West Control Solutions PMA Relay C, User Manual

Page 1: ...Rev 01 2019 PMA C3 60 210A Relay C 3PH from 60A to 210A User Manual www west cs co uk ...

Page 2: ...ations the actual scope of delivery may vary from the descriptions and drawings in this manual For questions please contact the manufacturer Before starting to work with the instrument and before commissioning in particular these operating instructions must be read carefully The manufacturer cannot be held responsible for damage and trouble resulting from failure to comply with the information giv...

Page 3: ...ion 21 10 1 Dimensions and weight 22 10 2 Fixing holes 22 11 Wiring instructions 23 11 1 Terminal Positions 23 11 2 Power Terminals 23 11 3 Control Terminals 24 11 3 1 Terminal block M1 24 11 3 2 Terminal block M3 24 11 4 Schematic 25 11 4 1 SSR Control Input Schematic 26 11 5 Connection Diagram for 3 phases 27 12 Control Panel 28 12 1 Menu navigation 29 12 2 Control Panel Led 30 12 3 Displayed al...

Page 4: ... Window 49 13 6 6 Data Log Configuration window 49 13 6 7 MSG view 50 13 6 8 Settings window 50 14 Firing type 51 14 1 Zero Crossing 51 14 2 Single Cycle 51 14 3 Burst Firing 51 14 4 Soft Start with Burst Firing 52 14 5 Phase Angle 52 14 6 Soft Start with Phase Angle 52 14 7 Delay Triggering with Burst Firing 53 15 Current Limit 54 15 1 Current Limit Setting 54 15 2 Current Limit tuning procedure ...

Page 5: ... triangle precedes an electric shock hazard CAUTION or WARNING safety statement Warning or Hazard that needs further explanation than the label on unit can provide Consult User s Guide for further information Unit is compliant with European Union directives See Declaration of Conformity for further details on Directives and Standards used for Compliance If available unit is a Listed device per Und...

Page 6: ... protective covers without first disconnecting and preventing power from being restored while servicing the unit WARNING Do not use in aerospace or nuclear applications WARNING The power controller s protection rating is IP20 with all covers installed and closed It must be installed in an enclosure that provides all the necessary additional protections appropriate for the environment and applicati...

Page 7: ...C filter across contactor coils relays and other inductive loads NOTE Provide a local disconnect to isolate the power controller for servicing NOTE The nominal current is specified for ambient temperatures at or below 40 C Ensure the application design allows for adequate cooling of each power controller The power controller must be mounted vertically The cooling design must prevent air heated by ...

Page 8: ...clean the heat sink and the protective grill of the fans The fre quency of this servicing depends on environmental pollution Also check periodically if the screw for the power cables and safety earth are tightened correctly See Connection Diagram www west cs co uk 8 ...

Page 9: ...ds that change resistance with temperature and with age 3 1 Advantages compared with analog thyristor unit Communication RS485 is a standard feature of Relay C this allows the use of many information like current power load state and all the parameters for diagnostic and configuration Ulterior advantages of the digital system vs the analogical is the flexibility and the possibility of implement sp...

Page 10: ...nd expenses Control modes contactor voltage current or power Satisfies a wide range of demanding thermal applications Load firing modes zero cross burst fire phase angle soft start single cycle delayed triggering Handles a wide range of load types including nichrome medium and long waveform infrared lamps moly transformers silicon carbide UV lamps and tungsten Protects and extends the life of conn...

Page 11: ...ration Anyway we suggest to check the unit on the machine with the Test unit section For install the software launch the program and follow the instructions on the screen Run the software configurator and set the correct serial port number by menu setting Serial Port port number To connect the unit at the PC it s necessary to use the micro USB 2 0 Modbus RTU cable USB connection need a driver to w...

Page 12: ...s on this manual verify that there isn t a short circuit on the load 4 Supply the auxiliary voltage of the unit in the Set menu Set the parameters Operative Load Voltage and Nominal Current of the load using the frontal keypad or Thyristor con figurator software The auxiliary voltage supply of the Relay C unit must be synchronized with load voltage power supply If the Auxiliary Voltage written on ...

Page 13: ...C 3PH V Nominal voltage of the load I Nominal current of the load P Nominal power of the load Delta wiring with resistive load control on two phases with PMA Relay C 3PH V Nominal voltage of the load I Nominal current of the load P Nominal power of the load I P 1 73V I P 1 73V V V www west cs co uk 13 ...

