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B 70.9040.0 Operating Instructions

1. fuse current limit load fail fullwave output adjust 1 Load 2 Super fast semiconductor fuse 3 Thyristor module with RC protection network 4 Driver stage for thyristor module 5 Power supply for control electronics 6 Optocoupler 7 Voltage converter 8 Current transformer Control electronics Trimmer on front panel Error signal output via relay or optocoupler Configuration switch Signal LEDs Master slave connections Output level setting operating inputs power level output signal Power units 02 06 11 1 Introduction 1 6 Front panel indicators and adjustments EG 1 Indicator LED for blown semiconductor fuse 2 LED for current indication 3 LED for load failure indication 4 LED for full output indication 5 Adjustment of current limit in phase angle operation with extra code TR or TO current limit oo load fail OO full wave OO output adjust Q angle set O 6 Adjustment of threshold for part load failure indication with extra code TR or TO 7 Adjustment of full output 8 Adjustment of power level signal 9 Spring clip to release cover 1 0 Adjustment of phase angle reduction for 1st half wave in burst firing operation 12 Power units 02 06 2 Operating modes 2 1 Phase angle control with soft start and current limiting Current limiting In this mode of operation the
2. 18 Installation site and climatic conditions eee eee 18 Wall mounting sitio ia EE SE 19 AA 1079 025 100 een doo ets eco a bn Ei minim 19 TYA 110 3 150 and TYA 110 3 250 see 20 DIN rail mounting 5 ooi eee eee eee eee ee eee eee 21 TYA 110 3 025 IT 21 Electrical connection eina item ga tuci 23 Connection diagram emma ellas 23 Type TYA 110 3 025 050 075 100 zv imme ii moment 25 9 UST T YASTTO RS 455 co a a Saus 25 TY DET YAR 10 83 l at lenta stets sto gels 25 Single phase operation line phase N 26 Single phase operation phase phase 27 Star configuration with star point connected to N 28 Open delta configuration six wire circuit 29 Power units 02 06 3 Contents 4 6 4 7 5 5 1 5 1 1 5 1 2 5 2 5 3 5 3 1 5 4 5 5 5 5 1 5 5 2 5 6 5 7 6 6 1 6 2 6 3 6 4 6 4 1 6 5 6 6 6 7 6 8 6 9 6 9 1 6 9 2 6 10 7 1 7 2 7 3 Free running economy circuit purely resistive loads 30 Master slave economy circuit with resistive inductive loads 31 COMMISSIONING sta baa aaa 33 Adjust control input full Wave 33 Setting the maximum
3. Remove the two hexagonal head fixing screws 1 for the semiconductor fuse and take out the fuse Insert a new semiconductor fuse 54 Power units 02 06 8 Faults Replacement fuses Replace the fixing screws Re assemble the housing Use only original replacement fuses If other fuses are used this will invalidate the warranty c Section 1 4 3 Accessories therefore only be carried out while the equipment is completely disconnected from the supply To avoid dangerous situations follow the regulations for Working on live equipment VDE 0100 Part 410 The pcbs carry supply line voltages Work on the circuitry must Power units 02 06 55 JUMO GmbH amp Co KG Street address MoltkestraBe 13 31 36039 Fulda Germany Delivery address MackenrodtstraBe 14 36039 Fulda Germany Postal address 36035 Fulda Germany Phone 49 661 6003 0 Fax 49 661 6003 607 E mail mail jumo net Internet www jumo net JUMO Instrument Co Ltd JUMO House Temple Bank Riverway Harlow Essex CM20 2TT UK Phone 44 1279 635533 Fax 44 1279 635262 E mail sales jumo co uk Internet www jumo co uk JUMO Process Control Inc 8 Technology Boulevard Canastota NY 13032 USA Phone 315 697 JUMO 1 800 554 JUMO Fax 315 697 5867 E mail info jumo us Internet www jumo us
4. Thyristor Power Units B 70 9040 0 Operating Instructions 02 06 00089951 Contents 1 1 1 2 1 2 1 1 2 2 1 3 1 4 1 4 1 1 4 2 1 4 3 1 5 1 6 2 1 2 2 2 3 3 1 3 2 3 3 3 4 3 4 1 3 4 2 3 5 3 5 1 4 1 4 1 1 4 1 2 4 1 3 4 2 4 3 4 4 4 5 TO ase ToT 7 Preface TT 7 Typographical conventions 8 VV ARI e TT ETT 8 Note SIGINS TTT 8 RL Tei le 9 Type GESIGHAUOMN iovcassomocitemsattsi stalmim tt tamb io simmen meiasceatgateca loi u sinlanssabnunu 9 Type extensions extra codes ee 10 Standard Le ee LT 10 Pee co REPRE 2 Ea 11 Block diagram iiiaio n aia eaaa aea aa aaa a a aa aaa iaa ataa ades 11 Front panel indicators and adjustments 12 Operating modes 4aaaaaaaaaaaannnannnnnnnnnnnnnnnnnnnnnnnnnnunnnnnnnnnnnnnnnnnnnnnnnn mnnn na 13 Phase angle control with soft start and current limiting 13 Burst firing operation for resistive loads 14 Burst firing operation for transformer loads and loads with a high positive tem perature coefficient TC mixed operation 15 Installation acci asi een a CERRO NN EU d Cua we 17 Important installation notes 17 Filtering and interference suppression
5. 1 Introduction 1 3 Description Application Operating modes Regulation Versions Standards A thyristor power unit can be used wherevere sizeable resistive or inductive loads are switched frequently for instance in industrial furnaces and plastics processing The thyristor power units can operate under phase angle control with adjust able current limiting or in burst firing mode depending on the setting of the in ternal switch An external switch may also be used to change over the operat ing mode In burst firing mode the phase angle can be cut back for the first half cycle for driving transformer loads Variations in the line supply voltage have no effect on the control loop regula tion during operation This is ensured by a subsidiary V P or I control loop An input signal attentuator trimmer permits the restriction of the control range and a base load can be set by an external potentiometer In burst firing mode an economy circuit can be used for multi phase loads With phase an gle control the target phase angle that is set by the controller is gradually ap proached from the initial 180 thus avoiding high surge currents soft start The power stage is composed of 2 thyristors connected in anti parallel the in sulated heatsink and the control electronics Thyristor units for up to 50A rat ed load can either be snapped onto a 35mm DIN rail or mounted on a bas plate fixed to a wall Units for 75
