Model 1032 User Manual - Precision Control Systems, Inc.
Contents
1. Figure 5 End view of 70 amp model 1032 Model 1032 4 of 9 Part No 5000095 1011 6 6 13 2003 DIMENSIONS Transformers 0 177 Dia 2 O 24 VAC Secondary 120 or 240 Volt Primary lige 2 375 s 120 240 VOLT PRIMARY TRANSFORMER 480 Volt Primary 24 VAC A Secondary 2 50 480 VOLT PRIMARY TRANSFORMER Model 1032 5 of 9 Part No 5000095 1011 6 6 13 2003 ELECTRICAL CONNECTIONS FUSING RECOMMENDED SEE PAGE 9 HE COMMAND CONNECTOR See Fig 7 PRIMARY TRANSFORMER SUPPLIED WITH CONTROLLER SEE PAGE 5 Figure 6 Power Connections 5 CCW W CW 5 CCW W CW 5 CCW W CW 5 CCW W CW i SS ees ee AAA POT 0 10Vdc 0 5Vdc 4 20 mAdc COMMAND COMMAND COMMAND COMMAND Figure 7 Signal Connections Model 1032 6 of 9 Part No 5000095 1011 6 6 13 2003 SPECIFICATIONS Control Mode Command Signal Control Range Linearity Zero and Span Adj Current Limit Adj Cooling Line voltage Load Current Diagnostic Indicators Physical Environment dv dt amp Transient Voltage Protection Heat dissipation Recommended Fusing Model 1032 Single phase Phase angle RMS value of the volt2. 42110 0460 350 42110 0460 390 CCl FUSEKIT FK 62T15 FK 62T25 FK 62T35 FK 62T50 FK 62T90 FK 62T15 FK 62T25 FK 62T35 FK 62T50 FK 62T90 FK 62T15 FK 62T25 FK 62T35 FK 62T50 FK 62T90 The assembly includes the SCR relay a thermal conductive pad an MOV and an instruction sheet The fuse kit includes two fuses of appropriate rating for the frame size and a fuseblock Control concepts recommends that fuses be rated at 120 to 125 of maximum load current MANUFACTURED BY CONTROL CONCEPTS 7870 PARK DRIVE CHANHASSEN MN 55317 U S A 952 474 6200 1 800 765 2799 FAX 952 474 6070 www ccipower com Model 1032 9 of 9 Part No 5000095 1011 6 6 13 2003
3. number of the controller Load voltage snaps on Determine that the primary of the circuit transformer is connected across the same phase as the controller and load See figure 6 on page 6 LOAD SSR CURRENT DRIVE LED LED COMMAND SIGNAL 24 Vac CONNECTOR CONNECTOR Figure 8 1032 Board Layout Part No 5000095 1011 6 6 13 2003 ORDERING PARTS REFERENCE DRAWINGS Firing Circuit Specify 1032 FC D1000532A1 Include the command range when ordering Transformer Inst Dwg Page 5 Schematic See below for numbers for spare SCR modules and recommended fuses If areplacement SCR module is ordered specify the voltage current rating and serial number of the failed unit REPLACEMENT PARTS RECOMMENDED FUSES typical Alternative fuse size is 125 of max load current RECOMMENDED REPLACEMENT SCR MODEL 1032 12 10 1032 12 20 1032 12 30 1032 12 40 1032 12 70 1032 24 10 1032 24 20 1032 24 30 1032 24 40 1032 24 70 1032 48 10 1032 48 20 1032 48 30 1032 48 40 1032 48 70 ASSEMBLY PART No 1652 12 10 1652 12 20 1652 12 30 1652 12 40 1652 12 70 1652 24 10 1652 24 20 1652 24 30 1652 24 40 1652 24 70 1652 48 10 1652 48 20 1652 48 30 1652 48 40 1652 48 70 CCI PART 42110 0460 315 42110 0460 325 42110 0460 335 42110 0460 350 42110 0460 390 42110 0460 315 42110 0460 325 42110 0460 335 42110 0460 350 42110 0460 390 42110 0460 315 42110 0460 325 42110 0460 335
4. Control Concepts Model 1032 Power Control System Instruction Manual a Series D 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 INSTRUCTION MANUAL MODEL 1032 CONTROL CONCEPTS 7870 PARK DRIVE FAX 952 474 6070 DESCRIPTION The model 1032 is a single phase phase angle SCR power controller with features of field adjustable cur rent limiting soft start and missing cycle detection The controller can be ordered to accept command signals of 0 10Vdc 0 to 5Vdc 1 5mA 4 20mA or a potentiometer signal Models are available for opera tion at 120 208 240 377 480 or 575Vac 50 60 hertz The controllers can be obtained with current ratings of 10 20 30 40 or 70 Amps The model 1032 linearly controls with respect to the command signal the RMS value of the voltage applied to the load The controller also has line voltage compensation which for a constant command sig nal maintains the load voltage constant independent of line or supply voltage variations The soft start and missing cycle detection features set the load voltage to zero on power interruptions of one half cycle or more and then increases the load voltage to the desired value at a predetermined rate This feature on start up or after pow
