C3000/C3000A SCR CONTROL CARD USER MANUAL
Contents
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3. PRACTICAL CONTROL SOLUTIONS C3000 C3000A SCR CONTROL CARD USER MANUAL C3000 manual C3000MANV1 6 doc5 CONTENTS Page No 1 0 Introduction 2 0 Installation 3 0 Commissioning 4 0 Operation 5 0 Maintenance 6 0 Terminal Schedule 7 0 Specification 8 0 Circuit Card Layout C3000 manual C3000MANV1 6 doc5 1 0 INTRODUCTION Thank you for purchasing the C3000 SCR control card Please read these instructions carefully before installing and running your controller The C3000 control card is designed for firing SCRs in three phase rectifier and AC power control applications The C3000A accessory card allows options such as current limit and current trip operation as a current source and relay outputs 1 1 PRINCIPAL OF OPERATION The C3000 controller can be operated in either burst or phase angle firing mode In burst firing mode the controller rapidly switches the output on and off in response to the control input signal In phase angle firing mode the controller conducts over a variable portion of the incoming AC cycle in response to the control input signal Contro mput bassi B VU phase angk firng burst firng 1 2 SAFETY This instruction manual gives details of safe installation and operation of the C3000 Note that there are mains voltages present within the C3000 enclosure and on parts of the control electronics circuit board High voltage areas on the circuit board a
4. temperature controller or PLC controlling the C3000 When performing this adjustment the SCR is set to maximum output power for a short time Many heaters have a maximum power density that cannot be exceeded or damage will occur For this reason it is Page 6 strongly recommended that for this adjustment the heaters be disconnected from the SCR and a dummy load used instead We can supply a compact portable dummy load or alternatively you can assemble one from household light bulbs 3 3 2 ZERO ADJUSTMENT With the dummy load connected set the control input signal to minimum i e 4 mA 0 VDC or 0 ohms Connect a volt meter across the SCR output and adjust the ZERO potentiometer until the output voltage is approximately zero Due to leakage through the SCRs some voltage will always be present across the SCR output 3 3 3 SPAN ADJUSTMENT 5 3 X 3 c d 3 gt 3 D 5 D n O A 5 o 3 2 o lt U O o 9 o A o 5 3 o gt a c a 5 D U gt Z potentiometer until the output voltage of the SCR is at maximum Check output voltage again at minimum and maximum control inputs and repeat the zero and span adjustments if necessary D D Q o o o E o Q 3 3 4 RISE The rise adjustment determines the speed that the C3000 responds to a change in the control input signal Test the SCR response by introducing a step change to the control input and measuring the t
5. the controller for a while at full output If any nuisance trips occur turn the TRIP potentiometer one more turn clockwise repeating until the nuisance trips stop Note that it is possible to set the current trip setpoint lower than the current limit setpoint Always adjust current limit first and set current trip to trigger at a higher current Page 7 3 3 6 POWER LIMIT OPTION Power limit sets the maximum output power by measuring output voltage across two phases and the average current Zero and Span adjustment must be correct before power limit is set Set the LIMIT potentiometer fully anticlockwise and the LIM SLP and TRIP potentiometers fully clockwise With the control input set to maximum slowly turn the limit potentiometer clockwise until the required power level has been reached Power limit has now been set Refer to section 3 3 5 2 to set current trip 3 3 7 LIMIT SLOPE The LIM SLP potentiometer is normally set full anticlockwise If the SCR output oscillates under current or power limit turn the LIM SLP potentiometer anticlockwise until output is stable 3 3 8 CURRENT SOURCE OPERATION OPTION The C3000 can be run as a voltage limited AC current source Output current is set by the control input signal Maximum output voltage is set either by the AUX V potentiometer on the main circuit card or by an external 10k potentiometer on terminals 9 10 and 11 or by an external 0 10V DC signal on terminals 9 and 10 To select extern
