PHASETRONICS
Contents
1. IPHASETRONICS SCR Power Control Specialists EP1 Series Power Control Single Phase SCR 85 to 1000 Amps OPERATION amp SERVICE MANUAL Phasetronics Inc P O Box 17159 13214 38th Street North Clearwater FL 34622 0159 813 573 1900 FAX 813 573 1803 Table of Contents Chapter T IAtFOOHE WON omeen inneemd engere ennen nen nent e 1 1 General 1 2 Receiving and Unpacking 1 3 Warning Chapter 2 Specifications nannnanannnennnnsnnnnrnnenenenennnnnnnnnnenenansnnennrnnennnenenen 2 1 Specifications 2 2 Protective Networks 2 3 Ambient Temperature 2 4 Cooling Chapter 3 Installati n mensen sdenndebnen setae cece eadenntwocessg estate vscatwanasapematan enk denten ria 3 1 Location 3 2 Initial Unit Inspection 3 3 Warning 3 4 Mounting and Cleaning 3 5 Mounting Enclosure Chapter 4 Connections aannemen nenenennenennnnnnrenenenenennennennnennenenennnenenennnen 4 1 Control Connections 4 2 Soft Start Standard 4 3 Power Connections 4 4 Control Options 4 5 Current Limit Option C Chapter 5 Start up asana eindneaneeerenrennnie nebe erbinnen sannnsnanedornedkn bunde in 5 1 Manual Control 5 2 Automatic Control 5 3 Power on Soft Start 5 4 Command Signal Change Soft Start Option S 5 5 Current Limit Option C 5 6 Current Trip Option T Chapter 6 DiaGramS prcirinleniloniiicigzanaanzine aiar 6 1 Mother Board 85 thru 1000 Amp Units 6 2 EP1 Series Option Board 6 3 Schematic 6 4 Dimension Configurations Ch2. e Inspect the unit for possible shipping damage if damaged you should notify the freight carrier and file a claim within 15 days of receipt e Verify the model number on the unit matches up with your purchase order 1 3 Warning DO NOT SERVICE EQUIPMENT WITH VOLTAGE APPLIED Unit can be a source of fatal electrical shocks To avoid shock hazard disconnect main power before JN working on unit EP1 Series SCR Power Control Chapter 2 Specifications 2 1 Specifications Back to Back configuration 120 208 240 308 415 480 575 Vac 10 to 15 50 60 Hz Resistive Inductive Lamp Factory set for initial half second of operation of power on Field adjustable via potentiometer from 0 2 seconds to 30 seconds A combination of a high potential gate pulse and a rapid rise time is used to prevent SCR damage due to di dt stress 4 20MA 0 5 Vdc 0 10 Volts 50 of gain maximum Optional feature to provide average load voltage regulation of plus or minus 2 for 10 to 10 of gain maximum 2t fuse protects against short circuit overloads Option F Integral MOV Metal Oxide Varistor protects against high potential transient voltage 2 5 times line rating minimum RC snubber networks prevent false firing due to dv dt characteristics Operating range is from 0 C thru 40 C 32 F thru 104 F Dependent on model configuration 2 2 Protective Networks Transient Voltage Suppressor Standard Integral MOV Metal Ox
3. potentiometer rotation 3 If output voltage appears to be normal turn the manual control fully counter clockwise CCW OFF Note lf the unit is connected for manual control only and optional current limit is provided proceed to current limit start up procedure Section 4 5 page 6 If operating under manual control only you have completed start up 5 2 Automatic Control The following procedure is used to set up the EP1 Series SCR Power Control for automatic operation 1 Gain and Offset Adjustments are factory calibrated and shipped to accept 4 20mA DC input signal If voltage input signal is used change jumper selector on main logic board See page 8 2 Apply milliamp or voltage input signal and observe output Unit output should be proportional to control input signal If a different control signal is desired or you want to check calibration proceed as follows e Apply minimum desired input control signal example 4mA e Adjust Offset potentiometer P1 until output voltage is at desired minimum output Clockwise CW rotation will decrease output Increase the amount of offset e Apply maximum desired input control signal example 20mA e Adjust Gain potentiometer P2 until output voltage is at desired maximum output Clockwise CW rotation will increase output If required repeat these steps to obtain specific output levels e When using the 0 5 or 0 10Vdc automatic signals optimum performance can be achieved by re zero
