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USER MANUAL PHASE ANGLE CONTROLLED AC POWER CONTROLLER

USER MANUAL

PHASE ANGLE CONTROLLED

AC POWER CONTROLLER

CONTENTS :

CHAPTER

1

PRODUCT OVERVIEW :

 
 

DESCRIPTION

1-1

PRODUCT CODE

1-1

TECHNICAL SPECIFICATION

1-2

ENVIRONMENT

1-2

CHAPTER

2

INSTALLATION :

 

MECHANICAL INSTALLATION

 

1

& 2 PHASE PCU

2-1

3

PHASE PCU

2-2

 

ELECTRICAL INSTALLATION WIRING GUIDELINES CONTROL WIRING

2-3

 

1 & 2 PHASE WITH AP-13

2-3

1 & 2 PHASE WITH AP-29

2-4

 

POWER

PHASE WITH AP-12 WIRING

3

2-5

 

1

& 2 PHASE

2-6

3

PHASE

2-7

CHAPTER

3

STANDARD FEATURE :

 

SWITCH SELECTION

3-1

POTENTIOMETER SETTING

3-2

SOFT STARTING

3-2

SYNCHRONISATION

3-2

DV / DT PROTECTION

3-2

ZERO SETTING

3-3

SPAN SETTING

3-3

CURRENT LIMIT

3-4

VOLTAGE REGULATION

3-4

CHAPTER

4

TROUBLE SHOOTING

 

NO OUTPUT

 

4-1

HIGH OUTPUT

4-2

APPENDIX A TEST CHART :

CHAPTER 1 PRODUCT OVERVIEW

DESCRIPTION :

AMEE POWER AC POWER CONTROLLER UNIT ( PCU ) IS A COMPACT OPEN EXCECUTION CHASSIS MOUNTED MODULE. IT CONSISTS OF MAINLY TWO PARTS - POWER SECTION AND CONTROL SECTION. THE POWER SECTION COMPRISES OF LAVISHLY RATED ANTI-PARALLEL CONNECTED SCRS MOUNTED ON ELECTRICALLY ISOLATED HEAT SINKS (UPTO 500 AMPS) WHERE AS THE CONTROL SECTION CONSISTS OF GATE FIRING AND TRIGGER CONTROL CIRCUIT, POWER SUPPLY X-MER,CTS AND RC SNUBBER CIRCUITS.

PRODUCT CODE :

ALL PCUS ARE FULLY IDENTIFIED USING SIX BLOCK ALPHANUMERIC CODE.

THIS CODE DETAILS THE PCU CALIBRATION AND SETTINGS ON DESPATCH FROM THE FACTORY. THE PRODUCT CODE APPEARS AS THE “ MODULE TYPE “ ON THE RATING LABEL AT THE RIGHT SIDE OF THE UNIT. DETAILS OF EACH BLOCK OF THE PRODUCT CODE ARE GIVEN BELOW :

MODULE TYPE :AP-

1 2 3 4 5 6 1 3 4 0 0 3 0 1
1
2
3
4
5
6
1 3
4 0 0 3
0
1

1

0

= ZERO FIRING

4

003 = 30 AMPS

1

= PHASE FIRING

005 = 50 AMPS

2

1

= SINGLE PHASE

007 = 70 AMPS

2

= TWO PHASE

009 = 90 AMPS

3

= THREE PHASE

015 = 150 AMPS

3

1

= 115 V

020 = 200 AMPS

2

= 230 V

025 = 250 AMPS

3

= OTHER VOLTAGES

035 = 350 AMPS

4

= 415 V

050 = 500 AMPS

5

0

= NONE

075 = 750 AMPS

1

= CURRENT REGULATION

- CR

100 = 1000 AMPS

2

= POWER REGULATION

- WR

135 = 1350 AMPS

3

= OVER CURRENT SHUT OFF

- OC

170

= 1700 AMPS

4

= SEMI CONDUCTOR FUSES

- SCF

210 = 2100 AMPS

5

= BLOWN FUSE MONITOR

- FM

240 = 2400 AMPS

6

0= DC DRIVE

300 = 3000 AMPS

1 = RESISTIVE LOAD

2 = INDUCTIVE LOAD

TECHNICAL SPECIFICATION :

CONTROL METHOD

:

ZERO FIRING OR PHASE ANGLE FIRING OF BACK TO BACK CONNECTED SCRS.

