JUMO B 70.9040 User manual

/00089951
Thyristor Power Units
B 70.9040
Operating Instructions
05.01

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Contents
1 Introduction ......................................................................................... 7
1.1 Preface .................................................................................................................... 7
1.2 Typographical conventions ................................................................................... 8
1.2.1 Warnings .................................................................................................................. 8
1.2.2 Note signs ............................................................................................................... 8
1.3 Description .............................................................................................................. 9
1.4 Type designation .................................................................................................... 9
1.4.1 Type extensions (extra codes) ................................................................................ 10
1.4.2 Standard accessories ............................................................................................ 10
1.4.3 Accessories ............................................................................................................ 11
1.5 Block diagram ...................................................................................................... 11
1.6 Front panel indicators and adjustments ............................................................ 12
2 Operating modes .............................................................................. 13
2.1 Phase-angle control with soft start and current limiting .................................. 13
2.2 Burst-firing operation, for resistive loads .......................................................... 14
2.3 Burst-firing operation for transformer loads and loads with a high positive tem-
perature coefficient TC (mixed operation) 15
3 Installation ......................................................................................... 17
3.1 Important installation notes ................................................................................ 17
3.2 Filtering and interference suppression .............................................................. 18
3.3 Installation site and climatic conditions ............................................................ 18
3.4 Wall mounting ....................................................................................................... 19
3.4.1 TYA-110/3, 025..100 .............................................................................................. 19
3.4.2 TYA-110/3,150 and TYA-110/3, 250 ...................................................................... 20
3.5 DIN rail mounting ................................................................................................. 21
3.5.1 TYA-110/3, 025 ..100 ............................................................................................. 21
4 Electrical connection ........................................................................ 23
4.1 Connection diagram ............................................................................................ 23
4.1.1 Type TYA-110/3, 025, - 050, - 075, - 100, ... .......................................................... 25
4.1.2 Type TYA-110/3, 150, ... ......................................................................................... 25
4.1.3 Type TYA-110/3, 250, ... ......................................................................................... 25
4.2 Single-phase operation: line/phase – N ............................................................. 26
4.3 Single-phase operation: phase – phase ............................................................. 27
4.4 Star configuration: with star point connected to N .......................................... 28
4.5 Open delta configuration (six-wire circuit) ........................................................ 29

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Contents
4.6 Free-running economy circuit, purely resistive loads ....................................... 30
4.7 Master-slave economy circuit, with resistive/inductive loads ......................... 31
5 Commissioning ................................................................................. 33
5.1 Adjust control input (full wave) ........................................................................... 33
5.1.1 Setting the maximum power output ....................................................................... 33
5.1.2 Input signal attenuator ........................................................................................... 33
5.2 Setting the base load ........................................................................................... 34
5.3 Setting the current limit ....................................................................................... 35
5.3.1 Alteration of the current limit Imax, as a function of the voltage on Terminal 9 ..... 36
5.4 Setting the phase angle for the first half-wave ................................................. 36
5.5 Load and part-load failure monitoring ............................................................... 37
5.5.1 Setting the threshold for load failure indication ................................................ 37
5.5.2 Setting for master-slave and free-running economy circuit ............................ 38
5.6 External changeover of operating modes ......................................................... 38
5.7 Blown fuse indication .......................................................................................... 38
6 Settings .............................................................................................. 39
6.1 Opening the housing ............................................................................................ 39
6.2 Adjustment switches S1 — 21 and pin headers X503 / X504 .......................... 40
6.3 Summary of possible settings ............................................................................ 42
6.4 Control inputs ....................................................................................................... 43
6.4.1 Combinations of external potentiometer and electronic controller ........................ 44
6.5 Subsidiary control loops ...................................................................................... 45
6.6 Actual (power) output .......................................................................................... 46
6.7 Load current adaptation (only with extra code TR/T0) ..................................... 47
6.8 Select operating modes and load types ............................................................ 47
6.9 Economy circuit .................................................................................................... 48
6.9.1 Free-running economy circuit (asynchronous switching) for resistive loads ......... 49
6.9.2 Master-slave economy circuit (synchronous switching) for resistive and transformer
loads 49
6.10 Firing-pulse inhibit ............................................................................................... 50
7 Technical data ................................................................................... 51
7.1 Load circuit ........................................................................................................... 51
7.2 Control ................................................................................................................... 51
7.3 General data ......................................................................................................... 51

