HPC-B SERIES USER MANUAL HIGH POWER
Contents
1. ONTROLS LAIT Rev 0 03 18 10 HPC B SERIES USER MANUAL HIGH POWER CONTROL MODULE BURST FIRING VERSION COPYRIGHT 2009 HBCONTROLS HPC B User Manual TABLE OF CONTENTS 1 Ordering O e eene 2 A a 2 3 MS ta 3 3 1 Mounting Instructions italia 3 3 2 Electrical Connections aea 3 3 AAV POWER Supply 3 24V Power deno oo 3 4 3 Command NUE e 3 4 3 1 Input Fail safe Protection 4 4 4 Cycle Times erc 4 4 5 Cycle Times 266mS Selection Fast Synchronous Burst Firing 4 4 5 1 Fast Synchronous Burst Firing Mode aia 4 4 5 2 Fast Synchronous Burst Firing 5 4 6 Line Voltage Compensation LVC 6 4 6 1 Line Voltage Compensation Nominal 7 47 POWER UVR eem 7 4 7 1 Power Limit Adjustment 7 48 Configuration Dipswitch m 7 age a a 8 4 10 Three Phase Operation OE 8 4 11 Wiring Multiple Units in Single Phase or Three Phase Applications 8 4 11 1 Connecting Power amp Commands In 8 5 Electrica2. on startup turn the pot fully CCW Then just turn the pot CW until the desired maximum output Power is achieved For this feature to work as a true max limit it is important that the Line Voltage Compensation be enabled this is the OFF position of Switch 1 If the line voltage compensation is set to OFF or not present in the ordering code the max limit will act as a percentage of output limit and the absolute max limit will change with line voltage 4 8 Configuration Dipswitch The configuration dipswitch is used for setting up the command input and Cycle Times Using a pen point gently push the switch up for on and down for off according to the setup outlined in the table below Command Input 4 5 6 0 5V Default OFF OFF OFF Potentiometer OFF OFF OFF Copyright 2009 HBCONTROLS HPC B User Manual 0 10V OFF OFF ON 4 20mA ON ON OFF 1 5V OFF ON OFF 2 10V OFF ON ON 4 9 Output LED The HPC s RED output LED will turn on when the output is on the LED should can used as a rough indication of SCR Drive and actual power output 4 10 Three Phase Operation Three 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 11 Wiring Multiple Units in Single Phase or Three Phase Applications If more than one is to be used from a non isolated or common command s
3. ROUNDED 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 3 1 Mounting Instructions The HPC 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 4 Operation 4 1 Power Supply The HPC power supply requirement is 24V AC 10 47 63Hz OR 24VDC 15 5 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 HPC is 100mA max 4 3 Command Input The HPC 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 the power supply When wir
4. ignals 1 A common power supply or transformer can be shared If the input selected is O 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 3 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 11 1 Connecting Power amp Commands In Parallel When multiple HPC power inputs and commands are wired in parallel all of the OV terminals must be connected together follows Power Command OV OV OV gt OV OV OV gt 24 24 24 gt IN IN IN gt No crossing of the power input feed or command signal is permitted If for some reason the power should become crossed it will cause a direct short in the system If properly fused the fuse will blow and the HPC will not be damaged If the command inputs are wired improperly damage to the HPC can result 5 Electrical Specifications Command Inputs 4 20mA 0 10V 0 5V Pot PWM Input Impedance 10K 0 10V 2500 4 20mA 100 0 5V Response Time lt 50mS Output Linearity lt 2 External Potentiometer Res 10KQ 25KQ Line Voltage Comp Range 15 15 up to 100 output Power Limit Range 5 100 of max load voltage A
5. ing multiple HPC s together follow the guidelines in the Wiring Multiple HPCs section Copyright 2009 HBCONTROLS HPC B User Manual 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 3 1 Input Fail safe Protection If the signal sent to the HPC s command input should become electrically open the control output will be forced to an off state 4 4 Cycle Times The cycle time refers to the total time between an on and off cycle x O Q lt O The HPC B has 4 available cycle times settable via the dipswitches The cycle times are specified below in of cycles and can be correlated to their respective times using the table below for both 50 and 60 Hz Line frequencies Dip Dip of Cycle Cycle Resolution Switch 1 Switch 2 cycles Time Time of FS 60Hz 50Hz OFF OFF 716 266mS 320mS 72196 ON OFF 60 15 1 28 1 66 OFF ON 600 105 125 0 166 ON ON 6000 100S 120S 0 0166 Synchronous Firing Method When burst firing AC with conventional PWM there is a tradeoff between resolution and cycle time Generally the cycle time should be chosen based on the mass of the load to be controlled the larger the load mass the longer the cycle time can be For the best possible resolution its standard practice to choose the longest cycle time that can be used without causing process ri
