Safety Information in this Manual Danger, Warning, and Caution symbols are used throughout the manual to help identify and avoid hazardous situations. Examples of each symbol are are shown and explained below.
DANGER Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations. It may also also be used to alert against unsafe practices. (Color: red)
WARNING Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. injury. It may also be used to alert alert against unsafe practices or cause product failure. (Color: orange)
Caution Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. injury. It may also be used to alert alert against unsafe practices. (Color: yellow)
Table of Contents Chapter 1 .................... .............................. .................... ..................... ..................... ..................... ..................1-1 .......1-1 Product Description......................................... Description.................................................................. ................................ ....... 1-1 Phase-Angle Phase-Angle Control.......................................................... Control..................................................................... ........... 1-2 Zero-Crossover Zero-Crossover Control ................................................. ................................................................ ............... 1-4 Standard Standard Features ................................................ ........................................................................ ........................ 1-7 Optional Features ................................................. ......................................................................... ........................ 1-8 Technical Technical Specifications Specifications ................................................ ............................................................... ............... 1-8 Part Number ................................................ ......................................................................... ................................. ........ 1-9
Chapter 2 .................... .............................. .................... ..................... ..................... ..................... ..................2-1 .......2-1 Hardware ............................................... ........................................................................ ......................................... ................ 2-1 Installation.................................... Installation.............................................................. ................................................. ....................... 2-1 Enclosure Enclosure........................ ................................................... ...................................................... ................................... ........ 2-1 Enclosure Enclosure Temperature Temperature .................................................. ................................................................ .............. 2-1 Vibration....................................... Vibration.................................................................. ................................................. ...................... 2-2 Mounting .................................................. ........................................................................... ..................................... ............ 2-2 Disconnect Disconnect Means ................................................. ........................................................................ ....................... 2-2 Wiring................................................. Wiring........................ .................................................. ........................................... .................. 2-2 Remote Feedback Feedback Wiring ............................................. ............................................................. ................ 2-4 Control Connections Connections .................................................. ..................................................................... ................... 2-5 Digital Inputs .................................................. ............................................................................ ............................... ..... 2-6 Digital Outputs .................................................... .............................................................................. .......................... 2-7 Analog Inputs................................................. Inputs............................................................................ ............................... .... 2-8 Analog Outputs ................................................... ............................................................................. .......................... 2-9 Remote Feedback................................................. Feedback....................................................................... ...................... 2-10 Over-temperature Over-temperature Sensing.................................................. Sensing.......................................................... ........ 2-10
Chapter 3 .................... .............................. .................... ..................... ..................... ..................... ..................3-1 .......3-1 Configuration............................. Configuration....................................................... .................................................... ............................ .. 3-1 Startup .................................................. ............................................................................ ........................................ .............. 3-1 Configuration Configuration Tool Installation Installation ................................................. ...................................................... ..... 3-2 Running the Configuratio Configuration n Tool ................................................. .................................................... ... 3-2 Configuration Configuration Tool Menu and Task Task Bar Descriptions.................... Descriptions.................... 3-5 Off-line Programming................................... Programming............................................................ ............................... ...... 3-10 On-line Programming................................... Programming............................................................ ............................... ...... 3-18 On-line Monitor ............................................... ......................................................................... ............................ .. 3-23 Flash Programming.................. Programming........................................... .................................................. ........................... 3-29
i
Loss of Communication .............................................................. 3-30
Chapter 4...............................................................................4-1 Calibration....................................................................................... 4-1 Current Rating............................................................................... 4-5 Voltage Rating .............................................................................. 4-5 Remote Voltage and Current Feedback........................................ 4-6 Calibration Procedure ................................................................... 4-7 Saving Calibration......................................................................... 4-9 Restoring Factory Calibration ..................................................... 4-10 Analog Calibration....................................................................... 4-12 Manual Calibration ...................................................................... 4-15 Magnetizing Sequence Calibration ............................................. 4-16 Repetitive Pulse Calibration........................................................ 4-16 Node Synchronization................................................................. 4-17
Chapter 5...............................................................................5-1 Local Digital Control Option ............................................................ 5-1 Display and Status ........................................................................ 5-1 Normal Mode Operation................................................................ 5-3 Display Select Mode Operation..................................................... 5-7
Chapter 6...............................................................................6-1 Serial Communication ..................................................................... 6-1 Hardware ...................................................................................... 6-1 Serial Protocols............................................................................. 6-3
Chapter 7...............................................................................7-1 Settings........................................................................................... 7-1 Voltage Input Rating ..................................................................... 7-1 Voltage Input High Fault ............................................................... 7-1 Voltage Input Low Alarm............................................................... 7-1 Voltage Input Phase Unbalance Alarm ......................................... 7-1 Voltage L1-L2 Input Actual............................................................ 7-1 Voltage L1-L2 Input Span ............................................................. 7-1 Voltage L2-L3 Input Actual............................................................ 7-2 Voltage L2-L3 Input Span ............................................................. 7-2 Voltage L3-L1 Input Actual............................................................ 7-2 Voltage L3-L1 Input Span ............................................................. 7-2 Voltage Input Actual...................................................................... 7-2
ii
Frequency Rating.......................................................................... 7-2 Frequency Actual .......................................................................... 7-2 Voltage Output Rating................................................................... 7-2 Voltage Output PT Secondary ...................................................... 7-2 Voltage Output Limit ..................................................................... 7-2 Voltage Output Setpoint................................................................ 7-2 Voltage Output Proportional Gain ................................................. 7-3 Voltage Output Integral Gain ........................................................ 7-3 Voltage Output Derivative Gain .................................................... 7-3 Voltage X1-X2 Output Actual ........................................................ 7-3 Voltage X1-X2 Output Zero........................................................... 7-3 Voltage X1-X2 Output Span.......................................................... 7-3 Voltage X2-X3 Output Actual ........................................................ 7-3 Voltage X2-X3 Output Zero........................................................... 7-3 Voltage X2-X3 Output Span.......................................................... 7-3 Voltage X3-X1 Output Actual ........................................................ 7-3 Voltage X3-X1 Output Zero........................................................... 7-3 Voltage X3-X1 Output Span.......................................................... 7-4 Voltage Output Actual................................................................... 7-4 Current Input Rating...................................................................... 7-4 Current Input Limit ........................................................................ 7-4 Current Input High Fault................................................................ 7-4 Current Input High Fault Retry Number ........................................ 7-4 Current Input High Fault Retry Time ............................................. 7-4 Current Input Overload Fault ........................................................ 7-4 Current Input Overload Time ........................................................ 7-4 Ground Fault Current .................................................................... 7-5 Ground Fault Time ........................................................................ 7-5 Current L1 Input Actual ................................................................. 7-5 Current L1 Input Zero.................................................................... 7-5 Current L1 Input Span................................................................... 7-5 Current L2 Input Actual ................................................................. 7-5 Current L2 Input Zero.................................................................... 7-5 Current L2 Input Span................................................................... 7-5 Current L3 Input Actual ................................................................. 7-5 Current L3 Input Zero.................................................................... 7-5 Current L3 Input Span................................................................... 7-5 Current Input Actual ...................................................................... 7-6
iii
Current Input Threshold Load Failure ........................................... 7-6 Current Output Rating................................................................... 7-6 Current Output Limit...................................................................... 7-6 Current Output Setpoint................................................................ 7-6 Current Output Proportional Gain ................................................. 7-6 Current Output Integral Gain......................................................... 7-6 Current Output Derivative Gain..................................................... 7-6 Current X1 Output Actual.............................................................. 7-6 Current X1 Output Zero ................................................................ 7-6 Current X1 Output Span ............................................................... 7-7 Current X2 Output Actual.............................................................. 7-7 Current X3 Output Actual.............................................................. 7-7 Current Output Actual ................................................................... 7-7 KVA Input Rating .......................................................................... 7-7 KVA Input...................................................................................... 7-7 Power Output Rating..................................................................... 7-7 Power Output Limit ....................................................................... 7-7 Power Output Setpoint.................................................................. 7-7 Power Output Proportional Gain ................................................... 7-7 Power Output Integral Gain .......................................................... 7-8 Power Output Derivative Gain ...................................................... 7-8 Power Output................................................................................ 7-8 Power Factor ................................................................................ 7-8 Duty Cycle Output......................................................................... 7-8 Duty Cycle Setpoint ...................................................................... 7-8 Local Digital Control Display Selection ......................................... 7-8 Local Digital Control Setpoint........................................................ 7-8 Local Primary Analog Setpoint...................................................... 7-8 Primary Analog Setpoint Zero....................................................... 7-9 Primary Analog Setpoint Span...................................................... 7-9 Local Secondary Analog Setpoint Selection ................................. 7-9 Local Secondary Analog Setpoint................................................. 7-9 Secondary Analog Setpoint Zero .................................................. 7-9 Secondary Analog Setpoint Span ................................................. 7-9 Analog Output #1 Selection ........................................................ 7-10 Analog Output #1........................................................................ 7-10 Analog Output #1 Bias ................................................................ 7-10 Analog Output #1 Span............................................................... 7-10
iv
Analog Output #2 Selection ........................................................ 7-10 Analog Output #2........................................................................ 7-10 Analog Output #2 Bias ................................................................ 7-10 Analog Output #2 Span............................................................... 7-10 Control Word............................................................................... 7-11 Status Word ................................................................................ 7-12 Ramp Up Time............................................................................ 7-13 Ramp Down Time ....................................................................... 7-13 Configuration Word..................................................................... 7-13 Control Strategy Selection .......................................................... 7-14 Magnetizing Sequence Calibration ............................................. 7-14 Repetitive Pulse Calibration........................................................ 7-14 Load Type Selection ................................................................... 7-14 Product Type .............................................................................. 7-14 Serial Number............................................................................. 7-14 Control Power Time On .............................................................. 7-14 Output Time On .......................................................................... 7-14 KW-Hour ..................................................................................... 7-14 Software Version......................................................................... 7-14 Network Loss .............................................................................. 7-15 Network Address......................................................................... 7-15 Network Baud Rate..................................................................... 7-15 MODBUS Address...................................................................... 7-15 MODBUS Baud Rate .................................................................. 7-15 Network Type.............................................................................. 7-15 Fault Code .................................................................................. 7-15 Fault Index .................................................................................. 7-15 Fault Buffer #1 ............................................................................ 7-15 Fault Buffer #2 ............................................................................ 7-16 Fault Buffer #3 ............................................................................ 7-16 Fault Buffer #4 ............................................................................ 7-16 Fault Buffer #5 ............................................................................ 7-16 Fault Buffer #6 ............................................................................ 7-16 Fault Buffer #7 ............................................................................ 7-16 Fault Buffer #8 ............................................................................ 7-16
Chapter 8...............................................................................8-1 Troubleshooting .............................................................................. 8-1 Control PCB LED Indicators ......................................................... 8-2
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Local Digital Control Option LED Indicators.................................. 8-3 Fault and Alarm Codes ................................................................. 8-4 Fault Reset ................................................................................... 8-9 Fault Buffer ................................................................................... 8-9 Troubleshooting Guide................................................................ 8-10
Appendix A .......................................................................... A-1 Mechanical Dimensions ..................................................................A-1
Appendix B .......................................................................... B-1 Electrical Drawings..........................................................................B-1
Glossary .................................................................................... i
vi
List of Figures Figure 1-1 853 DSPC Schematic Diagram...................................................................1-1 Figure 1-2 Phase-Angle Control Half Cycles................................................................1-2 Figure 1-3 Phase-Angle Duty Cycle Output .................................................................1-3 Figure 1-4 Zero-Crossover Control ..............................................................................1-4 Figure 1-5 Zero-Crossover Current Input Limit.............................................................1-5 Figure 1-6 Zero-Crossover Control Magnetizing Sequence .........................................1-6 Figure 1-7 Zero-Crossover Control Repetitive Pulse....................................................1-6 Figure 2-1 Mounting Dimensions ................................................................................. 2-2 Figure 2-2 Cover screw locations................................................................................. 2-3 Figure 2-6 Digital Input Schematic ............................................................................... 2-7 Figure 2-8 Analog Output Schematic ........................................................................... 2-9 Figure 3-1 Control PCB LED Location..........................................................................3-1 Figure 3-3 Configuration Tool..................................................................................... 3-11 Figure 3-4 Ratings & Limits Tab................................................................................. 3-12 Figure 3-5 Control Configuration Tab .........................................................................3-14 Figure 3-6 Fault Setup Tab ........................................................................................ 3-15 Figure 3-7 PID Setup Tab .......................................................................................... 3-16 Figure 3-8 Network Tab.............................................................................................. 3-17 Figure 3-9 Configuration Tool On-Line .......................................................................3-19 Figure 3-10 Monitor Summary Tab ............................................................................3-24 Figure 3-11 Monitor Control Tab ................................................................................ 3-26 Figure 3-12 Monitor Status Tab.................................................................................. 3-27 Figure 3-13 Fault History............................................................................................3-28 Figure 3-14 Flash Programming................................................................................. 3-29 Figure 4-1 Calibration (Voltage Tab) ............................................................................4-1 Figure 4-2 Voltage Calibration...................................................................................... 4-2 Figure 4-3 Current Calibration......................................................................................4-3 Figure 4-4 Analog Calibration....................................................................................... 4-4 Figure 5-1 Local Digital Control Panel ..........................................................................5-1 Figure 6-1 Nine Pin to Nine Pin Null Modem Cable Diagram .......................................6-1 Figure 6-2 Twenty-five Pin to Nine Pin Null Modem Cable Diagram ............................ 6-1 Figure 8-1 Control PCB LED indicator location ............................................................8-2 Figure 8-2 Local Digital Control .................................................................................... 8-3 Figure A-1 Mechanical Dimensions..............................................................................A-1 Figure B-1 Electrical Schematic Left Side ....................................................................B-2 Figure B-2 Electrical Schematic Right Side ..................................................................B-3 Figure B-3 40A Wiring Diagram ...................................................................................B-4 Figure B-4 90A Wiring Diagram ...................................................................................B-5 Figure B-5 175A Wiring Diagram .................................................................................B-6 Figure B-6 350A Wiring Diagram .................................................................................B-7
vii
List of Tables Table 1-1 Technical Specifications...............................................................................1-8 Table 2-1 Wiring Information ........................................................................................2-4 Table 2-2 Digital Interface Plug .................................................................................... 2-6 Table 2-3 Relay Contact Ratings ................................................................................. 2-7 Table 2-4 Analog Interface Plug................................................................................... 2-8 Table 3-1 Status Lamp Description ............................................................................ 3-20 Table 5-1 Display Selections........................................................................................5-2 Table 5-2 Digital Control Status ................................................................................... 5-3 Table 5-3 Pushbutton function in Normal mode, Local Digital Control ......................... 5-4 Table 5-4 Pushbutton function in Normal mode, Local Analog Control ........................ 5-5 Table 5-5 Pushbutton function in Normal mode, Remote Control ................................ 5-6 Table 5-6 Pushbutton function in Display Select Mode, Local Control ......................... 5-7 Table 5-7 Pushbutton function in Display Select Mode, Remote Control .....................5-8 Table 6-1 Serial Port Configuration ..............................................................................6-2 Table 6-2 MODBUS RTU Query (from Master) ............................................................6-3 Table 6-3 MODBUS RTU Read Response (from 853) ................................................. 6-4 Table 6-4 MODBUS RTU Write Response (from 853) ................................................. 6-4 Table 6-5 MODBUS RTU Exception Response (from 853 DSPC)............................... 6-5 Table 6-6 MODBUS RTU Exception Codes .................................................................6-5 Table 6-7 General 8 Byte Query (from Master) ............................................................6-6 Table 6-8 General 8 Byte Response (from 853)........................................................... 6-7 Table 7-1 List of Settings.............................................................................................. 7-1 Table 8-1 Control PCB LED Indicators......................................................................... 8-2 Table 8-2 Local Digital Control LED Indicators.............................................................8-3 Table 8-3 Fault and Alarm Codes ................................................................................ 8-4 Table 8-4 Troubleshooting Guide ............................................................................... 8-11
viii
Chapter 1 Product Description The 853 Digital SCR Power Controller (DSPC) from Spang Power Electronics offers the latest in Digital Signal Processing (DSP) technology and software. The DSPC is designed for a three-phase application. The 853 DSPC uses an advance d, dsp-based firing circuit to control a three phase, six SCR AC Switch. The 853 DSPC is capable of firing into either direct or transformer coupled loads. The basic circuit configuration is shown in the figure below.
Figure 1-1 853 DSPC Schematic Diagram
1-1
Product Description
February 2004
Phase-Angle Control In Phase-Angle control, the line is connected to the load for a portion of each half cycle. It is disconnected from the load for the remainder of the half cycle. The period during which the load is connected is varied in response to the control signal providing proportional control of power to the load. A sample picture of Phase-Angle control is shown below.
Figure 1-2 Phase-Angle Control Half Cycles
1-2
February 2004
Product Description
Phase-Angle Control Method The 853 DSPC controls its output based on regulation mode. The regulation modes are Open Loop, Voltage Output, Current Output, and Power Output. Each mode regulates to within 1% of rated output. The Current Input Limit is accomplished by comparing the Current Input to the Current Input Limit. If the Current Input exceeds the Current Input Limit the Current Output setpoint is lowered, which in turn will lower the Current Input. A flow diagram of the control is shown below.