4. removing the clamp to facilitate proper torquing of the new SCR device 13 3 Label location of wires connected to SCR 4 Remove any lugs MOVs snubbers printed circuit boards and associated wiring that may get in the way of reaching the faulty SCR Document the location and wiring of all parts before removing them to facilitate the re installation of the devices later 5 Document the position of the indicator on the SCR clamp Then remove top clamp holding SCR stack together Remove the top heatsink 6 Remove faulty SCR device noting the direction the SCR is oriented The new SCR puck must be inserted in the same direction 7 Make sure the SCR mounting surface tools and hands are clean and free from dirt nicks and scratches Do not sand or scrape SCR mounting surface If necessary super fine Scotch Brite pad can be used to clean the heatsink before installing the new SCR 8 Apply a thin 3 mil thick layer of thermal grease uniformly along both sides of the SCR Spread the grease to cover the entire surface of both sides of the SCR in a manner that minimizes air pockets The grease must be free of contamination 9 Locate the centering pin in the bottom of the heatsink and center it in the SCR hole making sure that the SCR is pointed in the same direction as the SCR which was removed in step 6 Locate the centering pin in the top heatsink and center it in the SCR hole Hand tighten the clamps evenly so that the same number of th
5. value of any non repetitive transient reverse voltage which occurs across an SCR RMS Abbreviation stands for root mean square and refers to the effective value of voltage and current Rating The ultimate or limiting condition stated for a given device parameter either maximum or minimum beyond which the device will not operate properly and or is not guaranteed by the manufacturer Rectifier A two terminal device where current can flow only on in the direction of anode to cathode Low current rectifiers are frequently called diodes Reverse Direction Describes the direction on which a semiconductor is nonconducting SCR Silicon Controlled Rectifier Principle member of the thyistor family Is basically a rectifier with a control feature added This three terminal device anode cathode and gate is a controllable on off switch Set Back The voltage level ina precipitator control which is less than the voltage level of the last Spark or arc occurrence Surge Current The peak value of a single half wave ie 180 degrees of a sine wave current impulse at 60Hz This rating is non repetitive and may occur 100 times within the life of the device Soft Start The time from the application of line voltage until full output voltage This also includes ramp time Solid State An electrical device or circuit using semiconductor devices Uses no tubes rotaries m g sets thyratrons ignitions and
6. 00 52 0050 0600 52 0080 0600 Option Phasetronics Letter Part Number 52 0150 0600 52 0150 0600 52 0200 0600 52 0250 0600 PCM1200 T 15 EP1 Series SCR Power Control Chapter 9 Options The following options are available on the EP1 Series but must be specified when ordering When options are ordered a separate option card is mounted on top of the main logic board 9 1 Soft Start Option S Provides soft start on a signal change or when lockout is released This will help protect fuses The unit is set up so that either of these two soft start modes can be disabled by removing X1 amp X2 on the option card See figure 6 below or Option board page 9 The unit will ramp up on a signal change if the command signal drops to 0 9 2 Current Limit Option C Provides flexibility for changing loads and helps protect the unit Adjustable from 10 110 of unit rating Current limit will override control input signal to limit the output current Current transformer included To disable remove X1 amp X3 on option card See figure 6 below or Option board page 9 9 3 Current Trip Option T Used as a protective measure This option will shut down the unit when the current exceeds an adjusted preset level Adjustable from 75 200 for instantaneous trip if current exceeds set level Unit can be connected for manual reset Current transformer included To disable remove X4 See figure 6 below or Option board page 9 9 4 Li
7. N x 24 El amp E2 RATE OF CHANGE INDICATES THAT PAD E2 BOARD POWER IS PRESENT X63 PCL1002 SOFT START DISABLE INDICATES SOHZ REMOVE TO CIRCUIT ACTIVE DISABLED INDICATES THAT SOFT START IS IN ACTION INDICATES OUTPUT FROM GATE DRIVE Li Le IF NO OPTION CARD IS PRESENT TBI ELIs E Note 380 575 volt units are not dual connectable 415 volts is dual connectable 208 415 6 2 EP1 Series Option Board Z O O bE Za O mm A O rt QZ F al X zZz x lt I lt O a o lt N Z Z mr Z aa LJ LJ lt LJ A Y MX Le Ll LH Y Li LJ a4 Lul DI D D DCO D L YN OO AO OO REMOVE TO REMOVE TO DISABLE S OPTIO DISABLE xe N CURRENT TRIP N x3 _ X4 REMOVE TO DISABLE CURRENT LIMIT PCM1603 TBI TB2 1 2 2 RESET CONTACT Le Note All Options are shown here P1 P2 P3 amp P4 Individual configurations may be different depending on the type of options purchased 6 3 Schematic 6 4 Dimension Configurations 4 Hr en ela je fie e a EEEN ow er ow om 7 ew CE e o CN ENEN EN EP1 EP1 EP 1 Call Factory EP1 xx1000 F 1000 12 120 Volts C Mounting Hole Diameter 20 208 Volts F Unit may include optional fuse 24 240 Volts Dimensions subject to change Xx 38 380 Volts 41 415 Volts 48 480 Volts me EP1 Series SCR Pow
