Page 1
JUMO TYA 202
709062/8-01-150
709062/8-01-200
709062/8-01-020
709062/8-01-50
709062/8-01-100
709062/8-01-250
709062/8-01-32
SCR Power Controller
in a Three-Phase Economy Circuit
B 709062.0
Operating Manual
2012-12-31/00561073
Page 2
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.
Page 3
Content
1 Introduction ................................................................................ 7
1.1 Preface ........................................................................................................ 7
1.2 Typographical conventions ....................................................................... 8
1.2.1 Warning symbols ...................................................................................................8
1.2.2 Note signs .............................................................................................................. 9
1.2.3 Performing an action............................................................................................. 9
1.2.4 Representation ......................................................................................................9
1.3 Order details ............................................................................................. 10
1.3.1 Scope of delivery ................................................................................................. 11
1.3.2 Accessories.......................................................................................................... 11
1.3.3 General accessories............................................................................................ 11
1.4 Brief description ....................................................................................... 12
1.5 Standards, approvals, and conformity ................................................... 13
2 Installation ................................................................................ 15
2.1 Important installation notes .................................................................... 15
2.1.1 Ambient conditions .............................................................................................16
2.1.2 Filtering and interference suppression..............................................................17
2.1.3 Permissible load current depending
on the ambient temperature and the installation height..................................17
2.1.4 Wall mounting with screws (ex works)..............................................................19
2.1.5 Mounting on DIN rail (accessories).................................................................... 22
2.2 Dimensions ............................................................................................... 23
2.2.1 Type 709062/X-0X-020-XXX-XXX-XX-25X .........................................................23
2.2.2 Type 709062/X-0X-250-XXX-XXX-XX-25X ........................................................ 24
2.2.3 Type 709062/X-0X-050-XXX-XXX-XX-25X .........................................................25
2.2.4 Type 709062/X-0X-100-XXX-XXX-XX-25X .........................................................26
2.2.5 Type 709062/X-0X-150-XXX-XXX-XX-25X
Type 709062/X-0X-200-XXX-XXX-XX-25X .........................................................27
2.2.6 Type 709062/X-0X-250-XXX-XXX-XX-25X .........................................................28
2.2.7 Clearances (all types)..........................................................................................28
3 Electrical connection .............................................................. 29
3.1 Plug-in screw terminals ........................................................................... 29
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Content
3.1.1 Type 709062/X-0X-20-XXX-XXX-XX-25X ...........................................................29
3.2 Cable lugs and plug-in screw terminals ................................................ 30
3.2.1 Type 709062/X-0X-032-XXX-XXX-XX-25X .........................................................30
3.2.2 Type 709062/X-0X-050-XXX-XXX-XX-25X .........................................................31
3.2.3 Type 709062/X-0X-100-XXX-XXX-XX-25X .........................................................32
3.2.4 Type 709062/X-0X-150-XXX-XXX-XX-25X
Type 709062/X-0X-200-XXX-XXX-XX-25X .........................................................33
3.2.5 Type 709062/X-0X-250-XXX-XXX-XX-25X .........................................................34
3.3 Connection diagram ................................................................................ 36
3.3.1 Rotary current economic circuit master-slave for resistive loads in star or
delta connection or transformer loads (resistive-inductive) ........................... 38
4 Operation .................................................................................. 39
4.1 Display after switching on the device .................................................... 39
4.1.1 Display and control elements............................................................................. 39
4.1.2 Displaying measured values............................................................................... 40
4.1.3 Meaning of the displayed measured values...................................................... 41
4.1.4 Display in the configuration level....................................................................... 42
4.1.5 Display of error messages and special states..................................................43
4.2 Operator level ........................................................................................... 44
4.2.1 Device data ..........................................................................................................44
4.2.2 Power controller ..................................................................................................44
4.2.3 Setpoint value configuration ..............................................................................45
4.2.4 Monitoring ............................................................................................................ 46
5 Configuration ........................................................................... 49
5.1 Configuration level ................................................................................... 49
5.1.1 Device data ..........................................................................................................50
Temperature unit.......................................................................................................... 50
Display contrast ........................................................................................................... 50
Switch-off..................................................................................................................... 50
Display lighting............................................................................................................. 50
Apply factory settings .................................................................................................. 50
5.1.2 Power controller ..................................................................................................50
SCR control.................................................................................................................. 50
Subordinate control loop .............................................................................................51
Cycle time .................................................................................................................... 52
Min. ON period............................................................................................................. 52
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Content
α start........................................................................................................................... 52
Angle α start................................................................................................................. 52
Soft start....................................................................................................................... 52
Soft start type............................................................................................................... 53
Soft start duration ........................................................................................................ 53
Current limiting............................................................................................................. 53
Current limit value ........................................................................................................ 54
Resistance limitation .................................................................................................... 54
Resistance limit value................................................................................................... 54
Dual energy management ............................................................................................ 54
5.1.3 Analog inputs ....................................................................................................... 55
Current measuring range ............................................................................................. 55
Current measuring range, start .................................................................................... 55
Current measuring range, end ..................................................................................... 55
Voltage measuring range ............................................................................................. 55
Voltage measuring range, start .................................................................................... 55
Voltage measuring range, end ..................................................................................... 55
5.1.4 Setpoint value configuration ..............................................................................56
Setpoint input............................................................................................................... 56
Input in the event of an error........................................................................................ 56
Value in the event of an error ....................................................................................... 56
Maximum actuating variable ........................................................................................ 56
Base load ..................................................................................................................... 57
5.1.5 Monitoring ............................................................................................................ 58
Limit value monitoring.................................................................................................. 58
Min. limit value alarm ................................................................................................... 58
Max. limit value alarm .................................................................................................. 58
Limit value hysteresis................................................................................................... 59
Load monitoring ........................................................................................................... 59
Limit value load monitoring..........................................................................................59
Load type load monitoring ........................................................................................... 59
