JUMO 709050 User Manual

JUMO IGBT-Power Converter

70/100 A with amplitude control

B 70.9050.0.1

Operating Manual

02.08

/00440431

1 Contents

1 Contents ............................................................................................ 3

2 Introduction ....................................................................................... 5

2.1 Preface .................................................................................................................. 5

2.2 Typographical conventions ................................................................................. 6

2.2.1 Warning signs ........................................................................................................ 6

2.2.2 Note signs .............................................................................................................. 6

2.2.3 Performing an action ........................................................................................... 7

2.3 Order details ......................................................................................................... 8

2.3.1 Standard accessories ............................................................................................ 8

2.3.2 Accessories ........................................................................................................... 9

2.4 Brief description ................................................................................................ 10

2.5 Interpretation of the LEDs ................................................................................ 11

3 Installation ....................................................................................... 13

3.1 Important notes on installation ........................................................................ 13

3.1.1 Correctly wire all components ............................................................................. 13

3.2 Filtering and interference suppression ............................................................ 16

3.3 Ambient conditions ........................................................................................... 18

3.4 Spacings ............................................................................................................. 20

3.4.1 Opening the housing ........................................................................................... 21

4 Electrical connection ...................................................................... 23

4.1 Screw connections in the power section ........................................................ 23

4.1.1 Suitable cables and cross-sections ..................................................................... 25

4.1.2 Electrical isolation ................................................................................................ 26

4.1.3 Use of residual current protection devices .......................................................... 26

4.1.4 Replacing the two semiconductor fuses ............................................................. 26

4.1.5 Wiring of the screw terminals .............................................................................. 28

5 Settings ............................................................................................ 31

5.1 Operating principle ............................................................................................ 31

5.2 Setting switches S101, S103, S104, S105, S106 and X106 ............................ 32

5.3 Subordinate control loop .................................................................................. 33

5.4 Load voltage adjustment .................................................................................. 33

5.5 Control inputs .................................................................................................... 34

5.5.1 Combination of external potentiometer and electronic controller ....................... 35

5.6 Firing pulse inhibit ............................................................................................. 36

5.7 Resistance output .............................................................................................. 36

02.08 [IGBT Power Converter 70/100A] 3

5.8 Trimmer settings ................................................................................................ 37

5.8.1 Resistance limiting (R-control) ............................................................................. 37

5.8.2 SIC voltage reserve (SIC reserve) ........................................................................ 38

5.8.3 Control input adjustment (max. Power adjust) .................................................... 38

5.8.4 Setting for maximum power (max. Power adjust) ............................................... 39

5.8.5 Input signal attenuation ....................................................................................... 39

5.9 Setting the base load (min. Power adjust) ...................................................... 39

5.10 Setting the current limit (max. current adjust) ................................................ 40

5.11 Total and partial load failure monitoring (load fail adjust) ............................. 40

5.11.1 Setting the load fault indication ........................................................................... 42

5.12 Safety cut-out in the power section ................................................................. 43

5.13 Adjusting the output level signal (output adjust U2, P , I2 ) ............................ 43

6 Technical data ................................................................................. 45

6.1 Voltage supply .................................................................................................... 45

6.2 Control ................................................................................................................ 45

6.3 Fault signal output ............................................................................................. 45

6.4 General characteristics ..................................................................................... 45

6.5 Choke data ......................................................................................................... 47

6.6 EMC filter ............................................................................................................ 47

7 Troubleshooting .............................................................................. 49

4 [IGBT Power Converter 70/100A] 02.08

2.1 Preface

B

A

H

2 Introduction

Please read this operating manual before commissioning the instrument. Keep
the operating manual in a place accessible to all users at all times.

Your comments are appreciated and may assist us in improving this operating
manual.

Phone: [phone]
Fax [phone]

The IPC must only be used with the original JUMO choke and an original
JUMO supply filter.
Please check that the chosen supply filter is adequate for the maximum
current drawn from the electrical supply to avoid it being overloaded.

All necessary settings are described in this operating manual.
Manipulations not described in the manual or expressly forbidden will
jeopardise your warranty rights.
Please contact the nearest subsidiary or the head office, should you encounter
problems.

Service hotline For technical questions

Phone support in Germany:

Phone: [phone] or -653 or -899
Fax: [phone]
E-mail: [e-mail]

Austria:

Phone: [phone]
Fax: [phone]
E-mail: [e-mail]

Switzerland:

Phone: [phone]
Fax: [phone]
E-mail: [e-mail]

When accessing the inner parts of the unit and returning controller modules,

E

assemblies or components, please observe the regulations according to DIN
EN 61340-5-1 and DIN EN 61340-5-2 „Protection of electrostatic sensitive
devices“. Only use ESD packaging for transport.

