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TC1028 User manual issue 2

1. oo oo a a a 6 6 o e a SIS 9 2 eg 2 2 a S 52 ao EIE SE Bez ag 8 zzauat osg fir Sab als aulo E Au a alulo E m o a3 E E SIE EN m ol x Sagzs s B3a8zssds lt 5228383 amp ox 2 22 s 4 3 da2 22 248 fia 2 2 d 2 5 Driver board 1 Driver board 2 Driver board 3 Figure 3 8 Parallel input configuration TC1028 User Manual 3 13 Cabling Serial configuration The inputs must be configured in terms of current The serial configuration is possible if all the thyristor units are configured for the same current signal 0 20 mA for example For the 0 20 mA and 4 20 mA inputs the impedance of an imput is 250 Q For each input a 5 V voltage for the current at 20 mA is required Control signal 0 20 mA 4 20 mA At 0 Switches N C Thyristor unit enable Switch open inhibition gQ g Q e o 6 i e Sch 9 ad 9 2 alZ E B a MEAN a amp 2Z5 a o El algio olEl2 le 565 o Eg 5las 0 g Ezg S9 o EIEN uE Z 59 a ol3ti2si a gol3
2. Fixing The control wires must be grouped together in a shielded cable passing through the cable clamp under the unit Control cable clamp Tightening screw Lower cover View of unit from below EE Figure 3 3 Control cable clamp location Important To facilitate the earthing of the cable shield and to ensure maximum immunity to electromagnetic interference the metal cable clamp is fixed directly to the ground of the unit TC1028 User Manual 37 Cabling Connection of the shield to the ground To insert the control cable and earth its shield Strip the shielded cable as shown in figure 3 4 a The control wires must be long enough for the connection between the metal cable clamp and the board user terminal blocks with the door open The cabling inside the unit must be as short as possible Control wires Shield Insulating sheath 1 5 to 2 cm a 20 to 40 cm lt Cohtreliwires Insulating sheath Shield folded back b Figure 3 4 Control cable stripping Fold back the shield on the insulating sheath figure 3 4 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 MAP AFF PF Tightening screw le clamy ERES Cable clamp VASA C
3. the connector for diagnostics the bargraph indicating the mean current of the rms current optional the partial load failure detection adjustment potentiometer the Test push button to test the PLF alarm adjustment the indicator light to display the partial load failure detection 1 4 TC1028 User Manual Identification Safet eart Power supply N connection Screw Filter Internal fuse for thyristor protection Load connection Connection cable PLF switch Filter board terminal block Reference Ground voltage connection Potentiometer board Driver board RMS option board Figure 1 2 TC1028 series thyristor unit electronic boards TC1028 User Manual Identification The TC1028 thyristor units have the following thyristor firing modes thyristor firing angle variation Phase angle cyclic firing ratio modulation from 0 to 100 Burst mode Burst mode firing is characterised by different modes afiring or non firing cycle Single cycle slow cycle modulation time 10 s at 50 setpoint fast cycle modulation time 0 6 s at 50 setpoint burst firing fast or slow with soft start in thyristor firing angle variation burst firing fast or slow with soft start and end in thyristor firing angle variation The soft start for high temperature coefficient resistive loads and the delayed firing angle at the f
4. I LIMIT I P LOAD OUTPUT V LOAD OUTPUT 10V ov Figure 3 12 External potentiometer configuration for the threshold current limit 3 Fixed external limit The fixed current limit equal to 110 of the thyristor unit nominal current is maintained by connecting the I LIMIT input terminal 5 to 10 V terminal 2 Attention If the external current limit is not used terminals 5 and 2 must be connected TC1028 User Manual 3 17 Cabling Retransmission signal configuration The load current and voltage images are available on the control terminal block The voltage image is retransmitted as a double alternation rectified signal which is proportional to the instantaneous value of the load voltage The value of this signal is 5 V RMS 4 3 V mean for the nominal voltage The voltage image is available between terminals 3 V Load output and 1 0 V The retransmission of the current image depends on the presence of the RMS option board In the basic version without RMS option the signal available between terminals 4 I Load O P and 1 0 V is a double alternation recitified signal proportional to the instantaneous value of the load current The value of the retransmitted signal is 5 V RMS 4 3 V mean for the thyristor unit nominal current With the RMS option the retransmitted signal between terminals 4 and 1 of the driver board is proportional to the TRMS value of t
5. of the nominal voltage the thyristor unit is inhibited thyristor control removed The unit is re enabled automatically if the voltage returns to a value greater than or equal to 80 of the nominal value Attention N Given the inhibition at 80 96 of the nominal voltage the nominal voltage of the thyristor unit must be as close as possible to the nominal voltage of the supply used TC1028 User Manual 6 3 Commissioning Reference voltage The reference voltage of the control electronics must correspond to the power voltage and is adapted by the position of the jumpers and by the selection of the transformers on the power board The transformers for the power supply to the electronics are selected in the factory according to the order code see Configuration chapter page 4 3 Input signals The jumper configuration on the driver board must be compatible with the levels chosen for the signals used for control see page 4 5 Partial load failure detection The voltage used for the PLF detection circuit is that of the reference phase neutral Therefore this voltage must correspond to the power voltage Attention The PLF alarm switch must be connected in the circuit with a voltage which N must never exceed 230 V single phase or three phase 230 V supply 6 4 TC1028 User Manual Commissioning DIAGNOSTIC UNIT For easier commission and adjustment operations and for the thyristor unit state
6. put the upper protective cover back in place to ensure the specified degree of protection Danger Before any connection or disconnection make sure that the power and control cables and wires are separated from the voltage sources For safety reasons the safety earth cable must be connected before any other connection during cabling and the last cable to be disconnected The safety earth is connected to the screw located on the strip provided for this purpose in the top part of the unit behind the phase terminal and labelled as follows one Danger Due to electromagnetic compatibility requirements make sure that TC1028 is bolted to the metal ground panel or cabinet and going on good electrical contact If not it is necessary to add a ground connection not greater than 10 cm length between the earth and the reference ground connection This connection is intended for providing a good earth lead It cannot be used as a safety earth connection 3 2 TC1028 User Manual Cabling FIXING THE POWER CABLES The supply side power cables pass through the opening of the upper protective cover of the TC1028 unit The upper covers of the units are raised in order to facilitate the connection of these cables For connection this cover which is fixed to the unit must be raised In order to do this open the door by unfastening the front screw on the top left hand corner of the door raise the door in order to
7. when the thyristor unit leaves the factory and the fuse swhich can be used for replacements during maintenance Maximum line to line voltage 480 V Nominal current Part No Th unit A Table 7 1 Fuse A EUROTHERM LA172468U400 LA172468U500 LA172468U630 FERRAZ BUSSMANN H300065 170M5458 K300067 170M5460 M300069 170M5462 Recommended high speed fuses for thyristor protection N The use of any fuses other than those recommended for thyristor protection invalidates the thyristor unit guarantee TC1028 User Manual Maintenance FUSE BLOWN INDICATION MICRO SWITCH As an option high speed fuses 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 insulation between the cabling of the micro switches and the power and the cover TC1028 power thyristor units are supplied with three flag type lugs and insulating sleeves Each external terminal of the fuse blown indication micro switch must be cabled with a flag lug and an insulating sleeve in compliance with figure 7 1 Line busbar Fuse Flange EDV lt Break make micro contact Figure 7 1 Use of flag lugs and insulating sleeves to observe insulating distances 74 TC1028 User Manual Mainten
8. 2 Control signal Lower threshold 0 96 Upper threshold 100 Table 4 2 Control signal types and scales Input configuration The input signal can be configured with a choice of four voltage levels and two current levels Jumpers K5 to K10 are used for this configuration Control External Position of jumpers K2 K3 K4 Table 4 3 TC1028 thyristor unit input configuration TC1028 User Manual Configuration Thyristor firing mode The firing modes available for the power thyristor units can be configured using jumpers K5 to K9 and K11 to K13 installed on the driver board Thyristor firing Position of jumpers mode Firing angle variation Single cycle Fast cycle Fast cycle with soft start Fast cycle with soft start and end Slow cycle Slow cycle with soft start Slow cycle with soft start and end Table 4 4 Thyristor firing mode configuration Note intable 4 4 indicates that the jumper position is insensitive 4 6 TC1028 User Manual Configuration RMS current retransmission The retransmission of the RMS value of the load current is ensured by installing the RMS option board on the driver board see figure 4 2 This board is installed using 3 groups of pins labelled with the numbers 1 to 12 If the RMS option board is not installed and therefore the current retransmission an
9. Kanthal Super use the Special 603 which has an increased start time TC1028 User Manual 5 5 Operation Over current elimination for the inductive load The Fast cycle and Slow cycle Burst firing modes composed of whole periods start at zero voltage for purely resistive loads For inductive loads firing at zero voltage generates transient operation which could in certain cases induce a saturation of the magnetic circuit the appearance of over currents figure 5 5 a and a blow out of the high speed fuse thyristor protection To prevent this saturation the first firing of the thyristors for inductive loads can be delayed with reference to the corresponding zero voltage figure 5 5 b The optimum delay angle i must be adjusted with the Delay Retard potentiometer on the front fascia see adjustment as a function of the load max delay 90 Over current ot 9 gt u i b ot 0 o a Delay angle Figure 5 5 Inductive load switching at zero voltage a and with delay angle b ramp for transformer primary circuits 5 6 TC1028 User Manual Operation FEEDBACK Feedback function The TC1028 series power thyristor units contain an internal feedback loop The thyristor unit output power is linear between 0 and 100 of the maximum voltage for the input signal varies between 4 and 84 of the maximum scale v2 10096 50 0 4 50 84 100 S
