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SCR POWER CONTROLLERS - Control Concepts, Inc.

1. 44 APPENDIX A SPECIFICATIONS 45 APPENDIX B DIGITAL FIELDBUS areren anana teg dauern 47 APPENDIX C REMOTE DISPLAY 48 Screen CIRCITER 48 Parameter 48 APPENDIX D FUSING OPTIONS mmm 49 Touchsafe Kits Single Phase 49 Touchsafe Kits Three 49 APPENDIX E 18 PART eee mmm 50 APPENDIX E PART NUMBERS 51 a CONTROL CONCEPTS 1 OVERVIEW MicroFUSION is an ultra compact high performance microprocessor based power controller available in single three phase or three phase two leg models to control AC loads Resistive or transformer connected loads can be controlled in either Phase Angle Zero Cross or Zero Cross Transformer ZCT Mode Output is controlled linearly with respect to command signal and can be set to the average or RMS value of the voltage and current as well as true instantaneous power or external feedback o 2 4 MicroFUSION Series power controllers are available in current ratings from 8 16 32 50 80 amps AC Auto ranging voltage circuitry enables main supply voltage from 24 600 VAC 45 65 Hz eliminating the need for hardware jumpers or stocking multiple controllers for international voltage
2. 35 Digital PUM SIO 35 7 5 5 Setpoint Resolution SP 115 eco pnt stain eu nens 36 Analog OSIDOIL TS 36 TRU sinaua naen raga apah anaha Em 36 7 7 Limits and anana aana dude 37 7 7 1 Voltage Limit SP 11 aaa 37 fora NANG bet 37 7 7 3 Over Current Trip SP nean 37 Ff A EEUU 38 7 8 Tap Change lndication TET EE 38 7 8 1 Setting Using Control Panel 5 38 mg 39 8 1 Alarm Relay ISPTO SP85 39 8 2 Isolated I O Optional aeres 39 83 General 40 8 4 General Purpose Input Function 5 133 40 8 5 Pulse Width Modulation 40 SORET etur REM RDUM 40 Meg EQ E A EA 41 9 1 Network LED lIndicators en eee 41 9 2 Auto Terminating Resistor NC 41 42 9 4 External Fieldbus Module erar eaaa esa da 43 TO ACCESSORIES nega aa Re 44 44 10 2 Fieldbus Module 44 10 3 Remote ead ga aa 44 10 4 Din Rail Power Supplies nona nao upbeat en 44 GADIS
3. T fuses Installed in enclosure with two omen asec approximate lv 125 1 s0 tWorFasAcigJor 00 COOLING 10 8 50 Amp Natural Convection 19 80 Amp Forced Air with 1 fan PN 1608VL 05W B60 Din Rail Forced Air with 1 fan 3100KL 05W B60 30 Liquid Cooled Flow rate 1 GPM 3 79 LPM Maximum inlet temperature 122 F 30 C Maximum pressure 60 PSI 4 137 Bar External Panel Mount Natural convection Control Concepts Inc 2014 WWW Ccipower com 1 800 765 2799 MicroFUSION Operator s Manual Rev 2 37 CONTROL CONCEPTS 4 APPENDIX B DIGITAL FIELDBUS TO BE DETERMINED MicroFUSION Operator s Manual Rev 2 37 1 800 765 2799 Control Concepts Inc 2014 After applying universal input power the user can now edit i ine parameters via the display or the MicroFUSION Control Panel Software Line Va Auto Scroll Im Line la 5 button display has auto scroll State STOP and manual scroll display list CmdOut Setpoint Pictured right are examples of how eee m screens will appear Temp A Manual Scroll a tit The controller will automatically start in auto scroll mode The screen will change every few seconds Press the arrow keys to access the manual scroll display list C e The up and down buttons will also scroll through dif
4. Option L Option R OUTB OUT A MicroFUSION Operator s Manual Rev 2 37 www ccipower com 1 800 765 2799 Control Concepts Inc 2014 Gasket included Inlet outlet Use 1 4 18 NPT fittings 1 1 2 brass plug is shipped with the controller See liquid cooled connection for ratings PANEL MOUNT 7 00 177 8 14 60 370 8 4 amp 0 228 5 8 EXTERNAL MOUNT 0 80 7 6 3 50 88 8 3 50 88 8 3 50 88 9 2 00 50 8 AAN 2 00 50 8 196 48 5 6 10 154 8 3 00 76 2 1 85 48 5 fo 0 70 17 8 12 10 32 UNF 2B M5x0 8 PANEL CUTOUT 0 89 17 5 13 71 348 2 3 1 4 18 LIQUID OUTLET 7 50 190 5 4 15 105 4 2 eL af eL e Layout for water inlet position See Multizone Datasheet for ordering information Option L Option R OUT E OUT A OUT B Ea Mm Control Concepts Inc 2014 WWW Ccipower com 1 800 765 2799 MicroFUSION Operator s Manual Rev 2 37 CONTROL CONCEPTS Gasket included Inlet outlet Use 1 4 18 NPT fittings 1 1 2 brass plug is shipped with the controller See liquid cooled connection for ratings PANEL MOUNT EXTERNAL MOUNT O30 76 255 54 8 350889 3 50 88 9 3 50 88 9 350 88 9 3 50 88 9 2 55 64 8 6
5. MicroFUSION Operator s Manual Rev 2 37 www ccipower com 1 800 765 2799 Liquid External Mount Recommended Y 10 32 UNF 2B M5x0 8 6H not provided E Star Washer not provided S Enclosure wall Gasket N N C Liquid Cooled Heatsink Note Gasket should be compress approximately 5096 All water connections are kept outside of the panel Liquid Panel Mount 4 00 228 5 80 Mounting holes screws bolts not provided Star Washer not provided Liquid Cooled Heatsink Panel Back Plate N 1 Note All water connections are internal gasket is not used The gasket has an adhesive on one side It is intended to be installed on the heatsink prior to the final installation of the heatsink on the enclosure This is to prevent any damage to the gasket during shipping or initial stages of installation gt PUT 2 si Figure 5 Adhering gasket to heatsink Control Concepts Inc 2014 WWW ccipower com 1 800 765 2799 MicroFUSION Operator s Manual Rev 2 37 CONTROL CONCEPTS 2 4 Cooled Connections There are three 1 4 18 NPT and each heatsink is shipped with 1 brass plug not installed Use the outlet that is most convenient for panel layout and use the plug in the other Multiple liquid cooled can be connected together as long as the liquid is operating under the rated s
6. TUV S D America Inc Suite 104 1774 Old Highway 8 NW New Brighton MN 55112 1891 Name of Authorized Representative Cory Watkins Title of Authorized Representative President Place of Issue Chanhassen Minnesota USA Date of Issue April 2014 Control Concepts Inc 2014 WWW Ccipower com 1 800 765 2799 MicroFUSION Manual Certifications CONTROL CONCEPTS External EMI filters must be used in conjunction with the FUSION series power controllers to maintain CE immunity approval The following filters were used during the immunity testing Universal input power Line input power Schaffner filter Schaffner filter P N FN 2030 3 06 P N FN 3270H 35 33 The Schaffner filter for universal input power or it s equivalent may be used as listed above The line input power filter however will need to be sized accordingly for your load Please contact Schaffner EMC Inc for help finding the appropriate filter Schaffner EMC Inc 52 Mayfield Avenue Edison New Jersey 08837 USA T 1 800 367 5566 T 732 225 9533 F 732 225 4789 usasales schaffner com http www schaffner com us No filtering is required for emissions Wire filters as shown below 1 Phase Controller Line B Line A PE GND PE Line Input FN 2030 3 06 Filter td mE PD 65B oo 4345678910 Tests were conducted with Mean Well USA Inc 24 Vdc power supply model PD 65B MicroFUSION Manu
7. 7 There are four possible setpoints two digital and two analog To designate which setpoint the controller uses the Setpoint Source SP102 SP103 and Control Setpoint Select SP104 need to be setup within the System Tab of the Control Panel software Control Concepts Inc 2014 WWW Ccipower com 1 800 765 2799 MicroFUSION Operator s Manual Rev 2 37 43 CONTROL CONCEPTS 7 5 1 Setpoint Source Setpoint 1 Source amp Setpoint 2 Source SX HX Analog SP1 Included Included Analog SP2 Optional Digital Fieldbus Included Included Digital Keypad Included Included Optional The Analog SP2 and the Pulse Width Modulated PWM input are only available if the I O section of the model number contains a 2 3 6 or 7 There are two setpoints that can be configured They can both be set to digital or both to analog or a combination of either analog or digital The controller will use the Control Setpoint Select SP104 parameter to determine which setpoint to use Defaults SP102 Setpoint 1 Source Analog SP1 or Digital Fieldbus if a communication module is onboard SP103 Setpoint 2 Source Analog SP2 or Digital Keypad if the Analog SP2 feature is not enabled For a PWM input the signal must be connected to Analog SP1 7 5 2 Control Setpoint Select 5 104 SX HX Setpoint 1 Source SP102 Included Included Setpoint 2 Source SP103 Included Included The Control Setpoint Select de
