Thermokon TS1 3Ph Series Instruction manual

Thermokon Sensortechnik GmbH - Thyristor controller TS1 3Ph, TS1 SP 3Ph
1
Start-up instructions
Thyristor controller
Type: TS1 3Ph, TS1 SP 3Ph
Three phase controller W3C
Version: 2018/06/25
TS1 3Ph...
TS1 SP 3Ph...
L1 L2 L3
Content
Page
1.
2.
3.
3.1 Explanation phase angle control Ph....................................................................4
3.2 Explanation multicycle control SP (burst-firing-control)....................................... 5
4.
5.
6.
7 Meaning of the clamp connections and LEDs..................................................... 9
8.
9. Survey of the individual types.............................................................................11
10. Technical data....................................................................................................12
Important safety instructions................................................................................2
General instructions.............................................................................................2
Technical explanations of thyristor controllers.................................................... 3
Installation of the thyristor controller TS1 3Ph, TS1 SP 3Ph............................... 6
EMC-equitable assembly.....................................................................................6
Operation.............................................................................................................8
Basic circuit........................................................................................................10

2
1.
This manual contains instructions, which have to be observed for your personal safety and for the pre-
vention of material damage. The instructions about your personal safety are highlighted with a warning
triangle labelled with three exclamation marks, hints about material damages are listed with a warning
triangle and one exclamation mark.
Danger-symbol
Personal injury may occur, if appropriate safety precautions are
not taken.
Caution-symbol
Material damages may occur, if appropriate safety precautions are
not taken into account.
Disposal regulations
The devices contain electrical components and must not be disposed together with house-
hold garbage. The devices for disposal have to be recycled according to local and currently
valid regulations for electronic waste.
Qualified personnel
The corresponding device/system may only be set up and operated in conjuntion with this documenta-
tion. Commissioning and operation of the device/system may only be performed by qualified person-
nel. Qualified personnel within the meaning of the safety instructions in this documentation are per-
sons with the authority to put electric circuits into operation, provide ground connections and label them
according to current safety regulations.
The device should only be used in applications described in this document. The reliable and proper use
of the product depends on appropriate transport, storage, installation and careful commissioning.
2.
Use of the document
This instruction should demonstrate the technical application possibilities of the thyristor controller to
the engineer in charge.
Target group
The document should assist the user during commissioning. It also helps in case of service and main-
tenance work. It supports the planner and project engineer with the conception of new plants.
Necessary competence
Generic skills in the field of electrical engineering are necessary.
Validity
The present document is valid for the thyristor controller of the type . It contains the
currently valid description of the unit. We reserve the right to attach new descriptions of the devices.
This involves types and options with modified version status of the technical documents.
Standards and approvals
The thyristor controller of the type are based on the IEC/EN 60947-4-3
standard.
Important safety instructions
General instructions
TS1 3Ph, TS SP 3Ph
TS1 3Ph, TS1 SP 3Ph
Disclaimer
It lies within the responsibility of the plant manufacturer of the technical equipment or machine to ensu-
re the proper overall function. The producer can not guarantee all properties of the overall system or
the machine.
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Thermokon Sensortechnik GmbH - Thyristor controller TS1 3Ph, TS1 SP 3Ph