5. adjusted at the factory and should require no further adjustments If adjustments become necessary the following procedures should be used see figure 8 on p 8 for location of adjustments 1 Setthe command signal to minimum and adjust the zero potentiometer until the output is zero 2 Setthe command signal to maximum and adjust the span potentiometer until the output is at the desired maximum value 3 The span and zero adjustments may interact It may be necessary to repeat steps 1 and 2 Note Loads with variable resistance may cause the current limiting feature to limitthe output ofthe controller which would appear as though the span is not adjusted properly To test for current limiting rotate the current limit pot 1 turn counterclockwise If the load current decreases the current limitis controlling the output Part No 5000095 1011 6 6 13 2003 DIMENSIONS 10 40 Amp Frame Figure 2 Mounting dimensions of 10 to 40 Amp model 1032 LET Figure 3 End view of 10 to 40 Amp model 1032 Model 1032 3 of 9 Part No 5000095 1011 6 6 13 2003 DIMENSIONS 70 Amp Frame 0 32 wide X 0 45 long 4 es Pe ae Figure 4 Mounting dimensions of 70 Amp model 1032
6. age applied to the load Signal Impedance 0 5Vdc 100K 0 10Vdc 200K 1 to 20 K Pot 200K 4 20mA 300 ohms 6 to 97 of line voltage typical RMS load voltage is linear within 296 of span of the command signal User adjustable over a range of 2096 of span User adjustable over a range from 2096 to 11096 of rated current Dielectric strength input line amp load voltage heatsink 2500 V Rws Insulation resistance input line amp load voltage heatsink 101 ohms Maximum capacitance input to output 8 pf Convection Must be mounted on vertical surface with fins vertical Units may be mounted adjacent to each other Heat sink is electrically isolated from circuit and power 120 240 480 amp 575Vac 10 20 50 60 Hertz Consult factory for other voltages 10 20 30 40 amp 70 Amps A C 50 60 Hertz The intensity of the SSR DRIVE LED varies proportionally to the Voltage applied to the load The intensity of the LOAD CURRENT LED varies as a function of the load current These LED s provide a quick and safe means to check controller operation Weight 10 thru 40 amps 5 Ibs max Dimensions 70 amps 9 Ibs max See installation drawings pages 3 amp 4 Oto 55 C 32to 131 F 40to 80 C 40to 176 F 0 to 95 Non condensing 200 volts usec minimum A dv dt snubber and a metal oxide varistor MOV are provided to protect against high frequency transients dv dt and voltage spikes 1 5 watt per amp of controlle
7. d specify the voltage current rating and serial number of the failed unit MAXIMUM LOAD VOLTAGE CANNOT BE REACHED Determine that the primary of the circuit transformer is connected across the same supply as the controller and load This problem could be caused by the primary being connected across the load and line connection at the controller or across a different phase than the controller and load Fig 6 on P 6 The current limit feature may prevent maximum line voltage from being applied to the load To determine ifthe current limitfeature is preventing full voltage from being applied to the load rotate the potentiometer labeled LIMIT 1 turn counter clockwise If the load voltage decreases the load current is being limited Model 1032 8 of 9 LOAD POWER IS MAXIMUM AND CANNOT BE REDUCED SCR DRIVE Len is on Determine that the command signal is zero To do this remove the command signal connector If the LED remains on the circuit card has likely failed SCR DRIVE rep is off Remove the 24Vac power connector Ifthe load still has power the SSR module has probably failed To determine if the SSR module is shorted remove the line and load connections and measure the resistance across the line and load terminals of the controller lf the resistance is less than 10 000 ohms the SCR module has probably failed If a replacement SCR module is ordered specify the voltage current rating and serial
8. d current Special semiconductor fuses are not required It is recommended that the controller and load be protected with fast acting class T fuses such as Bussmann type JJS or JJN fuses Control Concepts maintains an inventory of fuses and fuse holders for your convenience Operating Storage Humidity 7 of 9 Part No 5000095 1011 6 6 13 2003 TROUBLE SHOOTING CAUTION High voltage exists on the supply and load terminals of this controller and may exist on other equipment located near the controller Use extreme caution to avoid electrical shock Two LED s on the circuit board may be used to aid in determining problems with the controller The SSR DRIVE ep varies in intensity proportional to the drive signal to the Solid State Relay and is proportional to the load voltage The LOAD CURRENT rep varies in intensity proportional to the current through the load If the load current reaches the current limit setting the intensity of the LOAD CURRENT LEp will no longer increase and the load current will remain fixed THE FOLLOWING ARE SYMPTOMS AND POSSIBLE SOLUTIONS NO LOAD POWER The LOAD CURRENT rep is not on the intensity of the SCR DRIVE rep can be varied Determine that the load is wired correctly to the controller Determine that all fuses are OK If the voltage across the SCR module is equal to the line voltage the SCR module has probably failed If a replacement SCR module is ordere
