Constant Current(Current Limited) Module

  I. Brief Introduction

 Intelligent controlling constant current thyristor modules can regulate voltage and smooth down current, which have inner automatic regulating circuits, thyristor and phase-shift triggering circuits, current sample circuits and current regulating circuits.

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

Intelligent controlling thyristor modules have two types: common constant current modules and special constant current modules. The precision of common constant current modules is less than 3 percent . The precision of special constant current models is greater than that of common constant current modules because of their specific design and high current sample precision.

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

Table   1 

Name	Type	Specification
3-phase rectifier constant current	MZKS－ZL－WL－2400	2400A 450V
	MZKS－ZL－WL－1800	1800A 450V
	MZKS－ZL－WL－1200	1200A 450V
	MZKS－ZL－WL－800	800A 450V
	MZKS－ZL－WL－600	600A 450V
	MZKS－ZL－WL－400	400A 450V
	MZKS－ZL－WL－200	200A 450V
	MZKS－ZL－WL－100	100A 450V
	MZKS－ZL－WL－50	50A 450V
	MZKS－ZL－WL－25	25A 450V
3-phase AC constant current modules	MZKS－JL－WL－1800	3×1800A 450V
	MZKS－JL－WL－1350	3×1350A 450V
	MZKS－JL－WL－900	3×900A 450V
	MZKS－JL－WL－600	3×600A 450V
	MZKS－JL－WL－450	3×450A 450V
	MZKS－JL－WL－300	3×300A 450V
	MZKS－JL－WL－150	3×150A 450V
	MZKS－JL－WL－75	3×75A 450V
	MZKS－JL－WL－40	3×40A 450V
	MZKS－JL－WL－20	3×20A 450V
Single-phase rectifier constant current modules	MZKD－ZL－WL－2400	2400A 450V
	MZKD－ZL－WL－1800	1800A 450V
	MZKD－ZL－WL－1200	1200A 450V
	MZKD－ZL－WL－800	800A 450V
	MZKD－ZL－WL－600	600A 450V
	MZKD－ZL－WL－400	400A 450V
	MZKD－ZL－WL－200	200A 450V
	MZKD－ZL－WL－100	100A 450V
	MZKD－ZL－WL－50	50A 450V
	MZKD－ZL－WL－25	25A 450V

 

 

Table  2

Name	Type	Specification
Single-phase AC constant current modules	MZKD－JL－WL－1800	1800A 450V
	MZKD－JL－WL－1350	1350A 450V
	MZKD－JL－WL－900	900A 450V
	MZKD－JL－WL－600	600A 450V
	MZKD－JL－WL－450	450A 450V
	MZKD－JL－WL－300	300A 450V
	MZKD－JL－WL－150	150A 450V
	MZKD－JL－WL－75	75A 450V
	MZKD－JL－WL－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、Special constant current models are only made to order and the current value and precision are complied by customers.

 

III. Module Parameters

1、Module Main Parameters（include common parameters and parameters of table 3 and table 4）

 (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

 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 constant current modules	MZKS-ZL-WL-2400	1.35VIN	1800	2400	400	≤80
	MZKS-ZL-WL-1800		1400	1800	400	≤80
	MZKS-ZL-WL-1200		960	1200	400	≤80
	MZKS-ZL-WL-800		600	800	400	≤80
	MZKS-ZL-WL-600		480	600	400	≤80
	MZKS-ZL-WL-400		320	400	400	≤80
	MZKS-ZL-WL-200		160	200	400	≤80
	MZKS-ZL-WL-100		80	100	400	≤85
	MZKS-ZL-WL-50		40	50	400	≤88
	MZKS-ZL-WL-25		20	25	300	≤88
3-phase AC constant current modules	MZKS-JL-WL-1800	1.0VIN	1800	3×1800	400	≤80
	MZKS-JL-WL-1350		1350	3×1350	400	≤80
	MZKS-JL-WL-900		900	3×900	400	≤80
	MZKS-JL-WL-600		600	3×600	400	≤80
	MZKS-JL-WL-450		450	3×450	400	≤80
	MZKS-JL-WL-300		300	3×300	400	≤80
	MZKS-JL-WL-150		150	3×150	400	≤85
	MZKS-JL-WL-75		75	3×75	400	≤85
	MZKS-JL-WL-40		40	3×40	400	≤88
	MZKS-JL-WL-20		20	3×20	300	≤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 constant current modules	MZKD-ZL-WL-2400	0.9VIN	2666	2400	400	≤80
	MZKD-ZL-WL-1800		2000	1800	400	≤80
	MZKD-ZL-WL-1200		1333	1200	400	≤80
	MZKD-ZL-WL-800		888	800	400	≤80
	MZKD-ZL-WL-600		666	600	400	≤80
	MZKD-ZL-WL-400		444	400	300	≤80
	MZKD-ZL-WL-200		222	200	300	≤80
	MZKD-ZL-WL-100		111	100	300	≤85
	MZKD-ZL-WL-50		55	50	300	≤85
	MZKD-ZL-WL-25		28	25	300	≤88
Single-phase AC constant current modules	MZKD-JL-WL-1800	1.0VIN	1800	1800	400	≤80
	MZKD-JL-WL-1350		1350	1350	400	≤80
	MZKD-JL-WL-900		900	900	400	≤80
	MZKD-JL-WL-600		600	600	400	≤80
	MZKD-JL-WL-450		450	450	400	≤80
	MZKD-JL-WL-300		300	300	400	≤80
	MZKD-JL-WL-150		150	150	400	≤85
	MZKD-JL-WL-75		75	75	400	≤85
	MZKD-JL-WL-40		40	40	400	≤88