10. Supply voltage variation compensation 5 8 Selective trigger pulse blocking ee ee Re 5 9 Current litmits eee OE AR EE MISERIS 5 10 Linear current limit iese ees ee ee EE Ee Ge ee Re ee 5 10 Threshold current mit 5 11 Partial load failure detection A 5 12 Retransmission 2 edP de v e d e 5 13 Retransmission signal 5 13 Load current image oi e e eee tees 5 13 Load voltage image ees ese ee ee ee ee ee ee ee 5 13 Bargraph indication see 5 13 Enable Inhibition AAA 5 14 Master Slave operation iese ee ke Re AR ee 5 14 TC1028 User Manual Cot3 Contents Continued Chapter 6 Chapter 7 COMMISSIONING PROCEDURE Page Commissioning procedure safety iese see ke ee ee 6 2 Checking the characteristics iese ee ee Re Re ee ee eene 6 3 Load current eighteen avais 6 3 Supply voltage EE 6 3 Reference voltage 6 4 Ulli EE 6 4 Partial load failure detection ee ee Re Re 6 4 Diagnostic Unit RR Sele EE OE OE eren en 6 5 Preliminary adjustments AA 6 8 Resistive load with low resistance variations 6 10 Resistive load with high resistance variations 6 10 Inductive load see ER n nnn ene ntt 6 11 Partial load failure detection adjustment 6 12 Current limit adjustment esee 6 13 Linear limit iot D uates 6 13 Thireshold limit eii ertet 6 14 Checks in the e
11. and terminal 1 0 V of the driver board The enable is effective when a 10 V dc voltage is applied to terminal 9 4 V minimum 32 V maximum with reference to terminal 1 see figure 3 7 on page 3 12 To enable the thyristor unit the connection using a normally closed switch of the Enables I P terminal to the User 10 V voltage output terminal 2 can be used Opening this switch inhibits the thyristor unit MASTER SLAVE OPERATION The logic signal 10 Vdc 10 mA is available between terminals 8 Slave Firing O P and 1 0 V when the TC1028 thyristor unit is in slow cycle fast cycle or single cycle firing mode The Slave Firing O P is used to control solid state contactors Using this logic signal output it is possible to perform a Master Slave operation configura tion of a TC1028 thyristor unit Master which controls one or more TC1027 series solid state contactors Slaves for the economical control of single phase or three phase loads see Cabling chapter 5 14 TC1028 User Manual Commissioning Chapter 6 COMMISSIONING PROCEDURE Contents Page Commissioning procedure safety eek RA RR 6 2 Checking the characteristics esse ee ee Re ee ee ee ee 6 3 Coad CUATE OE MA E EE 6 3 Supply voltage en See ie 6 3 Reference Voltage eese 6 4 Input signals enr taie aedi ed 6 4 Partial load failure detection ee ke Re ee 6 4 Diagnostic UNIE Sg See t
12. on the part of the user there is no guarantee that the thyristor unit and this information corresponds to the information related to the unit coding 1 12 TC1028 User Manual Installation Chapter 2 INSTALLATION Contents page Safety during installation seseseseessss 2 2 RIIT 2 3 Mechanical mounting iese ee ee Re Re Re ee 2 5 Installation details 2 6 TC1028 User Manual 2 1 Installation Chapter 2 INSTALLATION SAFETY DURING INSTALLATION Danger TC1028 units must be installed by a person authorised to work in an p industrial low voltage electrical environment Units must be installed in fan cooled electric cabinets guaranteeing the absence of condensation and pollution The cabinet must be closed and connected to the safety ground 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 TC1028 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 that the air expelled by one unit cannot be admitted into the unit located above it Attention The un
13. release it from its notches open the door completely by pulling it towards you remove the upper cover by unfastening its two fixing nuts by sliding it one cm forwards to release the two catches located at the rear and raising it The supply side connection is performed on the terminal of the fuse at the upper part of the unit labelled LINE see figure 3 1 The load side power cables are placed inside the unit through a cable sheath below the unit The load is cabled on screws located in the bottom part of the unit and labelled LOAD see figure 3 1 The capacities of the power terminals and cabling screws are given in table 3 1 Tightening must not exceed the limit values according to the same table Terminal Cabling details Supply and load 185 to 2x150 mm Earth cable 95 to 185 mm Fuse terminal M10 Tightening torque 26 N m Load screw M12 Tightening torque 28 8 N m Earth screw M12 Tightening torque 28 8 N m Table 3 1 Details of power cabling for TC1028 units The cross section of the connection wires to be used must correspond to the Standard IEC 943 TC1028 User Manual 33 Cabling Fuse for thyristor protection Safety earth connection Supply phase connection Load connection Figure 3 1 Power cable fixing points 3 4 TC1028 User Manual Cabling Description of distance Earth busbar and upper fixing hole Earth busbar and left fixing hole L
14. the power unit These marks must indicate specific points The entire manual remains applicable It is the responsibility of the user and it is highly recommended given the value of the equipment controlled using TC1028 to install independent safety devices This alarm must be tested regularly Eurotherm can supply suitable equipment As a result of the constant improvement of its products Eurotherm may modify these specifications without warning 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 Printed in France 09 98 HA 174804 ENG Is 2 0 EUROPEAN DIRECTIVES COMPONENT TC1028 thyristor unit is a component according to the Directive 89 336 EEC designed to be fitted in systems submitted to CE Marking according to the same Directive It is the responsibility of the installer to affix the CE Mark and to establish the CE declaration of conformity of its overall system in relation to the applicable European Directives In order to facilitate the integration of our components in the systems concerned by the CE Mark Eurotherm has taken the following measures SAFETY For safety the TC1028 products installed and used in compliance with this manual meet the essential requirements of the Low Voltage Directive 73 23 EEC of 19 02 73 amended by the Directive 93 68 EEC of 2
15. three phase operation the power and reference voltage configuration is determined by the load configuration The most economical three phase application is to use the TC1028 thyristor unit as a Master with TC1027 series solid state contactors operating as Slaves The Slave firing O P logic signal output is provided on the TC1028 control terminal block The auxiliary power supply configuration for TC1027 solid state contactors is described in the C1027 Series User Manual Part No HA 174762 The TC1027 solid state contactor inputs must be configured for a 10 V logic signal and connected in parallel Important In Master Slave three phase operation only the Burst firing thyristor firing modes Single cycle fast and slow cycle without soft operation are possible 3 20 TC1028 User Manual Cabling Load in star with neutral Line protection and main circuit breaker user installation Master Slave connection Control signal Figure 3 15 Configuration of a TC1028 thyristor unit Master and two TC1027 solid state contactors Slaves Load in star with neutral Low temperature coefficient resistive loads only TC1028 User Manual 3 21 Cabling Load in open delta For the open delta load configuration 6 wire configuration 3 TC1028 series power thyristor units can be used with all the available firing modes The power configuration shown in the figure below must be obser
16. 2 07 93 according to their design ELECTROMAGNETIC COMPATIBILITY For Electromagnetic Compatibility a distinction is made between immunity and conducted and radiated emissions Immunity For immunity the TC1028 products installed and used in compliance with this manual meet the essential requirements of the Electromagnetic Compatibility Directive 89 336 EEC of 03 05 89 amended by the Directives 92 31 EEC of 12 05 92 and 93 68 EEC of 22 07 93 according to their design Radiated emission For radiated emission the TC1028 products installed and used in compliance with this manual meet the essential requirements of the above mentionned Electromagnetic Compatibility Directive according to their design Conducted emission To reduce the noise due to the utilization of its thyristor units Eurotherm can supply specific filters The purpose of these filters is to help you to filter your system and to make it compliant with the essential requirements of the Electromagnetic Compatibility Directive A declaration attesting the above mentionned statements is available on request Printed in France 09 98 Part No HA 174804 ENG Is 2 0 C MARKED APPARATUS Eurotherm can supply equipment made of a thyristor unit and a filter that both form a CE Marked apparatus and is intended to be used in an installation For the filter application contact your Eurotherm office Please also refer to the installation guide of the filters In order to
17. 28 thyristor unit external analogue input parameters The external signal is applied to terminals 1 and 7 of the control terminal block at terminal 7 Switch N C O Thyristor unit Control enable _ Signal Switch open inhibition 8 6 5 4 3 2 1 Driver board SLAVE FIRING O P AUTO INPUT MANUAL INPUT I LIMIT I P LOAD O P V LOAD O P 10V ENABLES Up OV Figure 3 7 External control signal configuration For the normal operation of the TC1028 series thyristor unit also connect the Enables I P input terminal 9 at the 10 V user voltage terminal 2 e the I limit I P input terminal 5 at the 10 V user voltage Manual input terminal 6 at terminal 1 0 V 3 12 TC1028 User Manual Cabling Control of multiple thyristor units Multiple thyristor unit inputs can be configured in parallel or in series For these types of configuration all the thyristor units must have the same type of firing and the inputs must be configured for the same signal Parallel configuration The inputs must be configured in terms of voltage The input impedance for each thyristor unit is 50 KQ The current required for each thyristor unit is 0 2 mA at full scale Control signal 0 5 V 1 5 V 0 10 V 2 10 V 9 Switch N C Thyristor unit enable Switch open inhibition