6. LEDS Indicator leds are provided to alert operators to fault conditions and to show control status during normal operation They are mounted on the main control card with a second set of mimic leds mounted on the lid of the controller 4 1 1 POWER 4 2 o O a 2 o t n o 2 jo o o o D gt 2 e o 2 ct gt O O o o o Q o 2 2 9 5 lt 4 1 2 POWER OK The Power OK led indicates that all three phases are present and in the correct sequence If this led is not lit check all phases are present on terminals L1 L2 and L3 If all phases are present but the led is not o jo gt O Lo gt D o n 3 o c 2 a 4 1 3 ENABLE The Enable led indicates that the enable link is closed and that the C3000 is in operating mode If this led is not lit check for continuity between terminals 4 1 4 LIMIT This led is fitted when current or power limit is specified options CL PL or when the controller is run as a current source options CCS CCH CCA When operating in current limit condition the Limit led will light When the controller is operated as a current source the Limit led will be permanently lit provided the load impedance is low enough Page 10 4 1 5 ELEMENT LIFE This led is fitted when element end of life indication option EL is specified It indicates th
7. al control of maximum output voltage remove solder link X4 on the C3000A circuit card 3 3 8 1 OUTPUT VOLTAGE ADJUSTMENT CURRENT SOURCE Connect the controller to a dummy load With the control input set to maximum adjust the AUX V or external signal source until the maximum desired output voltage has been reached A true RMS reading meter should be used for this measurement Set the control input to minimum and reconnect the load 3 3 8 2 ZERO ADJUSTMENT CURRENT SOURCE PE 2 e DE D o o Q o 2 2 D D Q o D y D Q o 2 gt 5 jo c o Q v O 3 2 3 c 3 A 3 2 o lt O O o o o ca pl 3 n O o 2 2 D 5 ammeter to measure the controller output current and adjust the ZERO potentiometer until the output current is zero 3 3 8 3 SPAN ADJUSTMENT CURRENT SOURCE n Q 5 D x 3 E 3 Q o 5 o 5 S a 5 v o gt D n O Az D o 3 2 eo lt o e A o gt 3 a gt 2 c a gt D n gt Z potentiometer until the output current of the SCR is set to the maximum allowable level Check output current again at minimum and maximum control inputs and repeat the zero and span 3 3 9 PARTIAL LOAD FAILURE DETECTION OPTION o 2 c 6 a 3 O 5 5 gt D O n Q lt The partial load failure option give a latched relay output if the load curren
8. ansformer inputs for current limit partial load i pi P current sensor input remote current limit failure or constant current AC feedback options for DC current limit input or constant current P options 25 26 27 29 30 31 32 33 34 35 36 37 E E NO NC RA ff E 5 enable relay output Tem uc uc GI hall effect voltage voltage pulse output meter 2 meter 3 input option option Voltage sensor input for DC voltage feedback option p 22 9 38 39 40 44 42 43 44 45 46 47 48 49 NO NC NO NC NO NC NO NC stack over temperature current trip phase loss element life relay output relay output relay output relay output 50 51 52 NO NC partial load failure relay output 7 0 SPECIFICATIONS Control mode Phase angle or fast cycle burst user selectable Control input User selectable from 4 20mA DC 0 10V DC 0 10K ohm potentiometer Other inputs available on request Control range 0 100 Voltage 110 240 380 415 480 VAC 50 or 60 Hz Other voltages available on request Current Standard range to 340 amps per phase higher currents to special order Firing modes Fast cycle burst or phase angle with soft start Protection RC snubber protection and fast semiconductor protection fuses standard Operating temperature 50 degrees C maximum Thermal cut out standard Operating humidity 0 85 RH non condensing Isolation gt 1kV St
9. at the controller is operating at full line voltage and that new heating elements are required or a transformer tap change to a higher voltage is required when a tapped transformer is being used The EL option is normally used with silicon carbide heaters 4 1 6 PHASE LOSS The Phase loss led lights when any one of the incoming phases is missing 4 1 7 TRIP The Trip led is fitted with the current power limit or constant current options options CL PL or CCA This lights when the controller is disabled on an over current trip 4 1 8 PARTIAL LOAD FAILURE PLF This led is fitted with the partial load failure option option PLF It lights when a partial load failure is detected 4 1 9 OVER TEMPERATURE The Overtemp led lights when the SCR assembly is over its allowable operating temperature or when terminals J25 and J26 are open The controller output is disabled until the operating temperature drops below the trip point 4 2 RESETTING CURRENT TRIP On current trip the controller is disabled To reset the controller either break and then make the enable link on terminals 1 and 2 or turn the three phase power to the controller off then on Page 11 5 0 MAINTENANCE Fault condition Possible cause Corrective action No output from SCR polarity is correct input phases Input phase lost or missing If PHASE LOSS led is lit identify missing phase and reconnect Check fuses for continuity and replace if requi
