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CONTROL PANEL SOFTWARE

1. 37 6 4 5 Param Link SP 160 5 5 nuUa cu o danda 38 6 5 Hardware Profile aues uariis ee 38 DAIS SI REM 39 GIOCO meee ee 40 40 6 6 3 MODBUS Interface via 0 40 6 6 4 Service Times HP 41 6 6 5 Calibration ISelo8t 2 EE Draw MAE Ra EE RES 41 NEN peu 42 6 7 1 AC Line Status MP 942 IAM PM uit unique 42 6 7 2 EEProm Status MP 395 sasco susct t sens un Ex nes 43 250513 MT 44 6 7 4 Module EEProm Status MP 337 45 6 7 5 Module B EEProm Status 46 6 7 6 Module C EEProm Status MP 339 a En aon an 47 6 7 7 Module D EEProm 40 2 48 6 7 8 Aux EEProm Status MP 341 e rrt 49 6 8 OEM OEM Version OR erin er unter cup i Mn 49 ael cir PH 50 NA eoe MIO 50 o c P set 51 7 2 1 Advanced Settings
2. 52 6 DATA LOGGER TAB eee 54 QD Concerts CONCEPTS The FUSION Control Panel Software is intended to assist during installation parameter setup operation and troubleshooting through a simple Windows interface Note This manual refers to Build 8 of the Control Panel FUSION Control Panel 3 50 Build 7 Digital Setpoint 1 Digital Selpoinl 2 Analog setPt 1 Analog amp otPt 2 fone 1 fone 3 fone 4 POQOR X U Devices Connection Slats Disconnecke Version o oo d Connect use Modbus Ethemet C Medbus RTU RS 465 uve config File Load Config File Restore MFG Default Chans Settings Data Logger State EE Fone 88 O Out 96 3 Normal SetFt Ref 4 Normal Controller_Stalus Feedback system fone 1 2 zont 3 cane 4 L igital comm Hardware Profile Diagnostics 1 M Limits Feedback Type Zone 1 Voltage Zone 1 Finng Made Zane 1 Gurreni Limit Zone 1 Control Made 1 v Current Limit Type zone 1 Ramp Time zone 1 Current Trip 1 Control Response Factor Zone 1 Power Limit Zone 1 D evwatlon Band Zone 1 Full stale settings QUT But in Full Scala Full calp Voltagp zone 1 LoadvoltPct Zone 1 Full Srale Current
3. 2 RETE 2 COMMS IAG 2 3 PROCESSOR amp FAULT asini cmd une ot PEE tm EPA und ao utin ie nA 3 a DEVICE INEJ 25 eee E 3 MEE CONNEC B UNO 3 4 2 Interface els MET MON EL ee ee ae ae een aa 4 Save Config BURON 4 4 4 Load Config Button 4 A WSS CONN ES 4 4 6 Flash Firmware Button s oou roti oae tup Deu case naut deed 5 4 7 Restore MFG Defaults 5 SW Dg eB OS HBOARD T ee ee ee ee 6 Og gt ls neces m 6 6 5 1 2 Control Loop 6 52 CONTOS STUS 7 5 3 C mmand amp Auxiliary 19 T 5 4 Module Operating T SEE le zig a EEE AE T 6 TAB SGCREEN SETTINGS 8 SEEE E
4. E E AE 8 6 1 1 System 8 6 1 2 Analog SCO MANS and appe 11 6 1 3 SP085 Relay 1 Alarms SP 85 SP086 Relay 2 Alarms SP 86 15 ONE MEI Reli 16 6 1 5 User Settings OT 18 6 1 6 Digital System Command 2 18 WAdop NI 20 021 see 21 6 2 2 Full Scale Settings 23 6 2 3 Zero Cross 25 SPADA RR 25 D 5 UME Dobis tameii eee te cupiat iu 26 6 2 6 SP016 Relay 1 Alarms SPO17 Relay 2 Alarms SP 16 17 SP 36 37 SP 56 57 clair MET 26 VO Optional 28 SAN Ap 28 6 3 2 AUX Digital Q M ee 29 6 3 3 AUX RS AIS npe A M IND 30 6 4 Digital Comm 33 6 4 1 Common Settings 34 one IE 35 6 4 3 R5 485 ComrmunieatiOfi epe t Ee o na ta pntat Rad 36 6 4 4 DeviceNet
5. 1 LoadCurrentPct 1 Full scale Power 1 uM LoadPowerPct Zone 1 Calculate Power amp Limits Grots Sailings Burst Angie Zone 1 Phase 20 Senich Zone i cycle Phase Angle Start Tuning FIGURE 1 00 Diagnostics 2 nzP l1b6Hgelay 1 Alarms Lear LI Digital Enable Limit Current Pawer Limit Shorted SCR Lind Phase Loss Heatsink Warning Temp Current Trip LI Heatsink Cuer Temp SPO17 Relay 2 Alarms Low Output LI Digital Enable Voltage Limit Cument Limit Limit Shorted SCR Line Phase Lost Heatsink Warning Temp Current Trip Heatsink Over Temp Configuring the controller is made easier with the software as multiple things may be viewed at the same time The screen is broken into 3 main sections Device Info Dashboard and Tab Screens See Figure 1 00 Each of these will be described in detail within this manual The different Tab screens allow for an easy system setup even with multiple zones of control Once a controller is set up with desired settings a configuration file can be saved This file can then be loaded to other systems for quick and easy setup Connection to the Fusion Control Panel Software is accomplished with a USB cable from the controller to a PC ZN Load the CD containing the FUSION Control P
6. CONTROL CONCEPTS 6 1 3 5 085 Relay 1 Alarms SP 85 5 086 Relay 2 Alarms SP 86 Click on the checkbox next to the particular alarm function to energize the relay if the condition is met Both relays can be mapped to any number of conditions and both relays can contain the same condition See the Installation and Maintenance Manual for wiring and ratings These relay outputs work in conjunction with SP 16 SP 36 SP 56 SP 76 for Relay 1 and SP 17 SP 37 SP 57 SP 77 for Relay 2 Processor Error Trap These are rare types of errors where the controller will not be functioning Errors that are included are flash program error stack over flow error math error address error and DMA conflict To clear these errors follow the message s on the display For further assistance contact Control Concepts Inc Communications Error A communication problem when using digital communications only Memory Error EEPROM check failure MP 210 bit 6 See the Diagnostics 2 tab for errors Watchdog Timeout Specific processor error trap MP 210 bit 7 PLL Lock Loss Phase Locked Loop lost its lock on the AC line MP 210 bit 2 In State When the Controller State MP 248 is in Run Run Enable When the Controller State MP 248 is in Run Dig Sys Bit 10 5 085 Relay 1 Alarms SP 85 bit 15 only Directly control Relay 1 with the Digital System Command SP 129 bit 10 Dig Sys Bit 11 5 0
7. Baud Rate 72 Current Limit Zone 4 2 C 73 Current Limit Type Zone 4 74 Current Trip Zone 4 H Feedback Type Zone 2 45 22 Out Zone 2 47 23 Control Mode Zone 2 24 lamp Time Zone 2 124 Nie Cher Dut FIGURE 6 04 By default the password is 4000 Once the initial password is entered you may also change the password by selecting the Change Password checkbox and entering a new 4 number combination into the field You may select the checkboxes of parameters you wish to lock or use the Lock All or Unlock All buttons to select deselect all available parameters An editable parameter will appear on the controller display with a dot preceding the text Pressing the green checkmark key will allow you to edit the parameter value When the parameter is locked an asterisk appears instead and the green checkmark key will prompt you to enter the password Use the arrow keys to enter the correct combination pressing the green key to move forward to the next number If the correct password is entered all parameters are unlocked and can be locked again by pressing and holding the plus sign key SP 1 2 USER Wi JNLOCK sDisitasl SP 1 21 4 n ij m EST eves 7 2 Locked parameter Password prompt Unlocked display Editable parameter FIGURE 6 05 Auto Scroll Enable SP 116 If the Auto Scroll Enabled checkbox is s
8. CONCEPTS Module D Line MP 342 bit 3 Present Absent Indicates if the AC line is present on module D Phase Rotation MP 342 bit 4 TBD OK Indicates if the phase rotation has been determined Phase Rotation MP 342 bit 5 1 2 3 3 2 1 Indicates the phase rotation Control Timing MP 342 bit 6 Blank OK The timing for SCR firing This must be OK in order for the SCR to turn ON ADC Timing MP 342 bit 7 Blank OK The timing for feedback data collection synchronization 6 7 2 Main EEProm Status MP 336 Status Color Green Bit Definition Bit 15 2 TBD 14 13 EE SP Def Update Req OK 12 EE Write Protected Not Protected Protected 11 User SP Backup Fail OK 10 DC Current Backup Fail OK 9 DC Current Comp Fail OK Table 8 Hepair Record Table Fail OK 7 Error Record Table Fail OK 6 MFG Table Fail OK 5 Cal Table Fail OK 4 CalV Table Fail OK MFG SP V Table Fail OK 2 User SP V Table Fail OK 1 lnitialized Init Required Initialized Bit O Read Write Fail OK Read Write MP 336 bit 0 OK Fail During power up checks to see if the EEPROM is functional Initialized Init Required MP 336 bit 1 The EEPROM has been initialized User SP V Table MP 336 bit 2 OK Fail Status of the user setup parameter table Control Concepts Inc 2013 www ccipower com 1 800 765 2799 FUSION Control Panel Manual Rev 3 50 MFG SP V Table MP 3
9. CONTROL CONCEPTS T V Se LL ILL LL LLL _ H 0 0 BM et 2 E Ou qe LL 0 71111111 I ee ee 4 LL EL LL LLL IL LL LIE LL e I FUSION Control Panel Manual Rev 4 00 lt E ower com 1 800 765 2799 Control Concepts Inc 2013 CONTROL CONCEPTS CONTROL CONCEPTS INC 2 YEAR LIMITED WARRANT Y CONTROL CONCEPTS INC warrants that the products delivered will be as described in the sales order or contract CONTROL CONCEPTS INC warrants to the original user that CONTROL CONCEPTS INC products will be free from defects in materials and workmanship for a period of two 2 years after the date CONTROL CONCEPTS INC ships such products If any CONTROL CONCEPTS INC product is found to be defective in material or workmanship during the applicable warranty period CONTROL CONCEPTS INC s entire liability and purchasers sole and exclusive remedy shall be the repair or replacement of the defective product at CONTROL CONCEPTS INC s election CONTROL CONCEPTS INC shall not be liable for any costs or expenses whether direct or indirect associated with the installation removal or re installation of any defective product All shipping and freight costs a
10. Digital Out 2 High Active SP 157 high This is only used when Digital Out 1 FX SP 156 Digital Out 2 FX SP 157 is set for Direct Out Control Concepts Inc 2013 www ccipower c 1 800 765 2799 FUSION Control Panel Manual Rev 3 50 The outputs configured similarly to the analog inputs The two retransmits can be configured independently as either a current source 0 20 mA or as a voltage source 0 10 Meter 1 Signal SP 141 Meter 2 Signal SP 148 Here is a picture of a 4 zone Compact FUSION to help determine the proper Setting to use A three phase controller would only have Modules A B and C A multizone single phase would use Module A for Zone 1 Module B for Zone 2 and so on The Module letters also represent values that can be seen in the Dashboard section of this manual MODULE oo 0 100 240 Ref A Vac Figure 6 09 FUSION Control Panel Manual Rev 3 50 www ccipower com 1 800 765 2799 Control Concepts Inc 2013 CONTROL CONCEPTS RMS Load Volt A The load voltage for module A AVG Load Voltage A The load voltage for module A RMS Load Current A The load current for module A AVG Load Current A The load current for module Load Power A The load power for module A RMS Load Voltage B The load voltage for module B AVG Load Voltage B The load voltage for module B RMS Load Current B The load current for module B AVG Load C
11. 6 7 7 Module D EEProm Status MP 340 Status Color Red Bit Definition Bit 7 6 5 Main EE Cal Backup Fail 4 Repair Record Table Fail 3 Cal Table Fail 2 MFG Table Fail 1 Initialized Init Required Bit 0 Read Write Fail Read Write MP 340 bit 0 OK Fail During power up checks to see if the EEPROM is functional Initialized Init Required MP 340 bit 1 The EEPROM has been initialized MFG Table MP 340 bit 2 OK Fail Status of manufacturing data table Cal Table MP 340 bit 3 OK Fail Status of the calibration data table Repair Record Table MP 340 bit 4 OK Fail Status of the repair record table Main EE Cal Backup MP 340 bit 5 OK Fail Status of the backup calibration data table EE Write Protected EE Not Write Protected MP 340 bit 7 The status of the EEPROM write protection FUSION Control Panel Manual Rev 3 50 WWW Ccipower com 1 800 765 2799 Green EE Write Protected Not Protected Protected OK OK OK OK Initialized OK Control Concepts Inc 2013 CONTROL CONCEPTS 6 7 8 Aux EEProm Status MP 341 Status Color Red Green Bit Definition Bit 7 EE Write Protected Not Protected Protected 6 TBD 5 Main EE Cal Backup Fail OK 4 Repair Record Table Fail OK 3 Cal Table Fail OK 2 MFG Table Fail OK 1 Initialized Init Required Initialized Bit 0 Read Write Fail OK Read Write MP 341 bit 0 OK Fail During power up check