Page 14: ...s If the product has a fault please contact the dealer from which you purchased the product The identification s label gives all the information regarding the factory settings of the Thyristor unit this label is on the unit like represented in figure Verify that the product is the same thing as ordered www west cs co uk 14 ...

Page 15: ...6 690 Vac 540 to 759 Vac 7 INPUT SSR S 0 20 mA B 4 20 mA A 0 10 V DC V 10 kΩ potentiometer K FIRING START OPTION Burst Firing BF No soft start B Linear Soft Starter J Phase Angle No Soft Start P Linear Soft Starter E Delayed Triggering No Soft Start D Zero Crossing No soft start Z Linear Soft Starter R CONTROL MODE Open Loop O Voltage U Voltage Square U Q Current I Current Square I A Power U x I W...

Page 16: ...ction totalizes the energy consumption of the load allowing the calculation of heat treatment 1 Since the supply voltage of the electronics is used for synchronization it must be in phase with the load voltage LOAD TYPE Normal Resistive Load with 3 Phase Star with neutral Connection 0 Normal Resistive Load with 3 Phase Delta Connection 1 IRSW Infrared Short wave with 3 Phase Star Connection with n...

Page 17: ...atures Analog Input V 0 to 10 Vdc impedance 15 kΩ Analog Input I 4 to 20 mA Impedance 100 Ω Potentiometer 10 kΩ min Digital Input 4 to 30Vdc 5mA Max ON 4Vdc OFF 1Vdc 9 3 Output features power device Current Nominal Voltage range Ue Repetitive peak reverse voltage Uimp Latching current Max peak one cycle Leakage current FUSE I2T value Suggested A2s at500V Frequency range Power loss Thyristor Fuse I...

Page 18: ...c ta Qv total power losses w thyristor fuse power loss ta ambient temperature C tc cabinet temperature C V fan air mass flow m h f altitude coefficient see table on right Altitude 0 100 meters f 3 1 m K Wh 100 250 meters f 3 2 m K Wh 250 500 meters f 3 3 m K Wh 500 750 meters f 3 4 m K Wh The formulas used are for information only and is not a substitute for a proper thermal rating done by a quali...

Page 19: ...ooling on heat sink Maintain the minimum distances in vertical and in Horizontal as represented this area must be free from obstacle wire copper bar plastic channel When more unit has mounted inside the cabinet maintain the air cir culation like represented in figure without obstacle for the air flow Is necessary to install a fan to have better air circulation as calculated previously The V Air fl...

Page 20: ...ype W H D Weight 3PH 60A no Fan 279 mm 269 mm 170 mm 10 2 kg 3PH 90 210A with Fan 279 mm 273 mm 170 mm 10 6 kg 10 2 Fixing holes H1 3PH 60A no Fan 256 3PH 90 210A with Fan 260 W D H 5 5 5 5 5 5 129 5 129 5 H1 www west cs co uk 20 ...

Page 21: ...ly wire ranges AWG wire terminal type ZMVV terminal tightening torque in the table below Power cable torque suggested Type Connector Type Torque Lb in N m Wire Range mm AWG MAX Current Terminals Wire Terminals UL Listed ZMVV 060 090 120 Screw M6 70 8 8 0 16 5 25 3 35 2 150 Fork Spade Terminal Copper Tube Crimp Lug 150 180 210 Screw M8 141 6 16 0 50 0 70 00 90 000 250 Fork Spade Terminal Copper Tub...

Page 22: ...c 4 20mA Analog Setpoint 7 Output 10Vdc stabilized 1 mA MAX 8 Analog Input2 0 10Vdc 4 20mA Reference ext feed back 9 Slave Output 10 Retransmission Output 11 RS485 A 12 RS485 B 13 0V GND 14 C Common contact alarm relay output 15 NO Normally Open contact alarm relay output Thermal or SC HB CL 16 NC Normally Close contact alarm relay output Thermal or SC HB CL Terminal Description F1 Fan supply 230V...

Page 23: ...n external fuse following national electric code guide for resistive heating of 125 load current rating to protect external wires 2 For SSR input connection follow next page schematic MICRO USB 2 0 Analog Inp 1 Analog SetPoint Ethernet M4 Profibus Option Second Serial RS485 Function Thermal SC HB Analog Inp 2 Reference Ext FeeDBack 14 16 15 M1 SLAVE OUT RETRANS OUT 13 9 10 24V 2 Branch Circuit Pro...