8. al Control 1 DO If manual potentiometer is not used proceed to Automatic Control Manual potentiometer does not have to be connected for unit to operate Connect manual potentiometer to TB2 3 wiper TB2 4 high and TB2 6 low per connection diagram See figure 1 for connection amp figure 3 for jumper locations Manual potentiometer is 10K ohm 2 watts linear taper lf you are using only manual control proceed to power connections page 6 4 1 2 Automatic Control 1 jumper X3 installed 4 20 mA connection jumper X1 installed factory setting 0 5 Vdc connection jumper X2 installed Connect DC voltage or milliamp input signal to pins 1 positive and 2 negative on TB2 You must select the proper jumper for 4 20 mA 0 5 Vdc or 0 10 Vdc See location of jumpers on main logic board diagram section 6 1 If manual and automatic control are both used consider using an external auto manual switch to prevent the manual setting from overriding the automatic signal See location of jumpers and pins figure 3 ection 5 7 oY lt De so x de I LI gt A x T LE Sa ag 5 LS amp RS LAA u g D W no x AN x SH NON NA NON NIE LL AE Ue lee e eS YX INC INC INC Us E PI Pe P3 RATE OF CHANGE PAD E2 X62 SOFT START Control Board Layout D17 DISABLE REMOVE TO DISABLED Figure 3 TB2 Connections 4 2 Soft Start Standard The standard soft s
9. apter 7 Troubleshooting sssrinin anaana 12 7 1 Failure Analysis 7 2 SCR Testing Procedure 7 3 Replacing Printed Circuit Boards 7 4 Replacing SCR Device Chapter 8 Spare PaFIS aanneemt regia nidi 15 8 1 SCRs 8 2 Main Circuit Board Chapiler9 OplionS 1 uil 16 9 1 Soft Start Option S 9 2 Current Limit Option C 9 3 Current Trip Option T 9 4 Line Voltage Regulation Option R EP1 Series SCR Power Control Chapter 1 Introduction This chapter is a brief introduction to the EP1 Series SCR power controls 1 1 General The EP Series of Phase Angle SCR Power Controls assures smooth proportional output power from 0 to 100 This high quality SCR control is offered in a single phase with a variety of options These options include current limit current trip voltage regulation soft start on signal change and I t fusing The unit is ideally suited for all resistive and inductive loads The soft start feature assures a slow rising output voltage to prevent an inrush on inductive or variable resistance loads The control input is adjustable to match all standard temperature and process controllers The control signal sensitivity is adjustable by gain and offset potentiometers The unit can also be controlled from an external manual potentiometer MOVs standard protect the SCRs from transient voltages False firing dv dt protection is also standard 1 2 Receiving Upon receipt of this product you should immediately do the following
10. ation Voltage Regulation Circuit that senses load output voltages and automatically readjusts the firing angle of the SCRs ti maintain constant load output voltage with no input control change Zero Voltage Firing SCR gate turned on at zero crossover of the line current a Time proportional SCR turned on for a specific time for a specified period of time and off for the remainder of that period b Distributed Cycle SCR turned on equal amount of time within the time base period 2 Leg Control Three phase electronics controlling a zero voltage firing circuit controlling SCRs in two phases and the third phase is not controlled
11. er Control Chapter 7 Troubleshooting 7 3 SCR Testing Procedure JN Remove line power from the unit and lock out Disconnect load and line leads Remove line power from the unit and lock out Disconnect the load and line leads Disconnect SCR connections to the main circuit board Note the type of color coding of the wires going to the SCR plug Phasetronics uses two possible configurations The first configuration consists of 4 wires color coded black yellow grey and white The second configuration consists of 4 wires color coded red white red white The testing procedure for SCRs is comprised of two separate tests The first procedure tests the anode to cathode integrity of the SCR by performing the following ohm checks L1 Lug T1 Lug Greater than 10k ohm Less than 10k ohm The second procedure tests the gate to cathode integrity of the SCR Place the leads of an ohm meter into the receptacle that was unplugged from the main circuit board Ohm the pair of wires on one end of the plug black yellow or grey white Then ohm the pair of wires on the other end of the plug black yellow or grey white The chart below indicates good verses bad readings For wire that is color coded black yellow gray and white Gray White Between 5 and 100 ohms Less than 5 or greater than 100 ohms Gray White Between 5 and 100 ohms Less than 5 or greater than 100 ohms For wire that is color coded red white red and white White Between sand i0
