JUMO 709061 User Manual

JUMO TYA 201

709061/8-01-020

709061/8-01-050

709061/8-01-150
709061/8-01-200

709061/8-01-250

709061/8-01-100

709061/8-01-032

Single-Phase SCR Power Controller

B 709061.0

Operating Manual

2012-12-01/00561071

All parameter settings are described in detail in the chapter "Configuration".

This operating overview shows all possible parameters of the device series.
Depending on the order specifications or current configuration, any parameters that are not required are hidden.

Inhalt

1 Introduction..................................................................................5

1.1 Preface ........................................................................................................ 5

1.2 Typographical conventions ....................................................................... 6

1.2.1 Warning symbols ................................................................................................. 6

1.2.2 Note signs ............................................................................................................ 7

1.2.3 Performing an action ........................................................................................... 7

1.2.4 Representation .................................................................................................... 7

1.3 Order details ............................................................................................... 8

1.3.1 Scope of delivery ................................................................................................. 9

1.3.2 Accessories ......................................................................................................... 9

1.3.3 General accessories ............................................................................................ 9

1.4 Brief description ....................................................................................... 10

1.5 Standards, approvals, and conformity ................................................... 11

2 Installation..................................................................................13

2.1 Important installation notes .................................................................... 13

2.1.1 Ambient conditions ........................................................................................... 14

2.1.2 Filtering and interference suppression ............................................................ 15

2.1.3 Permissible load current depending

on the ambient temperature and the installation height ................................ 15

2.1.4 Wall mounting with screws (ex works) ............................................................ 17

2.1.5 Mounting on DIN rail (accessories) .................................................................. 20

2.2 Dimensions ............................................................................................... 21

2.2.1 Type 709061/X-0X-020-XXX-XXX-XX-25X ....................................................... 21

2.2.2 Type 709061/X-0X-032-XXX-XXX-XX-25X ....................................................... 21

2.2.3 Type 709061/X-0X-050-XXX-XXX-XX-25X ....................................................... 22

2.2.4 Type 709061/X-0X-100-XXX-XXX-XX-25X ....................................................... 22

2.2.5 Type 709061/X-0X-150-XXX-XXX-XX-25X

Type 709061/X-0X-200-XXX-XXX-XX-25X ....................................................... 23

2.2.6 Type 709061/X-0X-250-XXX-XXX-XX-25X ...................................................... 24

2.2.7 Clearances (all types) ........................................................................................ 24

3 Electrical connection ................................................................25

3.1 Plug-in screw terminals ........................................................................... 25

2012-12-01/00531796 [Thyristor Leistungsschalter TYA201] 1

Inhalt

3.1.1 Type 709061/X-0X-20-XXX-XXX-XX-25X ......................................................... 25

3.2 Cable lugs and plug-in screw terminals ................................................ 26

3.2.1 Type 709061/X-0X-032-XXX-XXX-XX-25X ....................................................... 26

3.2.2 Type 709061/X-0X-050-XXX-XXX-XX-25X ....................................................... 27

3.2.3 Type 709061/X-0X-100-XXX-XXX-XX-25X ....................................................... 28

3.2.4 Type 709061/X-0X-150-XXX-XXX-XX-25X

Type 709061/X-0X-200-XXX-XXX-XX-25X ....................................................... 29

3.2.5 Type 709061/X-0X-250-XXX-XXX-XX-25X ....................................................... 30

3.3 Connection diagram ................................................................................ 32

3.3.1 Single-phase operation: phase / N .................................................................. 34

3.3.2 Single-phase operation: phase / phase ........................................................... 35

3.3.3 Star connection with accessible star point (N) ............................................... 36

3.3.4 Open delta connection (six wire connection) ................................................. 37

3.3.5 Free-running economy circuit with purely resistive loads ............................. 38

3.3.6 Master-slave three-phase current economy circuit for resistive loads in star,

delta connection, or transformer loads (resistive-inductive) ........................ 39

4 Operation....................................................................................41

4.1 Display after switching on the device .................................................... 41

4.1.1 Display and control elements ........................................................................... 41

4.1.2 Displaying measured values ............................................................................. 42

4.1.3 Meaning of the displayed measured values .................................................... 43

4.1.4 Display in the configuration level ..................................................................... 44

4.1.5 Display of error messages and special states ................................................ 45

4.2 Operator level ........................................................................................... 46

4.2.1 Device data ........................................................................................................ 46

4.2.2 Power controller ................................................................................................ 46

4.2.3 Setpoint value configuration ............................................................................ 47

4.2.4 Monitoring .......................................................................................................... 48

5 Configuration .............................................................................51

5.1 Configuration level ................................................................................... 51

5.1.1 Device data ........................................................................................................ 52

5.1.2 Power controller ................................................................................................ 52

5.1.3 Analog inputs ..................................................................................................... 58

2 2012-12-01/00531796 [Thyristor Leistungsschalter TYA201]

Inhalt

5.1.4 Setpoint value configuration ............................................................................ 59

5.1.5 Monitoring .......................................................................................................... 61

5.1.6 Binary inputs ...................................................................................................... 63

5.1.7 Binary output ...................................................................................................... 65

5.1.8 Actual value output ............................................................................................ 66

5.1.9 RS422/485 .......................................................................................................... 66

5.1.10 PROFIBUS-DP .................................................................................................... 67

5.1.11 Changing codes ................................................................................................. 67

5.2 Configuration example ............................................................................ 68

6 Special device functions...........................................................69

6.1 Detection of load faults ........................................................................... 69

6.1.1 Teach-in .............................................................................................................. 71

6.2 Manual mode ............................................................................................ 72

6.2.1 Default setpoint value in manual mode ........................................................... 72

6.2.2 Configuring the teach-in (prerequisite for teach-in in manual mode) .......... 72

6.2.3 Performing teach-in in manual mode .............................................................. 73

6.3 Default setpoint value via potentiometer .............................................. 74

6.4 Dual energy management ....................................................................... 74

6.5 Subordinate control ................................................................................. 76

6.5.1 Closed control loop without subordinate control ........................................... 76

6.5.2 Closed control loop with subordinate control ................................................ 77

6.6 Resistance limitation (R control) ............................................................ 82

6.7 Current limiting ........................................................................................ 83

6.8 α start ........................................................................................................ 84

6.9 Monitoring of the supply voltage drop ................................................... 84

6.10 Firing-pulse inhibit ................................................................................... 84

6.11 SCR control logic (switch) ....................................................................... 85

7 Setup program...........................................................................87

7.1 Hardware .................................................................................................. 87

7.2 Compatible operating systems ............................................................... 87

7.3 Installation ................................................................................................ 88

2012-12-01/00531796 [Thyristor Leistungsschalter TYA201] 3

Inhalt

7.4 Program start ........................................................................................... 90

7.5 Forgotten the code? ................................................................................ 91

7.6 Changing the language of the device texts ........................................... 92

8 Fault messages and alarms......................................................93

8.1 Binary signal for collective fault ............................................................. 97

8.2 Replacing a defective semi-conductor fuse ......................................... 98

8.2.1 Accessories: semi-conductor fuses ................................................................ 99

8.2.2 Semi-conductor fuses type 709061/X-0X-20... ............................................... 99

8.2.3 Semi-conductor fuses type 709061/X-0X-32... ............................................. 100

9 What to do, if ...........................................................................103

10 Technical data..........................................................................105

10.1 Voltage supply, load current ................................................................. 105

10.2 Electrical isolation ................................................................................. 105

10.3 Analog inputs ......................................................................................... 106

10.4 Analog output (actual value output) ..................................................... 106

10.4.1 Display and measuring accuracy ................................................................... 106

10.5 Binary inputs ........................................................................................... 106

10.6 Binary output (fault signal output) ........................................................ 106

10.7 General characteristic data .................................................................. 107

10.8 Approvals/approval marks .................................................................... 109

4 2012-12-01/00531796 [Thyristor Leistungsschalter TYA201]

1.1 Preface

1 Introduction

Please read this operating manual before starting up the device.

B

This operating manual is valid from device software version [256.01.05].
Keep the operating manual in a place that is 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 power controller produces the power that is needed at the analog input or
in manual mode. Safety systems independent of the power controller must be
installed that safely switch off the following heating process in the event of ex­cess temperatures.

The power controller may only be operated using original JUMO semi-conduc­tor fuses.
In the event of replacement, please check that the correct replacement part
has been used.

All necessary settings are described in this operating manual. Manipulations
not described in the operating manual or expressly forbidden will jeopardize
your warranty rights.
If you have any problems, please contact the nearest subsidiary or the head
office.

Service hotline For technical questions

Phone support in Germany:

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

Austria:

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

Switzerland:

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

2012-12-01/00561071 [SCR Power Controller TYA201] 5

1 Introduction

E

V

E

When accessing the inner parts of the device and returning device modules,
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 from electrostatic phenomena". Use only ESD packaging for transport.

Please note that we cannot accept any liability for damage caused by ESD
(electrostatic discharge).

ESD=Electro Static Discharge

1.2 Typographical conventions

1.2.1 Warning symbols

Caution

This symbol is used when danger to personnel may occur if the in­structions are disregarded or not followed correctly.

Caution

ESD

Dangerous volt­age

Hot
surface,
fire hazard

This symbol is used when damage to devices or data may occur
if the instructions are disregarded or not followed correctly.

This symbol is used if precautions must be taken when handling
components liable to damage through electrostatic discharge.

This symbol is used if dangerous voltages will cause an electric shock
if contact with live parts is made.

This symbol is used if burns can result from touching a hot surface.

Do not install any heat-sensitive components and devices close to
the power controller.

6 2012-12-01/00561071 [SCR Power Switch TYA201]

1.2.2 Note signs

v

B

Note:

Reference

Footnote

abc

1 Introduction

This symbol is used to indicate particularly important informa­tion.

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

1

Footnotes are remarks that refer to specific parts of the text. Foot­notes consist of two parts:
An identification marking in the text, and the footnote text itself.
The identification markings in the text are arranged as sequential
superscript numbers.

1.2.3 Performing an action

Action
instruction

Vital text

Command se­quence

h Plug in the

connector

Config. level r Power controller r
Operating mode

1.2.4 Representation

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 proceeding.

Small arrows between words are intended
to facilitate faster location of parameters in
the configuration level.

Keys

Keys are displayed as symbols or text.
Key combinations are represented by a plus sign.

2012-12-01/00561071 [SCR Power Controller TYA201] 7

1 Introduction

a

UL approval in preparation

b

Load voltage = voltage supply for control electronics

Important information:

Subordinate control loop U

2

, code 100: voltage control

Subordinate control loop I

2

, code 010: enables partial load failure detection, dual energy management, and current limiting
Subordinate control loop P, code 001: enables partial load failure detection, dual energy management, current limiting, free-running
economy circuit, and R control

At a load current of 250 A, observe voltage supply for fan!
v Chapter 3.2.5 "Type 709061/X-0X-250-XXX-XXX-XX-25X"

1.3 Order details

The nameplate is affixed to the right-hand side of the case.

(1) Basic type

709061 TYA 201 single-phase SCR power controller

(2) Version

8 Standard with factory settings

9 Customer-specific programming according to specifications

(3) National language of display texts

01 German (set at factory)
02 English
03 French

(4) Load current

020 AC 20 A
032 AC 32 A
050 AC 50 A
100 AC 100 A
150 AC 150 A
200 AC 200 A
250 AC 250 A

(5) Subordinate control loop

100 U, U
010 I, I
001 P (can be set to I, I

a

2

2

(can be set to U, U2)

2

or U, U2)

(6) Load voltage

024 AC24V -20to+15%, 45to63Hz
042 AC42V -20to+15%, 45to63Hz
115 AC 115 V -20 to +15 %, 45 to 63 Hz
230 AC 230 V -20 to +15 %, 45 to 63 Hz
265 AC 265 V -20 to +15 %, 45 to 63 Hz
400 AC 400 V -20 to +15 %, 45 to 63 Hz
460 AC 460 V -20 to +15 %, 45 to 63 Hz
500 AC 500 V -20 to +15 %, 45 to 63 Hz

00 None
54 RS485/422
64 PROFIBUS-DP

(1) (2) (3) (4) (5) (6) (7) (8)

/-----/Order code

709061 / 8 - 01 - 100 - 100 - 400 - 00 / 252 Order example

b

(7) Interface

(8) Extra codes

252

Relay (changeover contact) 3 A

257 Optocoupler

8 2012-12-01/00561071 [SCR Power Switch TYA201]

1.3.1 Scope of delivery

1 operating manual B709061.0
1 SCR power controller in the version ordered

1.3.2 Accessories

Article Part no.

Setup program 709061 (TYA 201) 00544869
USB cable A-connector B-connector 3 m 00506252

Mounting set for DIN rail installation:

Type 709061/X-01-20... 00555169
Type 709061/X-01-32... 00555526

1.3.3 General accessories

1 Introduction

Semi-conductor
fuses

A semi-conductor fuse is fitted in the power controller to protect the SCR
module. The "LED Fuse" is lit red in the event of a fault.

v Chapter 8.2 "Replacing a defective semi-conductor fuse"

Article Load current

I

= I

Super fast semi-conductor fuse 40 A I
Super fast semi-conductor fuse 80 A I
Super fast semi-conductor fuse 80 A I
Super fast semi-conductor fuse 160 A I
Super fast semi-conductor fuse 350 A I
Super fast semi-conductor fuse 550 A I
Super fast semi-conductor fuse 550 A I

nom.

= 20 A 00513108

N

= 32 A 00068011

N

= 50 A 00068011

N

= 100 A 00081801

N

= 150 A 00083318

N

= 200 A 00371964

N

= 250 A 00371964

N

N

Part no.

