt Gn LED1 Dy GR2 SES 222222525 GE GE2 9 9 9 9 9 9 0m N 7 Y gt GE2 GS1 652 653 054 GS6 and 6057 Input signal Firing mode Burst firing length Load connection configuration configuration configuration GS5 configuration Not used Figure 4 1 Location of configuration coffee beans on the driver board solder side view The coffee beans are labelled GR GE or GS depending on their function 4 4 TE300 User manual Configuring the type of load connection The controller is configured for the type of load connection by means of coffee beans GS6 and GS7 located on the driver board Load configuration Code Coffee beans GS6 GS7 Star without neutral 3 wire 35 Closed delta 3 wire 3D X Star with neutral 4 wire 45 X O pen delta 6 wire 6D X X Table 4 2 Configuration of load connection type TE300 User manual 4 5 Control signal configuration The three coffee beans GE1 to are used to configure the con
32. roduction TE300 controllers have the following thyristor firing modes Burst firing with configurable cycle time Advanced Single cycle firing by cycles and non firing by half cycles Logic ON OFF As an option DC component elimination for 3 wire configuration is available in Burst firing and Logic modes They can be re configured by the user as described in the chapter entitled Configuration 5 2 TE300 User manual 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 Load voltage t gt 0 lt gt lt TNF gt lt gt Figure 5 1 Burst firing mode firing time modulation time Thyristor firing and non firing are synchronised with the mains and for a resistive load are performed at zero voltage for each 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 In Burst firing mode the power delivered to the load depends on the firing time Tp and the non firing time Typ The load power is proportional to the firing ratio t which is defined by the ratio of the firing time TF to the modulation time Tp Typ The firing ratio or duty cycle is expressed by the following ratio The load power can be expressed by
33. st be protected by a 0 5A fuse 3 10 TE300 User manual 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 operation TE300 series units have a protective cover DANGER Before any connection or disconnection ensure that power and control cables or leads are isolated from voltage sources For safety reasons the safety earthing cable must be connected before any other connection is made during wiring and it should be the last cable to be disconnected The safety earth is connected to the screw located on the slot at the side of the controller and is denoted by the symbol Attention To ensure correct grounding of the TE300 unit make sure that it is 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 DANGER This connection which is intended to ensure good ground continuity can never be used to replace the safety earth connection TE300 User manual 3 11 3 12 TE300 User manual
34. ternal input wiring The external control signal can be Analogue for Burst firing and Single cycle thyristor firing modes Logic for ON OFF mode of operation The external signal must be connected to the control terminal block between terminal 8 Input and terminal 9 OV This input is configured by means of the coffee beans solder linked pads Eurotherm 2000 series controller EUROTHERM 2216 1A fuse Mains phase Mains neutral 1A fuse if second phase Analogue or logic output Control Control signal connector signal OV b View of TE300 LOAD controller from below Figure 3 5 External control signal wiring 3 8 TE300 User manual Control wiring local mode The controller can be driven in local mode by a potentiometer or by a dry contact For operation with manual control a 10 external potentiometer must be used connected between terminals 9 OV and 7 5V 0 5mA The potentiometer wiper is connected to the control terminal block input terminal 8 10k Potentiometer 1 User 5V Control signal connector View of TE300 controller from below LOAD Figure 3 6 Manual control wiring using an external potentiometer For operation in logic mode ON OFF contacts can be connected between terminals 8
35. the fixing plate back plate of controller on to the upper DIN rail 2 Clip the controller by spring clips on to the lower DIN rail making sure that the clip is properly engaged TE300 User manual 2 5 Two fixing plates are provided for this type of mounting For this type of mounting use the following instructions Drill three holes for M6 screws following the dimensions given in Figure 2 4 Fix the upper plate on to the panel using the oblong hole at the top of the controller Install the lower plate with two M6 screws Insert the fixing lugs of the controller into the lower plate Slightly undo the central screw holding the upper plate in order to slide it upwards position the controller and slide the plate back down into the slots on the heatsink Tighten the central screw m Upper fixing plate 208 1 3 holes for M6 screws Slot on back of Fixing plates heatsink Figure2 4 Bulkhead 120 ng and mounting E controller 2 6 TE300 User manual Chapter 3 WIRING Contents INSTALLATION SAFETY 3 2 WIRING SAFETY 22455 oe eee he C a headed Yo 3 2 POMERWIRIN urn REC HEC eae Ene Ses 3 3 3 3 POWER WIRING DIAGRAMS 3 3 STAR WITHO UT NEUTRAL AND CLOSED DELTA CONFIGURATION 3 4 STAR WITH NEUTRAL CONFIGURATION 3
36. troller input Type and range of control signal Coffee beans GE1 GE2 GE3 Voltage 0 to 5V analogue amp 5V logic 0 to 10V analogue amp 10V logic X Current 410 20mA analogue Z mX logic X X tocat control tke potentiometer 0 to 5V ts 0 to 5V Table 4 3 Control signal configuration using coffee beans Thyristor firing mode configuration The firing mode is configured by soldering coffee beans GS1 amp GS2 In Burst firing mode the number of firing cycles is configured by coffee beans GS3 amp GS4 this number is given for the cycle corresponding to 50 power Thyristor firing mode Coffee beans 651 652 653 654 Logic All or nothing Burst firing 1 cycle X 8 cycles X X 16 cycles X X 128 cycles X X X Advanced Single cycle E i X X p Table 4 4 Thyr stor firing mode configuratipn 4 6 TE300 User manual Chapter 5 Contents THYRISTOR FIRING MODES 5 2 GENERAL INTRO DUCTION 5 2 BURSFFIRING 5 3 SINGLE CYCLE MO DE 1 CYCLE BURST FIRING 5 5 ADVANCED SINGLE CYCLE MODE 5 6 LOGIC MODE oram cs 5 7 CONTROLOPERATION 5 8 TE300 User manual 5 1 Chapter 5 OPERATION THYRISTOR FIRING MODES General int
37. ve 73 23 EC of 19 2 73 amended by the Directive 93 68 EC of 22 7 93 For safety reasons TE300 products installed and used in compliance with this User Manual meet the essential requirements of the European Low Voltage Directive ELECTROMAGNETIC COMPATIBILITY EMC For an industrial environment only must not be used in domestic environments Eurotherm certifies that TE300 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 TE300 products are concerned EMC test standards Immunity Standards EN 50082 2 EN 61000 4 2 EN 61000 4 3 EN 61000 4 4 EN 61000 4 6 ENV 50204 Emission Standards EN 50081 2 EN 55011 class EN61800 3 second environment Internal EMC filters EMC filters are incorporated in the TE300 to reduce conducted emission in accordance with the test standard 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 025464 This guide lists the rules generally applicable for EMC iv TE300 User manual DECLARATION CE CONFORMITY Availability A declaration of CE conformity is available on request Validation by Competent Body Eurotherm has validated the compliance of TE300 products with the
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