NWUPCM-1P Series User Manual
Contents
1. KUTA NWUPCM 1P SERIES USER MANUAL Rev 1 3 12 13 PHASE ANGLE SCR POWER CONTROL DRIVER BOARD FOR RESISTIVE LOADS COPYRIGHT 2013 NUWAVE TECHNOLOGIES INC NWUPCM 1P User Manual TABLE OF CONTENTS T ee 2 19 0 RE EEN 2 o D 3 2 j Lei o dey Into aO eene E o 3 3 1 Mounting WIS TU CHON EE 4 3 2 gre ie catenei maia anii dia a emite ici em iata item iei oi i eat ina a ea 4 3 3 SCR Output Snubbers and Transient Protection eee nana 4 3 3 1 Commutation Problems cts ceeace oma aaa e aan da tati manea i re i ej eo a i ea idea 4 3 3 2 GW Al PTODIGITIS ai ia 4 3 3 3 NUDE SIZING set iati gal i maieu lu HB ai tata a el ia i i 4 3 3 4 O eeh EE 4 3 4 LEA LE CI Wat se se aaa i enum emcee e ii Dl o eat ia ae a vai 5 OO Mis eine etc qa rele ie e pe menta Ig det ae o a 5 4 1 POWSESUDO E 5 4 2 O SS A o e O E POE ri Pro 5 4 3 o r AA 5 4 4 PWM Command A e e dneesarecasasddednteteledacetedssateseccdeeadigece tates 5 4 4 1 Se VOR lee ri dl cita i ti oda a a ae ati it aia 5 4 4 2 Input Fail safe Protection EEN 6 4 5 Hne voltade Compen aUo EE 6 4 5 1 Line Voltage Compensation Nominal Adjustmeni eee kk kK kk AA 6 4 6 A 6 4 7 po o AAA ERE o PO E BIE OO RO oe CUE PR EA 7 4 7 1 Voltage Limit Adjustment bDrocedure eee eee KK KK KK KK KA 7 4 8 Configuration Dipswitch eee nana 7 4 9 SSR Drive Output NWUPCM 1P GG 8 4102 A in ia Dalma A E E etala ai aia iata alai tao ei MAUA ai date 8 Adl Tires Phase ee c2. NWUPCM 1P SSR 3 PHASE 4 WIRE WYE POTENTIOMETER Revision O DC 070709 e e avo1 INMd S1NdNI ONYWWOD wurr AOL O gt NI YIMOd IVA POTENTIOMETER avol SLAdNI ONYWWOD wu A0L 0 gt POTENTIOMETER Copyright 2013 NUWAVE TECHNOLOGIES INC NWUPCM 1P User Manual 10 WIRING DIAGRAM 3 PHASE 4 WIRE Y CONNECTION SCR MNMd WMd LU a E O o LU ro SLOdN I ONVAINOO a SEH ui 24 wwoz y A0L 0 9 2 2 lt f ZT ele 2 Glo NI Y3IMOd E 5 OVA Z gt O DE Q 230 NO NYNL YOS 3d0id 401 qalin 03 YISINNS WNYILXI avol SLAdN ONYWWOD VWOZ p A0L 0 o gt LETE N POTENTIOMETER NI HMOd MAP 340 NO NYANI YIS H3dOHd YOI qali N03I YASENNS WNYILXI SS ZOO HOS HOWE OL HOVE WIMd WMd SLAdN ONYWWOD vuoz A0L 0 e POTENTIOMETER NI Y3MOd BON 330 NO NYNL 495 H3dO0Hd HOS OHIO Y398NNS WNYALKS L1 avol m ng ge diy d Senan ai ca INON YIS HOWE OL HOVE Copyright 2013 NUWAVE TECHNOLOGIES INC NWUPCM 1P User Manual 11 WIRING DIAGRAM 3 PHASE INSIDE DELTA CONNECTION SCR J j Copyright 2013 MNMd WMd SINANI GNVWWOO VUE A0L 0 NI YSMOd WAKE 330 NO NYNLYOS Y3JOYA YO 3 Q3xINDOSY YASENNS TVN YILX3 rz i i e m JINGOW OS HOVE OL WOVE NMd Ad L INIdNIMN lt SINANI GNVWWOS NI HMOd BOCH 330 NO NHNLY
3. OS H3dOHd HOS O3YINO3Y HIBBNNS TVNYLX3 3 11 QO0W YOS HOSE OL HOVE WMd WMd WOdNMN SINT GNVWINOO vuoz AOL O NI YIMOd BOCH 4340 NO NINLH9S H3dOHd HOS qaud no3t YASENNS TWNYALXS PL Ss ee A JINON 495 HOVE OL HOVE o o VUE A0L 0 gt gt POTENTIOMETER POTENTIOMETER POTENTIOMETER LOAD LOAD NWUPCM 1P SCR 3 PHASE INSIDE DELTA 8 Revision 0 DC 070709 NUWAVE TECHNOLOGIES INC NWUPCM 1P User Manual 12 Contact Information NuWave Technologies Inc 866 379 3597 www nuwaveproducts com Copyright 2013 NUWAVE TECHNOLOGIES INC
4. S INC NWUPCM 1P User Manual The NWUPCM 1 contains fragile components that if damaged can cause improper operation failure or fire While all units are inspected and tested at the factory damage can occur during shipping or installation Before applying power inspect each module for damage paying specific attention to the pulse transformer drive coil If there are any abrasions or scratches on the coil wires DO NOT APPLY POWER The unit should be sent back to the factory for repair 3 1 Mounting Instructions The NWUPCM 1 mounts in a 3 0 snap track and can be installed on a dinrail 3 2 Electrical Connections see the WIRING DIAGRAMS at the end of this document Make sure the module ordered is the correct module for the application before wiring Before wiring the module all Dip Switch settings for the command input and special features should be setup properly per the Dipswitch Configuration Section 3 3 SCR Output Snubbers and Transient Protection 3 3 1 Commutation Problems When an SCR or TRIAC is used to control an inductive load the load current lags the mains voltage When the device turns off at zero current the rate of rise of the reapplied voltage can retrigger the device and produce half cycling and blown fuses To limit this rate of rise and obtain reliable commutation an R C resistor capacitor snubber circuit should be connected in parallel with the SCR TRIAC 3 3 2 dv dt Problems When voltage transients occu
