© 2014 Power-Tronics, Inc.
The Power-Tronics PC1500 Series Phase
controls are a self-contained complete
Phase control. The PC1500 Series Phase
control is designed for continuous
operation at up to 105vdc for PC1500AF
models and 210vdc for PC1500BF models
at 100adc!
The PC1500 Series is uniquely designed
to sit in a compact footprint while being
passively convection cooled for a long
service life. Because of its unique
modular design, the PC1500 minimizes
downtime should a repair ever be
necessary! The PC1500 Series’ compact
design allows a wide variety of installation
methods, including installations where
space is at a premium.
The PC1500 Series is a time-proven
design, utilizing high-reliability components
and a unique modular design to simplify
repair. The PC1500 Series is designed to
provide a lifetime of service and is
specifically built to minimize failures and
potential downtime!
The PC1500 Series is also capable of
operation with Power-Tronics’ wide variety
of optional accessories, which allow them
to be remotely operated by dry contact
switching or by a PLC controller!
The PC1500 Series Phase control is the
latest upgrade to the PC1500A and
PC1500B series of phase controls and
replaces all previous Power-Tronics
PC1500A, PC1500AX, PC1500B, and
PC1500BX Phase controls!
PC1500 Series
Phase control
Specifications
Input Voltage: 208 - 240vac
Frequency: 50 or 60 Hz
Control Range: 0-100%
Output Voltage: 0-210vdc @ 240vac input (PC1500BF)
0-105vdc @ 240vac input (PC1500AF)
Maximum Continuous Output: 100adc
Minimum Field Resistance: 2.1Ω @ 210vdc output (PC1500BF)
1.05Ω @ 105vdc output (PC1500AF)
Physical Size: 10 x 20 x 8 in.
Weight: 18 lb.
Phase control: PC500X
Repairable: Yes
Internal Protection: Fuses, cartridge type
External Voltage Adjustment: Yes
System Operating Indicator: Yes
Optional External Controls Yes
PC1500BF Shown
PC1500AF Similar
© 2014 Power-Tronics, Inc.
Table of Contents
Introduction and Functional Description:....................................................................3
Determining Application Sizing:...................................................................................4
PC1500BF Connection Diagram:...................................................................................6
PC1500AF Connection Diagram:...................................................................................7
Initial Setup and Commissioning:.................................................................................8
Optional Power-Tronics Add-On Modules:..................................................................9
Bench Check Procedures:...........................................................................................10
Installation Warranty Form:.........................................................................................11
Product Warranty Certificate:......................................................................................12
© 2014 Power-Tronics, Inc.
Introduction and Functional Description
Caution: Read This Installation
Manual Carefully and Entirely!
Warning: Do not use digital equipment to read voltage, Hz, or amperage
during this installation. Use only Analog sensing equipment! Failure to do so
may result in damage to equipment or in personal injury!
ALWAYS perform all setup procedures off-line
ALWAYS wear eye protection
ALWAYS strip wire insulation properly or use insulated connectors
ALWAYS use analog metering equipment when setting up the phase control
ALWAYS ensure the phase control receives ample airflow
ALWAYS use adequate fusing
NEVER hold the phase control in your hand or lap when energized
NEVER install the phase control in a place it can get wet or is exposed to the elements
NEVER mount the phase control over a screw, bolt, rivet, seam, or other fastener
NEVER remove the PC500X cover while the unit is in operation
NEVER insert a screwdriver or other object under the regulator cover
NEVER touch any exposed part of the PC1500 during operation (LIVE HEATSINKS)
NEVER install a switch in the DC portion of the phase control’s wiring
NEVER USE A DIGITAL FREQUENCY METER (It can give a false reading!)
Functional Description
The PC1500 Series Phase Control is the result of over 20 years of engineering efforts and offers
high-demand features at a competitive price point. The PC1500 is a proven design and is
engineered to greatly simplify setup while offering extreme reliability. When properly installed, the
PC1500 Series Phase Control is designed to provide a lifetime of service.
