T672 3000 Series Brochure 12PP (Page 2)€¦ · their world leading brand of (MoSi2) heaters known...

imagine making theimpossible possible

EPower™Controller

PLMPLMPLMPLMPredictive Load Management

The EPower controller is the latest product in the Eurothermrange of power controllers. It uses the newest technologiesand innovations to manage your process and reduce yourenergy costs. On every level it brings you the flexibility youneed to best meet your requirements now and in the future.Let us look after your power control for you with EPowercontrollers and give you the peace of mind that you have thebest for your process – even as it changes.

Eurotherm has a significant R&D capability and a policy ofcontinuous development, improvement and innovation.Investing in EPower controllers will keep options and newdevelopments within your reach as you can upgrade to meetyour changing requirements at any point.

www.eurotherm.com/EPower

EPower™ controller –extraordinary power controlOur formidable range of power products cover all types of load and voltage but imaginehaving the power to save energy. With many features like high performance alarm strategyand advanced diagnostic load fault detection, Eurotherm is the only choice for your powercontrol applications. Add to this, a strong sales team comprised entirely of degree qualifiedengineers who understand your process, an absolute commitment to innovation, and 5% ofour total sales continuously re-invested in research and development; we can and doimagine making the impossible possible for our customers.

• Flexibility – advanced technologies in harmonywith modularity and ease of use to deliver yourpower control needs

• Efficiency – world class power control withinnovative features to minimise your energy costswith exceptional process performance

• Peace of mind – a power controller that will bringyou return on investment and can be adapted inthe future if your requirements change - oneproduct for all solutions


imagine having thepower to save energy

Easy configuration to save you engineering costs ...

Efficiency through advanced technologies...EPower controllers have measurement accuracy,functionality and innovation that will deliver youextraordinary power control to help your process,environment and budget.

• Measurement accuracy (better than 1%) to help saveenergy

• Load management for better distribution of energy andto minimise peak energy usage costs

• Reduce energy bills and other costs with a selection ofadvanced firing modes to best suit your load type:

– Minimise electrical disturbance

– Increase lifetime of heater elements

EPower™ controller – total flexibilityfrom precision power control

The EPower controller has been designed for easyconfiguration and modification. The front, integral displayhas a “QuickStart” facility that leads the user through initialset up in a series of simple steps. To further saveengineering this QuickStart code can be specified withyour order and the instrument shipped pre-configured.

More advanced configuration can be achieved utilisingiTools PC configuration software – which provides thesignificant assistance of graphical wiring tools anddownloadable function blocks to minimise engineeringtime and cost.

Once you have created your application you can easilysave and clone your work – either as a back-up or todownload to multiple instruments that need the same orsimilar configuration – keeping your work safe and saverepeat engineering costs.

• “QuickStart” for easy commissioning

• Easy save and clone of configuration

• Advanced graphical wiring configuration tools

• Integral front panel operator interface

• Remote display option – can also be used asindependent policeman

• Easy ordering, configuration and maintenancethrough modular design

• If your requirements change EPower controller canbe easily adapted to your needs

• Minimum spares holding – many optionsconfigurable through a common driver modulee.g. firing mode, load phases, control etc.

• Up to four power modules provide single andmulti-phase control

• Software configurable options to bring youflexibility:

You no longer need to be restricted to the optionsthat you order – EPower controller provides you withconfigurable options and modular hardware to giveyou the flexibility to match your process now and inthe future. Combine this with an instrument thatprovides easy configuration via the integral displayand full graphical configuration via iTools PCconfiguration tool as standard – you have a powercontroller that makes life that bit easier.

Revolutionary modularity andconfigurability to meet your needs...

Success stories commercial benefitsTypical saving case – power factor improvement with burst firing

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30 KW EACH

SCR NORMAL TRANSFORMER

Phase angle 0.71 720 h 3,000 kW 3,001 KVAR 4,243 KVA

73,781 € 30,595 € 104,376 €

512,758 €

BUSHING USE 80%

EPOWER LTC 2 TAPS

Burst firing 0.92 720 h 3,000 kW 1,264 KVAR 3,256 KVA

73,781 € 12,891 € 186,672 € 17,704 € 212,450 € 393,402 € 331,806 €

BUSHING 100 ZONES

COMPARATIVE ANALYSIS

Firing modePower factorConsumption for one month / 720hActive energyReactive energyInstalled powerCost for one monthActive power Reactive powerTOTALMONTHLY SAVING ANNUAL VARIABLE SAVINGInstalled power fixed rateANNUAL TOTAL SAVING PRICE LIST Edf GREEN A5

