JUMO 709062/8-01-50, 709062/8-01-100, 709062/8-01-150, 709062/8-01-250, 709062/8-01-32 Operating Manual

...
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
Thyristor power controller
in a three-phase economy circuit
Operating Manual
70906200T90Z001K000
V3.01/EN/00561073
Page 2
All parameter settings are described in detail in the chapter "Configuration".
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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
Table of contents
1 Introduction..................................................................................9
1.1 Editorial ....................................................................................................... 9
1.2 Typographical conventions ..................................................................... 10
1.2.1 Warning symbols ............................................................................................... 10
1.2.2 Note symbols ..................................................................................................... 11
1.2.3 Performing an action ......................................................................................... 11
1.2.4 Display types ...................................................................................................... 11
1.3 Order details ............................................................................................. 12
1.3.1 Scope of delivery ............................................................................................... 13
1.3.2 Accessories ........................................................................................................ 13
1.3.3 General accessories .......................................................................................... 13
1.4 Brief description ....................................................................................... 14
1.5 Standards, approvals, and conformity ................................................... 15
2 Mounting ....................................................................................17
2.1 Important installation notes .................................................................... 17
2.1.1 Environmental conditions ................................................................................. 18
2.1.2 Filtering and interference suppression ............................................................ 19
2.1.3 Admissible load current depending on the ambient temperature and the site
altitude ................................................................................................................ 19
2.1.4 Wall mounting with screws (default) ................................................................ 21
2.1.5 Mounting on DIN rail (accessories) .................................................................. 24
2.2 Dimensions ............................................................................................... 25
2.2.1 Type 709062/X-0X-020-XXX-XXX-XX-25X ....................................................... 25
2.2.2 Type 709062/X-0X-032-XXX-XXX-XX-25X ...................................................... 26
2.2.3 Type 709062/X-0X-050-XXX-XXX-XX-25X ....................................................... 27
2.2.4 Type 709062/X-0X-100-XXX-XXX-XX-25X ....................................................... 28
2.2.5 Type 709062/X-0X-150-XXX-XXX-XX-25X
Type 709062/X-0X-200-XXX-XXX-XX-25X ....................................................... 29
2.2.6 Type 709062/X-0X-250-XXX-XXX-XX-25X ....................................................... 30
2.2.7 Clearances (all types) ........................................................................................ 30
3 Electrical connection ................................................................31
3.1 Plug-in screw terminals with 20 A .......................................................... 31
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Table of contents
3.1.1 Type 709062/X-0X-20-XXX-XXX-XX-25X ......................................................... 31
3.2 Cable lugs and plug-in screw terminals as of 32 A .............................. 32
3.2.1 Type 709063/X-0X-032-XXX-XXX-XX-25X
Type 709063/X-0X-050-XXX-XXX-XX-25X ....................................................... 33
3.2.2 Type 709062/X-0X-100-XXX-XXX-XX-25X ....................................................... 35
3.2.3 Type 709062/X-0X-150-XXX-XXX-XX-25X
Type 709062/X-0X-200-XXX-XXX-XX-25X ....................................................... 36
3.2.4 Type 709062/X-0X-250-XXX-XXX-XX-25X ....................................................... 37
3.3 Connection diagram ................................................................................ 38
3.4 Switch-on sequence ................................................................................ 41
3.4.1 Three-phase economic circuit Master-Slave for resistive loads in star-, delta
connection or transformer loads (resistive-induktive) ................................... 41
4 Operation....................................................................................43
4.1 Display after switching on the device .................................................... 43
4.1.1 Display and control elements ........................................................................... 44
4.1.2 Appearance of measured values ...................................................................... 44
4.1.3 Meaning of the displayed measured values .................................................... 45
4.1.4 Appearance in the configuration level ............................................................. 47
4.1.5 Appearance of error messages and special statuses .................................... 47
4.2 Operating level ......................................................................................... 48
4.2.1 Device data ........................................................................................................ 48
4.2.2 Power controller ................................................................................................ 49
4.2.3 Setpoint value configuration ............................................................................ 49
4.2.4 Monitoring .......................................................................................................... 51
5 Configuration .............................................................................53
5.1 Configuration level ................................................................................... 53
5.1.1 Device data ........................................................................................................ 54
Language wizard active................................................................................................... 54
Temperature Unit............................................................................................................. 54
Display contrast ............................................................................................................... 54
Switch-off......................................................................................................................... 54
display lighting................................................................................................................. 54
Apply default settings ...................................................................................................... 54
5.1.2 Power controller ................................................................................................ 54
Thyristor control............................................................................................................... 54
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Table of contents
Subordinate control loop ................................................................................................. 55
Cycle time........................................................................................................................ 56
Min. ON period ................................................................................................................ 56
α start............................................................................................................................... 56
α start angle..................................................................................................................... 56
Soft start .......................................................................................................................... 56
Soft start type .................................................................................................................. 57
Soft start duration............................................................................................................ 57
Current limiting ................................................................................................................ 57
Current limit value............................................................................................................ 58
Resistance limitation........................................................................................................ 58
Resistance limit value ...................................................................................................... 58
Dual energy management................................................................................................ 58
5.1.3 Analog inputs ..................................................................................................... 59
Current measuring range................................................................................................. 59
Current measuring range, start........................................................................................ 59
Current measuring range, end......................................................................................... 59
Voltage measuring range................................................................................................. 59
Voltage measuring range, start........................................................................................ 59
Voltage measuring range, end......................................................................................... 59
5.1.4 Setpoint value configuration ............................................................................ 60
Setpoint specification ...................................................................................................... 60
Input in the event of an error............................................................................................ 60
Value in the event of an error........................................................................................... 60
Maximum actuating variable............................................................................................ 60
Base load......................................................................................................................... 61
5.1.5 Monitoring .......................................................................................................... 62
> Limit value monitoring .................................................................................................. 62
Min. limit value alarm ....................................................................................................... 62
Max. limit value alarm ...................................................................................................... 63
Limit value hysteresis....................................................................................................... 63
>Load monitoring............................................................................................................. 63
Limit value load monitoring.............................................................................................. 63
Load type load monitoring............................................................................................... 63
Teach-In type load monitoring......................................................................................... 63
>Mains voltage drop monitoring...................................................................................... 64
>Control loop monitoring................................................................................................. 64
5.1.6 Digital inputs ...................................................................................................... 65
External toggling of setpoint specification....................................................................... 65
Setpoint specification when toggling............................................................................... 65
Value when toggling......................................................................................................... 65
Ext. current limiting.......................................................................................................... 65
External current limit value............................................................................................... 65
Key lock ........................................................................................................................... 66
External switch-off of display lighting.............................................................................. 66
Inhibit input control direction........................................................................................... 66
Control direction, digital input1 ....................................................................................... 66
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Table of contents
Control direction, digital input2 ....................................................................................... 66
5.1.7 Digital output ...................................................................................................... 67
Output mode.................................................................................................................... 67
Control direction, digital output ....................................................................................... 68
5.1.8 analog output ..................................................................................................... 69
Signal type, actual value output ...................................................................................... 69
Value to be output ........................................................................................................... 69
Signal range start value ................................................................................................... 69
Signal range end value .................................................................................................... 69
5.1.9 RS422/485 .......................................................................................................... 69
Baud rate ......................................................................................................................... 69
Data format...................................................................................................................... 69
Device address ................................................................................................................ 69
Min. response time .......................................................................................................... 69
5.1.10 PROFIBUS-DP .................................................................................................... 70
Device address ................................................................................................................ 70
Data format...................................................................................................................... 70
5.1.11 EtherCAT ............................................................................................................ 70
Fieldbus ........................................................................................................................... 70
Device ID.......................................................................................................................... 70
(Alias-Adr.) ....................................................................................................................... 70
5.1.12 Changing codes ................................................................................................. 70
Code, manual mode ........................................................................................................ 70
Code, operating level....................................................................................................... 70
Code, config. level ........................................................................................................... 70
5.2 Configuration example ............................................................................ 71
6 Special device functions...........................................................73
6.1 Detection of load faults ........................................................................... 73
6.1.1 Teach-In .............................................................................................................. 75
6.2 Manual mode ............................................................................................ 76
6.2.1 Setpoint specification in manual mode ........................................................... 76
6.2.2 Configuring Teach-In (prerequisite for Teach-In in manual mode) ............... 76
6.2.3 Performing Teach-In in manual mode ............................................................. 77
6.3 Setpoint specification via potentiometer .............................................. 78
6.4 Dual energy management ....................................................................... 78
6.5 Subordinate control loop ......................................................................... 81
6.5.1 Closed control loop without subordinate control ........................................... 81
6.5.2 Closed control loop with subordinate control ................................................ 82
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Table of contents
6.6 Resistance limitation (r-control) ............................................................. 87
6.7 Current limiting ........................................................................................ 88
6.8 α start ........................................................................................................ 88
6.9 Monitoring of the mains voltage drop .................................................... 89
6.10 Firing pulse inhibit .................................................................................... 89
6.11 Thyristor control logic (switch) ............................................................... 90
7 Setup program...........................................................................91
7.1 Hardware .................................................................................................. 91
7.2 Compatible operating systems ............................................................... 91
7.3 Installation ................................................................................................ 92
7.4 Program start ........................................................................................... 94
7.5 Forgotten the code? ................................................................................ 95
7.6 Changing the language of the device texts ........................................... 96
8 Error messages and alarms......................................................97
8.1 Binary signal for collective fault ........................................................... 101
8.2 Replacing a defective semiconductor fuse ......................................... 102
8.2.1 Accessories: semiconductor fuses ................................................................ 103
8.2.2 Semi-conductor fuses type 709062/X-0X-20... ............................................. 103
8.2.3 Semi-conductor fuses type 709062/X-0X-32... ............................................. 104
9 What to do, if ...........................................................................107
10 Technical data..........................................................................109
10.1 Voltage supply, Fan specifications for 250A, load current ................. 109
10.2 Galvanic isolation ................................................................................... 109
10.3 Analog inputs (master only) .................................................................. 110
10.4 Analog output (actual value output master only) ................................ 110
10.4.1 Display and measuring accuracy ................................................................... 110
10.5 Digital inputs .......................................................................................... 110
10.6 Digital output (fault signal output master only) ................................... 110
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Table of contents
10.7 General specifications ........................................................................... 111
10.8 Approvals / approval marks .................................................................. 113
11 Certificates...............................................................................115
11.1 UL ............................................................................................................ 115
11.2 China ....................................................................................................... 117
8 V3.01/EN/00561073 [thyristor power controller TYA 202]
Page 9

