USER`S MANUAL THREE-PHASE POWER CONTROLLER RP3 Type
Contents
1. N I o Relay outputs gt ee NE LO AA E A A o o o gt c 8 A 4 gt a gt 9 o a o gt N o 2 O Z 3 5 O E o gt O A a Y Y Y 2 2 lt 8 2 33 z je 8 5 S x Z 4 Fig 4 Description of the LZ1 terminal strip 11 4 4 2 Input control signal Current Voltage Control from Input Input potentiometer 0 20 mA 0 5 V 4 20 mA 0 10 V 10kQ T slelsalel 21819 DOODA OOOO Fig 5 Connection of control signals a by analog signal The control from a voltage or current control signal source or from the potentiometer is possible In case of control from the potentiometer the voltage input should be set on the 0 5 V range b by impulse signal One must connect the control signal 4 32 V to termi2. In 60 mA 230 V a c d c Ron 35 Q 1500 Vrms Voltageless outputs they are not protected against y e overloads or shortings a 121852515881 8 8 z 0000000000000 Fig 8 Relay outputs 13 4 5 Connection of supply and load The power controller supply Gate triggering system UWB must be connected to L1 and N terminals of the LZ1 strip fig 3 The supply of the strong current circuit must be connected to U1 V1 W1 terminals however the load circuit to U2 V2 W2 terminals fig 1 and fig 2 Fuses in version RP3 1x 2x and 3x are accessible after removing the protection cover fig 1 4 5 1 Load connection in a 3 and 4 wire system ano ru RP3 S 177 wire load a 3 wire load Control 0 5 10 V NIL nu l u 127 Control 0 5 10 V b 4 wire load V 14 4 5 2 Load connection in a 6 wire system L3 L2 A E AAA AE N PE
3. Pons Pom X Where T period of the supply voltage Non number of turned periods on number of turned periods off ae UNI IN NIMM IS 7 Il BU E Fig 11 Impulse control with a variable impulse frequency runs of occurring signals The RP3 power controller has following kinds of pulse control e Quick cycle in which for 1 2 X X No Now 25 howeverf_ 1 Hz e Slow cycle in which for 1 2 X X_ _ max No Nop 250 however f 0 1 Hz Where X value of the analog control signal f max gt maximal impulse frequency i ma 17 Runs of characteristic quantities for the impulse control are presented on the fig 12 A fo Non Nor The filling factor y is described by the following dependence N on Y u No T Nos 1X Fig 12 Runs of characteristic quantities for the impulse control with variable pulse frequency 6 3 Phase control At phase control a continuous change of delivered power to the load occurs it is realised by the change of the load current turning on angle in the function of the analog control signal Runs of signals for this kind of control for a resistance load are presented on the fig 13 Current in lod the load circuit Continuous gt input signal a We 5 q gt Supplying
4. The housing must be closed during operation 6 Maintenance and servicing Please observe the manufacturer s documentation Read all product specific safety and application notes in this user s manual Before taking the power controller housing out one must turn the supply off The removal of the power controller housing during the warranty contract 3 POWER CONTROLLER SET The set consists of RP3 power controller 1 pc user s manual 1 pc warranty card 1 pc quick start card 1 pc When unpacking the power controller please check the delivery completeness and whether the type and version code on the data plate correspond to the order 4 INSTALLATION 4 1 Overall and assembly dimensions The RP3 power controller is destined to be mounted on a wall by means of holders Power controller overall dimensions spacing of assembly holes and the fixing way are presented on fig 1 and 2 In case of mounting in control cubicles it is recommended to apply a forced air cycle Terminals 4 x M6 PE Fuses B1 B2 B3 N Protective 1 2 e e e cover G 4 Terminal Fig 1 Overall dimensions and fixing way of the power controller for 40 A 70 A and 125 A versions 8 Terminals PE Terminal strip Fig 2 Overall dimensions and fixing way of the power controller for 200 A 300 A and 450 A versions 10 T 8 9 contro 2 W z
5. the automatic triggering stoppage and the display of the Error diode follows and the PK relay turning on p 4 4 5a The restart of the power controller is possible after removing damage reasons and the renewed supply turning on to UWB p 4 5 6 11 Overload protection The output circuit of the power controller is protected against its overload The protection is set on 12596 of the power controller rated current The exceeding of this value will cause the action of current limitation 20 7 SPECIFICATIONS Electrical parameters of the strong current circuit Table 2 Fuse parameters Max Supply voltage Lost nn gt Hs i HUP fi dt Designation manufacturer current circuit thyristors af 415 y 9 er ER ARIAS FE 7 gRB 000 BS 88 50 FERRAZ 3 400 V 50 Hz 350W 3600 100A 3 as gt PAM dep Y 2 160 200 200FEE Bussmann BOO OOTY 6 9 URB 000 BS 88 160 FERRAZ 250A 250FM Bussmann 6 9 URC 000 BS 882 250 FERRAZ 350A 350FM Bussmann 6 9 URC 000 BS 882 355 FERRAZ 500 500FMM Bussmann 6 9 URC2 000 BS 88Z 500 FERRAZ 3 400 V 50 Hz lt 950 W 28500 A s 3 400 V 50 Hz lt 1500 W 68500 A s 3 400 V 50 Hz lt 2200 W 180000 A s Minimal input current 196 of In range of the power controller output current Leakage current 20 mA Kind of load resistance or resistance inductance load acc to EN 60947 4 2 and EN 60947 4 3 Electrical parameters of th
