EPower CONTROLLER EUROTHERM® FLEXIBLE SOLUTIONS THE FUTURE OF POWER CONTROL ™ PLM PLM PLM Predictive Load Management EPower Controllers are the latest products in the Eurotherm range of power controllers. It uses the newest technologiesinnovations to manage your process and reduce your energy costs. On every level it brings you the flexibility you need to best meet your requirements nowin the future. Let us look after your power control for you with EPower Controllersgive you the peace of mind that you have the best for your process – even as it changes. Eurotherm has a significant R&D capabilitya policy of continuous development, improvementinnovation. Investing in EPower Controllers will keep optionsnew developments within your reach as you can upgrade to meet your changing requirements at any point. Flexibility – advanced technologies in harmony with modularityease of use to deliver your power control needs Efficiency – world class power control with innovative features to minimise your energy costs with exceptional process performance Peace of mind – a power controller that will bring you return on investmentcan be adapted in the future if your requirements change - one product for all solutions Revolutionary modularity and configurability to meet your needs... Easy ordering, configurationmaintenance through modular design If your requirements change EPower Controller can be easily adapted to your needs Minimum spares holding – many options configurable through a common driver module e.g. firing mode, load, phases, control etc. Up to four power modules provide single and multi-phase control Software configurable options to bring you flexibility: You no longer need to be restricted to the options that you order – EPower Controller provides you with configurable optionsmodular hardware to give you the flexibility to match your process nowin the future. Combine this with an instrument that provides easy configuration via the integral displayfull graphical configuration via iTools PC configuration tool as standard – you have a power controller that makes life that bit easier. www.eurotherm.com/EPower EPower™ Controller – extraordinary power control 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 Firing Modes Phase angle Half cycle Burst firing Fix modulation period Logic mode Load Type Standard Resistive Complex Resistive Inductive e.g. Transformer Short Wave Infrared Load Configuration Single phase Star Delta Star with neutral Open Delta Feedback V2 I2 True power RMS load voltage RMS load current Open loop The options that you need... A single driver module can support up to four power modules –hence four independent control loops. Power modules are available in current ratings covering a range from 100A to 400A. The driver module itself supports option boards to give you additional flexibility in your solution: Communications – RS485 Modbus RTU, Profibus, DeviceNet®Modbus TCP network protocols Predictive Load Management (PLM)* – A powerful feature to effectively manage your power requirements across multiple machines to save on your energy costs Flexible I/O – The driver module supports standard I/Oup to three additional I/O boards with analogue inputs, analogue outputs, digital I/O and relay outputs. * patent pending PLM PLM PLM Predictive Load Management The EPower Controller has been designed for easy configurationmodification. The front, integral display has a “QuickStart” facility that leads the user through initial set up in a series of simple steps. To further save engineering this QuickStart code can be specified with your orderthe instrument shipped pre-configured. More advanced configuration can be achieved utilising iTools PC configuration software – which provides the significant assistance of graphical wiring tools and downloadable function blocks to minimise engineering timecost. Once you have created your application you can easily saveclone your work – either as a back-up or to download to multiple instruments that need the same or similar configuration – keeping your work safesave repeat engineering costs. “QuickStart” for easy commissioning Easy saveclone of configuration Advanced graphical wiring configuration tools Integral front panel operator interface www.eurotherm.com/ E Power Easy configuration to save you engineering costs ... www.eurotherm.com/EPower EPower Controllers have measurement accuracy, functionalityinnovation that will deliver you extraordinary power control to help your process, environmentbudget. Measurement accuracy (better than 1%) to help save energy Load management for better distribution of energyto minimise peak energy usage costs Reduce energy billsother costs with a selection of advanced firing modes to best suit your load type: – Minimise electrical disturbance – Increase lifetime of heater elements Improve power factor Energy saving Easy maintenance Efficiency through advanced technologies... You can reduce your energy costs across your plant by utilising the Predictive Load Management (patent pending) functionality within the EPower Controller. This new feature provides a better distribution of energy across