1.1 Editorial

1 Introduction

Read this operating manual before putting the device into service. This operating manual is valid from device software version [256.03.01]. 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 safely switch off the subsequent heating process in the event of excess temperatures.
The power controller may only be operated using original JUMO semiconduc­tor fuses. In the event of replacement, please check that the correct spare 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 branch office or the head office.
Service hotline For technical questions
Phone support in Germany:
Phone: +49 661 6003-9135 Fax: +49 661 6003-881899 Email: service@jumo.net
Austria:
Phone: +43 1 610610 Fax: +43 1 6106140 Email: info@jumo.at
Switzerland:
Phone: +41 1 928 24 44 Fax: +41 1 928 24 48 Email: info@jumo.ch
V3.01/EN/00561073 [thyristor power controller TYA 202] 9
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1 Introduction
E
V
E
When accessing the inner parts of the device and returning device plug-in units, modules, or components, please observe the regulations according to DIN EN 61340-5-1 and DIN EN 61340-5-2 "Protection of electronic devices from electrostatic phenomena". Use only ESD packaging for shipment.
Please note that we cannot accept any liability for damage caused by ESD.
ESD=Electrostatic Discharge

1.2 Typographical conventions

1.2.1 Warning symbols

Caution
This character is used if personal injury may result from failure to follow instructions correctly or not at all!
Warning
ESD
Dangerous volt­age
Hot surface, fire hazard
This symbol is used when damage to devices or data may result from failure to follow instructions correctly or not at all!
This character is used if precautionary measures must be taken when handling electrostatically sensitive components.
This symbol is used if dangerous voltages will cause an electric shock in the event of contact with live parts.
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.
10 V3.01/EN/00561073 [thyristor power controller TYA 202]
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1.2.2 Note symbols

v
V
Note
Reference
Footnote
abc
1 Introduction
This symbol is used to draw your attention to a particular issue.
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 markers in the text are arranged as continuous superscript numbers.

1.2.3 Performing an action

Action instruction
Vital text
Command se­quence
h Plug in the
connector
Config. level rPower controller
rOperating mode

1.2.4 Display types

This symbol marks the description of a required action. The individual steps are marked by this asterisk
READ THE DOCUMENTATION!
This symbol, which is attached to the device, indicates that the as­sociated device documentation must be observed. This is nec­essary in order to recognize the nature of the potential danger and take the necessary measures to prevent it.
Small arrows between words are designed to make it easier to find parameters in the configuration level.
Keys
Keys are displayed as symbols or text. Key combinations are represented by a plus sign.
V3.01/EN/00561073 [thyristor power controller TYA 202] 11
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1 Introduction
Note: Subordinate control loop U, U
2
, code 100: enables voltage control
Subordinate control loop I
2
, code 010: enables voltage control, current control, partial load failure detection, dual energy management,
current limiting, and energy meter function Subordinate control loop P, code 001: enables voltage control, current control, power control, partial load failure detection, dual energy management, current limiting, r-control and energy meter function
At a load current of 250 A, observe voltage supply for fan! v Chapter 3.2.4 "Typ 709062/X-0X-250-XXX-XXX-XX-25X"

1.3 Order details

The nameplate is affixed to the right-hand side of the housing.
(1) Basic type
709062 TYA 202 Thyristor Power Controller in Three-phase Economy Circuit
(2) Version
8 Standard with default settings 9 Customer-specific programming according to specifications
(3) National language of device texts
01 German (default setting) 02 English 03 French
(4) Load current
020 AC 20 A 032 AC 32 A 050 AC 50 A 100 AC 100 A 150 AC 150 A 200 AC 200 A 250 AC 250 A
(5) Subordinate control loop (see note below)
100 U, U 010 I, I 001 P (can be set to I, I
2
2
(can be set to U, U2)
(6) Mains 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 84 EtherCAT/JUMO mTRON T
2
or U, U2)
(7) Interface
252 257 Optocoupler
a
-20 ... +15 %, 48 ... 63 Hz
-20 ... +15 %, 48 ... 63 Hz
-20 ... +15 %, 48 ... 63 Hz
-20 ... +15 %, 48 ... 63 Hz
-20 ... +15 %, 48 ... 63 Hz
-20 ... +15 %, 48 ... 63 Hz
-20 ... +15 %, 48 ... 63 Hz
-20 ... +15 %, 48 ... 63 Hz
(8) Extra code
Relay (changeover contact) 3 A
b
(1) (2) (3) (4) (5) (6) (7) (8)
/-----/Order code
709062 / 8 - 01 - 100 - 100 - 400 - 00 / 252 Order example
a.Mains voltage = Voltage supply for control electronics (always select phase voltage L1-L2 from the three-phase system)
b.Enables energy meter
12 V3.01/EN/00561073 [thyristor power controller TYA 202]
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1.3.1 Scope of delivery

1 operating manual 1 thyristor power controller in the version ordered 1:1 patch cable

1.3.2 Accessories

Item Part no.
Setup program 709061 TYA 201 (can also be run for TYA 202 power controllers)
USB cable A-connector B-connector 3 m 00506252
Installation kits:
Installation kit for DIN rail 20 A TYA 202 00555172 Installation kit for DIN rail 32 A TYA 202 00555527 Installation kit for DIN rail 50 A TYA 202 00600097
1 Introduction
00544869

1.3.3 General accessories

Semiconductor fuses
A semiconductor fuse is fitted in the power controller to protect the thyristor module. The "Fuse LED" lights up red in the event of a fault.
v Chapter 8.2 "Replacing a defective semiconductor fuse"
Item Load current
Super fast semiconductor fuse 40 A I Super fast semiconductor fuse 80 A I Super fast semiconductor fuse 80 A I Super fast semiconductor fuse 160 A I Super fast semiconductor fuse 350 A I Super fast semiconductor fuse 550 A I Super fast semiconductor fuse 550 A I
Part no.
= I
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
V3.01/EN/00561073 [thyristor power controller TYA 202] 13
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1 Introduction

1.4 Brief description

Device The JUMO TYA 202 represents the consistent development of JUMO power
controller technology. It switches ohmic-inductive loads using a three-phase current economy circuit in star-delta three-phase operation. The microproces­sor-controlled power controller displays all parameters in an LCD display with background lighting. It can be operated using the 4 keys at the front.
Application Thyristor power controllers are used where larger resistive and ohmic-induc-
tive loads have to be switched (e.g. in industrial furnace construction and plas­tics processing). The thyristor power controller consists of thyristors connect­ed in anti-parallel, the insulated heat sink, and the control electronics.
Mounting Thyristor 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 through to inductive loads are permitted.
Subordinate control loop
Standards The thyristor power controllers comply with VDE 0160 5.5.1.3 (5/88) and VDE
Advantages - Teach-In function for the detection of partial load failure
The TYA 202 works in burst-firing operation. In burst-firing operation, 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, to set current limiting or resistance limitation for the load. To avoid high starting currents, a soft start can be set.
In the case of transformer loads, the nominal induction of 1.2 tesla must not be exceeded (value is 1.45 T in the case of mains overvoltage).
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.
0106 Part 100 (3/83). The devices must be grounded as specified by the re­sponsible 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-
-Energy meter
14 V3.01/EN/00561073 [thyristor power controller TYA 202]
Page 15

1.5 Standards, approvals, and conformity

Device properties are inspected on the basis of the Low Voltage Directive DIN EN 50178. The EMC Directive is inspected on the basis of DIN EN 61326-1.
Standard
Electrical connection DIN VDE 0100 Protection type IP20 built-in devices DIN EN 60529 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
Interference emission Interference immunity
DIN EN 50178 2 III
DIN EN 61326-1 Class A - only for industrial use Industrial requirement
1 Introduction
Mechanical tests: Vibration test 3M2 Toppling test class 2M1
Labels, identification marking DIN EN 50178, DIN EN 61010-1
Approvals Standard Type
UL 508 (Category NRNT), pollution degree 2 C22.2 NO. 14-10 Industrial Control Equip­ment (Category NRNT7)
UL 508 (Category NRNT) C22.2 NO. 14-10 Industrial Control Equip­ment (Category NRNT7)
Can be used for electrical circuits with a short-circuit current capacity of 100 kA (the admissible mains voltage must correspond to the nominal voltage of the thyristor controller). For plant protection, a fuse up to class RK5 may be used.
DIN EN 60068-2-6, DIN EN 60721-3-3 DIN EN 60068-2-31, DIN EN 60721-3-2
709062/X-XX-020-... Load current 20 A
709062/X-XX-032... 709062/X-XX-050... 709062/X-XX-100... 709062/X-XX-150... 709062/X-XX-200... 709062/X-XX-250... Load current 32 to 250 A
CE conformity Low Voltage Directives 2006/95/EC
Marking Directives 93/68/EEC EMC Directives 2004/108/EC
Conformity Standard
RoHS 2002/95/EC
V3.01/EN/00561073 [thyristor power controller TYA 202] 15
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1 Introduction
16 V3.01/EN/00561073 [thyristor power controller TYA 202]
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2.1 Important installation notes

V

2 Mounting

Safety regulations
Fuse protection k Fuse protection of the voltage supply in accordance with the VDE regula-
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 accessing the inner parts of the device.
k Inside the device, safety clearances meet the requirements for double insu-
lation. When mounting the connecting cable, ensure that the cables are fitted ac­cording to regulations and that the safety clearances are maintained.
tions must be installed when wiring the voltage supply in the power section. The supply can also be protected with a circuit-breaker in the supply lead. The circuit-breaker must correspond to the power consumption of the pow­er controller.
k The connecting cables used for the terminals U1, U2, N/L2, V, and L1 must
have an electric strength of AC 500 V.
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 A semiconductor fuse is installed to protect the power controller in the
event of a ground fault. In the event of a defect, these may only be replaced with original JUMO semiconductor fuses.
v Chapter 8.2 "Replacing a defective semiconductor fuse"
Wiring Control cables (SELV potential) must be routed so that they are isolated from
cables with mains voltage potential. For supply protection, fuses (e.g. 2 A, Neozed type) must also be installed in the control circuit.
Master/slave 1:1 patch cable
PE connection h A direct protection conductor connection must be provided between the
Prior to startup, the enclosed 1:1 patch cable must be inserted into the mas­ter's X8 socket and connected to the slave device's X8 socket.
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 cables in the power section. In the event that the protection conductor is not a component of the supply cable or its encase-
2
ment, the selected conductor cross section may not be less than 2.5 mm
2
mechanical protection) or not less than 4 mm not protected mechanically).
(if the protection conductor is
(for
V3.01/EN/00561073 [thyristor power switch TYA 202] 17
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2 Mounting
v See VDE 0100 Part 540
Check h That the data on the nameplate (rated mains voltage, load current) corre-
sponds to the data for the plant.
h That the rotary electrical field has clockwise phasing if the economy circuit
configuration is used.
h That the configuration of the analog inputs, for example, corresponds to the
wiring.
h The analog input for the setpoint specification only needs to be connected
to the master. The slave receives its information via the 1:1 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 thyristors) is located between the U1
and U2 terminals.
h Where possible, load cables and cables for control inputs should be routed
so that they are isolated.
h Connect the mains voltage - thyristor power controller - load in accordance
with the connection diagram and check.
must have the same phase.
out for safe isolation from the mains voltage (SELV). To prevent the safe isola­tion from being impaired, ensure that all connected current circuits are also safely isolated. The required auxiliary supplies must be SELV voltages. The ground terminals X2_2/11 nected to one another.
or X2_1/6 of the master and slave must be con-

2.1.1 Environmental conditions

Incorrect use The device is not suitable for installation in potentially explosive areas.
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 loss Occurs as waste heat on the cooling body of the master and slave device and
- 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 (fur­nace)
- Avoid direct sunlight.
18 V3.01/EN/00561073 [thyristor power switch TYA 202]
Page 19
must be dissipated at the mounting site (e.g. in the control cabinet) in accor-
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
dance with the climatic conditions.

