User`s manual "RNS" ( PDF 1,16Mb )

USER’S MANUAL
TRIAC POWER CONTROLLER FOR ELECTRIC HEATERS
RNS-16
RNS-25
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CONTENTS
Safety requirements
3
Purpose
5
Delivery set
5
Designation key
5
Technical data
6
Design and operating principle
8
Mounting and set-up
10
Connection to power mains
12
Technical maintenance
17
Transportation and storage regulations
17
Manufacturer's warranty
18
Acceptance certificate
20
Seller information
20
Installation certificate
21
Warranty card
21
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This user’s manual consisting of the technical details, operating instructions and technical specification
covers the installation and mounting of the RNS triac power controller (hereinafter referred to as «the
controller» or «the unit» as mentioned in the «Safety requirements» and «Manufacturer’s warranty» sections
as well as in warnings and information blocks).

SAFETY REQUIREMENTS
Read the user’s manual carefully prior to installing and operating the unit.
Fulfil the user’s manual requirements as well as the provisions of all the applicable
local and national construction, electrical and technical norms and standards.
The warnings contained in the user’s manual must be considered most seriously
since they contain vital personal safety information.
Failure to follow the rules and safety precautions noted in this user’s manual may
result in an injury or unit damage.
After a careful reading of the manual, keep it for the entire service life of the unit.
While transferring the unit control the user’s manual must be turned over to
the receiving operator.
Symbol legend:
WARNING!
DO NOT!
UNIT MOUNTING AND OPERATION SAFETY PRECAUTIONS
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• Disconnect the unit from power
mains prior to any installation
operations.
• The unit must be grounded!
• Do not lay the power cable of
the unit in close proximity to
heating equipment.
• While installing the unit
follow the safety regulations
specific to the use of electric
tools.
• Do not change the power cable
length at your own discretion.
• Do not bend the power cable.
• Avoid damaging the power
cable.
• Do not put foreign objects on
the power cable.
• Do not operate the unit
outside the temperature
range stated in the user’s
manual.
• Do not operate the unit
in aggressive or explosive
environments.
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• Do not use damaged equipment
or cables when connecting the
unit to power mains.
• Unpack the unit with care.
• Do not touch the unit controls
with wet hands.
• Do not carry out the installation
and maintenance operations
with wet hands.
• Do not wash the unit with
water.
• Protect the electric parts of
the unit against ingress of
water.
• Do not allow children to operate
the unit.
• Disconnect the unit from
power mains prior to any
technical maintenance.
• Do not store any explosive or
highly flammable substances in
close proximity to the unit.
• When the unit generates
unusual sounds, odour or
emits smoke disconnect
it from power supply and
contact the Seller.
• Do not open the unit during
operation.
• Do not direct the air flow
produced by the unit towards
open flame or ignition
sources.
• Do not block the air duct when
the unit is switched on.
• In case of continuous
operation of the unit
periodically
check
the security of mounting.
• Do not sit on the unit and avoid
placing foreign objects on it.
• Use the unit only for its
intended purpose.
WARNING! The controller must only be used for regulating the power output of electric
heaters of appropriate capacity.
The total current consumption of the connected electric heaters must be within the limits
of the maximum load current (see «Technical data»).
Avoid running the controller at the maximum load current.
The controller operation requires connection of thermal contacts set to restart
the appliance automatically at +50°C and manually at +90°C as well installation of a duct
pressure switch.
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
PURPOSE
The RNS three-phase TRIAC power controller is designed for regulating the power output
of electric heaters with load current rating up to 120 A.
THE UNIT IS NOT INTENDED FOR OPERATION BY CHILDREN
OR PERSONS WITH REDUCED SENSORY OR MENTAL
CAPACITY OR THOSE LACKING THE APPROPRIATE TRAINING.
THE CONTROLLER MUST BE HANDLED ONLY BY PROPERLY
QUALIFIED PERSONNEL AFTER THE APPROPRIATE BRIEFING.