2012-12-01/00561071 [SCR Power Controller TYA201] 9

1 Introduction

1.4 Brief description

Device The JUMO TYA 201 represents the consistent development of the JUMO pow-

er controller technology. The microprocessor-controlled power controller
shows all parameters on a display with background lighting and is operated
using 4 keys at the front.

Application SCR power controllers are used where larger resistive and inductive loads

have to be switched (e.g. in industrial kiln construction and plastics process­ing). The SCR power controller consists of two SCRs connected in anti-paral­lel, the insulted cooling body, and the control electronics.

Installation All SCR power controllers up to a load current of 32 A can be either clipped to

a 35 mm mounting rail or fitted to the wall on a mounting plate. Devices with a
load current greater than 32 A can only be mounted on the wall.

Operating
modes

Load types All resistive loads through to inductive loads are permitted.

Subordinate
control loop

Standards The SCR power controllers are in accordance with VDE 0160 5.5.1.3 (5/88)

The keypad or setup program is used to select the phase angle control operat­ing mode with adjustable current limiting, burst-firing mode, or half-wave
mode.
In burst-firing mode, the phase angle of the first half-wave can be cut so that
transformer loads can also be operated. In phase control mode, the phase an­gle specified by the controller is slowly reduced, starting from 180 degrees, in
order to avoid high starting or inrush currents (soft start).
It is possible to specify a base load or, depending on the device type, set cur­rent limiting or resistance limitation for the load.

In the case of inductive loads, the nominal inductance may not exceed 1.2
Tesla (at grid overvoltage of 1.45 T).

Depending on the device type, U, U
dinate control loops. Variations in the mains voltage therefore have no effect
on the control-loop regulation during operation.

and VDE 0106 Part 100 (3/83). Grounding is required in conformity with the
regulations of the responsible energy utility company.

2

, I, I2, or P control are available as subor-

Advantages - Teach-in function for the detection of partial load failure

- Network load optimization through dual energy management

- Transmission of the setup data is possible even without voltage supply to
the device (power supply via USB port)

10 2012-12-01/00561071 [SCR Power Switch TYA201]

1.5 Standards, approvals, and conformity

Test basis for the device properties is the Low Voltage Directive DIN EN 50178.
Test basis for the EMC Directive is DIN EN 61326-1.

Standard

Electrical connection DIN VDE 0100
Protection type IP20 panel-mount-

ing devices
Climatic ambient conditions Class 3K3
Air temperature and rel. humidity DIN EN 60721-3-3
Storage temperature Class 1K5 DIN EN 60721-3-1
Operating conditions

Pollution degree
Overvoltage category

Test voltages DIN EN 50178
Residual current circuit breaker DIN EN 50178
Electromagnetic compatibility

Emitted interference
Interference resistance

Mechanical tests:
Vibration test 3M2
Toppling test Class 2M1

Labels, identification marking DIN EN 50178, DIN EN 61010-1

DIN EN 60529

DIN EN 50178
2
III

DIN EN 61326-1

Class A- For industrial applications only
Industrial requirements

DIN EN 60068-2-6, DIN EN 60721-3-3
DIN EN 60068-2-31, DIN EN 60721-3-2

1 Introduction

Approvals Standard

submitted UL 508 (Category NRNT)

C22.2 NO. 14-10 Industrial Control Equipment
(Category NRNT7)

Can be used for current circuits with a short-circuit current capacity of
≤ 100 kA (the admissible supply voltage must correspond to the nominal voltage of
the SCR power controller).
For system protection, a fuse up to Class RK5 may be used.

CE conformity Low Voltage Directives 2006/95/EC

Marking Directives 93/68EEC
EMC Directives 2004/108/EC

Conformity Standard

RoHs 2002 / 95 EC

2012-12-01/00561071 [SCR Power Controller TYA201] 11

1 Introduction

12 2012-12-01/00561071 [SCR Power Switch TYA201]

2.1 Important installation notes

V

2 Installation

Safety regula­tions

Fuse protection k Fuse protection of the supply lead in accordance with the VDE regulations

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

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

k The electrical connection must only be carried out by qualified personnel.
k An isolating switch should be wired between the voltage supply and the de-

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

k Inside the device, safety clearances meet the requirements for double insu-

lation.
When fitting the connecting cable, ensure that the cables are fitted accord­ing to regulations and that the safety clearances are maintained.

must be installed when wiring the voltage supply in the power section. The
supply protection can also be achieved by a circuit-breaker in the supply
lead. The circuit-breaker must correspond to the power consumption of the
power controller.

k For UL application, it must be ensured that the fuse for the supply protec-

tion of the control electronics is between 2 A and a maximum of 5 A. This
also applies to the fan connection.

k To protect the power controller in the event of an earth fault, a semi-con-

ductor fuse is installed. In the event of a defect, these may only be replaced
with original JUMO semi-conductor fuses.

v Chapter 8.2 "Replacing a defective semi-conductor fuse"

Wiring Supply voltage and control cables are to be wired isolated from one another.

For supply protection, fuses (e.g. 2 A Neozed) must also be installed in the
control circuit.

PE connection h A direct connection must be provided between the PE conductor of the

power controller and the PE conductor of the supply network. Connection
takes place at the PE connection terminal.

The cross section of the PE conductor must be at least as large as the cross
section of the voltage supply conductors to the power section. In the event
that the protective conductor is not a component of the supply lead or its en­casement, the selected conductor cross section may not be less than

2.5 mm

conductor is not protected mechanically).
v See VDE 0100 Part 540

Check h That the data given on the nameplate (rated load voltage, load current) cor-

2

(for mechanical protection) or not less than 4 mm2 (if the protection

responds to the data for the system.

h That, if the economy circuit configuration is used, the rotary electrical field

has clockwise phasing.

2012-12-01/00561071 [SCR Power Controller TYA201] 13

2 Installation

h That the configuration of the analog inputs, for example, corresponds to the

h The analog input for the default setpoint value in "Master-slave operation"

wiring.

only needs to be connected to the master. The slave receives its informa­tion via the patch cable.
However, the slave power controller can be disconnected separately by
means of its own inhibit input.

Load connec­tion

Phasing The voltage supply of the control electronics and the load voltage

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

h The electronic switch (2 anti-parallel SCRs) is located between the U1 and

U2 terminals.

h Load wiring and cables for control inputs should be routed separately, if

possible.

h Perform connection of supply voltage - SCR power controller - load in ac-

cordance with the wiring diagram and check.

must have the same phase.

out for safe isolation from the voltage supply (SELV). In order not to diminish
this safety isolation, all connected electrical circuits must also have safety iso­lation. The required auxiliary voltages must be safe extra-low voltages.

2.1.1 Ambient conditions

Incorrect use The device is not suitable for installation in potentially explosive atmospheres.

Mounting site The power controller must be installed in a fire-proof control cabinet.

The cabinet should be vibration-free, free from aggressive media, and free
from dust to prevent the ventilation slots from becoming blocked.

Climatic
conditions

Avoid additional
sources of heat

Power dissipa­tion

- Relative humidity: 5 to 85 % no condensation (3K3 according to EN 60721)

- Ambient temperature range: 0 to 45 °C (3K3 according to EN 60721-3-3)

- Storage temperature range: -30 to 70 °C class 1K5

- Ensure that the ambient temperature at the installation site is not increased
by other sources of heat or heat accumulation.

- Do not mount the power controller too close to the heating process (kiln)

- Avoid direct sunlight.

Occurs as waste heat on the cooling body of the power controller and must be
dissipated at the mounting site (e.g. in the control cabinet) in accordance with
the climatic conditions.

14 2012-12-01/00561071 [SCR Power Controller TYA201]

2.1.2 Filtering and interference suppression

45 50 60

75

20

200

T/°C

150

Load current in A

Reduction at a temperature of 45 °C:
2 %/kelvin

70 %

250

100

50

To prevent radio-frequency interference, such as occurs with a soft start in
phase angle control, electrical apparatus and systems must have interference
suppression implemented.

The control electronics of the SCR power controller correspond to the EMC re­quirements of EN 61326.

However, electrical modules such as SCR power controllers do not have any
purpose by themselves. They provide a function as part of a complete system
or installation.
Where applicable, the entire load circuit of the power controller must also have
suitable interference suppression filters fitted by the system provider.

There are a number of specialist companies that provide appropriate ranges of
filters to deal with any interference problems. Such filters are normally sup­plied as complete modules that are ready to be connected.

2.1.3 Permissible load current depending on the ambient temperature and the installation height

2 Installation

Ambient tem­perature

2012-12-01/00561071 [SCR Power Controller TYA201] 15

2 Installation

Destruction through overheating:

In the event of operation over a long period at maximum load current, the cool­ing body and its environment heats up.
For this reason, at ambient temperatures above 45 °C, the maximum load cur­rent must be reduced as shown in the image, as the SCR module would other­wise be destroyed.
The device temperature shown on the display may not exceed 100 °C.

At a device temperature of > 100 °C, the message "Attention! High tempera­ture" is displayed.
At a device temperature of > 105 °C, the output level is gradually decreased by
10 °C for each increase in temperature of one degree.
At a device temperature of > 115 °C, the power controller is switched off en­tirely.

v Chapter 8 "Fault messages and alarms"

Installation
height

In the case of air cooling, it must be noted that the effectiveness of the cooling
is reduced the higher up the device is installed. As a result, the current carrying
capacity of the SCR power controller decreases with such a cooler as the in­stallation height increases as shown in the image.

16 2012-12-01/00561071 [SCR Power Controller TYA201]

2.1.4 Wall mounting with screws (ex works)

TYA201
20A

TYA201
32A

TYA201

50A

Power controllers with a load current between 20 and 50 A are affixed to a fire­proof control cabinet wall with 2 screws. The left-hand hole is more easily ac­cessible in the upper section.
Power controllers with a load current between 100 and 250 A are affixed with 4
screws.

2 Installation

2012-12-01/00561071 [SCR Power Controller TYA201] 17

2 Installation

TYA201 100A

TYA201 150/200A

18 2012-12-01/00561071 [SCR Power Controller TYA201]

2 Installation

TYA201 250A

2012-12-01/00561071 [SCR Power Controller TYA201] 19

2 Installation

Hot
surface

The power controller heats up during operation to a maximum of
110 °C, depending on the load.
Ensure that the lamellae of the cooling body are vertically aligned to
allow the heat to be dissipated through natural convection.

Fire hazard:

Do not install any heat-sensitive components or devices close to the
power controller.

Integrated ventilator for 250 A power controller:

The intake air at the ventilation grid of the ventilator may not ex­ceed a maximum supply air temperature of 35 °C. Ensure that the
inlet air for the integrated ventilators can be taken in from below
and escape at the top without obstruction!

2.1.5 Mounting on DIN rail (accessories)

Power controllers up to 32 A can be affixed to a DIN rail using the correspond­ing accessories.

v Chapter 1.3.2 "Accessories"
h Hook the spring clip into the DIN rail from above

h Swivel the power controller downward until the lug engages with the DIN

rail with an audible click.

20 2012-12-01/00561071 [SCR Power Controller TYA201]

2.2 Dimensions

2.2.1 Type 709061/X-0X-020-XXX-XXX-XX-25X

2 Installation

2.2.2 Type 709061/X-0X-032-XXX-XXX-XX-25X

2012-12-01/00561071 [SCR Power Controller TYA201] 21

2 Installation

2.2.3 Type 709061/X-0X-050-XXX-XXX-XX-25X

2.2.4 Type 709061/X-0X-100-XXX-XXX-XX-25X

22 2012-12-01/00561071 [SCR Power Controller TYA201]

2.2.5 Type 709061/X-0X-150-XXX-XXX-XX-25X Type 709061/X-0X-200-XXX-XXX-XX-25X

2 Installation

2012-12-01/00561071 [SCR Power Controller TYA201] 23

2 Installation

2.2.6 Type 709061/X-0X-250-XXX-XXX-XX-25X

2.2.7 Clearances (all types)

h Allow a clearance of 10 cm from the floor.
h Allow a clearance of 15 cm from the ceiling.
h When fitted next to each other, no spacing between the devices is required.

24 2012-12-01/00561071 [SCR Power Controller TYA201]

3 Electrical connection

( 2)X2_

(X2_1) (X8) ( )X3

(U1)

(U2)

(N/L2)

(V)

(L1)

(PE)

Voltage supply

lectronicsControl e

Controlsection

Power section

Dangerous
voltage

h Disconnect the system from the voltage supply on all poles.

3.1 Plug-in screw terminals

Tools - Flat-blade screwdriver, blade width 2, 3, and 5 mm

- Ring or open-end wrench, width across flats 7, 10, 13 mm

3.1.1 Type 709061/X-0X-20-XXX-XXX-XX-25X

The device with a load current of 20 A is connected via plug-in screw termi­nals.

The electrical connection must only be carried out by qualified per­sonnel! Dangerous voltages will cause an electric shock if contact
with live parts is made!

Terminal Version Conductor cross-

X2_1 and X2_2 Slotted screws, blade width 2 mm

X3 Slotted screws, blade width 3 mm

U2, N/L2, V, L1, U1 Slotted screws, blade width 5 mm

For applications according to UL, only 60 °C or 60 °C / 75 °C copper conductors may be used!

Ground terminal PE M4 setscrew with hexagon

2012-12-01/00561071 [SCR Power Controller TYA201] 25

nut
Width across flats 7 mm

section

0.2 to 1.5 mm

0.5 to 2.5 mm

0.5 to 6 mm

2

Cable lug with
hole: 4 mm

Maximum
tightening
torque

2

2

0.25 Nm

0.5 Nm

0.6 Nm

3Nm

3 Electrical connection

3.2 Cable lugs and plug-in screw terminals

3.2.1 Type 709061/X-0X-032-XXX-XXX-XX-25X

Devices with a load current of 32 A and 50 A are equipped with plug-in screw
terminals in the control section and cable lugs in the power section.

