Model 1029C User Manual - Precision Control Systems, Inc.
Contents
1. 5 o Figure 9 Single voltage or mA current applied to the run input connections Terminals 10 amp 11 must be connected to enable the run input Effective 10 19 2007 the controller will be shipped with shorting jumper on pins 10 amp 11 IDLE POTENTIOMETER RUN POTENTIOMETER ccw ccw IK IK POT POT RUN IDLE SWITCH CLOSED ENABLES THE RUN INPUT OPEN ENABLES THE IDLE INPUT o uz EE Q gt cdiiz uczmolodw Q gt x gt L a Z 2 x O L lt Ww lt Zanr Off wm Figure 10 Run and Idle potentiometer connections MODEL 1029C 9 10 19 2007 COMMAND CONNECTIONS Continued POSITIVE POSITIVE IDLE INPUT RUN INPUT VOLTAGE OR CURRENT VOLTAGE OR CURRENT COMMAND SIGNAL COMMAND SIGNAL COMMON COMMON Suge x PROS a LU m i xo s i z2ucrzzazlzomw lt gt x Z gt gt 2 tiro lt mx lt lt O G mx m i wy 3 oOo ggu sew MU mx oD amp 72 Figure 11 Run and ldle voltage or current connections If itis desired to use a current command in both the Run and Idle command input the signals must either be common sourcing or they must be isolated from one another Contact factory for details CURRENT METERING VOLTAGE METERING OUTPUT OUTPUT o 2 uz seuss 529 Oz s Fa Z u gt 2 Lu A 5 Z BIO ul gt gt uU 5 x E lt a c ES LU 212. eu a a D O Figure 12 Output metering connections MODEL 1029C 10 10 19 2007 COMMAND CONNECTIONS Continued POSITIVE RUN INPUT VOLTAGE OR CURRENT COMMAND SIGNAL IDLE POTENTIOMETER CCW COMMON RUN IDLE SWITCH CLOSED ENABLES THE RUN INPUT OPEN ENABLES THE IDLE INPUT u z 5856 LIT LET lt 2 0 Ss m U gt Z G mx Lu gt cm gt 35 x o Q e ES LU m 2 I a os wn O Figure 13 Combination command signal potentiomter input connections This is the most common use of a run idle control POSITIVE POSITIVE EXTERNAL FEEDBACK SIGNAL RUN INPUT VOLTAGE OR CURRENT COMMAND SIGNAL COMMON COMMON o Sud eRe TO As m dz uczgolb5oc A gt Ho gt x O e lt 5 tx ETC D nc X sa OS wm O Figure 14 External feedback with signal applied to run input connections 0 5 or 0 50uA external feedback Terminals 10 amp 11 must be connected to enable the run input Effective 10 19 2007 the controller will be shipped with shorting jumper on pins 10 amp 11 MODEL 1029C 11 10 19 2007 POWER CONNECTIONS VOLTAGE SUPPLY LOAD VOLTAGE SUPPLY LOAD Soo como al Figure 16 Power Path MODEL 1029C 12 10 19 2007 FEEDBACK SELECTION START
3. 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 has 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 2007 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 7870 PARK DRIVE CHANHASSEN MN 55317 PHONE 952 474 6200 TOLL FREE 800 765 2799 FAX 952 474 6070 www ccipower com MODEL 1027 TABLE OF CONTENTS DESCRIPTION 1 FEATURES 1 SPECIFICATIONS 2 INSTALLATION 4 INSTALLATION DRAWINGS 5 COMMAND CONNECTIONS 8 POWER CONNECTIONS 12 FEEDBACK SELECTION 13 START UP 13 ADJUSTMENTS 14 TROUBLESHOOTING 16 MANUFACTURED BY 16 REPLACEMENT PARTS 17 MODEL NUMBER IDENTIFICATION 18 THEORY OF OPERATION 19 50 to 750 AMPS C UL US LISTED 3L32 FILE No E136219 gt INDUSTRIAL CO
4. 4 20mA or Potentiometer XXX Idle Command Signal 0 5Vdc 4 20mA or Potentiometer Example 1029C A 480V 80A IL75 R0 5V IPOT Will order a 1029C controller with average voltage feedback rated 480 Volts 80 Amps current limit set at 75 Amps run command signal of 0 to 5Vdc and a potentiometer on the idle command input If a SC VVV term is included it implies special calibration meaning that the controller has been calibrated for a maximum output of VVV voltage rather than the rated line voltage Contact factory for information MODEL 1029C 18 10 19 2007 THEORY OF OPERATION THE SCR The heart of the Control Concepts Inc power controller is the SCR silicon controlled rectifier sometimes referred to as a thyristor The SCR has two states ON and OFF and allows current to flow in only one direction when turned on SCRs can remain in the off state even though the applied potential may be up to 1600 volts In the on state they can pass several thousand amperes When a small signal is applied between the gate and cathode terminals Figure 20 the SCR will turn on within 10 100 microseconds Once turned on it will remain on until the current through it is reduced below a very low value referred to as the holding current CURRENT ANODE CATHODE GATE Figure 20 SCR symbol Because the SCR allows current to flow in only one direction two SCR s are connected in an inverse parallel back to back