Technical explanations on thyristor controllers
The power element of the
thyristor controller consists at the TS1 1Ph... of two, at the TS1 3Ph of six antiparallel connected
thyristors, the isolated cooling system and the electronic regulation and watching.
Type description:
Construction:
The thyristor controller agrees with Low voltage directive: 2014/35/EU, EN60947-4-3 and
EMC Directive: 2014/30/EU, EN60947-4-3 Kl.A.
3.
The thyristor controller is more and more used in sectors in which bigger loads of ohm and inductive
loads have to be regulated.
Due to its modular, compact construction and its controlling by a continual control signal, these wattage
regulators become a perfect device for industrial control of wattage input.
The thyristor controller TS1 3Ph... is integrated within a plastic housing (PA, UL 94 V-0).
It consists of two basic elements:
Auxiliary Voltage:
The devices are powered internal by the mains voltage. Optional can devices with different mains
voltage be supplied with an external auxiliary voltage.
• power unit with heat sink and thyristor wiring
• control unit with ignition and control electronics (diagnostic display, control output, etc.)
• optional can devices with different mains voltage be supplied by an external auxiliary voltage
3
TS1 1Ph...
TS1 3Ph...
The following devices use a cooling plate:
TS1 (SP) 3Ph 02
TS1 (SP) 3Ph 04
The following devices use a heat sink:
TS1 (SP) 3Ph 06
The following devices use a heat sink with fan
TS1 (SP) 3Ph 08
TS1 (SP) 3Ph 10
power
connections
connections for the
control electronic
auxiliary contact at 100%
Thyristor controller
TS1 3Ph...
TS1 SP 3Ph...
Mains 100% Ua
PE
Y1 Y2
34598
L1 T3 N
Option
L2 L3 T1 T2 L1
Monitoring LED’s:
TS1 SP 3Ph...
TS1 SP 1Ph...
single phase controller, phase angle control
three phase controller, multicycle control
single phase controller, multicycle control
three phase controller, phase angle control
Switch
Thermokon Sensortechnik GmbH - Thyristor controller TS1 3Ph, TS1 SP 3Ph

4
3.1 Explanation phase angle control Ph
The phase angle control is an electrotechnical method to regulate the electrical power of loads with
single phase current or three phase current. A typical use of this technology is dimming of light bulbs
and various inductive and ohmic components. The effective value of the voltage as well as the
electrical power consumption of the load can be changed by altering the switch-on moment. For many
electrical engines with suitable construction (for example universal motors, asynchronous motors, fan
motors or pump motors) a phase angle control can be used to control speed and torque. Due to the
controllability of the positive and negative half-wave it is possible to adjust exactly the load voltage and
to implement precise control applications. The variation of the phase angle α also allows the control of
transformers for softstart- and control applications.
ULAST
t
α
Thermokon Sensortechnik GmbH - Thyristor controller TS1 3Ph, TS1 SP 3Ph
P U I U V
V
st
= × × æ
è
çö
ø
÷
max max
[ ]
10
2
U U U V
V
st
= ×
max
[ ]
10
I I U V
V
st
= ×
max
[ ]
10
Umax
Imax
P
max
Voltage U, current I, active power P with linearized characteristic
Phase angle control
U, I, P (normalized to maximum values)
Voltage U, current I (normalized)
Active power P (normalized)

5
3.2 Explanation multicycle control SP (burst-firing control)
In this operating mode the thyristor controller ensures the targeted switching of individual full waves of
the power supply. Depending on the control signal individual halfwaves (positive half-waves, negative
half-waves) and wave packets can be switched, in which the switching point is always at the sinus zero
crossing. The impulse(T )-pause(T )-ratio controls the electrical power. This kind of operation mode
AN AUS
reduces system perturbation. As basis for the switching intervals (impulse-pause-ratio) the devices
normally operate with a time base T of one second (1s corresponds to 50 full-waves). Possible
application ares are electric heatings, heat technology, and drying technology. Newer models offer
combinations of phase angle control and multicycle control SP as well as different adjustment options
in relating to the implulse (T )-pause(T )-ratio.
AN AUS
For example:
A control signal of Ust = 5V with a control range of 0 to 10V creates a impulse duration T of 25 full-
AN
waves (500 ms) and a pause duration T of 25 full-waves (500ms).
AUS
TAN TAUS
T
t
ULAST
Thermokon Sensortechnik GmbH - Thyristor controller TS1 3Ph, TS1 SP 3Ph
P U I U V
V
st
= × ×
max max
[ ]
10
I I U V
V
st
= ×
max
[ ]
10
U U U V
V
st
= ×
max
[ ]
10
Umax
Imax
P
max
U, I, P (normalized to maximum values)
Voltage U, current I, active power P
multicycle control
Voltage U, current I (normalized)
Active power P (normalized)

