SanRex CALPOTE UG Series User manual

UG1 INSTRUCTION MANUAL
Thank you for your purchase of our Thyristor Type Power Regulator Unit CALPOTE UG1 Series.
In order to use this product safely and correctly, read this instruction manual thoroughly before
using this product.
Ensure that this manual is passed to the end user of this product.

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TABLE OF CONTENTS
1SAFETY PRECAUTIONS ........................................................................................................5
1.1 Usage/Storage Location ........................................................................................................................................7
1.2 Installation .........................................................................................................................................................................7
1.3 Wiring ....................................................................................................................................................................................8
1.4 Maintenance/Inspection .........................................................................................................................................8
2PRECAUTIONS DURING USAGE .....................................................................................9
3CHECKING THE PRODUCT ............................................................................................. 11
4UNIT CONNECTION DIAGRAM...................................................................................... 13
5EXTERNAL CONNECTIONS OF THE UNIT.......................................................... 14
5.1 Control Terminal Block ........................................................................................................................................ 14
5.2Connection Diagrams for Setting Methods .......................................................................................... 17
6UNIT CONTROL WIRING METHOD............................................................................. 29
6.1 Control Wiring Method ......................................................................................................................................... 29
6.2 Grounding ..................................................................................................................................................................... 29
7DISPLAY PANEL....................................................................................................................... 30
7.1 Names and Overview of the LED Lamps and Keys....................................................................... 30
7.2 Operations..................................................................................................................................................................... 31
Selecting and displaying modes and items ......................................................................... 31
Changing settings ................................................................................................................................. 32
7.3 Modes............................................................................................................................................................................... 33
MONITOR mode...................................................................................................................................... 33
PARAMETER mode ............................................................................................................................. 34
FUNCTION mode................................................................................................................................... 38
7.3.3.1 F0: Rated value............................................................................................................. 39
7.3.3.2 F1: Control method.................................................................................................... 40
7.3.3.3 F2: Parameter priority............................................................................................... 41
7.3.3.4 F3: Function characteristics ................................................................................ 43
7.3.3.5 F4: Conversion board............................................................................................... 44
7.3.3.6 F5: Communication board .................................................................................... 47
7.3.3.7 F6: Error output destination selection.......................................................... 48
7.3.3.8 F7: System setting....................................................................................................... 50
OPTION mode .......................................................................................................................................... 51
7.3.4.1 oP01: Error history check...................................................................................... 51
7.3.4.2 oP02: Heater resistance setting........................................................................ 51
8ERROR DETECTION............................................................................................................... 52
8.1 Er.01: Overcurrent Detection.......................................................................................................................... 54

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8.2 Er.02: Temperature Rise Error ....................................................................................................................... 54
8.3 Er.03: Fuse Blowout.............................................................................................................................................. 54
8.4 Er.07: CPU Error....................................................................................................................................................... 55
8.5 Er.08: Memory Error............................................................................................................................................... 55
8.6 Er.09: Emergency Stop........................................................................................................................................ 55
8.7 Er.10: Power Supply Voltage Drop............................................................................................................. 55
8.8 Er.11: Instantaneous Voltage Drop............................................................................................................ 55
8.9 Er.12: Frequency Error ........................................................................................................................................ 56
8.10 Er.13: Heater Disconnection............................................................................................................................ 56
8.11 Er.04, Er.05, Er.06, Er.14: Self-diagnostic Function...................................................................... 57
9UNIT OUTLINE............................................................................................................................ 58
9.1 External Dimensions .............................................................................................................................................. 58
9.2 External View.............................................................................................................................................................. 60
10 MAINTENANCE PARTS ...................................................................................................... 63
10.1 Fuse ................................................................................................................................................................................... 63
10.2 Cooling Fan .................................................................................................................................................................. 63
11 CONVERSION BOARD (OPTIONAL).......................................................................... 64
11.1 Before Use .................................................................................................................................................................... 64
Checking the product ........................................................................................................................ 64
How to install the conversion board ....................................................................................... 65
Connection diagrams.......................................................................................................................... 65
11.2 Functions....................................................................................................................................................................... 66
Model list...................................................................................................................................................... 66
Feedback control................................................................................................................................... 67
Detection value adjustment function ..................................................................................... 70
Heater disconnection detection function............................................................................. 71
Heater disconnection detection (standard version)..................................................... 72
11.2.5.1 Operation overview.................................................................................................... 72
11.2.5.2 Setting method.............................................................................................................. 73
Heater disconnection detection (highly functional version) ................................... 74
11.2.6.1 Operation overview.................................................................................................... 74
11.2.6.2 Connection method ................................................................................................... 75
11.2.6.3 Setting method.............................................................................................................. 75
11.3 Characteristics ........................................................................................................................................................... 77
Constant current control................................................................................................................. 77
Constant voltage control................................................................................................................. 78
Constant power control ................................................................................................................... 79
Constant power control (built-to-order products)....................................................... 80
11.4 External View.............................................................................................................................................................. 81
12 MAINTENANCE AND INSPECTION............................................................................ 82
13 TROUBLESHOOTING............................................................................................................ 83

