RKC THW-3 Instruction Manual

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RKC INSTRUMENT INC.

Three-phase Thyristor Unit

400 V AC Type

THW

Instruction Manual

IMR01V02-E1

 Company names and product names used in this manual are the trademarks or registered trademarks of

the respective companies.

Thank you for purchasing this RKC instrument. In order to achieve maximum performance and ensure proper operation of your new instrument, carefully read all the instructions in this manual. Please place this manual in a convenient location for easy reference.

SYMBOLS

WARNING

CAUTION

 An external protection device must be installed if failure of this instrument

could result in damage to the instrument, equipment or injury to personnel.

: This mark indicates precautions that must be taken if there is danger of electric

shock, fire, etc., which could result in loss of life or injury.

: This mark indicates that if these precautions and operating procedures are no

taken, damage to the instrument may result.

: This mark indicates that all precautions should be taken for safe usage.

: This mark indicates important information on installation, handling and operating procedures.

: This mark indicates supplemental information on installation, handling and operating procedures.

: This mark indicates where additional information may be located.

WARNING

 All wiring must be completed before power is turned on to prevent electric

shock, fire or damage to instrument and equipment.

 This instrument must be used in accordance with the specifications to

prevent fire or damage to instrument and equipment.

 This instrument is not intended for use in locations subject to flammable or

explosive gases.

 Do not touch the high-voltage sections such as power supply terminals,

power supply lines and input/output terminals. If touched, electric shock or injury may result.

 Do not enter the hand into the opening of this instrument. If entered, electric

shock or injury may result.

 RKC is not responsible if this instrument is repaired, modified or

disassembled by other than factory-approved personnel. Malfunction can occur and warranty is void under these conditions.

IMR01V02-E1

i-1

CAUTION

 This is a Class A instrument. In a domestic environment, this instrument may cause radio

interference, in which case the user may be required to take adequate measures.

 This instrument is protected from electric shock by reinforced insulation. Provide

reinforced insulation between the wire for the input signal and the wires for instrument power supply, source of power and loads.

 Be sure to provide an appropriate surge control circuit respectively for the following:

- If input/output or signal lines within the building are longer than 30 meters.

- If input/output or signal lines leave the building, regardless the length.



This instrument is manufactured on the assumption that it is mounted within a control

panel. All high-voltage connections such as power supply terminals must be enclosed in the control panel to avoid electric shock by operating personnel.

All precautions described in this manual should be taken to avoid damage to the



instrument or equipment.

 All wiring must be in accordance with local codes and regulations.  Always use this product at the rated power supply voltage, load current and power

frequency.

 All wiring must be completed before power is turned on to prevent electric shock,

instrument failure, or incorrect action.

 To prevent instrument damage or failure, protect the power line and the input/output lines

with a protection device such as fuse, etc.

 If this product is used for phase control, higher harmonic noise may be generated.

Therefore in this case, take such measures as installing an isolation transformer and separating the power line from the high-voltage line for load drive.

 Prevent metal fragments or lead wire scraps from falling inside instrument case to avoid

electric shock, fire or malfunction.

 Tighten each terminal screw to the specified torque found in the manual to avoid electric

shock, fire or malfunction.

 For proper operation of this instrument, provide adequate ventilation for heat dispensation.  Do not connect wires to unused terminals as this will interfere with proper operation of the

instrument.

 Turn off the power supply before cleaning the instrument.  Do not use a volatile solvent such as paint thinner to clean the instrument. Deformation or

discoloration will occur. Use a soft, dry cloth to remove stains from the instrument.

 To avoid damage to instrument display, do not rub with an abrasive material or push front

panel with a hard object.

NOTICE

 This manual assumes that the reader has a fundamental knowledge of the principles of electricity,

process control, computer technology and communications.

 The figures, diagrams and numeric values used in this manual are only for purpose of illustration.  RKC is not responsible for any damage or injury that is caused as a result of using this instrument,

instrument failure or indirect damage.

 RKC is not responsible for any damage and/or injury resulting from the use of instruments made by

imitating this instrument.

 Periodic maintenance is required for safe and proper operation of this instrument. Some

components have a limited service life, or characteristics that change over time.

 Every effort has been made to ensure accuracy of all information contained herein. RKC makes no

warranty expressed or implied, with respect to the accuracy of the information. The information in this manual is subject to change without prior notice.

 No portion of this document may be reprinted, modified, copied, transmitted, digitized, stored,

processed or retrieved through any mechanical, electronic, optical or other means without prior written approval from RKC.

i-2

IMR01V02-E1

1. OUTLINE .............................................................................. 1

1.1 Checking the Product ......................................................................................2

1.2 Parts Description ............................................................................................. 4

2. MOUNTING ........................................................................... 6

2.1 Mounting Environment.....................................................................................6

2.2 Mounting Cautions...........................................................................................7

2.3 Dimensions......................................................................................................8

2.4 Mounting Procedures ....................................................................................11

Page

3. WIRING ............................................................................... 12

3.1 Circuit Block Diagram ....................................................................................12

3.2 Wiring of Main Circuit ....................................................................................13

3.3 Wiring of the Step-Down Transformer ...........................................................15

3.4 Wiring of Controller (Auto Mode) ................................................................... 16

3.4.1 Wiring of the current input ..................................................................................17

3.4.2 Wiring of the voltage input or voltage pulse input ..............................................17

3.4.3 Wiring of the series connection (For current input) ............................................ 18

3.4.4 Wiring of the parallel connection (For voltage input or voltage pulse input)....... 18

3.5 Wiring for Input/Output Connector .................................................................19

3.5.1 Input/output connector pin number and details ..................................................19

3.5.2 Caution for wiring input/output connector (plug) ................................................20

3.5.3 Wiring of external manual setter ........................................................................20

3.5.4 Wiring of external gradient setter ....................................................................... 20

3.5.5 Wiring of external contact input.......................................................................... 21

3.5.6 Wiring of Auto mode (with gradient setter)......................................................... 21

3.5.7 Wiring of Auto/Manual mode selection............................................................... 22

3.5.8 Wiring of Auto/Manual mode selection (with gradient setter)............................. 22

3.5.9 Wiring of alarm output ........................................................................................ 23

3.5.10 Wiring of contact input...................................................................................... 23

3.5.11 Wiring of ON/OFF control................................................................................. 24

IMR01V02-E1 i-3

4. SETTING ............................................................................. 25

4.1 Mode Menu....................................................................................................25

4.2 Monitor Mode 1..............................................................................................27

4.2.1 Display sequence............................................................................................... 27

4.2.2 Description of each monitor item........................................................................ 28

(1) Input signal monitor 1 (InS1)............................................................................ 28

(2) Phase angle ratio monitor (PHAr).................................................................... 30

(3) Current value monitor (CT) .............................................................................. 30

(4) Voltage value monitor (Vo) .............................................................................. 30

(5) Power value monitor (PoW)............................................................................. 30

4.3 Monitor Mode 2..............................................................................................31

4.3.1 Display sequence............................................................................................... 31

4.3.2 Description of each monitor item........................................................................ 32

(1) Power frequency monitor (IFrq) ....................................................................... 32

(2) Input signal monitor 2 (InS2)............................................................................ 32

(3) External gradient set value monitor (EGr) .......................................................32

(4) External manual set value monitor (EMAn) ..................................................... 32

(5) Contact input state monitor (dIST)................................................................... 32

Page

4.4 Setting Mode .................................................................................................33

4.4.1 Display sequence............................................................................................... 33

4.4.2 Changing parameter settings ............................................................................. 34

4.4.3 Description of each parameter ........................................................................... 36

(1) Internal manual set value (IMAn)..................................................................... 36

(2) Internal gradient set value (IGr) ....................................................................... 36

(3) Soft-start time (SoFS) ...................................................................................... 36

(4) Soft-down time (SoFd)..................................................................................... 36

(5) Maximum load current set value for alarm (MAXC)......................................... 37

(6) Heater break alarm 1 set value setting (HbA1)................................................ 37

(7) Thyristor break-down set value setting (THb).................................................. 38

(8) Heater break alarm 2 set value setting (HbA2)................................................ 38

(9) Current limiter value setting (CT)..................................................................... 39

(10) Set data lock setting (LCK) ............................................................................39

4.5 Engineering Mode .........................................................................................40

4.5.1 Transfer to engineering mode ............................................................................ 40

4.5.2 Display sequence............................................................................................... 42

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IMR01V02-E1

Page

4.5.3 Description of each parameter ........................................................................... 43

(1) Function block 24 (F24.) .................................................................................. 43

 Contact input action (dISL)............................................................................. 43

(2) Function block 30 (F30.) .................................................................................. 43

 Output mode for phase control (oS)............................................................... 43

 Alarm 1 output logic (LGA1), Alarm 2 output logic (LGA2)............................. 44

(3) Function block 45 (F45.) .................................................................................. 44

 Number of heater break alarm 1 delay times (HbC1) .................................... 44

 Heater break alarm 1 type (AS1) ................................................................... 45

 Alarm interlock (ILS)....................................................................................... 45

(4) Function block 46 (F46.) .................................................................................. 45

 Number of heater break alarm 2 delay times (HbC2) .................................... 45

 Heater break alarm 2 type (AS2) ................................................................... 45

(5) Function block 51 (F51.) .................................................................................. 46

 Control method (ConT) .................................................................................. 46

 RUN/STOP action (rSA)................................................................................. 46

 Input signal (InSS).......................................................................................... 46

(6) Function block 52 (F52.) .................................................................................. 47

 Output limiter (high) (oLH).............................................................................. 47

 Output limiter (low) (oLL)................................................................................ 47

 Output limiter (high) at operation start (SoLH) ............................................... 47

 Output limiter (high) time at operation start (SoLT)........................................ 47

 Base-up set value (bAUP).............................................................................. 47

(7) Function block 60 (F60.) .................................................................................. 48

(8) Function block 91 (F91.) .................................................................................. 48

 ROM version .................................................................................................. 48

 Integrated operating time [upper 2 digits] (WTH) ........................................... 48

 Integrated operating time [lower 4 digits] (WTL) ............................................ 48

5. FUNCTIONS........................................................................ 49

5.1 Control Method ..............................................................................................49

5.2 Ramp Function (Soft-Start/Soft-Down Function) ...........................................49

5.3 Gradient Setting Function.............................................................................. 50

5.4 Output Limiter (High and Low).......................................................................50

5.5 Output Limiter (High) at Operation Start ........................................................51

5.6 Base-Up Setting Function.............................................................................. 52

5.7 Output Mode for Phase Control .....................................................................53

IMR01V02-E1

i-5

Page

5.8 Current Limiter Function ................................................................................56

5.9 Automatic Power Frequency Detection

and Power Frequency Monitoring Function ................................................... 56

5.10 Alarm Interlock Function.............................................................................. 57

5.11 Heater Break Alarm 1 (HBA1), Heater Break Alarm 2 (HBA2)

and Thyristor Break-Down Alarm.................................................................57

5.11.1 Number of alarm delay times ........................................................................... 57

5.11.2 Heater break alarm for phase control (Type 1) ................................................ 58

5.11.3 Heater break alarm for phase control (Type 2) ................................................ 64

5.11.4 Heater break alarm for zero-cross control........................................................ 65

5.12 FAIL Alarm...................................................................................................68

5.13 Negative Phase Sequence Alarm................................................................68

5.14 Over Current Alarm (optional)......................................................................68

5.15 Fuse Break Alarm (optional) ........................................................................68

5.16 Set Data Lock Function ...............................................................................68

5.17 External Contact Input (DI) Function ...........................................................69

6. MAINTENANCE .................................................................. 70

6.1 Daily Inspection .............................................................................................70

6.2 Troubleshooting.............................................................................................71

6.3 Replacement of the Fast-Blow Fuse.............................................................. 72

6.3.1 Replacement of the fast-blow fuse (without microswitch) .................................. 72

6.3.2 Replacement of the fast-blow fuse (with microswitch) ....................................... 75

7. SPECIFICATIONS .............................................................. 77

APPENDIX .............................................................................. 81

 How to fix the terminal cover (optional).......................................................... 81

 Description of terms ....................................................................................... 82

 Character symbols ......................................................................................... 82

i-6

IMR01V02-E1

1. OUTLINE

This instrument is a three-phase thyristor unit for power supply voltage 400 V AC. It is possible to adjust power supplied to heaters, etc. by setting the signal from the controller, setter (potentiometer) or front keys.

Gradient setter

Manual setter

Switch, etc.

Alarmer, etc

External gradient setting

External manual mode

External contact input:

uto mode/Manual mode,

RUN/STOP,

larm interlock release

larm output: Heater break, Thyristor break-down, etc.

Step-down

transformer

(Heater, etc)

Three-phase power supply

THW-3

Load

Front keys

Internal manual mode, Internal gradient setting, Alarm setting, etc.

Controller

Auto mode

 The rated currents of six types are available.

Power supply voltage

Rated current

20 A 30 A 45 A 60 A 80 A 100 A

400 V AC

 The input signal and set value can be checked on the display unit.

The display unit can check the input signal, phase angle, power frequency, current and set value of each parameter, etc.

 The front keys can set the gradient setting and manual setting.

In addition to the setting by an ordinary setter (potentiometer), it is possible to set internal gradient setting and internal manual setting values by the front keys while checking these numeric values shown on the display unit.

 Automatic power frequency detection

The instrument automatically detects a power supply frequency (50/60 Hz) when the power is turned on.

 The control of three types can be selected.

It is possible to select by the front keys and then use any one of phase control, zero-cross control (continuous) and zero-cross control (input synchronous type).

IMR01V02-E1 1

1. OUTLINE

1.1 Checking the Product

Before using this product, check each of the following:

• Model code

• Check that there are no scratch or breakage in external appearance (case, heat radiation fin, front

panel, or terminal, etc).

• Check that all of the items delivered are complete. (See below)

THW - 3 4 PZ  -  ∗

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

  -

The code shown in (8) is printed on the nameplate when the relevant accessory is specified as an option.

(1) Power supply

4: Three-phase 400 to 440 V AC

(2) Control method

PZ: Phase control/Zero-cross control (configurable)

(3) Rated current

020: 20 A 060: 60 A 030: 30 A 080: 80 A 045: 45 A 100: 100 A

(4) Input signal

4: Voltage input 0 to 5 V DC 7: Current input 0 to 20 mA DC 5: Voltage input 0 to 10 V DC 8: Current input 4 to 20 mA DC 6: Voltage input 1 to 5 V DC

(5) Output mode

N: Standard (Proportional phase angle to input, Proportional voltage to input, Proportional square

voltage (electric power) to input)

6: Standard and Constant voltage control (No heater break alarm) V: Standard and Constant voltage control (With heater break alarm and current limiter function *) E: Standard and Constant current control (With heater break alarm and current limiter function *) W: Standard and Constant power control (With heater break alarm and current limiter function *)

* When the Heater break alarm and Current limiter are provided, the Over current and Thyristor break-down

alarm are available.

