JUMO TYA 202 User manual

JUMO TYA 202
SCR Power Controller
in a three-phase economy circuit
B 709062.0
Operating Manual
2011-07-02/00561073
709062/8-01-150
709062/8-01-200
709062/8-01-020
709062/8-01-50 709062/8-01-100
709062/8-01-250
709062/8-01-32

All parameter settings are described in detail in the chapter "Configuration".
This operating overview shows all possible parameters of the device series.
Depending on the order specifications or current configuration, any parameters that are not required are hidden.

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Content
1 Introduction..................................................................................7
1.1 Preface ........................................................................................................ 7
1.2 Typographical conventions ....................................................................... 8
1.2.1 Warning signs ...................................................................................................... 8
1.2.2 Note signs ............................................................................................................ 9
1.2.3 Perform an action ................................................................................................ 9
1.2.4 Representation .................................................................................................... 9
1.3 Order specifications ................................................................................ 10
1.3.1 Scope of delivery ............................................................................................... 10
1.3.2 Accessories ........................................................................................................ 11
1.3.3 General accessories .......................................................................................... 11
1.4 Brief description ....................................................................................... 12
1.5 Standards, approvals and conformity .................................................... 13
2 Installation..................................................................................15
2.1 Important installation notes .................................................................... 15
2.1.1 Ambient conditions ........................................................................................... 16
2.1.2 Filtering and interference suppression ............................................................ 16
2.1.3 Permissible load current depending on the ambient temperature ............... 17
2.1.4 Wall mounting with screws (ex factory) ........................................................... 18
2.1.5 Fixing onto DIN rail (accessories) .................................................................... 21
2.2 Dimensions ............................................................................................... 22
2.2.1 Type 709062/8-0X-020-XXX-XXX-XX-25X ........................................................ 22
2.2.2 Type 709062/8-0X-032-XXX-XXX-XX-25X ....................................................... 23
2.2.3 Type 709062/8-0X-050-XXX-XXX-XX-25X ........................................................ 24
2.2.4 Type 709062/8-0X-100-XXX-XXX-XX-25X ........................................................ 25
2.2.5 Type 709062/8-0X-150-XXX-XXX-XX-25X
Type 709062/8-0X-200-XXX-XXX-XX-25X ........................................................ 26
2.2.6 Type 709062/8-0X-250-XXX-XXX-XX-25X ....................................................... 27
2.2.7 Clearances (all types) ........................................................................................ 27
3 Electrical Connection................................................................29
3.1 Plug-in screw terminals ........................................................................... 29
3.1.1 Type 709062/8-0X-20-XXX-XXX-XX-25X .......................................................... 29

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Content
3.2 Cable lugs and plug-in screw terminals ................................................ 30
3.2.1 Type 709062/8-0X-032-XXX-XXX-XX-25X ........................................................ 30
3.2.2 Type 709062/8-0X-050-XXX-XXX-XX-25X ........................................................ 31
3.2.3 Type 709062/8-0X-100-XXX-XXX-XX-25X ........................................................ 32
3.2.4 Type 709062/8-0X-150-XXX-XXX-XX-25X
Type 709062/8-0X-200-XXX-XXX-XX-25X ........................................................ 33
3.2.5 Type 709062/8-0X-250-XXX-XXX-XX-25X ........................................................ 34
3.3 Connection diagram ................................................................................ 35
3.3.1 Three-phase economy circuit, Master/Slave for resistive loads in star, delta
circuit or transformer loads (resistive-inductive) ........................................... 37
4 Operation....................................................................................39
4.1 Display after switch-on of the device .................................................... 39
4.1.1 Display and control elements ........................................................................... 39
4.1.2 Display of measured values .............................................................................. 40
4.1.3 Display in the configuration level ..................................................................... 41
4.1.4 Display of error messages and particular statuses ....................................... 42
4.2 Operator level ........................................................................................... 43
4.2.1 Device data ........................................................................................................ 43
4.2.2 Power controller ................................................................................................ 43
4.2.3 Set point value configuration ........................................................................... 44
4.2.4 Monitoring .......................................................................................................... 45
5 Configuration .............................................................................47
5.1 Configuration level ................................................................................... 47
5.1.1 Device data ........................................................................................................ 48
Temperature unit.............................................................................................................. 48
Display contrast ............................................................................................................... 48
Switch off......................................................................................................................... 48
Apply factory settings.................................................................................................... 48
5.1.2 Power controller ................................................................................................ 48
SCR control ..................................................................................................................... 48
Cascade control............................................................................................................... 49
Cycle time........................................................................................................................ 50
Min. duty cycle................................................................................................................. 50
a start............................................................................................................................... 50
Angle a start..................................................................................................................... 50
Soft start .......................................................................................................................... 50