18. Es als o B E 2 s lt 5 2 IG 98 S lt 5 2Z 2 0 9 lt 5 2 2 9 9 lal z 2 2 s 5 s lozxi32l l fla 22 5 Driver board 1 Driver board 2 Driver board 3 Figure 3 9 Serial input configuration 3 14 TC1028 User Manual Cabling Manual control configuration The power thyristor unit can be controlled by an external potentiometer manual control This 5 KQ external potentiometer must be connected between terminals 1 0 V and 2 10 V The viper is connected to terminal 6 Manual Input The power thyristor unit input must be configured to 0 5 V 5k potentiometer 100 0 Switch N C Thyristor unit enable Switch open inhibition foe Driver board E E F D gt OD gt ao 2 5 a DIE Q la z ba Er EE O w t SO a al o S EIS S s 4 5 2 5 9 2 a 3 la z 2 2 5 4 28 Figure 3 10 TC1028 thyristor unit manual input configuration When the manual control is used terminal 7 of the external input labelled Auto input must be connected to 0 V terminal 1 Attention If the input signal is not diconnected from terminal 7 the 2 signals external and manual are added together TC1028 User Manual 3 15 Cabling External current limit configuration The TC1028 power thyristor units use 2 types of current limit see Operation chapter linear limit internal limit a
19. G current Series Nominal Nominal voltage mode Input signal Thyristor firing Options 00 Series Single phase power thyristor unit for inductive loads or with high resistance variation Nominal current 300 amperes 400 amperes 500 amperes Nominal voltage 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 TC1028 For other voltages contact your EUROTHERM office Input signal Code Thyristor firing mode Phase angle Single cycle Fast cycle 0 6 s Fast cycle with soft start Fast cycle with soft start and end Slow cycle 10 s Slow cycle with soft start Slow cycle with soft start and end Options Code Frequency 60 Hz 60H RMS current retransmission and display RMS PLF alarm switch closed in alarm status IPF Fuse blown ind micro switch No internal fuses FUMS NOFUSE TC1028 User Manual Identification CODING EXAMPLE TC1028 thyristor unit and installation parameters Nominal load current 250 amperes Nominal supply voltage 440 volts line to line Analogue input signal 0 10 volts Firing mode Fast cycle burst mode firing with soft start Options Partial load failure alarm relay switch closed in alarm status Fuse blown indication micro switch RMS current display and retransmissio
20. O P output OV Modulation 0 13 5 V 10 2 V 0 13 5 V Power demand 0 V mean 1V peak 6 25 V 12 5 V peak 12 5 V 10V reference 10 V 0 1 V Rectified double alternation 24 V 20 V Pulse output 26 V pulses 15 V supply 15 V 150mV Oscillator input 6 4 V peak 15 V supply 15 V 150mV 0 voltage crossing pulse 10 5 V 12 5V peak 0 5ms OV OV Saw tooth generator 3 6V 8V peak 10ms Enable 10 V Table 6 2 Description of the positions of the EUROTHERM type 260 diagnostic unit Fast cycle and Single cycle TC1028 User Manual 6 7 Commissioning PRELIMINARY ADJUSTMENTS The preliminary adjustment is used to adapt the first thyristor firings to the type of load used For resistive loads with low resistance variations firing at zero voltage does not generate steep voltage fronts thus minimising the electromagnetic interference produced For resistive loads with high resistance variations use the Burst firing modes with the soft start which reduces the current requirement when the load is cold with a low resistance Forinductive loads the first firing with a delay eliminates the transient over current see Operation chapter This delay can be adjusted between 0 and 90 and only acts on the first alternation The preliminary adjustment is made using the potentiometer labelle
21. OAD terminal and lower fixing hole LOAD terminal and left fixing hole LINE terminal and upper fixing hole Table 3 2 Power cabling details Dimension Attention The power cables to a load pass through cable sheaths which must be tightened correctly after cabling TC1028 User Manual 35 Cabling REFERENCE VOLTAGE CONNECTION The reference voltage second phase or neutral used by the electronics is connected to a plug in user terminal block located on the right hand side below the unit The max wire cross section is 1 5 mm control terminal tightening 0 5 N m To second phase or neutral according to the load configuration Control cable clamp N L2 71 View of unit from Reference voltage below connection terminal block Figure 3 2 Reference voltage connection terminal block The reference voltage second phase or neutral must correspond to the load configuration voltage For the 2 phase control of the three phase load the reference voltage is that of the direct phase phase not controlled by the power unit A 1 A external fuse must protect the reference voltage wire 3 6 TC1028 User Manual Cabling CONTROL CABLES Attention The control connections must be made with shielded cables connected to the earth Lo at both ends in order to ensure satisfactory immunity against interference Separate the control cables from the power cables in the cable routes
22. Retransmission signal configuration 3 18 Single phase load wiring diagram eesseeseess 3 19 Three phase load wiring diagram eseeeeeees 3 20 Load in star with neutral 3 21 Load in open delta 3 22 Load in star without neutral or in closed delta 2 phase control i iion tei etate eei rode 3 23 PLF alarm signalling ees ee ee Re Re auia Re ee ee ee ee 3 24 TC1028 User Manual Contents Continued Page Chapter A CONFIGURATION Safety during configuration sese 4 2 Power board ti REELE ER ee PD Ge N ee OE GE FR ee ee De 4 3 Voltage selection sesse ee ee a ee ee 4 3 Driver board cuir et ee een dime Pc 4 4 Input signal kisata e evene 4 5 Control signal type ee Re ee Re ee ek ee 4 5 Input configuration ees ee ee m 4 5 Thyristor firing mode sees ee ee ee Re Re EG ee ee ee 4 6 RMS current retransmission eee 4 7 rede EA RE RR EE EE NE ENa 4 8 Chapter 5 OPERATION Thyristor firing modes e 5 2 General EE RE ee ER Eed 5 2 Phase angle mode c s cccesecceeeeceeeeeeeteseeeeseeseeeeseeenes 5 2 Burst firing mode ees ee ese ee ee ee Ke ee ee ee ee Ee 5 3 Single cycle mode arme m ect 5 3 Modulation period AAA 5 4 Soft start end WEE 5 5 Over current elimination for the inductive load 5 6 Feedback de Feedback function
23. Thyristor power units TC1028 series Control of Single phase inductive and resistive loads User Manual Copyright Eurotherm Automation 1996 Allrights 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 Printed in France 09 98 HA 174804 ENG Is 2 0 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 Important precautions and special information are indicated in the manual by two symbols AN This symbol means that failure to take note of the information may have serious consequences for the DANGER Safety of personnel and may even result in the risk of electrocution This symbol means that failure to take note of the Lo information may have serious consequences for the installation ATTENTION result in the incorrect functioning of
24. abe Shield folded back Left hand side view Figure 3 5 Cable tightening and shield grounding The possible diameters of the cables with the shield folded back are 5 to 10 mm per cable clamp 3 8 TC1028 User Manual Cabling CONTROL TERMINAL BLOCK The following connections are made on the driver board user terminal block e the external or manual input signal e the thyristor unit operation validation e the threshold current limit the load current and voltage retransmission e the logic signal output to control a solid state contactor in Master Slave operation The terminal block can be accessed by opening the front door Danger AN Dangerous live parts may be accessible when the door is open if the TC1028 thyristor unit power is on Driver board ENABLE Up SLAVE FIRING Up AUTO INPUT MANUAL INPUT LIMIT I P LOAD OUTPUT V LOAD OUTPUT 10V OV Figure 3 6 TC1028 thyristor unit control terminal labelling Control terminal block terminal capacity 0 22 mm to 1 5 mm Control terminal tightening 0 5 N m The input is insulated from the power supply and from the load circuit TC1028 User Manual 39 Cabling Terminal Name on label Destination Common 0 V 10 V 10 V user voltage V LOAD O P SORTIE U CHARGE Load voltage image retransm
25. able inductive load primary transformer circuit with a load with low resistance variations as a function of the temperature for example use on request the Special 669 not current limit not PLF TC1028 User Manual Commissioning PARTIAL LOAD FAILURE DETECTION ADJUSTMENT The partial load failure PLF detection is adjusted using the potentiometer labelled Adjust Seuil on the front fascia see figure 6 2 The purpose of this adjustment is to adapt the PLF detection with the maximum sensitivity to the real thyristor unit load To guarantee correct operation of the PLF detection circuit the load current must not be less than 10 of the thyristor unit nominal current in the case of use of a bulb as a load for a thyristor unit test in the workshop the load fail indicator light is always lit During commissioning the following adjustment must be made First of all make sure that the thyristor unit is connected correctly and that the thyristors are in permanent firing mode Turn the PLF detection adjustment potentiometer completely anti clockwise and check that the Load Fail indicator light on the front fascia is off Turn the Adjust Seuil potentiometer slowly clockwise until the indicator light comes on Turn the potentiometer slowly anti clockwise until the Load Fail indicator light has just gone off The potentiometer adjusted in this way is used to obtain maximum sensitivity for the partial load failu
26. ance PROTECTION FUSES FOR REFERENCE VOLTAGE CONNECTION These fuses must be installed in the connection wires of the reference voltage see Cabling chapter Reference 1A fuse Fuse Overall Fuse voltage 6 3 x 32 mm isolator isolator dimensions max support mm CS174289U1A0 CP174293 63x15x52 Table 7 2 Recommended protection fuse for the reference voltage connection SERVICING TC1028 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 Attention 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 Danger AN Every six months check that the screws of the power cables and safety earth are tightened correctly see Cabling page 3 3 TC1028 User Manual Li Maintenance TOOLS Operation Opening closing of front door Safety earth connection Power connection supply side and thyristor fuse change Load connection Cable clamp tightening Control and reference voltage connection Board fixing Commissioning and calibration Table 7 3 To