6. 1 0 2 eod o o 1 position O position 1 pin header X 504 ed low current w overcurrent HIT Power units 02 06 41 da 6 Settings 6 3 Summary of possible settings position 1 1 o o pole position O position 1 2 a ges position 2 l Ec Switch number 1 2 13 4 5 6 7 8 9 10 11 12 13 14 115 16 17 18 19 20 21 factory setting 0H MH 1 HH job specific setting Control input 0 20mA 1 4 20 mA 0 0 10V 1 2 10V 0 1 0 0 Switch position o o o o c o o o o c i 0 BV 1 5V Logic signals 0 10V 0 5V 0 20mA or floating contact A OI GOI GO OI GO O H O GOI GO O N MI POY I N Subsidiary control loop v 1 lo jo P 0 P o o Actual power output v 1 0 0 P 0 P o jo H Load current adaptation lL IL lt 0 5 HhyN 0 IL 0 5 Hhyn 1 Firing pulse inhibit external make contact 1 external break contact 2 Operating mode Phase angle control for transformer resistive load 1 1 JO JO JO 1 Burst firing mode W for resistive load 0 1 JO 1 1 11 W for transformer load 0 o 1 1 1 1 1 2 R constant 0 JO cs o eo Rw gt 1 soft start K 1 1 fixed cycle 500ms 2 variable cycle 1 Economy circuit free running W for resistive load O JO 1 JO 1 JO JO JO 1 1
7. 1096 of the rated curent for the thyristor power unit If the load current is below the rated current of the power unit then the num ber of turns required is reduced in the same proportion If load current I lt 0 5 x rv then internal switch S15 must be in position O c Section 6 3 Summary of possible settings Power units 02 06 37 5 Commissioning Alternative setting Simulate a load failure and then adjust the load fail trimmer so that the yel low load fail LED just lights up 5 5 2 Setting for master slave and free running economy circuit When using master slave and free running economy circuits the Se settings must be made in both thyristor power units The smallest change of resistance that can be detected is 5 of CE the nominal load resistance 10 in an economy circuit 5 6 External changeover of operating modes For this to be possible an external switch must be wired between Terminal 8 and Terminal 6 Switch Operating mode firi t os open burst firing mode closed phase angle control os 6 ee esc En The external svvitch can only be used to change from burst firing to CE phase angle control when the internal switch S3 is open since this switch is in parallel with the external switch S If the switches S12 and S13 are closed an external changeover to phase angle control is not possible c Section 6 3 Summary o
8. 5 means that the external potentiometer must be set to 5096 of the full scale value Adjustment Set the potentiometer to the calculated fraction of the full scale e g 50 96 Apply the maximum current e g 20 mA to the current input Turn the full wave trimmer clockwise or counter clockwise until the green LED for full wave just light up in phase angle control and does not light up in burst firing mode 34 Power units 02 06 5 Commissioning 5 3 Setting the current limit Internal current Current limiting is only possible in the phase angle mode of control limiting The trimmer 5 current limit on the front panel can be used to limit the effective rms value of the load current over a range from 10 100 of the rated current for the thyristor control unit I thyn 1 5 turns clockwise correspond to increasing the threshold by about 10 of the rated current current limit oo load fail OO full vave OO output adjust Q 9 angle set GS ds The red LED lights up when the current limit is reached Current limiting is achieved by limiting the ON phase angle so that the set value for effective current is not exceeded External cur An external voltage signal in the range 0 10 V can be applied to Terminal 9 rent limiting to influence the internal current limit max set by the current limit trimmer OV means no effect 10 V means the maximum effect the threshold i
9. Extra Low Voltage Housing TYA110 3 25 50 110x 195 x 152mm TYA110 3 75 100 125 x 195 x 170mm TYA110 3 150 250 150 x 220 x 280mm Weight TYA110 3 5 50 2 8 kg TYA110 3 Es 100 3 7 kg TYA110 3 150 8 6 kg TYA110 3 250 9 0 kg Standard 1 mounting plate for vvall mounting accessories 1 Operating Instructions B 70 9040 52 Power units 02 06 8 Faults The thyristor power unit does not require any maintenance In the event of a fault the following points should be observed 8 1 Fault finding If faults occur during commissioning we recommend that you first check the positions of the internal switches c Section 6 3 Summary of possible settings If the fault persists check the following items sthe supply voltage present for the thyristor power unit Check the phase sequence as well Are all other connections also correct sthe controller operating properly Check the operation manually by using an external potentiometer c Section 6 4 Control inputs 8 2 Replacing the semiconductor fuse If the red LED fuse lights up this means that a semiconductor fuse has blown Disconnect the system from the supply voltage c Section 6 1 Opening the housing 8 2 1 Type TYA 110 3 025 to 100 Wrench 10 mm a f Power units 02 06 53 8 Faults 8 2 2 Type TYA 110 3 150 Wrench 13 mm a f 8 2 3 Type TYA 110 3 250 Wrench 13 mm a f
10. power output sees eee eee eee 33 Input signal attenuator 223524 pa eee ted eee eee 33 Setting the base load eee 34 Setting the current limit eliminat ea oc HU Rp rele 35 Alteration of the current limit Imax as a function of the voltage on Terminal 9 36 Setting the phase angle for the first half wave eee 36 Load and part load failure monitoring 37 Setting the threshold for load failure indication 37 Setting for master slave and free running economy circuit 38 External changeover of operating modes 38 Blown fuse indication 38 Ina 39 Opening the housing ss 39 Adjustment switches S1 21 and pin headers X503 X504 40 Summary of possible settings eee ee eee eee eee 42 Control Ts SL EL EM US 43 Combinations of external potentiometer and electronic controller 44 Subsidiary control loops sse 45 Actual power output 2 eee eee 46 Load current adaptation only with extra code TR TO 47 Select operating modes and load types sss 47 Economy CIFCUIU ino sido e Mosca veta race dre Utt laa 48 Free running economy circuit asynchronous switching for resistive loads
