Word Pro - cu10L1r7stagingpdf.lwp
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1. DIP Switch 2 Switches 1 to 4 set the number of stages in addition to the modulating stage For a single unit without slaves 5 is the maximum valid number Switch Setting 1LSB 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 2 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 3 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 4 MSB 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 Number of 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 non modulating stages When switches are set to 0000 the modulating stage output is fed to all stages allowing simultaneous modulating of all stages without rewiring Not suitable for use with contactors 5 Off No function The outputs are rotated round the stages every 5 hours see section on On Stages rotate Stage rotation See also appendix 1 on page 8 for different software f versions 6 Off Output ramp function off When the ramp function is on the modulating output ramps in response to On Output ramp function on a step change of input The time to ramp from 0 100 is set on P2 T Off Stand alone unit or master Sets whether the unit is a master or a slave A master unit may be used On Slave Unit alone for 6 stages or with 1 or 2 slaves for 11 or 16 stages Slave units do not have a modulating output 8 Off Slave Unit 1 stages 7 11 The setting on this switch only takes effect if switch 2 7 is set on and On Slave Unit 2 stages 12 16 determines how the master unit treats the slave Initial versions of the staging controller do not support slave operation Set swi2. Line3 gt Line2 gt Line1 gt Control Transformer AUTO MANUAL K OP6 OP5 OP4 OP3 Rn ora 12V OP1 12V ey z g a ANALOGUE Siang ANALOGU Controller SIGNAL FROM TEMPERATURE GONTROLLER THYRISTOR THYRISTOR THYRISTOR a Q Og E z Typical wiring schematic 3 stage all thyristor system STAGE 1 STAGE 3 Page 7 Appendix 1 A number of different software versions have been made available for this instrument The resulting instruments have been assigned part numbers as follows For Logic Output Types All thyristor control CU02 Logic The standard instrument which operates as described in this document CU02 Logic CU07E5 CU02 Logic CU07E8 Fast Rotating Stages When DIP switch 2 5 is switched on the function of the outputs is rotated every 2 seconds For example consider a 6 stage system The signal level might be set so that 2 stages are required to be on and the modulating stage is required to be at 50 power In the standard instrument Output 1 would be modulati
3. Each time a stage switches either on or off a timer is set which prevents further stage switching until it times out The timer is adjustable by potentiometer P1 between 0 25s and 1 minute The timer prevents rapid cycling of the stages and ensures that on initial switch on when the input control signal to the controller may be at maximum the load is switched on in stages in a controlled manner It also inevitably means that the load cannot be switched off suddenly by reducing the control signal to zero and if this is a requirement eg in emergency some other means must be provided for cutting the load power The timer should not be set longer than necessary as this may have an adverse effect on control stability The longer the time set the longer the integral time constant in a PID temperature controller will have to be Ramp Function DIP switch 2 6 switches on this function When it is enabled the modulating stage is restrained from making step changes in its output It responds to a step change in input demand in either direction by ramping its output at a rate set on potentiometer P2 As it is the modulating stage reaching either zero or full output which triggers stage switching this function may be used in addition to or instead of the stage switc hing delay to control the rate at which load power can be increased or decreased P3 adjusts the time taken for the controller given a step change from 0 100 in input signal to switch on a
4. MM TUH UUE aL 04 S 0uj UO UOpo 07 zZ pa gt a g ma 2 Pat ak o Be ea ea 0e Oo e G a EL T eS Ses S Z p2 g S38 Qgg EEE 8 2 ER oe EOE EPA oO E lt lt 2 T K ot ct oot oS 3 3 ob SS a K S MT Ss ano fw Po soe ca DH HN lt OS D so Ab E pe Ed ec Q c Oc bL HI ZI 91 Cl vt et cb Ul Ob bB LDL bL oak S t gt vr O id SHAI NY IE SIL LIONI al 117 TAS cAS O NOI L Page 6 Control Transformer ii AUTO MANUAL L N le OP1 LOGIC OTHERS RELAY 5 INPUT SIGNAL 7 Staging Controller THYRISTOR CONTACTOR CONTACTOR a oS Typical wiring schematic 3 stage contactor system with modulating thyristor stage STAGE 1 MODULATING
