Lumel RP1 User manual

POWER CONTROLLER
RP1
USER’S MANUAL

2

3
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

4

5
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.

6
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)

7
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

8
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.

9
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

10
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

11
Fig. 7. Triggering stoppage
In case of using the current limitation potentiometer on the power controller frontal
plate, one must short-circuit 5 V and Limit terminals, fig. 5.
4.4.4. Triggering stoppage
One can carry out the triggering stoppage, short-circuiting 5Vand STOP termi-
nals on the terminal strip. The STOP input is active in the 4...32 V/5 mA voltage
range.
4.4.5. Analog outputs
a) Output U = f (Io)
0...5 V/5 mA output voltage, proportional to the current value in the load circuit.
b) Output M/S
The output of „Master/Slave” type is used when the power controller works
as a master device.
The slave power controller must be set in the turn on working mode at the zero
across of the supply voltage. Output load-carrying capacity: max 5 mA Example
of connection is shown on the fig. 13.
Fig. 8. Analog output

12
4.4.6. Relay outputs
Semiconductor relays of MOSFET type.
a) Output PK1
Signalling of damaged fuse
b) Output PK2
Signalling of an incorrect working state:
- lack of supervision on the control - ERROR,
- active signal of triggering stoppage - STOP,
- lack of synchronisation,
- fuse damage,
- exceed of allowable radiator temperature.
Fig. 9. Relay outputs
IN = 60 mA/ 230 V a.c./d.c.
Ron = 35 
Uisol = 1500 VRMS
Voltageless outputs, they are not
protected against overloads or
shortings.
4.5. Connection of supply and load
U1 and U2 high-current sockets to connect supplies of the load circuit, the ter-
minal PE of the protection wire and the fuse B1, are accessible after removing
the protective cover, fig.10.
The protective cover is closed by two lateral fasteners, fig. 1.

13
Fig. 10. View of the high-current power controller circuit
4.5.1. Connection of the supply and synchronisation circuit to the LZ1
terminal strip
One must connect the Gate Triggering System (GTS) to the LZ1 terminal strip
depending on the power controller version, 115 V/60 Hz or 230 V/50 Hz.
S1 and S2 terminals of the synchronisation system should be connected to the
load supply circuit.
Fig. 11. Description of the LZ1 terminal strip

14
4.5.2. Load connection in single-phase system
Fig. 12. Connection diagram of load in single-phase system
a) Load supply: Uload = 230 V, UGTS supply = 230 V
b) Load supply: Uload = 400 V, UGTS supply = 230 V

15
4.5.3. Load connection in three-phase system
The power control is possible in the three-wire three-phase system using two
power controllers.
The presented way of control concerns the on-off control type in the zero-cross
of the supplying voltage or the pulse control with the turned soft-start and current
limitation off.
5. POWER CONTROLLER SERVICE
„S-Start” and „Limit” potentiometers must be set on minimum, and „max” and
„Span” potentiometers, on maximum. In such settings, corresponding functions
to them are inactive.
One must carry out successively following operations:
a) install the power controller, according to p.4.1
b) carry out electrical connections, according to p. 4.2., p. 4.4. and p. 4.5.
c) set the controll type and the input control signal, according to p. 4.3.
Fig. 13 Connection diagram of a load in three-phase system

16
[1]
d) turn on the supply voltage of the load circuit and of the gate triggering
system, according p. 4.5.
e) set the current limitation*, according to p. 6.4. set the „Limit” potentiometer
on maximum. Observing indication of the meter measuring the load current (at
the maximal value of the input control signal), set the required current value
decreasing the setting on the „Limit” potentiometer.
f) set the triggering delay*, according to p.6.5.
g) set the initial value of the triggering angle*, according to p. 6.6. Increase
the input control signal up to reach the current value Ir necessary to the motor
start, next decrease gradually on the „max” potentiometer, up to turn off,
fig. 5. In this case, the control range depends on the set current Ir value to the
rated load current In value.
h) set the amplification of the imput line*, according to p. 6.7.
* One can reach experimentally the obtainment of proper settings by
means of potentiometers and this should be carried out by a suitably
trained personnel.
6. DESCRIPTION OF CONTROL TYPES
6.1. Control of ON-OFF type
At the on-off control, the delivered power to the load is described by the following
dependence:
Where: Po- delivered power to the load
Xin - value of the input control signal
The power controller works in the semi-conductor relay mode. The feed of the
voltage signal on the control input, p. 4.4.2b, causes the turn of the load current
on. Depending on the setting configuration (table 1). The turn on follows imme-
diately or at the nearest actual supply voltage value transition across zero. Runs
of signals describing the power controller operation for the control of on-off type
are shown on the fig. 14.
Po=
Po max
0 for
for
Xin = 0
Xin = Xmax

