Saftronics SH6 Series User manual

Saftronics SH6 Manual

1
SH6- HEATER CONTROLLER SERIES
PUBLICATION : PUB2-550-SH1
EFFECTIVE : JULY 2003
SH6 - HEATER SERIES
SECTION 1
DESCRIPTION
PAGE
1
1.1
FEATURES
PAGE
1
1.2
CONFIGURATION
PAGE
1 TO 4
1.3
TECHNICAL DATA
PAGE
4
1.4
PROTECTIVE MEASURES
PAGE
5 TO 6
1.5
INDICATORS
PAGE
6
SECTION 2
MECHANICAL LAYOUT AND MOUNTING
PAGE
7
2.1
UNIT DIMENSIONS
PAGE 7 TO 8
2.2
ACCESS
PAGE 8 TO 9
2.3
COOLING
PAGE 10
SECTION 3
3.1
CONNECTIONS
PC550 CONTROL TERMINALS
PAGE 11 TO 12
PAGE 12 TO 13
3.2
FUSE RATINGS
PAGE 13 TO 14
3.3
POWER CONNECTIONS
PAGE 14
SECTION 4
START UP INSTRUCTIONS
PAGE 15
4.1
SYSTEM SET UP PRIOR TO OPERATION
PAGE 15
4.2
START UP PROCEDURE
PAGE 15 TO 17
SECTION 5
TROUBLE SHOOTING
PAGE 18
5.1
STOCK LIST
PAGE 18
5.2
TROUBLE SHOOTING TABLE
PAGE 19

2
SH6- HEATER CONTROLLER SERIES
1. DESCRIPTION
1.1 FEATURES
Saftronics Heater Controller SH6 series are solid state,
variable voltage controllers for three phase resistance or
primary transformer controller banks.
They provide 2 methods of controlling:
A. VOLTAGE RAMP MODE
B. VARIABLE VOLTAGE CONTROL
Each controller contains 6 x SCR's in the power circuit. The
power circuit is controlled by means of a Saftronics PC550
series control card.
Saftronics solid-state controllers are constructed in a manner,
which permits rapid removal, and replacement of PC boards,
SCR's, control fuses, etc. This ensures minimum downtime in
the unlikely event of failure of one of these devices.
In the case of loss, or insufficient cooling air resulting in
overheating of the heat sink, a thermal switch will open and
shut down the controller thereby protecting the SCR's from
excessive heating.
1.2 CONFIGURATION
The SH6 range of heater controllers covers power ratings from
69Kw to 730Kw with 380V or 525V supplies as standard.
Larger powers and different voltages are available on request.

3
SH6- HEATER CONTROLLER SERIES
TABLE 1.1 380v SH6 SERIES
TYPE
LOAD
POWER
(380 V)
LOAD
POWER
(525 V)
(NOMINAL)
LINE
VOLTAGE
LOAD
CURRENT
SIZE
SH6 – 100
69 kW
90 kW
380V / 525V
100 Amps
B
SH6 – 150
100 kW
135 kW
380V / 525V
150 Amps
B
SH6 – 200
130 kW
180 kW
380V / 525V
200 Amps
B
SH6 – 300
200 kW
275 kW
380V / 525V
300 Amps
C
SH6 – 400
260 kW
360 kW
380V / 525V
400 Amps
D
SH6 – 600
400 kW
550 kW
380V / 525V
600 Amps
E
SH6 - 800
525 KW
730 KW
380V / 525V
800 Amps
E
The SH6 range of heater controllers come in three
configurations.
1.2.1 KIT FORM (CHASSIS) for mounting into a customer's
enclosure.
This consists of thyristor stack and PC550 control card
only.
1.2.2 KIT FORM (ENCLOSED) for mounting between an
existing MCC and ELEMENTS.
This consists of thyristor stack and PC550 control card
in an IP23 enclosure.
1.2.3 STANDARD FORM
This is a complete heater controller consisting of;
thyristor stack, PC550 control card. isolator, high speed
fuses, potentiometer and stop/start pushbuttons in an
IP23 enclosure.
1.2.4 OPTIONAL FEATURES
1 Multi motor starting
2 Line disconnect
3 Line fuses
4 Isolating contactor
5 Start / Stop pushbuttons
6 Bypass contactor
1.3 TECHNICAL DATA

