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| 1 RS Elektroniksysteme GmbH - Thyristor controller Tyco-3Ph, Tyco-3Ph/SP Start-up Instructions Thyristor controller Type: Tyco-3Ph, Tyco-3Ph/SP Content Page 1. General information .......................................... 2 2. Installation of the thyristor controller Tyco-3Ph, Tyco-3Ph/SP .......... 3 3. Operation .................................................. 4 4. Meaning of the clamp connections ............................... 5 5. Description of the front side .................................... 6 6. Meaning of the control inputs ................................... 9 7. Basic circuits............................................... 10 7.1 Basic circuit for Tyco-3Ph... or Tyco-3Ph/SP with controlclamps ....... 11 8. Survey of the individual types .................................. 12 9. Technical data.............................................. 13 Version: 2015/07/17 Elektroniksysteme GmbH Development and production of electronical systems Eichelreuth 13 Phone: +49 8641 598360 83224 Grassau Fax: +49 8641 598364 E-Mail: [email protected] Internet: http://www.rs-steiner.com

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  • | 1

    RS Elektroniksysteme GmbH - Thyristor controller Tyco-3Ph, Tyco-3Ph/SP

    Start-up Instructions

    Thyristor controllerType: Tyco-3Ph, Tyco-3Ph/SP

    Tyco-3Ph...

    Tyco-3Ph/SP...

    L1 L2 L3

    Content

    Page1. General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22. Installation of the thyristor controller Tyco-3Ph, Tyco-3Ph/SP . . . . . . . . . . 33. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44. Meaning of the clamp connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55. Description of the front side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66. Meaning of the control inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97. Basic circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107.1 Basic circuit for Tyco-3Ph... or Tyco-3Ph/SP with controlclamps . . . . . . . 118. Survey of the individual types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129. Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

    Version: 2015/07/17

    E l e k t r o n i k s y s t e m e G m b HDevelopment and production of electronical systems

    Eichelreuth 13 Phone: +49 8641 59836083224 Grassau Fax: +49 8641 598364

    E-Mail: [email protected]: http://www.rs-steiner.com

  • | 2

    RS Elektroniksysteme GmbH - Thyristor controller Tyco-3Ph, Tyco-3Ph/SP

    1. General information

    The situations in which thyristor controllers have to be employed can be found in all the areas where greater resistor and inductive loads have to be controlled (e.g. industrial heating systems, tems, plastics processing, transformers, infrared elements, etc.)Because of its modular, compact assembly and the controlling with a continuous control signal these power controllers have to be regarded as a perfect final controlling device for the industrial power controlling.The power device of the thyristor controllers consists of six thyristor moduls, an isolated heat sink and the control unit. On account of the use of function modules the adaptation to any application is one of the largest advantages of these devices.

    Type description:

    Tyco-1Ph... alternating current power controller, phase angle control for single phase systems

    Tyco-1Ph/SP... alternating current power controller for multi-cycle control

    Tyco-3Ph... three phase controller, phase angle control for three phase systems

    Tyco-3Ph/N...three phase controller, phase angle control for three phase systems with neutral point connnnection (option)

    Tyco-3Ph/SP... three phase controller for multicycle control

    Tyco-3Ph/SP/N... three phase controller for multicycle control with neutral point connection (option)

    Construction:

    The thyristor controller agrees with VDE 0558 part 1 and VDE 0160 table 4.

    The thyristor controller Tyco-3Ph... is assembled modularly. It consists of three basic elements:

    power element with cooling system and thyristor modules control unit with firing and control board (diagnostic display, control outputs, etc.)

    Application of Tyco-3Ph/SP... (Tyco-3Ph...) and Tyco-3Ph/SP/N... (Tyco-3Ph/N...)

    When using the load in neutral or delta connection the type: Tyco-3Ph/SP... is used. Here the con-nectors L3 - T3 are bridged in order to realize a flow of current due to the linked-phase voltage and the ignition of the semiconductor at zero crossing.

    The type: Tyco-3Ph/SP/N... and Tyco-3Ph/N.... is using when the star point of the load is connected with the neutral wire.

  • | 3

    RS Elektroniksysteme GmbH - Thyristor controller Tyco-3Ph, Tyco-3Ph/SP

    2. Installation of the thyristor controller Tyco-3Ph, Tyco-3Ph/SP

    The thyristor controller (IP 40) should be mounted vertically in a housing. The upper and lower side of the heat sink have to be kept free to allow cooling air to circulate freely. Controllers must be mounted on a flat surface to ensure that cooling air is channelled to the heat sink. The thyristor configuration is indifferent to the order of the supply phase rotation. It is the users responsibility to ensure that the nominal values of the thyristor unit are compatible with the conditions of installation and operation before commissioning the the thyristor unit.