An automatic phase control has several automated tasks it must perform in order to provide
reliable, clean, and regulated electricity. It must maintain a preset setpoint and protect both itself
and the connected load should a fault situation arise.
The PC1500 Series uses field-replaceable cartridge fuses to protect its internal circuitry should a
fault occur and the load current exceeds what the phase control is capable of delivering. It also
contains reliable circuitry that is designed to maintain a setpoint regardless of outside influences
or ambient temperature.
Due to its extreme simplicity, the PC1500 Series Phase Control is uncommonly reliable and offers
features and accuracy usually only offered by much more complicated and often much more
expensive phase controls.
© 2014 Power-Tronics, Inc.
Determining Correct Application Sizing
The PC1500BF Phase control is designed for use with 208-240VAC input. It contains internal
suppression for use with brush-type loads such as synchronous motors. Before installation, it is
necessary to verify that the PC1500BF is the correct product for your application.
To determine if the PC1500BF is the correct product for your load you need to know any two of
the following 3 specifications from the rating plate of your load:
1: Control Field Voltage (in DC Volts) [Generally given in full load Voltage on nameplates]
2: Control Field Resistance (in Ohms) [See Note Below]
3: Connected Load Amperage (in DC Amps) [Generally given in full load Amps on nameplates]
Using the specifications obtained from your connected load, verify
that your load fits the specifications from the chart or graph below:
• Exciter full load voltage is 63VDC or less, and your exciter field resistance is
1.05Ω or greater. CHOOSE PC1500AF PHASE CONTROL
• Connected load full load voltage is 125VDC or less, and your control field
resistance is 2.1Ω or greater. CHOOSE PC1500AF PHASE CONTROL
PC1500AF Sizing Chart
PC1500BF Sizing Chart
© 2014 Power-Tronics, Inc.
Note about Field Resistance
When measuring field resistance on a brush-type device, such as
a synchronous motor, measure the resistance through both the
field leads as well as directly on the slip rings themselves.
The readings you obtain should ideally be the same, but no
more than 1% difference.
If you show more than 1% difference in reading your device has
brush and ring contact problems and will need cleaning or
maintenance before installing the PC1500BF.
Failure to correct brush and ring contact problems will
result in severe damage to the phase control as well
as possible PERMANENT damage to the slip rings
themselves!
NEVER use emery cloth, carborundum stones, “comm
sticks”, or Tuner cleaner to dress or clean slip rings!
They will make a bad problem much, much worse! Only use
Garnet or Flint sandpaper and clean with a clean rag soaked with
Acetone for best results!
© 2014 Power-Tronics, Inc.
PC1500BF Connection Diagram
WARNING: The PC1500BF Phase Control is NOT
Suitable for use on Electrical Generators!!!
The PC1500BF is a Full-Wave rectified phase control, which allows a maximum of
210VDC at 100 ADC continuous with an input voltage of 240VAC.
This product is typically used on slip-ring synchronous motors or on inductive loads with
full load control field voltages of 125VDC or less and full load exciter field amperages
between 30 and 90ADC.
Note that the maximum input voltage to the PC1500BF Phase control is 240VAC!
DO NOT input 277VAC into the PC1500BF! Severe damage to the unit will result!
For use on 480V or higher systems, connect the PC1500BF to an appropriate stepdown transformer to supply 240VAC to the PC1500BF.
Diagram Assumes a 208-240V Input Voltage
For 480V or higher systems, use a 31KVA (or
larger) Transformer with a 240V Secondary!
NOTE:
It is not necessary
to jumper terminals
E and F if not using
the Remote Voltage
Adjustment!
NEVER install a switch or
breaker on the DC or Exciter
side of the phase control!
Only install a switch or
disconnect on the AC Side of
the phase control!
Internal
Voltage
Adjustment
System
Status
Off/On
Switch
Main Disconnect
208-240VAC
From Power
Supply
Internal
Sensitivity
Adjustment
© 2014 Power-Tronics, Inc.