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14 UNIT SPECIFICATIONS ........................................................................................................ 85
15 OPTIONAL ITEM SPECIFICATIONS............................................................................ 87
APPENDIX A. PARAMETER LIST ................................................................................... 89
APPENDIX B. PANEL TRANSITION DIAGRAM.................................................... 94
APPENDIX C. ERROR CODE LIST.................................................................................. 95

5
1SAFETY PRECAUTIONS
Read this instruction manual to ensure that work is performed correctly and safely.
In order to prevent injury to people, and to prevent damage to property, the following label
categories and symbols are used to explain the items that must be observed.
Explanation of label categories
WARNING
This indicates information that involves the risk of death or serious
injury.
CAUTION
This indicates information that involves the risk of injury or property
damage.
Explanation of symbols
Required
This is an item that must be carried out.
Prohibited
This is an item that is prohibited.

6
WARNING
Required
Installation, wiring, maintenance, and inspection must all
be performed by contractors who specialize in this work.
Before installing, wiring, maintaining, and inspecting this
product, turn OFF the input power supply of the
distribution panel and check that the power supply is OFF.
Secure a safe space before performing installation, wiring,
maintenance, and inspection.
Remove wristwatches and other such metal objects and
wear clothing that is appropriate in terms of safety before
performing installation, wiring, maintenance, and
inspection. There is the risk of electric shock or injury if
you perform work while wearing metal objects.
When performing installation, wiring, maintenance, and
inspection, use tools for which insulation countermeasures
have been carried out. There is the risk of electric shock if
you use other tools.
If you detect an odd smell or sound, stop work immediately
and stop operating the product. There is the risk of fire if
this instruction is not followed.
Prohibited
Do not use the product with the unit cover open. There is
the risk of electric shock if this instruction is not followed.
Do not insert fingers, metal bars, etc. into the openings.
There is the risk of electric shock or injury if this
instruction is not followed.
While input power is supplied, do not touch the
conducting parts or the wires. There is the risk of electric
shock or burns if this instruction is not followed.
During installation, wiring, maintenance, and inspection,
individuals other than the workers must not touch the
distribution panel. Workers must prevent others from
easily touching the distribution panel by erecting a sign
stating “Do not turn the power ON.”
Individuals other than the workers must not enter the
installation, wiring, maintenance, or inspection work area.
Workers must prevent others from easily entering this area
by erecting a sign stating “No entry.”

7
1.1 Usage/Storage Location
CAUTION
Prohibited
Do not use or store the product in locations such as the
following. There is the risk of fire due to factors such as
product failure, damage, and deterioration if this instruction
is not followed.
Hot, cold, or humid locations that are not in compliance
with the operating environments specified by the
instruction manual.
Locations exposed to direct sunlight
Locations subject to vibration or impact
Locations close to a device that produces sparks
Locations exposed to direct contact with heat from a
dryer or other heat source
Locations exposed to contact with water
Locations where there is dust, salt, corrosive gas, or
flammable gas
Outdoors
1.2 Installation
CAUTION
Required
Depending on the product specifications, the unit weight
may exceed 15 kg. Keep safety in mind during installation.
For example, perform the work with two or more
individuals.
Install the unit so it is oriented vertically. Orienting the unit
horizontally will cause its temperature to increase
abnormally, leading to product failure.
Install the product so its front door can be opened and
closed.
Provide sufficient space on the top, bottom, left, and right
of the unit for heat dissipation.

