Powtier Controls MAXIWAT TC230E Series User manual

Powtier Controls Limited TC230E Instruction Manual
230E\IM - 1 - 20 June 1998
Issue 1.0
TC230E
MAXIWAT RANGE OF
THYRISTOR SWITCHING UNITS
INSTRUCTION MANUAL
DESCRIPTION................................2
EMC COMPLIANCE........................2
INSTALLATION...............................3
DIAGNOSTIC AID - LEDs...............6
SPECIFICATION ............................7
ORDERING INFORMATION........... 7
CONTENTS

TC230E Instruction Manual Powtier Controls Limited
20 June 1998 - 2 - 230E\IM
Issue 1.0
The MAXIWAT TC230E 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 125A/440V per phase, the TC230E
family comprises assemblies with line current
capacities of 40A, 55A, 75A, 100A and 125A. Each
assembly is fully isolated and incorporates high
speed fuse, excess voltage protection and an over
temperature thermal cutout.
A standard feature of MAXIWAT TC230E 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
EMC COMPLIANCE
Emission
The TC230E complies with the requirement of BS
EN 50081-2: 1994, the European Generic emission
standard, for industrial environment - provided a
TC003 filter is connected to the three phase
incoming supply lines.
Further information, see EMC Filter TC003 data
sheet.
Immunity
The TC230E complies with the requirement of BS
EN 50082-2: 1995, the European Generic immunity
standard, for industrial environment.

Powtier Controls Limited TC230E Instruction Manual
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Issue 1.0
Under normal operating conditions it is important
that the TC230E power switching unit should be
 mounted VERTICALLY (as shown in figure 1
and 2), with the FAN end facing DOWNWARDS.
Also the ambient temperature should not exceed
50ºC.
If the TC230E cannot be mounted vertically or if the
ambient temperature is higher than 50ºC, 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
There are four basic load configurations to the
three-phase zero-voltage thyristor switching units;
and these are:-
Figure 1b. 3-phase, star connected load.
Figure 1c. 3-phase, 3-wire, closed delta connected
load.
Figure 2b. 3-phase, 4-wire, star connected load.
Figure 2c. 3-phase, open-delta connected load.
The basic wiring is as follow: the (LINE) terminal
must be connected to the load supply L1, L2 or L3.
One end of the load must be connected to the
(LOAD) terminal LOAD1, LOAD2 or LOAD3. The
loads can be connected in star or delta as shown in
figure 1 and 2.
When connecting the LINE and LOAD to the
TC230E, it is important to have the user connection
and internal connection right next to each other so
that the two crimps make direct contact. This is to
minimise contact resistance.
The input logic signal supply must be connected to
the terminals marked with `I/P+' and `I/P-', and
these can be connected in parallel. The
recommended minimum input cable size is 0.5mm
square.
Table 1. Fuses and fuse ratings for the TC230E
MAXIWAT range.
Current Voltage Tactical Equivalent
Rating Rating Part no. Type
(Arms) (Vrms)
40A 240V FUS-50LET BRUSH-50LET
440V FUS-45ET BRUSH-45ET
55A 240V FUS-63LET BRUSH-63LET
440V FUS-80ET BRUSH-80ET
75A 240V FUS-80LET BRUSH-80LET
440V FUS-90EET BRUSH-90EET
100A 240V FUS-140EET BRUSH-140EET
440V FUS-140EET BRUSH-140EET
125A 240V FUS-160EET BRUSH-160EET
440V FUS-160EET BRUSH-160EET
INSTALLATION
M6 SCREW
SPRING WASHER
PLAIN WASHER
M6 NUT
PCB
USER CONNECTION
INTERNAL CONNECTION
User connection for LOAD and LINE.

