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

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

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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.

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

V3.01/EN/00561073 [thyristor power controller TYA 202] 3

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

4 V3.01/EN/00561073 [thyristor power controller TYA 202]

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

V3.01/EN/00561073 [thyristor power controller TYA 202] 5

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

6 V3.01/EN/00561073 [thyristor power controller TYA 202]

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

V3.01/EN/00561073 [thyristor power controller TYA 202] 7

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]

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: [phone]

Fax: [phone]

The power controller produces the power that is needed at the analog input or
in manual mode. Safety systems independent of the power controller must be
installed. 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: [phone]
Fax: [phone]
Email: [e-mail]

Austria:

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

Switzerland:

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

V3.01/EN/00561073 [thyristor power controller TYA 202] 9

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]

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

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]

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

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]

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

1 Introduction

16 V3.01/EN/00561073 [thyristor power controller TYA 202]

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

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]

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

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]

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

V3.01/EN/00561073 [thyristor power switch TYA 202] 21

2 Mounting

TYA202
150/200A

TYA202
150/200A

22 V3.01/EN/00561073 [thyristor power switch TYA 202]

2 Mounting

TYA202 250ATYA202 250A

V3.01/EN/00561073 [thyristor power switch TYA 202] 23

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]

2.2 Dimensions

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

2 Mounting

V3.01/EN/00561073 [thyristor power switch TYA 202] 25

2 Mounting

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

26 V3.01/EN/00561073 [thyristor power switch TYA 202]

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

2 Mounting

V3.01/EN/00561073 [thyristor power switch TYA 202] 27

2 Mounting

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

28 V3.01/EN/00561073 [thyristor power switch TYA 202]

2.2.5 Type 709062/X-0X-150-XXX-XXX-XX-25X Type 709062/X-0X-200-XXX-XXX-XX-25X

2 Mounting

V3.01/EN/00561073 [thyristor power switch TYA 202] 29

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]

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

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]

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

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]

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

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]

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

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]

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

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

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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]

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

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]

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

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]

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

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]

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

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]

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

4 Operation

Steuersignal

P

Grundlast: 680 W

Maximaler
Stellgrad: 3680 W

0 mA

20 mA

3000W 0...20mA

Ⳏ

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]

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

V3.01/EN/00561073 [thyristor power switch TYA 202] 51

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]

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.

V3.01/EN/00561073 [thyristor power switch TYA 202] 53

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]

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

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

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"

V3.01/EN/00561073 [thyristor power switch TYA 202] 57

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]

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)!

V3.01/EN/00561073 [thyristor power switch TYA 202] 59

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

60 V3.01/EN/00561073 [thyristor power switch TYA 202]

5 Configuration

Control signal

P

Base load: 680 W

Maximum
Output level: 3680 W

0 mA

20 mA

3000W 0...20mA

Ⳏ

Base load

Base load 0... 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

V3.01/EN/00561073 [thyristor power switch TYA 202] 61

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.

62 V3.01/EN/00561073 [thyristor power switch TYA 202]

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.

V3.01/EN/00561073 [thyristor power switch TYA 202] 63

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

64 V3.01/EN/00561073 [thyristor power switch TYA 202]

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

V3.01/EN/00561073 [thyristor power switch TYA 202] 65

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

66 V3.01/EN/00561073 [thyristor power switch TYA 202]

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

V3.01/EN/00561073 [thyristor power switch TYA 202] 67

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

68 V3.01/EN/00561073 [thyristor power switch TYA 202]

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

V3.01/EN/00561073 [thyristor power switch TYA 202] 69

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

70 V3.01/EN/00561073 [thyristor power switch TYA 202]

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

V3.01/EN/00561073 [thyristor power switch TYA 202] 71

5 Configuration

72 V3.01/EN/00561073 [thyristor power switch TYA 202]

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.

V3.01/EN/00561073 [thyristor power switch TYA 202] 73

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.

74 V3.01/EN/00561073 [thyristor power switch TYA 202]

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.)

V3.01/EN/00561073 [thyristor power switch TYA 202] 75

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

76 V3.01/EN/00561073 [thyristor power switch TYA 202]

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.

V3.01/EN/00561073 [thyristor power switch TYA 202] 77

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.

78 V3.01/EN/00561073 [thyristor power switch TYA 202]

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

V3.01/EN/00561073 [thyristor power switch TYA 202] 79

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!

80 V3.01/EN/00561073 [thyristor power switch TYA 202]

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.

V3.01/EN/00561073 [thyristor power switch TYA 202] 81

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-

82 V3.01/EN/00561073 [thyristor power switch TYA 202]

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-

V3.01/EN/00561073 [thyristor power switch TYA 202] 83

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.

84 V3.01/EN/00561073 [thyristor power switch TYA 202]

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.

V3.01/EN/00561073 [thyristor power switch TYA 202] 85

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

86 V3.01/EN/00561073 [thyristor power switch TYA 202]

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.

V3.01/EN/00561073 [thyristor power switch TYA 202] 87

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.

88 V3.01/EN/00561073 [thyristor power switch TYA 202]

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.

V3.01/EN/00561073 [thyristor power switch TYA 202] 89

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

90 V3.01/EN/00561073 [thyristor power switch TYA 202]

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

V3.01/EN/00561073 [thyristor power switch TYA 202] 91

7 Setup program

7.3 Installation

h Install the setup program

Installation
steps

Enter
license number

Appearance on the PC screen

12

34

56

92 V3.01/EN/00561073 [thyristor power switch TYA 202]

7 Setup program

Installation
steps

Installation
complete

Launch
setup program

Appearance on the PC screen

78

9

V3.01/EN/00561073 [thyristor power switch TYA 202] 93

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.

94 V3.01/EN/00561073 [thyristor power switch TYA 202]

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

V3.01/EN/00561073 [thyristor power switch TYA 202] 95

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

96 V3.01/EN/00561073 [thyristor power switch TYA 202]

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

V3.01/EN/00561073 [thyristor power switch TYA 202] 97

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).

98 V3.01/EN/00561073 [thyristor power switch TYA 202]

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

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]