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Thyristor power units TC3000 Three

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1. output N 38938 83 J31 to J35 S a Auxiliary input K1 to K13 configuration A a Operating modes J11 to J15 Main setpoint Figure 4 2 Location of configuration and calibration jumpers on the driver board TC3000 User Manual 47 Configuration Auxiliary power supply Two soldered links LK1 and LK2 on the driver board are used to configure the auxiliary voltage the electronic and fan power supply as 100 V to 120 V oras 200 V to 240 V Note The power board also contains jumpers which are labelled LK Auxiliary voltage 100 110 115 120 V Link soldered on the driver board in the factory 200 220 230 240 V Table 4 4 Auxiliary power supply configuration The fans for fan cooled units are single voltage A They cannot be powered with a voltage other than that indicated on the fan Consequently the auxiliary power supply voltage configuration must correspond to the nominal voltage of the fan 4 8 TC3000 User Manual Configuration Main setpoint configuration The five jumpers J11 to J15 are used to configure the analogue control main setpoint signal type voltage or current and the signal scale from the six available scales Main setpoint signal Position of jumpers type and scale J12 Voltage J13 J14 Current Table 4 5 Main setpoint signal configuration Process value co
2. 1 2 Techrical data iei epe reete e ce cecus 1 7 COMING e ED 1 10 Simplified or complete coding 1 12 Coding example 5 3 x ere cinere te tp eite 1 13 Thyristor unit and installation parameters 1 13 GOING eee 1 13 Serial number labels cccccccesceeeeseeeeeeeeeeeeseeeesseeeeeees 1 14 TC3000 User Manual H Identification Chapter 1 IDENTIFYING THE THYRISTOR UNITS GENERAL INTRODUCTION TO THE TC3000 SERIES The TC3000 series thyristor units are designed to control the electrical power on industrial three phase loads The TC3000 series is designed to control the following loads inductive inductors or primary transformer coils resistive with low temperature coefficient composed of short wave infrared elements The three phase loads can be connected instar with neutral in star without neutral in closed delta in open delta The TC3000 thyristor units current ratings are from 25 A to 500 A The nominal line to line voltage can be between 100 V and 500 V The thyristor unit connection is indifferent to the order of the power supply phase rotation A TC3000 series thyristor unit is composed of 3 channels containing a pair of thyristors mounted in anti parallel 1 2 TC3000 User Manual Identification Protective cover Door fixing screw PA Ramp CY De Rampe AP Retard TO Setting Response T Cl T
3. 4 3 Voltage selectlori ieecnii citet tr reiten 4 4 Adaptation to the load connection type 4 5 Boiorum 4 6 Auxiliary power supply eee m 4 8 Main setpoint configuration eeeenne 4 9 Process value configuration seseeeeeeeesees 4 9 Auxiliary input output configuration 4 10 Thyristor firing mode configuration 4 11 Load type and configuration type sssssss 4 12 Alarm relay contact type 4 12 Under voltage alarm level seeeneee 4 13 auicm Cn 4 13 Calibration Operation eene 4 14 Chapter 5 OPERATION Block diagratri itcr iere A ees 5 2 Inu cc ae aa ad Eae aiis 5 3 Power DOAN isisa iraa a 5 3 Potentiometer board 1 nectit 5 3 Display n ei ee ERR EIE ee es 5 3 DiagnostliC Socket ite eite cesi reatus 5 3 BIBerip ee Em 5 4 Thyristor firing modes cerent nnt nen 5 5 Phase angle iode sissies reete tret tee 5 5 Logic mode Burst firing mode Setting potentiometer functions ssseeess 5 13 PA Ramp CY Delay potentiometer seeessss 5 15 Setpoint change ramp Soft start end sse Delay angle Response time potentiometer seeeeeeeee 5
4. Delay angle Figure 5 6 Inductive load switching at zero voltage a and with a delay angle b TC3000 User Manual 59 Operation The table below gives the possible types of operation in Logic mode code LGC Standard Corresponding operation ON time corresponds to the time that the control signal is present Code RES Thyristor zero voltage switching on each phase each new firing starts at the different zero voltage Code IND On each phase the first firing is delayed by an adjustable angle Soft Adjustable time Soft start with thyristor firing angle variation from zero to full firing Immediate stop at end of cycle Default code RES Soft start and end with thyristor firing angle variation from zero to full firing and from full firing to zero Default code RES Table 5 2 Possible types of operation in Logic ON OFF mode 5 10 TC3000 User Manual Operation Burst firing mode The Burst firing mode is a proportional cycle which consists of supplying a series of complete power supply voltage cycles to the load A Load voltage t gt 0 lt TF gt lt TNF gt lt TM Figure 5 7 Burst firing mode T firing time T modulation time The Burst firing mode with a single firing mains cycle or a single non firing mains cycle is called the Single cycle firing mode Thyristor firing and non firing
5. Chapter 8 ALARMS The alarms used by the TC3000 thyristor unit protect the thyristors and the installation against abnormal operation and give the user information on the type of failures that have occurred Warning AN Alarms cannot be used to replace personnel protection It is the user s responsibility and it is highly recommended given the value of the equipment controlled by the TC3000 to install independent safety devices which should be checked regularly For this purpose Eurotherm can supply several types of alarm detectors ALARM STRATEGY The TC3000 thyristor unit alarms are entirely managed by the microprocessor of the driver board which retransmits its data alarms enabled or not using the display on the thyristor unit front panel and the alarm relay The alarms are given levels see figure 8 1 The detection of a high level alarm inhibits the processing of lower level alarms The enabled state of all the alarms is indicated by the front panel display see pages 7 2 to 7 4 and the alarm relay The highest level alarms detect the following failures absence of one or more power supply phases under voltage supply frequency deviation external measurement signal failure neutral failure fuse blow out on the power board The detection of one of these failures causes the thyristor unit operation to be inhibited display F The low level alarms display E monitor the over volt
6. TC3000 User Manual 341 Wiring Alarm contacts The TC3000 thyristor units are equipped with a general alarm relay see Alarms chapter Lower cover General alarm contact To the alarm or terminal block signalling system View of thyristor unit from below Figure 3 8 General alarm and PLF contact connection view from below The alarm relay contact output is provided on the user terminal blocks below the thyristor unit and is available without opening the front door Important IN The relay contact is protected against interference by internal RC snubbers The type of contact specifying the alarm state is determined by the thyristor unit coding Alarm type Terminals Contact type Coding General alarms 61 62 N O open in alarm state Standard N C closed in alarm state IPU Table 3 3 Destination of alarm contact terminals 3 12 TC3000 User Manual Wiring CONTROL CABLES Caution A N The control connections must be made with shielded cables connected to the earth at both ends in order to ensure satisfactory immunity against interference Separate the control cables from the power cables in the cable trays Fixing The control wires must be grouped together in a shielded cable passing through the cable clamp under the unit To facilitate the safety earthing of the cable shield and to ensure maximum immunity to electromagnetic interference the metal cable clamp is con
7. sseeeeeee 3 6 Open delta configuration eeeenee 3 7 User terminal blocks cinere rtc 3 8 General introduction sssseeeennen 3 8 Auxiliary power supply eeeem 3 10 Reference ne ttal rcc ecrit aa 3 11 Alarm contacts e peine tete eee guten eb re Eget eo ern 3 12 Control cables nune Ie enero NOE de exa diia o aa 3 13 ij 3 13 Connection of the shield to the ground sssse 3 14 Control terminal DlOCKS odor cene cette cette 3 15 General introduction ssssennene 3 16 External controlinpLut iecore akade 3 17 Manual control 2 etit ri eite etre nid ta 3 17 Auxiliary Input OUTtDUE niese aiden 3 18 Alarm acknowledge eem 3 18 TC3000 User Manual 31 Wiring Chapter 3 WIRING SAFETY DURING WIRING A Warning Wiring must be performed by personnel who are qualified to work with low voltage electrical equipment It is the user s responsibility to wire and protect the installation in accordance with current professional standards A suitable device guaranteeing electrical separation of the equipment and the power supply must be installed upstream from the unit in order to perform the operation in complete safety TC3000 series units possess two protective covers upper and lower The upper cover should be raised to facilitate wiring After connection and before power
8. The duration of the thyristor firing angle change is set using the potentiometer P1 for both the start and the end T always equal to T The soft start and end duration can be set using the potentiometer P1 from 0 to the number of modulation times The maximum soft start end duration corresponds to the number of burst times in the basic cycle selected modulation time The setting position of the potentiometer P1 can be read using a EUROTHERM type 260 diagnostic unit in the form of a setting voltage in position 11 P1 Soft start end duration Ts Ts Setting voltage read in position 11 Number of 50 Hz 60 Hz of the diagnostic unit cycles power supply power supply Table 5 7 Soft start end duration 5 20 TC3000 User Manual Operation Delay angle The potentiometer P1 adjusts the delayed firing angle of the first half cycle for the control of inductive loads in the following firing modes Logic and Burst firing A 90 delay angle is obtained with P1 turned completely clockwise A 0 delay angle is obtained with P1 turned completely anti clockwise The scale in figure 5 12 gives the equivalence between the setting voltage V1 read in position 11 of the diagnostic unit and the delay angle Firing angle 90 80 60 40 20 Setting voltage V11 0 1 0 2 0 3 0 4 0 5 0 V Figure 5 12 Delay angle setting
9. In this table VLINE RMS line to line voltage line voltage VN nominal line voltage VL RMS load voltage VLN nominal load voltage VgxT external measurement signal OP input signal output power f power supply frequency Conditions Over voltage Alarm ON Ving gt 120 VN Alarm OFF Vine lt 110 VN Inhibit Display Absence of power supply phases Absence of synchronisation pulses After appearance Under voltage Vine 70 VN Vue 2 70 VN Frequency error 40 Hz gt f gt 70 Hz 40 Hz lt f lt 70 Hz External meas signal failure VExT 0 OP 0 After disappearance Thermal switch permanent cooling only Fan cooling failure After acknow ledgement and cooling Neutral failure Neutral fuse blown on neutral not connected 4 wire configuration Table 8 1 Appearance of neutral circuit Alarm characteristics TC3000 User Manual Alarms ALARM RELAYS The general alarm relay is located on the driver board The detection of any other alarm changes the state of the general alarm relay The contact N O or N C depending on the configuration can be used to indicate the alarm state or in the monitoring system The contact is available on the user terminal block below the thyristor unit terminals 61 62 The relay contact can be connected without opening the front door of the thyristor unit The alarm rela
10. Power board Auxiliary power supply terminal block ce Driver board Figure 1 2 TC3000 thyristor unit electronic boards TC3000 User Manual Identification TECHNICAL DATA The TC3000 series is a series of power thyristor units designed for the control of 3 phases of industrial three phase loads using thyristors Warning J An isolating device must be installed between the equipment and the mains supply in order to perform the maintenance in complete safety Thyristors are not isolating devices Touching load terminals even if there is no loads current unit in the off state is as dangerous as touching power supply terminals Caution N It is the user s responsibility to ensure that the nominal values of the thyristor unit are compatible with the conditions of installation and operation before commissioning the thyristor unit Power Nominal current per phase Nominal line to line voltage Operating voltage calibration Power supply frequency Dissipated power Cooling Fans Load Load connection Load configuration 25 A to 500 A 240 V to 500 V 4 10 15 100 V to 500 V Inhibit below 70 or 50 of calibrated voltage 42 Hz to 68 Hz Automatic adaptation Inhibit outside 40 to 70 Hz 1 3 W approximately per ampere and per phase Natural convection 25 A to 75 A Permanent fan cooling from 100 A 2 for 100 A to 250 A 3 for 300 A to 500 A Consumption 25 VA per fan Po
11. Thyristor power units TC3000 Three phase load control User Manual Copyright Eurotherm Automation 1996 All rights reserved All reproduction or transmission in any form or using any procedure electronic or mechanical including photocopying and recording without the written permission of EUROTHERM AUTOMATION is strictly prohibited EUROTHERM AUTOMATION have taken particular care to ensure the accuracy of these specifications However in order to maintain our technological lead we are dedicated to the continual improvement of our products and this may lead to modifications or omissions in the current specifications We cannot be held responsible for any material or bodily damage losses or costs incurred Part No HA174835 ENG Issue 3 1 06 01 Old part No HA 174836 l CE EUROPEAN DIRECTIVES SAFETY The TC3000 products installed and used in accordance with this User Manual are designed to comply with the essential protection requirements of the European Low Voltage Directive 73 23 EEC dated 19 02 73 amended by Directive 93 68 EEC dated 22 07 93 CE MARK The CE Mark of TC3000 products implies that the essential protection requirements of the European Low Voltage Directive are observed The TC3000 Technical Construction File is approved by a Notified Body LCIE Laboratoire Central des Industries Electriques C DECLARATION OF CONFORMITY A CE Declaration of Conformity is available on request For furt
