RE-PR3-DIN

Issue: 5.4
Date Of Issue: 03/12/2009
© 2009 Sontay Limited. All rights reserved.

Three-Phase 12 & 18kW Heater Controllers

Features

• 0-10Vdc Control input

• Over temperature protection with auto reset
• No additional heatsinks required
• No external RFI filters required

Specification Product Codes

Input signal 0-10Vdc RE-PR3-DIN-12

External supply (control)24Vac/dc ±10% @40mA Din rail mount, 3-phase 12kW electric heater
Supply (load) 3-Phase 24 to 440Vac RMS controller
50Hz/60Hz
Power/current ratings: RE-PR3-DIN-18
RE-PR3-DIN-12 12kW (16.7A per phase) @ 415Vac Din rail mount, 3 phase 18kW electric heater
RE-PR3-DIN-18 18kW (25A per phase) @ 415Vac controller
Fusing (recommended):
RE-PR3-DIN-12 20A High speed semiconductor
fuses or equivalent Z curve MCB’s
RE-PR3-DIN-18 30A High speed semiconductor
fuses or equivalent Z curve MCB’s
Terminal connections:
Control Rising cage for 2.5mm² cable max.
Power Rising cage for 6mm² cable max.
Terminal torque setting 0.8Nm (only required for power
terminals)
Over temperature:
Trip temp. @ 90°C ±5°C
Reset temp. @ 85°C ±5°C
Fault condition 24Vac/dc (as power supply)
LED indication T1 & T3 LED’s pulse when output is
ON
Ambient temperature 0-40°C max.
Dimensions (W, H, D):
RE-PR3-DIN-12 217 x 87 x 90mm
RE-PR3-DIN-18 217 x 87 x 110mm
Conformity CE Marked
Country of origin UK

UK Sales Tel: 0845 345 7253 International Tel: +44 1732 861225
Page 1 of 5
 RE-PR3-DIN
Issue: 5.4
Date Of Issue: 03/12/2009
© 2009 Sontay Limited. All rights reserved.

SAFETY REQUIREMENTS & ADVICE SHEET

Introduction Fusing
The objective of this leaflet is to provide information to en- We recommend that semiconductor, fast acting to BS88 IEC
sure that the safety of the person(s) installing or maintain- 269, type fuses or circuit breakers (Semiconductor - MCB)
ing the equipment is not compromised and its location and should be used for unit and/or device protection. The ap-
method of installation does not endanger others, either propriate maximum load current should be known to select
during or after installation. the required SCR fuse or Z curve MCB, but must not exceed
Customers should be aware of the Health and Safety at the equipment rating. The I² t (A² s) rating of the selected
Work Act 1974 (HSW 1974) and the EC “Provision and Use fuse must be less than that of the equipment so as to pro-
of Work Equipment Regulations 1992” (PUWER). Both are tect the equipment’s discrete device. Further appropriate
available from the Health and Safety Executive (HSE) publi- fusing may be required for protection of the unit supply
cations, within the UK. using standard fuse links and holders. Failure to address
these requirements and the use of incorrectly selected fuses
Installation may cause the equipment to fail.

CE Directives Earthing
These are European regulations which apply to our industry. The protective conductor terminal of the equipment must be
They affect the equipment emissions and immunity to Radio utilised at all times and bonded to a ‘good’ Earth (ground).
Frequency Interference (RFI) and various elements of safety The earth bonding (strapping) leads of any combined equip-
for electrical equipment. ment should be as short as possible and be substantial, i.e.
The European Community ‘CE’ Directives that mainly con- at least rated higher than the equipment’s load. For further
cern Sontay Ltd are, the Low Voltage Directive (LVD) and information, refer to BS7671. Following these simple guide-
the Electromagnetic Compliance Directive (EMC). lines will ensure optimum use of any appropriate filter cir-
A Declaration of Conformity may be supplied with the prod- cuits which may be required.
uct or supplied on request.
Insulation (over-voltage category) and Protection
Torque Settings from electric shock Classification of Equipment
Good working practises must be adhered to ensuring appro- All equipment, unless otherwise stated, is rated to CLASS II
priate electrical and mechanical installation. This would in- Insulation (Over-voltage category) and CLASS I (Protection
clude the mechanical fixing of potentiometer bushes and category).
electrical set screw and/or pillar connections. These Electri-
cal Connections and Mechanical Fastenings must not be over Maintenance
tightened. We would recommend a typical torque setting of Before any servicing is carried out, reference should be
1 to 5Nm. For specific product information, see appropriate made to appropriate installation instructions, drawings and
product data sheet, where applicable. labelling which may come with the equipment. Personnel
should switch off the unit supply before accessing or remov-
Cooling Requirements ing any safety cover and be aware of hazardous live parts.
The use of an additional heatsink (this could be a conductive
panel) suitably attached or mounted with the unit, will help
to dissipate heat away from the device(s). An alternative or
additional method would be forced air-cooling (using a fan),
to assist the natural convection of airflow over an existing
heatsink within the unit. The product fins should be
mounted in line with the forced and/or natural airflow.
The equipment’s environment and its initial ambient tem-
perature also need to be considered, as this could have an
adverse effect on the overall operating conditions.