Terminal Version Conductor cross-

section

X2_1 and X2_2 Slotted screws, blade width 2 mm

X3 Slotted screws, blade width 3 mm

U2, U1 M6 recessed head screws

For applications according to UL, only 60 °C or 60 °C / 75 °C copper conductors may be used!

N/L2, V, L1 Slotted screws,

blade width 3 mm

Ground terminal PE M6 setscrew with hexagon

nut
Width across flats 10 mm

0.2 to 1.5 mm

0.5 to 2.5 mm

6 to 25 mm

0.5 to 4 mm
(0.5 to 2.5 mm

ferrule)
(for UL application
AWG 20-12)

Cable lug
hole: 6 mm

2

2

2

2

or

2

with

Maximum
tightening
torque

0.25 Nm

0.5 Nm

5Nm

0.5 Nm

5Nm

26 2012-12-01/00561071 [SCR Power Controller TYA201]

3.2.2 Type 709061/X-0X-050-XXX-XXX-XX-25X

3 Electrical connection

2012-12-01/00561071 [SCR Power Controller TYA201] 27

3 Electrical connection

3.2.3 Type 709061/X-0X-100-XXX-XXX-XX-25X

Devices with a load current of 100 A are equipped with plug-in screw terminals
in the control section and cable lugs in the power section.

Terminal Version Conductor cross-section Maximum

tightening
torque

X2_1 and X2_2 Slotted screws, blade width 2 mm

X3 Slotted screws, blade width 3 mm

U2, U1 M6 hexagon screws, width across

0.2 to 1.5 mm

0.5 to 2.5 mm

16 to 50 mm

2

2

2

flats 10 mm

For applications according to UL, only 75 °C copper conductors may be used!

N/L2, V, L1 Slotted screws,

blade width 3 mm

0.5 to 4 mm
(0.5 to 2.5 mm

2

or

(for UL application AWG 20-

12)

Ground terminalPEM6 setscrew with hexagon nut

Width across flats 10 mm

Cable lug
hole: 6 mm

2

with ferrule)

0.25 Nm

0.5 Nm

5Nm

0.5 Nm

5Nm

28 2012-12-01/00561071 [SCR Power Controller TYA201]

3 Electrical connection

3.2.4 Type 709061/X-0X-150-XXX-XXX-XX-25X Type 709061/X-0X-200-XXX-XXX-XX-25X

Devices with a load current of 150 A are equipped with plug-in screw terminals
in the control section and cable lugs in the power section.

Terminal Version Conductor cross-section Maximum

tightening
torque

X2_1 and X2_2 Slotted screws, blade width 2 mm

X3 Slotted screws, blade width 3 mm

U2, U1 M8 hexagon screws, width across

0.2 to 1.5 mm

0.5 to 2.5 mm

95 to 150 mm

2

2

2

flats 13 mm

For applications according to UL, only 75 °C copper conductors may be used!

N/L2, V, L1 Slotted screws,

blade width 3 mm

0.5 to 4 mm
(0.5 to 2.5 mm

2

or

(for UL application AWG 20-

12)

Ground terminalPEM8 setscrew with hexagon

nut, width across flats 13 mm

Cable lug
hole: 8 mm

2

with ferrule)

0.25 Nm

0.5 Nm

12 Nm

0.5 Nm

12 Nm

2012-12-01/00561071 [SCR Power Controller TYA201] 29

3 Electrical connection

3.2.5 Type 709061/X-0X-250-XXX-XXX-XX-25X

Devices with a load current of 200 to 250 A are equipped with plug-in screw
terminals in the control section and cable lugs in the power section.

Terminal Version Conductor cross-section Maximum

tightening
torque

X2_1 and X2_2 Slotted screws, blade width 2 mm

X3 Slotted screws, blade width 3 mm

U2, U1 M8 hexagon screws, width across

0.2 to 1.5 mm

0.5 to 2.5 mm

95 to 150 mm

2

2

2

flats 13 mm

For applications according to UL, only 75 °C copper conductors may be used!

N/L2, V, L1 Slotted screws,

blade width 3 mm

0.5 to 4 mm
(0.5 to 2.5 mm

2

or

(for UL application AWG 20-

12)

Ground terminalPEM8 setscrew with hexagon

nut, width across flats 13 mm

Fan X14 Slotted screws, blade width 3 mm

Cable lug
hole: 8 mm

0.5 to 2.5 mm

2

Depending on the load voltage, the fan terminal X14 must be supplied with the
voltage specified below.
The lead protection must be between 2 A and a maximum of 5 A.
The fan is temperature-controlled, switches on automatically when the device
temperature reaches 85 °C, and remains in operation until the device tempera­ture falls below 70 °C.

2

with ferrule)

0.25 Nm

0.5 Nm

12 Nm

0.5 Nm

12 Nm

0.5 Nm

Voltage supply
for
fan

Load voltage on the pow­er controller

Tolerances Fan specifica-

tions

Load voltage AC 24 V -20 to +15 %, 45 to 63 Hz AC 24 V / 30 VA
Load voltage AC 42 V -20 to +15 %, 45 to 63 Hz
Load voltage AC 115 V -15 to +6 %, 45 to 63 Hz AC 115 V / 30 VA
Load voltage AC 230 V -15 to +6 %, 45 to 63 Hz AC 230 V / 30 VA
Load voltage AC 265 V
Load voltage AC 400 V
Load voltage AC 460 V

Load voltage AC 500 V

30 2012-12-01/00561071 [SCR Power Controller TYA201]

3 Electrical connection

2012-12-01/00561071 [SCR Power Controller TYA201] 31

3 Electrical connection

V V

PE PE

U2

U1

N/L2

L1

2

1

+

–

I

x

4

3

+

–

U

x

E

S

A

3

4

5

5kW

External manual

adjustment with

7

8

3,3V

10k

W

11

9

3,3V

10k

W

10

3,3V

10k

W

12

11

+

–

3.3 Connection diagram

Connection for Screw terminals Connection side Device

side

Voltage supply for control electronics
(Corresponds to the max. load voltage
of the ordered device type)

Protective earth PE

L1
N/L2
V

Load connection in the

tion

power sec-

U1
U2

Fan X14 20, 21 (only for load current 250 A)

Control section

Connection for Screw terminal X2_1

Current setpoint input 1

2

Voltage setpoint input (surge proof
up to max. DC +32 V)

Output DC 10 V fixed voltage

3 (GND)
4

5

(max. +10 V, 2 mA)
Ground potential 6 (GND)

Connection for Screw terminal X2_2

Firing-pulse inhibit
Surge proof up to max. DC 32 V
OFF logical "0" = 0 to +0.8 V
ON logical "1" = +2 to 3.3 V

Binary input1
Surge proof up to max. DC 32 V
OFF logical "0" = 0 to +0.8 V
ON logical "1" = +2 to 3.3 V

Binary input2
Surge proof up to max. DC 32 V
OFF logical "0" = 0 to +0.8 V
ON logical "1" = +2 to 3.3 V

GND 7, 11 Ground potential
Analog output

Various internal controller variables can
be output as a standard signal 0(4) to
20 mA, 0(2) to 10 V, 0(1) to 5 V.

8
7 (GND)

9
11 (GND)

10
11 (GND)

12

Connection side Device side

Connection side Device side

v Chapter 10.4 "Analog output (actu-

al value output)"

Master-slave
connection

Connection RJ 45 socket X8

For master-slave operation in
three-phase current economy circuit

32 2012-12-01/00561071 [SCR Power Controller TYA201]

1:1 patch cable

3 Electrical connection

13

14
15

E

S

C

Ö

P

Optocoupler

Relay

16

17

19
18

6

7

8

9

2

3

4

5

1

16

17

19
18

(RS422/485 )Modbus

ProfibusDP

Fault signal
output

Connection for Screw terminal X3 Connection side Device side

Relay or optocoupler 13 N/O contact or collector

14 N/C contact
15 pole or emitter

Interfaces

Connection Modbus RS422 RS485 Connection PROFIBUS-DP

Plug-in screw
terminals on
the
bottom of the
case

19 TxD (-) RxD/TxD B(-) SUB-D sock­18 TxD (+) RxD/TxD A(+) 8 B(-)
17 RxD (-) - 6 VCC

et 9-pin
(on the front)

16 RxD (+) - 5 GND

3 A(+)

Shielding

2012-12-01/00561071 [SCR Power Controller TYA201] 33

3 Electrical connection

3.3.1 Single-phase operation: phase / N

In the case of power controllers with a load current of 250 A, the fan terminal
X14 must also be supplied with the specified voltage!
The lead protection must be between 2 A and a maximum of 5 A.

v Chapter 3.2.5 "Type 709061/X-0X-250-XXX-XXX-XX-25X"

34 2012-12-01/00561071 [SCR Power Controller TYA201]

3.3.2 Single-phase operation: phase / phase

3 Electrical connection

In the case of power controllers with a load current of 250 A, the fan terminal
X14 must also be supplied with the specified voltage!
The lead protection must be between 2 A and a maximum of 5 A.

v Chapter 3.2.5 "Type 709061/X-0X-250-XXX-XXX-XX-25X"

2012-12-01/00561071 [SCR Power Controller TYA201] 35

3 Electrical connection

3.3.3 Star connection with accessible star point (N)

In the case of power controllers with a load current of 250 A, the fan terminal
X14 must also be supplied with the specified voltage!
The lead protection must be between 2 A and a maximum of 5 A.

v Chapter 3.2.5 "Type 709061/X-0X-250-XXX-XXX-XX-25X"

36 2012-12-01/00561071 [SCR Power Controller TYA201]

3 Electrical connection

3.3.4 Open delta connection (six wire connection)

In the case of power controllers with a load current of 250 A, the fan terminal
X14 must also be supplied with the specified voltage!
The lead protection must be between 2 A and a maximum of 5 A.

v Chapter 3.2.5 "Type 709061/X-0X-250-XXX-XXX-XX-25X"

2012-12-01/00561071 [SCR Power Controller TYA201] 37

3 Electrical connection

3.3.5 Free-running economy circuit with purely resistive loads

For this electrical circuit, no master-slave connection is necessary.

In the case of power controllers with a load current of 250 A, the fan terminal
X14 must also be supplied with the specified voltage!
The lead protection must be between 2 A and a maximum of 5 A.

v Chapter 3.2.5 "Type 709061/X-0X-250-XXX-XXX-XX-25X"

38 2012-12-01/00561071 [SCR Power Controller TYA201]

3 Electrical connection

Advantages The free-running economy circuit has the advantage that, on average, the sup-

ply voltage is subject to less impact stresses (asynchronous switching).
Both power controllers operate independently of each other and control the
required three-phase power precisely.

Even a possible partial load failure will not necessarily have an effect on the
temperature stability of the control loop.

709061/X-XX-XXX-001-XXX-XX-XXX (code 001) is required in the order code
for both power controllers.

3.3.6 Master-slave three-phase current economy circuit for resistive loads in star, delta connection, or transformer loads (resistive-inductive)

Note: The three-phase current economy circuit should be implemented with the TYA

202 type 709062 version, which is available ex works as a fully assembled and
configured unit, and behaves exactly like two single TYA 201 devices in mas­ter-slave operation.

However, it is also possible to operate two devices from the TYA 201 series in
master-slave operation. For this, one device is configured as the master and
the other as the slave. As soon as the devices are connected via the patch ca­ble and switched on at the same time, the devices work in sync.
All further configuration steps are only performed on the master device and
the slave device can no longer be operated.
The slave device can be identified as the device on which no measured values
are displayed and "Slave unit" is shown on the display.

Prerequisite To facilitate symmetrical operation, the devices must have the same type key

and the same device software version.
The two devices are connected by means of a patch cable (max. length of
30 cm).

The wiring of two TYA 201 devices is shown in the diagram below.

Operating mode In the standard version, the master-slave economy circuit operates with a U

control. The control electronics of the master power controller assume the ac­tual power control function, and drive the slave power controller in synchroni­zation. This makes it possible to drive transformer loads. In combination with

2

the fixed cycle time and the U
ual load resistances can be achieved.

control, high voltage consistency of the individ-

2

2012-12-01/00561071 [SCR Power Controller TYA201] 39

3 Electrical connection

In the case of power controllers with a load current of 250 A, the fan terminal
X14 must also be supplied with the specified voltage!
The lead protection must be between 2 A and a maximum of 5 A.

v Chapter 3.2.5 "Type 709061/X-0X-250-XXX-XXX-XX-25X"

40 2012-12-01/00561071 [SCR Power Controller TYA201]

4 Operation

(1)

(2)

(3)
(4)

(5)

(7)

(6)

Observe the
switch-on se-

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

quence

Under no circumstances should the voltage supply for the control elec­tronics be switched on before the load voltage! This is particularly im­portant for the operation of transformer loads and resistance loads with
a high temperature coefficient (TC >> 1)!

4.1 Display after switching on the device

Sequence If everything is wired correctly and the voltage supply is switched on, the Pow-

er LED is permanently lit in green.
At the same time, an hourglass appears on the display, after which the supply

voltage is displayed.

Error messages v Chapter 8 "Fault messages and alarms"

4.1.1 Display and control elements

Legend Comment Fig.

1

2

3

4
5 Keys:

The Power LED (green) is permanently lit when the voltage sup­ply is connected.
Flashes at regular intervals if display lighting is switched off.

v Chapter 9 "What to do, if ..."

Display (96 x 64 pixels) with white background lighting. The in­formation line at the bottom of the display shows the current
settings and error messages.

