ControlIR Model 930 User Manual - Precision Control Systems, Inc.
Contents
1. Instruction Manual Operating Instructions Installation This section describes how to install and wire the Model 930 power control system The features and options mentioned here are identified in the model number found inside the enclosure WARNING Hazardous voltages are present at the main disconnect switch and load terminals Setting the setpoint potentiometer or control signal to minimum does NOT eliminate these hazardous voltages Always remove AC line voltage from the system before making contact with internal assemblies line or load wiring or fuses Also remove AC line voltage from the system before making connections equipment changes or resistance measurements MOUNTING THE The Model 930 Power Control System may be mounted to a wall with the supplied SYSTEM brackets on a stand or bench The Model 930 must be mounted in a vertical position When mounting to a wall the top of the enclosure should not be over 74 inches 1880 mm above the floor Figure 3 1 Wall Mounting Dimensions D The weight of the Model 930 varies slightly with the options installed The maximum weight of the system is Research Inc Page 4 of 25 Model 930 ControlIR Instruction Manual Operating Instructions WIRING Conduit entry into the system should be made near the right s2. chiller contactor circuit to TB 100 pins 24 NC 25 COM 26 NO as required Page 6 of 25 Model 930 ControlIR Instruction Manual Operating Instructions Cooling Flow Switch This feature provides shutdown of the heater power in case of low or no cooling flow Interlock This is accomplished by opening the heater power controller contactor The cooling sensor may be a water flow or air flow switch Use a switch with contacts that are open during the fault condition Connect the flow switch to TB 100 pins 2 and 3 If both water and air cooling flow switches are used in a system wire the switches in series and then connect to the system Heater Over Temperature This feature provides shutdown of the heater power in case of a heater over Thermo switch Interlock temperature This is accomplished by opening the heater power controller contactor If a thermo switch is not included with your heater use a thermo switch with contacts that will open during the over temperature condition If this feature is desired or provided with the heater connect using the following procedure 1 Remove the factory installed jumper at TB 100 pins 4 and 5 2 Connect the thermo switch to TB 100 pins 4 and 5 3 If more than 1 thermo switch is used in a system wire the switches in series and then connect to the system Remote Interlock Switch This feature provides for remote process interlock shutdown of the heater power This is accomplished by open
3. Contacts rated for 120 VAC at 100 mA Heater over temp thermoswitch Contacts rated for 120 VAC at 100 mA Remote interlock switch Contacts rated for 120 VAC at 100 mA Research Inc Page 5 of 25 Model 930 ControlIR Instruction Manual Operating Instructions Power Wiring Connections Line Connections Load Connections Figure 3 2 CONTROL CONNECTIONS Cooling Flow On Off Relay Output Research Inc Referring to the wiring specification in Table 3 1 connect the external power lines to the top of the disconnect switch The model 930 power control system has 2 3 pole load fuseblocks for distributing the Three phase power to your process For the 120 Amp systems do not exceed more than 60 amps 3 phase per fuseblock For the 160 Amp systems do not exceed more than 80 amps 3 phase per fuseblock The heater load should be wired to evenly distribute the number of individual lamps or heating elements to the 2 three phase load circuits It is suggested to balance the load circuits by having the same number and size of lamps or heating elements per phase and per load circuit ELECTRICAL REPRESENTATI TO F TO F TTOM HALF HEATER ER HALF HEATERS TO F a Refer to Figure 3 3 for connection of the following items This feature provides a normally closed and open form C dry contact relay output to control cooling flow Connect the cooling solenoid