27. ansmission iieiaeie Ge ennt tornano Se eN see GEE eg ee Retransmission signal Load current image Load voltage image Bargraph indication Enable Inhibition Master Slave operation TC1028 User Manual 5 1 Operation Chapter 5 OPERATION THYRISTOR FIRING MODES General The TC1028 series power thyristor units possess the following thyristor firing modes Phase angle Single cycle mode Fast cycle burst firing modulation period at 50 96 power 0 6 s Slow cycle burst firing modulation period at 50 power 10 s Fast cycle with soft start and end adjustable between 0 and 250 ms Slow cycle with soft start and end adjustable between 0 and 250 ms They can be reconfigured by the user as described in the Configuration chapter Phase angle mode In Phase angle mode the power transmitted to the load is controlled by firing the thyristors for a part of the supply voltage alternation see figure 5 1 The firing angle varies in the same direction as the output power with the control system The power emitted is not a linear function of the firing angle Supply Load voltage voltage ct Figure 5 1 Phase angle firing mode 5 2 TC1028 User Manual Operation Burst firing mode The Burst firing mode is a proportional cycle which consists of supplying a series of complete supply voltage to the load Thyristor firing and non firing are synchronis
28. ant The 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 compatible with the application modify if necessary certain characteristics of the unit on site Danger For safety reasons the reconfiguration of the thyristor unit using jumpers AN must be performed with the unit switched off and by qualified personnel only Before starting the reconfiguration procedure check that the thyristor unit is insulated 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 TC1028 User Manual Configuration POWER BOARD Adaptation to the nominal supply voltage is performed on the power board Voltage selection The nominal line to line voltage specified on the order is configured by the position of jumpers JP1 to JP6 and by the type of auxiliary power supply transformer 3 types of transformer are used see table 4 2 In the factory the line voltage is configured according to the code on the thyristor unit identification label E B E o_o 6 0 1 o o ol 0 1 o_o 6 0 1 J5 Neutral 1 Neutral 2 JP6 s722 0 1 JP5 s 7272 0 1 JP4 s 55 JP3 JP2 JP1 Figure 4 1 Location of jumpers on t
29. at start up using thyristors Attention It is the user s responsibility to ensure that the nominal values of the N thyristor unit are compatible with the conditions of installation and operation before commissioning the thyristor unit Power 300 A 400 A 500 A 100 Vac to 480 Vac 10 15 Nominal current Nominal line to line voltage Supply frequency Dissipated power Cooling Fan Load Environment Operating temperature Storage temperature Protection Thyristor protection Cabling Atmosphere Humidity Pollution Altitude Dimensions Inhibition below 80 of the nominal voltage response time 10 ms automatic reset 2 s after return to nominal 50 or 60 Hz 2 Hz 1 3 W approximately per ampere Permanent fan cooling Consumption 6 5 W 24 V dc fan Auto power supply by the power circuit Resistive with high temperature coefficient or inductive transformer primary circuit or inductor 0 C to 50 C in vertical position 40 C for 500 A nominal current at 50 C redimension to 450 A 10 C to 70 C 2 covers providing IP20 protection on the front fascia Internal high speed fuse in fuse blown indication micro switch option Varistor and RC snubber To be performed according to the standards IEC 364 Non explosive non corrosive and non conducting RH of 5 to 95 without condensation Degree 2 admissible defined by IEC 664 2000 m maximum 570 mm H x 248 mm W x 268 mm D Wt 16 5 k
30. basic version of the TC1028 series thyristor unit is equipped with a thyristor firing board power board which generates the thyristor firing and current and voltage measurement pulses a driver board which generates the firing start signals a potentiometer board for the adjustment of the delayed thyristor firing for inductive loads and the soft start time a filter board to protect the thyristor unit operation against transient interference As an option the TC1028 power thyristor unit can be equipped with a board which be plugged into the driver board and converts the instantaneous current into an image of the RMS current RMS option board The rms value of the load current is displayed using a bargraph and is retransmitted by a signal from the user terminal block The control system performs as a function of an analogue input signal the feedback of the squared voltage or the squared load current automatic selection of the highest value The TC1028 thyristor units possess supply variation compensation in the range of 10 to 15 of the nominal voltage The TC1028 series thyristor units are used to control electrical loads such as loads with high resistance variations as a function of temperature transformer primary circuits inductors The following are found on the front fascia the delay adjustment potentiometer for the first firing on inductive loads or soft start adjustment potentiometer
31. circuit or inducer firing at Zero voltage generates transient operation which is conveyed by an over current at the start of each burst see Operation chapter and in certain cases the blowing of thyristor protection high speed fuses To prevent these over currents at the start of each burst for the not saturable inductive load the first thyristor firing must be delayed in relation to the corresponding zero voltage The optimum delay angle 90 max must be adjusted according to the load used by the Delay Retard thyristor firing delay angle adjustment potentiometer For this adjustment Apply a control signal corresponding to approximately 20 of the maximum setpoint Make sure that the Delay Retard potentiometer is turned completely clockwise Turn the Delay Retard potentiometer anti clockwise in order to reduce the peak current displayed by bargraph without RMS option or the over current visible on the screen of an oscilloscope as much as possible at the start of each burst In the factory the Delay Retard potentiometer is adjusted as shown in table 6 4 Thyristor firing mode Fast cycle Slow cycle Single cycle Position of Delay Retard potentiometer Completely anti clockwise Minimum delay Soft start Soft start and end Completely clockwise Maximum ramp Phase angle No effect Position insensitive Table 6 4 Adjustments in factory In the case of the control of a satur
32. d Delay Retard on the front fascia The effect of this adjustment potentiometer depends on the thyristor firing mode Thyristor firing mode Phase angle Effect of Delay Retard potentiometer No effect Single cycle Slow cycle Fast cycle Delay of first firing of thyristors at the start of each firing cycle Burst firing with soft start Soft start duration in thyristor firing angle variation Burst firing with soft start and end Soft start and end duration in thyristor firing angle variation Table 6 3 Effect of the Delay potentiometer on the front fascia 6 8 TC1028 User Manual Commissioning Bargraph PLF detection indicator light Load Fail Linear current limit D f Charge adjustment Adjust potentionmeter il PLF adjustment T SE potentiometer ost limit ET Re Limit Delay x R PLF test SS push button Delayed firing or soft start adjustment potentiometer EUROTE Diagnostic connector Figure 6 2 Front fascia of the TC1028 thyristor unit TC1028 User Manual 6 9 Commissioning Resistive load with low resistance variations For loads with low resistance variations as a function of temperature the adjustment must guarantee thyristor firing at zero voltage in burst mode Turn the Delay Retard potentiometer on the front fascia completely anti clockwise delay angle 0 Switch on the thyristor u
33. d the bargraph display are in instantaneous values pins 11 and 12 and pins 7 and 8 must be short circuited by the jumpers supplied see figure 4 2 Figure 4 3 RMS option board With the RMS option the jumper M1 on the RMS option board must be in position 1 2 as shown in figure 4 3 TC1028 User Manual 4 7 Configuration Frequency In the standard version the operating frequency of the TC1028 is 50 Hz As an option code 60 H the frequency is 60 Hz The value of the frequency used is configured using jumper K10 on the driver board Position of jumper K10 60 Hz 0 Table 4 5 Frequency configuration of the supply used 4 8 TC1028 User Manual Operation Chapter 5 OPERATION Contents page Thyristor firing modes seen 5 2 General 5 2 Phase angle mode 5 2 Burst firing mode 5 8 Single cycle mode 5 8 Modulation period ses 5M Softstait end EES SR EES EED tet wee 5 5 Over current elimination for the inductive load we 5 6 IST Le 5 7 Feedback function nennen 5 7 Supply voltage variation compensation 5 8 Selective trigger pulse blocking 5 9 Current limit d ses Ve ESEG eege ER AU We SEE ESE EER GE Te ds 5 10 Linear current limit oo ee Re ee ee ee ee 5 10 Threshold current limit ese ee RR ee RR ee ee 5 11 Partial load failure detection ee ee ke AA de 5 12 Retr
34. dback in V2 and the current limit in P provide the best control in all the feedback zones 5 10 TC1028 User Manual Operation Threshold current limit This type of limit is used to limit the load current to a desired value independently of the input signal and the linear current limit The I Limit I P input terminal 5 of the control terminal block can be controlled by an external adjustment potentiometer by a 0 10 V external dc voltage When the threshold limit by potentiometer or by voltage is not used terminal 5 of the driver board user terminal block must be connected directly to the 10 V user voltage terminal 2 Otherwise the threshold current limit is at zero and the thyristor unit cannot output In this case the current is limited to 110 of the thyristor unit nominal current Without current limit Without current limit 80 limit threshold Resulting limit 60 limit threshold inear limit 0 5096 100 0 50 100 Setpoint Setpoint Figure 5 8 Threshold current limit a and use of 2 types of limit simultaneously b TC1028 User Manual 5 11 Operation PARTIAL LOAD FAILURE DETECTION The partial load failure PLF alarm detects an increase in the load impedance due to the failure of heating elements for example The sensitivity of the PLF circuit is used to detect the increase in the load impedance to 20 46 which detects the failure of one el