Page 24: ...11 4 1 SSR Control Input Schematic For SSR input follow the schematic below and configure Digital Input 1 as Fast enable Analog Input 1 SSR INPUT M1 www west cs co uk 24 ...

Page 25: ...be electrically isolated from the supply this allows the qualified people to work in safety Load Type Delta Star T1 T2 T3 T1 T2 T3 Star Neutral T1 T2 T3 N Open Delta T1 L1 L3 L2 T2 T3 Relay Thermal or SC HB Analog Inp 2 0 10VDC 4 20mA Reference Ext FeeDBack Analog Inp 1 0 10VDC 4 20mA ANALOG SET POINT SLAVE OUT RETRANS OUT 13141516 Fan Supply only from 90 to 210A See order code for the Value www w...

Page 26: ... are used as follows Press To Function Scroll through the parameters on the home page Local Remote Switch between local and remote set point for power demand Up Increment power demand set point when set to local Down Decrement power demand set point when set to local Press and hold for about two seconds to access the menus L R F L R F L R F L R F L R F L R F To view the status parameters Press Fun...

Page 27: ...ssword see the table 5 Press function to enter the password and advance to the first parameter of the menu 6 Press Up to advance tot he next parameter and repeat to reach the desired parameter 7 Press function to start editing the parameter The parameter name flashes in the upper display 8 Use Up and or down to edit the parameter setting 9 Press function to enter the new setting The parameter name...

Page 28: ...Communications Flashing Active communications 4 Alarm On Active alarm Off No alarm Alarm or message Description Heater Break Heater Break Aux High Aux voltage too high Aux Low Aux voltage too low Bakeout Heater Bakeout function active Watchdog Communication Watchdog error Line Loss Line power not detected I Limit Output limited by current limit feature only single phase SD Card Error SD card error...

Page 29: ...ates the average RMS power output 0 to 100 12 Read Only V Input Indicates the average RMS voltage input 0 to 65535 V 47 Read Only Frequency Indicates frequency of the power input 0 to 655 35 Hz 9 Read Only Power Factor Indicates power factor of the output power 0 to 1000 102 Read Only Load Ω Indicates the resistance of the load 0 to 655 35 Ω 46 Read Only I Limit Indicates the maximum percent of th...

Page 30: ...ingle Cycle 2 Burst Firing 3 Phase Angle 4 Burst firing start ramp 19 12 5 Setup Menu This section describes each item on the setup menu Use this menu to configure the power controller for the load The password to access this menu is 2 Parameter Name Description Default Range Unit Modbus Address Par Type I Limit Set the maximum percent of the nominal current that the power control allows This para...

Page 31: ...d power Set the gain for the main loop A smaller proportional band yields a larger adjustment for a given deviation 10 0 to 255 26 Read Write Integral power Set how aggressively the integral part of the control algorithm acts A smaller settings yields a larger adjustment for a given deviation over a given time 50 0 to 255 27 Read Write Prop band current Set the gain for the main loop A smaller pro...

Page 32: ...20 mAdc 3 DEFAULT 0 10V 10k Pot 1 Option Description Value 0 10V 10k Pot 0 to 10 Vdc or 10 000Ω 1 4 20mA 4 to 20 mAdc 2 0 20mA 0 to 20 mAdc 3 DEFAULT 0 10V 10k Pot 1 Option Description Value I Limit Current Limit Set point 0 Feed back External feed back 1 Set Point Power Demand set point 2 DEFAULT I Limit 0 Parameter Name Description Default Modbus Address Par Type Digital In 1 Function Choose how...

Page 33: ...ch conditions the digital output indicates alarm The output always indicate an alarm when the heat sink is over temperature The digital output is energized for normal operating condition and de energized when the power controller is off or when there is an alarm Note The power controller monitors for heater break or short circuit condition only when included in the option selected for Alarm Output...

Page 34: ...to 10 VDC Max Value Set Point 100 4mADC 0 20mADC 100 0mADC 0 20mADC 100 0VDC 0 10VDC 100 100 0 V Output xV where x is the Nominal Line Voltage 4mADC 0V 20mADC xV 0mADC 0V 20mADC xV 0VDC 0V 10VDC xV 999 9 I Output xA where x is the Nominal Line Current 4mADC 0A 20mADC xA 0mADC 0A 20mADC xA 0VDC 0A 10VDC xA 999 9 Power 100 4mADC 0 20mADC 100 0mADC 0 20mADC 100 0VDC 0 10VDC 100 100 Parameter Name Des...