4. TS1 3Ph, TS1 SP 3Ph
The built-in device according to IP 40 has to be mounted in a housing or a switchboard panel. Take care
of adequate cooling (separate ventilation, for instance). The environment temperature must not ex-
ceed the value of 50°C. The device is to be mounted on a vertical plane, avoiding that the ventilating
pipes of the cooling element are not placed vertical. The device has to be mounted in a dry room.
Further conditions to the operating area:
Ÿ protection from dust and moisture
Ÿ protection from aggressive atmosphere
Ÿ free from vibrations
No other devices should be placed closer than 50 to 100mm
to the device, in order to provide adequate cooling.
The housing design according to IP 54 (Option)
can be mounted in places which are not protected from dust and humidity.
Wiring the device:
The mains connections (L1, L2, L3) have to be connected by using a disconnecting switch and usual
fuses.
The connection for mains cable and the connections for controlling have to be laid in channels and
protector tubes.
The electric installation always has to comply with the essential protection requirements of the Euro-
pean Low Voltage Directive 2014/35/EU and Electromagnetic compatibility Directive 2014/30/EU.
5. EMC-equitable assembly
According to EMC standards thyristor controllers are regarded as components, which do not fulfil any
intended use by themselves. The devices constitute a functional unit of the entire plant. The control
electronics of the thyristor controllers are implemented according to valid EMC standards.
The builder of the plant has to supply the plant with appropriate mains chokes and mains filters. These
components can also be obtained from us. Thyristor controllers with multicycle control usually do not
require any additional mains filter circuit.
It should be noted that the standards of the resource category A are not sufficient in a special industrial
sector, for example if sensitive measuring channels are affected. In this case, the user has to apply
equipment of class B.
The class A is the usual class of equipments, which is normally intended for the use in the industrial sec-
tor. The devices are connected to the industrial network via an assigned transformer. Power controllers
of class B are required if they should be used in the area of industry and small-scale industry and if they
should be connected to the public low-voltage system.
Use of mains chokes:
On the input side of the thyristor controllers, mains chokes reduce the current-dependent line reactions
and effect an improvement of the performance factor. This reduces the current harmonics and impro-
ves the mains quality. The use of mains chokes is particularly recommended when connecting thyristor
controllers with phase angle control to a grid-feeding point and when other electronic devices are
attached to this network.
Installation of the thyristor controller
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!
6
50-100mm
50-100mm
H
W
D
TS1 3Ph
TS1 SP 3Ph
Thermokon Sensortechnik GmbH - Thyristor controller TS1 3Ph, TS1 SP 3Ph

Use of mains filters:
Radio interference filters and mains filters (combination of radio interference filter and one mains
choke) serve for protection against high-frequency disturbances, which are sent out via the power
cable or the radiation of the power cable. The high-frequency disturbances should be limited to a
mandatory or legal degree. Mains filters should possibly be mounted close to the thyristor controller
and moreover it is necessary to ensure that the connecting cable between the thyristor controller and
the mains filter is as short as possible.
CAUTION: The mounting surfaces of the thyristor controllers and the radio interference filters have to
be free from paint and well conducting in the high-frequency range.
Furthermore, mains filters have leakage currents, which may become significantly larger than the
nominal values in case of failure (phase failure, unbalanced load). To avoid dangerous voltages, the
mains filters have to be grounded. As the leakage currents are high-frequent disturbances, the
grounding measures have to be low-resistance and extensive.
With leakage currents, which exceed the value of 3,5mA, VDE 0160 or EN 60335 specify that either:
Ÿ the cross section of the protective conductor has to be ≥ 10mm²,
Ÿ the protective conductor has to be monitored on interruption or
Ÿ a second protective conductor has to be laid.
Shielding measures:
Shielding measures help to reduce the radiated interference energy. Electrical lines between thyristor
controller and load can be laid shielded. Thereby the shield must not replace the PE line. Four-wire
cables (three phases + PE), whose shield is double-sided and extensive laid on earth potential (PES),
are recommended. The shield must not be applied over the connecting wires. Interruptions of the
shielding e.g. in the case of clamps, contactors, mains chokes etc. have to be bridged with low-resis-
tance and appropriate space considerations.
In practice this can be done for example by interrupting the shield close to the assembly and then
connecting it extensively with the earth potential (PES, shield clamp). The free cables, which are not
shielded, should not be longer than 100mm.
Grounding measures:
Grounding measures are absolutely necessary to fulfil legal provisions. They constitute a prerequisite
for an efficient use of further measures such as filters and shielding. All conductive, metallic housing
components have to be electroconductive connected with the earth potential. For the EMC-measure,
the important factor is not the cable´s crosssection, but its surface, since this is where high frequency
current flows to earth. Once again, all grounding points have to be led directly, extensively and with low-
resistance to the central grounding point (equipotential bonding bar, star-shaped grounding system).
The contact points have to be free from paint and corrosion (use galvanized mounting plate and
materials).
7
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Thermokon Sensortechnik GmbH - Thyristor controller TS1 3Ph, TS1 SP 3Ph