2.1.2 Filtering and interference suppression

To prevent radio-frequency interference, generated with a soft start in phase­angle operation for example, electrical apparatus and plants must have inter­ference suppression implemented.
The control electronics of the thyristor power controller comply with the EMC requirements of EN 61326.
However, modules such as thyristor power controllers do not have any pur­pose by themselves. They only serve as a component function within a plant. Where applicable, the power controllers's entire load circuit must also have suitable interference suppression filters fitted by the plant provider.
There are a number of specialist companies that provide appropriate ranges of interference suppression filters to deal with any interference problems. These filters are normally supplied as complete modules that are ready to be con­nected.
2 Mounting

2.1.3 Admissible load current depending on the ambient temperature and the site altitude

Ambient tem­perature
V3.01/EN/00561073 [thyristor power switch TYA 202] 19
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2 Mounting
1000 2000
40
20
100
site altitude in m above sea level
80
Ampacity in %
91,4%
60
3000 4000 5000
Reduction over 1000m above sea level: 0,86 %/100m
Destruction through overheating:
In the event of operation at maximum load current over an extended period, the heat sink and its surroundings heat up. For this reason, at ambient temperatures above 45 °C, the maximum load cur­rent must be reduced as shown in the image, as the thyristor module could otherwise be destroyed. The master or slave device temperature shown on the display may not exceed 100 °C.
At a device temperature of >100 °C, the message "Warning - high tempera­ture" is displayed. At a device temperature of >105 °C, the load current is gradually reduced by 10 % of the nominal current each time the temperature increases by one de­gree. At a device temperature of >115 °C, the power controller current is completely switched off.
v Chapter 8 "Error messages and alarms"
Site altitude In the case of air cooling, it must be noted that the effectiveness of the cooling
is reduced as the site altitude increases. As a result, the ampacity of the thyris­tor power controller decreases with such a cooler as the site altitude increas­es, as shown in the diagram.
20 V3.01/EN/00561073 [thyristor power switch TYA 202]
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2.1.4 Wall mounting with screws (default)

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 Mounting
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2 Mounting
TYA202 150/200A
TYA202 150/200A
22 V3.01/EN/00561073 [thyristor power switch TYA 202]
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2 Mounting
TYA202 250ATYA202 250A
V3.01/EN/00561073 [thyristor power switch TYA 202] 23
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2 Mounting
Hot surface
During operation, the power controller heats up to a maximum of 110 °C, depending on the load. Ensure that the lamellae of the heat sink 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 fan for 250 A power controller:
The intake air at the ventilation grid of the fan may not exceed a maximum inlet air temperature of 35 °C. Ensure that the inlet air for the built-in fans 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 50 A can be affixed to a DIN rail using the correspond­ing accessories.
v Chapter 1.3.3 "General accessories" h Hook the spring saddle into the DIN rail from above.
h Swivel the power controller downward until the lug engages with the DIN
rail with an audible click.
24 V3.01/EN/00561073 [thyristor power switch TYA 202]
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2.2 Dimensions

2.2.1 Type 709062/X-0X-020-XXX-XXX-XX-25X

2 Mounting
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2 Mounting

2.2.2 Type 709062/X-0X-032-XXX-XXX-XX-25X

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2.2.3 Type 709062/X-0X-050-XXX-XXX-XX-25X

2 Mounting
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2 Mounting

2.2.4 Type 709062/X-0X-100-XXX-XXX-XX-25X

28 V3.01/EN/00561073 [thyristor power switch TYA 202]
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2.2.5 Type 709062/X-0X-150-XXX-XXX-XX-25X Type 709062/X-0X-200-XXX-XXX-XX-25X

2 Mounting
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2 Mounting

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 devices is required.
30 V3.01/EN/00561073 [thyristor power switch TYA 202]
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3 Electrical connection

(N/L2)
(V)
(L1)
(2)X2_
(X2_1)
(X8)
()X3
(PE)
Master
Slave
(U1)
(U2)
Control section
Power section
Voltage supply
Control electronics
no
function
no
function
Dangerous volt­age

3.1 Plug-in screw terminals with 20 A

Tools - Flat-blade screwdriver, blade width 2, 3, and 5 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 pluggable screw termi­nals.
The electrical connection must only be carried out by qualified per­sonnel! Dangerous voltages will cause an electric shock in the event of contact with live parts!
h Disconnect the plant from the mains voltage on all poles. All screw terminals supplied ex works must be inserted and
screwed tight during operation!
V3.01/EN/00561073 [thyristor power switch TYA 202] 31
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3 Electrical connection
K
Terminal Version Conductor
cross section
Maximum tightening torque
X2_1 and X2_2 Slotted screws, blade width 2 mm
X3 Slotted screws, blade width 3 mm
U2, 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
0.2-1.5 mm
0.5-2.5 mm
0.5-6 mm
Cable lug with hole: 4 mm
2
0.25 Nm
2
0.5 Nm
2
0.6 Nm
3Nm
Master-slave connection
Terminal Connection for
RJ 45 socket X8 Master-slave
The 1:1 patch cable (included in scope of delivery) must be plugged in for correct oper­ation (X8 connection to slave).

3.2 Cable lugs and plug-in screw terminals as of 32 A

Tools - Flat-blade screwdriver, blade width 2, 3, and 5 mm
- Ring or open-end wrench, width across flats 7, 10, 13 mm
32 V3.01/EN/00561073 [thyristor power switch TYA 202]
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3.2.1 Type 709063/X-0X-032-XXX-XXX-XX-25X
(2)X2_
(X2_1)
(X8)
()X3
(U1)
(U2)
(N/L2)
(V)
(L1)
(PE)
keine
Funktion
keine
Funktion
Type 709063/X-0X-050-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.
3 Electrical connection
Terminal Version Conductor cross sec-
tion
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
2
2
2
Maximum tightening torque
0.25 Nm
0.5 Nm
5Nm 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
0.5 to 4 mm
2
(0.5 to 2.5 mm
or
2
with
0.5 Nm
ferrule) For UL AWG 20-12)
Ground terminal PE M6 setscrew with hexagon nut
Width across flats 10 mm
Cable lug hole: 6 mm
5Nm
Master-slave connection
Terminal Connection for
RJ 45 socket X8 Master-slave
The 1:1 patch cable (included in scope of delivery) must be plugged in for correct oper­ation (X8 connection to slave).
V3.01/EN/00561073 [thyristor power switch TYA 202] 33
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3 Electrical connection
(2)X2_
(X2_1)
(X8)
()X3
(U1)
(U2)
(N/L2)
(V)
(L1)
(PE)
keine
Funktion
keine
Funktion
34 V3.01/EN/00561073 [thyristor power switch TYA 202]
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3.2.2 Type 709062/X-0X-100-XXX-XXX-XX-25X

(2)X2_
(X2_1)
(X8)
()X3
(U1)
(U2)
(N/L2)
(V)
(L1)
(PE)
keine
Funktion
keine
Funktion
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.
3 Electrical connection
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 hex-headed screws, width across
16 to 50 mm
2
2
2
flats 10 mm For applications according to UL, only 75 °C copper conductors may be used! N/L2, V, L1 Slotted screws,
blade width 3 mm
0.5 to 4 mm (0.5 to 2.5 mm
2
or
2
with ferrule) for UL AWG 20-12
Ground terminal PE M6 setscrew with hexagon nut
Width across flats 10 mm
Cable lug hole: 6 mm
Master-slave connection
Terminal Connection for
RJ 45 socket X8 Master-slave
The 1:1 patch cable (included in scope of delivery) must be plugged in for correct oper­ation (X8 connection to slave).
Maximum tightening torque
0.25 Nm
0.5 Nm 5Nm
0.5 Nm
5Nm
V3.01/EN/00561073 [thyristor power switch TYA 202] 35
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3 Electrical connection
(2)X2_
(X2_1)
(X8)
()X3
(U1)
(U2)
(N/L2)
(V)
(L1)
(PE)
keine
Funktion
keine
Funktion

3.2.3 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.
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 hex-headed screws, width across
95 to 150 mm
2
2
2
flats 13 mm For applications according to UL, only 75 °C copper conductors may be used! N/L2, V, L1 Slotted screws,
blade width 3 mm
0.5 to 4 mm (0.5 to 2.5 mm
2
or
2
with ferrule) for UL AWG 20-12
Ground terminal PE M8 setscrew with hexagon
nut, width across flats 13 mm
Cable lug hole: 8 mm
Master-slave connection
Terminal Connection for
RJ 45 socket X8 Master-slave
The 1:1 patch cable (included in scope of delivery) must be plugged in for correct oper­ation (X8 connection to slave).
Maximum tightening torque
0.25 Nm
0.5 Nm 12 Nm
0.5 Nm
12 Nm
36 V3.01/EN/00561073 [thyristor power switch TYA 202]
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3.2.4 Type 709062/X-0X-250-XXX-XXX-XX-25X