6. l Specifications sarta dond ET TES 8 b Mechanical Dimensions naa 10 7 WIRING DIAGRAM SINGLE PHASE ccoo ia 10 8 WIRING DIAGRAM 3 PHASE 4 WIRE Y CONNECTION Error Bookmark not defined 9 WIRING DIAGRAM 3 PHASE INSIDE DELTA CONNECTIONError Bookmark not defined 10 iei or ei o o e t tero iaa 10 1 Ordering Codes Part Description HPC P Phase Angle Control Module SCR GATE DRIVE see HPC 1P User Manual HPC B Burst Firing Control Module SCR GATE DRIVE HPC B LVC Burst Firing Control Module SCR GATE DRIVE w Line Voltage Compensation 2 Description The HPC is a phase angle burst fire control module designed for use with high power back to back SCR modules The power delivered to the load is proportional to the command input signal Features e Zero Cross Firing for low EMI Fast Synchronous Burst Algorithm provides true linear power at fast cycle times Command input accepts 4 20mA 0 10V 0 5V Pot PWM Automatic frequency operation 45 to 65Hz Adjustable Power 96 Limit Drives SCR gates directly Single phase and three phase control Copyright 2009 HBCONTROLS HPC B User Manual 3 Installation 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 it This control must be installed in a G
7. mbient Temperature Range 0 to 50 C Power Supply 24VAC DC 10 10 lt 100mA Current Draw Line Frequency Range 45 to 65Hz Line Voltage Range 100 600VAC SCR Firing AC Zero Cross Fired Copyright 2009 HBCONTROLS HPC B User Manual SCR Gate Drive Characteristics 16KHz Burst for 2mS every half cycle Initial pulse peak current of 600mA maintain pulses 300mA 10uS pulse width per pulse rise time of 100nS Copyright 2009 HBCONTROLS HPC B User Manual 6 Mechanical Dimensions 7 WIRING DIAGRAM Line 2 N 2 gt n 9 5 G2 K2 Ki Gi L2 L1 120VAC 24V AX 5V Vin OV 24VDC Control Input 8 Contact Information a e prima pros Hg TO 508 676 7345 C 3 e lWredagemiXWACFan 1 1 2 1 HBControls 221 Weaver St Fall River MA 02720 508 676 7345 www hbcontrols com Copyright 2009 HBCONTROLS
8. pple Longer cycle times generally provide greater control resolution but the Fast Synchronous Burst setting provides excellent resolution at a fast cycle time 4 5 Cycle Times 266mS Selection Fast Synchronous Burst Firing When the HPC B cycle time is set to 266mS 320mS 50Hz the Fast Synchronous Burst Firing mode is turned on The cycle time becomes longer near zero and full power levels to provide improved control resolution For Example since the HPC 1B generally modulates 16 AC cycles the lower limit in power that will maintain the cycle time is 1 16 6 25 The HPC B will use increased off periods below 6 25 power and above 94 75 power 4 5 1 Fast Synchronous Burst Firing Mode Copyright 2009 HBCONTROLS HPC B User Manual As shown below the HPC B s Fast Synchronous Burst Firing mode selectively fires fractional numbers of cycles Since pulse width modulation alone would limit the resolution to 16 steps or 6 2596 when modulating 16 AC cycles a proprietary algorithm is employed to provide improved resolution of 0 5 196 In this firing mode the cycle time is varied as well as the on time To select the Fast Synchronous Burst Firing Mode set Diswitches 1 and 2 to the off position 25 power 266mS Cycle Time 33 power 200mS Cycle Time 35 7 power Variable Cycle Time 50 power 266mS Cycle Time 75 power 266mS Cycle Time 4 5 2 Fast Synchronous Burst Firing Advantages The two plots below are act
9. rt 4 When line voltage compensation is specified only the fast synchronous burst cycle time is available the dipswitch setting of cycle times is disabled Copyright 2009 HBCONTROLS HPC B User Manual With a 1096 drop in line voltage load powerdropslessthan 2 120V 1KW 14 4 Ohm Load Without Line Voltage Compensation With HPC Line Voltage Compensation 120VAC 120VAC 108VAC 7 10 108VAC 1096 1KW LOAD POWER LOAD POWER 0 81KW 20 4 6 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 7 Power Limit The Power Limit feature is used in conjunction with the Line Voltage Compensation feature to limit the actual voltage delivered to the load The Power 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 HPC 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 Power Limit Adjustment Procedure The Power Limit is adjustable from 5 to 100 of the max power Setting the Power Limit potentiometer half way corresponds to a Power limit of approximately 55 With the command input set to approximately 100
10. ual data for a 425 degF capable 10KW resistive heater ramped from 0 10096 power over two hours The first plot shows straight 16 cycle 266mS cycle time PWM Note the nonlinearity humps due to poor resolution The second plot shows the linearity improvement with the Fast Synchronous Burst Any visible overall curvature is a normal heater characteristic Copyright 2009 HBCONTROLS HPC B User Manual T T T T T 17 30 00 17 55 00 18 20 00 18 45 00 19 10 00 h min s Fast PWM of zero cross fired loads can result in poor linearity resolution above T T T T T 15 00 00 15 25 00 15 50 00 16 15 00 16 40 00 Fast Synchronous Burst algorithm results in excellent linearity resolution above 4 6 Line Voltage Compensation LVC Option The HPC 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 HPC 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 document 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 On the HPC B Line Voltage compensation can be ordered by adding to the suffix of the pa
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