851 Product Manual

June 2008

Safety Information in this Manual

Danger, Warning, and Caution symbols are used throughout the manual to help identify and avoid hazardous situations. Examples of each symbol are shown and explained below.

DANGER

Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations. It may also be used to alert against unsafe practices. (Color: red)

WARNING

Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. It may also be used to alert against unsafe practices or cause product failure. (Color: orange)

Caution

Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. (Color: yellow)

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Table of Contents Chapter 1........................................................................................1-1

Product Description......................................................................... 1-1 Phase-Angle Control..................................................................... 1-2 Zero-Crossover Control ................................................................ 1-4 Standard Features ........................................................................ 1-7 Optional Features ......................................................................... 1-8 Technical Specifications ............................................................... 1-9 Floating Point Data and Current Range ...................................... 1-10 Part Number ............................................................................... 1-10

Chapter 2........................................................................................2-1

Hardware ........................................................................................ 2-1 Installation..................................................................................... 2-1 Enclosure...................................................................................... 2-1 Enclosure Temperature ................................................................ 2-1 Vibration........................................................................................ 2-1 Mounting ....................................................................................... 2-2 Disconnect Means ........................................................................ 2-2 Wiring............................................................................................ 2-2 Remote Feedback Wiring ............................................................. 2-5 Control Connections ..................................................................... 2-6 Digital Inputs .....................................Error! Bookmark not defined. Digital Outputs .............................................................................. 2-9 Analog Input......................................Error! Bookmark not defined. Analog Output ............................................................................. 2-11 Remote Feedback....................................................................... 2-11 Over-temperature Sensing.......................................................... 2-11

Chapter 3........................................................................................3-1

Configuration................................................................................... 3-1 Startup .......................................................................................... 3-1 Configuration Tool Installation ...................................................... 3-2 Running the Configuration Tool .................................................... 3-3 Configuration Tool Menu and Task Bar Descriptions.................... 3-5 Off-line Programming.................................................................. 3-10 On-line Programming.................................................................. 3-17 On-line Monitor ........................................................................... 3-22 Fault History................................................................................ 3-25

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Flash Programming..................................................................... 3-26 Loss of Communication .............................................................. 3-27

Chapter 4........................................................................................4-1

Calibration....................................................................................... 4-1 Current Rating............................................................................... 4-3 Voltage Rating .............................................................................. 4-3 Remote Voltage and Current Feedback........................................ 4-4 Calibration Procedure ................................................................... 4-5 Saving Calibration......................................................................... 4-7 Restoring Factory Calibration ....................................................... 4-8 Analog Calibration....................................................................... 4-10 Manual Calibration ...................................................................... 4-13 Magnetizing Sequence Calibration ............................................. 4-14 Repetitive Pulse Calibration........................................................ 4-14

Chapter 5........................................................................................5-1

Local Digital Control Option ............................................................ 5-1 Display and Status ........................................................................ 5-1 Normal Mode Operation................................................................ 5-3 Display Select Mode Operation..................................................... 5-7

Chapter 6........................................................................................6-1

Serial Communication ..................................................................... 6-1 Hardware ...................................................................................... 6-1 Serial Protocol – MODBUS RTU................................................... 6-3 Floating Point Data and Current Scaling....................................... 6-5 Additional Serial Information ......................................................... 6-6

Chapter 7........................................................................................7-1

Settings ........................................................................................... 7-1 Voltage Input Rating ..................................................................... 7-1 Voltage Input High Fault ............................................................... 7-1 Voltage Input Low Alarm............................................................... 7-1 Voltage Input Actual...................................................................... 7-1 Voltage Input Span ....................................................................... 7-2 Frequency Rating.......................................................................... 7-2 Frequency Actual .......................................................................... 7-2 Voltage Output Rating................................................................... 7-2 Voltage Output PT Secondary ...................................................... 7-2 Voltage Output Limit ..................................................................... 7-2

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Voltage Output Setpoint................................................................ 7-2 Voltage Output Proportional Gain ................................................. 7-2 Voltage Output Integral Gain ........................................................ 7-2 Voltage Output Derivative Gain .................................................... 7-2 Voltage Output Actual ................................................................... 7-3 Voltage Output Zero...................................................................... 7-3 Voltage Output Span..................................................................... 7-3 Current Input Rating...................................................................... 7-3 Current Input Limit ........................................................................ 7-3 Current Input High Fault................................................................ 7-3 Current Input High Fault Retry Number ........................................ 7-3 Current Input High Fault Retry Time ............................................. 7-3 Current Input Overload Fault ........................................................ 7-3 Current Input Overload Time ........................................................ 7-3 Current Input Actual ...................................................................... 7-4 Current Input Zero......................................................................... 7-4 Current Input Span........................................................................ 7-4 Current Input Threshold Load Failure ........................................... 7-4 Current Output Rating................................................................... 7-4 Current Output Limit...................................................................... 7-4 Current Output Setpoint ................................................................ 7-4 Current Output Proportional Gain ................................................. 7-4 Current Output Integral Gain......................................................... 7-4 Current Output Derivative Gain..................................................... 7-4 Current Output Actual ................................................................... 7-4 Current Output Zero...................................................................... 7-5 Current Output Span..................................................................... 7-5 KVA Input Rating .......................................................................... 7-5 KVA Input...................................................................................... 7-5 Power Output Rating..................................................................... 7-5 Power Output Limit ....................................................................... 7-5 Power Output Setpoint.................................................................. 7-5 Power Output Proportional Gain ................................................... 7-5 Power Output Integral Gain .......................................................... 7-5 Power Output Derivative Gain ...................................................... 7-6 Power Output ................................................................................ 7-6 Power Factor ................................................................................ 7-6 Duty Cycle Output......................................................................... 7-6

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Duty Cycle Setpoint ...................................................................... 7-6 Local Digital Control Display Selection ......................................... 7-6 Local Digital Control Setpoint........................................................ 7-6 Local Analog Setpoint ................................................................... 7-6 Analog Setpoint Zero .................................................................... 7-6 Analog Setpoint Span ................................................................... 7-7 Analog Output Selection ............................................................... 7-7 Analog Output ............................................................................... 7-7 Analog Output Bias ....................................................................... 7-7 Analog Output Span...................................................................... 7-7 Control Word................................................................................. 7-8 Status Word .................................................................................. 7-9 Ramp Up Time.............................................................................. 7-9 Ramp Down Time ......................................................................... 7-9 Configuration Word ..................................................................... 7-10 Control Strategy Selection .......................................................... 7-10 Magnetizing Sequence Calibration ............................................. 7-10 Repetitive Pulse Calibration........................................................ 7-10 Load Type Selection ................................................................... 7-10 Product Type .............................................................................. 7-10 Serial Number ............................................................................. 7-11 Control Power Time On .............................................................. 7-11 Output Time On .......................................................................... 7-11 KW-Hour ..................................................................................... 7-11 Software Version......................................................................... 7-11 Network Loss .............................................................................. 7-11 Network Address......................................................................... 7-11 Network Baud Rate..................................................................... 7-11 MODBUS Address ...................................................................... 7-11 MODBUS Baud Rate .................................................................. 7-12 Network Type.............................................................................. 7-12 Fault Code .................................................................................. 7-12 Fault Index .................................................................................. 7-12 Fault Buffer #1 ............................................................................ 7-12 Fault Buffer #2 ............................................................................ 7-12 Fault Buffer #3 ............................................................................ 7-12 Fault Buffer #4 ............................................................................ 7-12 Fault Buffer #5 ............................................................................ 7-12

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Fault Buffer #6 ............................................................................ 7-12 Fault Buffer #7 ............................................................................ 7-13 Fault Buffer #8 ............................................................................ 7-13

Chapter 8........................................................................................8-1

Troubleshooting .............................................................................. 8-1 Control PCB LED Indicators ......................................................... 8-2 Local Digital Control Option LED Indicators.................................. 8-3 Fault and Alarm Codes ................................................................. 8-3 Fault Reset ................................................................................... 8-6 Fault Buffer ................................................................................... 8-6 Troubleshooting Guide.................................................................. 8-7

Appendix A ...................................................................................A-1

Mechanical Dimensions ..................................................................A-1

Appendix B ...................................................................................B-1

Electrical Drawings..........................................................................B-1

Glossary.............................................................................................i

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List of Figures

Figure 1-1 851 DSPC Schematic Diagram...................................................................1-1 Figure 1-2 Phase-Angle Control Half Cycles................................................................1-2 Figure 1-3 Phase-Angle Duty Cycle Output .................................................................1-3 Figure 1-4 Zero-Crossover Control ..............................................................................1-4 Figure 1-5 Zero-Crossover Current Input Limit.............................................................1-5 Figure 1-6 Zero-Crossover Control Magnetizing Sequence .........................................1-6 Figure 1-7 Zero-Crossover Control Repetitive Pulse....................................................1-6 Figure 2-1 Mounting Dimensions .................................................................................2-2 Figure 2-2 Cover screw locations.................................................................................2-3 Figure 2-3 Input & Output Power Lug locations (200A unit) .........................................2-3 Figure 2-4 Input & Output Power Lug locations (50A unit) ...........................................2-4 Figure 2-5 Remote Feedback Terminal........................................................................2-5 Figure 2-6 Control Connectors .....................................................................................2-6 Figure 2-7 Typical Control Connections .......................................................................2-7 Figure 2-8 Digital Input Schematic ...............................................................................2-8 Figure 2-9 Analog Input Schematic ............................................................................2-10 Figure 2-10 Analog Output Schematic .......................................................................2-11 Figure 3-1 Control PCB LED Location..........................................................................3-1 Figure 3-2 Print Preview Window .................................................................................3-9 Figure 3-3 Configuration Tool.....................................................................................3-11 Figure 3-4 Ratings & Limits Tab.................................................................................3-12 Figure 3-5 Control Configuration Tab.........................................................................3-13 Figure 3-6 Fault Setup Tab ........................................................................................3-14 Figure 3-7 PID Setup Tab ..........................................................................................3-15 Figure 3-8 Network Tab..............................................................................................3-16 Figure 3-9 Configuration Tool On-Line .......................................................................3-18 Figure 3-10 Monitor Window ......................................................................................3-23 Figure 3-11 Fault History............................................................................................3-25 Figure 3-12 Flash Programming.................................................................................3-26 Figure 4-1 Calibration...................................................................................................4-1 Figure 4-2 Remote Feedback.......................................................................................4-4 Figure 4-3 Manual Calibration Window ......................................................................4-13 Figure 5-1 Local Digital Control Panel..........................................................................5-1 Figure 6-1 A 9 Pin to 9 Pin Null Modem Cable Diagram ..............................................6-1 Figure 6-2 A 25 Pin to 9 Pin Null Modem Cable Diagram ............................................6-1 Figure 8-1 Main Control PCB LED indicator location....................................................8-2 Figure 8-2 Local Digital Control ....................................................................................8-3 Figure A-1 50A Model ..................................................................................................A-1 Figure A-2 100A Model ................................................................................................A-2 Figure A-3 200A Model ................................................................................................A-3 Figure B-1 Electrical Schematic ...................................................................................B-3 Figure B-2 - 50A Model ................................................................................................B-4 Figure B-3 - 100A Model ..............................................................................................B-5 Figure B-4 - 200A Model ..............................................................................................B-6

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List of Tables Table 1-1 Technical Specifications...............................................................................1-9 Table 2-1 Wiring Information ........................................................................................2-4 Table 2-2 Digital Interface Plug ....................................... Error! Bookmark not defined. Table 2-3 Relay Contact Ratings .................................................................................2-9 Table 2-4 Analog Interface Plug...................................... Error! Bookmark not defined. Table 3-1 Status Lamp Description ............................................................................3-19 Table 5-1 Display Selections........................................................................................5-2 Table 5-2 Digital Control Status ...................................................................................5-3 Table 5-3 Pushbutton function in Normal mode, Local Digital Control .........................5-4 Table 5-4 Pushbutton function in Normal mode, Local Analog Control ........................5-5 Table 5-5 Pushbutton function in Normal mode, Remote Control ................................5-6 Table 5-6 Pushbutton function in Display Select Mode, Local Control .........................5-7 Table 5-7 Pushbutton function in Display Select Mode, Remote Control .....................5-8 Table 6-1 Serial Port Configuration ..............................................................................6-2 Table 6-2 MODBUS RTU Query (from Master) ............................................................6-3 Table 6-3 MODBUS RTU Read Response (from 851) .................................................6-4 Table 6-4 MODBUS RTU Write Response (from 851) .................................................6-4 Table 6-5 MODBUS RTU Exception Response (from 851)..........................................6-5 Table 6-6 MODBUS RTU Exception Codes .................................................................6-5 Table 7-1 List of Settings..............................................................................................7-1 Table 8-1 Control PCB LED Indicators.........................................................................8-2 Table 8-2 Local Digital Control LED Indicators.............................................................8-3 Table 8-3 Fault and Alarm Codes ................................................................................8-4 Table 8-4 Troubleshooting Guide.................................................................................8-8

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Chapter 1

Product Description

The 851 Digital SCR Power Controller offers the latest in Digital Signal Processing (DSP) technology and software. The 851 is designed for a single-phase application. The 851 uses an advanced, dsp-based firing circuit to control a single phase, two SCR AC Switch. The 851 is capable of firing into either direct or transformer coupled loads. The basic circuit configuration is shown in the figure below.