Teach In type load monitoring ..................................................................................... 59
Mains voltage drop monitoring .................................................................................... 59
5.1.6 Binary inputs ........................................................................................................60
Ext. current limiting ...................................................................................................... 60
External current limit value........................................................................................... 60
Key lock........................................................................................................................60
External switch-off, display illumination....................................................................... 60
Control direction inhibit input....................................................................................... 61
Control direction, binary input1.................................................................................... 61
Control direction, binary input2.................................................................................... 61
5.1.7 Binary output........................................................................................................62
Control direction, binary output ................................................................................... 62
5.1.8 Actual value output.............................................................................................. 63
Signal type, actual value output................................................................................... 63
Value to be output........................................................................................................ 63
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Content
Signal range start value................................................................................................ 63
Signal range end value................................................................................................. 63
5.1.9 RS422/485 ............................................................................................................63
Baud rate...................................................................................................................... 63
Data format .................................................................................................................. 63
Device address............................................................................................................. 63
Min. response time....................................................................................................... 63
5.1.10 PROFIBUS-DP......................................................................................................64
Device address............................................................................................................. 64
Data format .................................................................................................................. 64
5.1.11 Changing codes................................................................................................... 64
Code, manual mode.....................................................................................................64
Code, operator level..................................................................................................... 64
Code, config. level .......................................................................................................64
5.2 Configuration example ............................................................................ 65
6 Special device functions ......................................................... 67
6.1 Detection of load faults ........................................................................... 67
6.1.1 Teach-In ................................................................................................................69
6.2 Manual mode ............................................................................................ 70
6.2.1 Default setpoint value in manual mode.............................................................70
6.2.2 Configuring the Teach-In (prerequisite for Teach-In in manual mode)........... 70
6.2.3 Performing Teach-In in manual mode ............................................................... 71
6.3 Default setpoint value via potentiometer .............................................. 72
6.4 Dual energy management ....................................................................... 72
6.5 Subordinate control ................................................................................. 75
6.5.1 Closed control loop without subordinate control.............................................75
6.5.2 Closed control loop with subordinate control .................................................. 76
6.6 Resistance limitation (R control) ............................................................ 81
6.7 Current limiting ........................................................................................ 82
6.8 α start ........................................................................................................ 82
6.9 Monitoring of the supply voltage drop ................................................... 83
6.10 Firing-pulse inhibit ................................................................................... 83
6.11 SCR control logic (switch) ....................................................................... 84
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7 Setup program ......................................................................... 85
7.1 Hardware .................................................................................................. 85
7.2 Compatible operating systems ............................................................... 85
7.3 Installation ................................................................................................ 86
7.4 Program start ........................................................................................... 88
7.5 Forgotten the code? ................................................................................ 89
7.6 Changing the language of the device texts ........................................... 90
8 Fault messages and alarms .................................................... 91
8.1 Binary signal for collective fault ............................................................. 95
8.2 Replacing a defective semi-conductor fuse ......................................... 96
8.2.1 Accessories: semi-conductor fuses .................................................................. 97
8.2.2 Semi-conductor fuses type 709062/X-0X-20... ................................................. 97
8.2.3 Semi-conductor fuses type 709062/X-0X-32... ................................................. 98
9 What to do, if ... ...................................................................... 101
10 Technical data ........................................................................ 103
10.1 Voltage supply, load current ................................................................. 103
10.2 Electrical isolation ................................................................................. 103
10.3 Analog inputs (master only) .................................................................. 104
10.4 Analog output (actual value output master only) ................................ 104
10.4.1 Display and measuring accuracy..................................................................... 104
10.5 Binary inputs ........................................................................................... 104
10.6 Binary output (fault signal output master only) ................................... 104
10.7 General characteristic data ................................................................. 105
10.8 Approvals / approval marks .................................................................. 107
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Content
6 2012-12-31/00561073 [SCR power switch TYA202]
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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: +49 661 6003-727
Fax: +49 661 6003-508
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. They should additionally 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: +49 661 6003-9135
Fax: +49 661 6003-881899
E-mail: service@jumo.net
Austria:
Phone: +43 1 610610
Fax: +43 1 6106140
E-mail: info@jumo.at
Switzerland:
Phone: +41 1 928 24 44
Fax: +41 1 928 24 48
E-mail: info@jumo.ch
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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 or devices close to the
power controller.
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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 rController
rOperating mode
1.2.4 Representation
Keys
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 are displayed as symbols or text.
Key combinations are represented by a plus sign.
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1 Introduction
1
UL approval in preparation
2
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 709062/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
709062 TYA 202 - Three-phase SCR Power Controller in Three-phase Economy Circuit
(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
100 U, U
010 I, I
001 P (can be set to I, I
1
(5) Subordinate control loop
2
2
(can be set to U, U2)
2
or U, U2)
(6) Load voltage
024 AC 24 V
042 AC 42 V
115 AC 115 V
230 AC 230 V
265 AC 265 V
400 AC 400 V
460 AC 460 V
500 AC 500 V
00 None
54 RS485/422
64 PROFIBUS-DP
(1) (2) (3) (4) (5) (6) (7) (8)
/------Order code
709062 / 8 - 01 - 100 - 100 - 400 - 00 - 252 Order example
2
-20 to +15 %, 45 to 63 Hz
-20 to +15 %, 45 to 63 Hz
-20 to +15 %, 45 to 63 Hz
-20 to +15 %, 45 to 63 Hz
-20 to +15 %, 45 to 63 Hz
-20 to +15 %, 45 to 63 Hz
-20 to +15 %, 45 to 63 Hz
-20 to +15 %, 45 to 63 Hz
(7) Interface
(8) Extra codes
252
Relay (changeover contact) 3 A
257 Optocoupler
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1.3.1 Scope of delivery
1 operating manual B709062.0
1 SCR power controller in the version ordered
1:1 patch cable
1.3.2 Accessories
Article Part no.
Setup program 709061 TYA201
(can also be run for TYA202 power controllers)
USB cable A-connector B-connector 3 m 00506252
Mounting set for DIN rail installation:
Type 709062/X-01-20... 00555172
Type 709062/X-01-32... 00555527
1.3.3 General accessories
1 Introduction
00544869
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 50 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.
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1 Introduction
1.4 Brief description
Device The JUMO TYA 202 represents the consistent development of the JUMO pow-
er controller technology. It switches ohmic-inductive loads using a threephase current economy circuit in star-delta three-phase operation. The microprocessor-controlled power controller shows all parameters in an LCD display
with background lighting and is operated by 4 keys at the front.
Application SCR power controllers are used where larger resistive and ohmic-inductive
loads have to be switched (e.g. in industrial kiln construction and plastics processing). The SCR power controller consists of SCRs connected in anti-parallel, the insulated cooling body, and the control electronics.