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Content
Type of soft start.............................................................................................................. 51
Soft start duration............................................................................................................ 51
Current limiting ................................................................................................................ 51
current limit ...................................................................................................................... 51
Resistance limitation........................................................................................................ 52
Resistance limit value ...................................................................................................... 52
Dual energy management................................................................................................ 52
5.1.3 Analog inputs ..................................................................................................... 53
Current measuring range ................................................................................................. 53
Current measuring range, start........................................................................................ 53
Current measuring range, end......................................................................................... 53
Voltage measuring range................................................................................................. 53
Voltage measuring range, start........................................................................................ 53
Voltage measuring range, end......................................................................................... 53
5.1.4 Set point value configuration ........................................................................... 54
Default set point value ..................................................................................................... 54
Default value in the event of a fault.................................................................................. 54
Value in the event of a fault.............................................................................................. 54
Maximum control variable ............................................................................................... 54
Base load......................................................................................................................... 55
5.1.5 Monitoring .......................................................................................................... 56
Limit value monitoring...................................................................................................... 56
Min. limit value alarm ....................................................................................................... 56
Max. limit value alarm ...................................................................................................... 56
Limit value hysteresis....................................................................................................... 56
Load monitoring............................................................................................................... 57
Limit value, load monitoring............................................................................................. 57
Load type, load monitoring.............................................................................................. 57
Teach-in type, load monitoring........................................................................................ 57
Monitoring of the supply voltage drop............................................................................. 57
5.1.6 Binary inputs ...................................................................................................... 58
Ext. current limiting.......................................................................................................... 58
External current, limit value.............................................................................................. 58
Key lock ........................................................................................................................... 58
External display lighting................................................................................................... 58
Control direction, inhibit input ......................................................................................... 58
Control direction, binary input1 ....................................................................................... 59
Control direction, binary input2 ....................................................................................... 59
5.1.7 Binary output ...................................................................................................... 60
Control direction, binary output....................................................................................... 60
5.1.8 Actual value output ............................................................................................ 61
Signal type of actual value output ................................................................................... 61
Value to be output ........................................................................................................... 61
Signal range
start value ........................................................................................................................ 61
Signal range

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Content
end value ......................................................................................................................... 61
5.1.9 RS422/485 .......................................................................................................... 61
Baud rate ......................................................................................................................... 61
Data format ...................................................................................................................... 61
Device address ................................................................................................................ 61
Min. response time .......................................................................................................... 61
5.1.10 PROFIBUS-DP .................................................................................................... 62
Device address ................................................................................................................ 62
Data format ...................................................................................................................... 62
5.1.11 Changing codes ................................................................................................. 62
Code Manual mode ......................................................................................................... 62
Code User level................................................................................................................ 62
Code Config.level ............................................................................................................ 62
5.2 Configuration example ............................................................................ 63
6 Special device functions...........................................................65
6.1 Detection of load faults ........................................................................... 65
6.1.1 Teach-In .............................................................................................................. 67
6.2 Manual mode ............................................................................................ 68
6.2.1 Default set point value in manual mode .......................................................... 68
6.2.2 Configuring the teach-in (prerequisite for teach-in in manual mode) .......... 68
6.2.3 Performing teach-in in manual mode .............................................................. 69
6.3 Default set point value via potentiometer ............................................. 70
6.4 Dual energy management ....................................................................... 70
6.5 Cascade control ....................................................................................... 73
6.5.1 Closed control loop without cascade control ................................................. 73
6.5.2 Closed control loop with a subordinate control ............................................. 74
6.6 Resistance limitation (R control) ............................................................ 79
6.7 Current limiting ........................................................................................ 80
6.8 a start ........................................................................................................ 80
6.9 Monitoring of the supply voltage drop ................................................... 80
6.10 Firing-pulse inhibit ................................................................................... 81
7 Setup program ...........................................................................83
7.1 Hardware and software, minimum requirements ................................. 83
7.1.1 Notes for Windows 2000/XP: ............................................................................ 83