6.
To begin with, all electronical connections have to be established according to the circuit diagrams L1,
L2, L3, T1 (U), T2 (V), T3 (W). The thyristor controller has to be connected to the mains according to the
electric regulations (Low Voltage Directive) so that they can be separeted by disconnecting switches
(e.g. load interrupter, contactor etc.) from the mains.
Cabling must be performed by personnel who are qualified to work low voltage electrical equipment.
Before any connection or disconnection, make sure that the power and control cables and wires are
isolated from the voltage sources.
Recommended connection:
The mains connections, the connection to the load and the control connections have to be laid in sepa-
rate cables. In order to avoid faults the electronic control connections should be separated from the
power wires and/or contactor control wires and one should twist the control wires. In order to reduce
risks related to the effects of electromagnetic interference depending on the installation of the product
please consider the rules for electromagnetic compatibility.
Fuses:
The net-lateral security depends on the recommended and/or the used cross-section of a wire and has
to be made according to DIN 57100 part 430/VDE 0100 part 430/6.81 (Low Voltage Directive).
Operation
8
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Thermokon Sensortechnik GmbH - Thyristor controller TS1 3Ph, TS1 SP 3Ph

7. Meaning of the clamp connections and LEDs
9
Mains voltage (Ui)
Load voltage (Ua)
Control
Activation
Option
T1, T2, T3
3, 4
L1, L2, L3
5
Y1, Y2 closed
open
connection of the maximum load (see table on page 9)
control signal 0...10V DC or 0...20mA DC (switchabel with DIP-switch)
activated
ready
connection of 400V/50Hz
(optional: any other voltages can be realized upon request)
reference voltage 10V DC
(voltage supply for potentiometer control)
Uref (+10V) Ust 0V/M
Switch
Monitoring LED’s:
Y1 Y2 34598
Thyristor controller
TS1 3Ph...
TS1 SP 3Ph...
Mains 100% Ua
0...20mA
0...10V
ON
100% Ua
0...10V
or
0...20mA
0V/
Activation 2,5kW...10kW
alternative
controlling
Load
voltage
Ua
Mains voltage
Ui
Output terminals
100% Ua
PE L1 L2 L3 T1 T2 T3
Thermokon Sensortechnik GmbH - Thyristor controller TS1 3Ph, TS1 SP 3Ph
Meaning of the LED’s
Mains
100% Ua
mains voltage is available, device is ready for use
Switching output
8, 9
switching output 100% Ua
(switching contact will be closed after reaching of 100% output voltage)
Contact rating: AC1: 250V AC, 3A
AC1: 24V DC, 3A
device has reached full conduction (full transfer of the mains voltage to load)