PC1500AF Connection Diagram
WARNING: The PC1500AF Phase Control is NOT
Suitable for use on Electrical Generators!!!
The PC1500AF is a Half-Wave rectified phase control, which allows a maximum of
105VDC at 100 ADC continuous with an input voltage of 240VAC.
This product is typically used on slip-ring synchronous motors or on inductive loads with
full load control field voltages of 63VDC or less and full load exciter field amperages
between 30 and 90ADC.
Note that the maximum input voltage to the PC1500AF Phase control is 240VAC!
DO NOT input 277VAC into the PC1500AF! Severe damage to the unit will result!
For use on 480V or higher systems, connect the PC1500AF to an appropriate stepdown transformer to supply 240VAC to the PC1500AF.
Diagram Assumes a 208-240V Input Voltage
For 480V or higher systems, use a 15KVA (or
larger) Transformer with a 240V Secondary!
NOTE:
It is not necessary
to jumper terminals
E and F if not using
the Remote Voltage
Adjustment!
NEVER install a switch or
breaker on the DC or Exciter
side of the phase control!
Only install a switch or
disconnect on the AC Side of
the phase control!
Internal
Voltage
Adjustment
System
Status
Off/On
Switch
Main Disconnect
208-240VAC
From Power
Supply
Internal
Sensitivity
Adjustment
© 2014 Power-Tronics, Inc.
Initial Setup and Commissioning
1. Install the PC1500 and wire up according to the wiring diagram on page 6 or 7.
2. If installing the PC1500 on a load containing slip rings and brushes, verify that
the brushes and brush riggings are isolated, ungrounded, and connected ONLY
to the PC1500.
3. The PC1500 generally comes preset from the factory for full range with the
remote adjustment control. If you need to adjust these settings, follow the
instructions below:
4. Turn the internal voltage control (Shown on page 6 and 7 [and below with cover
of PC500X removed for clarity]) 15 or more turns counter clockwise (left) or until
you hear the screw click. This procedure is necessary in case the original factory
settings have been altered.
5. If you are using a remote voltage adjustment, set it at 50% of adjustment.
6. If you are using the PC1500BF on a synchronous motor, bring the motor up to
operating speed and turn on the phase control switch (if used).
7. Set the internal voltage adjustment to the desired voltage setting for the
connected load by turning the adjustment screw clockwise (right).
Note that the voltage adjustment is a 25-turn pot!
8. Check remote adjustment range (if used) for satisfactory sensitivity. If the
adjustment range is too sensitive, slowly turn the Stability adjustment clockwise
until a satisfactory adjustment range is achieved. NOTE: You may need to
adjust your Voltage adjustment during this process!
9. Observe operation during no-load and full-load conditions. Once the voltage is
set and adjustment characteristics are satisfactory the installation procedure is
complete.
Internal
voltage
adjustment
System
indicator
light
Sensitivity
adjustment
© 2014 Power-Tronics, Inc.
Optional Power-Tronics Add-On Modules
Power-Tronics offers a wide array of optional add-on modules for the PC1500
Series Phase Control. For more information on any of the modules below, visit
our online catalog at:
www.power-tronics.com
UIC200
Optical Interface
Allows the PC1500 to be
controlled externally by virtually
any digital load-sharing controller,
VAR controller, genset controller,
or digital governor controller!
MP12/24
Motorized Potentiometer
Allows the PC1500 to be
externally controlled by older
automated controllers using
pulsed signals or dry contacts
for control!
© 2014 Power-Tronics, Inc.
Bench Check Procedures
1. Wire up the PC1500 as shown in the figure below (PC1500BF shown, PC1500AF similar).
2. Connect up two 120 volt 50 to 150 watt light bulbs in series to the F+ and F- Terminals (Use a
single light bulb for PC1500AF models).
3. Install a temporary jumper wire between terminals C and D on TB1 Terminal Board.
4. Turn the internal voltage adjustment on the PC1500 Phase Control fully Counter-Clockwise (Left)
before beginning the testing procedures below.