2.Thyristor Chip Main Parameters   

Table 5

Type	IT(AV)	VRRM  VDRM	ITSM	IRRMIDRM	Tj	di/dt	dv/dt
	Tj＝125℃	Ts＝125℃	45℃10mA	Ts＝125℃	max	.	.
	A	V	A	mA	℃	A/μs	V/μs
MZKS-ZL-WL-800	320	1200～2200	8000	20	125	100	500
MZKS-ZL-WL-600
MZKS-JL-WL-600
MZKS-JL-WL-450
MZKD-ZL-WL-800
MZKD-ZL-WL-600
MZKD-JL-WL-600
MZKD-JL-WL-450
MZKS-ZL-WL-400	250		6400	15
MZKS-JL-WL-300
MZKS-ZL-WL-200	110		2200	10
MZKS-JL-WL-150
MZKD-ZL-WL-400	200		5000	15
MZKD-JL-WL-300
MZKD-ZL-WL-200	100		1800	10
MZKD-JL-WL-150
MZKS-ZL-WL-100	50	1200～1800	1100	10
MZKS-JL-WL-75
MZKD-ZL-WL-100
MZKD-JL-WL-75

         

IV. Forms of Electrical Connection in Modules

[

詞匯翻譯：

輸出： Output     

輸入： Input    

移相調(diào)控器：Phase-shift controller 

電流設(shè)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

]

1. Single-phase rectifier constant current modules

 

2. Single-phase AC constant current modules

 

                           

   3、3-phase rectifier constant current modules

     4、3-phase AC constant current modules

V. Electrical Connection Forms of Module Output Load

[

詞匯翻譯：

輸出： Output   

輸入： Input   

分流器：Current tap

]

 

1、Single-phase rectifier constant current modules

 

  2、Single-phase AC constant current modules

                                  

  3、3-phase rectifier constant current modules

 

 

                

  4、3-phase AC constant current modules

                                         

VI. Installation and Operation of Modules   

1.Modules type selection:

Current of choosed modules must be two times than maximal current of  load in order to make equipments safely work.

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) Specification , color and function of control port pins, see table 6 and figure 9-10.

 

[

詞匯翻譯：

輸出： Output      輸入： Input    

電流設(shè)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.9  five-pin socket  specification             Fig.10  fifteen-pin socket Specification

Table  6

function	color	five-pins socket	fifteen-pin socket
＋12V	red	5	1
GND	Black	4	2
control signal input	black	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.11  hand control interface        Fig.12  computer control interface

                                 

Fig.13  instrument control interface（regulator diode: 2.4ｖ- 2.7ｖ）

4、Constant current using method

(1)Connect with constant current signal output and control signal input. The value of constant current voltage.can be changed through adjusting the resistor. Then output current we want  is constant.

(2)The output current is not constant when we disconnect constant current signal output and control signal input. Now the module works as a fully controlling voltage regulated module. Change the value of control signal input can regulate output voltage of the module through adjusting resistor. See figure 14.

 

              Fig.14  fully controlling voltage regulated connection

VII. Module Protection

1.Over-current protection

The simplest protection method is to connect quick fuses outside of modules. Quick fuses are connected in AC input sides(See figure 15-16).The rated voltage of selected quick fuses must be greater than that of working voltage in circuits. About rated voltage, see table 7.