12. SP 137 Analog Lo Out SP 92 SP 97 mA or V 0 Analog SP Lo Cmd Analog Hi SP 91 SP 96 SP 93 SP 98 Analog 0 Analog SP 100 FIGURE 6 01 This is a graphical representation of how the Analog Setpoints and the Monitor Values are configured Control Concepts Inc 2013 WWW ccipower com 1 800 765 2799 FUSION Control Panel Manual Rev 3 50 Analog SP1 Type SP 90 Voltage Voltage input scalable from 0 10 Current Default Current input scalable from 0 20 mA default 4 20mA This selects the input signal type for Analog Setpoint 1 The wiring diagram for the inputs can be found in the Installation and Maintenance manual Analog SP1 Function SP 88 Setting Description Normal Uses the Analog Setpoint 1 to control the Set Point Default Reference MP 250 To Be Determined Uses the Analog Setpoint 1 as a monitor variable that can be scaled for monitoring purposes Under Normal operation the setpoint is used for control When Monitor is chosen it can be scaled with a full scale parameter SP 136 The monitor value is then viewed with parameter MP 208 When using the Monitor setting the controller will not use Analog Setpoint for control Analog SetPt 1 Signal MP 204 This gives the value of the setpoint signal Analog SP1 Lo Cmd SP 91 Default value 4 00 mA This is paired with Analog SP1 Lo Out SP 92 This parameter is the signal value at the
13. Disabled e Hero Mode is disabled Enabled Hero Mode is enabled Note Controller warranty is voided when Hero Mode is Enabled AND an over temperature condition occurs When the controller is operating within proper environment and specifications it is extremely rare that the SCR would exhibit an over temperature condition Contact factory for details about this feature If Hero Mode is enabled the over temperature inhibit alarm will be disabled The over temp alarm is designed to shut the controller down when the SCR temperature exceeds its safety ratings This is designed in for customers that need to keep their process in operation even if it may damage the SCR power controller When enabled and an over temp condition occurs Inhibit Alarm MP 210 will still indicate the over temp condition If a relay mask SP 16 or SP 17 has Heatsink Over Temp Selected the relay will energize Meanwhile the controller will stay in the Run State The display will register Warning Alarm Heatsink Temp and the Status LED on the front lid of the controller will flash orange The over temp indications will clear when the temperature drops below the over temp limit threshold Control Concepts Inc 2013 www ccipower com 1 800 765 2799 FUSION Control Panel Manual Rev 3 50 SYNC GUARD OVERVIEW SYNC GUARD is a feature for zero cross controllers only It reduces the possibility of synchronous operation of two or more zero cross contr
14. load voltages load currents and temperatures for each module and also the line frequency For Compact FUSION controllers there is an additional Fuse Blown indicator for each module 5 5 Inhibit Alarms This area shows any alarms that when activated inhibit the controller s operation and places the controller in a Stop or Fault state The most common inhibit alarms are Phase Lock Phase Loss when line power is not present A Current Trip alarm requires a fault reset in order to clear the fault An Over Temp alarm also requires a fault reset for the particular zone to be cycled and the temperature to return to normal operating range in order to clear the fault See Section 3 for more information on resetting the controller O Control Concepts Inc 2013 WWW ccipower com 1 800 765 2799 FUSION Control Panel Manual Rev 3 50 6 TAB SCREEN SETTINGS There are two different tab controls horizontal and vertical in the tab screens section The vertical section contains Settings Charts and Data Logger The Settings and the Charts tab each contain a horizontal section System zone 1 fone 3 fone 4 Aux 170 Digital Comm Hardware Profile Diagnostics 1 Diagnostics 2 puso Relay Alarms Relay 2 Alarms Display Contro User Settings Processor Error Trap Processor Error Trap Default Screen List save to Backup Communications Error Communications Error z a Custom Screen List Res
15. 133 Disabled Use switch setting on P1 connector pins 7 and 8 Enabled Override P1 connector Use SP 129 bits 12 15 If Enabled the controller will use the Digital System Command to determine setpoint type Analog Digital SP 129 bits 12 15 Each zone is set to Analog 0 by default P1 10 Override SP 134 Sew Dm Disabled Use switch setting on P1 connector pins 7 10 Enabled Override P1 connector Use SP 129 bits 4 7 If Enabled the controller will use the Digital System Command to determine the setpoint setpoint 1 setpoint 2 SP 129 bits 4 7 Each zone is set to Setpoint 1 0 by default Relay 1 checkbox SP 129 bit 10 When the checkbox for Dig Sys Bit 10 SP 85 bit 15 under 5 085 Relay 1 Alarms has been checked checking this box SP 129 bit 10 will energize Relay 1 18 FUSION Control Panel Manual Rev 3 50 www ccipower com 1 800 765 2799 Control Concepts Inc 2013 CONTROL CONCEPTS Relay 2 checkbox SP 129 bit 11 When the checkbox for Dig Sys Bit 11 SP 86 bit 15 under 5 086 Relay 2 Alarms has been checked checking this box SP 129 bit 11 will energize Relay 2 Digital Enable Always On XP 3401 Bits 0 3 NIC RN Use the Digital System Command to put the controller in a RUN Stop state During power up reset initialization Disabled Digital System Command SP 129 defaults to put all Default zones into S
16. Modbus Address SP 120 Default value 1 This is the address of the controller on the network RS 485 Baud Rate SP 121 Setting 9600 bps 9600 bits per second bps 19200 bits per second RS 485 Byte Format SP 122 peson No parity 8 data bits 1 stop bit E81 Even parity 8 data bits 1 stop bit RS 485 Char Out SP 123 Seti Description onis RTU 5 pit binary protocol Modbus ASCII ASCII character protocol Modbus ASCII protocol is included for troubleshooting only and therefore has limited capabilities FUSION Control Panel Manual Rev 3 50 www ccipower com 1 800 765 2799 Control Concepts Inc 2013 CONTROL CONCEPTS 6 4 4 DeviceNet For DeviceNet communications only For more details on this section see the DeviceNet manual DeviceNet Mac ID SP 118 Default value 63 This is the address of the controller on the network DeviceNet Baud Rate SP 119 Setting Description 125000 bits MM L second 250Kbps 250000 bits 250000 bits per second second 500 Kbps 500000 bits per second Poll I O Default EPR SP 198 Default value 0 ms This is the expected packet rate value assigned to the connection while it is in the Configuration state Note During the configuration state no Inactivity timer is running so this does nothing Bus Off Interrupt SP 199 bit 0 Setting Description Hold in When
17. be used unless directed to by Control Concepts O Control Concepts Inc 2013 WWW ccipower com 1 800 765 2799 FUSION Control Panel Manual Rev 3 50 39 6 6 1 I O Contol Diagnostic Enable CAL 395 Description Disabled Disable diagnostic mode Default Do not change unless directed to do so Diagnostic Ch Select CAL 396 Setting Description 0000000 Diag Bits The diagnostic bits are OFF OFF Default Do not change unless directed to do so 6 6 2 System Control Retrieve Fault History button Every time the controller experiences a fault the fault information is recorded This button retrieves the fault information and saves it to a text txt file with the controller s serial number Upon saving this file a text file will open and display the Error Index Error Time Error Code and Error String This file can be useful when determining unknown fault states Clear Error Latch button Clears that error latch register MP 345 Clear Fault History button This clears the fault history record in the controller Clear Trap button This clears the processor error trap records Program CPLD button Used when loading a new CPLD program 6 6 3 MODBUS Interface via USB Read Hold Register button Enter the number of the parameter you wish to read into the Register box next to the Read Hold Register button Selecting this button will read the value of the parameter and display it in the Value FUS
18. of the possibility of such damages By purchasing CONTROL CONCEPTS INC s products the purchaser agrees to the terms and conditions of this limited warranty WARNING The Control Concepts Inc power controllers use power thyristors to switch voltage to the connected load Line voltage must be assumed at the output terminals at all times even when the control signal has been removed and the load voltage appears to be off It has been mandated by the National Electrical Code and the Occupational Safety and Heath Act of 1970 that a physical disconnect be opened ahead of all remotely actuated controls before performing any maintenance work on the controller or its connected load PROPRIETARY DATA Copyright 2009 10 Control Concepts Inc Chanhassen MN 55317 The information and design disclosed herein are the property of Control Concepts Inc and may not be used reproduced or disclosed in any form except as granted in writing by CONTROL CONCEPTS INC 18760 LAKE DRIVE EAST CHANHASSEN MN 55317 PHONE 952 474 6200 TOLL FREE 800 765 2799 FAX 952 474 6070 www ccipower com FUSION Control Panel Manual Rev 4 00 WWW Cccipower com 1 800 765 2799 Control Concepts Inc 2013 TABLE OF CONTENTS 1 e ere eee I 1 2 GE TIING STARTED utentes tense matu NR I 1 2 1 Minimum Requirements ERA b en
19. percent displayed in SP 92 This is typically your lowest possible signal value that can be achieved Analog SP1 Lo Out SP 92 Default value 0 00 This is paired with Analog SP1 Lo Cmd SP 91 This parameter is the percentage at the signal value displayed in SP 91 Analog SP1 Hi Cmd SP 93 Default value 20 00 mA This is paired with Analog SP1 Hi Out SP 94 This parameter is the signal value at the percent displayed in SP 94 This is typically the highest possible signal value that can be achieved 12 FUSION Control Panel Manual Rev 3 50 www ccipower com 1 800 765 2799 Control Concepts Inc 2013 CONTROL CONCEPTS Analog SP1 Hi Out SP 94 Default value 100 00 This is paired with Analog SP1 Hi Cmd SP 93 This parameter is the percentage at the signal value displayed in SP 93 Analog SP1 Monitor Full Scale SP 136 Default value 1000 This is for scaling the Analog Setpoint 1 Monitor Value MP 208 This value can be scaled for any type of user input If this value is desired to be monitored on the Display it can be viewed by adding MP 208 to the custom screen list On the custom screen list window a four character title can be edited and up to three characters may be entered for units to be displayed with MP 208 Analog SP1 Monitor Value MP 208 The Analog Setpoint 1 monitor value that is calculated from the analog input signal and scaled by the full scale setting SP 136 Ana