11. 11 Master slave master resistive load 0 slave resistive load 0 master transformer load 0 Slave transformer load 0 1 5 S6 S8 S9 815 only have an effect with extra code TR or TO 2 The jumpers on pin header X503 must be turned through 90 Section 6 2 Adjustment switches S1 21 and pin headers X503 X504 A changeover to phase angle control is not possible for burst firing mode with a transformer load and soft start c Section 2 3 olol o HO N App N App EE ee 42 Power units 02 06 6 Settings 6 4 Control inputs The internal switches S1 S2 16 819 S20 can be used to adapt the thyris tor power unit to suit the available control signal controller output signal There are separate voltage and current control inputs The current inputs are designed for a differential current signal i e they can have a common po tential that is up to 10V above or below the ground reference potential 1 If the current and voltage inputs are used simultaneously they have an addi tive effect Both analog and logical controller output signals may be used Control signal Internal switch Signal start Signal end S1 S2 S16 S19 S20 0 mA 20 mA 1 0 0 1 4mA 20 mA 0 0 0 2 OV 10V 1 0 0 1 2V 10V 0 0 0 2 OV 5V 1 0 1 1 1V BV 0 0 1 2 logic levels 0 10V 0 5V 0 20mA or 0 1 1 2 1 fl
12. 3 Burst firing operation for transformer loads and loads with a high positive temperature coefficient TC mixed operation 6 9 2 Master slave economy circuit synchronous switching for resistive and transformer loads In the standard version the master slave economy circuit operates with a V control With extra code TO TR it is also possible to use a P control and part load regulation The control electronics of the master unit takes on the actual power control function and drives the slave unit in synchronization This makes it possible to drive transformer loads The combination of the fixed cycle time of the V control and the delta load configuration makes it possible to achieve good voltage regulation for the indi vidual load resistances even in the event of a part load failure c Section 4 7 Master slave economy circuit with resistive inductive loads The jumpers on pin header X503 of the slave unit must be turned Ee through 90 c Section 6 2 Adjustment switches S1 21 and pin headers X503 X504 Power units 02 06 49 6 Settings 6 10 Firing pulse inhibit Inhibiting the firing pulses is a simple way of switching high powers In phase angle control the thyristor power unit commences with a soft start after firing pulse inhibit has been used In burst firing operation with a transformer load the power unit first starts up in phase angle cont
13. 4 7 Master slave economy circuit with resistive inductive loads Only possible in burst firing mode L1 L2 L3 N PE Un control circuit fuses e g 2A BE 1 1 R uw SY Q LXY S ir D o 1 N I star connected transformer load resistive load CAUTION U U Check that the electrical field has p p right hand clockwise rotation wx Thyristor units must be dimensioned worse o Xm for the phase phase voltage U phase phase voltage Prot total controlled power UN phase neutral voltage current in phase conductor Uthy voltage on thyristor power unit lryy current in thyristor power unit Power units 02 06 31 4 Electrical connection 32 Power units 02 06 5 Commissioning 5 1 Adjust control input full wave The trimmer 7 full wave on the front panel can be used to adjust the thyris tor power unit so that the 100 full wave firing point is reached at the maxi mum output signal of the preceding controller current limit oo load fail OO full waveO O output adjust e angle set O VN D D S 5 1 1 Setting the maximum power output Apply the maximum controller output signal Turn the full wave trimmer clockwise or counter clockwise until the green LED for full wave just light up in phase angle control and does not light up in burst firing mode E When using a logical control output e g from a
14. 49 Master slave economy circuit synchronous switching for resistive and transformer loads 49 Firing pulse inhibit sees eee eee eee 50 Technical s 1 TTT 51 Load circult A hove ci eG ee ee 51 Control a SL ES IN A hes EO ROB DEL a 51 General data 4603 Ate te aie oe eth io ca a as 51 Power units 02 06 Contents 8 gf HHHH 53 Sek Faultfinding 5o ca I ee ee ee UE 53 8 2 Replacing the semiconductor fuse 53 8 2 1 Type TYA 110 3 025 to 100 eee 53 8 2 2 Type TYA 110 3 150 racerne a a n E E R E 54 8 2 9 Type I NA 110 3 290 dei ii nomia k 54 Power units 02 06 5 Contents 6 Power units 02 06 1 Introduction 1 1 Preface LI Please read these operating instructions before starting up the instrument Keep them in a place that is accessible to all users at all times Please help us to improve this manual Your suggestions will be welcome Fax in Germany 0661 6003 862 ee abroad 49 661 6003 607 If any difficulties arise during commissioning you are asked not to carry out any unauthorized manipulation You could endanger your rights under the instrument warranty Please contact the nearest subsidiary or the main factory in such a case When returning chassis modules or components the regulations of EN 100 015 Protection of electrostatically sensitive compo nents must be observed Use only the appropriate ESD packag ing for
15. A or higher rated load can only be wall mounted The thyristor power units meet VDE 0160 5 5 1 3 5 88 and VDE 0106 Part 100 3 83 Earthing must be carried out in accordance with the regulations of the local electrical supply utility 1 4 Type designation The basic version TYA 110 3 includes the following features Voltage current and potentiometer input Input signal is freely selectable Operating mode is freely selectable Phase angle reduction of 1st half wave for burst firing operation Supply line voltage monitoring Input signal attentuation by trimmer Soft start in phase angle operation V control with adjustable power level output signal Master slave economy circcuit Firing pulse inhibit Power units 02 06 1 Introduction TYA 110 3 Um none j El Thyristor povver unit for analog control 025 Load current 25A 050 Load current 50A 075 Load current 75A 100 Load current 100A 150 Load current 150A 250 Load current 250A 024 Rated load voltage 24V 1 042 Rated load voltage 42V 1 115 Rated load voltage 115V 1 230 Rated load voltage 230V 1 265 Rated load voltage 265V 400 Rated load voltage 400V 1 460 Rated load voltage 460V 1 500 Rated load voltage 500V TR Indication of part load failure or blown fuse through built in relay and LED TO Indication of part load failure or blown fuse through optocoupler MS Master slave circuit 2 pre assemble
