Fully controlling Module

  I. Brief Introduction

 Fully controlling modules can regulate and automatically control the voltage of electric power, which have inner automatic regulating circuits, thyristor and phase-shift triggering circuits.

1.    Product Application

Modules can be widely used in adjusting power, AC and DC current stabilzer, AC motor soft starting, DC motor adjusting speed, industrial heater and temperature control , industrial electrical automations, solid-state switches, various electrical equipments and various power supplies(such as stabilized voltage, electroplate, temperature control, excitation, light control and so on.)

2.Product Features:

1. Advanced technics and high quality

 Using DCB(Direct Copper Bonded Ceramic Substrates) technics and import high performance chips and it makes the modules have long life time and up to 10,000 times of thermal cycling loader.

 2. Easy and safe opeation

(1) Using 0-10V(or 0-12V) DC signal can regulate the output voltage and current smoothly.

(2) Easily controlled by hand, instrument or microprocessor.

(3) Triggering circuit systems and thyristors and thermal conductive bagaplates are isolated each other and the insulated strength is greater than 2500V.

(4) No limited for phase series in AC input of 3-phase modules.

(5) Suitable for resistance load

II. Product Type

Specifications and types of common constant current modules, see table 1 and table 2.

Table   1 

name	type	specification
3-phase rectifier modules	MZKS－ZL－2400	2400A 450V
	MZKS－ZL－1800	1800A 450V
	MZKS－ZL－1200	1200A 450V
	MZKS－ZL－800	800A 450V
	MZKS－ZL－600	600A 450V
	MZKS－ZL－400	400A 450V
	MZKS－ZL－200	200A 450V
	MZKS－ZL－100	100A 450V
	MZKS－ZL－50	50A 450V
	MZKS－ZL－25	25A 450V
3-phase AC modules	MZKS－JL－1800	3×1800A 450V
	MZKS－JL－1350	3×1350A 450V
	MZKS－JL－900	3×900A 450v
	MZKS－JL－600	3×600A 450V
	MZKS－JL－450	3×450A 450V
	MZKS－JL－300	3×300A 450V
	MZKS－JL－150	3×150A 450V
	MZKS－JL－75	3×75A 450V
	MZKS－JL－40	3×40A 450V
	MZKS－JL－20	3×20A 450V

 

Table  2                                         

name	type	specification
single-phase rectifier modules	MZKD-ZL-2400	2400A 450V
	MZKD-ZL-1800	1800A 450V
	MZKD-ZL-1200	1200A 450V
	MZKD-ZL-800	800A 450V
	MZKD-ZL-600	600A 450V
	MZKD-ZL-400	400A 450V
	MZKD-ZL-200	200A 450V
	MZKD-ZL-100	100A 450V
	MZKD-ZL-50	50A 450V
	MZKD-ZL-25	25A 450V
single-phase AC modules	MZKD-JL-1800	1800A 4500V
	MZKD-JL-1350	1350A 450V
	MZKD-JL-900	900A 450V
	MZKD-JL-600	600A 450V
	MZKD-JL-450	450A 450V
	MZKD-JL-300	300A 450V
	MZKD-JL-150	150A 450V
	MZKD-JL-75	75A 450V
	MZKD-JL-40	40A 450V

Note：

1、In specification volume, the current is the maximal DC average current or AC virtual current. The voltage is the maximal input virtual line voltage.

2、All modules listed are fully controlling modules.

 

III. Module Parameters

1、Module Main Parameters（include common parameters and parameters of table 3）

 (1) Operating frequency: 50HZ
(2) Input line voltage V_in(RMS) range: 30-450V(AC)
(3) Control voltage VCON  range:  0-10V(DC)

(4) Control current: ≤10μA

(5) Unbalanced degree of output voltage: ＜6％

(6) Temperature coefficient of output voltage: ＜600PPM/℃

(7) Insulation voltage V_ISO(RMS): >2500V

About other parameters, see table 3 and table 4.