Figure 1-1 851 DSPC Schematic Diagram

Product Description June 2008

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Phase-Angle Control

In Phase-Angle control, the line is connected to the load for a portion of each half cycle. It is disconnected from the load for the remainder of the half cycle. The period during which the load is connected is varied in response to the control signal providing proportional control of power to the load. A sample picture of Phase-Angle control is shown below.

Figure 1-2 Phase-Angle Control Half Cycles

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Phase-Angle Control Method

The 851 controls its output based on regulation mode. The regulation modes are Open Loop, Voltage Output, Current Output, and Power Output. Each mode regulates to within 1% of rated output. The Current Input Limit is accomplished by comparing the Current Input to the Current Input Limit. If the Current Input exceeds the Current Input Limit the Current Output setpoint is lowered, which in turn will lower the Current Input. A flow diagram of the control is shown below.

Figure 1-3 Phase-Angle Duty Cycle Output

RFI

Phase-Angle control can generate Radio Frequency Interference (RFI). This may, depending upon the installation and magnitude, affect other electronic equipment (computers, telephones, etc.). Where RFI may be a problem, Zero-Crossover control can be used for many of the electric heating applications. The source inductance, load inductance, and circuit impedances determine the amount of RFI generated by Phase-Angle control. Additional components may be required to reduce or eliminate RFI, such as the use of an isolation transformer between the line and the 851 or the addition of line filters.


1-4

Zero-Crossover Control

In Zero-Crossover control, the line is connected to the load for a number of complete cycles. It is then disconnected for a number of complete cycles. This on-off pattern is repeated continuously with the 851 turning on (and off) at the zero crossing of the sine wave. The ratio of the number of cycles ON to the number OFF is varied in response to the control signal providing proportional control of the power to the load. The 851 has predefined the total number of cycles to be 100. Therefore, the cycles ON and the cycles OFF must equal 100. This will allow the output to be set to 1% or 1 cycle out of a 100. A sample picture of the Zero-Crossover control is shown below.

Figure 1-4 Zero-Crossover Control

Zero-Crossover Control Method

The Zero-Crossover control method is based on calculation. The actual voltage output, current output, and power output are calculated every cycle and compared to each respective setpoint. The cycles continue until the calculated feedback exceeds its respective setpoint and then the unit turns off after the next cycle. This necessitates a minimum of two cycles or 2% output since the first cycle is used for calculation and turn off does not occur until after the second cycle.


1-5

Zero-Crossover Current Input Limit

The Zero-Crossover control method controls cycles and can only control Current Input by applying Phase-Angle control to the individual cycles. The Phase-Angle control of the individual cycles will limit the input current, and since the Zero-Crossover control is adaptive, the number of cycles will automatically increase based on the voltage output, current output, and power output setpoints. The Phase-Angle control of individual cycles does eliminate some of the features of the Zero-Crossover control such as high power factor and low RFI. However, it does protect the load by limiting the current that in some cases would be more important than the Zero-Crossover features. A sample picture of the Zero-Crossover control with Current Input Limit is shown below.

Figure 1-5 Zero-Crossover Current Input Limit

Heating Loads

Resistance type heating loads fall into two general categories. The first category consists of heating elements made from materials that exhibit relatively constant resistance whether hot or cold. These include such elements as nichrome, calrod, chromolox and various steels. No particular precautions need be taken in using such materials. The second category consists of elements made from materials that exhibit low initial (cold) resistance such as tungsten, molybdenum, platinum, moly-disilicide, silicon carbide (which ages) and quartz infrared lamps. Such elements require the use of the current limit option that prevents more than a preset value of current from flowing during the initial low resistance condition of the elements.

Zero-Crossover Load Type

The very nature of Zero-Crossover control, firing full cycles of power, tends to cause large inrush currents into the load. This is especially true when transformers are connected to the output. This is because transformers rely on their magnetic field to limit the current, which is present only after current has been flowing for a short time. In order to eliminate this problem from happening, the Load Type setting can be set for Direct Coupled or Transformer Coupled loads.


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Magnetizing Sequence

The Magnetizing Sequence causes the specified number of cycles to start in Phase-Angle control in order to limit the current inrush when the 851 is first turned on. A sample picture of the Zero-Crossover control magnetizing sequence is shown below.

Figure 1-6 Zero-Crossover Control Magnetizing Sequence

Repetitive Pulse

After the cycle has started, the Repetitive Pulse causes only the first cycle to start in Phase-Angle control again in order to limit the current inrush. A sample picture of the Zero-Crossover control Repetitive Pulse is shown below.

Figure 1-7 Zero-Crossover Control Repetitive Pulse


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Standard Features

The 850 Series digital product family offers the following features:

• Flexibility. Configurable operating modes, ratings, limits, external inputs, and setpoints.

• On-Board Diagnostics. Fault memory (the last eight faults are available in fault buffer storage) allows the user to record problems and, through the use of a computer, observe trends that could indicate a need for process modification, troubleshooting or preventative maintenance.

• Computerized Setup and Calibration. RS-232 serial Configuration Tool for setup, digital calibration and diagnostics

• Touch-Proof Mechanical Design prevents unintentional contact with hazardous voltage

• Advanced Process and Fault Monitoring. Real-time monitor of voltage, current, power and fault conditions. Real-time adjustment of the setpoint. Changes can be made any of four different ways:

Locally, using an analog control signal. Locally, using the Configuration Tool software. Locally, with optional Local Digital Control feature. Remotely, with optional Network Communications feature.

• Operates on universal line voltages, from 24 to 600 VAC and 50/60 Hz.

• DSP-based control

• 1600 Volt SCR's

• 20KHZ pulse transformer coupled SCR gating circuit

• 50KHZ digital firing control

• True RMS calculation of voltage, current, and power at 10KHZ sampling

• Simultaneous regulation of voltage, current, and power

• User-configurable analog input

• User-configurable analog output

• Non-volatile storage of all digital settings

• Support of MODBUS RTU protocol

• Support of multiple baud rates on the serial port


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Optional Features

The following optional features are available for the 851:

• Network Interface, allowing for remote control and monitoring of the 851. The networks supported are DeviceNet™, MODBUS (MODBUS RTU protocol), Profibus, and Ethernet (MODBUS TCP protocol).

• Local Digital Control. User has a 4-digit LED display, 12 independent status LEDs and 4 pushbuttons, which allow local control of the 851. The user can control unit output and change the desired set point, as well as monitor voltage, current, or power on the LED display. Fault and alarm conditions are displayed.


1-9

Technical Specifications

Table 1-1 Technical Specifications

Input Line Voltage 24 to 600 VAC RMS

Input Line Frequency 50/60 ± 2 HZ

Current Rating 50 to 600 A; higher ratings are available, consult factory

50 Hz 60 Hz

50/100A - 1,273ARMS 50/100A - 1,336ARMS

200A - 3,111ARMS 200A - 3,267ARMS

Short Circuit Current Rating

600A - 8,839ARMS 600A - 9,281ARMS

50 Hz 60 Hz

50/100A - 16,200 A2sec 50/100A - 14,885 A2sec

200A - 96,800 A2sec 200A - 88,940 A2sec

Fuse I2t Rating

600A - 781,250 A2sec 600A - 717,813 A2sec

Control Voltage 85 to 265 VAC

Control Power 50 VA

Analog Input 0 to 10 VDC or 0 to 20mA (250Ω)

Analog Output 0 to 5 VDC or 0 to 20mA (10V max)

Digital Input 0 to 5 VDC

Regulation 1 %

Isolation to ground 2500 VAC

Ambient Temperature Range 0 to 50ºC


1-10

Floating Point Data and Current Range

Floating point data (data containing a decimal point) in the 851 are stored and transferred (serial, network, etc. send and receive) as 16 bit integers. In order to preserve accuracy, the floating point value is scaled (multiplied) by 10 before being sent. Likewise, floating point data received by the controller are adjusted (divided) by a factor of 10. For example, a Voltage Setpoint equal to 208.7 Volts will be transferred as 2087.

In order to accommodate high numeric values for current and power in the 851, the concept of a Current Range has been implemented.

The low current range is selected by resetting bit 11 of the Configuration Word setting (#97). With the low current range selected, the current range is 0 – 1,000 Amps. The accuracy of current and power values is .1 unit (.1Amp), (.1KW), (.1KVA). Floating point values related to current and power are scaled by a factor of 10 (x10) before transfer.

The high current range is selected by setting bit 11 of the Configuration Word setting (#97). With the high current range selected, the current range is 0 – 10,000 Amps. The accuracy of current and power values is 1 whole unit (1Amp), (1KW), (1KVA); there is no scaling of floating point values related to current or power.

For example, if the unit is configured for high current, and the Current Setpoint is 209 Amps, it will be transferred as 209. Note that only current and power values are affected by the Current Range selection. The Voltage Setpoint referenced above would continue to be transferred as 2087.

Part Number

The Part Number format for the 851 is described below.

851 AAAA 00 00

Product Series

Current Rating: 50A 100A 200A

Product Options: Dx - DeviceNet™

Px - Profibus Ex - Ethernet

x1 - Local Control x2 - Remote Control

Reserved for future use.

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Chapter 2

Hardware

Installation

Prior to installation, the 851 should be carefully checked for shipping and/or handling damage such as loose or broken parts or wires. All covers and panels should be removed for internal inspection and any shipping braces should be removed.

WARNING

The 851 is intended to be mounted in a protective enclosure to prevent the hazard of electrical shock. Unless supplied with an enclosure, it is considered to be a component that must be mounted in an enclosure by the user.

Enclosure

The 851 must be mounted in a protective enclosure to prevent the hazard of electrical shock and also to avoid exposing the circuitry to damaging contaminants. A NEMA 1 enclosure for providing protection from electric shock is available as an option. If the 851 must be located in an area of dust, falling debris, splashing or falling water, adequate protection must be supplied. These conditions necessitate the use of a special NEMA enclosure. Custom NEMA enclosures for the afore-mentioned conditions are also available.

WARNING

An incorrectly applied or installed system can result in component damage or reduction in product life. Wiring or application errors, incorrect or inadequate AC supply, or excessive ambient temperature may result in malfunction of the system.

Enclosure Temperature

The 851 is rated at 50°C maximum ambient temperature. If the 851 is mounted in an enclosure other than one designed and built by Spang Power Electronics, care must be taken to allow sufficient cooling air to the SCR heatsink. Consult the factory for enclosure temperatures above 50°C but less than 65°C.

Vibration

If the mounting site has a vibration concern, the 851 should be mounted using industry standard shock mounting techniques.

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Mounting

The 851 is intended to be mounted in a vertical position, and is provided with mounting flanges on both sides of the unit. Each flange has 5/16” diameter holes at the top, and 5/16″ slots on the bottom. Suitable mounting hardware would consist of a 1/4" bolt, a flat washer, and a lock washer in each of the four mounting holes.

Allow four inches on each side and a minimum of four inches above and below the 851 for adequate cooling. It is recommended that the enclosure exhaust vents be located above the top of the heatsink. Allow additional room for wiring as required by the individual application.

Figure 2-1 Mounting Dimensions

Disconnect Means

It is required that a circuit breaker, fused disconnect or fuses be installed upstream of the 851 for wire protection. Fuses are not necessary if the distribution system current surge rating is limited to below the specification for the unit. Optional semiconductor fuses (externally mounted) are available to prevent surge or transient currents from damaging the semiconductors. The semiconductor fuses are oversized (90A for the 50A unit, 150A for the 100A unit, and 250A for the 200A unit) to prevent nuisance fuse blowing and, for this reason, cannot be used for steady state overload protection.

Wiring

Wire should be sized in accordance with the appropriate specific code guidelines. Ambient operating temperature should be taken into account. All large cables should be routed to allow access to the 851. It is up to the discretion of the installer to allow access room to service the unit.

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The Phillips head cover screws are located at the four corners of the unit, and are removed to open the covers on their inside hinges, providing access to the power wiring terminals.

Figure 2-2 Cover screw locations

The input power lugs are located under the top cover. The output power lugs, the remote feedback terminal block, and the chassis ground lug are located under the bottom cover as shown in the following 2 figures.

Figure 2-3 Input & Output Power Lug locations (200A unit)

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Figure 2-4 Input & Output Power Lug locations (50A unit)

DANGER

The user is responsible for conforming with all applicable local, national, and international codes; wiring practices, grounding, disconnects, and overcurrent protection are of particular importance. Failure to observe this precaution could result in severe bodily injury or loss of life.

