Powtier Controls MAXIWAT TC210 Series User manual

Powtier Controls Limited TC210 Instructional Manual
210IM - 1 - 20 June 1996
Issue 2.1
TC210
MAXIWAT RANGE OF
THYRISTOR SWITCHING UNITS
INSTRUCTION MANUAL
DESCRIPTION................................2
INSTALLATION...............................3
DIAGNOSTIC AID - LEDs ...............6
SPECIFICATION ............................7
ORDERING INFORMATION........... 7
DIMENSIONS.................................8
CONTENTS

TC210 Instructional Manual Powtier Controls Limited
20 June 1996 - 2 - 210IM
Issue 2.1
The MAXIWAT TC210 range of thyristor switching
units, combine high power capability with compact
dimensions. With the emphasis on safety and
reliability, the units are ruggedly housed.
They incorporate zero-voltage switching modules
which are fully encapsulated for durability; the units
accept d.c. drive signals from any suitable
temperature or power controller.
Rated for up to 102 KW/660V per phase, the TC210
family comprises assemblies with line current
capacities of 16A, 25A, 40A, 55A, 75A, 100A, 125A
and 155A. Each assembly is fully isolated and
incorporates high speed fuse, excess voltage
protection and an over temperature thermal cutout
for units with forced air cooling.
A standard feature of MAXIWAT TC210 units is the
clear visual indication, by two LEDs, of input logic
signal and fuse/load/thyristor integrity. The
combination of the states of these two LEDs aids
system fault finding.
DESCRIPTION

Powtier Controls Limited TC210 Instructional Manual
210IM - 3 - 20 June 1996
Issue 2.1
TC210 Instructional Manual Tactical Controls Limited
Under normal operating conditions it is important
that the TC210 power switching unit should be
mounted VERTICALLY (as shown in figure 3), with
the FAN end facing DOWNWARDS if fitted. Also
the ambient temperature should not exceed 50 deg
C.
If the TC210 cannot be mounted vertically or if the
ambient temperature is higher than 50 deg C.,
please contact your supplier or Tactical Controls'
directly to determine suitability and possible
operating constraints.
PROTECTION FUSE
The integral fuse in a MAXIWAT thyristor unit is
designed primarily to protect the thyristors from any
excessive over current condition. In the event of a
fuse blowing, the replacement must be a high
speed H.R.C. fuse of an approved type.
Replacement fuses can be ordered directly from
Tactical Controls or an equivalent type can be used.
Fuse types for different current ratings are given in
Table 1.
WIRING
The wiring diagrams are shown in figure 1.
The basic wiring is as follow: the (L) terminal must
be connected to the load supply. One end of the
load must be connected to the (LOAD) terminal.
The other end of the load is returned to the
`NEUTRAL' terminal or `LINE 2' or `LINE 3' of the
mains supply, according to the load configuration.
The input logic signal supply must be connected to
the terminals marked with `I/P+' and `I/P-'. The
recommended minimum input cable size is 0.5mm
square.
Table 1. Fuses and fuse ratings for the TC210
MAXIWAT range.
Current Voltage Tactical Equivalent
Rating Rating Part no. Type
(Arms) (Vrms)
16A 240V FUS-660V-20A FERRAZ-660V-
20A
440V FUS-660V-20A FERRAZ-660V-
20A
25A 240V FUS-660V-30A FERRAZ-660V-
30A
440V FUS-660V-30A FERRAZ-660V-
30A
40A 240V FUS-50LET BRUSH-50LET
440V FUS-45ET BRUSH-45ET
500V FUS-45ET BRUSH-45ET
660V FUS-45ET BRUSH-45ET
55A 240V FUS-63LET BRUSH-63LET
440V FUS-80ET BRUSH-80ET
500V FUS-80ET BRUSH-80ET
660V FUS-80ET BRUSH-80ET
75A 240V FUS-80LET BRUSH-80LET
440V FUS-90EET BRUSH-90EET
500V FUS-90EET BRUSH-90EET
660V FUS-90EET BRUSH-90EET
100A 240V FUS-140EET BRUSH-140EET
440V FUS-140EET BRUSH-140EET
500V FUS-140EET BRUSH-140EET
660V FUS-140EET BRUSH-140EET
125A 240V FUS-160EET BRUSH-160EET
440V FUS-160EET BRUSH-160EET
500V FUS-160EET BRUSH-160EET
660V FUS-160EET BRUSH-160EET
INSTALLATION

TC210 Instructional Manual Powtier Controls Limited
20 June 1996 - 4 - 210IM
Issue 2.1
Figure 1a. Single phase 16 to 25A wiring. Figure 1b. Single phase 40 to 55A wiring.