12. iconductor LFM Linear feet per minute Rate of air flow moving across a cooling surface Leakage Current The small currents which get through or around the blocking characteristics of a semiconductor device capacitor or insulator Line Voltage Regulation Control circuit responding to keep output voltage constant with line voltage changes Lockout Fast shutdown that acts at extremely high speed to sense high currents and to remove the SCR gate signal Load voltage and currents are removed in less than 10 milliseconds once the set current is reached Unit will not restart until reset Offset Adjustment used to adjust the minimum input required to start to have output The input is from a temperature controller Parameter A value condition or characteristic that is a measurable property of a device It may be electrical mechanical or thermal and can be expressed for a given set of operational and environmental conditions Phase Control Firing SCR turned on proportional from 0 to 180 degrees conduction for 0 to 100 output voltage Ramp Time The time for the power control to gradually increase from the initiation of control signal to full output voltage Repetitive Forward Blocking Voltage The maximum instantaneous value of the forward voltage which occurs across the SCR including all repetitive voltages Repetitive Peak Reverse Voltage of a Reverse Blocking SCR The maximum instantaneous
13. ide Varistor protects against high potential voltage spikes RC Snubber Standard RC Snubber networks are used to prevent false firing due to dv dt characteristics SCR Peak Inverse Voltage PIV Rating Line Voltage Continuous SCR Rating 120 480 1200 Volts 2 3 Ambient Temperature Ambient temperature operating range 0 to 40 degrees C 32 to 104 degrees F Output current rating decreases by 10 for each 5 degrees C rise 9 degrees F in ambient temperature over 40 degrees C 104 degrees F to a maximum of 60 degrees C 140 degrees F Transportation and storage range 30 to 65 degrees C 30 to 149 degrees F 2 4 Cooling Units rated from 10 to 175 Amps are convection cooled Units rated at 225 Amps and above are fan cooled and have a thermostat that will shut down on over temperature De EP1 Series SCR Power Control Chapter 3 Installation 3 1 Location Proper location of the EP1 Series is necessary to achieve specified performance and normal operation lifetime The EP1 Series should always be installed in an area where the following conditions exist e Ambient operating temperature Enclosed unit 0 to 40 degrees C 32 to 104 degrees F Type 1 ventilated enclosure Chassis unit 0 to 50 degrees C 32 to 122 degrees F e Protected from rain and moisture e Humidity 5 to 95 non condensing e Free from metallic particles conductive dust and corrosive gas e Free from excessive vibration below 0 5G e Open
14. ing the unit using the offset potentiometer P1 5 3 Power on Soft Start When initial power is applied and a command signal is present the output voltage is ramped to the desired commmand signal level over an adjustable interval The interval can be adjusted from 0 to 30 seconds using potentiometer P3 on the main logic board 5 4 Command Signal Change Soft Start Option S Provides soft start on a reapplication of command signal The unit is set up so that either of these two soft start modes can be disabled if desired The unit will ramp up on a reapplication of command signal if this signal is brought to 0 The interval can be adjusted from 0 30 seconds using P2 on the option card 5 5 Current Limit Option C Adjustable from 0 110 of unit rating Current limit will override control input signal to limit the output current Current transformer included The level of current limit can be adjusted from 0 125 using P4 on the option card 5 6 Current Trip Option T Adjustable from 50 200 for instantaneous trip if current exceeds set level Unit can be connected for manual or automatic reset Current transformer included The level of current trip can be adjusted using P3 on the option card Pi EP1 Series SCR Power Control Chapter 6 Diagrams 6 1 Main Logic Board for EP1 Series 85 thru 1000 Amp Units E 5 a Oe e ye oS Ss amp lt 6 LJ Qoe na O R P ILL ar z5 v z ce 108 sa ag E lt q AT o Se CU LO LI Ww Yo