35. diagnostics it is advisable to use the EUROTHERM type 260 diagnostic unit The 20 way switch of the diagnostic unit is used to display the values of the thyristor unit and feedback parameters The unit displays two decimal places in order to permit the precise indication of the selected values The diagnostic unit possesses a flat cable which is plugged into the 20 pin connector diagnostic connector provided on the front fascia of the thyristor unit The signals from the diagnostic connector may also be viewed using an oscilloscope Delay O Retard YT o Diagnostic E connector TC1028 E m zy Flat cable Digital display diagnostic unit EUROTHERM Oscilloscope connection terminals insulated from power 9 V supply Battery or rechargeable battery Battery charger Figure 6 1 Connection of the EUROTHERM type 260 diagnostic unit and the thyristor unit The following table gives the description of each position of the diagnostic unit and the typical values of the signals measured mean dc values TC1028 User Manual 6 5 Commissioning Position Description Current image nominal load 0 of setpoint Os 0 50 of setpoint 9 90 100 of setpoint 180 Manual input if used PLF output not in alarm In alarm status Ex
36. e 3 12 Control of multiple thyristor units iese ese ee ee Re 3 13 Parallel configuration eene 3 13 Serial configuration saer aaee aean aeei e ion e E E RARE 3 14 Manual control configuration eeeeeees 3 15 External current limit configuration sess 3 16 Retransmission signal configuration 3 18 Single phase load wiring diagram sesseesss 3 19 Three phase load wiring diagrams sesse Re ee ee 3 20 Load in star with neutral 3 21 Load in open delta ee see ee ee ee Ee ee Ee ee 3 22 Load in star without neutral or in closed delta 2 phase control eet 3 23 PLF alarm signalling eee Re ee ee ee ee ee 3 24 TC1028 User Manual 24 Cabling Chapter 3 CABLING SAFETY DURING CABLING Danger A Cabling must be performed by personnel who are qualified to work with low voltage electrical equipment It is the user s responsibility to cable and protect the installation in accordance with current professional standards A suitable device guaranteeing electrical separation of the equipment and the supply must be installed upstream from the unit in order to perform the operation in complete safety TC1028 series units possess two protective covers upper and lower The upper cover should be raised to facilitate cabling After connection and before power up
37. e cabling of the thermal switches on the power board 1 5 Check the presence of the thyristor firing pulses pulses at 20 V for Phase angle firing pulses at 26 V in Burst firing mode in position 13 of the diagnostic unit 1 6 Check that the power limit is not at zero position 5 of the diagnostic unit and that the setpoint is present external input in position 4 or manual input in position 2 1 7 Check that the supply voltage is greater than or equal to 80 of the thyristor unit nominal voltage TC1028 User Manual 6 15 Commissioning Symptom 2 The transient over current during the inductive load start is too high Action 2 1 Check that the load cabling is correct 2 2 Check the level of the oscillator input signal signal in position 15 of the diagnostic unit is 6 4 V peak for measurement use an oscilloscope 2 3 The pre adjustment at 90 in the factory of the firing delay angle has not been readjusted Decrease this angle slightly by turning the Delay potentiometer on the front fascia of the thyristor unit anti clockwise See Preliminary adjustment of the inductive load page 6 11 If the fault persists after all these checks contact your nearest EUROTHERM office where technicians will be able to advise you and assist you during commissioning 6 16 TC1028 User Manual Maintenance Chapter 7 MAINTENANCE Contents Thyristor protection e ee ee Re ee ee R
38. e ee ee ee ee Thyristor protection fuse Fuse blown indication micro switch A 7 4 Protection fuses for reference voltage connection 7 5 SEIVIGING EE 7 5 TOONS 24 RE MA eee 7 6 TC1028 User Manual 1 Maintenance Chapter 7 MAINTENANCE Danger N The unit must be maintained by gualified personnel only THYRISTOR PROTECTION The thyristors of the TC1028 series power units are protected as follows the internal high speed fuse against over currents the RC snubber and the varistor against too fast voltage variations and transient over voltages when the thyristors are not firing the thermal switch in the event of accidental overheating of the cooler the thermal switch opens which causes the thyristor firing to be stopped 7 2 TC1028 User Manual Maintenance THYRISTOR PROTECTION FUSE The standard version of TC1028 series units is supplied with the high speed fuse mounted on the line busbar Attention of thyristors against wide amplitude over loads High speed fuses are only used for the internal protection This high speed fuse may under no circumstances be used to protect the installation A Danger The user s installation must be protected upstream non high speed fuse thermal or electromagnetic circuit breaker suitable fuse isolator and comply with current standards Table 7 1 contains all the references of the original internal fuses
39. ed with the supply and are performed at zero voltage for a resistive load This firing eliminates the steep fronts of the supply voltage applied to the load does not produce interference on the supply and in particular prevents the generation of parasites In the Burst firing thyristor firing mode the power supplied to the load depends on firing periods T and non firing periods Ty The load power is proportional to the firing rate t and is defined by the ratio of the thyristor firing period T and the modulation period Tu TEE T The firing rate or cyclic ratio is expressed by the following ratio T To Ty Typ The load power can be expressed by P T Pyax where P represents the load power during thyristor firing MAX Load voltage 0 lt TF gt lt TNF gt Le TM gt Figure 5 2 Periods of a Burst firing cycle Single cycle mode The Burst firing mode with a single firing or non firing period is called the Single cycle mode TC1028 User Manual 5 3 Operation Modulation period The modulation period in Burst firing mode is variable according to the output power Due to this type of feedback the TC1028 unit possesses adjustment precision adapted to each specific setpoint zone At 50 power the typical value of the modulation period is 0 6 s for the Fast cycle 10 s for the Slow cycle Fora zone less than 50 of the maximum setpoint the firin
40. ei eoe ee aia aed 6 5 Preliminary adjustments AAA 6 8 Resistive load with low resistance variations 6 10 Resisitve load with high resistance variations 6 10 Inductive load ecc eene 6 11 Partial load failure detection adjustment 6 12 Current limit adjustment ese ee ee Re Re ee ee 6 13 Linear limit EER er ted ap Se Re REPRE 6 13 Threshold limit 23 testes eer ette 6 14 Checks in the event of abnormal operation 6 15 TC1028 User Manual 6 1 Commissioning Chapter 6 COMMISSIONING PROCEDURE Read this chapter carefully before commissioning the thyristor unit COMMISSIONING PROCEDURE SAFETY AN Danger 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 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 w
41. ement out of 5 identical elements mounted in parallel On the TC1028 thyristor unit the alarm is indicated by an indicator light mounted on the front panel and labelled Load Fail lit when a partial load failure is detected by the alarm relay switch switch ouput is available on terminals 51 and 52 on the user terminal block at the bottom left hand corner of the thyristor unit The alarm relay is exited outside alarm status when the thyristor unit power is on The alarm switch cut out capacity 0 25 A at 250 Vac or 30 Vdc in the standard version is open in alarm status or in the event of a supply failure As an option code IPF this switch is closed in alarm status The PLF alarm relay switch output is suitable for the control of an alarm unit The PLF alarm relay is acknowledged either by switching off the thyristor unit or by resetting to the nominal current 5 12 TC1028 User Manual Operation RETRANSMISSION The TC1028 thyristor units possess retransmission of load current and voltage images in the form of a signal available on the control terminal block and a bargraph current display on the front fascia Retransmission signal Load current image The Load current image is available on the control terminal block between terminals 4 I Load O P and 1 0V It can be used for tests or for an external measurement In the standard version the double alternation rectified output signal is directly pro
42. etpoint Figure 5 6 Controlled parameter as a function of the setpoint The squared RMS load voltage represents the power dissipated in a purely resistive load the value of which is constant with the temperature variation The accuracy of the power feedback is guaranteed to be within 2 of the maximum voltage The feedback system automatically selects the higher value of two parameters V ou I For loads with low resistance variation as a function of temperature nickel chromium aluminium Inconel iron alloys etc the feedback in V is sufficient Feedback with automatic transfer between the two controlled values is very important for loads with high resistance variation as a function of the temperature molybdenum molybdenum bisilicide tungsten platinum etc For this type of load the operation is as follows P feedback at start when cold automatic feedback type change to V when hot which allows optimum control and feedback at all temperatures TC1028 User Manual 5 7 Operation Supply voltage variation compensation The supply variation compensation acts in the range 10 to 15 of the thyristor unit nominal voltage This voltage is self supplied on the power and reference phases Without a supply voltage variation compensation a 10 decrease or increase in the supply voltage would induce a 20 46 decrease or increase in the power supplied to the thyristor unit load For a constant resis
43. f the alarm is connected to the user terminal block under the unit on the left The switch output terminals are marked 51 and 52 on the terminal block label The PLF alarm relay is de energised in alarm status In the standard version the relay switch available between terminals 51 and 52 is open in alarm status In the IPF option the alarm relay switch is closed in alarm status The partial load failure detection alarm relay switch is protected against interference by an RC snubber on the driver board PLF alarm i switch terminal View of thyristor block unit from below Figure 3 18 PLF alarm relay switch connection 3 24 TC1028 User Manual Configuration Chapter 4 CONFIGURATION Contents page Safety during configuration ees ee ee ee RR Re ee ke 4 2 Power board reg cen nee baie 4 3 Voltage selection eese 4 3 Driver board 5 it E eit ie 4 4 Input sigrial EE ines 4 5 Control signal ypa ee ee ER ee Re Re ee ee 4 5 Input configuration OE RR iere 4 5 Thyristor firing mode AA 4 6 RMS current retransmission ees ee ee ee ee ee 4 7 Frequerioy einen iet erre d ERU Te ce UR ER TERI 4 8 TC1028 User Manual 4 Configuration Chapter 4 CONFIGURATION SAFETY DURING CONFIGURATION The thyristor unit is configured in the factory using moveable jumpers and soldered links The thyristor unit is reconfigured on site using jumpers Import