IMR01V02-E1

(6) Fuse

N: No fast-blow fuse is provided F: Built-in fast-blow fuse S: Built-in fast-blow fuse (With microswitch)

(7) Option function

N: No function

(8) Accessories

1: Setter (potentiometer, knob and scale plate) [1 set] and Input/Output connector (plug) 2: Setter (potentiometer, knob and scale plate) [2 set] and Input/Output connector (plug) 9: Input/Output connector (plug) A: Terminal cover

 Accessories (Order Separately)

1. OUTLINE

THVP-S01: Setter (potentiometer, knob and scale plate) THWP-C01: Input/Output connector (plug) THWP-T01: Step-down transformer (for instrument power supply) THWP-F22: Fast-blow fuse for 20 A THWP-F32: Fast-blow fuse for 30 A THWP-F42: Fast-blow fuse for 45 A and 60 A THWP-F82: Fast-blow fuse for 80 A THWP-FA2: Fast-blow fuse for 100 A THWP-F23: Fast-blow fuse for 20 A (With microswitch) THWP-F33: Fast-blow fuse for 30 A (With microswitch) THWP-F43: Fast-blow fuse for 45 A and 60 A (With microswitch) THWP-F83: Fast-blow fuse for 80 A (With microswitch) THWP-FA3: Fast-blow fuse for 100 A (With microswitch) THWP-A02: Terminal cover for 20 A, 30 A, 45 A and 60 A THWP-A03: Terminal cover for 80 A and 100 A

The accessories attached to product

Instruction Manual (IMR01V02-E1)................................................................... 1

Short bar (The short bar is connected to the “input terminals.”)......................... 1

Step-down transformer (for instrument power supply: THWP-T01).................. 1

If any of the products are missing, damaged, or if your manual is incomplete, please contact RKC sales office or the agent.

IMR01V02-E1

1. OUTLINE

1.2 Parts Description

(1) Main circuit terminals (power supply side)

(13) Power

terminals

(2) Power lamp

(3) Display

(4) SET key

(5) Shift key

(6) DOWN key

(7) UP key

(12) Input/output

connector

(8) Indication

lamps

(9) Input terminals

(10) Grounding

terminal

(11) Main circuit terminals (load side)

The name is the same as for each type (20 to 100 A).

No. Name Description No. Name Description

(1) Main circuit terminals

(power supply side) (1/L1, 3/L2, 5/L3)

(2) Power lamp (green) Lit when the power is turned

(3) Display • Display (upper):

• Display (lower):

(4)

(5)

• Shift digits when settings

(6)

(7)

(SET key)

(Shift key)

(DOWN key)

(UP key)

Used to connect three-phase power supply.

on.

Display the parameters symbols and numeric value.

Display the input signal value and each set value.

Used for parameter calling up and set value registration.

• Used to select the mode. (12) Input/Output

are changed.

• Used to select the monitor item and function block (F).

• Decrease numerals.

• Used to select the monitor

item and function block (F).

• Increase numerals.

(8) Indication lamps

(red)

(9) Input terminals Used to connect input signal

(10) Grounding terminal Used to connect the

(11) Main circuit terminals

(load side)

(2/T1, 4/T2, 6/T3)

connector (socket)

[Optional] contact or controller.

(13) Power terminals

(7/l1, 8/l2, 9/l3)

Lights when any error occurs.

For details, see the Description of Indication lamp (P. 5).

wires (controller, etc.).

grounding terminal.

Used to connect the load.

Used to connect with a setter (potentiometer), external

In addition, used to alarm output.

Used to connect the power supply of THW-3.

IMR01V02-E1

 Description of indication lamp

If an error occurs, the indication lamp lights.

INDICATION LAMP

FAIL



FREQ



PHASE



HBA1



THY.B



HBA2



OCR



FUSE



1. OUTLINE

THW-3

The name is the same as for each type (20 to 100 A).

Symbol Description

FAIL (Board error)

FREQ (Power frequency error)

PHASE (negative phase sequence)

HBA1 (Heater break alarm 1)

THY.B (Thyristor break-down alarm)

HBA2 (Heater break alarm 2)

OCR (Over current)

FUSE (Fuse break)

This lamp lights if a board error of this instrument is detected by the self-diagnosis function.

This lamp lights if power frequency is out of the allowable range (detecting range) when power is turned on or during operation.

This lamp lights if negative phase sequence or the open phase is detected.

Lights when Heater break alarm 1 output is turned on. HBA1 is not available when heater break alarm is not provided.

Lights when thyristor break-down alarm output is turned on. Thyristor break-down alarm is not available when heater break alarm is not provided.

Lights when Heater break alarm 2 output is turned on. HBA2 is not available when heater break alarm is not provided.

This lamp lights if the current of more than 1.2 times the rating of this instrument flows. when heater break alarm is not provided.

This lamp lights if the fast-blow fuse in this instrument blew. Fuse break alarm is not available when the fast-blow fuse (with microswitch) is not provided.

The over current alarm is not available

Action taken when

an error occurs

Thyristor output OFF

Thyristor output OFF The output can be turned ON when the error is canceled.

Thyristor output OFF

Control is continued.

Control is continued. When shorted: Thyristor output continues to be turned ON.

When broken: Thyristor output OFF

Control is continued.

Thyristor output OFF

IMR01V02-E1

2. MOUNTING

 In order to prevent electric shock or instrument failure, always mount or remove

this instrument after power supplied to the entire system is turned off.

 As the temperature of this instrument becomes high, mount the instrument on

a non-inflammable material (metal plate, etc.).

 As this instrument generates a large amount of heat, it is cooled by circulating

air by convection. Therefore, if mounted in any direction other than specified, accident or failure may result.

 When carrying this instrument, hold the heat radiation fin. In addition, always

carry it with the heat radiation fin cooled.

WARNING

2.1 Mounting Environment

Avoid the following conditions when selecting the mounting location:

• Ambient temperature of less than 0 °C or more than 40 °C. (The rated current drops when the ambient temperature exceeds 40 °C.)

Load current (%)

100

10 20 30 40 50 55

Temperature characteristic of load current

• Ambient humidity of less than 5 % or more than 95 % RH. (Absolute humidity: MAX. W. C 29 g/m

dry air at 101.3 kPa)

• Rapid changes in ambient temperature which may cause condensation.

• Corrosive or inflammable gases.

Temperature (°C)

• Such a place where there are inflammable materials near this instrument.

• Direct vibration or shock to the mainframe.

• Water, oil, chemicals, vapor or steam splashes.

• Excessive dust, salt or iron particles.

• Excessive induction noise, static electricity, magnetic fields or noise.

• Exposure to direct sunlight.

• Excessive heat accumulation.

6 IMR01V02-E1

2.2 Mounting Cautions

Take the following points into consideration when mounting this instrument.

 Mount this instrument in the direction shown below.

Vertical direction

Upper

2. MOUNTING

THW-3

 Provide adequate heat radiation space so that heat does not build up.

 At least 20 mm is necessary on the left and right and at least 100 mm on the top and bottom.

 If the panel inside temperature rises due to self-generation of heat, install a forced circulation fan

so that the panel inside is fully ventilated with the open air.

Unit: mm

100 or more

THW-3 THW-3

20 or more20 or more

100 or more

20 or more

THW-3 THW-3

100 or more 100 or more

IMR01V02-E1 7

2. MOUNTING

2.3 Dimensions

 Dimensions

2-φ6

8 7

2-φ12

B C

D *

* Dimensions when the connecto

plug (optional) is connected. When connecting the connecto plug, install the thyristor by taking

enough space for its wiring into account.

Unit: mm

Dimensions

Types

A B C D

20 A, 30 A, 45 A and 60 A types

80 A and 100 A types

314.0 200.0 203.0 212.0

347.0 230.0 235.0 244.0

IMR01V02-E1

 Mounting dimensions

20 A, 30 A, 45 A and 60 A types 80 A and 100 A types

2. MOUNTING

単位: mm

4-M5

±0.2

302.0

±0.2

183.0

 Setter (Potentiometer, Knob and Scale plate)

φ6





2.8

18.7

16.1

Knob

M9 × 0.75

φ24

13.5

10 10

Potentiometer

(Resistance 5 kΩ, variation characteristic: B)

±0.2

335.0



4-M5

213.0

Scale plate

±0.2

100

THW-3

Unit: mm

IMR01V02-E1







Set the potentiometer full counterclockwise and combine with

a scale plate.

When setting the knob on the scale plate, align the arrow on

the knob with 0 on the scale plate.

2. MOUNTING

 Fast-blow fuse (For 20 A, 30 A, 45 A and 60 A)

18.5

Code: THWP-F22 (20 A) THWP-F32 (30 A) THWP-F42 (45 A/60 A)

62.0

17.5

12.0

25.0

Unit: mm

34.5

27.0

76.0

Without microswitch With microswitch

 Fast-blow fuse (For 80 A and 100 A)

34.0

Code: THWP-F82 (80 A) THWP-FA2 (100 A)

Without microswitch With microswitch

70.0

40.0

95.0

30.0

25.0

 Step-down transformer (THWP-T01)

117

Code: THWP-F23 (20 A)

THWP-F33 (30 A) THWP-F43 (45 A/60 A)

47.0

33.5

Code: THWP-F83 (80 A) THWP-FA3 (100 A)

Unit: mm

39.5

Unit: mm

L1 L2 L3 I1 I2 I3

5-4

IMR01V02-E1

2. MOUNTING

2.4 Mounting Procedures

1. Prepare the holes as specified in 2.3 Dimensions.

2. Place the instrument in mounting position.

3. Insert the mounting screws into the holes, and then tighten them with a screwdriver. Customer

must provide the set of screws.

Screw size Recommended tighten torque

M5 3.6 N⋅m (36 kgf⋅cm)

Mounting hole Mounting hole

IMR01V02-E1

Mounting hole Mounting hole

The Figure shows the type of 20 A to 60 A. However, the mounting procedure is the same as for the type of 80 A/100 A.

3. WIRING

To prevent electric shock or instrument failure, do not turn on the power until all the wiring is completed.

WARNING

3.1 Circuit Block Diagram

Step-down transforme

External gradient setting

External manual mode

RUN/STOP transfer

larm interlock release

uto mode/Manual

mode transfer

L1 L2 L3 I1 I2 I3

Power terminals

Connecter

CT/PT

circuit

RST

1/L1 3/L2 5/L3

7/I18/I29/I3

Snubber

circuit

Fast-blow fuse

Snubber

circuit

Three-phase

400 to 440 V AC

(50/60 Hz)

Fast-blow fuse

Snubber

circuit

Fast-blow fuse

NFB

Input

terminals

2/T1 4/T2 6/T3

UVW

Load

4 to 20 mA DC

(Auto mode)

1 2 3

Controller

Grounding

terminal

−+

24 V DC

Alarm 1

Relay

Alarm 2

−

Relay

The fast blow-fuse, CT and PT are optional.

12 IMR01V02-E1

3.2 Wiring of Main Circuit

Conduct wiring by referring to the wiring diagram and the tightening torque table.

CAUTION

 Always conduct wiring so that the R, S and T phases of 3-phase power coincide

with the main circuit terminals (power side), 1/L1, 3/L2 and 5/L3 on this instrument, respectively. Otherwise the instrument may not function properly or the load may be damaged. R → Connect to the 1/L1 terminal. T → Connect to the 5/L3 terminal. S → Connect to the 3/L2 terminal.

 Always coincide the main circuit terminals (load side), 2/T1, 4/T2 and 6/T3 on this

instrument with the U, V and W phases of the load, respectively. Otherwise the instrument may not function properly or the load may be damaged. 2/T1 terminal → Connect to the U. 6/T3 terminal → Connect to the W. 4/T2 terminal → Connect to the V.

 When controlling the primary side of the transformer, do not open its secondary side of

circuit during operation. In addition, do not operate the instrument below the minimum load current.

 When controlling the primary side of the transformer, set magnetic field density of the

transformer to about 0.8T (8,000-gauss). If the transformer is saturated, overcurrent flows through it to cause the thyristor to be damaged.

 Imbalance between each phase of the load may result in a large error of the input/output

characteristic.

 No power switch is provided in this instrument. Therefore install the switches near the

instrument, if necessary.

 To avoid noise induction, keep input signal wire of controller away from instrument

power line, load lines and power lines of other electric equipment. If wiring near high-voltage power is unavoidable, use shielded wires.

 For safety, always ground the grounding terminal.  Tighten the hexagon headed bolts on the main circuit terminals using a torque wrench.

Always tighten each of them by contacting the diagonal surfaces of the wrench with those of each hexagon head.

Recommended tool: Manufactured by TOHNICHI MFG. CO., LTD.

Model code of adjustable type torque wrench with

ratchet head

20 A/30 A QL3N M4 45 A/60 A QL6N M6

80 A/100 A QL12N M8

 Use wires satisfying the rated current capacity.  Firmly tighten each terminal hexagon headed bolt with the tightening torque specified

below. Otherwise, electric shock, fire or heat generation may result.

Terminal hexagon bolt size and tightening torque list

Hexagon bolt size M4 M6 M8

Recommended tightening torque 1.6 N⋅m (16.31 kgf⋅cm) 3.8 N⋅m (38.74 kgf⋅cm) 9.0 N⋅m (91.77 kgf⋅cm)

Main circuit terminal (1/L1 to 5/L3 and 2/T1 to 6/T3)

20 A/30 A 45 A/60 A 80 A/100 A

Socket size

3. WIRING

Continued on the next page.

IMR01V02-E1 13

3. WIRING

Continued from the previous page.

 When using a solderless terminal lug, use ring type.

Ring type solderless terminal size

Ring type solderless terminal

Main circuit terminal (1/L1 to 5/L3 and 2/T1 to 6/T3)

20 A/30 A 45 A/60 A 80 A/100 A

dimension 4.3 mm or more 6.4 mm or more 8.4 mm or more

D dimension 9.5 mm or less 12.0 mm or less 22.0 mm or less

 Wiring of the main circuit

Table of calorific values (400 to 440V AC)

1/L1 3/L2 5/L3

2/T1 4/T2 6/T3

Three-phase

400 to 440 V AC

(50/60 Hz)

R S T

U V W

NFB

Rated current Calorific values

20 A 82 W

30 A 118 W

45 A 172 W

60 A 226 W

80 A 298 W

100 A 370 W

Load

IMR01V02-E1

3.3 Wiring of the Step-Down Transformer

CAUTION

 Use the step-down transformer only for stepping down the voltage of power supplied to

this instrument.

 Always coincide the R, S and T phases of 3-phase power with the step-down

transformer terminals (primary side: L1, L2 and L3, and secondary side: I1, I2 and I3) and the power terminals, 7/I1, 8/I2 and 9/I3 of this instrument, respectively. Otherwise the instrument may not function properly or the load may be damaged. R  Connect to the L1 terminal l1 terminal  Connect to the 7/l1 terminal S  Connect to the L2 terminal I2 terminal  Connect to the 8/l2 terminal T  Connect to the L3 terminal I3 terminal  Connect to the 9/l3 terminal

3. WIRING

 Use wires satisfying the rated current capacity.

 When using a solderless terminal lug, use ring type.