12. For M4 nut Table 9 4 Tools Electrical equipment Ammeter or RMS clip Oscilloscope recommended EUROTHERM type 260 diagnostic unit recommended TC3000 User Manual
13. The alarm is acknowledged by connecting terminal 11 ACKNOWL on the control terminal block to 10 V terminal 16 or to the external 10 volts with the common 0 V 3 18 TC3000 User Manual Configuration Chapter 4 CONFIGURATION Contents page Safety during Configuration i 2 2 tte tienen 4 2 Power board s A Voltage selection sse 24 4 Adaptation to the load connection type 4 5 Driver Board eer cette cies 46 Auxillary power supply ineat ntn tnn 4 8 Main setpoint configuration enne 4 9 Process value configuration eene 4 9 Auxiliary input output configuration 4 10 Thyristor firing mode configuration s ATT Load type and configuration type wee 4 12 Alarm relay contact type we 4 12 Under voltage alarm level enne 4 13 Initial ramp ierit eni tene ettet een 4 13 Galibration Operation tiec nre e 4 14 TC3000 User Manual a Configuration Chapter 4 CONFIGURATION SAFETY DURING CONFIGURATION The thyristor unit is configured in the factory using moveable jumpers and soldered links The thyristor unit can be reconfigured on site using jumpers Important The thyristor unit is supplied fully configured in accordance with the code on the identification label This chapter is included in order to check that the configuration is compat
14. This safety ramp is applied at tart at the control electronics power up after an inhibition after the microprocessor reset Make sure that the RMS current does not exceed the nominal thyristor unit current when the setpoint is 100 and the potentiometer P3 is turned completely clockwise The control signal can be read in position 7 of the diagnostic unit 5V corresponds to 100 of the input signal TC3000 User Manual 611 Commissioning Delayed firing setting on inductive load To eliminate the transient operation over current during the power up of inductive loads the first firing on each phase in the Burst firing and ON OFF modes must be delayed with reference to the corresponding zero voltage see page 5 9 The optimum delay angle depends on the load used and can be adjusted with potentiometer P1 CY Delay on the front panel In the factory the delay angle is adjusted to 90 To adjust the delay angle during commissioning follow the procedure below Check that the position of the jumper K7 on the driver board is 1 inductive load and that the potentiometer P1 is at the maximum value i e turned completely clockwise After the power up turn the potentiometer P1 slowly anti clockwise until the transient current at firing displayed on the oscilloscope has a minimum amplitude Data on the delayed firing angle is available in voltage form in position 11 of the diagnostic unit 5 V corresponds
15. less than 100 the current passing in the neutral of the loads can be up to 25 greater than the line current in full firing Caution This current requires an adapted design of the neutral cable especially for loads composed of short wave infrared elements L1 L2 L3 N Line protection and main circuit breaker user installation Thyristor Power board protection fuses LOAD Hai Figure 3 2 Power safety earth and neutral wiring diagram for a load connected in Star with neutral 4 wires Neutral connection LOADS TC3000 User Manual 35 Wiring Closed delta configuration L1 L2 L3 Line protection and main circuit breaker user installation Safety earth Thyristor protection fuses LOADS Figure 3 3 Power and safety earth wiring diagram for a load connected in Closed delta 3 wires 3 6 TC3000 User Manual Wiring Open delta configuration Important The load wiring diagram given below must be observed L1 L2 L3 Line protection and main circuit breaker user installation Safety earth Thyristor protection fuses Figure 3 4 Power and safety earth wiring diagram for a load connected in Open delta 6 wires TC3000 User Manual 37 Wiring USER TERMINAL BLOCKS General introduction The user terminal blocks located below the TC3000 thyristor units are intended for the following connecti
16. reponse L1 Setpoint limit Limit de consigne potentiometers Display Diagnostic socket Control cable d NEN 71 Auxiliary power NS P d General Neutral supply terminal alarm contact terminal block block Power cable gland terminal block Figure 1 1 Overall view of the TC3000 thyristor unit TC3000 User Manual 18 Identification The TC3000 thyristor units have the following functions two control modes V2 external measurement signal several thyristor firing modes logic ON OFF thyristor firing angle variation Phase angle cycle time modulation Burst firing mode soft operation adjustable soft start and or stop to eliminate over currents on loads with low resistance when cold or for other applications permanent monitoring of the power supply voltage and the frequency The thyristor unit is controlled with analogue or logic signals For the input analogue signals there are four possible voltage levels 0 5 V 1 5 V 0 10 V 2 10 V and two current levels 0 20 mA and 4 20 mA The instantaneous state of the thyristor unit its operating mode and the active state of alarms are indicated by messages on a 7 segment display located on the front panel The front panel also includes 3setting potentiometers for the main operating parameters adiagnostic socket An alarm system detects abnormal variations in the voltage and fr
17. 22 Standard reponse time in Phase angle 5 22 Number of mains cycle in the Burst firing basic cycle 5 23 Setpoint limit potentiometer eseeeeeene 5 24 Control Operation 3 iene hens ene 5 25 Squared load voltage 0 0 eeceeeeeeeeeeeeeeeeeeeneeeeeeeeneeseeeeeeeeaes 5 26 External M aSUreMent ccessececeseeeeesseneesseeeeeseeenerseeeees 5 26 Cart2 TC3000 User Manual Contents Continued Page Chapter 6 COMMISSIONING Commissioning procedure safety sssssssssssss 6 2 Checking the characteristics eeseseeses 6 3 load CUITOrt rrr n iet dre terere 6 3 Load configuration type esee 6 3 Power supply voltage esee 6 4 Auxiliary power supply voltage eeeeeeeeeee 6 4 Input signals inttr eie oe aE dues sedanceds 6 4 DIAQMOSUG lr 6 5 Thyristor unit calibration ee 6 7 Load voltage calibration eese 6 9 Calibration in calibration mode position 6 9 Calibration in normal operation position 6 9 Line voltage calibration cesses 6 9 COMMISSIONING e T 6 10 Preliminary settings eese 6 10 PoWGI Up eiit naesece tine pde aede dese ie ea Ea 6 11 Delayed firing setting on
18. 380 V Figure 1 3 Example of identification label for a TC3000 thyristor unit The information corresponds to the coding example The second identification label and a configuration label are located inside the thyristor unit SERIAL No LC1111 001 001 12 95 TC3000 FACTORY SETTINGS INPUT 0 10 V FIRING 8 SUPPLY CYCLES BURST FIRING CONFIGURATION STAR WITHOUT NEUTRAL RESISTIVE LOAD CONTROLLED PARAMETER V2 AUX INPUT OUTPUT RETRANSMISSION V2 UNDER VOLTAGE DETECTION THRESHOLD 70 ANY NON SPECIFIED FUSE INVALIDATES GUARANTEE SEE USER MANUAL FERRAZ X300055 BUSSMANN 170M3465 Figure 1 4 Example of configuration label for a TC3000 thyristor unit Caution A Any reconfiguration done by the user will render obsolete the original in house configuration code shown on the label 1 14 TC3000 User Manual Installation Chapter 2 INSTALLATION Contents page Safety during installation ssseeseesss 2 2 DIMENSIONS 3 nderit obitu Pc rede v tee 2 3 Installation details sssssssssseeeeees 2 5 TC3000 User Manual 2 1 Installation Chapter 2 INSTALLATION SAFETY DURING INSTALLATION Warning TC3000 units must be installed by a person qualified and authorised to work in an AN industrial low voltage electrical environment Units must be installed in correctly fan cooled electric cabinets guaranteeing the absence of condensation and pol
19. 4 11 Load configuration Position of jumpers on power board LK7 LK8 LK9 Star without neutral 3 wires Star with neutral 4 wires Connection of the neutral wire to the user terminal block below the thyristor unit Closed delta 3 wires Open delta 6 wires Table 4 2 Load connection type configuration For the star with neutral configuration 4S code the neutral resistor is fitted on the power board R5 see figure 4 1 The R5 value depends of unit voltage For other configurations 3S 3D 6D codes the R5 is not fitted N Caution The factory configurated unit for 3 or 6 wires can be reconfigurated to star with neutral according to table 4 2 but this requires to fit R5 resistor on power board For this reconfuguration or for in case of operating voltage change the resistor R5 3 W has to be ordered according to following part numbers CZ 17498810K for 120 V max 10 kQ CZ 17498827K for 240 V max 27 kQ CZ 17498833K for 440 V max 33 kQ CZ 17498856K for 500 V max 56 KQ TC3000 User Manual 45 Configuration DRIVER BOARD The driver board jumpers are used to configure the auxiliary power supply the control signals the thyristor firing mode the load configuration type the operation type the alarm relay contact type The functions of the driver board jumpers are summarised in the table below Function Auxiliary power supply Jum
20. firing basic cycle The firing or non firing time in the Burst firing mode is set using the potentiometer P2 Important The potentiometer P2 sets the duration of the basic cycle firing time for less than 50 power the duration of the basic cycle non firing time for a power greater than or equal to 50 The setting varies between a single supply cycle Single cycle firing mode and 255 supply cycles The setting made can be read using the Eurotherm type 260 diagnostic unit in position 10 in the form of a setting voltage P2 Basic firing or non firing time Setting voltage read in position 10 Number of 50 Hz 60 Hz of the diagnostic unit cycles power supply power supply 16 6 ms 33 3 ms 83 3 ms 133 3 ms 266 6 ms 533 3 ms 1 07 s 2 13 s 4 25 s Table 5 9 Basic cycle firing or non firing time TC3000 User Manual 523 Operation Setpoint limit potentiometer The potentiometer P3 labelled Setpoint limit on the front panel can be used to limit the input signal setpoint The input signal limit function is enabled in the Phase angle and Burst firing modes but does not act when the TC3000 thyristor unit is configured in Logic firing mode The setpoint limit setting made using the potentiometer P3 can be read using the Eurotherm type 260 diagnostic box in position 9 in the form of a setting voltage V 9 The setting voltage value Vg of the limit input signal E 4 in 96 of t
21. for the safety of personnel and may DANGER even result in the risk of electrocution JAN This symbol means that failure to take note of the information may have serious consequences for the installation ATTENTION result in the incorrect functioning of the power unit These marks must indicate specific points The entire manual remains applicable PERSONNEL The installation configuration commissioning and maintenance of the power unit must only be performed by a person qualified and authorised to perform work in an industrial low voltage electrical environment INDEPENDENT SAFETY It is the responsibility of the user and it is highly recommended given the value of the equipment controlled using TC3000 to install independent safety devices This alarm must be tested regularly Eurotherm can supply suitable equipment FURTHER INFORMATION For any further information and if in doubt please contact your EUROTHERM office where technicians are at your disposal should you require advice or assistance with the commissioning of your installation IV TC3000 User Manual TC3000 USER MANUAL CONTENTS Page Chapter 1 IDENTIFYING THE THYRISTOR UNITS General introduction to the TC3000 series 1 2 E renmlioc ier i e X 1 7 iere C HO 1 10 Simplified or complete coding 1 12 Coding example sese 1 13 Thyristor unit and installatio
22. mA Input impedance 100 Q Second input with low win action Logic On 2 50 of the configuration input signal Off 25 of the configuration input signal e Squared load voltage V External measurement Open loop Linearity 1 in Phase angle 2 in Burst firing Stability 1 in Phase angle 2 in Burst firing with variations of the power supply voltage 10 1596 of the temperature 0 to 50 C Adjustable response time To change from 1046 to 9096 power in Phase angle 120 ms to 1 5 s in Burst firing 0 3s to 150 s Outputs 0 to 10 V of the controlled parameter DC signal 1 8 TC3000 User Manual Identification Alarms and Monitoring Voltage alarms Frequency alarm Monitoring Diagnostics Retransmissions Environment Operating temperature Altitude Storage temperature Thyristor protection Protection External wiring Operating environment Humidity Pollution Dimensions 25 A to 250 A 300 A to 500 A Electromagnetic compatibility The TC3000 installed and used in accordance with User Manual see European Directives chapter Electrical safety CE Mark Absence of power supply voltage on any phase Under voltage thyristor firing stopped below 70 or 50 of the nominal thyristor unit voltage Over voltage alarm for a voltage greater than the nominal thyristor unit voltage by 20 Above 70 Hz or below 40 Hz Permanent data on the alarm type and its degree of
23. neutral or in closed delta 3 wire configuration is composed of portions of two or three phase waves according to the thyristor firing angle value In two phase operation the thyristor output voltage between LOAD terminals is the voltage between two firing phases In the star without neutral configuration this voltage is applied to the 2 arms of the load in series In the closed delta configuration this voltage is applied to one load arm connected between 2 firing phases and on the other 2 load arms in series In three phase operation the voltage of each load arm is the phase voltage for the star without neutral configuration or the line to line voltage for the closed delta configuration The figure below shows two examples of three phase resistive voltages configured in star without neutral Half voltages between firing phases at x Half voltage Phase voltage between firing phases a a ot gt Figure 5 3 Resistive load voltage star without neutral in Phase angle For a small firing angle 0 30 the load voltage is composed of portions of half voltages between phases figure 5 3 a For a large firing angle 0230 the load voltage is composed of portions of voltage of one phase and portions of half voltages between phases figure 5 3 b 5 6 TC3000 User Manual Operation The Phase angle mode is used to start with small thyristor firing angles to prevent over currents when