Fuse LED (red) is lit in the event of a defective semi-conductor
fuse

K1 LED (yellow) fault signal display

Increase value / previous parameter
Decrease value / next parameter
Abort / one level back
Programing / one level forward

6
7

USB setup interface
Spring clip to release the plastic case

v Chapter 8.2 "Replacing a defective semi-conductor

fuse"

2012-12-01/00561071 [SCR Power Controller TYA201] 41

4 Operation

Designation

Measured value

Info line or error

Using and the current measured values such as currents, voltage
actual values, setpoint value load resistance, device temperature, and power
can be viewed.

This information is also displayed in the diagnosis window of the setup pro­gram.

v Chapter 7 "Setup program"

4.1.2 Displaying measured values

Overview of
measured val­ues

Meaning of the
symbols in the
info line

At this level, the designation of the measured value is displayed in the top row,
and the numerical value together with the unit of measurement is displayed in
the middle row.

The info line shows the selected input (with terminal designation), the set sub­ordinate control loop, and the operating mode.
It is also used to display temporary states (e.g. error messages).
v Chapter 8 "Fault messages and alarms"

Input signal Subordinate

control loop

Voltage None Phase angle control

Current U

Interface I

2

2

Operating mode
load output

Soft start in phase an­gle control

Burst-firing mode

Binary input1 U Burst-firing mode with

α start

Binary input2 I Half-wave control

Input signal in­correctly
configured

42 2012-12-01/00561071 [SCR Power Controller TYA201]

P General logic

Logic
(switch)

Invalid control
configured

Logic with α start

Logic with α default
values

Logic with α start and
α default values

Firing-pulse inhibit

4 Operation

4.1.3 Meaning of the displayed measured values

Measured value Meaning Unit

Supply voltage Effective value of the measured supply voltage

(measured between the L1 and N/L2 terminals)

Load voltage

4

Effective value of the measured load voltage
(measured between the V and U2 terminals)

Load current
Power

1, 4

Load
resistance

1, 4

Output level

1, 4

4

Effective value of the measured load current
Measured effective power

Measured effective resistance

Output value of the subordinate control loop

Setpoint value Effective setpoint value for the subordinate control loop (with calculated

base load and max. output level)

Actual value
Phase

control angle

2, 4

3, 4

Measured value as a percentage of the set control variable U2, U, I2, I, or P
Currently output phase control angle

Supply frequency Currently measured supply frequency
Device

Currently measured temperature inside the power controller

temperature

V

V

A

W or
kW

?

%

%

%

°el

Hz

°C or
°F

Current input Measured value of the current input of the power controller

(measured between terminals 1 and 2 on X2_1)

Voltage
input

Measured value of the voltage input of the power controller
(measured between terminals 3 and 4 on X2_1)

1.

Is only displayed if the current transformer is fitted (option I2- / I- or P control)

2.

Is not displayed if the subordinate control loop is switched off

3.

Is only displayed for phase angle control mode

4.

Is only displayed in half-wave control operating mode

mA

V

2012-12-01/00561071 [SCR Power Controller TYA201] 43

4 Operation

4.1.4 Display in the configuration level

Scroll bar The entry highlighted in black is selected and contains further parameters.

If there are more than 3 entries in one level, a scroll bar that shows the current
position in the menu appears.

Navigation

Numerical entry
or
selection

Once you have reached the required parameter, the or key can be
used to enter a numerical value or to select a parameter.

h Save the setting using .
If you do not want to apply the value, the entry can be aborted by selecting

.

44 2012-12-01/00561071 [SCR Power Controller TYA201]

4.1.5 Display of error messages and special states

4 Operation

Cyclical
display

Examples

The symbols for input, subordinate control loop, and operating mode are dis­played alternately with error messages or important information regarding spe­cial states in the info line.

v Chapter 8 "Fault messages and alarms"

All parameters for the maximum device extension level are listed in the fol­lowing tables. Parameters that are not required are hidden depending on the
order details (see nameplate or device information) or the current configura­tion.

2012-12-01/00561071 [SCR Power Controller TYA201] 45

4 Operation

4.2 Operator level

Here you will find the parameters that can be modified during ongoing oper­ation without restarting (resetting) the device.

They can be accessed ex works without a password, but can also be protect­ed with a 4-digit code, if necessary.

v Chapter 5.1.11 "Changing codes"
During ongoing operation, the power controller can be adapted to the plant

and optimized.

h In the measured value overview, press the key
h Select the operator level and press again.

Editing a pa­rameter

4.2.1 Device data

The changes are effective immediately.
Once the correct setting, e.g. for display contrast, has been found, the param-

eter can be stored by pressing .
If you do not want to apply the value, the entry can be aborted by pressing

.

Value range Description
0 to 50 to 100 % 50 % is set ex works.

0000 to 1440 min 0000 minutes are set ex works,

which means the display is not switched off.

k / bold = factory setting

4.2.2 Power controller

Value range Description

0 to 70 to 90 °el 70 °el are set ex works.

If "α start" is set to "No" in the configuration, this window is
not displayed and α start is set to 0 °el.

46 2012-12-01/00561071 [SCR Power Controller TYA201]

4 Operation

10 % to max. load
current for the de­vice type +10 %

Current load current

0 to 999.99 Ω

Current resistance

k / bold = factory setting

4.2.3 Setpoint value configuration

Value range Description
0 to 180 °el In logic operation, the phase angle of each sinusoid can

Current limiting:

It is possible to modify the current limit value in phase
angle control mode during operation.
This window is not displayed if "Current limiting" is set to
"no" in the configuration.

Resistance limitation:

Indirect temperature limit for a heating element with pos­itive temperature coefficients

be varied.
This means that excessive electrical impact stresses on
the load can be prevented.

Current load voltage
and current

Current load voltage

Current load voltage

0 to U
of the load voltage,
0 to P
of the power

0 to I
of the max. load current
0 to 100 %
of the output level

0 to U
of the load voltage,
0 to P
of the power

0 to I
of the max. load current
0 to 100 %
of the output level

k / bold = factory setting

nom.

nom.

nom.

nom.

nom.

nom.

to 1.15 U

to 1.15 P

nom.

nom.

In the case of continuous SCR control via the analog in­put, the maximum actuating variable at the measuring
range end (e.g. 20 mA) can be varied during operation.

The displayed value depends on the "Subordinate control
loop" setting:

2

U

and U: display in V (example: 0 to 230 to 264.5 V)

P: display in W (example: 0 to 4600 to 5290 W)

2

I

and I: Display in A (example: 0 to 20 A)

None: Display in % (example: 0 to 100 %)
In the case of continuous SCR control via the analog in-

put, the base load at the measuring range start (e.g. 0 mA)
can be varied during operation.
The displayed value depends on the "Subordinate control
loop" setting.

2012-12-01/00561071 [SCR Power Controller TYA201] 47

4 Operation

4.2.4 Monitoring

Current measured
value

The value to be monitored can be adjusted.
v Chapter 5.1.5 "Monitoring"
The load voltage was used in this example.

Value range Description
0 to 9999.9 The absolute minimum limit value of load voltage, load current, pow-

er, resistance, supply voltage, or device temperature can be moni­tored.

v Chapter 5.1.5 "Monitoring"

Example:
If the voltage falls below 20 V, an alarm is issued.

0 to 9999.9 The absolute maximum limit value of load voltage, load current, pow-

er, resistance, supply voltage, or device temperature can be moni­tored.

v Chapter 5.1.5 "Monitoring"

Current measured
value

Current deviation
from teach-in.
I.e. at > 0 %
the load has become
more high-resis­tance; at < 0 % the
load is more low-re­sistance.

0 to 1 to

9999.9

0 to 10 to
100 %

Example:
If the voltage exceeds 100 V, an alarm is issued.

The switching differential at the minimum or maximum limit value

Partial load failure or partial load short circuit:
The monitoring value for the percentage modification of the load is

set (undercurrent or overcurrent).

v Chapter 5.1.5 "Monitoring"

By displaying the current deviation from the teach-in value, it is possi­ble to check whether, for example, an output level-dependent resis­tance modification is present.

k / bold = factory setting

48 2012-12-01/00561071 [SCR Power Controller TYA201]

4 Operation

This function is not configured ex works.
This window only appears if the following setting has been
made in the configuration level:

h Press the key to switch to the configuration level
h Set Monitoring
h Press the key

The "Manual teach-in" function is now configured.

h Change to the operator level

teach-in
h Press the key
A screen now appears asking whether the state should be ap-

plied now. If so:
h Press the key to apply the current load state as the OK

status.
A change in the load (load error) will be evaluated by the device

on the basis of this status.

k / bold = factory setting

rTeach-in type load monit. rManual

rMonitoring rLoad monit.

2012-12-01/00561071 [SCR Power Controller TYA201] 49

4 Operation

50 2012-12-01/00561071 [SCR Power Controller TYA201]

5.1 Configuration level

or PROFIBUS-DP

v Chapter 5.1.1 "Device data"
v Chapter 5.1.2 "Power control-

ler"
v Chapter 5.1.3 "Analog inputs"
etc.

The configuration level contains parameters for configuring the power control­ler.
If the parameters at this level are modified during operation, the power control­ler is locked (inhibit) as a result. In this state, it does not provide any power.
When the configuration level is exited, a restart (reset) is performed and the
power controller provides the required power once again.

This level can be locked with a password.
However, no password is set ex works.

All parameters for the maximum device extension level are listed in the fol­lowing tables. Depending on the device version (see nameplate) or configura­tion, parameters that are not required are hidden.

The configuration level can be accessed from the overview of measured val­ues by pressing the following keys:

h In the measured value overview, press the key

5 Configuration

Parameter
groups

h Select the configuration level and press .
The parameters are combined in the following groups, which are explained in

detail as sub-chapters in the tables on the following pages.

2012-12-01/00561071 [SCR Power Controller TYA201] 51

5 Configuration

5.1.1 Device data

Basic settings for display and temperature unit.

Value/settings Description

Temperature unit

°C Defines the unit for the displayed temperatures, such as the
°F

device temperature.

Display contrast
Switch-off

display lighting

Apply factory set­tings

0 to 50 to 100 % Bright/dark contrast setting
0000 to 1440 min After the set number of minutes, the background lighting of

Apply now? If the PGM key is pressed, the factory settings are restored.

k / bold = factory setting

5.1.2 Power controller

Settings for the switching behavior of the power controller in the system.

Value/settings Description

Mains switching
variant

Single-phase opera­tion

Free-running
economy circuit

Economy circuit
master

Economy circuit
slave

the display switches off. Power LED (green flashes).
0000 means: lighting is always switched on

v Chapter 3.3.1 "Single-phase operation: phase / N"

or
Chapter 3.3.2 "Single-phase operation: phase /
phase"

Note:

- Check for clockwise phasing

- Only possible with P-control (code 001 in order code)

v Chapter 3.3.5 "Free-running economy circuit with

purely resistive loads"

One device is set as the MASTER and the other as the SLAVE.
This makes a three-phase current economy circuit possible.

v Chapter 3.3.6 "Master-slave three-phase current

economy circuit for resistive loads in star, delta con­nection, or transformer loads (resistive-inductive)"

v B 709062.0

SCR control Continuous (power

controller)
Logic (switch) Note:

k / bold = factory setting

The power controller provides the power for the load continu­ously depending on the default setpoint value.

Subordinate control loop cannot be set!
The power controller acts like a switch and provides the power

by either switching ON or OFF.

52 2012-12-01/00561071 [SCR Power Controller TYA201]

Operating mode

u

t

a

u

t

a

u

t

(Is displayed in the
measured value lev­el in the info line)

Value/settings Description

Burst-firing
mode

- For slow control loops

- For free-running economy circuit

- Low EMC interference through zero-voltage switching

- No reactive power is generated

5 Configuration

Phase angle
control mode

Half-wave control

- For fast control loops,
such as lighting controls

- No flickering

Note:

Subordinate control loop cannot be set!
The half-wave control operating mode is only possible in sin­gle-phase power controller operation. It is a special type of
phase angle control mode used, for example, for vibrating
magnets. In half-wave control, one SCR branch remains per­manently locked so that only the positive half-wave is allowed
to pass through.
The specified setpoint value is converted to a phase control
angle of 180 °el. to 0 °el.
In this operating mode, it is not possible to measure either
load voltage or load current, which makes a subordinate con­trol loop impossible.

k / bold = factory setting

2012-12-01/00561071 [SCR Power Controller TYA201] 53

5 Configuration

Phase angle α

0 to 20 mA
0 to 10 V

Analog input

Value/settings Description

Subordinate control
loop

U2, U, I2, I, P Note:

The subordinate control loop only appears for:

Power controller r SCR control rContinuous (control­ler).

Subordinate control loops are used to eliminate or compen­sate external
disturbances, such as fluctuations in the supply voltage and
changes in load resistance, which would have a negative ef­fect on the control loop.

The U setting is used when the load voltage should be directly
proportional to the default setpoint value.
The I setting is used when the load current should be directly
proportional to the default setpoint value.

The following subordinate control loops have proven advanta­geous for heating elements that do not have a linear tempera­ture behavior or are subject to aging:

2

U

is used for:

- Positive temperature coefficient, molybdenum disilicide

- If

R ∪ is constant

- Brightness controls

2

I

is used for:

- Negative temperature coefficient (TC)

P is used for:

- Temperature-dependent temperature coefficient

- Free-running economy circuit

- General applications

- SIC load with automatic aging compensation

Switched off The diagram shows how the phase angle is specified via a

standard signal without a subordinate control loop.

54 2012-12-01/00561071 [SCR Power Controller TYA201]

k / bold = factory setting

Value/settings Description

u

t

500ms

520

u

t

500ms

520

u

t

u

t

a a

Cycle time Fixed (500 ms)

(For slow heating ele­ments)

5 Configuration

Note:

This setting is only available in burst-firing mode.
For example, for a fixed period of 500 ms, 5 sine waves are

switched on and 20 switched off at an output level of 20 %.