4
SH6- HEATER CONTROLLER SERIES
1.3.1 SH6 INPUT DATA
NOTE: The stack input voltage and the control circuit
supply must be synchronised i.e. R to R, S to S, T to T!!
STACK INPUT:
Voltage Type
SCR Voltage Rating
- 3 Phase Input
- 2,5 x line-line
AC
Voltage (min)
Type SH6-XX-3 - 420V Max Continuous
RMS voltage
Type SH6-XX-5 - 580V Max Continuous
RMS Voltage
Line Frequency - 50Hz +2Hz
PC550 CONTROL SUPPLY
Voltage Type - 3 Phase Input
Selectable 380/525V
Link at 380V Position - 340v - 420v
Link at 525V Position - 470v - 580v
Line Current - Less that 25mA
Line Frequency - 50Hz ± 2Hz
FAN SUPPLY
Type SH6 -100 to SH6-800 - AC220V, 50Hz, 0,5A
1.3.2 SH6 OUTPUT DATA
Unless otherwise specified, the currents listed below are
maximum at a maximum ambient temp of 40 DegºC and at an
altitude of 1500m max.
OUTPUT CURRENT
Type SH6 - 100 - 100 A Max. Cont. Current

SH6- HEATER CONTROLLER SERIES
Type SH6 - 150 - 150A Max. Cont. Current
Type SH6 - 200 - 200A Max. Cont. Current
Type SH6 - 300 - 300A Max. Cont. Current
Type SH6 - 400 - 400A Max. Cont. Current
Type SH6 - 600 - 600A Max. Cont. Current
Type SH6 - 800 - 800A Max. Cont. Current
OVER CURRENT
Amount - 110% (Max Continuous Current) Max
Different ratings available on request.
DERATING
At higher temperature than 40 Deg. C. - 1.5% per 1 Deg.C.
At higher altitude than 1500m - 1% per 100m
1.4 PROTECTIVE MEASURES
In order to ensure high system reliability protective measures
have been taken which protect both the controller and the
load.
NOTE: For complete protection of the SH6 heater controller high
speed input fuses must be installed.
1.4.1 DRIVE PROTECTION MEASURES
5

SH6- HEATER CONTROLLER SERIES
PHASE ROTATION - In order to prevent misfiring in the
case of swopped phases, a phase rotation sensing
circuit has been installed. If phases are swopped, start
up is inhibited and the PHASE LED extinguishes.
THERMAL CUT-OUT - A thermal cut-out element is
mounted near the power devices. This element is a
normally closed contact, which opens at approximately
80 degrees. In order to protect the drive, should the
temperature rise, the element must be connected in the
stop circuit of the drive.
dv/dt SUPPRESSION - The power devices have been
suppressed by means of an RC network to ensure that
their dv/dt ratio is not exceeded.
LINE IMPEDANCE - For increased protection against
noise and overvoltages as well as for short circuit
protection it is recommended that AC line reactors are
used. Consult Saftronics in this regards.
ISOLATION - The control circuits are electrically isolated
from the power circuits.
1.5 INDICATORS
There are 4 LED indicators on the PC550/7 control card.
PHASE ROT- If the drive is correctly phased with
the incoming supply the PHASE
LED will be lit.
+12V - If the power supplies on the
PC550/7 control card are healthy the
+V LED will be lit.
RUN - When the drive is started the RUN
LED will light. The RUN LED is
extinguished when the drive is
stopped.
BYPASS - When the Bypass Timer has been
selected, the BYPASS LED will be lit.
6

SH6- HEATER CONTROLLER SERIES
7
2. MECHANICAL LAYOUT AND MOUNTING
2.1 UNIT DIMENSIONS
The complete range of SH6 soft starters are divided into 4
physical sizes. Namely Size B,C,D and E.
WARNING : ISOLAT E
BEFORE REMOVING
COVER.
DO NOT LIFT ON COVER
DANGE R! LIVE B USBARS
FIG 2.1 - SH6 SERIES - SIZE B OVERALL DIMENSIONS