 Table  3

Type		Output Voltage	Maximal Input Current per phase	Maximal Output Current	Triggering Current	Working Surface Temperature
		VOU（AV）or VOUT（RMS）	IIN（RMS）	IOUT（AV） or IOUT（RMS）	IE	Tc
		V	A	A	mA	℃
3-phase rectifier modules	MZKS-ZL-2400	1.35VIN	1800	2400	400	≤80
	MZKS-ZL-1800		1440	1800	400	≤80
	MZKS-ZL-1200		960	1200	400	≤80
	MZKS-ZL-800		600	800	400	≤80
	MZKS-ZL-600		480	600	400	≤80
	MZKS-ZL-400		320	400	400	≤80
	MZKS-ZL-200		160	200	400	≤80
	MZKS-ZL-100		80	100	400	≤85
	MZKS-ZL-50		40	50	400	≤88
3-phase AC modules	MZKS-JI-1800	1.0VIN	1800	3×1800	400	≤80
	MZKS-JI-1350		1350	3×1350	400	≤80
	MZKS-JI-900		900	3×900	400	≤80
	MZKS-JI-600		600	3×600	400	≤80
	MZKS-JI-450		450	3×450	400	≤80
	MZKS-JI-300		300	3×300	400	≤80
	MZKS-JI-150		150	3×150	400	≤85
	MZKS-JI-75		75	3×75	400	≤85
	MZKS-JI-40		40	3×40	400	≤88

                             

  Table  4 

Type		Output Voltage	Maximal Input Current per phase	Maximal Output Current	Triggering Current	Working Surface Temperature
		VOUT（AV） or VOUT（RMS）	IIN（RMS）	IOUT（AV） or IOUT（RMS）	IE	Tc
		V	A	A	mA	℃
single- phase rectifier modules	MZKD-ZL-2400	0.9VIN	2666	2400	400	≤80
	MZKD-ZL-1800		2000	1800	400	≤80
	MZKD-ZL-1200		1333	1200	400	≤80
	MZKD-ZL-800		888	800	400	≤80
	MZKD-ZL-600		666	600	400	≤80
	MZKD-ZL-400		444	400	300	≤80
	MZKD-ZL-200		222	200	300	≤80
	MZKD-ZL-100		111	100	300	≤85
	MZKD-ZL-50		55	50	300	≤85
single- phase AC modules	MZKD-JL-1800	1.0VIN	1800	1800	400	≤80
	MZKD-JL-1350		1350	1350	400	≤80
	MZKD-JL-900		900	900	400	≤80
	MZKD-JL-600		600	600	400	≤80
	MZKD-JL-450		450	450	300	≤80
	MZKD-JL-300		300	300	300	≤80
	MZKD-JL-150		150	150	200	≤80
	MZKD-JL-75		75	75	200	≤85
	MZKD-JL-40		40	40	200	≤88

2.Thyristor Chip Main Parameters   

Table 5

　

IV. Forms of Electrical Connection in Modules

[

詞匯翻譯：

輸出： Output     

輸入： Input    

移相調控器：Phase-shift controller 

]

1 Forms of Electrical Connection in Modules

(1）single-phase rectifier modules

 

(2) single-phase AC modules

　

　

　

　

（3）3-phase rectifier modules

　

　

　

　

　

　

（4）3-phase AC modules

　

2、Electrical Connection Forms of Module Output Load

See figure 5 – figure 8.

Fig.5 single-phase rectifier modules             Fig.6 single-phase AC modules

Fig.7 3-phase rectifier modules                 Fig.8 3-phase rectifier modules 

 

V. Output Performance Curve

The load performance of output curve is like that of a resistor in this chart. The chart is only a reference for customers.  

 

 

 

[

詞匯翻譯：

輸出： output     

輸入： input    

三相整流：3-phase rectifier

三相交流：3-phase AC

單相整流：single-phase rectifier

控制：control

]

                                                 

  Fig.9  fully controlling module           

     

                                                                     

   Fig.10  half controlling module   

 

 

       

 

       

VI. Installation and Operation of Modules   

 

1. Installation and Operation of Modules 

(1).Modules type selection:

Current of choosed modules should be 1.5～3 times than current of  load in order to make equipments safely work.. Current of load shouldn’t be greater than rated current of modules during the working process.