(2)X2_
(X2_1)
(X8)
()X3
(U1)
(U2)
(N/L2)
(V)
(L1)
(PE)
keine
Funktion
keine
Funktion
(X14)
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.
3 Electrical connection
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 hex-headed screws, width across
95 to 150 mm
2
2
2
flats 13 mm For applications according to UL, only 75 °C copper conductors may be used! N/L2, V, L1 Slotted screws,
blade width 3 mm
0.5 to 4 mm (0.5 to 2.5 mm
2
or
2
with ferrule) for UL AWG 20-12
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
Cable lug hole: 8 mm
2
Master-slave connection
Terminal Connection for
RJ 45 socket X8 Master-slave
The 1:1 patch cable (included in scope of delivery) must be plugged in for correct oper­ation (X8 connection to slave).
Maximum tightening torque
0.25 Nm
0.5 Nm 12 Nm
0.5 Nm
12 Nm
0.5 Nm
V3.01/EN/00561073 [thyristor power switch TYA 202] 37
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3 Electrical connection
-
.FBTVSJOHMPBEWPMUBHF
$POUSPM FMFDUSPOJD
1IBTF--
1IBTF--
7
/-
5:"
U2
U1
Load
Phase
(L1, L2, L3)
PE
PE
TYA
20 21
Voltage supply for fan
+
I
x
Current­input
TYA
2
1
Depending on the Mains 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.
Voltage supply for fan
Mains voltage on the power controller
Mains voltage AC 24 V -20 ... +15 %, 48 ... 63 Hz AC 24V/2x30 VA Mains voltage AC 42 V -20 ... +15 %, 48 ... 63 Hz Mains voltage AC 115 V -15 ... +10%, 48 ... 63 Hz AC 115V/2x30 VA Mains voltage AC 230 V -15 ... +10%, 48 ... 63 Hz AC 230V/2x30 VA Mains voltage AC 265 V Mains voltage AC 400 V
To ler anc es F an
specifications
Mains voltage AC 460 V
Mains voltage AC 500 V

3.3 Connection diagram

Connection for screw terminals Connection side Device side
Voltage supply for control electronics (Corresponds to the max. mains voltage of the ordered device type)
Load connection in the
power section
and protective conductor connection
Fan X14 20, 21
Control section
Connection for screw terminal X2_1
Setpoint specification for current input 1
L1 N/L2 V
U1 U2 PE
(only for load current of 250 A)
Connection side Device side
2
38 V3.01/EN/00561073 [thyristor power switch TYA 202]
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3 Electrical connection
E
S
A
5kW
TYA
DC +10 V
4
3
+
U
x
3
5
4
external Setpoint specification with potentiometer
Voltage
input
EIN
AUS
11
10
3,3V
10kW
TYA
8
7
+
U
88
77
EIN
AUS
11
10
3,3V
10kW
TYA
9
11
+
U
11
9
11
9
EIN
AUS
11
10
3,3V
10kW
TYA
10
11
+
U
11
10
11
10
+
TYA
12
11
Analog­output
E
S
C
Ö
P
13
14
15
Relay- or optocoupler Output
TYA
Setpoint specification for voltage input (surge proof up to max. DC +32 V)
Binary input SPS 0/24 V ON logical „1“ = DC +5...32 V
3 (GND) (for continous control) 4
3 (GND) (for SPS-Logic signals) 4
OFF logical „0“ = DC 0...< 5 V
Output DC 10 V fixed voltage
5
(max. +10 V, 2 mA) Ground potential 6 (GND)
Connection for screw terminal X2_2
Firing pulse inhibit
ON logical "1" = DC +2 to 32 V OFF logical "0" = DC 0 to +0.8 V
Digital input1
ON logical "1" = DC +2 to 32 V OFF logical "0" = DC 0 to +0.8 V
Digital input2
ON logical "1" = DC +2 to 32 V OFF logical "0" = DC 0 to +0.8 V
8 (not for SPS-Logic signals) 7 (GND)
9 (not for SPS-Logic signals) 11 (GND)
10 (not for SPS-Logic signals) 11 (GND)
Connection side Device side
GND 7, 11 Ground potential
The ground terminals X2_2/11 or X2_1/6 of the master and slave must be connected to one anoth­er.
analog output
Various internal controller variables can be output as a standard signal of 0(4) to 20 mA, 0(2) to 10 V, and 0(1) to 5 V.
12 11 (GND)
v Chapter 10.4 "Analog output (ac-
tual value output master only)"
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
Master-slave connection
Terminal Connection for
RJ 45 socket X8 The 1:1 patch cable (included in scope of delivery) must be plugged in for correct
operation between the master and slave (X8 connection to slave).
V3.01/EN/00561073 [thyristor power switch TYA 202] 39
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3 Electrical connection
16
17
19 18
6
7
8
9
2
3
4
5
1
16
17
19 18
(RS422/485 )Modbus
PROFIBUS-DP
6\VWHPEXV,1
6\VWHPEXV287
8
1
Interfaces
Connection Modbus RS422 RS485 Connection PROFIBUS-DP
Plug-in screw terminals on the bottom of the housing
19 TxD (-) RxD/TxD B(-) SUB-D sock­18 TxD (+) RxD/TxD A(+) 8 B(-) 17 RxD (-) - 6 VCC 16 RxD (+) - 5 GND
The shield of the Modbus cables must be routed to ground potential (PE)!
et 9-pin (on the front)
3 A(+)
Shield
Connection JUMO mTRON T system bus or
2 RJ-45 sockets (on the front)
EtherCAT conf. tested
1 TX+ Transmission
data +
2 TX- Transmission
data -
3 RX+ Received
data +
6 RX- Received
data -
40 V3.01/EN/00561073 [thyristor power switch TYA 202]
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3.4 Switch-on sequence

3 Electrical connection
Observe the general switch­on sequence
Switch-on se­quence when using bus sys­tems
The S2 switch is not required if no bus system is used. The control section and power section are switched on simultaneously switch S1.
This is particularly important for the operation of transformer loads and resistance loads with a high temperature coefficient (TC >> 1). This makes sure the necessary load start functions (soft start, current limiting, etc.) are activated ac­cordingly.
When using a bus system, the control section and power section are switched on via S1 and S2.
The TYA's control section must remain connected to the mains voltage at all times (e.g. S1 permanently connected) to maintain the flield-bus communi-
cation. S2 is used to activate the load. In the event of transformer loads or loads with a large temperature coefficient (TC >> 1), the controller output must be blocked using the inhibit function prior to opening S2. After closing S2, the controller output must be reactivated via the inhibit function.
via

3.4.1 Three-phase economic circuit Master-Slave for resistive loads in star-, delta connection or transformer loads (resistive-induktive)

Prerequisite To facilitate master-slave operation, the devices must have the same order
code and the same device software version. The two devices are connected by means of a 1:1 patch cable (max. length of 30 cm).
The image shows the wiring of a TYA 202, which is available ex works as a ful­ly assembled and configured unit, and behaves exactly like two single TYA 201 devices in master-slave operation.
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
V3.01/EN/00561073 [thyristor power switch TYA 202] 41
Page 42
3 Electrical connection
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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 3.2.4 "Type 709062/X-0X-250-XXX-XXX-XX-25X"
42 V3.01/EN/00561073 [thyristor power switch TYA 202]
Page 43

4.1 Display after switching on the device

4 Operation

Hourglass and national lan­guage selection
Language wizard
Initially, 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 devices and rotary field detection is carried out. If everything is wired correctly, the power controller shows a national lan­guage selection on the display.
Select the national language and confirm your selection with .
This option enables you to select whether the language wizard should be reac­tivated the next time the device is started.
Select "Yes" or "No", press . Measured values then appear on the device. v Chapter 4.1.2 "Appearance of measured values".
Error messages The following chapter explains the error messages that may appear in the info
line at the bottom of the screen: v Chapter 8 "Error messages and alarms"
V3.01/EN/00561073 [thyristor power switch TYA 202] 43
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4 Operation
(1)
(2)
(3) (4)
(5)
(7)
(6)
(7)
Designation
Measured value
Info line or error

4.1.1 Display and control elements

Legend Comment Diagram
1
2
3
4 5 Keys:
The Power LED (green) lights up permanently when the voltage supply is connected. Flashes at regular intervals if the display lighting is switched off.
v Chapter 9 "Was tun, wenn ..."
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 indicator
Increase value / previous parameter Decrease value / next parameter Cancel / one level back Programming / one level forward
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 housing
v Chapter 8.2 "Defekte Halbleitersicherung aus-
tauschen"
and can be used to view the current measured values such as cur­rents, actual voltage values, load resistance setpoint value, device tempera­ture, and power.
This information is also displayed in the diagnosis window for the setup pro­gram.
v Chapter 7 "Setup program"

4.1.2 Appearance of measured values

Overview of measured val­ues
At this level, the description of the measured value is displayed in the top line, and the numerical value together with the unit is displayed in the middle.
44 V3.01/EN/00561073 [thyristor power switch TYA 202]
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4 Operation
The info line shows the selected input (with terminal designation), the active subordinate control loop, and the operating mode. It is also used to display temporary states (e.g. error messages). v Chapter 8 "Fehlermeldungen und Alarme"
Mains frequency
Meaning of the symbols in the info line
In this window, the rotary field direction is shown alongside the supply fre­quency. The small triangle indicates the corresponding direction of rotation.
Input signal Subordinate
control loop
Voltage None
Current U
Interface I
Digital input1 U Burst-firing operation
Digital input2 I Half-wave control
2
2
Operating mode load output
Soft start with phase­angle control
Burst-firing operation
with α start
Input signal in­correctly configured
P General logic
Logic (switch)
Invalid control configured
Logic with α start
Logic with α input
Logic with α start and α input
Firing pulse inhibit

4.1.3 Meaning of the displayed measured values

Measured value Meaning Unit
Master mains voltage
Mains voltage Slave
Effective value of the mains voltage – measured on the master between the L1 and N/L2 terminals
Effective value of the mains voltage – measured on the slave between the L1 and N/L2 terminals
V
V
V3.01/EN/00561073 [thyristor power switch TYA 202] 45
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4 Operation
Master4 load volt­age
Load voltage
4
Slave Master
1, 4
load cur-
Effective value of the supply voltage U12 - measured on the master be­tween the V and U2 terminals
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
rent Load current
1, 4
Slave Master
1, 4
Effective value of the load current l3 measured from the slave
Effective power measured from the master
power Power
1, 4
Slave Three-phase
current Master
1.4
1, 4
load re-
Effective power measured from the slave
Overall effective power (total effective power contributed by master and slave)
Effective resistance measured from the master
sistance Output level
4
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 active control variable U2, U, I2, I, or P
V
V
A
A
W or kW
W or kW
W or kW
Ω
%
%
%
Phase control angle
3, 4
Currently output phase control angle
Mains frequency Currently measured mains frequency Master device tem-
Currently measured temperature inside the master power controller
perature
Slave device tem-
Currently measured temperature inside the slave power controller
perature
Current input
Measured value of the current input – measured on the master power 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 operation
4.
Is not displayed in half-wave control operating mode
°el
Hz
°C or °F
°C or °F
mA
V
46 V3.01/EN/00561073 [thyristor power switch TYA 202]
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4 Operation

4.1.4 Appearance in the configuration level

Scroll bar The entry highlighted in black is selected and contains further parameters.
If there are more than three 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 wish to apply the value, the entry can be canceled by selecting
.