Figure 1-3 Phase-Angle Duty Cycle Output RFI Phase-Angle control can generate Radio Frequency Interference (RFI). This may, depending upon the installation and magnitude, affect other electronic equipment (computers, telephones, etc.). Where RFI may be a problem, Zero-Crossover control can be used for many of the electric heating applications. The source inductance, load inductance, and circuit impedances de termine the amount of RFI generated by Phase-Angle control. Additional components may be required to reduce or eliminate RFI, such as the use of an isolation transformer between the line and the 853 DSPC or the addition of line filters.
1-3
Product Description
February 2004
Zero-Crossover Control In Zero-Crossover control, the line is connected to the load for a number of complete cycles. It is then disconnected for a number of complete cycles. This on-off pattern is repeated continuously with the 853 DSPC turning on (and off) at the zero crossing of the sine wave. The ratio of the number of cycles ON to the number OFF is varied in response to the control signal providing proportional control of the power to the load. The 853 DSPC has predefined the total number of cycles ON and OFF to be 100. This will allow the output to be set to 1% or 1 cycle out of 100. A sample picture of the Zero-Crossover control is shown below.
Figure 1-4 Zero-Crossover Control Multiple 853 DSPC’s can achieve power leveling by using the Network Address and Node Synchronization. This allows each independent 853 DSPC to start at a different time based on the Network Address, which allows one 853 DSPC to turn on when the other unit is off, therefore causing power leveling on the common AC power source. Zero-Crossover Control Method The Zero-Crossover control method is based on calculation. The actual voltage output, current output, and power output are calculated every cycle and compared to each respective setpoint. The cycles continue until the calculated feedback exceeds its respective setpoint and then the unit turns off after the next cycle. This necessitates a minimum of two cycles or 2% output since the first cycle is used for calculation and turn off does not occur until after the second cycle.
1-4
February 2004
Product Description
Zero-Crossover Current Input Limit The Zero-Crossover control method controls cycles and can only control Current Input by applying Phase-Angle control to the individual cycles. The Phase-Angle control of the individual cycles will limit the input current, and since the Zero-Crossover control is adaptive, the number of cycles will automatically increase based on the voltage output, current output, and power output setpoints. The Phase-Angle control of individual cycles does eliminate some of the features of the Zero-Crossover control such as high power factor and low RFI. However, it does protect the load by limiting the current that in some cases would be more important than the Zero-Crossover features. A sample picture of the Zero-Crossover control with Current Input Limit is shown below.
Figure 1-5 Zero-Crossover Current Input Limit Heating Loads Resistance type heating loads fall into two general categories. The first category consists of heating elements made from materials that exhibit relatively constant resistance whether hot or cold. These include such elements as nichrome, calrod, chromolox and various steels. No particular precautions need be taken in using such materials. The second category consists of elements made from materials that exhibit low initial (cold) resistance such as tungsten, molybdenum, platinum, moly-disilicide, silicon carbide (which ages) and quartz infrared lamps. Such elements require the use of the current limit option that prevents more than a preset value of current from flowing during the initial low resistance condition of the elements. Zero-Crossover Load Type The very nature of Zero-Crossover control, firing full cycles of power, tends to cause large inrush currents into the load. This is especially true when transformers are connected to the output. This is because transformers rely on their magnetic field to limit the current, which is present only after current has been flowing for a short time. In order to eliminate this problem from happening, the Load Type setting can be set for Direct Coupled or Transformer Coupled loads. Transformer Coupled loads require two additional settings; Magnetizing Sequence and Repetitive Pulse.
1-5
Product Description
February 2004
Magnetizing Sequence The Magnetizing Sequence causes the specified number of cycles to start in Phase-Angle control in order to limit the current inrush when the 853 DSPC is first turned on. A sample picture of the ZeroCrossover control magnetizing sequence is shown below.
Figure 1-6 Zero-Crossover Control Magnetizing Sequence Repetitive Pulse After the cycle has started, the Repetitive Pulse causes only the first cycle to start in Phase-Angle control again in order to limit the current inrush. A sample picture of the Zero-Crossover control Repetitive Pulse is shown below.
Figure 1-7 Zero-Crossover Control Repetitive Pulse
1-6
February 2004
Product Description
Standard Features The 850 Series digital product family offers the following features: •
Flexibility. Configurable operating modes, ratings, limits, external inputs, a nd setpoints.
•
On-Board Diagnostics. Fault memory (the last eight faults are available in fault buffer storage) allows the user to record problems and, through the use of a computer, observe trends that could indicate a need for process modification, troubleshooting or preventative maintenance.
•
Computerized Setup and Calibration. RS-232 serial Configuration Tool for setup, digital calibration and diagnostics
•
Touch-Proof Mechanical Design prevents unintentional contact with hazardous voltage
•
Advanced Process and Fault Monitoring. Real-time monitor of voltage, current, power and fault conditions. Real-time adjustment of the setpoint. Changes can be made any of four different ways:
Locally, using an analog control signal. Locally, using the Configuration Tool software. Locally, with optional Local Digital Control feature. Remotely, with optional Network Communications feature.
•
Operates on universal line voltages, from 24 to 600 VAC and 50/60 Hz.
•
DSP-based control
•
1600 Volt SCR's
•
20KHZ pulse transformer coupled SCR gating circuit
•
50KHZ digital firing control
•
True RMS calculation of voltage, current, and power at 10KHZ sampling
•
Simultaneous regulation of voltage, current, and power
•
User-configurable analog input
•
User-configurable analog outputs
•
Non-volatile storage of all digital settings
•
Support of MODBUS RTU protocol
•
Support of multiple baud rates on the serial port
1-7
Product Description
February 2004
Optional Features The following optional features are available for the 853 DSPC: •
Network Interface, allowing for remote control and monitoring of the 853. The networks supported are DeviceNet™, MODBUS (MODBUS RTU protocol), Profibus, and Ethernet (MODBUS TCP protocol).
•
Local Digital Control. User has a 4-digit LED display, 12 independent status LEDs and 4 pushbuttons, which allow local control of the 853. The user can control unit output and change the desired set point, as well as monitor voltage, current, or power on the LED display. Fault and alarm conditions are displayed.
Technical Specifications
Table 1-1 Technical Specifications Input Line Voltage
24 to 600 VAC RMS
Input Line Frequency
50/60 ± 2 HZ
Current Rating
40 to 350 A; consult factory for higher ratings
Current Surge Rating
40A - 1,800A for 10 msec 90/175A - 8,000A for 10 msec 350A - 14,500A for 10 msec
2
Fuse I t Rating
2
40A - 16,200 A sec 2
90/175A - 320,000 A sec 2
350A - 1,051,000 A sec Control Voltage
85 to 265 VAC
Control Power
50 VA
Analog Inputs (2)
0 to 5 VDC or 0 to 20mA (250Ω)
Analog Outputs (2)
0 to 5 VDC or 0 to 20mA (10V max)
Digital Inputs
0 to 5 VDC
Regulation
1%
Isolation to ground
2500 VAC
Ambient Temperature Range
0 to 50ºC
1-8
February 2004
Product Description
Part Number The Part Number format for the 853 DSPC series product is 853-AAAA-00-00 and is described in detail below.
853
AAAA
00
00
Product Series
Current Rating: 40A 90A 175A 350A
Product Options: Dx - DeviceNet™ Px - Profibus Ex - Ethernet x1 - Local Control x2 - Remote Control
SL – Special Lugs Reserved for future use.
1-9
Chapter 2 Hardware Installation
DANGER The user is responsible for conforming to all applicable local, national, and international codes; wiring practices, grounding, disconnects, and overcurrent protection are of particular importance. Failure to observe this precaution could result in severe bodily injury or loss of life.
Prior to installation, the 853 DSPC should be carefully checked for shipping and/or handling damage such as loose or broken parts or wires. All covers and panels should be removed for internal inspection and any shipping braces should be removed.
WARNING The 853 DSPC is intended to be mounted in a protective enclosure to prevent the ha zard of electrical shock. Unless supplied with an enclosure, it is considered to be a component that must be mounted in an enclosure by the user.
Enclosure The 853 DSPC must be mounted in a protective enclosure to prevent the hazard of electrical shock and also to avoid exposing the circuitry to damaging contaminants. A NEMA 1 enclosure for providing protection from electric shock is available as an option. If the 853 DSPC must be located in an area of dust, falling debris, splashing or falling water, adequate protection must be supplied. These conditions necessitate the use of a special NEMA enclosure. Custom NEMA enclosures for the afore-mentioned conditions are also available.
WARNING An incorrectly applied or installed system can result in component damage or reduction in product life. Wiring or application errors, incorrect or inadequate AC supply, or excessive ambient temperature may result in malfunction of the system.
Enclosure Temperature The 853 DSPC is rated at 50°C maximum ambient temperature. If the 853 DSPC is mounted in an enclosure other than one designed and built by Spang Power Electronics, care must be taken to allow sufficient cooling air to the SCR heatsink. Consult the factory for enclosure temperatures above 50°C but less than 65°C.
2-1
Hardware
February 2004
Vibration If the mounting site has a vibration concern, the 853 DSPC should be mounted using industry standard shock mounting techniques. Mounting Allow four inches on each side and a minimum of four inches above and below the 853 DSPC for adequate cooling. It is recommended that the enclosure exhaust vents be located above the top of the heatsink. Allow additional room for wiring as required by the individual application.
Figure 2-1 Mounting Dimensions
Disconnect Means It is required that a circuit breaker, fused disconnect or fuses be installed upstream of the 853 DSPC for wire protection. Fuses are not necessary if the distribution system current surge rating is limited to below the specification for the unit. Optional semiconductor fuses (externally mounted) are available to prevent surge or transient currents from damaging the semiconductors. The semiconductor fuses are oversized (90A for the 40A unit, 250A for the 90/175A unit and 500A for the 350A unit) to prevent n uisance fuse blowing and, for this reason, cannot be used for steady state overload protection. Wiring Wire should be sized in accordance with the appropriate specific code guidelines. Ambient operating temperature should be taken into account. All large cables should be routed to allow access to the 853 DSPC. It is up to the discretion of the installer to allow access room to service the unit.
2-2
February 2004
Hardware
The Phillips head cover screws are located at the four corners of the unit, and are removed to open the covers on their inside hinges, providing access to the power wiring terminals.
Figure 2-2 Cover screw locations The input power lugs are located under the top cover. The output power lugs, the remote feedback terminal block, and the chassis ground lug are located under the bottom cover as shown in the following figure.
Figure 2-3 Input and Output Power Lug locations (175A unit)
2-3
Hardware
February 2004
Table 2-1 Wiring Information Unit size
Power Lugs
Ground Lug
Feedback Terminal
Wire Range
Screw Head
Wire Range
Screw Head
Wire Range
Screw Head
40A
14-2 [8*] AWG
Slotted
14-2 [8*] AWG
Slotted
8-24 [14*] AWG
Slotted
90A
14-1/0 [4* ] A WG Slotted
14-2 [8*] AWG
Slotted
8-24 [14*] AWG
Slotted
175A
6-250MCM[2/0*] AWG 5/16 inch hex 14-2 [4*] AWG
Slotted
8-24 [14*] AWG
Slotted
350A
4-500MCM [350MCM*] AWG
8-24 [14*] AWG
Slotted
1/2 inch hex
6-3/0 [2*] AWG ¼ inch hex
Note: Size in brackets [*] is recommended for 90ºC wire insulation. Remote Feedback Wiring If remote feedback is used, the connections are made to the Remote Feedback Terminal. Current feedback is connected to TB1 terminals 1 (+) and 2 (common), and voltage feedback is connected to TB2 terminals 1 (X1), 2 (X2) and 3 (X3). The current feedback signal should be about 2.5 Vrms at the rated output current, and the voltage feedback signal should be in the same range as the input voltage. Allowable ranges are 300-600V, 150-300V, 75-150V, 37.5-75V and 2437.5V.
Figure 2-4 Remote Feedback Terminals Note: The existing current and voltage feedback connections must be removed and insulated before connecting new remote current and voltage feedback to the Remote Feedback Terminal.
2-4
February 2004
Hardware
Control Connections
Control connections are made using the pluggable terminal blocks that are located on the right side of the 853 DSPC. These terminals accept fine stranded wire up to 12 AWG. The 853 DSPC requires 85-265VAC 50/60Hz @ 50VA control power for the circuit boards and cooling fans. This must be wired to the twoposition plug labeled Control Power .
Figure 2-5 Control Connectors The following figure shows a typical wiring diagram for control connections.
Figure 2-6 Typical Control Connections
2-5
Hardware
February 2004
WARNING This equipment is at line voltage when AC power is connected. Disconnect and lock out all ungrounded conductors of the AC power line. Failure to observe these precautions could result in severe bodily injury or loss of life.
Digital Inputs The digital inputs (Remote/Local, Enable, and External Fault) provide power for each input designed for low voltage contacts or switches. The voltage/current rating of the contact or switch should be 15V and 10mA. If interfacing to automated equipment, it is possible to connect a 10V signal directly into the input without using the power connection. The digital interface consists of the thirteen-position plug labeled Digital Interface. The following table describes each terminal and its default operation. Terminals 1, 3, 5, 7 and 9 provide 15 volts through a 470 Ω resistor in order to develop a 10 volt, 10 mA signal into the appropriate digital input. A typical schematic of the digital inputs follows the table.
Table 2-2 Digital Interface Plug Terminal Number
Note:
Terminal description
Standard operation (see Note below)
1
External Fault #1 power
2
External Fault #1 input
3
External Fault #2 power
4
External Fault #2 input
5
External Fault #3 power
6
External Fault #3 input
7
Remote/local power
8
Remote/local input
9
Enable power
10
Enable input
11
Fault common
Fault relay common connection.
12
Fault NC
Contact opens when a fault occurs.
13
Fault NO
Contact closes when a fault occurs.
Shorting 1 to 2 provides an external fault input. Open indicates no remote fault.
Shorting 3 to 4 provides an external fault input. Open indicates no remote fault.
Shorting 5 to 6 provides an external fault input. Open indicates no remote fault.
Shorting 7 to 8 puts the unit into remote mode. Open defaults to local mode.
Shorting 9 to 10 enables the unit. Open inhibits operation.
The external faults are programmed by default as normally open (NO). Refer to the Settings Chapter (Configuration Word) for more information on contacts.
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February 2004
Hardware
Figure 2-6 Digital Input Schematic External Fault Input One typical use for the External Fault Input would be the micro switch on an external semiconductor fuse. The default state is for a normally open switch to indicate a “normal” condition. It may be programmed by the user for a normally closed switch to indicate a “normal” condition. Remote/Local Input The Remote/Local Input is used to select the control mode. Remote control is selected to allow control from the network (when present). The default state (open) is for local control. Enable Input The Enable Input is used to provide a local enable/inhibit function. The default state (open) inhibits the unit (prevents the SCR from firing). Digital Outputs The digital outputs (Fault – Common, NC, and NO) are relay contacts from a miniature relay on the digital control printed circuit board. It is very important to not exceed the contact ratings listed in the table below.
Table 2-3 Relay Contact Ratings Load Type
Voltage
Current
Resistive
125VAC
0.30A
Resistive
30VDC
1.0A
Inductive
125VAC
0.20A
Inductive
30VDC
0.50A
2-7
Hardware
February 2004
A pilot relay can be used to interface to larger relays or contactors if required. Analog Inputs The analog input (Analog Setpoint) is designed to accept potentiometer, voltage, or current inputs. The potentiometer input is designed for a 10K potentiometer that is connected between the Analog Supply, Analog Setpoint, and Analog Ground. The voltage input requires a 0 to 5VDC input to achieve 0 to 100% setpoint. The current input requires a 0 to 20mA input to achieve 0 to 100% setpoint. In order to use the current input, jumper JP2 must be shorted for the Primary Analog Input and jumper JP4 must be shorted for the Secondary Analog Input. This connects a 249 ohm resistor into the circuit for the current input to use. It is possible to use a 4 to 20mA current input by utilizing the Primary or Secondary Analog Setpoint Zero calibration to offset the 4mA input to be 0% setpoint. Also, other voltages and currents less than 5VDC and 20mA are acceptable b y utilizing the Primary or Secondary Analog Setpoint Span calibration to set 100% setpoint. The analog interface consists of the ten-position plug labeled Analog Interface. The following table describes each terminal and its default operation.
Table 2-4 Analog Interface Plug Terminal Number
Terminal description
1
Analog #1 supply
2
Analog #1input
3
Analog #1 ground
4
Analog #2 supply
5
Analog #2input
6
Analog #2 ground
7
Analog #1 output
8
Analog #1ground
9
Analog #2 output
10
Analog #2ground
Standard operation
Connecting a 10k potentiometer with JP2 OFF provides a local analog control.
Connecting a 10k potentiometer with JP4 OFF provides a local analog control.
Provides a configurable analog output of 0-5 volts (JP3 on) or a mA output (JP3 off).
Provides a configurable analog output of 0-5 volts (JP5 on) or a mA output (JP5 off).
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February 2004
Hardware
The Analog Input Circuit. If a mA input signal is desired, Jumper JP2 (input #1) or JP4 (input #2) is inserted to connect the 249 ohm burden resistor. If a 0-5 volt signal is desired, connect the signal source between terminal 2 (+) and 3 (-) for input #1 or 5 (+) and 6 (-) for input #2.