5. basic model number X The type of feedback A Specifies average voltage feedback With average voltage feedback the controller varies the conduction angle or ON time of the SCRs such that the average voltage applied to the load is proportional to the command signal E Specifies external feedback The external feedback being proportional to some parameter such as speed current etc that is ultimately being controlled by the action of the controller Specifies RMS current feedback The load current is linearly controlled with respect to the command signal P XXXAMPS The letter P specifies power feedback and therefore the load power is linearly controlled with respect to the command signal XXX equals amp level for control of power MAX LOAD POWER VOLTS V x P AMPS V Specifies RMS voltage feedback With RMS voltage feedback the controller varies the conduction angle or ON time of the SCRs such that the RMS voltage applied to the load is proportional to the command signal XXX V Operating Voltage 120 208 240 277 380 415 480 or 575 Vac Note unless otherwise specified the controller is shipped with a transformer that has primary voltage taps at 240 480 or 575 volts 50 60 Hz XXX A Operating Current 50 80 120 160 200 250 300 380 425 500 600 or 750 consult factory for 1000 amp 2000 Amps IL XXX Current Limiting Up to 105 of controller rating R XXX Run Command Signal 0 5Vdc
6. factory set for 10596 of the rated current unless otherwise specified VOLTAGE METER OUTPUT A filtered metering signal equals 5 0 Vdc when the nominal line voltage is applied to the load Metering load 5mA max CURRENT METER OUTPUT A filtered metering signal equals 5 0 Vdc when the frame rating current is applied to the load Metering load 5mA max GATE DRIVE An optical coupled current source of 250mA with a minimum compliance of 10 volts provides the gate drives to the SCRs Duration or back porch is approximately 1 4 milliseconds 60 electrical degrees VOLTAGE COMPENSATION When using voltage feedback the load voltage remains constant independent of supply voltage changes within 1096 15 POWER DISSIPATION 1 5 Watts per amp of load current CERTIFICATION Model 1029C 120 575 Volts 50 750 Amps is U L listed U L File No E136219 EU M FEEDBACK AVG User has choice of True RMS Voltage or True RMS Current Power feedback can be factory installed if desired Only one type of feedback may be selected EXTERNAL FEEDBACK An external 0 to 5Vdc or 0 to 50uA signal derived from the load may be used for external feedback into the controller See Figure 19 for connections LINEARITY The controlled variable is linear within 296 of Span with respect to command signal COMMAND INDICATOR This green LED indicates that the gate drive is present LOAD CURRENT INDICATOR The intensity of this green LED is proportional to
7. fuses can be confirmed by determining that the supply voltage exists between Line 1 and Load 1 terminals when the command signal is zero MODEL 1029C LOAD VOLTAGE WILL NOT GO TO ZERO If RMS value of the load voltage is greater than 10 percent of the supply voltage Determine SHORTED SCR LED status while varying the command signal With power removed and the load disconnected from terminal Load 1 the resistance between terminals Line 1 and Load 1 should be greater than 100K ohms If the resistance between Line 1 and Load 1 is less than 100K ohms the SCR module has failed If the shorted SCR led is ON amp the resistance between Load 1 and Line 1 is greater than 1000 ohms the failure is likely associated with the circuit board Determine by removing the circuit board and applying power Determine that the supply to line 2 and the load are connected to the same supply If the RMS value of the load voltage is less than 10 percent of the supply voltage Determine that the command signal is correct Adjust the zero and span potentiometers to achieve the desired output Note The Zero and span potentiometers are factory set Adjustment should be made with caution FULL VOLTAGE CANNOT BE OBTAINED Determine that the control signal is at maximum Determine that the controller is not in current limit Decrease the current limit by rotating the current limit potentiometer counterclocklwise the controller is in current limit i