(2). Environment required:

Modules must be worked or stored in  places that are dried, ventilated, dusty-less and have no corrosive gases. Atmosphere temperature required varies from －25℃ to ＋45℃.  

(3) .Installation steps

① Install radiators and wind machines in order to accord with cooling requirement. The surface of radiators must be plat and clean. A layer of thermal conductive silica gel must be laid equably between the module thermal conductive bagaplates and the surface of radiators. Then screw modules on radiators with equal strength.

② Mutliple section copper wires must be used to connect with modules because of their large current. Aluminium wires are prohibited. Wire section is selected according to current density(＜4A/mm²).Must’t connect copper wires with module poles directly.   

③ Tie up copper wires with junction nose rings for fear of additional quantity of heat caused by bad connection, then place insulative pyrocondensation cannula on wires and make them shrink with hot wind or water. Screw junction noses in module poles and make them connected well in their surface.

④ Don’t lift up poles for fear of breaking off poles.

⑤ Two types are applied for control port: one has five pins, the other has fifteen pins.About specification , see table 6 and figure 11-12.

 

[

詞匯翻譯：

輸出： Output      輸入： Input    

電流設定： Initialization current

穩(wěn)流輸出信號：Constant current signal output

控制信號輸入: Control signal input

地：GND

]

Fig.11  five-pin socket  specification             Fig.12  fifteen-pin socket Specification

Table  6

pin function	color	five-pin socket	fifteen-pin socket
＋12V	red	5	1
GND	black	4	2
control signal input	black(gray)	3	3
constant current signal output	yellow	2	4
initialization current	orange	1	5

 

Hand control（using resistors）interface, computer control interface and instrument control interface, see figure 11-13.

[

翻譯說明

計算機D/A輸出(0-10V)： computer D/A output (0-10V)

]

 

Fig.13  hand control interface        Fig.14  computer control interface

                                 

Fig.15  instrument control interface（regulator diode: 2.4ｖ- 2.7ｖ）

 

Fig.16  inteface with 0－5ｖsignal

Orange pin connects to 10.5V DC power supply in modules. Red pin connects to anode of 12V DC stable power supply which output current value is greater than 1A. The power of transformer should be greater than 15W and it has better that two filter capacitor(2200μF/25V) is shunt-wound if a transformer rectifier stable power supply is adopted. Pay attention not to connect reversely, otherwise it will destroy modules.

2.Simple Measurement of Modules

It should be attended that a load must be connected to output pin and the minimum output current value is greater than 10 mA when we measure output voltage. It is not accurate when no load is connected. If we measure output voltage with a multi-meter, please take read pin and black pin of multi-meter on phase in AB,BC,CA order, otherwise the voltage value we get is not accurate.

VII. Module Protection

1.Over-current protection

The simplest protection method is to connect quick fuses outside of modules. Only a brief introduction is given as follows.

(1) Connection

Quick fuses are connected in AC input sides. A example is given to 3-phase rectifier modules and single-phase AC modules.See figure 15 and figure 16.

[

翻譯說明

[輸出： Output     

輸入： Input

]

Fig.17  3-phase rectifier modules                        Fig.18  single-phase AC modules

(2) selection of quick fuses

①The rated voltage of selected quick fuses must be greater than that of working voltage in circuits

②About rated current selection of fuses, see table 7 and table 8.

Table 7 

module type(3-phase)	fuse
	rated voltage（～V）	rated current(A)	quantity
MZKS-ZL-2400	500	1200	3
MZKS-JL-1800
MZKS-ZL-1800		900	3
MZKS-JL-1350
MZKS-ZL-1200		480	3
MZKS-JL-900
MZKS-ZL-800		400	3
MZKS-JL-600
MZKS-ZL-600		300	3
MZKS-JL-450
MZKS-ZL-400		160	3
MZKS-JL-300
MZKS-ZL-200		80	3
MZKS-JL-150
MZKS-ZL-100		40	3
MZKS-JL-75
MZKS-ZL-50		25	3
MZKS-JL-40
MZKS-ZL-25
		16	3
MZKS-JL-20