4. Operation h C C Oaa 12 Principles of SCR Power Control C CC C O 12 Principles of Phase Angle Control 12 Model 930 ControlIR Instruction Manual MAINTENANCE AND TROUBLE SHOOTING Routine Maintenance Troubleshooting Calibration Temperature Controller Option Line Voltage Re Configuration DIMENSIONS AND SPECIFICATIONS Specifications Dimensions Ordering Information Ordering Example Spare and Replacement Parts Contents 16 16 17 17 18 18 19 20 22 24 24 25 Model 930 ControlIR Instruction Manual Introduction GENERAL DESCRIPTION Figure 1 1 Model 930 Three Phase Power Controller STANDARD FEATURES Research Inc Introduction The Model 930 power control system is a complete power solution featuring a number of elements integrated into a single ready to install package The Model 930 is a three phase power control system available in two configurations of 120 and 160 Amps at 480 Volts These systems are ideally suited for many industrial power control applications and have been specifically optimized for use with Research Inc infrared heating systems Standard features include e Local 10 turn potentiometer with digital dial for precise manual control of load voltage s Remote control capability with a 0 5 VDC or 0 20 mA signal e Heater power switch with remote interlocks The load voltage may be enabled or disabled without turning off the main disconnect switch e Heater O
5. of the value represented by the command signal The current limiting action will affect the slew rate if the load current is greater than the current rating of the SCRs Wiring Specifications Wire Ratings Wire Temperature Rating 75 C or Higher Line Load Wiring Voltage Rating 240 VAC systems 300 VAC Minimum Line Load Wiring Voltage Rating 480 VAC systems 600 VAC Minimum Control Wiring 300 VAC Minimum Allowable Wire Sizes Current Line Load Ground Control Rating of Connections Connections Connection Circuit System Connections 120 Amp 6 250 MCM 6 250 MCM 4 1 0 AWG 22 10 AWG 160 Amp 6 250 MCM 6 250 MCM 4 1 0 AWG 22 10 AWG Recommended Minimum Wire Sizes NOTE Wire temperature and connector ampacity ratings are based on NEC table 310 16 using 75 C copper wire derated for 50 C ambient environment Current Line Load Ground Control Rating of Connections Connections Connection Circuit System Connections 1 AWG 6 AWG 6 AWG 2 0 AWG 4 AWG 6 AWG Electrical Inputs Heater open interlock switch Contacts Rated for 120 VAC at 2 0 A Cooling flow interlock switch Contacts rated for 120 VAC at 100 mA Heater over temp thermo switch Contacts rated for 120 VAC at 100 mA Remote interlock switch Contacts rated for 120 VAC at 100 mA Research Inc Page 21 of 25 Model 930 ControlIR Instruction Manual Dimensions and Specifications Specifications for Options Temp
6. 7 is negative is in REMOTE Opera 2 Units with Temperature control option Place tion O K with Setpoint temperature controller in manual mode with 50 switch in LOCAL if not percent output Verify 2 5VDC at TB 100 pins 16 see above and 17 Refer to the temperature controller manual regarding repairs Full voltage cannot be 1 Verify the load lamps or heaters are not drawing obtained current at full capacity of the system Rotate the current limit pot on the power controller 1 turn counterclockwise If the load current decreases the current limit is controlling the output 2 Verify the line voltage Load voltage maximum is approximately 98 percent of the line voltage 3 Test in LOCAL setpoint mode Set the Local Setpoint potentiometer to 900 The voltage should be 216 240 volt line or 432 480 volt line Adjust the RUN SPAN potentiometer of the power controller as necessary 4 Faulty power controller SCR or control circuit Refer to the power controller manual regarding repairs Load voltage will not go 1 Verify the load voltage will go to zero with the SCR to zero switch set to DISABLED If it does not refer to the power controller manual regarding repairs 2 If the shorted SCR indicator of the power controller is on an SCR has failed 3 Units with the Product Detect option Normal operation of the idle circuit The idle potentiometer maintains the voltage at idle 4 Units with the Conveyo
7. ATORS Main Disconnect Switch Heater ON OFF Switch Cooling ON OFF Switch Heater On Indicator Cooling On Indicator Heater Over Temperature Indicator Lamp Out OCT SCR Indicator Research Inc Operating Instructions Figure 4 1 shows the location of the controls and indicators The main disconnect switch turn on and off the power control system Note the following Before turning on the disconnect switch check the following 1 The load is wired and ready for power to be applied to it 2 All safety precautions are observed The Heater ON OFF switch allows the operator to enable or disable the power going to the load This is accomplished by removing power from the AC contactor This in turn removes power from the SCR controller The cooling on indicator must be on before the heater power can be turned on The Cooling ON OFF switch allows the operator to turn on or off the heater cooling e Indicator light on steady indicates power is applied to the heater power controller e Indicator light flashing indicates that the Remote Interlock is open and heater power can not be applied e Indicator light on steady indicates adequate cooling flow e Indicator light flashing indicates that the cooling is in a one minute shutoff delay cycle The one minute delay cycle is activated any time that the heater power contactor is opened after the initial heater on cycle is activated e Indicator light on steady indicates a