Min. ON period

α start

Fastest possible
(For quick-response

heating elements)

With this setting, the cycle time is variable. At the required out­put level, the device attempts to find the shortest possible cy­cle time for entire sine wave cycles. At an output level of 20 %,
this relates to one sine wave ON and four sine waves OFF.

None
3 full sine waves Dependent on the cycle time setting.

At least 3 full sine waves are always let through.
At an output level of 50 % and fastest possible cycle time,

3 sine waves are switched on and 3 switched off.

Note:

Particularly suitable for the control of transformer loads

No Note:
Yes

This setting is available in continuous burst-firing mode and in
logic operation.

No: for resistive load
Yes: for transformer loads

If set to "Yes", the first half-wave of each pulse group is cut
with the set phase control angle α.

Angle α start 0 to 70 to 90 °el Phase control angle for α start
Soft start

2012-12-01/00561071 [SCR Power Controller TYA201] 55

No This setting determines the starting behavior of the power

controller after power ON and is deactivated ex works.

k / bold = factory setting

5 Configuration

u

t

Softstartzeit

u

t

Cycle time

Value/settings Description

Yes "Yes" means that a soft start with phase angle control or pulse

groups is performed after power ON.

Soft start type

With phase angle
control

This parameter only appears if soft start is set to "Yes."
Soft start type "With phase angle control" is available in the

phase angle control mode and in the burst-firing mode.

Phase angle control:

Starting from 180°, the phase control angle α is steadily re­duced until the correct phase angle for the default setpoint
value is reached.

Burst-firing mode:

Starting from 180°, the phase control angle α is steadily re­duced until a full wave has passed through.
This ends the soft start and a switchover to burst-firing mode
is performed.

Note: If the output level is reduced to 0 % for longer than 8
seconds, a soft start is initiated again as soon as the output
level is increased again.

If, during the soft start phase, current limiting is activated, the
soft start duration is extended because the phase control an­gle cannot be reduced further during current limiting.

With pulse groups This setting is only available in burst-firing operating mode

with a fixed cycle time and with the fastest possible cycle
time.
During the soft start time, the ON/OFF ratio is
increased from 0 to a maximum of 100 %.

Soft start duration 1 to 65535 s Specifies the duration of the soft start.

Note: Due to the system, when current limiting is switched on,

the soft start duration is at least 4 s, even if a shorter duration
is configured as the soft start duration.

k / bold = factory setting

56 2012-12-01/00561071 [SCR Power Controller TYA201]

Value/settings Description

Current limiting No No current limiting

Yes The current limiting is implemented via phase angle control. In

this case, the load current is monitored on the basis of the set
current limit value and only the phase control angles that do
cause the current limit value to be exceeded are permitted.

If burst-firing mode is set, the current limiting only operates
during the soft start that is realized via a time-limited phase
angle control.

It is also possible to activate an external current limit value
via a binary input.

v Chapter 5.1.6 "Binary inputs"

5 Configuration

Current limit value 10 % to max. load

current +10 % of the
device type

Resistance limita­tion

No No limitation through load resistance
Yes The load resistance is monitored to ensure the set resistance

Resistance limit
value

Load type resis­tance limitation

0 to 999.99 Ω If the load resistance is greater than this value,

Resistive load This setting is to be used for purely resistive load.
Transformer load This setting is only to be used for a resistive load via a trans-

Varies depending on the device type.
For 20 A power controllers, 2 to 22 A can be set.

v Chapter 1.3 "Order details"

Note:
Resistance limitation is only possible in the case
controllers with integrated subordinate control loop P (code
001 in the

limit value is not exceeded.
For phase angle control, the limitation is implemented through
the phase control angle α.
For burst-firing mode, the limitation is implemented through
the ON/OFF ratio of the sine waves.

order code).

of power

v Chapter 6.6 "Resistance limitation (R control)"

limitation is implemented through phase angle control or limi­tation of the switched sine waves.

Note:

This parameter only appears in the phase angle control oper­ating mode.

former.

Dual energy man­agement

Switched off This parameter only appears with the following settings:
Device1
Device2

Cycle time: fixed (500 ms),
Operating mode: burst-firing mode.

This setting allows 2 devices to be configured in such a way
that they do not simultaneously draw power from the power
supply at small output levels.
This prevents current peaks.

v Chapter 6.4 "Dual energy management"

k / bold = factory setting

2012-12-01/00561071 [SCR Power Controller TYA201] 57

5 Configuration

5.1.3 Analog inputs

The power controller has a voltage and a current input.
These inputs (default setpoint value) specify the output to be provided by the
power controller at the load output.

In most cases, this signal is sent as a standard signal from an electronic con­troller or PLC and is adjusted with these settings.

Value/settings Description

Current measuring
range

0 to 20 mA This setting specifies which current standard signal is con­4 to 20 mA
Customer-specific

nected.

1

v Chapter 3.3 "Connection diagram"

Current measuring
range, start

Current measuring
range, end

Voltage measuring
range

Voltage measuring
range, start

Voltage measuring
range, end

0 to 20 mA Note: This parameter only appears if "Customer specific" is

set for the current measuring range (see above)!

0 to 20 mA Note: This parameter only appears if "Customer specific" is

set for the current measuring range (see above)!

0 to 10 V This setting specifies which voltage standard signal is con­2 to 10 V
0 to 5 V
1 to 5 V
Customer-specific

0 to 10 V Note: This parameter only appears if "Customer specific" is

0 to 10 V Note: This parameter only appears if "Customer specific" is

k / bold = factory setting

1.

Analog input inverting:

If, for example, the current measuring range start is set to 20 mA and the current measuring range en
to 0 mA, the power controller is switched off at 20 mA and switched on at 0 mA.

nected.

v Chapter 3.3 "Connection diagram"

1

set for the voltage measuring range (see above)!

set for the voltage measuring range (see above)!

58 2012-12-01/00561071 [SCR Power Controller TYA201]

5.1.4 Setpoint value configuration

u

t

a

-Vorgabe

Phase angle α

0 to 20 mA
0 to 10 V

Analog input

This setting determines which input specifies the setpoint value, how high the base
load is, and which alternative value should be applied in the event of an error.

Value/settings Description

Setpoint input

Current input This setting specifies which analog input supplies the setpoint

value for the power output.
Note:

Voltage input

These inputs can also be used for logic operation.

v For switching level, see Chapter 10.7 "General char-

Binary input1 Note:

This setting is only available if power controller

rLogic (switch) is set.

Binary input2

Via interface Means that the setpoint value for the power output is provided

In this case, the power controller is controlled in the same way
as a solid-state relay (SSR) via binary input 1 or 2:
Contact: closed
(for control direction set ex works).

via an interface.

5 Configuration

acteristic data"

rSCR control

r100 % and open r0%

α input

This setting is only available power controller rSCR control rLogic (switch) is set.
This setting specifies which signal
should be fixed

.

the α default values should control or whether it

The "α default values" value is a phase angle with which all sine waves are cut to limit
the power.
Not to be confused with the value for α start!

No input No phase angle is specified (full sine waves)
Voltage input or cur-

rent input

This standard signal specifies the phase angle as shown in
the diagram.

Value, adjustable The phase angle is entered as "α default value".
Via interface The phase angle is set via an interface.

α input value

0 to 180 °el This is the phase angle if "Value, adjustable" was set under α

input value.

2012-12-01/00561071 [SCR Power Controller TYA201] 59

5 Configuration

Control signal

P

Base load: 680 W

Maximum
Output level: 3680 W

0 mA

20 mA

3000W 0...20mA

Ⳏ

Base load

Input in the event of
an error

Value in the event
of an error

Maximum
actuating variable

Current, voltage, and interface input are monitored for errors
(wire breaks or bus errors). This setting specifies which alter­native value the power controller should use if the default set­point value is incorrect.
The last valid value is used ex works.

Last value
Voltage input or cur-

rent input

If, for example, an error (e.g. wire break) now occurs at the
current input, which is set ex works for the default setpoint
value, the power controller uses the value at the voltage input.

Value, adjustable This means that the "Value in the event of an error" is used.

000.0 This value is used in the event of an error.

0 to U

om.

of the load voltage,
0 to P
P

nom.

of the power

nom.

nom.

to 1.15 U

to 1.15

In the case of continuous SCR control via the analog input,

n-

the maximum actuating variable at the measuring range end
(e.g. 20 mA) can be varied during operation.

Note:
This setting is only available if power controller

rSCR control

rContinuous (power controller) is set.

0 to I

nom.

of the max. load cur­rent
0 to 100 %
of the output level

The unit depends on the setting for subordinate control loop
and device type:

2

- U

and U: display in V (example: 0 to 230 to 264.5 V)

- P: display in W (example: 0 to 4600 to 5290 W)

2

- I

and I: display in A (example: 0 to 20 A)

- None: display in % (example: 0 to 100 %)

Base load

0 to U

nom.

of the load voltage,
0 to P
of the power

nom.

Note:
This setting is only available if power controller

rContinuous (power controller) is set.

The unit depends on the setting for subordinate control loop
and device type:

0 to I

nom.

of the max. load cur­rent
0 to 100 %
of the output level

- For voltage: 0 to 100 % of the max. load voltage (e.g. 0V)

- For current: 0 to 100 % of the max. load current (e.g.
0A)

- For power: 0 to 100 % of the power (e.g. 0W)

- None: 0 to 100 % of the output level (e.g. 0%)

v Chapter 1.3 "Order details"

k / bold = factory setting

rSCR control

60 2012-12-01/00561071 [SCR Power Controller TYA201]

5.1.5 Monitoring

This allows an internal measured value to be monitored for compliance with
limit values.
Depending on the switching behavior, an overrange or underrange is output at
the binary output (option: relay or optocoupler).

Value/settings Description

Limit value moni­toring

Switched off No monitoring
Load voltage
Load current
Power (in W)
Power (in kW)
Resistance
Supply voltage
Device temperature

5 Configuration

These measured values can be monitored and are dependent
on the ordered device type.

Min. limit value
alarm

Max. limit value
alarm

Note: (as of software version 256.01.08)

If power controller -> SCR control -> Logic (switch) and Moni­toring -> Limit value monitoring -> Load voltage, load current,
power (in W) or power (in kW) is set,
the limit value monitoring only operates in the periods in which
the SCRs have been fired.
If the SCRs block, as a general rule, the min. and max. alarms
are switched off.

0 to 9999.9 The absolute minimum limit value for load voltage, load cur-

rent, power, resistance, supply voltage, or device temperature
can be monitored.
If the measured value falls below this value, an error message
appears at the bottom of the display and the yellow K1 LED
lights up. Depending on the set control direction, the binary
output switches as shown in the diagram.
The unit of the limit value corresponds to the monitored mea­sured value.

0 to 9999.9 The absolute maximum limit value of load voltage, load cur-

rent, power, resistance, supply voltage, or device temperature
can be monitored.

If the measured value exceeds this value, an error message
appears at the bottom of the display and the yellow K1 LED
lights up.
Depending on the set control direction, the binary output
switches as shown in the diagram.
The unit of the limit value corresponds to the monitored mea­sured value.

2012-12-01/00561071 [SCR Power Controller TYA201] 61

5 Configuration

Limit value hystere­sis

Load monitoring

Limit value load
monitoring

Load type load
monitoring

Teach-in type load
monitoring

0 to 1 to 9999.9 Switching differential at the upper and lower limit of the moni-

toring range

None The load is not monitored.
Undercurrent
Overcurrent

Note:
This parameter is only available if the device type is equipped
with an I, I
surement can therefore be performed.

2

, or P subordinate control loop and current mea-

v Chapter 6.1 "Detection of load faults"

Note:
This setting is only available if load monitoring has been set
to under- or overcurrent.

0 to 10 to 100 % Partial load failure or partial load short circuit:

This setting specifies the percentage by which the load resis­tance must have decreased or increased for a load error to be
triggered.

Standard Default setting (suitable for most load types)

Infrared radiator
(short-wave)

Automatic, once The teach-in value is automatically determined once after

Especially suitable for short-wave infrared radiators

each power ON.

v Chapter 6.1.1 "Teach-in"

Manual Teach-in can be performed in manual mode or at the opera-

tor level.

v Chapter 6.2.2 "Configuring the teach-in (prerequisite

for teach-in in manual mode)"

Mains voltage drop
monitoring

v Chapter 4.2.4 "Monitoring"

Automatic, cyclical Teach-in is performed cyclically at a time interval of 1 minute.

No No monitoring
Yes

k / bold = factory setting

If the effective values of the analyzed half-waves are more
than 10 % apart, an alarm message is displayed and the bina­ry output for the collective alarm switches depending on the
set control direction.
Immediate firing-pulse inhibit prevents the connected trans­former loads from destroying the semi-conductor fuse due to
a DC component.
If there are no further supply voltage drops, the firing-pulse in­hibit is removed and the power controller continues operation,
e.g. with a soft start.

62 2012-12-01/00561071 [SCR Power Controller TYA201]

5.1.6 Binary inputs

There are 2 binary inputs and one additional binary input for firing-pulse inhibit
available, to which a potential-free contact can be connected.
The following functions can be triggered with binary input 1 and 2:

h

Switch to the configuration level rBinary inputs using the key

Value/settings Description

Changeover, phase
angle control

Switched off No changeover
Binary input1
Binary input2
Ext. binary input1
Ext. binary input2

5 Configuration

Note:

The changeover to phase angle control mode is only possible
if the setting
firing mode has been made in the configuration level.