Mounting SCR power controllers up to a load current of 32 A can either be 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 and transformer loads are permitted.
Subordinate
control loop
Standards The SCR power controllers are in accordance with VDE 0160 5.5.1.3 (5/88)
Advantages - Teach In function for the detection of partial load failure
The TYA 202 works in burst firing mode.
In burst firing mode, the first half-wave can be optimally cut with an adjustable
phase angle so that transformer loads can also be operated.
It is possible to specify a base load or, depending on the device type, set current limiting or resistance limitation for the load.
To avoid high starting currents, a softstart can be set.
Depending on the device type, U, U
dinate control loops. Fluctuations in the mains voltage therefore have no effect
on the control-loop regulation during operation.
and VDE 0106 Part 100 (3/83). The system must be grounded as specified by
the competent energy supplier.
- 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)
2
, I, I2, or P controls are available as subor-
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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
1 Introduction
Protection type IP20 panel-mounting 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
Approvals Standard
Submitted UL 508 (Category NRNT)
C22.2 NO. 14-10 Industrial Control Equipment
(Category NRNT7)
DIN EN 60529
DIN EN 50178
2
III
DIN EN 61326-1
Class A - only for industrial use
Industrial requirements
DIN EN 60068-2-6, DIN EN 60721-3-3
DIN EN 60068-2-31, DIN EN 60721-3-2
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
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1 Introduction
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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.
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2 Installation
h That the configuration of the analog inputs, for example, corresponds to the
h The analog input for the default setpoint value only needs to be connected
wiring.
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 master and slave device and
must be dissipated at the mounting site (e.g. in the control cabinet) in accordance with the climatic conditions.
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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
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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 could otherwise be destroyed.
The master or slave device temperature shown on the display may not exceed
100 °C.
If a device temperature exceeds 100 °C, the message "Warning - high temperature" is displayed.
If a device temperature exceeds 105 °C, the load current is gradually reduced
by 10 % of the rated current each time the temperature increases by one degree.
If a device temperature exceeds 115 °C, the power controller current is completely switched off.
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.
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2.1.4 Wall mounting with screws (ex works)
TYA202
20A
TYA202 32A
TYA202 50A
Power controllers with a load current between 20 and 50 A are affixed to a fireproof control cabinet wall with 4 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 6 screws.
2 Installation
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2 Installation
TYA202 100A
TYA202
150/200A
TYA202
150/200A
20 2012-12-31/00561073 [SCR power switch TYA202]
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2 Installation
TYA202 250ATYA202 250A
2012-12-31/00561073 [SCR power switch TYA202] 21
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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 built-in 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.
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2.2 Dimensions
2.2.1 Type 709062/X-0X-020-XXX-XXX-XX-25X
2 Installation
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2 Installation
2.2.2 Type 709062/X-0X-250-XXX-XXX-XX-25X
24 2012-12-31/00561073 [SCR power switch TYA202]
Page 27
2.2.3 Type 709062/X-0X-050-XXX-XXX-XX-25X
2 Installation
2012-12-31/00561073 [SCR power switch TYA202] 25
Page 28
2 Installation
2.2.4 Type 709062/X-0X-100-XXX-XXX-XX-25X
26 2012-12-31/00561073 [SCR power switch TYA202]
Page 29
2.2.5 Type 709062/X-0X-150-XXX-XXX-XX-25X Type 709062/X-0X-200-XXX-XXX-XX-25X
2 Installation
2012-12-31/00561073 [SCR power switch TYA202] 27
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2 Installation
2.2.6 Type 709062/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 units is required.
28 2012-12-31/00561073 [SCR power switch TYA202]
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3 Electrical connection
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 709062/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!
K
Terminal Version Conductor
cross-section
Maximum
tightening
torque
2
2
0.25 Nm
2
0.5 Nm
0.6 Nm
3Nm
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 nut
Width across flats 7 mm
0.2 to 1.5 mm
0.5 to 2.5 mm
0.5 to 6 mm
Cable lug with
hole: 4 mm
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3 Electrical connection
3.2 Cable lugs and plug-in screw terminals
3.2.1 Type 709062/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 0.2 to 1.5 mm
X3 Slotted screws, blade width 3 mm 0.5 to 2.5 mm
U2, U1 M6 recessed head screws 6 to 25 mm
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
0.5 to 4 mm
(0.5 to 2.5 mm
with end sleeve)
(for UL AWG 20-12)
Cable lug
hole: 6 mm
2
2
2
2
or
2
Maximum
tightening torque
0.25 Nm
0.5 Nm
5Nm
0.5 Nm
5Nm
30 2012-12-31/00561073 [SCR power switch TYA202]
Page 33
3.2.2 Type 709062/X-0X-050-XXX-XXX-XX-25X
3 Electrical connection
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Page 34
3 Electrical connection
3.2.3 Type 709062/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
X2_1 and X2_2 Slotted screws, blade width 2 mm 0.2 to 1.5 mm
X3 Slotted screws, blade width 3 mm 0.5 to 2.5 mm
U2, U1 M6 hexagon screws, width across 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
Ground terminal PE M6 setscrew with hexagon nut
Width across flats 10 mm
16 to 50 mm
0.5 to 4 mm
(0.5 to 2.5 mm
with end sleeve)
(for UL AWG 20-12)
Cable lug
hole: 6 mm
2
2
2
2
or
2
Maximum
tightening torque
0.25 Nm
0.5 Nm
5Nm
0.5 Nm
5Nm
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Page 35
3.2.4 Type 709062/X-0X-150-XXX-XXX-XX-25X Type 709062/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.
3 Electrical connection
Terminal Version Conductor cross-
section
2
2
2
2
or
2
with
X2_1 and X2_2 Slotted screws, blade width 2 mm 0.2 to 1.5 mm
X3 Slotted screws, blade width 3 mm 0.5 to 2.5 mm
U2, U1 M8 hexagon screws, width across 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
Ground terminal PE M8 setscrew with hexagon
nut, width across flats 13 mm
95 to 150 mm
0.5 to 4 mm
(0.5 to 2.5 mm
end sleeve)
(for UL AWG 20-12)
Cable lug
hole: 8 mm
Maximum
tightening torque
0.25 Nm
0.5 Nm
12 Nm
0.5 Nm
12 Nm
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3 Electrical connection
3.2.5 Type 709062/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
X2_1 and X2_2 Slotted screws, blade width 2 mm 0.2 to 1.5 mm
X3 Slotted screws, blade width 3 mm 0.5 to 2.5 mm
U2, U1 M8 hexagon screws, width across 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
Ground terminal PE M8 setscrew with hexagon
nut, width across flats 13 mm
Fan X14 Slotted screws, blade width 3 mm 0.5 to 2.5 mm
95 to 150 mm
0.5 to 4 mm
(0.5 to 2.5 mm
with end sleeve)
(for UL AWG 20-
12)
Cable lug
hole: 8 mm
2
2
2
2
or
2
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.
