Precision Control Systems 1029C User Manual

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Page 1

Control Concepts

Model 1029C

Po w er Co ntrol System

Instruction Manu al

(952) 949-9009 Fax (952) 949-9559

Another quality product from:

7128 Shady Oak Road

Eden Prairie, MN 55344 USA

www.researchinc.com

Page 2

CONTROL

CONCEPTS

INC.

INSTALLATION MANUAL

MODEL 1029C

7870 PARK DRIVE

CHANHASSEN, MN 55317

(952) 474-6200

1-800-765-2799

FAX (952) 474-6070

www.ccipower.com

Page 3

CONTROL CONCEPTS, INC. 2 YEAR LIMITED WARRANTY

CONTROL CONCEPTS, INC. warrants that the products delivered will be as described in the sales order or contract.

CONTROL CONCEPTS, INC. warrants to the original user that CONTROL CONCEPTS, INC. products will be free from defects in materials and workmanship for a period of two (2) years after the date CONTROL CONCEPTS, INC. ships such products.

If any CONTROL CONCEPTS, INC. product is found to be defective in material or workmanship during the applicable warranty period, CONTROL CONCEPTS, INC.’s entire liability, and purchasers sole and exclusive remedy, shall be the repair or replacement of the defective product at CONTROL CONCEPTS, INC.’s election. CONTROL CONCEPTS, INC. shall not be liable for any costs or expenses, whether direct or indirect, associated with the installation, removal or re-installation of any defective product. All shipping and freight costs are the responsibility of the customer. CONTROL CONCEPTS, INC.’s limited warranty shall not be effective or actionable unless there is compliance with all installation and operating instructions furnished by CONTROL CONCEPTS, INC., or if the products have been modified or altered without the written consent of CONTROL CONCEPTS, INC., or if such products have been subject to 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 FOR A PARTICULAR PURPOSE, any implied warranty arising out of a course of dealing or of performance, custom or usage of trade.

CONTROL CONCEPTS, INC. SHALL NOT, UNDER ANY CIRCUMSTANCES BE LIABLE FOR ANY DIRECT, INDIRECT, INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES (INCLUDING, BUT NOT LIMITED TO, LOSS OF PROFITS, REVENUE OR BUSINESS) OR DAMAGE OR INJURY TO PERSONS OR PROPERTY IN ANY WAY RELATED TO THE MANUFACTURE OR THE USE OF ITS PRODUCTS. The exclusion applies regardless of whether such damages are sought based on breach of warranty, breach of contract, negligence, strict in tort, or any other legal theory, even if CONTROL CONCEPTS, INC. has notice of the possibility of such damages.

By purchasing CONTROL CONCEPTS, INC.’s products, the purchaser agrees to the terms and conditions of this limited warranty.

WARNING: The Control Concepts, Inc. power controllers use power thyristors to switch voltage to the connected load. Line voltage must be assumed at the output terminals at all times, even when the control signal 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

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

Page 4

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

LISTED 3L32 FILE No: E136219 INDUSTRIAL CONTROL EQUIPMENT

NOTE: THE 1000 AMP UNIT IS NOT UL LISTED

MODEL 1029C i 10/19/2007

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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 & 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 or 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 representing the load current are provided for remote monitoring.

MODEL 1029C 1 10/19/2007

Page 6

SPECIFICATIONS

The following specifications apply over an ambient temperature of 0 to 55ºC and a supply voltage of 85% to 110% of the nominal supply voltage rating.

CONTROL MODE: Single phase SCR phase-angle control.

FRAME SIZE: The “[AMPS]A” term within the model number specifies the maximum continuous

RMS current rating at the maximum operating ambient temperature of 55ºC.

RUN COMMAND SIGNAL AND/OR IDLE COMMAND SIGNAL:

OPERATING VOLTAGE: The control transformer installed in this controller has three selectable voltages;

SCR RATINGS: Peak forward and reverse voltage 1600 volts

SCR SURGE CURRENT RATINGS :

(peak one cycle non-repetitive I

@ 125°C)

TSM

SCR PROTECTION: dV/dT rating = 200 volts/microsecond.

RUN/IDLE CONTROL: A contact closure selects either the run command signal input or the idle command

ELECTRICAL CONNECTIONS: # of LUGS PER LINE/LOAD CONNECTIONS

ELECTRICAL ISOLATION: 50-160 Amp heatsink to supply and load voltage: 2500 Volts Peak

Command signal Input Impedance 1/5mA 1200 ohms 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.

240, 480 & 575 Vac. Other voltages are be available - contact factory for details.

Controller Rating Surge Current Rating 50 & 80 Amp: 1750 Amps Peak 120 Amp: 1900 Amps Peak 160 Amp: 4000 Amps Peak 200 Amp: 4500 Amps Peak 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

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.

signal input. See Figure 10.

