West Control Solutions PMA Relay C User manual

Rev. 01/2019
PMA-C3-60-210A
Relay C
3PH from 60A to 210A
User Manual
www.west-cs.co.uk

A publication of:
PMA
Prozeß- und Maschinen-Automation GmbH
P.O.Box 310 229 • D-34058 Kassel • Germany
All rights reserved.
No part of this document may be reproduced or published in any form or by any means without
prior written permission from the copyright owner.
Liability and warranty
Any information and notes in these operating instructions were composed under consideration of
the applicable regulations, the present state of the art and our extensive know-how and experience.
With special versions, additional ordering options or due to the latest technical modications, the
actual scope of delivery may vary from the descriptions and drawings in this manual.
For questions, please, contact the manufacturer.
Before starting to work with the instrument and before commissioning, in particular, these
operating instructions must be read carefully! The manufacturer cannot be held responsible
for damage and trouble resulting from failure to comply with the information given in this
manual.
This product may be subject to change due to improvements of the product features in the
course of further development.
Copyright
This operating manual should be considered as condential information, intended only for persons
who work with the instrument.
Contraventions are subject to payment of damages. Further claims reserved.
www.west-cs.co.uk 2

Contents
1. Important warnings for safety.............................................................................................................................. 5
2. Maintenance........................................................................................................................................................... 10
3. Introduction............................................................................................................................................................ 11
A thyristor unit is semiconductor device which acts as a switch formed by two thyristors in ant parallel..... 11
3.1. Advantages compared with analog thyristor unit ........................................................................................... 11
3.2. Overview ............................................................................................................................................................. 12
4. Software Congurator........................................................................................................................................... 13
Thyristor congurator software is free and is Thyristor congurator software is free and is .......................... 13
5. Quick Start ............................................................................................................................................................. 14
6. Basic Connections and sizing.............................................................................................................................. 15
7. Identication .......................................................................................................................................................... 16
7.1. Identication of the unit..................................................................................................................................... 16
8. Order Code............................................................................................................................................................. 17
8.1. Notes on the options:......................................................................................................................................... 18
8.1.1 I LIMIT (CURRENT LIMIT) ............................................................................................................................... 18
8.1.2. Heaterbreak Alarm (HB) .................................................................................................................................... 18
8.1.3. Datalogger ......................................................................................................................................................... 18
8.1.4. Energy totalizer.................................................................................................................................................. 18
9. Technical specications ....................................................................................................................................... 19
9.1. General features ................................................................................................................................................. 19
9.2. Input features...................................................................................................................................................... 19
9.3. Output features (power device)......................................................................................................................... 19
9.4. Fan Specication (only from 90 to 210A)......................................................................................................... 19
9.5. Environmental installation conditions ............................................................................................................. 20
9.6. Derating curve .................................................................................................................................................... 20
9.7. Calculating ow capacity of the fan ................................................................................................................. 20
10. Installation............................................................................................................................................................ 21
10.1. Dimensions and weight ................................................................................................................................... 22
10.2. Fixing holes ........................................................................................................................................................ 22
11. Wiring instructions.............................................................................................................................................. 23
11.1. Terminal Positions............................................................................................................................................ 23
11.2. Power Terminals ............................................................................................................................................... 23
11.3. Control Terminals ............................................................................................................................................. 24
11.3.1. Terminal block M1 ............................................................................................................................................ 24
11.3.2. Terminal block M3 ........................................................................................................................................... 24
11.4. Schematic.......................................................................................................................................................... 25
11.4.1 SSR Control Input Schematic .......................................................................................................................... 26
11.5 Connection Diagram for 3 phases ................................................................................................................... 27
12. Control Panel ...................................................................................................................................................... 28
12.1. Menu navigation ............................................................................................................................................... 29
12.2. Control Panel Led............................................................................................................................................. 30
12.3. Displayed alarms.............................................................................................................................................. 30
12.4. Parameter list.................................................................................................................................................... 31
12.4.1 Operator Menu.................................................................................................................................................. 31
12.5 Setup Menu ........................................................................................................................................................ 32
12.5.2 Advanced Setup Menu ..................................................................................................................................... 32
12.5.3 Hardware Menu................................................................................................................................................ 34
12.5.4. Communication Menu ..................................................................................................................................... 37
12.5.5 Monitoring Menu.............................................................................................................................................. 38
13. Using the Congurator ....................................................................................................................................... 41
13.1 Typical Uses ..................................................................................................................................................... 41
13.2 Communicating with Power Controllers ......................................................................................................... 41
13.3 Recipes............................................................................................................................................................... 41
