No part of this document may be reproduced or published in any form or by any means without
prior written permission from the copyright owner.
Liability and warranty
Any information and notes in these operating instructions were composed under consideration of
the applicable regulations, the present state of the art and our extensive know-how and experience.
With special versions, additional ordering options or due to the latest technical modications, the
actual scope of delivery may vary from the descriptions and drawings in this manual.
For questions, please, contact the manufacturer.
Before starting to work with the instrument and before commissioning, in particular, these
operating instructions must be read carefully! The manufacturer cannot be held responsible
for damage and trouble resulting from failure to comply with the information given in this
manual.
This product may be subject to change due to improvements of the product features in the
course of further development.
Copyright
This operating manual should be considered as condential information, intended only for persons
who work with the instrument.
Contraventions are subject to payment of damages. Further claims reserved.
www.west-cs.co.uk2
Contents
1. Important warnings for safety .............................................................................................................................. 5
7.1. Identication of the unit ..................................................................................................................................... 16
8. Order Code ............................................................................................................................................................. 17
8.1. Notes on the options: ......................................................................................................................................... 18
8.1.1 I LIMIT (CURRENT LIMIT) ............................................................................................................................... 18
8.1.4. Energy totalizer .................................................................................................................................................. 18
9.1. General features ................................................................................................................................................. 19
9.2. Input features ...................................................................................................................................................... 19
9.3. Output features (power device)......................................................................................................................... 19
9.4. Fan Specication (only from 90 to 210A) ......................................................................................................... 19
9.7. Calculating ow capacity of the fan ................................................................................................................. 20
11.2. Power Terminals ............................................................................................................................................... 23
11.3. Control Terminals ............................................................................................................................................. 24
11.4.1 SSR Control Input Schematic .......................................................................................................................... 26
11.5 Connection Diagram for 3 phases ................................................................................................................... 27
12. Control Panel ...................................................................................................................................................... 28
12.1. Menu navigation ............................................................................................................................................... 29
12.2. Control Panel Led ............................................................................................................................................. 30
12.4. Parameter list .................................................................................................................................................... 31
12.4.1 Operator Menu .................................................................................................................................................. 31
12.5 Setup Menu ........................................................................................................................................................ 32
12.5.2 Advanced Setup Menu ..................................................................................................................................... 32
12.5.3 Hardware Menu ................................................................................................................................................ 34
12.5.4. Communication Menu ..................................................................................................................................... 37
12.5.5 Monitoring Menu .............................................................................................................................................. 38
13. Using the Congurator ....................................................................................................................................... 41
13.3.1 Upload a recipe ................................................................................................................................................ 41
13.3.2 Download a recipe............................................................................................................................................ 41
13.4 How To ................................................................................................................................................................ 41
13.4.1 Install and communication with the power controller ...................................................................................... 41
13.5 Using the Congurator ..................................................................................................................................... 42
13.5.1 To view or save a power controller’s settings ................................................................................................... 42
using “Simple” view section: ........................................................................................................................................ 42
13.5.2 To edit a setting in a recipe: ............................................................................................................................. 43
13.5.3 To download a recipe le into a power controller: ............................................................................................ 43
13.5.4 To monitor a power controller with the Test view: ............................................................................................ 43
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13.5.5 To log in on the test view to change the digital input and analog input functions: ............................................ 43
13.5.6 To log out the test view: .................................................................................................................................... 43
13.5.7 To view data on the scope: ............................................................................................................................... 44
13.5.8 To reset the power totals: ................................................................................................................................. 44
13.5.9 Setting Up and Using Data Logging ................................................................................................................. 44
13.5.10 To retrieve a data log le from the power controller: ...................................................................................... 45
13.6 Software General information .......................................................................................................................... 45
13.6.1 Program Window .............................................................................................................................................. 45
13.6.3 Test Section ...................................................................................................................................................... 46
14. Firing type ............................................................................................................................................................ 51
14.1 Zero Crossing .................................................................................................................................................... 51
14.2 Single Cycle ....................................................................................................................................................... 51
14.6 Soft Start with Phase Angle .............................................................................................................................. 52
14.7 Delay Triggering with Burst Firing ................................................................................................................... 53
15. Current Limit ........................................................................................................................................................ 54
15.1 Current Limit Setting ......................................................................................................................................... 54
15.2 Current Limit tuning procedure ....................................................................................................................... 54
16. Bakeout in function ............................................................................................................................................. 55
16.1 What is heater bakeout? ................................................................................................................................... 55
16.2 How does heater bakeout work? ..................................................................................................................... 55
17. Control Mode (feed-back) ................................................................................................................................... 56
18. Supply the Electronic Board .............................................................................................................................. 57
19. RS485 Serial port ................................................................................................................................................. 58
20. Fieldbus communication option ....................................................................................................................... 58
This chapter contains important information for the safety. The not observance of these instructions may result
in serious personal injury or death and can cause serious damages to the Thyristor unit and to the components
system included.
