Sontay RE-PR3-E Series User manual

Page 1
36 & 54kW 3-Phase panel mount, heater controller
RE-PR3-E-36/54
Data Sheet Ref: 90501161
Issue: 5.2
International Tel: [phone]
UK Sales Tel: [phone]
International Fax: [phone]
UK Sales Fax: [phone]
www.sontay.com
Whilst every effort has been made to ensure the accuracy of this specification, Sontay cannot accept responsibility for damage, injury, loss or
expense resulting from errors or omissions. In the interest of technical improvement, this specification may be altered without notice.
90800066 Issue 1
Technical Overview
Features
Specification Product Codes
The RE-PR3-E-xx are a range Thyristor control assemblies
that provides full seamless control of 3-phase resistive loads
of up to 36 & 54kW, using two thirds control technique. They
are controlled by a 0-5Vdc, 0-10Vdc signal or manual 5KΩ
pot.
This burst fire control assemblies use fast pulse, zero volt,
switching technology to minimise flicker and eliminate RFI
problems.
They also incorporate a temperature trip, automatic reset,
alarm output, LED ’output on’ indication and heatsink.
Applications include electric heater batteries and dust heat-
ers.
• 0-5Vdc, 0-10Vdc or manual 5KΩpot control input
• Over temperature protection with auto reset
• No additional heatsinks required
Input signal 0-5Vdc, 0-10Vdc or manual 5KΩpot
Supply (control) 24Vac/dc ±10% (by dipswitch)
Supply (load) 3-Phase 400V RMS ±10% 50/60Hz
Power /current ratings:
RE-PR3-E-36 36kW (50A per phase)
RE-PR3-E-54 54kW (75A per phase)
Fusing:
RE-PR3-E-36 56A H/S semiconductor (integral)
RE-PR3-E-54 80A H/S semiconductor (integral)
Terminal connections:
Auxiliary alarm Rising cage for 2.5mm² cable max.
Control Rising cage for 2.5mm² cable max.
Power:
RE-PR3-E-36 Rising cage for 10mm² cable max.
RE-PR3-E-54 Rising cage for 16mm² cable max.
Terminal torque settings:
RE-PR3-E-36 2Nm (power terminals only)
RE-PR3-E-54 2.5Nm (power terminals only)
Over temperature:
Trip in temp. @ 90°C ±1°C
Trip out temp. @ 85°C ±1°C
Fault condition Relay rated at 230Vac @ 8A
Fault status:
Phase loss LED flashes in 1.5 sec. pulse bursts
Sensor loss LED flashes in 0.5 sec. pulse bursts
Ambient temperature 65°C (maximum operational)
Dimensions (L, W, H):
RE-PR3-E-36 205 x 155 x 120mm
RE-PR3-E-54 250 x 155 x 120mm
Conformity CE Marked
Country of origin UK
RE-PR3-E-36
Panel mount 3-phase 36kW electric heater controller
RE-PR3-E-54
Panel mount 3-phase 54kW electric heater controller

Page 2
36 & 54kW 3-Phase panel mount, heater controller
RE-PR3-E-36/54
Data Sheet Ref: 90501161
Issue: 5.2
International Tel: [phone]
UK Sales Tel: [phone]
International Fax: [phone]
UK Sales Fax: [phone]
www.sontay.com
Whilst every effort has been made to ensure the accuracy of this specification, Sontay cannot accept responsibility for damage, injury, loss or
expense resulting from errors or omissions. In the interest of technical improvement, this specification may be altered without notice.
90800066 Issue 1
SAFETY REQUIREMENTS & ADVICE SHEET
Introduction
The objective of this leaflet is to provide information to en-
sure that the safety of the person(s) installing or maintaining
the equipment is not compromised and its location and
method of installation does not endanger others, either dur-
ing or after installation.
Customers should be aware of the Health and Safety at
Work Act 1974 (HSW 1974) and the EC “Provision and Use
of Work Equipment Regulations 1992” (PUWER). Both are
available from the Health and Safety Executive (HSE) publi-
cations, within the UK.
Installation
CE Directives
These are European regulations which apply to our industry.
They affect the equipment emissions and immunity to Radio
Frequency Interference (RFI) and various elements of safety
for electrical equipment.