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1.3 Wiring
WARNING
Required
Use wires whose dielectric strength corresponds to the
circuit voltage. There is the risk of electric shock if you use
wires without dielectric strength.
Fully cover the input and output terminals and the
conducting parts of the wires with tubes, tape, or other
such insulating objects. There is the risk of electric shock if
you touch exposed parts. If the input and output terminals
cannot be fully covered, ensure that direct contact with
the exposed parts is not possible.
CAUTION
Required
Use wires with the appropriate diameters to wire the input
and output terminals. There is the risk of heating or fire if
the wire diameters are too small.
Use crimp terminals with the appropriate size to wire the
input and output terminals. There is the risk of heating or
fire if the crimp terminals are not the appropriate size.
1.4 Maintenance/Inspection
WARNING
Required
Replace parts with ones having the same ratings and
model. There is the risk of fire if different parts are used.
Prohibited
Do not touch the transformer, heat dissipation fins, and
other such parts that reach high temperatures. There is
the risk of burns if this instruction is not followed, even
after the input power supply is turned OFF (at which time
these parts may still be hot).

9
2PRECAUTIONS DURING USAGE
Pay attention to the following when using the unit.
The main circuit thyristor may be damaged in short circuit mode. To prevent fire and
property damage in case of ground faults, ensure that the design is safe by, for example,
installing protective functions on the power input side of the unit main circuit using breakers
or other devices.
It is not recommended to operate this product while switching the output between 0% and
100% at intervals of a few minutes repeatedly. The main circuit thyristor will reach the upper
limit of the power cycle, breaking down earlier than specified. Reduce the output variation
range, select a model with sufficient capacity for the rated current, or take other measures
to prevent the early breakdown.
To wire the main circuit, use cables with sufficient capacity for the rated current of the unit.
To wire the main circuit, connect the K terminal to the power supply side and the L terminal
to the load side.
Be sure to match the phases of the main circuit power supply and the control circuit power
supply.
Do not bundle the control circuit cables together with the main circuit cables.
When storing the unit in the distribution panel cabinet, provide ventilation in consideration of
the internal calorific value of the unit.
(See “9 UNIT OUTLINE” for the internal calorific value.)
Note that dust, moisture, overheating, vibration, and other issues may degrade the
performance of the unit or cause it to fail.
Be sure to install the unit upright and vertical and keep space around the unit as instructed
in the installation precautions. Installing the unit horizontally or reducing the space may
degrade the cooling performance, and may lead to abnormal high temperature.
Install the unit so that its front door can be opened and closed for maintenance or
inspection.
When operating the unit with cycle control, it is preferable to use a fuse-attached model of
the unit.
The unit cannot be operated with cycle control with inductive loads. Be sure to operate the
unit with phase control when inductive loads are applied.
(Contact us for customized products.)
If the load capacity is small, a leakage current is applied to the load side even when the
signal is off, causing malfunctions. To prevent this, connect a bleeder resistor in parallel with
the load. (The minimum load current is 1 A.)
If the load capacity is small (approximately 10% of the rated capacity or lower), error code
Er.14 is displayed with the self-diagnostic function. This, however, does not cause any
problems during operation.
Do not apply 5 V or more or 20 mA or more from the temperature controller.

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A load must be connected during test operation. When test operation is performed with no
load, voltage continues to be applied to the output terminal. Additionally, do not perform test
operation with no load while the external potential transformer (PT) is connected. Doing so
may damage the unit.
When the unit is operated with an inductive load (including a transformer load) and the
feedback PT, resonance may be caused due to the load being low or nonexistent, generating
abnormal voltage. Additionally, when the unit is operated with a transformer load, voltage
higher than the rating may be generated on the load side of the unit due to surge voltage
caused by gate blocking (including the unit being turned ON/OFF with the GT terminal),
power supply stoppage, or other causes. When the unit is operated under the above
conditions, install a CR absorber on the load side of the unit as shown in the following figure.
Unit current
200 V system unit
400 V system unit
(A)
Capacitor (µF)
Resistor (Ω)
Capacitor (µF)
Resistor (Ω)
25 to 100
0.5 (400 VAC)
50 (120 W)
1 (800 VAC)
50 (120 W)
150 to 350
1 (400 VAC)
20 (120 W)
1 (800 VAC)
20 (120 W)
450
2 (400 VAC)
20 (120 W)
2 (800 VAC)
20 (120 W)
〜
UG1 unit
•Inductive load
•Transformer load
•PT
•Meter
C
R

11
3CHECKING THE PRODUCT
Check the following before installation.
Check that the product and parts with the correct specifications are included as ordered.
No.
Included item name
Quantity
1
UG1 unit
1
2
Screws, nuts, etc. for output wiring
(1) Screw
For models with a rated
current of 25 to 250 A
2
(2) Bolt
2
(3) Washer
Models with a rated
current of 350 or 450 A
4
(4) Spring washer
2
(5) Nut
2
3
Ground terminal connection screw
1
4
Adjuster set
(1) Adjuster (1 kΩ, B characteristic)
1
(2) Knob
1
(3) Insulating sheet
1
(4) Nameplate
(manual output adjustment, gradient setting)
2
5
Easy lock
2
6
Cautionary guide
1
(1) (2) (3) (4) (5)
(1) (2) (3) (4)