24. of the thyristor unit terminal 15 ENABLE must be connected to 10 V available on the same terminal block terminal 16 This connection can be permanent or made via a contact opening under the effect of a device used to inhibit the thyristor unit during the next half period 3 16 TC3000 User Manual Wiring External control input The external control signal external analogue setpoint or logic signal is connected to the control terminal block on the driver board between terminal 14 INPUT and terminal 17 0 V ANA The input signal is jumper configurable External control signal O OVANA N C contact gt thyristor unit enabled contact open inhibited DODO board Control terminal block H12 Driver Figure 3 13 External control connection Manual control The thyristor unit can be driven using the manual control For operation with the manual control a 4 7 kQ to 10 KQ external potentiometer connected between terminals 17 0 V ANA and 16 10 V must be used The potentiometer wiper is connected to the control terminal block analogue input terminal 14 The manual input signal must be configurated in 0 10 V 4 7 kQ to 10 kQ external potentiometer N C contact thyristor unit enabled contact open inhibited 2000000 ME e s 4 eee board Control terminal block OV ANA Figure 3 14 Manual control connection using an external pote
25. parameter is the square of the RMS load voltage This voltage is taken according to the load configuration type The control voltage is taken between phases 1 and 2 of the load for closed or open delta and star without neutral configurations The control voltage is taken between phase 1 of the load and the neutral for a star with neutral configuration External measurement The external feedback signal has four voltage scales and two current scales Voltage 0 5V 1 5V 0 10V 2 10 V Input impedance gt 100 KQ Current 0 20mA 4 20mA Input impedance 100 O 5 26 TC3000 User Manual Commissioning Chapter 6 COMMISSIONING PROCEDURE Contents page Commissioning procedure safety ssssssssseseee 6 2 Checking the characteristics cete ce ees 6 3 Load current etri int er reo es nis 6 3 Load configuration type ottenere 6 3 Power supply voltage erri nonne 6 4 Auxiliary power supply voltage eeeee 6 4 Input sighals 1 ntn ttc en nene Diagnostic Uo s C Thyristor unit calibration Load voltage calibration 2 rre 6 9 Calibration in calibration mode position 6 9 Calibration in normal operation position 6 9 Line voltage calibration iot 6 9 Commissioning 6 10 Preliminary settings 6 10 POWeI Up ei iere reet 23
26. severity with a display and with relays Socket for diagnostic unit used to adjust control and calibrate the thyristor unit locally using 20 test signals Outputs of the controlled parameter 0 to 10 Vdc 0 C to 50 C 40 C for 500 A at 50 C rated at 450 A Maximum 2000 m 10 C to 70 C Internal high speed fuses Varistor and RC snubber IP20 on front panel according to Standards IEC 529 To be performed according to the Standards IEC 364 Non explosive non corrosive and non conductive RH from 5 to 95 without condensation Degree 2 admissible defined by IEC 664 480 mm H x 248 mm W x 268 mm D Weight 16 kg 250 A 18 kg 570 mm H x 373 mm W x 268 mm D Weight 21 kg Immunity comply with Standards EN 61000 4 2 EN 61000 4 4 EN 61000 4 3 Radiated emission comply with EN 55011 Conducted emission comply with EN 50081 2 without external filter in Burst firing on resistive load with an external filter for other configurations comply with EN 61800 3 without external filter Comply with Low Voltag Directive 73 23 EEC The TC3000 products are CE marked see European Directives chapter Caution AN Due to the continual improvement of products Eurotherm may be required to modify specifications without prior notice For any further information and in the event of doubt contact your Eurotherm Office TC3000 User Manual Identification CODING Nominal TC3000 curren
27. switching on cold low resistance loads or transformer primary coils The gradual increase in the firing angle depends on the operation selected by the user ramp on the setpoint change or is under the control of the initial safety ramp 32 supply cycles The ramp on the setpoint change can be positive gradual increase in the firing angle during the power increase request or positive and negative gradual increase and decrease in the thyristor firing angle The table below gives the possible types of operation in Phase angle firing mode code PA Corresponding operation Standard Thyristor firing angle dependent on the control signal Positive ramp with adjustable slope on the setpoint change Positive and negative ramps with adjustable slopes on the setpoint change Table 5 1 Possible types of operation in Phase angle mode TC3000 User Manual 57 Operation Logic mode The Logic thyristor firing mode ON OFF controls a power in the load proportionally to the firing time set by the logic control signal This firing mode is activated from an input signal greater than 50 of the full scale and as long as the input signal is not less than 25 of the full scale 100 Load voltage 50 Input signal 0 25 50 75 100 Figure 5 4 Voltage Logic signal diagram Important To reduce an emission of electrical interference a
28. voltage is 115V auxiliary power supply codes 100V to 120V Terminal 43 of the user terminal block is used if the auxiliary power supply voltage is 230V auxiliary power supply codes 200V to 240V L 115 V power supply L 230V power supply O N N 4t l Fx 3 115v 42 fuse q 230v 43 LT CO LI i Auxiliary B Auxiliary power supply power supply terminal block terminal block Figure 3 6 Auxiliary power supply connection A N Caution Each wire to a power supply phase must be protected with a 1 A fuse 3 10 TC3000 User Manual Wiring Reference neutral The reference neutral is connected to terminal 71 located on the neutral terminal block to the right below the thyristor unit see figure 3 5 Caution A N This connection is only made for the star with neutral load configuration Load in Star with Neutral L1 Thyristors L2 L3 TC3000 Control cable clamp Neutral terminal block View of thyristor unit from below Figure 3 7 Neutral connection In the event of a neutral connection failure incorrect electrical connection blow out of F1 fuse on the power board etc an artificial power failure is created in order to stop the thyristor unit operation since the feedback system receives an incorrect feedback signal This failure is signalled with the message FP on the front panel display
29. 00 V Line voltage 3 wire configuration Vin 380 V Vun 400 V Calibration voltage Vc 21V x 1Vx 1 05 V ViN 380 V The potentiometer P6 must be turned to obtain 1 05 V in position 20 on the display Example 2 Same conditions as in example 1 but in star with neutral configuration Calibration voltage Vc 1 05 V x 3 1 82 V The potentiometer P6 must be turned to obtain 1 82 V in position 20 on the display Calibration in normal operation mode position M1 1 The signal read by the diagnostic unit is the rectified value corresponding to the voltage actually measured In full firing sinusoidal load voltage operation the DC value read on position 20 must be 1 67 V for normal load voltage in full conduction Line voltage calibration The line voltage read by the microprocessor can be adjusted using the potentiometer labelled P18 located on the driver board see figure 4 2 page 4 7 Caution A N This setting is made in the factory 4 V in point test PT11 and must not be modified TC3000 User Manual 69 Commissioning COMMISSIONING Preliminary settings e After checking the wiring make sure that the Enable input terminal 15 on the driver board is connected directly or via a closed contact to 10 V terminal 16 on the same terminal block or to an external voltage between 5 V and 10 V referenced in relation to terminal 17 0 V e After calibration check that the Calibration Operation jumper M
30. 1 are in the operating position 1 The initial position of the potentiometer P1 depends on the thyristor firing mode Phase angle operation turn potentiometer P1 on the front panel completely anti clockwise except if the ramp is used This position corresponds to the absence of the ramp Burst firing operation on the inductive load or on a transformer primary coil turn potentiometer P1 completely clockwise 90 delay in the first thyristor firing e Set the potentiometer P3 Setpoint limit to zero i e completely anti clockwise This position corresponds to the absence of the setpoint signal irrespective of the input signal 6 10 TC3000 User Manual Commissioning Power up During power up automatic recognition of the phase rotation order is performed for the correct thyristor firing of different phases Switch on the thyristor unit Note If the control power is supplied before the power up the Phase absent alarm is displayed Check that the load current is equal to 0 in the absence of the control signal Apply a control signal to the input terminal 14 of the driver board Turn the potentiometer P3 Setpoint limit slightly clockwise and check that the current increases in the load Important N Depending on the configuration selected using the jumper K12 the thyristor unit can start with a safety ramp of 32 periods in firing angle variation see Configuration
31. 5 Ramp 1 5 V E1V5 soft start end 0 10 V E0V10 2 10 V E2V10 0 20 mA E0mA20 Without ramp and without 4 20 mA E4mA20 soft start end Positive ramp or Second setpoint 0 5 V WO0V5 soft start 1 5 V WIVS 0 10 V W0V10 Positive and negative 2 10 V W2V10 ramps or soft 0 20 mA W0mA20 start end 4 20 mA W4mA20 Load connection Code Options Code Delta 3 wires Alarm relay contact Star without neutral 3 wires closed in alarm state IPU Star with neutral 4 wires Fuse blown indication micro switch FUMS Open delta 6 wires Without internal fuses NOFUSE TC3000 User Manual 111 Identification Simplified or complete coding Coding can be performed with a complete code all fields or with a simplified code in which only the following are specified the nominal current the line voltage the auxiliary power supply the calibration voltage operating voltage the options With a simplified code the TC3000 thyristor unit is supplied configured as shown below Input signal Thyristor firing mode Ramp soft start end Load connection Load type Under voltage alarm threshold Start up 4 20mA Phase angle Without ramp or soft start end Star without neutral 3 wires Inductive 70 of nominal voltage Initial safety ramp 32 supply cycles TC3000 User Manual Identification Coding example Thyristor unit and installation parameters Nominal load current Nominal power supply vo
32. 547 Operation Soft start end Soft operation start or start and end can be configured in the following firing modes Logic and Burst firing The soft start duration Ts is the time taken for the thyristor unit output power to change from 0 to 100 with thyristor firing angle variation from 0 to full firing The soft end duration T g is the time taken for the thyristor unit output power to change from 100 to 0 with thyristor firing angle variation from full firing to 0 Soft start with Soft end with increase in the decrease in the firing angle firing angle Full firing Figure 5 10 Soft start and end in Logic mode 5 18 TC3000 User Manual Operation Soft start with Soft end with increase in the decrease in the firing angle firing angle Figure 5 11 Soft start and end in Burst firing mode In the Burst firing mode the number of soft start cycles or soft end cycles is limited to the number of supply cycles in the selected firing time The soft start time Tc is not included in the firing time Tg but all the power sent in the load is taken into account in the control After the soft start with thyristor firing angle variation the thyristor unit remains in full firing during the time the input signal is present T in Logic mode during the firing time of one modulation time Ty in Burst firing mode TC3000 User Manual 549 Operation
33. 6711 Delayed firing setting on inductive load sss 6 12 TC3000 User Manual 61 Commissioning Chapter 6 COMMISSIONING PROCEDURE Read this chapter carefully before commissioning the thyristor unit COMMISSIONING PROCEDURE SAFETY Important J Eurotherm cannot be held responsible for any damage to persons or property or for any financial loss or costs resulting from the incorrect use of the product or the failure to observe the instructions contained in this manual It is therefore the user s responsibility to ensure that all the nominal values of the power unit are compatible with the conditions of use and installation before commissioning the unit Warning AN Dangerous live parts may be accessible when the front door is open Only personnel qualified and authorised to work in industrial low voltage electrical environments can access inside the unit Access to internal components of the thyristor unit is prohibited to users who are not authorised to work in industrial low voltage electrical environments The temperature of the heatsink may exceed 100 C Avoid all contact even occasional with the heatsink when the unit is in operation The heatsink remains hot approximately 15 min after the unit has been switched off 6 2 TC3000 User Manual Commissioning CHECKING THE CHARACTERISTICS Caution Before connecting the unit to an electrical supply make sure tha