15. ion with option card 4 4 Control Options This option will limit the output current at a preset level C C Limi adjustable from 0 110 of controller rating Current urrent Limit limit will override control input signal to limit current output Adjustable from 50 200 for instantaneous trip if ili Current Trip current exceeds set level Unit is connected for manual reset Current transformer included This provides an integral l2t fuse which protects against Provides soft start on loss of command signal Allows Optional Soft Start unit to ramp upona loss of command signal 4 5 Current Limit Option C Current limit is typically adjusted for full rated current therefore appropriate load must be used for this adjustment to function properly 1 Apply input control signal to achieve full output 2 Adjust Current Limit potentiometer P4 on option board to desired level Counter clockwise CCW rotation of potentiometer will decrease output current level lower the current limit set point 6 EP1 Series SCR Power Control Chapter 5 Start up 5 1 Manual Control The following procedure is used for manual control start up for the EP1 Series SCR Power Control 1 Ifthe unithas a milliamp or voltage input and a manual control potentiometer is also used set the milliamp or voltage input signal to minimum 0 2 Slowly rotate manual control potentiometer in a clockwise CW direction Output voltage should slowly increase with
16. ling or punching holes in the enclosure cover the electrical assembly to prevent metal filings from becoming lodged in areas which can cause clearance reduction or actually short out electronics After work is complete thoroughly clean the area and reinspect the EP1 Series unit for foreign material Make sure there is sufficient clearance six inches all around the EP1 Series unit for cooling wiring and maintenance purposes To maximize effective air flow and cooling the unit must be installed with its heat sink ribs oriented vertically and running parallel to the mounting surface If unit has a fan install unit so the fan blows upward vertically In dirty or contaminated atmospheres the unit should be cleaned on a regular basis to insure proper cooling Do not use any chemicals to clean the unit to remove surface dust use 80 to 100 psi clean dry compressed air only A three inch high quality dry paint brush is helpful to loosen up the dust prior to using compressed air on the unit We 3 5 Mounting Enclosure 85 100 150 225 and 135 Amp units require a 120 cfm box ventalation fan for NEMA 1 enclosures 500 Amp and larger units require a 240 cfm vent fan See example below Box Fan _ Air Flow Note Type 1 Box size should be selected incoordination with minimum field wiring bending space requirements per local and National Electrical Codes NEC Article 373 and table 373 6A EP1 Series 4 1 Control Connections 4 1 1 Manu
17. minal of a transistor Blocking Voltage Ability of a semiconductor to withstand a specific voltage stress without conducting current Breakdown Voltage Maximum voltage a semiconductor can support on its nonconducting direction Bridge Combination of discrete power devices on heat sinks generally in circuit configurations to change AC current to DC current Burst Fire Term used on zero voltage swithching when SCRs are turned on for a specified number AC current to DC current CFM Cubic Feet per Minute Amount of air being moved CFM LFM x cross sectional area of heat sink Case Temperature Temperature of package measured at a specific location Indirectmethodfor determin ing Junction temperature For stud devices proper thermocouple loca tion is center of any hex flat for disc devices mount thermocouple on rim radial edge of pole face Cathode One of two high current terminals of rectifier or SCR the other terminal is the anode In the electronic symbol for a rectifier or SCR an arrow points toward the cathode Circuit Breaker An electronic switching device capable of making carrying and breaking currents under normal circuit conditions and also making carrying for a specified time and breaking currents under specified abnormal circuit conditions such as those of short circuit Contactor A device either electromechanical or solid state used to control electric circuits by closi