6. voltage 4 a UN of load circuit X d mE M XP XUL ay V ER RE Fig 13 Phase control runs of occurring signals runs of occurred signals in relation to the neutral wire resistance load 18 6 4 Limitation of the load current If the current value in the load circuit exceeds the boundary value set by means of the Limit potentiometer then the current limitation operates regardless of the control signal value It is possible to assign it from an external potentiome ter p 4 4 3 The setting of the potentiometer on minimum means the turn of the current limitation operation off The maximal value of the current flowing in the load circuit can be set in the full range of the power controller rated value The current limitation does not operate for the on off control type in the turn on configuration at across zero voltage In case of exceeding of the current boundary value the Load diode is alight in red 6 5 Triggering delay of soft start type The soft start function enables a soft accretion of the voltage from zero up to the rated value or value resulting from the current limitation action in the time set by means of the S Start potentiometer In the case of phase control or on off control type the soft start time ts s is controlled in the range from 0 up to 10 s In case of the impulse control this time is equal to 1 Be 5 S S 6 6 Control of the inp
7. 01 vi wi mul Jana ru RP3 U2 V2 W2 171 Control 0 4 20 mA 6 wire load Fig 9 Relay outputs 5 POWER CONTROLLER SERVICE S Start and Limit potentiometers must be set on minimum and the Span potentiometers on maximum In such settings corresponding functions to them are inactive One must carry out successively following operations a install the power controller according to p 4 1 b carry out electrical connections according to p 4 2 p 4 4 and p 4 5 set the control type and the input control signal according to p 4 3 d turn on the supply voltage of the load circuit and next the gate trig gering system UWB according p 4 5 e set the current limitation according to p 6 4 Set the Limit potentiometer on maximum Observing indication of the meter measuring the load current at the maximal value of the input control signal set the required current value decreasing the setting on the Limit potentiome ter f set the triggering delay according to p 6 5 g set the amplification of the input line according to p 6 6 One can reach experimentally the obtainment of proper settings by means of potentiometers and this should be carried out by a suitably trained personnel 19 6 DESCRIPTION OF CONTROL TYPES 6 1 Control of ON OFF type At the on off control th
8. 0529 IP 20 acc to EN 60529 This product is an equipment of class A Its application in an habitat environment can cause radio interference what can re quire the use of additional preventive measures by users to limit disturbances In case of phase control the power controller fulfils requirements of the electromagnetic compatibility in relation to the interference emission only when working near of the supply voltage transition through zero 22 8 ORDERING CODES Table 3 Power controller RP3 X X Current range maximal output current 40 1 maximal output current 70A 2 maximal output current 125A load voltage 3 maximal output current 200A a iid kaka 4 maximal output current 300A 5 maximal output current 450 6 Acceptance tests without an additional quality inspection certificate 8 with an extra quality inspection certificate other requirements wawy oic ea een ORDERING EXAMPLE The code RP3 3 8 means RP3 power controller of RP1 type 3 maximal output current 125 A for the range of voltage 3 400 V supplying the load circuit 8 without an additional quality inspection certificate 9 MAINTENANCE AND WARRANTY The RP3 power controller does not require any special periodical maintenance In case of some incorrect operations After the dispatch date and within the period stated in the warranty card One sh