VOLTAGE RATING

:

115V , 230V

OR 415 VAC, 50HZ.

CUURENT RATING

:

30, 50, 70, 90, 150, 200, 275, 350, 500,

 
 

750, 1000, 1350, 1750, 2100,2400

& 3000 AMPS.

COMMAND SIGNAL

:

MOST STANDARD PROCESS SIGNALS 0-5 V DC 0-10 V DC 0-20 mA DC 2-12 mA DC 4-20 mA DC 10-50 mA DC VOLT PULSE

LIKE :

ISOLATION

:

2500 VOLTS RMS FROM POWER CIRCUIT TO COMMAND SIGNAL AND TO GROUND.

LINEARITY

:

AVERAGE

OUTPUT VOLTAGE IS LINEAR TO

COMMAND SIGNAL.

ENVIRONMENT :

OPERATING

TEMPERATURE

:

0-50

* C

 

STORAGE

TEMPERATURE

:

-10 * C

TO

55 * C

SHIPPING TEMPERATURE

:

- 10 * C

TO

70 * C

HUMIDITY

:

MAX. 85 % RH AT 40 * C

CHAPTER 2 INSTALLATION

MECHANICAL INSTALLATION :

MOUNTING

THE AMEE POWER PCU

MUST BE MOUNTED VERTICALLY ON

A SOLID FLAT

VERTICAL SURFACE. ALL PCUS ARE DIRECT WALL MOUNTABLE.

DIMENSIONS FOR 1 PH & 2PH PCU : w1 w h h1
DIMENSIONS FOR 1 PH & 2PH PCU :
w1
w
h
h1

ALL DIMENSIONS ARE IN MM

d FRAME -1
d
FRAME -1

current

 

h

w

d

h1

w1

wt

25

70A

frame - 1

230

205

107

207

233

5 kgs

100A

frame - 1

           

150A

frame - 2

           

200A

frame - 2

           

250

350A

frame - 3

           

DIMENSIONS FOR 3 PH PCU:

w1 d d w h h1
w1
d d
w
h
h1
DIMENSIONS FOR 3 PH PCU: w1 d d w h h1 d   FRAME -1 FRAME

d

 

FRAME -1

FRAME -2

FRAME -3

ALL DIMENSIONS ARE IN MM

 

current

 

h

w

d

h1

w1

 

wt

25

70A

frame - 1

345

270

190

330

230

10

kgs

100A

frame - 1

345

270

230

330

230

11

kgs

150A

frame - 2

460

270

300

418

175

13

kgs

200A

frame - 2

510

270

300

468

175

14

kgs

250

350A

frame - 3

400

270

270

360

242

15

kgs

NOTE: FRAME-3 COMES WITH ADDITIONAL 3PH 440V COOLING FAN

EXT. CL

mA I/P

V I/P

GND

ELECTRICAL INSTALLATION WIRING GUIDELINES

THE THREE PHASE AMEE POWER PCUS ARE DESIGNED TO ACCEPT 3 PHASE , 3 WIRE 415 V +/- 10 % , 50 HZ +/- 5% AC INPUT SUPPLY. WHEREAS THE SINGLE PHASE AMEE POWER PCUS ARE DESIGNED TO ACCEPT 1 PHASE / 2 PHASE , 2 WIRE 230 / 415 V + / - 10 % , 50 HZ + / - 5 % AC INPUT SUPPLY. WARNING : DO NOT CONNECT THE AC INPUT TO THE OUTPUT TERMINALS. IT WILL DAMAGE THE PCU. CAUTION : ENSURE ALL SCREWS ARE TIGHTENED PROPERLY. PLEASE FOLLOW ALL LOCAL ELECTRICAL AND SAFETY CODES.

CONTROL WIRING

CONTROL WIRING FOR SINGLE OR TWO PHASE PCU :

THE DIAGRAM BELOW SHOWS THE TYPICAL CONTROL CONNECTIONS REQUIRED FOR OPERATION AS A PCU.