20. 0 Volts The voltage that will be applied when the load is at full capacity The closer the full scale voltage is to the actual voltage the more accurate the controller will be Setting this slightly higher than the actual voltage is common This should not be set to more than 2X the expected maximum voltage Full Scale Current SP 9 SP 29 SP 49 SP 69 Default value Frame Rating for controller in Amps The current that will be applied when the load is at full capacity The closer the full scale current is to the actual current the more accurate the controller will be Setting this slightly higher than actual current is common This should not be set to more than 2X the expected maximum current Full Scale Power SP 10 SP 30 SP 50 SP 70 The power in kilowatts that will be applied when the load is at full capacity This should not be set to more than 2X the expected maximum power The default value is calculated from the following For 1 Phase AC and for DC controllers Full Scale Voltage X Full Scale Current For 3 Phase AC with Delta 3 or 4 wire wye loads Full Scale Voltage X Full Scale Current X v3 For 3 Phase AC with Inside Delta load or 4 wire wye loads Full Scale Voltage X Full Scale Current X 3 After setting up the Full Scale Voltage and Full Scale Current the Calculate Power amp Limits button can be used to set the Full Scale Power Calculate Power amp Limits button By pressing this button the Full Scale
21. 3 ParamLink Inst 29 3 Bus Off Interrupt ParamLink_Inst_1l2_Attr_3 FaramLink Inst 30 Attr 3 Holdin Reset Auto Reset to Online FaramLink Inst 13 Attr 3 ParamLink Inst 31 Attr 3 Explicit Connection Watchdog Action ParamLink Inst 14 Attr 3 ParamLink Inst 32 3 ah 2 Auto Delete Deferred Delete ParamLink Inst 15 Attr 3 ParamLink Inst 33 Attr 3 ParamLink Inst 16 Attr 3 ParamLink Inst 34 Attr 3 pr XU S ParamLink Inst 17 Attr 3 ParamLink Inst 35 3 ransitian to Timed Qu uto Rese ParamLink Inst 18 Attr 3 d ParamLink Inst 36 3 DeviceNet Control Concepts Inc 2013 WWW ccipower com 1 800 765 2799 FUSION Control Panel Manual Rev 3 50 6 4 1 Common Settings Communications Heartbeat Timer SP 125 For Ethernet IP Modbus and Profinet communications only Default value 0 s When the first message to the controller s address is received the heartbeat timer starts Subsequent messages reset the timer If the heartbeat timer expires the Network Timeout Action SP 128 bit O is executed A notification of a communication timeout will be indicated on the display of the controller When the timer is timed out the next valid message will reset the timer When the heartbeat time is set to O seconds the timer will never expire Network Timeout Action SP 128 bit 0 for more details for what happens when a timeout occurs Network Timeout Action SP 128 bit 0 For a
22. 36 bit 3 OK Fail Status of the manufacturing setup parameter table Cal V Table MP 336 bit 4 OK Fail otatus of the calibration setup parameter table Cal Table MP 336 bit 5 OK Fail Status of the calibration data table MFG Table MP 336 bit 6 OK Fail Status of manufacturing data table Error Record Table MP 336 bit 7 OK Fail Status of the error record table Repair Record Table MP 336 bit 8 OK Fail Status of the repair record table DC Current Comp Table MP 336 bit 9 OK Fail Status of the DC current compensation table DC Current Backup MP 336 bit 10 OK Fail Status of the backup DC current compensation table User SP Backup MP 336 bit 11 OK Fail Status of the backup user setup parameter table EE Write Protected EE Not Write Protected MP 336 bit 12 The status of the EEPROM write protection EE SP Def EE SP Def Update Req MP 336 bit 13 The status of the setup parameter definition table 6 7 3 Misc Status MP 335 Compatible CPLD Present Incompatible CPLD Present MP 335 bit 1 Not Waiting on Enter Key Waiting on Enter Key MP 335 bit 3 FUSION Control Panel Manual Rev 3 50 WWW Ccipower com 1 800 765 2799 Control Concepts Inc 2013 CONTROL CONCEPTS 6 7 4 Module A EEProm Status MP 337 Status Color Red Green Bit Definition Bit 7 EE Write Protected Not Protected Protected 6 TBD 5 Main EE Cal Backup Fail OK 4 Repair Record Tabl
23. 65 2799 Control Concepts Inc 2013 CONTROL CONCEPTS Data Trace Trigger Drop box Seng Desoripfon SSS None Starts on the next AC line positive half cycle MN When controller is in Run state Next Zero Cross fire pulse Next Zero Cross fire pulse on the positive half cycle Positive Next Zero Cross fire pulse on the negative half cycle Negative Any limit Voltage Current Power Shorted SCR Shorted SCR event Curren Over Current Trip event Data Trace Cycles Range 0 100 Cycles 0 continuous After trigger data is collected until the set number of cycles then the trace stops and holds data for the last two cycles collected For example If Data Trace Cycles 10 10 cycles of data will be collected and the last 2 cycles will be saved for viewing Control Concepts Inc 2013 www ccipower com 1 800 765 2799 FUSION Control Panel Manual Rev 3 50 8 DATA LOGGER 1 2 3 4 5 amp 8 10 15 30 45 60 i i j i Interval Sec Data Logger Charts Settings FIGURE 8 00 The Datalogger Tab is a vertical tab found to the left of the active tab screen This tool logs the runtime data for the FUSION Power Controller to a csv file which can be imported into a spreadsheet program The tool is useful for logging process cycles and machine start ups Start the logger by first selecting the log interval in seconds and then click the red bu
24. 86 Relay 2 Alarms SP 86 bit 15 only Directly control Relay 2 with the Digital System Command SP 129 bit 11 controller will have an inhibit alarm present Control Concepts Inc 2013 www ccipower com 1 800 765 2799 FUSION Control Panel Manual Rev 3 50 6 1 4 Display Control In Firmware versions 4 00 and later you may customize the controller screen list so that the controller displays the most relevant data for your application Default Screen List Pressing the Default Screen List button will return the controller s screen list to the manufacturing defaults gt Custom Display List Display List 8 Lines Param 8 0 BLANK LINE 1 1 Feedback Zone 1 2 2 Uut Zone 1 2 3 Control Mode Zone 1 2 amp Time Zone 1 2 5 CL Response Set Zone 1 2 amp Burst Angle Zone 1 2 7 PAto2C Thid Zone 1 2 0 FullScale Volks Zone 1 2 3 FullScale 20 1 2 10 Kw Zure 1 2 11 Vultaue Limit Zone 1 2 1 Current Limit Zone 1 2 13 Current Limit Type Zone 1 14 Cunent Trip Zone 7 15 Power Limit Zone 2 I6 Relay Mask Zone 1 2 17 Relay 2 Mask Zone 1 2 18 Deviation Band Zone 1 2 21 Feedback Type Zone 2 2 22 Control Type Zone 2 2 23 Control Mode Zone 2 2 24 Ramp Time Zone 2 2 25 CL Response Set Zone 2 2 20 Durst Angle Zone 2 2 27 PA to ZE Thid Zune 2 2 Custom Text Screen List Sho
25. Auxl O Digital Comm Hardware Profile Common settings C Heartbeat Time 0 sec 0 Infinite Su p all Comm Heartbeat Time ol sec 0 Infinite Network Timeout Action Network Timeout Action Continue stop Continue Stop eb 5 48 Communication i TCP IP Settings E Address 0 0 a a Ra4Hb Baud Rate BPS 19200 4 2 w Comm Watchdog 0 see 0 Disabled m Ra4Hb Protocol Modbus 5 im c 5 s 26 2 m m T c Modbus RTU Modbus TCP EtherNet IP PROFINET System fone 1 Aux 0 Digital Gamm Hardware Profile Diagnostics 1 Diagnostics 2 Common settings Param Link Include in Include in Assembly Assembly Poll Timeout Action ParamLink Inst 1 Attr 3 ParamLink Inst 19 Attr 3 Continue Stop ParamLink_Inst_2_Attr_3 ParamLink_Inst_20_Attr_3 Explicit Timeout Action ParamLink Inst_3 Attr 3 ParamLink Inst 21 3 Continue Stop ParamLink Inst 4 3 ParamLink Inst 22 Attr 3 Network Power Loss ParamLink Inst 5 Attr 3 ParamLink Inst 23 Attr 3 Continue Stop ParamLink_Inst_6_Attr_3 ParamLink Inst 24 3 DeviceNet ParamLink Inst 7 Attr 3 ParamLink Inst 25 3 DeviceNet ID ParamLink Inst 8 Attr 3 ParamLink Inst 26 Attr 3 BPS 125Kbps ParamLink Inst 9 Attr 3 ParamLinlk Inst 27 Attr 3 ws ParamLink Inst 10 Attr 3 ParamLink Inst 28 Attr 3 e 2 O ms ParamLink Inst 11
26. Bus Off condition occurs transition to the Bus Off Reset state Default Auto Reset Transition back through connection Reset and gain to On Line access on the network to the On Line unallocated state Explicit Connection Watchdog Action SP 199 bit 1 Setting Description __ Connection transitions to non existence state Deferred The explicit connection will remain as long as the poll Delete connection exists Control Concepts Inc 2013 WWW ccipower c 1 800 765 2799 FUSION Control Panel Manual Rev 3 50 Poll Connection Watchdog Action SP 199 bit 2 Transition to Timed Out Transition to timed out Default Auto Reset The connection does not time out 6 4 5 Param Link SP 160 SP195 For DeviceNet communications only For more details on this section see the DeviceNet manual See Figure 6 12 in the beginning of this section for default settings These set Attribute 3 of parameter link instances 1 through 36 Instances 1 through 24 have checkboxes next to the parameter Place a checkmark on the parameters that will be included in the Poll messages ParamLink Instance 1 through 8 are the Output Assembly checkbox SP196 bit O bit 7 ParamLink Instance 9 through 24 are the Input Assembly checkbox SP 197 bit O bit 15 6 5 Hardware Profile System Zone 1 Zone 2 Zone 3 Zone 4 Aun 70 Digital comm Hardware Profile Diagnostics 1 Diagno
27. ION Control Panel Manual Rev 3 50 www ccipower com 1 800 765 2799 Control Concepts Inc 2013 CONTROL CONCEPTS Write Hold Register button Enter the number of the parameter into the Register box and the value that you wish to write into the Value box next to the Write Hold Register button Selecting this button will write the value to the parameter NOTE Some values require a high and low word and therefore have a high and low parameter associated with them Check the Long Word checkbox to read or write both of these parameters When Long Word is checked enter only the parameter number for the high word The high word parameter is designated in the parameter list by HI MSW in the title Write Command button Writes special commands to the controller This is not used unless under direct support from Control Concepts 6 6 4 Service Times This displays the hours the card has been value displays as 0 the card is not present Processor MP 309 Firing card hours Gate A MP 311 Gate Drive A hours Gate B MP 313 Gate Drive B hours Gate C MP 315 Gate Drive C hours Gate D MP 317 Gate Drive D hours Aux MP 319 Auxiliary Board hours 6 6 5 Calibration Reload Load Calibration button From the checkboxes beside the calibration tables can be reloaded from a configuration file This should not be used unless directed to do so from Control Concepts Control Concepts saves a configu
28. ONTROL CONCEPTS 5 1 3 Warning Alarms The following alarms may register on the Control Panel for each zone Voltage Limit Current Limit Power Limit Temp Shorted SCR Low Output Any warnings for the zone will be displayed to the right of the zones Control Loop data 5 2 Controller Status For each zone this area shows whether the controller is enabled or disabled fault conditions and whether it is at setpoint Each zone has a Digital Enable check box which is in series with the Run Reset of Pin 9 of the P1 connector This allows Run Reset control of each zone independently through the digital communications interface if desired The Setpoint column is for monitoring when the controller output of each zone is within the deviation band of the desired setpoint See the settings section of this manual Note The Digital Enable feature will quickly turn off the controller but it is limited to communincation rates and software timing It is therefore not as fast as using the hardware based Run Reset Pin 9 on the P1 connector Control Concepts strongly recommends continuing to use the hardware based Run Reset for emergancy situations 5 3 Command amp Auxiliary I O This area allows you to view the current state of the digital I O of the command connector The Aux I O will always be displayed but is only active if the Auxiliary I O expansion card is present 5 4 Module Operating Values This area shows line voltages