[

翻譯說明

[輸出： Output     

輸入： Input

]

Fig.15 3-phase modules              Fig.16 single-phase modules

Table 7  current selection of fuses

Module type	Rated current of refuses	Module type	Rated current of refuses
MZKS-ZL-WL-2400	1200	MZKD-ZL-WL-2400	960
MZKS-JL-WL-1800		MZKD-JL-WL-1800
MZKS-ZL-WL-1800	900	MZKD-ZL-WL-1800	720
MZKS-JL-WL-1350		MZKD-JL-WL-1350
MZKS-ZL-WL-1200	480	MZKD-ZL-WL-1200	480
MZKS-JL-WL-900		MZKD-JL-WL-900
MZKS-ZL-WL-800	400	MZKD-ZL-WL-800	320
MZKS-JL-WL-600		MZKD-JL-WL-600
MZKS-ZL-WL-600	300	MZKD-ZL-WL-600	240
MZKS-JL-WL-450		MZKD-JL-WL-450
MZKS-ZL-WL-400	160	MZKD-ZL-WL-400	160
MZKS-JL-WL-300		MZKD-JL-WL-300
MZKS-ZL-WL-200	80	MZKD-ZL-WL-200	80
MZKS-JL-WL-150		MZKD-JL-WL-150
MZKS-ZL-WL-100	40	MZKD-ZL-WL-100	40
MZKS-JL-WL-75		MZKD-JL-WL-75
MZKS-ZL-WL-50	25	MZKD-ZL-WL-50	25
MZKS-JL-WL-40		MZKD-JL-WL-40
MZKS-ZL-WL-25	16	MZKD-ZL-WL-25	16
MZKS-JL-WL-20		.

 

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 can restrain over-voltage produced by thyristors when they vary form connection to shutoff. It can effectively avoid breaking down of modules. About electrical circuits, see figure 17-20. About the value of resistors and capacitors, see table 8-9.

 [

翻譯說明

[輸出： Output     

輸入： Input

]

 

                        

 Fig.17  3-phase rectifier constant current modules           Fig.18 single-phase rectifier constant current modules

                       

 Fig.19  3-phase AC constant current modules                     Fig.20 single-phase AC constant current modules

　

Table  8   

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

Table  9                                      

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

 

(2) Press-sensitive resistors can absorb over-voltage which have more energy and last more time produced by thunder. About electrical circuits, see figure 21-22.The voltage value in press-sensitive resistors varies from 710V to 1000V, that is 710≤V1mA≤1000V.

   [

翻譯說明

[輸出： Output     

輸入： Input

]

 

            

                

 Fig.21  3-phase circuits           Fig.22 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 10 selection of radiators

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

                                      

Table  11

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

   

About shape and dimension of radiators, see figure 23-24.                     

 

      

Fig.23  DXC-578

                                　

Fig.24 DXC-573

VIII. Note                       

1.Modules are commonly prohibited to work with large current when voltage is small. If we do so it will make modules produce more heat and maybe destroy modules because the lead angle is small. The virtual current value is not large even through the peak current value of  thyristors is very large. It is recommended that modules work with large current in the condition of a large lead angle.

2.The signal input voltage of common constant current modules varies from 0V to 10V(or 0～12V).It can be gotten directly from the center junction of a resistor when the resistor is connected to a 12V power supply.

3. 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.

4.Control port required: voltage of power supply is 12V and current is great than 1A.Pay attention not to connect reversely, otherwise it will destroy modules. Resistor value is 10KΩ and the power is greater than 1W.

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

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

7. The content of charts and tables in this specification is only a reference for customers.

  Append: Shape and dimension of radiators(mm)

Table 12                               

Module type	L1	L2	L3	B1	B2	B3	h	4-Φ6-Φ
MZKS-ZL-WL-2400	74	160	185	129	195	220	70	8.5
MZKS-JL-WL-1800
MZKS-ZL-WL-1800
MZKS-JL-WL-1350
MZKD-ZL-WL-2400
MZKD-JL-WL-1800
MZKD-ZL-WL-1800
MZKD-JL-WL-1350
MZKS-ZL-WL-800
MZKS-JL-WL-600
MZKS-ZL-WL-600
MZKS-JL-WL-450
MZKD-ZL-WL-800
MZKD-JL-WL-600
MZKD-ZL-WL-600
MZKD-JL-WL-450

 

MZKS-ZL-WL-200	74	154	174	74	99	120	68	8.5
MZKS-JL-WL-900
MZKD-ZL-WL-1200
MZKD-JL-WL-900
MZKS-ZL-WL-400
MZKS-JL-WL-300
MZKD-ZL-WL-400
MZKD-JL-WL-300
MZKS-ZL-WL-200	40	102	116	41	60	74	41	6.2
MZKS-JL-WL-150
MZKD-ZL-WL-200
MZKD-JL-WL-150
MZKS-ZL-WL-100	32	79	92	32	48	61	42	5.2
MZKS-JL-WL-75
MZKD-ZL-WL-100
MZKD-JL-WL-75
MZKS-ZL-WL-50
MZKS-JL-WL-40
MZKD-ZL-WL-50
MZKD-JL-WL-40
MZKS-ZL-WL-25
MZKS-JL-WL-20
MZKD-ZL-WL-25