 

61

62

63

64

 
 

FRC CABLE

   

1234

   
 

CONTROL CARD TYPE : AP-13

 
 

+ VCC

 
   

1

2

3

4

 

5

6

7

8

41

 

42

 

43

 

44

 

55

 

56

 

57

58

 
44   55   56   57 58   L/O NC=ON CT SIGNAL FUSE LINK 1

L/O

NC=ON

CT

SIGNAL

FUSE LINK 1 2 P/S CARD TYPE : AP-13P LED2 LED1 01 02 FRC CABLE
FUSE LINK
1
2
P/S CARD
TYPE : AP-13P
LED2
LED1
01
02
FRC CABLE

LED1 - +12V LED2 - -12V

CONTROL WIRING :

CONTROL WIRING FOR SINGLE OR TWO PHASE PCU :

THE DIAGRAM BELOW SHOWS THE TYPICAL CONTROL CONNECTIONS REQUIRED FOR OPERATION AS A PCU.

12345678 9 10 11 12 CONTROL CARD TYPE : AP-29.01 1 2 3 456 7
12345678
9
10
11
12
CONTROL CARD
TYPE : AP-29.01
1
2
3
456
7
8
9
10
11
12
13
14
15
16
17
18
19
20
+
-
+
-
FB
CT1
L/O
NC=ON
V
20V
0V 15V
0V 15V
0V 10V
0V
G1
K1 G2
K2
41
+ 12V
42
GND
43
- 12V
73
44
LOGIC O/P
74
45
75
46
76
47
V CC
77
48
VOLT I/P
78
49
MA I/P
79
50
INCH I/P
80
51
52
53
61
54
62
63
64
58
+ VCC
59
60
EXT. CL

NOTE: CONNECT POT AT TERMINAL NO 5,6 & 7 ONLY WHEN RAMP CIRCUIT IS REQUIRED

CONTROL WIRING FOR THREE PHASE PCU :

THE DIAGRAM BELOW SHOWS THE TYPICAL CONTROL CONNECTIONS REQUIRED FOR OPERATION AS A PCU.

1 2 3 45 6 7 8 9 10 11 12 13 14 15 16
1
2
3
45
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
CONTROL CARD
TYPE : AP-12
1
2
3
456
7
8
9
10
11
12
13
14
15
16
17
18
19
20
+
-
-
+
-
FB
CT1
CT2
L/O
NC=ON
V
G1 K1 G2 K2 G3 K3 G4 K4 G5 K5 G6 K6
20V
0V 15V
0V 15V
0V 10V
0V
41
61
+ 12V
42
62
GND
43
63
- 12V
44
64
LOGIC O/P
45
65
46
66
47
67
V CC
48
68
VOLT I/P
49
69
MA I/P
50
70
INCH I/P
71
72
51
52
53
73
54
74
55
75
56
76
77
58
78
+ VCC
59
79
60
80
EXT. CL

NOTE: CONNECT POT AT TERMINAL NO 5,6 & 7 ONLY WHEN RAMP CIRCUIT IS REQUIRED

POWER WIRING POWER WIRING FOR SINGLE / TWO PHASE PCU :

ALWAYS CONNECT THE POWER SUPPLY LINE TO INPUT BUSBAR P & N. MAKE SURE TO CONNECT THE NEUTRAL TO BUSBAR N VIA A MOLDED-CASE CIRCUIT BREAKER ( MCCB) OR A FUSE. MAKE SURE TO GROUND THE GROUND TERMINAL ACCORDING TO THE LOCAL GROUNDING CODE.