8. 4 20mA 0 20mA z default The Analog SP2 is only available if the I O section of the model number contains a 2 3 6 or 7 The inputs allow a wide array of input scaling for the user The hardware capabilities are 0 10 Vdc for voltage and 0 20 mA for current To make changes to the analog inputs open the Control Panel software and check the Analog I O Tab 7 6 Run Stop This refers to pins 8 amp 9 of the P1 connector Pin 9 is directly connected to the gates and monitored by the processor When pin 9 is pulled low connected to pin 8 the output of the controller is enabled Run state With no connection between these two pins the controller will remain in a Stop state Run state does not mean the controller is outputting Run state means the controller is able to output as long as a command setpoint is present digital or analog and there are no inhibit alarms Control Concepts Inc 2014 WWW Ccipower com 1 800 765 2799 MicroFUSION Operator s Manual Rev 2 37 m CONTROL CONCEPTS 7 Limits and Trip Parameters SX HX optional Included Included Power Limit optional The Limit and Trip parameters are only available if the Performance section of the model number contains an L or These are safety features designed to help protect from excessive voltage current and or power being applied to the Load 7 7 1 Voltage Limit SP 11 SX HX Adjustable Limits
9. CONTROL CONCEPTS MICROFUSION SCR POW USER S MANUAL CONTROL CONCEPTS CONTROL CONCEPTS INC 2 YEAR LIMITED WARRANTY CONTROL CONCEPTS INC warrants that the products delivered will be as described in the sales order or contract CONTROL CONCEPTS INC warrants to the original user that CONTROL CONCEPTS INC products will be free from defects in materials and workmanship for a period of two 2 years after the date CONTROL CONCEPTS INC ships such products If any CONTROL CONCEPTS INC product is found to be defective in material or workmanship during the applicable warranty period CONTROL CONCEPTS INC s entire liability and purchasers sole and exclusive remedy shall be the repair or replacement of the defective product at CONTROL CONCEPTS INC s election CONTROL CONCEPTS INC shall not be liable for any costs or expenses whether direct or indirect associated with the installation removal or re installation of any defective product All shipping and freight costs are the responsibility of the customer CONTROL CONCEPTS INC s limited warranty shall not be effective or actionable unless there is compliance with all installation and operating instructions furnished by CONTROL CONCEPTS INC or if the products have been modified or altered without the written consent of CONTROL CONCEPTS INC or if such products have been subject to ac
10. 10 1549 3 00 76 2 09 129 2 6 09 1154 6 Layout for water inlet position See Multizone Datasheet for ordering information Option L Option R LJ 1 1 o bia ol ial o o fin j ATAT 27272 o TH SOLO 2121 MicroFUSION Operator s Manual Rev 2 37 www ccipower com 1 800 765 2799 Control Concepts Inc 2014 2 1 9 Three Phase External Mount Heatsink 16 50 Amps Dimensions Inches mm 12 00 304 8 Height 12 00 304 8 Width Depth 5 47 138 9 Note Fins must be mounted vertically Gasket and gasketed washers included ca OF 3 02 76 7 E o 5 47 138 9 2 41 61 1 _ eee 1 70 43 2 3 50 88 9 1 45 36 8 A 1 88 47 6 B 1 20 30 5 3 00 76 2 7 55 191 8 PANEL CUTOUT 3 00 76 2 1 10 27 9 2 20 55 9 10 10 32 UNF 2B M4x0 7 6H 5 60 142 2 2 05 52 1 4 Control Concepts Inc 2014 www ccipower com 1 800 765 2799 MicroFUSION Operator s Manual Rev 2 37 AA CONTROL CONCEPTS 2 1 10 Three Phase Liquid Cooled Heatsink 16 80 Amps Dimensions Inches mm Height 6 00 152 4 Width Gasket included 3 25 82 55 Inlet outlet Use 1 4 18 NPT fittings Depth 1 1 2 brass plug is shipped with the controller see liquid cooled connection for ratings 5 10 129 54 EXTERNAL MOUN
11. Rev 2 37 www ccipower com 1 800 765 2799 Control Concepts Inc 2014 Note Fins must be mounted vertically Gasket and gasketed washers included 1 70 64 8 3 50 88 9 3 50 88 9 3 50 88 9 3 50 88 9 3 50 88 9 2 55 64 8 1 425 36 2 1 95 49 5 6 10 154 9 3 00 76 2 1 95 49 5 1 1 83 46 4 PANEL CUTOUT 16 10 32 UNF 2B M5x0 8 6H 2 15 54 6 21 78 553 3 gt 9 75 247 7 n 26 00 660 4 a Control Concepts Inc 2014 WWW Ccipower com 1 800 765 2799 MicroFUSION Operator s Manual Rev 2 37 CONTROL CONCEPTS 2 1 6 Three Position Liquid Cooled Gasket included Inlet outlet Use 1 4 18 NPT fittings 1 1 2 brass plug is shipped with the controller See liquid cooled connection for ratings PANEL MOUNT EXTERNAL MOUNT 030 76 0 30 7 6 1 95 49 5 7 00 177 8 6 10 154 9 3 00 76 2 1 95 49 5 8 60 218 4 4 amp 0 228 5 8 and 0 70 17 8 8 10 32 2 5 8 6H PANEL CUTOUT 0 74 18 8 7 66 194 6 18 pe eje 7 50 190 5 LIQUID OUTLET 1 68 42 5 0 50 12 7 _ 0 50 12 7 1 00 25 4 9 10 231 1 Layout for water inlet position See Multizone Datasheet for ordering information
12. portion of the half cycle that it conducts Power is regulated by advancing or delaying the point at which the SCR is turned ON within each half cycle Light dimmers are an example of phase angle control Phase angle control provides a very fine resolution of power and is used to control fast responding loads such as tungsten filament lamps or loads in which the resistance changes as a function of temperature Single Phase Operation Tek A a M Pus LI Tek Jl n Princ LI Tek JL n Princ bi 5 amp IN X A y 4 M mm 250 250ma 250ma uw 16 5 08 0307 pan ahis JANG a ahi MGG 10026 Load Power 50 Load Power 25 Load Power Three Phase Operation Tek Jl Bs TARAFA Tek JL Bs Tek JA Bs MTS b 7 N N h JM H AJA JAYA 2p Mode VISIT E L a um CH T 250m DE CHe TN H 250m nmm om DA m TUN 250m LA Wk CHa WLIW rnt Ov iSo CHa 09529 Ini Rz 100 Load Power 50 Load Power 25 Load Power MicroFUSION Operator s Manual Rev 2 37 www ccipower com 1 800 7
13. terminal A1 and A2 use 10 or M5 ring terminal See drawing above for wiring MicroFUSION Operator s Manual Rev 2 37 www ccipower com 1 800 765 2799 Control Concepts Inc 2014 PE GND O 0000 0000 Note 0 60 mA maximum through Ref connection at 600 Vac WWW ccipower com 1 800 765 2799 MicroFUSION Operator s Manual Rev 2 37 Control Concepts Inc 2014 CONTROL CONCEPTS FUSES 1 C1 c Mi B1 A1 PE GND O 000 0000 Control Concepts Inc 2014 www Ccipower com 1 800 765 2799 MicroFUSION Operator s Manual Rev 2 37 y po o d _ LL C2 8281 A2 A1 0000 0000 FUSES Note 0 60 mA maximum through Ref connection at 600 Vac The MicroFUSION controllers normally display line and load voltages from Line to Line When the controller is in 4 Wire Wye operation the line voltages read Line to Line while the load voltages read Line to Neutral NEUTRAL PE GND Control Concepts Inc 2014 WWW CCipower com 1 800 765 2799 MicroFUSION Operator s Manual Rev 2 37 CONTROL CONCEPTS When wiring this controller if must be wired as per the diagram Load A must return to Line B Load B must return to Line C Load C must return to Line A FUSES C1 B1 PE GND 0000 0000 Equivalent circuit Control Concepts Inc 2014 www Ccipowe
14. transformers with an open or unloaded secondary It is recommended that Scott T transformer be limited to a maximum of 480 Volts NOTE It is recommended that a Delta to 4 Wye transformer be used to power a 4 wire Wye load Delta to 3 wire Wye transformers are acceptable but Wye to Wye transformers not suited for use between the controller and load due to possible transient conditions Control Concepts Inc 2014 www ccipower com 1 800 765 2799 MicroFUSION Operator s Manual Rev 2 37 CONTROL CONCEPTS 2 INSTALLATION 2 1 Mounting Considerations Dimensions Inches 93026 PSI 9 6 5444 6000006 NG 0700076 RRR eer jeep Air Flow Keep Out Area LILLI X 40309404019 OLS LLL LLL LLLI LL 00000 0 SLLLS QQQ Mount controllers vertically The keep out area on the top and bottom is for air circulation The top and bottom of the controller must have a minimum of 3 00 76 2 free from obstructions as measured from the edge of the heatsink fins Dimensions above are measured from the edge of the heatsink base Mounting hardware Not included Figures above show dimensions for din rail mounting For mounting hardware when not using din rail use the following Single Phase 10 or M5 screws with star washers Three Phase 8 or M4 screws with star washers Din rail and or screws are not provided MicroFUSION Operator s Manual Rev 2 37 www