Please note that we cannot accept any liability for damage caused by ESD.
ESD=Electro Static Discharge

02.08 [IGBT Power Converter 70/100A] 5

2 Introduction

2.2 Typographical conventions

2.2.1 Warning signs

Danger

This symbol is used when there may be danger to personnel if the
instructions are ignored or not followed correctly!

V

Caution:

This symbol is used when there may be damage to equipment or

A

ESD

data if the instructions are ignored or not followed correctly!

This symbol is used where special care is required when handling
components liable to damage through electrostatic discharge.

E

2.2.2 Note signs

Note

Reference

Footnote

H

v

1

abc

This symbol is used when your special attention is drawn to a
remark.

This symbol refers to further information in other manuals,
chapters or sections.

Footnotes are remarks that refer to specific points in the text.
Footnotes consist of two parts:
A marker in the text and the foot note text itself.
The markers in the text are arranged as continuous superscript
numbers.

6 [IGBT Power Converter 70/100A] 02.08

2.2.3 Performing an action

Action
instruction

Vital text

h Plug in the

connector

B

2 Introduction

This symbol indicates that an action to be performed is
described. The individual steps are marked by this asterisk.

This text contains important information, and it is vital that you
read it before going any further.

02.08 [IGBT Power Converter 70/100A] 7

2 Introduction

2.3 Order details

The nameplate is glued onto the right panel of the housing.

x

x

x
x
x

(1) Basic version

709050/82

709050/92 Customer-specific version

11 115V AC +15/-20%, 48 ... 63Hz

xx 12 230V AC +15/-20%, 48 ... 63Hz

115 115V AC +15/-20%, 48 ... 63Hz

x 230 230V AC +15/-20%, 48 ... 63Hz

x 400 400V AC +15/-20%, 48 ... 63Hz

x x 020
x x 060
x x 090
x x 120
x x 150
x x 210

x 270
x 380

IGBT power converter 70 or 100A
(max. load voltage 380V) standard version

(2) Voltage supply to the control section

(only for 115V AC in the power section)

(3) Voltage supply to power section

(4) Load voltage

20V DC
60V DC
90V DC
120V DC
150 V DC
210V DC
270V DC
380V DC

xx 070

x
x

xx 100

x x 252 Relay (changeover contact) 3A

x
x

x x 257 Optocoupler Ic

Order code - - - -/

Order example 709050/82 - 12 - 230 - 150 - 100 / 252

2.3.1 Standard accessories

1 Operating Manual

(5) Load current

70A DC
100A DC

(6) Extra code for fault signal output

= 2mA, U

max.

(1) (2) (3) (4) (5) (6)

CEO max.

= 32V

8 [IGBT Power Converter 70/100A] 02.08

2.3.2 Accessories

2 Introduction

Choke: L=0.6mH/I

= 100A, protection rating IP 20, as per EN 60 529

N

Dimensions Connection

Height: 208 mm
Width: 200 x 200 mm

Via screw terminals
up to max. 10...50

2

mm

Choke: L=0.6mH/I

= 75A, protection rating IP 20, as per EN 60 529

N

Dimensions Connection cross-

section

Diameter: 155 mm
Height: 135 mm
Diameter of fixing
hole: 10.4 mm

Via screw terminals
up to max. 4...25 mm

2

EMC filter

For voltage supply to power section

Nominal voltage,

nominal current

115V/250V/440V
AC,
I

= 16A

Nom

115V/250V/440V AC,

= 20A

I

Nom

115V/250V/440V
AC,
I

= 32A

Nom

115V/250V/440V
AC,
I

= 63A

Nom

115V/250V/440V
AC,
I

= 100A

Nom

For voltage supply to the control section

115V/250V AC,

= 1A

I

Nom

Dimensions

(L x W x H)

(255 x 60 x 130) mm 0.6 ... 0.8 Nm approx.

(289 x 70 x 140) mm 1.5 ... 1.8 Nm approx. 5.5

(324 x 90 x 160) mm 1.5 ... 1.8 Nm approx.

(380 x 117 x 190) mm 2 ... 2.3 Nm approx.

(445 x 150 x 220) mm 6 ... 8 Nm approx. 26

80 x 45 x 30 mm - approx.

Tightening torque
for
screw terminals

Tightening torque
for screw terminals

max. 6...8 Nm approx.

Tightening torque
for screw terminals

max. 4...4.5 Nm approx.

Weight Sales No.

20kgs

Weight Sales No.

7.5 kgs

Weight Permissibl

4kgs

kgs

9.5kgs

17kgs

kgs

120g

70/00415759

70/00392474

Sales
e ambient
temperatu

No.

re

40°C 70/00399527

40°C 70/00438775

40°C 70/00409831

40°C 70/00409990

40°C 70/00431997

40°C 70/00413620

Semiconductor fuse

2 extra fast semiconductor fuses are installed in the converter, to protect the
IPC in the event of an earth short.