Ring type solderless terminal size

Ring type solderless terminal

Power terminal (L1, L2, L3 and l1, l2, l3)

dimension 3.2 mm or more

D dimension 6.5 mm or less

Recommended tightening torque 0.6 to 0.9 N⋅m (6.1 to 9.1 kgf⋅cm)

 Wiring of the step-town transformer

Primary side

L1 L2 L3 l1 l2 l3

Step-down transformer

Secondary side

Three-phase

400 to 440 V AC (50/60 Hz)

RST

1/L1 3/L2 5/L3

NFB

Power terminals

7/l18/l29/l3

IMR01V02-E1

3. WIRING

3.4 Wiring of Controller (Auto Mode)

When using a solderless terminal lug, use ring type.

Ring type solderless terminal size

D dimension

Recommended tightening torque

Ring type

solderless terminal

Input terminal (1, 2 and 3)

dimension

3.2 mm or more

5.5 mm or less

0.4 N⋅m (4 kgf⋅cm)

 On input signal change

The input signal is set as specified when ordering at the time of being unpacked. When changing the input signal, conduct the following two settings.

• Set the type of input signal by Input signal by Input signal (InSS) in Engineering mode. (See P. 46)

• Change the position of the short bar to match the input type. (See the next page.)

In addition, the input signal is divided into two pieces of hardware. The input signal in the same hardware is selectable but the input signal in the other hardware cannot be selected.

Current input 0 to 20 mA DC

Voltage input 0 to 5 V DC

Current input 4 to 20 mA DC

Voltage input 1 to 5 V DC

Voltage pulse input 0/12 V DC

Hardware 1 Hardware 2

Cannot be selected to the input signal in the other hardware.

Voltage input 0 to10 V DC

Voltage pulse input 0/12 V DC

Voltage pulse input 0/24 V DC

n input type change may only be made within the hardware groups.

IMR01V02-E1

−

3.4.1 Wiring of the current input

For current input (0 to 20 mA DC, 4 to 20 mA DC), short terminal No.1 with terminal No.2.

Current input

0 to 20 mA DC, 4 to 20 mA DC

+ −

12 3

THW-3 input terminal Input impedance: 100 Ω

Short

3. WIRING

Short bar

Controller: 0 to 20 mA DC,

4 to 20 mA DC output

3.4.2 Wiring of the voltage input or voltage pulse input

For voltage input (0 to 5 V DC, 1 to 5 V DC or 0 to 10 V DC) or voltage pulse input (0/12 V DC, 0/24 V DC), short terminal No.2 with terminal No.3.

Voltage input: 0 to 5 V DC, 1 to 5 V DC, 0 to 10 V DC

Voltage pulse input: 0/12 V DC, 0/24 V DC

1 2 3

THW-3 input terminal Input impedance: Hardware 1 (0 to 5 V DC, 1 to 5 V DC and 0/12 V DC): 30 kΩ Hardware 2 (0 to 10 V DC, 0/12 V DC and 0/24 V DC): 68 kΩ

Short

Short bar

Controller: 0 to 5 V DC, 1 to 5 V DC,

0 to 10 V DC, 0/12 V DC,

0/24 V DC output

IMR01V02-E1

3. WIRING

3.4.3 Wiring of the series connection (For current input)

Current input: 0 to 20 mA DC, 4 to 20 mA DC

+ −

1 2 3

THW-3 input terminal Input impedance: 100 Ω

THW-3 THW-3 THW-3

The number of thyristor that can be connected depends on the resistance of temperature controller being used. For resistance of controller, see controller instruction manual.

3.4.4 Wiring of the parallel connection (For voltage input or voltage pulse input)

Voltage input: 0 to 5 V DC, 1 to 5 V DC, 0 to 10 V DC Voltage pulse input: 0/12 V DC, 0/24 V DC

+ −

1 2 3

THW-3 input terminal Input impedance: Hardware 1 (0 to 5 V DC, 1 to 5 V DC, 0/12 V DC): 30 kΩ Hardware 2 (0 to 10 V DC, 0/12 V DC, 0/24 V DC): 68 kΩ

THW-3 THW-3 THW-3

The number of thyristor that can be connected depends on the resistance of temperature controller being used. For resistance o controller, see controller instruction manual.

Controller 0 to 20 mA DC, 4 to 20 mA DC output

−

Controller:

0 to 5 V DC, 1 to 5 V DC, 0 to 10 V DC, 0/12 V DC or 0/24 V DC outputs

−

IMR01V02-E1

3.5 Wiring for Input/Output Connector

The input/output connector is used for the following wiring.

• External manual setting

• External gradient setting

• External contact input (Auto/Manual mode transfer, RUN/STOP transfer, alarm interlock release)

• Alarm output

3.5.1 Input/Output connector pin number and details

Pin No. Details

+5 V output 0 V External gradient setting input

(0 to 5 V input by the gradient setter) External manual setting input

(0 to 5 V input by the manual setter) External contact input (DI) Auto/Manual mode transfer: Contact closed: Manual mode

Contact open: Auto mode External contact input (DI) RUN/STOP transfer: Contact closed: RUN

Contact open: STOP When using RUN/STOP transfer, it is necessary to set RUN/STOP action (rSA) to “1: Used.”

(See P. 46) External contact input (DI) Alarm interlock release: Closing the contact releases the

alarm interlock Unused 24 V DC (+) Alarm 1: Open collector output In order to output an alarm, it is necessary to select the type

of alarm by Alarm 1 output logic (LGA1).

(See P. 44) Alarm 2: Open collector output In order to output an alarm, it is necessary to select the type

of alarm by Alarm 2 output logic (LGA2).

(See P. 44) 0 V

2 3

7 8

Pin number

1 2 3

8 9

3. WIRING

IMR01V02-E1

3. WIRING

3.5.2 Caution for wiring input/output connector (plug)

• Use stranded wire of size 0.14 to 0.5 mm2 for the leadwires.

• Strip off the sheath from 8 mm from the leadwire end.

8 mm

Size 0.14 to 0.5 mm (AWG28-20)

Input/output connector (plug)

3.5.3 Wiring of external manual setter

External manual setter

Short

3.5.4 Wiring of external gradient setter

THW-3

Input/Output connector

External gradient setter

THW-3

Input/Output connector

IMR01V02-E1

−

3.5.5 Wiring of external contact input

3. WIRING

uto/Manual mode

transfer

RUN/STOP transfer

larm interlock

release

uto/Manual mode transfer

Contact closed: Manual mode Contact open: Auto mode

RUN/STOP transfer

Contact closed: RUN Contact open: STOP

larm interlock release

Contact closed: Alarm interlock release

Input/Output connector

THW-3

3.5.6 Wiring of Auto mode (with gradient setter)

External gradient setter

For controller wiring, see page 16.

THW-3

Input/Output connector

Controller

Input

terminal

uto mode

IMR01V02-E1

3. WIRING

−

3.5.7 Wiring of Auto/Manual mode selection

External manual setter

uto/Manual mode transfer

Contact closed: Manual mode Contact open: Auto mode

Input/Output connector

For controller wiring, see page 16.

THW-3

Input

terminal

Controller

uto mode

3.5.8 Wiring of Auto/Manual mode selection (with gradient setter)

External gradient setter

External manual setter

uto/Manual mode transfer

Contact closed: Manual mode Contact open: Auto mode

THW-3

Input/Output connector

Input

terminal

For controller wiring, see page 16.

Controller

uto mode

IMR01V02-E1

3.5.9 Wiring of alarm output

A diode should be used and connected as show in the diagram, when using a relay.

24 V DC

−

Alarm 1

3.5.10 Wiring of contact input

Alarm 2

THW-3

Input/Output connector

3. WIRING

Controller

ON/OFF signal

(Relay contact output)

Controller

C: Common NO: Normally open

The thyristor output is turned on/off by the ON/OFF signal from the controller.

+5 V output

Short

Input/Output connector

THW-3

IMR01V02-E1

3. WIRING

3.5.11 Wiring of ON/OFF control

ON/OFF control

ON/OFF signal

(Relay contact output)

Controller

NO: Normally open NC: Normally closed C: Common

Low limit setter

High limit setter

Short

THW-3

Input/Output connector

IMR01V02-E1

4. SETTING

This chapter describes various monitor screens, parameters or setting method. Set any mode necessary for customer’s operation. When setting the mode for the first time, set it in the order of Engineering mode and Setting mode.

4.1 Mode Menu

THW-3 has four different modes, and all settable parameters belongs to one of them. The following chart show how to access different mode.

 Monitor mode 1: The Input signal, Phase angle ratio, Current and other values can be

monitored.

 Monitor mode 2: The Power frequency, External gradient, External manual and other values

can be monitored.

 Setting mode: The parameters (Soft-start/Soft-down, Internal gradient, Set data lock and

others) can be set.

 Engineering mode: This is the mode to set parameters which are almost unrequired to be

changed hereafter as far as normally used, it set once so as to meet the operating condition.

Power ON

The rated current and

specifications are displayed.

(Display for

approx. 2 seconds)

Monitor mode 1

(See P. 27)

Press the SET key for 2 seconds.

Display (upper): The rated current is displayed. Display (lower): Specification is displayed. (See next page)

Press the shift key.

Monitor mode 2

(See P. 31)

Press the SET key for 2 seconds.

Setting mode

(See P. 33)

This instrument returns to the monitor mode 1 if no key operation is performed for more than 1 minute.

Engineering

(See P. 40)

fter the set data lock is released, press the

shift key while pressing the SET key.

If the engineering mode is locked, the engineering mode

mode

is not displayed. For details on releasing the lock, see on the page 40.

IMR01V02-E1 25

4. SETTING

 The rated current and specification display

THW-3 immediately confirms the rated current and specification following power ON.

Power ON

(1) The rated current display

Parameter Rated current

Display changes automatically

Input signal monitor 1

(1) Rated

current

(2) Specification

20 A

30 A

45 A

60 A

80 A

100 A

(2) Specification display

0 fixed

Fuse

0: Without fast-blow fuse 1: Built-in fast-blow fuse

(without microswitch)

2: Built-in fast-blow fuse

(with microswitch)

Output mode

0: Constant voltage and constant power

controls are not provided. 1: Constant voltage control is provided. 2: Constant power control is provided.

Heater break alarm

0: Heater break alarm is not provided. 1: Heater break alarm is provided.

IMR01V02-E1

4. SETTING

4.2 Monitor Mode 1

When the power is turned on, THW-3 goes to this mode after self-diagnostics. The following items are displayed in the monitor mode 1.

• Input signal value • Current value • Power value

• Phase angle ratio value • Voltage value

4.2.1 Display sequence

To go to the next monitor screen, press UP or DOWN key. To go back to the first monitor screen, keep pressing the keys until it is displayed again.

Press the UP key.

Input signal monitor 1

(InS1)

Phase angle ratio monitor

Current value monitor *

Voltage value monitor *

Press the DOWN key.Press the UP key.

(PHAr)

Press the DOWN key.Press the UP key.

(CT)

Press the DOWN key.Press the UP key.

(Vo)

Press the DOWN key.Press the UP key.

Power value monitor *

(PoW)

Press the DOWN key.

* These parameters may not be displayed depending on the specification.

IMR01V02-E1

4. SETTING

4.2.2 Description of each monitor item

(1) Input signal monitor 1 ( )

Select and then display one input signal value from among three input signal values. The type of input signal to be displayed can be selected by the external contact input.

Input signal type: Auto set value (Value of Auto mode)

External manual set value

Display range: 0 to 100 %

The internal manual set value displayed on Input signal monitor 1 is that whose digits following the decimal point are truncated.

 Application (Procedure required until the internal manual set value is displayed)

Internal manual set value

Wiring of Auto/Manual mode transfer

Wiring of controller

Select the Setting mode.

Unlock the Engineering mode.

Select the Engineering mode.

Select the contact input action.

Set the “1: Internal manual mode ↔ Auto mode.”

Select the Setting mode.

When not wired, see the following page. Wiring of Controller (P. 16) Wiring of Auto/Manual mode selection (P. 22)

See P. 25

See P. 39

See P. 25

See P. 42

See P. 43

See P. 25

IMR01V02-E1

Lock the Engineering mode.

See P. 39

Select the input signal monitor 1.

See P. 25 and 27

Display the internal

manual set value.

No (Display the auto set value

)

YES

Close the contact of Auto/Manual mode transfer.

Open the contact of Auto/Manual mode transfer.

Auto set value: Input signal from controller

The internal manual set value is displayed.

If the internal manual set value or auto set value display is selected, control is also performed at the set value thus selected.

The auto set value is displayed. 2

When necessary to display any other input signal, first select the external contact action by referring to the following table and then select the external contact.

State of External contact

Contact input action

0: External manual mode

↔ Auto mode

1: Internal manual mode

↔ Auto mode

2: Internal manual mode

(fixed)

Displays the External manual set value.

Displays the Internal manual set value.

Contact closed

(Manual mode)

Displays the Internal manual set value.

Contact open

(Auto mode)

Displays the Auto set value.

4. SETTING

0: External manual mode ↔ Auto mode 1: Internal manual mode ↔ Auto mode 2: Internal manual mode (fixed) Displays the Internal manual set value.

IMR01V02-E1

When no wiring of “Auto mode/Manual mode transfer” is conducted, the contact keeps opening and as a result Input signal monitor 1 displays the input signal value in the following table.

Contact input action

State of contact

(Contact open: Auto mode)

Displays the Auto set value.

4. SETTING

(2) Phase angle ratio monitor ( )

Displays the phase angle of the trigger point by percentage. Phase angle is obtained by performing such computation as Soft-start/Soft-down time, Gradient setting, Output limiter setting or Base up setting to the input signal.

Display range: 0 to 100 %

Display the 0 % when the phase angle is 210°. Display the 100 % when the phase angle is 0°.

Phase angle

0°

100 %

Output waveform

Phase angle

210

57 %

0 %

Displays this value.

(3) Current value monitor ( )

Displays the current value (Input value of CT). The display range varies depending on the instrument specification.

Display range: 20 A type: 0.0 to 26.0 A

30 A type: 0.0 to 39.0 A 45 A type: 0 to 58 A 60 A type: 0 to 78 A 80 A type: 0 to 104 A 100 A type: 0 to 130 A

The current value monitor is not displayed when the heater break alarm function is not provided.

(4) Voltage value monitor ( )

Displays the voltage value (Input value of PT).

Display range: 0 to 500 V

The voltage value monitor is not displayed when the constant voltage control is not provided.

(5) Power value monitor ( )

Displays the power value.

Display range: 0.0 to 84.0 kW

The power value monitor is not displayed when the constant power control is not provided.

IMR01V02-E1

4. SETTING

4.3 Monitor Mode 2

The following items are displayed in the monitor mode 2.

• Power frequency • Auto set value (value of auto mode)

• External gradient set value • External manual set value

• State of contact (open/closed state)

4.3.1 Display sequence

To go to the next monitor screen, press UP or DOWN key. To go back to the first monitor screen, keep pressing the keys until it is displayed again.

Press the UP key.

