RS Elektroniksysteme GmbH - Thyristor controller Tyco-3Ph, Tyco-3Ph/SP Elektroniksysteme GmbH Development and production of electronical systems Eichelreuth 13 83224 Grassau Phone: +49 8641 598360 Fax: +49 8641 598364 E-Mail: [email protected] Internet: http://www.rs-steiner.com Start-up Instructions Thyristor controller Type: Tyco-3Ph, Tyco-3Ph/SP L1 L2 L3 Tyco-3Ph... Tyco-3Ph/SP... Content Page 1. General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2. Installation of the thyristor controller Tyco-3Ph, Tyco-3Ph/SP . . . . . . . . . . . 3 3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4. Meaning of the clamp connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5. Description of the front side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 6. Meaning of the control inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7. Basic circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7.1 Basic circuit for Tyco-3Ph... or Tyco-3Ph/SP with controlclamps . . . . . . . 11 8. Survey of the individual types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 9. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Version: 2014/10/30 | 1 RS Elektroniksysteme GmbH - Thyristor controller Tyco-3Ph, Tyco-3Ph/SP 1. General information The situations in which thyristor controllers have to be employed can be found in all the areas where greater resistor and inductive loads have to be controlled (e.g. industrial heating systems, tems, plastics processing, transformers, infrared elements, etc.) Because of its modular, compact assembly and the controlling with a continuous control signal these power controllers have to be regarded as a perfect final controlling device for the industrial power controlling. The power device of the thyristor controllers consists of six thyristor moduls, an isolated heat sink and the control unit. On account of the use of function modules the adaptation to any application is one of the largest advantages of these devices. Type description: Tyco-1Ph... Tyco-1Ph/SP... Tyco-3Ph... Tyco-3Ph/N... Tyco-3Ph/SP... Tyco-3Ph/SP/N... alternating current power controller, phase angle control for single phase systems alternating current power controller for multicycle control three phase controller, phase angle control for three phase systems three phase controller, phase angle control for three phase systems with neutral point connnnection (option) three phase controller for multicycle control three phase controller for multicycle control with neutral point connection (option) Construction: The thyristor controller agrees with VDE 0558 part 1 and VDE 0160 table 4. The thyristor controller Tyco-3Ph... is assembled modularly. It consists of three basic elements: • power element with cooling system and thyristor modules • control unit with firing and control board (diagnostic display, control outputs, etc.) Application of Tyco-3Ph/SP... (Tyco-3Ph...) and Tyco-3Ph/SP/N... (Tyco-3Ph/N...) When using the load in neutral or delta connection the type: Tyco-3Ph/SP... is used. Here the connectors L3 - T3 are bridged in order to realize a flow of current due to the linked-phase voltage and the ignition of the semiconductor at zero crossing. The type: Tyco-3Ph/SP/N... and Tyco-3Ph/N.... is using when the star point of the load is connected with the neutral wire. | 2 RS Elektroniksysteme GmbH - Thyristor controller Tyco-3Ph, Tyco-3Ph/SP 2. Installation of the thyristor controller Tyco-3Ph, Tyco-3Ph/SP The thyristor controller (IP 40) should be mounted vertically in a housing. The upper and lower side of the heat sink have to be kept free to allow cooling air to circulate freely. Controllers must be mounted on a flat surface to ensure that cooling air is channelled to the heat sink. The thyristor configuration is indifferent to the order of the supply phase rotation. It is the user´s responsibility to ensure that the nominal values of the thyristor unit are compatible with the conditions of installation and operation before commissioning the the thyristor unit. Additional points must be considered when mounting the unit: • Vibration free environment • Protection against hazardous environments • Protection against dust and humidity Please avoid to mount other components in distance of 100mm around the controller as the cooling system can be affected. The