Precision Control Systems 3629C User Manual

Control Concepts

Model 3629C

Power Control System

Instruction Manual

Another quality product from:

7128 Shady Oak Road

Eden Prairie, MN 55344 USA

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CONTROL

CONCEPTS

INC.

INSTALLATION MANUAL

MODEL 3629C

7870 PARK DRIVE

CHANHASSEN, MN 55317 [phone] 1-800-765-2799

FAX [phone] www.ccipower.com

CONTROL CONCEPTS, INC. 2 YEAR LIMITED WARRANTY

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

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

If any CONTROL CONCEPTS, INC. product is found to be defective in material or workmanship during the applicable warranty period, CONTROL CONCEPTS, INC.’s entire liability, and purchasers sole and exclusive remedy, shall be the repair or replacement of the defective product at CONTROL CONCEPTS, INC.’s election. CONTROL CONCEPTS, INC. shall not be liable for any costs or expenses, whether direct or indirect, associated with the installation, removal or re-installation of any defective product. All shipping and freight costs are the responsibility of 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

© Copyright 2007, Control Concepts, Inc. Chanhassen, MN 55317

The information and design disclosed herein are the property of Control Concepts, Inc. and may not be used, reproduced or disclosed in any form except as granted in writing by:

CONTROL CONCEPTS, INC

7870 PARK DRIVE

CHANHASSEN, MN 55317 PHONE: [phone] TOLL FREE: [phone] FAX: [phone] www.ccipower.com

MODEL 3629C TABLE OF CONTENTS

DESCRIPTION	1
FEATURES	1
SPECIFICATIONS	3
INSTALLATION	5
INSTALLATION DRAWINGS	6
COMMAND CONNECTIONS	11
POWER CONNECTIONS	15
ADJUSTMENTS	18
TROUBLESHOOTING	20
REPLACEMENT PARTS	22
MANUFACTURED BY	22
MODEL NUMBER IDENTIFICATION	23
THEORY OF OPERATION	24

50 to 750 AMPS

LISTED 3L32 FILE No: E136219

INDUSTRIAL CONTROL EQUIPMENT

NOTE: THE 1000 or AMP UNIT IS NOT UL LISTED

MODEL 3629C

04/10/2007

DESCRIPTION

The model 3629C is a phase-angle SCR controller which linearly controls, with respect to a command signal, the voltage applied to a three phase electrical load. The controller can be connected either in-line or inside delta configuration. (See Figure 23 & Figure 24.)

The 3629C can be configured to control a 4 wire wye load or with the addition of a 3-phase bridge can control a DC load. (See Figures 25 & Figure 27.)

The 3629C controller can accept a 0 to 5Vdc command signal or a potentiometer control. The controller may also be configured to accept a 4/20mA current loop or a 0-10Vdc command signal . (See Figure 30.)

The command signal input terminals are electrically isolated from the line and load voltages. The line and load voltages are isolated from the heatsink on the 50, 80, 120 and 160 Amp units.

FEATURES

1.RMS Current Limit, sets the maximum load current to a desired value. The circuit senses the highest current on the three loads. This feature is useful for variable resistance loads, or loads that have a low resistance when cold.

2.Current Limit Metering, contacts on command connector ease calibration of the current limit setting. (See Figure 22.)

3.Over Current Trip, latches the controller off until reset, energizes a relay with form "C" contacts and lights an LED if the load current exceeds a preset value. These contacts, available on the command connector, may be used to operate an alarm or other devices. (Contacts are rated 250 Volts at 5 Amps.)

4.Over Current Trip Setting, allows independent adjustment of the over current trip point. Factory set at 175%.

5.Over Current Trip Metering, contacts on command connector ease calibration of the O.C.T. feature. (See Figure 21.)

6.Top adjust pots, make it possible to calibrate the controller without the necessity of removing the lid.

7.60 Degree Gate Drive, provides stable operation of the SCR's.

8.A shorted SCR detector, lights an LED and energizes a relay with form "C" contacts if an SCR fails in the shorted mode. These contacts, with connections available on the command connector, may be used to operate an alarm. (Contacts are rated 250 Volts at 5 Amps.)

