EST APC-TF Series User manual

MODEL
1125-2 Sankyok-dong, Puk-ku, Taegu, KOREA
TEL : [phone] A/S : [phone]
FAX : [phone]
mail : [email protected]
http://cafe.daum.net/EST-KOREA
ACTIVE POWER CONTROLLER
USER MANUAL
APC-TF Series
VER_2013.12

Copyright 2003-2013 CSM CO.,LTD
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ACTIVE POWER CONTROLLER
PRECAUTIONS
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.
ATTENTION
SAFETY
EARTH
Controller must be installed in electrical cabinets correctly
fan-cooled to ensure that condensation and pollution are
excluded.
The units are designed to be used at an ambient
temperature less than 40°C and 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. And this may in turn cause damage to the
components.
Overheating at overload driving can be produced.
Work after cool enough in case of do checking, full
equipment.
DANGER
AND
ATTENTION
DANGER
Precautions and description
Safety symbols
Item
This symbol is marking contents about danger (electric
shock, electrical impact etc..) that can happen by electric
problem.
This product of when repairs, shut off main power of
controller, controlled source and cooling - fan's power
certainly, and works after is discharged perfectly measuring
residual voltage in controller load side according to load's
kind
This symbol is marking contents of mistake or failure that can
happen serious missing incorrect operation or on sequences
for the installation of the power unit.
Please observe guideline of this manual certainly.
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 terminal block of the PCB.:

Copyright 2003-2013 CSM CO.,LTD
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GENERAL INTRODUCTION TO THE APC-TF SERIES
Warranty of quality and A/S regulation of product
Confirm ordering product specification and whether agree.
 Confirm whether it is no defect to damage or product while transport.
 Quality term of guarantee of this product is during 1 year when use normally.
 Being onerous service regulation and item;
- The case not to be a power unit PCB inside failure.
- The failure from the natural disaster is due.
- A failure occurrence as long as is by user's treatment carelessness and wrong repair or
nonprofessional repair.
- Damage (exaggeration harmonic inclusive) that occur exceeding rated voltage/rated current
- Due failure which not keep observance of user manual contents.
Observance item of power unit operation environment
 Wrong establishment place becomes factor that generate degradation of
product and unstable control. Below, please avoid place correspond to item.
- Place that there are a lot of moistures and air flow does not become well.
- Place that dust or impurities piles.
- Place that surrounding atmosphere temperature is high.
- Place that can mechanical vibration is heavy or deals mechanical impact directly
- Place that corrosive gas, flammable gas happens around.
- Is leaked in ceiling or place that dew forms.
- Place that receive direct influence in water, oil, medicines, stream, salt, iron etc.
- Obstacle by electrical inductive current is large place.
- Place that heat reduced scale by direct ray of light and radiant heat etc. happens.

Copyright 2003-2013 CSM CO.,LTD
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Understanding SCR Power Controls
When selecting SCR Power Controls, it is important to have a basic understanding of how
SCRs work. This will help you select the right SCR for your application.
•How SCR Power Controls Work
A silicon controlled rectifier (SCR) is a solid state switching device which can provide fast, infinitely
variable proportional control of electric power. Not only does this give maximum control of your heat
process, but it can extend heater life many times over other control methods. Since the SCR is solid
state, it can cycle on and off over a billion times, if properly used.
•PHASE ANGLE FIRED
controls proportionally turn on a percentage of each power line half cycle. This gives smooth,
infinitely variable application of power to the heaters. Imagine a light dimmer and how it provides
power to a light bulb. This method will provide the most precise control of heaters. Phase angle
fired SCR's will respond the fastest to load changes and provide maximum heater life.
Options including Voltage Limit, Soft Start and Current Limit are only available with Phase Angle
Fired SCR's.
•ZERO VOLTAGE SWITCHED ( ZERO VOLTAGE CROSSING)
controls proportionally turn on and off each full cycle of the power line cycle. By varying the
number of AC power line cycles, the SCR provides power to the heaters. With a variable time base,
the optimum number of cycles turned on/off is achieved. The switching is done at fractions of a
second during the zero voltage crossing of the power line cycles. For IR heating with a fast element,
you would see the elements flickering. On a ceramic heater, or more massive medium wave heater
you can control within very tight tolerances.
•ON/OFF CONTROL
works like a mechanical or mercury relay. When the SCR is turned on it fires full voltage into the
heater until the command signal turns it off.
•The advantages of SCR Controls over other temperature control methods
- Improved response time
- Closer process control
- Extended heater life
- Reduced maintenance costs
- Silent operation
- Reduced peak power consumption
Remember, a heating element is made of wire in most cases. If you use a mechanical relay to turn
on your heater, it will cycle on or off within 30 seconds or longer. The heater will expand and
contract, getting more and more brittle each time. This is called thermal shock. Temperature
overshoot may also occur. Relays also arc, spark and will burn out on a regular basis.