5. be required to increase by 20 before the second stage is switched back on It will be seen that the oversizing creates a switching hysteresis which reduces the number of times stages switch on and off in response to the input control signal If the stages are of equal size there is strictly speaking no hysteresis In practice in this controller a small hysteresis of 1 is introduced In conjunction with the timed switching delay function this results in acceptable switching frequency but at the expense of a potential loss of control accuracy Setting the Oversize The controller must be set up to match the oversize of the modulating stage of the heater battery if appli cable The default setting is no oversize To set up the oversize switch on DIP switch 1 8 Setup The 0 5V analogue output terminals 8 and 9 now represents modulating stage oversize 0 100 which may be monitored on a digital volt meter For 10 seconds after switching on the switch the value transmitted is the current saved setting and if the switch is switched off again within the 10 seconds this value will be retained After 10 seconds the value transmitted is read from potentiometer P2 and may be adjusted to the value required The previous stored value is now lost When it is set correctly switch off DIP switch 1 8 The value is then stored in EEPROM and the analogue output reverts to its normal function Stage Rotation DIP switch 2 5 enables stage rotation This rot
6. Caledon Controls Ltd S IRE Unit 2 Block 4 Castlehill Ind Est Carluke Lanarkshire Scotland ML8 5UF Website www caledoncontrols co uk Email info caledoncontrols co uk Data Sheet and User Manual CU02 Staging Controller for Load Sequencing Control Up to 6 Stages in one unit Up to 16 stages with slave units l LUTT Directly interfaces to low cost logic input thyristors or to contactors Built in Burst fire or Single Cycle Control Algorithms Separate analogue output may be used with phase angle thyristors Allows modulating stage oversizing for stable control Stage rotation facility to balance heater usage Check availability Application The staging controller is designed for use with a large process heating system which is split into several banks of heaters all of which apply heat input to the same heating load The staging controller balances the required heating demand by switching on the number of stages heater banks which most nearly match the demand and modulating one additional stage to make up the difference Versions are available with combined relay logic outputs and all logic outputs A single analogue output is also provided Relay logic types are used with contactor stages 1 modulating thyristor stage all logic outputs are used when all the stages are controlled by thyristors The analogue output may be used to drive one modulating thyristor which accepts a standard analog
7. ates which output on the controller is assigned to each stage on a fixed periodic basis Standard period is 5 hours The purpose is to help balance the usage of all the heater stages in the battery over time Stage rotation can only be used and must only be set when 1 All the heater stages are of the same power rating 2 All the heater stages are thyristor controlled 3 The logic outputs are used for all stages Modulating Stage Thyristor Firing Modes The logic output offers two firing modes burst fire and single cycle burst fire Burst fire control is a method of controlling the load power by switching the current on and off The current is on for a number of supply cycles and off for a number of cycles The load power is varied by varying the ratio of on time to off time In burst fire mode the fastest cycle time offered by this controller is 0 3s at 50 duty cycle corresponding to approximately 8 cycles on and 8 cycles off at 50Hz Potentiometer P3 may be used to adjust the cycle time between 0 3s and 20s Single cycle burst fire control is the fastest type of burst fire control possible At 50 duty cycle power one mains cycle on is followed by one off Above 50 power only one mains cycle is allowed to be off before another on cycle Any number of on cycles may follow each other consecutively Below 50 power only one mains cycle is allowed to be on before another off Page 4 cycle Any number of off cycles may follow each other conse
8. ch on If the thyristors have 3 line control the ones in the typical schematics have only 2 line control the controller power supply may be derived across two of the lines via a step down transformer as shown in the schematics or connected line to neutral DIP switch 1 2 must be set to match If the thyristors have only 2 line control the power supply must be derived across the two lines which are controlled by the thyristor as shown in the schematics This is to avoid the need to know the supply rotation With this proviso the supply rotation is immaterial in all cases DIP switches 1 3 and 1 4 must be set to match the load configuration When operating with burst fire control DIP switch 1 6 may be switched on which unsynchronises the logic output from the mains cycles The phase relationship of the controller power supply to the load power supply is then immaterial and the setting of DIP switches 1 2 to 1 4 will have little effect It may be beneficial to use synchronous operation particularly with fast cycle rates as the synchronous algorithm used is designed to maintain load balance and eliminate small DC components from the load current If the supply to the controller is phased correctly it allows the flexibility to change to single cycle operation if found desirable If synchronous operation is chosen then the power supply connection and DIP switch settings must be adhered to as for single cycle operation Delay between Stage Switching
