JUMO TYA 202
SCR Power Controller
in a three-phase economy circuit
709062/8-01-50
709062/8-01-32
709062/8-01-100
709062/8-01-150
709062/8-01-200
709062/8-01-250
709062/8-01-020
B 709062.0
Operating Manual
2011-07-02/00561073
All parameter settings are described in detail in the chapter "Configuration".
This operating overview shows all possible parameters of the device series.
Depending on the order specifications or current configuration, any parameters that are not required are hidden.
Content
1 Introduction..................................................................................7
1.1 Preface ........................................................................................................ 7
1.2 Typographical conventions ....................................................................... 8
1.2.1 Warning signs ...................................................................................................... 8
1.2.2 Note signs ............................................................................................................ 9
1.2.3 Perform an action ................................................................................................ 9
1.2.4 Representation .................................................................................................... 9
1.3 Order specifications ................................................................................ 10
1.3.1 Scope of delivery ............................................................................................... 10
1.3.2 Accessories ........................................................................................................ 11
1.3.3 General accessories .......................................................................................... 11
1.4 Brief description ....................................................................................... 12
1.5 Standards, approvals and conformity .................................................... 13
2 Installation..................................................................................15
2.1 Important installation notes .................................................................... 15
2.1.1 Ambient conditions ........................................................................................... 16
2.1.2 Filtering and interference suppression ............................................................ 16
2.1.3 Permissible load current depending on the ambient temperature ............... 17
2.1.4 Wall mounting with screws (ex factory) ........................................................... 18
2.1.5 Fixing onto DIN rail (accessories) .................................................................... 21
2.2 Dimensions ............................................................................................... 22
2.2.1 Type 709062/8-0X-020-XXX-XXX-XX-25X ........................................................ 22
2.2.2 Type 709062/8-0X-032-XXX-XXX-XX-25X ....................................................... 23
2.2.3 Type 709062/8-0X-050-XXX-XXX-XX-25X ........................................................ 24
2.2.4 Type 709062/8-0X-100-XXX-XXX-XX-25X ........................................................ 25
2.2.5 Type 709062/8-0X-150-XXX-XXX-XX-25X
Type 709062/8-0X-200-XXX-XXX-XX-25X ........................................................ 26
2.2.6 Type 709062/8-0X-250-XXX-XXX-XX-25X ....................................................... 27
2.2.7 Clearances (all types) ........................................................................................ 27
3 Electrical Connection................................................................29
3.1 Plug-in screw terminals ........................................................................... 29
3.1.1 Type 709062/8-0X-20-XXX-XXX-XX-25X .......................................................... 29
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Content
3.2 Cable lugs and plug-in screw terminals ................................................ 30
3.2.1 Type 709062/8-0X-032-XXX-XXX-XX-25X ........................................................ 30
3.2.2 Type 709062/8-0X-050-XXX-XXX-XX-25X ........................................................ 31
3.2.3 Type 709062/8-0X-100-XXX-XXX-XX-25X ........................................................ 32
3.2.4 Type 709062/8-0X-150-XXX-XXX-XX-25X
Type 709062/8-0X-200-XXX-XXX-XX-25X ........................................................ 33
3.2.5 Type 709062/8-0X-250-XXX-XXX-XX-25X ........................................................ 34
3.3 Connection diagram ................................................................................ 35
3.3.1 Three-phase economy circuit, Master/Slave for resistive loads in star, delta
circuit or transformer loads (resistive-inductive) ........................................... 37
4 Operation....................................................................................39
4.1 Display after switch-on of the device .................................................... 39
4.1.1 Display and control elements ........................................................................... 39
4.1.2 Display of measured values .............................................................................. 40
4.1.3 Display in the configuration level ..................................................................... 41
4.1.4 Display of error messages and particular statuses ....................................... 42
4.2 Operator level ........................................................................................... 43
4.2.1 Device data ........................................................................................................ 43
4.2.2 Power controller ................................................................................................ 43
4.2.3 Set point value configuration ........................................................................... 44
4.2.4 Monitoring .......................................................................................................... 45
5 Configuration .............................................................................47
5.1 Configuration level ................................................................................... 47
5.1.1 Device data ........................................................................................................ 48
Temperature unit.............................................................................................................. 48
Display contrast ............................................................................................................... 48
Switch off......................................................................................................................... 48
Apply factory settings.................................................................................................... 48
5.1.2 Power controller ................................................................................................ 48
SCR control ..................................................................................................................... 48
Cascade control............................................................................................................... 49
Cycle time........................................................................................................................ 50
Min. duty cycle................................................................................................................. 50
a start............................................................................................................................... 50
Angle a start..................................................................................................................... 50
Soft start .......................................................................................................................... 50
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Content
Type of soft start.............................................................................................................. 51
Soft start duration............................................................................................................ 51
Current limiting ................................................................................................................ 51
current limit...................................................................................................................... 51
Resistance limitation........................................................................................................ 52
Resistance limit value ...................................................................................................... 52
Dual energy management................................................................................................ 52
5.1.3 Analog inputs ..................................................................................................... 53
Current measuring range ................................................................................................. 53
Current measuring range, start........................................................................................ 53
Current measuring range, end......................................................................................... 53
Voltage measuring range................................................................................................. 53
Voltage measuring range, start........................................................................................ 53
Voltage measuring range, end......................................................................................... 53
5.1.4 Set point value configuration ........................................................................... 54
Default set point value ..................................................................................................... 54
Default value in the event of a fault.................................................................................. 54
Value in the event of a fault.............................................................................................. 54
Maximum control variable ............................................................................................... 54
Base load......................................................................................................................... 55
5.1.5 Monitoring .......................................................................................................... 56
Limit value monitoring...................................................................................................... 56
Min. limit value alarm ....................................................................................................... 56
Max. limit value alarm ...................................................................................................... 56
Limit value hysteresis....................................................................................................... 56
Load monitoring............................................................................................................... 57
Limit value, load monitoring............................................................................................. 57
Load type, load monitoring.............................................................................................. 57
Teach-in type, load monitoring........................................................................................ 57
Monitoring of the supply voltage drop............................................................................. 57
5.1.6 Binary inputs ...................................................................................................... 58
Ext. current limiting.......................................................................................................... 58
External current, limit value.............................................................................................. 58
Key lock ........................................................................................................................... 58
External display lighting................................................................................................... 58
Control direction, inhibit input ......................................................................................... 58
Control direction, binary input1 ....................................................................................... 59
Control direction, binary input2 ....................................................................................... 59
5.1.7 Binary output ...................................................................................................... 60
Control direction, binary output....................................................................................... 60
5.1.8 Actual value output ............................................................................................ 61
Signal type of actual value output ................................................................................... 61
Value to be output ........................................................................................................... 61
Signal range
start value ........................................................................................................................ 61
Signal range
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Content
end value ......................................................................................................................... 61
5.1.9 RS422/485 .......................................................................................................... 61
Baud rate ......................................................................................................................... 61
Data format ...................................................................................................................... 61
Device address ................................................................................................................ 61
Min. response time .......................................................................................................... 61
5.1.10 PROFIBUS-DP .................................................................................................... 62
Device address ................................................................................................................ 62
Data format ...................................................................................................................... 62
5.1.11 Changing codes ................................................................................................. 62
Code Manual mode ......................................................................................................... 62
Code User level................................................................................................................ 62
Code Config.level ............................................................................................................ 62
5.2 Configuration example ............................................................................ 63
6 Special device functions...........................................................65
6.1 Detection of load faults ........................................................................... 65
6.1.1 Teach-In .............................................................................................................. 67
6.2 Manual mode ............................................................................................ 68
6.2.1 Default set point value in manual mode .......................................................... 68
6.2.2 Configuring the teach-in (prerequisite for teach-in in manual mode) .......... 68
6.2.3 Performing teach-in in manual mode .............................................................. 69
6.3 Default set point value via potentiometer ............................................. 70
6.4 Dual energy management ....................................................................... 70
6.5 Cascade control ....................................................................................... 73
6.5.1 Closed control loop without cascade control ................................................. 73
6.5.2 Closed control loop with a subordinate control ............................................. 74
6.6 Resistance limitation (R control) ............................................................ 79
6.7 Current limiting ........................................................................................ 80
6.8 a start ........................................................................................................ 80
6.9 Monitoring of the supply voltage drop ................................................... 80
6.10 Firing-pulse inhibit ................................................................................... 81
7 Setup program...........................................................................83
7.1 Hardware and software, minimum requirements ................................. 83
7.1.1 Notes for Windows 2000/XP: ............................................................................ 83
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Content
7.2 Installation ................................................................................................ 84
7.3 Program start ........................................................................................... 86
7.4 Forgotten the code? ................................................................................ 87
7.5 Changing the language of the device texts ........................................... 88
8 Fault messages and alarms......................................................89
8.1 Binary signal for collective fault ............................................................. 93
8.2 Replace defective semi-conductor fuse ................................................ 94
8.2.1 Accessories: Semi-conductor fuses ................................................................ 95
8.2.2 Semi-conductor fuses type 709062/8-0X-20... ................................................ 95
8.2.3 Semi-conductor fuses type 709062/8-0X-32... ................................................ 96
9 What to do if ..............................................................................99
10 Technical data..........................................................................101
10.1 Voltage supply, load current ................................................................. 101
10.2 Electrical isolation ................................................................................. 101
10.3 Analog inputs (only master) .................................................................. 102
10.4 Analog output (actual value output, only master) ............................... 102
10.4.1 Display and measuring accuracy ................................................................... 102
10.5 Binary inputs ........................................................................................... 102
10.6 Binary output (fault signal output, only master) .................................. 102
10.7 General characteristic data .................................................................. 103
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Content
6 2011-07-01/00561073 [Thyristor Leistungssteller TYA202]
1.1 Preface
1 Introduction
Please read this operating manual before starting up the device.
B
This operating manual is valid from device software version [256.01.02].
Keep the operating manual in a place accessible to all users at all times.
We welcome any suggestions you may have to help us improve this operating
manual.
Phone +49 661 6003-727
Fax +49 661 6003-508
The power controller produces the power required at the analog input or in
manual mode. Safety devices operating independently of the power controller
must be fitted to safely switch off the downstream heating process in the event
of temperature overranges.
The power controller may only be operated with original JUMO semiconductor fuses.
Please check that the correct spare part has been used during fuse
replacement.
All necessary settings are described in this Operating Manual.
If the power controller is handled in any way that is not described in the
Operating Manual or that is expressly forbidden, this will jeopardize your
warranty rights.
Please contact the nearest subsidiary or the head office should you encounter
any problems.
Service hotline For technical questions
Phone support in Germany:
Phone: +49 661 6003-300 or -653 or -899
Fax: +49 661 6003-881729
Email: service@jumo.net
Austria:
Phone: +43 1 610610
Fax: +43 16106140
Email: info@jumo.at
Switzerland:
Phone: +41 1,928 24 44
Fax: +41 1 928 24 48
Email: info@jumo.ch
2011-07-01/00561073 [SCR Power Controller TYA202] 7
1 Introduction
E
V
E
When accessing the inner parts of the device and returning device modules,
assemblies or components, please observe the regulations as per EN 613405-1 and EN 61340-5-2 "Protection of electronic devices from electrostatic
phenomena". Only use ESD packaging for transport.