5. WIRING DIAGRAM SINGLE PHASE SSR OR SCR WIRING FOR MODELS NWUPCM 1P SCR PHASE ANGLE NWUPCNM 1B SCR BURST EXTERNAL SNUBBER REQUIRED FOR PROPER SCR TURN ON OFF r L1 EXTERNAL LINE SYNCH INPUT MODULE DIMENSIONS 3 00 X 2 50 X 1 25 NWUPCM 1 NOMINAL OUTPUT ADJUST VOLTAGE LIMIT ADJUST NOMNL V LIMIT e le see e kull SL i RAN lalo Ell Ke OPTICALLY ISOLATED MODELS PWM INPUT NWUPCM 1P SSR PHASE ANGLE y K PLC INTERFACE NWUPCM 1B SSR BURST PWM PWM 24VAC POWER IN 0 10V 4 20mA COMMAND INPUTS POTENTIOMETER NWUPCM 1 SINGLE PHASE WIRING Revision 1 DC 070109 Copyright 2013 NUWAVE TECHNOLOGIES INC NWUPCM 1P User Manual 8 WIRING DIAGRAM 3 INSIDE DELTA CONNECTION SSR WMd WMd L HNOdflMN lt H ul a w 2 CHE n lt loa E gt CHE w zi CE a de CR SLNANI GNVWINOOQ D z CE l E hn en 3 vWOZ p A0L 0 3 a gt lt i 2 o 5 6 2 gl o a Be NI H3MOd g 2 8 wa 3 2 o j d O 0 m ah 4 WOdNMN lt iels gt CE 2 LW de a SLAdNI QNVWWNOOQO e 9 8 o E o el g e A O cl L WOd NAN S1NdNI ONVAINOO E VUE AOL O 2 e NI 43MOd Ow u vc Copyright 2013 NUWAVE TECHNOLOGIES INC NWUPCM 1P User Manual 9 WIRING DIAGRAM 3 PHASE 4 WIRE Y CONNECTION SSR INMd INMd S1NdNI ONYWWOD WIDE A0L 0 e
6. alfunction return it to the factory If defective it will be repaired or replaced at no charge 2 There are no user serviceable parts on this unit This warranty is void if the unit shows evidence of being tampered with or subjected to excessive heat moisture corrosion or other misuse misapplication 3 Components which wear or damage with misuse are excluded e g relays 4 NuWave Technologies Inc shall not be responsible for any damage or losses however caused which may be experienced as a result of the installation or use of this product NuWave Technologies Inc liability for any breach of this agreement shall not exceed the purchase price paid E amp O E 4 Operation 4 1 Power Supply The NWUPCM 1 power supply requirement is 24V AC 10 47 63Hz The line synchronization for phase angle and certain modes of burst firing has an input voltage range of 100 to 600VAC 30 to 90Hz 4 2 24V Power Fusing Fusing may be accomplished by fusing each module separately or fusing groups of the modules with either primary or secondary fusing The current draw of each NWUPCM 1 is 100mA max 4 3 Command Input The NWUPCM 1 can accept 4 20mA 0 10V 0 5V and Potentiometer and PWM inputs All analog command inputs are not isolated from the 24V power Input The type of command input can be configured via the dipswitch The default setting is 0 5V potentiometer The PWM digital command input PLC Interface is optically isolated from th
7. cument Line Voltage Compensation can be enabled or disabled using the configuration dipswitch The default setting is enabled Switch 1 is OFF To disable the Line Voltage Compensation set switch 1 to the ON position With a 10 drop in line voltage NWUPCM 1 load power drops less than 2 120V 1KW 14 4 Ohm Load Without Line Voltage Compensation NWUPCM 1 Line Voltage Compensation 120VAC 120VAC 108VAC S SI 10 108VAC 10 MAINS VOLTAGE IKW IKW LOAD POWER LOAD POWER 0 81KW 20 4 5 1 Line Voltage Compensation Nominal Adjustment The nominal adjustment pot sets the nominal level of output for the current line voltage being measured via the 24VAC input 4 6 Soft Start The Soft Start feature ramps up to the command value over a period of approximately 5 seconds at 60Hz The soft start time resets if the command value goes to zero less than 4 of the input range or power is cycled Soft start is useful on high inrush heaters such as Quartz Molybdenum Tungsten or Graphite heaters Soft Start can be set on or off using the configuration dipswitch The default setting is off Soft start times below 5 seconds are available and can be ordered by adding a XSS to the ordering code where X is the time in seconds Soft Start Period STL AEE SSI A ae fn The Soft Start ramps the voltage up slowly over the soft start period Copyright 2013 NUWAVE TECHNOLOGIES INC NWUPCM 1P User Manual H