Page 35: ... Par Type Port 1 Baud Choose the baud rate for the primary serial port 2 30 Read Write Option Value 9600 0 19200 1 38400 2 115200 3 DEFAULT 38400 2 Parameter Name Description Default Range Unit Modbus Address Par Type Port 1 Address Set the address for the primary serial port 1 0 to 255 31 Read Write Port 2 Baud Choose the baud rate for the primary serial port 2 45 Read Write Option Value 9600 0 1...

Page 36: ...for a message before triggering the watchdog error 5 0 to 255 Sec 143 Read Write Wi Fi Address Indicate the IP address of the WiFi connection in the power controller 0 to 255 94 95 96 97 Read Only Ethernet Address Indicate the IP address of the power controller with the Modbus TCP or Profinet option 0 to 255 71 72 73 74 Read Only Ethernet Subnet Indicate the subnet mask of the the power controller...

Page 37: ...er the power controller is local or remote set point mode 14 bit1 Read Only Option Description Value Remote Set Point via analog input 0 Local Set Point via keypad or communication 1 Parameter Name Description Range Unit Modbus Address Par Type Analog In 1 Indicates the percent of full scale measured by analog input 1 0 to 100 0 138 Read Only Analog In 2 Indicates the percent of full scale measure...

Page 38: ...1 Read Only Max Current Indicates the maximum current capacity of the power controller 0 to 9999 A 62 Read Only Aux Voltage Indicates the measured line voltage 0 to 1023 V 43 Read Only Serial Number Indicates the serial number of the power controller 0 to 9999 149 150 151 152 Read Only SCR Temperature Indicates whether the SCR is below or above the factory set trip point 127 Read Only Option Descr...

Page 39: ... possible inspect it before applying power NOTE the power of the USB port is limited and not designed to power industrial cards so it manages to feed only the essential parts of the electronics For complete control you need to power up the auxiliaries of the power controller 13 3 Recipes A recipe is a file that store the settings of power controller internal parameter Is used to save a power contr...

Page 40: ...orts COM LPT looking for the COM port named LPC USB VCOM Port COMx where x is the port number In the configurator software open the software without connect the unit and see the available com port on con port window setting close the com setting window connect the USB cable to the power controller wait for the USB driver to install if necessary open the com setting window and see the added com num...

Page 41: ...e Click Save button 13 5 3 To download a recipe file into a power controller 1 Click Simple if not already on the Simple view 2 Click Open existing recipe 3 Locate and select the recipe file and click Open 4 Click OK 5 Click Download to unit 6 Set the address if necessary 7 Click SEND 8 Wait for the software to write the parameter settings 9 Click OK 13 5 4 To monitor a power controller with the T...

Page 42: ...Click Load Analyzer 4 On the Load Analyzer view click Data Log 5 In the Data Log window ensure the slider is set to Log Enabled 6 Click Set Time 7 If necessary Set the date and time and close the date time window 8 Set Log Time to the number of seconds between records 9 Click Connect 10 Click Config 11 Click Load Configuration to view the current list of logged parameters 12 For up to ten paramete...

Page 43: ...menu Message Log open a serial communication message view About displays the About dialog with the program name and version and contact information Instruments selector Select the right instrument to use HOME the default view Relay C open the Simple and Test views for a single phase power controller Relay C 3PH access the Simple and Test views for a three phase power controller MSG opens a serial ...

Page 44: ...wnload to unit option 13 6 3 Test Section This section is used to monitor and adjust the operation of the power controller in real time using RS485 or USB communication port After select the model is possible access to this section clicking the TEST tab below the main menu Operating on TEST Section Online button is the button to start or stop communication updates with the power controller After c...

Page 45: ...ttons setup options Firing view and set the firing type and the associated parameters Feedback view and set feedback type Communication view and set communication options for ports protocols and fieldbus Configure and monitor the analog inputs Analog Input 1 click Ai 1 to view the signal type Input Local Remote selection button click to toggle between using the signal received at analog input 1 re...

Page 46: ... click to open the Data Log window The History options to control the movement of the chart Scroll left click move the chart left to view more recent data Stop Play click toggle the live view or Hystorical view of graphic signal Scroll right click move the chart right to view older data The Actions to Clear to clear the data from the graph Save to save a JPEG image of the Load Analyzer window with...