8. Model 930 Power Control System Instruction Manual Publication No A105328 001 Rev A ontrolViik SCR Power Controllers December 2000 Another quality product from RESEARCH INC PROVIDING CONTROLLED ENERGY DRYING 4 CURING 4 HEATING 7128 Shady Oak Rd Eden Prairie MN 55344 Phone 952 949 9009 Fax 952 949 9559 www researchinc com 00 INC Dear Customer Thank you for purchasing a Model 930 ControlIR Power Control System We believe it is the finest system of its type and are confident you will think so too For technical assistance training replacement parts and assemblies or any other problems or questions contact our Field Service specialists They will do everything they can to help you or will put you in touch with someone who can This instruction manual has been carefully prepared to make sure you get out of your system all the capabilities we designed and built into it To tell us how we could make the system our support of it or this manual even more useful we invite your to call our product manager with your suggestions and recommendations Additional copies of this manual are available at a reasonable cost from our Customer Service Department Once again let us welcome you to the growing family of Research Inc customers We look forward to working with you in the future Sincerely Terry Nigon President Research Inc Model 930 ControlIR Instruction Manual Contents S
9. N OFF switch controls an AC contactor to remove power from the SCR controller and the load e Cooling power switch to control air or water cooling flow e Cooling flow interlock contacts Low cooling turns off the heater contactor e Heater open interlock contacts A heater open condition turns off the heater contactor e Heater over temperature contacts Heater over temperature condition turns off the heater contactor e Indicators lights for heater on cooling on heater over temperature and SCR fault condition Page 1 of 25 Model 930 ControlIR Instruction Manual Introduction OPTIONAL FEATURES Research Inc e Fail safe operation of the heater contactor The contactor will not automatically re energize after a power failure or an alarm condition that shuts down the heater e Programmable Logic Controller for operating and alarm logic control The following standard options are available Automatic Temperature Control Option The automatic temperature control option allows the power level to be adjusted based on an entered temperature setting for the process The temperature controller uses PID type control and is pre wired for a K type thermocouple option code TCT or a 4 20mA pyrometer signal option code TCP Voltmeter Option The true RMS load voltage is displayed with a digital meter A true RMS voltage transmitter is provided for isolation and operator safety Lamp out Detection Option The lamp out dete
10. VAC Model XT19 Temperature Controller Thermocouple Input Model XT19 Temperature Controller 4 20mA Pyrometer Input Main Disconnect Switch 3P 200A Handle for Disconnect Switch Contactor 3 Pole 200A Model 3629B Power Controller 160A Model 3629B Power Controller 120A Programmable Logic Controller 8AC in 6 Relay out with 915 935 PRJ Software Fuse Load 80A 600VAC Load Fuse 120A Version Fuse Load 100A 600VAC Load Fuse 160A Version Control Transformer 100VA 240 480 120V Part Number 089330 001 086160 015 086445 015 087146 002 097832 002 09783 1 005 099366 001 055769 004 042952 000 087543 002 087543 004 087545 001 087545 001 092452 001 097399 002 097399 003 105286 001 105287 001 105289 001 099458 043 099458 041 099559 001 086797 001 086160 010 075475 001 Research Inc Page 25 of 25
11. VAC units 1 875 VDC 7 Verify that the panel voltmeter reads the voltage as set in Step 5 above If necessary carefully remove the front cover of the meter and adjust the span potentiometer for a 1 reading Temperature Controller Refer to the temperature controller manual for calibration instructions Option Research Inc Page 18 of 25 Model 930 ControlIR Instruction Manual Maintenance and Trouble Shooting LINE VOLTAGE The AC line voltage for the Model 930 Power Control System may be re configured On transformer T100 a wire with wire number 1070 is connected to pins 3 or 4 Move this RE CONFIGURATION wire to the pin corresponding to the desired line voltage Pin 3 240 VAC Pin 4 480 VAC See Figure 5 1 below Figure 5 1 AC Voltage Tap d OL g LX a H e E o AAAA AAAA A Ht A cr 7 BO F BERG WIRE 1070 SHOWN ON 480 VAC TAP On transformer T200 it is necessary to re configure the primary wires per the following see Figure 5 2 240VAC 480VAC Jumper H1 to H3 Jumper H3 to H2 Jumper H2 to H4 Figure 5 2 T200 Transformer H1 H2 H4 A Y S S o 1 _ o S IG Research Inc e 19 of 25 Model 930 ControlIR Instruction Manual Dimensions and Specifications SPECIFICATIONS Research Inc Dimensions and Specifications Environmental Limit