15. 0 W UL contact ratings 250 Vac 0 25 A 62 5 VA 125 Vac 0 50 A 62 5 30 2 A 60 W 8 2 Isolated I O Optional The Isolated I O provides 500 VAC of isolation to the Analog Inputs General Purpose Input Run Stop and the Retransmits The option is only available when ordering from the factory and is not field upgradable MicroFUSION Operator s Manual Rev 2 37 www ccipower com 1 800 765 2799 Control Concepts Inc 2014 8 3 General Purpose Input SX HX Pin 10 functionality of P1 connector optional optional The General Purpose Input is only available if the I O section of the model number contains a 2 3 6 or 7 The General Purpose Input uses pins 8 and 10 of the P1 connector When using this feature the General Purpose Input Function SP133 must be defined When pin 10 is pulled low connected to pin 8 the controller will toggle the function defined in the General Purpose Input Function parameter 8 4 General Purpose Input Function SP133 Opening and closing the connection between pin 8 amp pin 10 of the P1 connector toggles 5 133 Function Selections See this parameter for reference a Setpoint 1 Source Open Control Setpoint Select Setpoint 2 Source Closed Control Setpoint Select SP104 Open Loop Open Open Closed Loop Closed Loop Closed Control Mode SP3 Other selections may be available Contact factory for special requests 8 5 Pulse Width M
16. 1 4 Six Position Multizone External Mount 9 2 1 5 Ten Position Multizone External Mount 10 2 1 6 Three Position Liquid 11 2 1 7 Six Position Liquid Cooled 12 2 1 8 Ten Position Liquid 13 2 1 9 Three Phase External Mount Heatsink 16 50 Amps 14 2 1 10 Three Phase Liquid Cooled Heatsink 16 80 Amps 15 2 2 External and Panel 16 2 3 Mounting Instructions D ETE 17 2 4 Liquid Cooled 19 M udlilcm 20 3 1 Torque ___________ 20 3 2 Line Load Connectiongs sasae eaaa 21 3 2 1 Single 21 3 2 2 Three Phase 2 Leg sasarane nhe orna 22 3 2 3 Three Phase Delta or 23 3 2 4 Three Phase Four Wire Wye 24 3 2 5 Three Phase Inside Delta eee 25 COMO C KAEN KT 26 3 3 1 P1 10 Pin Command Connector 26 3 3 2 P2 8 Pin Comman
17. 16 Amps 32 32 Amps 50 50 Amps 80 80 Amps Performance Available with SX S Standard L Adjustable Current Limit and current feedback Available with HX L Adjustable Current Limit current feedback load voltage feedback amp voltage limit P High Performace Includes Load Voltage Feedback True RMS Power Control Current Limit Power Limit High Resolution Control Loop None Only applicable for SX HX board is equipped with an alarm relay by default 1 Alarm Relay 1x Form 2 General Purpose Input Analog Input Channel 2 Pulse Width Modulation Input Alarm Relay and General Purpose Input Analog Input Channel 2 Pulse Width Modulation 4 Isolated 5 Isolated I O with Alarm Relay 6 Isolated I O with Gen Purpose Input Analog Input Channel 2 Pulse Width Modulation 7 Isolated with Alarm Relay and Gen Purpose Input Analog Input Channel 2 Pulse Width Modulation Retransmits None R Retransmits Two 16 bit analog retransmits for voltage current or power Sync 0 5 Digital SYNC GUARD Zero Cross Transformer Mode Z Zero Cross Transformer Mode Branch Rated Class T Fuse Options Blank None F010 10A F015 15A F020 20A F025 25A F030 30A F035 35A F040 40A F045 45A F050 50A F060 60A F070 70A F080 80A F090 90A F100 100A oee Fusing Options page 7 for more information 80 Amps not available for external panel mo
18. 65 2799 Control Concepts Inc 2014 1 2 2 Zero Cross Tk amah M Pos 0 0005 Teh M Pos 0 000s a B NANA NA JAM AH ANA DHA ANAN JAMAN WAWAN JANIAI In control load power is turned the sinusoidal waveform is zero Load power E E is controlled by switching the SCRs ON fora on 1 n number of complete electrical half cycles and then OFF for a number of complete electrical mesi Tek Moc half cycles a The wave form in the top left shows the 1 phase AC waveform into the controller This would also be the representation of the output with the command at 100 The rest of the waveforms show the ON and OFF cycles of the output at various setpoints The tabulation on the right shows the sequence of ON and OFF electrical half cycles that are applied to the load to achieve the percentage of load power indicated The percentage of load power is equal to the ratio of the number of electrical half cycles that power is applied to the total number of electrical half cycles From the tabulation it can be seen that power is applied for 16 out of 32 electrical half cycles to achieve 5096 load power and that power is applied for 136 out of 160 electrical half cycles to obtain 85 power When operating with a 60 Hz supply the sequence of ON and OFF cycles repeats 0 266 se
19. Amp Rating Current Trip 50 450 of continuous rating Power Dissipation 1 3 Watt per amp of load current per phase Control Power Operates Internal Control Electronics 24 Vdc 10 15 ENVIRONMENTAL Surrounding Air Operating Temperature 32 F 0 C 122 F 50 C with no derating 32 F 0 C 140 F 60 C with current derating 140 F 60 C 16AFrame 16A Max Output 140 F 60 32A Frame 25A Max Output 140 F 60 C 50A Frame 40A Max Output 140 F 60 C 80A Frame 60A Max Output 2096 to 9096 RH Non Condensing Rated Operating Altitude Up to 6000 ft 1750m at full rated current Contaminates ROHS Compliant CE Pollution Degree 2 Storage Temperature 4 to 176 F 20 to 80 C Humidity MicroFUSION Operator s Manual Rev 2 37 www ccipower com 1 800 765 2799 Control Concepts Inc 2014 45 0G DC POWER CONSUMPTION ISOLATION 8 50 Amp Single Phase 9 Watts Signal to Line Load 3750 Vac minimum 80 Amp Single Phase 11 Watts Line Load to Ground 2500 Vac minimum 16 80 Amp Three Phase 24 Watts Signal to Ground 1500 Vac minimum Line to Load 1400 Vac minimum SMG AOD nS Remote Display IP 65 UL Type 1 amp 12 Signal to Processor 1500 Vac minimum Remote Display 2500 Vac minimum RELIABILITY Mean Time Between Failure MTBF Designed for 50 000 Hours SCCR All controllers have 100kA when using Frame1 or3 RecommendedFusing sccRRaung 1255 than or equal to 100 Amp class J or
20. L CONCEPTS APPENDIX D FUSING OPTIONS All touchsafe kits have 600 VAC Branch Rated Class T Fusing Single phase controllers require 2 Pole Fuseblocks while Three Phase controllers require 3 Pole Fuseblocks Touchsafe Kits Single Phase MODEL PART NUMBER NUMBER AMP SIZE DESCRIPTION F010 SFKTS62T10 2 Pole Assy 2 x Fuse 1 x Block 2 x Cover F015 SFKTS62T15 2 Pole Assy 2 x Fuse 1 x Block 2 x Cover F020 SFKTS62T20 2 Pole Assy 2 x Fuse 1 x Block 2 x Cover 2060 sEKTS62T60 60s 2 Pole Assy 2 x Fuse 1 x Block 2xCover _________ Foso sFKkrseireO jso 1 Pole Assy 1 x Fuse 1 x Block 1 x Cover 2 required F090 SFKTS61T00 90 1 Assy 1 x Fuse 1 x Block 1 x Cover 2 required F100 1 Pole Assy 1 x Fuse 1 x Block 1 x Cover 2 required Touchsafe Kits Three Phase MODEL PART NUMBER NUMBER AMP SIZE DESCRIPTION F010 3 Pole Assy 3 x Fuse 1 x Block 3 x Cover F015 3 Pole Assy 3 x Fuse 1 x Block 3 x Cover F020 3 Pole Assy 3 x Fuse 1 x Block 3 x Cover 025 3 Pole Assy 3 x Fuse 1 x Block 3 x Cover F030 3 Pole Assy 3 x Fuse 1 x Block 3 x Cover F035 3 Pole Assy 3 x Fuse 1 x Block 3 x Cover F040 3 Pole Assy 3 x Fuse 1 x Block 3 x Cover F050 3 Pole Assy 3 x Fuse 1 x Block 3 x Cover Foso 58 7563760 60 ______ 8 Assy 3 x Fuse 1 x Block 3xCover Fogo ______ 6 8 80 ______ 8 3 x Fuse 1 x Block 3xCover __
21. LY PART NUMBERS DATE ADDED FUSION O10 0 00000 0 0000 0000 CF 00 0 00000 0 0000 0000 uF 1 OO000 00 00000 uF3 O000000 00 0000 Authorized Signature Date Last Updated Cory Watkins President CONTROL CONCEPTS INC 18760 LAKE DRIVE EAST CHANHASSEN MN 55317 952 474 6200 1 800 765 2799 FAX 952 474 6070 www ccipower com MicroFUSION Manual Certifications WWW ccipower com 1 800 765 2799 Control Concepts Inc 2014 TABLE OF CONTENTS DECLARATION OF CONFORMITY i CERTIFICATE OF COMPLIANCE eese nnne V joli iane 1 1 1 Certifications Markings oer ient 1 1 2 Points OUTIL ini 2 1 3 Feature aane 3 1 4 Model Options 4 Description 4 to Bley ore aaa anaa T aa anan ANG a 4 2 INO TALLA TON ag ER EEN a a Na a A 5 2 1 Mounting 5 2 1 1 Single Phase 8 32 6 2 1 2 Single Phase 50 80 7 2 1 3 Three Phase 16 80 8 Three Phase Two Leg 16 80 8 2
22. T 0 30 7 6 3 50 88 9 1 45 36 8 1 45 36 8 a PANEL MOUNT 1 50 38 1 3 00 76 2 7 50 190 5 8 40 213 4 PANEL CUTOUT 3 00 76 2 1 10 27 9 o 10 10 32 UNF 2B M5x0 8 6H 0 70 17 8 5 70 144 8 0 65 16 5 4 20 228 5 8 3 1 4 18 NPT LIQUID OUTLET B LIQUID INLET 4 67 118 6 6 56 166 6 LIQUID OUTLET A og o 1 89 48 0 0 50 12 7 0 50 12 7 MicroFUSION Operator s Manual Rev 2 37 www ccipower com 1 800 765 2799 Control Concepts Inc 2014 1 5 o 2 2 External and Panel Mounting External and Panel mount options help to reduce the internal temperature of the enclosure that the controllers are mounted in There is a finned heatsink that is intended to be mounted externally only There is also a liquid cooled heatsink that can be mounted externally or within the panel When mounting externally a cutout needs to be made in the side of the enclosure see panel cutout dimensions in section 2 1 When the heatsink is mounted on the outside of the panel the controllers remain inside the panel All of the electrical connections are made within the enclosure With liquid cooled heatsink remaining on the outside of the enclosure all of the liquid connection remain on the outside away from all electrical connections Mounting hardware is not provided due to varying panel thicknesses and multiple mounting options With the finned heatsink gasket washers a