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Contents
8 Faults .................................................................................................. 53
8.1 Fault-finding .......................................................................................................... 53
8.2 Replacing the semiconductor fuse .................................................................... 53
8.2.1 Type TYA-110/3, 025 to 100, ... .............................................................................. 53
8.2.2 Type TYA-110/3, 150, ... ......................................................................................... 54
8.2.3 Type TYA-110/3, 250, ... ......................................................................................... 54

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Contents

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1 Introduction
1.1 Preface
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 [phone]
abroad [phone]
HIf 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.
HWhen 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 transport.
Please note that we cannot accept any responsibility for damage
caused by ESD (electrostatic discharge).
B

1 Introduction
8 Power units 05.01
1.2 Typographical conventions
1.2.1 Warnings
The signs for Danger and Caution are used in this manual under the following
conditions:
V
Danger
This symbol is used where there may be danger to personnel if the instruc-
tions are disregarded or not followed accurately!
ACaution
This symbol is used where there may be damage to equipment or data if the
instructions are disregarded or not followed accurately!
E
Caution
This symbol is used if precautions must be taken when handling electrostati-
cally sensitive components.
1.2.2 Note signs
HNote
This symbol is used to draw your special attention to a remark.
vReference
This symbol refers to additional information in other manuals, chapters or
sections.
abc1Footnote
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.
hHandling instructions
This symbol marks the description of a required action.
The individual steps are indicated by asterisks, for example:
hDisconnect the instrument completely from the supply
hRemove the instrument cover

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1 Introduction
1.3 Description
Application A thyristor power unit can be used wherevere sizeable resistive or inductive
loads are switched frequently – for instance, in industrial furnaces and plastics
processing.
Operating
modes
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.
Regulation Variations in the line supply voltage have no effect on the control-loop regula-
tion during operation. This is ensured by a subsidiary V2, P or I2control 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).
Versions 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 75A or higher rated load can only be wall-
mounted.
Standards 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
2-control with adjustable power level output signal
- Master-slave economy circcuit
- Firing-pulse inhibit

1 Introduction
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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 I ≤IN/2
- Free selection of the subsidiary control-loop type (V2, I2or P).
A free-running economy circuit can be implemented with P-control!
- Power level output signal can be switched to: V2, P, I2
TO as for TR, but with signaling via optocoupler
MS Master-slave circuit: 2 pre-assembled power units on a mounting plate, ready
for connection.
1.4.2 Standard accessories
1 Mounting plate for wall-mounting
1 Operating Instructions
TYA-110/3 , . . . , . . . , . . Thyristor power 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 1
400 Rated load voltage 400V 1
460 Rated load voltage 460V 1
500 Rated load voltage 500V 1
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-assembled power units on a mounting plate,
ready for connection

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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, Sales No. 70/00068009
80A for IN= 50A, Sales No. 70/00068011
125A for IN= 75A, Sales No. 70/00081800
160A for IN= 100A, Sales No. 70/00081801
350A for IN= 150A, Sales No. 70/00083318
550 A for IN= 250A, Sales No. 70/00371964
Assembly kit for DIN rail mounting, for 25A and 50A versions,
Sales No. 70/00067312
1.5 Block diagram
(
(1) Load (9) Control electronics
(2) Super-fast semiconductor fuse (10) Trimmer on front panel
(3) Thyristor module with RC
protection network
(11) Error signal output
via relay or optocoupler
(4) Driver stage for thyristor module (12) Configuration switch
(5) Power supply for control electronics (13) Signal LEDs
(6) Optocoupler (14) Master-slave connections
(7) Voltage converter (15) Output level setting, operating inputs,
power level output signal
(8) Current transformer