THE CHOICE OF UNIT INSTALLATION LOCATION MUST PREVENT
UNAUTHORIZED ACCESS BY UNATTENDED CHILDREN.

DELIVERY SET
Power controller
1 piece
Temperature sensor
1 piece
User's manual
1 piece
Packaging
1 piece

DESIGNATION KEY
RNS-X
TRIAC power controller
for electric heaters
Maximum power output of heater connected
to first cascade of controller, [kW]
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
TECHNICAL DATA
RNS Characteristics:
230 V single-phase or 400 V three-phase load connection (see wiring diagram on pages 13-16).
Proportional supply air temperature sensing control.
Expandable with two booster heating cascades. The power output of each of the two booster
cascades may not exceed the power output of the regulated heater cascade.
RNS operating modes:
1 Maintaining the pre-set duct temperature according to the duct temperature sensor
feedback.
2 Regulation of the heating output within the 0 to 100 % range by using the 0-10 V control
input.
The controller is connected in series between the power supply unit and the star-connected
or delta-connected electric heater. Delta circuits allow for simultaneous connection of various
capacity loads.
The controller is intended for wall mounting.
Controller Appearance:
1 ON/OFF button.
2 Heating temperature control knob (from -30 °C up to +30 °C).
3 Indicators.
3
1
2
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Parameters
RNS-16
RNS-25
Max. load current (single cascade), [A]
25
40
Heater output (single cascade), [kW]
16
25
Max. load current (three cascades), [A]
-
120
Heater output (three cascades), [kW]
-
75
Control circuit supply voltage
Nominal current of control circuit board fuse, [A]
~230 V / 50 Hz
0,5
Cross-section area of screw terminal block input
pin, [mm2]
4...10
Protection class
IP54
Outside dimensions, [mm]
Weight, [kg]
170x255x140
1,2
Electric mains parameters:
Voltage, [V]
Frequency, [Hz]
Phases
Operating temperature range, [°C]
210-255, 380-415
50-60
1 or 3
+5...+40
Note: Intrinsic heat generation: RNS-16 controller – 50 W, RNS-25 controller – 80 W.
Control parameters
Regulation time, [s]
Cycle length, [s]
Indication
Type of temperature sensor used
0.1 (fixed)
1...10 (adjustable)
Power, operation and emergency indicator
LM 60
Input signal parameters, [V]
0...10 (direct current)
Set temperature range, [°C]
from -30 to +30 (adjustable)
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
DESIGN AND OPERATING PRINCIPLE
Electric power output is regulated by proportional connection and disconnection of the full
load depending on the pre-set heating temperature.
For example, intermittent connection and disconnection of the load in 5 s intervals
generates 50 % of the maximum output.
The cycle length - i.e. the combined period of load connection and disconnection - is
adjustable within the 1 to 10 s range.
Reduction of the total cycle length increases the heating intensity and output temperature
variance amplitude.
The RNS-16 capabilities are limited to only one heating cascade.
Unlike the smaller model the RNS-25 is capable of controlling one or three heating
cascades with the power output equal or exceeding that of the controlled cascade.
The power output of the first cascade is controlled in a stepless manner by switching the full
load on and off.
The second and third cascades are controlled in steps.
For example, if the first cascade power output is insufficient for reaching the pre-set
temperature, the second cascade of the electric heater engages at 100 % capacity whereas
the first cascade output is dropped to 0 % and then increased to the required level to ensure
reaching the target temperature.
To connect two extra heating cascades install an electric contactor for activating each heater
cascade.
For overheating protection the electric heater must be equipped with two built-in thermal
contacts: TK50 with intervention temperature of +50 °C and automatic restarting and TK90 with
intervention temperature of +90 °C and manual restarting.
The air temperature is set by means of the integral pot resistor or an external control device
generating a 0-10 V control input signal for increasing the duct temperature proportionally in
the range from -30 to +30 °C.
The duct temperature sensor must be installed downstream of the heater in the direction of
the air stream travel at the minimum distance of 50 cm from the heater.