12. ayed so the SCRs start conducting some time later than the beginnings of the half cycles Operation of a phase angle controller at partial output is depicted in figure 4 4 SCR 1 INPUT LINE VOLTAGE i GATING SIGNAL GATING SIGNAL SCR 2 OUTPUT LINE VOLTAGE FIRING CIRCUITRY CONTROL SIGNAL Page 13 of 25 Model 930 ControlIR Instruction Manual Operating Instructions Figure 4 5 Phase angle power control Research Inc The average power a phase angle controller delivers to its load is determined by the number of electrical degrees by which the gating signal that turns on the SCRs is delayed past the beginnings of the half cycles The later in each half cycle the SCRs fire the less the time the SCRs conduct during each half cycle and therefore the less power is delivered to the load see figure 4 5 The 0 5 VDC control signal received by the phase angle firing circuit determines the amount by which the gating signal is delayed 135 PHASE ANGLE LOW POWER OUTPUT 0 90 180 270 360 90 180 270 360 90 PHASE ANGLE MEDIUM POWER OUTPUT 0 90 180 270 360 90 180 270 360 45 PHASE ANGLE HIGH POWER OUTPUT 0 90 180 270 360 90 180 270 360 AC PHASE ANGLE Kaha AC LINE VOLTAGE OUTPUT VOLTAGE TO LOAD Page 14 of 25 Model 930 ControlIR Instruction Manual Operating Instructions The output voltage of a phase angle controller does
13. ction option is designed to detect a lamp failure or load loss when using multiple infrared heaters or zones of lamps in a single heater The SCR fault Lamp out indicator flashes during this condition Product Detect PD Option The product detect option automatically adjusts the heater or lamp intensity between run and idle states when a product is detected on the conveyor A single turn idle potentiometer is provided on the front panel Idling the process saves energy and equipment wear Page 2 of 25 Model 930 ControlIR Instruction Manual Operating Instructions Safety WARNING Hazardous voltages are present at the main disconnect switch and load terminals Setting the setpoint potentiometer or control signal to minimum does NOT eliminate these hazardous voltages Always remove AC line voltage from the system before making contact with internal assemblies line or load wiring or fuses Also remove AC line voltage from the system before making connections equipment changes or resistance measurements CAUTION Up to 480 volts AC is present within the power control solution system Do not make any wiring connections when power is applied Disconnect power before performing any maintenance or service to the system Use extreme caution when adjusting calibration potentiometers on modules when power is applied Always use an isolated oscilloscope for checking waveforms Research Inc Page 3 of 25 Model 930 ControlIR
14. duct until its anode to cathode voltage drops to zero so the SCR continues to conduct until the end of the half cycle INPUT LINE VOLTAGE GATING SIGNAL CATHODE FIRING CIRCUITRY ANODE H H P P D s a x V D C s s a c c Sane OUTPUT LINE VOLTAGE CONTROL SIGNAL Page 12 of 25 Model 930 ControlIR Instruction Manual Operating Instructions Figure 4 3 Conduction of two SCRs connected in reverse parallel when turned on at the beginning of half cycles Principles of Phase Angle Control Figure 4 4 Conduction of two SCRs connected in reverse parallel when turned on after the beginning of the half cycles Research Inc Because an SCR is a type of diode it can conduct only during every other half cycle of the applied voltage Therefore SCRs used to control AC power are usually installed in pairs connected in reverse parallel as shown in figure 4 3 One of the SCRs then can be fired during the positive half cycle and the other can be fired during the negative half cycle SCR 1 N INPUT LINE VOLTAGE GATING SIGNAL GATING SIGNAL SCR 2 OUTPUT LINE VOLTAGE FIRING CIRCUITRY CONTROL SIGNAL In phase angle controllers the SCRs conduct during all or part of every half cycle When delivering full power the SCRs start conducting at the beginnings of the AC half cycles When delivering less than maximum power the gating signal is de l