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Check that the optional items with the correct specifications are included as ordered.
For included items, refer to the installation manual that comes with each optional item.
Optional item
Model
Optional item that needs to be
purchased separately
Display panel
UG-DP
Extension cable
Conversion
board
UG-TB*** (eight types including 1A
and 1V)
Current transformer (CT), PT
Communication
board
UG-CL, UG-MB
–

13
4UNIT CONNECTION DIAGRAM
L
Conversion
board
UG-TB
Communication
board
UG-CL
UG-MB
CN503
CN502
Load
Power
supply
Control
board
PCB1
Power supply, gate board
PCB2
200
0
1A
1C
HA
HC
+
S
-
PS
RT
HL
AT
ST
GT
PH
VE3
VF2
VH2
VL2
VE1
I1
D1
V1
CT1
THS1
THY1
F1
TF1
FAN1
Snubber circuit
PCB4
Display circuit
PCB3
K E
※Ensure that the design is safe by installing protective functions on the input side of the
main circuit using breakers or other devices.
※If the power supplied to the main circuit is not 200/220 V, use a transformer to change
the control power supply to 200/220 V.
※Wire the main circuit and control circuit with the correct polarities.
THY
Thyristor
CT
Current transformer
FAN
Cooling fan (air-cooled models only)
PCB
Printed circuit board
F
Fuse (only models with a fuse)
CN
Connector
TF
Fuse warning contact (only models with a fuse)
THS
Thermal switch

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5EXTERNAL CONNECTIONS OF THE UNIT
5.1 Control Terminal Block
Wire the control terminal block of the unit according to the following table. (Terminal screw: M3)
Terminal
Description about functions and purposes
When not in use
200
0
The inputs for the control power supply. These terminals need
to be wired according to the main circuit polarity.
Models with a rated current of 25 to 75 A: 25 VA, models with
a rated current of 100 to 450 A: 50 VA
–
1A
1C
External warning relay (1) output signal
The contact is closed when an error occurs. normally open ,
250 VAC and 1 A, 30 VDC and 1 A
Open
HA
HC
External warning relay (2) output signal
The contact is closed when an error occurs. normally open ,
250 VAC and 1 A, 30 VDC and 1 A
Open
+
S
–
Temperature control signal input
Connect (+) of temperature controller to (+) terminal and (-) of
temperature controller to (-) terminal.
Short-circuit “+” with “S” when the temperature controller is
a current source. 4 to 20 mA (DC)
Open “S” when the temperature controller is a voltage source.
0 to 5 VDC
Open
PS
Temperature control signal output
This terminal is used when a single temperature controller
controls multiple units.
You can also control multiple units by connecting a temperature
controller in parallel with them, instead of using PS.
PS
terminal
Advantage
Disadvantage
When
used
Control accuracy can
be retained even
when the number of
units connected in
parallel increases.
When the power supply to
one unit is interrupted, the
subsequent units also stop.
When
not
used
Even when the power
supply to one unit is
interrupted, the other
units can continue to
be operated.
When the number of units
connected in parallel increases,
the temperature controller
signal level lowers, decreasing
the control accuracy.
Open

15
Terminal
Description about functions and purposes
When not in use
VF2
VF2: Gradient (proportional) signal input
Short-circuited
with VE3
VH2
VH2: Manual (upper limit) signal input
Open
VL2
VL2: Lower point (lower limit) signal input
Short-circuited
with VE1
VE3
VE3 –VE1: +5 VDC output for a variable resistor
↑
VE1
When a variable resistor (1 kΩ) is connected, the inputs from
these terminals are used for setting. The output level is
determined by a combination of the three inputs. Setting
examples are shown in the following figure.
* Short-
circuiting is not
required when
the settings are
configured via
the panel or
communication.
HL
Two-position control signal input
• Short-circuited: Acts according to the manual (upper limit)
setting.
• Open: Acts according to the lower point (lower limit) setting.
Open
AT
Automatic/manual switching signal input
• Short-circuited: Automatic (control with a temperature
controller or two-position control)
• Open: Manual (control with the manual signal input)
–
Lower point setting Gradient setting
Ex.1 0% 100%
Ex.2 20% 100%
Ex.3 0% 50%
Ex.4 20% 50%