Table 2-1 Wiring Information

Unit size Power Lugs Ground Lug Feedback Terminal

Wire Range Screw Head Wire Range Screw Head

Wire Range Screw Head

50A 14-2 [8*] AWG Slotted 14-2 [8*] AWG Slotted 8-24 [14*] AWG Slotted

100A 14-1/0 [2*] AWG Slotted 14-1/0 [8*] AWG Slotted 8-24 [14*] AWG Slotted

200A 6-3/0 [2/0*] AWG ¼ inch hex 14-1/0 [4*] AWG Slotted 8-24 [14*] AWG Slotted

Note: Size in brackets [*] is recommended for 90ºC wire insulation.

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Remote Feedback Wiring

If remote feedback is used, the connections are made to the Remote Feedback Terminal. Current feedback is connected to terminals 1 (+) and 2 (common), and voltage feedback is connected to terminals 3 (X1) and 4 (X2).

Note: The existing current and voltage feedback connections must be removed and insulated before connecting new remote current and voltage feedback to the Remote Feedback Terminal.

The current feedback signal should be about 2.5 Vrms at the rated output current, and the voltage feedback signal should be in the same range as the input voltage. Allowable ranges are 300-600V, 150-300V, 75-150V, 37.5-75V and 24-37.5V.

Figure 2-5 Remote Feedback Terminal

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Control Connections

Control connections are made using the pluggable terminal blocks that are located on the right side of the 851. These terminals accept fine stranded wire up to 12 AWG.

The 851 requires 85-265VAC 50/60Hz @ 50VA control power for the circuit boards and cooling fans. This must be wired to the two-position plug labeled Control Power.

Figure 2-6 Control Connectors

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The following figure shows a typical wiring diagram for control connections.

Figure 2-7 Typical Control Connections

WARNING

This equipment is at line voltage when AC power is connected. Disconnect and lock out all ungrounded conductors of the AC power line. Failure to observe these precautions could result in severe bodily injury or loss of life.

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Digital Interface

The digital interface consists of the nine-position plug labeled Digital Interface. The following table describes each terminal and its default operation. Terminals 1, 3, and 5 provide 15 volts through a 470 Ω resistor in order to develop a 10 volt, 10 mA signal into the appropriate digital input. A typical schematic of the digital inputs follows the table.

Table 2-2 Digital Interface Plug

Terminal Number

Terminal description Standard operation.

1 External Fault power

2 External Fault input

Shorting 1 to 2 provides a external fault input. Open indicates no remote fault.

3 Remote/local power

4 Remote/local input

Shorting 3 to 4 puts the unit into remote mode. Open defaults to local mode.

5 Enable power

6 Enable input

Shorting 5 to 6 enables the unit.

Open inhibits operation.

7 Fault common Fault relay common connection.

8 Fault NC Contact opens when a fault occurs.

9 Fault NO Contact closes when a fault occurs.

Note: Bit 2 of the Configuration word is used to select Normally Open (NO) or Normally Closed

(NC) switch operation for the external fault. The default setting is (NO).

Figure 2-8 Digital Input Schematic

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The digital inputs (Remote/Local, Enable, and External Fault) provide power for each input designed for low voltage contacts or switches. The voltage/current rating of the contact or switch should be 15V and 10mA. If interfacing to automated equipment, it is possible to connect a 10V signal directly into the input without using the power connection.

External Fault Input

One typical use for the External Fault Input would be the micro switch on an external semiconductor fuse. The default state is for a normally open switch to indicate a “normal” condition. It may be programmed by the user for a normally closed switch to indicate a “normal” condition.

Remote/Local Input

The Remote/Local Input is used to select the control mode. Remote control is selected to allow control from the network (when present). The default state (open) is for local control.

Enable Input

The Enable Input is used to provide a local enable/inhibit function. The default state (open) inhibits the unit (prevents the SCR from firing).

Digital Outputs

The digital outputs (Fault – Common, NC, and NO) are relay contacts from a miniature relay on the digital control printed circuit board. It is very important to not exceed the contact ratings listed in the table below.

Table 2-3 Relay Contact Ratings

Load Type Voltage Current

Resistive 125VAC 0.30A

Resistive 30VDC 1.0A

Inductive 125VAC 0.20A

Inductive 30VDC 0.50A

A pilot relay can be used to interface to larger relays or contactors if required.

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Analog Interface

The analog interface consists of the five-position plug labeled Analog Interface. The following table describes each terminal and its default operation.

Table 2-4 Analog Interface Plug

TerminalNumber

Terminal description Standard operation.

1 Analog supply

2 Analog input

3 Analog ground

Connecting a 10k potentiometer with JP2 OFF provides a local analog control. See Figure 2-9.

4 Analog output

5 Analog ground

Provides a configurable analog output of 0-5 volts (JP1 on) or a mA output (JP1 off).

Analog Input

The analog input (Analog Setpoint) is designed to accept potentiometer, voltage, or current inputs. The potentiometer input is designed for a 10K potentiometer that is connected between the Analog Supply, Analog Setpoint, and Analog Ground. The voltage input requires a 0 to 10VDC input to achieve 0 to 100% setpoint. The current input requires a 0 to 20mA input to achieve 0 to 100% setpoint. In order to use the current input, jumper JP2 must be shorted. This connects a 249 ohm resistor into the circuit for the current input to use. It is possible to use a 4 to 20mA current input by utilizing the Analog Setpoint Zero calibration to offset the 4mA input to be 0% setpoint. Also, other voltages and currents less than 10VDC and 20mA are acceptable by utilizing the Analog Setpoint Span calibration to set 100% setpoint.

The Analog Input Circuit. If a mA input signal is desired, Jumper JP2 is inserted to connect the 249 ohm burden resistor. If a 0-5 volt or a 0-10 volt signal is desired, connect the signal source between terminal 2 (+) and 3(-).

Figure 2-9 Analog Input Schematic

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Analog Output

The analog output (Analog Output) is designed to be a current or voltage output. The Analog Output Selection defines what internal signal is connected to the analog output. The analog output will generate 0 to 20mA for 0 to 100% of the selected internal signal. To convert the analog output to voltage, short JP1, which connects a 249 ohm resistor, that converts 0-20mA to 0-5VDC. Alternatively, a 500 ohm resistor can be connected externally that converts 0-20mA to 0-10VDC. Just as on the analog input, the analog output can calibrate the output for different levels by using the Analog Output Bias and the Analog Output Span.

The Analog Output Circuit. If a 5 volt output signal is desired, Jumper JP1 is inserted to connect the 249 ohm burden resistor. If a 10 volt signal is desired, an external 500 ohm resistor should be connected across the output terminals.

Figure 2-10 Analog Output Schematic

Remote Feedback

It is standard for the output voltage and current to be sensed internally. The 851 also provides for a separate voltage and current feedback from a remote source, such as the secondary of a transformer on the output of the 851. An internal terminal board is provided for remote voltage and current feedbacks. The voltage potential transformer (PT) used for the remote voltage feedback must be designed such that the PT output voltage is close to the input voltage of the 851. The Voltage Output PT Secondary setting is used to define the specific PT output connected as a remote voltage feedback. The current transformer (CT) burden resistor must be selected such that 100% current output, defined by Current Output Rating will equal 2.5V. For example, if a CT with a rating of 200A to 5A is used on a 200A 851 unit, the burden resistor would be 2.5V/5A or 0.8 ohms.

Over-temperature Sensing

A temperature sensor is mounted on the heatsink of the 851 to detect and indicate an over temperature condition. The standard temperature sensor is supplied with contacts that are normally closed (NC).

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3-1

Chapter 3

Configuration

Startup

Once the 851 is mounted, and the wiring is in place, apply control power to the unit. It is not necessary for main power to be applied at this time.

DANGER


When control power is applied, check the LED’s on the control board to verify that the power supplies are on and the DSP is operating. At this time the red FAULT LED will be on, the three green power supply status LED’s will be on, and the HEARTBEAT LED will be blinking at about a 1 second rate.

Figure 3-1 Control PCB LED Location

With control power applied and status lights operating properly, the unit is ready for configuration. Configuration is accomplished using the Configuration Tool software running on a host computer, connected to the unit via the Serial Interface Port. In most cases, the unit will be pre-configured at the factory, and only minor changes will be made at the user site.

The Serial Interface consists of a standard DB9 connector (9 pin male), which plugs into the host computer’s serial port using a Null Modem cable. The wiring for typical Null Modem cables is illustrated in the Serial Communication Chapter. Spang offers a null modem cable (P/N 835472005) and a USB to Serial Converter (P/N 835472000) to use with the 851.

WARNING

An incorrectly applied or installed system can result in component damage or reduction in product life. Wiring or application errors, incorrect or inadequate AC supply, or excessive ambient temperature may result in malfunction of the system.

Configuration June 2008

3-2

Configuration Tool Installation

The 851 Configuration Tool is a serial configuration/monitoring tool that runs on a Windows-based PC. The minimum system requirements are:

Windows 98 or higher, 64MB ram, 10MB hard disk space, an available serial port (can use USB to serial converter)

The 851 Configuration Tool allows off-line editing and storage of configuration files. The Configuration Tool also allows on-line, real-time changes to the 851 settings through the serial port. The capabilities of the Configuration Tool include: on-line configuration, setpoint changes, operation, monitoring, calibration, and file storage and retrieval.

The Configuration Tool is delivered on CD-Rom and includes ‘auto-run’ capability. However, should the CD NOT run automatically once inserted into the cd-rom drive, browse for the cd-rom drive, and double-click on the file ‘setup.exe’.

The Configuration Tool default install location is:

C:\Program Files\Spang Power Electronics\ 851 Configuration Tool vxxx

Once successfully installed, the Configuration Tool will be accessible via the Start Menu.

Note: The install process updates the computer’s system registry with the required configuration information.

June 2008 Configuration

3-3

Running the Configuration Tool

Run the Configuration Tool from the start menu:

Start button -> Programs -> Spang Power Electronics -> 851 Configuration Tool vxxx

Click on the [Start] button to continue the Configuration Tool startup (the program will automatically continue after 10 seconds).

At this point the Configuration Tool is off-line, that is, the Tool is not communicating with the 851. The setting values have been read from a setup (.csv) file stored on the computer running the configuration tool.


3-4


3-5

Configuration Tool Menu and Task Bar Descriptions

The 851 Configuration Tool menu bar is shown below, followed by a description of each option.

File Menu

File Menu including the ‘Save Calibration’ menu choice.

The ‘Save Calibration’ menu choice is visible only under certain conditions, and should be used only by authorized service personnel.

File Menu including the ‘Restore Calibration’ menu choice.

The ‘Restore Calibration’ menu choice is visible only under certain conditions, and should be used only by authorized service personnel.

File Option Description

Open Open a standard dialog box listing the configuration files available for loading and editing. (Configuration files are of the form <filename>.csv) and are read from and saved to the host system.

Save Save and close changes made to the configuration file.

Print Open the Print Preview window; display 851 settings in tabular form.

Print Setup Open the standard dialog box that provides the selection of a printer and print characteristics.

Save Calibration Save current calibration values as factory defaults in 851 eeprom.

Restore Calibration

Restore calibration values from factory defaults stored in 851 eeprom.

Exit Close the Configuration Tool


3-6

Com Setup Menu

Com Options Description

Com1 Com2 Com3 Com4 Com5 Com6 Com7 Com8

The Com Setup menu is used to select the serial port on the host computer available for use with the 851.

Window Menu

Window Options Description

Settings Open the Settings Pane. (This is the default upon program entry).

Monitor Establish on-line communication and open the Monitor pane to view 851 operation.

Calibration Establish on-line communication and open the Calibrate pane.

Fault History Open the Fault History window (useful only if on-line).

Flash Programming

Open the Flash Programming window. Intended for use by authorized service personnel only.


3-7

Help Menu

Help Options Description

Manual

About

Open (in a separate browser window) this product manual in pdf format.

Display the version number of the Configuration Tool software.


3-8

Taskbar

The Configuration Tool Taskbar provides shortcuts to frequently used options.

Taskbar Items

Description

Open Folder Same as the File->Open menu option

Floppy Same as the File->Save menu option.

Printer Same as the File->Print menu option.

Monitor Same as the Window->Monitor menu option.

Calibrate Same as the Window->Calibrate menu option.

Settings This button appears on the taskbar if either the Monitor or Calibration window is visible. Same as the Window->Settings menu option.

Fault Same as the Window->Fault History menu option.

Offline/Online Toggle between Off-line programming and On-line communication with the 851. The caption and color of the button indicate the current status of communication between the configuration tool and the 851.

A Red button with an Offline caption indicates No Communication between the Configuration Tool and the 851.

A Yellow button with an Online caption indicates one of two possibilities: the 851 is under Remote (network) Read Only control; or the 851 is under Analog (vs Digital) control).

A Green button with an Online caption indicates Read/Write local communication between the Configuration Tool and 851.