Table  8

module type（single-phase）	fuse
	rated voltage(～V)	rated current(A)	quantity
MZKD-ZL-2400	500	960	1
MZKD-JL-1800
MZKD-ZL-1800		720	1
MZKD-JL-1350
MZKD-ZL-1200		480	1
MZKD-JL-900
MZKD-ZL-800		320	1
MZKD-JL-600
MZKD-ZL-600		240	1
MZKD-JL-450
MZKD-ZL-400		160	1
MZKD-JL-300
MZKD-ZL-200		80	1
MZKD-JL-150
MZKD-ZL-100		40	1
MZKD-JL-75
MZKD-ZL-50		25	1
MZKD-JL-40
MZKD-ZL-25

 

2、Over-voltage protection

Resistor-capacitor absord and press-sensitive resistor method is recommended to used together in order to realize over-voltage protection.

(1) Resistor-capacitor absord circuits

Capacitors absorb electromagnetic energy of over-voltage and store to electrostatic energy. Resistors prevent resonance of capacitors and inductances. This absord circuits can restrain over-voltage produced by thyristors when they vary form connection to shutoff and effectively avoid breaking down of modules. About electrical circuits, see figure 19-22. About the value of resistors and capacitors, see table 9-10.

[

翻譯說明

[輸出： Output     

輸入： Input

]

 

   。         

                

Fig.19 3-phase rectifier modules Fig.20  single-phase rectifier modules

                  

Fig.21  3-phase AC modules  Fig.22  single-phase AC modules

Table  9 

name	module type	R（Ω/W)	C(μF)630VAC	quantity
3-phase rectifier modules	MZKS-ZL-2400	4/20	0.68	each 18
	MZKS-ZL-1800
	MZKS-ZL-1200
	MZKS-ZL-800			each 6
	MZKS-ZL-600
	MZKS-ZL-400
	MZKS-ZL-200	8/10	0.32	each 6
	MZKS-ZL-100	30/6	0.22	each 6
	MZKS-ZL-50	60/3	0.22	each 6
	MZKS-ZL-25
3-phase AC modules	MZKS-JL-1800	4/20	0.68	each 9
	MZKS-JL-1350
	MZKS-JL-900
	MZKS-JL-600			each 3
	MZKS-JL-450
	MZKS-JL-300
	MZKS-JL-150	8/10	0.32	each 3
	MZKS-JL-75	30/6	0.22	each 3
	MZKS-JL-40	60/3	0.22	each 3
	MZKS-JL-20

 

Table  10

name	module type	R（Ω/W)	C(μF)630AC	quantity
single-phase rectifier modules	MZKD-ZL-2400	4/20	0.68	each 12
	MZKD-ZL-1800
	MZKD-ZL-1200
	MZKD-ZL-800			each 4
	MZKD-ZL-600
	MZKD-ZL-400
	MZKD-ZL-200	8/10	0.32	each 4
	MZKD-ZL-100	30/6	0.22	each 4
	MZKD-ZL-50	60/3	0.22	each 4
	MZKD-ZL-25
single-phase AC modules	MZKD-JL-1800	4/20	0.68	each 3
	MZKD-JL-1350
	MZKD-JL-900
	MZKD-JL-600			each 1
	MZKD-JL-450
	MZKD-JL-300
	MZKD-JL-150	8/10	0.32	each 1
	MZKD-JL-75	30/6	0.22	each 1
	MZKD-JL-40	60/3	0.22	each 1

  

 

（2）壓敏電阻吸收回路

    壓敏電阻吸收由于雷擊等原因產生的能量較大、持續(xù)時間較長的過電壓。壓敏電阻電壓選?。?10V≤V_1mA≤1000V。V_1mA是壓敏電阻標稱電壓，是指壓敏電阻流過1_mA電流時它兩端的電壓。接線方法見圖23－圖24:

 

(2) Press-sensitive resistor absord circuits

Press-sensitive resistors can absorb over-voltage which have more energy and last more time produced by thunder. The voltage value should be: 710V≤V_1mA≤1000V。V_1mA is rated voltage of press-sensitive resistors. That is the voltage value in resistors when 1_mA current flows. About electrical circuits, see figure 23-24.

