TS-1
TPC Cataloge
Products guide-2001
T P C
Thyristor Power Controller
SCR-UNIT
Technology Star Electronics CO.,LTD
#35-207 1364 Jung Wang-Dong Shiheung-City Kyung Ki-Do Korea
Tel: 82-031-430-5231/3 Fax: 82-031-430-5233
Home Page :
E-mail :
The Technology Star Electronics Co., Ltddesigns and buildsTPC SCR-Unit to the highestStandards in the industry. Proper Installation and Maintenance is necessary in order to realize Optimum Utilization of Equipment and Maximum Productivity.
Model Identification
T P C—3 2 2—2 0 0
200A
220V
3 phase(1: 1 phase)
Thyristor Power Controller
Basic Specifications of TPC SCR-Unit
Type / Three Phase(3 ) SCR Single Phase(1 )SCR.Application / Heater control.
Input voltage / 3 Unit and 1 Unit : 220/380/440V.
Others: on customer’s specs.
Frequency / 50 and 60 Hz. @ Single Phase Unit adopts the combined use.
Current / 25, 35, 40, 60, 70, 90, 110, 130,150, 200, 250, 300, 350, 400, 500, 600, 800 AND 1000A.
Ambient / -25~60 [℃], Humidity: RH≦90% (without dew).
Load / Heater: resistive Transformer: inductive
Control / Phase Control ( Local/Remote operation).
Control input / a. ON/ OFF(H-L). b. Voltage input signal:1.5v(1.5KΩ). c. Current input signal: 4~20mA( ≧250Ω).
Output range / 0~97% in Input.
Alarm /
- Over-current. b. disconnection of the Load
Start/stop / Soft Up and Soft Down.
Cooling / Heat sink Temp.: ≦60[℃]:self-cooling, ≧60: fan cooling
Isolation / 220V: 2000V, 380/440v: 2500V at short of main circuit
Isolation Resistance / 25 MΩ(DC 500V MEGGER)
General Characteristics
It can achieve a permanent operation because of a non-contact.
It can precisely control the temperature because of the high speed feedback.
It can perform the fully automatic temperature control because of the easiness of continuous
ON/OFF program control.
It is not electrical hazard because of complete safety protection
It is more compact than previous version and increases the feedback speed and ripple ratio with
composing of bi-directional SCR.
It can achieve a simple operation and maintenance, and installs the control parts outside for
a free operation between Local and Remote.
It alarms at high temperature of the Heat sink by installing temp. sensor on its surface.
@ Temp. sensor is not applied to 1 SCR-Unit. @ It is recommendable to install the exhaust fan inside the panel.
Overall Inspection
Confirmation
Prior to installation of the Unit, please inspect the Unit and confirm as below.
Is it fully complied with the ordered specifications ? mainly on the power voltage rating and
its capacity.
Are there any damaged parts in the Unit ? please keep in mind it may happen on the way
of delivery.
Cautions
When the Unit is installed in the panel it is recommendable to install the exhaust fan inside
the panel in order to maintain a proper Temperature and humidity.
Be careful of High Speed Fuse or SCR not to be damaged by an improper isolation at loads or
the short between the phases.
Distribute the respective phase load uniformly when loads(when unbalance is over 30 %, S.L
LED turns on).
Check the properness of input voltage when input power to the Unit.
Function of the Unit
Function of Over- Current Detection
The Unit adopts the electronic Over – Current Detection Circuit (EOCR) and its range is set by
Load-amp. Volume. In case the current over the setting value flows to the Unit, EOCR activates
and stops the gate signal of the Unit to turns it off, while O.C LED turns on at the panel on the
Unit and also the internal relay activates then enables the Alarm circuit.
In order to normalize the Unit , please turn power S/W off and then push the Reset Button.
( display of cycle ) (internal relay contacts)
1.5 C B A (alarm circuit terminals)
1.0 @contact cap.: AC 250V 2A
0.5 normal abnormal
sec CA open close
100% 200% CB close open
vs. O.C setting value
@ Load-amp Volume is set properly according to the load so as to completely protect the SCR and
heater from damages.