16. O free choice of V2 P 12 control via internal switches Power units 02 06 51 7 Technical data Actual power output V signal as standard With extra code TR or TO free choice between V2 P or P signal via internal switches adjustable from 0 5V to 0 10V Imax gt 2 MA Electrical connection Control wiring by screw terminals for conductor cross sections 0 2 2 5 mm Load connections by cable lugs to DIN 46 212 Protection IPOO as per EN 60 529 heatsink is grounded Permitted ambient temperature range 0 45 C Permitted current derated by 2 for each C increase in ambient temperature the maximum permissible ambient temperature must not exceed 60 C Permitted storage temperature range 10 to 70 C Climatic conditions rel humidity lt 75 annual mean no condensation Cooling natural convection Operating position vertical Operating conditions The thyristor power unit is designed as a built in unit to VDE 0160 5 5 1 3 5 88 VDE 0106 Part 100 3 83 pollution degree 2 to VDE 0110 Part 1 4 2 1 89 overvoltage category U III to VDE 0160 5 7 5 88 Test voltage to VDE 0160 Table 4 6 88 Electromagnetic compatibility Control electronics to EN 61 326 Creepage distance control electronics to load circuit gt 10mm control electronics to housing gt 10mm Unit can be connected to SELV circuits SELV Seperate
17. d power units on a mounting plate ready for connection 1 Rated load voltage supply voltage for the control electronics 1 4 1 Type extensions extra codes TR Extended version with indication of part load failure adjustable by trimmer or blown fuse through common relay contact and LED This version also includes Current limiting internal external and rated current adjustment at lt IN 2 Free selection of the subsidiary control loop type V2 I or P A free running economy circuit can be implemented with P control Power level output signal can be switched to V2 P 1 TO as for TR but vvith signaling via optocoupler MS Master slave circuit 2 pre assembled povver units on a mounting plate ready for connection 1 4 2 Standard accessories 1 Mounting plate for vvall mounting 1 Operating Instructions 10 Povver units 02 06 1 Introduction 1 4 3 Accessories Super fast semiconductor fuses to protect the thyristors from short circuits no supply line fusing 32A for IN 25A 80A for IN 50A 125A for IN 75A 160A for lv 100A 350A for IN 150A 550 A for IN 250A Sales No 70 00068009 Sales No 70 0006801 1 Sales No 70 00081800 Sales No 70 00081801 Sales No 70 00083318 Sales No 70 00371964 Assembly kit for DIN rail mounting for 25A and 50A versions Sales No 70 00067312 1 5 Block diagram N L2 L1 supply power SELV potential
18. e front panel The limiting is based on the rms value of the load current Fusing super fast semiconductor fuse TSE circuit RC network as standard Power loss 1 3V x Ii A Control accuracy Supply voltage fluctuations within the tolerance range 20 15 are accurately compensated Fluctuations lt 0 5 Control signal Input signal attenuation 0 4 20mA R 2500 0 2 10V R 25kQ 0 1 BV Rj 12kQ 0 10V 0 5 V R 12kQ 0 20mA Rj 500 floating contact or manual control by an external 5 kQ potentiometer adjustment range 100 20 7 3 General data Circuit variants single phase operation star circuit with accessible star point open delta circuit economy circuit using master slave principle and subsidiary V2 control in burst firing operation free running economy circuit star or delta only with subsidiary P control in burst firing operation Operating modes phase angle control for resistive and transformer loads with soft start with current limiting for extra codes TR TO burst firing operation for resistive or transformer load Features Two single phase units can be linked to form an economy circuit for burst firing operation free running economy circuit for resistive loads master slave economy circuit for resistive and transformer loads Subsidiary control types V2 control as standard VVith extra code TR or T
19. e table phase phase voltage regardless of whether the load is wired in a The thyristor power units must always be dimensioned for the star or delta configuration It is vital to ensure that the roating electrical field is right handed i e clockwise rotation Terminal V must be linked to phase L2 on both power units c Section 4 6 Free running economy circuit purely resistive loads and Section 4 7 Master slave economy circuit with resistive inductive loads 48 Power units 02 06 6 Settings 6 9 1 Free running economy circuit asynchronous switching for resistive loads A free running economy circuit has the advantage that the average loading of the supply network is reduced Both power units operate independently and regulate the required 3 phase power quite precisely Even a possible part load failure will not necessarily have an effect on the temperature stability of the control loop A subsidiary P control loop is required for both power units Switch S3 S4 S5 S6 10 S11 12 S13 S14 S17 S18 S20 S21 Economy circuit free running W resistive load 0 0 1 0 1 0 0 0 1 1 1 2 master slave W resistive load master function 0 1 0 1 1 1 1 slave function 0 1 0 0 2 2 1 W transformer load master function 0 0 1 1 1 1 1 1 2 1 slave function 0 0 1 1 1 0 2 2 2 1 If 12 and S13 are closed it is not possible to change over to phase angle control c Section 2
20. f operating mode 6L C phase angle or burst firing operation 8 ls 06 o8 Actual power output 0 10V 10 nn Imax 2MA 6L y L o 6 Master slave connection for 6L master slave economy circuit 11 644 M 012 External current limiting 5 Start 10V 2mA A with 5 kQ potentiometer 6 End 1 S 9 Slider og 24 Power units 02 06 4 Electrical connection 4 1 1 Type TYA 110 3 025 050 075 100 cos Bodo Mere 4 1 2 Type TYA 110 3 150 4 1 3 Type TYA 110 3 250 E FE aal Power units 02 06 25 4 Electrical connection 4 2 Single phase operation line phase N L N PE UN load circuit fuse I control circuit fuse e g 2A Urny Un my tot N Irny I U phase phase voltage Piot total controlled power UN phase neutral voltage l current in phase conductor Urny voltage on thyristor power unit Irpy current in thyristor power unit 26 Power units 02 06 4 Electrical connection 4 3 Single phase operation phase phase L1 L2 N PE UL load circuit fuses Il Il control circuit fuse e g 2A Urny U Piot Thy 7 L Irny I Piot total controlled power U phase phase voltage UN phase neutral voltage l current in phase conductor Uthy voltage on thyristor power unit Thy Current in thyristor power unit Power units 02 06 27 4 Electrical connection 4 4 Star c