If the controller runs in the heating power output mode irrespective of the temperature
sensor feedback, no duct temperature sensor is necessary whereas the heating power output is
regulated in the 0 to 100% range by means of the 0-10 V control input signal.
CAUTION! Ensure a constant airflow to the heating elements of the heater while the RNS
is operational.
The fan choice must account for the minimum air flow through the heater of 1.5 m/s.
The blowing fan of the heating element must operate for at least two minutes after
the system shutdown.
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FUNCTIONAL SWITCHES AND INDICATORS
There are three lights on the indicator panel:
• Power – AC mains (green);
• Current state – operation (yellow) and alarm/booster heating (red).
AC mains
Operation
Alarm
Current state and malfunction indication
AC mains green
Operation yellow
Alarm red
EVENT
-
-
-
AC mains disconnected
Temperature sensor feedback operation
ON
BLINKING
-
«Temperature boosting:
T set > T flow»
ON
ON
-
«Reaching mode parameters:
T set = T flow»
Power output mode
The blinking frequency is proportional to the
power supplied to the heating elements.
ON
BLINKING
-
ON
-
ON
TK50 thermal contact actuation
ON
-
BLINKING
Duct pressure switch signal lost or no enabling
signal
ON
-
BLINKING
double
intermittent
Temperature sensor shorting or sensed value
out of range (t < -40 0C )
ON
-
BLINKING
triple
intermittent
Temperature sensor breakout or sensed value
out of range (t < +90 0C )
Alarms
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
MOUNTING AND SET-UP
Controller circuit board functional outputs:
1 - Internal or external 0-10 V control input
selection;
2 - Control mode selection;
3 - Cycle length adjustment resistor (factory set);
4 - TRIAC operation indicator;
5 - Heating cascade 1 indicator;
6 - Heating cascade 2 indicator ;
7 - Heating cascade 3 indicator;
8 - Terminal block for temperature sensor
connection;
9 - Terminal block for external 0-10 V control
input;
10 - Terminal block for protection and enabling
contacts;
11 - Control circuit board fuse;
12 - Operation indication relay:
NO - Alarm or no enabling signal;
NC - Unit operation.
External 0-10 V control input
Integral 0-10 V pot resistor
Jumper 2
Temperature sensor feedback
mode using three cascades
Temperature sensor
mode using cascade 1
Heating power output maintenance
mode using three cascades
10
RB
22 23
RA
21
TK50
TK50
18 19 20
12
PD1
PD1
16 17
GND
15
IN1
Tset
+10 V
GND
PTin
13 14
PT+
12
24
25
1
out
X9
K1
DA1
C3
X10
ICSP
Z1
X12 X13
SCR
K1
7 6 5
K3
4
R3
R1
R4
R2
K4
T1
U4
U3
R5
X2
8
7
6
5
4
DO2
DO2
X3
9
DO1
C10
Q3
R9
X4
11 10
DO1
C9
CQ
R8
R6
Q1
C8
Q2
R7
C6
U2
U1
X1
F1
500 mA
3
2
1
PE
3
K2
K3
X14
K2
DA3
C5
VD10
VD6 VD7 VD8 VD9
2
R73
DA2
C4
C7
N
X11
X8
X6
L
Tset
C1
C2
X5
in
feedback
Heating power output maintenance
mode using cascade 1
9
GND
8
Jumper 1
11
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CAUTION! After transporting or storing at subzero temperatures subject the unit to room
temperature for at least 4 hours before connecting it to the electric mains.
Inspect the unit visually and check the casing for integrity.
Attach the controller to the mating surface by using the holes in the mounting plates of the unit.
CAUTION!
THE CONTROLLER IS
INTENDED FOR VERTICAL
MOUNTING ONLY!
Undo the self-tapping screws 3 and remove the controller front lid. If necessary, disconnect
the flexible flat cable.
Connect the controller to the electric mains according to the connections diagram.
Route the electric power cables into the casing through sealed leadins 4 and secure them with the terminal screws 5 on the block.
The stationary wiring must be equipped with an automatic circuit breaker.