Figure 2-7 Analog Input Schematic Analog Outputs The analog output (Analog Output) is designed to be a current or voltage output. The Primary or Secondary Analog Output Selection defines what internal signal is connected to the Primary or Secondary Analog Output. The analog output will generate 0 to 20mA for 0 to 100% of the selected internal signal. To convert the analog output to voltage, jumper JP3 must be shorted for the Primary Analog Output and jumper JP5 must be shorted for the Secondary Analog Output, which connects a 249 ohm resistor, that converts 0-20mA to 0-5VDC. Alternatively, a 500 ohm resistor can be connected externally that converts 0-20mA to 0-10VDC. Just as on the analog input, the analog output can calibrate the output for different levels by using the Primary or Secondary Analog Output Bias and the Primary or Secondary Analog Output Span.
The Analog Output Circuit. If a 5 volt output signal is desired, Jumper JP3 (output #1) or JP5 (output #2) is inserted to connect the 249 ohm burden resistor. If a 10 volt signal is desired, an external 500 ohm resistor should be connected across the appropriate output terminals.
Figure 2-8 Analog Output Schematic
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Hardware
February 2004
Remote Feedback It is standard for the output voltage and current to be sensed internally. The 853 DSPC also provides for a separate voltage and current feedback from a remote source, such as the secondary of a transformer on the output of the 853 DSPC. An internal terminal board is provided for remote voltage and current feedbacks. The voltage potential transformer (PT) used for the remote voltage feedback must be designed such that the PT output voltage is close to the input voltage of the 853 DSPC. The Voltage Output PT Secondary setting is used to define the specific PT output connected as a remote voltage feedback. The current transformer (CT) burden resistor must be selected such that 100% current output, defined by Current Output Rating will equal 2.5V. For example, if a CT with a rating of 1000 to 1 is used on a 350A 853 DSPC unit, the burden resistor would be 2.5V/.35A or 7.14 ohms. Over-temperature Sensing A temperature sensor is mounted on the heatsink of the 853 DSPC to detect and indicate an over temperature condition. The standard temperature sensor is supplied with contacts that are normally closed (NC).
2-10
Chapter 3 Configuration Startup
WARNING An incorrectly applied or installed system can result in component damage or reduction in product life. Wiring or application errors, incorrect or inadequate AC supply, or excessive ambient temperature may result in malfunction of the system.
Once the 853 is mounted, and the wiring is in place, apply control power to the unit. It is not necessary for main power to be applied at this time.
DANGER This equipment is at line voltage when AC power is connected. Disconnect and lock out all ungrounded conductors of the AC power line. Failure to observe these precautions could result in severe bodily injury or loss of life.
When control power is applied, check the LED’s on the control board to verify that the power supplies are on and the DSP is operating. At this time the red FAULT LED will be on, the three green power supply status LED’s will be on, and the HEARTBEAT LED will be blinking at about a 1 second rate.
Figure 3-1 Control PCB LED Location With control power applied and status lights operating properly, the unit is ready for configuration. Configuration consists of telling the unit what it is rated (power rating, input and output voltage and current, etc.) and what type of control is to be used. Configuration is accomplished using the Configuration Tool software running on a host computer, connected to the unit via the Serial Interface Port. In most cases, the unit will be pre-configured at the factory, and only minor changes (such as limit settings and/or control mode) will be made at the user site.
3-1
Configuration
February 2004
The Serial Interface consists of a standard DB9 connector (9 pin male), which plugs into the host computer’s serial port using a Null Modem cable. The wiring for typical Null Modem cables is illustrated in the Serial Communication Chapter . Configuration Tool Installation The 853 Configuration Tool is a serial configuration/monitoring tool that runs on a Windows-based PC. The minimum system requirements are: Windows 95, 32MB ram, 10MB hard disk space, an available serial port
The 853 Configuration Tool allows off-line editing and storage of configuration files. The Configuration Tool also allows on-line, real-time changes to the 853 settings through the serial port. The capabilities of the Configuration Tool include: on-line configuration, setpoint changes, operation, monitoring, calibration, and file storage and retrieval. The Configuration Tool is delivered on CD-Rom and includes ‘auto-run’ capability. However, should the CD NOT run automatically once inserted into the cd-rom drive, browse for the cd-rom drive, and doubleclick on the file ‘setup.exe’. The Configuration Tool default install location is: C:\Program Files\Spang Power Electronics\ 853 Configuration Tool vxxx Once successfully installed, the Configuration Tool will be accessible via the Start Menu. Note:
The install process updates the computer’s system registry with the required configuration information.
Running the Configuration Tool Run the Configuration Tool from the start menu: Start button -> Programs -> Spang Power Electronics -> Configuration Tool vxxx
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February 2004
Configuration
Click on the [Start] button to continue the Configuration Tool startup (the program will automatically continue after 10 seconds). At this point the Configuration Tool is off-line, that is, the Tool is not communicating with the 853. The setting values have been read from a setup (.csv) file stored on the computer running the configuration tool. There are five settings 'tabs' which can be viewed off-line. While off-line, settings can be modified two ways: either by opening an existing setup file, whose data is read into the Configuration Tool, or by modifying the settings individually in the six “Settings” tabs of the Configuration Tool.
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Configuration
February 2004
3-4
February 2004
Configuration
Configuration Tool Menu and Task Bar Descriptions The 853 Configuration Tool menu bar is shown below, followed by a description of each option.
File Menu File Menu including the ‘Save Calibration’ menu choice.
File Menu including the ‘Restore Calibration’ menu choice.
The ‘Save Calibration’ menu choice is visible only under certain conditions, and should be used only by authorized service personnel.
The ‘Restore Calibration’ menu choice is visible only under certain conditions, and should be used only by authorized service personnel.
File Option
Description
Open
Open a standard dialog box listing the configuration files available for loading and editing. (Configuration files are of the form .csv) and are read from and saved to the host system.
Save
Save and close changes made to the configuration file.
Print
Open the Print Preview window; display 853 settings in tabular form.
Print Setup
Open the standard dialog box that provides the selection of a printer and print characteristics.
Save Calibration
Save current calibration values as factory defaults in 853 eeprom.
Restore Calibration
Restore calibration values from factory defaults stored in 853 eeprom.
Exit
Close the Configuration Tool
3-5
Configuration
February 2004
Com Setup Menu
Com Options
Description
Com1 Com2 Com3
The Com Setup menu is used to select the serial port on the host computer available for use with the 853.
Com4
Window Menu
Window Options
Description
Settings
Open the Settings Pane. (This is the default upon program entry).
Monitor
Establish on-line communication and open the Monitor pane to view 853 DSPC operation.
Calibration
Establish on-line communication and open the Calibrate pane.
Fault History
Open the Fault History window (useful only if on-line).
Flash Programming
Open the Flash Programming window. Intended for use by authorized service personnel only.
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February 2004
Configuration
Help Menu
Help Options
Description
Manual
Open (in a separate browser window) this product manual in pdf format.
About
Display the version number of the Configuration Tool software.
3-7
Configuration
February 2004
Taskbar The Configuration Tool Taskbar provides shortcuts to frequently used options.
Taskbar Items
Description
Open Folder
Same as the File->Open menu option
Floppy
Same as the File->Save menu option.
Printer
Same as the File->Print menu option.
Monitor
Same as the Window->Monitor menu option.
Calibrate
Same as the Window->Calibrate menu option.
Settings
This button appears on the taskbar if either the Monitor or Calibration window is visible. Same as the Window->Settings menu option.
Fault
Same as the Window->Fault History menu option.
Offline/Online
Toggle between Off-line programming and On-line communication with the 853. The caption and color of the button indicate the current status of communication between the configuration tool and the 853 DSPC. A Red button with an Offline caption indicates No Communication between the Configuration Tool and the 853 DSPC. A Yellow button with an Online caption indicates one of two possibilities: the 853 DSPC is under Remote (network) Read Only control; or the 853 DSPC is under Analog (vs Digital) control). A Green button with an Online caption indicates Read/Write local communication between the Configuration Tool and 853 DSPC.
3-8
February 2004
Configuration
Print Preview The File->Print menu selection, or the printer icon on the Taskbar, opens the Print Preview window. The Print Preview window displays a tabular summary of the settings stored in the Configuration Tool.
Figure 3-2 Print Preview Window Click [Print] to send a copy of the table to the printer port of the host computer. Click [Close] to exit the Print Preview window.
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Configuration
February 2004
Off-line Programming Off-line programming allows the user to edit 853 settings without actually writing them to the controller. All work is done on the host computer and can be saved. The Configuration Tool starts in Off-Line Programming mode. The tool opens with the last settings file saved. If there is no saved settings file, the default settings are loaded from the default.csv file ( included with the configuration tool). Load/Save the Configuration File To load a configuration file from the host computer to the Configuration Tool, ●
Select the File->Open menu option, (or click the file folder icon on the Taskbar)
●
Browse the files in the ‘file open’ dialog, and select the desired configuration (*.csv) file.
The settings as defined in the configuration file are loaded into the Configuration Tool, and can be viewed and/or modified. To save settings to a .csv file on the host computer, ●
Select the File->Save menu option, (or click the floppy icon on the Taskbar)
●
Specify .csv .
The settings currently in the Configuration Tool are written to the specified file on the host computer.
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February 2004
Configuration
Configuration Tool Settings Windows The initial 853 Configuration Tool window is shown below.
Figure 3-3 Configuration Tool The left pane is used for general status and control information related to the 853 DSPC. In Off-line mode, only control information is visible in the left-hand pane: ‘Regulation Mode’ is a drop-down box containing the regulation choices. ‘Local Control’ is a button that toggles between Local Analog and Digital control. On start up, the right-hand side of the window displays the Settings tab, as read from the latest (or default) configuration file. Settings information is organized into several tabs: Ratings and Limits, Control Configuration, Fault Setup, PID Setup, and Network. Offline programming allows edits to any writable setting, as defined in the Settings Chapter . Read-only settings are indicated by a (cyan) shadowed background and cannot be changed.
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Configuration
February 2004
Ratings and Limits Tab The Ratings and Limits Tab holds the settings for Voltage Input Rating
Current Input Rating
*Voltage Output Rating
Current Output Rating
Voltage Output Limit
Current Input Limit
*Voltage Output PT Secondary
Current Output Limit
Power Output Rating - Read Only
Frequency Rating
Power Output Limit
Ramp Up Time
KVA Input Rating – Read Only
Ramp Down Time
* For a direct-coupled load (Load Type) the Voltage Output Rating and the Voltage Output PT Secondary are Read Only and follow the Voltage Input Rating.
Figure 3-4 Ratings & Limits Tab
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February 2004
Configuration
White fields indicate Read/Write Cyan fields indicate Read Only information
3-13
Configuration
February 2004
Control Configuration Tab The Control Configuration Tab holds settings for Control Strategy
Primary Analog Output Selection
Load Type
Secondary Analog Output Selection
* Magnetizing Sequence
Secondary Analog Setpoint Selection
* Repetitive Pulse 1 and 2
Local Digital Display Selection
* Only used for Zero Crossover with transformer coupled load applications. The [Auto Set] function allows the 853 to automatically tune the repetitive pulses for the minimum measured current pulses. To enable the [Auto Set] function, insert jumper JP1 with control power applied to the unit.
Figure 3-5 Control Configuration Tab White fields indicate Read/Write Cyan fields indicate Read Only information
3-14
February 2004
Configuration
Fault Setup Tab The Fault Setup Tab holds the settings for: Voltage Input High
Ground Fault Current
Voltage Input Low
Ground Fault Time
Voltage Input Phase Unbalance
Current Input Overload
Current Input High
Current Input Overload Time
Current Input High Retries
Current Input Threshold Load Failure
Current Input High Retry Time
Figure 3-6 Fault Setup Tab White fields indicate Read/Write Cyan fields indicate Read Only information
3-15
Configuration
February 2004
PID Setup Tab The PID Setup Tab holds the PID settings for Power Output
Voltage Output
Current Output
Proportional Gain
Proportional Gain
Proportional Gain
Integral Gain
Integral Gain
Integral Gain
Derivative Gain
Derivative Gain
Derivative Gain
Figure 3-7 PID Setup Tab White fields indicate Read/Write Cyan fields indicate Read Only information
3-16
February 2004
Configuration
Network Tab The Network Tab holds settings for Network Type
MODBUS Address
Network Baud Rate
MODBUS Baud Rate
Network Address
Network Loss Option Software Version Serial Number
Figure 3-8 Network Tab White fields indicate Read/Write Cyan fields indicate Read Only information
3-17
Configuration
February 2004
On-line Programming On-line programming involves actual serial communication between the configuration tool and the 853 DSPC. Settings are read from and written to the 853 DSPC using a serial protocol described in the Serial Communication chapter. The On-line communication capability of the configuration tool allows real-time monitoring and calibration of the 853 DSPC. To establish on-line communication between the Configuration Tool and the 853 unit, ●
Connect a standard, 9-pin null modem cable from the serial port of the host computer to the serial port of the 853
●
Assign the correct comm port to the configuration tool
●
Click [Online/Offline ] on the taskbar
If any settings have been modified using the configuration tool offline, the following message will appear:
If settings have been modified offline, either individually or by loading a .csv file, the user has the option of transferring, or writing, the settings stored in the 853 Configuration Tool to the 853. If no modifications have been made, the prompt will not appear.
Click Yes to write settings from the tool to the 853; click No if settings are NOT to be written to the 853. Depending on the response, the configuration tool will either write its settings to the 853 and then read them all back, or will read all settings from the 853 into the configuration tool. In either case, online communication is established. The On-line indicator turns green in the Tool Bar. Note:
If the serial link cannot be established, the following message appears:
Check both ends of the serial connection, make sure that power is applied to the 853 (check LEDs) and click [Online] again. If there is still no communication, with the serial cable connected, cycle power to the unit, and click [Online].
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February 2004
Configuration
When the Configuration Tool is communicating on-line with the 853 DSPC, status, control and setting information is continuously read from the 853 DSPC and refreshed in the Configuration Tool. Additional status and control information is visible in the left-hand pane. Note that when only the control power is applied, a low voltage warning (A-34) is displayed. This is normal, and will remain as long as the main power is off. It is not necessary to be On-line to review and change the settings – but it is necessary to be On-line to write the changes to the unit. It is also necessary for the Remote/Local switch to be in the Local position for the Configuration Tool to allow online changes to the settings.
Figure 3-9 Configuration Tool On-Line
3-19
Configuration
February 2004
Status indicators are described in the table below:
Table 3-1 Status Lamp Description Lamp
Color
Description
Enable input
Green
The 853 DSPC is Enabled
Red
The 853 DSPC in Inhibited
Output Status
Remote/Local input
Green
Output is ON
Red
Output is OFF
Green Red
On/Off button Alert indicator
Local control is active Remote (network) control is active Toggles the 853 output
Flashing Yellow
Indicates an Alarm Condition (described in the message box below the lamps)
Flashing Red
Indicates a Fault Condition is present (described in the lower message box) Note: During normal operation, message reads: No detected faults or alarms
Fault Reset button
Click to send a ‘Fault Reset’ to the 853. The 853 will attempt to recover from the alert condition. If recovery is accomplished, normal operation will resume.
On-Line Navigation and Changes To edit settings: • • • • • •
Press [Tab] or [Enter ] to move forward and select a setting Press [Shift+Tab] to move backward and select a setting Double-click the mouse over a setting to select it Once selected, enter the desired setting value or click a choice from the drop down list Press [Tab], [Enter ] or click outside setting Press [Escape] to cancel.
When a change is made to a setting, the following prompt appears:
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February 2004
Configuration
A Yes response to the message prompts the Configuration Tool to write the setting to the 853 DSPC. If unsuccessful, an error message may appear, and the setting reverts to its previous value. Factors Affecting Write Capability Write capability from the configuration tool to the 853 DSPC is affected by several factors: No writes are accepted from the configuration tool to the 853 DSPC if the Remote/Local input is in Remote. The 853 DSPC must be in Local mode to enable Configuration Tool control.
The Configuration Tool is considered to be a source of Local Digital control to the 853 DSPC. If the 853 DSPC is operating under Local Analog control, setpoints cannot be written from the Configuration Tool to the 853 DSPC. The following prompt will appear:
In order to write a setpoint from the Configuration Tool to the DSPC, the unit must be under Local Digital control.
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Configuration
February 2004
The 853 DSPC settings related to actual 853 DSPC status, such as voltage out, power out, current out, etc, are Read Only, and cannot be written under any circumstances. Rating information, PT Secondary, frequency, Control strategy, Load Type, zero calibration, and magnetic sequencing can be written only when the 853 DSPC output is off. Voltage Output Span and Current Output Span can be written only when the 853 DSPC output is on. When a setting cannot be written the following message appears:
Refer to the Settings Chapter for programming factors specific to each setting.
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February 2004
Configuration
On-line Monitor The Monitor mode provides a real-time view of 853 operation. Each setting in Monitor mode is updated approximately every 2 seconds. To access the on-line Monitor mode, select the Window Taskbar.
Monitor menu item, or click [Monitor ] on the
Monitor information is organized into several tabs: Summary, Control, Status and Timing. Read-only settings are indicated by a (cyan) shadowed background and cannot be changed.
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Configuration
February 2004
Summary Tab The Monitor Summary Tab includes the following data Duty Cycle Setpoint
Current Input
Duty Cycle Output
Current Output Setpoint
Power Output Setpoint
Current Output
Power Output
Analog Input
Voltage Input
KVA Input
Voltage Output Setpoint
Power Factor
Voltage Output
Frequency Actual
The Duty Cycle Setpoint can be written ONLY under Open Loop regulation.