9. E AND WARRANTY 24 1 APPLICATION The RP3 power controller is a contactless three phase power energy electronic device which includes a thyristor connector and an electronic gate triggering system This power controller allows the control of the power delivered from a three phase voltage source to an electrical energy load in function of the control signal input The RP3 power controller is destined for three phase actuators with resistance or resistance inductance loads in control systems and automatic temperature control The application area of RP3 power controllers comprises e electrical furnaces and drying constructions particularly industrial tunnels and belt type furnaces furnaces for annealing and hard soldering crucible furnaces and smelters furnaces for hardening in salt baths e devices of mechanical engineering aggregates and extruding presses for plastics devices for winding and tempering of springs spot welding and seam welders e production of glass and glazing installations and devices for drying in infrared and ultraviolet radiation ladles for glass melt and heating of feeding devices furnaces for glass forming e chemical and petroleum industries facing heaters of tube installations preheating installations 2 BASIC REQUIREMENTS OPERATIONAL SAFETY Power controllers are applied in high current installations in which live devices occur tha
10. ES A LZ Ay C 12345 Span R amp P LS AS LO 5 lt o o 00 Flu o 2 ce Fig 3 Panel Following Servicing elements are disposed on the power controller frontal plate Fig 3 Signalling diodes e Control two colour diode 1 supply correctness and power controller readiness to work e Load two colour diode 2 passage of current through the load when lload gt 5 In of the controller e Stop red diode 3 external triggering stoppage e Error red diode 4 control error or incorrect supply connection e Over Temp red diode 5 exceeding of the allowable temperature e Fuse Fail red diode 6 fuse burnout Potentiometers and switch e S START potentiometer 7 control of the soft start function duration e Limit potentiometer 8 limitation of the load current e Span potentiometer 9 control of the input line amplification e Switch DIP SWITCH 10 to configure analog inputs and the control mode 4 2 Electrical connections One must carry out electrical connections by means of following wires a to LZ1 terminal strips fig 3 wires with cross section from 0 35 up to 2 5 mm b to high current terminals fig 1 and 2 RP3 1x version 40A wires of 16 mm
11. THREE PHASE POWER CONTROLLER Type USER S MANUAL C C THREE PHASE POWER CONTROLLER RP3 Type USER S MANUAL CONTENTS T APPLICATIDN OCR ici 5 2 BASIC REQUIREMEMNTS OPERATIONAL SAFETY 5 3 POWER CONTROLLER eee 6 4 INSTALLATION 6 4 1 Overall and assembly 6 4 2 Electrical CONMECIION Sussie dni 8 4 3 Selection of the control type GA 8 4 4 Connection of control signals 9 4 5 Connection of supply arid load u een 12 5 POWER CONTROL SERVICE cc ooo 15 6 DESCRIPTION OF CONTROL TYPES 16 61 Contralor ON OFF Ype Mm 16 6 2 Impulse COMMON sn Aids dd a 17 o A an 19 64 Limitation of the load current asada 19 6 5 Triggering delay of soft start type a na 19 6 6 Control of the input line amplification cc 20 6 7 Control and current signalling in the load circuit 20 6 8 Signalling of supply 20 6 9 Signalling of maximal radiator temperature exceeding 21 o ae en a E 21 6 11 Overload protection caian dodo 21 Ts SPECIFICATIONS cuisine lcd 22 8 ORDERING CODES sense 24 9 MAINTENANC
12. by inappropriate handling Do not damage or destroy any electrical components since this might endanger your health 4 Electrical connection Before switching the power controller on one must check the correctness of connection to the network In case of the protection terminal connection with a separate lead one must remember to connect it before the connection of the power controller to the mains When working on live instruments or devices the applicable national regulations for the prevention of accidents must be observed The electrical installation must be carried out according to the appropriate regulations cable cross sections fuses PE connection Additional information can be obtained from the user s guide The documentation contains information about installation in compliance with EMC shielding grounding filters and cables These notes must be observed for all CE marked products The manufacturer of the installation or installed devices is responsible for the compliance with the required limit values demanded by the EMC legisla tion 5 Operation Installations including RP3 power controllers must be equipped with protection devices according to the corresponding standard and regulations for prevention of accidents After the power controller has been disconnected from the supply voltage live components and power connections must not be touched immediately because capacitors can be charged