Please note that we cannot accept any liability for damage caused by ESD
(electrostatic discharge).
ESD=Electro Static Discharge
1.2 Typographical conventions
1.2.1 Warning signs
Caution
This symbol is used if there is a risk of injury to persons if the
instructions are ignored or not followed correctly.
Caution
ESD
Dangerous
voltage
Hot
surface,
fire hazard/
danger of burns
This symbol is used if there is a risk of damage to equipment or
data if the instructions are ignored or not followed correctly.
This symbol is used where special care is required when handling
components susceptible to damage through electrostatic
discharge.
This symbol indicates dangerous voltage that will cause electric
shock if you come into contact with live components.
This symbol indicates the presence of a hot surface that can cause
burns if touched.
Do not install any heat sensitive components and devices close to
the power controller.
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1.2.2 Note signs
v
B
Note
Reference
Footnote
abc
1 Introduction
This symbol indicates particularly important information.
This symbol refers to further information in other manuals,
chapters or sections.
1
Footnotes are remarks referring to specific points in the text.
Footnotes consist of two parts:
A marker in the text and the footnote text itself.
The markers in the text consist of consecutive superscript
numbers.
1.2.3 Perform an action
Action to be
performed
Vital text
Chain of
command
h Insert
plug
Configuration level ➔ Power
controller
1.2.4 Representation
This symbol indicates the description of an action to be
performed. The individual steps are marked by an asterisk.
This text contains important information, and it is vital that you
read it before proceeding.
Small arrows between words are intended
➔ Operating mode
to facilitate faster location of parameters in
the configuration level.
Keys
Keys are shown as symbols or text.
Key combinations are shown with a plus sign.
2011-07-01/00561073 [SCR Power Controller TYA202] 9
1 Introduction
1.3 Order specifications
The type plate is affixed to the right-hand side of the case.
1.3.1 Scope of delivery
1 Operating Manual B70.9062.0
1 SCR power controller in the version ordered
1:1 patch cable
10 2011-07-01/00561073 [SCR Power Controller TYA202]
1.3.2 Accessories
1 Introduction
Semiconductor fuses
A semi-conductor fuse is fitted in the power controller to protect the SCR
module. The "LED Fuse" is lit red in the event of a fault.
v Chapter 8.2 „Replace defective semi-conductor fuse“
Part Load current
Super fast semi-conductor fuse 50A IN = 20A 70/00513108
Super fast semi-conductor fuse 80A IN = 32A 70/00068011
Super fast semi-conductor fuse 80A IN = 50A 70/00068011
Super fast semi-conductor fuse 160A IN = 100A 70/00081801
Super fast semi-conductor fuse 350A IN = 150A 70/00083318
Super fast semi-conductor fuse 350A IN = 200A 70/00083318
Super fast semi-conductor fuse 350A IN = 250A 70/00083318
1.3.3 General accessories
Part Sales No.
Setup program 70.9061 TYA 201
(also runs for the TYA 202)
USB cable A-plug B-plug 3m 70/00506252
Mounting set for DIN rail installation:
Type 70.9062/8-01-20... 70/00555172
Types 70.9062/8-01-32 and 70.9062/8-01-50 70/00555527
Sales No.
Inom. = IN
70/00544869
2011-07-01/00561073 [SCR Power Controller TYA202] 11
1 Introduction
1.4 Brief description
Device The JUMO TYA 202 represents a consistent further development of the JUMO
power controller technology and switches resistive-inductive loads via a threephase current economy circuit in the star/delta three-phase mode. The microprocessor controlled power controller displays all parameters in a back-lighted
LCD display and is operated using the 4 keys on the front.
Application SCR power controllers are employed where larger resistive and resistive-in-
ductive loads have to be switched, e.g. in industrial kiln construction and in
plastics processing. The SCR power controller comprises SCRs connected in
anti-parallel, the insulated cooling body and the control electronics.
Installation SCR power controllers units up to a load current of 32A can be either clipped
onto a 35 mm mounting rail or fitted to the wall on a mounting plate. Devices
with a load current exceeding 32A have to be fitted to the wall.
Operating
modes
Cascade
control
Standards The SCR 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 operates in burst-firing mode. In burst-firing mode, the first halfcycle can be optimally cut back by means of an adjustable phase angle for
driving transformer loads.
It is possible to preset a base load, and depending on the device type, to set a
current limit or a resistance limitation for the load.
A soft start can be set to avoid high starting or inrush currents.
2
Available cascade controls are U, U
loop is not affected by fluctuations in the supply voltage during the control
process.
0106 Part 100 (3/83). Grounding is required in conformity with the regulations
of the responsible electric utility company.
- Network load optimization through dual energy management
- Transmission of the setup data is also possible without voltage supply to
the device (supply via USB port)
, I, I2 or P control. Therefore the control
12 2011-07-01/00561073 [SCR Power Controller TYA202]
1.5 Standards, approvals and conformity
Test basis for the device characteristics is the Low Voltage Directive DIN EN
50178.
Test basis for the EMC Directive is DIN EN 61326-1.
Standard
Electrical connection DIN VDE 0100
Protection rating IP 20 panel-
mounting devices
Climatic ambient conditions Class 3K3
Air temperature and rel. humidity DIN EN 60721-3-3
Storage temperature Class 1K5 DIN EN 60721-3-1
Operating conditions
Pollution degree
Overvoltage category
Test voltages
Impulse withstand voltage
AC voltage RMS
DIN EN 60529
DIN EN 50178
DIN EN 50178
1 Introduction
Residual current circuit breaker DIN EN 50178
Electromagnetic compatibility
Emitted interference
Interference resistance
Mechanical tests/inspections:
Vibration test 3M2
Toppling test Class 2M1
Inscriptions/labels, marking DIN EN 50178, DIN EN 61010-1
Approvals Standard
cUL applied for
(not for type: 70.9061/8-0X-20...)
CE conformity Low Voltage Directives 2006/95/EC
Conformity Standard
RoHs 2002 / 95 EC
DIN EN 61326-1
Class A- For industrial applications only
Industrial requirements
IN EN 60068-2-6, DIN EN 60721-3-3
DIN EN 60068-2-31, DIN EN 60721-3-2
508C Power Conversation Equipment
(Category NRNT2)
C22.2 NO. 14-05 Industrial Control Equipment
(Category NRNT8)
Marking Directives 93/68 EEC
EMC Directives 2004/108/EC
2011-07-01/00561073 [SCR Power Controller TYA202] 13
1 Introduction
14 2011-07-01/00561073 [SCR Power Controller TYA202]
2.1 Important installation notes
V
2 Installation
Safety regulations
Fuse protection k Fuse protection in accordance with VDE regulations must be installed for
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/national regulations.
k Only allow qualified electricians to carry out the electrical connection.
k An isolating switch must be connected between the supply and the device
to allow disconnection of the device (all poles) from the voltage supply before the inside of the device is accessed.
k Clearance/safety distances in the device meet the requirements for double
insulation.
When mounting the connecting cable, ensure that the cables are fitted according to regulations and that the safety gaps are maintained.
the wiring of the voltage supply in the power section. The supply protection
can also be achieved by a circuit-breaker in the supply lead. This must be
dimensioned for the power consumption of the power controller.
k A semi-conductor fuse is installed to protect the controller in the event of a
ground fault/short circuit. In the event of a fault/defect, it may only be replaced by an original JUMO semi-conductor fuse.
v Chapter 8.2 „Replace defective semi-conductor fuse“
Wiring Load and control cables should be laid separately if possible. Fuses (e.g. 2A
type Neozed) must also be fitted in the control circuit for lead protection.
PE connection h Provide a direct connection between the PE of the supply network and PE
of the power controller. Connect to the PE terminal.
The cross-section of the PE conductor must be at least as large as the crosssection of the voltage supply conductors to the power section. If the protective earth conductor is not part of the supply cable or its sheathing, the chosen
2
conductor must have a cross-section of at least 2.5 mm
tected) or at least 4mm
v see VDE 0100 Part 540
Check h that the data given on the type plate (rated load voltage, load current) corre-
sponds to the data for the system.
h that the rotary electrical field has clockwise phasing (if the economy circuit
configuration is used).
h that the configuration e.g. of the analog inputs correspond to the wiring.
h Only connect the analog input for default set point values to the master. The
slave receives its information via the patch cable.
2
(if the PE conductor is not mechanically protected).
(if mechanically pro-
Load
connection
h The electronic switching device (2 antiparallel SCRs) are in circuit between
the terminals U1 and U2.
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2 Installation
h Load leads and cables for control inputs should be routed separately as far
as possible.
h Wire up the connections from supply line – SCR power controller – load as
per the wiring diagram, and check them.
Phase position The voltage supply for the control electronics and the load voltage
must have an identical phase position.
Control inputs The terminal strips for the control connections (inputs and outputs) are de-
signed for safety separation from the supply line input (SELV). In order not to
impair this safety separation, all connected circuits must also have safety separation. The auxiliary voltages which are required must be safe extra-low voltages (SELV).
2.1.1 Ambient conditions
Incorrect use The device is not suitable for use in potentially explosive atmospheres.
Vibration, dust
and soiling
Climatic
conditions
Avoid additional heat
sources
Power dissipation
Ensure that the installation site is free from vibrations, aggressive media and
dust so that the ventilation slits do not become clogged.
- Relative humidity: 5...85 % without condensation (3K3 as per EN 60721)
- Ambient temperature range: 0 ... 45 °C (3K3 as per EN 60721-3-3)
- Storage temperature range: -30...70 °C Class 1K5
h Ensure that the ambient temperature at the installation site is not increased
by other heat sources or heat accumulation.
- Do not install the controller too near to the heating process (kiln).
- Avoid exposure of the controller to direct sunlight.
Occurs in the form of dissipated heat at the cooling body of the master and
slave device and has to be dissipated at the place of installation (e.g. in the
switch cabinet) according to the climatic conditions.
2.1.2 Filtering and interference suppression
In order to prevent radio-frequency interference, such as would occur with soft
start in phase-angle mode, electrical apparatus and systems must have interference suppression implemented.
The control electronics of the SCR power controller meets the EMC requirements of EN 61 326.
However, electrical modules such as SCR power controllers do not have any
purpose by themselves. They provide a function as part of a complete system
or installation.
Where applicable, the entire load circuit of the power controller must have
suitable interference suppression filters fitted in addition by the system provider.
There are a number of specialist companies that provide appropriate ranges of
16 2011-07-01/00561073 [SCR Power Controller TYA202]
2 Installation
45 50 60
75
20
200
T/°C
150
Load current/A
Reduction at a temperature of 45°C:
2%/Kelvin
70%
250
100
50
filters to deal with any interference problems. Such filters are usually provided
as complete modules, ready to be wired into the system.
2.1.3 Permissible load current depending on the ambient temperature
Destruction due to overheating:
During prolonged operation with maximum load current, the cooling body and
the area around it will heat up.
For this reason, at ambient temperatures above 45°C it is necessary to reduce
the maximum load current as shown in the diagram to prevent destruction of
the SCR module.
Ensure that the device temperature for master or slave shown on the display
does not exceed 100°C.
At a device temperature >100°C the message "Attention: High temperature"
appears.
At a device temperature >105°C, the load current is reduced in increments for
each degree of temperature increase by 10% of the rated current.
