Lumel RP7 User manual

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POWER CONTROLLER
RP7
USER’S MANUAL

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CONTENTS
1. APPLICATION .......................................................................................................................5
2. BASIC REQUIREMEMNTS, OPERATIONAL SAFETY.........................................................5
3. POWER CONTROLLER SET ...............................................................................................7
4. DESCRIPTION OF THE DESIGN and OPERATION ...........................................................7
5. INSTALLATION and SETTING TO WORK............................................................................9
6. SPECIFICATIONS...............................................................................................................10
7. ORDERING CODES ...........................................................................................................12
8. MAINTENANCE AND GUARANTEE...................................................................................13
POWER CONTROLLER
RP7 TYPE
USER’S MANUAL

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1. APPLICATION
The RP7 power controller is destined to control the load power in function of the input control
signal for following types of loads:
resistance loads,
resistance-inductance loads, and the control of induction motors and commutator motors
at not high loads.
The application area of RP7 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. RP7 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. 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.
Symbols located in this user’s manual mean:
WARNING!
Warning of potential, hazardous situations. Especially important. One must be fami-
liar 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 EEC Low-Voltage
Directive (EN 61010 -1 issued by CENELEC).

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Remarks concerning the operator safety:
1. General
The RP7 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.
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,). 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 legislation.
5. Operation
Installations including RP7 power controllers must be equipped with protection devices
according to the corresponding standard and regulations for prevention of accidents.

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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 guarantee contract period may
cause its cancellation.
3. POWER CONTROLLER SET
The set consists of:
- RP7 power controller 1 pc.
- user’s manual 1 pc.
- guarantee card 1 pc.
- fuse 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. DESCRIPTION OF THE DESIGN AND OPERATION
The RP7 power controller is destined to be mounted on a wall or on a rail (E-06292,
DIN EN 50 022-35) by means of a special catch.
Power controller overall dimensions, spacing of assembly holes and the fixing way are presen-
ted on the fig. 1.
Fig. 1. Overall and assembly dimensions
1 - protection cover, 2 - terminal strip, 3 - terminal of the protection wire
4 - fuse, 5 - DIP switch, 6 - radiator, 7 - catch, 8 - rail.

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Servicing elements are disposed on the power controller frontal plate.
- terminal strip, enabling the connection of load circuit wires, control wires
or the potentiometer,
- potentiometer „Ilim”, serving to the load current limitation,
- potentiometer „max”, serving to the triggering angle limitation,
- lighting green diode (1), signalling the exceeding over 70% of the set power,
- lighting red diode (2), signalling the fuse damage.
The RP7 power controller has a bidirectional thyristor switch, which is a link controlled by the
gate triggering system. It also includes a fuse destined to protect semiconductor elements,
an RC two-terminal network and a varistor, protecting against commutation or connection
overvoltages.
The connection of the load is realised by the change of the load current connection angle in
the function of the control analog signal or by means of the potentiometer.
Runs of signals for this control are shown on the fig. 2.
Fig. 2. Phase control, runs of occurring signals
Power delivered to
the load
Input signal
Voltage supplying the
load circuit
Current in the
load circuit
The RP7 power controller has functions ensuring a reliable and safe operation:
Limitation of the current load
If the current value in the load circuit exceeds the threshold value set by the „Ilim” potentiome-
ter, then the current limitation will operate independently on the control signal.
The maximal value of the current flowing in the load circuit can be set in the range from 20%
to 100% Io(for rated power load higher than 1/2 maximal power of the power controller).
Limitation of the triggering angle
In case of power controller work with motors on can set the current Ir value necessary for the
motor start by means of the „max” potentiometer.
The control range in this case is depended on the set current Irvalue to the rated current In
value. If the control signal value is lower than the value corresponding to the Irvalue, then the
triggering stoppage follows.

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Triggering delay of „Soft-start” type
The „soft-start” type enables the change of the connection angle from to 0 rad in the time
ca 1.5 s, after the supply connection (switch W, fig. 3).
Detection and signalling of the load circuit current
The 70% exceeding of the set current limitation value is signalled by the lighting of the
green diode - 1
Signalling of fuse damage
In case of the fuse damage, the voltage on fuse terminals supplies the signalling system of the
fuse damage (lighting of the red diode - 2).
5. INSTALLATION AND SETTING TO WORK
After fixing the power controller according to the fig. 1, one must carry out connections of
external circuits as shown on the fig. 3.
Fig. 3. Marking and description of external terminals
Cross-sections of supply wires:
- to the load circuit (U1 and U2 terminals) 1.5 mm2
- to the system of gate triggering (U terminal) 0.35 mm2
- protective lead (terminal ) 1.5 mm2
Maximal cross-section of supply wires: 2.5 mm2
Connect the L1, N supply to terminals 1 (U), 3 (U2).
Connect the load between the terminal 2 (U1) and the phase L1 of the supply voltage.
One must connect the input signal to terminals 4 (0 V), 5 (U/I).
The manufacturer input signal is set on 0...10 V.
The range of the input signal and the adaptation of the power controller to the load type can
be chosen by the appropriate position of the DIP switch section, accessible after removing the
power controller cover, fig. 1.
The way of the switch setting is given in the table 1.

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The power controller setting to work includes:
- The setting of the load current limitation (set the handwheel of the „max” potentiometer on
maximum).
Set the handwheel of the „Ilim” potentiometer on minimum. Observing indications of the instru-
ment measuring the load current (at the maximal value of the input control signal), set the
required value of the load current by means of the „Ilim” potentiometer handwheel.
- The setting of the triggering angle limitation (use at the control of motor rotational speed).
Set the handwheel of the „max” potentiometer on maximum. Set the value of the control
signal corresponding to the current Ir necessary to start the motor. Then, turn the „max”
potentiometer handwheel till the moment of the triggering stoppage.
6. SPECIFICATIONS
Continuous input signal: 0...5 V input resistance: 3 k
0...10 V input resistance: 6 k
0...20 mA input resistance: 250 
4...20 mA input resistance: 250 
Assignment from the potentiometer potentiometer: 10 k
Maximal output current 5 A, 10 A, 15 A
The characteristic of the load capacity is presented on the fig. 4.
0 - switch in OFF position
1 - switch in ON position
In case of assignment from the potentiometer, set the control signal on the range 0...10.
Table 1
Switch sections
1 2 3 4 5
Control signal 0...5 V
0...10 V
0...20 mA
4...20 mA
Kind of load Resistance
Resistance-in-
ductance
- - - - 0
- - - - 1
0 1 0 0
0 0 0 0
1 1 0 0
1 1 1 1
Fig. 4. Maximal output current value in the
function of the ambient temperature