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709040
User Manual
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User Manual
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JUMO 709040 User Manual

Thyristor Power Units
B 70.9040.0
Operating Instructions
02.06
/00089951
Contents
1 Introduction ......................................................................................... 7
1.2.1 Warnings .................................................................................................................. 8
1.2.2 Note signs ............................................................................................................... 8
1.4.1 Type extensions (extra codes) ................................................................................ 10
1.4.2 Standard accessories ............................................................................................ 10
1.5 Block diagram ...................................................................................................... 11
1.6 Front panel indicators and adjustments ............................................................ 12
2 Operating modes .............................................................................. 13
2.1 Phase-angle control with soft start and current limiting .................................. 13
2.2 Burst-firing operation, for resistive loads .......................................................... 14
2.3 Burst-firing operation for transformer loads and loads with a high positive tem-
perature coefficient TC (mixed operation) 15
3 Installation ......................................................................................... 17
3.1 Important installation notes ................................................................................ 17
3.2 Filtering and interference suppression .............................................................. 18
3.3 Installation site and climatic conditions ............................................................ 18
3.4 Wall mounting ....................................................................................................... 19
3.4.1 TYA-110/3, 025..100 .............................................................................................. 19
3.4.2 TYA-110/3,150 and TYA-110/3, 250 ...................................................................... 20
3.5 DIN rail mounting ................................................................................................. 21
3.5.1 TYA-110/3, 025 ..100 ............................................................................................. 21
4 Electrical connection ........................................................................ 23
4.1 Connection diagram ............................................................................................ 23
4.1.1 Type TYA-110/3, 025, - 050, - 075, - 100, ... .......................................................... 25
4.1.2 Type TYA-110/3, 150, ... ......................................................................................... 25
4.1.3 Type TYA-110/3, 250, ... ......................................................................................... 25
4.2 Single-phase operation: line/phase – N ............................................................. 26
4.3 Single-phase operation: phase – phase ............................................................. 27
4.4 Star configuration: with star point connected to N .......................................... 28
4.5 Open delta configuration (six-wire circuit) ........................................................ 29
Power units 02.06 3
Contents
4.6 Free-running economy circuit, purely resistive loads ....................................... 30
4.7 Master-slave economy circuit, with resistive/inductive loads ......................... 31
5 Commissioning ................................................................................. 33
5.1 Adjust control input (full wave) ........................................................................... 33
5.1.1 Setting the maximum power output ....................................................................... 33
5.1.2 Input signal attenuator ........................................................................................... 33
5.2 Setting the base load ........................................................................................... 34
5.3 Setting the current limit ....................................................................................... 35
5.3.1 Alteration of the current limit Imax, as a function of the voltage on Terminal 9 ..... 36
5.4 Setting the phase angle for the first half-wave ................................................. 36
5.5 Load and part-load failure monitoring ............................................................... 37
5.5.1 Setting the threshold for load failure indication ................................................ 37
5.5.2 Setting for master-slave and free-running economy circuit ............................ 38
5.6 External changeover of operating modes ......................................................... 38
5.7 Blown fuse indication .......................................................................................... 38
6 Settings .............................................................................................. 39
6.1 Opening the housing ............................................................................................ 39
6.2 Adjustment switches S1 — 21 and pin headers X503 / X504 .......................... 40
6.3 Summary of possible settings ............................................................................ 42
6.4 Control inputs ....................................................................................................... 43
6.4.1 Combinations of external potentiometer and electronic controller ........................ 44
6.5 Subsidiary control loops ...................................................................................... 45
6.6 Actual (power) output .......................................................................................... 46
6.7 Load current adaptation (only with extra code TR/T0) ..................................... 47
6.8 Select operating modes and load types ............................................................ 47
6.9 Economy circuit .................................................................................................... 48
6.9.1 Free-running economy circuit (asynchronous switching) for resistive loads ......... 49
6.9.2 Master-slave economy circuit (synchronous switching) for resistive and transformer loads 49
6.10 Firing-pulse inhibit ............................................................................................... 50
7 Technical data ................................................................................... 51
7.1 Load circuit ........................................................................................................... 51
7.2 Control ................................................................................................................... 51
7.3 General data ......................................................................................................... 51
4 Power units 02.06
Contents
8 Faults .................................................................................................. 53
8.1 Fault-finding .......................................................................................................... 53
8.2 Replacing the semiconductor fuse .................................................................... 53
8.2.1 Type TYA-110/3, 025 to 100, ... .............................................................................. 53
8.2.2 Type TYA-110/3, 150, ... ......................................................................................... 54
8.2.3 Type TYA-110/3, 250, ... ......................................................................................... 54
Power units 02.06 5
Contents
6 Power units 02.06