The European Community ‘CE’ Directives that mainly con-
cern Sontay Ltd are, the Low Voltage Directive (LVD)and
the Electromagnetic Compliance Directive (EMC).
A Declaration of Conformity may be supplied with the prod-
uct or supplied on request.
Torque Settings
Good working practises must be adhered to ensuring appro-
priate electrical and mechanical installation. This would in-
clude the mechanical fixing of potentiometer bushes and
electrical set screw and/or pillar connections. These Electri-
cal Connections and Mechanical Fastenings must not be
over tightened. We would recommend a typical torque set-
ting of 1 to 5Nm. For specific product information, see ap-
propriate product data sheet, where applicable.
Cooling Requirements
The use of an additional heatsink (this could be a conductive
panel) suitably attached or mounted with the unit, will help to
dissipate heat away from the device(s). An alternative or
additional method would be forced air-cooling (using a fan),
to assist the natural convection of airflow over an existing
heatsink within the unit. The product fins should be mounted
in line with the forced and/or natural airflow.
The equipment’s environment and its initial ambient tem-
perature also need to be considered, as this could have an
adverse effect on the overall operating conditions.
Fusing
We recommend that semiconductor, fast acting to BS88 IEC
269, type fuses or circuit breakers (Semiconductor - MCB)
should be used for unit and/or device protection. The appro-
priate maximum load current should be known to select the
required SCR fuse or MCB, but must not exceed the equip-
ment rating. The I² t (A² s) rating of the selected fuse must
be less than that of the equipment so as to protect the equip-
ment’s discrete device. Further appropriate fusing may be
required for protection of the unit supply using standard fuse
links and holders. Failure to address these requirements
and the use of incorrectly selected fuses may cause the
equipment to fail.
Earthing
The protective conductor terminal of the equipment must be
utilised at all times and bonded to a ‘good’ Earth (ground).
The earth bonding (strapping) leads of any combined equip-
ment should be as short as possible and be substantial, i.e.
at least rated higher than the equipment’s load. For further
information, refer to BS7671. Following these simple guide-
lines will ensure optimum use of any appropriate filter cir-
cuits which may be required.
Insulation (over-voltage category) and Protection from
electric shock Classification of Equipment
All equipment, unless otherwise stated, is rated to CLASS II
Insulation (Over-voltage category) and CLASS I (Protection
category).
Maintenance
Before any servicing is carried out, reference should be
made to appropriate installation instructions, drawings and
labelling which may come with the equipment. Personnel
should switch off the unit supply before accessing or remov-
ing any safety cover and be aware of hazardous live parts.

Page 3
36 & 54kW 3-Phase panel mount, heater controller
RE-PR3-E-36/54
Data Sheet Ref: 90501161
Issue: 5.2
International Tel: [phone]
UK Sales Tel: [phone]
International Fax: [phone]
UK Sales Fax: [phone]
www.sontay.com
Whilst every effort has been made to ensure the accuracy of this specification, Sontay cannot accept responsibility for damage, injury, loss or
expense resulting from errors or omissions. In the interest of technical improvement, this specification may be altered without notice.
90800066 Issue 1
Location & ventilation Back-up protection and load supply
The RE-PR3-E-xx power controllers are designed for mount-
ing on a vertical panel, with the heatsink fins to the bottom. It
is important that free air movement around the heatsink is
not restricted. Allow sufficient air space between adjacent
units to allow optimum performance of the heatsink.
The maximum ambient of 65°C should not be exceeded.
Where necessary control panels & enclosures should be
ventilated with a fan.
Load considerations
The RE-PR3-E-xx series of power controllers are designed
for resistive type loads only. Capacitive, or unusual heating
loads such as Molybdenum, Platinum or Tungsten, (which
can have a 10:1 hot to cold resistance ratio) are not suitable.
Over temperature monitoring
The RE-PR3-E-xx are fitted with a thermal protection device
to protect against over temperature. The unit will automati-
cally switch off the load in the event of the heatsink tempera-
ture exceeding safe limits (90°C ±1°C). Once the tempera-
ture has fallen to a safe level (85°C ±1°C) the load will be
switched on again if the supply is still present.
Under normal operating conditions the heatsink will not
reach 90°C but this might occur, for example when the ambi-
ent temperature exceeds 65°C.
