Lumel RP3 User manual

Three-phase power conTroller
RP3
user’s manual

2

3
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..........................................................................11
4.3. Selection of the control type................................................................11
4.4. Connection of control signals ..............................................................11
4.5. Connection of supply and load............................................................15
5. POWER CONTROL SERVICE ...................................................................16
6. DESCRIPTION OF CONTROL TYPES ......................................................17
6.1. Control of ON-OFF type ......................................................................17
6.2. Impulse control....................................................................................18
6.3. Phase control ......................................................................................19
6.4. Limitation of the load current...............................................................20
6.5. Triggering delay of soft-start type........................................................20
6.6. Control of the input line amplification ..................................................20
6.7. Control and current signalling in the load circuit..................................20
6.8. Signalling of supply correctness..........................................................20
6.9. Signalling of maximal radiator temperature exceeding .......................21
6.10. Error signalling ..................................................................................21
6.11. Overload protection ...........................................................................21
7. SPECIFICATIONS.......................................................................................22
8. ORDERING CODES ...................................................................................24
9. MAINTENANCE AND WARRANTY ...........................................................25
THREE-PHASE POWER CONTROLLER RP3 Type
USER’S MANUAL

4

5
1. APPLICATION
The RP3 power controller is a contactless three-phase power energy electronic
device which includes a thyristor connector and an electronic gate triggering
system.
This power controller allows the control of the power delivered from a three-
phase voltage source to an electrical energy load in function of the control signal
input.
The RP3 power controller is destined for three-phase actuators with resistance
or resistance-inductance loads in control systems and automatic temperature
control.
The application area of RP3 power controllers comprises:
electrical furnaces and drying constructions, particularly industrial tunnels
and belt- type furnaces, furnaces for annealing and hard soldering, crucible
furnaces and smelters, furnaces for hardening in salt baths.
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, furnaces for glass forming.
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 live devices
occur, that can be a source of hazard.
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.
RP3 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 starting system, 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
Symbols located in this user’s manual mean:
WARNING!
Warning of potential, hazardous situations.
Especially important. One must be familiar with this before
connecting the power controller.
The non-observance of notices marked by these symbols
can occasion severe injuries of the personnel
and the damage of the device.
CAUTION!
Designates a general useful note. If you observe it,
handling of the power controller is made easier.
One must take note of this, when the power controller
is working inconsistently to the expectations.
Possible consequences if disregarded !
In the security scope the power controller meets the requirements of the Low-
Voltage Directive (EN 61010 -1).
Remarks concerning the operator safety:
1. General
- The RP3 power controller is destined to co-operate with other devices.
- Non-authorized removal of the required housing, inappropriate use, incorrect
installation or operation creates the risk of injury to personnel or damage to
equipment. For more detailed information please study the user’s manual.
- All operations concerning transport, installation, and commissioning as well as
maintenance must be carried out by qualified, skilled personnel and national
regulations for the prevention of accidents must be observed.
- According to this basic safety information, qualified, skilled personnel are
persons who are familiar with the installation, assembly, commissioning,
and operation of the product and who have qualifications necessary for their
occupation.
2. Transport, storage
Please observe the notes on transport, storage and appropriate handling.
Observe the climatic conditions given in Technical Data.
3. Installation
- The power controller must be installed according to the regulation and instructions
given in this user’s manual.
- Ensure proper handling and avoid mechanical stress.

7
- Do not bend any components and do not change any insulation distances.
- Do not touch any electronic components and contacts.
- Electronic Instruments may contain electrostatically sensitive components,
which can easily be damaged by inappropriate handling.
- Do not damage or destroy any electrical components since this might endanger
your health!
4. Electrical connection
- Before switching the power controller on, one must check the correctness
of connection to the network.
- In case of the protection terminal connection with a separate lead one must
remember to connect it before the connection of the power controller to the
mains.
- When working on live instruments or devices, the applicable national regulations
for the prevention of accidents must be observed.
- The electrical installation must be carried out according to the appropriate
regulations (cable cross-sections, fuses, PE connection).
Additional information can be obtained from the user’s guide.
- The documentation contains information about installation in compliance with
EMC (shielding, grounding, filters and cables). These notes must be observed
for all CE-marked products.
- The manufacturer of the installation or installed devices is responsible for
the compliance with the required limit values demanded by the EMC legisla-
tion.
5. Operation
- Installations including RP3 power controllers must be equipped with protection
devices according to the corresponding standard and regulations for prevention
of accidents.
- After the power controller has been disconnected from the supply voltage, live
components and power connections must not be touched immediately because
capacitors can be charged.
- The housing must be closed during operation.
6. Maintenance and servicing
- Please observe the manufacturer’s documentation.
- Read all product-specific safety and application notes in this user’s manual.
- Before taking the power controller housing out, one must turn the supply off.
- The removal of the power controller housing during the warranty contract