2

The I

t value of the semiconductor fuse must be less than 20000 A2s!

Sales No. 70/00434229

02.08 [IGBT Power Converter 70/100A] 9

2 Introduction

2.4 Brief description

Instrument The J IPC is a IGBT power converter for controlling heater loads that

previously required a transformer (either a variable transformer or a
combination of transformer and thyristor power unit).
Its function is that of an electronic transformer with a pulsed DC output.

Advantages It combines the advantages of a conventional variable transformer, such as

amplitude control which is the sinusoidal current loading, with the advantages
of a thyristor power switch, such as current limiting, load monitoring,
subordinate control action, etc.

There is no electrical isolation between the voltage supply and the

A

Application This power converter is employed wherever large resistive loads need to be

load voltage.

switched and no electrical isolation is required between the supply voltage
and the load voltage. Thanks to the amplitude control (the current drawn from
the supply is always sinusoidal), synchronous clock controls (as for burst-firing
operation) and power-factor compensation networks (for the reactive power
resulting from phase-control) are no longer required.

10 [IGBT Power Converter 70/100A] 02.08

2 Introduction

2.5 Interpretation of the LEDs

fuse

Two semiconductor fuses are integrated in the IPC, to protect it in the event of an earth short. If an earth
short occurs, one or both of the semiconductor fuses will trip. Tripping of one or both of the fuses is
indicated by the "Fuse" LED and the drop-out of the fault signal relay.

v Chapter 4.1.4 „Replacing the two semiconductor fuses“

overheat

This LED lights up if the maximum permitted temperature is
exceeded. The fault signal relay drops out at the same time.
The load output remains disconnected until the temperature has
fallen below the limit value again.

v Chapter 3.3 „Ambient conditions“

IGBT

This LED lights up when the electronic safety cut-out of the load circuit
has tripped.
(e.g. because of a wiring fault).
The safety cut-out remains activated until the IPC has been completely
(all-pole) disconnected from the supply and then switched on again.
The fault signal relay drops out at the same time.

v Chapter 5.12 „Safety cut-out in the power section“

current limit

This LED lights up if the converter is working at the current limit.

v Chapter 5.10 „Setting the current limit (max. current

adjust)“

load fail

This LED lights up if a total or partial load failure has been
detected.
The fault signal relay drops out at the same time.

v Chapter 5.11 „Total and partial load failure

monitoring (load fail adjust)“

R-control

This LED lights up if the converter is working at the
resistance limit.

v Chapter 5.8.1 „Resistance limiting (R-

control)“

SIC reserve

This LED lights up when the IPC has reached its
max. load voltage, so there is no longer
automatic compensation for ageing at SIC load.
The fault signal relay drops out at the same time.

v Chapter 5.8.2 „SIC voltage reserve (SIC

reserve)“

This LED indicates that the control section is
connected to the voltage supply.
It does not indicate the status of the power
section!

Power

02.08 [IGBT Power Converter 70/100A] 11

2 Introduction

12 [IGBT Power Converter 70/100A] 02.08

3.1 Important notes on installation

3 Installation

Safety
regulations

V

k The choice of cable, the installation and the electrical connection of the

instrument must conform to the requirements of VDE 0100 "Regulations on
the Installation of Power Circuits with Nominal Voltages below 1000 V AC"
or the appropriate local regulations.

k The electrical connection must only be carried out by qualified personnel.
k An isolation switch should be wired between the supply and the converter

to be able to disconnect the converter from the voltage supply on all poles
prior to starting internal work.

Caution!

The converter has 2 power supplies (to the control section and to the power
section). Disconnect both supplies (all poles) prior to starting work on the
converter.

Allow 1 minute to elapse after switching off prior to starting work on the
converter, since potentially fatal voltages could be present in the converter
interior and at the terminals.

k Inside the converter, safety gaps meet the requirements for double

insulation.
When installing the connecting cable, ensure that the cables are fitted
according to regulations and that the safety gaps are maintained.

Electrical
supply types

Fuse protection k Fuse protection in accordance with the VDE regulations must be installed

V

The IPC is suitable for operation with TN and TT supply networks.
h Carry out installation in accordance with EN 50178.

for the voltage supply to the power section. The supply protection can also
be achieved by a circuit-breaker in the supply lead. This must be
dimensioned for the power consumption of the power converter and the
rated current of the downstream EMC filter.

k Two semiconductor fuses are incorporated to protect the IPC in the event

of an earth short.

2

(The I

v Chapter 4.1.4 „Replacing the two semiconductor fuses“
k Provide an appropriate control circuit fuse for control section lead

protection. The control section consumes approx. 75 VA.

t value of the semiconductor fuse must be smaller than 20000 A2s)!