The installation should be performed by qualied persons.
In the manual are used symbols to give more evidence at the notes of safety and operativity for the attention
for the user:
This icon is present in all the operational procedures where the Improper operation may result in serious
personal injury or death by Electrical Shock Hazard Symbol (a lightning bolt in a triangle) precedes an
electric shock hazard CAUTION or WARNING safety statement.
Warning or Hazard that needs further explanation than the label on unit can provide. Consult User’s Guide
for further information.
Unit is compliant with European Union directives.
See Declaration of Conformity for further details on Directives and Standards used for Compliance.
If available, unit is a Listed device per Underwriters Laboratories. It has been investigated to ANSI/UL®
508 standards for Industrial Control Switches and equivalent to CSA C22.2 #14.
For more detail search for File E505847 on www.ul.com
ESD Sensitive product, use proper grounding and handling techniques when installing or servicing product.
Do not throw in trash, use proper recycling techniques or consult manufacturer for proper disposal.
www.west-cs.co.uk5
A “NOTE” marks a short message to alert you to an important detail.
A “CAUTION” safety alert appears with information that is important for protecting your equipment and performance.
Be especially careful to read and follow all cautions that apply to your application.
A “WARNING” safety alert appears with information that is important for protecting you, others and equipment
from damage. Pay very close attention to all warnings that apply to your application.
1.1. Safety notes
WARNING! To avoid damage to property and equipment, injury and loss of life, adhere to applicable electrical
codes and standard wiring practices when installing and operating this product. Failure to do so could result in
damage, injury and death.
WARNING! All service including inspection, installation, wiring, maintenance, troubleshooting, fuse or other user
serviceable component replacement must be performed only by properly qualied personnel. Service personnel
must read this manual before proceeding with work. While service is being performed unqualied personnel
should not work on the unit or be allowed in the immediate vicinity.
WARNING! When in use the power controller is connected to dangerous voltages. Do not remove the protective
covers without rst disconnecting and preventing power from being restored while servicing the unit.
WARNING! Do not use in aerospace or nuclear applications.
WARNING! The power controller’s protection rating is IP20 with all covers installed and closed. It must be
installed in an enclosure that provides all the necessary additional protections appropriate for the environment
and application.
WARNING! Ground the power controller via the provided protective earth grounding terminal. Verify ground is
within impedance specications. This should be veried periodically.
WARNING! Electric Shock Hazard: when the power controller has been energized, after shutting o the power, wait at least one minute for internal capacitors to discharge before commencing work that brings you in to
contact with power connections or internal components.
WARNING! The installation must be protected by electromagnetic circuit breakers or by fuses. The
semiconductor fuses located inside the power controller are classied for UL as supplementary protection for semiconductor devices. They are not approved for branch circuit protection.
WARNING! When making live voltage or current measurements, use proper personal protective equipment for
the voltages and arc-ash potentials involved.
WARNING! Verify the voltage and current ratings of the power controller are correct for the application.
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CAUTION: To avoid compromising the insulation, do not bend wire or other components beyond their bend
radius specications.
CAUTION: Protect the power controller from high temperature, humidity and vibrations.
CAUTION: The power controller warranty is void if the tested and approved fuses are not used.
CAUTION: Only trained and authorized personnel should access and handle the internal electronics and they
must follow proper electro-static prevention procedures.
CAUTION: Install an appropriately sized RC lter across contactor coils, relays and other inductive loads.
NOTE! Provide a local disconnect to isolate the power controller for servicing.
NOTE! The nominal current is specied for ambient temperatures at or below 40° C. Ensure the application
design allows for adequate cooling of each power controller. The power controller must be mounted vertically.
The cooling design must prevent air heated by one power controller from causing power controllers mounted
above to exceed the ambient operating temperature limit. When power controllers are mounted side by side
allow a minimum spacing of 15mm between them.
NOTE! Use only copper cables and wires rated for use at 90°C or greater.