9.Auto Phase Rotation Sensing, The controller is not phase rotation sensitive.

10.Missing cycle detection, if the power is momentarily interrupted, the load voltage is set to zero and then increased to the desired value at a rate equal to a time constant of approximately 0.2 seconds when power is reapplied.

11.Soft start, causes the controller to increase power to the desired value at a rate equal to a time constant of approximately 0.2 seconds.

12.Transient protection, a snubber circuit consisting of a non-inductive resistor in series with a capacitor, is connected

in parallel with each SCR pair to protect against high frequency transients. An MOV (metal oxide varistor) is also connected across each SCR pair to protect against high voltage transients.

13.Choice of Feedback:

A.RMS Voltage feedback (internal) allows the RMS value of the load voltage, to be linear with respect to the command signal.

B.Average voltage feedback, (factory installed option) allows the average value of the load voltage to be linear with respect to the command signal. Average voltage feedback is most often used for DC applications.

C.External feedback, may also be selected. (See Figure 18). Contact the factory with questions about your application.

MODEL 3629C

04/10/2007

FEATURES (Continued)

14.Connection for a remote reset switch, which, if momentarily closed, resets the Over Current Trip relay and resets the circuit to allow the load voltage to ramp from zero to the desired value.

The switch can also be used to provide remote "on-off" control. Closure of the switch immediately interrupts the SCR operation and removes load voltage. (See Figure 20.)

15.Eight status indicators provide the following information:

A."COMMAND INDICATOR" LED, the intensity of which, is proportional to the command signal. B."LINE C" LED, the intensity of which, is proportional to the magnitude of the line 3 load current. C."LINE B" LED, the intensity of which, is proportional to the magnitude of the line 2 load current. D."LINE A" LED, the intensity of which, is proportional to the magnitude of the line 1 load current. E."LINE-OK" LED when on, indicates that all three phases are applied.

F."SHORTED SCR" LED, when on, indicates that an SCR has failed in the shorted mode or is repeatedly miss firing.

G."OVER CURRENT" LED, when on, indicates that the over current trip point has been reached and the SCRs are de-energized.

H."CURRENT LIMIT" LED, when on, indicates that the load current has reached the current limit setting and cannot be increased by raising the command signal.

16.Controller Ready Signal, is available on the command connector. (See Figure 14). When this signal remains high, it indicates one or more of the following events have occurred:

A.Over current.

B.One or more of the line phases is not present.

C.One or more phases are not present on the firing circuit board. (Circuit fuse may be cleared.)

D.The phase lock is not enabled.

E.The gate drive is not enabled.

F.The Over Current Trip reset switch may be closed.

17.Choice of Command Signal, (See Figure 12 & Figure 13)

A.0 to +5 Volts DC.

B.Potentiometer. 1 Kohm to 20 Kohms.

C.Placing a jumper across the pins on JP1, allows the controller to accept a command signal of 0 to +10 Volts DC.

D.By replacing one resistor, the controller may be configured to accept a 4 to 20mA current loop command signal. (See Figure 30.)

18.Operating Modes

The model 3629C was designed to offer four user selectable operating modes. A switch on the circuit board allows the operator to select the desired mode. (See Figure 30). Unless ordered otherwise, the controller is shipped with the switch in the in-line mode.

IN-LINE

This is an ideal configuration for inductive loads, unbalanced resistive loads and transformer coupled loads. (See Figure 23, Figure 27 & Figure 28.)

INSIDE DELTA

Three phase inside delta control is basically three single phase controllers on the same frame that are operating from the same command signal. 3629C controllers incorporate SCR's with higher PIV ratings to accommodate the voltages encountered in an inside delta configuration (See Figure 24.)

SIX SCR DC

As the name implies, this mode is made to drive a three-phase diode bridge to provide power for many applications requiring a variable DC source. The gate drive is limited to 120 degrees for this mode. (This is full on for a DC controller.) (See Figure 25.)

4-WIRE WYE

When powering a WYE load, it is desirable to use the 4-wire configuration to reduce voltage surges due to open loads. These open load surges could destroy an SCR. (See Figure 26.)