different loads in your installation, by managing the priority and, if necessary, load shedding, The EPower Controller prevents overshoot of the nominal power. This will keep you within the limits of your electrical contract for your installationprevent increases in energy tariffs imposed by your supplier. Unlike other software offering this type of feature, Predictive Load Management from Eurotherm anticipates your energy usage rather than just reacting when you have already exceeded your tariff peak. Using EPower Controllers with Predictive Load Management could well be one of the best value decisions you could make for your plant! www.eurotherm.com/ E Power Predictive Load Management – the best innovation for energy management Power consumed with “Predictive Load Management” PLM PLM PLM Predictive Load Management Power consumed without “Predictive Load Management” www.eurotherm.com/EPower A product to integrate into a complete solution EPower Controllers have not only been designed to be world-class power controllers that you can rely on, they have been designed to integrate perfectly into a wider control system. Whatever your system communication preferences are – Modbus RTU, Profibus, DeviceNet, Modbus TCP/IP – EPower Controllers can easily be integrated into your systemsend the information 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 new system or to upgrade an existing system – Eurotherm can help you. Our expertise is not limited to power control – the full benefit of EPower Controllers can be optimised using our engineers as experts in creating complete solutionstotal, plant-wide DCS. Throughout our product ranges – controllers, recorders, power controllers, signal conditioning, automation solutionsDCS – you will get expert knowledge, supportworld class solutions. We can assist you with smalllarge applicationsoffer complete life cycle supportpartnership engineering teams – whatever you need, we are there to work with you. 3RD PARTY INTEGRATION OPERATIONS SERVER OPC SERVER BUSINESS SYSTEMS OPE V T820 LOCAL HMI 3216 CONTROLLER T2550 PROGRAMMABLE AUTOMATION CONTROLLER T2550 PROGRAMMAB AUTOMATION CONT EPOWER CONTROLLER www.eurotherm.com/ E Power 3RD PARTY INTEGRATION EYCON 20 VISUAL SUPERVISOR EYCON™ 10 VISUAL SUPERVISOR 6180A PAPERLESS GRAPHIC RECORDER ERATIONS VIEWER ACTIVE FACTORY T820 LOCAL HMI 32H8I EPOWER CONTROLLER REMOTE DISPLAY BLE TROLLER EPOWER CONTROLLER www.eurotherm.com/EPower Real-world applications VACUUM FURNACE IN HEAT TREATMENT BOOSTING POWER CONTROL AND MONITORING IN GLASS INDUSTRY Molten glass is a conductor of electricity. Passing high currents through the glass produces direct heating in the resistance presented by the glass, named boosting. This heating is beneficial as it heats the‘colder’ bottom glass in the furnace. This heated bottom glass rises towards the tophas a stirring effect which helps with melting, heat transfertemperature homogenisation. Boosting is often used to meet periodic fluctuations in production demand or to support the pull rate of a furnace at the end of its operating life. Boosting may also help to reduce NOx emissions. In this application the EPower Controller is controlling the power injected by the electrodes in the molten glass while controlling the true power or the current (the power injected is self compensated by the glass temperature) Controlled convection currents to promote homogeneity Accurate true power or electrodes current control Digital communication allowing process parameters to be monitored by a supervisor: current, voltage, poweralarms Electrodes Molten glass Three phase power supply T2550 Input/output control Eycon™ Visual Supervisor Vacuum furnace control Energy control Efficiency optimization EPower Controller Control Modularity Energy information Several switching modes iTools software configuration Digital communications Vacuum device Digital communication COMPOSITE MATERIAL In composite material production polymerisation is made in an autoclave at very high temperature. EPower Controller controls heating by providing: Detection of total and/or partial load failure Optimization of the distribution of heating control in the different areas providing real cost savings Standard communications for process controlmonitoring on HMI Down time reduction due to the modular design Policeman/Remote display Heater element control Power repartition in heating elements providing energy saving Alarm strategy Digital communication allowing supervisory control Use Predictive Load Management across multiple furnaces to reduce energy costs PLM PLM PLM Predictive Load Management Melting is one of the first steps in the ‘float’ process’. At this stage glass is in liquid state in a molten furnace at around 1550°C. Roof heating is made by silicon carbide heaters. EPower Controller controllers provide all the solutions to the multizone control of this specific heater elements. Ageing compensation of the silicon carbide heaters with power control Power distribution control in the heater elements providing cost savings: suppression of inrush current for a better energy managementa minimum stress on the power