The power controller current is switched off completely at a device temperature >115°C.
v Chapter 8 „Fault messages and alarms“
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2 Installation
TYA202
20A
TYA202 32A
TYA202 50A
2.1.4 Wall mounting with screws (ex factory)
The power controllers with load current 20...100A are fastened to a fire resistant switch cabinet wall with 2 screws. The left-hand hole is better accessible
in the top area.
The power controllers with load current 150 ... 250A are fastened with 4
screws.
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TYA202 100A
2 Installation
TYA202
150/200A
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2 Installation
TYA202 250A
20 2011-07-02/00561073 [SCR Power Controller TYA202]
Hot
surface
2 Installation
The power controller heats up during operation depending on the
load up to a temperature of 105°C.
Ensure that the lamellae of the cooling body are vertically aligned to
allow the heat to be dissipated through natural convection.
Fire hazard:
Do not install any heat sensitive components and devices close to
the power controller.
Integrated ventilator in 250A power controller:
The temperature of the air drawn in through the ventilation grille
must not exceed 35° C. Ensure that the inlet air of the built-in ventilators can be extracted from the bottom and escape at the top
without any obstructions.
2.1.5 Fixing onto DIN rail (accessories)
The power controllers up to 32A can be fastened to a DIN rail using the respective accessories.
v Chapter 1.3.3 „General accessories“
h Hook the spring clip into the DIN rail from above.
h Swivel the power controller down until the lug engages on the DIN rail with
an audible click.
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2 Installation
144
132.2
1.5
25.3
150 8.4
12.2
3.5
155
90
36936
17.4
8.4
2.2 Dimensions
2.2.1 Type 709062/8-0X-020-XXX-XXX-XX-25X
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2.2.2 Type 709062/8-0X-032-XXX-XXX-XX-25X
Subject to technical alterations!
2 Installation
2011-07-01/00561073 [SCR Power Controller TYA202] 23
2 Installation
Subject to technical alterations!
2.2.3 Type 709062/8-0X-050-XXX-XXX-XX-25X
24 2011-07-01/00561073 [SCR Power Controller TYA202]
2.2.4 Type 709062/8-0X-100-XXX-XXX-XX-25X
Subject to technical alterations!
2 Installation
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2 Installation
250
126 120
13.1
1.5
285
18
250
320
112
13
112
30
11.2
Subject to technical alterations!
2.2.5 Type 709062/8-0X-150-XXX-XXX-XX-25X Type 709062/8-0X-200-XXX-XXX-XX-25X
26 2011-07-01/00561073 [SCR Power Controller TYA202]
2.2.6 Type 709062/8-0X-250-XXX-XXX-XX-25X
120126
18
1.5
285
13.1
250
250
350
112
13
112
30
11.2
Subject to technical alterations!
2 Installation
2.2.7 Clearances (all types)
h Allow a clearance of 10 cm from the floor.
h Allow a clearance of 15 cm from the ceiling.
h When fitted next to each other, no spacing between the units is required.
2011-07-01/00561073 [SCR Power Controller TYA202] 27
2 Installation
28 2011-07-01/00561073 [SCR Power Controller TYA202]
3 Electrical Connection
Dangerous voltage
h Disconnect the system from the electrical supply (all poles).
3.1 Plug-in screw terminals
Tools - Slotted screwdrivers, blade width 2, 3 and 5 mm
- Ring or open jaw spanner, width across flats 7, 10, 13 mm
3.1.1 Type 709062/8-0X-20-XXX-XXX-XX-25X
The device with a load current of 20A is connected via plug-in screw terminals.
Only allow qualified electricians to carry out the electrical connection!
Dangerous voltage will cause electric shock if you come into contact
with live components.
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
Ground terminal PE Threaded pin M4 with hexagon
nut,
0.2-1.5mm
0.5-2.5mm
0.5-6 mm
Cable lug with
Hole: 4 mm
2
2
2
0.25 Nm
0.5 Nm
0.6 Nm
3 Nm
width across flats 7mm
2011-07-01/00561073 [SCR Power Controller TYA202] 29
3 Electrical Connection
3.2 Cable lugs and plug-in screw terminals
3.2.1 Type 709062/8-0X-032-XXX-XXX-XX-25X
Devices with load current 32...50A 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...1.5mm
X3 Slotted screws, blade width 3 mm 0.5...2.5mm
U2, U1 M6 recessed head screws 6...25mm
Only use 60°C or 60°C / 75°C copper lines for applications as per UL!
N/L2, V, L1 Slotted screws,
blade width 3 mm
Ground terminal PE Threaded pin M6 with hexagon
nut,
width across flats 10mm
0.5...4mm
(0.5...2.5mm
ferrule)
Cable lug
Hole: 6 mm
2
2
2
2
or
2
with
Maximum
tightening torque
0.25 Nm
0.5 Nm
5 Nm
0.5 Nm
5 Nm
30 2011-07-01/00561073 [SCR Power Controller TYA202]
3.2.2 Type 709062/8-0X-050-XXX-XXX-XX-25X
3 Electrical Connection
2011-07-01/00561073 [SCR Power Controller TYA202] 31
3 Electrical Connection
3.2.3 Type 709062/8-0X-100-XXX-XXX-XX-25X
Devices with load current 75...100A are equipped with plug-in screw terminals
in the control section and cable lugs in the power section.
Terminal Version Conductor cross-
section
2
2
or
2
2
2
with
X2_1 and X2_2 Slotted screws, blade width 2 mm 0.2...1.5mm
X3 Slotted screws, blade width 3 mm 0.5...2.5mm
U2, U1 M6 hexagon screws, width across flats
10 mm
Only use 75°C copper lines for applications as per UL!
N/L2, V, L1 Slotted screws,
blade width 3 mm
Ground terminal PE Threaded pin M6 with hexagon
nut,
width across flats 10mm
16...50mm
0.5...4mm
(0.5...2.5mm
ferrule)
Cable lug
Hole: 6 mm
Maximum
tightening torque
0.25 Nm
0.5 Nm
5 Nm
0.5 Nm
5 Nm
32 2011-07-01/00561073 [SCR Power Controller TYA202]
3.2.4 Type 709062/8-0X-150-XXX-XXX-XX-25X Type 709062/8-0X-200-XXX-XXX-XX-25X
Devices with load current 150A 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...1.5mm
X3 Slotted screws, blade width 3 mm 0.5...2.5mm
U2, U1 M8 hexagon screws, width across flats
13 mm
Only use 75°C copper lines for applications as per UL!
N/L2, V, L1 Slotted screws,
blade width 3 mm
Ground terminal PE Threaded pin M8 with hexagon
nut,
width across flats 13mm
95...150mm
0.5...4mm
(0.5...2.5mm
ferrule)
Cable lug
Hole: 8 mm
2
2
2
2
or
2
Maximum
tightening torque
0.25 Nm
0.5 Nm
12 Nm
0.5 Nm
with
12 Nm
2011-07-01/00561073 [SCR Power Controller TYA202] 33
3 Electrical Connection
3.2.5 Type 709062/8-0X-250-XXX-XXX-XX-25X
Devices with load current 200...250A are equipped with plug-in screw terminals in the control section and cable lugs in the power section.
Terminal Version Conductor cross-
section
2
or
2
2
2
2
with
X2_1 and X2_2 Slotted screws, blade width 2 mm 0.2...1.5mm
X3 Slotted screws, blade width 3 mm 0.5...2.5mm
U2, U1 M8 hexagon screws, width across flats
13 mm
Only use 75°C copper lines for applications as per UL!
N/L2, V, L1 Slotted screws,
blade width 3 mm
Ground terminal PE Threaded pin M8 with hexagon
nut,
width across flats 13mm
95...150mm
0.5...4mm
(0.5...2.5mm
ferrule)
Cable lug
Hole: 8 mm
Maximum
tightening torque
0.25 Nm
0.5 Nm
12 Nm
0.5 Nm
12 Nm
34 2011-07-01/00561073 [SCR Power Controller TYA202]
3 Electrical Connection
V V
PE PE
U2
U1
N/L2
L1
2
1
+
–
I
x
4
3
+
–
U
x
E
S
A
3
4
5
External manual
adjustment with po-
tentiometer
7
8
3,3V
5k
W
9
3,3V
5k
W
11
10
3,3V
5k
W
12
11
+
–
3.3 Connection diagram
Connection for Screw terminals Connection side Device side
Voltage supply for control electronics
(corresponds to the max. load voltage of
the
ordered device type)
Protective earth PE
L1
N/L2
V
Load connection in the
power section U1
U2
Control section
Connection for screw terminal X2_1
Current set point input 1
2
Voltage set point input 3 (GND)
4
Output DC 10V fixed voltage 5
Ground potential 6 (GND)
Connection side Device side
Connection for Screw terminal X2_2
Firing-pulse 8
7 (GND)
Binary input 1 9
11 (GND)
Connection side Device side
Binary input 2 10
11 (GND)
GND 7, 11 Ground potential
Analog output
12
Different internal controller sizes can be
output as a standard signal 0(4)...20mA,
0(2)...10V, 0(1)...5V.
v Chapter 10.4 „Analog output (actual
value output, only master)“
Master/slave
connection
Connection for RJ 45 bush X8
three-phase current economy circuit
Master-slave mode
2011-07-01/00561073 [SCR Power Controller TYA202] 35
1:1 patch cable
3 Electrical Connection
13
14
15
E
S
C
Ö
P
Optocoupler
Relay
16
17
19
18
6
7
8
9
2
3
4
5
1
16
17
19
18
(RS422/485 )Modbus
Profibus DP
Fault signal
output
Connection for screw terminal X3 Connection side Device side
Relay or optocoupler 13 N/O contact or collector
14 N/C contact
15 pole or emitter
Interfaces
Connection Modbus RS422 RS485 Connection PROFIBUS-DP
Plug-in screw
terminals on
the
case
bottom
19 TxD (-) RxD/TxD B(-) SUB-D bush
18 TxD (+) RxD/TxD A(+) 8 B(-)
17 RxD (-) - 6 VCC
9-pin
(on the front)
3 A(+)
16 RxD (+) - 5 GND
Shielding
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3 Electrical Connection
3.3.1 Three-phase economy circuit, Master/Slave for resistive loads in star, delta circuit or transformer loads (resistive-inductive)
Prerequisites The devices have to have the same type code and the same device software
version to allow the Master/Slave operation.
The two devices are connected by a max. 30 cm patch cable.
The figure shows the wiring of a TYA 202 that is available completely installed
and configured at the factory but behaves identically to two individual TYA 201
devices in Master/Slave mode.
Operating
method
In the standard version, the master-slave economy circuit operates with a U
control. The control electronics of the master power controller perform the actual power control function, and drive the slave unit in synchronization. This
makes it possible to drive transformer loads. The combination of the fixed cy-
2
cle time and the U
tion for the individual load resistances, even in the event of a partial load failure.
control makes it possible to achieve good voltage regula-
2
2011-07-01/00561073 [SCR Power Controller TYA202] 37
3 Electrical Connection
38 2011-07-01/00561073 [SCR Power Controller TYA202]
4 Operation
(1)
(2)
(3)
(4)
(5)
(7)
(6)
(7)
Adhere to the
switch-on
The voltage supplies to the control electronics and to the power section must
be switched on simultaneously.
sequence
Under no circumstances may the voltage supply for the control
electronics be switched on before the load voltage! This is especially
important for operating transformer loads and resistive loads with a
large temperature coefficient (TC >> 1)!