10. atus output contacts 2 amps 240 VAC Page 13 8 0 CIRCUIT CARD LAYOUT J1 ceca EXT_FUNCTION HEADER ci Bl oo fas 1 y c29 Exe pee xiz 15 je 2 C20 c 837 jo 22 m 182 SLY Ta4 ras C3000 TOP 0 LAW ras__REU2 11 97 187 131415 16 17 18 19 20 2122 2324 LIM TRIP LIM SL PLF 25 26 27 28 28 30 31 32 33 34 35 36 37 38 39 40 41 42 43 45 46 47484950 51 52 Ir SERIAL No THERMAL SWITCH a Nes 1 026 Hi
11. ave a neutral terminal that must be wired in Failure to do this will result in incorrect operation The neutral connection to the C3000 is for the AC fan s where fitted and as a phase reference for the controller It can be run in light gauge wire 2 2 8 POWER WIRING Incoming three phase power supply must be wired in the correct sequence R W B corresponds 120 degrees between phases The load can be wired in floating star star with neutral delta and six wire delta If the load is star with neutral the 4W four wire option must be specified Page 3 T3000 controller Delta Floating star XM F 2 Vv MEM A 5 Es 11 L3 W 4 J9 J10 Load configuration T3002 two leg control 73000 controler Delta Star with optional neutra 17 gt L1 i U n 4 33 3877 J gt L2 T V 4 4 5 38 n2 11 gt T L3 4 gt W 4 A y 0 Load confguration 73003 three bg control 2 2 9 POWER WIRING FOR SIX WIRE DELTA LOADS When used with six wire loads the incoming three phase power supply must be wired in the correct sequence R W B and also the returns from the heating load must be wired in the correct sequence T3000 controller gt 4 L1 P U ea _ 4 di L2 gt V 4 a 13 1 gt w Six wire load configuration Pa
12. ement end of life indication phase EL AC voltage feedback AVF phase Phase loss either Current source mode CCS phase CCH CCA T3002 burst Two leg control 3 2 START UP The controller must be connected to a load in order to run correctly After switching power to the controller on the POWER POWER OK and ENABLE leds should be lit If the POWER led is unlit check that all three phases are present and that the fuses are not blown The POWER Ok led indicates that the phase rotation is correct If it is unlit swap two incoming phases around If the ENABLE led is unlit bridge out terminals 1 and 2 with wire or through volt free contacts 3 3 ADJUSTMENTS Adjustments are made by potentiometers on the electronic circuit cards Refer to section 7 0 for detail of potentiometer positions Note that potentially lethal mains level voltages are present on these circuit cards and on power components within the C3000 enclosure adjustments should be carried out by suitably qualified personnel There are several sealed potentiometers that are factory set and must not be adjusted by the user 3 3 1 ZERO AND SPAN Zero and span adjustment ensures that the controller output is from 0 to 100 over the full control input range Your C3000 is supplied pre calibrated This procedure need only be carried out as a periodic calibration check In practice any slight errors in calibration will be compensated for by the
13. ge 4 2 3 AC VOLTAGE FEEDBACK FOR SIX WIRE LOADS If the C3000 controller is to be used with a six wire load and has the AC voltage feedback option wire link LK8 must be removed and replaced by link LK9 Link LK7 is used only for four wire loads These links are found on the C3000 circuit card The following table summarises the AC voltage feedback link configuration Load Configuration LK7 LK8 LK9 Four wire star with neutral IN OUT OUT Three wire star or delta OUT IN OUT Six wire delta OUT OUT IN Default configuration for non four wire controllers 2 4 TRANSFORMER PRIMARY CONTROL The C3000 can safely be used to control transformer coupled loads through the transformer primary with the following recommendations The controller must be set to phase angle mode firing The current or power limit trip option is highly recommended to protect the transformer from DC saturation in the event of a partial SCR failure The normal transformer configuration is delta primary star secondary 2 5 TRANSFORMER SECONDARY CONTROL The C3000 can be used on the secondary of any transformer provided the voltage specified for the C3000 is the same as the transformer secondary voltage 2 6 FUSING Fuses supplied with the C3000 are special fast fuses for the protection of the SCRs only Wiring and other circuit elements must be fused separately with circuit breakers or HRC fuses 2 7 ISOLATION SCRs and their RC protection networks snubbers inhere