Power frequency monitor

(IFrq)

Input signal monitor 2

External gradient set value monitor

External manual set value monitor

Press the DOWN key.Press the UP key.

(InS2)

Press the DOWN key.Press the UP key.

(EGr)

Press the DOWN key.Press the UP key.

(EMAn)

IMR01V02-E1

Press the DOWN key.Press the UP key.

Contact input state monitor

(dIST)

Press the DOWN key.

4. SETTING

4.3.2 Description of each monitor item

(1) Power frequency monitor ( )

Displays the power frequency.

Display range: 0 to 70 Hz

The automatic power frequency detection and power frequency monitoring function is available with the THW-3. For details, see the function description (P. 56).

(2) Input signal monitor 2 ( )

Displays the Auto set value (value of auto mode).

Display range: 0 to 100 %

(3) External gradient set value monitor ( )

Displays the external gradient set value.

Display range: 0 to 100 %

(4) External manual set value monitor ( )

Displays the external manual set value.

Display range: 0 to 100 %

(5) Contact input state monitor ( )

Displays the state of the contact input.

Display item: 0: Contact open

1: Contact closed

Contact input state monitor

Auto/Manual mode transfer 0: Contact open (Auto mode) 1: Contact closed (Manual mode)

RUN/STOP transfer 0: Contact open (STOP) 1: Contact closed (RUN)

Alarm interlock release 0: Contact open 1: Contact closed (alarm interlock release)

IMR01V02-E1

4. SETTING

4.4 Setting Mode

In Setting mode, the following operations are possible.

• Internal gradient can be set. • Soft-start time and Soft-down time can be set.

• Heater break alarm set value can be set. • Current limit value can be set.

• Maximum load current set value for alarm, etc.

4.4.1 Display sequence

To go to the next parameter (setting item), press SET key. To go back to the first setting item, keep pressing SET keys until it is displayed again.

Internal manual set value

Internal gradient set value

Soft-start time

Soft-down time

Press the SET key.

(IMAn)

(IGr)

(SoFS)

(SoFd)

Thyristor break-

(THb)

down set value setting *

Press the SET key.

Heater break

(HBA2)

alarm 2 set value setting *

Press the SET key.

Current limit

(CL)

value setting *

Press the SET key.

Set data lock

(LCK)

setting

Maximum load current set value for alarm

Heater break alarm 1 set value setting *

IMR01V02-E1

Press the SET key.

(MAXC)

Press the SET key.

(HbA1)

Press the SET key.

Return to internal manual set value

* These parameters may not be displayed

depending on the specification.

4. SETTING

4.4.2 Changing parameter settings

 When set the internal gradient set value to “0.50”

1. Press the SET key for 2 seconds to change to Setting mode.

Monitor mode 1

Setting mode

Internal manual set value

SET SET

2. Press the SET key to enter the Internal gradient set value.

Setting mode

Internal manual set value

Internal gradient

set value

SET SET

3. Press the shift key to high-light the one decimal place on display (lower).

Internal gradient

set value

Internal gradient

set value

SET SET

4. Press the DOWN key to change the number to “0.5.”

Internal gradient

set value

SET SET

Internal gradient

set value

IMR01V02-E1

5. Press the SET key to store the new value. The display goes to the next parameter.

4. SETTING

Internal gradient

set value

Soft-start time

SET SET

To store a new value for the parameter, always press the SET key. A new value will not be stored without pressing SET key after the new value is displayed on the display.

After a new value has been displayed by using the UP and DOWN keys, the SET key must be pressed within one minute, or the new value is not stored and the display will return to the monitor mode 1.

If the following setting is tried to be set, no set value is registered even if the SET key is pressed. In addition, it does not go to the next parameters.

• When in zero-cross control, it is tried to set constant current control, constant voltage control or constant power control.

• When in constant current control, constant voltage control or constant power control, it is tried to set zero-cross control.

Other parameters can be set in the same way as the example above.

Every time the shift key is pressed, the high-lighted digit moves as follows.

IMR01V02-E1

4. SETTING

4.4.3 Description of each parameter

(1) Internal manual set value ( )

Use to set the Internal set value.

Setting range: 0.0 to 100.0 % Factory set value: 0.0

(2) Internal gradient set value ( )

Use to set the Internal gradient set value.

Setting range: 0.00 to 1.00 Internal gradient is 0 % when set 0.00.

Internal gradient is 100 % when set 1.00

Factory set value: 1.00

For the gradient output characteristic, see page 50.

(3) Soft-start time ( )

Use to set the Soft-start time.

CAUTION

If a load generating large rush current is used, thyristor break-down may occur when no soft-start time is appropriately set. In zero-cross control, no rush current can be suppressed even if the Soft-start time is set.

Setting range: 0.0 to 99.9 seconds Factory set value: 0.1

For the function description, see page 49.

(4) Soft-down time ( )

Use to set the Soft-down time.

Setting range: 0.0 to 99.9 seconds Factory set value: 0.1

For the function description, see page 49.

IMR01V02-E1

4. SETTING

(5) Maximum load current set value for alarm ( )

Use to set the maximum heater current value (maximum load current value) for Heater break alarm. The maximum load current value means a current value which flows through the heater at an output of 100 % (phase angle: 0°). After the wiring is complete, check a current value which flows through the heater at an output of 100 % (phase angle: 0°) on the current monitor (see P. 30). Phase angle can be checked on the Phase angle ratio monitor (see P. 30).

Always set the maximum load current value if the heater break alarm function is provided.

If the maximum current value which flows through the heater changes due to heater

secular change or deterioration, change the maximum load current value.

Setting range: 20 A type: 0.0 to 22.0 A Factory set value: 20 A type: 20.0

30 A type: 0.0 to 33.0 A 30 A type: 30.0 45 A type: 0 to 50 A 45 A type: 45 60 A type: 0 to 66 A 60 A type: 60 80 A type: 0 to 88 A 80 A type: 80 100 A type: 0 to 110 A 100 A type: 100

This parameter is not displayed when the heater break alarm function is not provided.

For the application, see 5.11 Heater Break Alarm 1 (HBA1), Heater Break Alarm (HBA2) and Thyristor Break-down Alarm (see P. 57).

(6) Heater break alarm 1 set value setting ( )

Use to set the heater break alarm 1 set value. For the heater break alarm 1 set value, make the setting as follows.

When the control method is Phase Control, RKC recommends:

Set the heater break set value to approximately 20 % of the maximum load current value for heater break alarm Type 1. Set the heater break set value to approximately 5 % of the maximum load current value for heater break alarm Type 2.

When the control method is Zero-cross Control, RKC recommends:

Set the heater break alarm set value to approximately 80 % of the reading of current transformer input. Set the heater break alarm set value to a slightly smaller value to prevent a false alarm when power supply variation is large. Set the heater break alarm set value to a slightly larger value to detect a failure of one heater when more than one heaters are connected in parallel. But the set value should be less than the maximum reading of current transformer input.

Setting range: 0 to 100 % (0: Heater break alarm 1 unused) Factory set value: 20

This alarm value is the deviation setting when the heater break alarm 1 type is type 1.

This parameter is not displayed when the heater break alarm function is not provided.

For the function description, see P. 57.

IMR01V02-E1 37

4. SETTING

(7) Thyristor break-down set value setting ( )

Use to set the thyristor break-down set value. For the thyristor break-down set value, make the setting as follows.

When the control method is Phase Control, RKC recommends:

When the control method is Zero-cross Control, RKC recommends:

Set the heater break set value to approximately 30 % of the maximum load current value.

Setting range: 0 to 100 % (0: Thyristor break-down alarm unused) Factory set value: 20

This alarm value is the deviation setting when the heater break alarm 1 type is type 1.

This parameter is not displayed when the heater break alarm function is not provided.

For the function description, see P. 57.

(8) Heater break alarm 2 set value setting ( )

Use to set the heater break alarm 2 set value. For the heater break alarm 2 set value, make the setting as follows.

When the control method is Phase Control and heater break alarm Type 1 is selected, RKC

recommends:

Set the value must be equal or less than the heater break alarm 1 set value.

When the control method is Phase Control and heater break alarm Type 2 is selected:

For the type 2, this item is not available. Set the “0: Heater break alarm 2 unused.”

When the control method is Zero-cross Control is selected:

For the zero-cross control, this item is not available. Set the “0: Heater break alarm 2 unused.”

Setting range: 0 to 100 % (0: Heater break alarm 2 unused) Factory set value: 15

This alarm value is the deviation setting when the heater break alarm 2 type is type 1.

This parameter is not displayed when the heater break alarm function is not provided.

For the function description, see P. 57.

IMR01V02-E1

(9) Current limiter value setting ( )

Use to set the current limiter value.

Setting range: 20 A type: 0.0 to 22.0 A

30 A type: 0.0 to 33.0 A 45 A type: 0 to 50 A 60 A type: 0 to 66 A 80 A type: 0 to 88 A 100 A type: 0 to 110 A

Factory set value: 20 A type: 22.0

30 A type: 33.0 45 A type: 50 60 A type: 66 80 A type: 88 100 A type: 110

If a current limit value is set to its maximum value, the current limit function is deactivated. Factory set value is deactivation state.

This parameter is not displayed when the heater break alarm function is not provided.

For the function description, see P. 56.

(10) Set data lock setting ( )

4. SETTING

The Set Lock Function limits access of unauthorized personnel to the parameter and prevents parameter change by mistake. Parameters of Setting mode and Engineering mode can be locked.

Setting range:

Set data lock

Setting mode

0: Setting mode unlock 1: Setting mode lock

Engineering mode

0: Engineering mode lock 1: Engineering mode unlock

Unused

Factory set value: 0000

If the parameters of Engineering mode are locked, those parameters are not displayed.

IMR01V02-E1

4. SETTING

4.5 Engineering Mode

Parameters in Engineering mode should be set according to the application before setting any parameter related to operation. Once the Parameters in the Engineering mode are set correctly, those parameters are not necessary to be changed for the same

4.5.1 Transfer to engineering mode

When changing to the Engineering mode, it is necessary to unlock the Engineering mode lock.

1. Change to setting mode.

application under normal conditions.

All parameters of the engineering mode are displayed regardless of the instrument specification.

Setting mode (Internal manual set value )

SET

2. Press the SET key several times to change to the set data lock setting.

Set data lock setting

SET

3. Press the shift key to high-light the tens digit of display (lower).

Set data lock setting

SET

IMR01V02-E1

4. Press the UP key to change 0 to 1 in the tens digit.

Set data lock setting

Set value 0000: Engineering mode lock 0010: Engineering mode unlock

SET

5. Press the SET key to unlock the engineering mode. The display goes to the first parameter in engineering mode.

Set data lock setting

Internal manual

set value

4. SETTING

SET SET

6. Press the shift key while pressing the SET key to change to the engineering mode. The display goes to the function block 24.

Internal manual

set value

SET SET

Engineering mode

Function block 24

IMR01V02-E1

4. SETTING

4.5.2 Display sequence

Setting items are classified into groups (function block: F) within the Engineering mode.

• Change to the function block (F.): To go to the next function block, press UP or DOWN keys.

• Change to parameter: To go to the next parameter, press SET key.

To function block 91 (F91.)

(F24.)

(F30.)

(F45.)

(F46.)

(F51.)

(F52.)

DOWN key

Contact input

(P. 43)

SET key

DOWN key UP ke

(P. 43)

SET key

DOWN key UP ke

(P. 44) (P. 44) (P. 45) (P. 45)

DOWN key UP ke

(P. 45) (P. 45) (P. 45)

DOWN key UP ke

(P. 46) (P. 46) (P. 46) (P. 46)

DOWN key UP ke

(P. 47) (P. 47) (P. 47) (P. 47) (P. 47)

action

Output mode for

phase control

Number of heater break

alarm 1 delay times

Number of heater break

alarm 2 delay times

Control method

Output limiter

(high)

(P. 43)

SET key

(dISL)

(P. 43) (P. 44) (P. 44)

SET key

(oS) (LGA1) (LGA2)

SET keySET key SET key

(HbC1) (AS1) (ILS)

SET key SET keySET key

(HbC2) (AS2)

SET key SET keySET key

(ConT) (rSA)

SET key SET keySET key

Return to F24.

Alarm 1

output logic

Heater break

alarm 1 type

Heater break

alarm 2 type

RUN/STOP

action

Output limiter

(low)

SET key

Output limiter (high)

output logic

Alarm interlock

Return to F46.

Input signal

at operation start

Alarm 2

SET key

(InSS)

Output limiter (high)

time at operation start

SET key

Return to F30.

Return to F45.

Return to F51.

SET key

Function block 24

Function block 30

Function block 45

Function block 46

Function block 51

Function block 52

(oLH) (oLL) (SoLH) (SoLT)

Base-up

DOWN key UP ke

Function block 60

(F60.)

Function block 91

(F91.)

UP ke

To function block 24 (F24.)

(P. 48)

This item cannot be used.

DOWN key UP ke

(P. 48) (P. 48) (P. 48) (P. 48)

ROM version

Integrated operating time (upper 2 digits)

SET key

set value

Return to F 52.

Integrated operating time (lower 4 digits)

SET keySET key

(WTH ) (WTL )

SET key

Return to F91.

(P. 47)

(bAUP)

IMR01V02-E1

4. SETTING

4.5.3 Description of each parameter

For details on changing the numeric value, see 4.2.2 Procedure for changing numerical

(1) Function block 24 ( )

 Contact input action ( )

Use to select the contact input action of auto/manual mode transfer. This selection also affects the display of the input signal monitor 1.

Setting item: 0: External manual mode ↔ Auto mode

Factory set value: 0

value (P. 34).

1: Internal manual mode ↔ Auto mode 2: Internal manual mode (fixed)

Relationship between Contact input action and Contact input

Contact input action

Contact input state

Closed Open

0: External manual mode ↔ Auto mode External manual mode

Auto mode

1: Internal manual mode ↔ Auto mode Internal manual mode

2: Internal manual mode (fixed) Internal manual mode

(2) Function block 30 ( )

 Output mode for phase control ( )

Use to select the output method for phase control with linearity load (resistor load).

When constant current control is selected, no normal operation is performed if the rated current of thyristor differs from that maximum load current flowing through the heater. In such a case, set the gradient so that the maximum load current value which flows through the heater is obtained at an input signal of 100 %. (For the setting

Setting item: 0: Proportional phase angle to input

Factory set value: Factory set value varies depending on the instrument specification.

method, see P. 54.)

Any output mode not specified when ordering is invalid even if set.

Output mode setting is invalid when zero-cross control is selected.

The output mode is invalid in zero-cross control. However, it is impossible to go to the next parameter if not set to any one of 0, 1, and 2.

1: Proportional voltage to input 2: Proportional square voltage (electric power) to input 3: Constant current control 4: Constant voltage control 5: Constant power control

For the output characteristic, see P. 53.