23. YNC GUARD feature The probability of this happening is highest when many controllers transition into the RUN state and therefore turn ON at the same time It is recommended that more than 10 controllers be linked together with SYNC GUARD over Link The figures below show the total current as a function of time for three controllers with and without SYNC GUARD and various load powers To set up the SYNC GUARD feature see the Installation manual CONTROLLER 3 ON CONTROLLER 2 ON CONTROLLER 2 ON CONTROLLER CONTROLLER 1 ON 3 ON AMPS AMPS o n CONTROLLER CONTROLLER CONTROLLER CONTROLLER 1 1 ON 2 ON 3 ON TIME TIME TIME Three controllers providing 33 3 Three controllers providing 33 3 Three controllers with SYNC power each operating synchronously power each with SYNC GUARD GUARD two providing 33 3 without SYNC GUARD power amp one providing 66 696 power Control Concepts Inc 2014 WWW ccipower com 1 800 765 2799 MicroFUSION Operator s Manual Rev 2 37 CONTROL CONCEPTS 9 4 External Fieldbus Module The external fieldbus module connects to other Control Concepts devices over the CCI Link bus See Fieldbus Module in the Accessories Section of this manual for more details MicroFUSION Operator s Manual Rev 2 37 www ccipower com 1 800 765 2799 Control Concepts Inc 2014 10 ACCESSORIES 10 1 CCI Link Cabl
24. _________ F090 SFKTSeSTO0 ___ 90 ______ 8 Assy 3 x Fuse 1 x Block 3xCover __________ 3 Pole Assy 3 x Fuse 1 x Block 3 x Cover MicroFUSION Operator s Manual Rev 2 37 www ccipower com 1 800 765 2799 Control Concepts Inc 2014 40mm APPENDIX 10 PART NUMBERS uF1 000 00 00000 0000 Board SX Standard HX High performance Terminal T Pluggable terminal block R Ring terminal Frame Style 16 32A Panel Mount DIN Rail B 50 80A Panel Mount DIN Rail E 8A Panel Mount DIN Rail Option Board None E Modbus TCP EtherNet IP N PROFINET Amp Size 8 8 Amps 32 32 Amps 80 80 Amps 16 16 Amps 50 50 Amps Performance Available with SX S Standard L Adjustable Current Limit and current feedback Available with L Adjustable Current Limit current feedback load voltage feedback amp voltage limit P High Performace Includes Load Voltage Feedback True RMS Power Control Current Limit Power Limit High Resolution Control Loop O None Only applicable for SX HX board is equipped with an alarm relay by default 1 Alarm Relay 1x Form 2 General Purpose Input Analog Input Channel 2 Pulse Width Modulation Input 3 Alarm Relay and General Purpose Input Analog Input Channel 2 Pulse Width Modulation 4 Isolated I O 5 Isolated I O with Alarm Relay 6 Isolated I O with Gen Purpose Inpu
25. al Certifications WWW ccipower com 1 800 765 2799 Control Concepts Inc 2014 3 Phase Controller Line C Line B Line Input Filter Line A PE GND O 0000 0000 Tests were conducted with Mean Well USA Inc 24 Vdc power supply model PD 65B Other wire diagrams are available for models not listed here by contacting Control Concepts Inc ATTENTION This product has been designed for class A equipment Use of this product in domestic environments may cause radio interference in which case the user may be required to employ additional mitigation methods NOTICE This product has been designed for environment A Use of this product in environment B may cause unwanted electromagnetic disturbances in which case the user may be required to take adequate mitigation measures MicroFUSION Manual Certifications WWW CCipower com Control Concepts Inc 2014 CONTROL CONCEPTS PB FREE REDUCTION OF HAZARDOUS SUBSTANCE RoHS CERTIFICATE OF COMPLIANCE ROHS COMPLIANT 9 This document certifies that Control Concepts Inc s products listed in the table are fully ROHS complient as of Nov 13 2009 in accordance with EU RoHS Directive 2002 95 EC The products listed in the table have been identified as ROHS compliant do not exceed the maximum limit for the six substances Lead Mercury Cadmium Hexavalent chromium Polybrominated biphenyls and Polybrominated diphenyl ether PRODUCT FAMI
26. ccipower com 1 800 765 2799 Control Concepts Inc 2014 Dimensions Height Inches mm Width 2 00 50 8 Depth 5 10 129 54 oC 0000 0000 mE 0000 0000 LE Pluggable terminal block Ring Terminal MicroFUSION Operator s Manual Rev 2 37 Control Concepts Inc 2014 WWW CCipower com 1 800 765 2799 CONTROL N CONCEPTS gt Height 6 00 152 4 Width 3 25 82 55 Depth 5 10 129 54 Dimensions Inches mm 0000 0000 oC 0000 0000 BE Ring Terminal Pluggable terminal block Control Concepts Inc 2014 MicroFUSION Operator s Manual Rev 2 37 www ccipower com 1 800 765 2799 Dimensions Inches mm Width 5 50 139 7 Depth 6 40 162 56 0900 0000 Control Concepts Inc 2014 WWW ccipower com 1 800 765 2799 MicroFUSION Operator s Manual Rev 2 37 CONTROL CONCEPTS 2 1 4 Six Position Multizone External Mount Note Fins must be mounted vertically Gasket and gasketed washers included 2 00 50 8 3 50 88 9 3 50 88 9 3 50 88 9 2 00 50 8 1 425 36 2 1 95 49 5 6 10 154 9 3 00 76 2 1 95 49 5 1 83 46 4 PANEL CUTOUT 12 10 32 UNF 2B M5x0 8 6H 2 14 54 4 13 72 348 5 9 75 247 7 2 45 62 2 4 5 09 129 2 7 54 191 5 18 00 a MicroFUSION Operator s Manual
27. cident misuse mishandling tampering negligence or improper maintenance Any warranty claim must be submitted to CONTROL CONCEPTS INC in writing within the stated warranty period CONTROL CONCEPTS INC s limited warranty is made in lieu of and CONTROL CONCEPTS INC disclaims all other warranties whether expressed or implied including but not limited to any IMPLIED WARRANTY OF MERCHANTABILITY ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE any implied warranty arising out of a course of dealing or of performance custom or usage of trade CONTROL CONCEPTS INC SHALL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR ANY DIRECT INDIRECT INCIDENTAL SPECIAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF PROFITS REVENUE OR BUSINESS OR DAMAGE OR INJURY TO PERSONS OR PROPERTY IN ANY WAY RELATED TO THE MANUFACTURE OR THE USE OF ITS PRODUCTS The exclusion applies regardless of whether such damages are sought based on breach of warranty breach of contract negligence strict in tort or any other legal theory even if CONTROL CONCEPTS INC has notice of the possibility of such damages By purchasing CONTROL CONCEPTS INC s products the purchaser agrees to the terms and conditions of this limited warranty WARNING The Control Concepts Inc power controllers use power thyristors to switch voltage to the connected load Line voltage must be assumed at the output terminals at all times even when the control signal ha
28. conds on 50 and every 1 33 seconds at 85 power uS a M 50 0ms 1 on 3 50 0ms on Y Sep Us U3 3 j Sep U 93 53 ur 85 23 ON 4 OFF 23 ON Note Even though it takes 1 33 seconds to obtain precisely 85 power the load power during the 23 ON and 4 OFF cycles is 23 27 or 85 185 power and this cycle is repeated every 0 225 seconds Control Concepts Inc 2014 WWW Ccipower com 1 800 765 2799 MicroFUSION Operator s Manual Rev 2 37 m CONTROL CONCEPTS 7 2 3 Zero Cross Transformer Mode ZCT This is a Control Concepts proprietary algorithm that uses hybrid control to avoid the excessive inrush currents that can occur when firing into inductive or variable resistive loads In this firing mode the on off duty cycle is adjusted to obtain the desired amount of power to the load The portion of the output begins with a set number of cycles that increase to full conduction then it remains at full conduction for a number of cycles and then turns off This pattern restarts with each subsequent duty cycle When utilizing the Zero Cross Transformer ZCT firing mode the Power Factor measured by the controller is typically 0 90 with a setpoint that is greater than or equal to 50 When the setpoint is less than 50 the controller will maintain a measured Power Factor of approximately 0 70 Current Limit is enabled during the phase up section of each ON portion of the duty