   [

翻譯說明

[輸出： Output      

輸入： Input

]

　               

Fig.23  3-phase circuits           Fig.24 single-phase circuits

3. Selection of radiators

Radiators must be used during modules work because modules will produce much heat caused by the voltage difference in modules. Reliability and safety are directly depended on conditions of heat emanating.   

Generally, there are three ways of heat emanating: water-cooling, forced wind-cooling and natural cooling. In the first place water-cooling is choosed for it’s good cooling effectivity if we can use. Forced wind-cooling is the commonest way used to emanate heat ,but wind velocity of axis stream wind machines must be great than 6m/s. Natural cooling is seldom used because of its bad cooling effectivity and large cubage. We must make air convect better surround radiators if natural cooling is used.

We list types and length of radiators that required by different types of modules when modules work in condition of rated current and 40℃ atmosphere temperature so that a reference is given for customers. The length of radiator may reduce if modules work below full-load.

 Table 11 list of radiators                                    

Module type	Radiator type	Rediator length（mm）		Axis stream wind machine
		Forced wind-cooling	Natural cooling
MZKS-ZL--2400	DXC－573	1800	.	AC220V/50Hz/ 100W quantity:3
MZKS-JL--1800
MZKS-ZL--1800		1200	.
MZKS-JL--1350
MZKS-ZL--1200		900	.	AC220V/50Hz/44W 220×220×60 quantity:3
MZKS-JL--900
MZKD-ZL--2400
MZKD-JL--1800
MZKD-ZL--1800		780	.
MZKD-JL--1350
MZKD-ZL--1200
MZKD-JL--900

                                  

Table  12

Module type	Radiator type	Rediator length（mm）		Axis stream wind machine
		Forced wind-cooling	Natural cooling
MZKS-ZL--800	DXC－573	1800	.	AC220V/50Hz/100W
MZKS-JL--600
MZKS-ZL--600		1200	.
MZKS-JL--450
MZKS-ZL--400		300	.	AC220V/50Hz/44W 220×220×60
MZKS-JL--300
MZKD-ZL--800
MZKD-JL--600
MZKD-ZL--600		260	.
MZKD-JL--450
MZKS-ZL--200	DXC－578	300	.	AC220V/50Hz/38W 172×150×51
MZKS-JL--150
MZKD-ZL--400
MZKS-ZL--100		200	.
MZKS-JL--75
MZKD-JL--300
MZKD-ZL--200
MZKS-JL--40		160	.	AC220V/50Hz/10W 120×120×38
MZKS-ZL--50
MZKD-ZL--100
MZKD-JL--150
MZKS-ZL--25		.	120	.
MZKS-JL--20		.		.
MZKD-JL--75		.		.
MZKD-ZL--50		.		.
MZKD-ZL--25		.		.
MZKD-JL--40	DXC-721	.	80	.
MZKD-JL--20		.		.

 

About shape and dimension of radiators, see figure 25-26.

 

 

Fig.25  DXC-578       

                                                   

Fig.26  DXC-573

VIII. Note                       

1.Modules are prohibited to work with large current with a small lead angle(high input, low output). If we do so it will make modules produce more heat and maybe destroy modules. It is recommended that modules work with large current in the condition of a large lead angle(greater than 50 percent of regulated angle).

2. The temperature of modules(measurement points are in the surfaces of radiators which contact with bagaplates of modules tightly and are near the center of modules)should be less than 70℃ when modules work in a stable thermal status, otherwise it will destroy modules.

3.Don’t use modules to isolate electric network and people bodies. Air switchs should be installed before modules to ensure people’s safety.

4. Take and lay modules lightly to avoid strong knock and shock when modules are transferred and installed.

5. The content of charts and tables in this specification is only a reference for customers. Apologize for not inform customers if parameters change.