18. nd control power before starting this procedure IN may cause personal injury or death Label location of wires connected to SCR Remove mounting screws lugs and associated wiring from existing SCR Make sure the surface to which the power module mounts is clean and free from dirt nicks and scratches Apply thermal grease uniformly along the length of the power module Spread the grease thinly 3 mil thick to cover completely the base of the power module and minimize air pockets Grease must be free of contamination Replace screws and tighten down firmly Reconnect all busbars lugs and wires Check to make sure gate and cathode are wired correctly Load Cathode Output Load Lug Line Cathode Input Line Lug After verifying that all wiring is correctly connected apply power and test Changing an Isolated SCR Remove both line and control power from unit tag and lock out Warning Failure to remove both line and control power before starting this procedure IN may cause personal injury or death Phasetronics uses two type of clamps with gauges for reading the amount of torque on the device The first type of torque gauge uses a spin washer When the proper torque is applied the washer will be free to spin The second type of torque gauge uses a step indicator on the end of the lever Before proceeding note the type of clamp used and if the clamp has a step indicator document the position of the indicator before
19. ne Voltage Regulation Option R Provides more accurate linearity This option allows the unit to regulate load voltage with a varying line voltage The amount of control can be adjusted using P1 on the control board Will maintain output within 2 with a 10 line variation Option Card mounted on top of main logic board Z eee eee H Note The number of potentiometers on the option card will vary depending on the a 5 a options ordered a x oe o x lt Io O en N 2 mo ff 3 ia A Z vy re QZ Lu Lo X x LL Lu X Lul DO D D Da D N L N O O YOO O N N y i i SOFT ST IP Tk ees ese oe da Pl P2 P3 P N DM x1 REMOVE TO gt REMOVE TO DISABLE S OPTION DISABLE lt xe CURRENT TRIP x3 _ X4 REMOVE TO DISABLE CURRENT LIMIT Figure 6 Option setting locations 16 Warranty Policy Phasetronics warrants its products to be free from defects in material and or workmanship for a period of one year from date of installation to a maximum of 18 months from the date of shipment as indicated by the unit s date code The Company reserves the right to repair or replace any malfunctioning units under warranty at their option All warranty repairs must be performed by the Company factory or on site by a factory authorized service firms or personnel approved by the Company Solid state controls have different operation characteristics from those of electro mechanical equipment Becau
20. ng a physical or electrical path to allow current Collector One of the hig current terminals of a transistor the other terminal is the emitter Combination Starter A piece of equipment which incorporates a motor starter and means for manually or automatically disconnecting power to the motor starter Conduction Angle Number of electrical degrees that current flows A full cycle of AC voltage or current is 360 electrical degrees Current Limit A circuit that limits the maximum AC current to the load Current Regulation Circuit that senses load output current and automatically readjusts the firing angle of the SCRs to maintain constant load output current with no control input charge DC Regulation Feedback supplied from load through dropping resistor for regulation Overload Protection Class 10 A relay s maximum trip time of 10 seconds at 600 of full load amps Overload Protection Class 20 A relay s maximum trip time of 20 seconds at 600 of full load amps Diode See Recitifier Dry Contact Contacts of an electro mechanical device that will handle currents of 5mA to 50mA or a contact closure with no external voltage applied Duty Cycle Ratio of operating time to total operating plus non operating time dv dt Critical rate of rise of off state voltage The minimum value of the rate of rise of voltage which will cause switching from the off state to the on state Emi