Function of maximum load setting
Maximum load can be set by Max amp Volume controller and is automatically and safely
controlled without any increase of voltage and current capacity even at a overload. Further
it has Local and Remote control function which can externally set and operate.
Alarming Function at the failure of the Input power and Load Phase
In case the phases failure by the bad connections of Loads, impact or troubles in 3 SCR-Unit,
the detection circuit alarms by turning S.P LED on at the Input failure and doing S.L LED Load failure
Function of the Soft Start
The Unit can protect the flicker phenomena on the
(conventional type) (TPC-Unit) Output by managing an momentary peak current to the
transformer and by controlling ON and OFF very softly
at high load capacity.
The Soft Start Time is limited to 5 seconds to protect
SCR of the Unit from damage.
action time(T) action time(T)
@ starting time
High temp. Alarming Function of the Heat sink( for 3 SCR-Unit )
The temp. sensor detects a abnormally high temperature of the Heat sink and enables the O.T
Alarm Circuit to activate.
Operating Instructions
Check points
Are not there any damages and mistakes in connections of the Loads?
Are not there any damages and mistakes in isolation between the phases and case?
Is the voltage of the input power complied with the design requirements of the Unit?
Preparation for opration
Set the Auto/Hand S/W at “Hand”.
Set the Local/Remote S/W at “Local”.
Be sure the Run S/W at OFF.
Set Max-amp Volume at minimum.
Set Load-amp Volume at 90 %.
Turn on the relative NFB( Non- Fuse Breaker) of the Unit.
@ The setting of Over-Current Norm : When Load is normal. decrease the Load-amp Volume slowly
until O.C LED turns on, then set the O.C setting value at 10% higher than the Norm. The O.C
setting value is same in both of Hand and Auto operation.
Operation
“Hand-Local’ operation
-Turn the Run S/W on of the Unit and set Local/Remote S/W at the “ Local “ ( in case “ under 50A” of
the 1 SCR-Unit ).
- At the same conditions as performed by “Preparation for operation” above, increase the Max-amp
Volume slowly until it gains a proper heater Load.
-Be sure that the Output voltage is same as that of the Input voltage when the Max-amp Volume is
-At Maximum.
‘Hand-Remote’ operation
-Turn the Run S/W on of the Unit and set the Local/Remote S/W at the “Remote” ( incase “under50 A”
-Turn the Run S/W off on the panel. If it is not installed there or it is malfunctioning , turn the Run S/W
inside the Unit
-Control the Load with the Volume controller (B10 k) on the panel. If it is not there or is malfunctioning ,
-
set the Local/Remote S/W inside the Unit at the “Local” and then control the Load with the Max-amp Volume
( in case “under 50A of the 1 SCR-Unit)
“ Auto-Local “ operation
- Set the Auto/ Hand S/W at the “ Auto ” ..( in case “under 50A of the 1 SCR-Unit)
- and set the Local/Remote S/W at “Local“.( in case “under 50A of the 1 SCR-Unit)
- Confirm the correctness and properness of the cable connections of TIC4~20mA.
- Turn the Run S/W on of the Unit and set the Max-amp volume suitable for the Load.
- It is automatically operated by TIC4~20mA.
“ Auto-Remote” operation
-Set the Auto/Hand S/W at “Auto” and set Local/Remote S/W at the “Remote”.
- Turn the Run S/W off of the Unit and turn the Run S/W on the panel. If it is not there or it is malfunction-
ing, turn the Run S/W on inside the Unit.
- Control the Load with the Volume controller(B10 k). If it is not there or it is malfunctioning, set the
Local/Remote S/W of the Unit at the “Local” and control the Load with the Max-amp Volume controller.
- It is automatically operated by TIC 4~20mA.