4.1 Display after switch-on of the device
Sequence When the voltage supply is switched on, the LED Power is continuously lit
green first and an hour glass appears on the display. Then, the master is synchronised with the slave device and a rotary field detection is carried out. If all
devices are wired correctly, the controller displays the mains voltage.
Malfunction
messages
4.1.1 Display and control elements
Legend Remark Fig.
1
2
3
4
LED Power (green) is continuously lit when the voltage
supply is connected.
It flashes regularly when the display light is switched
off.
v Chapter 9 „What to do if ...“
Display (96 x 64 pixels) with white background lighting.
The info line at the bottom of the display indicates current settings and error messages.
The LED Fuse (red) is lit when the semi-conductor fuse
is blown on the corresponding power controller.
LED K1 (yellow) Malfunction message display
v Chapter 8 „Fault messages and alarms“
5 Keys:
Increasing the value / previous parameter
Reducing the value / next parameter
Cancel / one level back
Programming / one level deeper
6
7
USB setup interface
Configuration is carried out on the LH device and automatically transmitted to the RH device via the patch
cable.
Spring clip to release plastic case
v Chapter 8.2 „Replace defective semi-conduc-
tor fuse“
Use and to view current measured values such as currents, voltage
2011-07-01/00561073 [SCR Power Controller TYA202] 39
4 Operation
Designation
Measured value
Info line or error
actual value, set point value load resistance, device temperature and power.
This information is also shown in the diagnosis window of the setup program.
v Chapter 7 „Setup program“
4.1.2 Display of measured values
Measured value
overview
Meaning of the
symbols in the
info line
In this level, the designation of the measured value is shown in the top line and
the numerical value with the unit in the center.
The info line at the bottom shows the signal flow diagram: Input ->
Processing -> Output in the device at a glance. It is also used to display
temporary statuses (e.g. error messages).
v Chapter 8 „Fault messages and alarms“
Input signal Cascade
control
Voltage None
Current U
Interface I
2
2
Operating mode
load output
Soft start with phase
angle control
Burst-firing mode
Binary input1 U Burst-firing mode with
a start
Binary input2 I Half-wave control
Input signal
incorrectly
configured
40 2011-07-01/00561073 [SCR Power Controller TYA202]
P Logic, general
Logic
(switch)
Invalid
control
configured
Logic with a start
Logic with a default
values
Logic with a start and
a default values
Firing-pulse
inhibit
4 Operation
4.1.3 Display in the configuration level
Scroll bar The menu point marked with a black background is selected and contains
further parameters.
If there are more than 3 menu points in a level, a scroll bar appears showing
the current position in the menu.
Navigation
Numerical entry
or
selection
Once you have found the desired parameter, you can use or to
enter a numerical value or select a parameter.
h Save the setting using .
If you do not want to save the value, the entry can be aborted with .
2011-07-01/00561073 [SCR Power Controller TYA202] 41
4 Operation
4.1.4 Display of error messages and particular statuses
Cyclic
display
Examples
The symbols for input, cascade control and operating mode are displayed
alternately in the info line together with error messages or information about
particular statuses.
v Chapter 8 „Fault messages and alarms“
All parameters for the maximum device extension level are listed in the
following tables. Depending on the order specifications (see type plate or
device information) or current configuration, any parameters that are not
required are masked out.
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4.2 Operator level
This contains the parameters that can be changed during operation without a
restart (reset).
They are factory supplied without a password but can be protected if required
with a 4-digit code.
v Chapter 5.1.11 „Changing codes“
The power controller can be adapted to the system and optimized during
operation.
h From the measured value overview press the key
h Select the operator level and press the key again
4 Operation
Editing a
parameter
4.2.1 Device data
The changes will become effective immediately.
If the correct setting e.g. for the display contrast has been found, it can be
saved by pressing .
If you do not want to save the value, the entry can be aborted with .
Value range Your setting:
0...50...100 %
0000...1440 min
k / Bold = factory setting
4.2.2 Power controller
Value range Your setting:
0...70...90°el
2011-07-01/00561073 [SCR Power Controller TYA202] 43
4 Operation
10% ... max. load
current of the
device type +10%
Current load current
0...999.99
Current resistance
k / Bold = factory setting
4.2.3 Set point value configuration
Value range Your setting:
0 ... 180°el
Current load voltage
and load current
Current load voltage
Current load voltage
0 ...100...115%
- of the maximum
load voltage,
- of the max. load
current
or
- of the power
0 ...100%
- of the maximum
load voltage,
- of the max. load
current
or
- of the power
k / Bold = factory setting
44 2011-07-01/00561073 [SCR Power Controller TYA202]
4.2.4 Monitoring
Current measured
value
4 Operation
The value to be monitored is adjustable.
v Chapter 5.1.5 „Monitoring“
Load voltage is used in this example.
Value range Your setting:
0 ... 9999.9
0 ... 9999.9
Current measured
value
Current deviation
from teach-in
0 ...1 ... 9999.9
10...50%
k / Bold = factory setting
2011-07-01/00561073 [SCR Power Controller TYA202] 45
4 Operation
This function is not factory configured.
This window only appears after the following setting in
the configuration level:
h Use the key to change to the configuration level
h Monitoring
h Press the key
h Change to the operator level
h Press the key
Now a mask appears asking if the status is to be
applied now. If the answer to this is yes,
h Press the key and the current load status will be
Any change in the load (load error) will be evaluated by
the device on the basis of this status.
Overcurrent
k / Bold = factory setting
➔ Teach-in type load monit. ➔ Manual
setting
Now the function "Manual teach-in" has been
configured.
➔ Monitoring
➔ Load monit. teach-in
applied as the OK status.
46 2011-07-01/00561073 [SCR Power Controller TYA202]
5.1 Configuration level
or Profibus DP
v Chapter 5.1.1 „Device data“
v Chapter 5.1.2 „Power controller“
v Chapter 5.1.3 „Analog inputs“
etc.
The configuration level contains the parameters for the configuration of the
power controller.
If parameters of this level are changed during operation, this causes the power
controller to be locked (inhibited). In this state it does not provide any power.
When the configuration level is exited, a restart (reset) is performed and the
power controller will then provide the required power again.
Access to this level can be inhibited with a password.
However, it is factory supplied without a password.
All parameters for the maximum device extension level are listed in the
following tables. Depending on the device version (see rating plate) or
configuration, parameters that are not required are hidden.
The configuration level is accessed from the measured value overview using
the following keys:
h From the measured value overview press the key
5 Configuration
Parameter
groups
h Select Configuration level and press .
The parameters are assigned to the following groups that are explained in
detail in the form of tables in sub-chapters on the following pages.
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5 Configuration
5.1.1 Device data
Basic settings for display and temperature unit
Value/settings Description
Temperature unit
°C Defines the unit for displayed temperatures, such as the
°F
device temperature.
Display contrast
Switch off
display light
Apply factory settings
0...50...100 % Light/dark contrast setting
0000...1440 min The background lighting of the display is switched off after the
Apply now? The factory settings are restored when the PGM key is
k / Bold = factory setting
5.1.2 Power controller
Settings for the area of application of the power controller
Value/settings Description
SCR control Continuous (power
controller)
Logic (switch) The power controller behaves like a switch and regulates the
k/ bold = factory setting
set number of minutes. LED Power (green) flashes.
0000 means: Background lighting is always switched on
pressed.
The power controller regulates the power for the load continuously depending on the default set point value.
power by switching ON or OFF.
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5 Configuration
Value/settings Description
Cascade control U2, U, I2, I , P Note: Cascade control only appears when:
SCR control
Cascade control loops are used to eliminate or compensate
for external interference, such as fluctuations in the supply
voltage and changes in resistance which would have a negative effect on the control loop.
The setting U is used when the load voltage is to be directly
proportional to the default set point value.
The setting I is used when the load current is to be directly linear in relation to the default set point value.
If the temperature behavior of the heating elements is not linear or the heating elements are subject to aging, the following
cascade controls are advantageous:
2
is used for:
U
- positive temperature coefficient, molybdenum disilicide
R » is constant
- if
- brightness control.
➔ Continuous (controller).
2
is used for:
I
- negative temperature coefficient (TC)
P is used for:
- temperature-dependent TC
- free-running economy circuit
- general applications,
- SIC load with automatic aging compensation
switched off The diagram shows how the phase angle is specified via a
standard signal without cascade control.
k/ bold = factory setting
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5 Configuration
u
t
500ms
520
u
t
100ms
14
u
t
u
t
a a
Value/settings Description
Cycle time Fixed (500ms)
(for slow heating elements)
This setting is only available in burst-firing mode.
For a fixed period of 500ms, for example, at an output level of
20% 5 sine waves are switched on and 20 are switched off.
Min. duty cycle
a start
Fastest possible
(for heating elements
that respond quickly)
The cycle time is variable for this setting. The device tries to
find the shortest possible cycle time for whole sine wave cycles. For an output level of 20%, this means one sine wave ON
and four sine waves OFF.
None
3 full sine waves
(for controlling transformer loads)
Dependent upon the setting for cycle time.
At least 3 full sine waves are always let through.
At an output level of 50%, for example, 3 sine waves are
switched on and off at the fastest cycle time possible.
no This setting is only available in burst-firing mode.
yes
If "Yes" is set, the first half-wave of each pulse group is cut
back with the set phase angle a.
Angle a start 0 ...70...90°el Phase angle for a start Soft start
50 2011-07-01/00561073 [SCR Power Controller TYA202]
no This setting determines the starting behavior of the power
controller after power ON. The factory setting is "off".
yes
"yes" means that a soft start with phase angle control or pulse
groups is executed after mains ON.
k/ bold = factory setting
Value/settings Description
u
t
Softstartzeit
u
t
Taktzeit
Type of soft start With phase angle
control
With pulse groups This setting is present in the operating mode "burst-firing
5 Configuration
The phase angle is steadily reduced starting from 180° until
a full wave has passed through.
The soft start has been completed and the power controller
switches to burst-firing mode.
Note: If the output level drops to 0% for longer than 8 seconds, the power controller restarts with a soft start once the
output level increases again.
If the current limitation is activated during the soft start phase,
reaching the full wave depends on the current limitation.
mode with fixed cycle time" as well as "with fastest cycle time
possible".
During the soft start time the ON/OFF ratio is
increased from 0 to max. 100%.
Soft start duration 1 ... 65535s This is the duration of the soft start. Current limiting
no No current limiting
yes Current limiting is realized by means of phase angle control.
During this, the load current is monitored for the set current
limit value.
Only those phase angles are permitted that do not exceed the
current limit value.
It is also possible to activate an external current limit
via a binary input.
Chapter 5.1.6 „Binary inputs“
current limit 10% ... max. load
current +10% of the
device type
Varies according to the type of device.
For 20A power controllers it is possible to set 2 ... 22A.
v Chapter 1.3 „Order specifications“
Note:
Ensure that the value exceeds 10% of the max. controller current, i.e. >2 A for type 70.9062/8-01-020...
k/ bold = factory setting
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5 Configuration
Value/settings Description
Resistance limitation
Resistance limit value
Dual energy management
Note: Resistance limitation is only possible for controllers
with current and voltage measurement in which the cas-
cade control P (code 001 in the
no No resistance limitation
yes The load resistance is monitored to ensure that the set resis-
tance limit is not exceeded.