EPower/transformers investment + installation 500,000€ ROI 18 months

For the full stories and all our successes go to www.eurotherm.com/success

Control Type

Single phase

2 x single phase

3 x single phase

4 x single phase

Two phase

2 x two phase

True three phase

FiringModes

Phase angle

Half cycle

Burst firing

Fix modulationperiod

Logic mode

Load Type

StandardResistive

ComplexResistive

Inductivee.g. Transformer

Short WaveInfrared

LoadConfiguration

Single phase

Star

Delta

Star with neutral

Open Delta

Feedback

V2

I2

True power

RMS load voltage

RMS load current

Open loop

• Significant reduction of fixed rate costs

• Reduction of reactive power by almosttwo thirds

• Reduced annual cost for same powerconsumption

• Return on investment within 18 months

New technology to advance heater control and prevent all future overheating

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Customer ChallengeOur customer’s goals were to protect their heaters from over temperature, soextending the heater lifetime and to achieve maximum and consistent power.

Solution • Power controller installed in conjunction with Kanthal Super heaters.• EPower feature used to supply information about heater impedance• EPower unit controlled by a 2704 over Master Comms

Customer Benefits – using EPower controller• Significantly helps prevent overheating and ultimately extends lifetime of the

heater• Enables use of minimum margins for power demand while still preventing

overheating. This keeps the process time and costs down• Reports actual number of kWh or mWh used or saved; vital for precise analysis. • Can ensure the heat treatment process is running at optimum performance at all

times• Predictive Load Management leads to energy savings and possible cost savings


Our client successfully tested a feature of theEPower controller in a new way alongsidetheir world leading brand of (MoSi2) heatersknown as Kanthal Super. A key feature ofMOSi2 heaters is the relationship betweenimpedance and heater temperature.

The EPower controller – the bestsolution for your power controlWith EPower controllers you are not only buying one of the bestpower controllers in the world, you are supported by a global networkof application and control specialists from Eurotherm. While we are atruly global company, we have not forgotten that you still need localsupport and understanding. Our team will bring you technicalexpertise along with in depth experience and understanding innumerous application areas – from glass furnaces, to semiconductormanufacture, to the heat treatment of metals and many more. TheEPower controller is one product for all your solution needs.

We can provide you with a range of services to suit your needs – fromtraining to commissioning and maintenance contracts for yourinstallation.

Easy Maintenance

• Modular design for easy management of spareparts and quick mean time to repair (MTTR)

• Fast and easy configuration

• Easy wiring, installation and commissioning

• Remote Display option

The option that you need ...

Success for renewable energy wafer technology

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Customer ChallengeOur client needed to control immense power with absolutely no loss of stability oraccuracy.

Solution• Power control panel for reactor control• New Load Tap Changing block application with EPower controller• All enable manufacture of thin film solar modules and the result is best in class

Customer Benefits• Unmatched accuracy, stability and quality of power control • Perfect continuity of power during the transformer tap switches. The Load Tap

Changing application vastly improves power factor.• Huge savings expected to exceed future government energy cost saving target• Reduced energy bills• Unaffected high quality production• One of best power solutions in industry today

A single driver module can support up to four powermodules – and hence four independent control loops.Power modules are available in current ratings coveringa range from 50A to 630A in compact version and upto 4000A in high current version. The driver moduleitself supports option boards to give you additionalflexibility in your solution:

• Communications – RS485 Modbus RTU, Profibus,DeviceNet®, Modbus TCP network protocols, CC-Link, EtherNet/IP and ProfiNet

• Predictive Load Management (PLM) – A powerfulfeature to effectively manage your powerrequirements across multiple machines to save onyour energy costs

• Flexible I/O – The driver module supports standardI/O and up to three additional I/O boards withanalogue inputs, analogue outputs, digital I/O andrelay outputs

• LTC – The Load Tap changer option for single phaseunit applications only, allows for managing multi-tap transformers, preventing both increasedharmonics and the reduction of power factor

• Energy Counter – Available over communicationsand for display on user screens, customers canaccess up to 5 scalable counters, one per individualphases and a global energy usage counter

The high current version (decentralised) of EPower willbe able to manage current ratings from 800A to 4000Aand support from 1 to 4 phases. To make theintegration easy, the product is divided in two parts:

• The driver module providing all firing interfaces(MC : Module of Control)

• The power stack(s) cooled by air (800A to 2000A)or water (2000A and 4000A)

All the functionalities of the compact version remainavailable on the high current version (Quick startconfiguration, IO boards, PLM, comms capabilitiesetc.), providing all the benefits of flexibility, efficiencyand peace of mind.