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2. Maintenance
In order to have a corrected cooling, the user must clean the heat-sink and the protective grill of the fans. The frequency of this servicing depends on environmental pollution.
Also check periodically if the screw for the power cables and safety earth are tightened correctly
(See Connection Diagram).
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3. Introduction
A thyristor unit is semiconductor device which acts as a switch formed by two thyristors in ant parallel.
To switch on the alternating current the input signal will be on and the thyristor will switch o at rst Zero Crossing
voltage with no input signal.
The benets of thyristor units compared with electromechanical contactors are numerous: no moving parts, no
maintenance and capacity to switch very fast. Thyristors are the only solution to control transformers and special
loads that change resistance with temperature and with age.
L1
L2
Thyristor
Load
3.1. Advantages compared with analog thyristor unit
Communication RS485 is a standard feature of Relay C. this allows the use of many information like: current, power,
load state and all the parameters for diagnostic and conguration. Ulterior advantages of the digital system vs the
analogical is the exibility and the possibility of implement special characteristics without change the hardware.
Several strategies can be implemented and selected through the conguration parameters.
With the software Thyristor Congurator, you can have access to the conguration parameters.
To connect the Thyristor unit to the computer use a micro USB cable.
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3.2. Overview
Heater bakeout
• Protects heater upon start up
• Eliminates labour and time associated with checking for wet heaters
Integrated semiconductor fusing, current transformer and user interface
• Saves installation time and eases setup and commissioning
• Delivers a user-friendly, intuitive interface
Industry-leading design and serviceability
• Oers a robust SCR design to meet a rugged industrial environment’s high quality and
reliability needs
• Provides quick and easy access to maintain and service fuses and individual legs
in minimal time
• Enables fast troubleshooting by providing helpful thermal system diagnostics
Comprehensive power controller range
• Provides wide range of options from simple single phase to complex three-phase loads to
69 0V.
100KA short circuit current rating (SCCR) (Not reviewed by UL®)
• Enables greater protection in the event of a short circuit
c-UL® 508 listed
• Shortens project schedules, agency testing and expenses
Control modes: contactor, voltage, current or power
• Satises a wide range of demanding thermal applications
• Handles a wide range of load types including nichrome, medium and long waveform infrared
lamps, moly, transformers, silicon carbide, UV lamps and tungsten
• Protects and extends the life of connected loads
Wide range of communication protocols
• Enable factory and process automation with connectivity to process and equipment data via
Modbus® RTU, Modbus® TCP, Probus, Pronet, USB device (conguration and data le
transfers)
Open heater and shorted SCR indication
• Minimizes production downtime with easy to understand, intelligent, troubleshooting
diagnostics
Integrated USB and user interface for conguration
• Easily and safely program conguration settings as the user interface can be powered through
USB connection
• Eliminates need to work in a high voltage hazard environment. High voltage to the power
controller and system panel can be shut o and locked out for safety while conguring
controller.
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4. Software Congurator
Thyristor congurator software is free and is Thyristor congurator software is free and is
possible download it from our site.
If the Order Code is in line with requirement,
then unit has been already congured in
Factory and it’s ready to use.
You need the software only to modify the
ordered conguration. Anyway, we suggest
to check the unit on the machine with the
“Test unit” section.
For install the software, launch the program
and follow the instructions on the screen.
Run the software congurator and set the
correct serial port number by menu setting ->
Serial Port -> por t numbe r.
L/R EN Com AL
To connect the unit at the PC, it’s necessary to
use the micro USB 2.0 Modbus RTU cable.
USB connection need a driver to work properly,
you can nd it from our site.
However the conguration software installer will
install as default the correct driver.
Micro USB
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5. Quick Start
Attention: this procedure must be carried out by skilled people only.
If your Relay C code is in line with what you really need, then the main conguration is already done by Producer and
you just need to do the following steps:
1. Verify Relay C current sizing. Be sure that:
• the load current is equal or less than the nominal one of Relay C
• the main voltage is equal or less than the nominal voltage of Relay C
2. Verify the Installation
3. Verify the Wiring:
• all auxiliary connections must be done in line with wirings on this manual
• verify that there isn’t a short circuit on the load
4. Supply the auxiliary voltage of the unit in the Set menu
Set the parameters Operative Load Voltage and Nominal Current of the load using the frontal keypad or Thyristor con-
gurator software.
The auxiliary voltage supply of the Relay C unit must be synchronized with load voltage power supply.