Maximum
tightening torque
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
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3 Electrical connection
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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
potentiometer
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
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 of 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 only)"
Master-slave
connection
Connection for RJ 45 socket X8
Three-phase current economy circuit
Master-slave operation
36 2012-12-31/00561073 [SCR power switch TYA202]
1:1 patch cable
Page 39
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
PROFIBUS-DP
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
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3 Electrical connection
3.3.1 Rotary current economic circuit master-slave for resistive loads in star or delta connection or transformer loads (resistive-inductive)
Prerequisite To facilitate master-slave 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 image shows the wiring of a TYA202, which is available ex works as a fully
assembled and configured unit, and behaves exactly like two single TYA201
devices in master-slave operation.
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
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 709062/X-0X-250-XXX-XXX-XX-25X"
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4 Operation
(1)
(2)
(3)
(4)
(5)
(7)
(6)
(7)
(4)
(3)
(1)
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 As soon as the voltage supply is switched on, the Power LED is permanently lit
in green and an hourglass appears on the display. The master is then synchronized with the slave device and rotary field detection is carried out. If everything is wired correctly, the power controller shows the mains voltage on the
display.
Error messages v Chapter 8 "Fault messages and alarms"
4.1.1 Display and control elements
Legend Comment Fig.
1
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 ..."
2
3
4
5 Keys:
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 semiconductor fuse on the corresponding power controller.
K1 LED (yellow) fault signal display
Increase value / previous parameter
Decrease value / next parameter
Abort / one level back
6
7
USB setup interface
Configuration is performed on the left device and
transferred automatically to the right device via the
patch cable.
Spring clip to release the plastic case
v Chapter 8.2 "Replacing a defective semi-
Programing / one level forward
conductor fuse"
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4 Operation
Description
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
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"
Supply frequen-cyIn this window, the rotary field direction is shown alongside the supply fre-
quency. The small triangle indicates the corresponding direction of rotation.
Meaning of the
symbols in the
info line
40 2012-12-31/00561073 [SCR power switch TYA202]
Input signal Subordinate
control loop
Voltage None
Current U
Interface I
Binary input1 U Burst-firing mode with
Binary input2 I Half-wave control
2
2
Operating mode
load output
Soft start in phase angle control
Burst-firing mode
α start
Page 43
4 Operation
Input signal Subordinate
control loop
Input signal in-
P General logic
Operating mode
load output
correctly
configured
Logic
Logic with α start
(switch)
Invalid
control
Logic with α default
values
configured
Logic with α start and
α input
Firing-pulse (inhibit)
4.1.3 Meaning of the displayed measured values
Measured value Meaning Unit
Supply voltage Effective value of the supply voltage - measured on the master between
the L1 and N/L2 terminals
V
Supply voltage
Slave
Load voltage
4
Effective value of the supply voltage - measured on the slave between the
L1 and N/L2 terminals
Effective value of the supply voltage U12 - measured on the master between the V and U2 terminals
Load voltage
4
Slave
Load current
Load current
1.4
1.4
Effective value of the supply voltage U31 - measured on the slave between the V and U2 terminals
Effective value of the load current l1 measured from the master
Effective value of the load current l3 measured from the slave
Slave
Power
1.4
Power
1, 4
Slave
Three-phase
current
1.4
Load
resistance
Output level
1, 4
4
Effective power measured from the master
Effective power measured from the slave
Overall effective power (total effective power contributed by master and
slave)
Effective resistance measured from the master
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
2.4
Measured value as a percentage of the set control variable U2, U, I2, I, or P
V
V
V
A
A
W or kW
W or kW
W or kW
?
%
%
%
Phase
control angle
3, 4
Supply frequency Currently measured supply frequency
Currently output phase control angle
°el
Hz
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4 Operation
Device
temperature
Slave device
temperature
Current input
Currently measured temperature inside the master power controller
Currently measured temperature inside the slave power controller
Measured value of the current input - measured on the master pow-
°C or °F
°C or °F
mA
er controller
between terminals 1 and 2 on X2_1
Voltage
input
Measured value of the voltage input - measured on the master
power controller 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
V
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
.
42 2012-12-31/00561073 [SCR power switch TYA202]
Page 45
4.1.5 Display of error messages and special states
4 Operation
Cyclical
display
Examples
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 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.
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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
44 2012-12-31/00561073 [SCR power switch TYA202]
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.
Page 47
4 Operation
10 % to max. load
current for the device type +10 %
Current load current
0 to 999.99 Ω Resistance limitation:
Current resistance
k / bold = factory setting
4.2.3 Setpoint value configuration
Current limiting:
It is possible to modify the current limit value in phase angle
control mode during operation.
The current is limited in the master branch.
This window is not displayed if "Current limiting" is set to "no"
in the configuration.
Indirect temperature limit for a heating element with positive
temperature coefficients.
The resistance value is measured in the master branch.
Resistance cannot be measured directly in the three-phase
current economy circuit. However, the current resistance measured at an operating point can be used as a resistance limit
value.
v Chapter 5.1.2 "Power controller"
v Chapter 6.6 "Resistance limitation (R control)"
Current load voltage
Current load voltage
Value range Description
0 to U
om.
of the load voltage,
0 to P
of the power
nom.
nom.
to 1.15 U
to 1.15 P
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.
The measured values in the master branch are measured.
nom.
The displayed value depends on the "Subordinate control
loop" setting:
2
U
nom.