The connection must be made via an automatic circuit breaker integrated into the stationary
wiring.
Replace the controller front lid.
Supply the power voltage to the unit.
Press the On/Off button 1 and set the desired temperature by turning the temperature
control knob 2.
3
2
5
1
4
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
CONNECTION TO POWER MAINS
External connections diagram
Q1
Q1 CQ
CQ L3 L2 L1 PE PE L3 L2 L1 N
Power voltage input
for 230 V electric mains
CQ
CQ L3 L2 L1 PE PE L3 L2 L1 N
ТК90
Power voltage input
for 230 V circuit
Cascade
1 activation
Cascade
2 activation
Cascade
3 activation
Single-phase mains
connection
Power voltage input
for 400 V electric mains
Q1
t °C
Q2
Load connection
Power voltage input
for 230 V circuit
Cascade
1 activation
Q3
ТК90
Load Connection
Q2
t °C
Q3
Three-phase network
connection
Command unit connection diagrams
X5
X6
Gnd Tset +10V
16
17
Х9
Gnd In1 PD1 PD1
18
19
20
21
TK50 TK50
22
23
Х10
RA
RB
24
25
Gnd
15
0 - 10 V
14
Gnd
E+
13
Out
12
+10 V
Gnd PTin PT+
Х8
t ˚С
Temperature
sensor
Внешний
задатчик
External enabling
device contact
ТК50
Supply fan
pressure switch thermal contact
Unit operation
relay output
Electrical connections diagrams
To enable several heating cascades install a dedicated electric contactor for each heating
cascade.
Connect the contactors to the terminal block via the relay outputs according to the external
connections diagram.
Send the contactor supply voltage to the «CQ» input via the TK90 protective thermal contact
of the heater (thermal contact for calorifier protection, Tact.=90 °C) to enable the contactors.
Power the Q1 first heating cascade via the L1, L2, L3, and PE load connection terminals.
Connect the remaining contactors to the external network.
The contactor becomes redundant if only one heating cascade is used.
In this case the control circuit board power supply should be connected via the TK90
protective thermal contact.
The K1, K2, K3 electric contactors (starter switches) and the QF1 automatic circuit breaker
(see connection diagrams on pages 13-16) are purchased separately.
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Diagram for RNS-25 Triple-Cascade Controller Connection to Three-Phase Electric Mains
TK50
TK50
RA
RB
X9
X10
PE
+10 V
X8
L
N
HL1
HL2
Gnd
In 1
PD1
PD1
X5
+10 V
0-10 V
Gnd
Gnd
VD1
VD2
VD3
Gnd
Test
Gnd
PT in
PT +
Start
X6
CONTROLLER CIRCUIT BOARD
R85
HL3
DO2
DO2
DO1
DO1
Q3
Q2
Q1
CQ
INDICATOR
PANEL
SB
K3
K2
K1
~400 V
N
L1
L2
L3
Т2
QF1
Т1
K2.1 K2.2 K2.3
V116-2EN-01(RNS).indd 13
Heating element 3
ТК50 thermal contact
Supply fan
pressure switch
Temperature sensor
50 °C
K1.1 K1.2 K1.3
90 °C
Heating element 2
ТК90 thermal contact
K3.1 K3.2 K3.3
Heating element 1
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Diagram for RNS-25 triple-cascade controller connection to single-phase electric mains
TK50
TK50
RA
RB
X9
X10
PE
+10 V
X8
L
N
HL1
HL2
Gnd
In 1
PD1
PD1
X5
+10 V
0-10 V
Gnd
Gnd
VD1
VD2
VD3
Gnd
Test
Gnd
PT in
PT +
Start
X6
CONTROLLER CIRCUIT BOARD
HL3
DO2
DO2
DO1
DO1
Q3
Q2
Q1
CQ
INDICATOR
PANEL
SB
K3
K2
K1
~230 V
N
L
Т1
K2.1 K2.2
V116-2EN-01(RNS).indd 14
Heating element 3
ТК50 thermal contact
Supply fan
pressure switch
Temperature sensor
50 °C
K1.1 K1.2
90 °C
Heating element 2
ТК90 thermal contact
K3.1 K3.2
QF1
Heating element 1
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Diagram for RNS-16 and RNS-25 single-cascade controller connection to three-phase electric mains
RA
RB
X9
X10
PE