transformers Digital communication with standard protocols for an efficient process monitoring Use Predictive Load Management across the glass plant to reduce energy costs www.eurotherm.com/ E Power SEMICONDUCTOR MANUFACTURING Silicon was discovered in 1823 and is used in the manufacture of today''s semiconductors. Semiconductors need a silicon of a very high purity and, therefore, the silicon is transformed by successive stages (crystal growing, epitaxy) that need very slowaccurate heating. The EPower Controller will provide many solutions to this specific and expensive process: Precisesteady control of the heater elements Advancedconfigurable strategy enables the EPower Controller to adapt to the load state Secure your process utilising a comprehensive alarm strategyby transferring process information to a supervisor CONTINUOUS ANNEALING FURNACE After castingmilling, metals are passed through an annealing furnace in order to increase ductilityreduce brittleness. In the case of a continuous metal sheet, this is a multi-zone furnace consuming several Megawatts of power. Each zone consists of one or multiple thermocouples feeding the process variable (PV) into a temperature controller, Programmable Automation Controller (T2550 PAC) or PLC. The control device then calculates the required power input to meet the process set point (SP),sends this to the Power Controller via digital comms or via an analogue signal. The Power Controller then fires the element, either directly or via a transformer depending on the element specifications. Two-leg, true three phase control or 4 x single phase control available Load Sequencing - integral firing sequence control optimises instantaneous energy consumption across all zones Load Shedding - Predictive Load Management peak energy demand algorithm enables power smoothing to reduce peak demand Communication of PV, SPprocess data Remote configuration via comms or user interface TIN BATH FURNACE IN FLOAT MANUFACTURING Three phase power supply Multizone control Molten glass Multizone heating Roof heating with silicon carbide elements Supervisor Slave Master Network Multiple Slaves (1 per Zone) Zone 1 Zone n Continuous Annealing Furnace Transformer Transformer Molten tin PLM PLM PLM Predictive Load Management PLM PLM PLM Predictive Load Management With EPower Controllers you are not only buying one of the best power controllers in the world, you are supported by a global network of application and control specialists from Eurotherm. While we are a truly global company, we have not forgotten that you still need local supportunderstanding. Our team will bring you technical expertise along with in depth experienceunderstanding in numerous application areas – from glass furnaces, to semiconductor manufacture, to the heat treatment of metalsmany more. The EPower Controller is one product for all your solution needs. We can provide you with a range of services to suit your needs – from training to commissioning and maintenance contracts for your installation. Easy Maintenance Modular design for easy management of spare partsquick mean time to repair (MTTR) Fasteasy configuration Easy wiring, installationcommissioning Remote Display option www.eurotherm.com/EPower The EPower Controller – the best solution for your power control With EPower Controllers, you will obtain an excellent return on your investment www.eurotherm.com/ E Power Selection guidetechnical specifications DRIVER MODULE POWER MODULES (UP TO 4) SUPPLY VOLTAGE 85 to 264V ac SUPPLY FREQUENCY 47 to 63Hz POWER CONSUMPTION 120W TEMPERATURE LIMITS 0 to 50°C operating, -10 to 70°C Storage DISPLAY 4 lines dot LCD matrix array COMMUNICATIONS Modbus RTU 2 wire EIA485 Modbus TCP/IP 10baseT Ethernet Profibus DPv1 DeviceNet network protocol INPUTS AND OUTPUTS Standard 2 Analogue inputs 1 Analogue output 2 Digital inputs 2 Relay outputs (1= Watchdog) Optional modules (max 3) Per module - 1 Analogue input 1 Analogue output 2 Digital inputs 1 Relay MEASUREMENT ACCURACY Better than 1% REMOTE PANEL Dedicated remote panel port PlugPlay 32h8i panel indicator QUICKSTART Configurable by order code or on start up via dedicated front panel HMI PREDICTIVE LOAD MANAGEMENT (PLM) Optional module connecting up to 63 instruments over dedicated communications (CAN based). Configurable PLM (patent Pending) optimises energy usage APPROVALS CE (EN 60947-4-3), UL 508A VOLTAGE RANGES 100 to 600V ac, 100 to 690V ac CURRENT RANGES 100A, 160A, 250A, 400A, Nominal current range 16 to 400A FREQUENCY 47 to 63Hz POWER DISSIPATION 1.3 watts per Amp per Power module OPERATING TEMPERATURE Nominally 40°C, Operation 0 to 50°C de-rating applied over 40°C COOLING FANS ≥160A FAN SUPPLY 115V or 230V FIRING MODES Phase angle Half Cycle Burst Firing Fixed Modulation Logic LOAD TYPES Standard Resistive Complex Resistive Inductive loads e.g. Transformer LOAD CONFIGURATION Single phase Ph/Ph or Ph/N Two leg control 3 wire star or delta Three 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 Internal voltagecurrent Order option – External voltagecurrent FEEDBACK TYPES Open Loop V2 I2 True Power Vrms Irms APPROVALS CE (EN 60947-4-3), UL 508A