0 to I
of the max. load current
0 to 100 %
of the output level
and U: display in V (example: 0 to 400 to 460 V)
P: display in kW (example: 0 to 8.00 to 9.20 kW)
2
I
and I: display in A (example: 0 to 20 A)
None: display in % (example: 0 to 100 %)
0 to U
nom.
of the load voltage,
0 to P
of the power
nom.
In the case of continuous SCR control via the analog input,
the base load at the measuring range start (e.g. 0 mA) can
be varied during operation.
The measured values in the master branch are measured.
The displayed value depends on the "Subordinate control
0 to I
of the max. load current
nom.
loop" setting.
0 to 100 %
of the output level
k / bold = factory setting
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4 Operation
4.2.4 Monitoring
The value to be monitored can be adjusted.
v Chapter 5.1.5 "Monitoring"
The load voltage was used in this example.
Value range Your setting:
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.
The measured values in the master branch are measured.
v Chapter 5.1.5 "Monitoring"
Current measured
value
Current measured
value
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 cur-
rent, power, resistance, supply voltage, or device temperature
can be monitored.
The measured values in the master branch are measured
v Chapter 5.1.5 "Monitoring"
Example:
If the voltage exceeds 100 V, an alarm is issued.
0 to 1 to 9999.9 The switching differential at the minimum or maximum limit
value
0 to 10 to 100 %
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 deviations in all three phases of the-
Current deviation
from teach-in
(i.e. if it exceeds 0 %)
the load has become
high-impedance;
if it is below 0 %,
the load has become
low-impedance
k / bold = factory setting
Teach-In value, it is possible to check how, for example, the
resistance change behaves over the entire operating range.
The load monitoring limit value can then be adjusted accordingly.
Guide values for the identification of load errors:
v Chapter 6.1 "Detection of load faults"
46 2012-12-31/00561073 [SCR power switch TYA202]
Page 49
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
h Change to the operator level
h Press the key
A screen now appears asking whether the state should
be applied now. If so:
h Press the key to apply the current load state as
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
The "ManualTeach-In" function is now configured.
rMonitoring rLoad
monit.Teach-In
the OK status.
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Page 50
4 Operation
48 2012-12-31/00561073 [SCR power switch TYA202]
Page 51
5.1 Configuration level
or PROFIBUS-DP
v Chapter 5.1.1 "Device data"
v Chapter 5.1.2 "Power controller"
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.
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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
SCR control Continuous (power
controller)
Logic (switch) The power controller acts like a switch and provides the power
k / bold = factory setting
the display switches off. Power LED (green) flashes.
0000 means: lighting is always switched on
The power controller provides the power for the load continuously depending on the default setpoint value.
by either switching ON or OFF.
50 2012-12-31/00561073 [SCR power switch TYA202]
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Subordinate control
Phase angle α
0 to 20 mA
0 to 10 V
Analog input
loop
Value / settings Description
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 for external disturbances, such as mains voltage fluctuations and changes in load resistance that 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
5 Configuration
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.
2012-12-31/00561073 [SCR power switch TYA202] 51
k / bold = factory setting
Page 54
5 Configuration
u
t
500ms
520
u
t
100ms
1 4
u
t
u
t
a-Start
a-Start
Value / settings Description
Cycle time Fixed (500 ms)
(For slow heating elements)
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.
For example, 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
No This setting determines the starting behavior of the power
controller after power ON and is deactivated ex works.
Yes
"Yes" means that a soft start with phase angle control or pulse
groups is performed after power ON.
k / bold = factory setting
52 2012-12-31/00561073 [SCR power switch TYA202]
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Value / settings Description
u
t
Softstartzeit
u
t
Cycle time
Soft start type With phase angle
control
With pulse groups This setting is only available in burst-firing operating mode
5 Configuration
This parameter only appears if soft start is set to "Yes."
Starting from 180°, the phase control angle α is steadily re-
duced 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 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.
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.
Only the phase control angles that do cause the current limit
value to be exceeded are permitted.
It is also possible to activate an external current limit
value via a binary input.
Chapter 5.1.6 "Binary inputs"
k / bold = factory setting
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5 Configuration
Value / settings Description
Current limit value 10 % to max. load
current +10 % of the
device type
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:
The value must exceed 10 % of the maximum power controller current (i.e. > 2 A in the case of 709062/X-01-020...)
Resistance limitation
Resistance limit
value
Dual energy management
Note:
Resistance limitation is only possible in the case of power
controllers with integrated subordinate control loop P (code
001 in the order code).
No No limitation through load resistance
Yes The load resistance is monitored to ensure the set resistance
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.
v Chapter 6.6 "Resistance limitation (R control)"
0 to 999.99 Ω If the load resistance exceeds this value,
it is limited by phase angle control or limitation of the switched
sine waves.
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
that they do not simultaneously draw power from the power
supply at small output levels.
This prevents current peaks.
1
to be configured in such a way
v Chapter 6.4 "Dual energy management"
1. The master-slave group type 709062 is regarded as "one" device.
k / bold = factory setting
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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"
5 Configuration
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 con-
2 to 10 V
0 to 5 V
1 to 5 V
Customer-specific
0 to 10 V Note:
0 to 10 V Note:
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 end is set 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
This parameter only appears if "Customer specific" is set for
the voltage measuring range (see above)!
This parameter only appears if "Customer specific" is set for
the voltage measuring range (see above)!
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5 Configuration
5.1.4 Setpoint value configuration
This setting determines which analog 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.
acteristic data"
rSCR control
r100 % and open r0%
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 alter-
native value the power controller should use if the default set-
point value is incorrect.
Last value The last valid value is used ex works.
Voltage input or cur-
rent 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
Depending on which input is set for the setpoint selection, the
second free input may appear at this point.
If 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.
In the case of continuous SCR control via the analog input,
n-
the maximum actuating variable in the master branch at the
measuring range end (e.g. 20 mA) can be varied during opera-
tion.
Note:
This setting is only available if power controller
rSCR control
rContinuous (power controller) is set.
0 to I
of the max. load current
0 to 100 %
of the output level
nom.
The unit depends on the setting for subordinate control loop
and device type:
- U2 and U: display in V (example: 0 to 230 to 264.5 V)
- P: display in W (example: 0 to 4600 to 5290 W)
- I2 and I: display in A (example: 0 to 20 A)
- None: display in % (example: 0 to 100 %)
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5 Configuration
Control signal
P
Base load: 680 W
Maximum
Output level: 3680 W
0 mA
20 mA
3000W 0...20mA
Ⳏ
Base load
Base load 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.