+10 V
TK50
TK50
HL3
X8
L
N
HL1
HL2
X5
Gnd
In 1
PD1
PD1
+10 V
0-10 V
Gnd
Gnd
VD1
VD2
VD3
Gnd
Test
Gnd
PT in
PT +
Start
X6
CONTROLLER CIRCUIT BOARD
R85
DO2
DO2
DO1
DO1
Q3
Q2
Q1
CQ
INDICATOR
PANEL
SB
K1
~400 V
N
L1
L2
L3
Т2
QF1
Т1
V116-2EN-01(RNS).indd 15
50 °C
90 °C
ТК50 thermal contact
ТК90 thermal contact
Supply fan
pressure switch
Temperature sensor
K1.1 K1.2 K1.3
Heating element 1
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Diagram for RNS-16 and RNS-25 single-cascade controller connection to single-phase electric mains
RA
RB
X9
X10
PE
+10 V
TK50
TK50
HL3
X8
L
N
HL1
HL2
X5
Gnd
In 1
PD1
PD1
+10 V
0-10 V
Gnd
Gnd
VD1
VD2
VD3
Gnd
Test
Gnd
PT in
PT +
Start
X6
CONTROLLER CIRCUIT BOARD
R85
DO2
DO2
DO1
DO1
Q3
Q2
Q1
CQ
INDICATOR
PANEL
SB
K1
~230 V
N
L
QF1
Т1
V116-2EN-01(RNS).indd 16
50 °C
90 °C
ТК50 thermal contact
ТК90 thermal contact
Supply fan
pressure switch
Temperature sensor
K1.1 K1.2
Heating element 1
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
TECHNICAL MAINTENANCE
Make sure to schedule a periodic inspection of the external electrical leads connection to
the bolt-down terminals of the unit.
Possible malfunctions and their elimination
Problem
Controller will
not switch on
Heating element
overheating
Controller
malfunction

Possible reasons
Troubleshooting
The unit is not connected to the
power mains.
Make sure that the unit is properly
connected to the power mains and
make any corrections, if necessary.
Faulty fuse.
Replace the fuse.
The heater power output does
not match the power output
controller parameters.
Check the heater power output for
compliance with the RNS controller
specifications.
Install an appropriately rated heater.
Filter clogging.
Clean the filter.
Insufficient heating element air
cooling or no air cooling.
Eliminate the factors preventing
proper air cooling of the heating
element.
Temperature sensor
malfunction.
Replace the temperature sensor.
Incorrect operating mode
selection.
Check the jumpers for correct
installation (see Page 10).
TRANSPORTATION AND STORAGE REGULATIONS
The unit must be stored in the original packing in a dry ventilated area at temperatures from
+5 °C to +40 °C.
The air in the storage space must not contain any vapours or admixtures which may lead to
corrosion or compromise the insulation and seals.
Use only suitable lifting equipment for handling operations to prevent damage to the unit.
Follow the applicable moving regulations specific to the particular cargo type while loading
and unloading.
The unit can be transported in the original packing by any mode of transport without
limitation provided proper protection against precipitation and mechanical damage.
Avoid sudden jolts and impacts while loading and unloading the unit.
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
MANUFACTURER’S WARRANTY
The manufacturer hereby warrants normal operation of the unit for 12 months after the retail
sale date provided the user’s observance of the transportation, storage, mounting and operation
regulations.
Should any malfunctions occur in the course of the unit operation through the Manufacturer’s
fault during the guaranteed period of operation the user is entitled to elimination of faults by the
manufacturer by means of warranty repair at the factory free of charge.
The warranty repair shall include work specific to elimination of faults in the unit operation to
ensure its intended use by the user within the guaranteed period of operation.