29. P 97 This parameter is the signal value at the percent displayed in SP 97 This is typically your lowest possible signal value that can be achieved Analog SP2 Lo Out SP 97 Default value 0 00 This is paired with Analog SP2 Lo Cmd SP 96 This parameter is the percentage at the signal value displayed in SP 96 Analog SP2 Hi Cmd SP 98 Default value 5 00 V This is paired with Analog SP2 Hi Out SP 99 This parameter is the signal value at the percent displayed in SP 99 This is typically your highest possible signal value that can be achieved Analog SP2 Hi Out SP 99 Default value 100 00 This is paired with Analog SP2 Hi Cmd SP 98 This parameter is the percentage at the signal value displayed in SP 98 Analog SP2 Monitor Full Scale SP 137 Default value 1000 This is for scaling the Analog Setpoint 2 Monitor Value MP 209 This value can be scaled for any type of user input If this value is desired to be monitored on the Display it can be viewed by adding MP 209 to the custom screen list On the custom screen list window a four character title can be edited and up to three characters may be entered for units to be displayed with MP 209 Analog SP2 Monitor Value MP 209 The Analog Setpoint 2 monitor value that is calculated from the analog input signal and scaled by the full scale setting SP 137 FUSION Control Panel Manual Rev 3 50 www ccipower com 1 800 765 2799 Control Concepts Inc 2013
30. Power Current Limit Current Trip and Power Limit is calculated and set The software will automatically detect the controller type and uses the Full Scale Voltage and Full Scale Current to calculate the correct settings 24 FUSION Control Panel Manual Rev 3 50 www ccipower com 1 800 765 2799 Control Concepts Inc 2013 CONTROL CONCEPTS 6 2 3 Zero Cross Settings Burst Start Angle SP 6 SP 26 SP 46 SP 66 Only applies when Zero Cross Burst is selected as the Firing Mode Default value 90 Degrees This is the setting in phase angle degrees at which the SCRs are fired during the first half cycle Adjust this depending on the system design and the downstream transformer characteristics See the Operator Manual for why to use Burst Start Angle or consult with Control Concepts for more information Phase ZC Switch Time SP 7 SP 27 SP 47 SP67 Only applies when Zero Cross Transformer is selected as the Firing Mode Default value 12 Cycles This determines the number of cycles before switching to Zero Cross firing The Phase Angle Start Tuning button is helpful in determining the value for this parameter Phase Angle Start Tuning button Only applies if Zero Cross with Phase Angle Start is selected as the Firing Mode This is only on the Zone 1 tab The controller should be in RUN state with a 1096 setpoint This sets up the trigger for the DataTrace feature of the FUSION Control Panel Software which helps
31. Reset and Firmware buttons will indicate the progress of the flash programming operation Upon completion the USB FLASH PROGRAM COMPLETE message box will appear and the processor will automatically reset Check the display on the controller Press the enter button the green check box if directed to do so It is necessary to re connect using the Connect command button in order to re establish communications with the FUSION Power Controller 4 7 Restore MFG Defaults Button Use this button to restore the FUSION Power Controller setup parameters to the original factory settings A dialog box will ask you to confirm your intent to overwrite the current settings with factory settings See Figure 4 01 Warning Any changes made to settings will be lost by restoring factory defaults Warning Restore MFG Defaults This will overwrite all settings with the MFG defaults Are you sure you want to overwrite FIGURE 4 01 FUSION Control Panel Manual Rev 3 50 Control Concepts Inc 2013 www ccipower com 1 800 765 2799 5 THE DASHBOARD The dashboard contains runtime operating values for the FUSION Power Controller These values are updated every 250 msec whenever a FUSION power controller is connected via the USB cable The dashboard contains five sections the Zone tab s Controller Status Command amp Auxiliary I O Module Operating Values and Inhibit Alarms CONTROLLER MODULE OPERATING ZONE
32. TAB 5 VALUES Digital setpoint 1 Zone 1 Warnings Fnahle Status GSetpaint C Digital setpoint 2 one 1 M Normal Nn ine V ane Analog 1 9 Out 96 Normal Nu oad V Set Pt Ref UEM oad Feedback ontroller Status emp Error 1 0 Aux 1 0 ine Hz Power xcd nhibits COMMAND INHIBIT ALARMS AUXILIARY I O FIGURE 5 00 Each Zone Tab has a setpoint control loop and warning alarm section Single zone controllers have only one Zone Tab while multi zone controllers have a tab for each zone 5 1 1 Setpoints This area allows you to enter a control loop set point via the Digital Setpoint 1 and Digital Setpoint 2 text boxes as a percentage of full scale The analog signal value command percentages are displayed for Analog Setpoint 1 and Analog Setpoint 2 5 1 2 Control Loop Data This area shows the control loop values for the selected Zone State Run Stop or Fault Out Percent SCR is on for Phase Angle on for full conduction Zero Cross duty cycle Setpoint Ref The setpoint in engineering units based on the feedback selection Feedback engineering units read back based on feedback selection Error The difference between the SetPt Ref and Feedback Power Power in Watts delivered to the load FUSION Control Panel Manual Rev 3 50 www ccipower com 1 800 765 2799 Control Concepts Inc 2013 C
33. TOP State setting SP 129 Bits 0 3 0 Digital System Command SP 129 is used by default when digital setpoints are in use by the controller For all zones set the Digital System Command power up defaults to be in Run state This will still use the Run Reset connection on the P1 Connector Pin 7 and 9 to place the controller into Run state All Enabled The XP 3401 parameter was set without using this drop box To determine the power up defaults read parameter 3401 on the Diagnostics 1 tab Blank Not Selectable Enable this when only the RUN Stop from the P1 connector pins 7 and 9 is desired and the Digital System Command is not going to be used Control Concepts Inc 2013 www ccipower com 1 800 765 2799 FUSION Control Panel Manual Rev 3 50 6 2 Zone System Zone 1 fone 2 fone 3 fone 4 Aux 170 Digital Comm Hardware Profile Diagnostics 1 Diagnostics 2 Control Mode Limits SPO16 Relay 1 Alarms Voltage Limit zone 1 v Current Limit zone 1 Digital Enable C Voltage Limit Gurrent Limit Type zone 1 4 Power Limit C Shorted SCR Line Phase Loss Heatsink Warning Temp Current Trip Heatsink Qver Temp 1 LoadVoltPct Zone 1 5 017 Relay 2 Alarms NENNEN Feedback 1 Firing Made Zone 1 Gontro Made zone 1 Gurrent Trip zone 1 en Ramp Time Zone 1 Control Response Factor Zone 1 Power Limit zon
34. These are paired with Meter 1 Lo Value SP 142 Meter 2 Lo Value SP 149 These parameters are the signal value at the percent displayed in SP 142 SP 149 This is typically your lowest possible signal value that is the desired output Meter 1 Hi Value SP 144 Meter 2 Hi Value SP 151 Default value 100 00 96 These are paired with Meter 1 Hi Out SP 145 Meter 2 Hi Out SP 152 These parameters are the percentage at the signal value displayed in SP 145 SP 152 Meter 1 Hi Out SP 145 Meter 2 Hi Out SP 152 Default value 5 00 V These are paired with Meter 1 Out Direct SP 146 Meter 2 Out Direct SP 153 These parameters are the signal value at the percent displayed in SP 146 SP 153 This is typically your lowest possible signal value that is the desired output Meter 1 Out Direct SP 146 Meter 2 Out Direct SP 153 Default value 0 00 V This is only used when Meter 1 Signal SP 141 Meter 2 Signal SP 148 is set to Direct Out This will give a constant output signal at the level specified in these parameters FUSION Control Panel Manual Rev 3 50 www ccipower com 1 800 765 2799 Control Concepts Inc 2013 CONTROL CONCEPTS 6 4 Digital Comm Optional This tab screen is only present if digital communication is present on the controller The screen appearance changes depending on the type of communication option owstem fone 1 Aux L igi Hardware Profile y 0 Digital comm System zone 1
35. Trip Current Trip responds faster than the Current Limit and protects the controller from experiencing surge currents that could damage it A fault message will be recorded in the fault history After a current trip the fault must be reset See Section 3 for ways to reset the fault condition Power Limit SP 15 SP 35 SP 55 SP 77 Default 105 Full Scale Power setting Limits the load power to prevent the controller from exceeding this setting If the power reaches the limit value a Warning Alarm will be triggered indicating that the Power Limit has been achieved 6 2 5 Output in 96 Full Scale LoadVoltPct MP 350 MP 355 MP 360 MP 365 Displays the load voltage percentage based on the Full Scale Voltage setting LoadCurrentPct MP 351 MP 356 MP 361 MP 366 Displays the load current percentage based on the Full Scale Current setting LoadPowerPct MP 352 MP 357 MP 362 MP 367 Displays the load power percentage based on the Full Scale Power setting 6 2 6 SP016 Relay 1 Alarms SPO17 Relay 2 Alarms SP 16 17 SP 36 37 SP 56 57 SP 76 77 Default for Relay 1 Alarms Current Trip Heatsink Over Temp Default for Relay 2 Alarms Shorted 5 Heatsink Warning Temp Select the checkbox next to the particular alarm function that you wish to energize the relay if the alarm condition is met Any number of conditions may be mapped to either or both relays and both relays can contain the same conditions The relay output
36. ables the Shorted SCR alarm MP 301 bit 4 With the use of some particular load types the controller will detect false Shorted SCRs and trigger the alarm By disabling Shorted SCR Detection the controller will no longer trigger an alarm FOR MORE INFORMATION A shorted SCR can occur when excessive voltage and or current passes through the SCR in a short period of time The limit and trip features are intended to prevent damage to the controller SCR but may not respond fast enough in every scenario To determine if the SCR has a short make sure that the line and the load has been disconnected from the controller With a multimeter measure the resistance from the line connection to the load connection This gt measurement typically measures greater than 300kQ If ANALOG INPUT SCALING this measures less the SCR is likely to have ashort andin analog setpoint tutorial can be found need of repair on our Youtube channel Search ControlConceptsInc A false Shorted SCR warning can also happen if the controller does not have the settings in the Zone Tab correctly set up Check the Full Scale settings SP 8 SP 9 amp SP 10 If nuisance alarms are continuing to happen or if a Shorted SCR is thought to be present consult with Control Concepts Inc 6 1 2 Analog Setpoints Analog Setpoint _ Setup Analog SP Monitor Value vs Signal MP 207 MP 208 Analog SP Hi Out Analog SP 94 SP 99 Monilor Full Scale SP 136