9. control 1 3 Off Load connection for 2 line control Load star or delta Only 2 of the 3 lines are controlled The third is connected directly connected On Load connection for 3 line control All 3 lines are controlled by thyristors 1 4 Off 3 line control 3 wire load connection star or delta Only operative if 1 3 is on Must then match the load On 3 line control 4 wire star load connection connection 15 Off In auto mode the front panel potentiometer has no In manual mode the potentiometer controls the function output power independent of the input control signal On In auto mode the front panel potentiometer sets an Applies to software versions CUO7ESRx where x is upper limit on the input control signal the issue number Standard from 2005 Software version CU07E1Rx available on request offers proportioning of the input signal by the front panel potentiometer when in manual mode 1 6 Off No function On Modulating logic output signal not synchronised to Normally should be off See switch 1 2 above and the mains frequency section on Controller supply and synchronisation 1 7 Off Analogue inputs without offset 0 5V etc On Analogue inputs with offset 1 5V etc 1 8 Off Normal operating mode In set up mode potentiometer P2 may be used to set On Setup mode the oversize of the modulating stage See section on Oversizing the modulating stage Page 2
10. control Only one of the stages is modulating stage 1 output 1 but see Stage Rotation below but the non modulating stages are also switched by thyristors This is more satisfactory for loads which vary frequently as there is not the switching life problem associated with contactors The thyristors may all be logic input types or alternatively the modulating stage may be an analogue input type It is less important th an when using contactors that the modulating stage be oversized as other stages can be switched frequently However better control may be obtained if the modulating stage is oversized as there will always be time delays associated with the heating and cooling of elements etc as stages are switched in and out Oversizing the Modulating Stage Most heater batteries are designed with all stages having the same power rating From a control point of view there is an advantage in having the modulating stage oversized relative to the other stages Consider the case where the relative sizes of the modulating stage and the other stages are 100 80 As the input signal rises from zero the modulating stage output will increase until it is fully on At this point the second stage is switched in and the modulating output is cut back to 20 If t he input signal now starts to fall the modulating stage has to fall back by 20 before the second stage is switched back off and when this happens the modulating output is stepped up to 80 It must then
11. cutively The average ratio of on to off cycles is controlled to obtain the required average load power Single cycle control can be used for fast response loads or to minimise the effect of burst fire operation on supply generator speed control If phase angle control is preferred for the modulating stage the analogue output 0 5V may be used to drive a suitable thyristor stack which accepts an analogue input Controller Supply Connection Mains Synchronisation and Typical Wiring Schemes The controller must be adjusted for the correct supply voltage either 115V or 230V 10 15 The setting is adjusted by moving the jumper plug which is on the right hand side of the unit to the correct position To gain access undo the 2 screws at either end of the unit remove the cheeks and unclip the cover 115V is set with the plug moved toward the top of the unit and 230V with the plug moved toward the bottom of the unit as indicated by the small lines on the PCB which should be alongside the wire links in the plug Typical wiring schematics are given at the end of the manual for 3 stage 3 phase systems The controller logic output for the modulating stage is synchronised to the mains frequency This synchronisation is derived via the controller power supply When operating with single cycle control it is essential that the power supply be correctly phase related to the supply which feeds power to the heaters The thyristors must have zero voltage swit
12. f this could result in a dangerous situation then independent means of monitoring the load and removing power should be fitted This is a requirement of international standards Control of thyristors in single cycle mode gives rise to harmonic currents and electrical noise and it should be ascertained that these fall within acceptable limits for the application System Configuration Options and Requirements Two versions of the controller are available for use with thyristor only systems and contactor thyristor systems Typical wiring schematics for a 3 stage system of each type are given Contactor Thyristor Control This is the lowest cost option and is most suited to loads which do not va ry rapidly or tend to stabilise ata more or less constant value for long periods The controller is fitted with relays to operate the contactors A single modulating thyristor stage is used stage 1 and output 1 to exactly balance the load demand The thyristor may be either a logic input type driven by the stage 1 logic output on the staging controller or an analogue input type driven by the analogue output on the controller It is advantageous if the modulating stage is oversized relative to the contactor stages as this will help reduce the frequency of contactor switching and avoid the situation where the required power demand is met just at the point where one stage is switching on off All Thyristor Control This is a more versatile form of