13.3.1 Upload a recipe ................................................................................................................................................ 41
13.3.2 Download a recipe............................................................................................................................................ 41
13.4 How To................................................................................................................................................................ 41
13.4.1 Install and communication with the power controller ...................................................................................... 41
13.5 Using the Congurator ..................................................................................................................................... 42
13.5.1 To view or save a power controller’s settings ................................................................................................... 42
using “Simple” view section:........................................................................................................................................ 42
13.5.2 To edit a setting in a recipe: ............................................................................................................................. 43
13.5.3 To download a recipe le into a power controller:............................................................................................ 43
13.5.4 To monitor a power controller with the Test view: ............................................................................................ 43
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13.5.5 To log in on the test view to change the digital input and analog input functions:............................................ 43
13.5.6 To log out the test view:.................................................................................................................................... 43
13.5.7 To view data on the scope:............................................................................................................................... 44
13.5.8 To reset the power totals: ................................................................................................................................. 44
13.5.9 Setting Up and Using Data Logging................................................................................................................. 44
13.5.10 To retrieve a data log le from the power controller: ...................................................................................... 45
13.6 Software General information .......................................................................................................................... 45
13.6.1 Program Window .............................................................................................................................................. 45
13.6.2 Simple Section ................................................................................................................................................. 45
13.6.3 Test Section...................................................................................................................................................... 46
13.6.4. Load Analyzer.................................................................................................................................................. 48
13.6.5 Data Log Window ............................................................................................................................................. 49
13.6.6 Data Log Conguration window ....................................................................................................................... 49
13.6.7 MSG view ......................................................................................................................................................... 50
13.6.8 Settings window ............................................................................................................................................... 50
14. Firing type ............................................................................................................................................................ 51
14.1 Zero Crossing .................................................................................................................................................... 51
14.2 Single Cycle ....................................................................................................................................................... 51
14.3 Burst Firing ........................................................................................................................................................ 51
14.4 Soft Start with Burst Firing............................................................................................................................... 52
14.5 Phase Angle ....................................................................................................................................................... 52
14.6 Soft Start with Phase Angle.............................................................................................................................. 52
14.7 Delay Triggering with Burst Firing................................................................................................................... 53
15. Current Limit........................................................................................................................................................ 54
15.1 Current Limit Setting......................................................................................................................................... 54
15.2 Current Limit tuning procedure ....................................................................................................................... 54
16. Bakeout in function............................................................................................................................................. 55
16.1 What is heater bakeout?................................................................................................................................... 55
16.2 How does heater bakeout work? ..................................................................................................................... 55
17. Control Mode (feed-back) ................................................................................................................................... 56
18. Supply the Electronic Board .............................................................................................................................. 57
19. RS485 Serial port................................................................................................................................................. 58
20. Fieldbus communication option ....................................................................................................................... 58
21. Internal Fuse ........................................................................................................................................................ 59
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1. Important warnings for safety
This chapter contains important information for the safety. The not observance of these instructions may result
in serious personal injury or death and can cause serious damages to the Thyristor unit and to the components
system included.
The installation should be performed by qualied persons.
In the manual are used symbols to give more evidence at the notes of safety and operativity for the attention
for the user:
This icon is present in all the operational procedures where the Improper operation may result in serious
personal injury or death by Electrical Shock Hazard Symbol (a lightning bolt in a triangle) precedes an
electric shock hazard CAUTION or WARNING safety statement.
Warning or Hazard that needs further explanation than the label on unit can provide. Consult User’s Guide
for further information.
Unit is compliant with European Union directives.
See Declaration of Conformity for further details on Directives and Standards used for Compliance.
If available, unit is a Listed device per Underwriters Laboratories. It has been investigated to ANSI/UL®
508 standards for Industrial Control Switches and equivalent to CSA C22.2 #14.
For more detail search for File E505847 on www.ul.com
IND. CONT. EQ.
E231578 2RD5
ESD Sensitive product, use proper grounding and handling techniques when installing or servicing prod-
uct.
Do not throw in trash, use proper recycling techniques or consult manufacturer for proper disposal.
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A “NOTE” marks a short message to alert you to an important detail.
A “CAUTION” safety alert appears with information that is important for protecting your equipment and performance.
Be especially careful to read and follow all cautions that apply to your application.
A “WARNING” safety alert appears with information that is important for protecting you, others and equipment
from damage. Pay very close attention to all warnings that apply to your application.
1.1. Safety notes
WARNING! To avoid damage to property and equipment, injury and loss of life, adhere to applicable electrical
codes and standard wiring practices when installing and operating this product. Failure to do so could result in
damage, injury and death.
WARNING! All service including inspection, installation, wiring, maintenance, troubleshooting, fuse or other user
serviceable component replacement must be performed only by properly qualied personnel. Service personnel
must read this manual before proceeding with work. While service is being performed unqualied personnel
should not work on the unit or be allowed in the immediate vicinity.
WARNING! When in use the power controller is connected to dangerous voltages. Do not remove the protective
covers without rst disconnecting and preventing power from being restored while servicing the unit.
WARNING! Do not use in aerospace or nuclear applications.