37. ain EE Cal Backup OK EE Write Protected Module D EEProm Status Read Write OK Initialized MFG Table OK Cal Table 0K Record able OK Main EE Cal Backup OK EE Write Protected Initialized MFG Table Cal Table Repair Record Table OK Main EE Cal Backup OK EE Write Protected FIGURE 6 15 In the event that the Control Concepts Customer Service Department is needed to assist with the controller this diagnostics tab provides a quick useful picture of the internal settings of the controller In general disregard this tab and do not be concerned with the status colors as hardware presence can dictate that status color 6 7 1 AC Line Status MP 342 Bit Definition Bit 7 6 5 4 3 2 1 0 Bit ADC Timing Control Timing Phase Rotation Phase Rotation Module D Line Module C Line Module B Line Module A Line Module A Line MP 342 bit 0 Present Absent Indicates if the AC line is present on module A Module B Line MP 342 bit 1 Present Absent Indicates if the AC line is present on module B Module C Line MP 342 bit 2 Present Absent Indicates if the AC line is present on module C 42 FUSION Control Panel Manual Rev 3 50 WWW CCipower com Status Color Red Not OK Not OK 1 2 3 Blue TBD Absent Absent Absent Absent 1 800 765 2799 Green OK OK 3 2 1 OK Present Present Present Present Control Concepts Inc 2013 CONTROL
38. anel software into a PC Any previous versions of the control panel MUST be uninstalled before attempting features are to install a newer version Install FUSION Control Panel software by clicking Setup exe or Setup msi Follow instructions for installation details Before running the software for the first time a controller must be connected to the computer Apply universal input power to the controller Connect the USB cable from the PC to the controller Run the software via Fusion Control Panel exe 2 1 Minimum PC Requirements Intel Pentium Processor 1280 x 768 x 60 Hz Compatible Display Adapter 32 MB RAM Microsoft Windows XP Service Pack 3 10 MB of available hard disk space Microsoft NET Framework 3 5 The FUSION Control Panel is compatible with Windows XP Windows Vista and Windows 7 32 bit and 64 bit operating systems are supported 2 2 Connecting The Fusion Control Panel software can be utilized once the PC has the M eysian pa s 7770 no000 1000 software correctly installed the controller has the universal input power Serial Mo 64370013 applied and the USB cable is connected to the PC and the controller Connection Status Connected software ID 41 With the user interface open press the Connect button in the Device 5 00 05 Info amp Command Functions section See Figure 2 00 The USB status will change from Disconnected to Connecte
39. d Modbus TCP Modbus TCP module is present USB and DeviceNet module is present USB and Profinet USB and Ethernet IP Ethernet IP module is present This allows the user to change the communications type if a communications module is added in the field Each communication option has a separate communications module even though the connection looks the same Do not try and change this from one type of communication type to another without changing the communications module Consult with Control Concepts for changing the communication type in the field Profinet module is present 6 6 Diagnostics 1 System Zone 1 Zone 2 Zone 3 Zone4 Auxl O Digital Comm Hardware Profile Diagnostics 1 Diagnostics 2 1 0 Control Service Times Diagnostic_Enable Processor Diagnostic Ch Select v Gate ml System Control Gate C Retrieve Fault History Clear Error Latch Gate D Clear Fault History Clear Trap Calibration Reload Program CPLD Firing Processor Card Gate Drive A MODDUS Interface via USD v 5 TR 4 m ate Drive Load Read Hold Register NENNEN Long VVord C Gate Drive D calibration were 0 x 2 S c e FIGURE 6 14 This diagnostics tab provides a way to test controllers hardware and software check controller history program the CPLD and load calibration data This tab should not
40. d Trace is Disabled Line Load Trace ON Trace is ON collecting Data Snapshot Capture Once button Collects 2 cycles worth of data and displays the information on the graph Default Trig button The controller is constantly collecting data Over Current Trip is by default the only active trigger After an Over Current Trip the controller stops collecting data and saves the last 2 cycles of data The default trigger button resets the trigger so the controller will continually collect data again Save Data button This saves the data that is displayed to a csv file which can be imported into a spreadsheet program Retrieve Data button As long as the Status indicator on the lower right corner indicates Data Available data can be retrieved from the controller and displayed on the graph 7 2 1 Advanced Settings button When the Advanced Setting button is pressed a new window appears Data Trace Settings Select Channels UNE ALL Datalrace zone Line Load Load Line LoadV V Load DataTrace Trigger p _DataTrace_Cycles Line Load Capture All Capture Mane FIGURE 7 02 Select Channels Pick the channels that are desired to be saved Data Trace Zone Drop box Choose which zone the trigger will be active for If Zone All is used the data will be saved for the first zone to trigger the event FUSION Control Panel Manual Rev 3 50 www ccipower com 1 800 7
41. d and the controller s serial number software ID and version number will register Once connected the Dashboard will display readings from the controller and FIGURE 2 00 the tab screens will reflect the parameters the controller is using 2 3 Disconnecting To disconnect the controller simply disconnect the USB cable from the controller or the PC or close the FUSION Control Panel software window A message will appear stating that the controller has been disconnected With the controller disconnected the Dashboard will not update and parameters cannot be changed CONTROL CONCEPTS 3 PROCESSOR amp FAULT RESETS Fault Resets Toggle the Run Reset pin on the P1 controller Disable then re enable the Digital System command Processor Resets Using the Control Panel software press the Processor Reset button Cycle the controller power Processor Reset Key Sequence 1 Press and hold the Up and Down arrow keys for three seconds Press enter when the 5 5 RESET message displays If the Arrow keys are released the controller returns to normal operation When the Enter key is pressed Line 2 changes to Release Key 5 When all keys are released the Processor resets 2 3 4 FIISION PA 3 7 T 7 0 E 0000 1000 Serial 64370013 Connection Status Connected Software ID Figure 4 00 When a controller is connected this area shows the model 5 00 05 number and serial numb
42. determine the recommended number of cycles for Phase ZC Switch Time SP 7 Observe at the DataTrace waveforms for indication of saturation of the transformer 6 2 4 Limits Voltage Limit SP 11 SP 31 SP 51 SP 71 Default 630 Volts Limits the load voltage to prevent the controller from exceeding this value If the voltage reaches the limit value a Warning Alarm will be triggered indicating that the Voltage Limit has been achieved Current Limit SP 12 SP 32 SP 52 SP 72 Default 10596 Frame Rating of the controller in Amps Limits the lad current to prevent the controller from exceeding this value If the current reaches the limit value a Warning Alarm will be triggered indicating that the Current Limit has been achieved The maximum value for this is 105 of the frame rating Control Concepts Inc 2013 www ccipower com 1 800 765 2799 FUSION Control Panel Manual Rev 3 50 Current Limit Type SP 13 SP 33 SP 53 SP 73 Se ng Description SS RMS Use RMS current as the type of current for limiting Use Average current as the type of current for limiting Current Trip SP 14 SP 34 SP 54 SP74 Default for Phase Angle controllers 175 Frame Rating for controller in Amps Default for Zero Cross controllers 400 Frame Rating for controller in Amps If the current reaches this setting the controller will exhibit an Inhibit Alarm with a message indicating that the controller has experienced a Current
43. e 1 Deviation Band zone 1 Full Scale Settings Output in Full Scale Full Scale valtage Zone 1 Full cale Gurrent zone 1 LoadcurrentPct zone 1 9 C Low Output Digital Enable Calculate Power amp Limits C voltage Limit Current Limit zero Cross Settings Power Limit 5 Shorted SCR Line Phase Loss Heatsink Warning Temp Phase Angle Current Trip start Tuning Heatsink Over Temp Hu Full Scale Powrer zone 1 LaadPawerPct zone 1 Burst Start Angle Zane 1 Phase zG Switch Time zone 1 cycles HI lm F m ru m FIGURE 6 06 Tabs for Zones 2 3 4 have the same Layout as the Zone 1 tab Although the parameters on each of these tabs are alike they are specific to each zone indicated by 1 2 etc appended to each parameter name FUSION Control Panel Manual Rev 3 50 www ccipower com 1 800 765 2799 Control Concepts Inc 2013 CONTROL CONCEPTS 6 2 1 Control Mode Feedback Type SP 1 SP 21 SP 41 SP 61 Use RMS voltage as the control loop feedback AVG Voltage Use average voltage as the control loop feedback RMS Current Use RMS current as the control loop feedback AVG Current Use average current as the control loop feedback Power Use real power as the control loop feedback Use an external transducer that provides the feedback signal into Analog Setpoint 2 Analog SP2 Function SP 89 m
44. e Fail OK 3 Cal Table Fail OK 2 MFG Table Fail OK 1 Initialized Init Required Initialized Bit O Read Write Fail OK Read Write MP 337 bit 0 OK Fail During power up checks to see if the EEPROM is functional Initialized Init Required MP 337 bit 1 The EEPROM has been initialized MFG Table MP 337 bit 2 OK Fail Status of manufacturing data table Cal Table MP 337 bit 3 OK Fail Status of the calibration data table Repair Record Table MP 337 bit 4 OK Fail Status of the repair record table Main EE Cal Backup MP 337 bit 5 OK Fail Status of the backup calibration data table EE Write Protected EE Not Write Protected MP 337 bit 7 The status of the EEPROM write protection Control Concepts Inc 2013 www ccipower com 1 800 765 2799 FUSION Control Panel Manual Rev 3 50 6 7 5 Module B EEProm Status MP 338 Status Color Red Green Bit Definition Bit 7 EE Write Protected Not Protected Protected 6 TBD 5 Main EE Cal Backup Fail OK 4 Repair Record Table Fail OK 3 Cal Table Fail OK 2 MFG Table Fail OK 1 Initialized Init Required Initialized Bit 0 Read Write Fail OK Read Write MP 338 bit 0 OK Fail During power up checks to see if the EEPROM is functional Initialized Init Required MP 338 bit 1 The EEPROM has been initialized MFG Table MP 338 bit 2 OK Fail Status of manufacturing data table Cal Table MP 338 bit 3 OK Fail Status of the calibra
45. e it is current so here is the calculation that is used 80A X 20mA 4mA 100A 4 mA Example 2 A transducer outputs 0 5Vdc corresponding to 0 600 Vac RMS The Full Scale Voltage SP 8 480 Volts On the System tab Analog SP2 Type Voltage Analog SP2 Function 2 Normal Analog SP2 Lo Cmd z 0 00 Analog SP2 Lo Out 0 00 Analog SP2 Hi Cmd lt 4 00 Analog SP2 Hi Out 100 00 This needs to be scaled to the full scale setting For this example it is voltage so here is the calculation that is used 480Vac 600Vac X 5 Control Concepts Inc 2013 www ccipower com 1 800 765 2799 FUSION Control Panel Manual Rev 3 50 23 The scale settings are used throughout the system for command input scaling limits and control loop response It is also used for retransmits on the auxiliary card These values may be set within the range of the allowable limits for the parameters see Parameter List Manual for limits The controller has limit parameters that prohibit the controller from reaching values that are too large for the controller For example a 100 Amp controller can have the Full Scale Current set to 1000 Amps but limit parameters will prevent the controller from exceeding 105 105 Amps of the frame rating of 100 Amps It is required that the full scale settings should not be set to more than 2X the actual full load operating valve Full Scale Voltage SP 8 SP 28 SP 48 SP 68 Default value 48