8. the load current OVER CURRENT TRIP This amber LED when lighted indicates the over current limit has been exceeded INDICATOR and the Over Current Trip relay has been energized The SCR s will be prevented from turning on while this circuit is active Reset by closure between Pins 9 amp 10 or momentary power interruption See Figure 7 SHORTED SCR INDICATOR This red LED when lighted indicates a shorted SCR O C T amp SHORTED SCR The Over Current Trip and the Shorted SCR circuits each control a relay which RELAY CONTACT RATINGS has form C contacts rated for 5 Amps 120Vac The contacts are available on the command connector See Figure 7 CONTROL RANGE 0 to 98 of supply voltage ENVIRONMENT Operating temperature 0 C to 55 32 F to 132 F Storage temperature 40 C to 80 40 F to 176 F Humidity 0 to 9596 non condensing PHYSICAL 50 amp 80 Amp controllers 16 pounds 120 amp 160 Amp controllers 17 Pounds 200 to 425 Amp controllers 21 Pounds 500 to 750 Amp controllers 40 Pounds LINE 2 REQUIREMENTS The Line 2 connection is the return for the internal control transformer rated at 50 VA 18 ga wire MODEL 1029C 3 10 19 2007 INSTALLATION TRANSFORMER TAP Open lid and locate power transformer Check voltage tap is on desired line voltage MOUNTING AND LOCATION Mount controllers on a vertical surface with the fins oriented so that air may flow vertically between them For controllers with
9. 29C Potentiometer A 1k ohm to 20k ohm potentiometer 1 4 watt or more may be used to adjust the load voltage A 1k ohm potentiometer provides the maximum linearity See Figure 8 or Figure 10 Consult factory for other options POWER amp SAFETY CONNECTIONS Over Current Trip Relay Connections to the form C contacts of the over current relay are shown in Figure 7 The contacts are rated for 5 Amps at 120 Vac and are intended for activating an alarm and or removing power from the system by operating a contactor or a circuit breaker Over Current Trip Reset Momentary closure of a switch connected between terminals 9 and 10 on the command connector will reset the over current relay and will release the SCRs from the locked off state The reset switch can also be used as an on off control Closure of the switch causes the SCRs to be immediately turned OFF When the switch is opened the SCRs begin operation at zero conduction angle and slew at the soft start rate to the desired output The Over Current Trip circuit may also be reset by a momentary interruption of supply power Shorted SCR Relay Connections to the 5 Amp 120 Vac form C contacts are shown in Figure 7 This relay energizes if an SCR fails in the shorted mode and is intended to activate an alarm and or cause power to be removed from the system by operating a contactor or a circuit breaker Power Connections Figure 15 amp Figure 16 show typical electrical connecti
10. Amp 4500 Amps Peak lsu 125 C 250 Amp 5200 Amps Peak 300 Amp 7000 Amps Peak 380 Amp 10 000 Amps Peak 425 Amp 13 000 Amps Peak 500 Amp 10 000 Amps Peak 600 Amp 13 000 Amps Peak 750 Amp 16 500 Amps Peak SCR PROTECTION dV dT rating 200 volts microsecond dV dT circuit consists of a capacitor in series with a noninductive resistor This circuit is in parallel with the SCRs The SCRs are protected from voltage transients by a Metal Oxide Varistor RUN IDLE CONTROL A contact closure selects either the run command signal input or the idle command signal input See Figure 10 ELECTRICAL CONNECTIONS Connectors for line and load are provided for copper wire from 6 ga