Changeover is controlled by binary input1
Changeover is controlled by binary input2
Changeover is controlled via an interface
Changeover is controlled via an interface

rPower controller rOperating mode rBurst-

Ext. current limiting

Ext. current limit
value

Note:

This function can only be set if the following
presettings have been made:
Option 1:

Power controller
and
Power controller

Option 2:
Power controller

Power controller
Power controller

If, for example, "Binary input 1" is set here, when the binary in­put is closed, instead of the current limit value set under
"Power controller
"External current limit value" (further down in the table) be-

comes effective.
Switched off No ext. current limiting
Binary input1
Binary input2
Ext. binary input1
Ext. binary input2

10 % to max. load

current of the
device +10 %

Ext. current limiting is controlled by binary input1

Ext. current limiting is controlled by binary input2

Ext. current limiting is controlled via an interface

Ext. current limiting is controlled via an interface

Note:

This parameter is only available if a binary input is set for ext.

current limiting.

The max. load current varies depending on the device type.

For 20 A power controllers, 2 to 22 A can be set.

rOperating mode rPhase angle control

rCurrent limiting rYes

rOperating mode rPulse groups
rSoft start rYes
rCurrent limiting rYe s

rCurrent limit value" coming into effect, the

v Chapter 1.3 "Order details"

Key lock Switched off No key lock

Binary input1
Binary input2
Ext. binary input1
Ext. binary input2

k / bold = factory setting

Key lock is controlled by binary input1

Key lock is controlled by binary input2

Key lock is controlled via an interface

Key lock is controlled via an interface

2012-12-01/00561071 [SCR Power Controller TYA201] 63

5 Configuration

7

8

3,3V

10k

W

Value/settings Description

External switch-off,
display lighting

Switched off

Binary input1
Binary input2
Ext. binary input1
Ext. binary input2

No external switch-off, i.e. the background lighting

behaves according to the configuration in Chapter 5.1.1

Switch-off is controlled by binary input1

Switch-off is controlled by binary input2

Switch-off is controlled via an interface

Switch-off is controlled via an interface

Control direction
inhibit input

Control direction,
binary input1

Control direction,
binary input2

The firing-pulse inhibit can be triggered when the switching

contact is closed or open.

v Chapter 3.3 "Connection diagram"

Open, load ON Ex works:
Open, load OFF

Open, inactive The function for binary input1 can be triggered when the
Open, active

Open, inactive The function for binary input2 can be triggered when the
Open, active

k / bold = factory setting

Inhibit input open, power controller supplies power.

Inhibit input closed, power controller does not supply power.

switching contact is open or closed.

switching contact is open or closed.

64 2012-12-01/00561071 [SCR Power Controller TYA201]

5.1.7 Binary output

13

14
15

E

S

C

Ö

P

Optocoupler

Relay

13

14
15

E

S

Optocoupler

Relay

C

Ö

P

13

14
15

E

S

Optocoupler

Relay

C

Ö

P

13

14
15

E

S

C

Ö

P

Optocoupler

Relay

This parameter specifies which control direction the binary output should have. It is
controlled by the multi-input interference signal.

v Chapter 8.1 "Binary signal for collective fault"

Switch to the configuration level rBinary output using the key

h

Value/settings Description

Control direction,
binary output

N/O contact No fault message present:

5 Configuration

14 and 15 pole and N/C contact closed or

13 and 15 optocoupler collector-emitter loop high-impedance

Fault message present:

13 and 15 pole and N/O contact closed or

13 and 15 optocoupler collector-emitter loop low-impedance

N/C contact No fault message present:

13 and 15 pole and N/O contact closed or

13 and 15 optocoupler collector-emitter loop low-impedance

Fault message present:

14 and 15 pole and N/C contact closed or

13 and 15 optocoupler collector-emitter loop high-impedance

k / bold = factory setting

2012-12-01/00561071 [SCR Power Controller TYA201] 65

5 Configuration

5.1.8 Actual value output

The actual value output is an analog output at which different internal values
can be output as a standard signal.

Value/settings Description

Signal type, actual
value output

Switched off The actual value output does not issue a signal.
0 to 20 mA
4 to 20 mA
0 to 10 V
2 to 10 V
0 to 5 V
1 to 5 V

This setting specifies the standard signal that should be out-

put at the actual value output.

The actual value output outputs the "Value to be output" in the

form of a current signal.

The actual value output outputs the "Value to be output" in the

form of a voltage signal.

Value to be output

Signal range start
value

Signal range end
value

5.1.9 RS422/485

This setting specifies the value that should be output at the

actual value output.
Load voltage Example:
Load voltage
Load current
Load current
Power (in W)
Power (in kW)
Resistance
Supply voltage
Device temperature
Setpoint value

0 to 9999.9 Lower limit for the "Value to be output"

0 to 9999.9 Upper limit for the "Value to be output"

k / bold = factory setting

2

2

The load voltage can vary between 0 and 500 V depending on

the device type.

As the signal range is set ex works to 0 to 9999.9, the end val-

ue must be adjusted to 500.0 to make use of the full signal

range.

For master-slave switching operation, the following must be

observed:

These measured values are determined in the master branch.

Exception as of software version 256.01.08:

When the power is selected (in W or kW), the three-phase cur-

rent is output on the actual value output.

Note:

Load voltage

2

= load voltage squared

Interface parameters for RS422/485 (see interface description B709061.2)

Value/settings Description

Baud rate

Data format 8-1-none Data bits-stop bits-parity check

Device address
Min. response time 0 to 500 ms

9600
19200
38400

8-1-odd
8-1-even
8-2-none

1 to 255

k / bold = factory setting

66 2012-12-01/00561071 [SCR Power Controller TYA201]

5.1.10 PROFIBUS-DP

Interface parameters for PROFIBUS-DB (see separate manual)

Value/settings Description

Device address

1 to 125 If "0" is set as the device address, the bus fault error message

5 Configuration

is not displayed.

Data format

Motorola, Intel

k / bold = factory setting

5.1.11 Changing codes

Here, it is possible to assign passwords (4-digit numeric codes) for manual
mode, operator level, and configuration level to protect them from unau-

thorized access.

Value/settings Description

Code, manual
mode

Code, operator lev­el

Code, config. level

0000 to 9999

0000 to 9999 0000 means: no inhibit

0000 to 9999 0000 means: no inhibit

k / bold = factory setting

0000 means: no inhibit

9999 means: level is hidden

9999 means: level is hidden

2012-12-01/00561071 [SCR Power Controller TYA201] 67

5 Configuration

5.2 Configuration example

Requirements Load voltage 400 V

3 heating elements each with 1 kW connected in parallel
Load current: 3000 W/400 V = 7.5 A
Temperature coefficient TC = 1
Operating mode: phase angle control

Subordinate control loop: U
Base load: 0 %; maximum output level 100 %
Default setpoint value via standard signal of 0 to 20 mA.

These requirements are sufficient for the following power controllers:

Device type 709061/8-01-020-100-400-252

2

68 2012-12-01/00561071 [SCR Power Controller TYA201]

6 Special device functions

6.1 Detection of load faults

The load monitoring function can detect and signal a load failure, partial load
failure, or a partial load short circuit.

Undercurrent This function is used for one or more heating elements connected in parallel

that are to be monitored for breakage.

Overcurrent This function is used for several heating elements connected in series that are

to be monitored for short circuits.

Function This function does not only take the decreasing or increasing load current into

consideration but also includes the load voltage in the monitoring process.
The correct load ratios of the system are saved during teach-in.

Based on this status, the load changes are continuously monitored irrespec­tive of the required output level. In the event of a breakage or short circuit of a
heating element, the load current increases or decreases. This is detected by
the load monitor and a load fault is signaled.

Limit value A limit value must be entered in the configuration or operator level in % for the

load monitor. This limit value depends upon the number of heating elements
connected in parallel or in series.

Undercurrent

Number of
heating ele­ments

510% -

For heating elements with a high positive or negative temperature coefficient,
a suitable limit value must be determined independently. The % value shown
below (see arrow) can be used as an aid for this.
This value represents the current deviation from the teach-in value. If the value
is > 0 %, the load has become more more high-resistance; if the value is <
0 %, it has become more low-resistance. This window can be accessed via
Operator level

rMonitoring rLimit value load monit.

For heating elements with a temperature coefficient TC ∪ 1 the limit value can
be taken directly from the following tables:

Single-phase
operation

Star connection
with separate
star points without
neutral conductor

Star connection with
common star points
without neutral con­ductor

Delta connection

-

413% 10 % ­3 17 % 13 % 10 %
2 25 % 20 % 12 %

2012-12-01/00561071 [SCR Power Controller TYA201] 69

6 Special device functions

N

L1

L3L2L1

L3L2L1

L3L2L1

N

L1

L3L2L1

L

3

L2L1

Number of
heating ele­ments

150%

Example:
2 heating
elements

Overcurrent

Single-phase
operation

Star connection
with separate
star points without
neutral conductor

Star connection with
common star points
without neutral con­ductor

50 % 21%

The specifications in % refer to load current changes

Number of
heating ele­ments

Single-phase op­eration

Star connec­tion without
neutral conduc­tor

610% -

Delta connection

Delta connection

-

513%10 %

-

417%10 % 10 %
3 25 % 14 % 13 %
2 50 % 25 % 26 %

Example for 2
heating ele­ments

The specifications in % refer to load current changes

As a general rule, load monitoring does not yet take place during the soft start
phase (which can last for longer due to active current limiting) as the standard
operating range of the load has not yet been reached. Teach-in cannot yet be
performed in this phase either.

70 2012-12-01/00561071 [SCR Power Controller TYA201]

6.1.1 Teach-in

6 Special device functions

Depending on the configuration of the parameter "Load monit. teach-in",
teach-in, i.e. determination of the load measured values in the OK status, is ei­ther performed once automatically after power ON or automatically and cycli­cally, repeatedly every minute or manually.

"Manual"
teach-in

For "Manual teach-in", the power controller must be told once after the oper­ating point has been reached that it is now to perform the teach-in.
This is possible in the operator level or in manual mode.

v Chapter 4.2.4 "Monitoring"
v Chapter 6.2.2 "Configuring the teach-in (prerequisite for teach-in in manu-

al mode)"

The teach-in values are then permanently saved. It is not necessary to perform
the teach-in again when the power controller is switched off and on again.
The teach-in can be repeated whenever necessary. The old teach-in values are
then overwritten by the new ones.
The teach-in values are only deleted if the load monitoring teach-in parameter
is explicitly configured to "Manual teach-in" or when the factory setting is ap­plied. The teach-in is not affected by reconfiguration of other parameters.

From software version 256.01.08, the determined teach-in values are also
transferred when the set-up data of one power controller is transferred to an­other.

If "Manual teach-in" has been configured but no teach-in has been conducted,
the message "Teach-in load monitoring!" appears on the display as a remind­er.
Manual teach-in can only be performed on the device itself, not via the setup
program.

To ensure that the load ratios for later operation are recorded precisely, only
perform the teach-in at a load current of at least 20 % of the rated value.

Teach-in
"Automatically
(once)"

"Automatically (once)" means that the teach-in values are temporarily saved
after each power ON. This setting is only suitable for heating elements with a
temperature coefficient of TC ∪ 1.
They are deleted again when the power controller is disconnected from the
supply voltage. When the power is switched on again, the load monitoring
function is inactive until the new teach-in has been performed.
To ensure that the load ratios for later operation are recorded precisely, the
teach-in in phase angle control is not performed until the output level has
reached at least 30 %. (This constraint is not necessary for burst-firing mode
as the current of a fired SCR power controller is always high enough. In this
case, the teach-in is always performed shortly after power ON or – if config­ured – after completion of the soft start.)

2012-12-01/00561071 [SCR Power Controller TYA201] 71

6 Special device functions

Load voltage

Load current

Setpoint value

Teach-in
"Automatic (cy­clically)"

"Automatically (cyclically)" means that the teach-in values are temporarily
saved again at intervals of 1 minute. This setting is particularly suitable for SIC
heating elements as in this case the resistance in the load point changes with
time due to aging.
When the power controller is disconnected from the supply voltage, the teach­in values detected last are deleted and recalculated once voltage supply has
returned.

6.2 Manual mode

In this case, the setpoint value can be manually preset in % without the need
for external wiring via the analog input.

6.2.1 Default setpoint value in manual mode

Starting Manual mode, as set ex works, can be accessed without entering a code.

h Press the key once (selection menu)
h Press the key again (manual mode)
h Use the or key to increase or decrease the setpoint value

The changes become effective immediately at the load output and are indicat­ed on the display.

The setpoint value for manual mode is not saved in the event of a pow­er failure!

6.2.2 Configuring the teach-in (prerequisite for teach-in in manual mode)

The teach-in function records the current/voltage ratio of a load in the OK sta­tus.
This function is not configured ex works.

v Configuration level See "Teach-in type load monitoring" on page 62.

Configuring
"manual"
teach-in

The power controller is in the "Measured value overview" level.

h Press the key
h Config. level

rent

rTeach-in type load monit. rS "manual"

rMonitoring rLoad monitoring rUndercurrent or overcur-

h Press the key

II

h Press the key twice

The device performs a reset.

72 2012-12-01/00561071 [SCR Power Controller TYA201]

If the teach-in is being performed for the first time, the message "Teach-in load
monitoring" appears in the bottom line of the display.

6.2.3 Performing teach-in in manual mode

The power controller is in the "Measured value overview" level.
h Press the key twice to return to manual mode.
If the teach-in is being performed for the first time, the message "Teach-in load

monitoring" now appears in the bottom line of the display.

6 Special device functions

Repeating
teach-in

h Press the key and the following message will appear:

h Press the key to apply the current load state as the OK status.