In phase angle control mode, limitation is made via the phase
angle a.
In burst-firing mode, limitation is made via the ON/OFF ratio of
the sine waves.
order code) is integrated.
v Chapter 6.6 „Resistance limitation (R control)“
0...999.99 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 for the following settings:
Device1
Device2
Cycle time: Fixed (500ms),
v Chapter 5.1.2 „Power controller“ ➔ Cycle time
Operating mode: Burst-firing operation
This allows 2 devices
consume energy from the power supply at the same time for
small output levels.
This avoids current peaks.
1
to be set in such a way that they do not
v Chapter 6.4 „Dual energy management“
1. The Master/Slave connection, type 70.9062, is treated as "one“ device.
k/ bold = factory setting
52 2011-07-01/00561073 [SCR Power Controller TYA202]
5.1.3 Analog inputs
The power controller has a voltage and a current input.
These inputs (default set point value) specify the required output at the load
output.
In most cases this signal is transmitted as a standard signal by an electronic
controller or a PLC and is adjusted with these settings.
Value/settings Description
Current measuring range
0 ... 20mA This setting specifies which standard current signal is to be
4 ... 20mA
Customer specific
5 Configuration
connected.
v Chapter 3.3 „Connection diagram“
Current measuring range, start
Current measuring range, end
Voltage measuring range
Voltage measuring range, start
Voltage measuring range, end
0 ...20mA Note: This parameter only appears when "Customer specific"
is set for the current measuring range (see above).
0 ...20mA Note: This parameter only appears when "Customer specific"
is set for the current measuring range (see above).
0 ... 10V This setting specifies which standard voltage signal is to be
2 ...10V
0 ...5V
1 ... 5V
Customer specific
0 ...10V Note: This parameter only appears when "Customer specific"
0 ...10V Note: This parameter only appears when "Customer specific"
k / Bold = factory setting
1. Analog input inverting:
If, for example, 20mA is set for the start of the current measuring range and 0mA for
the end, the power controller is switched off at 20mA and switched on at 0 mA.
connected.
v Chapter 3.3 „Connection diagram“
1
is set for the voltage measuring range (see above).
is set for the voltage measuring range (see above).
2011-07-01/00561073 [SCR Power Controller TYA202] 53
5 Configuration
5.1.4 Set point value configuration
Here you can determine the analog input that specifies the set point value, how high
the base load should be and which alternative value is to be used in the event of a
fault.
Value/settings Description
Default set point value
Current input This setting specifies which analog input is to supply the set
point value for the power output.
Voltage input
Binary input 1 Note: This setting is only available when the controller ➔ SCR
control
In this case, the power controller is controlled like a solid state
Binary input 2
Via interface This means that the set point value for the power output is
relay (SSR) via binary input 1 or 2.
Contact: closed
(with factory-set control direction).
provided via an interface.
➔ Logic (switch) is set.
➔ 100% and open ➔ 0%
Default value in the event of a fault
Value in the event of a fault
Maximum control variable
Last value The current, voltage and interface inputs are monitored for
faults/errors (line/wire breaks or bus errors). This setting is
used for specifying which alternative value is to be used by the
power controller if the default set point value is faulty.
The factory setting specifies use of the last valid value.
Voltage input or cur-
rent input
Value, adjustable This means that the "Value in the event of a fault" is used.
000.0 This value is used in the event of a fault.
0 ...100...115%
- of the maximum
load voltage,
- of the power
0 ...100%
- of the max. load
current
Depending upon which input is set for the default set point
value, the second (still free) input appears at this point.
If a fault (e.g. line/wire break) occurs at the current input that is
factory set for the default set point value, the power controller
then uses the value at the voltage input.
This setting is only available when the controller ➔ SCR con-
➔ continuous (controller) is set.
trol
The unit depends on the setting for cascade control and de-
vice type:
- for I, I
- for U, U
- for P: 0 ...115% of the power 20A x 264.5V=5290W
2
: 0 ...100 % of the max. load current, e.g.20A)
2
: 0 ... 115% of the max. load voltage e.g. 264.5V
54 2011-07-01/00561073 [SCR Power Controller TYA202]
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 ...100%
- of the maximum
load voltage,
- of the max. load
current
- of the power
k/ bold = factory setting
Unit depending on the setting for cascade control and device
type:
- for voltage: 0 ... 115% of the max. load voltage, e.g. 264.5V
- for current: 0 ...100% of the max. load current, e.g. 20A)
- for power: 0 ...115% of the power 20A x 264.5V=5290W
v Chapter 1.3 „Order specifications“
2011-07-01/00561073 [SCR Power Controller TYA202] 55
5 Configuration
5.1.5 Monitoring
An internal measured value can be monitored to ensure the adherence to limit
values.
Depending on the switching behavior, an overrange or underrange is output at
the binary output (option: relay or optocoupler).
Value/settings Description
Limit value monitoring
Switched off No monitoring
Load voltage
Load current
Power
Resistance
Supply voltage
Device temperature
These measured values can be monitored and are dependent
upon the ordered device type.
Min. limit value alarm
Max. limit value alarm
Limit value hysteresis
0 ... 9999.9 If the measured value goes under the value specified here, a
fault message is displayed at the bottom of the display and
the yellow LED K1 lights up. The binary output switches
according to the set control direction, as described in the
diagram.
The unit of the limit value corresponds to the value to be
monitored.
0 ... 9999.9 If the measured value exceeds the value specified here, a fault
message is displayed at the bottom of the display and the
yellow LED K1 lights up.
The binary output switches according to the set control
direction, as described in the diagram.
The unit of the limit value corresponds to the value to be
monitored.
0 ...1 ... 9999.9 Hysteresis at the top and bottom limit of the monitoring range
56 2011-07-01/00561073 [SCR Power Controller TYA202]
Load monitoring None The load is not monitored.
Undercurrent
Overcurrent
Note: This parameter is only available if the device type is
equipped with a cascade control I, I
ment of the current.
v Chapter 6.1 „Detection of load faults“
Note: This setting is only available if load monitoring for un-
dercurrent or overcurrent has been set.
Limit value, load monitoring
0...10 ... 100% This setting is used to specify the percentage by which the
load current has to have decreased or increased to trigger a
load fault.
5 Configuration
2
or P, permitting measure-
Load type, load monitoring
Teach-in type, load monitoring
Monitoring of the supply voltage drop
Standard Standard setting (suitable for most load types)
Infrared radiators
automatic (once) The teach-in value is automatically determined once after
Specifically 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 operator
level.
v Chapter 6.2.2 „Configuring the teach-in (prerequisite
for teach-in in manual mode)“
v Chapter 4.2.4 „Monitoring“
Automatic (cyclically) Teach-in is cyclically performed at a time interval of 1 minute.
no no monitoring
yes
k/ bold = factory setting
If the effective values of the analyzed half-waves diverge from
each other by more than 10%, an alarm message is displayed
and the binary output for multi-input fault warning is switched
depending on the set control direction.
Immediate firing-pulse inhibit prevents connected transformer
loads from destroying the semi-conductor fuse due to a DC
component.
If there are no more supply voltage drops, the firing-pulse in-
hibit is canceled and the power controller continues operation
e.g. with a soft start.
2011-07-01/00561073 [SCR Power Controller TYA202] 57
5 Configuration
7
8
3,3V
5k
W
5.1.6 Binary inputs
2 binary inputs are provided, and an additional binary input for firing-pulse inhibit to which a potential-free contact can be connected.
The following functions can be triggered with binary input 1 and 2:
Ext. current limiting
External current, limit value
h Use the key to change to the Config level
Value/settings Description
This function can only be set with the following
presettings:
Possibility 1:
Controller
controller
Possibility 2:
Controller
Controller
Controller
If, for example, "Binary input 1“ is set here, the current limit
value set under "Controller
ten when the binary input is closed and the "External current
limit value“ (further down in the table) becomes effective.
switched off No ext. current limiting
Binary input 1
Binary input 2
Ext. binary input1
Ext. binary input2
10% ... max. load
current +10% of the
device type
External current limiting is controlled by binary input1
External current limiting is controlled by binary input2
External current limiting is controlled via an interface
External current limiting is controlled via an interface
This parameter only appears if a binary input is set for external
current limitation.
The max. load current varies according to the device type.
For 20A power controllers it is possible to set 2 ... 22A.
➔ Operating mode ➔ Phase angle control and
➔ Current limitation ➔ Ye s
➔ Operating mode ➔ Pulse groups
➔ Soft start ➔ yes
➔ Current limiting ➔ yes
➔ Current limit value“ is overwrit-
Chapter 1.3 „Order specifications“
➔ Binary inputs
Key lock switched off No key lock
External display lighting
Control direction, inhibit input
Binary input 1
Binary input 2
Ext. binary input1
Ext. binary input2
switched off
Binary input 1
Binary input 2
Ext. binary input1
Ext. binary input2
The key lock is controlled by binary input1
The key lock is controlled by binary input2
The key lock is controlled via an interface
The key lock is controlled via an interface
No external switch-off, i.e. the background lighting
behaves as configured in Chapter 5.1.1
Switch-off is controlled by binary input1
Switch-off is controlled by binary input2
Switch-off is controlled via an interface
Switch-off is controlled via an interface
The firing-pulse inhibit can be triggered when the change-over
contact is closed or open.
v Chapter 3.3 „Connection diagram“
Open, load ON
Open, load OFF
k/ bold = factory setting
58 2011-07-01/00561073 [SCR Power Controller TYA202]
Value/settings Description
5 Configuration
Control direction, binary input1
Control direction, binary input2
Open, inactive The function for binary input 1 can be triggered when the
Open, active
Open, inactive The function for binary input 1 can be triggered when the
Open, active
k/ bold = factory setting
change-over contact is open or closed.
change-over contact is open or closed.
2011-07-01/00561073 [SCR Power Controller TYA202] 59
5 Configuration
13
14
15
E
S
C
Ö
P
Optocoupler
Relay
13
14
15
E
S
Optocoupler
Relay
C
Ö
P
13
14
15
E
S
Optocoupler
Relay
C
Ö
P
13
14
15
E
S
C
Ö
P
Optocoupler
Relay
5.1.7 Binary output
This parameter is used to specify the control direction of the binary output. It is controlled by the multi-input interference signal.
v Chapter 8.1 „Binary signal for collective fault“
Control direction, binary output
h Use the key to change to the Config level
Value/settings Description
N/C contact No fault message pending:
14 and 15 pole and N/C contact closed or
13 and 15 optocoupler, collector-emitter loop high-impedance
Fault message pending:
13 and 15 pole and N/O contact closed or
13 and 15 optocoupler, collector-emitter loop low-impedance
N/O contact No fault message pending:
13 and 15 pole and N/O contact closed or
13 and 15 optocoupler, collector-emitter loop low-impedance
➔ Binary output
Fault message pending:
14 and 15 pole and N/C contact closed or
13 and 15 optocoupler, collector-emitter loop high-impedance
k/ bold = factory setting
60 2011-07-01/00561073 [SCR Power Controller TYA202]
5.1.8 Actual value output
The actual value output is an analog output at which different internal values
can be output as a standard signal.
Value/settings Description
Signal type of actual value output
Switched off No signal output at the actual value output.