14. ime it takes for the output to fully respond Adjust the RISE potentiometer until the desired level of response has been reached 3 3 5 CURRENT LIMIT AND TRIP OPTION Current limit and trip must be set with the dummy load removed and the actual load connected Zero and Span adjustment must be correct before current limit and trip are set 3 3 5 1 CURRENT LIMIT The current limit adjustment sets the maximum output current of the controller When used with the C3000 set to phase angle firing mode it limits instantaneous output current When used with the C3000 set to burst mode it limits the maximum average current over time Set the LIMIT potentiometer fully anticlockwise and the LIM SL feedback gain and TRIP potentiometers fully clockwise With the control input set to maximum slowly turn the limit potentiometer clockwise until the required current level has been reached Current limit has now been set Note that in general the output current waveform of the C3000 when used in phase angle firing mode is not sinusoidal For accurate current measurement a true RMS reading ammeter must be used 3 3 5 2 CURRENT TRIP After adjusting current limit and with the control input set to maximum slowly turn the TRIP potentiometer anticlockwise one turn at a time until the SCR current trip activates Adjust the potentiometer one turn clockwise and reset the trip by breaking and making the enable link or by turning power to the SCR off and on Run
15. n 2 SCR stack temperature The thermal switch should be volt free and normally closed If a stack over temperature switch is not to be used terminals J25 and J26 must be linked 2 2 3 RELAY OUTPUTS O o o 2 3 D o c mt jo lt gt n D D D lt o e 2 o Q 2 y 2 o c o o lt a D 2 z nm O A o lt D ct 3 o D c 3 Q c 2 trip phase loss element life and partial load failure The maximum relay current is 5 amps 2 2 4 PULSE OUTPUTS An optional pulse output feature gives a pulse output with frequency proportional to either current power or voltage 2 2 5 METERS Three optional 0 1mA meter outputs are available for transmission of output voltage current or power If necessary meter terminals can be made common 2 2 6 ENABLE LINK An ENABLE link is provided on screw terminals 1 and 2 which must be closed for the C3000 to operate The ENABLE link can be used as a convenient means of turning the controller on and off Ensure that any contacts switching the enable link are volt free Note that the enable link must not be used as a safety interlock It does not mechanically disconnect the SCR from the power supply and cannot be used as a means of safety isolation 2 2 7 NEUTRAL All units with the 4W option h
16. ntly leak voltage High voltages will be present on their output terminals even when in the off state For this reason the C3000 SCR cannot be relied upon as an isolating device The C3000 must be installed with a mechanical circuit breaking device in series with its supply so that work can be safely carried out on the unit 2 8 ENCLOSURE VENTILATION The C3000 is designed to operate at a maximum ambient temperature of 50 degrees C The electrical enclosure must have adequate ventilation to ensure that the internal temperature does not rise to a point above 50 degrees C In some cases forced ventilation is appropriate Page 5 3 0 COMMISSIONING 3 1 FIRING MODE SELECTION Two types of firing modes are available on the C3000 phase angle and fast cycle burst To select move the selector jumper to the phase or burst position as required Note that some options will not work correctly if the firing mode is changed Note also that some types of heating elements and transformer coupled loads should only be used with phase angle control If in doubt about the correct firing mode for your application contact us Required firing mode Comments Current limit amp trip either Phase control instantaneous limit Burst control average limit Power limit phase Phase control instantaneous limit Burst control average limit Current meter output either Voltage meter output either Power meter output M2 M3 phase Partial load failure PLF burst El
17. re marked by Page 1 2 0 INSTALLATION 2 1 MOUNTING The C3000 card has mains level voltages present on it Mount so that there is at least 15mm between the bottom of the card and the mounting surface 2 2 WIRING 2 2 1 SCR CATHODE amp GATE WIRING SCR gates and cathodes connect to the C3000 control card through quick connect terminals J1 to J12 Wire the control card exactly as per the diagram The C3000 card is phase rotation sensitive the phase sequence must be R W B as shown in the schematics below AC OUTPUT 3 WIRE 4 WIRE J6 J12J11 J6 12 11 J9 J10 DC OUTPUT FULL BRIDGE DOUBLE STAR Ji J2 J12 J11 SECONDARY STAR POINT The power for the card is taken through the auxiliary cathode leads in all cases except for DOUBLE STAR DC For double star dc the tracks under the board marked with an X will need to be cut and R W B connected to J15 J16 and J17 respectively If the supply voltage for the card is to be different to the supply voltage for the SCR s then the tracks under the board marked with an X will need to be cut and R W B connected to J15 J16 and J17 respectively Page 2 2 2 2 STACK OVERTEMPERATURE SWITCH o E Qo Q o 2 2 ct D 3 3 2 m o c N al 2 o c N O 3 D 2 S o a h O Q o 2 2 D Q o 2 2 o ct 2 D m 3 v o Oo 2 3 o 2 O