1.1 Preface

B

1 Introduction

Please read these operating instructions before starting up the instrument. Keep them in a place that is accessible to all users at all times.
Please help us to improve this manual.
Your suggestions will be welcome. Fax: in Germany (0661) 6003-862
abroad +49 661 6003-607
H
H
If any difficulties arise during commissioning, you are asked not to carry out any unauthorized manipulation. You could endanger your rights under the instrument warranty!
Please contact the nearest subsidiary or the main factory in such a case.
When returning chassis, modules or components, the regulations of EN 100 015 “Protection of electrostatically sensitive compo­nents” must be observed. Use only the appropriate ESD packag­ing for transport.
Please note that we cannot accept any responsibility for damage caused by ESD (electrostatic discharge).
Power units 02.06 7
1 Introduction

1.2 Typographical conventions

1.2.1 Warnings

The signs for Danger and Caution are used in this manual under the following conditions:
Danger This symbol is used where there may be danger to personnel if the instruc-
V
A
E
tions are disregarded or not followed accurately!
Caution
This symbol is used where there may be damage to equipment or data if the instructions are disregarded or not followed accurately!
Caution This symbol is used if precautions must be taken when handling electrostati-
cally sensitive components.

1.2.2 Note signs

Note
H
v
1
abc
h Handling instructions
This symbol is used to draw your special attention to a remark.
Reference
This symbol refers to additional information in other manuals, chapters or sections.
Footnote
Footnotes are comments that refer to specific parts of the text. Footnotes consist of two parts:
1) The marking in the text, arranged as continuous superscript numbers.
2) The footnote text at the bottom of the page, in a smaller typeface than the main text, and preceded by a number and a stop.
This symbol marks the description of a required action. The individual steps are indicated by asterisks, for example:
h Disconnect the instrument completely from the supply h Remove the instrument cover
8 Power units 02.06
1 Introduction

1.3 Description

Application A thyristor power unit can be used wherevere sizeable resistive or inductive

loads are switched frequently – for instance, in industrial furnaces and plastics processing.

Operating modes

Regulation Variations in the line supply voltage have no effect on the control-loop regula-

Versions The power stage is composed of 2 thyristors connected in anti-parallel, the in-

Standards The thyristor power units meet VDE 0160 5.5.1.3 (5/88) and VDE 0106 Part 100

The thyristor power units can operate under phase-angle control with adjust­able current limiting or in burst-firing mode, depending on the setting of the in­ternal switch. An external switch may also be used to change over the operat­ing mode. In burst-firing mode, the phase angle can be cut back for the first half-cycle, for driving transformer loads.
tion during operation. This is ensured by a subsidiary V An input signal attentuator (trimmer) permits the restriction of the control range, and a base load can be set by an external potentiometer. In burst-firing mode an economy circuit can be used for multi-phase loads. With phase-an­gle control, the target phase angle that is set by the controller is gradually ap­proached from the initial 180°, thus avoiding high surge currents (soft start).
sulated heatsink, and the control electronics. Thyristor units for up to 50A rat­ed load can either be snapped onto a 35mm DIN rail, or mounted on a bas­plate fixed to a wall. Units for 75A or higher rated load can only be wall­mounted.
(3/83). Earthing must be carried out in accordance with the regulations of the local electrical supply utility.
2
, P or I2 control loop.