WARNING! The power controller’s protection rating is IP20 with all covers installed and closed. It must be
installed in an enclosure that provides all the necessary additional protections appropriate for the environment
and application.
WARNING! Ground the power controller via the provided protective earth grounding terminal. Verify ground is
within impedance specications. This should be veried periodically.
WARNING! Electric Shock Hazard: when the power controller has been energized, after shutting o󰀨 the power,
wait at least one minute for internal capacitors to discharge before commencing work that brings you in to
contact with power connections or internal components.
WARNING! The installation must be protected by electromagnetic circuit breakers or by fuses. The
semiconductor fuses located inside the power controller are classied for UL as supplementary protection for
semiconductor devices. They are not approved for branch circuit protection.
WARNING! When making live voltage or current measurements, use proper personal protective equipment for
the voltages and arc-ash potentials involved.
WARNING! Verify the voltage and current ratings of the power controller are correct for the application.
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CAUTION: To avoid compromising the insulation, do not bend wire or other components beyond their bend
radius specications.
CAUTION: Protect the power controller from high temperature, humidity and vibrations.
CAUTION: The power controller warranty is void if the tested and approved fuses are not used.
CAUTION: Only trained and authorized personnel should access and handle the internal electronics and they
must follow proper electro-static prevention procedures.
CAUTION: Install an appropriately sized RC lter across contactor coils, relays and other inductive loads.
NOTE! Provide a local disconnect to isolate the power controller for servicing.
NOTE! The nominal current is specied for ambient temperatures at or below 40° C. Ensure the application
design allows for adequate cooling of each power controller. The power controller must be mounted vertically.
The cooling design must prevent air heated by one power controller from causing power controllers mounted
above to exceed the ambient operating temperature limit. When power controllers are mounted side by side
allow a minimum spacing of 15mm between them.
NOTE! Use only copper cables and wires rated for use at 90°C or greater.
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2. Maintenance
In order to have a corrected cooling, the user must clean the heat-sink and the protective grill of the fans. The fre-
quency of this servicing depends on environmental pollution.
Also check periodically if the screw for the power cables and safety earth are tightened correctly
(See Connection Diagram).
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L1
L2
Thyristor
Load
3. Introduction
A thyristor unit is semiconductor device which acts as a switch formed by two thyristors in ant parallel.
To switch on the alternating current the input signal will be on and the thyristor will switch o󰀨 at rst Zero Crossing
voltage with no input signal.
The benets of thyristor units compared with electromechanical contactors are numerous: no moving parts, no
maintenance and capacity to switch very fast. Thyristors are the only solution to control transformers and special
loads that change resistance with temperature and with age.
3.1. Advantages compared with analog thyristor unit
Communication RS485 is a standard feature of Relay C. this allows the use of many information like: current, power,
load state and all the parameters for diagnostic and conguration. Ulterior advantages of the digital system vs the
analogical is the exibility and the possibility of implement special characteristics without change the hardware.
Several strategies can be implemented and selected through the conguration parameters.
With the software Thyristor Congurator, you can have access to the conguration parameters.
To connect the Thyristor unit to the computer use a micro USB cable.
www.west-cs.co.uk 9

3.2. Overview
Heater bakeout
• Protects heater upon start up
• Eliminates labour and time associated with checking for wet heaters
Integrated semiconductor fusing, current transformer and user interface
• Saves installation time and eases setup and commissioning
• Delivers a user-friendly, intuitive interface
Industry-leading design and serviceability
• O󰀨ers a robust SCR design to meet a rugged industrial environment’s high quality and
reliability needs
• Provides quick and easy access to maintain and service fuses and individual legs
in minimal time
• Enables fast troubleshooting by providing helpful thermal system diagnostics
Comprehensive power controller range
• Provides wide range of options from simple single phase to complex three-phase loads to
690V.
100KA short circuit current rating (SCCR) (Not reviewed by UL®)
• Enables greater protection in the event of a short circuit
c-UL® 508 listed
• Shortens project schedules, agency testing and expenses
Control modes: contactor, voltage, current or power
• Satises a wide range of demanding thermal applications
Load ring modes: zero-cross, burst re, phase angle, soft start, single-cycle, delayed triggering
• Handles a wide range of load types including nichrome, medium and long waveform infrared
lamps, moly, transformers, silicon carbide, UV lamps and tungsten
• Protects and extends the life of connected loads
Wide range of communication protocols
• Enable factory and process automation with connectivity to process and equipment data via
Modbus® RTU, Modbus® TCP, Probus, Pronet, USB device (conguration and data le
transfers)
Open heater and shorted SCR indication
• Minimizes production downtime with easy to understand, intelligent, troubleshooting
diagnostics
Integrated USB and user interface for conguration
• Easily and safely program conguration settings as the user interface can be powered through
USB connection
• Eliminates need to work in a high voltage hazard environment. High voltage to the power
controller and system panel can be shut o󰀨 and locked out for safety while conguring
controller.
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