29. cycle A Power Factor of 0 90 Setpoint gt 50 or 0 70 Setpoint lt 50 may not be able to be achieved if the controller was current limiting the output to the load during the phase up time Set up After connecting the MicroFUSION controller to the MicroFUSION Control Panel Software click on the Zone 1 tab Set the Firing Mode to ZeroCross Transformer Set the Phase_ZC_Switch_Time to the desired number of cycles the controller will use to ramp up to full conduction This parameter is adjustable from 5 to 20 cycles default is 20 cycles If the controller is firing into a transformer the value entered should be set high enough so that the transformer does not saturate during the start section of the ON portion of the duty cycle Transformer Selection A transformer of at least 1 3 Tesla 13000 Gauss is preferred for best performance up to 1 5 Tesla 15000 Gauss is permissible 7 3 Control Mode SP 3 z default SX HX Open Loop Included Included Closed Loop Included Included Closed Loop adjusts the output so that the feedback equals the setpoint When using Open Loop the output percentage is directly proportional to the setpoint The feedback is not used MicroFUSION Operator s Manual Rev 2 37 www ccipower com 1 800 765 2799 Control Concepts Inc 2014 33 7 4 Full Scale Settings 7 4 1 Full Scale Voltage SP 8 The Full Scale Voltage is the voltage that will be applied when the load is at full capac
30. d 26 4 INDICATOR uane ee IIR EFE IUE PDT 27 D aana a aga kana gua a ang a 26 9 1 BCI PIE E LA TENGE 26 BOP TION BOAR 26 6 1 Internal Factory Industrial Communications 26 6 2 External Factory Industrial Communications 28 29 rv Feedback 29 7 1 1 Feedback Type 29 7 1 2 External Feedback 30 T 1 3 Feedback Source 30 Z2 Finglede OF cun EE 31 ANG a aa aneda 31 Ler LO SS 32 7 2 3 Zero Cross Transformer Mode ZCT 33 Ta Bio e SP 33 34 7 4 1 Full Scale Voltage SP 8 bet tha ed ome opo 34 7 4 2 Full Scale Current 34 7 4 3 Full Scale Power SP 10 34 dah ga A eee een 34 7 5 1 Setpoint Source Setpoint 1 Source Setpoint 2 Source 35 7 5 2 Control Setpoint Select 5 104 35 7 5 3 Digital Setpoints SP100 amp 5 101
31. d The controller will continue to operate but will not exceed the power specified in this field The recommended setting is 105 of the full scale power The default value is set to 105 of the full scale power 7 8 Tap Change Indication Certain types of loads change resistance over their lifespan which can affect the power factor when controlled with a phase angle power controller to achieve a constant output power To improve power factor a transfomer with multiple voltage taps may be used The tap change indication signals the user when to change these voltage taps to a higher or lower setting to achieve the user s desired output This feature uses the controller s output percent along with the thresholds set by the user to determine the indication These indications can be mapped to the dry contact relays read on the user display or read digitally via the warning alarm monitor parameter 7 8 1 Setting Using Control Panel Software To enable Tap Change indication set the High Low Out Alarm Display Text XP 3410 selection on the System Tab To set the High Low thresholds set parameters Tap Change Up Threshold XP 3402 and Tap Change Down Threshold XP 3403 on the Zone 1 Tab When enabling the Tap Change indicator there are a few visual changes to the Control Panel 1 Warning alarms in the Dashboard section Out High Low change to Tap Change Up Down 2 Zone 1 Tab Output High Low Alarm Threshold change to Tap Change Up Down Thre
32. es Available cable lengths 6 inch cable 0058003 0050 005 1 foot cable 0058003 0050 01 5 foot cable 0058003 0050 05 10 foot cable 0058003 0050 10 15 foot cable 0058003 0050 15 10 2 Fieldbus Module The Fieldbus Module has any one of the following fieldbus interfaces EtherCAT EtherNet IP DeviceNet Modbus RTU RS 485 Modbus TCP or PROFINET Powered from the CCI Link bus it can interface with up to 10 Control Concept devices Each device must be given a unique MAC ID All controllers can send or receive data over the Link bus via one IP address From the fieldbus interface configurations may be saved and loaded Performance and data logging are available with the use of a Real Time Clock and Calander RTCC The Fieldbus Module also takes advantage of the Auto Termination Resistor Circuit Electrical Characteristics 24 Vdc input power via CCI Link bus 100 mA maximum draw 3000 Vdc isolation 10 3 Remote Display Easily view and customize limits setpoints and alarm conditions 2 Line 16 character text display Figure 1 UL type 1 amp 12 ratings IP65 See Appendix C for Remote Display setup and operation instructions Figure 1 10 4 Din Rail Power Supplies Ratings 85 264 Vac input 24 Vdc output 24 Watt 0091011 0024 1 60 Watt 0091011 0060 1 96 Watt 0091011 0096 1 10 5 USB Cable 15 foot A to Micro B 0058006 0000 15 Control Concep
33. ferent screens To return to auto scroll press and hold either button for a minimum of two seconds If the display idles for ten minutes in manual scroll it will automatically return to auto scroll Changing Value On setable parameters there will be dot in front of the jun parameter name To adjust the value press the green button The dot will change to an arrow See examples right Press the Plus and Minus buttons to adjust the value up down After the desired value is reached press the green button to accept the changes The screen should appear as before with the adjusted value ZN Each controller is shipped with a customizable screen list that pertains to the hardware configuration of the controller The default lists will show things such as line load voltages load currents and heatsink temperatures If the controller is equipped with a communications card the default list will also show specific parameters pertaining to the communications settings Screen Lists The screen list can be customized by connecting to the MicroFUSION Control Panel software Within the software any combination of screens can be programmed onto the screen limit 50 screens Parameter Lock A parameter lock can be setup to prevent anyone from changing parameter values using the display keypad See direction on how to set this up in the Display Control section of the MicroFUSION Control Panel software manual CONTRO
34. ity The closer the Full Scale Voltage is to the actual voltage the more accurate the controller will be Setting this slightly higher than the actual voltage is common This should not be set to more than 2X the actual voltage The factory default is set to 480 V 7 4 2 Full Scale Current SP 9 The Full Scale Current is the current that the load will draw when the load is at full capacity The closer the Full Scale Current is to the actual current the more accurate the controller will be Setting this slightly higher than the actual current is common This should not be set to more than 2X the actual current The factory default is set to the frame rating of the controller 7 4 3 Full Scale Power SP 10 The Full Scale Power is the power consumed by the load when at full capacity This should not be set to more than 2X of the actual power The default value is calculated from the following 3 Phase AC TIERED Delta 3 amp 4 Wire Wye Inside Delta Full Scale V x Full Scale I Full Scale V x Full Scale I x V3 Full Scale V x Full Scale x 3 Note In the MicroFUSION Control Panel Software there is a Calculate button for these equations This will automatically fill in the full scale power once pressed It will also automatically set up the limit settings 7 5 Setpoints SX H Included default The Analog SP2 is only available if the I O section of the model number contains 2 3 6 or
35. l Rev 2 37 www ccipower com 1 800 765 2799 Control Concepts Inc 2014 1 4 Model Options amp Description Single Phase AC The single phase AC power controller is a phase angle or zero cross fired controller It linearly controls with respect to the setpoint the AC voltage current or true power applied to an electrical load Control is achieved by means of a pair of inverse parallel SCR s Three Phase Two Leg The three phase two leg AC power controller is a zero cross fired controller It linearly controls with respect to the setpoint the AC voltage current or true power applied to an electrical load Control is achieved by two pairs of inverse parallel SCR s Three Phase Three Leg The three phase three leg AC power controller is a phase angle or zero cross fired controller It linearly controls with respect to the setpoint the AC voltage current or true power applied to an electrical load Control is achieved by three pairs of inverse parallel SCR s 1 5 Load Loads Applications 1 Constant Resistive Loads Nickel Chromium 3 Transformer Coupled Loads 2 Variable Resistive Loads 4 Inductive not intended for motor applications a Silicon Carbide 5 Gas Discharge b Molybdenum Disilicide a Ultra Violet c Graphite 6 Electron Beam d Tungsten Lamps 7 Crystal Growing and Processing Transformers Scott T amp Wye transformers Excessive voltage transients can occur when operating Scott T
