Lumel RP1 User manual

POWER CONTROLLER
RP1
USER’S MANUAL

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POWER CONTROLLER RP1 type
USER’S MANUAL
CONTENTS
1. APPLICATION...............................................................................................5
2. BASIC REQUIREMEMNTS, OPERATIONAL SAFETY ...............................5
3. POWER CONTROLLER SET.......................................................................6
4. INSTALLATION.............................................................................................6
4.1. Overall and assembly dimensions .........................................................6
4.2. Electrical connections ............................................................................8
4.3. Choice of the control type ......................................................................8
4.4. Connection of control signals.................................................................9
4.5. Connection of supply and load.............................................................12
5. POWER CONTROL SERVICE ...................................................................15
6. DESCRIPTION OF CONTROL TYPES ......................................................16
6.1. Control of ON-OFF type.......................................................................16
6.2. Pulse control ........................................................................................17
6.3. Phase control.......................................................................................19
6.4. Limitation of the load current................................................................19
6.5. Triggering delay of soft-start type.........................................................19
6.6. Control of the initial triggering angle value...........................................20
6.7. Control of the input line amplification...................................................20
6.8. Check and current signalling in the load circuit....................................20
6.9. Signalling of supply correctness ..........................................................20
6.10. Signalling of maximal radiator temperature exceeding......................21
6.11. Error signalling ...................................................................................21
6.12. Overload protection............................................................................21
7. SPECIFICATIONS.......................................................................................22
7.1. Electrical parameters of the high-current circuit...................................22
7.2. Electrical parameters of the supply and control circuit.........................22
7.3. Other parameters.................................................................................23
7.4. Safety requirements.............................................................................23
7.5. Electromagnetic compatibility ..............................................................23
8. ORDERING CODES ...................................................................................24
9. MAINTENANCE AND WARRANTY ...........................................................25

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1. APPLICATION
The RP1 power controller is destined to control the load power in function of the
input control signal for following types of loads:
resistive, wit a positive temperature coefficient of resistance, heaters made
of alloys on the base of molybdenum (Mo), platinum (Pt), tantalum (Ta),
tungsten (W), iron (Fe),
resistive with a negative temperature coefficient resistance, heaters made
of sintered carbide, graphitical heaters,
resistive-inductance, transformer loaded by a resistive load, transformer
loaded by a rectifier system.
The application area of RP1 power controllers includes:
electrical furnaces and drying constructions, particularly industrial tunnel
and belt-type furnaces, furnaces for annealing and hard soldering, crucible
furnaces and furnaces for hardening in salt bath,
devices of mechanical engineering, aggregates and extruding presses for
plastics, devices for winding and tempering of springs, spot welding and
seam welders,
production of glass and glazing, installations and devices for drying in
infrared and ultraviolet radiation, ladles for glass melt and heating of
feeding devices,
chemical and petroleum industries, facing heaters of tube installations,
preheating installations
2. BASIC REQUIREMENTS, OPERATIONAL SAFETY
Power controllers are applied in high-current installations in which devices under
voltage can be a source of danger.
Considering the personnel safety, one should observe following principles:
Devices can be installed, serviced and maintained exclusively by a suitably
qualified personnel, having essential knowledge about equipment.
RP1 power controllers should be connected to the power network according
to the present operative regulations and standards concerning electrical
installations, and concerning specially the protection against electric
shocks.
During the start and operation of the device. One must comply with
recommendations included in this user’s manual (and specially to sections
4, 5 and 6). Qualified personnel defines persons which are acquainted with
the user’s manual, assembly starting and service of the product, and have
appropriate qualifications to carry out these activities.

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Fig. 1. Overall dimensions and fixing way of the RP1
power controller
3. POWER CONTROLLER SET
The set consists of:
- RP1 power controller 1 pc.
- user’s manual 1 pc.
- warranty card 1 pc.
- Quick start card 1 pc
When unpacking the power controller, please check the delivery complete-
ness and whether the type and version code on the data plate correspond
to the order.
4. INSTALLATION
4.1. Overall and assembly dimensions
The RP1 power controller is destined to be mounted on a wall by means of holders.
Power controller overall dimensions, spacing of assembly holes and the fixing
way are presented on the fig. 1.
*) Dimensions in parenthesis concern the version
with a fun. Version RP1- 4 x x (125 A)

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In case of mounting in a control cabinet, it is recommended to apply a forced
air cycle.
RP1 power controllers can be situated side by side preserving minimal spacing
according to the fig. 2.
Fig. 3 View of the frontal plate
Fig. 2. Intervals between power controllers

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Servicing elements are disposed on the power controller frontal plate (Fig. 3.)
Signalling diodes:
Control - two-colour diode [1], supply correctness and power controller
readiness to work.
Load - two-colour diode [2], passage of current through the load
(when Iload > 5%INof the controller).
Stop - red diode [3], external triggering stoppage.
Error - red diode [4], error related to the power controller work.
Over Temp. - red diode [5], exceeding of the allowable temperature.
Fuse fail - red diode [6], fuse burnout.
Potentiometers and switch:
S-Start - potentiometer [7], control of the soft-start function duration.
Limit - potentiometer [8], limitation of the load current.
max - potentiometer [9], control of the initial triggering angle value.
Span - potentiometer [10], control of the input line amplification.
Switch - DIP-SWITCH [11], to configure analog inputs and the control
mode
4.2. Electrical connections
One must carry out electrical connections by means of following leads:
a) to LZ1 and LZ2 terminal strips, - leads with cross-section
from 0.35 up to 2.5 mm2
b) to high-current terminals:
RP1-1xxx version - leads with 6 mm2cross-section
RP1-2xxx version - leads with 10mm2cross-section
RP1-3xxx version - leads with 16 mm2cross-section
RP1-4xxx version - leads with 35 mm2cross-section
c) to the protective terminal - lead with a cross-section at least the same
as leads in high-current circuits
It is recommended to shield leads in the synchronisation circuit with the network
voltage supplying the load and signalling leads on the LZ2 terminal strip.
4.3. Choice of the control type
Depending on the kind of control and the input control signal, one must suitably
set sections of the DIP, according to the table 1.

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Table 1
0 - Open switch, 1 - short-circuited switch,
DIP switch section
1 2 3 4 5
1 0
0 0
0 0
0 1
0 0 0
1 0 0
1 1 0
1 1 1
1 0 1
On-Off
(switching at zero voltage)
On-Off
(prompt switching)
Input control
signal
Kind
of control
0...5 V
0...10 V
0...20 mA
4...20 mA
Phase
Pulse - quick cycle
Pulse - slow cycle
- State resulting from other settings.
One must choose the kind of control at turned GTS supply off, (see p. 4.5.1)
4.4. Connection of control signals
4.4.1. Connection of control to the LZ2 terminal strip
It is recommended to use shielded leads and a separate control and high-current
installation to connect control signals to the LZ2 terminal strip.
Fig. 4. Description of the LZ2 terminal strip

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4.4.2. Input control signal
Fig. 5. Connection of control signals
a) by analog signal
The control from a voltage or current control signal source or from the potentio-
meter is possible. In case of control from the potentiometer, the voltage input
should be set on the 0...5 V range.
b) by pulse signal
One must connect the control signal (4...32 V) to terminals of the voltage input
IN-U, set on the 0...5 V range.
4.4.3. Limitation of the load current
There is the possibility to limit the load current from the external potentiometer
which should be connected according to the presented drawing. One must set
the „Limit” potentiometer on minimum.
Fig. 6. Limitation of the load current