Providing a total solution for your application, the MCEPower is supplied with all the necessary accessories(e.g. cable, current transformer, fuses etc.) to ensureoptimum performance.

Success stories commercial benefits

An exciting collaboration resulted inoutstanding solution for our client, a worldleader and pioneer in the design anddevelopment of wafer technologies used forthe manufacture of solar panels.


EPower controllers have not only been designed to beworld-class power controllers that you can rely on, theyhave been designed to integrate perfectly into a widercontrol system.

Whatever your system communication preferences are –Modbus RTU, Profibus, DeviceNet, Modbus TCP/IP, CC-Link, EtherNet/IP, ProfiNet – EPower controllers caneasily be integrated into your system and send theinformation you need about your load (current, voltage,alarms etc) so that you stay in control of your process.

Whether you need this latest power controller in a newsystem or to upgrade an existing system – Eurotherm canhelp you. Our expertise is not limited to power control – thefull benefit of EPower controllers can be optimised usingour engineers as experts in creating complete solutions andtotal, plant-wide DCS.

Throughout our product ranges – controllers, recorders,power controllers, signal conditioning, automation solutionsand DCS – you will get expert knowledge, support andworld class solutions. We can assist you with small andlarge applications and offer complete life cycle support andpartnership engineering teams – whatever you need, we arethere to work with you.


A product to integrate into acomplete solution

3RD PARTYINTEGRATION

3RD PARTYINTEGRATION

EYCON 20VISUAL SUPERVISOR

EYCON™ 10VISUAL

SUPERVISOROPERATIONS

SERVER

6180APAPERLESSGRAPHIC

RECORDER

BUSINESSSYSTEMS

OPERATIONSVIEWER

ACTIVEFACTORY

3216CONTROLLER

32h8eEPOWER CONTROLLER

REMOTE DISPLAY

T2550PROGRAMMABLE

AUTOMATIONCONTROLLER

T2550PROGRAMMABLE

AUTOMATIONCONTROLLER

EPOWER CONTROLLER

FACTORY ETHERNET

CONTROL ETHERNET

SERIAL COMMS


You can reduce your energy costs across yourplant by utilising the Predictive LoadManagement (patent pending) functionalitywithin the EPower controller. This new featureprovides a better distribution of energy acrossdifferent loads in your installation, bymanaging the priority and, if necessary, loadshedding.

The EPower controller prevents overshoot ofthe nominal power. This will keep you withinthe limits of your electrical contract for yourinstallation and prevent increases in energytariffs imposed by your supplier. Unlike othersoftware offering this type of feature, PredictiveLoad Management from Eurotherm anticipatesyour energy usage rather than just reactingwhen you have already exceeded your tariffpeak.

Using EPower controllers with Predictive LoadManagement could well be one of the bestvalue decisions you could make for your plant!

Predictive Load Management – the best innovation for energy management

Power consumed with “Predictive Load Management”

Power consumed without “Predictive Load Management”


Typical savings case with Predictive Load Management at peak rate

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• Reduced KW Power

• Reduced energy usage

• Reduced annual cost on electricity bill

• Return on investment within 4 months

2900 15000 3000 Hours 2309 1762 1553 2953 2201Fix rate calculationReduced power KWFix rate cost €ANNUAL SAVING €Variable rate calculationVariable rate cost €ANNUAL SAVING €

TOTAL SAVINGS €

TOTAL POWER OF FURNACES KWAVERAGE POWER DEMAND KWSUPPLY SUBSCRIPTION KW TypePeak (TTE)Winter peak hours (HPH)Winter off -peak hours (HCH)Summer peak hours (HPE)Summer off-peak hours (HCE)PRICE LIST Edf GREEN A5

EPower investment + installation £ 70,000€ ROI 4 months

20 ZONES FURNACE USE Power without PLM 1,500 1,500 1,500 1,500 1,500 without PLM 3,000 362,520

without PLM 334,317

145 85%Power with PLM 1,300 1,400 1,500 1,400 1,500 with PLM 1,398 168,934 193,568 with PLM 318,021 16,296

209,881

Success stories commercial benefits


Greater energy efficiency in buildings using the EPower controller to improve power factor

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Energy efficiency for electricity generation with EPower controller Predictive Load Management (PLM)

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Customer ChallengeOur client needed to control power usage across the whole process to comply withstrict emissions tolerance legislation to meet efficiency targets for 2020 which detailreduction in greenhouse gasses by 20% and an increase in usable energy efficiencyby 20%.