A change in the load (load error) will be evaluated by the device on the basis of
this status.

The teach-in can be repeated any number of times in manual mode.

h Press the key and the following message will appear:

h Press the key to apply the current load state as the OK status.

2012-12-01/00561071 [SCR Power Controller TYA201] 73

6 Special device functions

A

S

E

6.3 Default setpoint value via potentiometer

For this, a 5 kΩ potentiometer is connected to the voltage input.
It is supplied with DC 10 V at terminal 5 of the power controller.

h Configuration level

10 V

h Configuration level

voltage input

Now the power controller power is preset via the external potentiometer.

6.4 Dual energy management

This allows setpoint values of up to 50 % each to be preset on 2 power con­trollers without causing current peaks in the network when they are switched
on simultaneously.
No current peaks are caused in the network even if the setpoint values are
asymmetrically distributed, e.g. 30 % and 70 %.

More than
2 power con­trollers

Pre­requisites

If more than 2 power controllers are required in a system, they must be divided
into 2 groups.
The "Dual energy management" parameter (Device1 and Device2) has to be
set in each group.

- Both devices must be connected to the same phase

- The control electronics and the load circuit must have the same phase

- Synchronize both devices by switching them on simultaneously

- Burst-firing mode must be configured

- The cycle time must be set to 500 ms (fixed)

- In each group, one TYA201 power controller must be configured as

Device1 and the other TYA201 power controller as Device2.

rAnalog inputs rSet voltage measuring range 0 to

rSetpoint value config. rDefault setpoint value rSet

74 2012-12-01/00561071 [SCR Power Controller TYA201]

6 Special device functions

t

t

Device 1

Output level 20%

Device 2

Output level 60%

I

Thy2

t

I

mains

Sum of all

currentsMains

The power controllers switch on chronologically staggered. Starting from the
dashed lines, the dispersion of power takes place symmetrically to the left and
right (see arrows). For as long as the total output level of the two devices is be­low 100 %, overlaps of the two device currents in a single phase are prevent­ed. The next power level in the network is not started until the total output
level exceeds 100 %.

If a power controller performs a restart when the configuration level
is exited, it no longer operates synchronously with the others.
All power controllers have to be switched on again simultaneously
via a joint main switch!

2012-12-01/00561071 [SCR Power Controller TYA201] 75

6 Special device functions

Controller

Furnace

Sensor

SCR

power unit

Supply
voltage

y

R

x

y

-

w

P

230V

ΔP–

U0–1U,()

2

R

--------------------------

09U,()

2

R

------------------

0,81 P

230 V

•===

6.5 Subordinate control

Subordinate control loops are used to eliminate or compensate for external in­terference, such as fluctuations in the supply voltage and changes in resis­tance which would have a negative effect on the control loop.

6.5.1 Closed control loop without subordinate control

Example
Furnace/kiln
control system

The supply voltage is connected to the power controller. The controller derives
the output level y

from the difference between the set value (w) for the fur-

R

nace temperature and the actual value (x) which is acquired by a sensor inside
the furnace. The output level can vary over the range 0 to 100 % and is output
as a standard signal, for example 0 to 10 V. The output level is fed to the pow­er controller.

The task of the power controller is to feed energy to the heating elements in
the furnace, proportional to the controller output level:

- For an SCR power controller using phase angle control, this means that

it alters the firing angle over the range from 180 ° to 0 °, corresponding to a
controller output level of 0 to 100 %.

-If the SCR power controller is using the burst-firing mode, it increases

the duty cycle T from 0 to 100 %, corresponding to a controller output level
of 0 to 100 %.

If the supply voltage drops from AC 230 V to AC 207 V (-10 %) at a controller
output level YR, the power fed to the furnace is reduced by 19 %.

(2)

P

: Power in the load resistance at a supply voltage U of 230 V

230V

ΔP: Power reduction resulting from reduced supply voltage
R: Resistance of the load
This 19 % reduction in the energy being fed in means that the

furnace temperature falls.

Disadvantage: A continuing constant temperature is no longer assured.

76 2012-12-01/00561071 [SCR Power Controller TYA201]

The power controller recognizes the deviation through the relatively slow re-

6 Special device functions

Controller

Sensor

Controlled
system

SCR

power controller

Voltage supply

subordinate
control loop

y

R

x

y

w

-

P

Load

U

Load

2

R

--------------

=

(3)

P

Load

U

Load

2

∼

(4)

U

Load

2

input signal of power controller∼

(5)

sponse of the temperature control loop and increases its output level (yR) until
the furnace reaches the original temperature (250 °C) again.

6.5.2 Closed control loop with subordinate control

To avoid power variations caused by supply voltage fluctuations, a subordi­nate control loop is built into the power controllers. The subordinate control

loop immediately counterbalances any fluctuations in the amount of supplied
power. This means that the power controller always provides a power level at
the output (y) that is proportional to its input signal (y
subordinate control loop is shown in Figure .

). The principle of an

R

A distinction is made between U
most applications. There are however some applications where an I
trol has advantageous control-loop characteristics (requires recording of the
current in the power controller).
The three different types of subordinate control are described in the following
chapters.

2

U

control Considering the power P

by the voltage on the load, U

Equation 3 shows that, for a constant load resistance, the power in this resis­tance is proportional to U

A power controller with a U
square of the load voltage is proportional to the signal input (e.g. 0 to 20 mA)
to the controller.

2

, I2, and P control loops. U2 control is used in

in a resistive load, we know that it is determined

Load

and the resistance of load, R, as follows:

Load

2

.

Load

2

control will regulate in such a manner that the

2

or P con-

Combining equations 5 and 4, we can see that the power in the load resis­tance is proportional to the input signal to the power controller.

2012-12-01/00561071 [SCR Power Controller TYA201] 77

6 Special device functions

P

Load

input signal of power controller (0 to 20 mA)∼

U

Load

2

R

---------------

Heating elements that have a positive temperature coefficient (TC), i.e. where
the electrical resistance increases with increasing temperature, are usual-
ly driven by a power controller that incorporates a subordinate control (U
control) (Figure 1).

These are resistive materials such as

- Kanthal-Super

-Tungsten

-Molybdenum

- Platinum

- Quartz radiators
Their cold resistance is substantially lower than their resistance when hot (by a

factor of 6 to 16). These heating elements are usually run at temperatures
above 1000 °C.

(6)

2

Figure 1: Heating element with a positive TC

Power controllers need current limiting for the starting phase. The constant
current and the increasing resistance mean that, initially, the power in the heat­ing element increases in proportion to R, since the power P = I

2

· R.

When the current falls below the preset limit value, the automatic current limit­ing is no longer effective, and the power controller operates with the subordi-

2

nate U

control, i.e. if the resistance continues to increase at a constant volt­age level, the power fed to the heating elements is automatically reduced
P

= .

Load

78 2012-12-01/00561071 [SCR Power Controller TYA201]

6 Special device functions

This effect supports the complete control loop. As the furnace temperature ris­es towards the set value, the power fed to the furnace is reduced (at the same
load voltage level). This means that, through the power controller alone, the
approach to the setpoint value is slowed. This damps out any tendency to
overshoot the final temperature.

Other applications for U

2

control are:

- In lighting systems: in this case, the intensity of the lighting is proportional

- Some resistance materials have a TC that is close to 1. These include heat-

2

.

to U

ing elements made from nickel/chrome, constantan, etc. This does not
place any special demands on the SCR power controller (e.g. current limit­ing). The resistance characteristic for a heating element with a TC ∪ 1 is
shown in Figure 2.

Figure 2: Heating element with TC ∪ 1

2

control Current control (I2 control) is advantageous for heating elements with a nega-

I

tive TC, where the electrical resistance becomes smaller as the temperature
increases (Figure 3).

This behavior is shown by non-metallic materials such as graphite or glass
melts. Molten glass is not usually heated by heating elements but by letting a
current flow through the melt, so that the electrical energy is converted directly
into heat in the molten material. The current is applied through electrodes.

2012-12-01/00561071 [SCR Power Controller TYA201] 79

6 Special device functions

R

100 %

u

Up to 4 R

Aging

1050 °C

New

Figure 3: Heating element with a negative TC

Looking at the power equation P = I
same regulatory effect on the power as already described for the U

2

· R, we can see that an I2 control has the

2

control.
This means that, by regulating a constant current while the temperature rises,
the power in the process is automatically reduced as the resistance falls.

P control Power control (P control) is a continuous regulation of the product U · I, the

power. In this case, there is a precise linear relationship between the output
power and the level of the signal input (e.g. 0 to 20 mA) to the SCR power con­troller.

A typical application of this type of subordinate control is for regulating heating
elements which are subject to long-term aging combined with a temperature­dependent change in resistance, as is the case with silicon carbide elements
(Figure 4).

Figure 4: Resistance changes for silicon carbide

80 2012-12-01/00561071 [SCR Power Controller TYA201]

6 Special device functions

R

Old

4

----------

P

New

U

NewINew

•

U

Old

2

----------

2I

Old

• U

OldIOld

• P

Old

====

(12)

Silicon carbide heating elements have a nominal resistance that can alter by a
factor of 4 over the long term. So when dimensioning a system, it is necessary
to provide power controllers that can produce twice the (nominal) power for
the heating elements.
This results in double the current for the SCR power controller.

Which
operating mode
is suitable for
which load?

Old = old state of the heating element R

New

=

New = new condition of the heating element
The relationship is illustrated by the following formula:

P control is also used for free-running economy circuits running off a three­phase supply network.

Operating mode Resistive load Inductive

load

TC constant TC positive TC nega-

tive

Long­term ag­ing

Phase angle control XX
Phase angle control

XXX

with
current limiting

Burst-firing mode X
Burst-firing mode with

XX

α start
Burst-firing mode and

XXX

current limiting
Subordinate control

2

U

2

I

XX X

XX

P XX

2012-12-01/00561071 [SCR Power Controller TYA201] 81

6 Special device functions

6.6 Resistance limitation (R control)

.

This is only possible in power controllers with current and voltage
measurement that are fitted with subordinate control P (Code 001
in the order code) and only functions for load resistors with positive
temperature coefficient.

In three-phase economy circuits, no direct resistance limitation is
possible because the individual resistance value is not recorded.
However, the limiting function itself can be applied.

Function It operates both in burst-firing mode and phase angle control.

If the current measured value for resistance exceeds the resistance limit, it is
limited by phase angle control or limitation of the switched sine waves.

Limitation of the
power

The resistance limitation parameter can be used to activate a limitation of the
power output depending on the resistance value R when operating molybde­num disilicide heating elements in order to prevent overheating of the heating
element in the upper temperature range. By measuring the resistance of the
heating elements it is possible to assign a precise heating element tempera­ture.

If the load resistance exceeds this value, it is limited by phase angle control or
limitation of the switched sine waves.
This protects the heating element from overheating.

82 2012-12-01/00561071 [SCR Power Controller TYA201]

6 Special device functions

6.7 Current limiting

Current limiting is only possible for power controllers with load current

2

measurement, i.e. in the order details, subordinate control I, I
010 in the order code), or P (code 001 in the order code) must be se­lected.

The current limiting is implemented via phase angle control. It there­fore only operates permanently in phase angle control mode.
If burst-firing mode is set, current limiting only operates in the soft
start phase if "With phase angle control" is set as the soft start type.

In three-phase economy circuit, only the current in the strand of the
master power controller is limited to the configured value. As a result
of the economy circuit, significantly greater load currents can flow in
the other two phases.

Function Current limiting prevents overcurrents in the load current circuit. It limits the

load current independently of the load resistance and the setpoint value to the
required current limit value by enlarging the phase control angle, if necessary.

(code

Current limiting is unavoidable for heating elements with a high positive tem­perature coefficient, such as Kanthal-Super, for example. Without current limit­ing, the load current would accept inadmissibly high values when such heating
elements are in a cold state.

Factory setting Current limiting is not activated.

If necessary, current limiting must be switched on in the configuration level.
v Chapter 5.1.2 "Power controller"
The current limit value can be set both in the configuration level or in the oper-

ator level. In the operator level, it can be adjusted during operation.

2012-12-01/00561071 [SCR Power Controller TYA201] 83

6 Special device functions

u

t

a a

6.8 α start

Factory setting The phase angle of the first half-wave (α start) is not activated.

For transformer loads, the SCR power controllers operate in continuous burst­firing mode and in logic operation with phase angle control of the first half­wave.
The factory setting is an angle of 70 °el. (electrical). This value can be adjusted
at the configuration level or operator level within the range of 0 to 90 °el.

6.9 Monitoring of the supply voltage drop

If the effective values of the analyzed half-waves are more than 10 % apart, an
alarm message is displayed and the binary output for the collective alarm
switches depending on the set control direction.
Immediate firing-pulse inhibit prevents the connected transformer loads from
destroying the semi-conductor fuses due to a DC component.
If there are no further supply voltage drops, the firing-pulse inhibit is removed
and the power controller continues operation, e.g. with a soft start.

Factory setting Monitoring is not activated.

v Chapter 5.1.5 "Monitoring"

6.10 Firing-pulse inhibit

The inhibit function serves to protect the SCR power controller and the con­nected devices.

Internal The SCR output is locked during:

- Device switch-on (during the startup procedure)

- Reset or restart as a result of changes in the configuration level

- Insufficient or excessive supply voltage

- Master/slave data line interruption

- Master/slave synchronization failure

- Setup of data transfer to the device

- Device temperature greater than 115 °C

- Rotary electrical field error

- Short-term supply drops > 10 % within a half-wave

v Chapter 6.9 "Monitoring of the supply voltage drop"

External Via the "Inhibit" binary input

84 2012-12-01/00561071 [SCR Power Controller TYA201]

v Chapter 3.3 "Connection diagram"

6 Special device functions

Alternatively, the SCR output can also be switched off via the PROFIBUS,
RS422/485 interfaces.