    Additional points must be considered when mounting the unit:

    Vibration free environment Protection against hazardous environments Protection against dust and humidity

    Please avoid to mount other components in distance of 100mm around the controller as the cooling system can be affected.

    The housing design according to IP 54 (Option) can be fixed in places which are not protected from dust and humidity.

    Wiring the device:

    The mains connections L1, L2, L3, (N) have to be connected by using a disconnecting switch and usual fuses.

    The connection for mains cable and the connections for controlling have to be laid in channels and protector tubes.

    The electric installation always has to comply with the essential protection requirements of the Eu-ropean Low Voltage Directive 2006/95/EG and Electromagnetic compatibility Directive 2004/108/EG.

    S1

    S2U Last 100%

    U Load 100%

    (rt)

    (or) Run

    Betrieb Ready(gn)

    (gn) Start

    St u g r n

    Aussteuerung

    Level

    2,5

    5

    100

    7,5

    Sek

    TAnlauf

    Tim-e

    Ramp up

    Fault

    50-100mm

    50-100mm

    Tyco-3Ph

  • | 4

    RS Elektroniksysteme GmbH - Thyristor controller Tyco-3Ph, Tyco-3Ph/SP

    3. Operation

    To begin with, all electronical connections have to be established according to the circuit diagrammes L1, L2, L3, (N), T1, T2, T3.

    The thyristor control has to be connected to the mains according to the electric regulations (Low Voltage Directive) so that they can be separeted by disconnecting switches (e.g. load interrupter, contactor etc.) from the mains. Cabling must be performed by personnel who are qualified to work low voltage electrical equipment. Before any connection or disconnection, make sure that the power and control cables and wires are isolated from the voltage sources.

    Recommended connection:

    The mains connections, the connection to the load and the control connections have to be laid in separate cables.

    In order to avoid faults the electronic control connections should be separated from the power wires and/or contactor control wires and one should twist the control wires.In order to reduce risks related to the effects of electromagnetic interference depending on the in-stallation of the product please consider the rules for electromagnetic compatibility.

    Fuses:

    The net-lateral security depends on the recommended and/or the used cross-section of a wire and has to be made according to DIN 57100 part 430/VDE 0100 part 430/6.81 (Low Voltage Directive).

    Common information:

    Thyristor units for phase angle (Tyco-1Ph... and Tyco-3Ph...) are produced to control resister and inductive loads. The controlling of the devices is achieved by using continuous signals (0-10V or 0-20mA). The phase control angle and/or the switch on-off relation at multicycle control (Tyco-1Ph/SP... and Tyco-3Ph/SP...) will be continuously controlled by the control unit in order to receive a suf-ficient linearity between thyristor controller input and power output.Apart from these series we also produce three-phase thyristor units, which cover the upper current range to 1600A. These devices are also available within a short time.

  • | 5

    RS Elektroniksysteme GmbH - Thyristor controller Tyco-3Ph, Tyco-3Ph/SP

    4. Meaning of the clamp connections

    Clamps Function State Description of the functions1-2 start closed controlling activated

    open stand-by, ready for operation3-4 reset (key) actuated reset faults (e.g: over-temperature,

    PTC-input, phase failure, low volt-age)

    5-6 PTC-input switch off of power unit on overload (release of PTC or bridge is open)

    bridge connection without PTC-sensor

    7 Ucontrol-input 0-10V, 0-20mA, 2,5-10k(supply: Ground, Cl. 8)

    input of voltage and current signal and potentiometer adjustment

    8 ground (GND) for using of current, voltage, inverse, PWM and potentiometer input

    9-10 inhibited closed output voltage on T1, T2 T3open inhibit of power unit

    11 inverse input 10-0V(supply: Ground, Cl. 8)

    input of inverse voltage signal (op-tion)

    12 PWM-input 5V/5-10kHz input for impule signal (vt = 0-1)13-14-15 fault relay output 13-14 closed switching at fault16-17-18 relay output S2 16-17 closed switching at 100% ULoad19-20-21 relay output S1 19-20 closed switching if voltage at T1, T2, T3 >

    0V22-24 auxiliary voltage 230V/50-60Hz internal voltage supply23 not connected

    1 2 3 4 5 6

    13 14 15 16 17 18 19 20 21 22 23 24

    Uref (10VDC)

    10V-0V

    (invers)

    PWM

    Start Reset

    n.c.

    Ust

    0 ... 10 V

    0 ... 20 mA

    7 8 10 119 12

    Switch

    (Ri)

    2,5...10kOhm

    1 2 3 4 5 6

    13 14 15 16 17 18 19 20 21 22 23 24

    Uref (10VDC)

    10V-0V

    (invers)

    PWM

    Start Reset

    n.c.