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Content
7.2 Installation ................................................................................................ 84
7.3 Program start ........................................................................................... 86
7.4 Forgotten the code? ................................................................................ 87
7.5 Changing the language of the device texts ........................................... 88
8 Fault messages and alarms......................................................89
8.1 Binary signal for collective fault ............................................................. 93
8.2 Replace defective semi-conductor fuse ................................................ 94
8.2.1 Accessories: Semi-conductor fuses ................................................................ 95
8.2.2 Semi-conductor fuses type 709062/8-0X-20... ................................................ 95
8.2.3 Semi-conductor fuses type 709062/8-0X-32... ................................................ 96
9 What to do if ..............................................................................99
10 Technical data..........................................................................101
10.1 Voltage supply, load current ................................................................. 101
10.2 Electrical isolation ................................................................................. 101
10.3 Analog inputs (only master) .................................................................. 102
10.4 Analog output (actual value output, only master) ............................... 102
10.4.1 Display and measuring accuracy ................................................................... 102
10.5 Binary inputs ........................................................................................... 102
10.6 Binary output (fault signal output, only master) .................................. 102
10.7 General characteristic data .................................................................. 103

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Content

2011-07-01/00561073 [SCR Power Controller TYA202] 7
1 Introduction
1.1 Preface
Please read this operating manual before starting up the device.
This operating manual is valid from device software version [256.01.02].
Keep the operating manual in a place accessible to all users at all times.
We welcome any suggestions you may have to help us improve this operating
manual.
Phone [phone]
Fax [phone]
Service hotline For technical questions
Phone support in Germany:
Phone: [phone] or -653 or -899
Fax: [phone]
Email: [email protected]
Austria:
Phone: [phone]
Fax: [phone]
Email: [email protected]
Switzerland:
Phone: +41 1,928 24 44
Fax: [phone]
Email: [email protected]
A
The power controller produces the power required at the analog input or in
manual mode. Safety devices operating independently of the power controller
must be fitted to safely switch off the downstream heating process in the event
of temperature overranges.
A
The power controller may only be operated with original JUMO semi-
conductor fuses.
Please check that the correct spare part has been used during fuse
replacement.
H
All necessary settings are described in this Operating Manual.
If the power controller is handled in any way that is not described in the
Operating Manual or that is expressly forbidden, this will jeopardize your
warranty rights.
Please contact the nearest subsidiary or the head office should you encounter
any problems.
B

1 Introduction
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1.2 Typographical conventions
1.2.1 Warning signs
Caution
Caution
ESD
Dangerous
voltage
Hot
surface,
fire hazard/
danger of burns
E
When accessing the inner parts of the device and returning device modules,
assemblies or components, please observe the regulations as per EN 61340-
5-1 and EN 61340-5-2 "Protection of electronic devices from electrostatic
phenomena". Only use ESD packaging for transport.
Please note that we cannot accept any liability for damage caused by ESD
(electrostatic discharge).
ESD=Electro Static Discharge
V
This symbol is used if there is a risk of injury to persons if the
instructions are ignored or not followed correctly.
A
This symbol is used if there is a risk of damage to equipment or
data if the instructions are ignored or not followed correctly.
E
This symbol is used where special care is required when handling
components susceptible to damage through electrostatic
discharge.
This symbol indicates dangerous voltage that will cause electric
shock if you come into contact with live components.
This symbol indicates the presence of a hot surface that can cause
burns if touched.
Do not install any heat sensitive components and devices close to
the power controller.

