Motor Controllers 3-Phase Analog Power Controller Types RSC-AAM60/RSO ..... * Control and output modules for analogue control of 3-phase induction motors or heaters * Rated operational current: 3 x 10, 25, 50, 90, 110 AACrms * Rated operational voltage: Up to 600 VACrms * Supply voltage range: 10 to 32 VDC * Control current range: 0 to 20 mA/4 to 20 mA * LED-indication for line ON and load ON * Varistor protection Product Description The micro processor based control module RSC-AAM60 is used with output modules RSO... to achieve a voltage controlled soft start/soft stop of 3-phase motors and a possibility for energy reduction when e.g. a fan is running with a variable capacity. This function is achieved by controlling the control module with a current between 4 and 20 mA (0 and 20 mA). The output mod- Ordering Key ule can be selected according to the rated operational voltage and the size of the load. This phase angle controlled soft-start unit can be used for pumps, fans, heaters, lights and many other applications. RSC-AA M 60 Solid State Relay Soft starting/stopping Control module Output module Control input type Multivoltage Rated operational voltage Rated operational current LED indications for line ON and load ON gives a clear status indication. RSO 4050 Type Selection, Control Module Control current Mains Max. operational voltage Type Number 0-20 mA/4-20 mA Multivoltage 600 VAC RSC-AA M 60 Type Selection, Output Module Rated operational voltage 3 x 220 VAC 3 x 400 VAC 3 x 480 VAC 3 x 600 VAC Rated operational current 10 A 25 A 50 A RSO 2210 RSO 4010 RSO 4810 RSO 2225 RSO 4025 RSO 4825 RSO 2250 RSO 4050 RSO 4850 RSO 6050 90 A 110 A RSO 2290 RSO 4090 RSO 4890 RSO 6090 RSO 22110 RSO 40110 RSO 48110 RSO 60110 General Spec., Control Module Control Specifications Operational voltage range Line to line Operational frequency range Supply current @ no output current @ max. output current Supply voltage range CE-marking Approvals Minimum output voltage Output current short-circuit protected 150 to 660 VACrms 45 to 65 Hz < 30 mA < 180 mA 10 to 32 VDC Yes UL, CSA Specifications are subject to change without notice (30.09.2005) Power supply minus 8 VDC 150 mA DC Thermal Specifications Operating temperature Storage temperature -20 to +70C (-4 to +158F) -40 to +100C (-40 to +212F) 1 RSC -AAM60/RSO..... Control Input Specifications Insulation Control Module Control current A-input B-input Input impedance Power supply reset time Response time (input to trigger outputs) Rated insulation voltage Input to trigger outputs 0 to 20 mA 4 to 20 mA 250 300 ms 4000 VACrms 1 cycle Mode of Operation Operation Diagram The control module RSCAAM60 is used with the output module RSO..... to achieve analog control of 3phase induction motors. [%] 100 Heating elements can also be controlled with the RSC/RSO with the use of appropriate filters. 80 60 Urms/Un P/Pn 40 20 [mA] 0 0 4 5 8 10 12 15 16 20 20 Output as a function of control current @cos(o) = 0.9 Soft starting is achieved by increasing the motor voltage in accordance with the input current. Soft stopping is achieved by decreasing the motor voltage in accordance with the input current. When the motor is running idle, the motor voltage can be reduced by lowering the input current, whereby energy is saved. General Specifications, Output Module Operational voltage range Line to line Non-rep. voltage Varistor voltage CE-marking RSO 22... RSO 40... RSO 48... RSO 60... 