46. ecting to the controller via USB the digital communication settings can be changed for the desired network under the Digital Comm Tab See the Digital Comm Tab section of this manual for more details on what can be set up with the Control Panel software Each digital communications option has a seperate manual for communication structure and setup Options include Modbus DeviceNet EtherNet IP and PROFINET 4 3 Save Config Button This button saves a copy of all setup parameters and calibration data for the FUSION Power Controller to a readable xml file A dialog will appear prompting you to save the xml file The default file name is the units serial number A configuration file should be saved after all parameters are set to the desired values This file can then be loaded on to other controllers where the same configuration is desired This will save time when multiple systems are identical Even with one master configuration file that is loaded to multiple units it is recommended to save individual configuration files for each controller for future reference This file can also be sent to the factory in order to assist in troubleshooting purposes There is no limit to the number of times the file can be saved 4 4 Load Config Button This button loads only the setup parameters within the previously saved config file If a FUSI ON Power Controller is connected the setup parameters will be downloaded into the unit A d
47. elected the controller display will cycle through the approved parameters Auto scroll also resumes after ten minutes of inactivity and can be manually removed via the controller display keypad by pressing and holding the Up Arrow key Control Concepts Inc 2013 www ccipower com 1 800 765 2799 FUSION Control Panel Manual Rev 3 50 1 7 NN 6 1 5 User Settings Save to Backup button This saves all of the user setable parameter SP values from the main user table to the user SP back up table in the EEPROM If any of the SP values are setup incorrectly or differently in the future this back up table can be used to restore all of the SP values This is similar to the Save Load config file with the exception that only the SP values are saved in the EEPROM instead of the computer This can only be used to restore values that are stored in the backup table Note This does not save the screen list Restore from Backup button Writes the stored SP values from the user setpoint backup table in the EEPROM to the main user table 6 1 6 Digital System Command The Digital System Command is used mainly when using digital communications It is a 16 bit parameter that contains sections that put the controller into the RUN Stop state determines which setpoint to use and to turn the relays On Off For bit values see the FUSION Parameter list SP 129 This section is used to bypass the functionality of the P1 and P2 connector P1 8 Override SP
48. er This information is also displayed the frame label that is on the side of the controller 4 DEVICE INFO Connect Interface USB Upon opening the Control Panel the program will try to locate the controller Modbus TCP Ethemet connected to the PC via a USB cable 1 Device or 0 Device will display under the model number 1 Device indicates that controller is is ready to be connected to 0 Device indicates that no controller is available However note that if a controller is connected or disconnected via USB after the Control Panel is open the status will not change nave Contig File Load Config File Connection status displays if the controller is Connected or Disconnected Software ID refers to the specific firmware the controller is operating Version refers to the firmware release level the controller is operating Restore MFG Defaults 4 1 Connect Button FIGURE 4 00 This button is used to connect the controller to the FUSION Control Panel software This can only be done with the universal input power applied to the controller and a USB cable connected from PC to controller Control Concepts Inc 2013 www ccipower com 1 800 765 2799 FUSION Control Panel Manual Rev 3 50 4 2 Interface Options The USB radio button must be selected when connecting to the controller via USB This should be done regardless of whether the controller has a digital communication option installed After conn
49. he satellite and monitor icon is a link that can be used for video web conferencing 6 1 1 System Settings Run Logic SP 82 Closed for Connection on P1 between pin 7 and 9 must be Default CLOSED before a Run State can be achieved Connection on P1 between pin 7 and 9 must be OPEN before a Run State can be achieved Sets the Logic for Run Reset pin 9 of the P1 Command green 12 pin connector on the side of the controller 8 FUSION Control Panel Manual Rev 3 50 www ccipower com 1 800 765 2799 Control Concepts Inc 2013 am CONTROL CONCEPTS Three Phase Load Config SP 80 Load is configured as either a Delta or a 3 Wire Wye Load is configured as a 4 Wire Wye Load is configured as an Inside Delta FOR MORE INFORMATION This indicates the load wiring configuration This is i generally determined before the controller is ordered from the factory but can be changed in the field if a different load type is desired Note This is for three phase three leg controllers only jae 2 1 Se Changing this parameter requires an internal wiring change that can only be done with a wire harness from E 1 7 Control Concepts Inc THREE PHASE LOAD CONFIGURATION Instructions for wiring the controller for each load type can also be found in the Hero Mode Enabled SP 84 Installation and Maintenance Manual Semina 000000000
50. he signal using the selection box in the lower left corner of the screen The timescale is fixed However you can zoom in by click and dragging a vertical window region Undo the zoom using the newly presented symbol on the vertical scroll bar FUSION Control Panel Manual Rev 3 50 WWW Ccipower com 1 800 765 2799 Control Concepts Inc 2013 CONTROL CONCEPT Recorder Scope Line A 0 Load amp v 0 LoadA 0 LineB 0 LoadB iv 0 LoadB 0 Line 0 LoadC v 0 LoadC fl 0 LineD 0 LoadD v 0 LoadD I 0 Cursor X lt Capture Retrieve Data Status Data Available Save Data Advanced Settings Data Logger Charts Settings FIGURE 7 01 The scope feature records the line voltages load voltages and current waveforms for a period of 2 cycles This data can then be viewed on the graph The checkboxes beside the graph can turn ON OFF the desired waveform for viewing The graph has zooming capability by clicking and dragging a vertical window region Undo the zoom using the newly presented symbol on the horizontal and vertical scroll bar There is a status box on the lower right corner Data Available Data has been collected and is ready to be retrieved Waiting for Trigger No Data No data has been collected Line Load Trigger Enabled Trace is Enabled waiting for trigger The trigger event has not occured yet Disable
51. ialog will appear prompting you to load the xml file After loading select the Reset button to make sure all the changes have 4 5 Reset Button This button resets reboots the onboard processor when a FUSION Power Controller is connected FUSION Control Panel Manual Rev 3 50 taken effect WWW CCipower com 1 800 765 2799 Warning Do not attempt to load config while controller is in RUN state Warning Power to the load will be interrupted during the reset Control Concepts Inc 2013 CONTROL CONCEPTS 4 6 Flash Firmware Button Use this button to load the firmware for the onboard processor of a FUSION Power Controller into flash memory Control Concepts pre programs each power controller at the factory Do not load firmware unless directed to do so by Control Concepts Inc or an authorized representative Flashing Instructions 1 Connect your PC to the FUSION Power controller via a USB cable 2 Apply universal input power to the power controller 3 Start the FUSION Control Panel software Warning Do not disconnect 4 Select Flash Firmware the USB cable or control power 5 A dialog will open prompting you to select a hex file while flashing is in progress 6 Select the hex file provided by Control Concepts Inc Note Changing the firmware ID requires a password This will be provided by Control Concepts with the new firmware file A progress bar above the
52. ll communications types setting oes Continue Continue without fault Communication fault with controller shut down For Ethernet IP Modbus and Profinet communications only This is the action for when the heartbeat timer expires For DeviceNet communications only This is the action for when the Poll connection times out When Continue is selected and the timer expires the controller continues to operate without a communications fault occurring Stop will cause a communications fault and the controller will shut down When a communication fault is present the next valid message will reset the heartbeat timer but the fault also needs to be reset For DeviceNet when a fault occurs the connection has to be re established FUSION Control Panel Manual Rev 3 50 www ccipower com 1 800 765 2799 Control Concepts Inc 2013 CONTROL CONCEPTS Explicit Timeout Action SP 128 bit 1 For DeviceNet communications only Setting Description 000000 Continue Default Continue without fault Stop Communication fault with controller shut down When Continue is selected and the explicit connection times out the controller continues to operate without a communications fault occurring Stop will cause a communications fault and the controller will shut down When a communication fault is present the fault needs to be reset Network Power Loss SP 128 bit 2 For DeviceNet communication
53. log SP2 Type SP 95 Voltage Voltage input scalable from 0 10 Vdc default O 5 Vdc Default Current Current input scalable from 0 20 mA This selects the input signal type for Analog Setpoint 2 The wiring diagram for the input can be found in the Installation and Maintenance manual Analog SP2 Function SP 89 Normal Uses Analog Setpoint 2 to control the Set Point Default Reference MP 250 External CT Use to monitor the third leg current when using a three for Leg C phase 2 leg controller Uses Analog Setpoint 2 as a monitor variable that can be scaled for monitoring purposes Under Normal operation the setpoint is used for control When using the External CT for Leg C an external current transducer will be measuring the current on the third leg of a three phase 2 leg controller The scaling for the high and low commands are determined by the ratio of the current transducer with the full scale current SP 9 When Monitor is chosen it can be scaled with a full scale parameter SP 137 The monitor value is then viewed with parameter MP 209 When using the Monitor setting the controller will not use Analog Setpoint for control O Control Concepts Inc 2013 WWW ccipower com 1 800 765 2799 FUSION Control Panel Manual Rev 3 50 193 Analog SetPt 2 Signal MP 207 This gives the value of the setpoint signal Analog SP2 Lo Cmd SP 96 Default value 0 00 V This is paired with Analog SP2 Lo Out S