1.4 Type designation

The basic version, TYA-110/3, includes the following features:
- Voltage, current and potentiometer input
- Input signal is freely selectable
- Operating mode is freely selectable
- Phase-angle reduction of 1st half-wave for burst-firing operation
- Supply line voltage monitoring
- Input signal attentuation by trimmer
- Soft start in phase-angle operation
2
-V
-control with adjustable power level output signal
- Master-slave economy circcuit
- Firing-pulse inhibit
Power units 02.06 9
1 Introduction
TYA-110/3 , . . . , . . . , . . Thyristor power unit for analog control
025 Load current 25A 050 Load current 50A 075 Load current 75A 100 Load current 100A 150 Load current 150A 250 Load current 250A
024 Rated load voltage 24V 042 Rated load voltage 42V 115 Rated load voltage 115V 230 Rated load voltage 230V 265 Rated load voltage 265V 400 Rated load voltage 400V 460 Rated load voltage 460V 500 Rated load voltage 500V
TR Indication of part-load failure or blown fuse through
built-in relay and LED.
TO Indication of part-load failure or blown fuse through
optocoupler
MS Master-slave circuit
2 pre-assembled power units on a mounting plate, ready for connection
1
1
1
1
1
1
1
1
1. Rated load voltage = supply voltage for the control electronics

1.4.1 Type extensions (extra codes)

TR Extended version, with indication of part-load failure (adjustable by trimmer) or
blown fuse through common relay contact and LED. This version also includes:
- Current limiting (internal, external) and rated current adjustment at I ≤ I
2
- Free selection of the subsidiary control-loop type (V
, I2 or P).
/2
N
A free-running economy circuit can be implemented with P-control!
2
- Power level output signal can be switched to: V
, P, I
2
TO as for TR, but with signaling via optocoupler
MS Master-slave circuit: 2 pre-assembled power units on a mounting plate, ready
for connection.

1.4.2 Standard accessories

1 Mounting plate for wall-mounting 1 Operating Instructions
10 Power units 02.06

1.4.3 Accessories

Super-fast semiconductor fuses to protect the thyristors from short-circuits (no supply line fusing).
1 Introduction
32A for I 80A for I 125A for I 160A for I 350A for I 550 A for I
Assembly kit for DIN rail mounting, for 25A and 50A versions, Sales No. 70/00067312

1.5 Block diagram

= 25A, Sales No. 70/00068009
N
= 50A, Sales No. 70/00068011
N
= 75A, Sales No. 70/00081800
N
= 100A, Sales No. 70/00081801
N
= 150A, Sales No. 70/00083318
N
= 250A, Sales No. 70/00371964
N
(
(1) Load (9) Control electronics (2) Super-fast semiconductor fuse (10) Trimmer on front panel (3) Thyristor module with RC
protection network
(4) Driver stage for thyristor module (12) Configuration switch (5) Power supply for control electronics (13) Signal LEDs (6) Optocoupler (14) Master-slave connections (7) Voltage converter (15) Output level setting, operating inputs,
(8) Current transformer
(11) Error signal output
via relay or optocoupler
power level output signal
Power units 02.06 11
1 Introduction

1.6 Front panel indicators and adjustments

Indicator LED for blown semiconductor fuse
(1)
LED for current indication
(2)
LED for load-failure indication
(3)
LED for full-output indication
(4)
Adjustment of current limit in phase-angle
(5)
operation (with extra code TR or TO)
Adjustment of threshold for part-load failure
(6)
indication (with extra code TR or TO)
Adjustment of full output
(7)
Adjustment of power level signal
(8)
Spring clip to release cover
(9)
Adjustment of phase-angle reduction for 1st half-
(10)
wave in burst-firing operation
12 Power units 02.06

2 Operating modes

2.1 Phase-angle control with soft start and current limiting

In this mode of operation, the power is regulated by altering the phase angle. This method is suitable for transformer and resistive loads. During the switch­on period the phase-angle is gradually advanced by the controller to provide a soft start. This prevents high surge currents at switch-on.