Page 47: ...ases the selected file from the power controller Close closes the Data Log window and close the log mode on power controller 13 6 6 Data Log Configuration window Data log configuration window is used to view and set the parameter log table Close closes the window Load Configuration refresh and displays the list of parameters being logged Logged parameters list the parameters configuration table Pa...

Page 48: ...he Configurator software Language Available Languages choose the language used in the program NOTE to be active the language change need close and open again the configuration software Serial Port Set the serial port parameter Test click to test for communication with a power controller via the selected port Port select the computer s COM port to use to communicate with power controllers Baud rate...

Page 49: ... 25 the output is one cycle ON and three cycles OFF With input signal at 50 the output is one cycle ON and one cycle OFF With input signal at 75 the output is three cycles ON and one cycle OFF With input signal at 76 the output is the same of 75 but for each ON cycle the microprocessor divides 76 75 and when the sum of rests is one the unit does one more cycle ON For this firing is necessary to ha...

Page 50: ...ol of the power on the load for this firing the thyristor can be in conduction only for a part of the voltage cycle This part of the voltage cycle is adjustable in function of the input signal from 0 at 100 The PA firing is normally used for control the inductive loads and is also possible control a primary of transformer coupled with the cold resistances like Superkanthal Molybdenum Platinum Tung...

Page 51: ...to zero projected on the X axis the unit switch On In this case the instantaneous value of the currents are i1 i2 and i3 and this condition for the curve of magnetization could generate transient over currents that can blow the fuses With Delay Triggering the firing of the thyristor are triggered with a delay until the instantaneous value of the current i1 0 i2 positive and i3 negative like repres...

Page 52: ...nt Limit is setted with analog input 2 Terminals 11 e 4 This analog input is 0 10V and input impedance 10Kohm The settings functions by the analogic input 2 is called also External current limit profile because allows to change the profile of the Current Limit during the process Caution this procedure must be performed only by qualified persons 15 2 Current Limit tuning procedure Give the power su...

Page 53: ...the heater and prevent blown heaters and fuses 16 2 How does heater bakeout work During heater bakeout the Power Unit slowly increases voltage to the heater while monitoring the output current If the heater achieves full output before the bakeout time expires then the heater is dry and can be put into service If the output current reaches a user specified trip point during the bakeout as it would ...

Page 54: ...n of the incoming line supply I Current feed back The input signal is proportional to the current output This means that input signal becomes a current demand This control mode maintain the current also if the load impedance changes P VxI Power feed back The input signal is proportional to the power output This means that input signal becomes a power demand The power remains constant also if volta...

Page 55: ...ransformer depends of the chosen Voltage in the order code Attention never link all the jumpers JP1 JP2 JP3 at the same time or JP3 any other jumper JP3 must be always alone follow only the configuration shown Order Code As ordered Change to Jumper JP1 JP2 are linked Link only Jumper JP3 Transformer range Line voltage Transformer range Line voltage RC3_ _ _ _1 90 135V 100 120V 180 265V 200 208 220...

Page 56: ...rt may be done a network up to 127 Relay C M4 Terminal Description 1 24V 2 GND 3 Not connected 4 RS485 A 5 RS485 B 20 Fieldbus communication option Other serial communication port are available as option see Communication Manual for details Ethernet Configuration Profibus Configuration Second Serial 485 Configuration Connectors M4 www west cs co uk 56 ...

Page 57: ... 20400 150 20 559 20 200 200 660 17500 25000 180 20 559 20 250 250 660 30800 44000 210 20 559 20 315 315 660 53900 77000 Caution High speed fuses are used only for the thyristor protection and can not be used to protect the installation Caution The warranty of thyristor is null if no proper fuses are used See tab Warning When it is supply the Thyristor unit is subject to dangerous voltage don t op...

Page 58: ...d remove the screws then replace it with the correct fuse use the screws with a proper suggested torque indicated below Type Screw Torque Lb in N m Screw Torque Lb in N m 60 120A M6 44 2 5 0 M5 31 3 5 150 210A M6 44 2 5 0 www west cs co uk 58 ...

Page 59: ...west cs cn Website www west cs cn Telephone 86 400 666 1802 China Email fr west cs com Website www west cs fr Telephone 33 171 84 1732 France Contact Email enquiries west cs com Website www west cs co uk Telephone 44 0 1273 606271 Address The Hyde Business Park Brighton East Sussex BN2 4JU United Kingdom UK UM RC362 1 UK 1902 West Control Solutions is part of the Fortive Corporation Specifications...