IMR01V02-E1

4. SETTING

 Alarm 1 output logic ( )

Alarm 2 output logic ( )

Use to select the output logic of the alarm 1 or alarm 2. (open-collector output)

Setting item: 0: No output

1: Heater break alarm 1 (ON at alarm output) 2: Thyristor break-down alarm (ON at alarm output) 3: Heater break alarm 2 (ON at alarm output) 4: Logical OR of Heater break alarm 1 and Thyristor break-down alarm

(ON at alarm output)

5: Logical OR of Heater break alarm 1, Thyristor break-down alarm and Heater

break alarm 2 (ON at alarm output)

6: Logical OR of FAIL alarm, Power frequency error, Negative phase sequence,

Over current and Fuse break (ON at alarm output) 7: Logical OR of all alarms (ON at alarm output) 8: Heater break alarm 1 (OFF at alarm output) 9: Thyristor break-down alarm (OFF at alarm output) 10: Heater break alarm 2 (OFF at alarm output) 11: Logical OR of Heater break alarm 1 and Thyristor break-down alarm

(OFF at alarm output)

12: Logical OR of Heater break alarm 1, Thyristor break-down alarm and Heater

break alarm 2 (OFF at alarm output) 13: Logical OR of FAIL alarm, Power frequency error, Negative phase sequence,

Over current and Fuse break (OFF at alarm output) 14: Logical OR of all alarms (OFF at alarm output)

Factory set value: 0

The following alarms are optional. Any alarm not specified when ordering is not activated even if set.

• Heater break alarm 1 • Over current

• Heater break alarm 2 • Thyristor break-down alarm

• Fuse break

(3) Function block 45 ( )

 Number of heater break alarm 1 delay times ( )

Use to set the number of delay times of heater break alarm 1 and thyristor break-down alarm. This setting is common to both heater break alarm 1 and thyristor break-down alarm.

Setting item: 1 to 99 times Factory set value: 30

This item cannot be used when the heater break alarm function is not provided. The data is

invalid.

For the function description, see P. 57.

IMR01V02-E1

 Heater break alarm 1 type ( )

Use to select the type of heater break alarm 1 in the phase control.

Setting item: 0: Type 1 (Deviation alarm)

1: Type 2 (Absolute value alarm)

Factory set value: 0

This item cannot be used when the heater break alarm function is not provided. Invalid even when the data is set.

This data is invalid when zero-cross control is selected.

For the function description, see P. 57.

 Alarm interlock ( )

Use to select Use/Unuse of alarm interlock function.

Setting item: 0: Unused

1: Use

Factory set value: 0

For the function description, see P. 57.

For the release method of alarm interlock, see 5.17 Contact Input (DI) Function (P. 65).

(4) Function block 46 ( )

4. SETTING

 Number of heater break alarm 2 delay times ( )

Use to set the number of delay times of heater break alarm 2.

Setting item: 1 to 999 times Factory set value: 300

This item cannot be used when the heater break alarm function is not provided. The data is invalid.

For the function description, see P. 57.

 Heater break alarm 2 type ( )

Use to select the type of heater break alarm 2 in the phase control.

Setting item: 0: Type 1 (Deviation alarm)

1: Type 2 (Absolute value alarm)

Factory set value: 0

This item cannot be used when the heater break alarm function is not provided. Invalid even when the data is set.

This data is invalid when zero-cross control is selected.

For the function description, see P. 57.

IMR01V02-E1

4. SETTING

(5) Function block 51 ( )

 Control method ( )

Use to select the control method.

Setting item: 0: Phase control

1: Zero-cross control *

* When in constant current control, constant voltage control or constant power control, no zero-cross

control can be set. It cannot be registered even if the SET key is pressed after the corresponding

number is selected. Not to be changed to the next parameter.

Factory set value: 0

 RUN/STOP action ( )

Use to select Use/Unuse of RUN/STOP transfer function.

Setting item: 0: Unused

1: Use

Factory set value: 0

For the function description, see P. 69.

 Input signal ( )

Use to select the type of input signal.

For a voltage pulse input of 0/12 V DC or 0/24 V DC, it is not necessary to be changed as the setting is valid even if set to either “0” or “1.”

The current or voltage input is selected by a short bar on the input terminals. (See P. 17)

Setting item: 0: 0 to 20 mA DC, 0 to 5 V DC, 0 to 10 V DC *, 0/12 V DC, 0/24 V DC

1: 4 to 20 mA DC, 1 to 5 V DC, 0/12 V DC, 0/24 V DC

* As the hardware differs for 0 to 10 V DC, it is impossible to change to any input signal other than

the voltage pulse input.

Factory set value: Factory set value varies depending on the instrument specification.

Current input 0 to 20 mA DC

Voltage input 0 to 5 V DC

Current input 4 to 20 mA DC

Voltage input 1 to 5 V DC

Voltage pulse input 0/12 V DC

Hardware 1 Hardware 2

It is impossible to change to the input signal of differen hardware.

It is possible to change the input signal in the same hardware.

Voltage input 0 to 10 V DC

Voltage pulse input 0/12 V DC

Voltage pulse input 0/24 V DC

IMR01V02-E1

(6) Function block 52 ( )

 Output limiter (high) ( )

Use to set the high limit value of output.

Setting item: 0.0 to 100.0 % Factory set value: 100.0

Output limiter (high) value must be equal or higher than Output limiter (low).

For the function description, see P. 50.

 Output limiter (low) ( )

Use to set the low limit value of output.

Setting item: 0.0 to 100.0 % Factory set value: 0.0

Output limiter (low) value must be equal or lower than Output limiter (high).

The Base-up function cannot be used together. The output limiter [low] function is effective only when the Base-up setting is set to 0.0.

For the function description, see P. 50.

 Output limiter (high) at operation start ( )

4. SETTING

Use to set the high limit value of output at operation start. Output limiter (high) value at operation start must be lower than output limiter (high).

Setting item: 0.0 to 100.0 % Factory set value: 50.0

For the function description, see P. 51.

 Output limiter (high) time at operation start ( )

Use to set the high limit time of output at operation start.

Setting item: 0.0 to 600.0 seconds Factory set value: 0.0

For the function description, see P. 51.

 Base-up set value ( )

Use to set the base-up set value (output bias) of output.

Setting item: 0.0 to 100.0 % Factory set value: 0.0

The base-up set value is effective only when the output limiter (low) is set to 0.0.

The base-up set value will not exceed the output limiter (high).

For the function description, see P. 52.

IMR01V02-E1 47

4. SETTING

(7) Function block 60 ( )

Function block 60 cannot be used.

(8) Function block 91 ( )

Only displayed for the F91 function block.

 ROM version

Display the version of loading software.

 Integrated operating time [upper 2 digits] ( )

Display the integrated operating time (upper 2 digits) of instrument.

Details of display: 0 to 99 (Resolution of display: 10, 000 hours)

Up to 999,999 from 0 including the upper and lower digits can be displayed.

 Integrated operating time [lower 4 digits] ( )

Display the integrated operating time (lower 4 digits) of instrument. However, as the integral time is increments by 1 when the power is turned on or off. If the total integrated operating time exceeds 9,999 hours, these digits move to the integrated operating time display [upper 2 digits] ( ).

Details of display: 0 to 9999 (Resolution of display: 1 hours)

IMR01V02-E1

5. FUNCTIONS

5.1 Control Method

 Phase control

Phase control is to continuously control electric power supplied to a load by changing phase angle voltage applied to the load. Each half-cycle has ON and OFF time.

 Zero-cross control (Continuous)

Continuous Zero-cross control is to control electric power supplied to a load by turning the power supply voltage ON and OFF at the point of 0 V AC so that the high frequency noise can be suppressed compared with phase control. This on and off time is typically measured in milliseconds.

 Zero-cross control (Input synchronous type)

of AC

57 %

50 %

0 V (ON) 0 V (OFF)

Input Synchronous type Zero-cross control is to turn the power supply ON and OFF synchronously with

Input signal

OFF ON OFF

the pulse signal from a controller. This on and off time is typically measured in seconds.

5.2 Ramp Function (Soft-Start/Soft-Down Function)

Soft-start/soft-down function gradually ramps up/down the output voltage to the demand level over the set time to prevent a sudden change in load or voltage. The soft-start/soft-down time sets a period of time from 0 to 100 % or 0 to 100 %.

Output voltage

100%

0% 0%

Input signal

Manual setting

Soft-start

time

Soft-start

time

Soft-down

time

Output limiter (high) 80%

→ Time

→

Time

Soft-start/Soft-down action diagram

Output voltage

100%

Input signal

Manual setting

If a load generating large rush current is used, thyristor break-down may occur when

no soft-start time is appropriately set.

In zero-cross control, no rush current can be suppressed even if the soft-start time is set.

Soft-down

time

→ Time

→

Time

IMR01V02-E1 49

5. FUNCTIONS

5.3 Gradient Setting Function

Gradient setting is a multiplier to be applied to output voltage to the load to adjust the output value depending on an application. The following two types of gradient setting are available.

• Internal gradient setting set by the THW-3 front keys

• External gradient setting set by the external gradient setter (external potentiometer)

100

External gradient scale Internal gradient set value

100

1.00

Output (%)

→

0 25 50 75 100

Input signal (%)

→

Gradient output characteristics

0.80

0.60

0.40

0.20

0.00

The output value is adjusted by Gradient Setting Function as follows.

• (Output voltage calculated by Auto mode) × (Internal gradient setting) × (External gradient set value)

• (Output voltage calculated by Auto mode) × (Internal gradient set value)

• (Output by manual set value) × (Internal gradient set value) × (External gradient set value)

If it is necessary to make only the external gradient set value valid, set the internal gradient set value to 1.00.

5.4 Output Limiter (High and Low)

This function limits the output range. Output limiter function is related to other functions.

• Output limiter (high) and (low) have priority to the output value function. The maximum output from the instrument will not exceed the output limiter (high) and the minimum output will not go below the output limiter (low).

• Output limiter (high) has priority to the output value

calculated with Gradient Setting and Base-Up setting function. The maximum output from the instrument will not exceed the output limiter (high).

• When output limiter (low) is not set to zero (0.0), the base-up setting function is invalid.

Output value = (Input signal or manual set value) × (Gradient set value)

Output value = (Input signal or manual set value) × (Gradient set value) + (Base-up set value)

100

80.0 % Output limiter (high)

calculated with Gradient Setting

Output (%)

→

0 25 50 75 100

→ Input signal (%)

10.0 % Output limiter (low)

IMR01V02-E1

5. FUNCTIONS

5.5 Output Limiter (High) at Operation Start

This is the function used to restrict the output for any preset time [output limiter (high) time at the time of start] when power is turned on. It is possible to lessen rush current by using this function. The use of this function is effective for any heater (halogen lamp, platinum, tungsten, molybdenum, etc.) through which rush current flows.

Output limiter (high) set value

Output limiter (high) set value at operation start

Output limiter (low) set value

 Priority order of output limiter

Output (%)

Output limiter (high) time at operation start

Time (second)

If the output limiter (high) at the time of start is set to any value larger than the output limiter (high), the latter has priority over the former.

Output limiter (high) set value at operation start

Output limiter (high) set value

Output limiter (low) set value

Output (%)

Output limiter (high) time at operation start

Time (second)

If the output limiter (high) at the time of start is set to any value smaller than the base-up set value or output limiter (low), the former has priority over the latter.

Base-up set value

Output limiter (high) set value at operation start

Output (%)

Output limiter (high) time at operation start

Time (second)

Output (%)

Output limiter (low) set value

Output limiter (high) set value at operation start

Output limiter (high) time at operation start

Time (second)

Continued on the next page.

IMR01V02-E1

5. FUNCTIONS

Continued from the previous page.

If the output limiter (high) at the time of start is set to any value larger than the current limiter value, the latter has priority over the former.

Output limiter (high) set value at operation start

Current limiter set value

Output (%)

Output limiter (high) time at operation start

Time (second)

5.6 Base-Up Setting Function

Base-up setting function adds positive bias to the output value calculated with gradient setting function.

• Base-up setting is valid only when output limiter (low) is set to zero (0.0).

• Output limiter (high) has priority to the output value

Base-Up setting function. The maximum output from the instrument will not exceed the output limiter (high).

Output value = (Input signal or manual set value) × (Gradient set value) + (Base-up set value)

Base-up

100

Output (%)

→

0 25 50 75 100

Input signal (%)

→

* calculated with Gradient Setting and

Base-up setting 20 %

IMR01V02-E1

5. FUNCTIONS

5.7 Output Mode for Phase Control

When phase control is selected for a linearity load (resistance load), one of the following six output types can be selected. The factory set value is proportional square voltage (electric power) to input. (The output mode setting is invalid when the control method is zero-cross control.)

Proportional phase angle to input

100

Proportional voltage to input

100

Proportional square voltage

(electric power) to input

100

Phase angle ratio (%)

4 12 20

Input signal (mA)

Constant current control

100

8 mA12 mA16 mA 20 m

Output voltage (%)

50 75 100

Output current (%)

Constant power control

100

Output voltage (%)

40 50 60 80 100

Output current (%)

Input

signal

Input

signal

20 mA

16 mA

12 mA

8 mA

5 mA

Effective voltage (%)

41220

Input signal (mA)

100

Output voltage (%)

Electric power (%)

4 12 20

Input signal (mA)

Constant voltage control

40 60 80 100

Output current (%)

Input signal

20 m

16 m

12 m

8 mA

Constant current, Constant voltage and Constant power controls are optional.

IMR01V02-E1

5. FUNCTIONS

(1) Constant current control

This is the function used to keep the output current constant in proportion to the input signal. This function is effective when a heater with large resistance changes caused by temperature variations is used (such as tantalum, superkanthal, tungsten, platinum, or molybdenum). The maximum output current when the constant current control function is used coincides with the rated current in the thyristor specification.

Operating condition Stability

Power supply voltage variation ±10 %

±2 % of full scale

Load variation 2 times

 Caution for using constant current control function

If the rated current of thyristor differs from that maximum load current flowing through the heater, compensate for the difference by setting the gradient. If there is the difference, a section where control is disabled may come into existence. A compensation example when there is a difference between the currents flowing through the thyristor and the heater is shown in the following.

Example: When used in the following condition

• Rated current of Thyristor: 30 A

• Maximum load current of heater: 15 A

• Input signal from controller: 4 to 20 mA DC

• Soft-start time setting: 0.0 seconds

The soft-start function is activated during four cycles from load operation start even at a soft-start time of 0.0 seconds.

When used without setting the gradient, the maximum heater load current becomes 15 A at an input signal of 12 mA. In this case, control is disabled if the input signal exceeds 12 mA.

Constant current control

100

Maximum load current (15 A) of heater

Current (%)

4 12 20

Input signal (mA)

Control is disabled within this section.

Continued on the next page.

IMR01V02-E1

5. FUNCTIONS

Continued from the previous page.

In this case, set the gradient to 50 % so that the maximum heater load current will become 15 A at an input signal of 20 mA. The gradient is valid even if internally set or set by the external gradient setter.

Constant current control

100

Current (%)

Gradient setting 50 %

4 12 20

Input signal (mA)

Maximum load c urrent (15 A) of heater

(2) Constant voltage control

This is a control method of compensating power supply voltage and load variations so that no output voltage changes while in control.