4.1.5 Appearance of error messages and special statuses

Cyclical appearance
The symbols for input, subordinate control loop, and operating mode are dis­played alternately in the info line together with error messages or information about special statuses.
v Chapter 8 "Error messages and alarms"
Examples
V3.01/EN/00561073 [thyristor power switch TYA 202] 47
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4 Operation

4.2 Operating level

All parameters for the maximum device extension level are listed in the fol-
lowing tables. Depending on the order details (see nameplate or device infor­mation) or the current configuration, parameters that are not required are hid­den.
Here you will find the parameters that can be modified during ongoing oper- ation. They can be accessed without a password per default, but can also be pro­tected with a 4-digit code if necessary.
v Chapter 5.1.12 "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 operating 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 wish to apply the value, the entry can be canceled by pressing
.
Value range Description deutsch
english francais
National language4
0...50...100 % 50 % is set per default.
0000 to 1440 min 0000 minutes are set per default,
German (deutsch), English, and French (francais) are perma­nently stored in the device
1 additional national language can be subsequently loaded via Setup.
which means the display is not switched off.
k / bold = default setting
48 V3.01/EN/00561073 [thyristor power switch TYA 202]
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4.2.2 Power controller

Value range Description 0 to 75 to 90° el
4 Operation
75° el is set per default. If "α start" is set to "No" in the configuration, this window is
not displayed and α start is set to 0° el.
10 % to max. load
current for the de­vice type +10 %
Current load current
0 to 999.99 Ω Resistance limitation:
Current resistance
k / bold = default setting

4.2.3 Setpoint value configuration

Current limiting:
It is possible to modify the current limit value in phase-angle operation 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 a positive temperature coefficient. 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 a working 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
Value range Description
0 to U
om.
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
nom.
nom.
nom.
to 1.15 U
to 1.15 P
In the case of continuous thyristor control via the analog in-
n-
put, the maximum actuating variable at the measuring range end (e.g. 20 mA) can be varied during operation. The measurands in the master branch are measured.
nom.
The displayed value depends on the "Subordinate control loop" setting:
2
U
und U: display in V (linked value)
(example: 0... 400...460 V) P: display in kW (three-phase power/2)
(example: 0... 6.90...10.35 kW)
2
I
and I: display in A (example: 0 to 20 A)
None: display in % (example: 0 to 100 %)
V3.01/EN/00561073 [thyristor power switch TYA 202] 49
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4 Operation
Steuersignal
P
Grundlast: 680 W
Maximaler Stellgrad: 3680 W
0 mA
20 mA
3000W 0...20mA
Grundlast
Current load voltage
0... U
nom
of the load voltage, 0 to P of the power
0 to I of the max. load current
nom
nom.
0 to 100 % of the output level
In the case of continuous thyristor control via the analog in­put, the base load at the measuring range start (e.g. 0 mA) can be varied during operation. Note: This setting is only available if Power controller control
rContinuous (power controller) is set.
rThyristor
The unit depends on the setting for subordinate control loop and device type:
- With voltage: 0 to 100 % of max. load voltage (e.g. 0 V) (linked value)
- With current: 0 ... 100% of max. load current (e.g. 0 A)
- With power: 0 to ... 100 % of power (e.g. 0 W) (three-phase power/2)
- None: 0 to 100 % of output level (e.g. 0%) The measurands in the master branch are measured.
v Chapter 1.3 "Order details"
k / bold = default setting
50 V3.01/EN/00561073 [thyristor power switch TYA 202]
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4.2.4 Monitoring

4 Operation
The value to be monitored can be adjusted. v Chapter 5.1.5 "Überwachungen" The load voltage was used in this example.
Value range Your setting: 0 ... 9999.9 The absolute minimum limit values for load voltage, load cur-
rent, power, resistance, mains voltage, or device temperature can be monitored. The measurands in the master branch are measured.
v Chapter 5.1.5 "Monitoring"
Current measured value
Current measured value
Current deviation from Teach-In i.e. if it exceeds 0 % the load has become higher-impedance; if it is below 0 %, the load has become lower­impedance
Example: If the voltage falls below 20 V, an alarm is issued.
0 ... 9999.9 The absolute maximum limit values for load voltage, load cur-
rent, power, resistance, mains voltage, or device temperature can be monitored. The measurands in the master branch are measured.
v Chapter 5.1.5 "Monitoring"
Example: If the voltage exceeds 100 V, an alarm is issued.
0 ...1 ... 9999.9 The switching differential at the minimum or maximum limit
value
0...10...100 %
Partial load failure or partial load short circuit: The monitoring value for the percentage of change to the load
is selected (undercurrent or overcurrent).
v Chapter 5.1.5 "Monitoring"
By displaying the current deviations from the Teach-In value in all three phases, it is possible to check how, for example, the resistance change behaves over the entire setting range. The load monitoring limit value can then be adjusted accordingly. Guide values for the identification of load errors:
v Chapter 6.1 "Erkennung von Lastfehlern"
k / bold = default setting
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4 Operation
This function is not configured per default. This window only appears if the following setting has been selected in the configuration level:
h Press the key to switch to the configuration lev-
el
h Set Monitoring
h Press the key
The "Manual teach-in" function is now configured.
h Change to the operating level
monit.
Te ac h- In 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
the OK state. A change in the load (load error) will be evaluated by the
device on the basis of this state.
k / bold = default setting
rTeach-In type load monit.
rManual
rMonitoring rLoad
52 V3.01/EN/00561073 [thyristor power switch TYA 202]
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5.1 Configuration level

v Chapter 5.1.1 "Device data" v Chapter 5.1.2 "Power controller" v Chapter 5.1.3 "Analog inputs"
etc.
v see Chapter 5.1.9 "RS422/485" v see Chapter 5.1.10 "PROFIBUS-DP" v see Chapter 5.1.11 "EtherCAT"
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 function) as a result. It does not provide any power in this state.
When exiting the configuration level with the key, the power controller continues operation with the modified parameters.
This level can be locked with a password. However, no password is set per default.
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:

5 Configuration

Parameter groups
h In the measured value overview, press the key 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
Language wizard active
National language German
Temperature Unit
Yes A query appears when the device is started, asking which na-
No No query appears
English French Setup Spanish is added to Setup per default.
°C Defines the unit for the displayed temperatures, such as the °F
tional language is to be used to display the subsequent opera­tion.
Spanish can be replaced with other national languages if needs be.
device temperature.
Display contrast Switch-off
display lighting
Apply default set­tings
0...50...100 % Bright/dark contrast setting 0000 to 1440 min The background lighting for the display switches off once the
Apply now? The default settings are restored if the PGM key is pressed.
k / bold = default setting

5.1.2 Power controller

Settings for the switching behavior of the power controller in the plant
Value / settings Description
Thyristor control Continuous (power
controller) Logic (switch) Note:
k / bold = default setting
selected number of minutes has passed. Power LED (green) flashes.
0000 means: lighting is always switched on
The power controller provides the power for the load continu­ously according to the setpoint specification.
Subordinate control loop cannot be modified! The power controller acts like a switch and provides the power by either switching ON or OFF.
54 V3.01/EN/00561073 [thyristor power switch TYA 202]
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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 Thyristor control rContinuous (power 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 process.
The U setting is used when the load voltage should be linear to the setpoint specification. The I setting is used when the load current should be linear to the setpoint specification.
The following subordinate control loops have proven advanta­geous for heating elements that do not have linear temperature behavior or that 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
The load voltage, load current, or power measured by the mas- ter are always applied as the actual value for the subordinate control loop.
Switched off The diagram shows how the phase angle is specified via a stan-
dard signal without a subordinate control loop.
V3.01/EN/00561073 [thyristor power switch TYA 202] 55
k / bold = default setting
Page 56
5 Configuration
u
t
500ms
520
u
t
100ms
14
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 operation. 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)
The cycle time is variable with this setting. At the required out­put level, the device attempts to find the shortest possible cycle time for full sine waves. For an output level of 20 %, this means one sine wave ON and four sine waves OFF.
None 3 full sine waves Dependent on the cycle time setting.
At least three full sine waves are always let through. For example, at an output level of 50 % and the fastest possible
cycle time, three sine waves are switched on and three switched off.
Note:
Particularly suitable for the control of transformer loads
No Note: Yes
This setting is available in continuous burst-firing operation 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.
α start angle 0 to 75 to 90° el Phase control angle for α start Soft start
56 V3.01/EN/00561073 [thyristor power switch TYA 202]
No This setting determines the starting behavior of the power con-
troller after power ON and is deactivated per default
Yes
"Yes" means that a soft start with phase-angle control or burst­firing is performed after power ON.
k / bold = default setting
Page 57
Value / settings Description
u
t
Softstartzeit
u
t
Cycle time
5 Configuration
Soft start type With phase-angle
control
With burst firing This setting is available in burst-firing operation mode with a
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 the device switches to burst-firing operation.
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 once more.
If current limiting is activated during the soft start phase, the soft start duration is extended because the phase control angle cannot be reduced further during current limiting.
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 ... 65535s 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 time is configured as the soft start duration.
Current limiting
No No current limiting Yes Current limiting is implemented via phase-angle control.
In this case, the load current from the master is monitored on the basis of the set current limit value. Only phase control angles that do not cause the current limit value to be exceeded are permitted.
It is also possible to activate an external current limit
k / bold = default setting
value via a digital input.
Chapter 5.1.6 "Digital inputs"
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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. 22 A can be
selected.
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, if the load current is > 5% of the power controller's nominal current. For phase­angle operation, the limitation is implemented through the phase control angle α. For burst-firing operation, the limitation is implemented through the ON/OFF ratio of the sine waves.
v Chapter 6.6 "Widerstandsbegrenzung (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 operation. This setting allows 2 devices
that they do not simultaneously draw power from the mains at small output levels. This prevents current peaks.
1
to be configured in such a way
v Chapter 6.4 "Dual energy management"
The master-slave group type 709062 is regarded as "one" device.
k / bold = default setting
58 V3.01/EN/00561073 [thyristor power switch TYA 202]
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5.1.3 Analog inputs