54. ollers When using only one controller this feature is not used FOR MORE INFORMATION When using this feature all controllers should have the SYNC GUARD enabled The controllers must have the SYNC GUARD pins of the P1 connector wired in parallel One and only one controller should have the SYNC GUARD resistor SP 115 enabled Check our Youtube channel ControlConceptsInc and watch our To learn more about the advantages and applications SYNC GUARD overview video of SYNC GUARD see the Operator Manual For wiring and setup see the Installation and Maintenance Manual Sync Guard Resistor SP 115 Setting Description S Disabled SYNC GUARD resistor is disabled Enabled SYNC GUARD resistor is enabled When using this feature one and only one of the controllers should have the SYNC GUARD resistor enabled The controllers must have the SYNC GUARD pins of the P1 connector wired in parallel SYNC GUARD Enable SP 131 Setting Description Disabled m Sync Guard is disabled Enabled oync Guard is enabled When using this feature all controllers should have the SYNC GUARD enabled FUSION Control Panel Manual Rev 3 50 www ccipower com 1 800 765 2799 Control Concepts Inc 2013 CONTROL CONCEPTS Shorted SCR Detection SP 132 setting Description OOOO oO Disabled Shorted SCR Detection is disabled ue Shorted SCR Detection is enabled This dis
55. om text may be useful for naming a controller or giving instructions specific to your task Enter the text you wish to display in the Custom Text fields maximum of 16 characters highlight Custom Text from the Display list and choose Add or Replace Under Analog Input Monitor Params there are options to specify titles and units for Monitor parameters MP 208 and MP 209 These specifications apply to Monitor Options covered in 6 1 2 To approve changes select Program and close the Custom Screen List dialog box FUSION Control Panel Manual Rev 3 50 www ccipower com 1 800 765 2799 Control Concepts Inc 2013 CONTROL CONCEPTS Parameter Lock Many parameters can be accessed and edited from the controller display keypad Parameter lock prevents users from changing specific parameters unless they enter the right password SE Parameter Lock Check box to lock parameter Passcode ES Change Passend 125 CLhesponse Get zione d FulScale Fw Zone 3 75 Powe ne4 100 Dita Setpont 1 Zoo 1 129 Heartbeat Time 150 Meter 2 Signal Lo 51 Voltage Limit Zane 2 zi ou 101 Digital Setpoint 2 Zone 1 120 IP Address LI 151 Meter 2 Cmd Hi 52 Currenit Limit Zone 3 102 Digital Setpoint Zone 2 152 Meter 2 Signal Hi 53 Current Limit Type Zone 2 7 4 103 Digital Setpoint 2 Zore 2 120 Mon 153 Meter 2 Direct 54 Current Trip Z
56. one 3 104 Digital Setpoint 1 Zone 3 12 and bb Power Limit one 3 Ub Digtal Setpont 2 Zone 3 12 56 Relay 1 Mask Zone 3 pe 106 Digital Setpoint 1 Zone 4 5 Hel 2 T Digtal 1 Zone 4 2 58 Dewviaiun Bard fume 3 i 1 Feedback Zone1 2 Out TypeZore 1 3 Control Mode Zane 1 L 4 Ramp Tima Zane 15 ELHesponee SetZone1 amp Burst Angle Zone 1 Zone 1 amp Fulfrale Voks Zone 1 1 8 Fulcale Amps Zone 1 LJ 10 FulScale Kw Zone 1 11 vokage Limit Zone 12 Curent Limit Zone 1 C 13 Curent Limit Type Zone 1 38 Deviation 14 Current zone 1 15 Power Limit Zone 1 L 16 Flelau 1 Mask Zone 1 LI 1 2 Mask Zone 1 O 18 Posi Pore 1 51 Feedback Zone 4 62 Conbol Out Zono 4 ld 112 Temp Limit 63 Contol Mode Zone 4 Se 113 Temp Limit C 54 Ramp lime Zone 4 7 114 Temp Limit 65 CL Response Set Zone 4 FR Pore 4 al Lo IL 11 F realke 2 1 E7 PA to ZU Thid Zone 4 Pore 4 Signal Hi IL 118 ID E9 Fulscale Ampe one 4 Zune 3 70 lul5cale Zoned 95 Analog Selpont 2 71 Voltage Limit Zone 4 121
57. ration file on every controller prior to shipment if this is deemed necessary and a configuration file has not been saved by the customer Contact Control Concepts for this file Control Concepts Inc 2013 www ccipower com 1 800 765 2799 FUSION Control Panel Manual Rev 3 50 6 7 Diagnostics 2 System Zone 1 one2 Zone3 Zone 4 AC Line Status fodule A Line Absent fodule B Line Absent Line Absent Module D Line Absent Phase Rotation TBD Phase Rotation 1 2 3 Read Write Cal Table Control Timing ADC Timing EE SP Def OF Misc Statu Data Logger Charts Settings Aux O Main Status K User 5P VTable MFG SP VTable OK Cal Table OK MFG Table Error Record Table Repair Record Table OK DG Current Comp Table OK DC Current Backup OK User Dackup EE Write Protected Digital Comm Module EEProm Status Read Write OK Initialized MFG Table UK Cal Table Repair Record Table OK Main EE Cal Backup OK EE Write Protected Module C EEProm Status Read Write OK Initialized MFG Table OK Cal Table OK Repair Record lable OK Main EE Cal Backup OK EE Write Protected Compatible CPLD Present Not Waiting Cnter Key Hardware Profile Module B EEProm Status Read Write OK Diagnostics 1 Diagnostics 2 Aux 1 0 EEProm Status Read Write OK Initialized MFG Table OK Cal Table OK Repair Record Table OK M
58. re the responsibility of the customer CONTROL CONCEPTS INC s limited warranty shall not be effective or actionable unless there is compliance with all installation and operating instructions furnished by CONTROL CONCEPTS INC or if the products have been modified or altered without the written consent of CONTROL CONCEPTS INC or if such products have been subject to accident misuse mishandling tampering negligence or improper maintenance Any warranty claim must be submitted to CONTROL CONCEPTS INC in writing within the stated warranty period CONTROL CONCEPTS INC s limited warranty is made in lieu of and CONTROL CONCEPTS INC disclaims all other warranties whether expressed or implied including but not limited to any IMPLIED WARRANTY OF MERCHANTABILIT Y ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE any implied warranty arising out of a course of dealing or of performance custom or usage of trade CONTROL CONCEPTS INC SHALL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR ANY DIRECT INDIRECT INCIDENTAL SPECIAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF PROFITS REVENUE OR BUSINESS DAMAGE INJURY TO PERSONS OR PROPERTY IN ANY WAY RELATED TO THE MANUFACTURE THE USE OF ITS PRODUCTS The exclusion applies regardless of whether such damages are sought based on breach of warranty breach of contract negligence strict in tort or any other legal theory even if CONTROL CONCEPTS INC has notice
59. roller will have an inhibit alarm present Control Concepts Inc 2013 www ccipower com 1 800 765 2799 FUSION Control Panel Manual Rev 3 50 6 3 Aux I O Optional This tab screen is only present if the Auxiliary expansion Card is ordered 1 System fone 1 fone 2 fone 3 4 Digital Comm Hardware Profile Diagnostics 1 Diagnostics 2 AUX LO Aux Digital 0 Aux 10 ID Digital Input 1 FX Aux 10 Serial Hum Aux IO Lot Digital Out 1 FX w E Aux 170 Retransmits 5 Meter 1 Signal Meter 1 Lo Meter 1 Lo Qut Meter 1 Hi Value Meter 1 Hi Qut Meter 1 Out Direct m Meter 2 Signal Meter 2 Lo value Meter 2 Lo Qut Meter 2 Hi Value Meter 2 Hi Qut Meter 2 Out Direct a nm re nm FIGURE 6 08 6 3 1 Aux I O This section presents the identification of the Auxiliary card that is built into the frame These are read only fields that are only pertinent to Control Concepts Aux IO ID CP 655 This is the ID of the Auxiliary card that is associated with the model number Aux IO Serial Num CP 656 This is the serial number Aux IO Lot Num CP 658 This is the lot number associated with the batch of auxiliary cards Aux IO MFG Date CP 660 The date that the card was manufactured Aux IO Assy Rev CP 663 This is the revision of the card FUSION Control Panel Manual Rev 3 50 w
60. s correspond with SP 85 for Relay 1 and SP 86 for Relay 2 26 FUSION Control Panel Manual Rev 3 50 www ccipower com 1 800 765 2799 Control Concepts Inc 2013 CONTROL CONCEPTS Low Output The controller is at 10096 output and the Set Point Reference or command signal is higher than the Feedback In other words the controller is being asked to provide a higher output than the load is capable of Digital Enable If the bit for the Digital System Command SP 129 bit 0 SP 16 17 bit 1 SP 36 87 bit 2 SP 56 57 bit 3 SP 76 77 is set the relay will energize Voltage Limit If Voltage Limit is present the relay will energize Current Limit If Current Limit is present the relay will energize Power Limit If Power Limit is present the relay will energize Shorted SCR If a Shorted SCR is present the relay will energize Line Phase Loss If a phase loss is detected the relay will energize Heatsink Warning Temp If the heatsink temperature reaches within 5 C of the over temperature alarm the relay will energize Current Trip If a Current Trip occurs the relay will energize This will keep the relay energized until the fault condition is reset See section 3 on resetting the fault condition Heatsink Over Temp If the heatsink temperature reaches the over temperature alarm the relay will energize When the temperature drops into a safe range the relay will automatically de energize cont
61. s only Setting Description SSS Continue 4 Default Continue without fault Stop Communication fault with controller shut down When Continue is selected and DeviceNet network power is not present the controller continues to operate without a communications fault occurring Stop will cause a communications fault and the controller will shut down When a communication fault is present the fault needs to be reset 6 4 2 TCP IP Settings For Ethernet IP Modbus TCP and Profinet communications only Address SP 126 SP 127 Default value 255 255 255 255 This is the address of the controller on the network Get button Modbus TCP only This verifies the address is correctly programmed on the communications module of the controller Save Button This sets the address to the communications module of the controller Control Concepts Inc 2013 www ccipower com 1 800 765 2799 FUSION Control Panel Manual Rev 3 50 Comm Watchdog SP 135 Default value 0 Modbus TCP only When this is set to O the timer is disabled The minimum setting for this is 15 seconds and a maximum of 65535 seconds If this is set to a value of 1 through 14 the timer defaults to 15 seconds When this timer expires the communication modules configuration is interrogated by the controller to verify proper operation 6 4 3 RS 485 Communication For Modbus RTU communications only For more details on this section see the Modbus RTU manual
62. s to see if the EEPROM is functional Initialized Init Required MP 341 bit 1 The EEPROM has been initialized Table MP 341 bit 2 OK Fail Status of manufacturing data table Cal Table MP 341 bit 3 OK Fail Status of the calibration data table Repair Record Table MP 341 bit 4 OK Fail Status of the repair record table Main EE Cal Backup MP 341 bit 5 OK Fail Status of the backup calibration data table EE Write Protected Not Write Protected MP 341 bit 7 The status of the EEPROM write protection 6 8 OEM OEM Version Only Custom tabs are available if specific settings do not meet a customers needs The contents of the OEM tab will vary based on the collaboration between Control Concepts and the individual customer Contact Control Concepts for more information about Custom OEM controllers or for examples of previous models Control Concepts Inc 2013 www ccipower com 1 800 765 2799 FUSION Control Panel Manual Rev 3 50 7 CHART TAB Hecordet Scope 480 4 Data Logger Charts Setti ngs FIGURE 7 00 This tool charts the command value of the control loop against the feedback for voltage current or power Start the tool by clicking the red button Stop the chart tool by clicking the red button again Select the signal you would like to chart in the lower left drop down box This feature is only available for Zone 1 at this time You can select t