34. COMPETENT BODY In order to guarantee the best service Eurotherm has validated the compliance of the TC3000 products with EMC test standards through design and laboratory tests that have been validated with a Technical Construction File by a Competent Body LCIE Laboratoire Central des Industries lectriques EXTERNAL SERIES FILTERS To reduce the conducted emissions that occur when using thyristor units Eurotherm can supply external filters Nominal current of TC3000 Serial filter order code 25 Ato 60A FILTER TRI 63A 00 75 Aand 100A FILTER TRI 100A 00 For 150 A to 500 A nominal current consult your Eurotherm ofice EMC INSTALLATION GUIDE In order to help you reduce risks related to the effects of electromagneticinterference depending on the installation of the product Eurotherm can supply you with the EMC Installation Guide Part No HA025464 This guide gives the rules generally applicable for Electromagnetic compatibility TC3000 User Manual Ill MANUALS IN USE This TC3000 User Manual Part No HA174835 ENG Old Part No HA174836 intended for the TC3000 series power thyristor units manufactured beginning January 1996 The TC3000 User Manual Part No HA172247 is valid for products manufactured before this date PRECAUTIONS Important precautions and special information are indicated in the manual by two symbols hy This symbol means that failure to take note of the information may have serious consequences
35. F 1 Phase 1 is missing or over temperature detection thermal switch for fan cooled unit only 2 100 A nominal Power supply frequency outside normal operating limits 40 to 70 Hz Failure of neutral circuit in Star with neutral configuration fuse blow out on the power board etc Under voltage of supply V 70 of the nominal voltage or V 50 96 depending on the configuration External signal return failure for control on an external measurement except in Logic mode MICROPROCESSOR FAILURE I The display does not indicate any message or indicates incoherent messages The thyristor unit operation is inhibited by the Watchdog and the driver board must be replaced e Microprocessor reset to zero Reset Thyristor unit initialisation temporary message 7 4 TC3000 User Manual Alarms Chapter 8 ALARMS Contents page Alatimisttategy i uitae tei ete rti tert tbi gen es 8 2 High level alarms 8 4 Absence of power supply phases 8 4 Under voltage seen 8 4 Frequency error eese 8 5 Neutial failure eerie 8 5 External measurement signal failure 8 5 Low level alarm sseee 8 6 Alarm acknowledgement eseeesss 8 6 Alarm management sssee 8 7 Alarmittelay nte iR etes ce Prec ee 8 8 TC3000 User Manual Alarms
36. J Figure 2 1 TC3000 thyristor unit values TC3000 User Manual 2 3 Installation The dimensions and weights of the TC3000 thyristor unit are given in tables 2 1 and 2 2 Dimensions mm Values Nominal thyristor unit current Description fig 2 1 25 to 150A 250A 300 to 500 A Height without protective cover Height with protective cover Width Depth with door open 537 mm Distance between Earth busbar and panel Depth between LOAD terminal and panel Depth between LINE terminal and panel Table 2 1 TC3000 thyristor unit dimensions Nominal thyristor unit current 25 to 150A 300 to 500 A Weight kg 16 21 Table 2 2 TC3000 thyristor unit weights 2 4 TC3000 User Manual Installation INSTALLATION DETAILS TC 3000 series units are designed to be mounted directly on panels at the fixing points located on the rear of the unit TC 3000 thyristor units are equipped with two protective covers upper and lower The thyristor units can be fixed with their protective covers in place However for configuration the upper protective cover must be removed In order to do this open the door by unfastening the front screw located at the top left of the door Then raise the door in order to release it from its notches and open it completely by pulling it towards you Without 29 rot
37. User Manual 3 Maintenance Fuse blown indication micro switch As an option the high speed fuse may be equipped with a fuse blown indication micro switch FUMS option with the part No for BUSSMANN fuses EUROTHERM DC172267 or FERRAZ P96015 or BUSSMANN 170H0069 for FERRAZ fuses EUROTHERM DC172997 or FERRAZ G310 000 To ensure improved isolation between the cabling of the micro switch terminals and the power and the cover TC3000 power thyristor units are supplied with three flag type lugs and isolating sleeves Each external terminal of the fuse blown indication micro switch must be cabled with a flag lug and an isolating sleeve in compliance with figure 9 1 Line busbar Fuse Flange EDV 7 Break make micro switch Figure 9 1 Use of flag lugs and isolating sleeves to observe isolating distances 9 4 TC3000 User Manual Maintenance Auxiliary voltage connection protection fuses These fuses must be installed in the auxiliary voltage connection wires to the phases see Wiring chapter Auxiliary 1A fuse Fuse isolator Fuse Isolator voltage 6 3 x 32 mm support assembly dimensions max mm 500 V CS174289U1A0 CP174293 63x15x52 Table 9 2 Recommended fuse for auxiliary voltage connection protection Neutral protection fuse A neutral protection fuse is mounted on the power board in the Star with neutral configuration F1 on figu
38. age threshold Position of jumper K11 Voltage less than 50 96 Vy Voltage less than 70 Vy Table 4 13 Under voltage alarm level configuration In the above table Vw indicates the operating voltage of the thyristor unit or recalibrated operating voltage if unit has been recalibrated Initial ramp The TC3000 thyristor unit can be configured jumper K12 with a thyristor firing angle variation ramp during each power up or after a power cut for more than 20 ms The power up ramp initial ramp is applied during the first burst or in Logic mode For 32 supply cycles the thyristor firing angle in each channel gradually changes from the thyristor OFF state to full firing The initial ramp ensures easy power up The subsequent bursts start at zero voltage for purely resistive loads Initial ramp Position of jumper K12 No initial ramp Initial ramp activated Table 4 14 Initial ramp configuration TC3000 User Manual 4413 Configuration Calibration Operation The jumper M1 is used to configure the thyristor unit either in the voltage calibration position or in the normal operation position excluding the calibration procedure The thyristor unit can be calibrated easily using the potentiometer P6 on the potentiometer board see Commissioning chapter The analogue calibration signals or RMS current and load voltage images can be read using the EUROTHERM type 260 diagnostic unit see page 6 6 A diagnosti
39. age without a thyristor unit operation inhibit 8 2 TC3000 User Manual Alarms Inhibit Absence of phases Frequency outside or limits or neutral failure a General alarm relay Under voltage External measurement signal failure Display Over voltage an O General alarm relay Normal displays Figure 8 1 Alarm levels and strategy TC3000 User Manual 8 Alarms HIGH LEVEL ALARMS High level alarms detect the absence of or a significant drop in the power supply voltage whether the frequency limits have been exceeded neutral failure in the power board in the star with neutral configuration and external measurement signal failure These alarms are integrated for 5 s before being handled High level alarms stop the operation of the thyristor unit by inhibiting thyristor gate pulses and activate the general alarm relay Thyristor firing is stopped at the first zero current crossing The state of the high level alarms is indicated by flashing messages on the front panel display and by the general alarm relay contact N O or N C depending on the configuration Absence of power supply phases This alarm appears when one or more power supply phases are absent The phase absence alarm can be activated by power supply failures by fuse blow out by the opening of the circuit breakers or line contactors and also by the opening of a permanent cooling thyristor unit safet
40. al current are mounted in a module isolated from the heatsink The 300 A to 500 A unit heatsinks are not isolated from the thyristors Power board The thyristor firing pulses generated by the driver board are amplified and transmitted to the thyristors via pulse transformers which provide isolation A voltage transformer is used to measure the load voltage Three voltage transformers are used for synchronisation on the power supply voltage Potentiometer board Three operation potentiometers located on the potentiometer board which is mounted perpendicular to the driver board can be accessed on the front panel They are used to adjust the main thyristor unit operating parameters without having to open the front door One calibration potentiometer can be accessed when the front door is open The functions of the operation potentiometers are indicated on the front panel of the thyristor unit and are explained in the relevant paragraph page 5 13 If the thyristor unit is replaced the potentiometer board can be transferred to the new thyristor unit and thus retain all the settings specific to the application concerned Display The 7 segment display is used for steady and flashing messages indicating the current operating mode of the thyristor unit the alarm state and the error or failure type Diagnostic socket The values from the control and the operation of the thyristor unit are available on the diagnostic socket located
41. amp soft start or start and end The potentiometer functions are summarised in the table below Potentio meter Designation on front panel PA Ramp CY Delay Phase angle Function Ramp setpoint setting Logic Burst firing First half cycle delay angle setting for inductive loads only Response T Phase angle Control loop response time setting Burst firing Basic burst firing time setting Setpoint limit All excepted Logic mode Setpoint limit setting Table 5 4 Summary of the front panel potentiometer functions 5 14 TC3000 User Manual Operation PA Ramp CY Delay potentiometer The potentiometer P1 labelled PA Ramp CY Delay on the front panel is used to set the following the ramp on the setpoint changes Phase angle firing mode the soft start end Burst firing and Logic firing modes the delay angle Burst firing and Logic firing modes Conditions and positions of jumpers Functions of potentiometer P1 Firing PA Ramp CY Delay mode Operation No ramp No action Positive ramp Ramp duration setting number of supply cycles for setpoint changes The ramp is enabled for power increase requests Positive and Ramp duration setting negative ramp number of supply cycles for both power increase and decrease requests Resistive load No action No soft start Inductive load Setting of first No soft start alterna
42. are synchronised with the power supply and are performed at zero voltage for a resistive load Each new firing starts at the zero voltage of a different phase in order to rebalance the power consumption of the 3 phases and to eliminate the DC component firing signal rotation is covered by a Eurotherm patent In Burst firing mode control is performed with a constant firing time T or non firing time T and a variable modulation time T The firing time T is selected by the user Np Important For less than 50 power the firing time is constant For more than 5046 power the non firing time is constant For 50 power the firing time is equal to the non firing time The Burst firing modulation period time T is determined by the control as a function of the set firing or non firing time the setpoint the feedback and the process algorithm The control system adjusts the basic burst firing modulation times T in order to retain optimum accuracy irrespective of the output power TC3000 User Manual 541 Operation The Burst firing mode codes FC1 to 255 can be configured with soft start or start and end in thyristor firing angle variation during the required time limited by the firing time the firing delay of the first firing thyristor at each cycle The table below indicates possible operation in Burst firing mode Corresponding operation Standard Proportional cycle with a modulation time
43. c socket is provided for this purpose on the front panel of the thyristor unit Warning AN For safety reasons the reconfiguration of the thyristor unit using jumpers must be performed by a qualified person Calibrated parameter or image of an operating parameter Squared load voltage Corresponding jumper Position of jumpers Thyristor unit Thyristor unit calibration operation Table 4 14 Thyristor unit operating mode configuration calibration or normal operation After recalibration the jumper M1 must be set back to 1 position 4 14 TC3000 User Manual Operation Chapter 5 OPERATION Contents page Block diagram Thyristors Power board Potentiometer DOard sine nnne eto nee ei negas 5 3 DIS Play e 5 3 Diagnostic Soktare eneas enesenn m ente e EV OV RT EE da ee TR Ead 5 8 Driver DOANG qu 5 4 Thhyristor firing mod6es s cci cr t nece irr Rt e reet to cri erede 5 5 Phase angle mode uei cent cte pec ee Ev eo Re eia er Ran 5 5 Eero l rose eTo o eer 5 8 Burst fining MOOG eerte pico entero erre enia 5 11 Setting potentiometer functions eeseeeeeeeeeen 5 13 PA Ramp CY Delay potentiometer a 5 15 Setpoint change ramp rt nene rete esses 5 16 Soft statt end sc eee m pe epit ren den B e Rea 5 18 Delay angle s 5 21 Response time potentiometer 5 22 Standard repons
44. determined by the control system Number of firing or Code RES non firing Thyristor zero voltage switching on cycles each phase selected by without DC component the user Code IND On each phase the first firing is delayed by an adjustable angle Soft start with thyristor firing angle variation from zero to full firing Stop at end of supply cycle Adjustable ramp time Limited by Default code RES the basic cycle time Soft start and end with thyristor firing time firing angle variation from zero to full firing and from full firing to zero Default code RES Table 5 3 Possible types of operation in Burst firing mode 5 12 TC3000 User Manual Operation SETTING POTENTIOMETER FUNCTIONS Three potentiometers are provided to enable the user to set the operation of the TC3000 thyristor unit without opening the front door They are available on the top left section of the thyristor unit front panel PA Ramp CY Delay Rampe AP Retard TO gt Response T T r ponse Setpoint limit Limit de consigne Setting potentiometers Diagnostic socket Figure 5 8 Front panel potentiometers The setting potentiometers are 10 turns TC3000 User Manual 543 Operation The functions of the potentiometers P1 P2 and P3 depend on the selected firing mode and the thyristor unit configuration load type selected r