    Ust

    0...20mA

    0...10V

    7 8 10 119 12

    Switch

    (Ri)

    2,5...10kOhm

    SP

    PH

    Switch

    (U)

    Option: /UMSwitching mode (phase an-gle or multicycle control) by the help of Switch (U)

  • | 6

    RS Elektroniksysteme GmbH - Thyristor controller Tyco-3Ph, Tyco-3Ph/SP

    5. Description of the front side

    LED 1

    green ready for use as soon as auxiliary voltage is on terminals (22-24)

    red lights at fault and outputs T1, T2, T3 will be switched off

    LED 2(S1)

    green lights as soon as connection 1-2 (start) are bridged

    orange lights as soon as voltage on T1, T2, T3 > 0V

    LED 3(S2)

    yellow lights as soon as load voltage has reached 100%

    LED 4 yellow lights depending on the level of the load volt-age

    Tramp upserves for adjusting the ramp-up time 0-10s (on PWM-controlling: 0-10s)

    ~ ~

    Uload

    Start

    Uload

    100%

    S2

    S1 orange

    S1 green

    Run

    tan

    100 %

    switching function S1 was accomplished (connectors S1 and LED 2 (S1) (orange) are activated at the same time)

    switching function S2 was accomplished (connectors S2 and LED 3 (S2) are activated at the same time)

    S1

    S2U Last 100%

    U Load 100%

    (rt)

    (or) Run

    Betrieb Ready(gn)

    (gn) Start

    r nSt u g

    Aussteuerung

    Level

    2,5

    5

    100

    7,5

    Sek

    TAnlauf

    Time

    Ramp up

    Tyco-3Ph

    Fault

  • | 7

    RS Elektroniksysteme GmbH - Thyristor controller Tyco-3Ph, Tyco-3Ph/SP

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  • | 8

    RS Elektroniksysteme GmbH - Thyristor controller Tyco-3Ph, Tyco-3Ph/SP

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  • | 9

    RS Elektroniksysteme GmbH - Thyristor controller Tyco-3Ph, Tyco-3Ph/SP

    6. Meaning of the control inputs

    Controlling with voltage signal:

    Switch (Ri) set 0-10V (Ri>50k)

    Clamp:7 input signal (0-10V) 8 GND

    Controlling with current signal:

    Switch (Ri) set 0-20mAClamp:

    7 input signal (0-20mA )8 GND

    Controlling with potentiometer 2,5-10k:

    Switch (Ri) set 0-10V (Ri>50k)

    Clamp:

    2 reference voltage (10V, supply volt-age for potentiometer)

    7 sliding contact8 GND

    Controlling with inverse signal (option):

    Switch (Ri) set 0-20mA

    Clamp:11 signal input 10-0V8 GND

    Controlling with PWM:

    Switch (Ri) set 0-20mA

    Clamp:12 signal input 5V, 5-10kHz8 GND

    Annotation: When using PWM controlling the ramp-up time can be set within the interval of 0-10s.

  • | 10

    RS Elektroniksysteme GmbH - Thyristor controller Tyco-3Ph, Tyco-3Ph/SP

    7.

    Bas

    ic c

    ircu

    its

    L1

    L1

    L3

    L3

    L2

    L2

    NN

    PE

    PE

    F1

    F2

    Load

    or

    or

    or

    F1

    F2

    Load

    N (connection for neutral point)

    Attention!

    If the star point of the load is

    connected with the neutral wire

    the type

    Tyco-3Ph/N... and Tyco-3Ph/SP/N...

    must used.

    * For isolate you can use plug connection, fuses, circuit-breakers, load-breakers

    and residual current devices (RCDs). Contactor, however, can be used only

    in exceptional cases and due to isolate.

    **

    or:

    or:

    T1

    T1

    PE

    PE

    T2

    T2

    T3

    T3

    L1

    L1

    L2

    L2

    L3

    L3

    24

    24

    22

    22

    (N)

    (N)

    (L1)

    (L1)

    Tyco-3Ph...

    Tyco-3Ph/SP...

    Tyco-3Ph/N...

    Tyco-3Ph/SP/N...

  • | 11

    RS Elektroniksysteme GmbH - Thyristor controller Tyco-3Ph, Tyco-3Ph/SP

    7.1 Basic circuit for Tyco-3Ph... or Tyco-3Ph/SP with controlclamps

    L1

    L1

    L3

    L3

    L2

    L2

    N

    N

    PE

    PE

    T1

    T1

    T2

    T2

    T3

    T3

    L1

    L1

    L2

    L2

    L3

    L3

    PE

    PE

    F1

    F1

    F2

    F2

    Tyco-3Ph...

    Tyco-3Ph/SP...

    Tyco-3Ph...