5. Input 208-240VAC fused at no more than 5A into the PC1500. The test light should be OFF.
6. Slowly turn the internal voltage adjustment on the PC1500 Phase Control Clockwise (Right) until
the lights glow. The test light should light to FULL Brightness. NOTE: It may take several
turns of the adjustment screw before the lights illuminate!
7. Slowly turn the internal voltage adjustment of the PC1500 Phase Control Counter-Clockwise
(Left) until the lights go dark. The test light should be OFF. NOTE: It may take several turns
of the adjustment screw before the lights go dark!
8. Turn off power and disconnect the PC1500 from your power source. Inspect all electronic
components on the PC1500 to ensure they are isolated from touching any part of the PC1500
housing.
9. If you were able to successfully perform all of these tests, the PC1500 is good.
2x 120V 50-150W
Incandescent
208-240VAC
Jumper
Internal
Voltage
Adjustment
Fuse Replacement Information:
PC500X:
Rating: 5A @ 250VAC
Qty: 2
PTI Part # 5R3-403
Cooper–Bussman Part # BK/GDB-5A
PC1500:
Rating: 100A @ 250VAC
Qty: 2
PTI Part # 5R3-216
Cooper–Bussman Part # JJN-100
© 2014 Power-Tronics, Inc.
Installation Warranty Form
It is very important that you fill out this form completely when installing a phase control.
This form serves as a history record on the application. This form also contains the
information needed by Power-Tronics, Inc., for repair and troubleshooting of any
product you may be having problems with.
Failure to fill out this form during installation will result in a cancellation of
your warranty coverage! Filling out this form takes only minutes but will save
hours or days later on if your product should require service!
Product
Other options
Serial Number
Date of Installation
Type of Generator
Model #
Brush type
[ ]
Brushless
[ ]
AC Stator Information
Wired for
Volts
Phase
Hz Generator Configuration: Lead
Exciter/Rotor Information
Exciter field
resistance
Ω @ F+ / F-
Ω
Exciter field volts
vdc
@ Slip Rings
Ω
Description of problem with product or generator
Your phone number
Name:
Your fax number
Ship to Address:
Your email address
Ship to City, State, Zip:
© 2014 Power-Tronics, Inc.
PRODUCT WARRANTY
Power-Tronics, Inc., assumes no liability for damages due to incorrect voltage or other voltage
related damages resulting from either output of the generator or input to the generator exciter
system. These problems should be protected with external devices provided by the customer
such as fuses, surge suppressors, over/under voltage and frequency controls.
Power-Tronics, Inc., warranties only parts and workmanship of this product for a period of 2
years from the original date of purchase from Power-Tronics, Inc. Under warranty, Power-
Tronics, Inc. will replace, exchange or repair the defective product without labor or parts cost
to the customer. Remaining warranty of the original product will be transferred to the replaced
or repaired product. To obtain warranty, a copy of the original Installation Warranty Form must
be sent in with the defective product, which clearly shows the purchase date and serial number
of the defective part. A repair request form must be sent in with the product before repairs will
begin. You can obtain this form by contacting Power-Tronics, Inc.
Send repairs to: Power-Tronics, Inc., 2802 Cobbler Ln., Kerrville Texas USA 78028.
Send in repairs only by UPS or FedEx. USPS will NOT deliver to our facility!
Any one of the following conditions will void the warranty:
v Overheating of the power supply resistor on the printed circuit card.
v Overheating of the SCR or freewheeling diode.
v Physical damage to the printed circuit card, housing or components.
v Unauthorized repair or alteration of printed circuit card.
v Installation by anyone other than a qualified professional generator service technician.
v Conductive or corrosive contamination of the circuit card.
v Removal of our company identification from the product.
v Removal of any conformal coating of the printed circuit card or components.
v Overheating of foil on the printed circuit card.
v Inappropriate or infeasible application.
v Use with any external device other than manufactured by Power-Tronics, Inc.
v Failure to fill out the attached warranty card during installation
No other warranty is expressed or implied.
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