13. ll stages independent of the number of stages ramping the modulating stage after each time another stage switches in The time is adjustable from 5s to 50s Auto Manual Function This function enables an optional manual potentiometer to be connected as shown in the typical schematics Control by the potentiometer is selected by linking terminals 6 and 7 When control is by the manual potentiometer DIP switch 1 5 determines whether the potentiometer controls the power independent of the main control signal or whether it proportions the main control signal In the latter case the main auto control signal will have to be present to obtain any output in manual and the potentiometer will proportion the output over the range zero to the value of the main auto control signal Slave Units Slave operation is not yet available but when introduced will enable operation with a master unit and up to two slaves allowing up to 16 stages to be controlled Each slave unit will have 5 non modulating stages which are switched on and off under control of the master unit Because the modulating output is confined to the master unit stage rotation cannot be performed across slave units and is constrained to a maximum of six stages Page 5 7 7 3 MaR 253 169 yoy 3 8 Wy Ragan T3 1 aig DAHIHIMI auovayyy SINSHNGISSY VU l syuaulia D ans Wapen iON 20d
14. ng outputs 2 and 3 would be on and outputs 4 5 and 6 would be off In this instrument after 2 seconds output 1 would be off output 2 would be modulating outputs 3 and 4 would be on and outputs 5 and 6 would be off After a further 2 seconds Outputs 1 and 2 would be off output 3 would be modulating outputs 4 and 5 would be on and output 6 would be off etc This operation is only suitable for use with single cycle control and if heaters are distributed around a vessel ensures that the heat input is evenly distributed CU02 Logic CU07E9 Sequential Modulating Stage When DIP switch 2 5 is switched on the modulating output progresses as the demand increases For example consider a system with 4 equal stages Up to 25 demand only output 1 is on and modulating Between 25 and 50 power output 1 is full on and output 2 is modulating Between 50 and 75 power outputs 1 and 2 are full on and output 3 is modulating Between 75 and 100 power outputs 1 3 are full on and output 4 is modulating This mode only operates with equal stages and there is no hysteresis between stages The switching delay time and ramp function operate as standard For Relay Output Types Thyristor contactor control CU02 Relay The standard instrument which operates as described in this document CU02 Relay CU07E5 No other variants have currently been made for thyristor contactor control Cu10L1r7 Page 8
15. onal logic output for special applications selected by JMP2 13 12V 12V unregulated supply Common positive for logic output signals 14 Output 1 Logic output ve pull down NPN open collector output to drive a thyristor controller In systems with contactors or where the modulating control is not rotated around the heaters this stage will be the modulating stage Outputs 2 6 are either on or off 15 12V 12V unregulated supply Common positive for logic output signals 16 Output 2 These outputs are specified at the time of ordering as either logic ouputs NPN open 17 Output 3 collector pull down or N O relay outputs for driving contactors Contactor coils should be suppressed In systems with less than 6 stages the lower numbered outputs are used eg a 18 Output 4 3 stage system uses outputs 1 2 and 3 19 Output 5 20 Output 6 21 Relay Common Common for outputs 2 6 when these are specified as relay outputs 22 Supply Live Either 115V 10 15 or 230V 10 15 50 or 60 Hz Voltage is selected by jumper assembly at top right of module 23 No connection Do not make any connection to this terminal 24 Supply Neutral Page 3 Safety and Regulatory Considerations The controller must be wired in accordance with electrical standards applicable in the country of installation When controlling heating loads it is important to consider the effects of loss of control due to a fault eg the heating power being turned fully on I