The power controller has a voltage input and a current input. These inputs (setpoint specification) 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 ... 20 mA This setting specifies which current standard signal is con­4 ... 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 ... 10 V This setting specifies which voltage standard signal is con­2 to 10 V 0 to 5 V 1 ... 5 V Customer-specific
0 to 10 V Note:
0 to 10 V Note:
k / bold = default setting
1.
Inverting analog inputs:
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 replacement value should be applied in the event of a fault.
Value / settings Description
Setpoint specifica­tion
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 speci-
Via interface Means that the setpoint value for the power output is provided
via an interface.
Digital input1 Note:
This setting is only available if Power controller control
Digital input2
In this case, the power controller is controlled in the same way as a solid-state relay (SSR) via digital input 1 or 2: contact: closed r 100 % and open r 0 % (for control direction set per default).
fications"
rThyristor
rLogic (switch) is selected.
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 re­placement value the power controller should use if the set­point specification is incorrect.
Last value The last valid value is used per default. 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
0 to I of the max. load cur­rent 0 to 100 % of the output level
nom.
nom.
nom.
to 1.15 U
to 1.15
Depending on which input is set for the setpoint specification, the second input – which is still free – appears at this point. If an error (e.g. wire break) now occurs at the current input which is set per default for the setpoint specification, the pow­er controller uses the value at the voltage input.
In the case of continuous thyristor control via the analog in-
n-
put, the maximum actuating variable in the master branch at the measuring range end (e.g. 20 mA) can be varied during op­eration.
Note: This setting is only available if Power controller control The unit depends on the setting for subordinate control loop and device type:
- U (example: 0... 400...460 V)
- P: input in W (three-phase power/2) (example: 0... 4600 to 5290 W)
- I None: entry in % (example: 0 to 100 %)
rContinuous (power controller) is selected.
2
and U: input in V (linked value)
2
and I: entry in A (example: 0 to 20 A)
rThyristor
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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
Base load
Base load 0... 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
nom
nom
nom.
Note: This setting is only available if Power controller control
rContinuous (power controller) is selected.
rThyristor
The unit depends on the setting for subordinate control loop and device type:
v Chapter 1.3 "Order details"
- With voltage: 0 to 100 % of max. load voltage (e.g. 0 V) (linked value)
- With current: 0 ... 100% of max. load current (e.g. 0 A)
- With power: 0 to ... 100 % of power (e.g. 0 W) (three-phase power/2)
- None: 0 to 100 % of output level (e.g. 0%) The measurands in the master branch are measured.
k / bold = default setting
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5 Configuration

5.1.5 Monitoring

This allows an internal measurand to be monitored for compliance with limit values. Depending on the switching behavior, an overrange or underrange is output at the digital 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 Mains voltage Device temperature
These measurands can be monitored and are dependent on the ordered device type.
Min. limit value alarm
The limit values are monitored in the master and in the slave and, if the limit value is breached, the corresponding error message is shown in the info line at the bottom of the display (e.g. "Slave2:Limit val. MinVal reached") Note: If Power controller -> Thyristor control -> Logic (switch) and Monitoring -> Limit value monitoring -> Load voltage, load current, power (in W), or power (in kW) is selected, the limit value monitoring only operates in the periods in which the thyristors have been fired. If the thyristors are blocked, as a general rule, the min. and max. alarms are switched off.
0 ... 9999.9 The absolute minimum limit values for load voltage, load cur-
rent, power, resistance, mains voltage, or device temperature can be monitored. If the measurand 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 digital output switches as shown in the diagram. The unit of the limit value corresponds to the measurand to be monitored.
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5 Configuration
Max. limit value alarm
Limit value hystere­sis
>Load monitoring
Limit value load monitoring
0 ... 9999.9 The absolute maximum limit values for load voltage, load cur-
rent, power, resistance, mains voltage, or device temperature can be monitored.
If the measurand 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 digital output switches as shown in the diagram. The unit of the limit value corresponds to the measurand to be monitored.
0 ...1 ... 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 therefore be measured.
2
, or P subordinate control loop and the current can
v Chapter 6.1 "Erkennung von Lastfehlern"
Note: This setting is only available if load monitoring has been set to undercurrent or overcurrent.
0...10 ... 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 trig­gered.
Load type load monitoring
Teach-In type load monitoring
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 operat-
ing level.
v Chapter 6.2.2 "Configuring Teach-In (prerequisite for
Teach-In in manual mode)"
v Chapter 4.2.4 "Monitoring"
Automatic, cyclical Teach-In is performed cyclically at a time interval of 1 minute.
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5 Configuration
>Mains voltage drop monitoring
>Control loop mon­itoring
No No monitoring Yes
No No monitoring Yes
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 semiconductor fuse due to a DC component. If there are no further mains voltage drops, the firing pulse in­hibit is removed and the power controller continues operation (e.g. with a soft start).
Control loop monitoring is used mostly for monitoring SIC heating elements. It uses a binary signal to indicate when the power required by the setpoint specification can no longer be reached with the load present, potentially due to aging of the heating elements. This error is shown in the info line when the actual value of the subordinate control loop is smaller than the required setpoint value for an uninterrupted period of 15 minutes.
v Chapter 8 "Error messages and alarms"
k / bold = default setting
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5.1.6 Digital inputs

There are 2 digital inputs and one additional digital input for firing pulse inhibit available, to which a potential-free contact can be connected. The following functions can be triggered with digital input 1 and 2:
h
Use the key to switch to the configuration level r Digital inputs
Value / settings Description
External toggling of setpoint specifica­tion
Switched off No external toggling of setpoint specification Digital input1 Digital input2 Ext. digital input1 Ext. digital input2
5 Configuration
Toggling is controlled by digital input1 Toggling is controlled by digital input2 Toggling is controlled via an interface Toggling is controlled via an interface
Setpoint specifica­tion when toggling
Value when tog­gling
Ext. current limiting
Voltage input Selects the source that is used to specify the setpoint value Current input
Value, adjustable
0% ...100 % Note:
Switched off No ext. current limiting Digital input1 Digital input2 Ext. digital input1 Ext. digital input2
when external toggling of the setpoint specification is activat­ed.
Note:
The only analog inputs that are available here are those that have not yet been populated by a setpoint specification, for example.
This parameter is available only if "Value, adjustable" is se- lected for setpoint specification when toggling.
This function can only be set if the following presettings have been made: Option 1:
Power controller and Power controller
Option 2: Power controller
Power controller Power controller
If, for example, "Binary input 1" is set here, when the binary in­put is closed, the current limit value set under "Power control­ler
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 digital input1 Ext. current limiting is controlled by digital input2 Ext. current limiting is controlled via an interface Ext. current limiting is controlled via an interface
r Operating mode rPhase angle control r Current limiting rYes
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 digital input is selected 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. 22 A can be selected.
v Chapter 1.3 "Order details"
k / bold = default setting
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5 Configuration
11
10
3,3V
10kW
TYA
8
7
+
U
88
77
Value / settings Description
Key lock Switched off No key lock
Digital input1 Digital input2 Ext. digital input1 Ext. digital input2
Key lock is controlled by digital input1 Key lock is controlled by digital input2 Key lock is controlled via an interface Key lock is controlled via an interface
External switch-off of display lighting
Inhibit input con­trol direction
Control direction, digital input1
Switched off
No external switch-off, i.e. the background lighting
behaves according to the configuration in Chapter 5.1.1 Digital input1 Digital input2 Ext. digital input1 Ext. digital input2
Switch-off is controlled by digital input1
Switch-off is controlled by digital input2
Switch-off is controlled via an interface
Switch-off is controlled via an interface
The firing pulse inhibit can be triggered when the switching
contact is closed or open.
v Chapter 3.3 "Anschlussplan"
Open, load ON Per default: Open, load OFF
Open, inactive The function for digital input1 can be triggered when the Open, active
Inhibit input open, power controller supplies power.
Inhibit input closed, power controller does not supply power.
switching contact is open or closed.
Control direction, digital input2
Open, inactive The function for digital input2 can be triggered when the Open, active
switching contact is open or closed.
k / bold = default setting
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5.1.7 Digital output

70
90
t/ms
min. puls break
u
t/ms
40
10
30 ms
60
80 100 120
pulse length
Optocoupler: I = 2mA
Cmax
U = 32V
CEOmax
5 sine waves
30 ms
20 30
0
50
The digital output consists of a relay or an optocoupler, depending on the or­der code. With the digital output, it is possible to choose between the output mode
lective fault transmitter",
v Chapter 8.1 "Binärsignal für Sammelstörung" The control direction is used to select the switching behavior of the relay and
determine whether, in the event of an error message, it should switch on (error message via N/O contact) or drop out (error message via N/C contact). In the optocoupler, the control direction determines whether the collector-emitter loop should be conductive or high-impedance in the event of an error mes­sage.
The energy meter function can only be activated if extra code 257 optocoupler is integrated into the device.
v Chapter 1.3 "Bestellangaben"
h
Use the key to switch to the configuration level r Digital output
5 Configuration
"col-
"energy meter", and "Interf. signal".
Value / settings Description
Output mode
Collective fault trans­mitter
The digital output switches if a collective fault occurs on the
device. This can be configured as an "N/C contact" or as an
"N/O contact" (see below).
The K1 LEDs on the master, slave1, and slave2 also light up in
the event of a fault. Energy meter The digital output functions as an energy meter and emits
pulses depending on the energy consumed.
If a collective fault signal occurs in energy meter mode, the K1
LED lights up yellow at all points simultaneously.
Pulses per kWh:
1 ... 10000
Specifies how many pulses per kWh are to be emitted. Select
this value so that the maximum power (power controller
nominal power) can also be shown. Pulse length:
30 ... 2000 ms
Specifies how long the high phase of the pulse should be.
(Value is rounded up internally by the device to a multiple of
the half-wave length of the mains voltage)
Min. pulse interval:
30 ... 2000 ms
Specifies the minimum period for which the signal must be at
Low until a new pulse is emitted. (Value is rounded up internal-
ly by the device to a multiple of the half-wave length of the
mains voltage) Interf. signal
The digital output is controlled via an interface
k / bold = default 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
Value / settings Description
Control direction, digital output
Normally Open Con­tact
No error message or energy meter pulse OFF or
signal via interface is logically 0 "Low":
Switching behavior: 14 and 15 pole and N/C contact closed or
13 and 14 optocoupler collector-emitter loop high-impedance
Error message present or energy meter pulse ON or signal via
interface is logically 1 "High":
Switching behavior: 13 and 15 pole and N/O contact closed
or 13 and 15 optocoupler collector-emitter loop low-imped-
ance
Normally Closed Contact
No error message or energy meter pulse OFF or
signal via interface is logically 0 "Low":
Switching behavior: 13 and 15 pole and N/O contact closed or
13 and 15 optocoupler collector-emitter loop low-impedance
Error message present or energy meter pulse ON or
signal via interface is logically 1 "High":
Switching behavior: 14 and 15 pole and N/C contact closed
13 and 15 optocoupler collector-emitter loop high-impedance
k / bold = default setting
or
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5.1.8 analog 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 ... 20 mA 4 to 20 mA 0 ... 10 V 2 to 10 V 0 to 5 V 1 ... 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