SH6- HEATER CONTROLLER SERIES
8
FIG 2.2 - SH6 SERIES - SIZE C OVERALL DIMENSIONS

SH6- HEATER CONTROLLER SERIES
9
FIG 2.3 - SH6 SERIES - SIZE D OVERALL DIMENSIONS
FIG 2.4 - SH6 SERIES - SIZE E OVERALL DIMENSIONS
2.2 ACCESS
The SH6 is designed to allow easy access to major
components for easy maintenance.
WARNING: The unit contains non-insulated HIGH VOLTAGE
points. MAKE SURE that all the power inputs are
isolated before trying to access any internal point
!!
NOTE: It is NOT recommended that the unit is customer serviced
unless there is skilled and well trained
personnel that can do the job.

SH6- HEATER CONTROLLER SERIES
2.2.1 ACCESSIBILITY – SIZE B,C,D and E.
Remove the PC550 Control Card by unscrewing the 4 screws (1) as
indicated in Fig. 2.5.
WARNING: ISOLATE
BEFORE REMOVING
COVER.
DO NOT LI FT ON COVER
DANGER! LIVE BUSBARS DANGER! LIVE BUSBARS
FIG 2.5
2.3 COOLING
NOTE: All SH6 specifications are subject to proper cooling! The
following cooling requirements MUST be met to
ensure proper operation and high reliability.
2.3.1 POSITION
All SH6 drives are to be mounted vertically. Any other
rotation will impede the cooling of the drive.
2.3.2 FREE AIR
10

SH6- HEATER CONTROLLER SERIES
The SH6 heater controller must be provided with a free
air supply, i.e.
a) Mount the unit in a ventilated space of at least ten
cubic meters! If this space is unavailable see
Sect. 2.3.3 (mounting in an enclosure).
b) 100mm of uninterrupted air above and below the
drive must be left to ensure adequate cooling.
3. CONNECTIONS
Figures 3.1 to 3.4 show the physical positions of the control and
power connections for the SH6 range of soft starters.
FIG 3.1 - SIZE B CONNECTION LAYOUT
11

SH6- HEATER CONTROLLER SERIES
FIG 3.2 - SIZE C CONNECTION LAYOUT
FIG 3.3 - SIZE D CONNECTION LAYOUT
12

SH6- HEATER CONTROLLER SERIES
FIG 3.4 - SIZE E CONNECTION LAYOUT
3.1 PC550 CONTROL TERMINALS
13

SH6- HEATER CONTROLLER SERIES
FIG 3.5 - PC550 CONTROL TERMINALS
14

15
SH6- HEATER CONTROLLER SERIES
T1
-
L1,L2,L3
The 3 phase supply to the PC550/7 control
card. Care must be taken since the rotation
order of the phases is critical. (Internal
connection).
T2
-
CT1,CT2,CT3
CT connections used for current control.
(OPTIONAL).
GND
Tacho Negative – (Ground)
T3
-
F/B
Tacho Feedback Positive +
MIN SPD
Potentiometer Negative, 0 volt
VOLT REF
Potentiometer Wiper, control Voltage
+22V
Positive Card voltage
T4
-
+12V
Potentiometer Positive, 12 Volt
HOLD
Starting Latch
STRT
Start input
OT1
Over Temperature 1
T5
-
OT2
Over Temperature 2
RL2 COM
Relay 2 Common
RL2 N/O
Relay 2 Normally Open Contact
T6
-
RL2 N/C
Relay 2 Normally Closed Contact
RL3 COM
Relay 3 Common
RL3 N/C
Relay 3 Normally Closed Contact
T7
-
RL3 N/O
Relay 3 Normally Open Contact
mA+
mA-
Current analogue reference input Positive +
Analogue current reference input Negative–
3.2
FUSE RATINGS

16
SH6- HEATER CONTROLLER SERIES
3.2.1 CONTROL FUSES
The 3 phase supply to the PC550 control card is fused
by means of three 2A slow-blow fuses. They are
mounted separately from the PC550 control card.
Control supply fuses for drives up to the SH6-30 are not
supplied as standard.
3.2.2 MAIN FUSES
For complete protection it is recommended that the
system be protected by means of 3 high speed fuses
connected to the input terminals R,S and T.
The following table summarises the recommended value.
TYPE
FUSE RATING
SH6-100
125 AMP, 660V
SH6-150
200 AMP, 660V
SH6-200
250 AMP, 660V
SH6-300
315 AMP, 660V
SH6-400
400 AMP, 660V
SH6-600
630 AMP, 660V
SH6-800
800 AMP, 660V
TABLE 3.1 - AC FUSE RATINGS
3.3 POWER CONNECTIONS