21. onme C S Man 3 of greater tan 100 ohms White Between 5 and 100 ohms bene inal S or greater inan 100 ohms Note f any of the above readings are out of specification replace the faulty SCR 7 4 Replacing Printed Circuit Boards The printed circuit boards are not intended to be field repaired If the board is faulty the entire board should be replaced using the following procedure Important Use ESD Precautions any time you replace circuit boards Remove power from the unit and lock out Remove plug and tag plug with connector number Remove control wires from terminals and tag wires with terminal numbers Note the settings of all potentiometers and jumpers if applicable Remove mounting screws Remove old printed circuit board Mount new printed circuit board NOD B WN a 8 Install mounting screws 9 Set the potentiometers and jumpers on the new board to the same positions as on the old board 10 11 if applicable Install control wires in terminals matching tagged numbers Install plug matching tagged numbers 7 5 Replacing SCR Device Three types of SCRs are used in Phasetronics EP1 Series depending on the current rating of the SCRs Stud and isolated SCRs are used in smaller units and hockey puck type SCRs are used in larger units 7 4 1 1 7 4 1 Changing an Isolated SCR Remove both line and control power from unit tag and lock out Warning Failure to remove both line a
22. panel units must be mounted in the appropriate type of enclosure Enclosure size and type must be suitable to dissipate heat generated by the SCR power control NEMA 1 style enclosures can be forced ventilated to reduce size Use the following formulas for sizing non ventilated enclosures Non Vented painted gt Units maximum current FLA x 1 5 watts then metal enclosures watts 10 sq ft of exposed area Non vented stainless steel enclosures gt 5 x 1 5 sq ft of exposed area 3 2 Initial Unit Inspection Prior to installing the EP1 Series unit make a complete visual check of all the equipment for possible damage in shipping and handling Report damage immediately before attempting to run unit Check for loose mechanical assemblies or broken wires which may have occurred during transportation or installation Loose electrical connections will increase resistance and cause unit to function improperly Prior to beginning the installation verify that the EP1 Series unit is rated for the proper voltage and that the unit is rated for the appropriate load current 3 3 Warni ng Do not service equipment with voltage applied Unit can be source of fatal electrical shocks To avoid shock hazard remove all sources of power before working on JN controller Warning labels must be attached to terminals enclosure and control panel to meet local codes 3 4 Mounting and Cleaning lf mounting the EP1 Series unit in an enclosure requires dril
23. reads appear at both ends of the U clamp Tighten the clamp nuts 1 4 turn at a time alternating sides of the U clamp until the correct torque is reached Check the gauge or spin washer every time the clamp nuts are tightened 1 4 turn to ensure that the SCR is not over torqued The torque gauge reading should be similar to the initial reading taken in step 2 If the clamp uses the spin washer type of gauge verify that the washer spins freely after torquing down the clamp Once proper torque is reached make sure that the SCR pucks are securely held between the heatsinks 10 Replace any lugs MOVs snubbers printed circuit boards and associated wiring that was removed in step 4 11 After verifying that all wiring is correctly connected apply power and test unit 14 EP1 Series SCR Power Control Chapter 8 Spare Parts SCR Devices Unit Rating 120 480 Volts 575 Volts Amps Phasetronics Part Phasetronics Part 25 0040 1200SD 25 0040 1500SD 40 25 0055 1200SD 25 0050 1500SD 75 25 0090 1200SD 25 0090 1500SD 25 0940 1200 25 0940 1500 25 0940 1200 25 0940 1500 25 0940 1200 25 0940 1500 25 0940 1200 25 0940 1500 25 0940 1200 25 0940 1500 25 2170 1200 25 2170 1500 600 25 2170 1200 25 2170 1500 MOV Devices SCR Trigger Current Voltage Part Part Number eem sono eee sooo eeen 277 75 20 40 75 380 416 480 50 190 0510 PTR1400 480 Pt Fuse Devices Fuse Phasetronics Rating Part Number 52 0030 06
24. se of these differences and the wide variety of applications for solid state controls each application designer must verify that the solid state equipment is acceptable for his application In no event will Phasetronics be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The diagrams and illustrations in this document are included solely for illustrative purposes Because of the number of different applications Phasetronics can not be responsible or liable for actual use based on the examples or diagrams Glossary The terms that follow relate to different aspects of Power Controls offered by Phasetronics These terms may not apply to products offered by other manufacturers Acceleration Time The time required for a motor to go from initial speed to final speed Alternating Current AC A periodic current the average of which over a period is zero and reverses at regularly recurring intervals of time and which has alternatively positive and negative values Ambient Temperature The temperature of the air surrounding an electrical device If the device os enclosed the temperature of the air inside the enclosure Anode The positive power terminal of an SCR or Diode Assemblies Combination of discrete power devices on heat sinks connected in various circuit configurations Average Current Current integrated over a full cycle Base Control ter