Powtier Controls Limited TC210 Instructional Manual
210IM - 5 - 20 June 1996
Issue 2.1
Figure 1d. Single phase line to neutral connection Figure 1e. Single phase line to line connection
Figure 1c. Single phase 75 to 155A wiring.

TC210 Instructional Manual Powtier Controls Limited
20 June 1996 - 6 - 210IM
Issue 2.1
The light emitting diode, LED 1 near to the input
terminals is used to indicate the input status. When
the input is 0V, LED 1 is `OFF' and when the input
is greater than 5Vdc, LED 1 is `ON'.
Illumination of the light emitting diode LED 2
indicates that neither the fuse, nor load are open
circuit. When the input signal is 0V, LED 2 should
be `ON'. When the input is high (5 to 30 Vdc), LED
2 is `OFF'. Under normal operation, at any instant
either LED 1 or LED 2 is `ON'.
Combinations of the states of LEDs 1 and 2,
together with the state of the input logic signal,
which switches between `HIGH' and `LOW', provide
a valuable diagnostic aid to fault finding; a summary
of conditions and effects is given in Table 2.
A block diagram showing the diagnostic LEDs 1 and
2, is given in figure 2.
Only LED1 is fitted to 16A and 25A units.
Note 1
With the load supply `ON', the possible faults are:
a) fuse-blown or
b) open-circuited load or
c) short-circuited thyristor (power to load
permanently `ON').
Note 2
Thyristor fails to switch on indicated by LED 2
permanently `ON'. The possible faults are:
a) insufficient input logic drive signal ( must be
greater than 5Vdc) or
b) faulty open-circuited thyristor or
c) faulty drive circuitry
Note 3
Check for reversal of input signal leads.
Table 2. Use of LEDs 1 and 2 - a diagnostic aid.
INPUT/LED STATE
COMBINATIONS
INPUT LED1 LED2 CONDITION
HIGH on off normal and with
LOW off on load supply on
HIGH on off normal and with
LOW off off load supply off
HIGH on off faulty but
LOW off off see Note 1
HIGH on on faulty but
LOW off on see Note 2
HIGH off on faulty but
LOW off on see Note 3
W3C AC/AC full control wiring diagram.
DIAGNOSTIC AID - LEDs

Powtier Controls Limited TC210 Instructional Manual
210IM - 7 - 20 June 1996
Issue 2.1
The TC210 range can be orderd by description or
by the following code.
210 - - - - - -00
INPUT.............................: : : : :
CURRENT RATING................: : : :
VOLTAGE RATING........................: : :
FAN VOLTAGE.......................................: :
OPTIONS.........................................................:
INPUT
Logic
5-30 Vdc 1
Process inputs
4-20 mA 3
0-10 V 4
CURRENT RATING
16 A 16
25 A 25
40 A 40
55 A 55
75 A 75
100 A 100
125 A 125
155 A 155
VOLTAGE RATING
240 V 240
440 V 440
500 V 500
660 V 660
FAN VOLTAGE
110 Vrms 110
240 Vrms 240
Options
Protective cover PC
End of code 00
For applications other than constant resistive loads,
or any other currents and voltage ratings, not listed
above, please contact our sales office.
INPUT
Logic
5 - 30 Vdc
Must operate at >4.5 Vdc
Must release at <1.5 Vdc
Constant current 12 mA typical
Process inputs
4-20 mA 0-10 V
Input impedance 100 ohm 100 Kohm
OUTPUT
Supply voltage 100 to 660 Vrms
(+10 -15%)
Current rating 16 to 155 A.
Input/Output isolation 2500 Vrms.
Supply frequency 40 to 70 Hz.
Ambient operating temp. 0 to 50 Deg.C
Storage temperature -20 to 70 Deg.C
ORDERING INFORMATION
TECHNICAL SPECIFICATION

TC210 Instructional Manual Powtier Controls Limited
20 June 1996 - 8 - 210IM
Issue 2.1
Figure 3. Dimensions.
DIMENSIONS
Current Width Height Depth Fixing Fixing Fixing
rating "W" "H" "D" centre"A" centre"B" holes"C"
16-25A 70 106 106 62 85 5
40-55A 124 170 170 110 110 6
75 154 170 170 141 110 6
100-155A 154 1701200 141 110 6
All dimensions are in mm.
1. Due to the fan, the overall height is increased by 40 mm.
SUPPLIER INFORMATION
Powtier Controls Limited
Unit 4, Parkland Business Centre
Chartwell Road, Lancing
West Sussex BN15 8UE England
Tel: [phone]
Fax: [phone]
Email: [e-mail]

Powtier Controls Limited TC210 Instructional Manual
210IM - 9 - 20 June 1996
Issue 2.1
TC210-25A with soft-start wiring diagram.