EPowerCONTROLLER

EUROTHERM® FLEXIBLE SOLUTIONS

THE FUTURE OF POWER CONTROL

™

PLMPLMPLMPredictive Load Management

EPower Controllers are the latest products in theEurotherm range of power controllers. It uses the newesttechnologies and innovations to manage your process andreduce your energy costs. On every level it brings you theflexibility you need to best meet your requirements nowand in the future. Let us look after your power control foryou with EPower Controllers and give you the peace ofmind that you have the best for your process – even as itchanges.

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 tomeet your changing requirements at any point.

Flexibility – advanced technologies in harmony withmodularity and ease of use to deliver your powercontrol needs

Efficiency – world class power control with innovativefeatures to minimise your energy costs withexceptional process performance

Peace of mind – a power controller that will bringyou return on investment and can be adapted in thefuture if your requirements change - one product forall solutions

Revolutionary modularity andconfigurability to meet your needs...

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 module e.g.firing mode, load, phases, control etc.

Up to four power modules provide single andmulti-phase control

Software configurable options to bring you flexibility:

You no longer need to be restricted to the options thatyou order – EPower Controller provides you withconfigurable options and modular hardware to give youthe flexibility to match your process now and in thefuture. Combine this with an instrument that provideseasy configuration via the integral display and fullgraphical configuration via iTools PC configuration toolas standard – you have a power controller that makeslife that bit easier.

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EPower™ Controller – extraordinary power control

Control Type

Singlephase

2 x singlephase

3 x singlephase

4 x singlephase

Two phase

2 x twophase

True threephase

Firing Modes

Phase angle

Half cycle

Burst firing

Fixmodulation

period

Logic mode

LoadType

StandardResistive

ComplexResistive

Inductivee.g.

Transformer

Short WaveInfrared

LoadConfiguration

Single phase

Star

Delta

Star withneutral

Open Delta

Feedback

V2

I2

Truepower

RMS loadvoltage

RMS loadcurrent

Open loop

The options that you need... 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 100A to 400A. The driver module itselfsupports option boards to give you additional flexibilityin your solution:

Communications – RS485 Modbus RTU, Profibus,DeviceNet® and Modbus TCP network protocols

Predictive Load Management(PLM)* – A powerful feature toeffectively manage your powerrequirements across multiplemachines to save on your 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.

* patent pending

PLMPLMPLMPredictive Load Management

The EPower Controller has been designed for easyconfiguration and modification. The front, integral displayhas a “QuickStart” facility that leads the user throughinitial set 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 or similar configuration – keeping your worksafe and save repeat engineering costs.

“QuickStart” for easy commissioningEasy save and clone of configurationAdvanced graphical wiring configuration tools Integral front panel operator interface

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Easy configuration to save you engineering costs ...

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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 helpsave energy

Load management for better distribution ofenergy and to minimise peak energy usage costs

Reduce energy bills and other costs with aselection of advanced firing modes to best suityour 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 byutilising the Predictive Load Management (patentpending) functionality within the EPower Controller. Thisnew feature provides a better distribution of energyacross different loads in your installation, by managingthe priority and, if necessary, load shedding,

The EPower Controller prevents overshoot of thenominal power. This will keep you within the limits ofyour electrical contract for your installation and preventincreases in energy tariffs imposed by your supplier.Unlike other software offering this type of feature,Predictive Load Management from Eurotherm anticipatesyour energy usage rather than just reacting when youhave already exceeded your tariff peak.

Using EPower Controllers withPredictive Load Managementcould well be one of the bestvalue decisions you couldmake for your plant!

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Predictive Load Management – the best innovation for energy management

Power consumed with “Predictive Load Management”

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Power consumed without “Predictive Load Management”

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A product to integrate into a complete solution

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 –EPower Controllers can easily be integrated into yoursystem and send the information you need about yourload (current, voltage, alarms etc) so that you stay incontrol 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 –the full benefit of EPower Controllers can be optimisedusing our engineers as experts in creating completesolutions and total, plant-wide DCS.

Throughout our product ranges – controllers, recorders,power controllers, signal conditioning, automationsolutions and DCS – you will get expert knowledge,support and world class solutions. We can assist you withsmall and large applications and offer complete life cyclesupport and partnership engineering teams – whateveryou need, we are there to work with you.