3(Three Phase)SCR-Unit
Structure and Size
Structure Size
Size(mm)Current(A) / W / H / D / L / A / B
25--40 / 190 / 360 / 185 / 290 / 130 / 290
50~110 / 190 / 410 / 220 / 360 / 130 / 360
130~150 / 260 / 440 / 220 / 390 / 200 / 390
200~250 / 275 / 500 / 240 / 450 / 200 / 450
300~450 / 420 / 540 / 240 / 490 / 200 / 490
500~600 / 420 / 640 / 260 / 590 / 250 / 590
800~ : On customer’s specs
Remarks; This specs can be varied by design & MODIFICATION
Troubleshooting of 3 SCR-Uhit
In case S.P LED turns on
When the High Speed Fuse is intercepted.
By the Resistive Load.
-Check the disorder at the Loads. Usually about 100% troubles are occurred by this reason.
-Check the Phases connections at the Output(U.V.W).
-Check the isolation between the Output and case.
By the Inductive ( Transformer) Load.
-By the noise at the Input and a momentary power failure.
-When the wrong PCB, but it is rare.
When the Control Fuse is intercepted.
Check the Control Transformer of the Unit.
Check the isolation ofPCB Gate Driver.
Check the Operability of the Cooling Fan.
In case O.C LED turns on
When the Load-amp Volume is so low.
Check the isolation between the Phases and case.
Check the short between Phases.
@ It can turns on even on the way of Soft-Start of the Unit.
Check the functioning of the Load-Amp Volume.
@ When the O.C LED turns on, the Output stops and the Alarm Relay activates.
In case S.L LED turns on.
Check the connections between the Phases, and the difference of the Output current
between the Phases
Check if the CT(Current Transformer) is properly functioning or not.
@ When the S.P LED turns on, the Output fluctuates unevenly.
When the Output is abnormal.
Check the connection of TIC 4~20mA is normal if the Output is zero at 98% of Load at “Hand”
Perform a auto-tuning when the Temperature difference exceeds 5℃.
or “Auto” operation.
@ Recommendable to do the Auto-tuning at low temperature.
An improper fan-cooling may cause the Heat sink temperature exceptionally high and the SCR
of the Unit damaged.
In case the PCB troubles, the Output may fluctuate. The major reason of the PCB troubles is
caused by the SCR burnt or aged, which can be occurred from the frequent heater failures
and the current leakage.
Push the Reset Button after checking the system whenever above LEDs turned on.`
Standard connection of 3 SCR-Unit
@ Hand(ON/OFF type)(Internal volume) @Hand(ON/OFF type) (External volume)
@ Auto(4~20mA Type) @ Auto(4~20mA type)
(Internal volume) (External volume)
Internal connection of 3 SCR-Unit
1(Single Phase) SCR-Unit
Structure & Size
@ Structure @ Size
Size(mm)Current(A) / W / H / D / L
~50 / 120 / 210 / 125 / 150
70~110 / 120 / 310 / 180 / 250
130~200 / 120 / 360 / 210 / 300
250~300 / 145 / 410 / 230 / 350
350~500 / 145 / 500 / 230 / 440
600~ / On customer's specification
@ Products for 50A or higher have same structure
& size as those of Three Phase SCR-UNIT.
Control Parts and Function
Term / FunctionControls
SFT: Data Setting Button (option) / It is used to set the initial control current or voltage.PWR : Power LED / It turns on when the power is ON.
OC : Over-Current LED / Red : at Over-Current, Green :at disconnection of theTIC4~20mA
Yellow : at disconnection of the heater.
MAXAMP :Max. Ampere Vol. Controller / It controls the Load capacity.
LOADAMP: Load Ampere Vol. Controller / It controls the Over-Current setting value.
R & S / main Power Input connection.
U & V / Output connection to Load.
Terminals
Power Run S/W contact. / the contacts for the external ON/OFF.@ For an internal ON/OFF, connect 7and 8 terminals together.