9. e Bussmann Company See p 9 TORQUE TABLE FOR USD CONNECTORS Recommended Torque 35 in lbs 40 in Ibs 45 in Ibs 50 in Ibs NOTES Wiring should be installed per local electrical codes 24 Volts AC must be supplied to the circuit board from the same phase being controlled The transformer supplied with this controller has a primary voltage close to or at the voltage which the controller was designed to control The wiring from the transformer to the circuit board may be in the range of 18 to 24 gauge Model 1032 2 of 9 START UP Set the command to zero and apply system power The load voltage should start at zero and should increase as the command signal is increased The load voltage and current may be measured with any meter Because of the non sinusoidal wave form applied by the SCRs accurate measurements can only be made with true RMS meters ADJUSTMENTS Zero Factory set to provide zero load voltage when a zero command signal is applied The zero potentiometer is used to adjust the controller to provide zero load voltage when the command is zero Span Factory set to provide 100 output with 100 command The span determines the load voltage for a given command input Current Limit Factory set at 105 of rated current unless ordered with a specific current limit setting Counter clockwise rotation decreases the point at which current limit occurs CALIBRATION The span and zero have been
10. er failures prevents saturation of load transformers The feature also eliminates in rush currents that can occur due to loads with a low cold resistance Current limiting allows the user to adjust the maxi mum current the controller will apply to the load This feature is desired when controlling loads such as silicon carbide molybdenum disilicide or other ma terials in which the resistance changes with tempera ture and or time Electrical isolation of the circuit card and the heat sink is achieved by the use of an SCR that electrically isolates the SCRs from its mounting plate and which uses photo couplers to isolate the SCR gate signals MODEL No IDENTIFICATION MODEL NUMBER 1032 VV AA CS ILXX VV Rated voltage 12 120Vac 24 240Vac For 208 or 220 specify SC208 or SC220 48 480Vac for 377 specify SC38 57 575Vac AA Rated current capacity 10 20 30 40 or 70A CS Command Signal The standard controller accepts a 0 to 5Vdc a 0 to 10Vdc or a potentiometer signal If the controller has been supplied as a 4 20mA input a 4 20mA designator will be included in the model number An appropriate shunt resistor will be added to the circuit to provide proper scaling Check with factory for other mA input ranges The term ILXX added to the model number implies that the current limit will be factory adjusted for the value specified by XX When the ILXX term is not included t
11. he load is transformer coupled or inductive gt H e Figure 1A Simplified diagram of an SCR controller oor Figure 1C Voltage waveform as applied to load time shown by shaded area is varied to apply the desired load voltage Part No 5000095 1011 6 6 13 2003 INSTALLATION The controller must be mounted on a vertical surface such that the heat radiating fins are vertical as shown in fig 2 on P 3 amp fig 4on P 4 The controller should be located in an environment that will not exceed 135 F andis free of dust dirt and moisture Figures 6 amp 7 on P 6 show power and control connections All wiring must be per local electrical codes The supply and load terminals will accept aluminum wire from 2 to 8 and copper wires from 2 to 14 The control transformer supplied with the controller provides 24Vac to the circuit This transformer must be connected to the same electrical phase from which the controller and load are connected One transformer can be used to operate up to 6 controllers providing all controllers are connected to the same phase Acommon installation error is that of connecting the transformer to a different phase or being connected across the SCR module rather than from the power supply It is recommended that the controller and the load be protected with fast acting fuses such as the JJN and JJS class T series of fuses manufactured by th
12. he current limit will be factory set at 105 of the rated current Model 1032 1 of 9 THEORY OF OPERATION The heart of the power controller is the SCR Silicon Controlled Rectifier also sometimes re ferred 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 several thousand volts In the on state they can pass several thou sand amperes When a small signal is applied between the gate and cathode terminals 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 Since the SCR conducts in only one direction two are placed back to back in an inverse parallel configuration to control AC current Figure 1A Phase angle 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 1 B amp C 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 t
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