Connectors for line and load are provided for copper wire from 6 ga to 250MCM on controllers rated 50 to 425 Amps. Connectors for line and load are provided for copper wire from 1/0 to 500MCM on controllers rated 500 to 750 Amps.

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

Page 7

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 20% to 105% of the controller rating. (The current limit potentiometer is factory set for 105% 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 + 10%, -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.

INTERNAL 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 2% 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 the load current.

OVER CURRENT TRIP INDICATOR:

SHORTED SCR INDICATOR: This red LED, when lighted, indicates a shorted SCR.

O.C.T. & SHORTED SCR RELAY CONTACT RATINGS:

CONTROL RANGE: 0 to 98% of supply voltage.

ENVIRONMENT: Operating temperature 0ºC to 55ºC (32ºF to 132ºF)

PHYSICAL: 50 & 80 Amp controllers 16 pounds

LINE 2 REQUIREMENTS: The Line 2 connection is the return for the internal control transformer rated at 50

This amber LED, when lighted, indicates the over current limit has been exceeded 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 & 10 or momentary power interruption. See Figure 7.

The Over Current Trip, and the Shorted SCR circuits, each control a relay which has form C contacts rated for 5 Amps @ 120Vac. The contacts are available on the command connector. See Figure 7.

Storage temperature: -40ºC to 80ºC (-40ºF to 176ºF) Humidity: 0 to 95%, non-condensing

120 & 160 Amp controllers 17 Pounds 200 to 425 Amp controllers 21 Pounds 500 to 750 Amp controllers 40 Pounds

VA. # 18 ga wire.

MODEL 1029C 3 10/19/2007

Page 8

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 fans (excludes the 50 & 80 amp units) may be mounted in any direction.

COMMAND 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/Idle:

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.

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 & 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.

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.

RECOMMENDED TIGHTENING TORQUE

FOR EDGE CARD CONNECTOR:

WIRE SIZE (AWG) TORQUE

14 TO 26GA 4.4 - 5.5 IN-LBS

Power Connections:

Figure 15 & Figure 16 show typical electrical connections.

The LINE 1 and LOAD 1 connectors are approved for wire sizes from 6ga to 500 MCM.

ECOMMENDED TIGHTENING TORQUE

FOR THE LINE AND LOAD CONNECTORS

WIRE SIZE (AWG) OR

CIRCULAR MILLS

4 TO 6GA

1 TO 2GA 1/0 TO 2/0GA 3/0 TO 4/0GA

250 TO 350MCM

500MCM

TORQUE

100 IN-LBS 125 IN-LBS 150 IN-LBS 200 IN-LBS 250 IN-LBS 300 IN-LBS

MODEL 1029C 4 10/19/2007

Page 9

INSTALLATION DRAWINGS

7.65

6.65

0.50

LINE 1

GROUND

LOAD

LINE 2

1.125

)

10.6

10.

8.27

10.0

0.288 X 0.50 (2

0.60

0.29 (2)

Figure 1. Installation drawing for 50, 80, 120 & 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

Page 10

INSTALLATION DRAWINGS (Continued)

17.40

4.00

10.85

LOAD

LINE

W )

. METER

FB. BK.

I. METER

IDLE (+) W

RUN (+

COM(-) CCW

DANGER

HIGH VOLTAGE

COMMAND

LOAD

+5V

SHORTED

1234567891011121314151617

TED

SHOR

CURRENT

OVER

RELAY

CURRENT

OVER

RESET

COMMON

RUN/IDLE

SCR

INDICATOR

16.00

5/16 Dia. (4)

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

Page 11

26.

INSTALLATION DRAWINGS (Continued)

. METER

FB. BK.

I. METER

IDLE (+)

COM(-) CCW

DANGER

HIGH VOLTAGE

COMMAND

1234567891011121314151617

)

RESET

+5V

COMMON

SHOR

CURRENT

AY L

SCR

OVER

RELAY

CURRENT

OVER

5 .

RUN/IDLE

RUN (+

SHORTED

SCR

INDICATOR

LOAD

INDICATOR

. 5 2

Figure 5. Installation drawing

for 500 to 750 Amp units.

0.332 Dia. (4)

5.00

Figure 6.

ORIENTATION OF FUSE IN HOLDER

Fuse makes contact only when correctly installed.

MODEL 1029C 7 10/19/2007

Page 12

COMMAND CONNECTIONS

OVER CURRENT TRIP

RESET SWITCH

TO ALARM OR POWER DISCONNECT CIRCUIT

FB. BK.