to 250MCM on of LUGS PER LINE LOAD controllers rated 50 to 425 Amps CONNECTIONS Connectors for line and load are provided for copper wire from 1 0 to 500MCM on controllers rated 500 to 750 Amps ELECTRICAL ISOLATION 50 160 Amp heatsink to supply and load voltage 2500 Volts Peak 200 750 Amp heatsinks are at line voltage potential Command signal to supply and load voltage 1500 Volts Peak MODEL 1029C 2 10 19 2007 SPECIFICATIONS Continued ZERO AND SPAN Potentiometers on the circuit board allow zero and span adjustments of 25 of span for run and idle and are factory calibrated CURRENT LIMITING A potentiometer on the circuit board allows adjustment of the current limit setting from 2096 to 10596 of the controller rating The current limit potentiometer is
11. C 19 10 19 2007
12. Control Concepts Model 1029C Power Control System Instruction Vianual Series 2 Controlli i SCR Power Controllers Another quality product from RI RESEARCH INC DRYING 4 CURING 4 HEATING 7128 Shady Oak Road Eden Prairie MN 55344 USA 952 949 9009 Fax 952 949 9559 www researchinc com CONTROL CONCEPTS INC INSTALLATION MANUAL MODEL 1029C CONTROL CONCEPTS 7870 PARK DRIVE CHANHASSEN MN 55317 952 474 6200 1 800 765 2799 FAX 952 474 6070 www ccipower com 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
13. NTROL EQUIPMENT NOTE THE 1000 AMP UNIT IS NOT UL LISTED MODEL 1029C i 10 19 2007 DESCRIPTION MODEL COVERED This manual describes the Control Concepts model 1029C controller with the following ratings CURRENT 50 Amps to 750 Amps VOLTAGE 120 Vac to 575 Vac 50 60 Hz GENERAL DESCRIPTION The model 1029C is a single phase phase angle power controller that has selectable feedback dual command signals adjustable current limiting amp over current trip shorted SCR detection estimated output voltage metering and output current metering FEATURES CURRENT LIMITING A user adjustable setting prevents the load current from exceeding a presettable value This feature is useful where variable resistance loads have a heavy current draw as they are warming up OVER CURRENT TRIP If the SCR current exceeds this preset value a relay with form C contacts is energized an LED is lighted and the SCR s are prevented from turning on This provides a means to initiate an alarm or to remove system power in the event that excessive current occurs Momentary closure of a remote switch or momentary interruption of main power will reset the O C T circuit SOFT START AND MISSING CYCLE DETECTION The output voltage is ramped from zero to the desired output at a ramp rate equivalent to a time constant of 0 2 seconds on power interuptions of 1 2 cycle or more This feature minimizes inrush currents when controlling variable resistance loads o
14. UP Connector P2 on the circuit board allows the selection of feedback type See Figure 18 True RMS is the default voltage feedback mode Average voltage feedback mode may be requested when ordering the controller Voltage feedback may be selected by placing the jumper across pins P2 4 and P2 7 VFB Current feedback may be selected by placing the jumper across P2 3 and P2 8 IFB Power feedback if factory installed may be selected by placing the jumper across P2 5 and P2 6 PFB External feedback may be connected between terminals P1 14 Common and P1 18 FD BK on the command connector See Figure 19 A 0 5Vdc signal may be used for external feedback when the jumper is placed across pins P2 2 and P2 9 EXT A 0 100uA signal may be used for external feedback when the jumper is placed across pins P2 1 and P2 10 SJ Average voltage and True RMS voltage are of the feedforward technique MODEL 1029C Determine that the selected transformer tap corresponds to the line voltage If the customer wishes to determine that the controller and the command signals are wired and operating correctly before applying power to the load the following procedure may be followed A load capable of drawing at least one amp must be connected for the controller to operate properly 1 Move the feedback jumper to pins P2 4 amp P2 7 to select Voltage FB See Figure 18 2 Determine that terminals P1 10 amp P1 11 are electric