3-9

Print Preview

The File->Print menu selection, or the printer icon on the Taskbar, opens the Print Preview window. The Print Preview window displays a tabular summary of the settings stored in the Configuration Tool.

Figure 3-2 Print Preview Window

Click [Print] to send a copy of the table to the printer port of the host computer.

Click [Close] to exit the Print Preview window.


3-10

Off-line Programming

Off-line programming allows the user to edit 851 settings without actually writing them to the controller. All work is done on the host computer and can be saved.

The Configuration Tool starts in Off-Line Programming mode. The tool opens with the last settings file saved. If there is no saved settings file, the default settings are loaded from the 851default.csv file (included with the configuration tool).

Load/Save the Configuration File

To load a configuration file from the host computer to the Configuration Tool,

● Select the File->Open menu option, (or click the file folder icon on the Taskbar)

● Browse the files in the ‘file open’ dialog, and select the desired configuration (*.csv) file.

The settings as defined in the configuration file are loaded into the Configuration Tool, and can be viewed and/or modified.

To save settings to a .csv file on the host computer,

● Select the File->Save menu option, (or click the floppy icon on the Taskbar)

● Specify <filename>.csv .

The settings currently in the Configuration Tool are written to the specified file on the host computer.


3-11

Configuration Tool Settings Windows

The 851 Configuration Tool window is shown below.

Figure 3-3 Configuration Tool

The left pane is used for general status and control information related to the 851. In Off-line mode, only control information is visible in the left-hand pane:

‘Regulation Mode’ is a drop-down box containing the regulation choices.

‘Local Control’ is a button that toggles between Local Analog and Digital control.

On start up, the right-hand side of the window displays the Settings pane, as read from the latest (or default) configuration file. Settings information is organized into several tabs: Ratings and Limits, Control Configuration, Fault Setup, PID Setup, and Network. Offline programming allows edits to any writable setting, as defined in the Settings Chapter. Read-only settings are indicated by a (cyan) shadowed background and cannot be changed.


3-12

Ratings and Limits Tab

The Ratings and Limits Tab holds the settings for

Voltage Input Rating

*Voltage Output Rating

Voltage Output Limit

*Voltage Output PT Secondary

Power Output Rating - Read Only

Power Output Limit

KVA Input Rating – Read Only

Current Input Rating

Current Output Rating

Current Input Limit

Current Output Limit

Frequency Rating

Ramp Up Time

Ramp Down Time

Current Range

* For a direct-coupled load (Load Type) the Voltage Output Rating and the Voltage Output PT Secondary are Read Only and follow the Voltage Input Rating.

Figure 3-4 Ratings & Limits Tab


3-13

Control Configuration Tab

The Control Configuration Tab holds settings for

Thermostat NC/NO Select

External Fault NC/NO Select

Auto Start on Powerup Enable/Disable

Low Voltage Fault/Alarm Selection

Control Strategy

Load Type

* Magnetizing Sequence

* Repetitive Pulse

Analog Output Selection

Local Digital Display Selection

* Only used for Zero Crossover with transformer coupled load applications.

Figure 3-5 Control Configuration Tab

White fields indicate Read/Write

Cyan fields indicate Read Only information


3-14

Fault Setup Tab

The Fault Setup Tab holds the settings for:

Voltage Input High

Voltage Input Low

Current Input High

Current Input High Retry Number

Current Input High Retry Time

Current Input Overload

Current Input Overload Time

Current Input Threshold Load Failure

Figure 3-6 Fault Setup Tab




3-15

PID Setup Tab

The PID Setup Tab holds the PID settings for

Power Output Voltage Output Current Output

Proportional Gain

Integral Gain

Derivative Gain

Proportional Gain

Integral Gain

Derivative Gain

Proportional Gain

Integral Gain

Derivative Gain

Figure 3-7 PID Setup Tab




3-16

Network Tab

The Network Tab holds settings for

Network Type

Network Baud Rate

Network Address

MODBUS Address

MODBUS Baud Rate

Network Loss Option

Software Version

Serial Number

Figure 3-8 Network Tab




3-17

On-line Programming

On-line programming involves actual serial communication between the configuration tool and the 851. Settings are read from and written to the 851 using a serial protocol described in the Serial Communication chapter. The On-line communication capability of the configuration tool allows real-time monitoring and calibration of the 851.

To establish on-line communication between the Configuration Tool and the 851 unit,

● Connect a standard, 9-pin null modem cable from the serial port of the host computer to the serial port of the 851

● Assign the correct comm port to the configuration tool

● Click [Online/Offline] on the taskbar

If any settings have been modified using the configuration tool offline, the following message will appear:

If settings have been modified offline, either individually or by loading a .csv file, the user has the option of transferring, or writing, the settings stored in the 851 Configuration Tool to the 851. If no modifications have been made, the prompt will not appear.

Click Yes to write settings from the tool to the 851; click No if settings are NOT to be written to the 851.

Depending on the response, the configuration tool will either write its settings to the 851 and then read them all back, or will read all settings from the 851 into the configuration tool. In either case, online communication is established. The On-line indicator turns green in the Tool Bar. Note: If the serial link cannot be established, the following message appears:

Check both ends of the serial connection, make sure that power is applied to the 851 (check LEDs) and click [Online] again. If there is still no communication, with the serial cable connected, cycle power to the unit, and click [Online].


3-18

When the Configuration Tool is communicating on-line with the 851, status, control and setting information is continuously read from the 851 and refreshed in the Configuration Tool. Additional status and control information is visible in the left-hand pane.

It is not necessary to be On-line to review and change the settings – but it is necessary to be On-line to write the changes to the unit. It is also necessary for the Remote/Local switch to be in the Local position for the Configuration Tool to allow on-line changes to the settings.

Figure 3-9 Configuration Tool On-Line


3-19

Status indicators are described in the table below:

Table 3-1 Status Lamp Description

Lamp Color Description

Enable input

Green

Red

The 851 is Enabled

The 851 is Inhibited

Output Status Green

Red

Output is ON

Output is OFF

Remote/Local input Green

Red

Local control is active

Remote (network) control is active

On/Off button Toggles the 851 output

Alert indicator Flashing Yellow

Flashing Red

Indicates an Alarm Condition (described in the message box below the lamps)

Indicates a Fault Condition is present (described in the lower message box)

Note: During normal operation, message reads: No detected faults or alarms

Fault Reset button Click to send a ‘Fault Reset’ to the 851. The 851 will attempt to recover from the alert condition. If recovery is accomplished, normal operation will resume.

On-Line Navigation and Changes

To edit settings:

• Press [Tab] or [Enter] to move forward and select a setting • Press [Shift+Tab] to move backward and select a setting • Double-click the mouse over a setting to select it • Once selected, enter the desired setting value or click a choice from the drop down list • Press [Tab], [Enter] or click outside setting • Press [Escape] to cancel.

When a change is made to a setting, the following prompt appears:


3-20

A Yes response to the message prompts the Configuration Tool to write the setting to the 851. If unsuccessful, an error message may appear, and the setting reverts to its previous value.

Factors Affecting Write Capability

Write capability from the configuration tool to the 851 is affected by several factors:

No writes are accepted from the configuration tool to the 851 if the Remote/Local input is in Remote. The 851 must be in Local mode to enable Configuration Tool control.

The Configuration Tool is considered to be a source of Local Digital control to the 851. If the 851 is operating under Local Analog control, setpoints cannot be written from the Configuration Tool to the 851. The following prompt will appear:

In order to write a setpoint from the Configuration Tool to the 851, the unit must be under Local Digital control.


3-21

The 851 settings related to actual 851 status, such as voltage out, power out, current out, etc, are Read Only, and cannot be written under any circumstances.

Rating information, PT Secondary, frequency, Control strategy, Load Type, zero calibration, and magnetic sequencing can be written only when the 851 output is off.

Voltage Output Span and Current Output Span can be written only when the 851 output is on.

When a setting cannot be written the following message appears:

Refer to the Settings Chapter for programming factors specific to each setting.


3-22

On-line Monitor

The Monitor mode provides a real-time view of 851 operation. Each setting in the Monitor pane is updated approximately every 2 seconds.

To access the on-line Monitor mode, select the Window Monitor menu item, or click [Monitor] on the Taskbar.


3-23

The Monitor Window includes the following data

Duty Cycle Setpoint

Duty Cycle Output

Power Output Setpoint

Power Output

Voltage Input

Voltage Output Setpoint

Voltage Output

Current Input

Current Output Setpoint

Current Output

Analog Input

KVA Input

Power Factor

Frequency Actual

KiloWatt Hours

Control Power Time On

Output Time On

The [Zero] button, when clicked, sets the accumulated time to zero.

Figure 3-10 Monitor Window


3-24



Green field indicates regulation mode

The operating setpoint for each of the regulation modes is shown in the middle column. The setpoint associated with the selected regulation mode is displayed with a green background.

To change a setpoint:

● Select the setpoint to change and enter the desired value

● Press [Enter] or click outside the field to write the new setpoint.

• Setpoints can be modified only under Local DIGITAL control.

• Modified setpoints are italicized until written to the 851.

• Press the [Escape] key to cancel.

• The Duty Cycle Setpoint cannot be written unless Open Loop regulation mode is selected.

• The setpoint associated with the selected regulation mode is the control setpoint. The other setpoints become operating limits of their respective control loops.


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Fault History

The fault history lists the last eight faults recorded by the 851. The information is read from the 851 and displayed in tabular form.

To access the on-line Fault History mode, select the Fault History menu item, or click [Fault] on the Taskbar.

Figure 3-11 Fault History

Included in the Fault History table is the fault code, a description, and time (in hours) of the fault.

Click the [Print] button to send a copy of the information to the printer port of the host computer.

Click the [Close] button to close the Fault History window and return to the previous window.

With JP3 installed, click the [Zero] button to clear the fault buffers.


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Flash Programming

WARNING

During flash programming, an interruption in the serial communication, either by loss of power or a disconnected serial cable, will corrupt the 851 flash memory. This will require the 851 to be sent back to the factory for programming.

The Flash Programming function is available to authorized service personnel only and is used to update the 851 software.

Figure 3-12 Flash Programming


3-27

Loss of Communication

Momentary loss of communication between the Configuration Tool and 851 results in the most-recently-read setting to be displayed on a Red background. Subsequent communication recovery restores the normal background color.

If serial communication is not recovered within a reasonable time, the configuration tool will go Offline.


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4-1

Chapter 4

Calibration

Proper calibration of the 851 validates the values displayed on the Local Digital Control panel and made available over the network interface. Unit calibration also validates the analog signal levels. The feedback signal levels correlate to the internal gain capability of the 851. Changing the Voltage/Current Ratings or the Analog Input/Output signal levels requires recalibration.

Figure 4-1 Calibration

Calibration June 2008

4-2

The [Cal Enable] button must be clicked to enable calibration of voltage and current measurements.

Voltage Calibration

Voltage Output Zero

Voltage Input Span

Voltage Output Span

The [Zero] button, when clicked, uses the actual control reading and the zero adjustment, as currently set, to calculate a new zero adjustment. The result is an incremental change.

The [Set] button, when clicked, uses the actual control reading, the measured signal (meter reading), and the span adjustment, as currently set, to calculate a new span adjustment. The result is an incremental change.

Current Calibration

Current Input Zero

Current Output Zero

Current Input Span

Current Output Span



Analog Input/Output Calibration

Analog Setpoint Zero Analog Setpoint Span



Analog Output Bias Analog Output Span

Check the Enable box for Analog Output Calibration. Use the slide bars to adjust Analog Output Bias and Span. Uncheck the Enable box after Analog Output Calibration

June 2008 Calibration

4-3

Current Rating

The current feedback signal (at rated current) of the 851 must be between 1.25Vrms and 2.85Vrms. The typical unit is setup for a current feedback signal level of 2.50Vrms using the burden resistor of the current transformer. Standard units have the following burden resistors and feedback signals.

Unit Size CT Burden Resistor Feedback Signal

50A 1000:1 49.9Ω 2.50Vrms

100A 2000:1 49.9Ω 2.50Vrms

200A 3000:1 39.2Ω 2.61Vrms

Since the feedback signal on the standard unit is set to 2.5Vrms for the rating of the unit, changing the rating to 50% would reduce the feedback signal to 1.25Vrms. This is the lowest that the rating can be changed without also changing the current transformer burden resistor.