I. METER

V. METER

IDLE (+) W

+5V

RUN (+)

COM(-) CCW

RESET

COMMON

RUN/IDLE

SHORTED

SCR

RELAY

OVER

CURRENT

RELAY

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

I K

POT

CCW

WIPER

FB. BK.

I. METER

. METER V

IDLE (+)

+5V

COMMON

RUN/IDLE

RUN (+)

COM(-) CCW

RESET

TED

SCR

RELAY

SHOR

OVER

CURREN

RELAY

Figure 8. Single potentiometer applied to the run input connections.

(Terminals 10 & 11 must be connected to enable the run input.)

Effective 10/19/2007 the controller will be shipped with shorting jumper on pins 10 & 11.

MODEL 1029C 8 10/19/2007

Page 13

COMMAND CONNECTIONS (Continued)

POSITIVE(+)

RUN INPUT (VOLTAGE OR CURRENT COMMAND SIGNAL.)

SCR

REL

OVER

CURRENT

RELAY

FB. BK.

I. METER

V. METER

IDLE (+) W

+5V

RUN/IDLE

RUN (+)

COM(-) CCW

COMMON(-)

RESET

COMMON

TED

SHOR

Figure 9. Single voltage or mA current applied to the run input connections.

(Terminals 10 & 11 must be connected to enable the run input.)

Effective 10/19/2007 the controller will be shipped with shorting jumper on pins 10 & 11.

IDLE POTENTIOMETER

CCW

I K

POT

WIPER

FB. BK.

I. METER

V. METER

IDLE (+)

COM(-) CCW

RUN POTENTIOMETER

CCW

WIPER

RUN/IDLE SWITCH

CLOSED ENABLES THE RUN INPUT OPEN ENABLES THE IDLE INPUT

)

+5V

RUN (+

RUN/IDLE

RESET

COMMON

I K

POT

SHORTED

SCR

RELAY

OVER

RELAY

CURREN

Figure 10. Run and Idle potentiometer connections.

MODEL 1029C 9 10/19/2007

Page 14

COMMAND CONNECTIONS (Continued)

POSITIVE(+)

COMMON(-)

RESET

COMMON

SHORTED

RUN INPUT

(VOLTAGE OR CURRENT COMMAND SIGNAL.)

246810121416

SCR

OVER

RELAY

CURRENT

(VOLTAGE OR CURRENT*

IDLE INPUT

COMMAND SIGNAL.)

POSITIVE(+)

COMMON(-)

FB. BK.

I. METER

V. METER

IDLE (+) W

+5V

RUN/IDLE

RUN (+)

COM(-) CCW

Figure 11. Run and Idle voltage or current connections.

* If it is 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.

1357911131517

REL

CURRENT METERING

OUTPUT

FB. BK.

. METER

I. METER

IDLE (+)

COM(-) CCW

+5V

RUN/IDLE

RUN (+)

VOLTAGE METERING

OUTPUT

COMMON

RESE

COMMON

TED

SCR

SHOR

REL

OVER

RELAY

CURRENT

Figure 12. Output metering connections.

MODEL 1029C 10 10/19/2007

Page 15

COMMAND CONNECTIONS (Continued)

IDLE POTENTIOMETER

CCW

I K

POT

WIPER

POSITIVE(+)

RUN INPUT

(VOLTAGE OR CURRENT

COMMON(-)

RUN/IDLE SWITCH

CLOSED ENABLES THE RUN INPUT OPEN ENABLES THE IDLE INPUT

COMMAND SIGNAL.)

EXTERNAL

FEEDBACK

SIGNAL

FB. BK.

I. METER

V. METER

IDLE (+) W

+5V

RUN (+)

COM(-) CCW

RESET

COMMON

RUN/IDLE

SHORTED

SCR

REL

OVER

CURRENT

RELAY

Figure 13. Combination command-signal/potentiomter input connections.

(This is the most common use of a run/idle control.)

POSITIVE(+)

COMMON(-)

POSITIVE(+)

COMMON(-)

RUN INPUT

(VOLTAGE OR CURRENT COMMAND SIGNAL.)

FB. BK.

I. METER

V. METER

IDLE (+) W

COM(-) CCW

+5V

RUN (+)

RESE

COMMON

RUN/IDLE

SHORTED

SCR

RELAY

OVER

URRENT C

REL

Figure 14. External feedback with signal applied to run input connections.

0 - 5 Vdc or 0 - 50uA external feedback.

(Terminals 10 & 11 must be connected to enable the run input.)

Effective 10/19/2007 the controller will be shipped with shorting jumper on pins 10 & 11.

MODEL 1029C 11 10/19/2007

Page 16

POWER CONNECTIONS

LINE 2

VOLTAGE

SUPPLY

LOAD

LINE 1

LINE 2

VOLTAGE

SUPPLY

LINE 1

GND

Figure 15. Power Connections.