Interface parameters for RS422/485 (see interface description B709061.2)
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 Mains voltage Device temperature Setpoint value
0 ... 9999.9 Lower limit for the "Value to be output"
0 ... 9999.9 Upper limit for the "Value to be output"
k / bold = default setting
2
2
The load voltage can vary between 0 and 500 V depending on
the device type.
As the default setting for the signal range is 0 to 9999.9, the
end value must be adjusted to 500.0 to make use of the full
signal range.
These measured values are determined in the master branch.
Exception:
When selecting the power (in W or kW), the three-phase power
is output at the actual value output.
Note:
Load voltage
2
= load voltage squared
Value / settings Description
Baud rate
Data format 8-1-none Data bits-stop bits-parity check
Device address Min. response time 0 ... 500 ms
9600 19200 38400
8-1-odd 8-1-even 8-2-none
1 ...255
k / bold = default setting
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5 Configuration

5.1.10 PROFIBUS-DP

Interface parameters for PROFIBUS-DP (see separate manual)
Value / settings Description
Device address
1 ...125 If "0" is set as the device address, the bus fault error message
is not displayed.
Data format
Motorola®, Intel®
k / bold = default setting

5.1.11 EtherCAT

For communication with EtherCAT see documentation 70906108T92Z000K000. For communication with the JUMO mTRON T automation system, see documentation
70500153T90...
Value / settings Description
Fieldbus
Device ID (Alias-Adr.)
ECAT Conf. tested
SB JUMO mTRON T
0 ... 65535 0 ...99
k / bold = default setting

5.1.12 Changing codes

Here, it is possible to assign passwords (4-digit numeric codes) for manual
mode
, operating level, and configuration level to protect them from unautho-
rized access.
To connect TwinCAT or other EtherCAT Master To connect JUMO mTRON T automation system
in case of EtherCAT in case of Systembus JUMO mTRON T
If several TYA-20X devices are located in the JUMO mTRON T system bus or EtherCAT, the user can identify each individual device by entering various alias device addresses.
Value / settings Description Code, manual mode
Code, operating level
Code, config. level
0000 ... 9999
0000 ... 9999 0000 means: no inhibit
0000 ... 9999 0000 means: no inhibit
k / bold = default 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
L
U = phase-neutral voltage
N
U = voltage on thyristor power unit
Thy
P = total controlled power
tot
I = current in phase conductor
L
I = current in thyristor power unit
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 Mains voltage on the power controller 400 V
Load voltage 230 V 9 heating elements each with 1 kW Star connection with isolated star points 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 % Setpoint specification via standard signal of 0 to 20 mA.
These requirements are sufficient for the following power controllers:
Device type 709062/X-01-020-100-400-00/252
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5 Configuration
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6 Special device functions

6.1 Detection of load faults

The load monitoring function detects the percentage change of the load resis­tance. The function can also 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 failure.
Overcurrent This function is used for several heating elements connected in series that are
to be monitored for short circuits.
Function This function not only takes the decreasing or increasing load current into con-
sideration but also includes the load voltage in the monitoring process. The plant's correct load ratios are saved during Teach-In.
Based on this state, the load changes are continuously monitored irrespective of the required output level. In the event of a failure 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 as a % in the configuration or operating level for
load monitoring. 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 Operating 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 sepa-
rate star points without neu-
tral 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 resistance changes
Number of heating elements
Star connection without neutral conductor
Delta connection
6 ­5 10 % 4 10 % 10 % 3 14 % 13 %
-
-
2 25 % 26 %
Example for 2 heating elements
The specifications in % refer to load resistance changes
As a general rule, load monitoring does not yet take place during the soft start phase (which can last for an extended period due to active current limiting) as the standard working 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 state) 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 can be performed in the operating level or in manual mode.
v Chapter 4.2.4 "Monitoring" v Chapter 6.2.2 "Configuring Teach-In (prerequisite for Teach-In in manual
mode)"
In this variant of Teach-In, the Teach-In values are then permanently saved. Teach-In does not need to be performed again when the power controller is switched off and on again. 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 default setting is ap­plied. Teach-In is not affected when other parameters are reconfigured.
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 nominal value.
Teach-In "Automatically once"
"Automatically once" means that the Teach-In values are temporarily saved af­ter each power ON. This setting is suitable only for heating elements with a temperature coefficient TC » 1. When the power controller is disconnected from the mains voltage, the Teach­In values are deleted again. After another power ON, load monitoring therefore remains inactive until a new Teach-In process is performed. To ensure that the load ratios for later operation are recorded precisely, the Teach-In is only per­formed in phase angle control with at least 30 % of the output level. (In burst­firing operation mode, this restriction is not needed because a sufficiently high current always flows when the thyristor is fired. In this case, Teach-In is always performed shortly after a power ON or – if configured – after the completion of the soft start.)
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6 Special device functions
Load voltage
Load current
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 mains voltage, the most recently detected 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 Setpoint specification in manual mode

Starting Manual mode, as set per default, 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 Teach-In (prerequisite for Teach-In in manual mode)

The Teach-In function records the current/voltage ratio of a load in the OK state. This function is not configured per default.
v Configuration level See "Teach-In type load monitoring" on page 63.
Configuring "manual" Teach-In
The power controller is in the "Measured value overview" level
h Press the key h Config. level
rent
r Teach-In type load monit. r Set to "manual"
r Monitoring r Load monitoring r Undercurrent or overcur-
h Press the key
I
h Press the key twice
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If 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 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 state.
A change in the load (load error) will be evaluated by the device on the basis of this state.
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 state.
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6 Special device functions
A
S
E

6.3 Setpoint specification 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 Setpoint specification 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 plant, they must be divided into groups of two. The "Dual energy management" parameter (Device1 and Device2) is 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 operation 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
Fuse for control
electronics 2A
Semiconductor-
fuse
Semiconductor-
fuse
Ohmic load star connection
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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 s0ms
I
1 Device1
t
I
1
Sum of all
currentsMains
I
21Device
I
31
Device
I
1 Device2I2 Device2
I
3 Device2
I2I
3
The two power controllers switch on at different times. Starting from the dashed lines, the dispersion of energy 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 %, two device currents in a single phase are prevented from overlapping. The next current level in the network is not started until the total output level exceeds 100 %.
If one 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 loop

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 process.

6.5.1 Closed control loop without subordinate control

Example Furnace/kiln control system
The electrical voltage supply is connected to the power controller. The control­ler derives the output level y
from the difference between the set value (w) for
R
the furnace temperature and the actual value (x) which is acquired by a sensor inside the furnace. The controller output level can range from 0 to100 % and is output at the output of the controller as a standard signal, for example, 0 to10 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 thyristor 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 %. 100 %
-If the thyristor power controller is in burst-firing operation mode, it in­creases the duty cycle T from 0 to100 %, corresponding to a controller out­put level of 0 to 100 %
If the mains voltage drops from AC 230 V to AC 207 V (-10 %) at controller output level YR, the power fed to the furnace is reduced by 19 %.
(2)
P230
: Power in the load resistance at a mains voltage U of 230 V
V
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
Last
U
Last
2
R
-------------
=
(3)
P
Last
U
Last
2
(4)
U
Last
2
Eingangssignal des Leistungsstellers
(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 mains voltage fluctuations, a subordi­nate control loop is built into the power controllers. The subordinate control
loop immediately counterbalances any fluctuations in the amount of supplied power. This means that the power controller always provides a power level at the output (y) that is proportional to its input signal (y subordinate control loop is shown in Figure .
). The principle of an
R
) 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 Pl
by the voltage on the load, U
Equation 3 shows that, for a constant load resistance, the power in this resis­tance is proportional to V
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. 20 mA).
2
, I2, and P control loops. V2 control is used in
in a resistive load, we know that it is determined
oad
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
Last
Eingangssignal des Leistungsstellers (0 ... 20 mA)
U
Last
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 loop (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, current limiting is no longer
2
effective, and the power unit operates with the underlying V
control, i.e. if the resistance continues to increase, the power fed to the heater elements falls, since the voltage is held constant: P
= automatically becomes smaller.
load
This effect supports the complete control loop. As the furnace temperature ris-
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6 Special device functions
es towards the setpoint value, the power fed to the furnace is reduced (at the same load voltage level). This means that the power controller alone is able to slow the approach to the setpoint value. 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 thyristor power controller (e.g. current limiting). The resistance characteristic for a heater 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 heater elements with a negative
TC, where the electrical resistance becomes smaller as the temperature in­creases (Figure 3).
This behavior is exhibited by non-metallic materials such as graphite or molten glass. 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 U · I, the
power. In this case, there is a precise linear relationship between the output power and the level of the signal input (e.g. 0 to 20 mA) to the thyristor power controller.
A typical application of this type of subordinate control loop is for regulating heater elements which are subject to long-term drift combined with a tem­perature-dependent 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
Alt
4
---------
P
Neu
U
NeuINeu
U
Alt
2
---------
2I
Alt
U
AltIAlt
P
Alt
====
(12)
This doubles the current for the thyristor power controller.
Which operating mode is suitable for which load?
Old = old state of the heating element R
New
=
New = new condition of the heating element The relationship is illustrated by the following formula:
P control is also used for free-running economy circuits running off a 3-phase supply network.
Operating mode Resistive load Inductive
load
TC constant TC positive TC nega-
tive
Long­term ag­ing
Burst-firing operation X Burst-firing operation
XX
with α start Burst-firing operation
XXX
with current limiting Subordinate control
loop
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 a 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 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; in other words, subordinate control I,I order code), or P (code 001 in the order code) must be selected in the order details.
Current limiting is implemented via phase-angle control. It therefore only operates permanently in phase-angle operation mode. If burst-firing operation is active, current limiting only operates in the soft start phase if "With phase angle control" is selected as the soft start type.
In a 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 010 in the
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.
Default setting Current limiting is not activated.
v Chapter 5.1.2 "Power controller"
6.8 α start
Default setting The phase-angle control of the first half-wave (α start) is not activated.
For transformer loads, the thyristor power controllers operate in continuous burst-firing mode and in logic operation with phase-angle 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 mains 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 semiconductor fuse due to a DC component.If there are no fur­ther mains voltage drops, the firing pulse inhibit is removed and the power controller continues operation (e.g. with a soft start).
Default setting Monitoring is not activated.
v Chapter 5.1.5 "Überwachungen"