    Load

    Load

    Controlclamps

    Controlclamps

    *Only if required

    *Only if required

    *

    *

    *

    *

    1

    1

    2

    2

    3

    3

    4

    4

    5

    5

    6

    6

    13

    13

    14

    14

    15

    15

    16

    16

    17

    17

    18

    18

    19

    19

    20

    20

    21

    21

    22

    22

    23

    23

    24

    24

    Uref (10VDC)

    Uref (10VDC)

    Start

    Start

    Reset

    Reset

    Lock

    Lock

    S1

    Run

    S1

    Run

    S2

    100% Output

    S2

    100% Output

    Fault Relay

    Fault Relay

    (L1)

    (L1)

    n.c.

    n.c.

    (N)

    (N)

    switchable

    to SP

    PTC-

    Input

    PTC-

    Input

    2,5...10kOhm

    2,5...10kOhm

    0...10V

    or

    0...20mA

    0...10V

    or

    0...20mA

    0V

    0V

    10V-0V

    (invers)

    10V-0V

    (invers)

    PWM

    PWM

    Ust

    Ust

    Switch

    (Ri)

    Switch

    (Ri)

    Switch

    (U)

    7

    7

    8

    8

    10

    10

    11

    11

    9

    9

    12

    12

    Device version: Switchable between Tyco-3Ph... and Tyco-3Ph/SP...

    or

    or

    or

    or

    or

    or

    0...20mA

    0...10V

  • | 12

    RS Elektroniksysteme GmbH - Thyristor controller Tyco-3Ph, Tyco-3Ph/SP

    8. Survey of the individual types

    Type

    *

    Max

    . loa

    d cu

    rren

    t [A

    ]

    Rec

    . sem

    i-co

    nduc

    tor

    fuse

    s [A

    ]

    Mai

    ns fu

    se

    [A]

    Rec

    . cro

    ss-

    sect

    ion

    [mm

    2 ]

    Max

    . pow

    er

    [kW

    ]

    Wei

    ght

    [kg]

    Dim

    ensi

    ons

    WxH

    xD [m

    m]

    Tyco-3Ph 05 5 10 16 1,5 3 1,45 109x200x140**Tyco-3Ph 15 15 25 25 2,5 10 1,65 139x200x140Tyco-3Ph 25 25 30 35 4 16 1,85 139x200x140Tyco-3Ph 35 35 40 50 6 23 1,95 139x200x140Tyco-3Ph 50 50 60 63 10 33 1,95 139x200x140

    Errors and technical modifications excepted (Date: 2012/01)

    * The given details also apply to the version with multicycle control Tyco-3Ph/SP...

    ** without external fan

    The given values refer to the operation voltage of 3x400V AC. The values given for overload refer to a surrounding temperature exceed of max. 50C and an installation altitude of 1000m. Semiconduc-tor fuses can be ordered optionally.

    fan

    55

    109

    139

    200

    180

    =6

    =6

    fan

    W D

    H

    W

    H

    D

  • | 13

    RS Elektroniksysteme GmbH - Thyristor controller Tyco-3Ph, Tyco-3Ph/SP

    9. Technical data

    Tyco-3Ph 05

    Tyco-3Ph 15

    Tyco-3Ph 25

    Tyco-3Ph 35

    Tyco-3Ph 50

    Voltage of power circuit 400V AC +/- 15% (optional: 110V, 230V, 500V)Rated controller current 5A 15A 25A 35A 50AAuxiliary voltage 230V AC (optional: internal auxiliary voltage)Frequency 45-65Hz, self-synchronizing

    Input

    0-10V 0-20mA potentiometer: 2,5-10k 10-0V inverse input (option) 5V/5-10kHz input for PWM

    Input resistance switchable input resistance: 500, 50k

    Protetction system phase failure control and temperature exceedance control (red LED Fault and switch-off)LED-Display operation, Start, Run, 100% ULoad, Fault, levelPossible adjustments ramp-up time: 0-10s, on PWM controlling: 0-10s

    Control outputs

    fault condition: ter. 13,14 closed; Load: 2A, 230V AC, AC1;

    S1-relay output: ter. 19,20 closed; Load: 2A, 230V AC, AC1;

    S2-relay output: ter. 16,17 closed; Load: 2A, 230V AC, AC1;

    Power terminals L1, L2, L3 input voltage T1, T2, T3 output voltageKind of controlling phase angle (optional: multicycle control)Power loss 1,1W/AOperating temperature 0-50CStorage temperature -10-70CHumidity 5-95% relative humidity, not condensingEnviroment dry and non-conducting environmentsMax. altitude 1000mWeight 1,45kg 1,65kg 1,85kg 1,95kg 1,95kgProtection IP 40Installation vertically, power terminals belowDimensions (WxHxD) 109(with fan 139)x200x140mmMounting for screw mounting in a housing

    CE-markingDECLARATION OF CONFORMITY: 2006/95/EC (low volt-age directive), EMC Directive: 2004/108/EC for industrial environments

    Regulations VDE 0160, EN 60204Errors and technical modifications excepted (Date: 2012/01)