15. ection page INTRODUCTION General Description 1 Standard Features 1 Optional Features RAEN 3 INSTALLATION Mounting The sS VSteml e ma rin eee a cites a Oe a pet eee tte lo pin ae nn 4 Wiring COnNeCO OMS 6 at on eats ea Tie a nl al Oe oe aN 5 Power Wiring Connections f C Oaj 6 Tete AC OMMG CUO Ss 5 cn shen once yee siento cnet aire ooo E N 6 Load Connections si 6 Control Connections 6 Cooling Flow On Off Relay Output C C O 6 Cooling Flow Switch Interlock C O 7 Heater Over Temperature Thermo switch Interlock 7 Remoter Interlock Switch 6 ne eh oe chee cc ee ode ad ec eek 7 Heater Open Switch Interlock COOC C C O 7 Remote SEDO INDIE 9 Fee ac ha hovtarses tee tar eds ns dic anette See aoe cocdmeesting ee sates 8 Temperature Control Option Connections Option Codes TCT amp TCP 9 OPERATING INSTRUCTIONS Controls and Indicators s_ ss s i i i lt i lt lt CSO 10 Main Disconnect Switch RyC C O a 10 Heater ON OFF Switch iri 10 Cooling ON OFF Switch 10 Heater On Indicator OCC 10 Cooling On Indicator 10 Heater Over Temperature Indicator OOC O O 10 Lamp Out OCT SCR Indicator 10 Remote Local Setpoint Switch 11 Local Setpoint Potent om eter R RFCfjkj Oj 11 Load Volts Indicator Option Code VM f C O a 11 Temperature Control Opn sen oo els oh ioe eee na a ee sae etn chen ete uae ig lb accel 12 Setup S mmary lt oo eo ce NS ae E a SNS Ge Sl Te a Se 12 Theory of
16. emperature control option TCT is setup to use a K type thermocouple for the temperature input Temperature control option TCP is setup to use a pyrometer for the temperature input Alarm connections are provided if required for your process The alarm contacts are dry type rated for a maximum of 3 Amps resistive at 240 VAC If desired the process temperature alarm may be connected to the Front Paned Over Temp Alarm Indicator Make connections as follows 1 TCT option Use K type extension wire from the thermocouple to the system connections Connect the K thermocouple extension wire to TB 100 pins 18 and 19 2 TCP option The pyrometer should source the 4 20 mA current through it s circuitry If a 2 wire pyrometer is used an external power supply must be used The model 935 does not source current for pyrometer operation Connect the 4 20mA signal to TB 100 pins 18 and 19 3 TCT and TCP options To use the alarm output as an external process alarm Connect the device for the alarm output to TB100 pins 20 and 21 If a remote alarm output is not used the alarm may be connected to the front panel over temp alarm indicator Connect TB 100 pin 20 to pin 8 and TB 100 pin 4 to pin 11 The alarm indicator will flash while the temperature controller is in an alarm condition Page 9 of 25 Model 930 ControlIR Instruction Manual Operating Instructions CONTROLS AND INDIC
17. erature Controller Option Option Code Thermocouple type TCT Type K Sensor Input TCP 4 20mA scaled 0 2500 deg F Alarm relay rating 5A 120VAC resistive 3A 240VAC Sample rate 10 HZ TCT amp TCP Calibration accuracy 0 2 of full scale 1 digit Control modes PID or PI PD P only or On Off Temperature stability SuV C max 3uV C typical Noise Rejection Common Mode gt 100 dB Series Mode gt 70 dB Autotune Operator initiated Option Code Voltmeter Option RMS Voltage transducer 0 600 VAC to 0 5 VDC VM Overall accuracy 2 VAC DIMENSIONS Figure 6 1 displays the overall dimensions of the Model 935 power control system The dimensions include the side vents and door handle Figure 6 1 Model 930 A Dimensions d Overall HO E lt gt U L OB j b E el Ai 1 Page 22 of 25 Research Inc Model 930 ControlIR Instruction Manual Dimensions and Specifications Figure 6 2 shows the mounting dimensions using the supplied brackets i A Figure 6 2 Wall Mounting Dimensions aa L d Page 23 of 25 Research Inc Model 930 ControlIR Instruction Manual Dimen
18. heater over temperature condition A heater over temperature condition will open the heater power contactor removing power from the heater e Indicator light flashing indicates a process over temperature alarm This feature is available only if the Temperature Control Option is installed The indicator will flash only as long as the process alarm exists e Indicator light on steady indicates a power controller over current OCT or a power controller shorted scr SCR condition exists The OCT SCR alarm will open the heater contactor removing power from the load e Indicator light flashing indicates a lamp out condition This feature is available only if the lamp out LL option is installed The alarm will remain on as long as the lamp out condition exists Page 10 of 25 Model 930 ControlIR Instruction Manual Operating Instructions Remote Local Setpoint The remote local setpoint switch allows the operator to select the source for the power Switch level setting to the load lamps or heaters The selections include 1 LOCAL The power level is adjusted using the digital 10 Turn LOCAL SETPOINT potentiometer 2 REMOTE The power level is controlled from a remote location or device or the power level is controlled by the temperature controller if the TCT TCP temperature option is installed The operator will enter a desired temperature setpoint for the process The power level is adjusted based on the feedback from the temperatu