21. f possible settings 5 7 Blown fuse indication If a short circuit occurs the built in semiconductor fuse switches within half a supply cycle to protect the thyristors When the fuse is blown the fuse LED lights up c Section 8 2 Replacing the semiconductor fuse With extra code TR or TO an output signal is also available c Section 4 1 Connection diagram 38 Power units 02 06 6 Settings 6 1 Opening the housing Adjustments must only be made while the unit is disconnected A from the supply power It is easier if these adjustments are carried out before the unit is installed Use a screwdriver to lever the spring fixing lug outwards On the 150 A and 250 A versions press both spring lugs inwards Pull off the cover from the front Power units 02 06 39 6 Settings 1 14 S 17 19 Pin header X 503 o 20 S 15 16 21 Pin header X 504 6 2 Adjustment switches S1 21 and pin headers X503 X504 The switches S1 to 21 can be found on the back of the printed circuit board It is easier to access switches S15 S16 and S21 if the plug in CE screw terminals are first pulled off downwards 40 Power units 02 06 6 Settings View from above pin header X 503 jumpers factory rotated 90 setting for WU for slave unit master unit pin header X 503 D TNC oo os mi switch settings NT b N c o a Q Q E position
22. ible free from vibration Electro magnetic fields caused by equipment such as motors and transformers should be avoided The ambient temperature at the installation site must be within the range 0 to 45 C measured about 100 mm below the unit and the relative humidity must be lt 75 The thyristor power unit is intended for use in dry rooms The inside of the unit must be kept free from conductive dirt and corrosive gases The thyristor power unit must be mounted vertically to ensure good convec tion cooling If it is mounted in a switchgear cabinet adequate ventilation must be provided There must be at least 100 mm free space below and 150 mm 18 Power units 02 06 3 Installation above the unit The thyristor power unit has enclosure protection IPOO and so it must be mounted in such a way that bodily contact is prevented built in unit A The heatsink can become very hot in operation Incorrect use The unit is not suitable for installation in areas with an explosion hazard Ex areas The installation site should be free from vibration dust and corrosive media Ambient Side by side mounting of units is permitted conditions Relative humidity 75 no condensation Ambient temperature range 0 to 45 C Storage temperature range 10 to 70 C 3 4 Wall mounting Fix the aluminium mounting plate to the heatsink using the cheese head screws provided Fix the thyristor power unit with its m
23. lectromagnetic compatibility EMC meets the standards and regulations cited in the technical data Section 7 Technical data Load and control cables should be laid separately as far as feasible The appropriate fuses for control circuitry e g 2A type Neozed should be used to protect the wiring Check the data given on the nameplate rated load voltage load current against the data for the system Wire up the connections from supply line thyristor power unit load according to the wiring diagram and check them If the economy circuit configuration is used check that the rotary electrical field has clockwise phasing Check the settings for the setpoint inputs Check the switch positions Connect the supply voltage for the control electronics as shown in the wi ring diagram Link N L2 to V unless the economy circuit is being used slave unit The electronic switching devices 2 antiparallel thyristors are in circuit bet ween the screw connections U1 and U2 The supply voltage for the control electronics and the load voltage must have the same phase Terminal L1 must be connected via a control circuitry fuse to the same supply potential as terminal U1 Power units 02 06 17 3 Installation Switch on sequence Control inputs The supply voltages for the load and control circuitry must be switched on at the same time In no circumstances should the suppl
24. ment switches S1 21 and pin headers X503 X504 Cycle time S 20 Variable cycle time 1 The control unit uses the shortest available cycle time for fast control loops Fixed cycle time 500ms 2 Used for transformer loads slow control loops 14 Power units 02 06 2 Operating modes 2 3 Burst firing operation for transformer loads and loads with a high positive temperature coefficient TC mixed operation Soft start It is not possible to change over to phase angle control in this CE mode of operation For the first switch on of the thyristor power unit or after being switched off by inhibiting the firing pulses after a supply line interruption or if the setpoint was switched off for more than 8seconds there will always be a short phase angle controlled start area a in the diagram U After this soft start the controller switches over automatically to burst firing operation if the given setpoint is larger than the minimum setpoint 10 of the setpoint range area b in the diagram Example Setpoint range 2 10V The changeover to burst firing operation takes place at 2V 10 of 8V 2V 0 8V 2 8V After this changeover the power output is regulated to follow the setpoint in put provided FE If the povver unit runs into current limiting during the phase angle controlled start then the output is regulated according to the maxi mum current given by the curent limit set
25. oating contact Analog control inputs The thyristor povver unit can be operated by the follovving signals for analog povver regulation voltage signal Terminals 3 4 current signal Terminals 1 2 5 kQ potentiometer Terminals 3 4 5 A 10 V source is provided at Terminal 5 for use vvith a potentiometer The switch settings are the same as for a0 10 V signal 5kQ 88899899 Power units 02 06 43 6 Settings Logic control The thyristor power unit can also be operated by the following logical signals inputs e g two state single setpoint controller outputs switching pulse bursts on or off current signal 0 20mA Terminals 1 2 voltage signal 0 10V Terminals 3 4 floating contact Terminals 4 5 0 20 mA a 060600060006 6 4 1 Combinations of external potentiometer and electronic controller Controller with The voltage input Terminals 3 4 can be used together with the internal 10 V current output source and a 5 kQ potentiometer to provide manual setting Q Switch Sa Sb Automatic open open Manual closed closed To prevent unintended overdriving on the changeover to manual ce operation S4 should be mechanically coupled to Sp Otherwise the two signal sources will be added together for a moment 44 Power units 02 06 6 Settings Controller with This only uses the voltage in