MODEL 3629C

04/10/2007

SPECIFICATIONS

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

Control Mode:	Three-phase in line, Three-phase inside delta, 4-wire wye or DC. 6 SCR, phase
	angle control of the RMS or average load voltage. External feedback is available.
	See Power Connections section.
Command Signal:	Input signal	Input Impedance:
	0-5Vdc	200K ohms
	0-10Vdc	200K ohms
	Potentiometer	200K ohms
	4/20mA	300 ohms
	A 1K to 20K potentiometer is excited by 5Vdc, supplied by the circuit. Other input
	signals may be available. Check with factory for special applications.
Control Range:	0 to 98% of line voltage.
Linearity:	Output will be linear within 2% of span over entire range of control.
Current Limit Range:	Adjustable from 20% to 125% of frame current as specified in the "(Amps)A" term
	within the model number. If no IL term is specified when ordering, then current limit
	is factory set to 105% of frame current rating.
Over Current Trip Range:	Adjustable from 30% to 300% of frame current as specified in the "(Amps)A" term
	within the model number. If no OCT term is specified when ordering, then over
	current trip is factory set to 175% of frame current rating.
Zero and Span Adjustments:	Multi-turn potentiometers allow zero and span adjustments of ±25% of span.
Dissipation:	Approximately 1.5 watts per amp of current per phase dissipated by the controller.
Supply Voltage:	208, 240, 380, 415, 480, or 575Vac, 3 phase, @ 50/60 Hertz. Other operating
	voltages may be available by special order.
Environment:	Operating temperature 0 to 55°C (32 to 132°F).
	Storage temperature: -40 to 85°C (-40 to 176°F).
	Humidity: 0 to 95%, non-condensing.
Electrical Isolation:	Heat sink to supply
	Load voltage on units rated 50 to 160 Amps:		2500 volts peak.
	Command signal to supply and load voltage:		2500 volts peak.
Status Indicators:	LINE OK: Indicates power on all three phases and phase lock capture OK.
	COMMAND: The intensity of this LED is proportional to the command signal.
	LINE A, LINE B, LINE C: The intensity of these three LEDs is proportional to the
	current in each leg.
	SHORTED SCR: Indicates when an SCR has failed in the shorted mode.
	OVER CURRENT: Indicates excessive current has occurred.
	CURRENT LIMIT: Indicates when unit is in current limit mode.
Ready Signal:	An open drain Field Effect Transistor provides a signal which may be used to control
	an LED, a relay or a logic level shift. This signal will remain high if conditions exist
	within the controller that prevent the controller from providing a controlled output.
	(See Figure 14).
Cooling:	Convection cooling on 50 amp unit.
	Forced air fan cooling on all other models.

MODEL 3629C

04/10/2007

SPECIFICATIONS (Continued)

SCR Surge Current:	Peak 1 cycle surge current is:
	50 Amp rating	-	1,750 A Surge
	80 Amp rating	-	1,750 A Surge
	120 Amp rating	-	1,900 A Surge
	160 Amp rating	-	4,000 A Surge
	200 Amp rating	-	5,200 A Surge
	250 Amp rating	-	5,200 A Surge
	300 Amp rating	-	7,000 A Surge
	380 Amp rating	-	10,000	A Surge
	425 Amp rating	-	13,000	A Surge
	500 Amp rating	-	10,000	A Surge
	600 Amp rating	-	13,000	A Surge
	750 Amp rating	-	20,000	A Surge
	1000 Amp rating	-	26,000	A Surge
SCR I2T Rating:	50 Amp rating	-	15,000	A2S
	80 Amp rating	-	15,000	A2S
	120 Amp rating	-	18,000	A2S
	160 Amp rating	-	80,000	A2S
	200 Amp rating	-	135,000 A2S
	250 Amp rating	-	135,000 A2S
	300 Amp rating	-	245,000 A2S
	380 Amp rating	-	500,000 A2S
	425 Amp rating	-	845,000 A2S
	500 Amp rating	-	500,000 A2S
	600 Amp rating	-	845,000 A2S
	750 Amp rating	-	1,670,000 A2S
	1000 Amp rating	-	2,815,000 A2S
SCR Voltage Rating:	50-750 Amp Frames:		Peak forward and reverse voltage rating 1600V.
	1000 Amp Frame:		Peak forward and reverse voltage rating 1800V.
SCR DV/DT Rating:	200 volts/usec minimum.
Loads:	Resistive, Variable resistance, Inductive, Capacitive, Transformer or Lamps.
Slew Rate:	200 milli-seconds. (Slew rate is the time required for the load voltage to change 63%
	of the value represented by the command signal. The current limit action will change
	the slew rate if the load current is greater than the current rating of the SCRs.
Frame Size:	The "(Amps)A" term within the model number specifies the maximum continuous
	RMS current rating at the maximum operating ambient temperature of 55°C.