If the Auxiliary Voltage (written on the identication label) is dierent from Supply Voltage (to the load), use an
external transformer.
If your Relay C code is NOT in line with what you really need, use the congurator software tool to set-up the
unit. Install the software on your PC, select Relay C and click on test unit changing what you need.
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6. Basic Connections and sizing
Star wiring with resistive load (control on two phases with PMA-Relay C-3PH)
P
I=
1,73V
V
V = Nominal voltage of the load
I = Nominal current of the load
P = Nominal power of the load
Delta wiring with resistive load (control on two phases with PMA-Relay C-3PH)
P
I=
1,73V
V
V = Nominal voltage of the load
I = Nominal current of the load
P = Nominal power of the load
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7. Identication
7.1. Identication of the unit
Caution: Before to install, make sure that the Thyristor unit have not damages. If the product has a
fault, please contact the dealer from which you purchased the product.
The identication’s label gives all the information regarding the factory settings of the Thyristor unit, this label is on the
unit, like represented in gure.
Verify that the product is the same thing as ordered.
www.west-cs.co.uk14
8. Order Code
RC3xxx-xxxxxxxxxx
Current - Fuses
60 A - Fixed Fuses Included060
90 A - Fixed Fuses Included090
120 A - Fixed Fuses Included120
150 A - Fixed Fuses Included150
180 A - Fixed Fuses Included180
210 A - Fixed Fuses Included210
MAX VOLTAGE MAIN SUPPLY VOLTAGE 1*
480 V
600 V
690 V
MAIN SUPPLY VOLTAGE 1*Aux Voltage range
100/120 Vac
200/208/230/240 Vac
277 Vac
380/415/480 Vac
60 0 Vac
690 Vac540 to 759 Vac
INPUT
SSRS
0:20 mAB
4:20 m AA
0:10 V (DC)V
10 kΩ potentiometerK
START OPTION
FIRING
Burst Firing (BF)
Phase Angle
Delayed TriggeringNo Soft StartD
Zero Crossing
CONTROL MODE
Open LoopO
Volt ageU
Voltage Square U²Q
CurrentI
Current Square I²A
Power (U x I)W
OPTION
No Option0
Energy totalizer1
Datalogger2
Datalogger + Energy totalizer3
Heaterbreak Alarm (HB)8
Heaterbreak Alarm (HB) + Energy totalizer9
Heaterbreak Alarm (HB) + DataloggerA
Heaterbreak Alarm (HB) + Datalogger + Energy totalizerB
Current LimitG
Current Limit + Energy totalizer H
90 to 135 Vac
180 to 265 Vac
238 to 330 Vac
342 to 528 Vac
540 to 759 Vac
No soft startB
Linear Soft StarterJ
No Soft StartP
Linear Soft StarterE
No soft startZ
Linear Soft StarterR
4
6
7
1
2
3
5
6
7
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RC3xxx-xxxxxxxxxx
Current Limit + Datalogger I
Current Limit + Datalogger + Energy totalizer J
Current Limit + Heaterbreak Alarm (HB) O
Current Limit + Heaterbreak Alarm (HB) + Energy totalizer P
Current Limit + Heaterbreak Alarm (HB) + Datalogger Q
Current Limit + Heaterbreak Alarm (HB) + Datalogger + Energy totalizer R
FAN VOLTAGE
No fan < 90A0
Fan 110Vac (≥ 90A)1
Fan 230Vac (≥ 90A) – standard version2
24Vdc (≥ 90A) - standard version3
APPROVALS
CE0
cULusL
LOAD T YPE
Normal Resistive Load with 3 Phase Star with neutral Connection0
Normal Resistive Load with 3 Phase Delta Connection1
IRSW Infrared Short wave with 3 Phase Star Connection with neutral 2
IRSW Infrared Short wave with 3 Phase Delta Connection3
3 Phase Transformer coupled with normal resistance4
3 Phase Transformer coupled with cold resistance 5
*1 Since the supply voltage of the electronics is used for synchronization, it must be in phase with the load voltage.
A
B
C
D
E
8.1. Notes on the options:
8.1.1 I LIMIT (CURRENT LIMIT)
This option is used to keep the overcurrent inside setted limit. It’s necessary to drive primary transformers and cold
resistance. This option is not available on 30-35-40A units.
8.1.2. Heaterbreak Alarm (HB)
HB Alarm for partial or total load failure and Short Circuit on SCR (relay output).
8.1.3. Datalogger
This feature is important to see the historical data of parameter like Current, Voltage and Power and can be useful to
diagnose a fault.