8. e power supply When wiring multiple NWUPCM 1 s together follow the guidelines in the Wiring Multiple NWUPCM 1s section Any leg of the command input can tolerate shorts to the 0V input Connecting the 24V power to the command input may cause damage to the unit 4 4 PWM Command Input The NWUPCM 1 PWM Command input is designed to accept a signal from a PLC or a process temperature controller s SSR drive output This logic signal is used to generate a command setpoint 4 4 1 PWM Input The NWUPCM 1 accepts PWM signals from 500Hz 15KHz and logic voltages of 5VDC non isolated command input or 24VDC optically isolated PWM input When using the optically isolated PWM input the PWM Dip Switch 6 must be set to ON The PWM input provides a low cost way to interface with a PLC or PC DAQ Copyright 2013 NUWAVE TECHNOLOGIES INC NWUPCM 1P User Manual 4 4 2 Input Fail safe Protection If the signal sent to the NWUPCM 1 s command input should become electrically open the control output will be forced to an off state 4 5 Line Voltage Compensation The NWUPCM 1 s line voltage compensation keeps the power constant on the load as the line voltage changes The line voltage is measured via the 24V power applied to the NWUPCM 1 module To use the Line Voltage Compensation feature properly a 24VAC power transformer should be fed from the same mains as the load circuit to be controlled as per the wiring diagrams at the end of this do
9. eea teii ateu lau id ft de 8 4 12 Wiring Multiple Units in Single Phase or Three Phase Applications eee eee 8 4 12 1 Connecting Power amp Commands In Parallel 9 D elo ee ee o ee nn ese et eee meee eRe ne ee i Bla 9 O Mechanical DIMENSIONS III 9 7 WIRING DIAGRAM SINGLE PHASE SSR OR GC 11 8 WIRING DIAGRAM 3 INSIDE DELTA CONNECTION GH 12 9 WIRING DIAGRAM 3 PHASE 4 WIRE Y CONNECTION GG 13 10 WIRING DIAGRAM 3 PHASE 4 WIRE Y CONNECTION SCR eee ae 14 11 WIRING DIAGRAM 3 PHASE INSIDE DELTA CONNECTION SCR eee eee 15 12 Con WTO FINA Le RE RR RR RI RR RR RER RR a RR RR RE ARN PI RR NE mm IRI RR NI PNR RR mn 16 1 Ordering Codes Ordering Codes NWUPCM 1P Power Control edu 7 Single Pole Phase Angle SCR or SSR KSS Softstart Time seconds XSC Soft Change Time seconds REV Reverse Acting Output PWM PWM Input V Partit Description NWUPCM 1P SSR Phase Angle Control Module SSR DRIVE NWUPCM 1P SCR Phase Angle Control Module SCR GATE DRIVE NWUPCM 1B SSR NWUPCM 1B SSR Burst Firing Control Module SSR DRIVE see NWUPCM 1B User Manual NWUPCM 1B SCR Burst Firing Control Module SCR GATE DRIVE see NWUPCM 1B User Manual Copyright 2013 NUWAVE TECHNOLOGIES INC NWUPCM 1P User Manual 2 Description The NWUPCM 1p is a Phase Angle SCR Power Control Driver Board designed for use with Solid State Relays or high power back to back SCR modules The power delivered to the load is proport
10. ensity as the power output is increased Because the drive signal varies considerably to give linear power output the LED should only be used as a rough indication of SSR SCR Drive and not actual power output 4 11 Three Phase Operation Three NWUPCM 1s can be used to control three poles of a three phase load for inside delta or grounded WYE configurations The Module should be wired as shown in the wiring diagrams 4 12 Wiring Multiple Units in Single Phase or Three Phase Applications lf more than one NWUPCM 1 is to be used from a non isolated or common command signals 1 A common power