26. onfiguration with star point connected to N L1 L2 L3 N PE control circuit fuse e g 2A controller 0 10V P P 3U SU I l U phase phase voltage Piot total controlled power UN phase neutral voltage l current in phase conductor Uthy voltage on thyristor power unit Ir current in thyristor power unit 28 Power units 02 06 4 Electrical connection 4 5 Open delta configuration six wire circuit L1 L2 L3 N PE control circuit fuses e g 2A A c Bos ERA NE SR 3 U Controller l 0 20mA m Vg U phase phase voltage Piot total controlled power UN phase neutral voltage l current in phase conductor Uthy voltage on thyristor power unit Thy Current in thyristor power unit Power units 02 06 29 4 Electrical connection 4 6 Free running economy circuit purely resistive loads Only possible in burst firing mode with P control LL L2 L3 N PE control circuit fuses e g 2A delta load controller 0 20mA U U CAUTION R Check that the electrical field has P _ P right hand clockwise rotation ww S l Vas Thyristor units must be dimensioned for the phase phase voltage U phase phase voltage Piot total controlled power UN phase neutral voltage l current in phase conductor Uthy voltage on thyristor power unit lThy current in thyristor power unit 30 Power units 02 06 4 Electrical connection
27. ons Reserved for service purposes 1A test mode Load current adaptation Internal switch S 15 IL lt 0 5 x IThyN 0 LL gt 0 5 x IThyN 1 factory setting 6 8 Select operating modes and load types The internal switches S3 S10 813 and S20 are used to set the required mode of operation In both phase angle and burst firing modes the thyristor power unit basically operates with a subsidiary V control loop With extra code TO or TR this can be changed over from V to P or I control c Section 6 5 Subsidiary control loops Switch S3 S10 11 12 S13 S14 S17 S18 S19 Operating mode Phase angle control H for resistive or 1 1 0 0 1 1 1 transformer load Burst firing operation H resistive load 0 1 1 1 1 B transformer load 0 0 1 1 1 1 1 2 R constant 0 0 A a 21 1 1 fixed cycle 500ms 2 variable cycle 1 Power units 02 06 47 6 Settings It is not possible to change over to phase angle control if S12 and S13 are closed c Section 2 3 Burst firing operation for transformer loads and loads with a high positive temperature coefficient TC mixed operation 6 9 Economy circuit Two single phase units can be used at any time to implement an economy circuit in a 3 phase system The switch settings that are required for this depending on the type of load and circuit can be found in th
28. ounting plate to the wall using four Screws 3 4 1 TYA 110 3 025 100 Power units 02 06 19 3 Installation Dimensions in mm 150 and TYA 110 3 250 3 4 2 TYA 110 3 Power units 02 06 20 3 Installation 3 5 DIN rail mounting Fix the DIN rail Snap the thyristor power unit and its mounting plate onto a standard rail to DIN EN 50 022 and lock it in place with the lever This type of mounting is only possible for thyristor power units up to 50A rated current 3 5 1 TYA 110 3 025 100 Dimensions in mm In 25 50A 75 100A Power units 02 06 21 3 Installation 22 Power units 02 06 4 Electrical connection 4 1 Connection diagram Tools required Let S JA load failure signal output lt i pS ND with relay or optocoupler lt ee L current input voltage input manual adjustment firing pulse inhibit op mode selection power level output master slave link external current limiting The diagram shows the various connections that are available at the plug in screw terminals supply power for load connections control electronics Only properly qualified personnel are permitted to make electrical A connections Disconnect the equipment completely on all poles from the supply line 1 screwdriver 3 mm blade max 1 socket wrench 10 mm for TYA 110 3 100 1 socket w
29. power is regulated by altering the phase angle This method is suitable for transformer and resistive loads During the switch on period the phase angle is gradually advanced by the controller to provide a soft start This prevents high surge currents at switch on For loads with an initial cold resistance that is significantly lower than the re sistance after warming up such as Kanthal Super heater elements it is advi sable to make use of current limiting only with extra code TR or TO While current limiting is in operation the phase angle during soft start remains constant The maximum permissible effective rms current can be adjusted on the front panel by using the current limit trimmer c Section 5 3 Setting the current limit current limit U U I U U Power units 02 06 13 2 Operating modes 2 2 Burst firing operation for resistive loads In this mode of operation the power is regulated by changing the number of full wave cycles of the supply line voltage which are switched on during each control period This method is used for purely resistive loads which have a cold resistance that is roughly the same as the hot resistance Since switching only takes place at the zero crossing points this mode of operation produces very little RF interference U The internal switch S20 can be used to adjust the duty cycle to suit the system being controlled c Section 6 2 Adjust
30. put of the thyristor power unit A 5 RO potention voltage output meter is required on Terminals 3 and 5 for manual operation Q A Switch Sc Automatic operation position 1 Manual operation position 2 6 5 Subsidiary control loops Subsidiary control loops are primarily used to eliminate or compensate exter nal disturbances such as supply line fluctuations and changes in resistance which would have a negative effect on the regulation A subsidiary V control loop is set up ex factory With extra code TR or TO this can be changed to P or I control The free running economy circuit must operate with a P control loop c Section 6 2 Adjustment switches S1 21 and pin headers X503 X504 FG With P or I control loops extra code TR TO a load current adap tation must be made for operating currents that are less than half the rated load current c Section 6 7 Load current adaptation only with extra code TR TO Control Internal switches Application type S4 S5 S6 y2 1 0 0 positive TC R constant brightness controls Power units 02 06 45 6 Settings P 0 1 0 temperature dependent TC free running economy circuit 0 0 1 negative TC 6 6 Actual power output The factory setting is that the actual power signal output corresponds to the v signal at the output of the power unit and is therefore propor