Note:
This setting is only available if power controller
rContinuous (power controller) is set.
rSCR control
The unit depends on the setting for subordinate control loop
and device type:
- For voltage: 0 to 100 % of the max. load voltage (e.g. 0 V)
- For current: 0 to 100 % of the max. load current (e.g. 0 A)
- For power: 0 to 100 % of the power (e.g. 0 W)
- None: 0 to 100 % of the output level (e.g. 0 %)
The measured values in the master branch are measured.
v Chapter 1.3 "Order details"
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5 Configuration
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
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 Moni-
toring -> 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 mea-
sured 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 mea-
sured value.
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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 current
must have decreased or increased for a load error to be trig-
gered.
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 (prerequi-
site 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 bina-
ry output for the collective alarm switches depending on the
set control direction.
Immediate firing-pulse inhibit prevents the connected trans-
former loads from destroying the semi-conductor fuse due to
a DC component.
If there are no further supply voltage drops, the firing-pulse in-
hibit is removed and the power controller continues operation
(e.g. with a soft start).
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5 Configuration
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 r Binary input using the key
Value / settings Description
Ext. current limiting
Switched off No ext. current limiting
Binary input1
Binary input2
Ext. binary input1
Ext. binary input2
This function can only be set if the following
presettings have been made:
Option 1:
Power controller
Power controller rCurrent limiting rYes
Option 2:
Power controller
Power controller
Power controller
If, for example, "Binary input 1" is set here, when the binary in-
put is closed, the current limit value set under "Power control-
ler
rCurrent limit value" is overwritten and the "External
current limit value" (further down in the table) becomes effec-
tive.
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
rOperating mode rPhase angle control and
r Operating mode r Pulse groups
r Soft start r Yes
r Current limiting rYe s
External current
limit value
10 % to max. load
current of the
device +10 %
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.
v Chapter 1.3 "Order details"
Key lock Switched off No key lock
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
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
External switch-off,
display illumination
Binary input1
Binary input2
Ext. binary input1
Ext. binary input2
Switched off
Binary input1
Binary input2
Ext. binary input1
Ext. binary input2
k / bold = factory setting
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Control direction
7
8
3,3V
10k
W
inhibit input
Value / settings Description
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
Inhibit input open, power controller supplies power.
Inhibit input closed, power controller does not supply power.
5 Configuration
Control direction,
binary input1
Control direction,
binary input2
Open, inactive The function for binary input1 can be triggered when the
Open, active
switching contact is open or closed.
Open, inactive The function for binary input2 can be triggered when the
Open, active
switching contact is open or closed.
k / bold = factory setting
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5 Configuration
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
5.1.7 Binary output
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 r Binary input using the key
h
Value / settings Description
Control direction,
binary output
N/O contact No fault message present:
14 and 15 pole and N/C contact closed or
13 and 14 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 14 optocoupler collector-emitter loop high-impedance
k / bold = factory setting
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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
5 Configuration
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.
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 3-phase current
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
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5 Configuration
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
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
, operator level, and configuration level to protect them from unauthor-
mode
ized 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
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5.2 Configuration example
Attention:
- Make sure that the rotating
electric field is right handed!
- Only possible in burst firing mode
- SCR load voltage =U
L
Fuse for control
electronics 2A
Fusing to protect the
power section cabling
0(4)to 20mA
Setpoint lnput:
U = phase-phase voltage
U = phase-neutral voltage
U = voltage on thyristor power unit
L
N
Thy
P = total controlled power
I = current in phase conductor
I = current in thyristor power unit
tot
L
Thy
Ohmic load star
connection
U1U2
N/L2L1V
13
14
15
1211
1089
7
6
5
42
3
1
8
1
U1U2
Semiconductor-
fuse
Semiconductor-
fuse
N/L2L1V
13
14
15
1211
1089
7
6
5
42
3
1
8
1
S
Relay
Ö
P
+
Patchcable
TYA 202
E
Optocoupler
C
U= U
Thy L
I=
Thy
P
tot
3 · U
N
=
P
tot
3 UL·
I=
ThyIL
I
Thy
L1NL2
L3 PE
U
L
U
N
I
L
Requirements Load voltage on the power controller 400 V
Load voltage 230 V (for wye connection)
3 heating elements (each with 1 kW connected in parallel)
Load current: 9000 W / (3 x 230 V) = 13 A
Temperature coefficient TC = 1
5 Configuration
Subordinate control loop: U
2
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 709062/X-01-020-100-400-252
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5 Configuration
66 2012-12-31/00561073 [SCR power switch TYA202]
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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.
For heating elements with a high positive or negative temperature coefficient,
a suitable limit value must be determined independently. The values in % given below (see arrow) are used for this purpose.
A value in % is displayed for each of the three phases, which represents the
current deviation from the Teach-In values as a percentage. Access this window via Operator level
These values can be used to find out in what phase a load error occurred. If a
load break occurs in phase L3, for example, the value in % exceeds the set
limit value (10 % in the table).
r Monitoring r Limit value load monit.
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6 Special device functions
L3L2L1
L3L2L1
L3L2L1
L3L2L1
L3L2L1
For heating elements with a temperature coefficient TC ∼ 1 the limit value can
be taken directly from the following tables:
Undercurrent
Number of
heating elements
5 10 % 4 13 % 10 % 3 17 % 13 % 10 %
2 25 % 20 % 12 %
Star connection with separate star points without neutral conductor
Star connection with common star points without
neutral conductor
Delta connection
-
1 50 %
Example:
2 heating
elements
Overcurrent
50 % 21 %
The specifications in % refer to load current changes
Number of
heating elements
Star connection without neutral
conductor
6 5 10 %
4 10 % 10 %
3 14 % 13 %
Delta connection
-
-
2 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.
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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 man-
ual 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 setup 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 TC = 1.
When the power controller is disconnected from the supply voltage, the
Teach-In values detected last are deleted again. After another power ON, the
load monitoring therefore remains inactive until the new Teach-In is performed.
To ensure that the load ratios for later operation are recorded precisely, the
Teach-In is only performed in phase angle control at a load current of at least
30 % of the rated value. (In burst-firing mode, this restriction is not necessary
because a sufficiently high current always flows when the SCR is fired. In this
case, the Teach-In is always performed shortly after a power ON or - if configured - after the soft start.)