150 to 250 VACrms 1200 Vp 275 VAC Yes 220 to 420 VACrms 1200 Vp 420 VAC Yes 400 to 510 VACrms 1200 Vp 510 VAC Yes 400 to 625 VACrms 1600 Vp 625 VAC Yes Output Specifications, Output Module Rated operational current AC 51 AC 53a Off-state leakage current On-state voltage drop I2t for fusing t=1-10 ms Critical dI/dt Non-rep. surge current t=10 ms 2 RSO ..10 RSO ..25 RSO ..50 RSO ..90 RSO ..110 16 Arms 3 Arms 10 mArms 1.6 Vrms 130 A2s 50 A/s 25 Arms 5 Arms 10 mArms 1.6 Vrms 450 A2s 50 A/s 50 Arms 15 Arms 10 mArms 1.6 Vrms 1680 A2s 50 A/s 90 Arms 30 Arms 25 mArms 1.8 Vrms 6600 A2s 100 A/s 110 Arms 40 Arms 25 mArms 1.8 Vrms 18000 A2s 100 A/s 160 Ap 300 Ap 580 Ap 1150 Ap 1900 Ap Specifications are subject to change without notice (30.09.2005) RSC -AAM60/RSO..... Thermal Specifications Output Module Operating temperature Storage temperature Junction temperature Rth junction to case RSO ..10 RSO ..25 RSO ..50 RSO ..90 RSO ..110 -20 to +70C (-4 to +158F) -40 to +100C (-40 to +212F) 125C 0.7 K/W -20 to +70C (-4 to +158F) -40 to +100C (-40 to +212F) 125C 0.5 K/W -20 to +70C (-4 to +158F) -40 to +100C (-40 to +212F) 125C 0.25 K/W -20 to +70C (-4 to +158F) -40 to +100C (-40 to +212F) 125C 0.1 K/W -20 to +70C (-4 to +158F) -40 to +100C (-40 to +212F) 125 C 0.09 K/W Functional Diagram Wiring Diagram Mounting and connection of control module Control input and output 0 to 20 mA 4 to 20 mA Supply Mains input 1 Load ON 3 5 Load output 2 4 6 A B Supply/ Control input Accessories Heatsinks Fuses Temperature limit switch Power supply For further information refer to "General Accessories". M Dimensions RSC-AAM60 RSO ..... *** *** *** ** Temperature limit switch ** 39 Heat sink compound *** *** ** ** ** 2 ** = 0.4 mm *** = 0.5 mm All dimensions in mm Specifications are subject to change without notice (30.09.2005) All dimensions in mm 3 RSC -AAM60/RSO..... Heatsink Dimensions (load current versus ambient temperature) RSO ..10 RSO ..25 Load current [A] Thermal resistance [K/W] Power dissipation [W] Temp. protection [C] Load current [A] Thermal resistance [K/W] Power dissipation [W] 16 0.97 0.81 0.65 0.48 0.32 62 15 1.1 0.88 0.71 0.53 0.35 57 14 1.2 0.97 0.77 0.58 0.39 52 25 0.66 0.55 0.44 0.33 - 91 13 1.3 1.1 0.85 0.64 0.43 47 22.5 0.76 0.63 0.51 0.38 0.25 79 12 1.4 1.2 0.95 0.71 0.47 42 20 0.88 0.74 0.59 0.44 0.29 68 11 1.6 1.3 1.1 0.80 0.53 38 17.5 1.1 0.87 0.70 0.52 0.35 57 Temp. protection [C] 80C 10 1.8 1.5 1.2 0.90 0.60 33 15 1.3 1.1 0.85 0.63 0.42 47 9 2.1 1.7 1.4 1 0.69 29 12.5 1.6 1.3 1.1 0.79 0.53 38 7 2.8 2.3 1.9 1.4 0.93 21 10 2.1 1.7 1.4 1 0.69 29 5 4.2 3.5 2.8 2.1 1.4 14 7.5 2.9 2.4 1.9 1.4 0.96 21 3 7.4 6.2 4.9 3.7 2.5 8 5 4.5 3.8 3 2.3 1.5 13 1 23.8 19.8 15.9 11.9 7.9 3 2.5 9.4 7.8 6.3 4.7 3.1 6 20 30 40 50 20 30 40 50 TA 60 Ambient temp. [C] 60 80C TA Ambient temp. [C] RSO ..50 RSO ..90, RSO ..110 Thermal resistance [K/W] Load current [A] Power dissipation [W] Temp. protection [C] Heatsink/Thermal resistance [K/W] Load current [A] 50 0.33 0.28 - - - 181 45 0.38 0.32 0.25 - - 158 90 - - - - - 304 40 0.44 0.37 0.29 - - 136 80 - - - - - 260 35 0.52 0.43 0.35 0.26 - 116 70 0.27 - - - - 219 30 0.63 0.52 0.42 0.31 - 96 60 0.33 0.28 - - - 181 25 0.78 0.65 0.52 0.39 0.26 77 50 0.41 0.35 0.28 - - 145 20 1 0.84 0.67 0.50 0.34 60 40 0.54 0.45 0.36 0.27 - 111 15 1.4 1.2 0.93 0.69 0.46 43 30 0.75 0.63 0.50 0.38 0.25 80 10 2.2 1.8 1.4 1.1 0.72 28 20 1.2 0.99 0.79 0.59 0.39 51 5 4.5 3.8 3 2.3 1.5 10 2.5 2.1 1.7 1.2 0.83 24 20 30 40 50 20 30 40 50 60 80C 13 TA Ambient temp. [C] Temp. protection [C] Power dissipation [W] 60 80C TA Ambient temp. [C] Heatsink Selection Carlo Gavazzi Heatsink (see Accessories) No heatsink required RHS 300 Assy or backplate RHS 301 Assy RHS 301 F Assy Consult your distributor 4 Thermal resistance Rth s-a > 8.0 5.0 0.8 0.25 < 0.25 K/W K/W K/W K/W K/W Compare the value found in the load current versus temperature chart with the standard heatsink values and select the heatsink with the next lower value. It is recommended to protect the solid state relay against overheating. Therefore the chart also states the maximum switching temperature (70, 80 or 90 C) for the optional temperature limit switch. Specifications are subject to change without notice (30.09.2005) RSC -AAM60/RSO.... Housing Specifications Weight RSO ..10, ..25, ..50 RSO ..90, ..110 Housing material Colour Base plate @ 50 A @ 90 A Potting compound Approx. 