25. tart ramp adjustment is factory set P3 for 0 5 seconds The soft start ramp time can be increased to a maximum of 30 seconds by adjusting P3 in a clockwise CW direction SCR Power Control Chapter 4 Connections ITB2 4 high 10k OHM 2 WATT TB2 3 TAPER TBe 6 low Figure 1 Manual Connections 4 20 MA e TB2 0 10 VDC 0 5 VDC _ x oa Figure 2 Automatic Connections INDICATES THAT BOARD POWER IS PRESENT INDICATES 50HZ CIRCUIT ACTIVE Note Soft start is active only when initial power is applied and a command signal is present It has no effect on control signal change See Option S Section 9 1 if soft start is required on restart of mA signal or when lockout is released 5 4 3 Power Connections 1 Connectline 1 and supply side of load to power terminals See figure 4 below 2 Connect line 2 using 18 22 gauge wire to terminal 6 on TB1 EPCL1000 If option is present connect line 2 to terminal 7 of TB2 on option board See figure 4 and 5 below 3 Connect line 2 to the return side of load INDICATES OUTPUT FROM GATE DRIVE Main Logic Board L2 connection if no option card is present L1 Hot T1 To Load Figure 4 Power Connection no option card Option Card mounted on main logic board when options are ordered TBI TB2 TO MOTHER BOARD TB1 6 N C TRIP RESET CONTACT L L2 Connected to TB2 7 on option card Figure 5 Power Connect
26. tter One of high current terminals of a transistor the other terminal is the collector Firing Circuit Electronic assembly to control the firing pulse to turn on the power SCR Flag Lead Term used to describe top terminal on some stud mount devices Terminal is a rigid metal flag shaped connection Forward Direction The direction of current flow in a semiconductor Forward Polarity See Standard Polarity Free Wheeling Rectifier Diode Rectifier that is used to bypass the current due to the stored energy in the inductance Full Control Circuit utilizing all SCRs for controlling both half cycles in an AC circuit Fuse Device which protects the load circuit from excessive currents Gain Adjustments used to adjust maximum output of a Power Control for a specified input Input from a temperature controller GPM Gallons per minute Water flow rate trough liquid cooked heat sink Gate Control terminal of an SCR Half Control An arrangement of rectifiers and SCRs that control only half the cycle in AC circuits One SCR one Diode I Squared t This is a measure of a maximum forward nonrecurring over current capability for a very short pulse duration The value is valid only for the pulse duration specified the RMS amperes and t is the pulse duration in seconds Ft is necessary for fuse coordination Junction A transition region between the positive and negative layers of a sem
27. vacuum tubes are replaced by semiconductors Spike An unintended flow of electrical energy of short duration Graphically displayed on a scope as a very high voltage or current having a very short duration usually in the microsecond range Thermal Impedance Resis tance The resistance to heat flow through a material or from one ma terial to another The unit is de grees C per watt which means the centigrade degrees of temperature rise of the material per each watt of power dissipated at the source Thyristor One of three primary groups of solid state power devices rectifiers transistors and thyristors Principle members of the thyristor family include SCR triac GTO etc Time Base Reoccurring period of time that determines the amount of power delivered to the load of a zero voltage proportional control Time Proportional See zero voltage firing Transient Surge Suppressor An electrical device used to absorb the energy of extraneous high peaks of voltage of current Used to protect semiconductors from ruinous overloads Transient Voltages Extrane ous spikes of high voltage which appear across a device due to switching commutation interrup tions in associated circuitry or by natural forces such as lightening Transients are of very short dura tion usually in the microsecond range Transistor Three terminal base collector emitter device used primarily for switching and amplific
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