8. Basic circuit
10
L1
F1 F2
L2
L3
N
PE
Uref (+10V) Ust 0V/M
0...10V
or
0...20mA
0V/
Activation Poti 10kW
Monitoring LED’s:
PE L1 L1 N
L2 L3 T1 T2 T3
Y1 Y2 34598
load
ohm or
inductive
(Option)
if external
supply voltage
is used
Thyristor controller
TS1 3Ph...
TS1 SP 3Ph...
Mains 100% Ua
Switch
0...20mA
0...10V
ON
alternative
control
Output terminals
at 100% Ua activated
(contact rating: AC1: 250V AC, 3A
DC1: 24V DC, 3A)
Thermokon Sensortechnik GmbH - Thyristor controller TS1 3Ph, TS1 SP 3Ph

9. Survey of the individual types
Errors and technical modifications excepted (Date: 2018/06)
* The given details also apply to the version with multicycle control TS1 SP 3Ph...
The given values refer to the operation voltage of 3x400V AC. The values given for overload refer to a
surrounding temperature exceed of max. 50°C and an installation altitude of 1000m.
11
[kg][W][kW][mm²][A][A][A] [mm]
Type*
max. load
current
rec. semi-
conductor
fuses
rec. cross-
section
max. power
power loss
at nominal
rating
Weight
Dimensions
WxHxD
mains fuse
Frame size
TS1 3Ph
TS1 SP 3Ph
H
W
D
100 mm
100 mm
100 mm
75 mm 75 mm 75 mm
2 mm
33 mm
25 mm
Fan
Mains
Mains Mains
100% Ua
100% Ua100% Ua
PE
PE PE
Y1
Y1 Y1
Y2
Y2 Y2
3
3 3
4
4 4
5
5 5
9
9 9
8
8 8
L1
L1 L1
T3
T3 T3
N
N N
(Option)
(Option) (Option)
L2
L2 L2
L3
L3 L3
T1
T1 T1
T2
T2 T2
L1
L1 L1
Monitoring LED’s:
Monitoring LED’s: Monitoring LED’s:
Frame size A
Frame size B Frame size C
SwitchSwitch
Switch
TS1 3Ph 02
TS1 3Ph 10
TS1 3Ph 06
TS1 3Ph 04
TS1 3Ph 08
0,4
0,5
0,5
0,4
0,5
7
31
19
13
25
1,2
6,5
4,0
2,5
5,0
1,5
2,5
1,5
1,5
2,5
6
16
10
6
10
4
10
8
4
10
2
10
6
4
8
100x77x110
100x108x110
100x100x110
100x77x110
100x108x110
A
B
A
C
C
Thermokon Sensortechnik GmbH - Thyristor controller TS1 3Ph, TS1 SP 3Ph

10.
^
Technical data
see table on page 9 (2...10A)
self-synchronizing
phase angle control (optional: multicycle control)
48Hz...62Hz
ohmic and inductive load
according to VDE 0160, Tab. 6 / DIN EN50178 table 18
4G
F according to DIN 40040
PA, UL 94 V-0
VDE 0160, EN 60204, IEC 947-4-2
• housing: IP 40
• clamps: IP 23
mounting on a DIN rail
(DIN 46277-3; 35x7,5mm)
Declaration of Conformity 2014/35/EU (Low voltage directive)
EMC Directive 2014/30/EU for industrial environments
• operation: 0...45°C
• storage: -10...70°C
• LED „mains“ (green): device is ready for use
• LED „100% Ua“ (green): device has reached full conduction
Relais „100% Ua“
Contact rating: 250V AC 3A; 24V DC 3A
Max. load current
Phase sequence
Operation mode
Mains frequency
Kind of loads
Test voltage
Vibration resistance
Humidity class
Housing
Regulations
Inputs
Protection class
Mounting
CE-marking
Ambient temperature
Indication of operation state
Signal contact
Auxiliary Voltage
12
• 0...10V DC
• 0...20mA DC
• potentiometer input: 2,5kΩ...10kΩ
Thermokon Sensortechnik GmbH - Thyristor controller TS1 3Ph, TS1 SP 3Ph
Mains voltage
400V AC, 50-60Hz (optional: further mains voltages available)
generation internal