Figure 3-10 Monitor Summary Tab
3-24
February 2004
Configuration
White fields indicate Read/Write Cyan fields indicate Read Only information Green field indicates regulation mode Amber field indicates alarm status
The operating setpoint for each of the regulation modes is shown in the middle column. The setpoint associated with the selected regulation mode is displayed with a green background. To change a setpoint: ●
Select the setpoint to change and enter the desired value
●
Press [Enter ] or click outside the field to write the new setpoint. •
Setpoints can be modified only under Local DIGITAL control.
•
Modified setpoints are italicized until written to the 853.
•
Press the [Escape] key to cancel.
•
The Duty Cycle Setpoint cannot be written unless Open Loop regulation mode is selected.
•
The setpoint associated with the selected regulation mode is the control setpoint. The other setpoints become operating limits of their respective control loops.
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Configuration
February 2004
Control Tab The Monitor Control Tab includes the following data for monitor only Voltage L1-L2 Input Actual
Voltage X1-X2 Output Actual
Voltage L2-L3 Input Actual
Voltage X2-X3 Output Actual
Voltage L3-L1 Input Actual
Voltage X3-X1 Output Actual
Voltage Input Actual
Voltage Output Actual
Current L1 Input Actual
Current X1 Output Actual
Current L2 Input Actual
Current X2 Output Actual
Current L3 Input Actual
Current X3 Output Actual
Current Input Actual
Current Output Actual
Local Primary Analog Setpoint
Local Secondary Analog Setpoint
Figure 3-11 Monitor Control Tab Cyan fields indicate Read Only information
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February 2004
Configuration
Status Tab The Monitor Status Tab includes the following data Monitor Status Word
Status Word Bit Number
At Setpoint
Bit 9
Phase Rotation
Bit 10
External Input #1
Bit 11
External Input #2
Bit 12
External Input #3
Bit 13
Regulation Limit
Bits 6, 7, and 8
Calibration/Programming Jumper
Bit 15
Figure 3-12 Monitor Status Tab Green field indicates on status
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Configuration
February 2004
Fault History The fault history lists the last eight faults recorded by the 853 DSPC. The information is read from the 853 DSPC and displayed in tabular form. To access the on-line Fault History mode, select the Fault History menu item, or click [Fault] on the Taskbar.
Figure 3-13 Fault History Included in the Fault History table is the fault code, a description, and time (in hours) of the fault. Click the [Print] button to send a copy of the information to the printer port of the host computer. Click the [Close] button to close the Fault History window and return to the previous window. With JP1 installed, click the [Zero] button to clear the fault buffers.
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February 2004
Configuration
Flash Programming
WARNING During flash programming, an interruption in the serial communication, either by loss of power or a disconnected serial cable, will corrupt the 853 DSPC flash memory. This will require the 853 DSPC to be sent back to the factory for programming.
The Flash Programming function is available to authorized service personnel only and is used to update the 853 DSPC software.
Figure 3-14 Flash Programming
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Configuration
February 2004
Loss of Communication Momentary loss of communication between the Configuration Tool and 853 DSPC results in the mostrecently-read setting to be displayed on a Red background. Subsequent communication recovery restores the normal background color. If serial communication is not recovered within a reasonable time, the configuration tool will go Offline.
3-30
Chapter 4 Calibration Proper calibration of the 853 validates the values displayed on the Local Digital Control panel and made available over the the network interface. interface. Unit calibration also validates the the analog signal levels. The feedback signal levels correlate to the internal gain capability of the the 853. Changing the Voltage/Current Ratings or the Analog Input/Output signal levels requires recalibration.
Figure 4-1 Calibration (Voltage Tab)
4-1
Calibration Calibration
February 2004
Voltage Calibration The [Cal [Cal Enable] Enable] button must be clicked to enable voltage calibration. Voltage X1-X2 Output Zero and Span
Voltage L1-L2 Input Span
Voltage X2-X3 Output Zero and Span
Voltage L2-L3 Input Span
Voltage X3-X1 Output Zero and Span
Voltage L3-L1 Input Span
The [Zero [Zero]] button, when clicked, uses the actual control reading and the zero adjustment, as currently set, to calculate a new zero adjustment. The result is an incremental change. The output must be off to zero the output voltages.
The [Set [Set]] button, when clicked, uses the actual control reading, the measured signal (meter reading), and the span adjustment, as currently set, to calculate a new span adjustment. adjustment. The result is an incremental change.
The [Manual [Manual]] button, when clicked, opens an input window for direct entry of calibration calibration values. Jumper JP1 must be installed to enable Manual Calibration.
Figure 4-2 Voltage Calibration White fields indicate Read/Write Cyan fields indicate Read Only information
4-2
February 2004
Calibration
Current Calibration The [Cal [Cal Enable] Enable] button must be clicked to enable current calibration. Current L1 Input Zero and Span
Current X1 Output Zero and Span
Current L2 Input Zero and Span Current L3 Input Zero and Span The [Zero [Zero]] button, when clicked, uses the actual control reading and the zero adjustment, as currently set, to calculate a new zero adjustment. The result is an incremental change.
The [Set [Set]] button, when clicked, uses the actual control reading, the measured signal (meter reading), and the span adjustment, as currently set, to calculate a new span adjustment. adjustment. The result is an incremental change.
The [Manual [Manual]] button, when clicked, opens an input window for direct entry of calibration calibration values. Jumper JP1 must be installed to enable Manual Calibration.
Figure 4-3 Current Calibration White fields indicate Read/Write Cyan fields indicate Read Only information
4-3
Calibration
February 2004
Analog Calibration The Calibration Analog Tab holds the calibration settings for Primary Analog Setpoint Zero and Span
Secondary Analog Setpoint Zero and Span
The [Zero] button, when clicked, uses the actual control reading and the zero adjustment, as currently set, to calculate a new zero adjustment. The result is an incremental change.
The [Set] button, when clicked, uses the actual control reading, the measured signal (meter reading), and the span adjustment, as currently set, to calculate a new span adjustment. The result is an incremental change.
Check the Enable box for Analog Output Calibration. Use the slide bars to adjust Analog Output Bias and Span. Uncheck the Enable box after Analog Output Calibration. Analog Output #1 Bias and Span
Analog Output #2 Bias and Span
The [Manual] button, when clicked, opens an input window for direct entry of calibration values. Jumper JP1 must be installed to enable Manual Calibration.
Figure 4-4 Analog Calibration White fields indicate Read/Write Cyan fields indicate Read Only information
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February 2004
Calibration
Current Rating The current feedback signal (at rated current) of the 853 must be between 1.25Vrms and 2.85Vrms. The typical unit is setup for a current feedback signal level of 2.50Vrms using the burden resistor of the current transformer. Standard units have the following burden resistors and feedback signals.
Unit Size
CT
Burden Resistor
Feedback Signal
40A
800:1
62Ω
2.46Vrms
90A
1800:1
56.2Ω
2.53Vrms
175A
3500:1
41.2Ω
2.40Vrms
350A
7000:1
49.9Ω
2.50Vrms
Since the feedback signal on the standard unit is set to 2.5Vrms for the rating of the unit, changing the rating to 50% would reduce the feedback signal to 1.25Vrms. This is the lowest that the rating can be changed without also changing the current transformer burden resistor. If, for example, it is desired to change the 40A u nit to a 10A unit, the burden resistor should be changed so that the current feedback signal will produce 2.5Vrms when the primary current is 10A. Since the secondary current at 10A is 10/1000 = 10mA, the resistor should be: 2.5 / 10mA = 250Ω 2
The nearest standard value 1% resistor is 249Ω. The power in the resistor at rated current is (10mA) x 249 = 24.9mW, so a resistor with a power rating of 50mW or greater is required. A 1/4W or a 1/2W resistor should be used so that it will properly fit in the connector (J10, terminals 1 and 4). The actual voltage produced at rated current will be: 10/1000 x 249 = 2.49Vrms Voltage Rating The voltage feedback signal of a unit must be between 24Vrms and 600Vrms. The voltage sense circuit automatically sets the hardware gain of the sensed voltage in the following ranges:
Voltage Rating 300 to 600 150 to 300 75 to 150 37.5 to 75 24 to 37.5
4-5
Calibration
February 2004
Remote Voltage and Current Feedback The standard unit uses the same current feedback signal for both the input and output current. If an output current transformer is used with the 853, the jumpers connecting the input and output current feedback signals together must be removed, and the output current signal connected to the remote terminal provided on the 853. The internal voltage feedback signals must be removed and the remote voltage feedback connected to the remote terminals. The remote feedback terminals are shown below.
Figure 4-5 Remote Feedback Terminals If remote feedback is used, current feedback is connected to TB1 terminals 1 (+) and 2 (common), and voltage feedback is connected to TB2 terminals 1 (X1), 2 (X2) and 3 (X3). The Current Output feedback signal should be 2.5 Vrms at the rated output current. The Voltage Output feedback signal should be in the same range as the Voltage Input feedback signal. Allowable ranges are 300-600V, 150-300V, 75-150V, 37.5-75V and 24-37.5V. Note: The existing current and voltage feedback connections must be removed and insulated before connecting new remote current and voltage feedback to the Remote Feedback Terminal.
4-6
February 2004
Calibration
Calibration Procedure
WARNING An incorrectly applied or installed system can result in component damage or reduction in product life. Wiring or application errors, or improper calibration may result in malfunction of the system.
To calibrate the 853, the unit must be connected to its rated input source, have control power on, and have a load attached to the unit. Connect your computer to the 853 serial port using a null modem cable and open the 853 Configuration Tool program. Establish “ON line” communication with the unit and note the existing 853 settings.
Click on the [Calibrate] button to open the 853 Calibration window. Click the [Cal Enable] button to allow calibration. [Zero] is active when the unit output is off, [Set] is active when the unit output is on. Click [Zero] to correct for any bias/noise; click [Set] to change the reading of non-zero voltage or current values. There are separate tabs for voltage, current, and analog calibration. To calibrate the voltage and/or current, it is recommended that the unit be turned on in “open loop” regulation mode at the highest practical operating point (set the duty cycle to 100% on the Monitor Screen if possible). Measure the voltage and current and enter the values obtained in the column labeled “Meter Reading”, then click the [Set] button next to the value entered.
4-7
Calibration
February 2004
If the (re)calibration is a result of adding remote monitoring, be sure that the Load Type is set to “Transformer-Coupled”, and that the unit is calibrated to the actual signals being measured. The output voltage may be different than the input voltage, as may the current.
4-8
February 2004
Calibration
Saving Calibration If desired, the new calibration may be saved in the 853 as the “Factory Default” calibration. The unit must be on line, with the calibration window open. With control power turned on, install jumper JP1. JP1 is a two-position jumper located immediately to the right of the dsp on the control board.
From the File menu, select “Save Calibration”.
4-9
Calibration
February 2004
A dialog box will open asking if you want to replace the calibration defaults. Click [YES] to replace the default calibration settings with the new calibration settings.
Remove the jumper (JP1), when the procedure is complete. Restoring Factory Calibration To recalibrate the unit using the stored calibration values, the unit must be on line, with the settings window open. With control power turned on, install jumper JP1.
4-10
February 2004
Calibration
From the File menu, select “Restore Calibration”.
A dialog box will open asking if you want to restore calibration using the stored defaults. Click [YES] to write the default calibration settings to the unit.
Remove the jumper (JP1), when the procedure is complete.
4-11
Calibration
February 2004
Analog Calibration Analog signal settings are adjusted on-line in an iterative process to assure accurate signal readings and optimal 853 performance. If the analog input is used, it should be calibrated for the individual installation. To do this, both the control power and the main input voltage must be present. In the Configuration Tool program, open the Calibration window, and select the Analog Tab.
If the analog input is derived from a 10K p otentiometer, simply turn the pot full counterclockwise and “zero” the input by clicking the Primary or Secondary Analog In [Zero] button with the mouse pointer. Then turn the pot full clockwise, enter the number 100 in the Gain Setting box, and click the Primary or Secondary Analog In [Set] button. Alternately, click the Primary or Secondary Analog In [Zero] button with the pot turned down, and the Primary or Secondary Analog In [Set] button with the pot turned up until the readings are consistent. If the analog input is a 4 – 20 mA signal, install jumper JP2 for 4 - 20 mA to the Primary Analog In on terminals 2 and 3 or jumper JP4 for 4 – 20mA to the Secondary Analog In on terminals 5 and 6, then set the input to the minimum setting (4 mA) and click the Primary or Secondary Analog In [Zero] button. Then set the input to the maximum setting (20 mA), enter 100 in the Gain Setting box, and click the Primary or Secondary Analog In [Set] button. Again, repeat the minimum “Zero” and maximum “Set” selections until the readings are consistent. This calibration method causes the input to control to 100% of the rating with full input. If a control point other than the rating is required at full input, then enter the percent of the control setpoint divided by the rating. For example, if the analog input is a current setpoint, controlling 0-40A on a 50A unit, enter 80 (this equals 40/50*100) when maximum input signal is present.
4-12
February 2004
Calibration
To calibrate the analog output, set the analog output source to the Primary Analog Setpoint. It allows a full range of signal settings without having to actually power up the unit. Once calibrated, the analog output source may be changed to whichever variable is desired.
If the maximum analog output is less than the rating, set the analog reference (input) as the percentage of the analog output variable divided by the rating. For example, if the analog output is output current, controlling 0-35A on a 40A unit, set the analog reference to 75 (this equals 30/40*100) to represent maximum current output.
4-13
Calibration
February 2004
Check the Analog Output Enable box.
If the analog output is to be calibrated for a 0-5V output (as it may be for a typical digital meter), insert jumper JP3 for the Primary Analog Output and jumper JP5 for the Secondary Analog Output, then turn on the unit (both control power and main power). Since there is no “bias” setting, leave the “bias” adjustment at zero. Turn the analog reference signal to 100% and adjust the “gain” slider until you obtain exactly 5 volts on the analog output (terminals 7 to 8 for the Primary Analog Output and terminals 9 to 10 for the Secondary Analog Output on the analog interface plug). If the Analog Output is to be calibrated for a 4-20 mA signal, leave JP3 off for the Primary Analog Output and JP5 off for the Secondary Analog Output, then terminate the output into a suitable burden (maybe a milli-ammeter). With the analog input set at zero, adjust the appropriate “bias” slider until you read 4 mA on your meter. Then set the analog input for 100%, and adjust the appropriate “gain” slider until you read 20 mA on your meter. Other outputs (0 – 10V, 0 – 5V, 0 – 1mA, etc.) are done in the same fashion, using a suitable termination for the signal required. The maximum output of the circuit is about 24 mA at 100% input. Uncheck the Analog Output Enable box when calibration is complete.
4-14
February 2004
Calibration
Manual Calibration
WARNING An incorrectly applied or installed system can result in component damage or reduction in product life. Wiring or application errors, or improper calibration may result in malfunction of the system.
Direct entry of calibration values is possible from the Manual Calibration window of the 853 Configuration Tool. To open the Manual Calibration window, insert jumper JP1, select Calibration in the Config Tool, and click the [Manual] button. The Manual Calibration window looks like the following:
Figure 4-6 Manual Calibration Window Note the choices available for manual calibration: READ from CSV File – open a .csv file stored on the host computer and read the calibration values. READ from 853 Unit – read the current calibration values from the 853. Calculate Defaults – Calculate new calibration values based on the voltage and current ratings. WRITE to 853 Unit – Write all of the displayed calibration values to the 853. CLOSE the manual calibration window.
4-15
Calibration
February 2004
Magnetizing Sequence Calibration Setting number 99 is the Magnetizing Sequence Calibration, which is used for zero-crossing control into a transformer load. The purpose of this setting is to soft start a transformer load when first powered up. The setting defines the amount of phase control cycles which will occur during the first on cycle of zero-crossing control. A minimum setting of 3 will usually keep the inrush current within acceptable limits. If the inrush current is too high, increase the Magnetizing Sequence until the inrush current is within acceptable limits. Repetitive Pulse Calibration Setting number 100 is the repetitive pulse calibration, which is used for ze ro-crossing control into a transformer load. In the 853, the Repetitive Pulse setting contains two values; bits 0 – 7 are the Repetitive Pulse #1, and bits 8 – 15 are Repetitive Pulse #2. Repetitive Pulse Calibration Read/Write Condition: All Default: Low Byte 50 High Byte 30
100
The Repetitive Pulse Calibration is divided into two separate bytes, allowing the first positive zero crossing pulse to be set differently (ZeroCrossover control only).