31. rench 13 mm for TYA 110 3 150 and TYA 110 3 250 Connect the control cables conductor cross section 0 2 2 5 mm to the screw terminals Use cable lugs to DIN 46 212 for the load connections Power units 02 06 23 4 Electrical connection Connection for Pin assignment Symbol Supply voltage for control electronics L1 line phase 1 link V to N L2 unless economy circuit is being used N L2 neutral phase 2 MES V N L2 N L2 V o V Load connection U1 U2 U10 LI U 2 0 IIII N L2 Current input 1 _ 64 differential input 2 8 fe 2 Voltage input 3L referred to ground 4 om 3 o4 Logic input Current signal 0 20 mA 1 of 2 NM o2 Voltage signal 0 10 V 3L 4 qr L 03 o4 Floating contact 4 5 10V 2mA ha o5 External manual adjustment with 5 kQ potentiometer 13 Start 1 A via voltage input 4 Slider es 5 End 10V 2mA uL e E Firing pulse inhibit input ly 1mA 6L make or break contact 7 9 5 6 07 or E o7 Load failure output with relay L i switching capacity 5A at 230 V AC resistive load 16 P pole 16 Sou Relay drops out if fault occurs 15 O break contact 15 POT extra code TR 14 S make contact 14 Load failure output with optocoupler 15 Collector is lomax 2mA UGEO max 32V 16 Emitter CAI extra code TO 165A o o External changeover o
32. rol and then switches over to burst firing In order to be able to disconnect a system a contactor or main switch must be fitted in the supply line circuit A contact can be wired between Terminals 6 and 7 to shut off the thyristors at the next zero crossing point This external contact can be a make contact or a break contact depending on the position of S21 c Section 6 2 Adjustment switches S1 21 and pin headers X503 X504 Only a make contact can be used as the external contact for a ce master slave economy circuit a b External Internal switch Response contact 21 make a 1 Load is continuously shut off while the external contact is closed break b 2 Load is continuously shut off while the external contact is open 50 Power units 02 06 7 Technical data 7 1 Load circuit 7 2 Control Nominal load voltage 24V 20 15 AC 45 63Hz 42V 20 15 AC 45 63Hz 115V 20 15 AC 45 63Hz 230V 20 15 AC 45 63Hz 265V 20 15 AC 45 63Hz 400V 20 15 AC 45 63Hz 460V 20 15 AC 45 63Hz 500V 20 15 AC 45 63Hz supply voltage for control electronics nominal load voltage Continuous load current IL 25A 50A 75A 100A 150A 250A Load types resistive and resistive inductive loads B lt 1 2 Tesla Current limiting With phase angle control the load current can be adjusted over the range 10 100 IN by a trimmer on th
33. rt load failure monitoring The signal output is available either as a floating contact extra code TR or an optocoupler extra code TO If a part load fault occurs the relay drops out or the collector emitter of the optocoupler goes high impedance The signal out put is also produced if there is a blown fuse The response threshold can be set by the front panel trimmer 6 load fail to a value between 20 and 100 of the rated current for the power unit Part load failure monitoring functions in all operating modes 2 current limit OO 5 3 load fail O O 6 4 full wave Q O 8 tput adjust B PR set 8 9 10 EF The load part load failure monitoring low current monitoring can also be used for overcurrent monitoring To implement this remove the two jumpers on pin header X504 next to the angle set trim mer turn them through 90 and replace c Section 6 2 Adjustment switches S1 21 and pin headers X503 X504 5 5 1 Setting the threshold for load failure indication Factory setting is 5096 of rated load Connect up the load Apply full power Set the load fail trimmer so that the yellow load fail LED just goes out turn clockwise right LED lights up turn counter clockwise left LED goes out If necessary the threshold can be reduced by further counter clockwise ro tation whereby 1 5 turns of the trimmer potentiometer correspond to a load change of about
34. s reduced to the smallest value possible iiem Q Q Q A Povver units 02 06 35 5 Commissioning 5 3 1 Alteration of the current limit Imax as a function of the voltage on Terminal 9 With an internal limit of for example Imax 0 8 x lne the external range of variation is only O to 8V 0 8 1 K 8V 10V Voltage Terminal 9 5 4 Setting the phase angle for the first half wave In the mode burst firing with phase angle controlled start the thyristor power unit retards the firing point for the first half wave after the start in burst firing mode The factory setting is an angle a 90 electrical This value can be altered over the range a 0 90 by the trimmer 10 angle set The factory setting will be satisfactory in most cases 2 current limit OO 5 3 load fail OO 6 4 full waveO O 8 output adjust 2 9 angle set O If it is nevertheless necessary to make an adjustment then the S minimum switch on current at the start of the burst is the criterion for setting the angle a Counter clockwise left advance the firing angle o Clockwise right retard the firing angle a 36 Power units 02 06 5 Commissioning 5 5 Load and part load failure monitoring This function is only available with the extra code TR or TO If there is a change in the load resistance during operation this is detected and indicated by the pa