15. WINGS Continued SHORTED OVER SCR CURRENT DANGER COMMAND O INDICATOR Loan O moicaron Figure 5 Installation drawing for 500 to 750 Amp units 26 1 0 332 Dia 4 Figure 6 ORIENTATION OF FUSE IN HOLDER Fuse makes contact only when correctly installed MODEL 1029C 7 10 19 2007 COMMAND CONNECTIONS OVER CURRENT TRIP RESET SWITCH _ _ TO ALARM OR POWER DISCONNECT TO ALARM OR POWER DISCONNECT CIRCUIT S29 5 ex gt lr O E lt LU mx oc 1 j 7o gew Per 5 72 Figure 7 Voltage or current command connections OVER CURRENT RELAY CONTACTS CHANGE STATE WHEN AN OVERCURRENT CONDITION OCCURS SHORTED SCR RELAY CONTACTS CHANGE STATE WHEN AN SCR FAILS IN THE SHORTED MODE CW a gt gt O E lt ui lt mx nc X Per 5 72 o Figure 8 Single potentiometer applied to the run input connections Terminals 10 amp 11 must be connected to enable the run input Effective 10 19 2007 the controller will be shipped with shorting jumper on pins 10 amp 11 MODEL 1029C 8 10 19 2007 COMMAND CONNECTIONS Continued POSITIVE RUN INPUT VOLTAGE OR CURRENT COMMAND SIGNAL COMMON m u z Gnu 22 0 iB gt Z Q 5 m U gt Z mx LLI gt x Z gt L gt gt Z e mx lt G mx Q 3 O0 25
16. ally connected Apply a command signal to the run command signal input 3 Set the command signal to zero before applying system power The load voltage should start at zero and increase as the command signal is increased reaching optimum line output when command signal is maximum 4 Remove system power from controller Remove electrical connection from between P1 10 amp P1 11 Apply a command signal to the idle command signal input and repeat step 3 The load voltage and current may be measured with any meter However for accurate RMS voltage measurements use a True RMS responding meter Use an average responding meter for average voltage measurements 5 When start up tests have been completed move the feedback jumper to select the desired operating feedback The controller was calibrated at the factory If adjustments appear necessary see the zero and span adjustment instructions on page 14 Care is urged whenever working near high voltages and it is recommended that installation and service be done by a licensed electrician or experienced technician 13 10 19 2007 ADJUSTMENTS The I Span and V Span pots and Power Span and Power Zero pots when factory installed are sealed at the factory They are identified with an X in Figure 17 Under no circumstances should adjustment of these four pots be attempted The setting of each of these potentiometers is critical to the proper operation of the controller The pot
17. configuration to control AC current Figure 21 AC Switch PHASE ANGLE OPERATION In phase angle control each SCR of the back to back pair is turned on for a variable portion of the half cycle that it conducts Figure 22 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 Phase angle control is required if the load is transformer coupled capacitive inductive or a variable resistance load requiring current limiting Point at which SCR begins to conduct gt Figure 22 SCR ON time shown by shaded area is varied to apply the desired load voltage WARNING the Control Concepts Inc model 1029C power controller uses 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 has been removed and the load voltage appears to be off It has been mandated by the National Electrical Code and the Occupational Safety and Health 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 MODEL 1029