housing design according to IP 54 (Option) can be fixed in places which are not protected from dust and humidity. Wiring the device: The mains connections L1, L2, L3, (N) have to be connected by using a disconnecting switch and usual fuses. The connection for mains cable and the connections for controlling have to be laid in channels and protector tubes. The electric installation always has to comply with the essential protection requirements of the European Low Voltage Directive 2006/95/EG and Electromagnetic compatibility Directive 2004/108/EG. 50-100mm 50-100mm (gn) Betrieb Ready (rt) Störung Fault (gn) Start (or) Run U Last 100% U Load 100% S1 S2 Aussteuerung Level Tyco-3Ph TAnlauf Tim-e Ramp up 2,5 0 5 Sek 7,5 10 | 3 RS Elektroniksysteme GmbH - Thyristor controller Tyco-3Ph, Tyco-3Ph/SP 3. Operation To begin with, all electronical connections have to be established according to the circuit diagrammes L1, L2, L3, (N), T1, T2, T3. The thyristor control has to be connected to the mains according to the electric regulations (Low Voltage Directive) so that they can be separeted by disconnecting switches (e.g. load interrupter, contactor etc.) from the mains. Cabling must be performed by personnel who are qualified to work low voltage electrical equipment. Before any connection or disconnection, make sure that the power and control cables and wires are isolated from the voltage sources. Recommended connection: The mains connections, the connection to the load and the control connections have to be laid in separate cables. In order to avoid faults the electronic control connections should be separated from the power wires and/or contactor control wires and one should twist the control wires. In order to reduce risks related to the effects of electromagnetic interference depending on the installation of the product please consider the rules for electromagnetic compatibility. Fuses: The net-lateral security depends on the recommended and/or the used cross-section of a wire and has to be made according to DIN 57100 part 430/VDE 0100 part 430/6.81 (Low Voltage Directive). Common information: Thyristor units for phase angle (Tyco-1Ph... and Tyco-3Ph...) are produced to control resister and inductive loads. The controlling of the devices is achieved by using continuous signals (0-10V or 0-20mA). The phase control angle and/or the switch on-off relation at multicycle control (Tyco-1Ph/ SP... and Tyco-3Ph/SP...) will be continuously controlled by the control unit in order to receive a sufficient linearity between thyristor controller input and power output. Apart from these series we also produce three-phase thyristor units, which cover the upper current range to 1600A. These devices are also available within a short time. | 4 RS Elektroniksysteme GmbH - Thyristor controller Tyco-3Ph, Tyco-3Ph/SP 4. Meaning of the clamp connections Clamps 1-2 Function start 3-4 reset (key) 5-6 PTC-input State closed open actuated Description of the functions controlling activated stand-by, ready for operation reset faults (e.g: over-temperature, PTC-input, phase failure, low voltage) switch off of power unit on overload (release of PTC or bridge is open) connection without PTC-sensor bridge 7 Ucontrol-input 8 ground (GND) 9-10 inhibited 11 inverse input 12 13-14-15 16-17-18 PWM-input fault relay output relay output S2 19-20-21 relay output S1 22-24 23 auxiliary voltage not connected 0-10V, 0-20mA, 2,5- input of voltage and current signal 10kΩ and potentiometer adjustment (supply: Ground, Cl. 8) for using of current, voltage, inverse, PWM and potentiometer input closed output voltage on T1, T2 T3 open inhibit of power unit 10-0V input of inverse voltage signal (op(supply: Ground, Cl. 8) tion) 5V/5-10kHz input for impule signal (vt = 0-1) 13-14 closed switching at fault 16-17 closed switching at 100% ULoad 19-20 closed 230V/50-60Hz n.c. Switch (Ri) 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 Uref Start 0 ... 20 mA 0 ... 10 V Ust (10VDC) switching if voltage at T1, T2, T3 > 0V internal voltage supply 10V-0V PWM (invers) Reset 2,5...10kOhm n.c. 