45. e nominal thyristor unit voltage can be greater than or equal to the voltage between the phase and neutral of the power supply used A thyristor unit can be used on a three phase power supply of a voltage less than the voltage specified for the thyristor unit by reconfiguring it see table 4 1 page 4 4 If the power supply voltage is less than 70 of the nominal thyristor unit voltage or 50 depending on selected configuration after 5 s of integration the thyristor unit changes to inhibit thyristor control withdrawn The thyristor unit is re enabled automatically if the voltage returns to a value greater than or equal to 70 96 or 5096 of the nominal value of the thyristor unit Caution Given the inhibit at 70 96 or 5096 of the nominal voltage the operating N calibration voltage must be as close as possible to the nominal power supply voltage used Auxiliary power supply voltage The auxiliary power supply voltage must correspond to the supply available The voltage is selected in the factory according to the order code using soldered links on the driver board see page 4 7 Input signals The jumper configurations on the driver board must be compatible with the selected levels of the analogue signals used for control see page 4 9 the external measurement see pages 4 9 and 4 10 6 4 TC3000 User Manual Commissioning DIAGNOSTIC UNIT For easier commissioning and setting operations and for th
46. e thyristor unit state diagnostics it is advisable to use the EUROTHERM type 260 diagnostic unit The diagnostic unit possesses a flat cable which is plugged into the 20 pin socket diagnostic socket provided on the front panel of the thyristor unit The 20 way switch of the diagnostic unit is used to view the values of the thyristor unit and feedback parameters on its digital display The unit displays two decimal places for the precise indication of the selected values The signals from the diagnostic socket may also be viewed using an oscilloscope Setpoint limit Limit de consigne TC3000 i Diagnostic socket Flat cable Digital display EUROTHERM diagnostic unit Oscilloscope connection terminals isolated from power 9 Vdc Battery or rechargeable battery Battery charger Figure 6 1 Connection of the EUROTHERM type 260 diagnostic unit and the TC3000 thyristor unit The following table gives the description of each position of the EUROTHERM type 260 diagnostic unit and the typical values of the signals measured The values measured are DC means values TC3000 User Manual Commissioning Position Designation Electronics supply Typical value 5 6 V Reference 5 V Electronics supply 15 V Remarks User voltage 10 V Control term block Electronics supp
47. e time in Phase angle essessss 5 22 Number of mains cycle in the Burst firing basic cycle 5 23 Setpoint limit potentiometer sseeeeesse w 5 24 Control operatiOri cc eE serena 5 25 Squared load voltage rere ee e eaa 5 26 External measurement eee tne t cere em te aa 5 26 TC3000 User Manual 51 Operation Chapter 5 OPERATION BLOCK DIAGRAM The interaction between the main parts of the thyristor unit is shown in figure 5 1 L1 L2 L3 Neutral 4 wire Star configuration Auxiliary power supply Filter Load voltage board measurement Line voltage ments p User terminal Power board block comet Rear Retransmission EE terminal block Driver board Inhibit circuit Pulse generator Electronic and fan power mbi supply Synchroni Input signal Calibration sation ans converter retransmission amplifier amplifier Potentiometer board Ramp delay Response time Setpoint limit Microprocessor Multiplexer Calibration potentiometer Configuration User terminal block Alarm relay contacts Figure 5 1 TC3000 thyristor unit block diagram 5 2 TC3000 User Manual Operation Thyristors The 3 pairs of thyristors modulate the power supply voltage which is applied to the three phase load Warning AN Thyristors up to 250 A nomin
48. ective cover p P p S 13 E 018 4 drilling holes for M8 328 Screws T 9 W EY Y v 10 18 5 UM Figure 2 2 Fixing details TC3000 User Manual 2 5 Installation Dimensions mm Values Nominal current Description fig 2 2 25A to 150A 250A 300A to 500A Width between the fixing holes Distance between the LINE terminals Distance between the LOAD terminals Earth busbar and top fixing hole Earth busbar and left fixing hole LOAD terminal and bottom fixing hole LINE fuse and top fixing hole Table 2 3 Fixing values After drilling the support panel at the dimensions and values given above insert the fixing screws half way into the partition or mounting plate holes Position the TC3000 unit by first of all inserting the upper screws in the respective holes ofthe upper section Lower the thyristor unit making sure that it is positioned correctly at the level of the lower screws Then lower the thyristor unit completely until it is in place Fasten the 4 screws correctly 2 6 TC3000 User Manual Wiring Chapter 3 WIRING Contents page Safety d ring WIMMG reitera iniaiaiai eieaa 3 2 Power wiring diagrams eeeeeeeeeee ener 3 4 Star without neutral configuration sessesses 3 4 Star with neutral configuration sse 3 5 Closed delta configuration
49. equency and failures of the neutral when used or the external measurement circuit Failure detection is signalled by the contacts of two alarm relays and by the display 1 4 TC3000 User Manual Identification A TC3000 thyristor unit is equipped with athyristor firing board power board which generates thyristor firing pulses and measures the voltage a driver board for the auxiliary power supply the control circuit and the signal and operating mode configuration e a potentiometer board for the calibration of the thyristor unit current and voltage and for the setting of the main operating parameters filter boards to protect the thyristor unit operation against transient interference The user terminal blocks below the thyristor unit are used for the following connections without having to open the front door theauxiliary power supply the reference neutral the alarm relay contact The filters providing immunity against electromagnetic interference are fitted atthe reference neutral connection input between the power supply phases LINE and the safety earth connector between the load connections LOAD and the safety earth connector between the power phases for 300 A to 500 A nominal units TC3000 User Manual 15 Identification Potentiometer Filter board board 7 As Neutral terminal u m block Control terminal C blocks c Safety earth
50. he selected scale can be obtained according to the equation LIM LIM Vg SV x 100 where E represents the value of the limited input value E g Required setpoint limit E m 65 Setting voltage read in position 9 65 Vo 5V x 2 3 25V 100 This setting obtained means that when the input signal is 100 the output power reaches 65 of its nominal value or calibration value When the input signal is 20 the output power is only 13 of its nominal value 20 x 65 13 100 5 24 TC3000 User Manual Operation CONTROL OPERATION The internal control loop algorithm of the TC3000 series thyristor unit takes into account the feedback value selected by the user using the configuration jumpers see Configuration chapter The controlled parameters are as follows squared load voltage v2 external feedback measurement External measurement For the control signal applied on the analogue input the response curve is linear between 0 and 100 with dead bands between 0 and 2 and between 98 and 100 Output 10096 75 50 25 Input 96 of the Figure 5 13 Input Output response curve The output power of the thyristor unit is calibrated according to the selected process value and the thyristor unit calibration see Calibration section page 6 8 TC3000 User Manual 525 Operation Squared load voltage The V controlled
51. her information on CE Mark please contact your nearest Eurotherm office ELECTROMAGNETIC COMPATIBILITY EMC For industrial environments excluding residential environments The TC3000 products are considered as components without any direct function as defined in the EMC Directive The system or installation in which these products are incorporated must complies with the essential protection requirements of the EMC Directive However Eurotherm certifies that the TC3000 products when installed and used in accordance with their User Manual meets the following EMC test standards and enables the system or installation in which there are installed to comply with the EMC Directive in regards to the TC3000 products TC3000 User Manual EMC TEST STANDARDS EMC tests EMC test standards Electrostatic discharge EN 61000 4 2 06 1995 Fast transients EN 61000 4 4 01 1995 Radioelectric frequency prEN 61000 4 3 1984 electromagnetic fields Emission Radiated and Conducted EN 55011 2 1991 The choice of the Condacted Emission applicable standard depends on the application e EN 50081 2 1991 Without external filter in Burst firing on resistive load up to 250 A nominal With an external parallel filter in Burst firing on resistive load for 300A to 500 A With an external series filter for other configurations prEN 61800 3 1996 Without external filter Applies for the second environment VALIDATION BY
52. ible with the application modify if necessary certain characteristics of the thyristor unit on site Warning AN For safety reasons the reconfiguration of the thyristor unit using jumpers must be performed with the unit switched off and by qualified personnel authorised to work in an industrial low voltage electrical environment Before starting the reconfiguration procedure check that the thyristor unit is isolated and that an occasional power up is impossible After the reconfiguration of the unit correct the codes on the identification label to prevent any maintenance problems later 4 2 TC3000 User Manual Configuration POWER BOARD The power board jumpers are used to configure the three phase voltage selection for synchronisation and measurement the adaptation to the load connection type Load voltage Neutral Line voltage Neutral Neutral jumpers resistor jumpers jumper fuse LK10 LK11 R5 LK3 LK4 LK8 LK1 LK2 LK7 LK9 LK6 LK5 Internal ground Line voltage Load connection Line voltage jumpers type jumpers jumpers Figure 4 1 Location of jumpers on the power board TC3000 User Manual 43 Conf
53. iguration Voltage selection For the synchronisation of operation of the electronics and for measurement the TC3000 thyristor unit operation voltage must be configured according to the power supply voltage on which it is connected Operation of a TC3000 thyristor unit on a power supply voltage different to that specified on the order may require the repositioning of jumpers LK1 to LK6 three phase line voltage and LK10 and LK11 load voltage on the power board For some applications perturbed supply with over voltages transient for instance TC3000 line voltage can be chosen higher their operating voltage Operating voltage less Position of jumpers than or equal to LK1 LK3 LK5 LK2 LK4 LK6 and LK10 and LK11 100 110 115 120 V 200 220 230 240 V 380 400 415 440 V 480 500 V Table 4 1 Line voltage and load voltage configuration Caution J Do not use a thyristor unit with a power supply voltage higher than the power supply voltage specified for the thyristor unit 4 4 TC3000 User Manual Configuration Adaptation to the load configuration type A thyristor unit is configured according to the load configuration type using jumpers LK7 to LK9 on the power board and using jumpers K5 and K6 on the driver board see page 4 12 Caution AN It is necessary to check that the position of jumpers LK7 to LK9 table 4 2 corresponds to the position of jumpers K5 and K6 table
54. inductive load 6 12 Chapter 7 DISPLAY MESSAGES Generali deridet ntt etu leere d teria 7 2 Steady messages sessssssseseseeeeeenre nennen 7 2 Flashing M SSageS 2 reir teet ee rd eee er deme 7 3 sme 7 3 PANU e a 7 4 Microprocessor failure ic iiceiedctecistescvessneeesscvteesestendveeeseebecteened 7 4 TC3000 User Manual Cart3 Contents Continued Page Chapter 8 ALARMS Alarmi Strategy oirionn 8 2 High level alarms 8 4 Absence of power supply phases 8 4 Urider voltage creto ote tta ccr etr tes 8 4 Frequericy Grror ciiauiccee cannes d 8 5 Neutral fail re 2 innere erected 8 5 External measurement signal failure 8 5 Low level alarm eras 8 6 Alarm acknowledgement seeeeeess 8 6 Alarm management ssesee 8 7 Alatmirelay oci erre 8 8 Chapter 9 MAINTENANCE Thyristor protection 9 2 FUS IE US 9 2 Thyristor protection fuses sssse 9 3 Fuse blown indication micro switch 9 4 Auxiliary voltage connection protection fuses 9 5 Neutral protection fuse eeeeeees 9 5 SVICI pe OE 9 5 Eo 9 6 Cot TC3000 User Manual Identification Chapter 1 IDENTIFYING THE THYRISTOR UNITS Contents page General introduction to the TC3000 series
55. isplayed with a change in the relay contacts and with the message on the display The low level alarm is only active 5 s after the corresponding failure has appeared If the line voltage is greater than the nominal thyristor unit voltage by more than 20 the over voltage alarm is detected the general alarm relay is activated the flashing message E U appears on the front panel display In the event of over voltage the thyristor unit is not inhibited the control keeps the value of the controlled parameter for the given operating point constant If the unit returns to a voltage less than 110 of the nominal thyristor unit voltage the relay returns to the non alarm state ALARM ACKNOWLEDGEMENT The thyristor unit can only be started up again after inhibition due to memorised alarms external measurement failure after an acknowledgement To acknowledge the alarms it is possible to switch off the auxiliary power supply of the driver board connect terminal 11 Acknowledge on the driver board to terminal 16 10 V apply a 10 V external signal to terminal 11 Acknowledge Alarms can only be acknowledged using terminal 11 when the voltage between phases 1 and 2 is not available display F 1 8 6 TC3000 User Manual Alarms ALARM MANAGEMENT The main characteristics of all the TC3000 thyristor unit alarm types and the states of the alarm relays and the thyristors are given in table 8 1