16. potentially reduces the amount of stage switching required to maintain temperature control A single 0 5V analogue output is provided which may be used with an analogue input thyristor stack for the modulating stage if preferred this allows a phase angle stack to be used for example In the case of logic input thyristor only systems in which all the stages have the same power rating the stages may optionally be rotated around the heater banks which helps to balance the total usage of each heater bank Specifications Supply voltage Power consumption Ambient temperature Approximate Dimensions Input signal Auxiliary input signal Output signal Digital input signal Indicators Safety Standards EMC Standards Preset Potentiometers P1 Stage switching time delay P2 Ramp time In setup mode sets modulating stage oversize P3 Burst fire cycle time 115V or 230V AC 50 60 Hz 10 15 4VA 0 50 C 104mm high x 155mm wide x 80mm deep Symmetrical DIN rail mounted 0 5V 0 10V 1 5V 2 10V 0 20mA 4 20mA link selectable 0 5V manual input may be fed by a 10kQ potentiometer powered from the unit Non modulating stages relay or logic signal specified at time of ordering Modulating stage Logic signal for use with zero voltage switch on thyristors 1 off analogue signal 0 5V Relay contacts rated 250V AC 2A Contact closure or npn pull down switches unit to manual operation LED indicators for power manual operation selected outp
17. tches 7 and 8 off Terminal Function List Terminal Function Notes Number 1 Functional Earth Not a safety earth May be connected to chassis to improve EMC noise immunity 2 5V Output May be used to energise a 10K potentiometer connected to the manual input 3 Manual Input Accepts a 0 5V signal when the controller is in manual mode It is advisable to use a screened cable for the leads to the manual potentiometer particularly if they are longer than 1 metre to avoid interference pick up which could cause jitter when switching between stages The screen should be grounded adjacen to the controller or to terminal 1 if this is grounded 4 OV OV common for input signals manual potentiometer and analogue output 5 Setpoint input Accepts the setpoint signal power demand from a temperature controller Signal type determined by JMP1 setting 6 Auto manual select When off controller uses the main setpoint input 5 When linked to OV or pulled to OV by an NPN transistor controller uses manual input 3 7 OV OV common for input signals and analogue output 8 Analogue output 0 5V signal which represents the output value of the modulating stage 9 OV OV common for input signals analogue output and comms 10 Comms For future use to enable control of slave controllers Do not wire to these terminals 11 Comms 12 Auxiliary Output Not used provides an additi
18. ue input signal if preferred The staging technique provides the following advantages 1 On large electric heating systems the load is broken into banks of a smaller kilowatt rating and the maximum size of load being switched on or off at any one time is reduced This reduces the magnitude of switching disturbances on supply lines and is particularly useful where the load represents a significant proportion of the supply capacity 2 On systems where the load demand does not frequently vary over a wide range the non modulating stages may be contactor controlled and the modulating stage thyristor controlled Brief Description The Caledon staging controller accepts an analogue input signal from a temperature controller which represents heating demand A second input is provided for use with a manual potentiometer The controller provides outputs for 6 stages of heating and there is provision for future slaving of additional units to increase the number of stages to a maximum of 16 The stages may be either 5 relay outputs for use with contactors and 1 logic analogue output for a modulating thyristor or 6 logic outputs for use with thyristors Modulating logic outputs operate in either burst fire mode or single cycle burst fire mode Both are intended for use with thyristor controllers which accept a logic input signal and have zero voltage switch on The stages may either be of the same power rating or the modulating stage may be oversized which
19. uts on Complies with European Low Voltage Directive and major international standards Pollution degree 2 Overvoltage category 3 IEC 664 Complies with European EMC Directive for operation in an industrial environment 0 25s to 1 minute prevents rapid cycling of stages 5 50s see section on Ramp Function Jumper and DIP Switch Options Settings 0 100 0 3s to 20s at 50 duty cycle Jumpers Analogue Input Selection Off On JMP1A 0 5V 0 10V JMP1 B Voltage Input Current Input connects a 2500 resistor across the input Set Imp 1A off For signals with offset 1 5V 2 10V 4 20mA set switch 1 7 on DIP Switch 1 Function Notes Switches 1 2 to 1 4 must be set correctly for the modulating logic output to operate correctly in single cycle mode The controller power supply must also be wired correctly to match the setting on switch 1 2 The switches must also be set correctly for the logic output to operate correctly in burst fire mode unless switch 1 6 is on in which case the setting of these switches and the power supply connection is immaterial If the analogue output is used for the modulating stage the setting of these switches and the power supply connection is immaterial 1 2 Off Controller power supply in phase with line to line Normal operation supply On Controller power supply in phase with line to neutral Cannot be used with 2 line
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