36. odulation Input A pulse width modulation signal may be used as a setpoint The signal must be connected to Analog SP1 to function The setpoint source SP102 or SP103 must also be set to PWM input Input Range 20 Hz lt Frequency s 2 kHz 0 5 Vdc maximum 6 6 Retransmits SX HX Retransmit1 N A optional Retransmit2 N A optional The Retransmits are only available if the Retransmits section of the model number contains an The Retransmits are configured similarly to the analog inputs The two Retransmits can be configured independently as either a current source 0 20 mA or as a voltage source 0 10 Vdc The Retransmits may be mapped to Load Voltage Current or Power It can also be set to a direct out signal TG Control Concepts Inc 2014 WWW ccipower com 1 800 765 2799 MicroFUSION Operator s Manual Rev 2 37 m CONTROL CONCEPTS 9 CCI LINK This is a proprietary deterministic digital bus that enables multiple Control Concepts devices to communicate with each other 9 1 Network LED Indicators The CCI Link connector has 4 LEDs 2 yellow and 2 green There is one LED in each corner of the connector The Network LED indicators use the yellow and green LED located closest to the heatsink of the controller The yellow LED opposite of the heatsink is not used The green LED is used in the Auto Terminating Resistor Circuit Network State Green Yellow Descripti
37. on Wait 4 who s there OFF Blink 5 second interval Identify OFF Flash OFF Response to indentify request Connection timed out Comm Fault Bus OFF DUP MAC failure X don t care or same state as before is maintained Not on the network waiting When the controller does not detect any other devices on the CCI Link network the green LED will be OFF and the yellow LED will flash every 5 seconds The yellow network LED is also used to identify a specific controller on the CCI Link network When a controller is commanded to identify itself the yellow network LED will flash 5 times 9 2 Auto Terminating Resistor Circuit When connecting multiple devices on the CCI Link network a terminating resistor must be pulled in at each end of the network trunk line tree With the Auto Terminating Resistor Circuit the device automatically determines if the resistor needs to be pulled in based on if it is connected to one or two devices When the resistor is pulled in the green LED on the CCI Link connector furthest away from the heatsink will be illuminated MicroFUSION Operator s Manual Rev 2 37 www ccipower com 1 800 765 2799 Control Concepts Inc 2014 9 3 SYNC GUARD The SYNC GUARD feature reduces the possibility of synchronous operation of two or more zero cross controllers This feature does not alter the power applied to the load but adjusts the time when power is applied in such a manner as to reduce the
38. op feedback FF Voltage Use RMS Voltage based on line voltage as the control loop feedback RMS Voltage Use RMS Voltage as the control loop feedback AVG Voltage Use average voltage as the control loop feedback RMS Current Use RMS current as the control loop feedback AVG Current Use average current as the control loop feedback Power Use real power as the control loop feedback Apparent Power Use apparent power as the control loop feedback 7 1 1 Feedback Type Calculations Here are the formulas for how the feedback is measured RMS Voltage RMS Current Power The output is adjusted via the real gt Vi 2 gt li 2 Power V ns 2 0 707 Lm 24 n m n Lu n 0 707 m Real Power 2 n AVG Voltage AVG Current Apparent Power Vil _ Yr Real P Vag 1 11 0 707 1L 1 11 0 7071 Power Factor Pea Power _ n n Apparent Power V Peak Voltage Peak Current Vi Instantaneous Voltage sample Instantaneous Current sample number of samples in 1 AC line cycle MicroFUSION Operator s Manual Rev 2 37 www ccipower com 1 800 765 2799 Control Concepts Inc 2014 298 External feedback uses an external analog signal to represent the output to the load These types of signals often come from a transducer that measures voltage current temperature or power and scales it proportionally to a 0 5 or 4 20 mA signal Connect the exte
39. pecifications Liquid Cooled Ratings Description Rating Pressure Max 60 PSI 4 137 BAR Flow Rate 1 GPM 3 79 LPM Inlet Temperature Max 122 F 50 MicroFUSION Operator s Manual Rev 2 37 www ccipower com 1 800 765 2799 Control Concepts Inc 2014 3 WIRING Control Concepts configures and tests each controller before shipping Once received the controller is ready to install The following sections will describe how to properly wire the unit with the recommended fusing For line and load connections use copper conductors rated 75 C minimum See torque tables for proper tightening A ground wire is recommended for proper operation Use 10 AWG or larger wire Note Wire controllers to conform with the National Electric Code other local wiring codes 3 1 Torque Specifications Recommended Tightening For Line Load Connectors Wire Size AWG 24 IN LBS 2 70 Recommended Tightening Torgue For P1 P2 Connectors wires AWG Control Concepts Inc 2014 WWW ccipower com 1 800 765 2799 MicroFUSION Operator s Manual Rev 2 37 CONTROL WV CONCEPTS 3 2 AC Line Load PEGND Bl Al FUSES gt 12345678 12345678910 0 60 mA maximum through B1 connection 600 14 AWG Minimum wire size required for connector 00 0000 5 B1 A1 2 B1 uses 6 or M3 5 ring
40. possibility of two or more controllers being ON and OFF in unison SYNC GUARD is useful whenever there are two or more power controllers connected to the same power source with a zero cross firing mode selected The SYNC GUARD feature can significantly reduce the peak current required from a source that is connected to multiple power controllers while all are zero cross firing Zero cross firing is an ON OFF type of control where the desired voltage current or power is delivered to the load by varying the controller s ON OFF duty cycle With zero cross firing when the controller s output is ON full supply voltage and current are provided to the load Without SYNC GUARD multiple zero cross firing controllers could potentially be ON and OFF all at the same time This would require heavy current to be drawn from the source while the controllers are all ON and no current when they are all OFF The SYNC GUARD feature works to reduce the peak current draw required from the source over time by causing each controller to attempt to find a time to turn ON when fewer or no other controllers are firing Limitations As stated before the SYNC GUARD feature works to reduce the peak current draw required from the source for multiple controllers over time However each controller cannot predict when another controller is going to fire Therefore the probability of multiple controllers firing at the same time exists even when using the S
41. pts stocks 15 foot USB cables for customers to purchase P N 0058006 0000 15 6 OPTION BOARD 6 1 Internal Factory Industrial Communications A tieldbus interface options can be used Note Only one type of interface is available to communicate with a PLC or factory per unit For example a controller with control system PROFINET Modbus TCP Modbus cannot also have Modbus and EtherNet IP are available as internal fieldbus options Control Concepts highly recommends the use of shielded wiring and offers a variety of lengths to purchase 6 2 External Factory Industrial Communications DeviceNet EtherNet IP EtherCAT PROFINET Modbus RTU RS 485 or Modbus TCP are available through an external module Furthermore a single external network module can control up to 10 zones reducing system installation costs Control Concepts highly recommends the use of shielded wiring and offers a variety of lengths to purchase See Fieldbus module in the Accessories section of this manual for more details Control Concepts Inc 2014 WWW ccipower com 1 800 765 2799 MicroFUSION Operator s Manual Rev 2 37 CONTROL CONCEPTS 7 PERFORMANCE RMS Voltage Standard Standard ANG Voltage Standard Standard Standard Standard Real Power Optional Standard Apparent Power ____ Optional Standard 5 1 Default for SX 2 Default for HX The Feedback type determines the control lo