44. g TC1028 User Manual Identification Control Power supply Signal type Setpoint Input impedance Manual control Thyristor firing modes Delayed thyristor firing Validation Inhibition Diagnostics Feedback type Configuration Connection Auto power supply from the power circuit Connection of a reference phase or neutral Consumption 20 VA Analogue Voltage 0 5 V 1 5 V 0 10 V or 2 10 V Current 0 20 mA 4 20 mA Voltage 250kO Current 250 Q 5 kQ external potentiometer The following can be reconfigured by the user Phase angle Single cycle burst firing with a firing or non firing cycle Fast cycle typical modulation time at 50 power 0 6 s Slow cycle typical modulation time at 50 power 10 s Fast cycle with adjustable soft start between 0 and 250 ms with or without soft end Slow cycle with adjustable soft start between 0 and 250 ms with or without soft end For inductive loads the delayed firing of the first alternation of the burst mode firing without soft operation eliminates transient currents Using external switch or external voltage Response validation 2 s inhibition 25 ms Connector for diagnostic unit used to adjust and control the thyristor unit using 20 test signals Squared load current or squared voltage control Supply variation compensation Shielded cable connected to the ground at both ends 0 5 mm to 1 0 mm wires Tightenin
45. g 0 5 N m 1 8 TC1028 User Manual Identification RMS option board Retransmissions Display Current limit Linear limit Threshold limit RMS load current dc signal 0 to 10 V proportional to the real load current image Retransmission output on the user terminal block Display of RMS current using 10 segment bargraph Proportional load current limit 20 9o to 100 of the nominal current Adjustment using potentiometer on front fascia Maximum load current limit Adjustment possible using an external potentiometer Partial load failure detection Alarm Test Signalling Bargraph Display 20 current decrease detection Adjustment on front fascia using Adjust potentiometer Using front fascia Test push button Load Fail indicator light on the front fascia Alarm relay switch open in alarm status in standard version Switch closed in alarm status IPF option nstantaneous current filtered mean value to adjust the first thyristor firing for inductive loads basic version RMS value of the load current in Phase angle and Fast cycle firing modes with or without soft start or end with RMS option board Attention Due to the continual improvement of products Eurotherm may be required to T modify specifications without prior notice For any further information and in the event of doubt contact your Eurotherm Office TC1028 User Manual Identification CODIN
46. g period is decreased and the modulation period is increased Fora power zone greater than 50 96 the non firing period is decreased with the increase in the modulation period For example in the Fast cycle for 5 power T 250 ms T 75s for 90 power T 2 25 s T 2 5 s Modulation TE TNF 2035s Distributed 100 Figure 5 3 Modulation period as a function of power Fast cycle 5 4 TC1028 User Manual Operation Soft start end Soft operation start or start and end can be configured in the Slow cycle and Fast cycle Burst firing modes The soft start duration Ts is the time taken for the thyristor unit output power to change from 0 to 100 by varying the thyristor firing angle from 0 to full firing The soft end duration Tel is the time take for the thyristor unit output power to change from 100 to 0 by varying the thyristor firing angle 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 4 Soft start and end in Burst firing mode The soft end time Ts is not included in the firing period Tp but all the power sent to the load is taken into account in the feedback After the soft start by thyristor firing angle variation the thyristor unit remains in full firing during the firing time Note For soft starts of loads with very high resistance variations e g
47. guarantee the best service Eurotherm have validated the compliance of the TC1028 with the essential European Directive requirements through product design and laboratory tests described in a technical file for attention of official authorities A declaration of compliance with the European Directives is available on request ENVIRONMENT The electromagnetic compatibility of the TC1028 has been specially developed for the industrial environment and must not be used in residential type environments For further details contact your Eurotherm office Printed in France 09 98 Part No HA 174804 ENG Is 2 0 This TC1028 User Manual Part N HA 174804 ENG old Part N HA174805 intends for the TC1028 series power thyristor units manufactured from January 1996 For the products manufactured before this date no user manual is existing Please refer to the maintenance manual Part No HA 173328 In order to help you reduce risks related to the effects of electromagnetic interference depending on the installation of the product Eurotherm can supply you with the EMC Installation Guide Part No HA 025464 This guide gives the rules generally applicable for Electromagnetic compatibility Manufactured by Eurotherm Automation S A ISO 9001 EN 29001 certified Printed in France 09 98 Part No HA 174804 ENG Is 2 0 TC1028 USER MANUAL The safety instructions for the installation and use of TC1028 series units are give
48. he load current The value of this signal is 10 V for the thyristor unit nominal current Current image Voltage image Switch N C Thyristor unit enable l Switch open inhibition Driver board a E D D o IS S Eg Z 5 2 SE Sie al Fl 2 5 1 2 0 u LE 5 0 4 Jul m e O 2 EI DI lt 3 3 52 3 35 2 2 el io z S 3 3 5 5 3 Figure 3 13 Retransmission signal configuration The current image signal with or without the RMS option is displayed by the bargraph on the front fascia of the thyristor unit This bargraph has 10 segments each segment represents 10 of the thyristor unit nominal current 3 18 TC1028 User Manual Cabling SINGLE PHASE LOAD WIRING DIAGRAM The wiring diagram of the power safety earth and reference voltage of the TC1028 series thyristor unit for the control of a single phase load is given below L1 Neutral or L2 Line protection and main circuit breaker user installation Safety earth Internal fuse S for thyristor protection PLF relay switch 3 output Control signal Load Figure 3 14 TC1028 thyristor unit configuration with a single phase load TC1028 User Manual 3 19 Cabling THREE PHASE LOAD WIRING DIAGRAMS Although the TC1028 series thyristor units are single phase units they can be used to control three phase loads In
49. he power board Line to line Position of Transformer voltage jumpers Part No JP1 JP2 JP4 JP5 100 V 110 to 120 V Oo CO 174 973 CO 174 544 CO 174 613 CO 174 973 CO 174 544 CO 174 613 CO 174 544 CO 174 973 CO 174 613 127 V 200 V 220 V to 240 V 271 V 380 V to 415 V 440 V 480 V to 500 V m m m O O OOO CO E S am E aE oa ea COO CO OO OO OO OO OH ra Tableau 4 2 Voltage configuration Attention The voltage given in the above table must be less higher or equal N to the line to line voltage TC1028 User Manual 8 Configuration DRIVER BOARD The driver board jumpers are used to configure the thyristor firing mode the input signals the RMS option and the frequency of the supply used User terminal block 9 8 T6543 241 c OM WWW NO NO NO NO O Rz Potentiometer board Input configuration Thyristor mode configuration K4 ooo K5 COO Frequency configuration Firing mode configuration K11 poo Not used Links if RMS board absent O Location of the RMS 7f option board Figure 4 2 Location of configuration jumpers on the driver board 4 4 TC1028 User Manual Configuration Input signal Control signal type The TC1028 thyristor unit control signal parameters are given in table 4
50. ignal which can be reconfigured by the user has four voltage levels 0 5 V 0 10 V 1 5 V 2 10 V and two current levels 0 20 mA 4 20 mA Manual control using external potentiometers is possible The TC1028 series is equipped with the following functions electrical power control of inductive and resistive loads different thyristor firing modes decrease in the current requirement of high temperature coefficient loads for soft starts elimination of over currents when starting inductive loads current limit e partial load failure detection logic output to control other power units Slave firing output selective pulse locking circuit inhibition available on the user terminal block load current and voltage image retransmission current level display using a bargraph on the front fascia 1 2 TC1028 User Manual Identification Upper protective Bargraph PLF detection indicator light Load Fail D f Charge Current LO an limit PLF e Test adjustment limit Limit Dela Read e PLF test push button Delayed firing Diagnostic connector Control cable clamp Lower protective cover P id x E PLF switch Power cable sheath Reference phase neutral terminal block terminal block Figure 1 1 Overall view of the TC 1028 series thyristor unit TC1028 User Manual 1 3 Identification The standard version
51. irst alternation in the case of the control of inductive loads which may cause fuse blow out or trigger the protective circuit breaker minimise transient over currents The soft start and end time can be adjusted between 0 and 0 25 s using the potentiometer on the front fascia The TC1028 power thyristor units have two types of current limit linear limit adjustment using potentiometer on front fascia threshold limit adjustment using external potentiometer The partial load failure PLF detection circuit detects 25 96 increases in load impedance independently from the supply voltage variation The PLF detection is adjusted using a potentiometer on the front fascia for the real load current used The PLF alarm is signalled by the alarm relay switch and by the Load Fail indicator light on the front fascia Thermal protection is provided by a thermal switch which detects if the fan has stopped or the heatsink is overheated The TC1028 thyristor unit is equipped with active operation validation An external 10 V voltage 32 V max or a switch connected to the user terminal block is used to validate the thyristor unit operation The absence of the validation voltage or the opening of the switch causes the inhibition of the thyristor unit 1 6 TC1028 User Manual Identification TECHNICAL DATA The TC1028 is a power thyristor unit designed to control an industral single phase load with a high current requirement