6.11 SCR control logic (switch)

Operating mode If the power controller is set to rSCR control rLogic (switch), the power con-

troller operates as an electronic switch.
For as long as the configured binary or analog input is closed, the SCRs are
fired in zero crossing of the supply voltage and are only locked once again
when the binary or analog input is opened.

Transform er
loads

α input The full power is switched by closing the binary input. If this is too high for the

Time behavior If only short pulse packages with a defined number of sine wave cycles should

Example for
supply frequen­cy
of 50 Hz

In the case of transformer loads, the first supply voltage half-wave of each
pulse group must be cut. This can be done by configuring α start and entering
a value.

v Chapter 5.1.2 "Power controller"
The phase control angle for each first half-wave can be selected between 0

and 90 °.

case at hand (e.g. in the case of quick heat-up processes), the output power
can be reduced

v Chapter 5.1.4 "Setpoint value configuration"

be switched, the binary input (control direction "Open inactive") must be con­trolled via an optocoupler and the following timing must be observed:

by cutting all sine wave cycles (α input).

The power controller requires an internal processing time and does not switch
until the next zero crossing occurs. This results in delay time of 25 to 60 ms
(see arrows) between the binary signal and the switching operation of the sine
wave cycle.

Formula (50 Hz) Binary signal length for n sine wave cycles = (n  20 ms) ±5ms

If the binary signal is, for example, 48 ms long and therefore calculated longer
than for two sine wave cycles, it may be the case that the power controller
switches two or even three sine wave cycles.

Formula (60 Hz) Binary signal length for n sine wave cycles = (n  16.6 ms) ±5ms

2012-12-01/00561071 [SCR Power Controller TYA201] 85

6 Special device functions

86 2012-12-01/00561071 [SCR Power Controller TYA201]

The setup program enables convenient configuration of all data for the device
on a PC, which can then be transferred to the device.

For configuration of the power controller it is sufficient to insert the
USB cable into the power controller and connect it to the PC.

The configuration data is applied as soon as the device is switched on.

7.1 Hardware

- 500 MB hard disk space

-512MB RAM

7.2 Compatible operating systems

- Microsoft® Windows® 2000/XP/Vista

- Microsoft® Windows® 7 32-bit

- Microsoft® Windows® 7 64-bit

7 Setup program

Users

Software
versions

If several users are managed on the computer, ensure that the user who
will work with the program later is logged in.
The user must have administrator rights for the installation of the soft­ware. After installation, the rights can be restricted again.

In the event of non-observance of this information, correct and complete in­stallation cannot be guaranteed!

The software versions of the device and the setup program must be compati­ble. If this is not the case, an error message will appear!

h After switching on the device, press the key

The device software version is shown in the Device info menu.

h Click "Info" in the menu bar of the setup program

On the device In the setup program

2012-12-01/00561071 [SCR Power Controller TYA201] 87

7 Setup program

7.3 Installation

h Install the setup program

Installation
steps

Enter
license number

Display on the PC screen

12

34

56

88 2012-12-01/00561071 [SCR Power Controller TYA201]

7 Setup program

Installation
steps

Installation
complete

Launch
setup program

Display on the PC screen

78

9

2012-12-01/00561071 [SCR Power Controller TYA201] 89

7 Setup program

7.4 Program start

h Start the setup program via the Windows start menu

h Insert the supplied USB cable in the socket of the power controller and in

one of the PC's sockets

h Click Connect in the menu bar

Diagnosis The diagnosis window appears at the bottom of the screen and shows the de-

vice info and the current measured data. The connection has thus been estab­lished.

The power controller supplies no power while setup data is being transferred
"to the device". The device performs a restart after the transmission.

90 2012-12-01/00561071 [SCR Power Controller TYA201]

7.5 Forgotten the code?

If you have forgotten your password, you can read out the device data or enter
a new code via the setup program.

7 Setup program

Reading out
setup data

Entering new
codes

h Perform a Data transfer
The read out codes are visible in the Device data menu.

h Enter a new code
h Perform a Data transfer

After the setup data transfer, the device performs a restart and the codes
are activated.

rFrom the device

rTo the devic e

2012-12-01/00561071 [SCR Power Controller TYA201] 91

7 Setup program

7.6 Changing the language of the device texts

The language set ex works is specified in the order details. Only one language
can be transmitted to the device with the setup program.

h Connect the device to the PC using the USB cable
h Start the setup program
h Perform a Data transfer
h Edit
h Click Automatic detection and the dialog for the device language will ap-

h Select the desired language
h Continue in the hardware assistant by clicking Continue until it is completed

rExecute hardware and the hardware assistant will start

pear.

The device texts in the selected language have now been transferred in the
setup file.

rFrom the device

h Perform a Data transfer
h Save the setup file and wait until the data transmission has been success-

fully completed

The device now performs a restart and texts will appear on the display in the
desired language.

rTo the devic e

92 2012-12-01/00561071 [SCR Power Controller TYA201]

8 Fault messages and alarms

Cyclical
display

The symbols for input, subordinate control, and operating mode are displayed
alternately in the info line together with fault messages or information about
particular statuses.

v Chapter 4.1.2 "Displaying measured values"

Examples

Fault message Cause Remedy

Limit value monit.
Min. value reached

Limit value monit.
Max. value reached

Fault at
connected load

The value has gone below the set limit val­ue for the min. alarm

The set limit value for the max. alarm has
been exceeded

Break or short-circuit of a load resistor.

v Chapter 6.1 "Detection of load

-

-

Replace defective heating ele­ments.

faults"

Malfunction
Blown fuse
(red LED fuse is lit)

Malfunction
SCR breakage

SCR
short circuit

1. Semi-conductor fuse defective

v Chapter 8.2 "Replacing a defec-

tive semi-conductor fuse"

2. No voltage at terminal U1

- Check wiring

- Check the line fuse for the load
circuit

3. The voltage supply for the control elec­tronics L1/N does not have the same
phase as the load circuit U1/U2.

4. SCR in the master power controller de­fective (only with three-phase economy cir­cuit where nominal voltage < 230 V)

SCR defective The device must be returned to JUMO

Check wiring

The device must be returned to JUMO
for repair.

h Return the device

for repair.

h Return the device

SCR defective

Note:

Monitoring only functions when the load
resistance is so low that at least 10 % of
the power controller nominal current is
flowing.

The device must be returned to JUMO
for repair.

h Return the device

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8 Fault messages and alarms

Fault message Cause Remedy

Attention!
High temperature

Limiting active
high temperature

Supply voltage is
too low

Supply voltage is
too high

Temporary
drop in supply

Device temperature is higher than 100 °C
(excess temperature)

Device temperature is higher than 105 °C .
Device is too hot, output level is reduced!
(limited power due to excess temperature)

Supply voltage is not within specified toler­ance range

v Chapter 10.1 "Voltage supply, load

current"

Supply voltage is not within specified toler­ance range

Chapter 10.1 "Voltage supply, load cur­rent"

Dangerous temporary equal proportion for
transformer loads has been detected.

v Chapter 5.1.5 "Monitoring"

- Ensure adequate ventilation or
provide for additional cooling

- Reduce load current

- Use power controller with high­er maximum load current

- Ensure adequate ventilation or
provide for additional cooling

- Reduce load current

- Use power controller with high­er maximum load current

Check nominal voltage of the device
type

v Chapter 1.3 "Order details"

Check nominal voltage of the device
type

Chapter 1.3 "Order details"

Ensure stable mains supply.

Master-slave
rotary field error

Master-slave
incorrectly wired.

Rotary field detec­tion
failed

Wire break
Current input

Wire break
Voltage input

Malfunction
Bus error

Counterclockwise rotary field has been de­tected

Wiring fault has been detected

v Chapter 3.3.6 "Master-slave

three-phase current economy
circuit for resistive loads in star,
delta connection, or transformer
loads (resistive-inductive)"

Rotary field detection not possible

- Check connection

v Chapter 3.3 "Connection dia-

gram"

- Eliminate line disturbances

Input current too small for the set measur­ing range.

- Check wiring for wire breaks and
reverse polarity.

- Check upstream devices (con­trollers)

Input voltage too small for the set measur­ing range.

- Check wiring for wire breaks and
reverse polarity.

- Check upstream devices (con­trollers)

No connection to the Profibus master Check wiring and master device (PLC).

Master-slave
Error in comm.

Error in the data transfer between master
and slave

Is the patch cable plug connected cor­rectly?

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8 Fault messages and alarms

Fault message Cause Remedy

Data cable
faulty

Synchronization
failed

M/S incompatible
#0002...0008

Communication between master and slave
interrupted.

Slave device switched off or communica­tion between master and slave interrupted

- Master and slave are incompatible

- Different power controller types

Check the patch cable and replace, if
necessary

Check plug connection of patch cable
or voltage supply

Use same power controller types with
same software versions.

used (max. load current, load volt­age and subordinate control loop (if
applicable) do not match)

#0002 Different device software versions Update devices to same device soft-

ware versions

v Service hotline

#0003 VDN numbers of devices do not match Master/slave operation not possible
#0006 Different nominal voltages (device types) of

master and slave device.

#0007 Different nominal currents (device types) of

master and slave device.

#0008 Set subordinate control loop of the master

is not compatible with that of the slave de­vice.

Master/slave operation not possible

v Chapter 1.3 "Order details"

Change subordinate control loops of
both devices to U or U

2

.

Teach-in
load monitoring!

Slave: Limit value
Min. value reached

Slave: Limit value
Max. value reached

Slave: Fault at
connected load

Slave:
Blown fuse
(red LED fuse is lit)

Slave:
SCR breakage

Slave: SCR
short circuit

Reminder that "manual" teach-in has been
configured but not yet executed.

Perform teach-in

v Chapter 6.1 "Detection of load

faults"

The value has gone below the set limit val­ue for the min. alarm at the slave

The set limit value for the max. alarm has
been exceeded at the slave

Break or short-circuit of a load resistor.

Check why the value has gone below
the limit value.

Check why the limit value has been ex­ceeded.

Replace defective heating elements.

v Chapter 6.1 "Detection of load

faults"

1. Semi-conductor fuse defective

v Chapter 8.2 "Replacing a defec-

tive semi-conductor fuse"

2. No voltage at terminal U1

- Check wiring

- Check the line fuse for the load
circuit

SCR defective The device must be returned to JUMO

for repair.

h Return the device

SCR defective The device must be returned to JUMO

for repair.

h Return the device

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8 Fault messages and alarms

Fault message Cause Remedy

Slave: Attention!
High temp.

Slave: Limit.
active high temp.

Slave: Supply volt.
too low

Slave: Supply volt.
too high

Slave: Temp.
drop in supply

Device temperature is higher than 100 °C
(excess temperature)

Device temperature is higher than 105 °C.
Device too hot!
Output level is reduced.
(limited power due to excess temperature)

Supply voltage is not within specified toler­ance range

v Chapter 10.1 "Voltage supply, load

current"

Supply voltage is not within specified toler­ance range

v Chapter 10.1 "Voltage supply, load

current"

Dangerous temporary equal proportion for
transformer loads has been detected.

v Chapter 5.1.5 "Monitoring"

- Ensure adequate ventilation or
provide for additional cooling

- Reduce load current

- Use power controller with high­er maximum load current

- Ensure adequate ventilation or
provide for additional cooling

- Reduce load current

- Use power controller with high­er maximum load current

Check nominal voltage of the device
type

v Chapter 1.3 "Order details"

Check nominal voltage of the device
type

v Chapter 1.3 "Order details"

Ensure stable mains supply.

Inhibit by
inhibit input

Inhibit by
ext. inhibit

Soft start phase This message appears in the display until

Current limiting
active

Resistance
limitation active

A firing-pulse inhibit has been triggered via
a potential-free contact.
No power from the power controller.

The firing-pulse inhibit has been triggered
via an interface.

the soft start has been completed.

The required output level causes an exces­sive load current and is therefore limited to
the set value.

The desired output level leads to current/
voltage values that exceed the set load re­sistance. The output level is limited to the
permissible resistance to prevent overheat­ing.

v Chapter 3.3 "Connection dia-

gram"

Open contact between terminal 7 and
8 at screw terminal X_2.

v Interface manual "Ext. inhibit"

v Chapter 5.1.2 "Power controller"

-> Soft start duration

v Chapter 5.1.2 "Power controller"
"Current limiting" on page 57

v Chapter 5.1.2 "Power controller"

-> Resistance limitation

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8 Fault messages and alarms

8.1 Binary signal for collective fault

This signal is used for controlling the binary output and LED K1, and can also
be read out from the power controller via the interfaces.

Using the setup program it is possible to configure which events (alarm and
fault messages) are to be grouped together as a binary signal for a collective
fault.

All fault messages are OR-linked and output as a binary signal for collective
fault on the relay output or optocoupler.

In addition, LED K1 lights up yellow.
This alarm can switch a relay at the binary output.
v Chapter 5.1.7 "Binary output"

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8 Fault messages and alarms

A

B

8.2 Replacing a defective semi-conductor fuse

Opening the
case

Caution! Risk of burns!

The device can heat up during operation at the cooling body.
The current device temperature is shown on the display.

v Operating overview (on the first cover page)

h Disconnect the built-in device from the voltage supply (all poles)
v Chapter 3.3 "Connection diagram"
h Check that the device is isolated (green Power LED must not be lit)
h Press spring clip (A) to the right and lever up the plastic case (at the point

marked with an arrow) using a screwdriver (B).

A plug connection separates the display, keys, and interface from the power
section and you will be able to see the semi-conductor fuse.

98 2012-12-01/00561071 [SCR Power Controller TYA201]