% Min: 10 Max: 90
Low Byte – Bits 0 – 7 Repetitive Pulse #1 High Byte – Bits 8 – 15 Repetitive Pulse #2
The repetitive pulse settings represent a delay in the firing of the SCRs during the first cycle of each “burst” during zero-crossing control. This is necessary to avoid saturation of the load transformer and the resulting over current shut down of the unit. The setting is expressed as the percentage of the total wave passed through to the load. An automatic set function is built into the 853 power control unit, which will adjust the pulses at an accelerated rate and adjust for the minimum measured current pulses. To adjust the pulses automatically, control power must be applied to the unit. Insert jumper JP1. On the Control Tab of the Settings window of the Configuration Tool, click [Auto Set]. Note that if the system is sized close to the operating limit of the transformers, the unit may trip before the program can determine the proper settings. In such a case, it is necessary to manually “tune” the system. In order to tune the settings, it is desirable to have some means of observing the line current. Using the Configuration Tool program, turn the unit on with a duty cycle of between 10 and 50%. Start with both pulse settings at about 50%. If the unit trips during start-up, adjust the #1 pulse setting for an observed minimum peak current on the CФ line. When a minimum peak current is observed, leave the #1 setting and adjust the #2 setting to further reduce the observed peak current. It should be possible to adjust the two settings so that the unit will operate without tripping. Alternate between the two adjustments, until the minimum peak current is observed. As a check, monitor the AФ and BФ currents as well. If excessive peak currents are observed, minor adjustments in the pulse settings may be made to minimize the currents. It should be noted that transformer saturation will occur more readily with higher line voltages a nd heavier load currents. If possible, transformers should not be operated at higher than their design voltage ratings.
4-16
February 2004
Calibration
Node Synchronization The 850 series zero-crossing mode of operation uses a 100 cycle period of time as a “power cycle”. Power delivered to the load is proportional to the duty cycle of the unit, or the ratio of the “ON” vs. “OFF” time. For duty cycles between 2% and 100% this simply means that the duty cycle is the ratio of on cycles to 100. A 50% duty cycle would result in a unit being on for 50 cycles and off for 50 cycles. In order to insure proper measurements, units are always on for at least 2 cycles. The Network Address setting (setting 116) is used to determine the starting point of each unit’s power cycle. An algorithm was developed to allow multiple units to be given sequential network nodes and achieve power synchronization. Synchronization is achieved by applying power to, or enabling all the controllers at the same time. The starting point cycle based on network number is listed in the table below. Note that the synchronization calculation is valid for network addresses 1 – 63 only. Network Address 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
Starting point cycle 0 50 25 75 13 63 38 88 6 56 31 81 19 69 44 94 3 53 28 78 16 66 41 91 9 59 34 84 22 72 47 97 2 52 27 77 14 64
4-17
Calibration
February 2004
39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
39 89 8 58 33 83 20 70 45 95 5 55 30 80 17 67 42 92 11 61 36 86 23 73 48 98
4-18
Chapter 5 Local Digital Control Option The Local Digital Control Option is an add-on display/control interface. It is used in one of two modes and provides a four-digit numeric display, twelve LED’s and four pushbuttons that allow local control of the 853 DSPC. The Local Digital Control Panel is shown below.
Figure 5-1 Local Digital Control Panel Display and Status The four-digit numeric display is used to display a selected setpoint or output. It is also used to indicate alert conditions and special programming modes. There are four LED's to the right of the numeric display, and two below it. The LED’s describe the information shown on the numeric display, and are summarized in the following table.
5-1
Local Digital Control Option
February 2004
Table 5-1 Display Selections If this LED is lit …
Setting #76 equals …
Display Selection
Description
Volts
1
Voltage Output (V)
Voltage Output Actual in volts
2
Current Output (A)
Current Output Actual in amps
3
Power Output (KW)
Power Output in kilowatts
4
Regulation Mode Setpoint (unit)
Voltage Setpoint, Current Setpoint or Power Setpoint in appropriate units
5
Voltage Output (%)
Voltage Output Actual as % of rated voltage
6
Current Output (%)
Current Output Actual as % of rated current
7
Power Output (%)
Power Output as % of rated power
8
Regulation Mode Setpoint (%)
Voltage Setpoint, Current Setpoint or Power Setpoint as % of appropriate rating
Output Amps Output Kilowatts Output Setpoint Volts, Amps, or Kilowatts Volts % of Rated Output Amps % of Rated Output Kilowatts % of Rated Output Setpoint % of Rated Volts, Amps, or Kilowatts
5-2
February 2004
Local Digital Control Option
The six status LED’s are summarized in the following table.
Table 5-2 Digital Control Status LED Remote Status
Analog Status
Condition On
The Remote/Local input is in the Remote state.
Off
The Remote/Local input is in the Local state.
On
The Local mode is set to Analog, and the Remote/Local input is in the Local state.
Off Digital Status
Enable Status
On Status
Alert Status
Description
On
The Local mode is set to Digital, or the Remote/Local input is in the Remote state. The Local mode is set to Digital, and the Remote/Local input is in the Local state.
Off
The Local mode is set to Analog, or the Remote/Local input is in the Remote state.
On
The Enable/Inhibit input is in the Enable state.
Off
The Enable/Inhibit input is in the Inhibit state.
On
The DSPC output is active.
Off
The DSPC output is off.
On
Either a fault or alarm is present.
Off
No detected fault or alarm.
Normal Mode Operation Normal mode operation depends on two factors: the Remote/Local input, and the Analog/Digital control status. If the unit is under Local Digital Control, the four pushbuttons are used to increment/decrement the regulation mode setpoint, toggle the unit output, and toggle the control mode from digital to analog (and vice-versa). Normal operation under Local Digital Control is summarized in the following table:
5-3
Local Digital Control Option
February 2004
Table 5-3 Pushbutton function in Normal mode, Local Digital Control Display Selection
Up/Down Button
Select Button
On/Off/Reset Button
Voltage Output (V)
Display the Regulation Mode Setpoint in units; Increment/Decrement the Regulation Mode Setpoint
Press and Hold to toggle local Analog/Digital control
Toggle the unit On/Off
Current Output (A)
Display the Regulation Mode Setpoint in units; Increment/Decrement the Regulation Mode Setpoint
Press and Hold to toggle local Analog/Digital control
Toggle the unit On/Off
Power Output (KW)
Display the Regulation Mode Setpoint in units; Increment/Decrement the Regulation Mode Setpoint
Press and Hold to toggle local Analog/Digital control
Toggle the unit On/Off
Regulation Mode Setpoint (units)
Increment/Decrement the Regulation Mode Setpoint
Press and Hold to toggle local Analog/Digital control
Toggle the unit On/Off
Voltage Output (%)
Display the Regulation Mode Setpoint as % of rated; Increment/Decrement the Regulation Mode Setpoint
Press and Hold to toggle local Analog/Digital control
Toggle the unit On/Off
Current Output (%)
Display the Regulation Mode Setpoint as % of rated; Increment/Decrement the Regulation Mode Setpoint
Press and Hold to toggle local Analog/Digital control
Toggle the unit On/Off
Power Output (%)
Display the Regulation Mode Setpoint as % of rated; Increment/Decrement the Regulation Mode Setpoint
Press and Hold to toggle local Analog/Digital control
Toggle the unit On/Off
Regulation Mode Setpoint (%)
Increment/Decrement the Regulation Mode Setpoint
Press and Hold to toggle local Analog/Digital control
Toggle the unit On/Off
Pushbutton functions vary slightly under Local Analog Control. The setpoint can be viewed but cannot be changed. Normal operation under Local Analog Control is summarized in the following table:
5-4
February 2004
Local Digital Control Option
Table 5-4 Pushbutton function in Normal mode, Local Analog Control Display Selection
Up/Down Pushbutton
Select Pushbutton
On/Off/Reset Pushbutton
Voltage Output (V)
Display the Regulation Mode Setpoint in units
Press and Hold to toggle local Analog/Digital control
Toggle the unit On/Off
Current Output (A)
Display the Regulation Mode Setpoint in units
Press and Hold to toggle local Analog/Digital control
Toggle the unit On/Off
Power Output (KW)
Display the Regulation Mode Setpoint in units
Press and Hold to toggle local Analog/Digital control
Toggle the unit On/Off
Regulation Mode Setpoint (units)
Display the Regulation Mode Setpoint in units
Press and Hold to toggle local Analog/Digital control
Toggle the unit On/Off
Voltage Output (%)
Display the Regulation Mode Setpoint as % of rated
Press and Hold to toggle local Analog/Digital control
Toggle the unit On/Off
Current Output (%)
Display the Regulation Mode Setpoint as % of rated
Press and Hold to toggle local Analog/Digital control
Toggle the unit On/Off
Power Output (%)
Display the Regulation Mode Setpoint as % of rated
Press and Hold to toggle local Analog/Digital control
Toggle the unit On/Off
Regulation Mode Setpoint (%)
Display the Regulation Mode Setpoint as % of rated
Press and Hold to toggle local Analog/Digital control
Toggle the unit On/Off
5-5
Local Local Digital Control Option
February 2004
If the unit is under Remote under Remote Control, Control , the pushbuttons are inoperable, as summarized in the following table.
Table 5-5 Pushbutton function in Normal mode, Remote Control
Display Display Selection Selection
Up/Down Up/Down Pushbutt Pushbutton on
Select Select Pushbutt Pushbutton on
On/Off/Reset Pushbutton
Voltage Output (V)
No action
No action
No action
Current Output (A)
No action
No action
No action
Power Output (KW)
No action
No action
No action
Regulation Mode Setpoint (units)
No action
No action
No action
Voltage Output (%)
No action
No action
No action
Current Output (%)
No action
No action
No action
Power Output (%)
No action
No action
No action
Regulation Mode Setpoint (%)
No action
No action
No action
5-6
February 2004
Local Digital Control Option
Display Select Mode Operation To enter Display enter Display Select mode, press the [SEL [SEL]] pushbutton. pushbutton. Entry into the Display Select mode is indicated by the characters ‘SEL ‘SEL’’ in the four-digit four-digit numeric display. In this mode, the [Up [Up Arrow] Arrow ] and [Down Arrow] Arrow ] pushbuttons increment/decrement the Local Digital Control Display Selection . Display Select mode operation is summarized in the following tables:
Table 5-6 Pushbutton function in Display Select Mode, Local Control Display Selection
Up/Down Pushbutton Pushbutton
Select Pushbutton
On/Off/Reset Pushbutton Pushbutton
Voltage Output (V)
Increment/Decrement the display selection
Exit Display Select mode
Toggle the unit On/Off; exit Display Select mode
Current Output (A)
Increment/Decrement the display selection
Exit Display Select mode
Toggle the unit On/Off; exit Display Select mode
Power Output (KW)
Increment/Decrement the display selection
Exit Display Select mode
Toggle the unit On/Off; exit Display Select mode
Regulation Mode Setpoint (units)
Increment/Decrement the display selection
Exit Display Select mode
Toggle the unit On/Off; exit Display Select mode
Voltage Output (%)
Increment/Decrement the display selection
Exit Display Select mode
Toggle the unit On/Off; exit Display Select mode
Current Output (%)
Increment/Decrement the display selection
Exit Display Select mode
Toggle the unit On/Off; exit Display Select mode
Power Output (%)
Increment/Decrement the display selection
Exit Display Select mode
Toggle the unit On/Off; exit Display Select mode
Regulation Mode Setpoint (%)
Increment/Decrement the display selection
Exit Display Select mode
Toggle the unit On/Off; exit Display Select mode
5-7
Local Local Digital Control Option
February 2004
Table 5-7 Pushbutton function in Display Select Mode, Remote Control Display Selection
Up/Down Pushbutton Pushbutton
Select Pushbutton
On/Off/Reset Pushbutton Pushbutton
Voltage Output (V)
Increment/Decrement the display selection
Exit Display Select mode
Exit Display Select mode
Current Output (A)
Increment/Decrement the display selection
Exit Display Select mode
Exit Display Select mode
Power Output (KW)
Increment/Decrement the display selection
Exit Display Select mode
Exit Display Select mode
Regulation Mode Setpoint (units)
Increment/Decrement the display selection
Exit Display Select mode
Exit Display Select mode
Voltage Output (%)
Increment/Decrement the display selection
Exit Display Select mode
Exit Display Select mode
Current Output (%)
Increment/Decrement the display selection
Exit Display Select mode
Exit Display Select mode
Power Output (%)
Increment/Decrement the display selection
Exit Display Select mode
Exit Display Select mode
Regulation Mode Setpoint (%)
Increment/Decrement the display selection
Exit Display Select mode
Exit Display Select mode
5-8
Chapter 6 Serial Communication Hardware The serial port of the 853 DSPC is a standard, male, DB-9 connector. The hardware connection between a standard PC COM port and the 853 DSPC’s serial port is a null modem style link, shown below. Only pins 2, 3 and 5 (Receive, Transmit and Ground) of the DB-9 connector are needed to communicate; pins 7 and 8 (Request to Send and Clear to Send) are o ptional and provided for PC hardware handshake (fixed in the SEND OK state).
Figure 6-1 Nine Pin to Nine Pin Null Modem Cable Diagram
Figure 6-2 Twenty-five Pin to Nine Pin Null Modem Cable Diagram
6-1
Serial Communication
February 2004
The setup of the serial port is described below.
Table 6-1 Serial Port Configuration Baud Rate
4800, 9600, or 19200 baud
Parity
None
Length
8 bits
Stop
2 bits
Handshake
None
The default serial baud rate is 19200. The baud rate is accessible as setting #117, and can be modified either with the 853 Configuration Tool or through the (remote) network connection. In either case, the new baud rate setting will take effect only after control power to the 853 DSPC is cycled. The 853 Configuration Tool will detect baud rate automatically when on-line communication is established with the 853 DSPC.
6-2
February 2004
Serial Communication
Serial Protocols The 853 supports two serial protocols: MODBUS RTU and an 8-byte generic protocol. The 853 determines the protocol of each message sent. It looks for the start characters of a generic message (described later in this chapter). If the start characters are present, the received message is treated as a generic message. If the start characters are NOT present, the 853 will treat the received message as MODBUS RTU. In either case, the appropriate response is generated and sent. MODBUS RTU The MODBUS RTU protocol is a query/response or master/slave protocol. The 853 acts as a slave in the MODBUS master/slave relationship. The MODBUS query and response are summarized in the following tables.
Table 6-2 MODBUS RTU Query (from Master) Byte
Field Name
Description
1
Slave Address
853 MODBUS address, from setting #116, or 0 for a broadcast message.
2
Function
MODBUS function code, 3 (read) or 6 (write).
3
Address High
Always 0
4
Address Low
853 setting number.
5
# Points High (read) Data High (write)
Always 0 (read); High byte of 16-bit value to be written (write).
6
# Points Low (read) Data Low
Always 1 (read); Low byte of 16-bit value to be written (write).
Error Check
16-bit CRC, low byte first
7,8
6-3
Serial Communication
February 2004
Table 6-3 MODBUS RTU Read Response (from 853) Byte
Field Name
Description
1
Slave Address
853 MODBUS address, from setting #116.
2
Function
MODBUS function code 3 (read).
3
Byte count
Always 2
4
Data High
High byte of 16-bit value read.
5
Data Low
Low byte of 16-bit value read.
Error Check
16-bit CRC, low byte first
6,7
Table 6-4 MODBUS RTU Write Response (from 853) Byte
Field Name
Description
1
Slave Address
853 MODBUS address, from setting #116.
2
Function
MODBUS function code 6 (write).
3
Address High
Always 0
4
Address Low
853 setting number.
5
Data High
High byte of 16-bit value written (echo).
6
Data Low
Low byte of 16-bit value written (echo).
Error Check
16-bit CRC, low byte first
7,8
6-4
February 2004
Serial Communication
When a message is received correctly (no communication errors, CRC checks out), but cannot be executed, the 853 DSPC will generate an exception (error) response. No response is generated for a message received incorrectly, or incompletely. No response is generated for broadcast messages.
Table 6-5 MODBUS RTU Exception Response (from 853 DSPC) Byte
Field Name
Description
1
Slave Address
853 MODBUS address, from setting #116.
2
Function
MODBUS function code plus exception indication (80 hex).
3
Exception code
MODBUS exception code.
Error Check
16-bit CRC, low byte first
4,5
The 853 DSPC supports the following MODBUS exception codes:
Table 6-6 MODBUS RTU Exception Codes Exception Code
Description
01
Illegal function
02
Illegal data address (setting number).
03
Illegal data value.
6-5
Serial Communication
February 2004
General 8 Byte Protocol The 853 DSPC supports a generic 8 byte query/response protocol. As in the MODBUS RTU protocol, the 853 DSPC is implemented as a slave in a master/slave communication relationship.
Table 6-7 General 8 Byte Query (from Master) Byte
Field Name
Description
1
Start 1
Always 0xA5
2
Start 2
Always 0x5A
3
Command
0x00 (read), or 0x80 (write)
4
Setting
853 DSPC setting number.
5
Data High
Unused (read); High byte of 16-bit value to be written (write).
6
Data Low
Unused (read); Low byte of 16-bit value to be written (write).
7
Checksum
Calculated from the sum of the Command byte, Setting byte, Data high and Data low bytes.
8
End
Always 0x7E
6-6
February 2004
Serial Communication
Each General Protocol query sent to the 853 DSPC will result in a response. Included in byte 3 of the response is status information. The echo bit is set for all response messages. The error bit is set if an error occurred during the reception or execution of the query. In the event of an error, the information in the data bytes has no meaning.
Table 6-8 General 8 Byte Response (from 853) Byte
Field Name
Description
1
Start 1
Always 0xA5
2
Start 2
Always 0x5A
3
Command
Bit 0 - 3 reserved Bit 4 1 - network offline 0 - network online Bit 5 1- error bit Bit 6 1- echo bit Bit 7 1 - write operation 0 - read operation
4
Setting
853 DSPC setting number.
5
Data High
High byte of 16-bit value read (read). Unused (write);
6
Data Low
Low byte of 16-bit value read (read). Unused (write);
7
Checksum
Calculated from the sum of the Command byte, Setting byte, Data high and Data low bytes.