TC230E Instruction Manual Powtier Controls Limited
20 June 1998 - 4 - 230E\IM
Issue 1.0
LOAD
LOAD LOAD
LOAD1
LOAD2
TC230E/1
TC230E/2
L1
L2
L3
Figure 1b. 3-phase, 3-wire, star connected load.
LOAD
LOAD1
LOAD2
TC230E/1
TC230E/2
L1
L2
L3
LOAD LOAD
Figure 1c. 3-phase, 3-wire, closed delta connected
load.
FAN
LED1
LED1 (GREEN)
INPUT INDICATOR
LED1
I/P
N
L
FAN SUPPLY
115 OR 240 Vrms
TEMPERATURE
CONTROLLER
LOGIC SIGNAL
LED2 (RED)
FUSE/LOAD/THYRISTOR
INDICATOR
MUST
BE
MOUNTED
VERTICALLY
LED2 LED2
FUSE FUSE
TC230E/1 TC230E/2
FAN
LOAD L
LINE LINE
L
LOAD
FAN
LINE L1
LOAD1
LOAD2
LINE L2
AIR FLOW
VERTICALLY
UPWARD
Figure 1a. 3-phase 3-wire star or closed delta wiring.

Powtier Controls Limited TC230E Instruction Manual
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Issue 1.0
LOAD1
LAOD2
LOAD3
LOAD
LOAD LOAD
TC230E/1
TC230E/2
TC230E/3
L1
L2
L3
N
Figure 2b. 3-phase, 4-wire, star connected load.
LOAD
L1
LOAD1
L3LOAD3
L2
LOAD2
TC230E/2
TC230E/1
TC230E/3
L3
L2
L1
LOAD
LOAD
Figure 2c. 3-phase, 3-wire, open delta connected
load.
LED1
LED1 (GREEN)
INPUT INDICATOR
LED1LED1
FAN I/P
TEMPERATURE
CONTROLLER
LOGIC SIGNAL
N
L
FAN SUPPLY
115 OR 240 Vrms
LED2 (RED)
FUSE/LOAD/THYRISTOR
INDICATOR
MUST
BE
MOUNTED
VERTICALLY
LED2 LED2LED2
FUSE FUSE FUSE
TC230E/1 TC230E/2 TC230E/3
FAN
LOAD L
LINE LINE
L
LOAD
FANFAN
LOAD L
LINE
LINE L1LOAD1 LOAD3 LINE L3LINE L2LOAD2
VERTICALLY
AIR FLOW
UPWARD
VERTICALLY
AIR FLOW
UPWARD
Figure 2a. 3-phase 4-wire star or 3-wire open delta

TC230E Instruction Manual Powtier Controls Limited
20 June 1998 - 6 - 230E\IM
Issue 1.0
The light emitting diode, LED 1 (green) 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 (red)
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 3.
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
(green) (red)
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
Figure 3. LED1 and LED2 diagnostic aids.
DIAGNOSTIC AID - LEDs

Powtier Controls Limited TC230E Instruction Manual
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Issue 1.0
The TC230E range can be orderd by description or
by the following code.
230E - - - - - -00
INPUT.............................: : : : :
CURRENT RATING................: : : :
VOLTAGE RATING........................: : :
FAN VOLTAGE.......................................: :
LOAD CONFIGURATION................................:
INPUT
Logic
5-30 Vdc 1
CURRENT RATING
40 A 40
55 A 55
75 A 75
100 A 100
125 A 125
VOLTAGE RATING
240 V 240
440 V 440
FAN VOLTAGE
110 Vrms 110
240 Vrms 240
LOAD CONFIGURATIONO
4 wire, star (figure 3) 1
3 wire, closed-delta or star 2
(figure 1 and 2)
3 wire, open-delta (figure 4) 3
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
OUTPUT
Supply voltage 100 to 440 Vrms
(+10 -15%)
Current rating 40 to 125 A.
Input/Output isolation 2500 Vrms.
Supply frequency 40 to 70 Hz.
ENVIRONMENT
Ambient operating temp. 0 to 50 ºC
Storage temperature -20 to 70ºC
ORDERING INFORMATION
TECHNICAL SPECIFICATION

TC230E Instruction Manual Powtier Controls Limited
20 June 1998 - 8 - 230E\IM
Issue 1.0
FAN
C
B
H
D
W
A
Figure 4. Dimensions.
DIMENSIONS
Current Width Height Depth Fixing Fixing Fixing
rating `W' `H' `D' centre`A' centre`B' holes`C'
(For configurations in figure 1)
40-55A 280 165 250 260 80 6
75-155A 380 160 280 260 110 6
(For configurations in figure 2)
40-55A 280 165 250 260 80 6
75-155A 400 160 280 380 110 6
All dimensions are in 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]