56. litude The setting made using the potentiometer P1 can be read using the Eurotherm type 260 diagnostic unit in the form of a setting voltage in position 11 5 16 TC3000 User Manual Operation The T values in number of supply cycles elapsed in ramp and in time and the corresponding setting voltages are given in the table below P1 Setting voltage Ramp duration Tr read in position 11 Number 50 Hz 60 Hz of the diagnostic unit of cycles power supply power supply 4 0 08 s 0 066 s 8 0 16s 0 133 s 16 0 32 s 0 266 s 32 0 64 s 0 53 s 64 1 28 s 1 06 s 128 2 56 s 2125 256 5 12 s 4 24 s 512 10s 8 5 s 1 024 20s 17s 2 048 41s 34 s 4 096 1 min 22 s 1 min 8s 8 192 2 min 44 s 2 min 16 s 16 384 5 min 28 s 4 min 32s 32 764 11 min 9 min 65 528 22 min 18 min 131 000 44 min 36 min 262 000 1 hour 27 min 1 hour 12 min 534 000 3 hours 2 hours 30 min 1 050 000 6 hours 5 hours 2 100 000 12 hours 10 hours 4 190 000 24 hours 20 hours 8 390 000 48 hours 40 hours Table 5 6 Ramp setting during setpoint change in Phase angle The duration T set by the user is given in table 5 6 for a change of the input signal from 0 to 100 Important The positive ramp is completed as soon as the firing angle corresponding to the current setpoint has been reached see figure 5 9 After inhibition setpoint not changed electronics supply not switched off this ramp will not be active TC3000 User Manual
57. ltage Auxiliary power supply Calibration voltage Input signal Firing mode Connected loads Connection type Controlled parameter Auxiliary input output Option Coding 120 amperes 440 volts line to line 220 to 240 volts Installation at 380 volts 0 10 volts 8 cycle burst firing with soft start Resistive Star without neutral Load voltage Controlled parameter retransmission Fuse blown indication micro switch TC3000 150A 440V 220V240 380 0V10 FC8 URP SS RES V2 RTR FUMS 00 Caution The TC3000 thyristor unit operating voltage must be as close as possible to the power supply voltage to prevent problems of non operation in the event of a voltage drop to less than 70 96 of the nominal voltage after calibration The calibration voltage the operating voltage is considered as the nominal voltage of the thyristor unit TC3000 User Manual 143 Identification SERIAL NUMBER LABELS Two identification labels specifying the coding of the thyristor unit and a configuration label provide all the information relating to the factory settings of the thyristor unit An identification label is externally located on the right hand side panel of the unit El EUROTHERM 2 20 WORTHING ENGLAND 903 268500 MODEL TC3000 150A 440V 220V240 380 0V10 FC8 URP 3S RES V2 RTR FUMS 00 SERIAL No LC1111 001 001 12 95 RANGE 38 PHASE 150A 440V 40 70 Hz AUXILIARY POWER SUPPLY 220 240 V CALIBRATION VOLTAGE
58. lution The cabinet must be closed and connected to the safety earth in accordance with the standard IEC 364 or the current national standards For installations in fan cooled cabinets it is recommended to place a fan failure detection device or a thermal safety control in the cabinet Bulkhead mountings are possible with TC3000 series units The units must be mounted with the heatsink positioned vertically and with no obstructions either above or below which could block the passage of the ventilation air If multiple units are installed in the same cabinet they should be arranged in such a way way that the exhaust air from one unit cannot be admitted into the unit located above it Caution A N The units are designed to be used at an ambient temperature less than or equal to 50 C 40 C for 500 A nominal units Leave a minimum space of 20 cm between two units placed beside each other Excessive overheating may cause incorrect operation of the unit which in turn may cause damage in the components TC3000 series power thyristor units have permanent fan cooling from 100 A nominal 2 2 TC3000 User Manual Installation DIMENSIONS The overall dimensions of TC3000 thyristor units are given in figure 2 1 Protective cover I Rampe keeled TO Fenne rone Setpoint limit B Limit de consigne Diu io chao P limit imit 12 Limit A
59. ly 15 V 14 45 to 15 55 V 21 V Rectified filtered Input control signal at converter output 0 to5 V Setpoint limit 0to5V Potentiometer P3 Burst firing cycle time 0to5V Potentiometer P2 Ramp soft start end or delayed firing duration 0to5V Potentiometer P1 Synchronisation 5 V pulses Zero crossing Microprocessor reset 5 V pulses Normal operation OV Enable 5 V logic Inhibit 0 V Electronics supply Common 0 V Calibration of voltage M1 0 or Image of V in operation M1 1 In calibration 0to 10 V set 1 73 V for 3 phases with Neutral Jumper M1 2 0 Potentiometer P6 In normal operation 0 to 1 67 V Jumper M1 1 Table 6 1 Destination of the positions of the EUROTHERM type 260 diagnostic unit The positions 8 12 to 14 and 19 are not used in this version of the power thyristor unit 6 6 TC3000 User Manual Commissioning THYRISTOR UNIT CALIBRATION The thyristor unit is calibrated so that the maximum value of the selected control input signal scale corresponds to the nominal values of the voltage allowed by the load used The calibration performed also acts on the voltage retransmission signals and on the feedback signal selected for the process algorithm The potentiometer labelled P6 is used to calibrate the thyristor unit voltage It is located on the potentiometer board placed per
60. n parameters 1 13 COMING pct 1 13 Serial number labels mirserusiisi usiyane 1 14 Chapter 2 INSTALLATION Safety during installation eese 2 2 DIMENSIONS corti re oro Ee dre estie Ee Eees 2 3 Installation details eese 2 5 Chapter 3 WIRING Safety during wiring 3 2 Power wiring diagrams see 3 4 Star without neutral configuration sss 3 4 Star with neutral configuration ssssssss 3 5 Closed delta configuration sseeesss 3 6 Open delta configuration sesseeees 3 7 User terminal blocks spriin oya esinaise 3 8 General introduction sese 3 8 Auxiliary power supply eee 3 10 Reference neutral esee 3 11 Alarm contacts i eben ee 3 12 Gohnltrolcabl8S 5 soc pee teen el uei het 3 13 gj ETE 3 13 Connection of the shield to the ground 3 14 Control terminal blocks aerei 3 15 General introduction ssssee 3 16 External control MPU iisisti 3 17 Manual control eerte eene 3 17 Auxiliary input output sereisas 3 18 Alarm acknowledge sse 3 18 TC3000 User Manual Coti Contents Continued Page Chapter 4 CONFIGURATION Safety during configuration eeeeee 4 2 Power DONG ee
61. nd electromagnetic radiation the thyristors are switched at zero voltage for resistive loads This produces a slight unbalance of the power in the three arms of the load In order to eliminate the DC component generated on each phase firing rotation is performed patented by Eurotherm Automation This can only be used with resistive loads not with inductive loads Logic control signal A t Y gt F Switching at zero voltage Load voltage Stop at end of cycle Figure 5 5 Logic firing mode 5 8 TC3000 User Manual Operation The Logic can also be configured with a soft start or start and end in thyristor firing angle variation There are two possibilities start in Phase angle with the firing angle increased gradually and immediate stop at the end of the voltage supply cycle as soon as the control signal is less than 2596 soft start and non firing in Phase angle For inductive loads zero voltage crossing generates transient operation which may in certain cases induce a saturation of the magnetic circuit see fig 5 6 a and a high speed fuse blow out thyristor protection To prevent this saturation the firing on each phase can be delayed with reference to the corresponding zero voltage see figure 5 6 b The optimum delay angle 0 must be set with the front panel potentiometer PA Ramp CY Delay as a function of the load max delay 90 A yi Over current cot ot
62. nected directly to the ground of the TC3000 thyristor unit Control cable clamp Lower cover View of thyristor unit from below Figure 3 9 Control cable fixing TC3000 User Manual 343 Wiring Connection of the shield to the ground e Strip the shielded cable as shown in figure 3 10 a The control wires must be long enough for the connection between the metal cable clamp and the driver board user terminal blocks with the door open The wiring inside the unit must be as short as possible Control wires Shield Isolating sheath 20 to 40 cm Shield folded back b Figure 3 10 Control cable stripping Fold back the shield on the isolating sheath figure 3 10 b Insert the cable in the metal cable clamp so that the shield is located in the stirrup and does not enter the unit it must not pass the lower cover Tighten the stirrup 4 x 1 flat screwdriver tightening 0 7 N m Lower cover K Tightening screw Cable clamp 2 Shield folded back Cabe Left hand side view Figure 3 11 Cable tightening and shield grounding The possible cable diameters with the shield folded back are 5 to 10 mm per cable clamp 3 14 TC3000 User Manual Wiring CONTROL TERMINAL BLOCKS The control wires are connected on the driver board for the control setpoint con
63. nection the retransmissions of the voltage and controlled parameter indications Caution For electromagnetic compatibility reasons the connection must be A N made with shielded cables and wires which are shielded and earthed or grounded at both ends Control terminal tightening 0 7 N m The driver board terminal blocks can be accessed with the front door open To open the door unfasten the front screw release the door from its notches by raising it and pull it towards you Warning AN With the door open dangerous live parts may be accessible if the TC3000 thyristor unit supply is switched on TC3000 User Manual 345 Wiring General introduction Two user terminal blocks are located in the top right corner of the driver board The Control terminal block H12 contains 7 terminals labelled 11 to 17 AUX IN OUT ENT AUX zi o z x o d ENABLE Aaaa E H12 H11 Driver Control terminal block RELAY 2 board Figure 3 12 Driver board terminal blocks Terminal Designation on label Destination ACKNOWL ACQUIT Alarm acknowledge AUX IN OUT External feedback or ENT AUX retransmission of controlled parameter Not used INPUT ENTREE Control input ENABLE VALID Enables thyristor unit operation 10 V 10 V 0 V ANA 0 V of analogue signals Table 3 4 Control terminal block description For the correct operation
64. nfiguration The process value squared load voltage external feedback or operation in Open loop is selected using the position of jumpers K8 and K9 Process value Position of jumpers K8 Squared load voltage V External measurement Open loop Table 4 6 Process value configuration K9 When the control is performed on the external measurement the position of jumpers K10 J36 and SW1 is 0 TC3000 User Manual Configuration Auxiliary input output configuration The position of jumpers J36 and SW1 defines the destination of the auxiliary input output terminal 12 on the control terminal block the input used for the second setpoint and for the external measurement signal or the output used for the retransmission of the controlled parameter The scale of the retransmission output is 0 10 V The position of the jumper K10 determines the active state of the second setpoint low win selector control activated Auxiliary Position of jumpers input output type J36 Second setpoint Process value retransmission External measurement Table 4 7 Auxiliary input output type configuration See process value configuration table 4 6 When operating with external measurement or with the second setpoint is selected the type voltage or current and one of the six signal scales are configured using jumpers J31 to J35 Destination Signal type and Position of jumper
65. nsecutive displays for 1 25 s each the second display can be empty The display indicates two types of flashing message e Message E anerror The next message indicates the alarm type e Message F afailure The next message indicates the alarm type During these messages the decimal point on the display indicates the alarm ON state The flashing messages are used to identify certain alarms For the alarm display conditions and their detailed state see Alarms chapter Error The thyristor unit continues to operate I I Supply over voltage gt gt This message disappears at the same time as the over voltage TC3000 User Manual 3 Display messages Failures The detection of the following failures causes operation inhibit The thyristor unit returns automatically to normal operation as soon as the cause of the failure disappears phase missing frequency under voltage or after an acknowledgement thyristor short circuit over current external signal failure The messages below appear 5 s after the failure has appeared except for over current I Pi M rc One or more supply phases are missing The second message indicates the No of the missing phase e g phase 3 If several phases are concerned only the lowest No is displayed Display
66. ntiometer TC3000 User Manual 347 Wiring Auxiliary input output The auxiliary input output terminal 12 AUX IN OUT on the Control terminal block is depending on the configuration the controlled parameter output the external feedback input the second analogue setpoint input If retransmission of the controlled parameter has been configured the internal feedback signal is available between terminals 17 0 V ANA and 12 in the form of a DC signal with a scale 0 10V This retransmission represents the squared RMS load voltage If external measurement control is selected the external feedback signal must be connected between terminals 17 and 12 If alow win selector type feedback is selected the second setpoint must be connected between terminals 12 and 17 The TC3000 thyristor unit then controls the lower of the 2 control signals Terminals 15 and 16 of the control terminal block are connected to enable the thyristor unit External feedback O O Retransmission of controlled parameter m Ov ANA Second setpoint me N C contact thyristor unit enabled contact open inhibited 20000000 board Control terminal block H12 Figure 3 15 Auxiliary signal input or output connection Alarm acknowledge After the cause of certain alarms has disappeared see Alarms chapter it is necessary to acknowledge the memorised alarm to return to normal thyristor unit operation