LOAD 1

LINE 2

LOAD

LINE 1

MODEL 1029C 12 10/19/2007

LINE

1029C CONTROLLER

Figure 16. Power Path.

LINE 2

LOAD

Page 17

FEEDBACK SELECTION

START-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.

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 & P2-7 to select Voltage FB. (See Figure 18.)

2. Determine that terminals P1-10 & P1-11 are electrically 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 & 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.

MODEL 1029C 13 10/19/2007

Page 18

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 potentiometers labeled Run Span, Run Zero, Idle Span & 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 it is 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/Idle) 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).

It is important that meters capable of

accurately measuring the output of the

controller be used.

True 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.

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/Idle) 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.

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 Current Trip pot about 1/2 turn clockwise.

4. Reset the Over Current Trip circuit.

MODEL 1029C 14 10/19/2007

Page 19

ADJUSTMENTS (Continued)

Run Span Pot. Run Zero Pot.

Idle Span Pot. Idle Zero Pot.

THESE FOUR POTS, AND THE CURRENT LIMIT POT

ARE MOUNTED ON THE

BACK SIDE OF THE BOARD

TO SHOW THROUGH LID

Installed for power feedback only

X X

Figure 17. 1029C circuit board showing adjustment locations.

P2 FeedbackSelector. See Figure 18

DO NOT CHANGE ADJUSTMENTS ON POTS MARKED WITH AN ‘X’

Current Limit Pot. (shows through lid.) Over Current Trip

DO NOT CHANGE ADJUSTMENTS ON POTS MARKED WITH AN ‘X’

FEEDBACK SELECTION

SUMMING JUNCTION EXTERNAL F.B. CURRENT F.B. VOLTAGE F.B POWER F.B.

Figure 18. P2 Details

COMMON

EXTERNAL FEEDBACK INPUT CONNECTIONS

0-100mA or 0-5 V

FB. BK.

I. METER

V. METER

IDLE (+) W

+5V

RUN/IDLE

RUN (+)

COM(-) CCW

RESET

COMMON

SHORTED

SCR

RELAY

OVER

RELAY

CURRENT

Figure 19. External feedback connections.

MODEL 1029C 15 10/19/2007

Page 20

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 increased. 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 100%.

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 & 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 if 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

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 & 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 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 16 10/19/2007

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

Page 21

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

CURRENT

RAING Amps (A)

50 SCR/TT91-16 50 60 42110-0460-360

80 SCR/TT91-16 80 100 42110-0460-410

120 SCR/TT105-16 120 150 42110-0460-415

160 SCR/TT132-16 160 200 42110-0460-420

200 SCR/T240-14* 200 250 42110-0460-425

250 SCR/T340-14* 250 300 42110-0460-430

300 SCR/T490-14* 300 350 42110-0460-435

380 SCR/T600-14* 380 450 42110-0460-445

425 SCR/T760-14* 425 500 42110-0460-450

500 SCR/T600-14* 500 600 42110-0460-460

600 SCR/T760-14* 600 700 42110-0460-470

750 SCR/Z1400-14* 750 800 42110-0460-480

CONTACT FACTORY FOR INFORMATION ABOUT 1000 OR 2000 AMP FRAME

* 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.

CONTROL

CONCEPTS

PART No.

CONTROLLER

CURRENT

RATING Amps (A)

FUSE SIZE

Amps (A)

CONTROL

CONCEPTS

PART No.

REPLACEMENT CONTROL TRANSFORMER FUSES

Frame Size Location Fuse Type CCI Part No.

50 & 80 Amps F1 & F2 1/4 Amp Class CC TYPE R 42130-0460-2025

120 - 425 Amps F1 & F2 1/2 Amp Class CC TYPE R 42130-0460-205

500 - 750 Amps F1 1 Amp Class CC TYPE R 42130-0460-210

500 - 750 Amps F2 1/2 Amp Class CC TYPE R 42130-0460-205

MODEL 1029C 17 10/19/2007

Page 22

MODEL NUMBER IDENTIFICATION

1029C The 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.

I - 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.

1029C-[X]-[XXX]V-[XXX]A-IL[XXX]-R[XXX]-I[XXX]

[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 & 2000 Amps)

IL[XXX] Current Limiting Up to 105% of controller rating.

R[XXX] Run Command Signal 0/5Vdc, 4/20mA or Potentiometer

I[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

Page 23

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 FLOW

ANODE

CATHODE

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 transformercoupled, capacitive, inductive or a variable resistance load requiring current limiting.

Point at which SCR begins to

conduct

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) configuration to control AC current.

Figure 21. “AC Switch”

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.

Figure 22. SCR “ON” time, shown by shaded area, is

varied to apply the desired load voltage

MODEL 1029C 19 10/19/2007