8
End
Always 0x7E
Each serial message sent to the 853 DSPC results in a response message back. Byte 3 includes an echo bit and an error bit. The echo bit is always set if the message has been received. The error bit is set if the message has an error. If an error occurs, the values returned in Bytes 5 and 6 are not meaningful.
6-7
Serial Communication
February 2004
Additional Serial Information Error responses do not stop 853 operation. Message bytes are sent and received as binary values, and not as ASCII characters. Floating point data (data containing a decimal point) are transferred as 16 bit integers. The floating point value is scaled (multiplied) by 10 before transfer. Likewise, floating point data received by the controller are adjusted (divided) by a factor of 10. For example, a voltage equal to 208.7 will be transferred as 2087 Settings that are longer than two bytes (such as Serial Number) must be read with two individual transactions. The higher order word (2 bytes) is specified by the Setting number listed in the settings table, and the lower order word is specified by the Setting number plus 1. Care must be taken when reading four byte time values to check for lower order word overflow during the serial read operation, which would result in an invalid time value. Serial control of the unit is enabled when the Local/Remote switch is in LOCAL mode. 853’s without a local digital control option installed will revert to local Analog control unless serial messages are received at a rate of at least one message per every 1.5 seconds. The serial link can be used to monitor values when serial control is not enabled. This includes when the unit is being controlled remotely under network control or when the unit is being controlled locally under analog control.
6-8
Chapter 7 Settings Caution The 853 DSPC is configured using the programmable settings. Programming the settings incorrectly can cause the 853 DSPC to exhibit intermittent or full output conditions.
The following table summarizes the settings of the 853.
Table 7-1 List of Settings
Settings
No.
Units
Description
1
Vrms Min: 0.0 Max: 600.0
The input rating of the voltage supplied to the 853.
2
Vrms Min: 0.0 Max: 750.0
The level compared to Vinrms that causes a high voltage fault. It is limited to 125% of the Voltage Input Rating. Fault operation is further described in the Troubleshooting Chapter .
3
Vrms Min: 0.0 Max: 600.0
The level compared to Vinrms that causes a low voltage alarm. It is limited to 100% of the Voltage Input Rating. Fault operation is further described in the Troubleshooting Chapter .
4
% Min: 2% Max: 100%
The difference between each Phase voltage and the Voltage Input Actual expressed as a positive percentage. Exceeding this limit value causes an unbalanced input voltage alarm. Fault operation is further described in the Troubleshooting Chapter .
5
Vrms
Vinrms for Phase L1 to Phase L2.
6
Bits Min: 2000 Max: 16000
Digital span adjustment of the voltage L1-L2 input signal. Calibration is described in the Calibration Chapter .
Voltage Input Rating Read/Write Condition: Off Default: 480.0 V Voltage Input High Fault Read/Write Condition: All Default: 576.0 V Voltage Input Low Alarm Read/Write Condition: All Default: 384.0 V Voltage Input Phase Unbalance Alarm Read/Write Condition: All Default: 5.0 % Voltage L1-L2 Input Actual Read only Voltage L1-L2 Input Span Read/Write Condition: All Default: Factory
7-1
Settings
Settings
February 2004
No.
Units
Description
7
Vrms
Vinrms for Phase L2 to Phase L3.
8
Bits Min: 2000 Max: 16000
Digital span adjustment of the voltage L2-L3 input signal. Calibration is described in the Calibration Chapter .
9
Vrms
Vinrms for Phases L3 to L1 calculated using L1-L2 and L2-L3 voltages measured.
10
Bits Min: 2000 Max: 16000
Digital span adjustment of the voltage L3-L1 input signal. Calibration is described in the Calibration Chapter .
11
Vrms
Average of Vinrms for Phases L1-L2, L2-L3 and L3-L1.
12
Hertz Min: 50.0 Max: 60.0
The input line frequency rating.
13
Hertz
Measured input line frequency.
14
Vrms Min: 0.0 Max: 2000.0
The output rating of the voltage being controlled by the 853.
15
Vrms Min: 0.0 Max: 600.0
The secondary voltage of an external voltage Potential Transformer (PT). It is set equal to the Voltage Output Rating if no PT is used. It is very important that this setting be in the same calibration range as the Voltage Input Rating for proper operation.
16
Vrms Min: 0.0 Max: 2500.0
The maximum voltage the voltage output PID control will limit to. It is limited to 125% of the Voltage Output Rating.
17
Vrms Min: 0.0 Max: 2500.0
The setpoint for the voltage output PID control. It is limited to 100% of the Voltage Output Limit.
Voltage L2-L3 Input Actual Read only Voltage L2-L3 Input Span Read/Write Condition: All Default: Factory Voltage L3-L1 Input Actual Read only Voltage L3-L1 Input Span Read/Write Condition: All Default: Factory Voltage Input Actual Read only Frequency Rating Read/Write Condition: Off Default: 60.0 Hz Frequency Actual Read only Voltage Output Rating Read/Write Condition: Off Default: 480.0 V Voltage Output PT Secondary Read/Write Condition: Off Default: 480.0 V Voltage Output Limit Read/Write Condition: All Default: 528.0 V Voltage Output Setpoint Read/Write Condition: Remote Default: 480.0 V
7-2
February 2004
Settings
Settings
No.
Units
Description
18
% Min: 0.0 Max: 100.0
Voltage output control proportional gain.
19
% Min: 0.0 Max: 100.0
Voltage output control integral gain.
20
% Min: 0.0 Max: 100.0
Voltage output control derivative gain.
21
Vrms
Voutrms for Phase X1 to Phase X2.
22
Bits Min: 0 Max: 100
Digital zero adjustment of the voltage X1-X2 output signal. Calibration is described in the Calibration Chapter .
23
Bits Min: 2000 Max: 16000
Digital span adjustment of the voltage X1-X2 output signal. Calibration is described in the Calibration Chapter .
24
Vrms
Voutrms for Phase X2-X3.
25
Bits Min: 0 Max: 100
Digital zero adjustment of the voltage X2-X3 output signal. Calibration is described in the Calibration Chapter .
26
Bits Min: 2000 Max: 16000
Digital span adjustment of the voltage X2-X3 output signal. Calibration is described in the Calibration Chapter .
27
Vrms
Voutrms for Phases X3-X1 calculated using Phase X1-X2 and Phase X2-X3 measurements.
28
Bits Min: 0 Max: 100
Digital zero adjustment of the voltage X3-X1 output signal. Calibration is described in the Calibration Chapter .
Voltage Output Proportional Gain Read/Write Condition: All Default: 10.0 % Voltage Output Integral Gain Read/Write Condition: All Default: 10.0 % Voltage Output Derivative Gain Read/Write Condition: All Default: 0.0 % Voltage X1-X2 Output Actual Read only Voltage X1-X2 Output Zero Read/Write Condition: Off Default: Factory Voltage X1-X2 Output Span Read/Write Condition: On Default: Factory Voltage X2-X3 Output Actual Read only Voltage X2-X3 Output Zero Read/Write Condition: Off Default: Factory Voltage X2-X3 Output Span Read/Write Condition: On Default: Factory Voltage X3-X1 Output Actual Read only Voltage X3-X1 Output Zero Read/Write Condition: Off Default: Factory
7-3
Settings
Settings
February 2004
No.
Units
Description
29
Bits Min: 2000 Max: 16000
Digital span adjustment of the voltage X3-X1 output signal. Calibration is described in the Calibration Chapter .
30
Vrms
Average of Voutrms for Phases X1-X2, X2-X3, and X3-X1.
Read/Write Condition: Off Default: 350.0 A Current Input Limit
31
Irms Min: 0.0 Max: 1500.0
The input rating of the current to the 853.
Read/Write Condition: All Default: 350.0 A Current Input High Fault
32
Irms Min: 0.0 Max: 2250.0
The maximum Current Input Actual the 853 will allow to run continuously. It is limited to 150% of the Current Input Rating.
33
Ipeak Min: 0.0 Max: 5250.0
The level compared to the peak current of each phase individually. Exceeding this value causes an over current fault. The value is limited to 350% of the Current Input Rating. Fault operation is described in the Troubleshooting Chapter .
34
Selection Min: 0 Max: 5
The number of retries for the Current Input High Fault before the fault is latched. Fault operation is described in the Troubleshooting Chapter .
35
Seconds Min: 10.0 Max: 360.0
The time limit for fault retries before the fault will latch. Fault operation is described in the Troubleshooting Chapter .
36
Irms Min: 0.0 Max: 3750.0
The level compared to the Current Input Actual that causes a timed current fault. It is limited to 250% of the Current Input Rating. Fault operation is described in the Troubleshooting Chapter
37
Seconds Min: 0.0 Max: 360.0
The time limit on the current input overload level before a fault occurs. Fault operation is described in the Troubleshooting Chapter .
Voltage X3-X1 Output Span Read/Write Condition: On Default: Factory Voltage Output Actual Read only Current Input Rating
Read/Write Condition: All Default: 700.0 A
Current Input High Fault Retry Number Read/Write Condition: All Default: 0 Current Input High Fault Retry Time Read/Write Condition: All Default: 10.0 Sec Current Input Overload Fault Read/Write Condition: All Default: 470.0 A Current Input Overload Time Read/Write Condition: All Default: 10.0 Sec
7-4
February 2004
Settings
Settings
No.
Units
Description
38
Amperes Min: 2.0 Max: 1500.0
The amount of current calculated to be flowing to a ground (from phase current unbalances) allowed before starting Ground Fault Time countdown. Fault operation is described in the Troubleshooting Chapter .
40
Seconds Min: 0.0 Max: 360.0
The amount of time required to generate a ground fault. Fault operation is described in the Troubleshooting Chapter .
41
Irms
Iinrms for Phase L1.
Read/Write Condition: Off Default: Factory Current L1 Input Span
42
Bits Min: 0 Max: 100
Digital zero adjustment of the current L1 input signal. Calibration is described in the Calibration Chapter .
Read/Write Condition: On Default: Factory Current L2 Input Actual
43
Bits Min: 2000 Max: 16000
Digital span adjustment of the current L1 input signal. Calibration is described in the Calibration Chapter .
44
Irms
Iinrms for Phase L2.
45
Bits Min: 0 Max: 100
Digital zero adjustment of the current L2 input signal. Calibration is described in the Calibration Chapter .
46
Bits Min: 2000 Max: 16000
Digital span adjustment of the current L2 input signal. Calibration is described in the Calibration Chapter .
47
Irms
Iinrms for Phase L3.
48
Bits Min: 0 Max: 100
Digital zero adjustment of the current L3 input signal. Calibration is described in the Calibration Chapter .
49
Bits Min: 2000 Max: 16000
Digital span adjustment of the current L3 input signal. Calibration is described in the Calibration Chapter .
Ground Fault Current Read/Write Condition: All Default: 10.0 A Ground Fault Time Read/Write Condition: All Default: 10.0 Sec Current L1 Input Actual Read only Current L1 Input Zero
Read only Current L2 Input Zero Read/Write Condition: Off Default: Factory Current L2 Input Span Read/Write Condition: On Default: Factory Current L3 Input Actual Read only Current L3 Input Zero Read/Write Condition: Off Default: Factory Current L3 Input Span Read/Write Condition: On Default: Factory
7-5
Settings
Settings
February 2004
No.
Units
Description
50
Irms
Average of Iinrms for Phase L1, L2, and L3.
51
Irms Min: 0.0 Max: 1500.0
The individual phase current used to determine a load failure. It is limited from 2% to 10% of the Current Input Rating. Fault operation is described in the Troubleshooting Chapter .
52
Irms Min: 0.0 Max: 3000.0
The output rating of the current being controlled by the 853.
Read/Write Condition: All Default: 350.0 A Current Output Setpoint
53
Irms Min: 0.0 Max: 4500.0
The maximum current the current output PID control will limit to. It is limited to 150% of the Current Output Rating.
Read/Write Condition: Remote Default: 350.0 A Current Output Proportional Gain
54
Irms Min: 0.0 Max: 4500.0
The setpoint for the current output PID control. It is limited to 100% of the Current Output Limit.
55
% Min: 0.0 Max: 100.0
Current output control proportional gain.
56
% Min: 0.0 Max: 100.0
Current output control integral gain.
57
% Min: 0.0 Max: 100.0
Current output control derivative gain.
58
Irms
Ioutrms for Phase X1 measured.
59
Bits Min: 0 Max: 100
Digital zero adjustment of the Current X1 Output Actual signal. Calibration is described in the Calibration Chapter .
Current Input Actual Read only Current Input Threshold Load Failure Read/Write Condition: On Default: 10.0 A Current Output Rating Read/Write Condition: Off Default: 350.0 A Current Output Limit
Read/Write Condition: All Default: 10.0 % Current Output Integral Gain Read/Write Condition: All Default: 10.0 % Current Output Derivative Gain Read/Write Condition: All Default: 0.0 % Current X1 Output Actual Read only Current X1 Output Zero Read/Write Condition: Off Default: Factory
7-6
February 2004
Settings
Settings
No.
Units
Description
60
Bits Min: 2000 Max: 16000
Digital span adjustment of the Current X1 Output Actual signal. Calibration is described in the Calibration Chapter .
61
Irms
Ioutrms for Phase X2 calculated.
62
Irms
Ioutrms for Phase X3 calculated.
63
Irms
Average of Ioutrms for Phases X1, X2, and X3.
KVA
The KVA rating is the conversion factor that is used to convert the KVA Input from percent to KVA. It is calculated using the following equation.
Current X1 Output Span Read/Write Condition: On Default: Factory Current X2 Output Actual Read only Current X3 Output Actual Read only Current Output Actual Read only KVA Input Rating Read only 64
(Voltage Input Rating * SQRT(3) * Current Input Rating)/1000 KVA Input Read only
The KVA input is calculated by the following equation. 65
KVA (Voltage Input Actual * SQRT(3) * Current Input Actual.) /1000
Power Output Rating
The output rating of the Power being controlled by the 853. It is calculated by the following equation.
Read only 66
KW
(Voltage Output Rating * SQRT(3) * Current Output Rating)/1000 Power Output Limit Read/Write Condition: All Default: 291.0 KW Power Output Setpoint
67
KW Min: 0.0 Max: 1125.0
Read/Write Condition: Remote Default: 291.0 KW Power Output Proportional Gain
68
KW Min: 0.0 Max: 1125.0
The setpoint for the power output PID control. It is limited to 100% of the Power Output Limit.
69
% Min: 0.0 Max: 100.0
Power output control proportional gain.
Read/Write Condition: All Default: 10.0 %
7-7
The maximum power the power output PID control will limit to. It is limited to 125% of the Power Output Rating.
Settings
Settings
February 2004
No.
Units
Description
70
% Min: 0.0 Max: 100.0
Power output control integral gain.
71
% Min: 0.0 Max: 100.0
Power output control derivative gain.
72
KW
(Vin * Iin) rms , calculated by using the instantaneous product of the voltage and current samples.
Power Output Integral Gain Read/Write Condition: All Default: 10.0 % Power Output Derivative Gain Read/Write Condition: All Default: 0.0 % Power Output Read only Power Factor 73
Power Output / KVA Input.
Read only Duty Cycle Output 74
%
On time / Off time * 100.0
75
% Min: 0.0 Max: 100.0
The setpoint for open loop control.
Read only Duty Cycle Setpoint Read/Write Condition: Remote Default: 100.0 % Local Digital Control Display Selection
Defines what the Local Digital Control displays during operation. The Local Digital Control option is described in the Local Digital Control Option Chapter . The selection list is:
Read/Write Condition: All Default: 1
Local Digital Control Setpoint Read only Local Primary Analog Setpoint Read only
76
Selection Min: 1 Max: 8
1 – Voltage Output (V) 2 – Current Output (A) 3 – Power Output (KW) 4 – Control Setpoint (units) 5 – Voltage Output (%) 6 – Current Output (%) 7 – Power Output (%) 8 – Control Setpoint (%)
77
KW Vrms Irms
The setpoint of the local digital control module. It can be Vrms, Irms or KW depending on the setting of the regulation mode.
78
KW Vrms Irms
The setpoint of the local primary analog input. It can be KW, Vrms, or Irms depending on the setting of the regulation mode.
7-8
February 2004
Settings
Settings
No.
Units
Description
79
Bits Min: -100 Max: 500
Digital zero adjustment of the Local Primary Analog Setpoint input signal. Calibration is described in the Calibration Chapter .
80
Bits Min: 2000 Max: 16000
Digital span adjustment of the Local Primary Analog Setpoint input signal. Calibration is described in the Calibration Chapter .
Primary Analog Setpoint Zero Read/Write Condition: All Default: Factory Primary Analog Setpoint Span Read/Write Condition: All Default: Factory Local Secondary Analog Setpoint Selection Read/Write Condition: All Default: 1
Defines the operation of the Local Secondary Analog Setpoint during local analog control. The selection list is: 81
Selection Min: 1 Max: 3
1 – Current Setpoint 2 – Voltage Setpoint 3 – Power Setpoint Note: The Local Secondary Analog Setpoint will be ignored if it is set to the same regulation mode as the Local Primary Analog Setpoint
Local Secondary Analog Setpoint Read only
82
KW Vrms Irms
The setpoint of the Local Secondary Analog Setpoint input. It is defined by the Local Secondary Analog Setpoint Selection. The secondary analog setpoint is activated/deactivated in the Configuration Word.