67. on the front panel It is used to measure the voltages of 20 points on the electronic circuit with a EUROTHERM type 260 diagnostic unit TC3000 User Manual 53 Operation Driver board The analogue control signals and parameter retransmission are applied to the driver board user terminal blocks The pulse generator emits the firing pulses for the thyristor gates at the request of the microprocessor An inhibit line stops the oscillations if the thyristor unit is disabled by disconnecting the Enable input from the 10V terminal on the user terminal block or via the external input The synchronisation circuit supplies the microprocessor with three signals corresponding to the sign of the line voltages measured and a signal corresponding to the zero voltage crossing A squaring circuit supplies one signal corresponding to the square of the measurement load voltage V The multiplexer selects the signal applied to the analogue digital converter inside the microprocessor from the measurements front panel potentiometer voltages and the control signals according to the program procedure The driver board microprocessor controls the entire operation of the thyristor unit and the message display The amplification of the input signals converts the low level signals and amplifies the retransmission A relay is used for the external detection of the active alarm state N Important Each external link each control or re
68. ons the auxiliary power supply the reference neutral the alarm relay contact Control cable clamp ae LIITIN N al nev Ho UA Auxiliary Lower cover General alarm contact Power cable Neutral power supply terminal block glands terminal block terminal block View of thyristor unit from below Figure 3 5 User terminal blocks 3 8 TC3000 User Manual Wiring Terminal Destination numbers Auxiliary power supply Neutral 115 V single phase supply 230 V single phase or three phase line to line supplies General alarm relay contact Contact open in alarm state standard Contact closed in alarm state IPF option Reference neutral only in Star with neutral load configuration Table 3 2 Destination of user terminal block terminals The max cross section of the low level wires and cables is 1 5 mm Tightening 0 7 N m TC3000 User Manual 39 Wiring Auxiliary power supply The Auxiliary power supply user terminal block supplies power to the electronics for units from 100 A and the fans The terminal block is located to the left below the thyristor unit The electronics earth is connected inside the thyristor unit with the earth of the power section The auxiliary power supply neutral wire is connected to terminal 41 The auxiliary power supply must be connected to a 115V or to a 230V Terminal 42 is used if the auxiliary power supply
69. opped 9 2 TC3000 User Manual Maintenance FUSES Thyristor protection fuses The standard version of TC3000 series power thyristor units is supplied with high speed fuses mounted on the line busbar Warning AN High speed fuses are only used for the internal protection of thyristors against wide amplitude over loads These high speed fuses may under no circumstances be used to protect the installation The user s installation must be protected upstream non high speed fuses thermal or electromagnetic circuit breaker suitable fuse isolator and comply with current standards Table 9 1 contains all the part numbers of the original internal fuses when the thyristor unit leaves the factory and the fuses which can be used for replacements during maintenance Maximum line to line voltage 500 V Nominal current Part No Th unit Fuses EUROTHERM FERRAZ BUSSMANN LA172468U050 8300373 170M3459 LA172468U080 8300051 170M3461 LA172468U080 S300051 170M3461 LA172468U100 T300052 170M3462 LA172468U125 V300053 170M3463 LA172468U200 X300055 170M3465 LA172468U315 Q300003 170M4460 LA172468U400 H300065 170M5458 LA172468U500 K300067 170M5460 LA172468U630 M300069 170M5462 Table 9 1 Recommended high speed fuses for thyristor protection Caution J The use of any fuses other than those recommended for thyristor protection invalidates the thyristor unit guarantee TC3000
70. or the nominal voltage specified in the thyristor unit order The following calibration procedure is optional and is only to be performed for conditions when the nominal load voltage can be changed Important If the value is calibrated at its nominal value the corresponding reading on the diagnostic unit in position 20 is 1 V jumper M1 in calibration position For the firing calibration it should be taken into account that in full firing sinusoidal current operation the DC values rectified sinusoidal signals double alternations read in positions 20 of the EUROTHERM type 260 diagnostic unit are 1 67 V 1 885 V RMS or 2 61 V peak to peak on the oscilloscope 6 8 TC3000 User Manual Commissioning Load voltage calibration To calibrate the voltage of the TC3000 thyristor unit calculate the calibration voltage V c4 according to the following ratio Vun VaW 1Vx V LN where Vy nominal thyristor unit voltage see identification label Vi nominal load voltage line to line voltage of the power supply used Important 2 For a star with neutral configuration V must be multiplied by 3 Calibration in calibration mode position M1 0 TC3000 cannot conduct By turning the potentiometer P6 display the value V_ calculated on the diagnostic unit display in position 20 Reset the jumper M1 in the operating position 1 Example 1 Nominal TC3000 thyristor unit voltage Vyn 4
71. panel display This alarm is not memorised and disappears as soon as the power supply frequency returns to the normal operating limits Neutral failure For the correct operation of the thyristor unit in the star with neutral configuration 4 wires the neutral must be connected to the power board The Neutral user terminal block below the thyristor unit the neutral fuse and the jumper LK8 on the power board are used for the connection In the event of a failure of this circuit or a neutral fuse blow out only in 4 wire Star load configurations the Neutral failure alarm activates the general alarm relay e inhibits the thyristor unit displays the flashing message F P on the front panel display This alarm is not memorised and disappears as soon as the connection of the neutral to the power board is restored External measurement signal failure This alarm appears when the absence of the external measurement signal is detected if control on an external measurement is selected coding EX and E and the output power is not zero alarm deactivated in Logic mode The detection of an external signal failure inhibits the thyristor unit activates the general alarm relay e displays the message F E The unit can be restarted after the alarm acknowledgement TC3000 User Manual 8 Alarms LOW LEVEL ALARM The low level alarm does not inhibit the thyristor unit The anomaly detected over voltage is d
72. pendicular to the driver board see figure 1 2 The calibration potentiometer can be accessed with the front door open Each potentiometer can be adjusted by 10 turns Potentiometer board Driver board Potentiometer P6 Figure 6 2 Location of calibration potentiometer The calibration procedure must be performed using the EUROTHERM type 260 diagnostic unit enabling accurate reading of the calibrated value Note Calibration is not essential if the retransmission is not used or the load voltage is close to that of the TC3000 thyristor unit TC3000 User Manual 67 Commissioning There are two possible types of calibration depending on the position of calibration jumper M1 non firing calibration or full firing calibration Normally calibration must be performed during non firing the jumper M1 on the driver board is set to position 0 The calibration of the thyristor unit during non firing does not require the operation of the installation under nominal conditions Once the non firing calibrations have been performed the calibration jumpers must be reset to the operating position 1 Full firing calibration is performed if it is necessary to fine tune or readjust the calibration during thyristor unit operation In this case the calibration jumper must be left in the operating position In the factory the calibration signal is adjusted f
73. pers Soldered links LK1 and LK2 Configuration see page Main setpoint signals Auxiliary input or output Auxiliary input output type J11 to J15 J36 and SW1 J31 to J35 Thyristor firing mode Setpoint change ramp action or soft start end K1 and K2 K3 and K4 Load configuration type Load type K5 and K6 K7 Controlled parameter K8 and K9 Second setpoint action K10 Relay contact type VX2 Calibration Operation Initial ramp Under voltage alarm level Table 4 3 Driver board jumper functions MI K12 K11 The position of the jumpers S1 and S2 M2 to M3 and J21 to J25 is not important in this version of the thyristor unit The jumper K13 must always be set to 0 4 6 TC3000 User Manual Configuration VX2 Selection of N O or N C relay contact Control terminal block eo Auxiliary power supply LinkLK1 230V lt Link LK2 115V 4 C Links LK8 and LK9 must always be K14 to K16 mounted Spare LI L LI U jumpers K12 Initial ramp K11 Under voltage level K10 Low level selector M1 V calibration 486 and SW1 Auxiliary input or
74. re 4 1 page 4 3 Operating Rating Eurotherm voltage max Part No 500 V 6 6 3 x 32 mm Comes Table 9 3 Recommended fuse for neutral protection SERVICING TC3000 thyristor units must be mounted with the heatsink positioned vertically and with no obstructions either above or below which could block the passage of the ventilation air Caution N If multiple units are installed in the same cabinet they should be arranged in such a way that the air expelled by one unit cannot be admitted into the unit located above it In order to ensure correct cooling of the unit users are advised to clean the heatsink and the protective grill of the fans regularly according to the degree of environmental pollution Warning Every six months check that the screws of the power cables and safety earth are tightened correctly see Wiring page 3 3 TC3000 User Manual E Maintenance TOOLS Operation Opening closing of front door Safety earth connection Power connection supply side and fuse change Load connection Cable clamp tightening Control and auxiliary power supply voltage connection Board fixing Commissioning and calibration Flat screw driver mm Depending on M8 screw heads selected by the customer CHc No 4 for M5 screw HEX17 M10 HEX19 M12 HEX13 M8 25 to 250 A HEX17 M10 300 to 500 A HEX17 M10 25 to 250 A HEX19 M12 300 to 500 A
75. s of auxiliary scale J31 J32 J33 J34 J35 input output External Voltage 0 5V measurement or 1 5V Second 0 10V setpoint 2 10V Current 0 20mA 4 20mA Process value Voltage retransmission Table 4 8 Auxiliary input output scale configuration 4 10 TC3000 User Manual Configuration Thyristor firing mode configuration The thyristor firing mode and the presence of the setpoint change ramp or soft start end are determined by the position of jumpers K1 to K4 Thyristor firing Position of jumpers mode Logic ON OFF K1 Thyristor firing angle variation Phase angle Burst firing Table 4 9 Thyristor firing mode configuration Soft start end ramp Without ramp and without soft start end Position of jumpers K3 K4 Positive ramp in Phase angle or Soft start in Burst firing and in ON OFF Positive and negative ramps in Phase angle or Soft start end in Burst firing and in ON OFF Table 4 10 Presence of the ramp in soft start end The number of burst times of the Burst firing cycle the duration of the ramp on the setpoint changes or the soft start end time can be adjusted using the potentiometers on the front panel see Operation chapter TC3000 User Manual 411 Configuration Configuration type and load type The three phase load configuration is determined by the position of the jumpers K5 and K6 on
76. scale IIn the factory the potentiometer P1 is preset to 5 V 90 delay angle if the coding indicates inductive load configuration TC3000 User Manual 521 Operation Response T potentiometer The potentiometer P2 labelled Response T on the front panel is used to adjust the control loop response time in Phase angle firing mode or the number of firing cycle in Burst firing mode Phase angle Positions of jumpers K1 0 K2 1 Response T potentiometer functions Control loop reponse time setting The response time depends on the control loop gain No action Table 5 8 Functions of the potentiometer P2 Standard response time in Phase angle Setting of the number of firing or non firing cycles in the modulation times The control loop response time can be adjusted from 13 to 52 supply cycles using the potentiometer P2 When P2 is turned clockwise the response time is increased since the gain is decreased An increase in the gain can cause the setpoint to be exceeded transiently Stability can be increased but by decreasing the control loop gain A satisfactory stability gain compromise is obtained with a response time of approx 0 68 s This standard response time default setting corresponds to a setting voltage of 4 3 V read in position 10 of the EUROTHERM type 260 diagnostic unit 5 22 TC3000 User Manual Operation Number of mains cycles in the Burst