6.10 Firing pulse inhibit

The inhibit function serves to protect the thyristor power controller and the connected devices.
Internal The thyristor output is locked during:
- Device switch-on (during the startup procedure)
- Changes in the configuration level
- Insufficient or excessive voltage supply
- Master/slave data line interruption
- Master/slave synchronization failure
- Setup of data transfer to the device
- Device temperature greater than 115 °C
- Rotary field error
- Short-term supply drops > 10 % within a half-wave v Chapter 5.1.5 "Monitoring"
External Via the "Inhibit" digital input
v Chapter 3.3 "Connection diagram" Alternatively, the thyristor output can also be switched off via the PROFIBUS,
RS422/485 interfaces.
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6 Special device functions

6.11 Thyristor control logic (switch)

Operating mode If the power controller is set to rThyristor control rLogic (switch), the power
controller operates as an electronic switch. For as long as the configured digital or analog input is closed, the thyristors are fired in zero crossing of the mains voltage and are only locked again when the digital or analog input is opened.
Transform er loads
α input The full power is switched by closing the digital 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 mains frequen­cy of 50 Hz
In the case of transformer loads, the first mains voltage half-wave of each pulse group must be cut. This can take place 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 waves ("α input").
The power controller requires an internal processing time and does not switch until the next zero crossing occurs. This results in a delay 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 all data for the device to be configured conve­niently on a PC so that it 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/XP/Vista
- Windows® 7 32-bit
- Windows® 7 64-bit

7 Setup program

Users
Software versions
If several users are managed on one computer, make sure that the user who is logged in is the person who will be working with the program lat­er. The user must have administrator rights for installing the software. After installation, the rights can be restricted again.
Failure to observe this information means that correct and complete installa­tion cannot be guaranteed!
The software versions for the device and the setup program must be compati­ble. An error message will appear if this is not the case!
h After switching on the device, press
The device software version is shown in the Device info menu.
h Click "Info" in the setup program menu bar
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
Appearance on the PC screen
12
34
56
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7 Setup program
Installation steps
Installation complete
Launch setup program
Appearance on the PC screen
78
9
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7 Setup program

7.4 Program start

h Start the setup program using the Windows® Start menu
h Connect the socket of the power controller to a USB socket on the PC us-
ing the supplied USB cable
h Click Connect in the menu bar
Diagnostics The diagnosis window appears at the bottom of the screen and shows the de-
vice info and the current measurement data. The connection has been estab­lished.
The power controller supplies no power while setup data is being transferred "to the device". The device restarts after the transmission.
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7.5 Forgotten the code?

If you have forgotten your password, you can extract the device data or enter a new code word via the setup program.
7 Setup program
Extracting set­up data
Entering new codes
h Perform a Data transfer The extracted 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 default national language is specified in the order details. Only one nation­al language can be transmitted to the device with the setup program.
h Connect the device to the PC using the USB cable h Start the setup program h Perform a Data transfer h Edit h Click Automatic detection and the dialog for the device language will ap-
h Select the desired national language h Continue in the hardware wizard by clicking Continue until it is completed
r Execute hardware and the hardware assistant will start
pear.
The device texts in the selected national language can now be found in the setup file.
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 restarts and texts will appear on the display in the desired na­tional language.
r to the device
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8 Error messages and alarms

Cyclical appearance
The symbols for input, subordinate control loop, and operating mode are dis­played alternately in the info line together with error messages or information about special statuses.
v Chapter 8 "Error messages and alarms"
Examples
Error message Cause Remedy
Master: Limit val.Min­Val reached
Slave: Limit val.Min­Val reached
Master: Limit val. MaxVal reached
Slave: Limit val. Max­Val reached
The value has dropped below the set limit value for the min. alarm
The set limit value for the max. alarm has been exceeded
The following Error Messages are recognized seperately for Master or Slave
check why limit value has dropped below
check why limit value has been ex­ceeded
Master: Fault at con­nected load
Master: Malfunction Blown fuse (red LED fuse is lit)
Master: Malfunction Thyristor failure
Break or short-circuit of a load resistor.
v Chapter 6.1 "Detection of load faults"
1. Semiconductor 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. Thyristor in the master power controller de­fective (only with three-phase economy cir­cuit where nominal voltage < 230 V)
1. Thyristor defective
2. Fuse failure (only in operating states in which it is not possible to clearly distinguish between thyristor failure and fuse failure)
Replace defective heating ele­ments.
v Chapter 8.2 "Replacing a de-
fective semiconductor fuse"
-Check wiring
- Check the wire fuse for the load circuit
Check wiring
The device must be returned to JUMO for repair.
h Return the device Check fuse
If the fuse is not defective, this relates to a thyristor failure:
The device must be returned to JUMO for repair.
h Return the device
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8 Error messages and alarms
Error message Cause Remedy
Master: Thyristor short circuit
Master: Caution! High temperature
Master: Limit. active high temp.
Master: Mains volt. too low
Master: Mains volt. too high
Thyristor defective
Note:
Monitoring only works when the load resis­tance is so low that at least 10 % of the pow­er controller nominal current is flowing.
Device temperature is higher than 100 °C (Excess temperature)
Device temperature is higher than 105 °C Device is too hot, power is reduced! (Limited power due to excess temperature)
Mains voltage is not within specified toler­ance range
v Chapter 10.1 "Voltage supply, Fan
specifications for 250A, load current"
Mains voltage is not within specified toler­ance range
Chapter 10.1 "Voltage supply, Fan speci­fications for 250A, load current"
The device must be returned to JUMO for repair.
h Return the device
- Ensure adequate ventilation
- Reduce load current
- Use power controller with higher maximum load current
- 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 "Bestellanga-
ben"
Check nominal voltage of the de­vice type
v Chapter 1.3 "Bestellanga-
ben"
Master: Tempor. mains drop
Master-slave rotary field error
Master-slave wiring is wrong.
Rotary field detec­tion failed
Wire break Current input
Wire break Voltage input
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
Rotary field detection not possible
Input current for the set measuring range out­side the valid range.
Input current for the set measuring range out­side the valid range.
Ensure stable mains supply.
v Chapter 3.4.1 "Drehstrom
Sparschaltung Master-Slave für ohmsche Lasten in Stern­, Dreieckschaltung oder Tra­folasten (ohmsch-induktiv)"
- Check connection
v Chapter 3.3 "Anschlussplan"
- Eliminate mains disturbanc­es
- Check wiring for wire breaks and reverse polarity.
- Check upstream devices (controllers)
- Check wiring for wire breaks and reverse polarity.
- Check upstream devices (controllers)
Malfunction Bus error
No connection to the Profibus master Check wiring and master device
(PLC).
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8 Error messages and alarms
Error message Cause Remedy
Master-slave Error in comm.
Data cable faulty
Synchronization failed
Teach-In load monitoring!
Slave: Limit val. Min­Val reached
Slave: Limit val. Max­Val reached
Slave: fault at connected load
Slave: Blown fuse (red LED fuse is lit)
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
Reminder that "manual" Teach-In has been configured but not yet executed.
The value has fallen below the selected limit value for the min. alarm at the slave
The selected 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 faults"
1. Semiconductor fuse defective
2. No voltage at terminal U1
Check data connection of the 1:1 patch cable
Check the 1:1 patch cables and re­place if necessary
Check data connection of the 1:1 patch cable or voltage supply
Perform Teach-In
v Chapter 6.1 "Erkennung von
Lastfehlern"
Check why the value has fallen be­low the limit value.
Check why the limit value has been exceeded.
Replace defective heating ele­ments.
v Chapter 8.2 "Replacing a de-
fective semiconductor fuse"
-Check wiring
- Check the wire fuse for the load circuit
Slave: thyristor breakage
Slave: thyristor short circuit
Slave: Caution! High temp.
Slave: limit. active high temp.
Slave: supply volt. too low
1. Thyristor defective
2. Fuse failure (only in operating states in which it is not possible to clearly distinguish between thyristor failure and fuse failure)
Check fuse If the fuse is not defective, this relates to a thyristor failure:
The device must be returned to JUMO for repair.
h Return the device
Thyristor 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
Device temperature is higher than 105 °C Device too hot! Power is reduced. (Limited power due to excess temperature)
- Ensure adequate ventilation
- Reduce load current
- Use power controller with higher maximum load current
Mains voltage is not within specified toler­ance range
v Chapter 10.1 "Voltage supply, Fan
specifications for 250A, load current"
Check nominal voltage of the de­vice type
v Chapter 1.3 "Bestellanga-
ben"
V3.01/EN/00561073 [thyristor power switch TYA 202] 99
Page 100
8 Error messages and alarms
Error message Cause Remedy
Slave: supply volt. too high
Mains voltage is not within specified toler­ance range
v Chapter 10.1 "Voltage supply, Fan
specifications for 250A, load current"
Slave: Temp. mains drop
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.
Soft start phase This display appears until the soft start period
has elapsed.
Current limiting active
Resistance limiting active
The required output level causes an exces­sive load current and is 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 admissible resistance to prevent the heating element from overheating.
Check nominal voltage of the de­vice type
v Chapter 1.3 "Bestellanga-
ben"
Ensure stable mains supply.
v Chapter 3.3 "Anschlussplan"
Open contact between terminal 7 and 8 at screw terminal X_2.
v Interface manual "Ext. inhib-
it"
v Chapter 5.1.2 "Steller"
-> Softstartdauer
v Chapter 5.1.2 "Steller"
-> Strombegrenzung
v Chapter 5.1.2 "Steller"
-> Widerstandsbegrenzung
100 V3.01/EN/00561073 [thyristor power switch TYA 202]
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