Local/Remote S/W contacts. / 1)Local : contacts for the Load capacity control with the Vol. Controller in the Unit. @Connect the COM & LOCAL together,
2)Remote : contacts for the Load capacity with a Variable Resistor(10k) outside the Unit. @ Connect the COM & REMOTE(Internal)
Auto/Hand S/W contacts.. / 1)Auto : contacts for the Load capacity control with the TIC output.
(4~20mA)@ Connect the COM & AUTO together(Internal)
2) Hand : contacts for the Load capacity control with the MAXAmp
Vol. Controller. @ connect the COM & HAND together.(Internal)
: 4~20 mA contacts. / Contacts of the 4~20 mA contacts for the Load capacity with TIC.
: External Volume contacts. / Contacts for the Load capacity control at outside.
@ The Variable Resistor to be installed on the panel.
Alarm signal contacts. / When the Unit is stopped by the Over- Current & the disconnection
of 4~20mA, O.C LED illustrates & enable the relay circuit activate
to output the signal to the contacts outside.
Note : In case the SCR-Unit over 60A, the “Control Parts and Function “is same as that of “3 phase SCR-Unit”
Special Functions of the 1 SCR-Unit
No.1 S/W ( for below 50A) and No.2 S/W (for above 70A) inside the Unit adopt the “Phase” control
-The OFF switch selects the “Phase” control.
@ When deliver initially, it is installed in the “Phase” control.
No.2 S/W ( for below 50A) and No.1 (for above70A) in the rear side of the Unit adopt the selection function of
Alarm for the heater disconnection.
- The ON switch selects the “Alarm Use” function. - The OFF switch selects the “Alarm Non-use” function.
-The OFF switch selects the “Alarm Non-use” function.
@ When deliver initially, it is installed in the “Alarm Use” function.
The Unit adopts the Alarming function (by green LED illuminated) at the input signal disconnection of the
TIC 4~20mA, but the polarity change of the TIC is not effective on the control function of the Unit. And also
The Unit alarms by the yellow LED illuminated when the heater current differs by 20% or higher than its
Initial value.
The Unit has the automatic changeable function of the cycle between 50Hz and 60Hz.
Troubleshooting
Interception by the High Speed Fuse burnt
When occurred by the resistive load of the heater.
As usually almost 100% of these troubles are occurred by the disorder of heater side, perform as below.
-Check the connection of The Output (U.V) between the phases.
-Check the isolation between the Output and the case.
When occurred by the inductive load of the transformer’
-Check the Noise at the power Input. – Check if the PCB is in some improper.
-By a momentary Input power failure.
Alarm warnings
When the green LED illuminates, check the input connection of 4~20mA
When the red (OC) LED illuminates :
- Check if the minimum Load-Amp Volume is lower than Over-Current setting value or not.
- Check if the isolation between the case and the phases, and the connection between phases are in normal or not.
- Check if the Load-Amp Volume controller is properly functioning.
@ If OC LED turns on, the Output stops alarm relay activates.
If the yellow LED illuminates, check the disconnection of heater and check if the heater Input current is 20%
lower than its initial setting value.
Abnormal Output.
It occurs due to the improper operation. At the auto operation, check if the Output of the TIC 4~20mA
is automatically functioning. And perform an auto-tuning when the temperature difference between the
ON & OFF operation is higher than 5℃. @ Such gap means it is not operated in PID mode control.
It can be derived from a malfunction of the Control Transformer and wrong isolation at PCB Gate Drive.
Also it can be from the improper fan cooling
When the Output is 100% at “ Hand’ or stops at “Auto” operation, check the connection of theTIC4~20mA.
Standard connection of 1 SCR-Unit
Unit lower than 200A
@ Auto(4~20mA) operation @ Auto(4~20mA) operation
(internal volume) (external volume)
@Hand (ON/OFF) operation @ Hand (ON/OFF) operation
(internal volume) (external volume)
Unit higher than 200mA
@ Auto(4~20mA) operation @ Auto(4~20mA) operation
(internal volume) (external volume)
@ Hand(ON/OFF) operation @ Hand(ON/OFF) operation
(internal volume) (external volume)
Internal connection of 1 SCR-Unit