Current limiting For loads with an initial (cold) resistance that is significantly lower than the re-

sistance after warming up, such as Kanthal-Super heater elements, it is advi­sable to make use of current limiting (only with extra code TR or TO). While current limiting is in operation, the phase angle during soft start remains constant. The maximum permissible effective (rms) current can be adjusted on the front panel, by using the “current limit” trimmer.
v Section 5.3 “Setting the current limit”
Power units 02.06 13
2 Operating modes

2.2 Burst-firing operation, for resistive loads

In this mode of operation, the power is regulated by changing the number of full-wave cycles of the supply line voltage which are switched on during each control period. This method is used for purely resistive loads which have a cold resistance that is roughly the same as the hot resistance. Since switching only takes place at the zero-crossing points, this mode of operation produces very little RF-interference.
The internal switch S20 can be used to adjust the duty cycle to suit the system being controlled.
v Section 6.2 “Adjustment switches S1 — 21 and pin headers X503 / X504”
Cycle time S 20
Variable cycle time The control unit uses the shortest available cycle time (for fast control loops)
Fixed cycle time (≈ 500ms) Used for transformer loads, slow control loops
1
2
14 Power units 02.06
2 Operating modes

2.3 Burst-firing operation for transformer loads and loads with a high positive temperature coefficient TC (mixed operation)

It is not possible to change over to phase-angle control in this
H

Soft start For the first switch-on of the thyristor power unit, or after being switched off by

inhibiting the firing-pulses, after a supply line interruption, or if the setpoint was switched off for more than 8seconds, there will always be a short phase­angle controlled start (area a in the diagram).
mode of operation.
After this soft start, the controller switches over automatically to burst-firing operation if the given setpoint is larger than the minimum setpoint + 10% of the setpoint range (area b in the diagram).
Example: Setpoint range 2 — 10V The changeover to burst-firing operation takes place at 2V + 10% of 8V = 2V + 0.8V = 2.8V
After this changeover, the power output is regulated to follow the setpoint in­put provided.
H
1. with extra codes TR/TO
If the power unit runs into current limiting1 during the phase-angle controlled start, then the output is regulated according to the maxi­mum current given by the curent limit setting, even for low levels of the setpoint input.
Power units 02.06 15
2 Operating modes
For transformer loads, the thyristor power unit operates in burst-firing mode with a cut-back (retarded) phase-angle for the first half-wave. The factory set­ting is an angle α = 90°. This value can be altered on the front panel over a range α = 0 — 90°.
v Section 5.4 “Setting the phase angle for the first half-wave”
H
We recommend that this setting is not changed!
16 Power units 02.06

3.1 Important installation notes

3 Installation

Safety regulations

Fusing - In the event of a short-circuit in the load circuit, the power unit is protected

V

Interference suppression

Wiring Load and control cables should be laid separately, as far as feasible.

- The choice of cable, installation and electrical connection of the instrument must meet the requirements of VDE 0100 “Regulations for the Installation of Power Circuits with nominal voltages below 1000 V AC” or the corresponding local regulations.
- Electrical installation must only be performed by properly qualified personnel.
- The unit must be completely disconnected from the supply line (on all poles) if there is a risk of contact with live parts during work on the unit.
by the built-in semiconductor fuse.
v Section 8.2 “Replacing the semiconductor fuse”
- Do not connect any additional loads to the output load terminals.
- The electromagnetic compatibility (EMC) meets the standards and regulations cited in the technical data.
v Section 7 “Technical data”
The appropriate fuses for control circuitry (e.g. 2A, type Neozed) should be used to protect the wiring.

Connections h Check the data given on the nameplate (rated load voltage, load current)

against the data for the system.
h Wire up the connections from supply line – thyristor power unit – load
according to the wiring diagram, and check them
h If the economy circuit configuration is used, check that the rotary electrical
field has clockwise phasing.
h Check the settings for the setpoint inputs h Check the switch positions

Supply voltage h Connect the supply voltage for the control electronics as shown in the wi-

ring diagram.
h Link “N/L2” to “V”, unless the economy circuit is being used (slave unit).

Load connection

Phasing The supply voltage for the control electronics and the load voltage must

The electronic switching devices (2 antiparallel thyristors) are in circuit bet­ween the screw connections “U1” and “U 2”.
have the same phase.
h Terminal “L1” must be connected, via a control circuitry fuse, to the same
supply potential as terminal “U1”!
Power units 02.06 17
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