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1 Introduction
1.2.2 Note signs
Note
Reference
Footnote
1.2.3 Perform an action
Action to be
performed
Vital text
Chain of
command
1.2.4 Representation
Keys
H
This symbol indicates particularly important information.
v
This symbol refers to further information in other manuals,
chapters or sections.
abc1Footnotes are remarks referring to specific points in the text.
Footnotes consist of two parts:
A marker in the text and the footnote text itself.
The markers in the text consist of consecutive superscript
numbers.
hInsert
plug
This symbol indicates the description of an action to be
performed. The individual steps are marked by an asterisk.
This text contains important information, and it is vital that you
read it before proceeding.
B
Configuration level ➔Power
controller ➔Operating mode
Small arrows between words are intended
to facilitate faster location of parameters in
the configuration level.
Keys are shown as symbols or text.
Key combinations are shown with a plus sign.

1 Introduction
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1.3 Order specifications
The type plate is affixed to the right-hand side of the case.
1.3.1 Scope of delivery
1 Operating Manual B70.9062.0
1 SCR power controller in the version ordered
1:1 patch cable

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1 Introduction
1.3.2 Accessories
Semi-
conductor fuses A semi-conductor fuse is fitted in the power controller to protect the SCR module. The "LED Fuse" is lit red in the event of a fault.
vChapter 8.2 „Replace defective semi-conductor fuse“
1.3.3 General accessories
Part Load current
Inom. = IN
Sales No.
Super fast semi-conductor fuse 50A IN = 20A 70/00513108
Super fast semi-conductor fuse 80A IN = 32A 70/00068011
Super fast semi-conductor fuse 80A IN = 50A 70/00068011
Super fast semi-conductor fuse 160A IN = 100A 70/00081801
Super fast semi-conductor fuse 350A IN = 150A 70/00083318
Super fast semi-conductor fuse 350A IN = 200A 70/00083318
Super fast semi-conductor fuse 350A IN = 250A 70/00083318
Part Sales No.
Setup program 70.9061 TYA 201
(also runs for the TYA 202)
70/00544869
USB cable A-plug B-plug 3m 70/00506252
Mounting set for DIN rail installation:
Type 70.9062/8-01-20... 70/00555172
Types 70.9062/8-01-32 and 70.9062/8-01-50 70/00555527

1 Introduction
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1.4 Brief description
Device The JUMO TYA 202 represents a consistent further development of the JUMO
power controller technology and switches resistive-inductive loads via a three-
phase current economy circuit in the star/delta three-phase mode. The micro-
processor controlled power controller displays all parameters in a back-lighted
LCD display and is operated using the 4 keys on the front.
Application SCR power controllers are employed where larger resistive and resistive-in-
ductive loads have to be switched, e.g. in industrial kiln construction and in
plastics processing. The SCR power controller comprises SCRs connected in
anti-parallel, the insulated cooling body and the control electronics.
Installation SCR power controllers units up to a load current of 32A can be either clipped
onto a 35 mm mounting rail or fitted to the wall on a mounting plate. Devices
with a load current exceeding 32A have to be fitted to the wall.
Operating
modes The TYA 202 operates in burst-firing mode. In burst-firing mode, the first half- cycle can be optimally cut back by means of an adjustable phase angle for
driving transformer loads.
It is possible to preset a base load, and depending on the device type, to set a
current limit or a resistance limitation for the load.
A soft start can be set to avoid high starting or inrush currents.
Cascade
control Available cascade controls are U, U2, I, I2or P control. Therefore the control
loop is not affected by fluctuations in the supply voltage during the control
process.
Standards The SCR power controllers comply with VDE 0160 5.5.1.3 (5/88) and VDE
0106 Part 100 (3/83). Grounding is required in conformity with the regulations
of the responsible electric utility company.
Advantages - Teach-in function for the detection of partial load failure
- Network load optimization through dual energy management
- Transmission of the setup data is also possible without voltage supply to
the device (supply via USB port)