18. eased The COMMAND LED indicates the presence of gate drive The O C T LED is a fault indicator to warn that an Over Current condition has occurred the O C T relay is energized and the SCR s are prevented from turning on The SHORTED SCR LED is a fault indicator to warn that one or more SCR s may be shorted NO LOAD VOLTAGE Determine that the Command LED lights when the command signal is increased from zero If the command LED will not light Determine that the following conditions exist Measure voltages at screw terminals to ensure good electrical connections Determine if OVER CURRENT TRIP LED is ON Voltage between COM Pin 14 and 5CW Pin 12 must be 5 Volts 1 If not Circuit is not powered or command connections are shorting out supply Determine that line voltage exists between Line 1 and Line 2 terminals Determine that fuses on controller are OK Remove connections to CW terminal 12 Voltage or potentiometer inputs Determine that voltage from COM pin 14 to IDLE W or RUN W changes from 0 to 5 Vdc as command is changed from zero to 10096 4 20 mA inputs Determine that voltage from COM pin 14 to IDLE W or RUN W changes from 1 2 to 6 Vdc as command is changed from 4 to 20 mA Determine that there is no connection between terminals 9 amp 10 If the command LED can be made to light Determine that the load fuses are OK and that the load has continuity Load continuity including load
19. entiometers labeled Run Span Run Zero Idle Span amp Idle Zero have been calibrated at the factory and readjustment should not be necessary The zero pots are adjusted to provide zero output when the command signal is at minimum The span pots are adjusted to provide full output when the command signal is at maximum If itis determined that the adjustment should be changed the following procedure should be followed It is assumed that the load is resistive and can draw at least one or more amps Run Zero and Run Span Determine that pin P1 11 Run ldle is electrically connected to pin P1 10 Common Make sure that the command signal is connected between the Run input P1 13 Run Wiper and P1 14 Common 1 Set the command signal to minimum and adjust the Run zero potentiometer until the output is zero 2 Set the command signal to maximum and adjust the Run span potentiometer until the output is at the desired maximum value 3 The span and zero adjustments may interact making it necessary to repeat steps 1 and 2 Idle Zero and Idle Span Remove the electrical connection from between P1 11 Run ldle and P1 10 Common Make sure that the command signal is connected between the Idle input P1 15 Idle Wiper and P1 14 Common Repeat steps 1 2 and 3 above on the idle zero and span potentiometers MODEL 1029C It is important that meters capable of accurately measuring the output of the controller be used Tr
20. f the load voltage decreases If the problem occurs on initial start up determine that line 2 and the load are connected to the same supply MANUFACTURED BY CONTROL CONCEPTS 7870 PARK DRIVE CHANHASSEN MN 55317 TEL 952 474 6200 FAX 952 474 6070 TOLL FREE 800 765 2799 www ccipower com U S A 16 10 19 2007 REPLACEMENT PARTS SCHEMATIC DWG CCI No D1000954A ITS RECOMMENDED THAT THE CONTROLLER AND LOAD BE PROTECTED BY 600 VOLT CLASS T FUSES TO ORDER A SPARE SCR MODULE TO ORDER CLASS T FUSES CONTROLLER CONTROL CONTROLLER CONTROL CURRENT CONCEPTS CURRENT FUSE SIZE CONCEPTS RAING Amps A RATING Amps A PART No SCR TT91 16 42110 0460 360 SCR TT91 16 42110 0460 410 SCR TT105 16 42110 0460 415 SCR TT132 16 200 SCR T240 14 250 SCR T340 14 300 SCR T490 14 380 SCR T600 14 425 SCR T760 14 500 SCR T600 14 SCR T760 14 750 SCR Z1400 14 Because of critical assembly requirements it is recommended that replacement of SCRs on 200 Amp and larger controllers be done at the factory If you desire to try it yourself request a copy of our technical bulletin concerning replacement of SCR s on the 3629 controller 2 2 4 N al al 00 50 300 350 50 500 700 800 N a 42130 0460 2026 42130 0460 208 42130 0460 210 42130 0460 205 MODEL 1029C 17 10 19 2007 MODEL NUMBER IDENTIFICATION 1029C X IXXX V XXX A IL XXX R XXX I XXX 1029C E The