3RD PARTYINTEGRATION

OPERATIONSSERVER

OPCSERVER

BUSINESSSYSTEMS

OPEV

T820LOCAL HMI

3216CONTROLLER

T2550PROGRAMMABLE

AUTOMATION CONTROLLER

T2550PROGRAMMAB

AUTOMATION CONT

EPOWER CONTROLLER

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3RD PARTYINTEGRATION

EYCON 20VISUAL SUPERVISOR

EYCON™ 10VISUAL

SUPERVISOR

6180APAPERLESS GRAPHIC RECORDER

ERATIONSVIEWER

ACTIVEFACTORY

T820LOCAL HMI

32H8IEPOWER CONTROLLER

REMOTE DISPLAY

BLE TROLLER

EPOWER CONTROLLER

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Real-world applications

VACUUM FURNACE IN HEAT TREATMENT

BOOSTING POWER CONTROL ANDMONITORING IN GLASS INDUSTRY

Molten glass is a conductor of electricity. Passing highcurrents through the glass produces direct heating in theresistance presented by the glass, named boosting. Thisheating is beneficial as it heats the‘colder’ bottom glass inthe furnace. This heated bottom glass rises towards the topand has a stirring effect which helps with melting, heattransfer and temperature homogenisation. Boosting is oftenused to meet periodic fluctuations in production demand orto support the pull rate of a furnace at the end of itsoperating life. Boosting may also help to reduce NOxemissions.

In this application the EPower Controller is controlling thepower injected by the electrodes in the molten glass whilecontrolling the true power or the current (the powerinjected 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 tobe monitored by a supervisor: current, voltage, powerand alarms

Electrodes

Molten glass

Three phase power supply

T2550Input/output control

Eycon™ Visual SupervisorVacuum furnace controlEnergy controlEfficiency optimization

EPower ControllerControlModularityEnergy informationSeveral switching modesiTools software configurationDigital communications

Vacuumdevice

Digital communication

COMPOSITE MATERIAL

In composite material productionpolymerisation is made in an autoclave atvery high temperature. EPower Controllercontrols heating by providing:

Detection of total and/or partial loadfailure

Optimization of the distribution ofheating control in the different areasproviding real cost savings

Standard communications for processcontrol and monitoring on HMI

Down time reduction due to themodular 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 acrossmultiple furnaces to reduce energy costs PLMPLMPLM

Predictive Load Management

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 to themultizone control of this specific heater elements.

Ageing compensation of the siliconcarbide heaters with power control

Power distribution control in the heaterelements providing cost savings:suppression of inrush current for a betterenergy management and a minimum stresson the power transformers

Digital communication with standardprotocols for an efficient processmonitoring

Use Predictive LoadManagement across theglass plant to reduceenergy costs

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SEMICONDUCTORMANUFACTURING

Silicon was discovered in 1823 andis used in the manufacture oftoday's semiconductors.Semiconductors need a silicon of avery high purity and, therefore, thesilicon is transformed by successivestages (crystal growing, epitaxy)that need very slow and accurateheating.

The EPower Controller will providemany solutions to this specific andexpensive process:

Precise and steady control ofthe heater elements

Advanced and configurablestrategy enables the EPowerController to adapt to the loadstate

Secure your process utilising acomprehensive alarm strategyand by transferring processinformation to a supervisor

CONTINUOUS ANNEALING FURNACE

After casting and milling, metals are passed through an annealing furnace in orderto increase ductility and reduce brittleness. In the case of a continuous metal sheet,this is a multi-zone furnace consuming several Megawatts of power. Each zoneconsists of one or multiple thermocouples feeding the process variable (PV) into atemperature controller, Programmable Automation Controller (T2550 PAC) or PLC.The control device then calculates the required power input to meet the processset point (SP), and sends this to the Power Controller via digital comms or via ananalogue signal. The Power Controller then fires the element, either directly or via atransformer 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 instantaneousenergy consumption across all zones

Load Shedding - Predictive Load Management peak energy demand algorithmenables power smoothing to reduce peak demand

Communication of PV, SP and process 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 heatingwith silicon

carbide elements

Supervisor

SlaveMaster

Network

Multiple Slaves(1 per Zone)

Zone 1 Zone n

Continuous Annealing Furnace

Transformer Transformer

Molten tinPLMPLMPLM

Predictive Load Management

PLMPLMPLMPredictive Load Management

With EPower Controllers you are not only buying one ofthe best power controllers in the world, you aresupported by a global network of application andcontrol specialists from Eurotherm. While we are a trulyglobal company, we have not forgotten that you stillneed local support and understanding. Our team willbring you technical expertise along with in depthexperience and understanding in numerous applicationareas – from glass furnaces, to semiconductormanufacture, to the heat treatment of metals and manymore. The EPower Controller is one product for all yoursolution needs.

We can provide you with a range of services to suit yourneeds – from training to commissioning andmaintenance contracts for your installation.

Easy MaintenanceModular design for easy management of spare partsand quick mean time to repair (MTTR)

Fast and easy configuration

Easy wiring, installation and commissioning

Remote Display option

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The EPower Controller –the best solution for your power control

With EPower Controllers, you will obtain an excellent return on your investment

Thank you for reading this data sheet.

For pricing or for further information, please contact us at our UK Office, using the details below.

UK OfficeKeison Products,

P.O. Box 2124, Chelmsford, Essex, CM1 3UP, England.Tel: +44 (0)330 088 0560Fax: +44 (0)1245 808399

Email: sales@keison.co.uk

Please note - Product designs and specifications are subject to change without notice. The user is responsible for determining the suitability of this product.