The faults are eliminated by means of replacement or repair of the unit components or
a specific part of such unit component.
The warranty repair does not include:
•
routine technical maintenance
•
unit installation / dismantling
•
unit setup
To benefit from warranty repair the user must provide the unit, the user’s manual with
the purchase date stamp and the payment document certifying the purchase.
The unit model must comply with the one stated in the user’s manual.
Contact the Seller for warranty service.
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The manufacturer’s warranty does not apply to the following cases:
•
User’s failure to submit the unit with the entire delivery package as stated in the user’s
manual including submission with missing component parts previously dismounted by
the user.
•
Mismatch of the unit model and the brand name with the information stated on the unit
packing and in the user’s manual.
•
User’s failure to ensure timely technical maintenance of the unit.
•
External damage to the unit casing (excluding external modifications as required for
installation) and internal components caused by the user.
•
Redesign or engineering changes to the unit.
•
Replacement and use of any assemblies, parts and components not approved by
the manufacturer.
•
Unit misuse.
•
User’s violation of the unit installation regulations.
•
User’s violation of the unit control regulations.
•
Unit connection to the power mains with a voltage different from the one stated in
the user’s manual.
•
Unit breakdown due to voltage surges in the power mains.
•
Discretionary repair of the unit by the user.
•
Unit repair by any persons without the manufacturer’s authorization.
•
Expiration of the unit warranty period.
•
User’s violation of the unit transportation regulations.
•
User’s violation of the unit storage regulations.
•
Wrongful actions against the unit committed by third parties.
•
Unit breakdown due to circumstances of insuperable force (fire, flood, earthquake, war,
hostilities of any kind, blockades).
•
Missing seals if provided by the user’s manual.
•
Failure to submit the user’s manual with the unit purchase date stamp.
•
Missing payment document certifying the unit purchase.
FOLLOWING THE REGULATIONS STIPULATED HEREIN WILL ENSURE
A LONG AND TROUBLE-FREE OPERATION OF THE UNIT.
USERS’ CLAIMS SHALL BE A SUBJECT TO REVIEW ONLY UPON
PRESENTATION OF THE UNIT, THE PAYMENT DOCUMENT AND
THE USER’S MANUAL WITH THE PURCHASE DATE STAMP.
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
ACCEPTANCE CERTIFICATE
Unit Type
TRIAC POWER CONTROLLER FOR ELECTRIC HEATERS
RNS________________
Model
Serial Number
Manufacture Date
«is compliant with the technical specifications and is hereby declared ready for service. We hereby
declare that the product complies with the essential protection requirements of Electromagnetic
Council Directive2004/108/EC, 89/336/EEC and Low Voltage Directive 2006/95/EC, 73/23/EEC and CEmarking Directive 93/68/EEC on the
approximation of the laws of the Member States relating to electromagnetic compatibility.
This certificate is issued following test carried out on samples of the product referred to above.»
Quality Inspector's
Stamp

SELLER INFORMATION
Seller
Address
Phone Number
E-mail
Purchase Date
This is to certify acceptance of the complete unit delivery with the user’s
manual. The warranty terms are acknowledged and accepted.
Seller’s Stamp
Customer’s Signature
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
MOUNTING CERTIFICATE
The unit has been connected to power mains pursuant to the requirements
stated in the present user’s manual.
Company Name
Address
Phone Number
Installation
Full Name
Technician's
Installation Date:
Signature:
Seller’s Stamp
The unit has been installed in accordance with the provisions of all
the applicable local and national construction, electrical and technical
codes and standards.
The unit operates normally as intended by the manufacturer.
Signature:

WARRANTY CARD
Unit Type
TRIAC POWER CONTROLLER FOR ELECTRIC
HEATERS
Model
RNS________________
Serial Number
Manufacture Date
Purchase Date
Warranty Period
Seller
V116-2EN-01(RNS).indd 21
Seller’s Stamp
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22
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V116-2EN-01
V116-2EN-01(RNS).indd 24
29.07.2015 14:04:37