0 ... 20mA
4 ...20mA
0 ... 10V
2 ...10V
0 ...5V
1 ... 5V
5 Configuration
The standard signal to be output at the actual value output is
set here.
The "value to be output" is output in the form of a current
signal at the actual value output.
The "value to be output" is output in the form of a voltage
signal at the actual value output.
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 B70.9061.2)
Baud rate
The value to be output at the actual value output is selected
here.
Load voltage Each of these values has to undergo a plausibility check.
Load voltage
Load current
Load current
Power (in W)
Power (in W)
Resistance
Supply voltage
Device temperature
Set point value
0 ... 9999.9 Bottom limit for the "value to be output"
0 ... 9999.9 Top limit for the "value to be output"
k / Bold = factory setting
Value/settings Description
9600
19200
38400
2
2
Example:
Depending on the device type, the load voltage can be
between 0 and 500V.
As the signal range of 0 ... 9999.9 is factory set, the end value
must be adjusted to 500.0 to allow utilization of the full signal
range.
Data format 8-1-none Data bits-stop bits-parity check
8-1-odd
8-1-even
8-2-none
Device address
Min. response time 0 ... 500ms
1 ...255
k / Bold = factory setting
2011-07-01/00561073 [SCR Power Controller TYA202] 61
5 Configuration
5.1.10 PROFIBUS-DP
Interface parameter for PROFIBUS-DB (see separate manual)
Value/settings Description
Device address
1 ...125 If a "0" is set for the device address, the bus fault error
message is not displayed.
Data format
Motorola, Intel
k / Bold = factory setting
5.1.11 Changing codes
It is possible to enter passwords (4-digit numeric codes) for manual mode,
operator level and configuration level to protect them from unauthorized
access.
Value/settings Description
Code Manual mode 0000 ... 9999
Code User level
Code Config.level
0000 ... 9999 0000 means: No inhibit
0000 ... 9999 0000 means: No inhibit
k / Bold = factory setting
0000 means: No inhibit
9999 means: Level is hidden
9999 means: Level is hidden
62 2011-07-01/00561073 [SCR Power Controller TYA202]
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)...20mA
Setpoint lnput:
U = phase-phase voltage
U = phase-neutral voltage
U = voltage on thyristor power unit
L
N
Thy
P = total controlled power
I = current in phase conductor
I = current in thyristor power unit
tot
L
Thy
ohmic load star
connection
U1U2
N/L2L1V
13
14
15
1211
1089
7
6
5
42
3
1
8
1
U1U2
Semiconductor-
fuse
Semiconductor-
fuse
N/L2L1V
13
14
15
1211
1089
7
6
5
42
3
1
8
1
S
Relay
Ö
P
-
+
Patchcable
TYA 202
E
Optocoupler
C
U= U
Thy L
I=
Thy
P
tot
3 · U
N
=
P
tot
3 UL·
I=
ThyIL
I
Thy
L1NL2
L3 PE
U
L
U
N
I
L
Requirements Controller load voltage 400V
Load voltage 230V (star connection)
3 heating elements (3 elements with 1kW each connected in parallel)
Load current: 9000W/(3x230V)= 13A
Temperature coefficient TC = 1
Operating mode: Phase-angle control
5 Configuration
Cascade control: U
2
Base load: 0%; maximum output level 100%
Default set point value via input signal of 0 ... 20mA.
These requirements are sufficient for the following power controllers:
Device type 70.9062/8-01-020-100
-400-252
2011-07-01/00561073 [SCR Power Controller TYA202] 63
5 Configuration
64 2011-07-01/00561073 [SCR Power Controller TYA202]
6 Special device functions
L3L2L1
L3L2L1
L3L2L1
6.1 Detection of load faults
The load monitoring function can detect and signal a load failure, a partial load
failure or a partial load short circuit.
Undercurrent This function is used for one or more heating elements connected in parallel
that are to be monitored for breakage.
Overcurrent This function is used for several heating elements connected in series that are
to be monitored for short circuits.
Function This function does not only take the decreasing or increasing load current into
consideration but also includes the load voltage in the monitoring process.
The correct load ratios of the system are saved during teach-in.
Based on this status, the load changes are continuously monitored irrespective of the required output level. In the event of a breakage or short circuit of a
heating element, the load current increases or decreases. This is detected by
the load monitor and a load fault is signaled.
Limit value A limit value must be entered in the configuration or operator level in % for the
load monitor. This limit value depends upon the number of heating elements
connected in parallel or in series. For heating elements with a temperature coefficient TC 1 the limit value can be taken directly from the following tables:
Undercurrent
Number
of heating
elements
Star connection
with separate
star points without
neutral conductor
Star connection with
common star points
without neutral conductor
Delta connection
5 10% 4 13% 10% 3 17% 13% 10%
2 25% 20% 12%
1 50%
50% 21%
Example:
2 heating
elements
-
The specifications in % refer to load current changes
2011-07-01/00561073 [SCR Power Controller TYA202] 65
6 Special device functions
L3L2L1
L3L2L1
Overcurrent
Number of
heating elements
6 -
Star connection without
neutral conductor
Delta connection
-
Te mpe rat ure
coefficient (TC)
5 10%
-
4 10% 10%
3 14% 13%
2 25% 26%
Example for 2
heating elements
The specifications in % refer to load current changes
For heating elements with large positive or negative temperature coefficients it
is necessary to determine a suitable limit value yourself. It helps to monitor the
value of the current percentage deviation from the teach-in values. This value
is displayed in the operator level in the configuration window for the limit value
(Operator level
➔ Monitoring ➔ Limit value load monit.) in the bottom line:
No load monitoring takes place during the soft start phase (that can take longer
when current limiting is active) as the standard operating range of the load is not
yet reached. Teach-in cannot be performed in this phase either.
66 2011-07-01/00561073 [SCR Power Controller TYA202]
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 last measured values in the OK status, is either executed automatically once after mains ON or repeatedly automatically
(cyclically) after 1 minute has elapsed or manually.
"Manual"
teach-in
For "Manual teach-in", the power controller has to be told once after the operating point has been reached that it is to perform the teach-in.
This is possible in the operator level or in manual mode.
v Chapter 4.2.4 „Monitoring“
v Chapter 6.2.2 „Configuring the teach-in (prerequisite for teach-in in manual
mode)“
For this teach-in variant, the teach-in values are then permanently saved. It is
not necessary to perform the teach-in again when the power controller is
switched off and on again.
The teach-in can be repeated whenever necessary. The old teach-in values are
then overwritten by the new ones.
The teach-in values are only deleted if the parameter "Load monitoring teachin" is explicitly configured to "Manual teach-in" or when the factory setting is
applied. The teach-in is not affected by reconfiguration of other parameters.
If "Manual teach-in" has been configured but no teach-in has been conducted
yet, the message "Teach-in load monitoring!" appears on the display as a reminder. Manual teach-in can only be performed at the device itself, not via the
setup program.
To ensure that the load ratios for later operation are recorded precisely, only
perform the teach-in at a load current of at least 20% of the rated value.
Teach-in "Automatically
(once)"
Teach-in "Automatic (cyclically)"
"Automatically (once)" means that the teach-in values are temporarily saved
after each power ON. They are deleted again when the power controller is disconnected from the supply voltage. When the power is switched on again, the
load monitoring function is inactive until the new teach-in has been performed.
To ensure that the load ratios for later operation are recorded precisely, the
teach-in in phase angle control is not performed until the output level has
reached at least 30%. (This constraint is not necessary for burst-firing mode
as the current of a fired SCR power controller is always high enough. In this
case, the teach-in is always performed shortly after power ON or - if configured - after completion of the soft start.)
Automatically cyclically means that the teach-in values are temporarily saved
again at intervals of 1 minute. This setting is particularly suitable for SIC heating elements as in this case the resistance in the load point changes with time
due to aging.
When the power controller is disconnected from the supply voltage, the teachin values detected last are deleted again. When the power is switched on
again, the power controller starts the automatic teach-in detection again.
2011-07-01/00561073 [SCR Power Controller TYA202] 67
6 Special device functions
Load voltage
Load current
6.2 Manual mode
In this case, the set point value can be manually preset in % without the need
for external wiring via the analog input.
6.2.1 Default set point value in manual mode
Start Manual mode, as set in the factory, can be accessed without entering a code.
h Press the key 1 x (manual mode)
h Press the key again
h Increase or reduce the set point value with or
The changes will immediately become effective at the load output and are indicated on the display.
The set point value for manual mode is not saved in the event of a power failure!
After a power failure, the measured value overview is displayed.
6.2.2 Configuring the teach-in (prerequisite for teach-in in manual mode)
The teach-in function records the current/voltage ratio of a load in the OK status.
This function is not factory configured.
v Configuration level See “Teach-in type, load monitoring” on page 57.
Configure
"manual"
teach-in
The power controller is in the level "Measured value overview".
h Press the key
h Set to Config.level
Overcurrent
➔ Teach-in type load monit. ➔ "manually“
➔ Monitoring ➔ Load monitoring ➔ Undercurrent or
h Press the key
II
h Press the key 2 x
The device performs a reset.
68 2011-07-01/00561073 [SCR Power Controller TYA202]
If the teach-in is being performed for the first time, the message "Teach-in load
monitoring" appears in the bottom line of the display.
6.2.3 Performing teach-in in manual mode
The power controller is in the level "Measured value overview".
h Press the key 2 x to return to manual mode.
If the teach-in is being performed for the first time, the message "Teach-in load
monitoring" appears in the bottom line of the display.
6 Special device functions
Repeat the
teach-in
h Press the key and the following message will appear:
h Press the key and the current load status will be applied as the OK
status.
Any change in the load (load error) will be evaluated by the device on the basis
of this status.
The teach-in can be repeated any number of times in manual mode.
h Press the key and the following message will appear:
h Press the key and the current load status will be applied as the OK
status.
2011-07-01/00561073 [SCR Power Controller TYA202] 69
6 Special device functions
A
S
E
6.3 Default set point value via potentiometer
For this connect a potentiometer to the voltage input.
It is supplied with DC 10V at terminal 5 of the power controller.
h Set Configuration level
0...10V
h Set Configuration level
➔ Voltage input
Now the power controller power is preset via the external potentiometer.
6.4 Dual energy management
Thus, set point values of up to 50% can be preset for 2 Master/Slave controllers without current peaks occurring in the network due to them being
switched on simultaneously.
No current peaks are caused in the network even if the set point values are
asymmetrically distributed, e.g. 30% and 70%.
More than
2 controllers
Prerequisites
If more than 2 power controllers are required in a system, they have to be divided into groups of 2. The setting of the "Dual energy management" parameter (device 1 and 2) is carried out in each group.
- Ensure that the two master/slave devices are wired identically as shown in
the following figure.
- The control electronics and the load circuit must have the same phase.
➔ Analog inputs ➔ Voltage measuring range to
➔ Set point value config. ➔ Default set point value
- Synchronize both master/slave devices of one group by switching them on
simultaneously.
- Burst-firing mode must be configured.
- The cycle time must be set to 500ms (fixed).
- Within one group, one Master/slave device must be configured as Device1
and the other Master/slave device as Device2.