Operating condition Stability

Power supply voltage variation ±10 %

±2 % of full scale

Load variation 2 times

(3) Constant power control

This is a control method of outputting the root mean square power value proportional to the input signal even if there are power supply voltage and load variations while in control. This is suitable for heater control such as by silicon carbide or silicon unit which increases its resistance value due to temperature and secular changes.

Operating condition Stability

Power supply voltage variation ±10 %

±4 % of full scale

Load variation 2 times

The soft-start function is activated during four cycles from load operation start even at a soft-start time of 0.0 seconds.

IMR01V02-E1

5. FUNCTIONS

5.8 Current Limiter Function

This is the function of limiting a measured current value to a value not exceeding the preset current limit value. A current value is measured for each constant cycle and then the maximum phase angle not exceeding the current limit value is calculated from the above current value thus measured. If the phase angle at that current output is larger than the maximum phase angle calculated, the current is output at the maximum phase angle to restrict that current. The maximum phase angle is calculated during a time period of 0.1 seconds from the start of load operation, and the current limit function is activated after the maximum phase angle is calculated.

If a load through which large rush current flows is used, the current limit function

cannot restrict the above current. In this case, use the current limit function together with the soft-start function.

Even at a soft-start time of 0.0 seconds, the soft-start function is activated in order to calculate the maximum phase angle during a time period of 0.1 seconds from the start of load operation.

If a current value exceeds “Current limit value + Differential gap (0.5 A or 1.0 A) *” due to voltage variations or load resistance changes while the current limit function is being activated, the maximum phase angle is immediately re-calculated to restrict it within a cycle of 2.5 from the time when it exceeds “Current limit value + Differential gap.”

* Differential gap 0.5 A: 20 A, 30 A types

Differential gap 1 A: 45 A, 60 A, 80 A and 100 A types

If a current limit value is set to its maximum value, the current limit function is deactivated.

The current limiter function cannot be used when zero-cross control is selected.

5.9 Automatic Power Frequency Detection and Power Frequency Monitoring Function

 Automatic power frequency detection

The instrument automatically detects a power supply frequency (50 Hz or 60 Hz) when the power is turned on.

Detection range: 50 Hz: 45.0 to 54.9 Hz 60 Hz: 55.0 to 64.9 Hz Action on occurrence of error: FREQ lamp is lit.

Thyristor output is turned off.

 Power frequency monitoring function

This function monitors the power supply frequency and when it goes out of the detection range, the error message display appears.

Detection range: 50 Hz: 45.0 to 54.9 Hz 60 Hz: 55.0 to 64.9 Hz Action on occurrence of error: FREQ lamp is lit.

Thyristor output is turned off. (The output can be turned ON when the error is canceled.)

IMR01V02-E1

5. FUNCTIONS

5.10 Alarm Interlock Function

The alarm interlock function is used to hold the alarm state even if the power frequency or CT input value is out of the alarm zone after its entry into the alarm zone once. Power frequency error (FREQ), heater break alarm 1 (HBA1), thyristor breakdown alarm (THY. B) and heater break alarm 2 (HBA2) can be interlocked.

Indication lamp: This lamp continues lighting until the alarm is released. Alarm output: The alarm output continues being output until the alarm is released. Alarm interlock release: The Alarm interlock can be released by the external contact signal.

5.11 Heater Break Alarm 1 (HBA1), Heater Break Alarm 2

(HBA2) and Thyristor Break-Down Alarm Functions

The heater break alarm (HBA) and thyristor break-down alarm monitors the current flowing through the load by a dedicated current transformer (CT). The THW-3 compares the measured value with the set values, and detects a fault in the heating circuit. In addition, there are several types of alarms depending on control methods and applications of these alarms. Read this chapter carefully to choose an suitable method and set an appropriate set value.

5.11.1 Number of alarm delay times

The alarm delay function is that which delays the occurrence of alarm in order to prevent alarm malfunctioning. When an alarm condition becomes ON status, the output is suppressed until the preset number of sampling times elapses. After the preset number of sampling times elapses, if the alarm output is still ON status, the output will be produced. In addition, if the alarm state is released while the alarm delay function is being activated, the alarm output is not turned on.

When the alarm types are the Heater break alarm 1 and Thyristor break-down alarm:

Alarm state > 5 sampling cycles * × Number of alarm delay times (1 to 99 times)

When the alarm is the heater break alarm 2:

Alarm state > 5 sampling cycles * × Number of alarm delay times (1 to 999 times) * It is so designed that the alarm output is turned on when the alarm state corresponding to five

sampling times continues even with the number of alarm delay times not set.

Zero-cross control

HBA1 set value

CT input value

Alarm output



Capture

Alarm state

For the preset number of consecutive sampling cycles

ON OFF

IMR01V02-E1 57

5. FUNCTIONS

5.11.2 Heater break alarm for phase control (Type 1)

Type 1 can be used as follows by using three heater break alarm set values. (See Application 1 [P. 61].)

Heater break alarm 1 (HBA1) set value:

The alarm can be output when a heater break occurs by setting the heater break alarm set value.

Thyristor break-down set value:

It is possible to output an alarm when a thyristor element is shorted or broken by setting the thyristor breakdown set value.

Heater break alarm 2 (HBA2) set value:

This alarm set value can be used as an auxiliary alarm. For example, it can be used as a heater deterioration alarm if set to any value slightly smaller than the heater break alarm set value to output the alarm before a heater break occurs when the load current decreases due to heater deterioration, etc.

The heater break alarm of Type 1 cannot be used for heat generation substances such

as noble metals

In addition, it cannot be used for heat generation substances such as silicon carbide

making resistance changes with temperature variations and a lapse of time.

Noble metals (Such as platinum, molybdenum, tantalum, tungsten, or superkanthal)

Type 1 cannot be used for any load (such as lamp heater) whose resistance change due to a change in temperature is large.

Type 1 cannot be used for any power supply waveforms other than a sine waveform.

(1) How alarm is activated

* making large resistance changes with temperature variations.

• When heater current does not flow (Heater break, malfunction of the control device, etc.)

When the phase angle is equal to or more than 15% and the current transformer (CT) input value is equal to or less than the heater break alarm (HBA) set value for the preset number of consecutive sampling cycles, an alarm status is produced. However, in order to prevent

malfunctioning, it is so designed that no heater break alarm occurs at an phase angle of less than 15 % (less than 15 % of maximum load current).

• When heater current can not be turned off (Thyristor break-down or permanent damage)

When the current transformer (CT) input value is equal to or greater than the heater break alarm

set value

Thyristor break-down set value or Heater break alarm 2 (HBA2) set value

for the preset number of consecutive sampling cycles, an alarm status is produced.

The alarm will be turned off when the current transformer (CT) input value goes in and stays at non-alarm range for five consecutive cycles. (However, excepting a case where the alarm interlock function is used.)

IMR01V02-E1

5. FUNCTIONS

(2) Setting the Heater break alarm

When using the heater break alarm, it is necessary to set the maximum load current set value for alarm (MAXC). (See P. 37)

The following table shows the amount of current to be reduced when one heater is broken with heaters parallel connected. It shows how much current is reduced when one heater is broken at the output (phase angle) shown in the table. Set the heater break alarm set value by referring to the amount of current reduced.

 Delta connected

Break

(a) When heaters are not

parallel connected

(b) When two heaters are parallel

connected to each phase

Table 1: The amount of current reduced (Delta connected)

Number of parallel

connection of heater

When heaters are not parallel connected

When two heaters are parallel connected to each phase

When three heaters are parallel connected to each phase

In order to prevent malfunctioning, it is so designed that no heater break alarm occurs at an phase angle of less than 15 % (less than 15 % of maximum load current).

14 %

(180 °)

Reduction

of 6 %

Reduction

of 3 %

Reduction

of 2 %

29 %

(150 °)

Reduction

of 16 %

Reduction

of 7 %

Reduction

of 4 %

Output (Phase angle)

42 %

(120 °)

Reduction

of 26 %

Reduction

of 11 %

Reduction

of 7 %

57 %

(90 °)

Reduction

of 29 %

Reduction

of 13 %

Reduction

of 9 %

71 % (60 °)

Reduction

of 31 %

Reduction

of 15 %

Reduction

of 10 %

86 %

(30 °)

Reduction

of 31 %

Reduction

of 16 %

Reduction

of 11 %

100 %

(0 °)

Reduction

of 28 %

Reduction

of 16 %

Reduction

of 11 %

 Star connected (Y connected)

Break

(a) When heaters are not

parallel connected

IMR01V02-E1

(b) When two heaters are parallel

connected to each phase

Continued on the next page.

5. FUNCTIONS

Continued from the previous page.

Table 2: The amount of current reduced (Star connected)

Number of parallel

connection of heater

When heaters are not parallel connected

When two heaters are parallel connected to each phase

When three heaters are parallel connected to each phase

14 %

(180 °)

Reduction

of 8 %

Reduction

of 3 %

Reduction

of 2 %

29 %

(150 °)

Reduction

of 20 %

Reduction

of 8 %

Reduction

of 5 %

Output (Phase angle)

42 %

(120 °)

Reduction

of 32 %

Reduction

of 13 %

Reduction

of 8 %

57 %

(90 °)

Reduction

of 38 %

Reduction

of 16 %

Reduction

of 10 %

71 %

(60 °)

Reduction

of 43 %

Reduction

of 18 %

Reduction

of 11 %

86 %

(30 °)

Reduction

of 44 %

Reduction

of 19 %

Reduction

of 12 %

100 %

Reduction

of 42 %

Reduction

of 19 %

Reduction

of 12 %

In order to prevent malfunctioning, it is so designed that no heater break alarm occurs at an phase angle of less than 15 % (less than 15 % of maximum load current).

 Explanation of Table 1 and Table 2

(0 °)

Example: When heaters are not parallel connected with these heaters star-connected: (See table 2.)

Heater break alarm 1 (HBA1) is set at 20 % before factory shipment. The heater break alarm is turned on when the current reduces by more than 20 % from the computed heater current value at each output (phase angle) as shown in Table 2. In table 2, the current reduces by more than 20 % with one heater broken when the output is larger than 29 % (phase angle: 150 °).

Current value (A)

Maximum load current value (A)

The current value reduces by 20 %.

Heater break alarm ON



Computed heater current value



Heater break alarm 1 (HBA1) set value (20 %)



Current value (CT measured value) when one heater is broken

The heater break alarm is turned on as the computed heater current value reduces by 20 % at an output of 29 % (phase angle: 150 °).

HBA alarm is turned on ≥ Computed heater current value − (Maximum load current set value (A) × HBA1 set value [20 %])

(210°)

Heater break alarm

0 %

14 %

(180°)

OFF

29 %

(150°)

42 %

(120°)

57 %

(90°)

71 % (60°)

86 % (30°)

Output (Phase angle)

100 %

(0°)

IMR01V02-E1

 Setting example of Heater break alarm

Application: Heater with the specification of a maximum load current of 100 A

Three-phase star connected The heater is not connected in parallel. The set value of heater break alarm 1 (HBA1) is used for heater break detection. (The heater break alarm needs to be output at an output of more than 15 %.) The set value of heater break alarm 2 (HBA2) is used for heater deterioration detection.

Set the related parameters as follows.

Parameter in Setting mode

 Maximum load current set value for alarm (MAXC) *: 100 A

* Always set the maximum heater current value. (See P. 37)

 Heater break alarm 1 set value setting (HBA1): 8 %

When the heater break alarm is detected at an output of more than 15 %, check for a value near an output of 15 % by referring to Table 2. From Table 2, an output of 14 % (phase angle: 180 °) is very close to an output of 15 %. Therefore, set 8 % corresponding to the amount of current reduced at an output of 14 % (phase angle: 180 °) as the set value of heater break alarm 1 (HBA1).

 Heater break alarm 2 set value setting (HBA2): 6 %

As the heater deterioration alarm must detect the degree of deterioration before the heater break alarm occurs, set the set value of heater break alarm 2 (HBA2) to any value smaller than the set value of heater break alarm 1 (HBA1). Here, the former is set at 6 % as an example.

 Thyristor break-down set value setting (THb): 0 % [Thyristor break-down alarm unused]

Parameter in Engineering mode

The computed current value used for heater break alarm (HBA) determination point

The computed current value used for heater break alarm 1 (HBA1) determination point

= (Maximum load current set value) × (Heater break alarm 1 (HBA1) set value)

= 100 A × 8 % = 8 A Heater break alarm 1 (HBA1) current value 8 A

The computed current value used for heater break alarm 2 (HBA2) determination point

= (Maximum load current set value) × (Heater break alarm 2 (HBA2) set value)

= 100 A × 6 % = 6 A Heater break alarm 2 (HBA2) current value 6 A

The current value (8 Ampere) of heater break alarm 1 (HBA1) is set below the computed heater current value. The current value (6 Ampere) of heater break alarm 2 (HBA2) is set above and below the computed heater current value. (See the graph of next page.)

 Alarm 1 output logic (LGA1): 1 [Heater break alarm 1 (ON at alarm output)]  Alarm 2 output logic (LGA2): 3 [Heater break alarm 2 (ON at alarm output)]  Number of heater break alarm 1 delay times (HbC1): 1 time  Heater break alarm 1 type (AS1): 0 [Type 1 (deviation alarm)]  Alarm interlock (ILS): 0 [Unused]  Number of heater break alarm 2 delay times (HbC2): 1 time  Heater break alarm 2 type (AS2): 0 [Type 1 (deviation alarm)]  Control method (ConT): 0 [Phase control]

Continued on the next page.

5. FUNCTIONS

IMR01V02-E1

5. FUNCTIONS

Continued from the previous page.

Current value (A)

Maximum load current value (A)

Heater break alarm 2 (HBA2) set value (upper): 6 % (6 A)

Computed heater current value

Heater break alarm 2 (HBA2) set value (lower): 6 % (6 A)

Heater break alarm 1 (HBA1) set value: 8 % (8 A)

Current value (CT measured value) when one heater is broken

When the output is less than 15 % the heater break alarm is not activated. Therefore, the output of heater break alarm 1 (HBA1) is turned on if the computed heater current value reduces by more than 8 % at an output of more than 15 %. In addition, if the amount of computed heater current reduced is between 6 % and 8 % at an output of more than 15 %, the output of heater break alarm 2 (HBA2) is turned on.

0 %

(210°)

14 %

(180°)

29 %

(150°)

42 %

(120°)

57 %

(90°)

71 %

(60°)

86 % (30°)

Output (phase angle)

100 %

(0°)

The set value of heater break alarm 2 (HBA2) is set above and below the computed heater current value (deviation high/low alarm). The set value (above) of heater break alarm 2 (HBA2) is an alarm on the thyristor break-down side.

This setting example shows the operation performed under the following ideal condition. The actual operation differs depending on power supply voltage and load variations. Therefore, set the value meeting the customer’s operating condition.

• Power supply voltage: Constant

• Load variation: None

• Balanced three-phase load

How alarm is checked

If an alarm occurs, the indication lamp (HBA1/HBA2) at the front lights. In addition, the alarm signal is output from the alarm 1 or 2 of the input/output connector.