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 Uref (10VDC) Start Ust Switch Switch (Ri) (U) 0...20mA SP 0...10V Option: Switching mode (phase angle or multicycle control) by the help of “Switch (U)” PH 10V-0V PWM (invers) Reset 2,5...10kOhm | 5 RS Elektroniksysteme GmbH - Thyristor controller Tyco-3Ph, Tyco-3Ph/SP 5. Description of the front side green (gn) Betrieb Ready (rt) Störung Fault LED 1 (gn) Start (or) Run S1 U Last 100% LED 2 (S1) S2 U Load 100% Aussteuerung Level Tyco-3Ph TAnlauf Time Ramp up 2,5 0 5 Sek green lights as soon as connection 1-2 (start) are bridged orange lights as soon as voltage on T1, T2, T3 > 0V LED 3 (S2) yellow lights as soon as load voltage has reached 100% LED 4 yellow lights depending on the level of the load voltage Tramp up serves for adjusting the ramp-up time 0-10s (on PWMcontrolling: 0-10s) 7,5 10 red ready for use as soon as auxiliary voltage is on terminals (22-24) lights at fault and outputs T1, T2, T3 will be switched off Uload ~~ 100 % Start S1 green Run S1 orange Uload 100% S2 switching function S1 was accomplished (connectors S1 and LED 2 (S1) (orange) are activated at the same time) switching function S2 was accomplished (connectors S2 and LED 3 (S2) are activated at the same time) tan | 6 green green green green green 2 3 4 5 6 * no change green 1 * * State • auxiliary voltage at ter. 22 and 24 • device is ready for use green * * • “Start” is enabled ( ter. 1 and 2 connected) orange * yellow • device is ready for use 0-100% • “Start” is enabled • ULoad amounts to 0-100% • LED 4 lights depening on the input voltage 0-100% orange yellow yellow • device is ready for use 100% • “Start” is enabled • ULoad is 100% • LED 4 lights 100% orange yellow yellow • device is ready for use 100% • “Start” was disabled (ter. 1 and 2 open) • LED 2 (S1) lights red for a short moment • LED 2, 3, 4 die out orange * yellow • device is ready for use 100-0% • “Start” was disabled (ter. 1 and 2 open) • LED 2 (S1) lights red for a short moment • LED 2 and 4 die out * LED 2 LED 3 Pos. LED 1 LED 4 (S1) (S2) Indicating LEDs during operation: 0-100% 100% 100% 0-100% 0V 0V Control voltage at the beginning ter. 1617 are closed; as soon as LED 3 (S2) dies out, ter.17-18 are closed ter. 16-17 closed ter. 17-18 closed ter. 17-18 closed S2-relay-output (at the same time with LED 3) ter. 17-18 closed at the beginning ter. 19-20 ter. 17-18 closed are closed; as soon as LED 2 (S1) dies out, ter. 20-21 are closed at the beginning ter. 19-20 are closed; as soon as LED 2 (S1) dies out, ter. 20-21 are closed ter. 19-20 closed ter. 19-20 closed ter. 20-21 closed S1-relay output (at the same time with LED 2) ter. 20-21 closed RS Elektroniksysteme GmbH - Thyristor controller Tyco-3Ph, Tyco-3Ph/SP | 7 green green * 9 * no change red 8 green * red * * • device is ready 0-100% for use • “Start” is enabled • fault signal is flashing • device is ready 0-100% for use • “Start” is enabled LED 2 LED 3 Control LED 4 State (S1) (S2) voltage * * * • device is ready 0-100% for use • fault signal is flashing 7 Pos. LED 1 Indicating LEDs at fault: S2-relayFault output ter. 17-18 • PTC released closed • ter. 5-6 open check ter. 5 and 6 for proper connection (e.g. bridge, PTC-sensor, contacts) • cool down the device • check load • check power input • switch-off temperature threshold is at approx. 85°C Solution ter. 20-21 ter. 17-18 no operation closed closed check ter. 9 and 10 (closed) • temperature exceedance of heat sink • overload • too high load current • ambient temperature exceedance • one or more phases • check connections are not connected L1, L2, L3 with the net L1, L2, • check mains voltage L3 • device reacts to • undervoltage mains voltage smaller than 300V ter. 20-21 ter. 17-18 cf. pos. 7 cf. pos. 7 closed closed S1-relayoutput ter. 20-21 closed RS Elektroniksysteme GmbH - Thyristor controller Tyco-3Ph, Tyco-3Ph/SP | 8 RS Elektroniksysteme GmbH - Thyristor controller Tyco-3Ph, Tyco-3Ph/SP 6. Meaning of the control inputs Controlling with voltage signal: Switch (Ri) Clamp: set 0-10V (Ri>50kΩ) 7 input signal (0-10V) 8 GND Controlling with current signal: Switch (Ri) Clamp: set 0-20mA 7 8 input signal (0-20mA ) GND Controlling with potentiometer 2,5-10kΩ: Switch (Ri) Clamp: set 0-10V (Ri>50kΩ) 2 reference voltage (10V, supply voltage for potentiometer) 7 sliding contact 8 GND Controlling with inverse signal (option): Switch (Ri) Clamp: set 0-20mA 11 8 signal input 10-0V GND Controlling with PWM: Switch (Ri) Clamp: set 0-20mA 12 8 signal input 5V, 5-10kHz GND Annotation: When using