77. t Line voltage Auxiliary power supply Operating voltage calibration Input signal Nominal current 25 amperes 40 amperes 60 amperes 75 amperes 100 amperes 150 amperes 250 amperes 300 amperes 400 amperes 500 amperes Line voltage 240 volts 440 volts 480 volts 500 volts For other voltages contact your Operating voltage Code 100 volts 110 volts 115 volts 120 volts 200 volts 220 volts 230 volts 240 volts 277 volts 380 volts 400 volts 415 volts 440 volts 480 volts 500 volts Input signal Code 0 5 volts 1 5 volts 0 10 volts 2 10 volts 0 20 mA 4 20 mA Eurotherm Office Auxiliary power supply 110 volts 100V 110 to 120 volts 110V120 200V 220V240 200 volts 220 to 240 volts TC3000 User Manual Identification Thyristor Ramp soft Load Load Controlled Auxiliary Options 00 firing mode start end connection type parameter input output Thyristor firing mode Load type Logic ON OFF Inductive Phase angle Other loads Burst firing 1 supply cycle Controlled parameter Code 2 supply cycles 4 supply cycles External See Auxiliary input 8 supply cycles Squared load voltage 16 supply cycles Open loop 32 supply cycles 64 supply cycles m 128 supply cycles Auxiliary input output 255 supply cycles Controlled parameter retransmission External control if controlled parameter EX 0 5 V E0V
78. t the J identification code of the thyristor unit corresponds to the coding specified in the order and that the characteristics of the thyristor unit are compatible with the installation Load current The maximum load current must be less than or equal to the value of the nominal current of the thyristor unit taking the load and power supply variations into account If the three identical loads are configured in closed delta the current of each phase of the thyristor unit is N3 times higher than as the current of each arm of the load For the given power P of the three phase load and for the line voltage V line to line voltage the current to be compared with the nominal thyristor unit current is P I V3xV For the open delta the current to be compared with the nominal thyristor unit current is P I 3x V L Load configuration type Make sure that the configuration type used is correctly configured using the jumpers K5 and K6 on the driver board see page 4 12 LK7 LK8 and LK9 on the power board see page 4 5 TC3000 User Manual 63 Commissioning Power supply voltage The voltage applied to thyristors in the OFF state depends on the load configuration type For the star without neutral closed or open delta configurations the nominal value of the thyristor unit voltage must be greater than or equal to the line to line voltage of the power supply used For the star with neutral configuration th
79. the driver board and LK7 LK8 and LK9 on the power board Caution A N It is necessary to check that the position of the jumpers LK7 to LK9 table 4 2 corresponds to the position of the jumpers K5 and K6 table 4 11 Three phase load configuration type or Position of jumpers load type K5 K6 K7 Star without neutral 3 wires Star with neutral 4 wires Closed delta 3 wires Open delta 6 wires Resistive load Inductive load or transformer Table 4 11 Load connection type and load type configuration Alarm relay contact type The general alarm relay is deactivated at the time of the alarm or when the auxiliary power supply is switched off The jumper VX2 is used to select the type of N O and N C contact available on the user terminal block below the thyristor unit see figure 3 1 Important The relay contact is protected by RC snubbers against interference Relay contact Position of jumper VX2 type Normally open N O Normally closed N C Table 4 12 General alarm relay contact type configuration 4 12 TC3000 User Manual Configuration Under voltage alarm level If the supply voltage drops below the selected value 50 or 70 96 with reference to the operating voltage the under voltage alarm inhibits the thyristor unit operation and produces an indication using a relay and the front panel display The alarm threshold can be configured using the jumper K11 Volt
80. tion firing delay from 0 to 90 All loads Start duration setting Soft start number of supply cycles in thyristor firing angle variation Immediate stop after first 0 crossing All loads Setting of both start and Soft start and end end duration in thyristor firing angle variation Table 5 5 Functions of the potentiometer P1 for the various firing modes Note For the Burst firing and Phase angle burst modes the soft operation time is limited by the basic cycle TC3000 User Manual 545 Operation Setpoint change ramp The ramp duration Ty is the number of supply cycles therefore the time taken for the thyristor unit firing to change from 0 to 100 positive ramp or from 100 to 0 negative ramp The Setpoint change ramp function is only available in the Phase angle firing mode firing err B A y 10 Negative ramp Input setpoint la Input setpoint Output power b Output power Figure 5 9 Positive and negative ramps during setpoint change in Phase angle mode After the electronics power up the setpoint ramp is reset to zero If the setpoint has not changed the setpoint ramp is not enabled when the thyristor unit is re enabled after an inhibit Important The ramp duration is set for both the positive and negative ramps For the same T setting the slope of the ramp is constant irrespective of the setpoint change amp
81. to 90 the delay angle setting scale is given on page 5 20 6 12 TC3000 User Manual Display messages Chapter 7 DISPLAY MESSAGES Contents page eric Steady messages sess Flashing messages ENOT hirviin gc A E A A E E Microprocessor failure TC3000 User Manual 7 Display messages Chapter 7 DISPLAY MESSAGES GENERAL During the thyristor unit commissioning procedure and during its operation messages are displayed on the front panel display These messages inform the user on the type of thyristor unit operation the enabled alarms the errors and the failures Two types of message are shown on the display Steady messages indicating the current thyristor unit operating mode The thyristor unit operates normally or is inhibited Flashing messages indicating abnormal operation an error or a failure STEADY MESSAGES UR Normal operation in Phase angle mode l Normal operation in Burst firing mode Normal operation in Logic mode Ramp on a setpoint increase with thyristor firing angle variation Ramp on a setpoint decrease with thyristor firing angle variation Inhibit of thyristor unit terminal 15 Enable on the driver board is at 0 V or is not connected to 10V 7 2 TC3000 User Manual Display messages FLASHING MESSAGES A flashing message is composed of three co
82. transmission signal and the auxiliary power supply are protected against interference by an internal filter A diagnostic socket located on the front panel of the thyristor unit is used with the EUROTHERM type 260 diagnostic unit to control or measure the main thyristor unit operating parameters The watchdog monitors the correct functioning of the software in the event of a fault it sends a Reset signal to the microprocessor 5 4 TC3000 User Manual Operation THYRISTOR FIRING MODES Phase angle mode In Phase angle mode the power transmitted to the load is controlled by firing the thyristors on a part of the supply voltage half cycle For the three phase load configuration in star with neutral the load voltage is composed of portions of supply phase neutral half cycles For the three phase load configuration in open delta the load voltage is composed of portions of line to line voltage half cycles Resistive Power load supply voltage voltage ot gt Power supply Inductive voltage load voltage at gt Figure 5 2 Load voltage in Phase angle star with neutral or open delta The firing angle 0 varies in the same way as the control system signal The output power is not a linear function of the firing angle but is a linear fonction of the input signal TC3000 User Manual 55 Operation The three phase load voltage configured in star without
83. ue M12 28 8 Nm Cable sheath passage diameter Table3 1 TC3000 thyristor unit power wiring details The cross section of the connection wires to be used must comply with the Standard IEC 943 The power cables to the load should pass through cable sheaths These must be tightened as much as possible after the passage of the cables The cable sheath passage diameter is given in table 3 1 Important A N For loads composed of 3 primary transformer coils the coil connection direction must be observed TC3000 User Manual Wiring POWER WIRING DIAGRAMS The TC3000 power wiring diagram depends on the load configuration Four power and safety earth wiring diagrams are given below for the different types of load configuration Star without neutral configuration Line protection and main circuit breaker user installation Thyristor protection fuses Power board NE NEN o toAp o Loan rit Figure 3 1 Power and safety earth wiring diagram for a load connected in Star without neutral 3 wires LOADS 3 4 TC3000 User Manual Wiring Star with neutral configuration If the load is wired in Star with Neutral 4 wires the neutral must also be connected to the neutral terminal block terminal 71 below the thyristor unit In the Phase angle firing mode the neutral current contains the sum of the 3rd harmonics of each phase For small firing angles
84. up put the upper protective cover back in place to ensure the specified degree of protection A Warning Before any connection or disconnection make sure that the power and control cables and wires are isolated from the voltage sources For safety reasons the safety earth cable must be connected before any other connection during wiring and the last cable to be disconnected The safety earth is connected to the screw located on the busbar provided for this purpose in the top part of the unit behind the phase terminal and labelled as follows A A Lu Caution To ensure the correct grounding of the TC3000 unit make sure that the fixing is on the reference ground surface panel or bulkhead Failing this it is necessary to add a ground connection at most 10 cm long between the earth connection and the reference ground surface Warning This connection which is intended to ensure good ground conductivity can never be used to replace the safety earth connection 3 2 TC3000 User Manual Wiring The power terminal capacities are given in table 3 1 The tightening torques must observe the limit values in the same table Nominal current Power supply and load cables Safety earth cable 25A to 150A 4 to 70 mm 14 to 35 mm 300 A to 500 A 185 to 2x150 mm 95 to 185 mm Fuse terminals Tightening torque M8 MIO 25 N m Load screw Tightening torq
85. wer supply voltage 115 V or 230 V same as electronics supply Industrial three phase load resistive short wave infrared inductive Independent of the phase rotation order Closed 3 wires or open 6 wires delta Star without Neutral 3 wires or with Neutral 4 wires Load type and assembly configuration using jumpers TC3000 User Manual 17 Identification Control Supply voltage Thyristor firing modes Control signal Control mode Control quality Retransmissions 100 V to 240 V 41096 15 Consumption 20 VA add 25 VA par fan On Off Logic Burst firing number of firing times adjustable between 1 and 255 supply cycles For these two modes start at zero voltage for resistive loads with elimination of the DC component start at zero current on each phase for inductive loads with elimination of transient currents setting using potentiometer on front panel possibility of adjustable soft start and or end between 1 and 255 supply cycles for the start and end of each firing cycle thyristor firing angle variation selectable initial ramp in Phase angle 32 supply cycles Phase angle Possibility of soft start and or end with a linear ramp on a setpoint change increase decrease the duration of the ramp from 0 to 100 firing is 0 1 sto 40H setting using potentiometer on front panel Analogue Voltage 0 5 V 1 5 V 0 10 V or 2 10 V Input impedance 2100 kQ Current 0 20 mA 4 20
86. y contact connections are given on page 3 12 The switch cut off capacity is 0 25 A 250 Vac or 30 Vdc The cut off voltage must never be greater than 250 Vac The Alarm relay is deactivated in the alarm state or when the thyristor unit is switched off 8 8 TC3000 User Manual Maintenance Chapter 9 MAINTENANCE Contents page TihyriStot profe CT ON 4e ecuaciones 9 2 Fuses ER Thyristor protection fuses eene 9 3 Fuse blown indication micro switch eseesssss 9 4 Auxiliary voltage connection protection fuses 9 5 Neutral protection fuse eesssse 2 9 5 Servicing s 9 5 Jo rfe 9 6 TC3000 User Manual 9 Maintenance Chapter 9 MAINTENANCE Warning AN The thyristor unit must be maintained by qualified personnel only authorised to work in an industrial low voltage electrical environment THYRISTOR PROTECTION The thyristors of the TC3000 series thyristor units are protected as follows internal high speed fuses against over currents RC snubbers and varistors against excessively fast voltage variations and transient over voltages when the thyristors are not firing thermal switches in the event of accidental overheating of the cooler of fan cooled thyristor units the thermal switch opens which causes the thyristor firing to be st
87. y thermal switch in this case display F 1 The active alarm state can be seen on the display messages F 1 F 2 or F 3 depending on the absent phase and is signalled by the general alarm relay contact If several phases are cut off a single message is displayed with the lowest phase number of the absent phase numbers The power supply phase absence alarm is not memorised and disappears as soon as the three phases are present The thyristor returns to normal operation automatically Under voltage If the line voltage drops by over 30 or 50 depending on the configuration in relation to the calibrated nominal value the under voltage alarm is detected which inhibits the thyristor unit activates the general alarm relay e displays the flashing message F U on the front panel display The Under voltage alarm uses the voltage between phases 1 and 2 as a reference This alarm is not memorised and disappears as soon as the power supply voltage is greater than the set threshold The thyristor unit is started up again automatically if the voltage returns to over 70 or 50 depending on the configuration of the nominal voltage 8 4 TC3000 User Manual Alarms Frequency error If the supply frequency is outside the normal operating limits 40 to 70 Hz the frequency error alarm activates the general alarm relay inhibits the thyristor unit e displays the flashing message F P on the front

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