13. cross section RP3 2x version 70A wires of 25 mm cross section RP3 3x version 125A wires of 50 mm cross section RP3 4x version 200A rail of 100 mm cross section RP3 5x version 300A rail of 200 cross section RP3 6x version 450A rail of 300 mm cross section to the protective terminal wire rail of a cross section at least the same as wires in the high current circuit 4 3 Selection of the control type Depending on the kind of control and the input control signal one must suitably set sections of the DIP according to the table 1 One must choose the kind of control at turned UWB supply off see p 4 5 10 Table 1 DIP switch section Input control signal Phase Pulse quick cycle Pulse slow cycle On Off switching instantly Load configuration Three six wire four wire 0 open switch 1 shorted switch state resulting from other settings Kind of control the load six wire configuration requires the correction of the Span potentiometer one must set the potentiometer slide on the half range 4 4 Connection of control signals 4 4 1 Connection of control to the LZ1 terminal strip It is recommended to use shielded wires and a separate guidance of the control installation and the high current installation to connect control signals to the LZ1 erminal strip
14. e delivered power to the load is described by the following dependence 0 for 0 P z 1 P for X X o max n max Where Po delivered power to the load Xin value of the input control signal The power controller works in the semi conductor relay mode The feed of the voltage signal on the control input p 4 4 2b causes the instantly turn of the load current on The turning on with using the Soft Start function is possible Runs of signals describing the power controller operation for the control of on off type are shown on the fig 10 epus a UV UU UV UU UV Y a G Instantly turning on he load circuit LBARA bag 2 AVVVV Soft start turning on Fig 10 Control of on off type runs of occurring signals in relation to the neutral wire resistance load 16 6 2 Impulse control Pulse control consists on the change of the pulse duty factor and the frequency of power Po delivered to the load in function of the analog control signal at the same time the output current is turned on synchronously with the transition of the supply voltage across zero Runs of signals are presented on the fig 11 The power value in the pulse period according to the formula 2 is defined by the dependence 3 Non Nu 2 No X P
15. e supply and control circuit UWB supply voltage 195 230 253 V a c supply voltage frequency 50 Hz power consumption lt 8 VA voltage control input 0 5 V R 20 0 10 V R 40 current control input 0 4 20 1250 impulse control input 0 4 32 V R 20 STOP signal input 4 32 V 5 mA load carrying capacity of 5 V output 25 mA 21 load carrying capacity of o output load carrying capacity of relay outputs Other parameters working temperature storage temperature humidity working position dimensions versions 40 70 A 125A versions 200 A 300 A 450A weight versions 40A 70A 125A versions 200 A 300 A 450A Safety requirements maximal phase to earth working pollution degree installation category protection degree from terminal side housing protection degree Electromagnetic compatibility EN 60947 4 2 EN 60947 4 3 EN 60947 4 2 EN 60947 4 3 The RP3 power controller fulfils requirements of the EN 60947 4 3 standard The power controller overload capacity is defined by parameters of the applied immunity noise emission noise WARNING 5 mA 5 V 60 mA 350 V 350 Uo 71500 Vans 0 40 C 25 55 C lt 90 without condensation vertical 212 318 x 177 mm 383 x 433 x 281 mm 8 5 kg 37 kg 320 V for power and supply voltage circuits 50 V for other circuits P I IP 00 acc to EN 6
16. nals of the voltage input In U set on the 0 5 V range 4 4 3 Tripping stoppage 55 z 5 E 5 2 ooQooooOoo0Q9poooQ Fig 6 Tripping stoppage 1 There is the possibility to carry out the tripping stoppage shorting terminals 5 V and Stop on the terminal strip The Stop input is active in the range of voltages 4 32 V 5 mA 12 4 4 4 Analog outputs A a Output U f lo 0 5 V 5 mA output voltage proportional to the current value in the load circuit Note The measurement has a reference character f lo Output U cx gt gt e LD 5IE EJE S 8 2 00000000000000 Fig 7 Analog outputs 4 4 5 Relay outputs Semiconductor relays of MOSFET type a Output PK7 signalling at least one of the damaged fuse Fuse Fail error of control or improper connection of the supply lack of supply or wrong phase sequence Error b Output PK2 active signal of triggering stoppage STOP exceeding of the allowable radiator temperature OverTemp