MODEL 3629C

04/10/2007

INSTALLATION

MOUNTING

The 50 Amp model 3629C controller is convection cooled and must be mounted with the fins aligned vertically on a flat surface so that air may pass over the fins. Although larger model 3629C controllers are forced air cooled, it is recommended that all controllers be mounted vertically with power terminals on top. Allow at least 3" of space between controllers for air to enter and exit. The controller should be protected from dust and dirt, and must be located in an environment that does not exceed 55°C.

TRANSFORMER TAPS

If the line voltage input is to be changed, place the three fasten connectors on the transformer taps to correspond with the voltage to be applied.

NOTE: The transformer may fail if all three of the connections to the taps are not correctly placed. All fasten connectors must be moved to the same corresponding voltage tab on each phase as shown in the sample illustration.

POWER CONNECTIONS

The line and load connectors on the various sizes of controllers are rated for use with copper conductors with 90°C or higher insulation. The ratings are calculated for use in a 55°C ambient environment. Multiple connectors are provided in larger controllers to use parallel conductors in each line and load. See Figure 23 and Figure 24 for the 'inline' and 'inside delta' line and load connections.

STARTUP

Before applying power, determine that the transformer taps are in the correct positions, that the power and load wiring is correct, and electrical connections are tight. Set the command to zero and apply power to the controller. As the command signal is increased, the load voltage. It is recommended that the load and the controller be protected with the proper rated fuses. See Replacement Parts section.

SCOTT-T TRANSFORMERS

Excessive voltage transients can occur when operating Scott-T transformers with an open or unloaded secondary. It is recommended that Scott-T transformer be limited to 480 Volts maximum.

DELTA-WYE TRANSFORMERS

It is recommended that a Delta to 4-wire Wye transformer be used to power a 4-wire Wye load. Delta to 3-wire Wye transformers are acceptable, but Wye to Wye transformers are not suited for use between the controller and load due to transient conditions which may occur.

WIRE TERMINAL TORQUE RECOMMENDATIONS

TO AVOID FIRE OR DAMAGE TO EQUIPMENT, DETERMINE THAT WIRE CONNECTIONS ARE TIGHTENED TO THE TORQUE SPECIFICATIONS BELOW AND THE CONNECTION SURFACES ARE FREE OF OXIDATION.

		WIRE LUG INFORMATION					FRAME SIZE 50 & 80 AMPS
	FRAME	LUG		LUG	WIRE SIZE		WIRE SIZE	INCH-LBS
	SIZE (A)	CONNECTIONS					14 to 10 ga	35
	50-80	1 - per LINE/LOAD		USD	#2 - #14
							8 ga	40
	120-160	1 - per LINE/LOAD		CA-6	250MCM - #6
							6 to 4 ga	45
	200-425	2 - per LINE/LOAD		CA-6	250MCM - #6
							3 to 2 ga	50
	500-750	2 - per LINE/LOAD		CA-7	500MCM - #0
							FRAME SIZE 120 TO 1000 AMPS
	1000	4 - per LINE/LOAD		CA-7	500MCM - #0
							WIRE SIZE	INCH-LBS
							6 to 4 ga	100
	RECOMMENDED TIGHTENING TORQUE
							2 to 1 ga	125
	FOR EDGE CARD CONNECTOR:
							1/0 to 2/0	150
	WIRE SIZE (AWG)			TORQUE
							4/0 to 3/0	200
	14 TO 26GA			4.4 - 5.5 IN-LBS
							250 to 350 MCM	250
							500MCM	300
MODEL 3629C								04/10/2007