1 Introduction
12 Power units 05.01
1.6 Front panel indicators and adjustments
(1) Indicator LED for blown semiconductor fuse (6) Adjustment of threshold for part-load failure
indication (with extra code TR or TO)
(2) LED for current indication (7) Adjustment of full output
(3) LED for load-failure indication (8) Adjustment of power level signal
(4) LED for full-output indication (9) Spring clip to release cover
(5) Adjustment of current limit in phase-angle
operation (with extra code TR or TO) (10) Adjustment of phase-angle reduction for 1st half- wave in burst-firing operation

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2 Operating modes
2.1 Phase-angle control with soft start and current limiting
In this mode of operation, the 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.
Current limiting 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.
vSection 5.3 “Setting the current limit”

2 Operating modes
14 Power units 05.01
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.
The internal switch S20 can be used to adjust the duty cycle to suit the system
being controlled.
vSection 6.2 “Adjustment switches S1 — 21 and pin headers X503 / X504”
Cycle time S 20
Variable cycle time
The control unit uses the shortest available cycle time
(for fast control loops)
1
Fixed cycle time (≈500ms)
Used for transformer loads, slow control loops
2

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2 Operating modes
2.3 Burst-firing operation for transformer loads and loads with a
high positive temperature coefficient TC (mixed operation)
Soft start 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).
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.
1. with extra codes TR/TO
HIt is not possible to change over to phase-angle control in this
mode of operation.
HIf the power unit runs into current limiting1during the phase-angle
controlled start, then the output is regulated according to the maxi-
mum current given by the curent limit setting, even for low levels of
the setpoint input.

2 Operating modes
16 Power units 05.01
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 α = 90°. This value can be altered on the front panel over a
range α = 0 — 90°.
vSection 5.4 “Setting the phase angle for the first half-wave”
HWe recommend that this setting is not changed!

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3 Installation
3.1 Important installation notes
Safety
regulations
- 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.
Fusing - In the event of a short-circuit in the load circuit, the power unit is protected
by the built-in semiconductor fuse.
vSection 8.2 “Replacing the semiconductor fuse”
- Do not connect any additional loads to the output load terminals.
Interference
suppression
- The electromagnetic compatibility (EMC) meets the standards and
regulations cited in the technical data.
vSection 7 “Technical data”
Wiring 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.
Connections hCheck the data given on the nameplate (rated load voltage, load current)
against the data for the system.
hWire up the connections from supply line – thyristor power unit – load
according to the wiring diagram, and check them
hIf the economy circuit configuration is used, check that the rotary electrical
field has clockwise phasing.
hCheck the settings for the setpoint inputs
hCheck the switch positions
Supply voltage hConnect the supply voltage for the control electronics as shown in the wi-
ring diagram.
hLink “N/L2” to “V”, unless the economy circuit is being used (slave unit).
Load
connection
The electronic switching devices (2 antiparallel thyristors) are in circuit bet-
ween the screw connections “U1” and “U2”.
Phasing The supply voltage for the control electronics and the load voltage must
have the same phase.
hTerminal “L1” must be connected, via a control circuitry fuse, to the same
supply potential as terminal “U1”!
V

3 Installation
18 Power units 05.01
Switch-on
sequence
The supply voltages for the load and control circuitry must be switched on
at the same time.
Control inputs 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).
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 possible, 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 ≤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
AIn no circumstances should the supply voltage for the control
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!
VConnections must only be wired up by properly qualified
personnel!

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3 Installation
above the unit. The thyristor power unit has enclosure protection IP00, and so
it must be mounted in such a way that bodily contact is prevented (built-in
unit).
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
conditions
- Relative humidity ⱕ75 %, no condensation
- Ambient temperature range: 0 to 45 °C
Storage temperature range: -10 to 70 °C
3.4 Wall mounting
hFix the aluminium mounting plate to the heatsink, using the cheese-head
screws provided.
hFix the thyristor power unit with its mounting plate to the wall, using four
screws.
3.4.1 TYA-110/3, 025..100
VThe heatsink can become very hot in operation!

3 Installation
20 Power units 05.01
3.4.2 TYA-110/3,150 and TYA-110/3, 250