70 2011-07-01/00561073 [SCR Power Controller TYA202]
6 Special device functions
Fuse for control
electronics 2A
Fusing to protect the
power section cabling
U1U2
N/L2L1V
13
14
15
1211
1089
7
6
5
42
3
1
8
1
U1U2
Semiconductor-
fuse
N/L2L1V
13
14
15
1211
1089
7
6
5
42
3
1
8
1
S
Relay
Ö
P
0(4)...20mA
+
ohmic load star
connection
Patchcable
TYA 202
E
Optocoupler
C
I
1 (Device1)
L1NL2
L3 PE
U
L
U
N
U1U2
N/L2L1V
13
14
15
1211
1089
7
6
5
42
3
1
8
1
U1U2
N/L2L1V
13
14
15
1211
1089
7
6
5
42
3
1
8
1
S
Relay
Ö
P
0(4)...20mA
+
Setpoint lnput:
Patchcable
TYA 202
E
Optocoupler
C
Device 1
Device 2
I
2 (Device1)
I
3 (Device1)
I
3 (Device2)
I
2 (Device2)
I
1 (Device2)
I
1
I
2
I
3
Attention:
- make sure that the rotating electric field
is right handed!
- only possible in burst firing mode
- SCR load voltage =U
L
Setpoint lnput:
Semiconductor-
fuse
ohmic load star
connection
Fuse for control
electronics 2A
Semiconductor-
fuse
Semiconductor-
fuse
2011-07-01/00561073 [SCR Power Controller TYA202] 71
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 controllers switch on at an offset time. The energy output is symmetrical on each side of the broken line (see arrows). Overlapping of the two device
currents in one phase is avoided as long as the sum of the output level of the
two devices is lower than 100%. The next current level is only started in the
network if the sum of the output level exceeds 100%.
If a power controller performs a restart when the configuration level
has been exited, it no longer operates in synchronization with the
others.
All master/slave controllers have to be switched on again simultaneously via a common main switch!
72 2011-07-01/00561073 [SCR Power Controller TYA202]
6 Special device functions
Controller
Furnace
Sensor
SCR
power unit
Supply
voltage
y
R
x
y
-
w
P
230V
P–
U0–·1U
2
R
-------------------------------
09U
2
R
-------------------- - 0,81 P
230 V
===
6.5 Cascade control
Cascade control loops are used to eliminate or compensate for external
interference, such as fluctuations in the supply voltage and changes in
resistance which would have a negative effect on the control loop.
6.5.1 Closed control loop without cascade control
Example
Furnace/kiln
control system
The supply voltage is connected to the power controller. The controller derives
the output level y
from the difference between the set value (w) for the
R
furnace temperature and the actual (or process) value (x) which is acquired by
a sensor inside the furnace. The output level can vary over the range 0 ... 100
% and is produced as a standard signal output, e.g.0 ... 10 V. The output level
signal is fed to the power controller.
The task of the power controller is to feed energy to the heating elements in
the furnace, proportional to the controller output level:
- For an SCR power controller using phase-angle control, this means that
it alters the firing angle over the range from 180° to 0°, corresponding to a
controller output level of 0 ... 100 %.
-If the SCR power controller is using the burst-firing mode, it alters the
duty cycle T from 0 ... 100 % to correspond to the controller output level of
0 ... 100 %.
If the supply voltage drops from AC 230V to AC 207V (-10%) at a controller
output level YR, the power fed to the furnace is reduced by 19%.
(2)
P230V : Power in the load resistance at a supply voltage U of 230V
DP: Power reduction resulting from reduced supply voltage
R: Resistance of the load
This 19% reduction in the energy being fed means that
the furnace temperature falls.
Disadvantage: A continuing constant temperature is no longer assured.
2011-07-01/00561073 [SCR Power Controller TYA202] 73
6 Special device functions
Controller
Sensor
Controlled
system
SCR
power controller
Voltage supply
subordinate
control loop
y
R
x
y
w
-
P
Load
U
Load
2
R
---------------- -=
(3)
P
Load
U
Load
2
(4)
U
Load
2
Eingangssignal des Leistungsstellers
(5)
The controller recognizes the deviation through the relatively slow response of
the temperature control loop and increases its output level (yR) until the
furnace reaches the original temperature (250°C) again.
6.5.2 Closed control loop with a subordinate control
To avoid power variations caused by supply voltage fluctuations, a
subordinate control loop is built into the controller system. This makes an
instant correction for variations in the amount of energy provided. The result is
that the power controller always provides a power level (y) at the output that is
proportional to its input signal (yR). The principle of subordinate control loop is
shown in Figure .
A distinction is made between U
2
, I2 and P control loop. U2 control is used in
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
sections.
2
control Considering the power PLoad in a resistive load, we know that it is determined
U
by the voltage on the load, ULoad and the resistance of load, R, as follows:
Equation 3 shows that, for a constant load resistance, the power in this
resistance is proportional to U
A power controller with a U
Load2
.
2
control will regulate in such a manner that the
square of the load voltage is proportional to the signal input (e.g. 0 ... 20mA) to
the controller.
2
or P
Combining equations 5 and 4, we can see that the power in the load
resistance is proportional to the input signal to the power controller.
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6 Special device functions
P
Load
input signal of power controller (0 ... 20 mA)
U
Last
2
R
--------------- -
(6)
Heating elements that have a positive temperature coefficient (TC), i.e. where
the electrical resistance increases with increasing temperature, are
usually driven from a power controller that incorporates a subordinate 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 ... 16). These heating elements are usually run at temperatures
above 1000 °C.
2
Figure 1: Heating element with a positive TC
Power controllers need current limiting for the starting phase. The constant
current and the increasing resistance mean that, initially, the power in the
heating element increases in proportion to R, since the power P = I
2
· R.
When the current falls below the preset limit value, the current limiting is no
longer effective, and the power controller operates with the subordinate U
control, i. e. if the resistance continues to increase, the power fed to the
heating elements falls, since the voltage is held constant:
load
P
= automatically becomes smaller.
This effect supports the entire control loop. As the furnace temperature rises
towards the set value, the power fed to the furnace is reduced (for a given load
voltage), so the power controller itself slows the approach to the set point
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2
6 Special device functions
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 illumination is
proportional to U
- Some resistance materials have a TC that is close to 1. These include
heating elements made from nickel /chrome, constantan etc. This does not
place any special demands on the SCR power controller (e. g. current
limiting). The resistance characteristic for a heating element with a TC » 1 is
shown in Figure 2.
2
.
Figure 2: Heating element with TC » 1
2
control Current control (I2 control) is advantageous for heating elements with a
I
negative TC, where the electrical resistance becomes smaller as the
temperature increases (Figure 3).
This behavior is shown by non-metallic materials such as graphite or glass
melts. Molten glass is not usually heated by heating elements but by letting a
current flow through the melt, so that the electrical energy is converted directly
into heat in the molten material. The current is applied through electrodes.
Figure 3: Heating element with a negative TC
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6 Special device functions
R
Alt
4
----------
P
New
U
NewINew
U
Old
2
-----------
2I
Old
U
OldIOld
P
Old
====
(12)
Looking at the power equation P = I2 · R, we can see that an I2 control has the
2
same regulatory effect on the power as already described for the U
control.
In other words, 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 ... 20mA) to the SCR power
controller.
A typical application of this type of subordinate control is for regulating heating
elements which are subject to long-term aging combined with a temperaturedependent change in resistance, as is the case with silicon carbide elements
(Figure 4).
Figure 4: Resistance changes for silicon carbide
Silicon carbide heating elements have a nominal resistance that can alter by a
factor of 4 over the long term. So when dimensioning a system, it is necessary
to provide power controllers that can produce twice the (nominal) power for
the heating elements.
This results in double the current for the SCR power controller.
Old Ⳏ old condition of the heating element RNew =
New Ⳏ 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.
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6 Special device functions
Which
operating mode
is suitable for
which load?
Operating mode resistive load Inductive
burst-firing mode X
TC constant TC positive TC nega-
tive
load
Longterm aging
Burst-firing mode with
XX
a start
Burst-firing mode with
XXX
current limiting
Cascade control
2
U
2
I
XX X
XX
P XX
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6 Special device functions
6.6 Resistance limitation (R control)
.
This is only possible in power controllers with current and voltage
measurement that are fitted with cascade control P (Code 001 in
the order code) and only functions for load resistors with positive
temperature coefficient.
In three-phase economy circuits, no direct resistance limitation is
possible because the individual resistance value is not recorded.
However, the limiting function itself can be applied.
Function It operates both in burst-firing mode and phase angle control.
If the current measured value for resistance exceeds the resistance limit,
limited by phase angle control or limitation of the switched sine waves.
it is
Limitation of the
power
The resistance limitation parameter can be used to activate a limitation of the
power output depending on the resistance value R when operating molybdenum disilicide heating elements in order to prevent overheating of the heating
element in the upper temperature range. By measuring the resistance of the
heating elements it is possible to assign a precise heating element temperature.
If the load resistance exceeds this value, it is limited by phase angle control or
limitation of the switched sine waves. This protects the heating element from
overheating.
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6 Special device functions
u
t
a a
6.7 Current limiting
Factory setting No current limiting is activated.
v Chapter 5.1.2 „Power controller“
6.8 a start
Factory setting The phase angle of the first half-wave (a start) is not activated.
For transformer loads, the SCR power controllers are operated in burst-firing
mode with phase angle cut-back for the first half-wave.
The factory setting is an angle of 70°el. (electrical). This value can be adjusted
in the configuration level or operator level within the range of 0 ... 90°el.
6.9 Monitoring of the supply voltage drop
If the effective values of the analyzed half-waves diverge from each other by
more than 10%, an alarm message is displayed and the binary output for
multi-input fault warning is switched depending on the set control direction.
Immediate firing-pulse inhibit prevents connected transformer loads from destroying the semi-conductor fuse due to a DC component.
If there are no more supply voltage drops, the firing-pulse inhibit is canceled
and the power controller continues operation e.g. with a soft start.
factory setting No monitoring is activated.
v Chapter 5.1.5 „Monitoring“
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6 Special device functions
6.10 Firing-pulse inhibit
The inhibit function serves for protecting the SCR power controller and the
connected devices.
Internal The SCR output is inhibited for the following:
- Device switch-on (during the starting process)
- Reset or restart due to changes in the configuration level
- Insufficient or excessive supply voltage
- Master/slave data line interrupted
- Master/slave synchronization failed
- Setup data transmission to the device
- Device temperature higher than 115°C
- Rotary field errors
- Short-term drops in supply > 10% within a half-wave
v Chapter 5.1.5 „Monitoring“
External The SCR output can be switched off via the binary input "inhibit"
v Chapter 3.3 „Connection diagram“
or via the PROFIBUS, RS422/485 interfaces.
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6 Special device functions
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7 Setup program
The setup program allows all data for the device to be conveniently set using
the PC and transmitted to the device.
To configure the power controller, simply connect the power controller
to the PC with the USB cable.
As soon as the device is switched on, this configuration data is automatically
applied.
7.1 Hardware and software, minimum requirements
- PC Pentium III or higher
- 128 MB RAM, 16 MB free fixed disk memory
-CD-ROM drive
- Free USB interface, mouse connection
- Microsoft Windows® 2000/XP/Vista
7.1.1 Notes for Windows 2000/XP:
Users If the computer is accessed by more than one user, then the user who is
logged in must be the one who will subsequently be working with the program.
The user must have administrator rights for the installation of the software.