52. ission output I LOAD O P SORTIE I CHARGE Load current image retransmission output I LIMIT I P ENTREE LIMIT I Input for the threshold current limit MANUAL INPUT ENTREE MANU Input for the manual control signal AUTO INPUT ENTREE AUTO Input for the automatic control signal SLAVE FIRING O P SORTIE ESCLAVE Logic output to control other units in Master Slave operation ENABLES I P ENT VALIDATION Enables thyristor firing operation Table 3 3 TC1028 thyristor unit control terminal block terminal destination 3 10 TC1028 User Manual Cabling INPUT SIGNALS The control wires are connected on the pluggable user terminal block located on the driver board The control terminal block is accessible 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 Danger AN Dangerous live parts may be accessible when the door is open if the thyristor unit power is on The thyristor units can be controlled by an external analogue signal from a controller or another signal source or manually by an external potentiometer TC1028 User Manual 3 11 Cabling External analogue input The TC1028 thyristor unit can be configured with the choice of 4 voltage input signals or with 2 current input signals Signal type Signal level Input impedance Voltage Current Table 3 4 TC10
53. its 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 5 cm between two units placed beside each other AN Excessive overheating may cause incorrect operation of the unit which in turn may cause damage in the components TC1028 series power units have permanent fan cooling TC1028 User Manual 2 Installation DIMENSIONS The dimensions values and weights of the TC1028 series thyristor units are given in figure 2 1 and in table 2 1 Door fixing screw Upper protective cover ap l LEITET O 100 50 0 O KU oS O Tes nni B Reta v KS Le Y Lower protective cover lt C gt lt D gt G gt Door open Figure 2 1 Overall dimensions with and without upper protective cover TC1028 User Manual 2 3 Installation Values Dimensions Description Height without protective cover Height with cover Width Depth Width between the fixing holes Height between the fixing holes Depth with the door open Height of lateral fascias Distance between Earth busbar and panel Depth between LOAD terminal and panel Depth between LINE terminal and panel Table 2 1 Dimensions fixing values and weight of TC1028 series units TC1028 User Manual I
54. maximum Reduce the Threshold current limit setpoint gradually until the current starts to decrease Mark the current limit setpoint corresponding to position 5 of the diagnostic unit and increase it by approximately 10 so that it is only activated as a back up for the linear current limit Attention The threshold current limit can be pre adjusted when a thyristor unit is switched on but not firing The value of the squared RMS load current is proportional to the Threshold current limit setpoint observed at position 5 of the diagnostic unit Current limit signal position 5 of the diagnostic unit Table 6 5 Example of the threshold current limit The simultaneous use of the two limits is possible to set an absolute current limit with the threshold limit and to adjust the linear current limit with the potentiometer on the front fascia 6 14 TC1028 User Manual Commissioning CHECKS IN THE EVENT OF ABNORMAL OPERATION Symptom The thyristor unit is not fired after a firing demand Action 1 1 Check that the Enable input terminal 9 on the driver board is connected to 10 V terminal 2 1 2 Check that the control signal arrives correctly on the driver board user terminal block on terminal 7 with the external control on terminal 6 in manual control 1 3 Check that the input signal type and level are compatible with the type and level of the configured signal 1 4 Check th
55. n Thyristor unit coding TC1028 300A 440V 0V10 SFC IPF RMS FUMS 00 Attention The nominal voltage of the TC1028 thyristor unit must correspond to the supply voltage used to prevent problems of non operation for voltages lower than 80 of the nominal voltage TC1028 User Manual 1 11 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 TC1028 300A 440V 0V10 SFC IPF RMS FUMS 00 SERIAL No LC1111 001 001 11 95 RATING 1 PHASE 300A 440 V AUXILIARY SUPPLY SELF POWERED MADE IN FRANCE Figure 1 3 Example of identification label for a TC1028 model 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 11 95 TC1028 FACTORY SETTINGS INPUT 0 10 V DC FIRING FAST CYCLE OPTION S FUSE BLOWN INDICATION SWITCH SWITCH CLOSED IN ALARM STATUS RMS BOARD ANY NON SPECIFIED FUSE INVALIDATES GUARANTEE SEE USER MANUAL H300065 170M5458 Figure 1 4 Example of configuration label for a TC1028 thyristor unit Attention Following any reconfiguration
56. n on the following pages e installation 2 2 e cabling 3 2 3 5 3 9 3 11 e configuration 4 2 commissioning 6 2 6 3 6 13 e protection with fuses 7 2 maintenance 7 5 TC1028 User Manual Cort Contents Chapter 1 Chapter 2 Chapter 3 TC1028 USER MANUAL IDENTIFYING THE THYRISTOR UNITS Page General introduction to the TC1028 series 1 2 Technical ERROR AE EE OE RE EE 1 7 Coding ec R a b D ere eo n ORE 1 10 Coding WE Lu EEN 1 11 Serial number labels sese 1 12 INSTALLATION Safety during installation ne 2 2 Dimensions us uge ege re tto Dx Ruhe rd EE eid 2 3 Mechanical mounting eee 2 5 Installation SE RR edem RR OE OR N 2 6 CABLING Safety during cabling iese see ee ee seen 3 2 Fixing the power cables AAA 3 3 Reference voltage connection ee ee Ee 3 6 GontrolCcaples Es erit 3 7 ae AE EE EE AD EO 3 7 Connection of the shield to the ground 3 8 Control terminal block A 3 9 Input signals nire Ere te EE EE 3 11 External analogue input sesse ee ee ee RA ee ee Re ee 3 12 Control of multiple thyristor units ese ee ee ke Re ke 3 13 Parallel configuration sene 3 13 Serial configuration ee ee RA Re Re Re ke 3 14 Manual control configuration e ese ee ee ee Re ee 3 15 External current limit configuration sess 3 16
57. nd threshold limit external limit The external limit is controlled by voltage or by the external potentiometer and can be used with the automatic external control and with the manual control The external current limit can be adjusted in 3 different ways 1 External voltage adjustment For the threshold limit a 0 10 V external voltage must be connected between terminals 5 I LIMIT and 1 0 V terminal 5 is positive External current limit voltage 0 to 10 V Switch N C Thyristor unit enable Switch open inhibition o N o 0 elei TN Driver board a B D E E o 5 5g ZIE a an LE ao z Z E 2 lr zia ctia 9 Uu sz su aIiSio DIE Gi xrczzzzoz Z2 3 5 2 5 9 4 2 3s ic ell sl 3 9 Figure 3 11 External voltage configuration for the threshold current limit 3 16 TC1028 User Manual Cabling 2 Potentiometer adjustment For the threshold current limit it is possible to use an external potentiometer This 5 KQ potentiometer is connected between terminals 1 0 V and 2 10 V its viper is connected to terminal 5 I LIMIT 5k potentiometer 100 current 0 current Switch N C Thyristor unit enable Switch open inhibition Driver board ENABLE I P SLAVE FIRING I P AUTO INPUT MANUAL INPUT
58. nit On the external input terminal 17 of the control terminal block apply a signal corresponding to 0 of the control signal Using an RMS ammeter check that the load current does not pass e On the external input Auto Input terminal 7 or manual input Manual Input terminal 6 apply a signal corresponding to 100 of the control signal Using an RMS ammeter check that the current is equal to the nominal load current Resistive load with high resistance variations For loads with high temperature coefficients use the Phase angle mode or the soft start in thyristor firing angle variation The start or start and end time is adjusted using the Delay Retard potentiometer on the front fascia for the following thyristor firing modes slow cycle with soft start code SSC e fast cycle with soft start code SFC slow cycle with soft start and end code SDS e fast cycle with soft start and end code SDF The soft start or start and end ramp can be adjusted between 0 and 250 ms The maximum ramp is obtained with the Delay Retard potentiometer turned completely clockwise In the case of the control of a load with very high resistance variations as a function of the temperature Kanthal Super for example use on request the Special 603 not for Phase angle mode 6 10 TC1028 User Manual Commissioning Inductive load not saturable When the load has an inductive component primary transformer
59. nstallation MECHANICAL MOUNTING TC1028 units have two protective covers upper and lower The units can be fixed with the protective covers in place However for the connection the upper protective cover must be removed After drilling the support panel at the dimensions and values given above insert the fixing screws half way in the partition holes or mounting plate Position the thyristor unit by first inserting the upper screw heads in the respective holes of the upper section Lower the unit making sure that the lower screws can be inserted correctly Then lower the unit completely until it is in position Fasten the 4 screws correctly TC1028 User Manual 2 5 Installation INSTALLATION DETAILS TC1028 series units are designed to be mounted directly on panels at the fixing points located on the rear of the unit Protective cover A 4 drilling holes for M8 screws K F Y Y Figure 2 2 Fixing details TC1028 User Manual B Cabling Chapter 3 CABLING Contents page Safety during cabling esse see a Ee ee ee ee ee ee 3 2 Fixing the power cables AAA 3 3 Reference voltage connection ees ee Re Re ee ee 3 6 Control Cable AE EE EE eec 3 7 ie ER EE entere s 3 7 Connection of the shield to the ground 3 8 Control terminal block A 3 9 INPUT SIQN CEET 3 11 External analogue input ees sesse ee ee Re Re ee ee e
60. ols Flat screw driver Wrench Depending on MS screw heads selected CHc No 4 for M5 screw HEX19 M12 HEX17 M10 HEX19 M12 For M4 nut Electrical equipment Ammeter or RMS clip Eurotherm type 260 diagnostic unit recommended 7 6 TC1028 User Manual
61. operating problems firing instability fuse blow out It is therefore necessary to eliminate the trigger pulses when the thyristor is polarised in inverse mode This function is performed by the selective trigger pulse blocking circuit available for TC1028 thyristor units This selective trigger pulse blocking is essential for configuration in which multiple thyristor units are distributed between the phases of a three phase supply and have an electrical configuration which could induce a voltage phase shift For example control of heating electrodes in transformer secondary coil immersed in the same molten glass load in star with neutral with the central point of the star connected to the supply neutral by a wire of a non negligible resistance with reference to that of the load TC1028 User Manual 5 9 Operation CURRENT LIMIT The TC1028 thyristor units possess two types of current limit with the load current measurement alinear current limit and a threshold current limit These two limits are independent Linear current limit This function limits the squared RMS load current P In current limit the correspondence between the load current and the input signal can be adjusted using the potentiometer labelled I limit Limit I on the front fascia 2 Without current limit 100 75 limit 50 50 limit 0 50 100 Setpoint Figure 5 7 Linear current limit The power fee