If, for example, it is desired to change the 50A unit to a 10A unit, the burden resistor should be changed so that the current feedback signal will produce 2.5Vrms when the primary current is 10A. Since the secondary current at 10A is 10/1000 = 10mA, the resistor should be:

2.5 / 10mA = 250Ω The nearest standard value 1% resistor is 249Ω. The power in the resistor at rated current is (10mA)2 x 249 = 24.9mW, so a resistor with a power rating of 50mW or greater is required. A 1/4W or a 1/2W resistor should be used so that it will properly fit in the connector (J10, terminals 1 and 4). The actual voltage produced at rated current will be:

10/1000 x 249 = 2.49Vrms

Voltage Rating

The voltage feedback signal of a unit must be between 24Vrms and 600Vrms. The voltage sense circuit automatically sets the hardware gain of the sensed voltage in the following ranges:

Voltage Rating

300 to 600

150 to 300

75 to 150

37.5 to 75

24 to 37.5


4-4

Remote Voltage and Current Feedback

The standard unit uses the same current feedback signal for both the input and output current. If an output current transformer is used with the 851, the existing current feedback signals must be removed and insulated before the remote current feedback signal can be connected to the Remote Feedback Terminal provided on the 851. The internal voltage feedback signals must also be removed and insulated before a remote voltage feedback can be connected to the Remote Feedback Terminal. The terminals are shown below.

If remote feedback is used, the feedback connections are made to the Remote Feedback Terminal. The Current Output feedback signal is connected to terminals 1 (+) and 2 (common), and Voltage Output feedback signal is connected to terminals 3 (X1) and 4 (X2).

Note: The existing current and voltage feedback connections must be removed and insulated before connecting new remote current and voltage feedback to the Remote Feedback Terminal.

The Current Output feedback signal should be 2.5Vrms at the rated output current, and the Voltage Output feedback signal should be in the same range as the Voltage Input feedback signal. Allowable ranges are 300-600V, 150-300V, 75-150V, 37.5-75V and 24-37.5V.

Figure 4-2 Remote Feedback


4-5

Calibration Procedure

WARNING

An incorrectly applied or installed system can result in component damage or reduction in product life. Wiring or application errors, or improper calibration may result in malfunction of the system.

To calibrate the 851, the unit must be connected to its rated input source, have control power on, and have a load attached to the unit. The unit must be under local digital control. Open the Configuration Tool and establish serial communication with the unit.

Click on the [Calibrate] button to open the 851 Calibration window. Click the [Cal Enable] button to enable the function of the [Set] and [Zero] buttons for all but the analog input. [Zero] is active when the unit output is off, [Set] is active when the unit output is on. Click [Zero] to correct for any bias/noise; click [Set] to change the reading of non-zero voltage or current values.


4-6

To calibrate the voltage and/or current, it is recommended that the unit be turned on in “open loop” regulation mode at the highest practical operating point (set the duty cycle to 100% on the Monitor Screen if possible). Measure the voltage and current and enter the values obtained in the column labeled “Meter Reading”, then click the [Set] button next to the value entered.

Note: If calibration is necessary because of the addition of remote monitoring, set the Load Type

to “Transformer-Coupled”, and calibrate the unit to the actual signals being measured. The output voltage may be different from the input voltage, as may the current.


4-7

Saving Calibration

If desired, the new calibration may be saved in the 851 as the “Factory Default” calibration. The unit must be on line, with the calibration window open. With control power turned on, install jumper JP3. JP3 is a two-position jumper located immediately above connector J12 at the bottom of the control board.

From the File menu, select “Save Calibration”.


4-8

A dialog box will open asking if you want to replace the calibration defaults. Click [YES] to replace the default calibration settings with the new calibration settings.

Remove the jumper (JP3), and the unit is ready for operation.

Restoring Factory Calibration

To recalibrate the unit using the stored calibration values, the unit must be on line, with the settings window open. With control power turned on, install jumper JP3.


4-9

From the File menu, select “Restore Calibration”.

A dialog box will open asking if you want to restore calibration using the stored defaults. Click [YES] to write the default calibration settings to the unit.

Remove the jumper (JP3), and the unit is ready for operation.


4-10

Analog Calibration

Analog signal settings are adjusted on-line in an iterative process to assure accurate signal readings and optimal 851 performance.

If the analog input is used, it should be calibrated for the individual installation. To do this, both the control power and the main input voltage must be present. In the Configuration Tool program, open the Calibrate window.

If the analog input is derived from a 10K potentiometer, simply turn the pot full counterclockwise and “zero” the input by clicking the Analog In [Zero] button with the mouse pointer. Then turn the pot full clockwise, enter the number 100 in the Gain Setting box, and click the [Set] button with the mouse pointer. Alternately, click the [Zero] button with the pot turned down, and the [Set] button with the pot turned up until the readings are consistent (about 2 or 3 times).

If the analog input is a 4 – 20 mA signal, install jumper JP2 for 4 - 20 mA to terminals 2 and 3, set the input to the minimum setting (4 mA) and select the [Zero] button. Then set the input to the maximum setting (20 mA), enter 100 in the Gain Setting box, and click the [Set] button with the mouse pointer. Again, repeat the minimum “Zero” and maximum “Set” selections until the readings are consistent.

This calibration method causes the input to control to 100% of the rating with full input. If a control point other than the rating is required at full input, then enter the percent of the control setpoint divided by the rating. For example, if the analog input is a current setpoint, controlling 0-40A on a 50A unit, enter 80 (this equals 40/50*100) when maximum input signal is present.


4-11

To calibrate the analog output, set the analog output source to the analog setpoint. It allows a full range of signal settings without having to actually power up the unit. Once calibrated, the analog output source can be changed to whichever variable is desired.

If the maximum analog output is less than the rating, set the analog reference (input) as the percentage of the analog output variable divided by the rating. For example, if the analog output is output current, controlling 0-40A on a 50A unit, set the analog reference to 80 (this equals 40/50*100) to represent maximum current output.


4-12

Check the Analog Output Enable box in the Calibrate window.

If the Analog Output is to be calibrated for a 0-5V output (as it may be for a typical digital meter), insert jumper JP1 and turn on the unit (both control power and main power). Since there is no “bias” setting, leave the “bias” adjustment at zero. Turn the analog reference signal to maximum and adjust the “gain” slider until you obtain exactly 5 volts on the analog output (terminals 4 to 5 on the analog interface plug).

If the Analog Output is to be calibrated for a 4-20 mA signal, leave JP1 off and terminate the output into a suitable burden (maybe a milli-ammeter). With the analog input set at zero, adjust the “bias” slider until you read 4 mA on your meter. Then set the analog input for maximum, and adjust the “gain” slider until you read 20 mA on your meter.

Other outputs (0 – 10V, 0 – 5V, 0 – 1mA, etc.) are done in the same fashion, using a suitable termination for the signal required. The maximum output of the circuit is about 24 mA at 100% input.


4-13

Manual Calibration

WARNING

An incorrectly applied or installed system can result in component damage or reduction in product life. Wiring or application errors, or improper calibration may result in malfunction of the system.

Direct entry of calibration values is possible from the Manual Calibration window of the 851 Configuration Tool. To open the Manual Calibration window, insert jumper JP3, select Calibration in the Config Tool, and press the [Manual] button. The Manual Calibration window is shown below:

Figure 4-3 Manual Calibration Window

Note the choices available for manual calibration:

Read from CSV File – open a .csv file stored on the host computer and read the calibration values.

Read from 851 Unit – read the current calibration values from the 851.

Calculate Defaults – Calculate new calibration values based on the voltage and current ratings.

Write to 851 Unit – Write all of the displayed calibration values to the 851.

Close the manual calibration window.


4-14

Magnetizing Sequence Calibration

Setting number 99 is the Magnetizing Sequence Calibration, which is used for zero-crossing control into a transformer load.

The purpose of this setting is to soft start a transformer load when first powered up. The setting defines the amount of phase control cycles which will occur during the first on cycle of zero-crossing control. A minimum setting of 3 will usually keep the inrush current within acceptable limits. If the inrush current is too high, increase the Magnetizing Sequence until the inrush current is within acceptable limits.

Repetitive Pulse Calibration

Setting number 100 is the Repetitive Pulse Calibration, which is used for zero-crossing control into a transformer load.

The Repetitive Pulse represents a phase delay of the first on cycle during zero-crossing control. After the cycle has started, the Repetitive Pulse causes only the first cycle to start in Phase-Angle control in order to limit the current inrush. The setting is expressed as the percentage of the total cycle passed through to the load.

In order to tune the Magnetizing Sequence and Repetitive Pulse, it is desirable to have some means of observing the current. Using the Configuration Tool program, turn the unit on with a duty cycle of between 10 and 50%. Start with the pulse setting at about 50%. If the inrush current is too high, adjust the pulse setting either higher or lower until the inrush current is within acceptable limits.

5-1

Chapter 5

Local Digital Control Option

The Local Digital Control Option is an add-on display/control interface. It is used in one of two modes and provides a four-digit numeric display, twelve LED’s and four pushbuttons that allow local control of the 851. The Local Digital Control Panel is shown below.

Figure 5-1 Local Digital Control Panel

Display and Status

The four-digit numeric display is used to display a selected setpoint or output. It is also used to indicate alert conditions and special programming modes. There are four LED's to the right of the numeric display, and two below it. The LED’s describe the information shown on the numeric display, and are summarized in the following table:

Local Digital Control Option June 2008

5-2

Table 5-1 Display Selections

If this LED is lit Setting #76 equals … Display Selection Description

Volts Output

1 Voltage Output (V) Voltage Output Actual in volts.

Amperes Output

2 Current Output (A) Current Output Actual in amps.

Kilowatts Output

3 Power Output (KW) Power Output in kilowatts

Setpoint Volts, Amps, or Kilowatts

4 Regulation Mode Setpoint (unit)

Voltage Setpoint, Current Setpoint or Power Setpoint in appropriate units

Volts % of Rated

Output

5 Voltage Output (%) Voltage Output Actual as % of rated voltage.

Amps % of Rated

Output

6 Current Output (%) Current Output Actual as % of rated current.

Kilowatts % of Rated

Output

7 Power Output (%) Power Output as % of rated power.

Setpoint % of Rated

Volts, Amps, or Kilowatts

8 Regulation Mode Setpoint (%)

Voltage Setpoint, Current Setpoint or Power Setpoint as % of appropriate rating

June 2008 Local Digital Control Option

5-3

The six status LED’s are summarized in the following table.

Table 5-2 Digital Control Status

LED Condition Description

Remote Status On

Off

The Remote/Local input is in the Remote state.

The Remote/Local input is in the Local state.

Enable Status On

Off

The Enable/Inhibit input is in the Enable state.

The Enable/Inhibit input is in the Inhibit state.

Analog Status On

Off

The Local mode is set to Analog, and the Remote/Local input is in the Local state.

The Local mode is set to Digital, or the Remote/Local input is in the Remote state.

Digital Status On

Off

The Local mode is set to Digital, and the Remote/Local input is in the Local state.

The Local mode is set to Analog, or the Remote/Local input is in the Remote state.

On Status On

Off

The output is active.

The output is off.

Alert Status On

Off

Either a fault or alarm is present.

No detected fault or alarm.

Normal Mode Operation

Normal mode operation depends on two factors: the Remote/Local input, and the Analog/Digital control status. If the unit is under Local Digital Control, the four pushbuttons are used to increment/decrement the regulation mode setpoint, toggle the unit output, and toggle the control mode from digital to analog (and vice-versa). Normal operation under Local Digital Control is summarized in the following table:


5-4

Table 5-3 Pushbutton function in Normal mode, Local Digital Control

Display Selection Up/Down Button Select Button On/Off/Reset Button

Voltage Output (V) Display the Regulation Mode Setpoint in units; Increment/Decrement the Regulation Mode Setpoint

Press and Hold to toggle local Analog/Digital control

Toggle the unit On/Off

Current Output (A) Display the Regulation Mode Setpoint in units; Increment/Decrement the Regulation Mode Setpoint



Power Output (KW) Display the Regulation Mode Setpoint in units; Increment/Decrement the Regulation Mode Setpoint



Regulation Mode Setpoint (units)

Increment/Decrement the Regulation Mode Setpoint



Voltage Output (%) Display the Regulation Mode Setpoint as % of rated; Increment/Decrement the Regulation Mode Setpoint



Current Output (%) Display the Regulation Mode Setpoint as % of rated; Increment/Decrement the Regulation Mode Setpoint



Power Output (%) Display the Regulation Mode Setpoint as % of rated; Increment/Decrement the Regulation Mode Setpoint



Regulation Mode Setpoint (%)

Increment/Decrement the Regulation Mode Setpoint



Pushbutton functions vary slightly under Local Analog Control. The setpoint can be viewed but cannot be changed. Normal operation under Local Analog Control is summarized in the following table:


5-5

Table 5-4 Pushbutton function in Normal mode, Local Analog Control


Voltage Output (V) Display the Regulation Mode Setpoint in units



Current Output (A) Display the Regulation Mode Setpoint in units



Power Output (KW) Display the Regulation Mode Setpoint in units




Display the Regulation Mode Setpoint in units



Voltage Output (%) Display the Regulation Mode Setpoint as % of rated



Current Output (%) Display the Regulation Mode Setpoint as % of rated



Power Output (%) Display the Regulation Mode Setpoint as % of rated




Display the Regulation Mode Setpoint as % of rated




5-6

If the unit is under Remote Control, the pushbuttons are inoperable, as summarized in the following table.