After installation, the rights can be restricted again.
In the event of non-observance of this information, correct and complete
installation cannot be guaranteed.
Software
versions
The software versions of the device and setup program must be compatible,
otherwise an error message will appear.
h After switching on, press on the device.
The device software version is displayed in the device information menu.
h Click "Info" in the menu bar of the setup program.
In the device In the setup program
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7 Setup program
7.2 Installation
h Install the setup program.
h Start the setup program.
h Use the supplied USB cable to connect the socket of the power controller
to a USB socket of the PC.
The connected hardware will be detected.
Installation steps
12 3
45
67
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Installation steps
7 Setup program
Automatic
detection
Complete
language setting
89
10 11
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7 Setup program
7.3 Program start
h Start the setup program via the windows start menu
h Click Connect in the menu bar
Diagnosis The diagnosis window appears at the bottom of the screen with the current
measured data. The connection has thus been established.
There is no power from the power controller during the transmission of setup
data "to the device". The device performs a restart after the transmission.
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7.4 Forgotten the code?
If you have forgotten your password, you can read out the device data via the
setup program or enter a new code.
7 Setup program
Reading out
setup data
Entering new
codes
h Perform a Data transfer
The read out codes are visible in the device data menu.
h Enter a new code
h Perform a Data transfer
After the setup data transfer, the device performs a restart and the codes
are activated.
➔ From the device
➔ To the device
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7 Setup program
7.5 Changing the language of the device texts
The factory set language is specified in the order details. Only one language
can be transmitted to the device with the setup program.
h Connect the device to the PC using the USB cable
h Start the setup program
h Perform a Data transfer
h Edit
h Click Automatic detection and the dialog for the device language will
h Select the desired language
h Continue in the hardware assistant by clicking Continue until it is
➔ Execute hardware and the hardware assistant will start
appear.
completed.
Now the device texts in the selected language have been transferred to the
setup file.
➔ From the device
h Perform a Data transfer
h Save the setup file and wait until the data transmission has been
successfully completed.
Now the device will perform a restart and texts will appear on the display in the
desired language.
➔ To the device
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8 Fault messages and alarms
Cyclical
representation
Examples
Error message Cause Remedy
Limit value monit.
min. value reached
Limit value monit.
max. value reached
Fault at
connected load
The symbols for input, cascade control and operating mode are displayed alternately in the info line together with error messages or information about
particular statuses.
v Chapter 8 „Fault messages and alarms“
The value has gone below the set limit
value for the min. alarm
The set limit value for the max. alarm has
been exceeded
Break or short-circuit of a load resistor.
v Chapter 6.1 „Detection of load faults“
-
-
Replace defective heating elements.
Malfunction
Fuse break
(red LED fuse is lit)
Malfunction
SCR breakage
SCR
short-circuit
Attention!
High temperature
Limitation is active,
high temperature
1. Semi-conductor fuse defective v Chapter 8.2 „Replace defective semi-conductor fuse“
2. No voltage at terminal U1 - Check wiring
- Check the line fuse for the
load circuit
SCR defective The device must be returned to
JUMO for repair.
h Return the device
SCR defective The device must be returned to
JUMO for repair.
Return the device
Device temperature is higher than 100°C - Ensure adequate ventilation
- Reduce load current
- Use SCR power controller
with higher maximum load
current
Device temperature is higher than 105°C
device is too hot, power is reduced!
- Ensure adequate ventilation
- Reduce load current
- Use SCR power controller
with higher maximum load
current
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8 Fault messages and alarms
Error message Cause Remedy
Supply voltage is
too low
Supply voltage is
too high
Temp orary
drop in supply
Master/Slave
rotary field error
Master/Slave
incorrectly wired.
Rotary field detection
failed
Supply voltage is not within specified tolerance range
v Chapter 10.1 „Voltage supply, load
current“
Supply voltage is not within specified tolerance range
Chapter 10.1 „Voltage supply, load current“
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 - Check connection
Check nominal voltage of the
device type
v Chapter 1.3 „Order specifi-
cations“
Check nominal voltage of the
device type
Chapter 1.3 „Order specifications“
Ensure stable mains supply.
v Chapter 3.3.1 „Three-phase
economy circuit, Master/
Slave for resistive loads in
star, delta circuit or transformer loads (resistive-inductive)“
v Chapter 3.3 „Connection di-
agram“
Wire break
current input
Wire break
voltage input
Malfunction
bus error
Master/Slave
Error in comm.
Data cable
faulty
Synchronization
failed
- Eliminate line disturbances
Input current for the set measuring range
outside the valid range.
Input current for the set measuring range
outside the valid range.
No connection to the Profibus master Check wiring and master device
Error in the data transfer between master
and slave
Communication between master and
slave interrupted
Slave device switched off or communication between master and slave interrupted
- Check wiring for wire breaks
and reverse polarity.
- Check upstream devices
(controllers)
- Check wiring for wire breaks
and reverse polarity.
- Check upstream devices
(controllers)
(PLC).
Check data connection of patch
cable
Check the patch cables and, if
necessary, replace
Check data connection of patch
cable or voltage supply
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8 Fault messages and alarms
Error message Cause Remedy
M/S incompatible
#0002...0008
#0002 Different device software versions Update devices to same soft-
#0003 VDN numbers of devices do not match Master/slave operation not pos-
#0006 Different nominal voltages (device types)
#0007 Different nominal currents (device types)
#0008 Set cascade control of the master is not
Teach-in
load monitoring!
- Different software versions for master
and slave
- Different power controller types used
(max. load current, load voltage and
cascade controls (if applicable) do not
match)
of master and slave device.
of master and slave device.
compatible with that of the slave device.
Reminder that "manual" teach-in has
been configured but not yet executed.
Use same power controller
types with same software versions.
ware versions
v Service hotline
sible
Master/slave operation not pos-
sible
v Chapter 1.3 „Order specifi-
cations“
Change cascade controls of
both devices to U or U
Perform teach-in
v Chapter 6.1 „Detection of
load faults“
2
.
Slave: limit value
Min. value reached
Slave: limit value
Max. value reached
Slave: fault at
connected load
Slave:
Fuse breakage
(red LED fuse is lit)
Slave:
SCR breakage
Slave: SCR
short-circuit
The value has gone below the set limit
value for the min. alarm.
The set limit value for the max. alarm. has
been exceeded at the slave.
Break or short-circuit of a load resistor.
v Chapter 6.1 „Detection of load faults“
1. Semi-conductor fuse defective v Chapter 8.2 „Replace defec-
2. No voltage at terminal U1 - Check wiring
SCR defective The device must be returned to
SCR defective The device must be returned to
Check why the value has gone
below the limit value.
Check why the limit value has
been exceeded.
Replace defective heating elements.
tive semi-conductor fuse“
- Check the line fuse for the
load circuit
JUMO for repair.
h Return the device
JUMO for repair.
h Return the device
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8 Fault messages and alarms
Error message Cause Remedy
Slave: Attention!
high temp.
Slave: Limit.
active, high temp.
Slave: Supply volt.
too low
Slave: Supply volt.
too high
Slave: temporary
drop in supply
Device temperature is higher than 100°C - Ensure adequate ventilation
- Reduce load current
- Use SCR power controller
with higher maximum load
current
Device temperature is higher than 105°C
Device too hot!
Power is reduced.
Supply voltage is not within specified tolerance range
v Chapter 10.1 „Voltage supply, load
current“
Supply voltage is not within specified tolerance range
v Chapter 10.1 „Voltage supply, load
current“
Temporary equal proportion for transformer loads has been detected.
- Ensure adequate ventilation
- Reduce load current
- Use SCR power controller
with higher maximum load
current
Check nominal voltage of the
device type
v Chapter 1.3 „Order specifi-
cations“
Check nominal voltage of the
device type
v Chapter 1.3 „Order specifi-
cations“
Ensure stable mains supply.
v Chapter 5.1.5 „Monitoring“
Inhibit by
Inhibit input
Inhibit by
ext. inhibit
Soft start phase This display appears until the soft start
Current limitation
active
Resistance
limitation active
A firing-pulse inhibit has been triggered
via a potential-free contact.
No power from the power controller.
The firing-pulse inhibit has been triggered
via an interface.
has been completed.
The required output level causes an excessive load current and is therefore limited to the set value.
The desired output level leads to current/
voltage values that exceed the set load
resistance. The output level is limited to
the permissible resistance to prevent
overheating.
v Chapter 3.3 „Connection di-
agram“
Open the contact between terminal 7 and 8 on screw terminal
X_2.
v Interface manual "Ext. inhib-
it"
v Chapter 5.1.2 „Power con-
troller“
-> Soft start duration
v Chapter 5.1.2 „Power con-
troller“
-> Current limiting
v Chapter 5.1.2 „Power con-
troller“
->
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8 Fault messages and alarms
8.1 Binary signal for collective fault
This signal is used for controlling the binary output and LED K1, and can also
be read out from the power controller via the interfaces.
Using the setup program it is possible to configure which events (alarm and error messages) are to be grouped together as a binary signal for a collective
fault.
All error message are OR-linked and output as a binary signal for collective
fault on the relay output or optocoupler.
In addition, LED K1 lights up yellow.
This alarm can switch a relay at the binary output.
v Chapter 5.1.8 „Actual value output“
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8 Fault messages and alarms
A
B
8.2 Replace defective semi-conductor fuse
Opening the
case
Caution! Risk of burns!
The device can heat up during operation at the cooling body.
The current device temperature is shown on the display.
v Operating overview (on the first cover page)
h Disconnect the built-in device from the voltage supply (all poles)
v Chapter 3.3 „Connection diagram“
h Check that the device is isolated (check that green LED Power is NOT lit)
h Press spring clip (A) to the right and lever up the plastic case (at the point
marked with an arrow) using a screwdriver (B).
A plug connection separates the display, keys and interface from the power
section and you will be able to see the semi-conductor fuse.
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8 Fault messages and alarms
8.2.1 Accessories: Semi-conductor fuses
The design of the semi-conductor fuse differs according to the device type.
Power
controller
type
20A Tripping current: 50A Recessed head 3Nm 70/00513108
32 A Tripping current: 80A Recessed head 5Nm 70/00068011
50A Tripping current: 80A Recessed head 5Nm 70/00068011
Tripping current Screws Tighten-
ing
torque
Sales
number
100A Tripping current:
160A
150A Tripping current:
350A
200A Tripping current:
350A
250A Tripping current:
350A
Hexagon head, width across flats
10 mm
Hexagon head, width across flats
13 mm
Hexagon head, width across flats
13 mm
Hexagon head, width across flats
13 mm
8.2.2 Semi-conductor fuses type 709062/8-0X-20...
5Nm 70/00081801
12Nm 70/00083318
12Nm 70/00083318
12Nm 70/00083318
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8 Fault messages and alarms
h Undo 2 recessed head screws.
h Replace the defective semi-conductor fuse with a new one.
h Tighten the screws with the specified tightening torque.
8.2.3 Semi-conductor fuses type 709062/8-0X-32...
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8 Fault messages and alarms
h Undo 2 hexagon head screws.
Re-assemble
the case
h Replace the defective semi-conductor fuse with a new one.
h Tighten the screws with the specified tightening torque.
h Push the plastic case back into the guide rails until the spring clip engages.
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8 Fault messages and alarms
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