8.1.4. Energy totalizer
This function totalizes the energy consumption of the load allowing the calculation of heat treatment.
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9. Technical specications
9.1. General features
Cover and Socket
material
Utilization CategoryAC-51 AC-55b
IP Code20
Method of ConnectingLoad in Delta, Load in Star
Auxiliary voltageOrder Code RC3_ _ _-_1 = line voltage 100/120V voltage range 90:135V (8 VA Max)
Relay output for Heater Break Alarm
(only with HB option)
PolymericV2
Order Code RC3_ _ _-_2 = line voltage 200/208/220/230/240V voltage range 180:265V
(8 VA Max)
Order Code RC3_ _ _-_3 = line voltage 277 voltage range 238:330V (8 VA Max)
Order Code RC3_ _ _-_5 = line voltage 380/400/415/440/480V voltage range 342:528V
(8 VA Max)
Order Code RC3_ _ _-_6 = line voltage 600V voltage range 540:759V (8 VA Max)
Order Code RC3_ _ _-_7 = line voltage 690V voltage range 540:759V (8 VA Max)
0.5A a 125VAC
9.2. Input features
Analog Input V: 0 to 10 Vdc impedance 15 kΩ
Analog Input I:4 to 20 mA Impedance 100 Ω
Potentiometer10 kΩ min.
Digital Input4 to 30Vdc 5mA Max (ON ≥ 4Vdc OFF < 1Vdc)
9.3. Output features (power device)
Nominal
Current
(A)(V)(480V)(600V)(mAe)(10
6024÷600120016006001900151078047÷702903000
9024÷600120016006001900151078047÷705803000
12024÷600120016006001900151428047÷705983000
15024÷600120016003005000151750047÷705943000
18024÷600120016003005000153080047÷707403000
21024÷600120016003005000155390047÷708983000
Voltage
range
(Ue)
Repetitive peak
reverse voltage
(Uimp)
Latching
current
Max
peak
one cycle
msec.)
(A)
Leakage
current
(mAe)tp=
FUSE
I2T value
Suggested
A2s (at500V)
10msec
Frequency
range
(Hz)I =Inom
Thyristor
Power
loss
+ Fuse
(W)
Isolation
Voltage
(Ui)
(A)
9.4. Fan Specication (only from 90 to 210A)
Supply: 230V Standard Power 48W (16W for 3 Fan)
Supply: 115V Option Power 42W (14W for 3 Fan)
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9.5. Environmental installation conditions
Ambient temperature0-40°C (32-104°F) at nominal current.
Over 40°C-104°F use the derating curve.
Storage temperature-25°C to 70°C -13°F to 158°F
Installation placeDon’t install at direct sun light, where there are conductive dust, corrosive gas, vibration or
water and also in salty environmental.
AltitudeUp to 1000 meter over sea level. For higher altitude reduce
the nominal current of 2% for each 100m over 1000m
Humidity From5 to 95% without condense and ice
Pollution LevelUp to 2nd Level ref. IEC 60947-1 6.1.3.2
9.6. Derating curve
l max = l nominal x K
Derating
1,2
1
0,8
0,6
K
0,4
0,2
1
1111
0,9
0,8
For higher cabinet
temperature
contact the producer
of the unit
0
15 20 25 30 35 40 45 50 55
CABINET TEMPERATURE °C
9.7. Calculating ow capacity of the fan
All the thyristor units when are in conduction produces power loss that is dissipated inside cubicle in terms of
heating. Due to this fact the internal temperature of cubicle is higher than ambient temperature. To be cooled the
thyristor need of fresh air cooling and to do it is normally used a fan mounted on the front door or on the roof of the
cabinet.
Procedure to size Fan air mass ow (V): see power loss for each thyristor and fuse mounted indicated in the
manual related to the current (Output feature and Internal fuse Chapter).
V = f *
The formulas used are for information only and is not a substitute for a proper thermal rating
done by a qualied person.
Qv
tc-ta
Qv = total power losses (w) (thyristor + fuse power loss)
ta = ambient temperature (°C)
tc = cabinet temperature (°C)
V = fan air mass ow (m³/h)
f = altitude coecient (see
table on right)
Altitude
0:100 meters f = 3.1 m³K/Wh
100:250 meters f = 3.2 m³K/Wh
250:500 meters f = 3.3 m³K/Wh
500:750 meters f = 3.4 m³K/Wh
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