supply or transformer can be shared If the input selected is 0 10V or 0 5V the inputs should be wired in parallel 2 If multiple units must be powered from one power transformer and 4 20mA input is selected one module should be set for 4 20mA and the remaining modules should be set for 1 5V and wired in parallel Copyright 2013 NUWAVE TECHNOLOGIES INC NWUPCM 1P User Manual 3 If the command is 4 20mA and the command inputs are to be wired in series a separate power transformer or supply for each module is required to isolate the inputs 4 12 1 Connecting Power amp Commands In Parallel When multiple NWUPCM 1 power inputs and commands are wired in parallel all of the OV terminals must be connected together follows Power Command 24V 24V 24V gt No crossing of the power input feed or command signal is permitted If for some rea
11. igh Inrush Load soft Start used to limit the inrush Current Current Time Time 4 7 Voltage Limit The Voltage Limit feature is used in conjunction with the Line Voltage Compensation feature to limit the actual voltage delivered to the load The Voltage Limit is adjustable via a potentiometer located just below the input terminal block For this feature to work properly Line Voltage Compensation must be turned on and the power transformer for the NWUPCM 1 must be connected to the same mains as the load power is connected to This feature can be used without Line Voltage Compensation and will simply clip the command signal to a set level 4 7 1 Voltage Limit Adjustment Procedure The Voltage Limit is adjustable from 25 to 100 of the max load voltage Setting the Voltage Limit potentiometer half way corresponds to a power limit of approximately 55 or a voltage limit of 70 of the max load voltage The best way to set the voltage limit is using a voltmeter connected across the load With the command input set to approximately 100 on startup turn the pot fully CCW Then just turn the pot CW until the desired output voltage is achieved For this feature to work as a true voltage limit it is important that the Line Voltage Compensation be enabled this is the OFF position of Switch 1 lf the line voltage compensation is set to OFF the voltage limit will act as a percentage of output limit and the absolute voltage limit will change with l
12. ine voltage 4 8 Configuration Dipswitch The configuration dipswitch is used for setting up the command input line voltage compensation and soft start Using a pen point gently push the switch up for on and down for off according to the setup outlined in the table below Commandinput 2 4 5 6 gt om orl ON orl Or soma ol or ON Or e ol or orl Or 210 ON ON OF OF PWM isolated input OF OFF OFF ON Feature to Enable NA 3 Line Voltage Comp Enabled default Non ON OF Copyright 2013 NUWAVE TECHNOLOGIES NC NWUPCM 1P User Manual Soft Start Only Enabled ON ON Soft Start amp Line Voltage Comp Enabled OFF ON 4 9 SSR Drive Output NWUPCM 1P SSR The NWUPCM 1 s SSR output drive is a DC pulsed current limited 10V 15mA nominal drive signal This is more than enough current for driving most 3 32V standard SSRs however it is still important to review the data sheet for the SSR you would like to use for compatibility with the NWUPCM 1 s output drive The control output can tolerate a momentary direct short The following graph will allow you to verify the SSRs compatibility with the NWUPCM 1 over wide input voltage variations SSR DRIVE CURRENT mADC 0 5 10 15 20 SSR INPUT VOLTAGE DROP VDC NWUPCM 1 s Output Drive Current vs SSR Input Voltage Drop 4 10 Output LED The NWUPCM 1 s RED output LED will turn on when the output is on and increase in int