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1 Introduction
1.5 Standards, approvals and conformity
Test basis for the device characteristics is the Low Voltage Directive DIN EN
50178.
Test basis for the EMC Directive is DIN EN 61326-1.
Standard
Electrical connection DIN VDE 0100
Protection rating IP 20 panel-
mounting devices
DIN EN 60529
Climatic ambient conditions Class 3K3
Air temperature and rel. humidity DIN EN 60721-3-3
Storage temperature Class 1K5 DIN EN 60721-3-1
Operating conditions
Pollution degree
Overvoltage category
DIN EN 50178
Test voltages
Impulse withstand voltage
AC voltage RMS
DIN EN 50178
Residual current circuit breaker DIN EN 50178
Electromagnetic compatibility
Emitted interference
Interference resistance
DIN EN 61326-1
Class A- For industrial applications only
Industrial requirements
Mechanical tests/inspections:
Vibration test 3M2
Toppling test Class 2M1
IN EN 60068-2-6, DIN EN 60721-3-3
DIN EN 60068-2-31, DIN EN 60721-3-2
Inscriptions/labels, marking DIN EN 50178, DIN EN 61010-1
Approvals Standard
cUL applied for
(not for type: 70.9061/8-0X-20...)
508C Power Conversation Equipment
(Category NRNT2)
C22.2 NO. 14-05 Industrial Control Equipment
(Category NRNT8)
CE conformity Low Voltage Directives 2006/95/EC
Marking Directives 93/68 EEC
EMC Directives 2004/108/EC
Conformity Standard
RoHs 2002 / 95 EC

1 Introduction
14 2011-07-01/00561073 [SCR Power Controller TYA202]

2011-07-01/00561073 [SCR Power Controller TYA202] 15
2 Installation
2.1 Important installation notes
Safety regula-
tions
kThe choice of cable material, the installation and the electrical connection
of the device must conform to the requirements of VDE 0100 "Regulations
on the Installation of Power Circuits with Nominal Voltages below AC
1000 V" or the appropriate local/national regulations.
kOnly allow qualified electricians to carry out the electrical connection.
kAn isolating switch must be connected between the supply and the device
to allow disconnection of the device (all poles) from the voltage supply be-
fore the inside of the device is accessed.
kClearance/safety distances in the device meet the requirements for double
insulation.
When mounting the connecting cable, ensure that the cables are fitted ac-
cording to regulations and that the safety gaps are maintained.
Fuse protection kFuse protection in accordance with VDE regulations must be installed for
the wiring of the voltage supply in the power section. The supply protection
can also be achieved by a circuit-breaker in the supply lead. This must be
dimensioned for the power consumption of the power controller.
kA semi-conductor fuse is installed to protect the controller in the event of a
ground fault/short circuit. In the event of a fault/defect, it may only be re-
placed by an original JUMO semi-conductor fuse.
vChapter 8.2 „Replace defective semi-conductor fuse“
Wiring Load and control cables should be laid separately if possible. Fuses (e.g. 2A
type Neozed) must also be fitted in the control circuit for lead protection.
PE connection hProvide a direct connection between the PE of the supply network and PE
of the power controller. Connect to the PE terminal.
The cross-section of the PE conductor must be at least as large as the cross-
section of the voltage supply conductors to the power section. If the protec-
tive earth conductor is not part of the supply cable or its sheathing, the chosen
conductor must have a cross-section of at least 2.5 mm2(if mechanically pro-
tected) or at least 4mm2(if the PE conductor is not mechanically protected).
vsee VDE 0100 Part 540
Check hthat the data given on the type plate (rated load voltage, load current) corre-
sponds to the data for the system.
hthat the rotary electrical field has clockwise phasing (if the economy circuit
configuration is used).
hthat the configuration e.g. of the analog inputs correspond to the wiring.
hOnly connect the analog input for default set point values to the master. The
slave receives its information via the patch cable.
Load
connection
hThe electronic switching device (2 antiparallel SCRs) are in circuit between
the terminals U1 and U2.
V