Table 5-5 Pushbutton function in Normal mode, Remote Control


Voltage Output (V) No action No action No action

Current Output (A) No action No action No action

Power Output (KW) No action No action No action


No action No action No action

Voltage Output (%) No action No action No action

Current Output (%) No action No action No action

Power Output (%) No action No action No action


No action No action No action


5-7

Display Select Mode Operation

To enter Display Select mode, press the [SEL] pushbutton. Entry into the Display Select mode is indicated by the characters ‘SEL’ in the four-digit numeric display. In this mode, the [Up Arrow] and [Down Arrow] pushbuttons increment/decrement the Local Digital Control Display Selection. Display Select mode operation is summarized in the following tables:

Table 5-6 Pushbutton function in Display Select Mode, Local Control


Voltage Output (V) Increment/Decrement the display selection

Exit Display Select mode Toggle the unit On/Off; exit Display Select mode

Current Output (A) Increment/Decrement the display selection


Power Output (KW) Increment/Decrement the display selection



Increment/Decrement the display selection


Voltage Output (%) Increment/Decrement the display selection


Current Output (%) Increment/Decrement the display selection


Power Output (%) Increment/Decrement the display selection






5-8

Table 5-7 Pushbutton function in Display Select Mode, Remote Control


Voltage Output (V) Increment/Decrement the display selection

Exit Display Select mode Exit Display Select mode

Current Output (A) Increment/Decrement the display selection


Power Output (KW) Increment/Decrement the display selection





Voltage Output (%) Increment/Decrement the display selection


Current Output (%) Increment/Decrement the display selection


Power Output (%) Increment/Decrement the display selection





6-1

Chapter 6

Serial Communication

Hardware

The serial port of the 851 is a standard, male, DB-9 connector. The hardware connection between a standard PC COM port and the 851’s serial port is a null modem style link, shown below. Only pins 2, 3 and 5 (Receive, Transmit and Ground) of the DB-9 connector are needed to communicate; pins 7 and 8 (Request to Send and Clear to Send) are optional and provided for PC hardware handshake (fixed in the SEND OK state).

Figure 6-1 A 9 Pin to 9 Pin Null Modem Cable Diagram

Figure 6-2 A 25 Pin to 9 Pin Null Modem Cable Diagram

Serial Communication June 2008

6-2

The setup of the serial port is described below.

Table 6-1 Serial Port Configuration

Baud Rate 4800, 9600, or 19200 baud

Parity None

Length 8 bits

Stop 2 bits

Handshake None

The default serial baud rate is 19200. The baud rate is accessible as setting #117, and can be modified either with the Configuration Tool or through the (remote) network connection. In either case, the new baud rate setting will take effect only after control power to the 851 is cycled.

The Configuration Tool will detect baud rate automatically when on-line communication is established with the 851.

June 2008 Serial Communication

6-3

Serial Protocol – MODBUS RTU

The MODBUS RTU protocol is a query/response or master/slave protocol. The 851 acts as a slave in the MODBUS master/slave relationship. The MODBUS query and response are summarized in the following tables.

Table 6-2 MODBUS RTU Query (from Master)

Byte Field Name Description

1 Slave Address 851 MODBUS address, from setting #116, or 0 for a broadcast message.

2 Function MODBUS function code, 3 (read) or 6 (write).

3 Address High Always 0

4 Address Low 851 setting number.

5 # Points High (read) Data High (write)

Always 0 (read); High byte of 16-bit value to be written (write).

6 # Points Low (read) Data Low

Always 1 (read); Low byte of 16-bit value to be written (write).

7,8 Error Check 16-bit CRC, low byte first


6-4

Table 6-3 MODBUS RTU Read Response (from 851)


1 Slave Address 851 MODBUS address, from setting #116.

2 Function MODBUS function code 3 (read).

3 Byte count Always 2

4 Data High High byte of 16-bit value read.

5 Data Low Low byte of 16-bit value read.


Table 6-4 MODBUS RTU Write Response (from 851)



2 Function MODBUS function code 6 (write).

3 Address High Always 0

4 Address Low 851 setting number.

5 Data High High byte of 16-bit value written (echo).

6 Data Low Low byte of 16-bit value written (echo).


June 2008 Serial Communication

6-5

When a message is received correctly (no communication errors, CRC checks out), but cannot be executed, the 851 will generate an exception (error) response. No response is generated for a message received incorrectly, or incompletely. No response is generated for broadcast messages.

Table 6-5 MODBUS RTU Exception Response (from 851)



2 Function MODBUS function code plus exception indication (80 hex).

3 Exception code MODBUS exception code.


The 851 supports the following MODBUS exception codes:

Table 6-6 MODBUS RTU Exception Codes

Exception Code Description

01 Illegal function

02 Illegal data address (setting number).

03 Illegal data value.

Floating Point Data and Current Scaling

Floating point data (data containing a decimal point) are transferred as 16 bit integers. In order to preserve accuracy, the floating point value is scaled (multiplied) by 10 before transfer. Likewise, floating point data received by the controller are adjusted (divided) by a factor of 10. For example, a Voltage Setpoint equal to 208.7 Volts will be transferred as 2087

An exception to floating point scaling occurs with the use of the High Current Range (bit 11, Configuration Word). If the unit is configured for ‘Current Range 0 – 10,000Amps’, the accuracy of current and power values is 1 whole unit (1Amp, 1KW, 1KVA). Such data is not scaled before transfer. For example, if the unit is configured for ‘0 – 10,000 Amps’, and the Current Setpoint is 209 Amps, it will be transferred as 209. Note that only current and power values are affected by the Current Range selection. The Voltage Setpoint referenced above would continue to be transferred as 2087.


6-6

Additional Serial Information

Settings that are longer than two bytes (such as Serial Number) must be read with two individual transactions. The higher order word (2 bytes) is specified by the Setting number listed in settings table, and the lower order word is specified by the Setting number plus 1. Care must be taken when reading four byte time values to check for lower order word overflow during the serial read operation, which would result in an invalid time value.

Error responses do not stop 851 operation.

Message bytes are sent and received as binary values, and not as ASCII characters.

Serial control of the unit is enabled when the Local/Remote switch is in LOCAL mode. 851’s without a local digital control option installed will revert to local Analog control unless serial messages are received at a rate of at least one message per every 1.5 seconds.

The serial link can be used to monitor values when serial control is not enabled. This includes when the unit is being controlled remotely under network control or when the unit is being controlled locally under analog control.

7-1

Chapter 7

Settings

Caution

The 851 is configured using the programmable settings. Programming the settings incorrectly can cause the 851 to exhibit intermittent or full output conditions.

The following table summarizes the settings of the 851. It is important to note that current scaling affects the accuracy and limits of certain settings.

If the High Current Scale is selected (bit 11, setting #97), the accuracy of current settings is 1 Amp, the minimum allowable value is 10x the minimum listed in the table, and the maximum allowable value is 10x the listed maximum.

If the High Current Scale is selected, the accuracy of KVA and power settings is 1 KVA and 1 KW, respectively. The minimum allowable value is 10x the minimum listed in the table, and the maximum allowable value is 10x the listed maximum.

The settings that are affected by current scaling have a (Ix10) note.

Table 7-1 List of Settings

Setting No. Units Description

Voltage Input Rating

Read/Write Condition: Off Default: 480.0V

1 Vrms Min: 0.0 Max: 600.0

The input rating of the voltage supplied to the 851.

Voltage Input High Fault

Read/Write Condition: All Default: 576.0V

2 Vrms Min: 0.0 Max: 750.0

The level compared to Vinrms that causes a high voltage fault. It is limited to 125% of the Voltage Input Rating. Fault operation is further described in the Troubleshooting Chapter.

Voltage Input Low Alarm


3 Vrms Min: 0.0 Max: 600.0

The level compared to Vinrms that causes a low voltage alarm. It is limited to 100% of the Voltage Input Rating. Fault operation is further described in the Troubleshooting Chapter.

Voltage Input Actual

Read only 5 Vrms Vinrms

Settings June 2008

7-2


Voltage Input Span

Read/Write Condition: All Default: Factory

6 Bits Min: 2000 Max: 16000

Digital span adjustment of the voltage input signal. Calibration is described in the Calibration Chapter.

Frequency Rating

Read/Write Condition: Off Default: 60.0Hz

12 Hertz Min: 50.0 Max: 60.0

The input line frequency rating.

Frequency Actual

Read only 13 Hertz Calculated input line frequency.

Voltage Output Rating


14 Vrms Min: 0.0 Max: 2000.0

The output rating of the voltage being controlled by the 851.

Voltage Output PT Secondary


15 Vrms Min: 0.0 Max: 600.0

The secondary voltage of an external voltage Potential Transformer (PT). It is set equal to the Voltage Output Rating if no PT is used. It is very important that this setting be in the same calibration range as the Voltage Input Rating for proper operation.

Voltage Output Limit


16 Vrms Min: 0.0 Max: 2500.0

The maximum voltage the voltage output PID control will limit to. It is limited to 125% of the Voltage Output Rating.

Voltage Output Setpoint


17 Vrms Min: 0.0 Max: 2500.0

The setpoint for the voltage output PID control. It is limited to 100% of the Voltage Output Limit.

Voltage Output Proportional Gain

Read/Write Condition: All Default: 10.0%

18 % Min: 0.0 Max: 100.0

Voltage output control proportional gain.

Voltage Output Integral Gain


19 % Min: 0.0 Max: 100.0

Voltage output control integral gain.

Voltage Output Derivative Gain


20 % Min: 0.0 Max: 100.0

Voltage output control derivative gain.

June 2008 Settings

7-3


Voltage Output Actual

Read only 21 Vrms Voutrms

Voltage Output Zero

Read/Write Condition: Off Default: Factory

22 Bits Min: 0 Max: 100

Digital zero adjustment of the voltage output signal. Calibration is described in the Calibration Chapter.

Voltage Output Span


23 Bits Min: 2000 Max: 16000

Digital span adjustment of the voltage output signal. Calibration is described in the Calibration Chapter.

Current Input Rating

Read/Write Condition: Off Default: 200.0A

31

Irms Min: 0.0 Max: 1500.0 (Ix10)

The input rating of the current to the 851.

Current Input Limit

Read/Write Condition: All Default: 200.0A

32

Irms Min: 0.0 Max: 2250.0 (Ix10)

The maximum current input the 851 will allow to run continuously. It is limited to 150% of the Current Input Rating.

Current Input High Fault


33

Irms Min: 0.0 Max: 5250.0 (Ix10)

The level compared to the peak of Iinrms that causes an over current fault. It is limited to 350% of the Current Input Rating. Fault operation is described in the Troubleshooting Chapter.

Current Input High Fault Retry Number

Read/Write Condition: All Default: 0

34 Selection Min: 0 Max: 5

The number of retries for the Current Input High Fault before the fault is latched. Fault operation is described in the Troubleshooting Chapter.

Current Input High Fault Retry Time

Read/Write Condition: All Default: 10Sec

35

Seconds Min: 10 Max: 360

The time limit for fault retries before the fault will latch. Fault operation is described in the Troubleshooting Chapter.

Current Input Overload Fault


36

Irms Min: 0.0 Max: 3750.0 (Ix10)

The level compared to Iinrms that causes a timed current fault. It is limited to 250% of the Current Input Rating. Fault operation is described in the Troubleshooting Chapter.

Current Input Overload Time

Read/Write Condition: All Default: 10.0Sec

37 Seconds Min: 0 Max: 360

The time limit on the current input overload level before a fault occurs. Fault operation is described in the Troubleshooting Chapter.

Settings June 2008

7-4


Current Input Actual

Read only 41 Irms

(Ix10) Iinrms

Current Input Zero



Digital zero adjustment of the current input signal. Calibration is described in the Calibration Chapter.

Current Input Span

Read/Write Condition: On Default: Factory

43 Bits Min: 2000 Max: 16000

Digital span adjustment of the current input signal. Calibration is described in the Calibration Chapter.

Current Input Threshold Load Failure


51

Irms Min: 0.0 Max: 120.0 (Ix10)

Ifailrms – The current used to determine a load failure. It is limited from 2% to 10% of the Current Input Rating. Fault operation is described in the Troubleshooting Chapter.

Current Output Rating

Read/Write Condition: Off Default: 200.0A

52

Irms Min: 0.0 Max: 3000.0 (Ix10)

The output rating of the current being controlled by the 851.

Current Output Limit


53

Irms Min: 0.0 Max: 4500.0 (Ix10)

The maximum current the current output PID control will limit to. It is limited to 150% of the Current Output Rating.

Current Output Setpoint


54

Irms Min: 0.0 Max: 4500.0 (Ix10)

The setpoint for the current output PID control. It is limited to 100% of the Current Output Limit.

Current Output Proportional Gain


55 % Min: 0.0 Max: 100.0

Current output control proportional gain.

Current Output Integral Gain


56 % Min: 0.0 Max: 100.0

Current output control integral gain.

Current Output Derivative Gain


57 % Min: 0.0 Max: 100.0

Current output control derivative gain.