INPUT SUPPLY

EXTERNAL

PROTECTIVE

DEVICE

P N P N 1 6 L1 L2
P
N
P N
1
6
L1
L2

TO LOAD

NEUTRAL IS COMMON FOR BOTH I/P & O/P

POWER WIRING FOR THREE PHASE PCU :

PRIOR TO CONNECT THE POWER TO THE MODULE VIA A MOLDED-CASE CIRCUIT BREAKER ( MCCB) OR SEMI CONDUCTOR FUSE , PLEASE CHECK THE SWITCH POSITION AND PHASE SEQUENCE AT THE THREE PHASE INPUT SUPPLY. THE INPUT THREE PHASE SEQUENCE ROTATION MUST ALWAYS BE CLOCKWISE. ANTI-CLOCKWISE INPUT PHASE SEQUENCE MAY RESULT IN MALFUNCTIONING OF PCU AND HENCE THE UNCONTROLLED CURRENT MAY CLEAR THE FUSES OR THYRISTOR. PLEASE MAKE SURE TO GROUND THE GROUND TERMINAL ACCORDING TO THE LOCAL GROUNDING CODE.

INPUT SUPPLY

EXTERNAL

PROTECTIVE

DEVICE

R

Y

B

CODE. INPUT SUPPLY EXTERNAL PROTECTIVE DEVICE R Y B   R   Y   B  
 

R

 

Y

 

B

 
 
1 6
1
6
 
 

L1

 

L2

 

L3

TO LOAD

1 : + 12V

2 : - 12V

3 : G.P.S.

4 : SPAN

5 : ZERO

6 : C.L.

CHAPTER 3 STANDARD FEATURES

THE CONTROL CARD IS USED TO CONTROL THE THYRISTOR FIRING ANGLE , WHICH ALLOWS A SMOOTH VARIATION OF THE POWER THROUGHOUT THE CONTROL RANGE. IT MAINTAINS CONSTANT POWER AT THE PRESELECTED VALUE ( SET BY THE USER ) IRRESPECTIVE OF THE LOAD, TEMPERATURE OR SUPPLY VOLTAGE VARIATION. IT CAN BE USED IN TWO MODES. AUTO AND MANUAL MODE. IN AUTO MODE THIS CARD CAN ACCEPT INPUT SIGNALS ANYWHERE FROM THE AUTOMATION SYSTEM LIKE : PLC , PID , DCS, COMPUTER INTERFACE SYSTEM ETC. THE SIGNAL CAN BE 4 - 20 mA, 0 - 20mA, 10 - 50mA, 2 - 12 mA. WHERE AS IN MAUAL MODE IT CAN ACCEPT 0 TO 10V OR 0 TO 5V FROM AN EXTERNAL 10K,3W POTENTIOMETER.

SWITCH SELECTION ONLY FOR THREE PHASE PCU :

GENERALLY FOR AC POWER CONTROLLER APPLICATION , S/W - 2 ( J3 ) AND S/W - 5 ( J7 ) ARE ON AND OTHERS SWITCHES ARE OFF.

WHERE AS FOR CERTAIN APPLICATIONS SWITCH POSITION HAS TO BE RECONFIGURED AS UNDER. IF SWITCH IS ON OR JUMPER IS CLOSED, THE REQUIRED FEATURE IS MADE AVAILABLE.

S/W NO

JUMPER NO

FUNCTION

S/W - 1

J1

RAMP GENERATOR

S/W - 2

J3

WITHOUT FEEDBACK

S/W - 3

J4

WITH FEEDBACK

S/W - 4 S/W - 5

J7

NOT USED CURRENT LIMIT

S/W - 6

J6

CURRENT FEEDBACK

S/W - 7 S/W - 8

J5

VOLTAGE FEEDBACK NOT USED

POTENTIOMETER SETTINGS

AS SHOWN IN THE LAYOUT DIAGRAM THERE ARE FIVE SINGLE TURN TRIM POTENTIOMETERS ARE MOUNTED ON THE CARD.

LEGEND

FUNCTION OF THE

POTENTIOMETER

P3

RAMP UP TIME

P4

RAMP DOWN TIME

P5

ZERO SETTING

P6

SPAN SETTING

P8

CURRENT LIMIT SETTING

SOFT STARTING

THE PCU HAS BUILT-IN FACILITY OF SOFT STARTTING. WHEN AC POWER IS APPLIED TO THE PCU, A TIME DELAY OF APOPROXIMATELY 4 SECONDS INHIBITS ALL GATE SIGNALS TO THE SCRS AFTER THIS INITIAL DELAY THE SCRS ARE RAMPED ON TO THE LEVEL DETERMINED BY THE CONTROL SIGNAL, THIS UNIQUE CIRCUITRY PREVENTS THE EXCESSIVE INRUSH CURRENT TO THE LOAD.