IMR01V02-E1

5. FUNCTIONS

(3) Thyristor break-down alarm

The thyristor break-down alarm is turned on when the computed heater current value is larger than the thyristor break-down set value set at each output (phase angle).

Thyristor break-down alarm is turned on ≥ Computed heater current value + (Maximum load current set value (A) × Thyristor break-down set value [20 %])

Current value (A)



Thyristor break-down set value: 20 % (Factory set value)

Maximum load current value (A)

0 %

(210°)

14 %

(180°)

29 %

(150°)

42 %

(120°)

57 % (90°)

71 % (60°)

86 % (30°)



Computed heater current value

Output (phase angle)

100 %

(0°)

When using the thyristor break-down alarm, it is also necessary to set the maximum

load current set value for alarm (MAXC). (See P. 37)

Conduct the setting by referring to  Setting example of Heater break alarm (P. 61).

How alarm is checked

If an alarm occurs, the indication lamp (THY.B) at the front lights. In addition, the alarm signal is output from the alarm 1 or 2 of the input/output connector.

IMR01V02-E1

5. FUNCTIONS

5.11.3 Heater break alarm for phase control (Type 2)

Type 2 corresponds to a heater break alarm when one heater is used. (See  Application) Use the heater break alarm of Type 2 when a noble metal heater with large resistance changes caused by temperature variations is used.

 How alarm is activated

 Application (When heater break alarm 1 is used for heater break detection

No type 2 can be used when two or more heaters are used in parallel connection.

• When heater current does not flow (Heater break, malfunction of the control device, etc.)

When the phase angle is equal to or more than 15 % and the current transformer (CT) input value is equal to or less than the heater break alarm (HBA) set value for the preset number of consecutive sampling cycles, an alarm status is produced.

However, in order to prevent malfunctioning, it is so designed that no heater break alarm occurs at an phase angle of less than 15 % (less than 15 % of maximum load current).

• When heater current can not be turned off (Thyristor break-down or permanent damage)

When the current transformer (CT) input value is equal to or greater than the thyristor break down set value for the preset number of consecutive sampling cycles, an alarm status is produced.

and the thyristor break-down alarm, for thyristor element shorting detection)

For Type 2, no set value of heater break alarm 2 (HBA2) is used. Setting the parameter as shown in the following performs the operation as illustrated in the Figure (P. 65).

Set the heater break alarm 1 set value and thyristor break-down set value to approximately 5 % of the maximum load current value. Do not set the heater break alarm set value to more than 15 %.

Parameter in Setting mode

 Maximum load current set value for alarm (MAXC)

: 20.0 A

 Heater break alarm 1 set value setting (HBA1): 5 %  Thyristor break-down set value setting (THb): 5 %  Heater break alarm 2 set value setting (HBA2)

Always set the maximum heater current value. (See P. 37)

Always set the heater break alarm 2 to “0: Heater break alarm 2 unused.”

: 0 (Heater break alarm 2 unused)

The computed current value used for heater break alarm (HBA) and thyristor break-down alarm determination points

The computed current value used for heater break alarm 1 (HBA1) determination point

= (Maximum load current set value) × (Heater break alarm 1 (HBA1) set value) = 20.0 A × 5 % = 1.0 A Heater break alarm 1 (HBA1) current value 1.0 A

The computed current value used for thyristor break-down alarm determination point

= (Maximum load current set value) × (Thyristor break-down set value) = 20.0 A × 5 % = 1.0 A Thyristor break-down current value 1.0 A

Continued on the next page.

IMR01V02-E1

Continued from the previous page.

Parameter in Engineering mode

 Alarm 1 output logic (LGA1): 1 [Heater break alarm 1 (ON at alarm output)]  Alarm 2 output logic (LGA2): 2 [Thyristor break-down alarm (ON at alarm output)]  Number of heater break alarm 1 delay times (HbC1): 1 time  Heater break alarm 1 type (AS1): 1 [Type 2 (Absolute value alarm)]  Alarm interlock (ILS): 0 [Unused]  Number of heater break alarm 2 delay times (HbC2): This parameter does not use.  Heater break alarm 2 type (AS2): This parameter does not use.  Control method (ConT): 0 [Phase control]

(When the maximum load current value is set to 20 A)

Current (A)

5. FUNCTIONS

Alarm range of heater break alarm

(Thyristor break-down)

When the phase angle is 0 % and the current transformer input value is equal to or greater than the thyristo break-down set value for the preset number of consecutive sampling cycles, an alarm status is produced.

Heater break alarm 1 set value 5 % (1.0 A)

14.9 %

No heater break alarm occurs if within this range. However, the alarm occurs in the case of thyristor break-down.

100 % 0

larm range of heater break alarm

When the phase angle is equal to o more than 15% and the current transformer input value is equal to or less than the heater break alarm set value fo the preset number of consecutive sampling cycles, an alarm status is produced.

Phase angle (%)

How alarm is checked

If an alarm occurs, the indication lamp (HBA1, THY.B) at the front lights. In addition, the alarm signal is output from the alarm 1 or 2 of the input/output connector.

5.11.4 Heater break alarm for zero-cross control

The following usage is available in zero-cross control. (See  Application)

Heater break alarm 1 (HBA1) set value:

The alarm can be output when a heater break occurs by setting the heater break alarm set value.

Thyristor break-down set value:

It is possible to output an alarm when a thyristor element is shorted or broken by setting the thyristor break-down set value.

Heater break alarm 2 (HBA2) set value:

The heater break alarm 2 (HBA2) set value does not use when in the zero-cross control. Set the set value of Heater break alarm 2 to “0: Heater break alarm 2 unused.”

IMR01V02-E1

5. FUNCTIONS

 How alarm is activated

• When heater current does not flow (Heater break, malfunction of the control device, etc.)

When the control output is ON and the current transformer (CT) input value is equal to or less than the heater break alarm 1 (HBA1) set value for the preset number of consecutive sampling cycles, an alarm status is produced.

• When heater current can not be turned off (Thyristor break-down or permanent damage)

When the control output is OFF and the current transformer (CT) input value is equal to or greater than the thyristor break-down set value for the preset number of consecutive sampling cycles, an alarm status is produced.

 Application (When heater break alarm 1 is used for heater break detection

and the thyristor break-down alarm, for thyristor element shorting detection)

Parameter in Setting mode

 Maximum load current set value for alarm (MAXC)

: 20.0 A

 Heater break alarm 1 set value setting (HBA1): 80 %  Thyristor break-down set value setting (THb): 30 %  Heater break alarm 2 set value setting (HBA2)

Always set the maximum heater current value. (See P. 37)

Always set the heater break alarm 2 to “0: Heater break alarm 2 unused.”

: 0 (Heater break alarm 2 unused)

The computed current value used for heater break alarm (HBA) and thyristor break-down alarm

determination points

The computed current value used for heater break alarm 1 (HBA1) determination point

= (Maximum load current set value) × (Heater break alarm 1 set value) = 20.0 A × 80 % = 16.0 A Heater break alarm 1 (HBA1) current value 16.0 A

The computed current value used for thyristor break-down alarm determination point

= (Maximum load current set value) × (Thyristor break-down set value)

= 20.0 A × 30 % = 6.0 A Thyristor break-down current value 6.0 A

Parameter in Engineering mode

 Alarm 1 output logic (LGA1): 1 [Heater break alarm 1 (ON at alarm output)]  Alarm 2 output logic (LGA2): 2 [Thyristor break-down alarm (ON at alarm output)]  Number of heater break alarm 1 delay times (HbC1): 1 time  Heater break alarm 1 type (AS1): This parameter does not use.  Alarm interlock (ILS): 0 [Unused]  Number of heater break alarm 2 delay times (HbC2): This parameter does not use.  Heater break alarm 2 type (AS2): This parameter does not use.  Control method (ConT): 1 [Zero-cross control]

IMR01V02-E1

5. FUNCTIONS

20.0 A

HBA1 set value 80 % (16.0 A)

CT input value

Capture

Alarm output

18.5 A



15.5 A

For the preset number of consecutive sampling cycles

15.5 A 15.5 A 15.5 A 15.5 A 15.5 A

ON OFF

Heater break alarm

20.0 A 20.0 A 20.0 A

Thyristor break-down set value 30 % (6.0 A)

CT input value

Alarm output



Capture

For the preset number of consecutive sampling cycles

ON OFF

Thyristor break-down alarm

How alarm is checked

If an alarm occurs, the indication lamp (HBA1, THY.B) at the front lights. In addition, the alarm signal is output from the alarm 1 or 2 of the input/output connector.

IMR01V02-E1

5. FUNCTIONS

5.12 FAIL Alarm

An alarm occurs if a board error of this instrument is detected by the self-diagnostic function.

Action taken when an alarm occurs: The FAIL lamp lights. Thyristor output is turned off.

5.13 Negative Phase Sequence Alarm

It is fudged whether or not each phase is in positive phase sequence when power is turned on, and an alarm occurs if wiring is made by mistaking phase sequence. In addition, an alarm occurs also when only two phases are wired.

Action taken when an alarm occurs: The PHASE lamp lights. Thyristor output is turned off.

5.14 Over Current Alarm (optional)

An alarm occurs when the current exceeding 1.2 times the rating flows through this instrument.

Action taken when an alarm occurs: The OCR lamp lights. Thyristor output is turned off.

5.15 Fuse Break Alarm (optional)

An alarm occurs when the fast-blow fuse in this instrument blew.

Action taken when an alarm occurs: The FUSE lamp lights. Thyristor output is turned off.

Fuse break alarm is not available when the fast-blow fuse (with microswitch) is not provided.

5.16 Set Data Lock Function

The set lock level restricts parameter setting changes by key operation. This function prevents the operator from making errors during operation. The setting of data lock is made for each mode.

×: Mode unlock (Settable) −: Mode lock (Unsettable)

Set value Engineering mode Setting mode

0000

0001

0010

0011

− ×

− −

× ×

× −

The numeric value can be checked in Setting mode even if locked.

The Engineering mode cannot be called up if locked.

IMR01V02-E1

5. FUNCTIONS

5.17 External Contact Input (DI) Function

The following operation is performed by the external contact signal. The external contact state can be checked by the contact input state monitor.

(1) Auto/Manual mode transfer

Use to select the Auto/Manual mode by the external contact input.

When the external contact is open: Auto mode When the external contact is closed: Manual mode

 How auto set value or manual set value is checked

These values can be checked on the Input signal monitor 1 and Input signal monitor 2 (only auto set value).

 External contact action selection Auto/Manual mode transfer can select the operating item. The action type can be selected on the Contact input action (dISL). (P. 43).

(2) RUN/STOP transfer

The RUN/STOP can be selected by the external contact signal.

When the external contact is open: STOP When the external contact is closed: RUN

If the RUN/STOP transfer function is used, set the RUN/STOP action (rSA) to “1: Use.”

(See P. 46)

(3) Alarm interlock release

The alarm interlock is released by the external contact signal.

When the external contact is closed: Alarm interlock release

No alarm interlock can be released when in the alarm state. Release the alarm interlock after the cause of the alarm is cleared up.

IMR01V02-E1

6. MAINTENANCE

 In order to prevent electric shock or instrument failure, always conduct

necessary work after power supplied to the entire system is turned off.

 Conduct work after this instrument is cooled. As the temperature of this

instrument is very high just after the power is turned off, never touch the instrument while heated.

WARNING

6.1 Daily Inspection

In order to prevent accident and instrument failure, inspect the instrument periodically.

Check item Details

Inspecting main circuit terminal tightening torque

Cleaning of thyristor

As the large current flows through each hexagon headed bolt used for the main circuit terminal, the loosened bolt may generate heat to cause ignition.

Inspect the tightening torque of the bolt periodically. If loosened, tighten it with adequate torque.

Recommended tightening torque:

1.6 N⋅m (20 A, 30 A)

3.8 N⋅m (45 A, 60 A)

9.0 N⋅m (80 A, 100 A)

For the torque wrench, see page 13.

The attachment of dust to the heat radiation fins may worsen the cooling effect. Therefore, remove the dust attached using a cleaner.

70 IMR01V02-E1

6. MAINTENANCE

6.2 Troubleshooting

General causes to be assumed and measures to be taken when an error occurs in this instrument are described in the following. For any inquiries, please contact RKC sales office or the agent, to confirm the specifications of the product.

Problem Probable cause Solution

The FAIL lamp lights Error of board inside this instrument

The FREQ lamp lights

Not to be output

No gradient is set

There is no automatic setting input

The fast-blow fuse is broken. Replace the fast-blow fuse.

The FUSE lamp lights The fast-blow fuse is broken. Replace the fast-blow fuse.

The PHASE lamp lights

No output is turned off.

A thyristor element is shorted.

The HBA1 lamp lights A heater is broken. Turn off the power, and check or replace

The HBA2 lamp lights the heater, etc.

The THY.B lamp lights No soft-start time is appropriately set.

A thyristor element is damaged.

The OCR lamp lights

Power frequency is out of the allowable range (detection range) when power is turned on or during operation.

The power supply voltage is not being supplied

Wiring is conducted by mistaking phase sequence

The three-phase power supply is not supplied

The automatic set value is set to the maximum value.

A current of more than 1.2 times the rating of this instrument flowed.

Turn off the power once. If a lamp lights after the power is turned on again, please contact RKC sales office or the agent.

Check the value of power supply frequency, and turn off the power once. If a lamp lights after the power is turned on again, please contact RKC sales office or the agent.

Supply the power.

Set the external gradient or internal gradient.

Check whether or not wiring is conducted by mistaking the output signal of the controller and the type of thyristor input signal.

Check that the temperature controller normally operates.

Conduct wiring so that the phase of each power supply terminal (R, S or T) coincides with that of each main circuit terminal (1/L1, 3/L2 or 5/L3).

Supply the three-phase power.

Check the output signal of temperature controller.

Please contact RKC sales office or the agent.

If a load generating large rush current is used, thyristor break-down may occur when no soft-start time is appropriately set. In such a case, make the soft-start time longer.

For any causes other than the above, turn the power off and then contact to your nearest RKC sales agent or our sales office.

Turn off the power, and check or replace the heater, etc.

IMR01V02-E1 71

6. MAINTENANCE

6.3 Replacement of the Fast-Blow Fuse

CAUTION

Use a torque wrench for removing or tightening each hexagon headed bolt which fixes the fuse. Always remove or tighten the bolt by contacting the diagonal surfaces of the wrench with those of the bolt head.

Recommended tool:

- Torque wrench and Socket: Manufactured by TOHNICHI MFG. CO., LTD

- Extension: Manufactured by KTC (KYOTO TOOL)

Model code of adjustable type torque

wrench with ratchet head

20 A and 30 A QL6N M6

45 A to 100 A QL25N M10

Socket size

Model code of the extension

20 A to 100 A BE10-50

6.3.1 Replacement of the fast-blow fuse (without microswitch)

1. Loosen two screws which fix the cover using a Phillips head screwdriver.

Fixed screws

IMR01V02-E1

2. Slide the cover upward.

3. Slant the top of the cover and then pull out the cover.

6. MAINTENANCE

Cover

Cover guide

Main body guide

4. Remove two hexagon headed bolts which fix the fast-blow fuse using a torque wrench and then remove the blown fast-blow fuse.