35. single setpoint controller the full wave trimmer must be turned fully clockwise 5 1 2 Input signal attenuator Turning the full wave trimmer counter clockwise limits the maximum power output of the thyristor power unit When using the free running economy circuit both thyristor power units must be adjusted as described above When using the master slave economy circuit the adjustment is only made on the master power unit c Section 4 6 Free running economy circuit purely resistive loads und Section 4 7 Master slave economy circuit with resistive inductive loads Power units 02 06 33 5 Commissioning 5 2 Setting the base load A base load can be set in addition to the analog current input and the potenti ometer input Since these input signals are added together the input signal gain must be corrected by adjusting the full wave trimmer 7 current limit oo load fail OO full vvave OO output adjust Q 9 angle set E GS 100 33 base load t For instance if a heating system is to be operated with a 33 base load with the other 66 of the output being regulated by the controller then the proce dure is as follows Calculate the reduction factor of the controller signals In this example it would be 100 66 1 5 Multiply this factor by the intended base load setting In this case 1 5 x 3396 50 E 50 10V 90069 The factor 0
36. ting even for low levels of the setpoint input 1 with extra codes TR TO Power units 02 06 15 2 Operating modes For transformer loads the thyristor power unit operates in burst firing mode with a cut back retarded phase angle for the first half wave The factory set ting is an angle a 90 This value can be altered on the front panel over a range a 0 90 c Section 5 4 Setting the phase angle for the first half wave We recommend that this setting is not changed ee 16 Power units 02 06 3 Installation 3 1 Important installation notes Safety regulations Fusing A Interference suppression Wiring Connections Supply voltage Load connection Phasing The choice of cable installation and electrical connection of the instrument must meet the requirements of VDE 0100 Regulations for the Installation of Power Circuits with nominal voltages below 1000 V AC or the corresponding local regulations Electrical installation must only be performed by properly qualified personnel The unit must be completely disconnected from the supply line on all poles if there is a risk of contact with live parts during work on the unit In the event of a short circuit in the load circuit the power unit is protected by the built in semiconductor fuse Section 8 2 Replacing the semiconductor fuse Do not connect any additional loads to the output load terminals The e
37. tional to the power in the load R constant With the extra code TR TO it can be switched over to a P or I signal c Section 6 3 Summary of possible settings Actual power signal output Internal switches S7 S8 S9 2 1 0 0 P 0 1 0 2 0 0 1 Adjust output The signal at the actual povver output is a voltage in the range O 10V cor responding to O 10096 of the particular measurement range The trimmer 8 output adjust can be used to adjust the range end value Action Response Turn trimmer fully clockwise right Measurement range 0 100 corresponds to a signal 0 10V output adjust Cy Turn trimmer fully counter clockwise Measurement range 0 100 left corresponds to a signal 0 5V output adjust FE With P or I control loops a load current adaptation must be made for operating currents that are less than half the rated load current c Section 6 7 Load current adaptation only with extra code TR TO 46 Power units 02 06 6 Settings 6 7 Load current adaptation only with extra code TR TO With P or I control switch 15 must be in position 0 if the operating current is less than half the rated current This is to ensure proper measurement of the load current for the subsidiary control loop the current limiting and the over current low current detection The factory setting must not be altered on the 150A and 250A d versi
38. transport Please note that we cannot accept any responsibility for damage caused by ESD electrostatic discharge Power units 02 06 1 Introduction 1 2 Typographical conventions 1 2 1 Warnings A h gt The signs for Danger and Caution are used in this manual under the following conditions Danger This symbol is used where there may be danger to personnel if the instruc tions are disregarded or not followed accurately Caution This symbol is used where there may be damage to equipment or data if the instructions are disregarded or not followed accurately Caution This symbol is used if precautions must be taken when handling electrostati cally sensitive components 1 2 2 Note signs Note This symbol is used to draw your special attention to a remark Reference This symbol refers to additional information in other manuals chapters or sections Footnote Footnotes are comments that refer to specific parts of the text Footnotes consist of two parts 1 The marking in the text arranged as continuous superscript numbers 2 The footnote text at the bottom of the page in a smaller typeface than the main text and preceded by a number and a stop Handling instructions This symbol marks the description of a required action The individual steps are indicated by asterisks for example Disconnect the instrument completely from the supply Remove the instrument cover Power units 02 06
39. y voltage for the control d electronics be switched on before the voltage for the load This is especially important for operating transformer loads and re sitive loads with a large variation between hot and cold resistance The control connections inputs and outputs are designed for safety sepa ration from the supply line input SELV In order not to diminish this safety separation all connected circuits must also have safety separation The auxiliary voltages which are required must be safe extra low voltages SELV Connections must only be wired up by properly qualified A personnell 3 2 Filtering and interference suppression In order to prevent radio frequency interference such as would occur with phase angle control electrical apparatus and systems must have interference suppression implemented The control electronics of the thyristor power units conforms to the EMC Di rective EN 61 326 However modules such as thyristor power units have no use by themselves but only as a component function within a system For this reason the load circuit of the power unit must have suitable interference suppression filters fit ted by the system provider Specialist companies have appropriate ranges of filters available to deal with these problems Such filters are normally supplied as complete modules that are ready to be connected up 3 3 Installation site and climatic conditions The installation site should be as far as poss

B 70.9040.0 Operating Instructions

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