83
Bits Min: -100 Max: 500
Digital zero adjustment of the Local Secondary Analog Setpoint input signal. Calibration is described in the Calibration Chapter .
84
Bits Min: 2000 Max: 16000
Digital span adjustment of the Local Secondary Analog Setpoint input signal. Calibration is described in the Calibration Chapter .
Secondary Analog Setpoint Zero Read/Write Condition: All Default: Factory Secondary Analog Setpoint Span Read/Write Condition: All Default: Factory
7-9
Settings
Settings
February 2004
No.
Units
Description
Analog Output #1 Selection
Defines the operation of the Analog Output #1. The selection list is:
Read/Write Condition: All Default: 2
1 – Power Setpoint 2 – Power Output 3 – Voltage Setpoint 4 – Voltage Output 5 – Voltage Input 6 – Current Setpoint 7 – Current Output 8 – Current Input 9 –Analog Setpoint 10 – Duty Cycle Output
85
Selection Min: 1 Max: 10
86
%
An analog output as defined by Analog Output #1 Selection in percent.
87
Bits Min: -100 Max: 500
Digital zero adjustment of the Analog Output #1 signal. Calibration is described in the Calibration Chapter .
88
Bits Min: 2000 Max: 6000
Digital span adjustment of the Analog Output #1 signal. Calibration is described in the Calibration Chapter .
Analog Output #1 Read only Analog Output #1 Bias Read/Write Condition: All Default: Factory Analog Output #1 Span Read/Write Condition: All Default: Factory Analog Output #2 Selection
Defines the operation of the Analog Output #2. The selection list is:
Read/Write Condition: All Default: 4
1 – Power Setpoint 2 – Power Output 3 – Voltage Setpoint 4 – Voltage Output 5 – Voltage Input 6 – Current Setpoint 7 – Current Output 8 – Current Input 9 –Analog Setpoint 10 – Duty Cycle Output
89
Selection Min: 1 Max: 10
90
%
An analog output as defined by Analog Output #2 Selection in percent.
91
Bits Min: -100 Max: 500
Digital zero adjustment of the Analog Output #2 signal. Calibration is described in the Calibration Chapter .
92
Bits Min: 2000 Max: 6000
Digital span adjustment of the Analog Output #2 signal. Calibration is described in the Calibration Chapter .
Analog Output #2 Read only Analog Output #2 Bias Read/Write Condition: All Default: Factory Analog Output #2 Span Read/Write Condition: All Default: Factory
7-10
February 2004
Settings
Settings
No.
Units
Description
Control Word Read/Write Condition: All Default: Bit 0 – 0 Off Bit 1 – 0 No Reset Bit 2 - Reserved Bit 3 – 0 No Reset Bit 4 – 0 No Sync Bit 5 – 0 No Auto Set Bit 6 – 0 Bit 7 – 1 Voltage Bit 8 – 0 Save Calibration Bit 9 – 0 Restore Calibration Bit 10 – 15 Reserved
The control word is the digital inputs to the 853.
93
Bit 0 – Maintained 1 – On 0 - Off Bit 1 – Momentary 1 - Fault Reset 0 – No Reset Bit 3 – Momentary 1 – KW-hour Reset 0 – No Reset Bit 4 – Momentary 1 – Node synchronization 0 – No synchronization Bit 5 – Momentary 1 – Auto Set Repetitive Pulse 0 – No Auto Set Regulation Mode Bit 6 – 7 Maintained 0 – 0 No Regulation 1 – 0 Power Output Control 0 – 1 Voltage Output Control 1 – 1 Current Output Control Bit 8 – Momentary 1 – Save calibration data to eeprom 0 – No cal save Bit 9 – Momentary 1 – Restore calibration data from eeprom 0 – No cal restore
Bits
7-11
Settings
Settings
February 2004
No.
Units
Description
Status Word
The status word is the digital outputs from the 853.
Read only
94
Bit 0 1– On 0 – Off Bit 1 1 – Fault 0 – No Fault Bit 2 1 – Alarm 0 – No Alarm Bit 3 1 – Remote control selected 0 – Local control selected Bit 4 1 – Enable selected 0 – Inhibit selected Bit 5 1 – Local Digital control 0 – Local Analog control Regulation Limit Bit 6 – 7 – 8 0 – 0 – 0 No Limit 1 – 0 – 0 Power Output Limit 0 – 1 – 0 Voltage Output Limit 0 – 0 – 1 Current Output Limit 0 – 1 – 1 Current Input Limit 1 – 1 – 1 Maximum Voltage Output Bit 9 1 – At Setpoint 0 – Not at Setpoint Bit 10 1 – Phase Rotation L3-L2-L1 0 – Phase Rotation L1-L2-L3 Bit 11 1 – Ext Input #1 Closed 0 – Ext Input #1 Open Bit 12 1 – Ext Input #2 Closed 0 – Ext Input #2 Open Bit 13 1 – Ext Input #3 Closed 0 – Ext Input #3 Open Bit 14 Reserved Bit 15 1 – Program Jumper In 0 – Program Jumper Out
Bits
7-12
February 2004
Settings
Settings
No.
Units
Description The amount of time for the setpoint to go from 0 to100%.
The amount of time for the setpoint to go from 100 to 0%.
Ramp Up Time Read/Write Condition: All Default: 10 Sec Ramp Down Time
95
Seconds Min: 0 Max: 360
Read/Write Condition: All Default: 10 Sec Configuration Word
96
Seconds Min: 0 Max: 360
Read/Write Condition: All Default: Bit 0 – 1 Digital Bit 1 – 0 Secondary Analog Disabled Bit 2 Reserved Bit 3 – 1 Ext Fault #1 NO Bit 4 – 1 Ext Fault #2 NO Bit 5 – 1 Ext Fault #3 NO Bit 6 – 1 Int Fault #1 NO Bit 7 – 1 Int Fault #2 NO Bit 8 – 0 Thermostat NC Bit 9 – 0 Low voltage Fault Bit 10 – 11 Reserved Bit 12 – 1 Ext #1 Input Bit 13 – 1 Ext #2 Input Bit 14 – 1 Ext #3 Input Bit 15 – 0 Auto Start Disabled
The configuration word configures the digital inputs to the 853.
97
Bit 0 – Maintained 1 – Local Digital control 0 – Local Analog control Bit 1 – Maintained 1 – Secondary Analog enabled 0 – Secondary Analog disabled Bit 2 – Reserved Bit 3 – Maintained 1 – External Fault #1 NO 0 – External Fault #1 NC Bit 4 – Maintained 1 – External Fault #2 NO 0 – External Fault #2 NC Bit 5 – Maintained 1 – External Fault #3 NO 0 – External Fault #3 NC Bit 6 – Maintained 1 – Internal Fault #1 NO 0 – Internal Fault #1 NC Bit 7 – Maintained 1 – Internal Fault #2 NO 0 – Internal Fault #2 NC Bit 8 – Maintained 1 – Thermostat NO 0 – Thermostat NC Bit 9 – Maintained 1 – Low voltage results in Alert 0 – Low voltage results in Fault Bit 12 – Maintained 1 – External #1 generates fault 0 – External #1 input only Bit 13 – Maintained 1 – External #2 generates fault 0 – External #2 input only Bit 14 – Maintained 1 – External #3 generates fault 0 – External #3 input only Bit 15 – Maintained 1 – Enable Auto Start on Power up 0 – Disable Auto Start on Power up
Bits
7-13
Settings Settings
Settings
February 2004
No.
Units
Description
Control Strategy Selection Read/Write Condition: Off Default: 1 Magnetizing Sequence Calibration Read/Write Condition: Off Default: 10 Cycles Repetitive Pulse Calibration Read/Write Condition: All Default: Low Byte 50 High Byte 30
98
99
100
Defines the type of control strategy that is being run. The selection list is:
Selection Min: 1 Max: 2
1 – Phase-Angle Control 2 – Zero-Crossover Control
Cycles Min: 5 Max: 20
Number of cycles to ramp on in phase control – Zero-Crossover control only
The Repetitive Pulse Calibration is divided into two separate bytes, which allows the first positive zero crossing pulse to be set differently for the three phases – Zero-Crossover control only.
% Min: 10 Max: 90
Low Byte – Bits 0 – 7 Repetitive Pulse #1 High Byte – Bits 8 – 15 Repetitive Pulse #2
Load Type Selection Read/Write Condition: Off Default: 1 Product Type
101
Defines the type of load connected to the 853. The selection list is:
Selection Min: 1 Max: 2
1 – Direct Coupled 2 – Transformer Coupled
102
The product type is 853.
103 104
The numeric serial serial number of the 853. The Setting is read as two consecutive words because of its size.
Read only Serial Number Read only Factory set Control Power Time On Read only Factory reset Output Time On Read only Factory reset KW-Hour Read only
105 106
Hours x.x
The accumulated time control power has been applied to the 853. The Setting is read as two consecutive words because of its size.
107 108
Hours x.x
The accumulated time the 853 output has been on. The Setting is is read as two two consecutive words because of its size.
109 110
KW- Hours x.x
The accumulated Power Power Output in in KW hours. It can be reset remotely by writing a 1 to bit 3 of the Control Word. The Setting is is read as two two consecutive words because of its size.
Software Version 112
The control software version read as xx.xxx.
Read only
7-14
February 2004
Settings
Settings
No.
Units
Description
Network Loss Read/Write Condition: All Default: 1
113
Defines the action that is taken by the 853 control when there there is a network network loss. The selection list is:
Selection Min: 0 Max: 2
0 – Fault and Stop 1 – Ignore and Run 2 – Alarm and Run
Network Address Read/Write Condition: All Default: 63
Address Min: 0 Max: 126
For the DeviceNet™ and Profibus network types, defines the network interface card address. For Ethernet, it defines the upper two octets of the network address. Refer to the the network interface interface manual for a detailed description of the network interface.
115
Selection Min: 0 Max: 2
For the DeviceNet™ and Profibus network types, defines the network network baud rate. For Ethernet, it defines the lower two octets of the network address. Refer to the the network interface interface manual for a detailed description of the network interface.
116
Address Min: 1 Max: 247
Defines the device address for MODBUS messaging.
117
Selection Min: 4800 Max: 19200 (baud)
114
Network Baud Rate Read/Write Condition: All Default: 0 MODBUS Address Read/Write Condition: All Default: 247 MODBUS Baud Rate Read/Write Condition: All Default: 19200 Network Type Read/Write Condition: All Default: 0
118
Selection Min: 0 Max: 2
0 – DeviceNet™ 1 – Profibus 2 – Ethernet Fault condition condition code. Fault operation is described in the Troubleshooting Chapter .
119
Read only Factory reset Fault Buffer #1 Read only Factory reset
120
4800 9600 19200 Defines the selected network interface. The selection list is:
Fault Code Read only Fault Index
Defines the serial baud rate. The selection list is:
Index Min: 1 Max: 8
Fault buffer index number.
Saved fault condition code with a time stamp of time run.
121 122 123
Word 121 – Fault condition code Word 122/123 – Output time on stamp
7-15
Settings Settings
Settings
February 2004
No.
Units
Description
Fault Buffer #2 Read only Factory reset
Saved fault condition code with a time stamp of time run.
124 125 126
Word 124 – Fault condition code Word 125/126 – Output time on stamp
Fault Buffer #3 Read only Factory reset
Saved fault condition code with a time stamp of time run.
127 128 129
Word 127 – Fault condition code Word 128/129– Output time on stamp
Fault Buffer #4 Read only Factory reset
Saved fault condition code with a time stamp of time run.
130 131 132
Word 130 – Fault condition code Word 131/132 – Output time on stamp
Fault Buffer #5 Read only Factory reset
Saved fault condition code with a time stamp of time run.
133 134 135
Word 133 – Fault condition code Word 134/135 – Output time on stamp
Fault Buffer #6 Read only Factory reset
Saved fault condition code with a time stamp of time run.
136 137 138
Word 136 – Fault condition code Word 137/138 – Output time on stamp
Fault Buffer #7 Read only Factory reset
Saved fault condition code with a time stamp of time run.
139 140 141
Word 139 – Fault condition code Word 140/141 – Output time on stamp
Fault Buffer #8 Read only Factory reset
Saved fault condition code with a time stamp of time run.
142 143 144
Word 142 – Fault condition code Word 143/144 – Output time on stamp
7-16
Chapter 8 Troubleshooting DANGER Only qualified electrical personnel familiar with the construction and operation of the equipment and the hazards involved should install, operate, and/or service this equipment. Read and understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.
DANGER The user is responsible for conforming with all applicable local, national, and international codes; wiring practices, grounding, disconnects, and overcurrent protection are of particular importance. Failure to observe this precaution could result in severe bodily injury or loss of life.
DANGER This equipment is at line voltage when AC power is connected. Disconnect and lock out all ungrounded conductors of the AC power line. Failure to observe these precautions could result in severe bodily injury or loss of life.
DANGER Power must be applied to the 853 DSPC with the cover removed to perform certain troubleshooting procedures. Voltages on many components are at incoming line potential. to avoid electric shock hazard or damage to equipment, do not touch any component other than those specified in the manual. Failure to observe these precautions could result in severe injury or loss of life.
The 853 DSPC has a number of built in diagnostic features. These include LED indicators for quick visual indicators on the following: ●
the Main Control printed circuit board (PCB)
●
the Local Digital Control option
●
the network interface option
The four-digit display on the Local Digital Control option can be programmed to view key control signals and display fault or alarm codes.
8-1
Troubleshooting
February 2004
Control PCB LED Indicators The control printed circuit board has six LED’s. Remove the middle wiring cover of the 853 DSPC to view these particular LED’s. The LED’s and their functions are listed in below.
Table 8-1 Control PCB LED Indicators LED
Color
Description
+5V
Green
+5V power is present
+15V
Green
+15V power is present
-15V
Green
-15V power is present
On
Green
853 DSPC output is active
Heartbeat
Fault
Flashing Green Red
Digital Signal Processor is operating
853 DSPC has detected a fault condition
Figure 8-1 Control PCB LED indicator location
8-2
February 2004
Troubleshooting
Local Digital Control Option LED Indicators The Local Digital Control Option has six LED’s used for status. The LED’s and their functions are listed below.
Table 8-2 Local Digital Control LED Indicators Status LED
Color
Description
Remote
Green
The Remote input is present.
Analog
Green
The Local mode is set to Analog.
Digital
Green
The Local mode is set to Digital.
Enable
Green
The Enable input is present.
On
Green
The 853 DSPC output is active.
Alert
Amber
Either a fault or alarm is present.
Figure 8-2 Local Digital Control
8-3
Troubleshooting
February 2004
Fault and Alarm Codes If there is a fault, the 853 DSPC automatically stops and holds the fault code for the user. The fault codes are evaluated in their numeric order. This makes the lowest number codes the highest priority. The fault code is displayed on the Local Digital Control module. It can also be accessed as Setting #119 through either the serial or network interface. Alarm codes are warning conditions and do not stop the 853 DSPC. The alarm code is also displayed on the Local Digital Control module but not continuously. The display alternates between the selected display variable and the alarm code. It can also be accessed as Setting #119 through either the serial or network interface. A fault will always override an alarm and stop the 853 DSPC. The following table lists the fault and alarm codes.
Table 8-3 Fault and Alarm Codes Fault/Alarm Phase L1 Current Input High Fault
Phase L2 Current Input High Fault
Code 1
2
Description The fault occurs when the Current Input L1 Actual peak exceeds the Current Input High Fault at any time during the AC cycle for two consecutive samples. The fault will be reset and automatically restart based on the following conditions. 1.
The 853 will turn off and automatically restart based on the Current Input High Retry Number .
2.
The 853 will turn off and not automatically restart if the number of restarts occur within the Current Input High Retry Time.
The fault occurs when the Current Input L2 Actual peak exceeds the Current Input High Fault at any time during the AC cycle for two consecutive samples. The fault will be reset and automatically restart based on the following conditions. 1.
The 853 will turn off and automatically restart based on the Current Input High Retry Number .
2.
The 853 will turn off and not automatically restart if the number of restarts occur within the Current Input High Retry Time.
8-4
February 2004
Fault/Alarm Phase L3 Current Input High Fault
Current Input Timed Overload Fault
Troubleshooting
Code 3
5
Description The fault occurs when the Current Input L3 Actual peak exceeds the Current Input High Fault at any time during the AC cycle for two consecutive samples. The fault will be reset and automatically restart based on the following conditions. 1.
The 853 will turn off and automatically restart based on the Current Input High Retry Number .
2.
The 853 will turn off and not automatically restart if the number of restarts occur within the Current Input High Retry Time.
The fault occurs when the following conditions are met. 1.
The Current Input Actual exceeds the Current Input Overload Fault.
2.
The accumulated time of condition #1 is greater than the Current Input Overload Time .
Note: If the Current Input Actual goes below the Current Input Overload Fault then the accumulated time resets back to zero. Over Temperature Fault
6
The fault occurs when the thermostat input changes to the off state. The thermostat input is defined as NO (Normally Open) or NC (Normally Closed) depending on bit 8 of the Configuration Word.
Internal Fault #1
7
The fault occurs when internal fault input #1 changes to the off state. The internal fault input #1 is defined as NO (Normally Open) or NC (Normally Closed) depending on bit 6 of the Configuration Word.