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6 Special device functions
Load voltage
Load current
Setpoint value
Teach In
"Automatically
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
Teach-In values are deleted again. After another power ON, the power controller resumes automatic Teach-In detection.
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 59.
Configuring
"manual
"Teach-In
The power controller is in the "Measured value overview" level.
h Press the key
h Config. level
overcurrent
r Monitoring r Load monitoring r Undercurrent or
r Teach-In type load monit. r Set to "manual"
h Press the key
II
h Press the key twice
The device performs a reset.
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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.
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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
age input
Now the power controller power is preset via the external potentiometer.
r Analog inputs r Set voltage measuring range 0 to
r Setpoint config. r Default setpoint value r Set volt-
6.4 Dual energy management
This allows setpoint values of up to 50 % each to be preset on 2 master-slave
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 groups of 2. The "Dual energy management" parameter (Device1 and
Device2) has to be set in each group.
- The 2 master-slave devices must be wired identically as shown in the following image.
- The control electronics and the load circuit must have the same phase
- Synchronize both master-slave devices in a group 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 master-slave device must be configured as Device1
and the other master-slave device as Device2.
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6 Special device functions
Fuse for control
electronics 2A
Fusing to protect the
power section cabling
U1U2
N/L2L1V
13
14
15
1211
1089
7
6
5
42
3
1
8
1
U1U2
Semiconductor-
fuse
N/L2L1V
13
14
15
1211
1089
7
6
5
42
3
1
8
1
S
Relay
Ö
P
0(4)...20mA
+
Ohmic load star
connection
Patchcable
TYA 202
E
Optocoupler
C
I
1 (Device1)
L1NL2
L3 PE
U
L
U
N
U1U2
N/L2L1V
13
14
15
1211
1089
7
6
5
42
3
1
8
1
U1U2
N/L2L1V
13
14
15
1211
1089
7
6
5
42
3
1
8
1
S
Relay
Ö
P
0(4)...20mA
+
Setpoint lnput:
Patchcable
TYA 202
E
Optocoupler
C
Device 1
Device 2
I
2 (Device1)
I
3 (Device1)
I
3 (Device2)
I
2 (Device2)
I
1 (Device2)
I
1
I
2
I
3
Attention:
- Make sure that the rotating electric field
is right handed!
- Only possible in burst firing mode
- SCR load voltage =U
L
Setpoint lnput:
Semiconductor-
fuse
Ohmic load star
connection
Fuse for control
electronics 2A
Semiconductor-
fuse
Semiconductor-
fuse
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6 Special device functions
t
t
Device 1
Output level 20%
Device
Output level260%
250 ms 500 ms 750 ms 1 s0 ms
I
1 Device1
t
I
1
Sum of all
currentsMains
I
21Device
I
3 1
Device
I
1 Device2I2 Device2
I
3 Device2
I2I
3
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 master-slave devices have to be switched on again simultaneously via a joint main switch!
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6 Special device functions
Controller
Furnace
Sensor
SCR
power unit
Supply
voltage
y
R
x
y
-
w
P
230V
ΔP–
U01U,()–()
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 electrical supply voltage is connected to the power controller. The controller derives the output level y
the furnace temperature and the actual (or
from the difference between the set value (w) for
R
process
) value (x) which is acquired
by a sensor inside the furnace. The controller output level can range from 0 to
100 % and is output at the output of the controller as a standard signal, for example, 0 to 10 V. The output level signal 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.
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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 the power controller∼
(5)
Disadvantage: A continuing constant temperature is no longer assured.
The power controller recognizes the deviation through the relatively slow response of the temperature control loop and increases its output level (y
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 (yR). The principle of an
subordinate control loop is shown in Figure .
) until
R
A distinction is made between U
most applications. There are, however, some applications where an I
control 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
Combining equations 5 and 4, we can see that the power in the load resis-
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6 Special device functions
P
load
input signal of the power controller (0 to 20 mA)∼
U
load
2
R
-------------
tance is proportional to the input signal to the power controller.
(6)
Heating elements that have a positive temperature coefficient (TC)(i.e. where
the electrical resistance increases with increasing temperature) are usually 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.
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
This effect supports the complete control loop. As the furnace temperature ris-
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6 Special device functions
es 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
I
control Current control (I2 control) is advantageous for heating elements with a nega-
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.
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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 V · 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
Silicon carbide heating elements have a nominal resistance that can increase
by a factor of 4 over the long term. So when dimensioning a system it is necessary to adapt the power controller to produce twice the power for the heating elements.
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6 Special device functions
R
old
4
---------
P
new
U
newInew
•
U
old
2
---------
2I
old
• U
oldIold
• P
old
====
(12)
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
old
=
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 3-phase
supply network.
Operating mode Resistive load Inductive
load
TC constant TC positive TC nega-
tive
Longterm aging
Burst-firing mode X
Burst-firing mode with
XX
α start
Burst-firing mode with
XXX
current limiting
Subordinate control
2
U
2
I
XX X
XX
P XX
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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 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.
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6 Special device functions
u
t
a a
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.
v Chapter 5.1.2 "Power controller"
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 burst
firing mode and in logic operation with phase control of the first half-wave.
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.
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6 Special device functions
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
v Chapter 3.3 "Connection diagram"
Alternatively, the SCR output can also be switched off via the PROFIBUS,
RS422/485 interfaces.
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6 Special device functions
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.
Tran sf or me r
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 precisely defined number of sine wave cy-
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"
cles are to 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
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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 master 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, Windows® XP, Windows 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
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7 Setup program
7.3 Installation
h Install the setup program
Installation
steps
Enter
license number
Display on the PC screen
12
34
56
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7 Setup program
Installation
steps
Installation
complete
Launch
setup program
Display on the PC screen
78
9
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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.