19. ide of the cabinet for power wiring near the center of the cabinet for load wiring and near the left side for CONNECTIONS low voltage control wiring Assure that metal fragments are not allowed to fall into the equipment while holes are made for conduit fittings We suggest a separate conduit entry should be made for low level DC control wiring if used This includes the remote setpoint input or thermocouple wire temperature control option Table 3 1 Wiring Specifications Wire Ratings Wire Temperature Rating 75 C or Higher Line Load Wiring Voltage Rating 240 VAC systems 300 VAC Minimum Line Load Wiring Voltage Rating 480 VAC systems 600 VAC Minimum Control Wiring 300 VAC Minimum Allowable Wire Sizes Current Line Load Ground Control Rating of Connections Connections Connection Circuit System Connections 120 Amp 6 250 MCM 6 250 MCM 4 1 0 AWG 22 10 AWG 160 Amp 6 250 MCM 6 250 MCM 4 1 0 AWG 22 10 AWG Recommended Minimum Wire Sizes NOTE Wire temperature and connector ampacity ratings are based on NEC 310 16 using 75 C copper wire derated for 50 C ambient environment Current Line Load Ground Control Rating of Connections Connections Connection Circuit System Connections 120 Amp 1 AWG 6 AWG 6 AWG 16 AWG 160 Amp 2 0 AWG 4 AWG 6 AWG 16 AWG Electrical Inputs Heater open interlock switch Contacts Rated for 120 VAC at 2 0 A Cooling flow interlock switch
20. in disconnect energize switch 2 Verify remote heater open remote process interlocks or water flow switches if used are closed 3 If not using remote heater enable heater open interlocks or water flow switches verify the 2 pin jumpers are installed between TB 100 pins 2 to 3 10 to 11 and 14 to 15 4 Check fuses FU 1050 FU 1051 FU 107 FU 108 and TB 100 pin 1 Verify the Heater On indicator is illuminated No output to load heaters or lamps Setpoint switch 5 E Verify a 0 5 VDC signal is present on pins 13 and 14 is in LOCAL mode of the power controller connector This voltage is proportional to the setting of the local Setpoint potentiometer or the idle potentiometer product detect option if product is not detected 3 If the over current light on the controller is illuminated check the load wiring lamp or heater connections for short circuits 4 If the shorted SCR light is lit on the controller refer to the power controller manual regarding repairs 5 If the COMMAND led on the power controller is not lit and a control signal is greater than 10 percent is applied refer to the power controller manual regarding repairs Research Inc Page 16 of 25 Model 930 ControlIR Instruction Manual Maintenance and Trouble Shooting Symptom Action No output to load heaters 1 Verify the polarity of the remote input TB 100 pin or lamps Setpoint switch 16 is positive and 1
21. ing the heater power controller contactor With the interlock open the heater can not be turned on from the control system front panel The switch contacts must be open during the heater off condition If this feature is desired connect using the following procedure 1 Remove the factory installed jumper at TB 100 pins 10 and 11 2 Connect the normally open contacts of the switch to TB 100 pins 10 and 11 3 If more than 1 interlock switch is used in a system wire the contacts in series and then connect to the system Heater Open Switch This feature provides shutdown of the heater power if the heater is opened during Interlock operation This switch directly interlocks power to the heater contactor If a heater cavity open switch is not included with your heater use a switch with contacts that are open when the heater is open To implement feature connect using the following procedure 1 Remove the factory installed jumper at TB 100 pins 14 and 15 2 Connect the normally open contacts of the switch to TB 100 pins 14 and 15 3 If more than 1 heater open interlock switch is used in a system wire the contacts in series and then connect to the system NOTE If a remote Emergency Stop switch is desired wire the switch push pull type with maintained contacts in series with the heater open switch Research Inc Page 7 of 25 Model 930 ControlIR Instruction Manual Operating Instructions Remote Setpoint Input This feature a
22. llows the power level of the system to be controlled from a remote location or device This is accomplished by applying a 0 5 VDC or 0 20 mA signal input from a remote source This feature is not available when the Temperature Controller option is installed If this feature is desired use the following procedure 1 Fora 0 5 VDC input connect the source to TB 100 pins 16 and 17 2 Fora 0 20 mA input connect the source to TB 100 pins 16 and 17 Also install a 250 ohm resistor across terminals TB 100 16 and 17 Figure 3 3 Control Connections A FUSE F TACTOR A TIONAL EQUIPMENT 4 2 FUSE FOR HEATER XN ENGL E LNG F E WITH Research Inc Page 8 of 25 Model 930 ControlIR Instruction Manual Operating Instructions Temperature Control Option Connections Option Codes TCT amp TCP Research Inc T