42. r com 1 800 765 2799 MicroFUSION Operator s Manual Rev 2 37 3 3 24 Vdc Input 5 onboard supply up to 10 mA Analog Input SP 1 Analog Input SP 2 Run Stop General Purpose Input Optional Retransmit 1 5 Retransmit 2 No Connect T NO o Relay 250 VAC Form C NC Control Concepts Inc 2014 WWW Ccipower com 1 800 765 2799 MicroFUSION Operator s Manual Rev 2 37 CONTROL CONCEPTS 4 INDICATOR LEDs See chart below for LED Colors and indicated Operation 24VDC Green 24 Vdc present 24 Vdc wired backwards LINE OK No AC Line V Ok Locked Boot Segment 24 LINE LIMIT ALARM Red Phase Lock Loss LIMIT Red Current Limit _____ Flash Power Limit between Red Green ALARM Off Ok No Alarms Not in RUN Ok No Alarms in RUN Warning Alarm Inhibit Alarm OUTPUT Green LEDs turn green in pro portion to output Top LED Red Indicates 100 on MicroFUSION Operator s Manual Rev 2 37 www ccipower com 1 800 765 2799 Control Concepts Inc 2014 5 USB INTERFACE 5 1 USB Interface A MicroUSB interface is standard on all controllers Included with each controller is a software package titled MicroFUSION Control Panel This allows the user to connect to the controller using a computer and MicroUSB cable Control Conce
43. re provided to make proper seals for the UL ratings A gasket that mounts to the heatsink and surrounds the controllers is also provided to keep contaminants outside the enclosure and is required for both the finned and liquid cool heatsinks for the UL ratings Figure 2 amp 3 The controllers are mounted such that the heatsinks are on the outside of the enclosure 1 6 9 ta In n 204A pue kg eie apt aat d OANA ATAO Y NE Vrnaratnya 0 C 4 VAYA Nero ere mere an 0 00 2 45 VIICrFKOFUSOIUIN iVianua 4 m CONTROL CONCEPTS The heatsink is mounted directly to the back plate of the enclosure Use the 4 mounting holes in the corners of the heatsink With this type of mounting the liquid connections to the heatsink are made inside of the panel 3 Figure 4 Mounting liquid cooled heatsink inside of an enclosure Note Liquid connections are not present in photograph 2 3 Mounting Instructions Finned External Mount 10 32 UNF 2B M5x0 8 6H not provided gt Gasket washer SS Enclosure wall Ka Gasket X External Mount Heatsink Tighten to 32 in Ibs 3 6 Nm to ensure proper seal for gasketed washer Do not not over tighten damage may occur to washer Gasket should compress approximately 5096 Control Concepts Inc 2014
44. rnal feedback signal to an analog setpoint Select the correct Feedback Source SP19 Scale the external feedback by setting up the analog setpoint the Analog I O tab of the Control Panel software SX HX Included Included Analog SP1 Included Included Analog SP2 z default The Analog SP2 source is only available if the I O section of the model number contains a 2 3 6 or 7 This selects the type of feedback used For external feedback select Analog SP1 or SP2 Control Concepts Inc 2014 WWW Ccipower com 1 800 765 2799 MicroFUSION Operator s Manual Rev 2 37 AA CONTROL CONCEPTS 7 2 Firing Mode SP 2 SX H Optional default for three phase 2 leg default for all other models The Zero Cross Transformer mode is only available if the Zero Cross Transformer Mode section of the model number contains a Z Knowing the application and the type of load you are trying to control is critical for choosing the right mode of operation The MicroFUSION Series power controllers are capable of Phase Angle Zero Cross and ZCT operations The following sections will describe each type of operation and will show the expected output Note For proper load operation correct wiring is critical See the Wiring section of 7 24 Phase Angle the Installation amp Maintenance Manual In phase angle control each SCR of the back to back pair is turned on for a variable
45. roller Model Numbers Model uF followed by 1 or 3 followed by HX or SX followed by T R 4DY 6DY or 64Y or 6ID followed by A through Z followed by any number or letter followed by numbers 01 through 80 followed by and numbers and or letters Classification Solid State Power Controller Class Pollution Degree Rated Voltage 24 600 Vac Rated Frequency 45 65 Hz Meets the essential requirements of the following European Union Directive s using the relevant section s of the normalized standards and related documents shown EN 60947 4 3 2007 Low voltage switchgear and controlgear EMC Directive 2004 108 EC EN 61000 6 2 2005 EN61000 4 2 1995 Amendments A1 1998 A2 2001 ESD Immunity EN61000 4 3 2006 Radiated Immunity EN61000 4 4 2004 Corrigendum 2004 EFT Burst Immunity EN61000 4 5 2006 Surge Immunity EN61000 4 6 2007 Conducted Immunity EN61000 4 8 1993 Amendment A1 2001 Magnetic Field Immunity EN61000 4 11 Second Edition 2004 Voltage Dips amp Interruptions EN 61000 6 4 2007 Conducted amp Radiated Emissions Note 1 All power terminals must be populated as to keep the controller touch safe to comply with EN 60947 4 3 Note 2 Controller must be mounted in a shielded enclosure to comply with EMC Directive 2004 108 EC Note 3 Controller must have appropriate line and control power filter to comply with EN61000 6 2 Third party conformance testing conducted by TUV America
46. s A Separate 24 Vdc power source supplies the control electronics and maintains critical communications to your control system when the mains are absent weas FUSION Status LEDs and an LED bar graph make operation and troubleshooting simple plug n play USB interface and free MicroFUSION Control Panel software for the PC further simplifies installing and configuring the controller to your application For example controller settings can be duplicated simply by loading a configuration file saved from a previous unit Setpoints can be controlled through the standard analog or optional digital fieldbus interface The factory configured analog setpoint signal ranges 0 5 and 4 20 mA both of which are field scalable from 0 10 or 20 mA External fieldbus interface options include DeviceNet EtherNet IP EtherCAT PROFINET Modbus RTU RS 485 or Modbus TCP These can be used to communicate with a PLC or factory control system PROFINET Modbus TCP and EtherNet IP are available as internal fieldbus options Furthermore a single external network module can control up to ten zones reducing system installation costs The robust design of MicroFUSION allows for continuous full frame current operation without derating at up to 50 6000 ft altitude Cooling is accomplished through either natural convection forced air optional external panel mount or optional liquid cooled chill plate 1 1 Certifica
47. s available with one of two circuit boards SX is a lower cost alternative whereas HX is a fully populated board that can be field upgraded to include retransmits and other features Included O Field Upgradable Option O Option Available at Manufacturing Time Not available FEATURE LIST 24 600 VAC Auto Ranging Input Phase Angle and Zero Cross Firing Modes LED Bar Graph Touchsafe Design UL Listed CE 100 SCCR and RoHS certifications Micro USB Connection USB Plug N Play Free Control Panel Software DIN Rail Mountable Panel Mount RUN STOP Overcurrent Trip o gt lt gt lt Analog Input 0 10V 0 4 20 mA or potentiometer Link Connectivity Fixed Current Limit 105 of Frame Adjustable Current Limit Alarm Relay Current Control Load Voltage Control Voltage Limit Monitor Current Isolated I O Analog Channel 2 Input General Purpose Input Pulse Width Modulation Input Accessory Option Remote Display SYNC GUARD Connectivity External Fieldbus Options DeviceNet Modbus TCP Modubs RTU EtherNet IP PROFINET EtherCat Internal Fieldbus Options PROFINET Modbus TCP and EtherNet IP External Panel Mount Heatsink Water Cooled Heatsink Zero Cross Transformer Firing Mode Retransmit RTX 2x High Resolution Analog Retransmits 0 10 VDC or 0 4 20 mA Power Limit True Power Control Monitor True RMS Power High Resolution Control Loop MicroFUSION Operator s Manua
48. s been removed and the load voltage appears to be off It has been mandated by the National Electrical Code and the Occupational Safety and Heath Act of 1970 that a physical disconnect be opened ahead of all remotely actuated controls before performing any maintenance work on the controller or its connected load PROPRIETARY DATA Copyright 2009 Control Concepts Inc Chanhassen MN 55317 The information and design disclosed herein are the property of Control Concepts Inc and may not be used reproduced or disclosed in any form except as granted in writing by CONTROL CONCEPTS INC 18760 LAKE DRIVE EAST CHANHASSEN MN 55317 PHONE 952 474 6200 TOLL FREE 800 765 2799 FAX 952 474 6070 www ccipower com MicroFUSION Operator s Manual Rev 2 37 WWW ccipower com 1 800 765 2799 Control Concepts Inc 2014 CONTROL CONCEPTS Listed 3132 Industrial Control Equipment 100kA Short Circuit Current Rating File Number E136219 EN60947 4 3 IP 20 See CE Declaration of Conformity FC Part 15 Subpart B Class A Device ROHS H Pb Free See ROHS Certificate of Compliance MicroFUSION Manual Certifications WWW ccipower com 1 800 765 2799 Control Concepts Inc 2014 DECLARATION OF CONFORMITY MicroFUSION Series SCR Power Controller um Control Concepts Inc 18760 Lake Drive East Chanhassen MN 55317 USA Declares that the following product Designation MicroFUSION Series Power Cont