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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.
r from the device
r to the device
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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 Execute
h Click Automatic detection and the dialog for the device language will ap-
pear.
h Select the desired language
h Continue in the hardware assistant by clicking Continue until it is completed
The device texts in the selected language have now been transferred in the
setup file.
r hardware and the hardware assistant will start
r from 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.
r to the device
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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 8 "Fault messages and alarms"
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 SCR defective
1. Semi-conductor fuse defective
2. No voltage at terminal U1
3. The voltage supply for the control electronics L1/N does not have the same phase angle
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
Note:
Monitoring only functions when the load resistance is so low that at least 10 % of the
power controller nominal current is flowing.
v Chapter 8.2 "Replacing a
defective semi-conductor
fuse"
-Check wiring
- Check the line fuse for the
load circuit
Check wiring
The device must be returned to
JUMO for repair.
h Return the device
JUMO for repair.
h Return the device
The device must be returned to
JUMO for repair.
h Return the device
Caution!
High temperature
Device temperature is higher than 100 °C
(excess temperature)
- Ensure adequate ventilation
- Reduce load current
- Use power controller with
higher maximum load current
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8 Fault messages and alarms
Fault message Cause Remedy
Limiting active
high temperature
Supply voltage is
too low
Supply voltage is
too high
Temporary
drop in supply
Master-slave
rotary field error
Master-slave
incorrectly wired.
Device temperature is higher than 105 °C.
Device is too hot, power 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"
Counterclockwise rotary field has been detected
Wiring fault has been detected
- Ensure adequate ventilation
- 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.
v Chapter 3.3.1 "Rotary cur-
rent economic circuit master-slave for resistive loads
in star or delta connection
or transformer loads (resistive-inductive)"
Rotary field detection
failed
Wire break
Current input
Wire break
Voltage input
Malfunction
Bus error
Master-slave
Error in comm.
Data cable
faulty
Synchronization
failed
Rotary field detection not possible
- Check connection
v Chapter 3.3 "Connection
diagram"
- Eliminate line disturbances
Input current for the set measuring range outside the valid range.
- Check wiring for wire breaks
and reverse polarity.
- Check upstream devices
(controllers)
Input current for the set measuring range outside the valid 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).
Error in the data transfer between master and
slave
Communication between master and slave
interrupted.
Slave device switched off or communication
between master and slave interrupted
Check data connection of patch
cable
Check the patch cable and replace, if necessary
Check data connection of patch
cable or voltage supply
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8 Fault messages and alarms
Fault message Cause Remedy
M/S incompatible
#0002...0008
- Master and slave are using different
versions of the software
Use same power controller types
with same software versions.
- Different power controller types used
(max. load current, load voltage and
subordinate control loop (if applicable)
do not match)
#0002 Different device software versions Ensure that devices are using the
same software versions
v Service hotline
#0003 VDN numbers of devices do not match Master/slave operation not possi-
ble
#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.
Teach In
load monitoring!
Reminder that "manual" Teach-In has been
configured but not yet executed.
Master/slave operation not possible
v Chapter 1.3 "Order details"
Change subordinate control loops
of both devices to U or U
Perform Teach-In
2
.
v Chapter 6.1 "Detection of
load faults"
Slave: limit value
min. value reached
The value has gone below the set limit value
for the min. alarm at the slave
Check why the value has gone below the limit value.
Slave: limit value
min. value reached
Slave: fault at
connected load
Slave:
blown fuse
(red LED fuse is lit)
Slave:
SCR breakage
Slave: SCR
short circuit
Slave: caution!
High temp.
The set limit value for the max. alarm has
been exceeded at the slave
Break or short-circuit of a load resistor.
v Chapter 6.1 "Detection of load
Check why the limit value has been
exceeded.
Replace defective heating elements.
faults"
1. Semi-conductor fuse defective
v Chapter 8.2 "Replacing a
defective 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
Device temperature is higher than 100 °C
(excess temperature)
- Ensure adequate ventilation
- Reduce load current
- Use power controller with
higher maximum load current
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8 Fault messages and alarms
Fault message Cause Remedy
Slave: limit.
active high temp.
Slave: supply volt.
too low
Device temperature is higher than 105 °C
Device too hot!
Power is reduced.
(limited power due to excess temperature)
Supply voltage is not within specified tolerance range
v Chapter 10.1 "Voltage supply, load
current"
Slave: supply volt.
too high
Supply voltage is not within specified tolerance range
v Chapter 10.1 "Voltage supply, load
current"
Slave: temp. drop in
supply
Dangerous temporary equal proportion for
transformer loads has been detected.
v Chapter 5.1.5 "Monitoring"
Inhibit by inhibit input A firing-pulse inhibit has been triggered via a
potential-free contact.
No power from the power controller.
Inhibit by ext. inhibit The firing-pulse inhibit has been triggered via
an interface.
- Ensure adequate ventilation
- 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.
v Chapter 3.3 "Connection
diagram"
Open contact between terminal 7
and 8 at screw terminal X_2.
v Interface manual "Ext. in-
hibit"
Soft start phase This display appears until the soft start has
been completed.
Current limiting
active
Resistance limitation
active
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 are limited to the set load resistance value.
The output level is limited to the permissible
resistance to prevent the heating element
from overheating.
v Chapter 5.1.2 "Power con-
troller"
See "Soft start duration" on
page 53.
v Chapter 5.1.2 "Power con-
troller"
See "Current limiting" on
page 53.
v Chapter 5.1.2 "Power con-
troller"
-> 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.
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8 Fault messages and alarms
8.2.1 Accessories: semi-conductor fuses
The design of the semi-conductor fuse differs according to the device type.
Power
controller type
20 A Tripping current: 50 A Recessed head 3 Nm 70/00513108
32 A Tripping current: 80 A Recessed head 5 Nm 70/00068011
50 A Tripping current: 80 A Recessed head 5 Nm 70/00068011
Tripping current Screws Tighten-
ing
torque
Sales
no.
100 A Tripping current: 160 A Hexagon head, width across flats
10 mm
150 A Tripping current: 350 A Hexagon head, width across flats
13 mm
200 A Tripping current: 550 A Hexagon head, width across flats
13 mm
250 A Tripping current: 550 A Hexagon head, width across flats
13 mm
8.2.2 Semi-conductor fuses type 709062/X-0X-20...
5 Nm 70/00081801
12 Nm 70/00083318
12 Nm 70/00371964
12 Nm 70/00371964
h Undo 2 recessed head screws
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8 Fault messages and alarms
h Replace the defective semi-conductor fuse with a new one
h Tighten the screws with the specified tightening torque
8.2.3 Semi-conductor fuses type 709062/X-0X-32...
h Undo 2 hexagon head screws
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