17
SH6- HEATER CONTROLLER SERIES
FIG 3.6 - SH6 POWER CONNECTIONS
Figure 3.6 shows a typical power connection diagram. The
input terminals R,S and T are supplied with a 3 phase, fused
supply.
The load is connected to U, V and W.
The FAN input requires a 220V aux supply to be connected to
ensure adequate cooling of the stack. Failure to connect a
FAN supply can cause damage to the drive.
The O/T output is on overtemperature interlock, which must be
wired in series with the STOP circuit.
4. START UP INSTRUCTIONS AND CALIBRATION PROCEDURE
Don't apply power to the system yet!!!
NOTE: Before continuing with this procedure make sure that the
connections are in accordance to an approved system diagram
4.1 SYSTEM SET UP PRIOR TO OPERATION

18
SH6- HEATER CONTROLLER SERIES
4.1.1 SH6-100-X THROUGH SH6-800-X
Check that the switches and potentiometers on the
PC550/7 series control card are set as given in Table 4.1
for the specific heater controller.
SWITCHES
POSITION
SW1
Control Reference
SW1-1 ON –2 OFF
0-10Vdc input
SW1-1 OFF –2 ON
4-20mA input
SW2
Burden Resistor Selector
ON
4,7 Ohms
ON
10 Ohms
SW3
Burden Resistor Selector Switches
ON
33 Ohms
ON
56 Ohms
ON
100 Ohms
SW4
Soft Starter/ Phase controller Select
BOTH ON
Phase control
1 ON 2 OFF
Soft Starter
SW5
Bypass Activate Relay
BOTH ON
Activated
BOTH OFF
Deactivated
POTENTIOMETERS
POSITION
SH6-100 THRU -800
PHV
380v CCW
525v CW
BYP/TIME
MID RANGE
BIAS
FACTORY SET
MAX SPD
FULLY CCW
SPD STAB
FULLY CCW
GAIN
FACTORY SET
DECEL
FULLY CW
ACCEL
FULLY CW
CURR STAB
MID RANGE
MIN SPD
FULLY CCW
TORQ
FULLY CCW
MAX CURR
FULLY CCW
TABLE 4.1 - CONFIGURATION SETUP
4.2 START UP PROCEDURE

19
SH6- HEATER CONTROLLER SERIES
Before turning on power to the drive confirm that the voltage
rating of the drive is the same as that of the 3 phase input
supply.
SH6-XX-3 - 380V SUPPLY
SH6-XX-5 - 525V SUPPLY
Check the LK1 on PC550 is set to the correct input voltage.
If there are any problems during start up refer to Section 5 -
Trouble Shooting, for assistance.
4.2.1 SH6-100-X THROUGH SH6-800-X
This range of heater elements use the current control
method. Two current transformers are used to provide
current feedback to the PC550 control card. The burden
resistor DIP Switches on the PC550/7 card is selected so
that the current drawn by the load can be limited to a
max of 100% of FLC. See Table 4.1 - Current Burdens.
(Value 1 must be in parallel with Value 2).
DIP SWITCH SETTINGS
VALUE 1
VALUE 2
SH6-100
100? /5W DIP SWITCH 1
SH6-150
56? /5W DIP SWITCH 2
SH6-200
100? /5W DIP SWITCH 1
56? /5W DIP SWITCH 2
SH6-300
56? /5W DIPSWITCH 2
33? /5W DIP SWITCH 3
SH6-400
10? /5W DIP SWITCH 4
SH6-600
4.7? /5W DIP SWITCH 5
SH6-800
4.7? /5W DIP SWITCH 5
10? /5W DIP SWITCH 4
TABLE 4.1 – DIP SWITCH CURRENT BURDEN
The drive will ramp up under current control. The current limit is set to limit
the max current drawn by the load.