Caution: During the course of normal operation metal parts,
in particular the heatsink, may get very hot.
Control supply
The RE-PR3-E-36 and RE-PR3-E-54 are factory set for a
internal 24V power supply.
If using an external 24Vac/dc supply you must change the
DIP switch SW4 on the PCB prior to applying power. This
is polarity independent.
Important! The external 24Vac/dc supply MUST NOT be
commonly linked to the control 0V signal terminal. Failure to
comply with this may result in the on board transformer over-
heating, the 1A fuses blowing and damage to the bridge
rectifier.
If there is a requirement for the alarm relay and LED to ener-
gise when any of the 3 phases fails, the external, isolated
24Vac/dc supply option must be used.
Earth connection
The RE MUST be earthed. A protective earth connection is
provided in the main terminal connections.
The RE-PR3-E-xx are protected by internal quick acting
semiconductor type fuses.
Load cables must be sized such that they are rated in ex-
cess of the fuse ratings.
It is recommended that a load break switch and a break
contactor is installed in the load supply. The supply to the
contactor coil should be interrupted by an over-temperature
thermostat located in the heater battery and also upon de-
tection of airflow loss.
Fault conditions
The factory default setting of DIP switch SW1 is the ON
position. In this position, the alarm relay will be energised
only when a fault condition occurs.
Changing SW1 to the OFF position will cause the alarm
relay to be energised continuously until a fault condition
occurs.
If the internal 24V supply is used, a fault condition will occur
on over temperature or if the L1 phase only is missing. If an
external 24V supply is used, a fault condition will occur on
over temperature, temperature sensor failure, or if any of the
3 phases are missing.
Should the 24V supply fail the output of the unit will fail to
OFF with no output.
Phase loss with auxiliary supply
When any one of the three phase inputs are missing, the
relay changes state and the LED flashes ON/OFF bursts of
1.5 seconds.
Note - This is only true when using an external 24V supply.
Alarm relay
The alarm relay has contacts rated up to 8A @ 230Vac
(RMS) load. Where the internal 24V supply is used, the relay
obtains its supply from the transformer via two 20mm 1A
fuses, and are connected to the L2 and L3 phases. There-
fore the alarm relay can only change state when there is an
over-temperature condition, a sensor fault, or if the L1 phase
only is missing.
Manual control
The units output can be controlled manually by using a 5kΩ
linear potentiometer connected as shown on page 4, with
the input signal set to 5Vdc (SW4).
Note: A 5kΩlinear potentiometer MUST NOT be connected
at same time as an external control signal.

Page 4
36 & 54kW 3-Phase panel mount, heater controller
RE-PR3-E-36/54
Data Sheet Ref: 90501161
Issue: 5.2
International Tel: [phone]
UK Sales Tel: [phone]
International Fax: [phone]
UK Sales Fax: [phone]
www.sontay.com
Whilst every effort has been made to ensure the accuracy of this specification, Sontay cannot accept responsibility for damage, injury, loss or
expense resulting from errors or omissions. In the interest of technical improvement, this specification may be altered without notice.
90800066 Issue 1
Installation
1. The RE-PR3-E-xx should only be installed by a compe-
tent, suitably trained technician, experienced in installa-
tion with hazardous voltages. (>50Vac & <1000Vac or
>75Vdc & 1500Vdc)
2. Ensure that all power is disconnected before carrying out
any work on the RE-PR3-E-xx.
3. Maximum cable is 2.5mm² for control supply and 10mm²
for phase power. Care must be taken not to over tighten
terminals.
Connections
Dip Switches
SW1 (relay status):
ON = Standard
OFF = Reverse
SW3 (control signal):
ON = 0-10Vdc signal
OFF = 0-5Vdc signal
SW4 (remote supply):
INT = Uses internal transformer
EXT = External 24V supply
WARNING! Do not connect neutral to star point of heater.
Load
Load
Load
Load
Load
Load
Star configuration: Delta configuration:
Safety earth
Must be
connected
Heater
Auxiliary
0V
0-10/0-5Vdc
Input
signal
CW
CCW
5KΩ
Potentiometer
Volt free
alarm
contacts
Status
SW3 SW4
polarity
independent