Current Output Actual

Read only 58 Irms

(Ix10) Ioutrms

June 2008 Settings

7-5


Current Output Zero



Digital zero adjustment of the current output signal. Calibration is described in the Calibration Chapter.

Current Output Span

Read/Write Condition: On Default: Factory

60 Bits Min: 2000 Max: 12000

Digital span adjustment of the current output signal. Calibration is described in the Calibration Chapter.

KVA Input Rating

Read only

64 KVA (Ix10)

The KVA rating is the conversion factor that is used to convert the KVA Input from percent to KVA. It is calculated using the following equation.

(Voltage Input Rating * Current Input Rating)/1000

KVA Input

Read only 65 KVA

(Ix10) Vinrms * Iinrms

Power Output Rating

Read only 66 KW

(Ix10)

The output rating of the Power being controlled by the 851. It is calculated using the following equation.

(Voltage Output Rating *Current Output Rating)/1000

Power Output Limit

Read/Write Condition: All Default: 96.0KW

67

KW Min: 0.0 Max: 1125.0 (Ix10)

The maximum power the power output PID control will limit to. It is limited to 125% of the Power Output Rating.

Power Output Setpoint

Read/Write Condition: All Default: 96.0KW

68

KW Min: 0.0 Max: 1125.0 (Ix10)

The setpoint for the power output PID control. It is limited to 100% of the Power Output Limit.

Power Output Proportional Gain


69 % Min: 0.0 Max: 100.0

Power output control proportional gain.

Power Output Integral Gain


70 % Min: 0.0 Max: 100.0

Power output control integral gain.

Settings June 2008

7-6


Power Output Derivative Gain


71 % Min: 0.0 Max: 100.0

Power output control derivative gain.

Power Output

Read only 72 KW (Ix10)

(Vin * Iin)rms , calculated by using the instantaneous product of the voltage and current samples.

Power Factor

Read only 73 Power Output/KVA Input.

Duty Cycle Output

Read only 74 % On time / Off time * 100.0 in percent

Duty Cycle Setpoint

Read/Write Condition: All Default: 100.0

75 % Min: 0.0 Max: 100.0

The setpoint for open loop control.

Local Digital Control Display Selection



Defines what the Local Digital Control displays during operation. The Local Digital Control option is described in the Local Digital Control Option Chapter. The selection list is:

1 – Voltage Output (V) 2 – Current Output (A) 3 – Power Output (KW) 4 – Control Setpoint (units) 5 – Voltage Output (%) 6 – Current Output (%) 7 – Power Output (%) 8 – Control Setpoint (%)

Local Digital Control Setpoint

Read only 77

Vrms Irms KW

The setpoint of the local digital control module. It can be Vrms, Irms or KW depending on the setting of the regulation mode.

Local Analog Setpoint

Read only 78 Vrms Irms KW

The setpoint of the local analog input. It can be Vrms, Irms or KW depending on the setting of the regulation mode.

Analog Setpoint Zero


79 Bits Min: -100 Max: 500

Digital zero adjustment of the analog setpoint input signal. Calibration is described in the Calibration Chapter.

June 2008 Settings

7-7


Analog Setpoint Span


80 Bits Min: 2000 Max: 16000

Digital span adjustment of the analog setpoint input signal. Calibration is described in the Calibration Chapter.

Analog Output Selection



Defines the operation of the analog output. The selection list is:

1 – Power Setpoint 2 – Power Output 3 – Voltage Setpoint 4 – Voltage Output 5 – Voltage Input 6 – Current Setpoint 7 – Current Output 8 – Current Input 9 – Analog Setpoint 10 – Duty Cycle Output

Analog Output

Read only 86 % The programmed analog output as defined by

Analog Output Selection in percent.

Analog Output Bias


87 Bits Min: -100 Max: 500

Digital zero adjustment of the analog output signal. Calibration is described in the Calibration Chapter.

Analog Output Span


88 Bits Min: 2000 Max: 16000

Digital span adjustment of the analog output signal. Calibration is described in the Calibration Chapter.

Settings June 2008

7-8


Control Word

Read/Write Condition: All Default: Bit 0 – 0 Off Bit 1 – 0 No Reset Bit 2 – reserved Bit 3 – 0 No Reset Bit 4 – reserved Bit 5 – reserved Bit 6 – 0 Bit 7 – 1 Voltage Bit 8 – 0 No save Bit 9 – 0 No restore Bit 10 – 1 PING Bit 11 – 15 – reserved

93 Bits

The control word is the digital inputs to the 851.

Bit 0 – Maintained 1 – On 0 – Off Bit 1 – Momentary 1 – Fault Reset 0 – No Reset Bit 3 – Momentary 1 – KW-hour Reset 0 – No Reset Regulation Mode Bit 6 – 7 Maintained 0 – 0 Open Loop 1 – 0 Power Output 0 – 1 Voltage Output 1 – 1 Current Output Bit 8 – Momentary 1 – Save calibration to EEPROM 0 – No save Bit 9 – Momentary 1 – Restore calibration from EEPROM 0 – No restore Bit 10 – Maintained 1 – PING On 0 – Off

June 2008 Settings

7-9


Status Word

Read only

94 Bits

The status word is the digital outputs from the 851.

Bit 0 1– On 0 – Off Bit 1 1 – Fault 0 – No Fault Bit 2 1 – Alarm 0 – No Alarm Bit 3 1 – Remote control selected 0 – Local control selected Bit 4 1 – Enable selected 0 – Inhibit selected Bit 5 1 – Local Digital control 0 – Local Analog control Regulation Limit Bit 6 – 7 – 8 0 – 0 – 0 No Limit 1 – 0 – 0 Power Output Limit 0 – 1 – 0 Voltage Output Limit 0 – 0 – 1 Current Output Limit 0 – 1 – 1 Current Input Limit 1 – 1 – 1 Maximum Voltage Limit Bit 9 1 – At Setpoint 0 – Not at Setpoint Bits 10,11,14 Reserved Bit 12,13 1,1 – Current Range is 0 – 10,000 Amps 0,0 – Current Range is 0 – 1,000 Amps Bit 15 1 – Jumper JP3 In 0 – Jumper JP3 Out

Ramp Up Time

Read/Write Condition: All Default: 10 Sec


The amount of time for the setpoint to go from 0 to100%.

Ramp Down Time

Read/Write Condition: All Default: 10 Sec


The amount of time for the setpoint to go from 100 to 0%.

Settings June 2008

7-10


Configuration Word

Read/Write Condition: All Default: Bit 0 – 1 Digital Bit 1 – 1 NC Bit 2 – 0 NO Bit 9 – 1 ALERT on low voltage Bit 12,13 – 0,0 Current range 0 – 1,000A Bit 15 – 0 No auto start

97 Bits

The configuration word configures the 851 specific features of:

Local Control Mode Bit 0 – Maintained 1 – Digital 0 – Analog Thermostat Contacts Bit 1 – Maintained 1 – NC 0 – NO External Fault Contacts Bit 2 – Maintained 1 – NC 0 – NO Low voltage alert/fault Bit 9 – Maintained 1 – Low voltage causes an ALERT 0 – Low voltage causes a FAULT Current Range Bit 12,13 – Maintained 1,1 – Current Range 0 – 10,000 Amps 0,0 – Current Range 0 – 1,000 Amps Auto Start on Powerup Bit 15 – Maintained 1 – Auto start 0 – No auto start

Control Strategy Selection

Read/Write Condition: Off Default: 1


Defines the type of control strategy that is being run. The selection list is:

1 – Phase-Angle Control 2 – Zero-Crossover Control

Magnetizing Sequence Calibration


99 Cycles Min: 3 Max: 10

Number of cycles to ramp on in phase control when running in Zero Crossover with transformer coupled loads.

Repetitive Pulse Calibration

Read/Write Condition: All Default: 60%

100 % Min: 10 Max: 90

Percent of first positive zero crossing pulse at the beginning of each “on” cycle Zero-Crossover with transformer coupled loads.

Load Type Selection



Defines the type of load connected to the 851. The selection list is:

1 – Direct Coupled 2 – Transformer Coupled

Product Type

Read only 102 The product type is 851.

June 2008 Settings

7-11


Serial Number

Read only Factory set

103 104

The numeric serial number of the 851. The setting is read as two consecutive words because of its size.

Control Power Time On

Read only Factory reset

105 106 x.x Hours

The accumulated time control power has been applied to the 851. The setting is read as two consecutive words because of its size.

Output Time On


107 108 x.x Hours

The accumulated time the 851 output has been on. The setting is read as two consecutive words because of its size.

KW-Hour

Read only

109 110

x.x Hours (Ix10)

The accumulated Power Output * Time in seconds. It can be reset remotely by writing a 1 to bit 3 of the Control Word. The setting is read as two consecutive words because of its size.

Software Version

Read only 112 The control software version read as xx.xxx.

Network Loss



Defines the action the 851 takes when there is a network loss. The selections are:

0 – Fault and stop 1 – Ignore and run 2 – Alarm and run.

Network Address


114 Address Min: 0 Max: 126

For the DeviceNet™ and Profibus network types, defines the network interface card address. For Ethernet, it defines the upper two octets of the network address. Refer to the network interface manual for a detailed description of the network interface.

Network Baud Rate



For the DeviceNet™ and Profibus network types, defines the network baud rate. For Ethernet, it defines the lower two octets of the network address. Refer to the network interface manual for a detailed description of the network interface.

MODBUS Address


116 Address Min: 1 Max: 247

Defines the device address for MODBUS messaging.

Settings June 2008

7-12


MODBUS Baud Rate


117

Selection Min: 4800 Max: 19200 (baud)

Defines the serial baud rate. The selection list is:

4800 9600 19200

Network Type



Defines the selected network interface. The selection list is:

0 – DeviceNet™ 1 – Profibus 2 – Ethernet

Fault Code

Read only 119 Fault condition code. Fault operation is

described in the Troubleshooting Chapter.

Fault Index


120 Index Min: 1 Max: 8

Fault buffer index number.

Fault Buffer #1


121 122 123

Saved fault condition code with a time stamp of time run. Fault operation is described in the Troubleshooting Chapter. Word 121 – Fault condition code Word 122/123 – Output time on stamp

Fault Buffer #2


124 125 126


Fault Buffer #3


127 128 129


Fault Buffer #4


130 131 132


Fault Buffer #5


133 134 135


Fault Buffer #6


136 137 138


June 2008 Settings

7-13


Fault Buffer #7


139 140 141


Fault Buffer #8


142 143 144


Settings June 2008

7-14

8-1

Chapter 8

Troubleshooting

DANGER

Only qualified electrical personnel familiar with the construction and operation of the equipment and the hazards involved should install, operate, and/or service this equipment. Read and understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.

DANGER


DANGER


DANGER

Power must be applied to the 851 with the cover removed to perform certain troubleshooting procedures. Voltages on many components are at incoming line potential. to avoid electric shock hazard or damage to equipment, do not touch any component other than those specified in the manual. Failure to observe these precautions could result in severe injury or loss of life.

The 851 has a number of built in diagnostic features. These include LED indicators for quick visual indicators on the following:

● the Main Control printed circuit board (PCB)

● the Local Digital Control option

● the network interface option

The four-digit display on the Local Digital Control option can be programmed to view key control signals and display fault or alarm codes.

Troubleshooting June 2008

8-2

Control PCB LED Indicators

The control printed circuit board has six LED’s. Remove the middle wiring cover of the 851 to view these particular LED’s. These LED’s and their functions are listed in the table below.

Table 8-1 Control PCB LED Indicators

LED Color Description

+5V Green +5V power is present

+15V Green +15V power is present

-15V Green -15V power is present

On Green 851 output is active

Heartbeat Flashing Green

Digital Signal Processor is operating

Fault Red 851 has detected a fault condition

Figure 8-1 Main Control PCB LED indicator location

June 2008 Troubleshooting

8-3

Local Digital Control Option LED Indicators

The Local Digital Control Option has six LED’s used for status. These LED’s are clearly viewed on the bottom of the Local Digital Control Option. These LED’s and their functions are listed in the Table below.

Table 8-2 Local Digital Control LED Indicators

Status LED Color Description

Remote Green The Remote input is present.

Analog Green The Local mode is set to Analog.

Digital Green The Local mode is set to Digital.

Enable Green The Enable input is present.

On Green The 851 output is active.

Alert Amber Either a fault or alarm is present.

Figure 8-2 Local Digital Control

Fault and Alarm Codes

If there is a fault, the 851 automatically stops and holds the fault code for the user. The fault codes are evaluated in their numeric order. This makes the lowest number codes the highest priority. The fault code is displayed on the Local Digital Control module. It can also be accessed as Setting #119 through either the serial or network interface.


8-4

Alarm codes are warning conditions and do not stop the 851. The alarm code is also displayed on the Local Digital Control module but not continuously. The display alternates between the selected display variable and the alarm code. It can also be accessed as Setting #119 through either the serial or network interface.