49. shold Zone 1 Tab SP016 Relay 1 Alarm Output High Low change to Tap Change Up Down Control Concepts Inc 2014 WWW ccipower com 1 800 765 2799 MicroFUSION Operator s Manual Rev 2 37 m CONTROL CONCEPTS 8 1 Alarm Relay SP16 SP85 SX HX Relay Alarm Mask SP16 System Relay Mask SP85 The Relay is only available if the I O section of the model number contains a 4 Oe Eo or There is relay available on the MicroFusion controller Both the Relay Alarm Mask SP16 the System Relay Mask SP85 map to the same relay All alarms mapped to the relay are OR ed together The Relay Alarm Mask maps any or all of the following Heatsink Over Temperature Power Limit Output Low Tap Change Over Current Trip Current Limit Down Heatsink High Temperature Voltage Limit Digital Run Enable Run State Warning Deviation Alarm request AC Line Phase Loss Output 9e High Tap Change Up Phase Load Imbalance Shorted SCR Low Output The System Relay Alarm Mask maps any or all of the following Run Enable Switch terminals e Phase Lock Loop Lock Loss Communication Error closed Watchdog Timeout Processor Error Trap Controller is in Run State Memory Error Rating for the Relay are as follows 220 Vdc Maximum switching Voltage 250 Vac Maximum switching Current 2A Maximum switching capacity 60 W 62 5 VA 220 0 24 A 60 W 125 0 24 3
50. t Analog Input Channel 2 Pulse Width Modulation 7 Isolated I O with Alarm Relay and Gen Purpose Input Analog Input Channel 2 Pulse Width Modulation Retransmits None R Retransmits Two 16 bit analog retransmits for voltage current or power Sync None S Digital SYNC GUARD Zero Cross Transformer Mode None Z Zero Cross Transformer Mode Branch Rated Class T Fuse Options Blank None F010 10A F015 15A F020 20A F025 25A F030 30A F035 35A F040 40A F045 45A F050 50A F060 60A F070 70A F080 80A F090 90A F100 100A See Fusing Options page 7 for more information Contact factory for availability Only available with HX type board 50 Control Concepts Inc 2014 WWW Ccipower com 1 800 765 2799 MicroFUSION Operator s Manual Rev 2 37 CONTROL CONCEPTS APPENDIX PART NUMBERS 0000000 00 00000 0000 SX Standard HX Upgradable High Performance Load Configuration 4DY Three Phase 4 SCR 2 Leg 6DY Three Phase Delta Wye 6 SCR 64Y Three Phase 4 Wire Wye 6 SCR 6ID Three Phase Inside Delta 6 SCR Frame 16 32A Panel Mount Rail B 50 80A Panel Mount Din Rail C 16 32A External Mount D 50A External Mount E 16 32A Liquid Cooled F 50 80A Liquid Cooled Option Board None E Modbus TCP EtherNet IP N PROFINET Amp Size 16
51. termines which setpoint source the controller will use The setpoint source is configured using Setpoint 1 amp 2 Source SP102 amp SP103 By default this is set to Setpoint 1 Source 7 5 3 Digital Setpoints SP100 SP101 There are two digital setpoints Fieldbus Keypad The setpoints can be sent via USB a fieldbus interface or from the remote display keypad When using digital setpoints the Digital Run Stop SP129 must be used 7 5 4 Digital Run Stop SP129 When using a digital setpoint Digital Run Stop must be enabled It is common for this to be set to Run 1 whenever setpoint is assigned The Digital Run Stop Power up Default 5 3401 parameter found on the System Tab may be used to always have the Digital Run Stop set to Run 1 This is applied to Digital Run Stop SP 129 during a processor reset or power cycle MicroFUSION Operator s Manual Rev 2 37 Www ccipower com 1 800 765 2799 Control Concepts Inc 2014 7 5 5 Setpoint Resolution SP115 SX HX 10000 counts Included Included 64000 counts Included default The Setpoint Resolution sets the setpoint entry valve that equates to 100 output The count value equates to counts 0 output SP115 setting 10000 or 64000 100 output 7 5 6 Analog Setpoints Default Range Analog SP1 Vdc 0 5 10 10 Analog SP1 mA 4 20mA 0 20 Analog SP2 Vdc 0 5 0 10 Analog SP2 mA
52. the voltage applied to the load The recommended setting is 105 of the full scale voltage The default value is set to 630 Volts which is 105 of a 600 VAC frame voltage 7 7 2 Current Limit SP 12 SX HX Fixed Included Adjustable Included To adjust the Current Limit value for SX models the Performance section of the model number must contain This limits the current applied to the Load The recommended setting is 105 of the full scale current The default value is set to 105 of the frame rating The current can be limited by the RMS or AVG value Use the Current Limit Type parameter SP13 to change between RMS or AVG 7 7 3 Over Current Trip SP 14 SX HX Adjustable Included Included If the current exceeds the Over Current Trip setting the controller will shut down This responds faster than the Current Limit setting When experiencing an Over Current Trip the controller will disable the output and display the condition on the LED indicators and the remote display if present This feature is designed to protect the controller from experiencing surge currents that could damage the controller Hecommended settings Phase Angle firing mode 175 of frame rating Zero Cross firing mode 350 of frame rating MicroFUSION Operator s Manual Rev 2 37 www ccipower com 1 800 765 2799 Control Concepts Inc 2014 37 Ni 7 7 4 Power Limit SP 15 SX HX Adjustable Limits the power applied to the loa
53. tions Markings niis ou LISTED EN60947 4 15 SubpatB COMPLIANT Class Device In addition to certification markings the controllers will also be marked with Model Number Serial Number Voltage Range 24 600 Vac Current Size Control Concepts contact information Frequency 45 65 Hz Torque information on Line Load connections MicroFUSION Operator s Manual Rev 2 37 www ccipower com 1 800 765 2799 Control Concepts Inc 2014 1 2 Points of Interest A CCI LINK COMMAND CONNECTIONS A proprietary deterministic digital bus that P1 Analog inputs general purpose input 24 enables multiple Control Concepts devices to Vdc supply run stop communicate with each other F INDICATOR LEDs B DIGITAL COMMUNICATIONS OPTION Assist with Diagnostics PROFINET Modbus TCP and EtherNet IP are available as internal fieldbus options G CONTROLLER RESET MicroFUSION processor can be reset externally C RETRANSMITS amp RELAY CONNECTIONS P2 Retransmits and Relay H USB PORT Streamlines controller setup with the use of the D OPTIONAL REMOTE DISPLAY DISPLAY MicroFUSION control panel Shows parameter name with information such as setpoints limit settings monitor features alarms and more The display can be easily mounted outside an electrical panel for efficiency m igc FEgU CONTROL CONCEPTS 1 3 Feature Comparison MicroFUSION i
54. ts Inc 2014 WWW ccipower com 1 800 765 2799 MicroFUSION Operator s Manual Rev 2 37 CONTROL CONCEPTS APPENDIX A SPECIFICATIONS PERFORMANCE ________ Standard High Performance Option Setpoint Resolution 10 000 counts Selectable 10 000 or 64 000 counts Internal Control Loop Resolution 16 000 counts 64 000 counts Output Resolution 12 000 counts 50Hz 10 000 counts 50 000 counts 50Hz 42k 000 counts 60Hz 60Hz Accuracy Full Conduction Accuracy A 10 to 15 line voltage change will result A 10 to 15 line voltage change will result in a max output change of 0 5 from 5 to in a max output change of 0 05 from 5 to 100 output range 100 output range Temperature Drift Output shall not change greater than 0 5 per Output shall not change greater than 0 2 per degree C max over the operating temperature degree C max over the operating temperature range from 5 to 100 output range range from 5 to 100 output range POWER Line Voltage Auto Ranging 24 600 Vac Nominal 10 15 Contact factory for other options Line Frequency Auto Ranging 45 65 Hz Frame Current Ratings Amps Continuous RMS AC 8116132150180 Current Rating Peak Surge 20X frame rating Minimum Hold Latch Current 500 mA SCR Rating PIV 1600 V peak forward amp reverse Fusing Optional external Class T branch rated touch safe fusing Thermal Integrated heat sink thermal sensor Current Limit 20 105 of continuous rating of Frame
55. unt Only available with HX type board MicroFUSION Operator s Manual Rev 2 37 www ccipower com 1 800 765 2799 Control Concepts Inc 2014 51 nd

SCR POWER CONTROLLERS - Control Concepts, Inc.

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