Solution• EPower controller installed on heat treatment furnace• Using Predictive Load Management to regulate power input

Customer Benefits• Use of PLM means the EPower controller meets industrial demands for energy

efficiency and can reduce energy bills by 9%.• Reduced energy costs by providing more efficient distribution across a variety of

loads and conditions.• Enables customer to stay within emissions tolerance limits – better for the

environment • Accurate record keeping that provides proof of the provider’s compliance• More efficient energy production and distribution for the customer. • Company executives estimate that the solution will reduce energy costs by

improving overall process efficiency by as much as 10%”

With EPower controllers, you will obtain an excellentreturn on your investment

In today’s economy, energy efficiency or, moreaccurately, the lack of it, is a hotly debatedtopic. One point that often evades thespotlight is the amount of energy required toactually produce the world’s electricitysupplies.

Customer ChallengeOur client needed to improve effective climate management in a very large butolder office building to ensure a comfortable environment for all employeeswhile avoiding huge energy bills.

Solution• The Eurotherm solution included EPower three-phase modules, receiving set

point values via Modbus to a Field Controller, and driving Vulcan Radiatorelectric baseboard heaters

• Using the Predictive Load Management feature• Using Zero Cross firing – replacing phase angle SCRs

Customer Benefits• Improved energy savings • Reduced previous noise interference• Power factor improvements• Created a more comfortable and efficient working environment

Our prestigious client had the same problemthat most companies have, keeping employeescomfortable while they are at work.


Tin Bath furnace in float manufacturing Three phasepower supply

Multizone control

Molten glass

Multizone heating

Roof heatingwith silicon

carbide elements

Transformer Transformer

Molten tin

Melting is one of the first steps in the ‘float’ process’. At thisstage glass is in liquid state in a molten furnace at around1550°C. Roof heating is made by silicon carbide heaters.EPower Controller controllers provide all the solutions tothe multizone control of this specific heater elements.

• Ageing compensation of the silicon carbideheaters with power control

• Power distribution control in the heater elementsproviding cost savings: suppression of inrush currentfor a better energy management and a minimumstress on the power transformers

• Digital communication with standard protocolsfor an efficient process monitoring

• Use Predictive Load Management across theglass plant to reduce energy costs

00.000

0.100

0.200

0.300

0.400

0.500

0.600

0.700

0.800

0.900

1.000

10 20 30 40 50 60 70 80 90 100

Real-world applications

T2550Input/output control

Eycon™ Visual SupervisorVacuum furnace controlEnergy controlEfficiency optimization

EPower ControllerControlModularityEnergy informationSeveral switching modesiTools software configurationDigital communications

Vacuumdevice

Digital communication

Policeman/Remote display

Vacuum furnace in heat treatment• Heater element control

• Power repartition in heating elements providing energy saving

• Alarm strategy

• Digital communication allowing supervisory control

• Use Predictive Load Management across multiplefurnaces to reduce energy costs

Load tap changerThe load tap changer (LTC) is a method of improvingthe perceived power factor and harmonic distortionwhen controlling a load that is required to be driven inphase angle firing mode.

This is achieved by automatically switching a number oftaps on the load transformer. This control can beperformed on the primary of the transformer where themaximum tap voltage is the limiting factor or thesecondary of the transformer where the maximumcurrent is the limiting factor.

The Load Tap Changer requires the External Feedbackoption.

Primary connection

Secondary connection

The operating region of control will determine thenumber of taps required but a maximum of 4 is usuallysufficient.

Power Factor Curves for different numbers of taps.

Power (%)

Pow

er F

acto

r

Semiconductor manufacturingSilicon was discovered in 1823 and is used in the manufacture of today'ssemiconductors.

Semiconductors need a silicon of a very high purity and, therefore, the silicon istransformed by successive stages (crystal growing, epitaxy) that need very slow andaccurate heating.