8
3. POWER CONTROLLER SET
The set consists of:
– RP3 power controller 1 pc.
– user’s manual 1 pc.
When unpacking the power controller, please check the delivery completeness
and whether the type and version code on the data plate correspond to
the order.
4. INSTALLATION
4.1. Overall and assembly dimensions
The RP3 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 fig.1 and 2.
In case of mounting in control cubicles, it is recommended to apply a forced air
cycle.
Following Servicing elements are disposed on the power controller frontal
plate (Fig.3).
Fig. 4.1.a.Overall dimensions and fixing way of the power controller for 40 A,
70 A and 125 A versions.
177
212
182
302
318
Listwa
zaciskowa
Panel
Osłona
Osłona
Bezpieczniki
B1, B2, B3
4x M6
Widok bez osłon
zaciski PE
2otw. M6x15
Cover
Terminal
strip
Cover
Panel

9
Fig. 4.2.a. Overall dimensions and fixing way of the power controller
for 200 A, 300A i 450 A vesions.
Fig 4.1.b. The position of the power controller fuses for 40 A,
70 A and 125 A versions. (view after removing the cover)
Listwa
zaciskowa
Panel
Osłona
Osłona
Bezpieczniki
B1, B2, B3
Widok bez osłon
zaciski PE
2otw. M10
4x M8
390
281
409
433
339
345
Cover
Terminal
strip Cover
Panel
177
212
182
302
318
Listwa
zaciskowa
Panel
Osłona
Osłona
Bezpieczniki
B1, B2, B3
4x M6
Widok bez osłon
zaciski PE
2otw. M6x15
Fuses
Terminals PE
2 holes M6x15

10 Fig. 3. Panel.
Fig. 4.2.b. he position of the power controller fuses for 200 A, 300A and 450 A
versions (view after removing the cover)
Listwa
zaciskowa
Panel
Osłona
Osłona
Bezpieczniki
B1, B2, B3
Widok bez osłon
zaciski PE
2otw. M10
4x M8
390
281
409
433
339
345
Terminals PE
2 holes M10
Fuses

11
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], control error or incorrect supply connection.
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.
Span - potentiometer [9], control of the input line amplification.
Switch - DIP-SWITCH [10], to configure analog inputs
and the control mode.
4.2. Electrical connections
One must carry out electrical connections by means of following wires:
a) to LZ1 terminal strips (fig.4.3) - wires with cross-section
from 0.35 up to 2.5 mm2,
b) to high-current terminals (fig.4.1, 4.2):
RP3-1x version; 40 A - wires of 16 mm2cross-section,
RP3-2x version; 70 A - wires of 25 mm2cross-section,
RP3-3x version; 125 A - wires of 50 mm2cross-section,
RP3-4x version; 200 A - rail of 100 mm2cross-section,
RP3-5x version; 300 A - rail of 200 mm2cross-section,
RP3-6x version; 450 A - rail of 300 mm2cross-section.
c) to the protective terminal - wire (rail) of a cross-section at least
the same as wires in the high-current circuit.
4.3. Selection 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.
One must choose the kind of control at turned UWB supply off, (see p. 4.5.).
4.4. Connection of control signals
4.4.1. Connection of control to the LZ1 terminal strip

12
It is recommended to use shielded wires and a separate guidance of the control
installation and the high-current installation to connect control signals to the LZ1
erminal strip.
4.4.2. Input control signal
a) by analog signal
Table 1.
Fig. 4.5. Description of the LZ1 terminal strip.
0 - open switch, 1 - shorted switch,
- state resulting from other settings.
DIP switch section
1 2 3 4 5
1 0
0 0
0 0
0 1
0 0
0 1
1 0
1 1
0/1
On-Off
(switching instantly)
Three-, six-wire* / four-wire
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
Load configuration
*) - the load six-wire configuration requires the correction of the ,,Span” potentiometer
(one must set the potentiometer slide on the half range).

13
The control from a voltage or current control signal source or from the potentiometer
The Stop input is active in the range of voltages 4...32 V/5 mA.
Fig.4.6. Connection of control signals.
is possible.
In case of control from the potentiometer, the voltage input should be set on
the 0...5 V range.
b) by impulse 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. Tripping stoppage
There is the possibility to carry out the tripping stoppage by shorting terminals
5 V and Stop on the terminal strip.
Fig.4.7. Tripping stoppage.