3.1.1 Correctly wire all components

EMC filter

The IPC may only be used in conjunction with a suitable filter

A

(accessories). If a different filter is used, it must be of equal or better
characteristics. Otherwise, inductive voltages may be introduced into
the supply network. We decline any liability for damage caused as a
result.

02.08 [IGBT Power Converter 70/100A] 13

3 Installation

The EMC filters may only be used for interference suppression of the

H

The earth leakage current of the IPC power converter with a filter wired into the
supply lead is less than 3 mA. If the load conditions result in an earth leakage
current greater than 3.5 mA, a fixed supply connection is required as a
protection against hazardous potentials (also see EN 50178).

Electromagnetic compatibility conforms to the standards and regulations cited
in the technical data.

v Chapter 6 „Technical data“
h Load wiring (thick) and cables for control inputs (thin) should be routed

14 [IGBT Power Converter 70/100A] 02.08

IPC power converter. Other devices, such as controllers, power
supplies etc. must be suppressed, where necessary, with their own
EMC filters. Do not wire these devices in parallel to the IPC power
converter on the load side of the EMC filter.

separately, if possible.

3 Installation

Positioning of
the choke

Connection h Check the data given on the nameplate (voltage supply to the control

PE connection/
FB connection

Choke
connection

h The choke should be installed close to the converter.

section, voltage supply to the power section, load voltage and load current)
against the system data.

v Chapter 2.3 „Order details“
h Check the adaptation of the setpoint inputs.
h Check the switch settings.

h Provide a direct connection between the PE of the IPC and the PE of the

supply network. Connect to the PE terminal
of the IPC.

h If necessary, interference emission of the IPC can also be minimised by a

function equipotential bonding. The function equipotential bonding is
connected to the FB terminal of the IPC.

v Chapter 3.1.1 „Correctly wire all components“

h The choke is connected to terminals C and 1C.

Voltage
supply

Load
connection

h Connect the voltage supply to the control section to terminals L1 and N(L2)

(X109).

h Connect the voltage supply of the power section to terminals U and N(V).

An isolation switch should be wired between the supply and the

A

h The load is connected to terminals D and 1D.
h The cable between the load and the IPC should be as short as possible and

not exceed 50 m.

A

converter to be able to disconnect the converter from the voltage
supply on all poles prior to starting internal work!

The connection must only be carried out by qualified personnel!

Use a shielded cable to connect to the load, ensure that the
shielding is connected to earth on both ends.

v Chapter 3.2 „Filtering and interference suppression“

Choosing the suitable cables

v Chapter 4.1.1 „Suitable cables and cross-sections“

Control inputs The terminal strip for control connections (inputs and outputs) have been laid

out for safe isolation from the supply (SELV). To prevent the safe isolation from
being impaired, ensure that all connected current circuits are also safely
isolated. The required auxiliary supplies must be SELV voltages.

02.08 [IGBT Power Converter 70/100A] 15

3 Installation

Switch-on
sequence

The voltage supplies to the control section and to the power section must be
switched on simultaneously.

Under no circumstances may the voltage supply to the control

H

section be switched on before the load voltage. This is especially
important when operating resistive loads that have a high hot/cold
resistance ratio.

3.2 Filtering and interference suppression

System Compliance with the EMC standards can only be achieved through additional

EMC measures.
These include:

- a supply filter in the voltage supply

- a shielded cable for the voltage supply (from the supply filter (load) to the
IPC)

- a shielded cable to the load

- Functional equipotential bonding

Compliance with the EMC standards must be tested for the overall system.

Construction To keep interference emission through conducted and radiated interference

below the permissible levels defined in the pertinent EMC standards,
constructive measures must be taken in the installation and wiring stages in
addition to supply input filtering. Poor earth connection or shielding of the
EMC filter will reduce the effectiveness of the interference suppression
measures.

The following points should be noted in order to achieve good configuration
for EMC purposes:

h All metallic components of the converter or cabinet must be well bonded

for HF currents over a large surface area.

h The EMC filter should be installed close to the IPC, if possible, on a

common metal plate. Route cables for control inputs and signal cables as
far apart from each other as possible, and use shielded cables.

h If possible, do not route power cables in the same cable duct as control or

signal cables.

h The cable between the load and the IPC should be as short as possible and

not exceed 50 m.

Earthing The base plate, the supply filter and the shielding of the supply cable must be

earthed to a star point using HF braiding.

Choosing
a suitable
cable

k If the cable between the filter and the IPC is longer than 300 mm, we

recommend to use a shielded cable with the shielding earthed at both
ends. Route cables inside the switch cabinet as close as possible to
grounded surfaces, otherwise they can act as antennae and radiate
interference.

16 [IGBT Power Converter 70/100A] 02.08