18. red Over temperature trip activated If TEMP led lit shut off power and allow to cool Current trip activated If TRIP led lit find source of over current trip and correct Reset trip by turning off power or breaking and making enable link Load circuit open Check load circuit continuity and repair as required Leto iv 9 sui dei lt Controller output not Gate or cathode lead s Reconnect leads modulating with disconnected from SCRs respect to control input Gate or cathode leads wired Rewire gate and cathode leads incorrectly out of sequence to in correct sequence SCRs Rewire load in correct sequence wire load configuration Neutral reference not connected Connect neutral reference on four wire 4W load configuration A A rFr_81 ae Unequal output Unequal load resistance Check load circuit current over three phases Gate or cathode leads loose or Reconnect leads disconnected SCR block damaged Replace SCR Page 12 6 0 TERMINAL SCHEDULE Terminal schedule 2 3 4 5 6 7 9 10 11 enable Poor 0 10V Nut m 0 10V meter 1 option tb 0 10k Pot 0 10k Pot i i remote setpoint max output voltage main control input select one for constant current mode option select one 13 17 18 19 20 21 22 23 24 I i de TX LES NS s shunt hall effect 0 10k Pot option option current tr
19. st MV potentiometer until current is 1mA at full output voltage 3 3 10 2 METERS 2 8 3 Meters 2 amp 3 can be configured to transmit output current voltage or power if the appropriate options are fitted These meter outputs Current limit trip AC voltage feedback Power limit Firing mode need these options gt option CL option AVF option PWL Current meter output e Either Voltage meter output e Either Power meter output e e e Phase To change the output of meters 2 or 3 select the appropriate solder jumpers on the C3000A card as specified in the following tables Meter 2 X14 X15 X16 Current in out Out Power out in Out Volts out out In Meter 3 X11 X12 X13 Current in out Out Power out in Out Volts out out In Page 9 3 3 10 3 ADJUSTMENT METER 2 Connect a multimeter to measure 1mA DC across terminals 28 and 27 Adjust the output voltage current or power from zero to full and check the output current is approximately zero for zero output voltage current or power as appropriate 2 adjust CM2 potentiometer until current is 1mA at full output 3 3 10 4 ADJUSTMENT METER 3 Connect a multimeter to measure 1mA DC across terminals 30 and 29 Adjust the output voltage current or power from zero to full and check the output current is approximately zero for zero output voltage current or power as appropriate 2 adjust CM3 potentiometer until current is 1mA at full output 4 0 OPERATION 4 1 STATUS
20. t drops below a preset level set by the user Partial load failure will only operate correctly with the controller set to burst firing mode see section 3 1 Jumper links X6 and X7 on the circuit card marked C3000A determine the operating range of the partial load failure detection option The table below summarises the operating range for the various jumper configurations Page 8 Jumper Operating range of full load current X6 93 100 X7 86 100 X6 amp X7 79 100 The potentiometer marked PLF adjusts the trip point within the range determined by the jumper links To set the trip point With the control input set to maximum and the PLF potentiometer set anticlockwise disconnect one heater element Adjust the PLF potentiometer slowly clockwise until the partial load failure relay trips then reconnect the heater element Partial load failure is now set to trip at the failure of one heater element If the partial load failure trips at all potentiometer positions reset X6 and X7 so operation is over a wider range 3 3 10 METER OUTPUT OPTIONS Up to three optional meter outputs are available to transmit output voltage current or power The output signal is 0 1mA DC 3 3 10 1 ADJUSTMENT METER 1 Meter output 1 transmits output voltage Connect a multimeter to measure 1mA DC across terminals 7 and 8 Adjust the output voltage from zero to full and check 1 the output current is approximately zero for zero output voltage 2 adju
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