14
4.4.4. Analog outputs
4.4.5. Relay outputs
Semiconductor relays of MOSFET type.
a) Output PK1.
- signalling at least one of the damaged fuse - Fuse Fail
- error of control or improper connection of the supply
(lack of supply or wrong phase sequence) - Error
b) Output PK2.
- active signal of triggering stoppage - STOP,
- exceeding of the allowable radiator temperature - OverTemp.
Fig. 4.8. Relay outputs.
I N = 60 mA/ 230 V a.c./d.c.
R
on = 35 
U
isol = 1500 V RMS
Voltageless outputs, they
are not protected against
overloads or shortings.
a) Output U = f (Io)
0...5 V/5 mA output voltage,
proportional to the current value
in the load circuit.
Note: The measurement has a reference character.
Fig.4.8. Analog outputs.

15
4.5. Connection of supply and load
The power controller supply (Gate triggering system - UWB) must be connected
to L1 and Nterminals of the LZ1 strip (fig.3.).
The supply of the strong-current circuit must be connected to U1, V1, W1 terminals,
however the load circuit to U2, V2, W2 terminals (fig.1. and fig.2.)
Fuses in version RP3 -1x , 2x and 3x are accessible after removing the protection
cover, fig.4.1.
4.5.1. Load connection in a 3- and 4-wire system.
a) 3-wire load.
b) 4-wire load V.

16
5. POWER CONTROLLER SERVICE
„S-Start” and „Limit” potentiometers must be set on minimum, and the „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 control type and the input control signal, according to p. 4.3.
d) turn on the supply voltage of the load circuit and next, the gate trig-
gering system UWB, 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” potentiome-
ter.
f) set the triggering delay*, according to p.6.5.
g) set the amplification of the input line*, according to p. 6.6.
*) One can reach experimentally the obtainment of proper settings by means
of potentiometers and this should be carried out by a suitably trained personnel.
4.5.2. Load connection in a 6-wire system.
a) 6-wire load.

17
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:
[1]
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 instantly turn of the load
current on.
The turning on with using the Soft-Start function is possible.
Runs of signals describing the power controller operation for the control of on-off
type are shown on the fig.6.1.
Voltage supplying
the load circuit
Impulse
input signal
Current in
the load circuit
Fig.6.1. Control of on-off type, runs of occurring signals in relation
to the neutral wire - resistance load.

18
6.2. Impulse 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.6.2.
The power value in the pulse period according to the formula [2], is defined by
the dependence [3]:
The RP3 power controller has following kinds of pulse control:
Quick cycle, in which for X = 1/2 (Xmax - Xmin),
Non = Noff 25, however fi,max 1 Hz,
Slow cycle, in which for X = 1/2 (Xmax - Xmin),
Non = Noff 250, however fi,max 0.1 Hz.
Where: X - value of the analog control signal,
fi, max - maximal impulse frequency.
Where: Ts- period of the supply voltage,
Non - number of turned periods on,
Noff - number of turned periods off.
[2]
[3]
T = Ts(Non + Noff)
Po= Po max = Po max
Non + Noff
Non Xin
Xin max
Fig. 6.2. Impulse control with a variable impulse frequency,
runs of occurring signals .
Delivered
power to
the load
Continuous
input
signal
Supplying
voltage
of load circuit

19
Runs of characteristic quantities for the impulse control are presented on
the fig.6.3.
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 turning on angle in the function of
the analog control signal.
Runs of signals for this kind of control for a resistance load are presented on
the fig.6.4.
The filling factor y is described
by the following dependence:
[4]
Fig.6.3. Runs of characteristic quantities for the impulse control
with variable pulse frequency.
  Non + Noff
Non
Fig.6.4. Phase control, runs of occurring signals, runs of occurred
signals in relation to the neutral wire - resistance load.
Continuous
input signal
Current in
the load circuit
Supplying voltage
of load circuit

20
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 potentiome-
ter, p. 4.4.3. The setting of the potentiometer on minimum, means the turn of
the current limitation 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 on-off control 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, the soft-start time ts-s is
controlled in the range from 0 up to 10 s.
In case of the impulse control, this time is equal to:
[5]
tS-S = 1
4 fi, max
6.6. Control of the input line amplification
The ,,Span” potentiometer serves to set the input line amplification, in the control
range from 50 to 100% of the input control signal.
NOTE: in case of the load control in the six-wire configuration, one must set
the slide of the ,,Span” potentiometer on the half range.
6.7. Inspection and signalling of the current 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.
6.8. Signalling of the supply correctness
The two-colour „Control” diode is alight in green when the power controller
is ready to work.