13. ional to the command input signal Features e Provides true linear power output phase angle control and burst fire control Small 3 0 x2 5 module mounts in a snap track or a dinrail Command input accepts 4 20mA 0 10V 0 5V Pot PWM Configurable line voltage compensation increases stability of your process Configurable soft start for high inrush loads Wide frequency operation 30 to 90Hz Adjustable Voltage Limit Drives multiple solid state relays Drives SCR gates directly single phase and three phase control 3 Installation Safety Information Responsibility for determining suitability for use in any application equipment lies solely on the purchaser OEM and end user Suitability for use in your application is determined by applicable standards such as UL cUL and CE and the completed system involving this component should be tested to those standards WARNING FIRE HAZARD Even quality electronic components CAN FAIL KEEPING FULL POWER ON Provide a SEPARATE redundant OVER TEMPERATURE SHUTDOWN DEVICE to switch the power off if safe temperatures are exceeded WARNING HIGH VOLTAGE This control module has high voltage on it This control must be installed in a GROUNDED enclosure by a qualified electrician in accordance with applicable local and national codes including NEC and other applicable codes Provide a safety interlock on the door to remove power before gaining access to the device Copyright 2013 NUWAVE TECHNOLOGIE
14. r on the mains supply or load of an SCR TRIAC it can cause the device to turn on unexpectedly due to the fast rate of rise of voltage dv dt This can result in false firing and half cycling of the load that can cause blown fuses when driving inductive loads An R C snubber circuit will help to limit the dv dt seen by the device and will produce more reliable firing 3 3 3 Snubber Sizing When an SCR TRIAC using an R C snubber turns on the capacitor is discharged through the resistor into the device resulting in high peak currents It is critically important when sizing your snubber to make sure that the resistor value does not become so low that the ratings of the SCR TRIAC are exceeded when the capacitor is discharged 3 3 4 MOVs and TVSs Metal Oxide Varistors and Transient Voltage Suppressors are both used on TRIACS SCRs to clamp voltage spikes that can occur across the devices and damage them Snubbers are not a substitute for MOVs TVSs and vice versa Snubbers and MOVs TVs should be used together to get reliable performance and long life from the SCR TRIAC application External MOVs must be installed across the SCRs to limit peak voltages accepted by the NWUPCM to 850VDC Copyright 2013 NUWAVE TECHNOLOGIES INC NWUPCM 1P User Manual 3 4 Limited Warranty NuWave Technologies Inc warrant this product to be free from defect in workmanship and materials for a period of two 2 years from the date of purchase 1 Should unit m
15. son the power should become crossed it will cause a direct short in the system If properly fused the fuse will blow and the NWUPCM 1 will not be damaged If the command inputs are wired improperly damage to the NWUPCM 1 can result 5 Electrical Specifications Command Inputs Input Impedance Control Output Response Time PWM Input Frequency PWM Input Level Output Linearity External Potentiometer Res Line Voltage Comp Range Regulation Soft Start Period Voltage Limit Range Ambient Temperature Range Power Supply Line Frequency Range Line Voltage Range SCR Gate Drive Characteristics 6 Mechanical Dimensions Copyright 2013 4 20mA 0 10V 0 5V Pot PWM 10K Q 0 10V 2500 4 20mA 100KQ 0 5V SSR Drive DC pulse nominally 10V at 15mA lt 50mS 500Hz 15KHz 5 VDC non isolated or 24VDC isolated 3 10KQ 25KQ 15 15 up to 100 output 3 5 seconds to reach 100 output 25 100 of max load voltage 0 to 50 C 24VAC 10 10 lt 100mA Current Draw 30 to 90 Hz 100 600VAC External MOV must be installed across SCRs to limit peak voltages to 850VDC 16KHz Burst for 1 35mS every half cycle Initial pulse peak current of 600mA maintain pulses 300mA 10uS pulse width per pulse rise time of 100nS NUWAVE TECHNOLOGIES INC NWUPCM 1P User Manual 1 17 NWUPCM 1 MODULE MOUNTED IN SNAP TRACK Copyright 2013 NUWAVE TECHNOLOGIES INC NWUPCM 1P User Manual 7
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