21. fans excludes the 50 amp 80 amp units may be mounted in any direction COMMANDI INPUTS The 1029C has two command inputs RUN and IDLE which are selected by a contact closure A potentiometer a DC voltage or a DC current may be used as a command signal into either input These connections are made to the command connector as described below Run ldle A remote switch can be used as shown in Figure 10 to cause the controller to be controlled by either the run or idle inputs Connecting terminal 10 COM to terminal 11 RUN IDLE on the command connector causes the run signal input to be in control Opening the connection between terminal 10 and terminal 11 causes the idle signal input to be in control COMMAND SIGNAL OPTIONS Voltage A 0 to 5 Vdc signal may be used as the command signal by connecting the positive signal to terminal 13 run or terminal 15 idle Always connect negative common signal to terminal 14 common See Figure 9 or Figure 11 Current Connect positive current connection to terminal 13 run or terminal 15 idle Connect negative or return current connection to terminal 14 common See Figure 9 or Figure 11 When using a current command in both the run and idle command input they must either be sourcing or be isolated from one another Contact factory for details gt RECOMMENDED TIGHTENING TORQUE FOR EDGE CARD CONNECTOR Wire Size 14 ro 26cA 4 4 5 5 IN LBS MODEL 10
22. nting the load current are provided for remote monitoring MODEL 1029C 1 10 19 2007 SPECIFICATIONS The following specifications apply over an ambient temperature of 0 to 55 C and a supply voltage of 85 to 110 of the nominal supply voltage rating CONTROL MODE Single phase SCR phase angle control The AMPS A term within the model number specifies the maximum continuous RMS current rating at the maximum operating ambient temperature of 55 C RUN COMMAND SIGNAL Command signal Input Impedance AND OR 1 5mA 1200 ohms IDLE COMMAND SIGNAL 4 20mA 300 ohms 0 5Vdc 200K ohms Potentiometer 200K ohms 1K 1 4watt pot recommended for optimum linearity up to 20K permissible The control circuit supplies 5 Vdc to the potentiometer Other command signal ranges may be available Check with factory for special applications If it is desired to use a current command in both the run and idle command input the signals must be common sourcing or they must be isolated from one another Contact factory for more information OPERATING VOLTAGE The control transformer installed in this controller has three selectable voltages 240 480 amp 575 Vac Other voltages are be available contact factory for details SCR RATINGS Peak forward and reverse voltage 1600 volts SCR SURGE CURRENT Controller Rating Surge Current Rating RATINGS 50 amp 80 Amp 1750 Amps Peak 120 Amp 1900 Amps Peak peak one cycle 160 Amp 4000 Amps Peak non repetitive 200
23. ons The LINE 1 and LOAD 1 connectors are approved for wire sizes from 6ga to 500 MCM TORQUE 100 iN LBs 125 IN LBS 150 IN LBS 200 iN LBS 250 iN LBS 300 iN LBS RECOMMENDED TIGHTENING TORQUE FOR THE LINE AND LOAD CONNECTORS WIRE SIZE AWG OR CircuLAR MILLS 4 to 6GA 1 To 2GA 1 0 ro 2 0GA 3 0 ro 4 0cA 250 ro 350mcm 500mcm 10 19 2007 INSTALLATION DRAWINGS i 9609996009 9 o 0 50 a z 2 x O e 10 6 10 6 0 288 X 0 50 2 Figure 1 Installation drawing for 50 80 120 amp 160 Amp units NOTE THE 50 and 80 AMP UNITS ARE NOT FAN COOLED THEY MUST BE MOUNTED ON A VERTICAL SURFACE WITH THE FINS ORIENTED VERTICALLY SO THAT AIR MAY FLOW FREELY BETWEEN THE FINS 120 and 160 AMP UNITS ARE FORCED AIR COOLED THEY MAY BE MOUNTED IN ANY DIRECTION Figure 2 ORIENTATION OF FUSE IN HOLDER Fuse makes contact only when correctly installed Place flat end of fuse in cap then insert into holder MODEL 1029C 5 10 19 2007 INSTALLATION DRAWINGS Continued CURRENT SHORTED OVER Sci CURRENT DANGER COMMAND O INDICATOR LOAD O INDICATOR 10 85 16 00 17 40 5 16 Dia 4 vl e Figure 3 Installation drawing for 200 250 300 380 and 425 Amp units Figure 4 ORIENTATION OF FUSE IN HOLDER Fuse makes contact only when correctly installed MODEL 1029C 6 10 19 2007 INSTALLATION DRA