63. stics 2 System Modulo Module Model Module A ID Module B ID Legs Control Module Nur Module B senal Num Model Module Rating Module Lul Module B Lul Config Data Module A Rating Module Rating Config Data Module PCB Assy Rew Module B PCB Assy Rev Number Lot Number Module C Module D 5 Ma Pato Module C ID Module D ID Controller Rating Serial Mum Module I Serial Hur t Module Lot Mum Module D Lot Mum E POB Assy Rev DIS Module MFG Module D MFG Version E IE TUM iib ae i Special Product Module C Rating Module Rating 5 Module C Rev Module D Assy Rev m a e FIGURE 6 13 The tab describes the physical hardware within the FUSION Power Controller From this tab the board serial number lot number assembly revision and manufacturing data can be obtained These parameters are set at the factory and cannot be changed by the user with the only exception being the communications option FUSION Control Panel Manual Rev 3 50 www ccipower com 1 800 765 2799 Control Concepts Inc 2013 CONTROL CONCEPTS Communications CP 603 Setting Description USB communications only USB and Modbus RTU Modbus RTU module is present USB an
64. tion data table Repair Record Table MP 338 bit 4 OK Fail Status of the repair record table Main EE Cal Backup MP 338 bit 5 OK Fail Status of the backup calibration data table EE Write Protected EE Not Write Protected MP 338 bit 7 The status of the EEPROM write protection FUSION Control Panel Manual Rev 3 50 WWW Ccipower com 1 800 765 2799 Control Concepts Inc 2013 CONTROL CONCEPTS 6 7 6 Module C EEProm Status MP 339 Status Color Red Green Bit Definition Bit 7 EE Write Protected Not Protected Protected 6 TBD 5 Main EE Cal Backup Fail OK 4 Repair Record Table Fail OK 3 Table Fail OK 2 MFG Table Fail OK 1 Initialized Init Required Initialized Bit 0 Read Write Fail OK Read Write MP 339 bit 0 OK Fail During power up checks to see if the EEPROM is functional Initialized Init Required MP 339 bit 1 The EEPROM has been initialized MFG Table MP 339 bit 2 OK Fail Status of manufacturing data table Cal Table MP 339 bit 3 OK Fail Status of the calibration data table Repair Record Table MP 339 bit 4 OK Fail Status of the repair record table Main EE Cal Backup MP 339 bit 5 OK Fail Status of the backup calibration data table EE Write Protected EE Not Write Protected MP 339 bit 7 The status of the EEPROM write protection Control Concepts Inc 2013 www ccipower com 1 800 765 2799 FUSION Control Panel Manual Rev 3 50
65. tore from Backup Memory Error Memory Error Run Logic Three Phase Load GCanfig Hero Mode Enabled watchdog Timeout watchdog Timeout Parameter Lock PLL Lock Loss PLL Lock Loss Auto Scroll Enabled In Run State Digital System Command eync Guard Resistor O LI In Run State 5 y Run Enable C Run Enable P1 8 verride sync Guard Enable Dig Svs Cmd Bit 10 Dig Sys Cmd Bit 11 Pi 10 Override Sharted SCR Detection Relay 1 Relay 2 Analog Setpoints Analog 5 1 10 Cmd Analog 5 1 Ln Out Analog 5 1 Hi cmd Analog SP1 Hi Out D m J me 1 b Analog SP1 Monitor Full Scale CONTROL Analog SP1 Value 1 E PTS Analog SP2 Lo Analog SP2 Lo Out Analog SP2 Analog 5 2 Hi Out v MO 1 800 765 2799 Analog SPz Full Scale w CCIP Ower mE vis sp Mention 7 B copyright 2009 2042 All Rights Reserved FIGURE 6 00 Analog 5 1 Analog SP1 Functian Analog SetPt_1_ Signal Analog SP2 Analog SP Functian Data Logger Charts Settings Analog setPt 2 Signal 6 1 System Tab This tab allows setup of the system level settings analog setpoints and system alarm mapping to Relay 1 and or Relay 2 It also contains contact information along with a link to Control Concepts webpage T
66. troller to reach the full scale value from 096 output The ramp time is not used if the setpoint is changed from something other than 096 output Example If the controller is set for Voltage Feedback and the Full Scale Voltage is set to 100 Volts and the Ramp Time is set for 10 seconds when a setpoint is applied the output will rise at 10 volts a second the setpoint is set to 40 the ramp time will be 4 seconds Control Response Factor SP 5 SP 25 SP 45 SP 65 Default value 500 The control response factor controls how aggressively or slowly the system will respond to a change in feedback A smaller number will make the system respond faster and more aggressively A larger number will make the system respond slower It is important that the full scale settings are set appropriately in order for the default value to work correctly Deviation Band SP 18 SP 38 SP 58 SP78 Default value 100 96 This sets an error tolerance for the feedback The Zone Status parameter MP 344 bits 4 5 6 7 can then be monitored The corresponding bit is set if the Zone is at setpoint Example Deviation Band is set to 2 and the setpoint is set to 80 While the controller is approaching the setpoint the Zone Status parameter will read O until the controller reaches 7896 As long as the feedback remains within 296 of the setpoint the Zone Status bit will read 1 indicating that the zone is at setpoint FUSION Control Panel Manual Re
67. tton You will be prompted for the name and location to save the file The logger will log the data to the file at the selected interval as long as the program remains running and the USB communications remain intact Select the red button again to stop the logging FUSION Control Panel Manual Rev 3 50 WWW Ccipower com 1 800 765 2799 Control Concepts Inc 2013
68. urrent B The load current for module Load Power B The load power for module B RMS Load Voltage The load voltage for module AVG Load Voltage The load voltage for module C RMS Load Current C The load current for module C AVG Load Current The load current for module C Load Power C The load power for module C RMS Load Voltage D The load voltage for module D AVG Load Voltage D The load voltage for module D RMS Load Current D The load current for module D AVG Load Current D The load current for module D Load Power D The load power for module D The controllers load voltage Load Voltage For single phase only The controllers load current Load Current For single phase only The controllers load power Use Meter 1 Out Direct SP 146 Meter 2 Out Direct SP 153 to set the value of the output Control Concepts Inc 2013 www ccipower com 1 800 765 2799 FUSION Control Panel Manual Rev 3 50 Meter 1 Out Type SP 140 Meter 2 Out Type SP 147 Description Voltage Voltage output scalable from 0 10 Default Default 0 5 Vdc Current output scalable from 0 20 mA Meter 1 Lo Value SP 142 Meter 2 Lo Value SP 149 Default value 0 00 96 These are paired with Meter 1 Lo Out SP 143 Meter 2 Lo Out SP 150 These parameters are the percentage at the signal value displayed in SP 143 SP 150 Meter 1 Lo Out SP 143 Meter 2 Lo Out SP 150 Default value 0 00 V
69. ust be set to Normal Apparent Use apparent power as the control loop feedback Power Firing Mode SP 2 SP 22 SP 42 SP 62 Delon 000000 The load power is turned ON for a number of complete Zero Cross electrical half cycles and then turned OFF for a number of complete half cycles Zero Cross The first half cycle is fired at a user specified angle and Burst then works the same as Zero Cross mode Phase Angle The 5 is on for a variable portion of the half cycle Zero Cross firing method specifically for firing into a transformer This uses Phase ZC Switch Time SP7 for determining the number of soft start cycles before switching to Zero Cross firing Zero Cross Transformer Mode The default setting will be Zero Cross or Phase Angle which is determined at the time of ordering For DC controller this should be set to Phase Angle For more information see the Operation Modes section in the Operator Manual Control Concepts Inc 2013 www ccipower com 1 800 765 2799 FUSION Control Panel Manual Rev 3 50 Control Mode SP 3 SP 23 SP 43 SP 63 The output percentage is directly proportional the Spei setpoint Feedback is not used Closed Loop output is adjusted so that the feedback equals the rota setpoint Ramp Time SP 4 SP 24 SP 44 SP 64 Default value O seconds This parameter allows the user to set a maximum ramp time in seconds for the con
70. v 3 50 www ccipower com 1 800 765 2799 Control Concepts Inc 2013 CONTROL CONCEPTS 6 2 2 Full Scale oettings Feedback Type vs Setpoint Feedback type selects the signal you desire to control These settings deal directly with the full Full Scale Value scale settings Full Scale Voltage Full Scale 4 Current Full Scale Power When using one of Power the voltage feedback settings the setpoint will be proportional to the full scale voltage Likewise if using one of the current feedback settings the setpoint will correspond to full scale current Power works in the same way External feedback works in the same fashion with the exception that it uses an external transducer to provide the feedback signal into Analog Setpoint 2 0 The output signal of the transducer must be within Setpoint 0 Setpoint 100 10Vdc or 0 20mA The range is scaled the same way a typical analog setpoint is FIGURE 6 07 This figure shows how the setpoint Here is a quick example of how to setup an corresponds to the full scale value external feedback signal Example A signal condition CT outputs 4 20mA corresponding to O 100A RMS The Full Scale Current SP 9 80 Amps On the System tab Analog SP2 Type z Current Analog SP2 Function 2 Normal Analog SP2 Lo 4 00 Analog SP2 Lo Out 0 00 Analog SP2 Hi 16 80 Analog SP2 Hi Out 100 00 This needs to be scaled to the full scale setting For this exampl
71. wn As Screen 0 208 Monitor Value 1 209 Monitor Value 2 n Screen 1 1880 Custom Text 1896 Custom Text Screen 2 126 IP Address 0 IP Address Screen 3 323 NT Stat fi NT Stat Screen 4 248 5tate Zone 1 208 Monitor Value 1 Screen 5 208 Monitor Valuc 1 249 Out Zonc 1 Screen Screen 100 Digital 1 Zune 1 Digia SP 121 1880 Line FURNACE 1888 Bottom Line UNE 1 15 Chars Chars Custom Screen List eee Pressing the Custom Screen List 200 Monitor Param MP209 Monitor Param button opens a new window See ed ue e ie Figure 6 02 From here you can customize what data appears on your controller display rank the screens in order of relevance or create custom text FIGURE 6 02 The controller can display a maximum of 50 screens Each screen contains up to two lines of text To add a parameter to the Screen List select a parameter in the Screen List just below where you wish to add in the new parameter then select the parameter you wish to add from the Display List and select the Add button To remove a parameter from the Screen List select the parameter in the Screen List and select the Remove button To replace a parameter in the Screen List select the parameter you wish to replace in the Screen List and the parameter you wish to replace it with from the Display List and select the Replace button Cust
72. ww ccipower com 1 800 765 2799 Control Concepts Inc 2013 CONTROL CONCEPTS 6 3 2 Aux Digital I O Digital Input 1 FX SP 154 Seg 00000002 hrs Digital IN 1 P3 pin 2 amp 4 has no function Open Closed Switch Closed 2 Open Loop Loop Switch Open Closed Loop This is for a single zone controller only When set to Open Closed Loop it will override Control Loop SP 3 The Digital IN 1 P3 pin 2 amp 4 will work as follows When closed the controller will be in Open Loop mode When open the controller will be in Closed Loop mode Digital Out 1 FX SP 156 Digital Out 2 FX SP 157 Sening Delon None Digital OUT 1 pin 5 has no function low output Default Digital OUT 2 pin 6 has no function low output Sets output according to Digital Out 1 SP 158 Digital Wen de SP 159 Voltage Limit Limit Sets output high if controller is in Voltage Limit Limit Sets output high if controller is in Current Limit Sets output high if controller is in Power Limit Controller Sets output high if the controller is ready to output may Ready or may not be in the Run state Controller Sets output high if the controller is in a Run state may Output ON or may not be outputting Digital Out 1 Direct SP 158 Digital Out 2 Direct SP 159 Low Inactive P the output of Digital Out 1 SP 156 Digital Out 2 Default SP 157 low a the output of Digital Out 1 SP 156

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