PWM controlling the ramp-up time can be set within the interval of 0-10s. | 9 7. PE * F2 (N) L1 L2 L3 or or or T1 T2 T3 Tyco-3Ph... Tyco-3Ph/SP... 22 24 (L1) F1 Load or: L1 L2 L3 N PE * F2 (N) L1 L2 L3 PE Load or: N (connection for neutral point) T1 T2 T3 Tyco-3Ph/N... Tyco-3Ph/SP/N... 22 24 (L1) F1 Attention! If the star point of the load is connected with the neutral wire the type Tyco-3Ph/N... and Tyco-3Ph/SP/N... must used. * For isolate you can use plug connection, fuses, circuit-breakers, load-breakers and residual current devices (RCDs). Contactor, however, can be used only in exceptional cases and due to isolate. L1 L2 L3 N PE Basic circuits RS Elektroniksysteme GmbH - Thyristor controller Tyco-3Ph, Tyco-3Ph/SP | 10 RS Elektroniksysteme GmbH - Thyristor controller Tyco-3Ph, Tyco-3Ph/SP Basic circuit for Tyco-3Ph... or Tyco-3Ph/SP with controlclamps L1 L2 L3 N PE F2 F1 L1 L2 L3 Tyco-3Ph... Fault Relay S2 100% Output S1 Run (L1) n.c. Uref (10VDC) Controlclamps PE Switch (N) (Ri) 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 0...20mA 0...10V T1 T2 T3 Ust or Lock Reset * PTCInput * or 10V-0V PWM (invers) 2,5...10kOhm Start or Load 0...10V 0V or 0...20mA *Only if required Device version: Switchable between Tyco-3Ph... and Tyco-3Ph/SP... L1 L2 L3 N PE F2 F1 L1 L2 L3 Tyco-3Ph... Tyco-3Ph/SP... Fault Relay S2 100% Output switchable to SP S1 Run (L1) n.c. (N) 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 Controlclamps Uref (10VDC) 7.1 Start *Only if required Switch Switch (Ri) (U) T1 T2 T3 Ust or Lock Reset * PTCInput * 2,5...10kOhm PE or 10V-0V PWM (invers) or Load 0...10V 0V or 0...20mA | 11 RS Elektroniksysteme GmbH - Thyristor controller Tyco-3Ph, Tyco-3Ph/SP 3 10 16 23 33 Dimensions WxHxD [mm] Tyco-3Ph 05 5 10 16 1,5 Tyco-3Ph 15 15 25 25 2,5 Tyco-3Ph 25 25 30 35 4 Tyco-3Ph 35 35 40 50 6 Tyco-3Ph 50 50 60 63 10 Errors and technical modifications excepted (Date: 2012/01) Weight [kg] Max. power [kW] Rec. crosssection [mm2] Mains fuse [A] Rec. semiconductor fuses [A] Max. load current [A] Survey of the individual types Type * 8. 1,45 1,65 1,85 1,95 1,95 109x200x140** 139x200x140 139x200x140 139x200x140 139x200x140 * The given details also apply to the version with multicycle control Tyco-3Ph/SP... ** without external fan The given values refer to the operation voltage of 3x400V AC. The values given for overload refer to a surrounding temperature exceed of max. 50°C and an installation altitude of 1000m. Semiconductor fuses can be ordered optionally. W Ø=6 fan 180 200 H D Ø=6 W D 55 fan 109 H 139 | 12 RS Elektroniksysteme GmbH - Thyristor controller Tyco-3Ph, Tyco-3Ph/SP 9. Technical data Tyco-3Ph Tyco-3Ph Tyco-3Ph Tyco-3Ph Tyco-3Ph 05 15 25 35 50 Voltage of power circuit 400V AC +/- 15% (optional: 110V, 230V, 500V) Rated controller current 5A 15A 25A 35A 50A Auxiliary voltage 230V AC (optional: internal auxiliary voltage) Frequency 45-65Hz, self-synchronizing • 0-10V • 0-20mA Input • potentiometer: 2,5-10kΩ • 10-0V inverse input (option) • 5V/5-10kHz input for PWM Input resistance switchable input resistance: 500Ω, 50kΩ phase failure control and temperature exceedance control Protetction system (red LED “Fault“ and switch-off) LED-Display operation, “Start”, “Run”, “100% ULoad”, “Fault”, level Possible adjustments ramp-up time: 0-10s, on PWM controlling: 0-10s • fault condition: ter. 13,14 closed; Load: 2A, 230V AC, AC1; • S1-relay output: ter. 19,20 closed; Load: 2A, 230V AC, Control outputs AC1; • S2-relay output: ter. 16,17 closed; Load: 2A, 230V AC, AC1; • L1, L2, L3 input voltage Power terminals • T1, T2, T3 output voltage Kind of controlling phase angle (optional: multicycle control) Power loss 1,1W/A Operating temperature 0-50°C Storage temperature -10-70°C Humidity 5-95% relative humidity, not condensing Enviroment dry and non-conducting environments Max. altitude 1000m Weight 1,45kg 1,65kg 1,85kg 1,95kg 1,95kg Protection IP 40 Installation vertically, power terminals below Dimensions (WxHxD) 109(with fan 139)x200x140mm Mounting for screw mounting in a housing DECLARATION OF CONFORMITY: 2006/95/EC (low voltCE-marking age directive), EMC Directive: 2004/108/EC for industrial environments Regulations VDE 0160, EN 60204 Errors and technical modifications excepted (Date: 2012/01) | 13
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