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hLoad leads and cables for control inputs should be routed separately as far
as possible.
hWire up the connections from supply line – SCR power controller – load as
per the wiring diagram, and check them.
Phase position The voltage supply for the control electronics and the load voltage
must have an identical phase position.
Control inputs The terminal strips for the control connections (inputs and outputs) are de-
signed for safety separation from the supply line input (SELV). In order not to
impair this safety separation, all connected circuits must also have safety sep-
aration. The auxiliary voltages which are required must be safe extra-low volt-
ages (SELV).
2.1.1 Ambient conditions
Incorrect use The device is not suitable for use in potentially explosive atmospheres.
Vibration, dust
and soiling Ensure that the installation site is free from vibrations, aggressive media and dust so that the ventilation slits do not become clogged.
Climatic
conditions - Relative humidity: 5...85 % without condensation (3K3 as per EN 60721)
- Ambient temperature range: 0 ... 45 °C (3K3 as per EN 60721-3-3)
- Storage temperature range: -30...70 °C Class 1K5
Avoid addition-
al heat
sources
hEnsure that the ambient temperature at the installation site is not increased
by other heat sources or heat accumulation.
- Do not install the controller too near to the heating process (kiln).
- Avoid exposure of the controller to direct sunlight.
Power dissipa-
tion Occurs in the form of dissipated heat at the cooling body of the master and slave device and has to be dissipated at the place of installation (e.g. in the
switch cabinet) according to the climatic conditions.
2.1.2 Filtering and interference suppression
In order to prevent radio-frequency interference, such as would occur with soft
start in phase-angle mode, electrical apparatus and systems must have inter-
ference suppression implemented.
The control electronics of the SCR power controller meets the EMC require-
ments of EN 61 326.
However, electrical modules such as SCR power controllers do not have any
purpose by themselves. They provide a function as part of a complete system
or installation.
Where applicable, the entire load circuit of the power controller must have
suitable interference suppression filters fitted in addition by the system provid-
er.
There are a number of specialist companies that provide appropriate ranges of

2011-07-01/00561073 [SCR Power Controller TYA202] 17
2 Installation
filters to deal with any interference problems. Such filters are usually provided
as complete modules, ready to be wired into the system.
2.1.3 Permissible load current depending on the ambient temperature
vChapter 8 „Fault messages and alarms“
45 50 60
75
20
200
T/°C
150
Load current/A
Reduction at a temperature of 45°C:
2%/Kelvin 70%
250
100
50
A
Destruction due to overheating:
During prolonged operation with maximum load current, the cooling body and
the area around it will heat up.
For this reason, at ambient temperatures above 45°C it is necessary to reduce
the maximum load current as shown in the diagram to prevent destruction of
the SCR module.
Ensure that the device temperature for master or slave shown on the display
does not exceed 100°C.
At a device temperature >100°C the message "Attention: High temperature"
appears.
At a device temperature >105°C, the load current is reduced in increments for
each degree of temperature increase by 10% of the rated current.
The power controller current is switched off completely at a device tempera-
ture >115°C.

2 Installation
18 2011-07-01/00561073 [SCR Power Controller TYA202]
2.1.4 Wall mounting with screws (ex factory)
The power controllers with load current 20...100A are fastened to a fire resis-
tant switch cabinet wall with 2 screws. The left-hand hole is better accessible
in the top area.
The power controllers with load current 150 ... 250A are fastened with 4
screws.
TYA202
20A
TYA202 32A
TYA202 50A