UK Sales Tel: 0845 345 7253 International Tel: +44 1732 861225
Page 2 of 5
 RE-PR3-DIN
Issue: 5.4
Date Of Issue: 03/12/2009
© 2009 Sontay Limited. All rights reserved.

Technical Overview Maximum Heating Load

The RE-PR3-DIN series are a range of thyristor stacks which The total installed kW rating of the heating load must not
provides full seamless control of 415V supply loads, using exceed the maximum kW duty rating, see specification on
the two-thirds control technique, to provide adjustable con- page 1.
trol output in proportion to the demand control signal.
These burst fire control assemblies use zero volt switching Fuse Back-Up Protection
technology, to minimise RFI problems. They also incorporate
a temperature trip, automatic reset, alarm output, LED Fuses or MCB’s (circuit breakers) are required to provide
’output on’ indication and heatsink. back up protection. To select the required fuses or Z curve
Applications include electric heater batteries and dust heat- MCB’s (circuit breakers), the load current should be known,
ers. but not exceed the electric heater battery rating.

Location & Ventilation Alarm Output

The unit is designed to be installed on DIN rail in an electri- 24Vac/dc (as power supply) is normally present at the alarm
cal control panel, and should be installed with the heatsink terminal. In the event of over temperature, a sensor fault,
cooling fins in a vertical plane. Allow a minimum of 100mm or loss of power supply, the output of the unit will fail to
between units on the vertical axis. OFF with no output.
The maximum ambient of 40°C should not be exceeded.
Where necessary control panels & enclosures should be Manual Override
ventilated with a fan.
The unit can be placed in manual mode by setting the pcb
Over Temperature Monitoring jumper A/M to the M position. The RE is factory supplied
with the jumper in the A position. In the M position the RE
The RE-PR3-DIN series are fitted with a thermal protection will give a fixed load output of 100%.
device to protect against over temperature. The unit will
automatically switch off the load in the event of the heatsink Three-Phase Connections
temperature exceeding safe limits (90°C ±5°C). Once the
temperature has fallen to a safe level (85°C ±5°C) the load Three phase units can be installed with the heating load in
will be switched on again if the supply is still present. either star or delta configuration. It is essential that in the
Under normal operating conditions the heatsink will not star mode the star point is not connected to neutral. Termi-
reach 90°C but this might occur, for example when the am- nals L2 & T2 are internally linked. If local regulations permit,
bient temperature exceeds 40°C. the L2 supply can be connected directly to the heater ele-
ment (bypassing the RE unit).
Caution: During the course of normal operation metal
parts, in particular the heatsink, may get very hot. Load considerations

Control Supply The RE-PR3-DIN series of power controllers are designed for
resistive type loads only. Capacitive, or unusual heating
The control pcb is fully isolated from the load supply and loads such as Molybdenum, Platinum or Tungsten, (which
requires a 24Vac/dc supply to operate the electronics. The can have a 10:1 hot to cold resistance ratio) are not suit-
control supply common is internally linked to the input signal able.
common.

Load Supply

The RE-PR3-DIN series are designed for resistive type loads

in ’star’ or ’delta’ configurations. It is recommended that a
load break switch and a contact breaker is installed in the
load supply. The supply to the contactor coil should be inter-
rupted by an over-temperature thermostat located in the
heater battery and also upon detection of airflow loss.