A fault will always override an alarm and stop the 851. The following table lists the fault and alarm codes.

Table 8-3 Fault and Alarm Codes

Fault/Alarm Code Description

Current Input High Fault

1 The fault occurs when the Current Input Actual peak exceeds the Current Input High Fault at any time during the AC cycle for two consecutive cycles.

Note: The fault will be reset and automatically restart based on the following conditions.

1. The 851 will turn off and automatically restart based on the Current Input High Retry Number.

2. The 851 will turn off and not automatically restart if the number of restarts occur within the Current Input High Retry Time.

Current Input Timed Overload Fault

2 The fault occurs when all the following conditions are met.

1. The Current Input Actual exceeds the Current Input Overload Fault.

2. The accumulated time of condition #1 is greater than the Current Input Overload Time.

Note: If the Current Input Actual goes below the Current Input Overload Fault then the accumulated time resets back to zero.

Over Temperature Fault

3 The fault occurs when the thermostat input changes to the off state. The thermostat input is defined as NO (Normally Open) or NC (Normally Closed) depending on bit 1 of the Configuration Word.

Voltage Input High Fault

4 The fault occurs when the Voltage Input Actual exceeds the Voltage High Fault.

Voltage Input Low Fault

5 The fault occurs when the Voltage Input Actual is lower than 12.5% of the Voltage Input Rating, and bit 9 of the Configuration Word is NOT set.


8-5


SCR Shorted Fault 6 The fault occurs when the following conditions are met.

1. The Voltage Output Actual is greater than 75% of the Voltage Output Rating for one second.

2. The 851 is off.

External Fault 10 The fault occurs when the external fault input changes to the off state. The external fault input is defined as NO (Normally Open) or NC (Normally Closed) depending on bit 2 of the Configuration Word.

Configuration Fault 13 The fault occurs when the check byte of the onboard EEPROM is not correct.

Note: This fault will cause all Settings to be reset to default values on the next power up cycle.

Watchdog Fault 15 The fault occurs when the digital signal processor does not update the watchdog timer correctly.

Network Loss Fault 16 The fault occurs if there is a network loss and the Network Loss Selection is set to Fault and Stop.

Frequency Alarm 20 The alarm occurs when the Frequency Actual is outside of a 2.0 Hertz band as compared to the Frequency Rating

Voltage Input Low Alarm

21 The alarm occurs when the Voltage Input Actual is lower than the Voltage Input Low Alarm.

Current Input Load Failure Alarm

22 The alarm occurs when all of the following conditions are met.

1. The Current Input Actual is less than the Current Threshold Load Failure.

2. The Voltage Output Actual is greater than 10% of the Voltage Output Rating.

3. The setpoint has completed ramping up.

Voltage Output Limit Alarm

23 The alarm occurs when the Voltage Output Actual is being limited to the Voltage Output Setpoint by the voltage output control loop.

Current Output Limit Alarm

24 The alarm occurs when the Current Output Actual is being limited to the Current Output Setpoint by the current output control loop.


8-6


Power Output Limit Alarm

25 The alarm occurs when the Power Output Actual is being limited to the Power Output Setpoint by the power output control loop.

Current Input Limit Alarm

26 The alarm occurs when the Current Input Actual is being limited to the Current Input Limit

Maximum Voltage Output Alarm

27 The alarm occurs when the Duty Cycle of the controller reaches 100%.

Network Loss Alarm 28 The alarm occurs if there is a network loss and the Network Loss Selection is set to Alarm and Run.

Fault Reset

Faults can be cleared or reset by three different methods. Alarms are automatically cleared.

● Toggle the Enable/Inhibit switch from Enable to Inhibit.

● Press the Reset button on the Local Digital Control module.

● Use the fault reset bit (bit 1) of the Control Word. The bit must be momentarily set to enable a fault reset. The 851 automatically resets the bit after the fault has been cleared. It is very important not to leave the bit set in the control word.

Fault Buffer

The last eight faults are stored in Fault Buffers #1 - #8 and can be accessed from the serial interface. The fault buffer includes the Fault Code and a time stamp from Output Time On. Only faults that occur when the unit is running are buffered. The Fault Index indicates which buffer will be written to next. The fault buffers are connected in a circular fashion.


8-7

Troubleshooting Guide

DANGER

Only qualified electrical personnel familiar with the construction and operation of the equipment and the hazards involved should install, operate, and/or service this equipment. Read and understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.

DANGER


DANGER


DANGER

Power must be applied to the 851 with the cover removed to perform certain troubleshooting procedures. Voltages on many components are at incoming line potential. to avoid electric shock hazard or damage to equipment, do not touch any component other than those specified in the manual. Failure to observe these precautions could result in severe injury or loss of life.

The following table describes fault/alarm conditions with probable cause and corrective action for each condition.


8-8

Table 8-4 Troubleshooting Guide

Condition Probable Cause Corrective Action

No Control Power Insure the 851 has separate control power

Power Supply connection open

Check Power Supply connections to main control PCB

+5V LED off

+15V LED off

-15V LED off

Power Supply failed Replace Power Supply

Heartbeat LED off DSP on main control PCB failed

Check that jumper JP3 is removed before applying power

Replace main control PCB

Local Digital Control Display off or scrambled

Local Digital Control connection open or intermittent

Check Local Digital Control connection to main control PCB

Enable not present Check that the Enable status LED is on. The Output On status LED should also be on.

Local mode not selected Check that the Remote status LED is off.

Analog mode not selected Select Analog mode on Local Digital Control. Check that the Analog status LED on

Local Analog setpoint set to zero

Verify voltage at Analog Setpoint input

851 will not turn on in Local Analog mode

Local analog setpoint calibration incorrect

Verify Local analog setpoint calibration


8-9


Enable not present Check that the Enable status LED is on.

Local mode not selected Check that the Remote status LED is off.

Digital mode not selected Select Digital mode on Local Digital Control. Check that the Digital status LED is on

Output On not selected Press the On/Off/Reset pushbutton and check that the Output On LED is on.

851 will not turn on in Local Digital mode

Digital setpoint set at zero Press the increase pushbutton to increase the setpoint

Enable not present Check that the Enable status LED is on.

Remote mode not selected Check that the Remote status LED is on.

Network inoperable Check network cable and connections

Check 850 address and baud rate

Check the master device on the network (scanlist)

On/Off bit not set to one Set the On/Off bit to one in the Control Word and check that the Output On LED is on

851 will not turn on in Remote mode

Setpoint set at zero Verify that the setpoints for Voltage, Current, Power and Remote Duty Cycle are not zero

Calibration incorrect Check calibration 851 cannot provide full power to the load Power is being limited by one

of the three control loops Verify setpoints for the three control loops


8-10


851 is full on and cannot provide any more power

Duty Cycle is at 100.0%.

Review the load to verify that 100.0% voltage will allow 100.0% power.

Verify input voltage level to make sure it is not low

Output wiring intermittent or disconnected

Check the output wiring

Improper fuse rating Refer to the Hardware Chapter for correct fuse rating

Nuisance Input Fuse blowing

Fuse improperly tightened Tighten the fuses

Calibration incorrect Check calibration

Current Input Rating setting incorrect

Check Current Input Rating setting

Current Input High Fault setting incorrect

Check Current Input High Fault setting

F-01 - Current Input High Fault

Intermittent short in load Check load




Current Input Overload Fault setting incorrect

Check Current Input Overload Fault setting

Current Input Overload Time setting incorrect

Check Current Input Overload Time setting

F-02 – Current Input Timed Over Current Fault

Output transformer sized incorrectly

Verify size of output transformer

Thermostat contact state incorrect in Configuration Word setting

Check Configuration Word setting

Thermostat wiring open or shorted

Check thermostat wiring

F-03 – Over Temperature Fault

Cabinet is overheating Provide more cabinet ventilation or cooling


8-11


Unit is Overheating Check fan is functioning properly


Voltage Input Rating setting incorrect

Check Voltage Input Rating setting

Voltage Input High Fault setting incorrect

Check Voltage Input High Fault setting

Voltage Output PT Secondary setting incorrect

Check Voltage Output PT Secondary setting. Refer to the Configuration Chapter for details on correct setting

F-04 – Voltage Input High Fault

Incoming voltage out of tolerance

Correct incoming voltage level






F-05 – Voltage Input Low Fault

Blown input fuse Replace input fuse


Voltage Output Rating setting incorrect

Check Voltage Output Rating setting



F-06 – SCR Shorted Fault

Shorted SCR Replace SCR

External Fault contact state incorrect in Configuration Word setting

Check Configuration Word setting F-10 – External Fault

External Fault wiring open or shorted

Check External Fault wiring


8-12


F-13 – Configuration Fault

Failed EEPROM memory Replace main control PCB

F-15 Watchdog Fault

Failed DSP Replace main control PCB

F-16 - Network Loss Fault

Network failure Check network connection

Verify presence of network

Change Network Loss Option to allow device operation

Frequency Rating setting incorrect

Check Frequency Rating setting A-20 – Frequency Alarm

Incoming frequency out of tolerance

Correct incoming frequency




Voltage Input Low Alarm setting incorrect

Check Voltage Input Low Alarm setting


Check Voltage Output PT Secondary

A-21 – Voltage Input Low Alarm

Incoming voltage out of tolerance

Correct incoming voltage level


Current Threshold Load Failure setting incorrect

Check Current Input Threshold Load Failure setting





A-22 – Current Input Load Failure Alarm

Output load changed Verify output load

Calibration incorrect Check calibration A-23 – Voltage Output Limit Alarm




8-13




Voltage Output Setpoint setting incorrect

Check Voltage Output Setpoint setting

Controlling with Voltage Output PID

Change Voltage Output Setpoint


Current Output Rating setting incorrect

Check Current Output Rating setting

Current Output Setpoint setting incorrect

Check Current Output Setpoint setting

A-24 – Current Output Limit Alarm

Controlling with Current Output PID

Change Current Output Setpoint





Check Voltage Output PT Secondary setting.

Current Output Rating setting incorrect

Check Current Output Rating setting

Power Output Setpoint setting incorrect

Check Power Output Setpoint setting

A-25 – Power Output Limit Alarm

Controlling with Power Output PID

Change Power Output Setpoint




Current Input Limit setting incorrect

Check Current Input Limit setting

A-26 – Current Input Limit Alarm

Controlling Current Input with Current Output PID

Change Current Input Limit


8-14


A-27 - Maximum Voltage Output Alarm

Duty Cycle has reached 100%

Lower the control setpoint

A-28 - Network Loss Alarm

Network failure Check network connection

Verify presence of network

Change Network Loss Option to allow device operation

A-1

Appendix A Mechanical Dimensions

Figure A-1 50A Model

Mechanical Dimensions June 2008

A-2


June 2008 Mechanical Dimensions

A-3


B-1

Appendix B Electrical Drawings

Electrical Drawings June 2008

B-2

June 2008 Electrical Drawings

B-3

Figure B-1 Electrical Schematic


B-4

Figure B-2 - 50A Model

June 2008 Electrical Drawings

B-5



B-6


i

Glossary Glossary of common terms and abbreviations used in SCR Power Controllers and their applications

Term or Acronym Description

ADR Automatic Device Replacement

ASCII American Standard Code for Information Interchange

Bias Calibration factor to offset signal at zero output of control signal

CAN Controller Area Network

CT Current Transformer

DSP Digital Signal Processor

DSPC Digital SCR Power Controller

EDS Electronic Data Sheet

Heatsink Device to carry heat from power devices

I2t Subcycle current characteristic of an SCR or fast clearing fuse

I/O Input/Output

IRMS Amps Root Mean Squared

KVA One thousand volt amperes

LED Light emitting diode

MOV Metal Oxide Varistor – brand name of GE transient voltage suppressor

NC Normally closed contact

NO Normally open contact

NEC National Electric Code

NEMA National Electrical Manufacturers Association

ODVA Open DeviceNet™ Vendors Association

PCB Printed Circuit Board

PCMCIA Personal Computer Memory Card International Association

PCU Power Control Unit

Glossary June 2008

ii

Term or Acronym Description

Phase Angle Control by chopping each half cycle

PID Proportional, Integral Derivative Controller

PLC Programmable Logic Controller

PT Potential Transformer

RFI Radio Frequency Interference

RMS Root Mean Squared

Rx Receive

SCR Silicon Controlled Rectifier

Semiconductor Solid State device for controlling electric power

Setpoint Reference for PID control

Silicon Material from which semiconductors are made

Span Calibration signal to adjust maximum input of control signal

Thyristor Name of semiconductor family including SCR’s, TRIAC, etc.

Tx Transmit

TXID Transaction ID for Explicit Message Requests and Responses

VAC Volts Alternating Current

VDC Volts Direct Current

VRMS Volts Root Mean Squared

Zero Calibration signal to adjust minimum input of control signal to zero

Zero-Cross Control by integrating numbers of complete cycles

Documents

851 Product Manual