275 g Approx. 385 g Noryl, glass-reinforced Black Aluminium, nickel-plated Copper, nickel-plated Polyurethane, black Relay Mounting screws Mounting torque Control terminal Mounting screws Mounting torque Power terminal Mounting screws Mounting torque M5 1.5 Nm M3 0.5 Nm M5 x 6 1.5 Nm Applications The output module RSO ..110 is recommended for motors up to 22 kW @ 400 V. The RSO ..110 is designed for use in applications with high surge current conditions. Care must be taken to ensure proper heatsinking when the relays are to be used at high nominal currents. Adequate electrical connection between relay terminals and cable must be ensured. Example 1: Power dissipation RSO 40110: Iload = 40 Arms = 111 W See previous page. Connection to the mains Since no motor protective circuitry is included in the RSC/RSO, the motor must be protected in the usual way, i.e. either by a thermal relay, a PTC-resistor or a Klixon bimetal temperature switch near the motor windings. The smallest heatsink required is 1 K/W, and the power dissipation is 25 W. This gives: Control module: RSC-AAM60 Output module: RSO 4025 Heatsink:1K/W Pilot voltage 1/L1 3/L2 5/L3 The varistors are already mounted in the RSO output If short circuit protection is re- module and they are selected quired, fuses F1 to F3 should according to the rated operabe ultrafast and selected ac- tional voltage. cording to the load integral (I2t) of the RSO output module and the motor load. Example 2: Motor: 3 kW, 4 HP 3 x 400 VAC, 4-pole TA: 50C Starting time: 5 s For this application RSC-AAM60 must be used. The output module RSO4025 is selected according to the Selection Guide. Transient voltage protection With an unfiltered main supply, voltage transient may occur. Since these transients could have a high energy content, it is advisable to use varistors to protect the output module. Pilot voltage 1/L1 3/L2 5/L3 A B 2/T1 4/T2 6/T3 A B 2/T1 4/T2 6/T3 M Energy saving for motors in idle mode When motors are running idle, When the motor is idle, d1 will it not necessary to maintain a switch the control current from full magnetic field, as is the I1 > 20 mA to I2, which is case when the motor has to adjusted to a value at which produce full torque. By lower- the motor is still running at full ing the motor voltage, power speed, but at a lower voltage. losses inside the motor are Please remark that this type of also reduced. phase-angle controlled voltage reduction, demands additional filtering to fulfill EMC regulations. M + Stabilized voltage - Overload protection by thermal relay Ie Full/Id I2 I1 d1 R2 1/L1 3/L2 5/L3 A B R1 2/T1 4/T2 6/T3 M Specifications are subject to change without notice (30.09.2005) GND 5 RSC -AAM60/RSO..... Applications (cont.) In order to achieve a 4 to 20 mA signal from a 12 or 24 VDC source, a resistor and a potentiometer should be connected in series with the voltage source and the RSC controller. We define the Imax. to be e.g. 24 mA, which means that the series resistors must be: R1 (12 V) = U/I - Rint = 12 V/24 mA - 250 = 250 R1 (24 V) = U/I - Rint = 24 V/24 mA - 250 = 750 If the minimum current is defined to be e.g. 2.4 mA and the 250 Rint input resistance of the RSC is also calculated in: R2 (12 V) = U/I - R1 - Rint = 12/2.4 - 250 - 250 = 4500 R2 (24 V) = U/I - R1 - Rint = 24/2.4 - 750 - 250 = 9000 Selection Guide 400 VACrms and 480 VACrms motors Output module RSO ..10 RSO ..25 RSO ..50 RSO ..90 RSO ..110 Max. motor size 3 HP/2.2 kW 5 HP/4 kW 15 HP/11 kW 20 HP/15 kW 30 HP/22 kW Output module RSO 6050 RSO 6090 RSO 60110 Max. motor size 15 HP 30 HP 40 HP 600 VACrms motors Wiring Diagram (0-10 VDC control) 0-10 VDC 220 0.25W + Supply A (0-20mA) B (4-20mA) - Supply 6 Specifications are subject to change without notice (30.09.2005)