UK Sales Tel: 0845 345 7253 International Tel: +44 1732 861225
Page 3 of 5
 RE-PR3-DIN
Issue: 5.4
Date Of Issue: 03/12/2009
© 2009 Sontay Limited. All rights reserved.

Cycle Time Signal Rescaling (continued)

The cycle time is factory preset at 1 second. At this setting Potentiometer VR1 sets the maximum power output. This
and with the 0-10Vdc control signal at 5Vdc the RE will be can be measured using a multimeter across the test pins on
pulsed for 50% of the cycle time, i.e. 0.5 seconds. The cycle jumper HD3. At 100% output the measured voltage across
time can be adjusted to between 1 and 255 seconds to suit HD3 is 4Vdc
the application and/or any supply authority requirements. If required, the output can be changed to reduce the maxi-
mum output. The voltage at HD3 should be set at a propor-
Adjusting The Cycle Time tion of 4Vdc for a 10Vdc input, i.e. for a 75% output the
voltage at HD3 would be 75% of 4Vdc = 3Vdc for a 10Vdc
Adjustment is not normally required. See above for func- input.
tional description.
Installation
Apply the 24Vac/dc control supply.
1. The RE-PR3-DIN should only be installed by a compe-
The cycle time can be adjusted to any of the periods given tent, suitably trained technician, experienced in installa-
in the table below. tion with hazardous voltages. (>50Vac & <1000Vac or
>75Vdc & 1500Vdc)
Using a multimeter measure the dc voltage across the pins
on test jumper HD4. The cycle time is factory set at 1 2. Ensure that all power is disconnected before carrying out
second which equates to a measured voltage of 0Vdc. any work on the RE-PR3-DIN.
Adjust potentiometer VR2 until the desired dc voltage is
measured. 3. Maximum cable size is 2.5mm² (6mm² for power), care
must be taken not to over tighten terminals.
Cycle Time Adjustment Table: (Nominal voltages ±0.1Vdc)
4. When mounting the RE-PR3-DIN care should be taken
DC Volts Seconds DC Volts Seconds
not to stress the PCB when fitting to the DIN rail. If it is
0 1 1.8 90
necessary remove the module from the DIN rail, be sure
0.2 10 2 100
to use a flat bladed screwdriver to release the DIN clips.
0.4 20 2.3 120
0.6 30 2.7 140 5. The RE-PR3-DIN is designed to operate from a 24Vac/
0.8 40 3.1 160 dc supply (so that power can be drawn from a 24Vac
1 50 3.5 180 transformer used for other purposes if a 24Vdc supply is
1.2 60 3.9 200 not available). In either case one side of the supply is
1.4 70 4.3 220 common to the signal ground from the BEMS controller.
1.6 80 5 255
Caution: When monitoring 230Vac inputs, dangerous volt-
Signal Rescaling ages are present on the terminal blocks and on the printed
circuit board. Care MUST be exercised to avoid coming into
The RE is factory supplied to give 100% load output at contact with live components.
10Vdc input. For optimum control the signal input circuitry
can be rescaled to reduce the RE maximum power output
(see below). This feature can be utilised where only a pro-
portion of the installed heating load is needed
(NB - The total installed kW rating of the heating
load must not exceed the maximum RE kW duty rat-
ing).

Adjustment is not normally required.

Apply the 24Vac/dc control supply.

UK Sales Tel: 0845 345 7253 International Tel: +44 1732 861225
Page 4 of 5
 RE-PR3-DIN
Issue: 5.4
Date Of Issue: 03/12/2009
© 2009 Sontay Limited. All rights reserved.

Connections

HD3 HD4
T1 T3 M

A
VR1 VR2 L1 T1 L2 T2 L3 T3

Override
jumper Terminals L2 & T2 out are
connected internally. L2 supply
L1 may be connected directly to
Alarm output
0-10Vdc input signal
0V
24V

heater element if local regulations

L2
permit
L3

(Star)
(Delta)

Load (heater)

Alternative load
(heater) configuration

WARNING! Do not connect neutral to star point of

heater.

UK Sales Tel: 0845 345 7253 International Tel: +44 1732 861225
Page 5 of 5
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Whilst every effort has been made to ensure the accuracy of this specification, Sontay cannot accept responsibility for damage, injury, loss or
expense resulting from errors or omissions. In the interest of technical improvement, this specification may be altered without notice.