24. r inductive coupled loads SHORTED SCR DETECTION A relay with form C contacts and an LED is energized in the event an SCR fails in the ON state This provides a means to initiate an alarm or to remove system power in the event an SCR fails in the ON state STATUS INDICATORS Command Intensity of command indicator is proportional to the command signal and the ON time of the SCRs Load The intensity of the load indicator is proportional to the load current Shorted SCR When ON an SCR has failed in the shorted mode Over Current Trip When ON indicates that load current has exceeded the preset Over Current Trip level RUN OR IDLE INPUT SELECTION With this feature either of two command signals can be selected by a remote switch This allows the controller to be conveniently switched from a RUN to an IDLE state or from an AUTOMATIC to a MANUAL control CHOICE OF FEEDBACK The Average value of the load voltage the RMS value of the load voltage or the RMS value of the load current can be linearly controlled with respect to the command signal The power watts applied to the load can also be linearly controlled with respect to the command signal Power feedback is an option that must be factory installed The controller will also accept external feedback signals of 0 5 Vdc or 100 uA representing other process parameters OUTPUT METERING A filtered 0 5 Vdc signal representing the load voltage and a 0 5 Vdc signal represe
25. rrent Trip pot about 1 2 turn clockwise 4 Reset the Over Current Trip circuit 14 10 19 2007 ADJUSTMENTS Continued Run Span Pot Run Zero Pot THESE FOUR POTS AND THE CURRENT LIMIT POT ARE MOUNTED ON THE BACK SIDE OF THE BOARD Idle Span Pot TO SHOW THROUGH LID Idle Zero Pot P2 FeedbackSelector See Figure 18 DO NOT CHANGE ADJUSTMENTS ON POTS MARKED WITH AN 920 Current Limit Pot shows through lid Over Current Trip DO NOT CHANGE ADJUSTMENTS ON POTS MARKED WITH AN FEEDBACK SELECTION SUMMING JUNCTION EXTERNAL F B CURRENT VOLTAGE F B POWER F B Figure 18 P2 Details Figure 17 1029C circuit board showing adjustment locations COMMON EXTERNAL FEEDBACK INPUT CONNECTIONS 0 100mA or 0 5 V cia SS Lon ou OS 7 m T gt Z n 5 mc uizir52om LU gt x gt L gt D x E lt lt O m X Gil gt x ul B 29g 72 o Figure 19 External feedback connections MODEL 1029C 15 10 19 2007 TROUBLESHOOTING CAUTION HIGH VOLTAGES ARE PRESENT ON THIS CONTROLLER AND ON PORTIONS OF THE PRINTED CIRCUIT BOARD USE EXTREME CARE TO AVOID ELECTRICAL SHOCK Notes The LED s provide a convenient method of determining the general location of controller problems The LOAD LED indicates that 10 or more of rated load current is present The intensity of the LOAD LED should increase as the command signal is incr
26. 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 accident 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 FORA 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 UNDERANY CIRCUMSTANCES BE LIABLE FORANY 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
27. ue RMS meters should be used for accurate measurements of True RMS Voltage Current or Power RMS Volts times RMS current into a resistive load Average responding meters should be used for measurements of Average AC Voltage or DC voltage Current Limit The current limit pot is factory set at 105 of rated current unless specified differently by the IL term in the model Number Proper calibration of the current limit feature requires a True RMS current meter If it becomes desirable to reset the current limit level 1 Rotate the current limit pot fully counter clockwise This is a multiple turn pot 2 Carefully increase the command signal to maximum 3 Slowly rotate the current limit pot in a clockwise direction until the desired load current is reached If it is suspected that the current limit adjustment is causing the output of the controller to be lower than desired rotate the current limit pot clockwise If the load voltage increases the current limit adjustment has been controlling the output Follow the steps above to set current limit to the desired level OVER CURRENT TRIP This potentiometer has been factory set at 150 of rated frame current For optimum protection the customer may wish to reduce the level at which Over Current Trip occurs 1 Adjust command signal to maximum 2 Slowly rotate the Over Current Trip pot counterclockwise until the Over current Trip occurs 3 Rotate the Over Cu
Download Pdf Manuals
Related Search