Copyright 2003-2013 CSM CO.,LTD
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POWER CONTROL SELECTION GUIDE
The SCR power control can deliver electrical power to heaters in several ways: phase angle
fired, zero voltage switched and on/off control.
Phase angle fired controls proportionally turn on a percentage of each power line half cycle.
This gives smooth, infinitely variable application of power to the heaters. It is the most precise
method of control. Phase angle firing can increase heater life
up to seven times depending on
heater type.
Phase angle firing also allows options such as soft start, voltage limit and current
limit. These options are not available with any other means of control.
Zero voltage switching controls proportionally turn on and off each full cycle of the power line.
By varying the number of AC power line cycles, the SCR provides power to the heaters. With a
variable time base, the optimum number of cycles turned on/off is achieved. This method
produces less RFI line noise than phase angle fired SCRs.
On/Off controls function the same way as a mechanical or mercury relay, but with the
advantage of much faster cycle times.
Chart below shows how to best match SCR power control with typical applications.

Copyright 2003-2013 CSM CO.,LTD
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APC-TF Series TECHNICAL SPECIFICATION
The Model APC-TF Series is a new generation SCR Active Power Controllers for use with resistive,
inductive loads. This unit features the optimum conditions heatsinks with remote analog set-point
value for precise control. Basic include diagnostic load failure detection, a wide scope fault
detection. Fault indicates when a shorted device or an open load is detected.
•APC-TF Series TECHNICAL SPECIFICATION
State items Technical Specification Remarks
Line-to-line voltage AC 220V / 380V / 440V ±10%
Nominal current
(per phase) 35A – 500A Less then
70%
External control signal
Analogue voltage 0 to 5V or 1 to 5V;
current 0 to 20mA or 4 to 20mA
Contact (ON/OFF mode)
Potentiometer for manual set-point
(5 V supply available).
Application Heater control
Controls
•PHASE ANGLE FIRED
•ZERO VOLTAGE SWITCHED ( ZERO VOLTAGE
CROSSING)
•ON/OFF CONTROL
Loads
Inductive load , Resistive load with a low -
temperature coefficient or short-wave infrared
elements
Supply frequency 50Hz and 60Hz (±2Hz) automatic selection
Soft control Soft Start / Stop , Soft up / down 0 – 10 sec
Output range 0 – 97% of the input line-to-line voltage
Ambient
Temperature
Operating : 0 to +40 ℃(+32 to +104 ℉)
Storage : -40 to +80 ℃(-40 to +176 ℉)
Insulation (1 min test) 2000Vac between power and earth and 3600Vac
between power and control
Cooling Natural convection for less then 70A ratings
Permanent fan-cooling for more then 90A rating
Alarm functions
- Over current trip
- Heatsinks over temperature detect
- Load failure detect
- Fuse failure detect
- SCR failure detect

Copyright 2003-2013 CSM CO.,LTD
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APC-TF Series Model identification
①Application
▷APC : ACTIVE POWER CONTROLLER
▷MSC : MOTOR SOFT-START CONTROLLER
②Phase
▷S : SINGLE-PHASE AC
▷T : THREE-PHASE AC
⑥Controls
▷P : PHASE-ANGLE CONTROL
▷Z : Fixed time base ZERO-CROSS CONTROL
④Line-to-line voltage
▷2 : 220V AC
▷3 : 380V AC
▷4 : 440V AC
▷6 : 690V AC
⑤Nominal current (per phase)
▷30A/40A/55A/70A/90A/110A/130A/160A/200A/250A/300A/400A/500A
⑦User option
③DISPLAY type of outside panel
▷N : LED information display
▷F : FND, 7-segment
▷L : LCD
•APC-TF Series Model identification
APC – TF3 – 100 – P -
①②③④ ⑤⑥⑦