17
Fig. 14. Control of on-off type, runs of occurring signals (for resistive load).
Voltage supplying
the load circuit
Pulse input
signal
Current in the
load circuit
6.2. Pulse control
Pulse control consists on the change of the pulse-duty factor and the frequency
of power Po delivered to the load in function of the analog control signal, at the
same time the output current is turned on synchronously with the transition of the
supply voltage across zero. Runs of signals are presented on the fig. 15.
Fig. 15. Pulse control with a variable pulse frequency, runs of occurring signals
Continuous
input
signal
Supplying
voltage
of load circuit
Delivered
power to
the load

18
where: Ts- period of the supply voltage,
Non - number of turned periods on,
Noff - number of periods off.
The filling factor is described by
the following dependence:
[4]   Non + Noff
Non
[2]
[3]
T = Ts(Non + Noff)
Po= Po max = Po max
Non + Noff
Non Xin
Xin max
The power value in the pulse period according to the formula [2], is defined by
the dependence [3]:
The RP1 power controller has following kinds of pulse control:
Quick cycle, in which for X=1/2 (Xmax - Xmin),
Non = Noff = 10, however fi max = 2.5 Hz
Slow cycle, in which for X=1/2 (Xmax - Xmin)
Non = Noff = 100, however fi max = 0.25 Hz
Where: X- value of the analog control signal,
fi max - maximal pulse frequency
Runs of characteristic quantities for the pulse control are presented
on the fig, 16.
Fig. 16. Runs of characteristic quantities for the pulse control with variable
pulse frequency

19
6.3. Phase control
At phase control, a continuous change of delivered power to the load occurs, it
is realised by the change of the load current turn on angle in the function of the
analog control signal.
Runs of signals for this kind of control for a resistive load are presented on the
fig. 17.
Fig. 17. Phase control, runs of occurring signals
6.4. Limitation of the load current
If the current value in the load circuit exceeds the boundary value set by means
of the „Limit” potentiometer, then the current limitation operates regardless of
the control signal value. It is possible to assign it from an external potentiometer,
p. 4.4.3.
The setting of the potentiometer on minimum, means the turn of the current limi-
tation operation off. The maximal value of the current flowing in the load circuit
can be set in the full range of the power controller rated value.
The current limitation does not operate for the impulse control or on-off type in the
turn-on configuration at across zero voltage. In case of exceeding of the current
boundary value, the „Load” diode is alight in red.
6.5. Triggering delay of soft-start type
The soft-start function enables a soft accretion of the voltage from zero up to the
rated value or value resulting from the current limitation action, in the time set by
means of the „S-Start” potentiometer.
In the case of phase control or on-off control type in the configuration of immediate
turn on, the soft-start time ts-s is controlled in the range from 0 up to 10 s.
Continuous
input
signal
Supplying
voltage of
load circuit
current
in the the
load circuit

20
[5]
tS-S = 1
4 fi, max
In case of the pulse control, this time is equal to:
The function is not active in case of the on-off control type in the turn-on confi-
guration at zero voltage.
6.6 Control of the initial triggering angle value
During the power controller use for the rotational speed control of a single-phase
motor (fan), one can set the current value Ir necessary for the motor start by me-
ans of the „max” potentiometer.
In this case, the control is in the
range from the set value Ir of the
current up to the rated value In
of the current. The function does
not operate in case of the on-off
control type, in configuration
turned on at zero voltage.
Fig. 18. Action of the max function
6.7. Control of the input line amplification
The „Span” potentiometer serves to set the amplification of the input line in the
control range from 50 up to 100% of the input control signal.
6.8. Check and current signalling in the load circuit
The passage of current in the load circuit is signalled by means of a two-colour
„Load” diode.
During the normal work, the diode is alight in green, however in the moment of
the current limitation action it is alight in red.
6.9. Signalling of the supply correctness
The two-colour „Control” diode is alight in green during the normal work, however
in the moment of lack of power controller readiness to work, it is alight in red - the
power controller is locked.