SYNCHRONIZATION CKT

THE MAINS SIGNAL REQUIRED FOR SYNCHRONIZING THE FIRING IS DELIVERED FROM THE SECONDARY OF THE MAINS POWER SUPPLY TRANSFORMER. THE DERIVED SIGNAL IS FIRST FILTERED TO PREVENT LINE DISTURBANCES FROM AFFECTING THE RAMPS. THE FREQUIENCY OF THE FILTERED SIGNAL WILL BE 50HZ.

DV/DT PROTECTION

A HIGH RATE OF CHANGE OF VOLTAGE ( DV / DT ) CAN CAUSE THE SCR TO TURN ON. FOR DV/DT PROTECTION , SUITABLY RATED RC NETWORK ARE CONNECTED ACROSS ALL THE SCRS.

ZERO SETTING

ZERO ( BIAS ) POT ADJUSTMENT IS USED TO SET THE MINIMUM OUTPUT OF THE PCU. WITH CONTROL SIGNAL AT ITS MINIMUM, THE BIAS SHOULD BE ADJUSTED UNTIL OUTPUT VOLTAGE IS JUST AT ZERO SO THAT AS THE CONTROL SIGNAL IS TURNED ON, THE OUTPUT VOLTAGE INCREASES.

EXAMPLE :

FOR 4 TO 20 mA INPUT SIGNAL :

SET THE ZERO ( BIAS ) POT SO THAT TILL THE 4mA SIGNAL SCR WILL NOT FIRE AND AFTER THAT THE SCR JUST BEGINS TO FIRE.

FOR

SET THE COMMAND POTENTIOMETER AT MINIMUM POSITION, THEN ADJUST THE ZERO ( BIAS ) POT SO THAT THE SCR JUST BEGIN TO FIRE.

0 TO 10 V DC

INPUT SIGNAL :

SPAN SETTING

SPAN ( GAIN ) POT ADJUSTMENT IS USED TO SET THE MAXIMUM OUTPUT OF THE PCU. AFTER SETTING ZERO , TURN THE CONTROL SIGNAL UPTO ITS MAXIMUM VALUE AND ADJUST THE SPAN UNTIL THE OUTPUT VOLTAGE IS JUST AT MAXIMUM VOLTAGE LEVEL WHICH YOU HAVE TO APPLY ACROSS THE LOAD. SO BY THIS POT ONE CAN CLAMP THE UPPER LIMIT.

EXAMPLE :

FOR 4 TO 20 mA INPUT SIGNAL :

SET THE GAIN SO THAT THE SCRS ARE FULLY FIRED , WHEN PROCESS CON- TROLLER GIVES MAXIMUM OUTPUT OF APPROX. 20mA SIGNAL

FOR

SET THE COMMAND POTENTIOMETER AT MAXIMUM POSITION, THEN ADJUST THE SPAN ( GAIN ) POT SO THAT THE SCRS ARE FULLY FIRED.

0 TO 10 V DC

INPUT SIGNAL :

CURRENT LIMIT

NORMALLY CURRENT LIMIT ADJUSTMENT IS SET AT THE RATED OUTPUT OF THE PCU. THIS IS ADJUSTABLE ANY WHERE FROM 20% TO 110% OF THE RATED VALUE. TURNING THE POT CLOCKWISE WILL INCREASE THE CL SET VALUE WHERE AS TURNING THE POT ANTICLOCKWISE WILL REDUCE THE SET VALUE. IT IS RECOMMANDED TO SET THE CL VALUE AT YOUR REQUIRED CURRENT LEVEL. BECAUSE THE CURRENT LIMIT TAKES PRECEDANCE OVER THE CONTROL SIGNAL AND WILL PREVENT THE OUTPUT CURRENT FROM INCREASING BEYOND THE SETTING EVEN THOUGH THE CONTROL SIGNAL IS INCREASED.