The EPower Controller will provide many solutions to this specificand expensive process:

• Precise and steady control of the heater elements

• Advanced and configurable strategy enables the EPowerController to adapt to the load state

• Secure your process utilising a comprehensive alarm strategyand by transferring process information to a supervisor


LOA

D

Ph

N

Tap1

Tap2

V2

V1

LOAD

Tap1

Tap2V2

V1N



POWER MODULES (UP TO 4*)

FREQUENCY 47 to 63HzOPERATING TEMPERATURE Nominally 40° C,

Operation 0 to 50°C de-rating applied over 40°CCOOLING FANS/TURBINES ≥160AFAN/TURBINE SUPPLY 115V or 230VFIRING MODES Phase angle

Half CycleBurst FiringFixed ModulationLogic

LOAD TYPES Standard ResistiveComplex ResistiveInductive loads e.g. Transformer

LOAD CONFIGURATION Single phase Ph/Ph or Ph/NTwo leg control 3 wire star or deltaThree phase control 3 or 4 wire star, 3 or 6 wire delta

POWER MODULE COMBINATIONS 1, 2, 3 or 4 single phase (1, 2, 3 or 4 modules)1, or 2 x two leg (2 or 4* modules)1 x 3 phase (3 modules)

FEEDBACK TYPES Open LoopV2

I2True Power VrmsIrms

COMPACT POWER MODULE VOLTAGE RANGES 100 to 600V ac, 100 to 690V acCURRENT RANGES in compact version 50A, 100A, 160A, 250A, 400A, 500A, 630A

Nominal current range 16 to 630AFEEDBACK Internal voltage and current

Order option – External voltage and currentAPPROVALS CE (EN 60947-4-3), UL 508

MC POWER MODULE VOLTAGE RANGES 100 to 690V acCURRENT RANGES in high current version

Air cooled 800A, 1000A, 1300A, 1700A, 2000AWater cooled 2000A, 3000A, 4000A

TURBINE SUPPLY 115W or 230WFEEDBACK External voltage and currentAPPROVALS CE (EN 60947-4-3)


Selection guide andtechnical specifications

DRIVER MODULE º SUPPLY VOLTAGE 85 to 264V acSUPPLY FREQUENCY 47 to 63HzPOWER CONSUMPTION 120WTEMPERATURE LIMITS 0 to 50°C operating, -25 to 70°C StorageDISPLAY 4 lines dot LCD matrix arrayCOMMUNICATIONS Modbus RTU 2 wire EIA485

Modbus TCP/IP 10baseT EthernetProfibus DPv1DeviceNet network protocolCC-LinkEtherNet/IPProfiNet

INPUTS AND OUTPUTS Standard 2 Analogue inputs1 Analogue output2 Digital inputs/outputs2 Relay SPDT (1= Watchdog)

Optional modules (max 3) Per module - 1 Analogue input1 Analogue output2 Digital inputs1 Relay

MEASUREMENT ACCURACY Better than 1%REMOTE PANEL Dedicated remote panel port

32h8e panel indicatorQUICKSTART Configurable by order code or on start up via

dedicated front panel HMIPREDICTIVE LOAD Optional module connecting up to 63 instruments MANAGEMENT (PLM) over dedicated communications (CAN based).

Configurable PLM (optimises energy usageSOFTWARE OPTIONS Load Tap Changer (single phase)

Energy CounterAPPROVALS CE (EN 60947-4-3), UL 508

© Copyright Eurotherm Limited 2012

Invensys, Eurotherm, the Eurotherm logo, Chessell, EurothermSuite, Mini8, Eycon, Eyris, EPower, nanodac, Foxboro and Wonderware are trademarksof Invensys plc, its subsidiaries and affiliates. All other brands may be trademarks of their respective owners.

All rights are strictly reserved. No part of this document may be reproduced, modified, or transmitted in any form by any means, nor may it be storedin a retrieval system other than for the purpose to act as an aid in operating the equipment to which the document relates, withoutthe prior written permission of Eurotherm Limited.

Eurotherm Limited pursues a policy of continuous development and product improvement. The specifications in thisdocument may therefore be changed without notice. The information in this document is given in good faith, but isintended for guidance only.

Eurotherm Limited will accept no responsibility for any losses arising from errors in this document.

Part No. HA029668 Issue 6 Printed in England on recycled paper 01.12

Represented by:

Eurotherm is also represented in thefollowing countries:Eurotherm:

International sales and service

www.eurotherm.com

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ED66

T672 3000 Series Brochure 12PP (Page 2)€¦ · their world leading brand of (MoSi2) heaters known...

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Transcript of T672 3000 Series Brochure 12PP (Page 2)€¦ · their world leading brand of (MoSi2) heaters known...