62. ork 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 thyristor unit is in operation The heatsink remains hot approximately 15 min after the unit has been switched off 6 2 TC1028 User Manual Commissioning CHECKING THE CHARACTERISTICS Attention d Before connecting the unit to an electrical supply make sure that the 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 supply variations into account In three phase operation if the 3 identical loads are configured in closed delta the line current of the thyristor unit both Master and Slave is V3 times as high as the current of each arm of the load Supply voltage The nominal value of the thyristor unit voltage must be greater than or equal to the voltage of the supply used In three phase operation the nominal voltage of the thyristor unit must be greater than or equal to the line to line voltage Danger AN Never use a thyristor unit with a supply voltage greater than the thyristor unit nominal voltage specified in the coding If the line voltage is less than 80
63. portional to the instantaneous load current 4 4 V mean for the thyristor unit nominal current in full firing As an option RMS option board the retransmission signal 0 10 V is proportional to the RMS load current The value of this signal is 10 V for the thyristor unit nominal current Load voltage image The Load voltage image output is available between terminals 3 V Load O P and 1 0V on the driver board user terminal block In the standard version and in the RMS option this is a double alternation rectified signal 4 1 V mean representative of the load voltage in full firing produced using the auxiliary supply Bargraph indication The front fascia bargraph has 10 segments and displays the load current with an accuracy of within 10 of the thyristor unit nominal current e in the standard version the instantaneous load current in the RMS option the RMS value of the load current in phase angle single cycle and fast cycle firing modes with or without soft start or end TC1028 User Manual 5 13 Operation ENABLE INHIBITION The TC1028 thyristor units possess an active operation enable function requiring the application of a voltage on a control terminal block The absence of the enable voltage induces the inhibition of thyristor unit operation meaning that the thyristors cannot fire irrespective of the input signal The enable inhibition input is available between terminal 9 Enables I P
64. re detection really connected with the thyristor unit The push button on the front fascia labelled Test which simulates a current drop of 10 96 in the load is used to check the operation of the PLF circuit without having to disconnect the load This button must place the thyristor unit in alarm status if the adjustment has been performed correctly Reminder The PLF detection circuit does not use the load voltage but the reference voltage 6 12 TC1028 User Manual Commissioning CURRENT LIMIT ADJUSTMENT Linear limit The linear current limit can be adjusted using the I limit Limit I potentiometer on the front fascia Make sure that the load is connected When used in conjunction with the threshold current limit potentiometer or external signal make sure first of all that the Threshold limit setpoint terminal 5 I Limit I P on the control terminal block is at the maximum value Turn the I limit Limit I linear current limit potentiometer completely anti clockwise minimum current At the input apply a 0 V signal and connect the power voltage The RMS voltage at the load terminals must be zero Increase the input signal to 100 96 The load voltage must represent approximately 15 of the supply voltage Turn the current limit potentiometer gradually clockwise and check that the current rises slowly Adjust the I limit Limit I potentiometer in order to obtain the maximum current permi
65. ternal setpoint Example 0 10 V 5 V Threshold limit max approx 10 V Current image for PLF 2 5 V Load voltage image 2 05 V Amplified setpoint 2 5 V Slave Firing O P output Firing demand 0 V mean 1V peak not used 8 4 V 10V reference 10 VA O 1 V Rectified double alternation 24 V 20 V Pulse output 20 V without pulses 20 V pulses 20 V pulses 15 V supply 15 V 150mV Oscillator input OV 1 2 V 6 4 V peak 90 pulses 1 2 V 6 4 V peak 90 pulses 15 V supply 0 voltage crossing pulse 15 V 150mV 10 5 V 12V peak 0 5ms OV OV Saw tooth generator 3 6V 8 4V peak 10ms Enable 10V Table 6 1 Description of the positions of the EUROTHERM type 260 diagnostic unit Thyristor firing angle variation 6 6 6 TC1028 User Manual Commissioning Position Description Current image nominal load 0 of setpoint 50 9o of setpoint Modulation 0 44V 100 of setpoint Manual input if used 2 5 V PLF output not in alarm In alarm status 12 6 V 13 5 V External setpoint Example 0 5 V 2 5 V Threshold limit max approx 10 V Current image for PLF OV Modulation 0 4 6 V Load voltage image OV Modulation 0 4 1 V Amplified setpoint OV 2 5 V 5V Slave Firing
66. tive load the feedback with supply variation compensation is used to maintain the output power constant in spite of the supply voltage variations Supply voltage Setpoint Power supplied 46 variation range 90 With compensation Without compensation 96 0 to 10 100 to 121 5 to 10 81 to 109 10 to 10 65 to 97 15 to 10 50 to 85 Table 5 1 Feedback with supply variation compensation Table 5 1 shows the stabilisation of the output power on a constant resistance as a function of the supply variations It the voltage falls below 80 of its nominal value the thyristor unit is inhibited A compensation circuit simultaneously adjusts the thyristor firing time as a function of the supply variations This compensation prevents power fluctuations and the intervention of the feedback loop enabling a quicker response 5 8 TC1028 User Manual Operation Selective trigger pulse locking The TC1028 thyristor unit thyristors are fired by a trigger pulse train of a maximul duration of 5 ms In most single phase applications it is possible to send trigger pulses every 10 ms so that the thyristors are polarised in direct mode positive anode in relation to the cathode or in inverse mode negative anode Each thyristor is only fired when its voltage is positive when it is negative the anti parallel thyristor is fired In certain applications the trigger pulses on the polarised thyristor in inverse mode can lead to
67. tted by the load Attention For the current limit adjustment only use an ammeter which gives the N TRMS value to measure the load current in order to prevent risks of errors which may reach 50 96 For a three phase installation using 2 or 3 TC1028 thyristor units take care to turn each of the current limit potentiometers gradually in succession in order to maintain the balance of the currents in each phase Attention In the case of Star with neutral configuration the neutral current for a load with a high temperature coefficient when starting cold can be 1 7 times greater than the phase currents limited by the current limit Redesign the installation as a consequence TC1028 User Manual 6 13 Commissioning Threshold limit The threshold current limit is independent of the control signal it is one of the following 110 of the thyristor unit nominal current terminal 5 of the control terminal block directly connected to terminal 2 e controlled by an external potentiometer of approximately 5 KQ connected between terminal 2 10 V and terminal 1 0 V the viper is connected to terminal 5 controlled by an external dc voltage 0 10 V The threshold I Limit I P input impedance terminal 5 is greater than or equal to 150 kQ For the threshold current limit adjustment After adjusting the linear limit using the potentiometer on the front fascia switch on the thyristor unit set the control to
68. ved Danger AN The thyristor units and reference voltage circuits are at the line to line voltage Line protection and main circuit breaker user installation Control signal o Three phase load in Open delta configuration Figure 3 16 Wiring diagram of 3 TC1028 thyristor units in Open delta Non used for the three phase transformer primary circuits 3 22 TC1028 User Manual Cabling Load in star without neutral or in closed delta 2 phase control For three phase loads in a star without neutral or closed delta configuration 3 wire configuration it is recommended to use the 2 phase control A supply phase is direct not controlled In the 2 controlled phases a TC1028 thyristor unit which operates as a Master and a TC1027 solid state contactor operating as a Slave must be connected The SLAVE FIRING O P control logic output terminal 8 is provided on the TC1028 driver board user terminal block Line protection and main circuit breaker user installation e tine Control signal Three phase load in Star without neutral or Closed delta configuration Figure 3 17 Configuration of thyristor unit and a solid state contactor in 2 phase control Non used for the three phase transformer primary circuits TC1028 User Manual 3 23 Cabling PLF ALARM SIGNALLING The partial load failure PLF alarm relay switch which signals the active state o
69. vent of abnormal operation 6 15 MAINTENANCE Thyristor protection sn 7 2 Thyristor protection fuse A 7 3 Fuse blown indication micro switch eseeeeessse 7 4 Protection fuses for reference voltage connection 7 5 SOIVICING E 7 5 Tools RE N OD UR el eed dud 7 6 TC1028 User Manual Identification Chapter 1 IDENTIFYING THE THYRISTOR UNITS TC1028 User Manual Contents page General introduction to the TC1028 series 1 2 Technical data dur EEG 1 7 COMING SEE ER T NER 1 10 Coding example esee 1 11 Installation parameters eeeeeees 1 11 Thyristor unit coding eee 1 11 Serial number labels ssssssssssess 1 12 1 1 Identification Chapter 1 IDENTIFYING THE THYRISTOR UNITS GENERAL INTRODUCTION TO THE TC1028 SERIES The TC1028 series power thyristor units are designed for the control of industrial single phase loads The TC1028 series is designed to control inductive loads transformer primary circuits in particular or high temperature coefficient resistive loads A thyristor unit contains a pair of thyristors mounted in antiparallel on a heat dissipator The TC1028 series thyristor units control currents between 300 A and 500 A The nominal line to line voltage varies between 100 V and 480 V The control s

TC1028 User manual issue 2

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