16
Terminal
Description about functions and purposes
When not in use
ST
Start/stop switching signal input
• Short-circuited: Starts operation. The output is gradually
increased during the soft-start time.
• Open: Stops operation. In the phase control, the output is
gradually decreased during the time specified with the soft-start
time.
In the cycle control, the output is stopped regardless of the soft-
start time.
Start/stop can also be switched using the panel or via
communication, instead of using the ST terminal.
The ST terminal is prioritized over the panel and communication.
The concrete behavior is as follows:
• When the start/stop status is switched via the panel or
communication, ST needs to be opened.
• When ST is short-circuited, the output cannot be stopped via
the panel or communication.
• The output started via the panel or communication stops
when ST is opened, short-circuited, and then opened again.
Open
GT
Emergency stop signal. This terminal is used to stop the output
in emergencies.
• Short-circuited: Permits the output. If the output has been
switched to the start status via the ST terminal, communication,
or the panel, the output resumes with a soft start when this
terminal is short-circuited.
• Open: Emergency stop. The output is unconditionally,
immediately, and forcibly stopped.
Short-circuited
with PH
PH
The output of −15 VDC for HL, AT, ST, and GT
–
RT
Connection prohibited (for maintenance)
Open
V1
Connect this terminal to the 3 V terminal on the secondary side
of the external PT.
Open
D1
Connect this terminal to the l terminal on the secondary side of
the external CT and the 0 V terminal on the secondary side of
the external PT.
Open
I1
Connect this terminal to the k terminal on the secondary side of
the external CT.
Open

17
200
1A
HA
+
S
-
PS
HL
AT
ST
GT
PH
I1
D1
V1
RT
VE 1
VL2
VH2
VF2
VE 3
HC
1C
0
200
0
1A
1C
HA
HC
+
S
-
PS
RT
HL
AT
ST
GT
PH
VE3
VF2
VH2
VL2
VE1
I1
D1
V1
+
S
-
+5V
-15V
3V
0V
l
k
L
K
210V
0V
Temperature
controller
(current source)
+
-
Temperature
controller
(voltage source)
+
-
Subsequent
units
UG1
+
UG1
Layout of the control terminal block Terminal block connection example
5.2 Connection Diagrams for Setting Methods
(1) Manual adjustment
(2) Two-position control
(3) Automatic adjustment 1 (4 to 20 mA [DC])
(4) Automatic adjustment 2 (1 to 5 VDC)
(5) Automatic adjustment 3 (0 to 5 VDC)
(6) Manual –Automatic 1 switching (4 to 20 mA [DC])
(7) Manual –Automatic 2 switching (1 to 5 VDC)
(8) Manual –Automatic 3 switching (0 to 5 VDC)
(9) Control of two or more UG1 units using a single temperature controller (4 to 20 mA [DC])
with the gradient set for each unit
(10) Control of two or more UG1 units using a single temperature controller (1 to 5 VDC) with
the gradient set for each unit
(11) Control of two or more UG1 units using a single temperature controller (0 to 5 VDC) with
the gradient set for each unit
The settings need to be changed on the display panel in addition to establishing the connection
according to the diagrams shown on the following pages.
The settings that need to be changed are expressed as shown in the following instruction.
Change the settings according to “7 DISPLAY PANEL.”
Example: Set [F101: Temperature controller type] to [0: 4 to 20 mA (1 to 5 VDC)].

18
(1) Manual adjustment
Set [F101: Temperature controller type] to [0: 4 to 20 mA (1 to 5 VDC)].
(1) Standard (2) With the gradient setting
(3) With the lower point setting (4) With the gradient setting
and the lower point setting
Manual
Manual
Gradient
Manual
Gradient
Manual
Lower
point
Lower
point

19
(2) Two-position control
Set [F101: Temperature controller type] to [2: Two-position control].
(1) Standard (2) With the proportional setting
(3) Upper limit setting only (4) Upper limit setting
and proportional setting only
Upper
limit
Lower
limit
Upper
limit
Lower
limit
Ratio
Upper
limit
Upper
limit
Ratio

20
(3) Automatic adjustment 1 (4 to 20 mA [DC])
Set [F101: Temperature controller type] to [0: 4 to 20 mA (1 to 5 VDC)].
(1) Standard (2) With the gradient setting
(3) With the lower point setting (4) With the gradient setting
and the lower point setting
Gradient
Lower
point
Lower
point
Gradient
Temperature
controller
Temperature
controller
Temperature
controller
Temperature
controller