23. not change linearly with respect to the number of degrees the SCR conduction phase angle changes Therefore the SCR controllers have a built in load feedback circuit to linearize the relationship between the control signal and the voltage output The feedback circuit also adjusts the power controller output to compensate for changes in line voltage and load impedance this is called line and load regulation Phase angle power control offers a number of attractive features Because the power controller output level is adjusted by varying the SCR on time within each AC half cycle the controller s output is quite constant rather than being divided into multiple cycle periods of on time and off time In addition a variety of feedback and output indication metering circuits can easily be incorporated into the controller Research Inc Page 15 of 25 Model 930 ControlIR Instruction Manual Maintenance and Trouble Shootin Maintenance and Trouble Shooting ROUTINE The following bi monthly routine maintenance is suggested 1 Remove power connection to the system Lock out power if possible Carefully MAINTENANCE vacuum any dust or dirt collecting within the enclosure Use caution to not disturb the wiring Service more often in dust locations 2 Clean the outside of the enclosure with glass cleaner and a soft cotton cloth as necessary TROUBLESHOOTING Heater Contactor will not 1 Verify line voltage is applied to the ma
24. r Web speed option Normal operation The minimum idle potentiometer may be adjusted to lower the load voltage to zero if the web is stopped CALIBRATION Generally components of the power control system hold their calibration very well over a long period of time Usually verification of calibration is all that is necessary We suggest verification or calibration be performed on a yearly basis Calibration should be performed by qualified personnel as dangerous voltages are present Power Controller Refer to the power controller manual for specific calibration instructions Calibrate using step 1 2 or 3 below use whichever is used most often When LOCAL setpoint mode is selected the local setpoint potentiometer is used as the source for the input Adjust the zero and span potentiometers on the power controller The SPAN potentiometer is adjusted for 90 percent or rated line voltage for 900 dial divisions of the local setpoint pot The ZERO potentiometer is adjusted for 0 Volts output when the local setpoint is set to 000 dial divisions Research Inc Page 17 of 25 Model 930 ControlIR Instruction Manual Maintenance and Trouble Shooting 2 Voltmeter Option or No Options When REMOTE setpoint mode is selected use a 0 5 VDC source for an input Adjust the zero and span potentiometers on the power controller The SPAN potentiometer is adjusted for 90 percent of rated line voltage for 4 5 VDC input The ZERO potentiometer is adjus
25. r Input TCT option K type thermocouple scaled 0 2500 F Sensor Input TCP option AL 1 alarm 1 4 20mA signal scaled 0 2500 F Control Type PID proportional integral amp derivative Full scale high non latching set for 2000 F This alarm will trip a relay connected to TB100 pins 13 and 14 Control Output 0 20 milliamps This alarm may be re configured as necessary for your process SCR type power controllers control power by regulating when silicon controlled rectifiers SCRs conduct AC line current to the load A SCR is a solid state electronic switching device that turns on fires very quickly when a low level gating signal is applied to its gate electrode The timing of the gating signal and therefore the length of time the SCR conducts is determined by the controller s firing circuitry in response to a control signal The greater the percentage of time the SCR is on the greater the average power it allows to pass through to the load The Model 910 uses a random fire solid state relay within its SCR poser controller This relay is a package consisting of 2 SCRs and a gate drive circuit During the positive half cycle of the AC line voltage the SCR s anode is positive with respect to its cathode so during that half cycle the SCR will begin to conduct whenever a gating signal is applied to its gate electrode see figure 4 2 Once turned on an SCR will continue to con