17. ould return the power controller to the Manufacturer s Quality Inspection Dept If the device has been used in compliance with the instructions the Manufacturer guarantees to repair it free of charge The disassembling of the housing causes the cancellation of the granted Warranty After the warranty period One should send the device to repair it in an authorized service workshop Spare parts are available for the period of five years from the date of purchase Our policy is one of continuous improvement and we reserve the right to make changes in design and specifications of any products as engineering advances or necessity requires and revise the above specifications without notice 24 25 26 27 LUMEL Lubuskie Zaktady Aparat w Elektrycznych LUMEL S A ul Sulechowska 1 65 022 Zielona G ra Poland Tel 48 68 32 95 100 exchange Fax 48 68 32 95 101 www lumel com pl e mail lumel lumel com pl Export Department Tel 48 68 329 53 02 or 53 04 Fax 48 68 325 40 91 e mail export lumel com pl RP3 07 17 05 2010
18. t can be a source of hazard Considering the personnel safety one should observe following principles e Devices can be installed serviced and maintained exclusively by a suitably qualified personnel having essential knowledge about equipment e RP3 power controllers should be connected to the power network according to the present operative regulations and standards concerning electrical installations and concerning specially the protection against electric shocks e During the start and operation of the starting system one must comply with recommendations included in this user s manual and specially to sections 4 5 and 6 Qualified personnel defines persons which are acquainted with the user s manual assembly starting and service of the product and have appropriate qualifications to carry out these activities Symbols located in this user s manual mean WARNING Warning of potential hazardous situations Especially important One must be familiar with this before connecting the power controller The non observance of notices marked by these symbols can occasion severe injuries of the personnel and the damage of the device CAUTION Designates a general useful note If you observe it handling of the power controller is made easier One must take note of this when the power controller is working inconsistently to the expectations Possible consequences if disregarded In the security scope the power controller mee
19. ts the requirements of the Low Voltage Directive EN 61010 1 Remarks concerning the operator safety 1 General The RP3 power controller is destined to co operate with other devices Non authorized removal of the required housing inappropriate use incorrect installation or operation creates the risk of injury to personnel or damage to equipment For more detailed information please study the user s manual All operations concerning transport installation and commissioning as well as maintenance must be carried out by qualified skilled personnel and national regulations for the prevention of accidents must be observed According to this basic safety information qualified skilled personnel are persons who are familiar with the installation assembly commissioning and operation of the product and who have qualifications necessary for their occupation 2 Transport storage Please observe the notes on transport storage and appropriate handling Observe the climatic conditions given in Technical Data 3 Installation The power controller must be installed according to the regulation and instructions given in this user s manual Ensure proper handling and avoid mechanical stress 6 Do not bend any components and do not change any insulation distances Do not touch any electronic components and contacts Electronic Instruments may contain electrostatically sensitive components which can easily be damaged
20. ut line amplification The Span potentiometer serves to set the input line amplification in the control range from 50 to 100 of the input control signal NOTE in case of the load control in the six wire configuration one must set the slide of the Span potentiometer on the half range 6 7 Inspection and signalling of the current in the load circuit The passage of current in the load circuit is signalled by means of a two colour Load diode During the normal work the diode is alight in green however in the moment of the current limitation action it is alight in red 6 8 Signalling of the supply correctness The two colour Control diode is alight in green when the power controller is ready to work 19 6 9 Signalling of maximal radiator temperature exceeding The exceed of the 85 C radiator temperature causes the automatic triggering stoppage and the display of signalling on the Over Temp diode and the PK2 relay turning on p 4 4 6b The restart of the power controller is possible after the radiator cooling below 60 C and the supply turning on to UWB again p 4 5 1 6 10 Error signalling The power controller submits the error in following cases 8 improper phase sequence b lack of supply on U1 V1 and W1 terminals simultaneously C the current flows through the load despite of lack of triggering impulses e g as the result of a thyristor module damage In case of an error statement
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