Copyright 2003-2013 CSM CO.,LTD
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APC-TF Series DIMENSIONAL DETAILS
Single phase
40~90A
Single phase
110~500A and
Three phase
All models
*** More than nominal current 600A at order specification.
*** Dimensions of the upper product could be changed without notification for improving functions.
Model Nominal Current (A) H H` W W` D Mount
SN 25 106 96 75 62 70 M4
SN 40,55 180 170 65 56 126 M4
SF 40,55,70,90 195 181 133 114 148 M5
SF 110,130,160 271 258 123 83 185 M5
SF 200,250,300 300 286 173 130 220 M5
SF 400,500 395 381 173 130 230 M5
TF 30,40,55,70 252 238 173 130 170 M5
TF 90,110 300 286 173 130 220 M5
TF 130,160 395 381 173 130 230 M5
TF 200 415 397 262 200 243 M6
TF 250,300 456 440 262 200 243 M6
TF 400,500 510 485 310 200 260 M6

Copyright 2003-2013 CSM CO.,LTD
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- R, S, T : Main power input terminal labels.
-U, V, W : Load (heater) connection terminal labels.
- 4-20mA (+)(-) : Analogue input line
- Potentiometer for manual set-point : 10KΩ, External
- RUN / STOP : External contact, RUN or STOP
- AUTO/MANUAL : External contact, Automatic or Manual
operation
APC-TF Series
External form and wiring diagrams
•Automatic control
①
②
③
④
⑤
•Automatic with
remote control by
external potentio meter
•Manual operation
•ON/OFF control
•Product External form and description of the symbols
4-20mA (+)
4-20mA (-)
* The method of the RUN / STOP contact.
STOP RUN
①
②
③
④
⑤
4-20mA (+)
4-20mA (-)
10KΩ
External -
potentio-meter
①
②
③
④
⑤
①
②
③
④
⑤
AUTO MANUAL
Operation mode
Switch (PCB)
* Signal, control cables : Use the shield cable
(CVVSB: more then 0.75mm2)
* CVVSB : PVC INSULATED, COPPER WIRE
BRAID SHIELD AND PVC SHEATHED
CONTROL CABLE
•Manual with
remote control by
external potentio meter
External
potentio meter
10KΩ
AUTO MANUAL AUTO MANUAL AUTO MANUAL
⑥
⑦
AUTO/MAN
⑥
⑦
⑥
⑦
RUN/STOP
⑧
⑨
RUN/STOP
⑥
⑦
AUTO/MAN
⑧
⑨
RUN/STOP
⑧
⑨
⑧
⑨
AUTO/MAN
RUN/STOP
AUTO/MAN

Copyright 2003-2013 CSM CO.,LTD
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Explanation of product external form,
use terminology and function
•Explanation of product external form, use terminology and function
▷PHASE : 3 colors Light Emitting Diode, electric current value
indication of each phase.
RED : R-Phase , Yellow : S-Phase, Green : T-Phase
White : Average nominal current value
▷S.S : The time set for soft start, stop, up, down control.
(1-10 Sec)
▷MODE : Small type push button switch that select
value of a phase wanting to FND (7-segment).
▷P.W : It uses output voltage, current, conduction angle,
phase-shift and power factor to compute the power.
The “PW” potentio meter sets a limit on available
power from the power unit.
The adjustment range is 0 to 100% of the units rating.
▷O.C : Over-current trip is peak current sensing. This is important since the instantaneous peak current
can damage a SCR. The “OC” will shutdown the SCR within a half-cycle of AC current, usually
quick enough to protect the SCR.
A local or remote reset pushbutton must be pressed or complete removal of power to the SCR
Power Control is required to reset. Alarm relay output is available for alarming or shutdown.
The adjustment range is 10 to 115% of the unit’s current rating. When set-value less than 10%, do
not excess over-current detection.
▷PL L.E.D : Operation of PL L.E.D
* Running : Over a control output value 0 %, lighting hold
Control output value 0 %, lighting off
* Stop : Lighting off
* An input signal error (4-20mA) : 1 second cycle blinking
* P.W value 0 % : 2 second cycle blinking
▷Error status L.E.D
*OVER-CURRENT : Red color, lighting hold and alarm relay output is available for alarming or shutdown.
* OVER-TEMPERATURE : Red color, lighting hold and alarm relay output is available for alarming or shutdown.
* UNLOAD : Red color, load fault, SCR, FUSE or current transformer defect. During the make an analysis
about 10 second the led blinking and after lighting hold, alarm relay output is available for alarming .
* UNBALANCE : Optional function, red color, the load current of an each line-to-line the declination
over the 30%. During the make an analysis about 10 second the led blinking and after lighting hold,
alarm relay output is available for alarming .
* SCR FAULT : A current detection in a stopping condition, sell to SCR short fault.
Lighting hold and alarm relay output is available for alarming or shutdown.