26. re sensor connected to the process Local Setpoint The power level is adjusted using the digital 10 Turn LOCAL SETPOINT Potentiometer potentiometer when the Setpoint switch is in the Local position Load Volts Indicator This option provides indication of the True RMS load voltage Option Code VM Disconnect Switch Optional Temperature Controller or Optional Voltmeter Heater On Off Switch Heater On Indicator Remote Local Setpoint Switch Local Setpoint Potentiometer Cooling On Off Switch Cooling On Indicator Heater Over Temperature Indicator Over Current Shorted SCR Indicator and Optional Lamp Out Indicator Figure 4 1 Controls and Indicators lt A L L LA 4 Heater Heater Setpoint Off On On Rem Loc Cooling Cooling Heater Lamp Out Off On On Overtemp OCT SCR Research Inc Page 11 of 25 Model 930 ControlIR Instruction Manual Operating Instructions TEMPERATURE CONTROL OPTION Setup Summary Table 4 1 Temperature Controller Configuration THEORY OF OPERATION Principles of SCR Power Control Figure 4 2 Conduction of one SCR when turned on at the beginning of a half cycle Research Inc This section contains temperature controller configuration information for your system Refer to the Model XT19 installation and instruction manual for operating the temperature controller Table 4 1 displays factory configurations made for your system Senso
27. s Operating Temperature 0 50 deg C 32 122 deg F Storage Temperature 40 70 deg C 10 158 deg F Humidity 0 90 non condensing Clearance 4 100mm on right and left sides Weight The system weight varies slightly with the options installed The maximum weight of the system is pounds kg Operating Voltage 240 or 480 VAC 10 15 at 50 or 60 Hertz Voltage set at factory per order Operating Current and kW E Maximum Power kW at Continuous Current Rating at 50 C Current Rating of System 240 VAC 480 VAC 120 Amp 120 Amps 50 99 8 160 Amp 160 Amps 66 5 133 Line Fusing Current Rating of System Fuse Type Fuse Rating 120 Amp JJS 150 Class T 150 Amp 600 Volt 160 Amp JJS 200 Class T 200 Amp 600 Volt Power Control Control Mode SCR phase angle control of the voltage applied to a three phase load True RMS voltage feedback for load voltage regulation Control Range 0 98 of supply voltage Output Linearity RMS load voltage varies linearly with control signal within 2 percent of span over the entire range of control Page 20 of 25 Model 930 ControlIR Instruction Manual Dimensions and Specifications Electrical Isolation Heat sink to supply and load voltage 2500 Volts peak Command signal to supply and load voltage 1400 Volts peak Slew Rate 200 ms Slew rate is the time required for the load voltage to change 63
28. sions and Specifications Ordering Information Coxe 2 Code Product Description 935 Three Phase SCR Power Control System A Wall Mount 240 240 Volts AC 480 480 Volts AC 120 120 Amps 160 160 Amps Options TCP Temperature Controller 4 20 mA Pyrometer Input TCT Temperature Controller Thermocouple Input vm Digital Voltmeter LL Lamp out Detection 00 None Overall Dimensions including side vents door handle and mounting brackets 51 15 inches 1 High 1299 2mm x 16 34 inches Deep 415mm 2 System available with either option TCP TCT or VM Select one only Ordering Example Line Current Enclosure Typical Model Number Options Voltage 480 Capacity 930 A 120 TCP LL Research Inc Page 24 of 25 Model 930 Control IR Instruction Manual Dimensions and Specifications Spare and Replacement Parts Description Fuse 200 Amp 600 VAC For use with 160 Amp version Fuse 150 Amp 600 VAC For use with 120 Amp version Fuse 1 Amp Time Delay CC Fuse 2 Amp 5x20 mm Fast Act True RMS AC Voltage Transmitter Digital Meter 0 600 VAC Control Transformer 70 VA Potentiometer 1K 10 Turn Digital Dial Switch 2 Position Selector contact blocks separate see below Remote Local Switch 3 position spring return to center contact blocks sold separately Switch contact block 1 CON NO Switch contact block 2 CON NO NC Pilot Light Module 120
29. ted for 0 Volts output when the local setpoint is set to 000 dial divisions 3 Temperature Controller option only When AUTO setpoint mode is selected the temperature controller is used as the source for the input Adjust the zero and span potentiometers on the power controller The SPAN potentiometer is adjusted for 90 percent of rated line voltage for 90 percent output of the temperature controller The ZERO potentiometer is adjusted for 0 volts output when the temperature controller is set to 0 percent Panel Voltmeter The front panel load voltmeter is calibrated to match as closely as possible the true Calibration RMS voltage measured at the load terminals 1 Connect a true RMS DVM to load 1 and load 2 2 Connect another DVM across pins 1 and 2 of the EXT 200 RMS voltage transmitter 3 Turn the HEATER switch to OFF Measure the voltage of EXT 200 pins 1 and 2 to be 0 0 VDC 10 millivolts Adjust the EXT 200 zero potentiometer if necessary 4 Verify the panel voltmeter reads 0 volts If necessary carefully remove the front cover of the meter and adjust the zero potentiometer for 000 1 reading 5 Turn the Heater switch to ON Adjust the LOCAL SETPOINT potentiometer for the following load voltage based on the voltage your system is configured for 480 VAC units 450 VAC 240 VAC units 225 VAC 6 Measure the voltage of EXT 200 pins 1 and 2 to be the following voltage 10 millivolts 480 VAC units 3 750 VDC 240
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