Fast-blow fuse Hexagon headed bolts

Hexagon headed bolts size

20 A and 30 A: M6 45 A to 100 A: M10

IMR01V02-E1

6. MAINTENANCE

5. Replace the blown fast-blow fuse with a new one. First temporarily tighten these two hexagon headed bolts to fix the fast-blow fuse and then tighten them at specified torque using the torque wrench.

Always temporarily tighten the two hexagon headed bolts first.

Recommended tightening torque

20 A and 30 A

45 A to 100 A

5.0 N⋅m (50.98 kgf⋅cm)

23.5 N⋅m (239.63 kgf⋅cm)

6. Match the cover guide with the rear of the main body guide, and close the cover.

Cover guide

Main body guide

7. Tighten the two screws which fix the cover using the Phillips head screwdriver to finish the work.

IMR01V02-E1

6. MAINTENANCE

6.3.2 Replacement of the fast-blow fuse (with microswitch)

1. Remove the front cover according to the same way as replacing the fast-blow fuse (without microswitch).

2. Disconnect the connector which connects the fast-blow fuse to the main body.

Fast-blow fuse (with microswitch)

Microswitch

Disconnect the connector

Enlarged view

3. Remove two hexagon headed bolts which fix the fast-blow fuse using a torque wrench and then remove the blown fast-blow fuse.

Hexagon headed bolts

Hexagon headed bolts size

20 A and 30 A: M6 45 A to 100 A: M10

4. Replace the blown fast-blow fuse with a new one. First temporarily tighten these two hexagon headed bolts to fix the fast-blow fuse and then tighten them at specified torque using the torque wrench.

Always temporarily tighten the two hexagon headed bolts first.

Recommended tightening torque

20 A and 30 A

45 A to 100 A

IMR01V02-E1

5.0 N⋅m (50.98 kgf⋅cm)

23.5 N⋅m (239.63 kgf⋅cm)

6. MAINTENANCE

5. Connect the connector which connects the fast-blow fuse to the main body.

Fast-blow fuse (with microswitch)

Microswitch

Connect the connecter.

Enlarged view

6. Close the front cover to finish the work. Close the front cover according to the same way as fixing the fast-blow fuse (without microswitch).

IMR01V02-E1

7. SPECIFICATIONS

Number of phase: Three-phase

Rated current: 20 A AC, 30 A AC, 45 A AC, 60 A AC, 80 A AC and 100 A AC

(The rated current drops when the ambient temperature exceeds 40 °C.)

Minimum load current: 1 A

Power supply voltage: Main circuit: 360 to 484 V AC [Including power supply voltage variation]

(Rating: 400 to 440 V AC)

Control circuit: 180 to 264 V AC [Including power supply voltage variation]

(Rating: 200 to 240 V AC)

Power frequency: 50/60 Hz (Automatic discriminating)

Allowable power frequency variations:

Performance guarantee: 50 Hz ±1 Hz, 60 Hz ± 1 Hz

Operation guarantee: 45.0 to 54.9 Hz (50 Hz)

55.0 to 64.9 Hz (60 Hz)

Output voltage range: 0 to 98 % of rated voltage

Applicable load: Phase control: Linearity load (resistor load)

Control of primary side of a transformer

Recommended magnetic field density: Approx. 0.8 tesla (8, 000 gauss) or less

Zero-cross control: Linearity load (resistor load)

Output mode: Proportional phase angle to input

Proportional voltage to input Proportional square voltage (electric power) to input Constant current control (optional) Constant voltage control (optional) Constant power control (optional)

The output mode is valid only when the linearity load (resistor load) is used in the phase control.

Control method: Phase control

Zero-cross control

Input signal: Hardware 1: Current input: 0 to 20 mA DC, 4 to 20 mA DC

Voltage input: 0 to 5 V DC, 1 to 5 V DC Voltage pulse input: 0/12 V DC Dry contact input

Hardware 2: Voltage input: 0 to 10 V DC

Voltage pulse input: 0/12 V DC, 0/24 V DC Dry contact input (Specify either one of them when ordering. However, it is

possible to change if it is the input signal within the same hardware.)

IMR01V02-E1 77

7. SPECIFICATIONS

Input impedance: Current input 0 to 20 mA DC: 100 Ω

Current input 4 to 20 mA DC: 100 Ω Voltage input 0 to 5 V DC: 30 kΩ Voltage input 1 to 5 V DC: 30 kΩ Voltage input 0 to 10 V DC: 68 kΩ Voltage pulse input 0/12 V DC: 30 kΩ (Hardware 1), 68 kΩ (Hardware 2)

Voltage pulse input 0/24 V DC: 68 kΩ Dry contact input: 47 kΩ

Action at input break: Current input: Downscale (control output OFF)

Voltage input: Downscale (control output OFF) Voltage pulse input: Downscale (control output OFF)

Allowable input voltage: Current input: Equivalent to 0 to 2.2 V

Voltage input: 0 to 19 V (0 to 5 V DC, 1 to 5 V DC)

0 to 30 V (0 to 10 V DC)

Voltage pulse input: Hardware 1: 0 to 19 V (0/12 V DC)

Hardware 2: 0 to 30 V (0/12 V DC, 0/24 V DC)

External contact input (DI):

Number of input point: 3 points Input method: Dry contact input Dry contact: Open state: 500 kΩ or more

Closed state: 10 Ω or less Contact current: 10 mA or less Voltage when opened: Approx. 5 V DC Function: Auto/Manual mode transfer

Open state: Auto mode Closed state: Manual mode

RUN/STOP transfer

Open state: STOP Closed state: RUN

Alarm interlock release

Closed state: Alarm interlock release

Current transformer (CT) input (optional):

Number of input point: 2 or 3 points Input range: 0.0 to 100.0 A Sampling cycle: 20 ms (50 Hz), 16.6 ms (60 Hz)

Potential Transformer (PT) input (optional):

Number of input point: 3 points Input range: 0.0 to 510.0 V Sampling cycle: 20 ms (50 Hz), 16.6 ms (60 Hz)

IMR01V02-E1

External manual set value: 0 to 100 %

Set by the setter (optional)

Internal manual set value: 0.0 to 100.0 %

Set by the THW-3 front keys

External gradient set value: 0 to 100 %

Set by the setter (optional)

Internal gradient set value: 0.00 to 1.00 (0 to 100 %)

Set by the THW-3 front keys

Output limiter (high) set value: 0.0 to 100.0 %

Set by the THW-3 front keys

Output limiter (high) at the time of start:

0.0 to 100.0 % Set by the THW-3 front keys

Output limiter (high) time at the time of start:

0.0 to 600.0 seconds Set by the THW-3 front keys

Output limiter (low) set value: 0.0 to 100.0 %

Set by the THW-3 front keys

Base-up set value: 0.0 to 100.0 %

Set by the THW-3 front keys

Ramp (Soft-start/Soft-down) function:

0.0 to 99.9 seconds Set by the THW-3 front keys

Current limiter function (optional):

20 A: 0.0 to 22.0 A 30 A: 0.0 to 33.0 A 45 A: 0 to 50 A 60 A: 0 to 66 A 80 A: 0 to 88 A 100 A: 0 to 110 A Set by the THW-3 front keys

If a current limit value is set to its maximum value, the current limit function is deactivated.

7. SPECIFICATIONS

IMR01V02-E1

7. SPECIFICATIONS

Alarm function: Number of input point: 2 points

Output type: Open collector output

24 V DC, maximum 100 mA Alarm type: Power frequency error

Negative phase sequence alarm

Heater break alarm 1 (optional)

Thyristor break-down alarm (optional)

Heater break alarm 2 (optional)

Over current alarm (optional)

Fuse break (optional)

Self-diagnostic function: Check item: Board error

EEPROM error

Calibration data error

Range check of set value Error displays: The FAIL lamp lights

Ambient temperature: 0 to 40 °C (Performance guarantee range)

−15 to +55 °C (Operation guarantee range)

Ambient humidity: 5 to 95 %RH (Non-condensing)

Power consumption: 21 VA

Withstand voltage: Between main circuit and grounding terminals: 1 minute at 2000 V AC

Insulation resistance: Between main circuit and grounding terminals: 20 MΩ or more as 500 V DC

Cooling method: Natural convection

Mounting method: Vertical mounting

Dimensions: See 2.3 Dimensions (P. 8).

(Absolute humidity: MAX.W.C 29 g/m

dry air at 101.3 kPa)

Weight: Approx. 10.3 kg (20 to 60 A types)

Approx. 13.6 kg (80 and 100 A types)

Step-down transformer: Power frequency: 50/60 Hz

Primary side (input) voltage: 440 V Secondary side (output) voltage: 220 V Withstand voltage: Primary side and secondary side terminals: 1 minute at 2500 V AC Insulation resistance: 500 V DC, 100 MΩ

IMR01V02-E1

APPENDIX

 How to fix the terminal cover (optional)

In order to prevent electric shock or instrument failure, always fix or remove the terminal cover after power supplied to the entire system is turned off.

(1) Checking the product

If there is any shortage of accessories, contact the RKC sales office or your nearest RKC sales agent.

• Spacer……4 • Screw……4 • Terminal cover……2

(2) Mounting procedures

WARNING

Tools necessary for mounting: Flat blade screwdriver and Phillips screwdriver

 Install each spacer using a flat blade screwdriver. In this case, always tighten it with the

screwdriver inserted into the slit at its top. (Recommended tightening torque: 0.88 N･m [8.9 kgf⋅cm])

If tightened using a spanner, the insulating coating formed along the spacer may be

 Place the terminal cover at its mounting location.

separated. If the insulating coating was separated, poor insulation may result.

 Tighten each screw using the Phillips head screwdriver to fix the terminal cover.

(Recommended tightening torque: 1.08 N･m [11.0 kgf⋅cm])

Expanded view of

the top of the spacer

Slit

Terminal cover

Screw

Terminal cover

Spacer

Mounting holes

IMR01V02-E1 81

APPENDIX

 Description of terms

Following table is descriptions of term used in this manual.

Term Description

Maximum load current (value) The maximum load current value means a current value which flows through

the heater at an output of 100 % (phase angle: 0°).

Auto mode This is to automatically adjust power (output value) by the input signal from the

Manual mode (External/Internal)

Input signal In this manual, the following three items are called input signals.

Gradient setting (External/Internal)

RUN The operation of this instrument is started. STOP The operation of this instrument is stopped. HBA This is the Heater Break Alarm.

CT Current Transformer PT Potential Transformer

controller. Input signal type: 0 to 20 mA DC, 4 to 20 mA DC, 0 to 5 V DC, 1 to 5 V DC, 0 to 10 V DC, 0/12 V DC, 0/24 V DC External manual mode: This is to manually adjust power (output value) by manipulating the external

setter (potentiometer). Internal manual mode: This is to manually adjust power (output value) by manipulating the front keys.

• Auto set value (value of Auto mode) • Internal manual set value

• External manual set value

External gradient setting: This is to set the gradient value by the external setter (potentiometer). Internal gradient setting: This is to set the gradient value by the front keys.

HBA1: Heater Break Alarm 1 HBA2: Heater Break Alarm 2

 Character symbols

0 1 2 3 4 5 6 7 8 9

(d)

Degree

(q) (r)

／

A C E F G H I J K L

(b)

N O

M P S T U u V W

(n) (o)

X Y Z

 Lighting state of the character LED

: Dim lighting : Bright lighting : Flashing

Minus Period

IMR01V02-E1

The first edition: NOV. 2005 [IMQ00]

RKC INSTRUMENT INC.

HEADQUARTERS: 16-6, KUGAHARA 5-CHOME, OHTA-KU TOKYO 146-8515 JAPAN

PHONE: 03-3751-9799 (+81 3 3751 9799)

E-mail: info@rkcinst.co.jp

FAX: 03-3751-8585 (+81 3 3751 8585)

IMR01V02-E1 NOV. 2005

RKC THW-3 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SYMBOLS

CAUTION

NOTICE

CONTENTS

1. OUTLINE

1.1 Checking the Product

1.2 Parts Description

2. MOUNTING

2.1 Mounting Environment

2.2 Mounting Cautions

2.3 Dimensions

2.4 Mounting Procedures

3. WIRING

3.1 Circuit Block Diagram

3.2 Wiring of Main Circuit

3.3 Wiring of the Step-Down Transformer

3.4 Wiring of Controller (Auto Mode)

3.4.1 Wiring of the current input

3.4.2 Wiring of the voltage input or voltage pulse input

3.4.3 Wiring of the series connection (For current input)

3.4.4 Wiring of the parallel connection (For voltage input or voltage pulse input)

3.5 Wiring for Input/Output Connector

3.5.1 Input/Output connector pin number and details

3.5.2 Caution for wiring input/output connector (plug)

3.5.3 Wiring of external manual setter

3.5.4 Wiring of external gradient setter

3.5.5 Wiring of external contact input

3.5.6 Wiring of Auto mode (with gradient setter)

3.5.7 Wiring of Auto/Manual mode selection

3.5.8 Wiring of Auto/Manual mode selection (with gradient setter)

3.5.9 Wiring of alarm output

3.5.10 Wiring of contact input

3.5.11 Wiring of ON/OFF control

4. SETTING

4.1 Mode Menu

4.2 Monitor Mode 1

4.2.1 Display sequence

4.2.2 Description of each monitor item

4.3 Monitor Mode 2

4.3.1 Display sequence

4.3.2 Description of each monitor item

4.4 Setting Mode

4.4.1 Display sequence

4.4.2 Changing parameter settings

4.4.3 Description of each parameter

4.5 Engineering Mode

4.5.1 Transfer to engineering mode

4.5.2 Display sequence

4.5.3 Description of each parameter

5. FUNCTIONS

5.1 Control Method

5.2 Ramp Function (Soft-Start/Soft-Down Function)

5.3 Gradient Setting Function

5.4 Output Limiter (High and Low)

5.5 Output Limiter (High) at Operation Start

5.6 Base-Up Setting Function

5.7 Output Mode for Phase Control

5.8 Current Limiter Function

5.9 Automatic Power Frequency Detection and Power Frequency Monitoring Function

5.10 Alarm Interlock Function

5.11.1 Number of alarm delay times

5.11.2 Heater break alarm for phase control (Type 1)

5.11.3 Heater break alarm for phase control (Type 2)

5.12 FAIL Alarm

5.13 Negative Phase Sequence Alarm

5.14 Over Current Alarm (optional)

5.15 Fuse Break Alarm (optional)

5.16 Set Data Lock Function

5.17 External Contact Input (DI) Function

6. MAINTENANCE

6.1 Daily Inspection

6.2 Troubleshooting

6.3 Replacement of the Fast-Blow Fuse

6.3.1 Replacement of the fast-blow fuse (without microswitch)

6.3.2 Replacement of the fast-blow fuse (with microswitch)

7. SPECIFICATIONS