FOR OPERATING THE PCU AT THE DESIRED MAXIMUM CURRENT, FIRST TURN THE CL POT ANTI-CLOCKWISE UNTIL THE OUTPUT CURRENT JUST BEGINS TO DECREASE, THEN TURN THE POT SLIGHTLY CLOCKWISE. AN EXTERNAL CURRENT LIMIT POT ( 10K,3W ) MAY BE WIRED TO THE PCU. FOR EXTERNAL CL CONNECT THE POT VARIABLE AT TERMINAL NO 20.

VOLTAGE REGULATION

THIS FEATURE IS VERY USEFULL WHERE CLOSE- LOOP CONTROL IS REQUIRED WITHOUT SUDDEN OVERSHOOT OF VOLTAGE LEVEL. THE OUTPUT VOLTAGE OF THE PCU IS MONITORED CONTINEOUSLY AND MAINTAINED WITHIN THE TOLLARENCE OF + /- 2 % OF MAX. SET VALUE IRRESPECTIVE OF LINE AND LOAD VARIATION. THE PERMISSIBLE LINE VARIATION IS + / - 10 % OF INPUT SUPPLY VOLTAGE.

TROUBLE SHOOTING GUIDE:

NO OUTPUT:

1: INPUT POWER NOT PRESENT OR OUT OF PHASE. IF UNIT IS 3 PHASE, VERIFY CORRECT (CLOCKWISE) PHASE ROTATION.

2: CONTROL SIGNAL NOT PRESENT / POLARITY REVERSED. CHECK THAT CORRECT CONTROL SIGNAL IS APPLIED TO PROPER TERMINALS ON THE CONTROL AMPLIFIER AND THAT POLARITY OF SIGNAL IS CORRECT.

3: ZERO AND / OR SPAN POT OUT OF ADJUSTMENT. CHECK THAT CONTROL AMPLIFIER ZERO AND SPAN SETTING ARE NOT OUT OF ADJUSTMENT

4: CL POT IS AT ZERO POSITION. OUTPUT IS BLOCKED, SO INPUT IS HIGHER, BUT OUTPUT IS VERY LOW HENCE CHECK THE CURRENT LIMIT POT.

HIGH OUTPUT (NO CONTROL):

1: BIAS AND / OR GAIN OUT OF ADJUSTMENT. CHECK THAT THE CONTROL AMPLIFIER ZERO AND SPAN SETTINGS ARE NOT OUT OF ADJUSTMENT

2: SHORTED SCR. CHECK THAT SCRS HAVE NOT FAILED SHOTED.

3: FAULT IN THE CARD CHECK FOLLOWING LED STATES ON THE CONTROL CARD LED 1 : -12V LED 2 : +12V LED 3 : GATE POWER SUPPLY LED 5 : LOCKOUT LED 6 : HIGH FREQUINCY

IF LED1 AND LED2 ARE NOT LIT, PLEASE CHECK ALL THE TEST POINT ON THE CARD. IF LED5 IS NOT LIT, CHECK FOR LOCKOUT SIGNAL (INHIBIT SIGNAL) IT IS NORMALLY OPEN / CLOSE CONTACT.

4: RAMP FUNCITION:

RAMP GENERATOR IS NORMALLY USED TO ACHIEVE THE REFERENCE AT PRE DETERMINED RETE SO THAT THE SUDDEN JERKS AT STARTING CAN BE AVOIDED. IT HAS TWO ADJUSTABLE POT RAMP UP SETTING (P3) AND RAMP DOWN SETTING (P4) BY POT P3 YOU CAN ADJUST RAMP-UP (ACCELERATION) TIME AND BY POT P4 YOU CAN ADJUST RAMP-DOWN (DEACCELERATION) TIME.

TEST CHART FOR CARD AP-12

TEST CHART FOR CARD AP-12

REMARKS :

REMARKS : PLOT NO : 5303 , PHASE - 4 GIDC VATVA, AHMEDABAD TELEFAX : 079-25840079,

PLOT NO : 5303 , PHASE - 4 GIDC VATVA, AHMEDABAD TELEFAX : 079-25840079, 25840578 email 1l : ameepower@ameepower.com email 2 : mbg@ameepower.com