Internal Fault #2
8
The fault occurs when internal fault input #2 changes to the off state. The internal fault input #2 is defined as NO (Normally Open) or NC (Normally Closed) depending on bit 7 of the Configuration Word.
Voltage Input High Fault
9
The fault occurs when Voltage Input Actual (average of three phases) exceeds the Voltage High Fault.
Voltage Input Low Fault
10
The fault occurs when Voltage Input Actual (average of three phases) is lower than 12.5% of the Voltage Input Rating, and bit 9 of the Configuration Word is NOT set.
8-5
Troubleshooting
Fault/Alarm Phase L1 Loss
February 2004
Code 11
Description The fault occurs when the following conditions are met. 1.
The phase difference between Voltage L1-L2 Input Actual and Voltage L2-L3 Input Actual is less than 45 degrees or greater than 135 degrees.
2.
Voltage L2-L3 Actual is greater than Voltage Input Actual.
3.
The accumulated time of condition #2 is greater than 100 milliseconds.
Note: If condition #2 is not met, then the accumulated time resets back to zero. Phase L2 Loss
12
The fault occurs when the following conditions are met. 1.
The phase difference between Voltage L1-L2 Input Actual and Voltage L2-L3 Input Actual is less than 45 degrees or greater than 135 degrees.
2.
Voltage L3-L1 Actual is greater than Voltage Input Actual.
3.
The accumulated time of condition #2 is greater than 100 milliseconds.
Note: If condition #2 is not met, then the accumulated time resets back to zero. Phase L3 Loss
13
The fault occurs when the following conditions are met. 1.
The phase difference between Voltage L1-L2 Input Actual and Voltage L2-L3 Input Actual is less than 45 degrees or greater than 135 degrees.
2.
Voltage L1-L2 Actual is greater than Voltage Input Actual.
3.
The accumulated time of condition #2 is greater than 100 milliseconds.
Note: If condition #2 is not met, then the accumulated time resets back to zero.
8-6
February 2004
Fault/Alarm External Fault #1
Troubleshooting
Code 14
Description The fault occurs when the following conditions are met. 1.
Configuration Word bit 12 is a one.
2.
The External Fault Input #1 changes to the off state.
Note: External Fault Input #1 is defined as NO (Normally Open) or NC (Normally Closed) depending on bit 3 of the Configuration Word. External Fault #2
15
The fault occurs when the following conditions are met. 1.
Configuration Word bit 13 is a one.
2.
The External Fault Input #2 changes to the off state.
Note: External Fault Input #2 is defined as NO (Normally Open) or NC (Normally Closed) depending on bit 4 of the Configuration Word. External Fault #3
16
The fault occurs when the following conditions are met. 1.
Configuration Word bit 14 is a one.
2.
The External Fault Input #3 changes to the off state.
Note: External Fault Input #3 is defined as NO (Normally Open) or NC (Normally Closed) depending on bit 5 of the Configuration Word. Configuration Fault
17
The fault occurs when the 'check byte' of the onboard EEPROM is not correct. Note: [Reset] may clear this fault with no further action.
Watchdog Fault
18
The fault occurs when the digital signal processor does not update the watchdog timer correctly.
SCR Shorted Fault
19
The fault occurs when the following conditions are met.
Network Loss Fault
20
1.
The Voltage Output Actual is greater than 75% of the Voltage Output Rating for one second.
2.
The 853 is off.
The fault occurs if there is a network loss and the Network Loss Selection is set to Fault and Stop.
8-7
Troubleshooting
Fault/Alarm Ground Fault
February 2004
Code 21
Description The fault occurs when all the following conditions are met. 1.
The calculated ground current exceeds the Ground Fault Current.
2.
The accumulated time of condition #1 is greater than the Ground Fault Time.
Note: If the calculated ground current goes below the Ground Fault Current then the accumulated time resets back to zero. Frequency Alarm
30
The alarm occurs when the Frequency Actual is outside of a 2.0 Hertz band when compared to the Frequency Rating.
L1 Current Input Load Failure Alarm
31
The alarm occurs when all of the following conditions are met.
L2 Current Input Load Failure Alarm
L3 Current Input Load Failure Alarm
32
33
1.
The Current L1 Input Actual is less than the Current Input Threshold Load Failure .
2.
The Voltage Output Actual is greater than 10% of the Voltage Output Rating
3.
The setpoint has completed ramping up.
The alarm occurs when all of the following conditions are met. 1.
The Current L2 Input Actual is less than the Current Input Threshold Load Failure .
2.
The Voltage Output Actual is greater than 10% of the Voltage Output Rating
3.
The setpoint has completed ramping up.
The alarm occurs when all of the following conditions are met. 1.
The Current L3 Input Actual is less than the Current Input Threshold Load Failure .
2.
The Voltage Output Actual is greater than 10% of the Voltage Output Rating
3.
The setpoint has completed ramping up.
Voltage Input Low Alarm
34
The alarm occurs when the Voltage Input Actual is lower than the Voltage Input Low Alarm.
Voltage Output Limit Alarm
35
The alarm occurs when the Voltage Output Actual is being limited to the Voltage Output Limit by the voltage output control loop.
8-8
February 2004
Fault/Alarm
Troubleshooting
Code
Description
Current Output Limit Alarm
36
The alarm occurs when the Current Output Actual is being limited to the Current Output Limit by the current output control loop.
Power Output Limit Alarm
37
The alarm occurs when the Power Output Actual is being limited to the Power Output Limit by the power output control loop.
Current Input Limit Alarm
38
The alarm occurs when the Current Input Actual is being limited to the Current Input Limit.
Maximum Voltage Output Alarm
39
The alarm occurs when the Duty Cycle of the controller reaches 100%.
Network Loss Alarm
40
The alarm occurs if there is a network loss and the Network Loss Selection is set to Alarm and Run.
L1-L2 Input Voltage Unbalanced
41
The alarm occurs when the difference between the Voltage L1-L2 Input Actual and the Voltage Input Actual exceeds the Voltage Input Phase Unbalance Alarm (expressed as a percentage of the Voltage Input Rating).
L2-L3 Input Voltage Unbalanced
42
The alarm occurs when the difference between the Voltage L2-L3 Input Actual and the Voltage Input Actual exceeds the Voltage Input Phase Unbalance Alarm (expressed as a percentage of the Voltage Input Rating).
L3-L1 Input Voltage Unbalanced
43
The alarm occurs when the difference between the Voltage L3-L1 Input Actual and the Voltage Input Actual exceeds the Voltage Input Phase Unbalance Alarm (expressed as a percentage of the Voltage Input Rating).
Fault Reset Faults can be cleared or reset by three different methods. Alarms are automatically cleared. ●
Toggle the Enable/Inhibit switch from Enable to Inhibit.
●
Press the Reset button on the Local Digital Control module.
●
Use the fault reset bit (bit 1) of the Control Word. The bit must be momentarily set to enable a fault reset. The 853 automatically resets the bit after the fault has been cleared. It is very important not to leave the bit set in the control word.
Fault Buffer The last eight faults are stored in Fault Buffers #1 - #8 and can be accessed from the serial interface. The fault buffer includes the Fault Code and a time stamp from Output Time On. Only faults that occur
8-9
Troubleshooting
February 2004
when the unit is running are buffered. The Fault Index indicates which buffer will be written to next. The fault buffers are connected in a circular fashion. Troubleshooting Guide
DANGER Only qualified electrical personnel familiar with the construction and operation of the equipment and the hazards involved should install, operate, and/or service this equipment. Read and understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.
DANGER The user is responsible for conforming with all applicable local, national, and international codes; wiring practices, grounding, disconnects, and overcurrent protection are of particular importance. Failure to observe this precaution could result in severe bodily injury or loss of life.
DANGER This equipment is at line voltage when AC power is connected. Disconnect and lock out all ungrounded conductors of the AC power line. Failure to observe these precautions could result in severe bodily injury or loss of life.
DANGER Power must be applied to the 853 DSPC with the cover removed to perform certain troubleshooting procedures. Voltages on many components are at incoming line potential. to avoid electric shock hazard or damage to equipment, do not touch any component other than those specified in the manual. Failure to observe these precautions could result in severe injury or loss of life.
The following table shows different conditions with probable cause and corrective action for each condition.
8-10
February 2004
Troubleshooting
Table 8-4 Troubleshooting Guide Condition
Probable Cause
Corrective Action
+5V LED off
No Control Power
Insure the 853 DSPC has separate control power
Power Supply connection open
Check Power Supply connections to main control PCB
Power Supply failed
Replace Power Supply
DSP on main control PCB failed
Check that jumper JP1 has been removed before applying power
+15V LED off -15V LED off
Heartbeat LED off
Replace main control PCB Local Digital Control Display off or scrambled
Local Digital Control connection open or intermittent
Check Local Digital Control connection to main control PCB
853 DSPC will not turn on in Local Analog mode
Enable not present
Check that the Enable status LED is on. The Output On status LED should also be on.
Local mode not selected
Check that the Remote status LED is off.
Analog mode not selected
Select Analog mode on Local Digital Control. Check that the Analog status LED on
Local Analog setpoint set to zero
Verify voltage at Analog Setpoint input
Local analog setpoint calibration incorrect
Verify Local analog setpoint calibration
8-11
Troubleshooting
February 2004
Condition
Probable Cause
Corrective Action
853 DSPC will not turn on in Local Digital mode
Enable not present
Check that the Enable status LED is on.
Local mode not selected
Check that the Remote status LED is off.
Digital mode not selected
Select Digital mode on Local Digital Control. Check that the Digital status LED is on
Output On not selected
Press the On/Off/Reset pushbutton and check that the Output On LED is on.
Digital setpoint set at zero
Press the increase pushbutton to increase the setpoint
Enable not present
Check that the Enable status LED is on.
Remote mode not selected
Check that the Remote status LED is on.
On/Off bit not set to one
Set the On/Off bit to one in the Control Word and check that the Output On LED is on
Setpoint set at zero
Verify that the setpoints for Voltage, Current, Power and Remote Duty Cycle are not zero
Calibration incorrect
Check calibration
Power is being limited by one of the three control loops
Verify setpoints for the three control loops
853 DSPC is full on and cannot provide any more power
Duty Cycle is at 100.0%.
853 DSPC will not turn on in Remote mode
853 DSPC cannot provide full power to the load
Review the load to verify that 100.0% voltage will allow 100.0% power. Verify input voltage level to make sure it is not low
Output wiring intermittent or disconnected
8-12
Check the output wiring
February 2004
Troubleshooting
Condition
Probable Cause
Corrective Action
Nuisance Input Fuse blowing
Improper fuse rating
Refer to Hardware Installation Chapter for correct fuse rating
Fuse improperly tightened
Tighten the fuses
Calibration incorrect
Check calibration
Current Input Rating setting incorrect
Check Current Input Rating setting
Current Input High Fault setting incorrect
Check Current Input High Fault setting
Intermittent short in load
Check load
Calibration incorrect
Check calibration
Current Input Rating setting incorrect
Check Current Input Rating setting
Current Input Overload Fault setting incorrect
Check Current Input Overload Fault setting
Current Input Overload Time setting incorrect
Check Current Input Overload Time setting
Output transformer sized incorrectly
Verify size of output transformer
Thermostat contact state incorrect in Configuration Word setting
Check Configuration Word setting
Thermostat wiring open or shorted
Check thermostat wiring
Cabinet is overheating
Provide more cabinet ventilation or cooling
Unit is Overheating
Check fan is functioning properly
Internal Fault contact state incorrect in Configuration Word setting
Check Configuration Word setting
Internal Fault wiring open or shorted
Check Internal Fault wiring
F-01, F-02, F-03 Current Input High Fault
F-05 – Current Input Timed Over Current Fault
F-06 – Over Temperature Fault
F-07, F-08 – Internal Fault
8-13
Troubleshooting
February 2004
Condition
Probable Cause
Corrective Action
F-09 – Voltage Input High Fault
Calibration incorrect
Check calibration
Voltage Input Rating setting incorrect
Check Voltage Input Rating setting
Voltage Input High Fault setting incorrect
Check Voltage Input High Fault setting
Voltage Output PT Secondary setting incorrect
Check Voltage Output PT Secondary setting. Refer to Startup Chapter for details on correct setting
Incoming voltage out of tolerance
Correct incoming voltage level
Calibration incorrect
Check calibration
Voltage Input Rating setting incorrect
Check Voltage Input Rating setting
Voltage Output PT Secondary setting incorrect
Check Voltage Output PT Secondary setting. Refer to Startup Chapter for details on correct setting
Blown input fuse
Replace input fuse
Calibration incorrect
Check calibration
Blown input fuse
Replace input fuse
External Fault contact state incorrect in Configuration Word setting
Check Configuration Word setting
External Fault wiring open or shorted
Check External Fault wiring
Failed EEPROM memory
Try [Reset]
F-10 – Voltage Input Low Fault
F-11, F-12, F-13 – Phase Loss
F-14, F-15, F16 – External Fault
F-17 – Configuration Fault
If the fault remains, use the configuration tool offline to modify a setting or load a .csv file. Go online, and respond to the Write prompt with Yes. Replace main control PCB F-18 Watchdog Fault
Failed DSP
Replace main control PCB
8-14
February 2004
Troubleshooting
Condition
Probable Cause
Corrective Action
F-19 – SCR Shorted Fault
Calibration incorrect
Check calibration
Voltage Output Rating setting incorrect
Check Voltage Output Rating setting
Voltage Output PT Secondary setting incorrect
Check Voltage Output PT Secondary setting. See Startup Chapter for details on correct setting
Shorted SCR
Replace SCR
Network failure
Check network connection
F-20 - Network Loss Fault
Verify presence of network Change Network Loss Option to allow device operation F-21 – Ground Fault
A-30 – Frequency Alarm
Calibration incorrect
Check calibration
Current Input Rating setting incorrect
Check Current Input Rating setting
Ground Fault Current setting incorrect
Check Ground Fault Current setting
Intermittent short to ground
Check for ground
Frequency Rating setting incorrect
Check Frequency Rating setting
Incoming frequency out of tolerance
Correct incoming frequency
8-15
Troubleshooting
February 2004
Condition
Probable Cause
Corrective Action
A-31, A-32, A-33 – Current Input Load Failure Alarm
Calibration incorrect
Check calibration
Current Threshold Load Failure setting incorrect
Check Current Input Threshold Load Failure setting
Voltage Output Rating setting incorrect
Check Voltage Output Rating setting
Voltage Output PT Secondary setting incorrect
Check Voltage Output PT Secondary setting. Refer to Startup Chapter for details on correct setting
Output load changed
Verify output load
Calibration incorrect
Check calibration
Voltage Input Rating setting incorrect
Check Voltage Input Rating setting
Voltage Input Low Alarm setting incorrect
Check Voltage Input Low Alarm setting
Voltage Output PT Secondary setting incorrect
Check Voltage Output PT Secondary setting. Refer to Startup Chapter for details on correct setting
Incoming voltage out of tolerance
Correct incoming voltage level
Calibration incorrect
Check calibration
Voltage Output Rating setting incorrect
Check Voltage Output Rating setting
Voltage Output PT Secondary setting incorrect
Check Voltage Output PT Secondary setting. Refer to Startup Chapter for details on correct setting
Voltage Output Setpoint setting incorrect
Check Voltage Output Setpoint setting
Controlling with Voltage Output PID
Change Voltage Output Setpoint
A-34 – Voltage Input Low Alarm
A-35 – Voltage Output Limit Alarm
8-16
February 2004
Troubleshooting
Condition
Probable Cause
Corrective Action
A-36 – Current Output Limit Alarm
Calibration incorrect
Check calibration
Current Output Rating setting incorrect
Check Current Output Rating setting
Current Output Setpoint setting incorrect
Check Current Output Setpoint setting
Controlling with Current Output PID
Change Current Output Setpoint
Calibration incorrect
Check calibration
Voltage Output Rating setting incorrect
Check Voltage Output Rating setting
Voltage Output PT Secondary setting incorrect
Check Voltage Output PT Secondary setting. Refer to Startup Chapter for details on correct setting
Current Output Rating setting incorrect
Check Current Output Rating setting
Power Output Setpoint setting incorrect
Check Power Output Setpoint setting
Controlling with Power Output PID
Change Power Output Setpoint
Calibration incorrect
Check calibration
Current Input Rating setting incorrect
Check Current Input Rating setting
Current Input Limit setting incorrect
Check Current Input Limit setting
Controlling Current Input with Current Output PID
Change Current Input Limit
Duty Cycle has reached 100%
Lower the control setpoint
A-37 – Power Output Limit Alarm
A-38 – Current Input Limit Alarm
A-39 - Maximum Voltage Output Alarm
8-17
Troubleshooting
February 2004
Condition
Probable Cause
Corrective Action
A-40- Network Loss Alarm
Network failure
Check network connection Verify presence of network Change Network Loss Option to allow device operation
A-41, A-42, A-43 – Input Voltage Unbalance Alarm
Calibration incorrect
Check calibration
Voltage Input Phase Unbalance setting incorrect
Check Voltage Input Phase Unbalance Alarm setting
Voltage Input Rating setting incorrect
Check Voltage Input Rating setting
Voltage Input Supply not balanced
Check Voltage Input Supply
8-18
Appendix A Mechanical Dimensions
Figure A-1 Mechanical Dimensions
A-1
Mechanical Dimensions
February 2004
A-2
Appendix B Electrical Drawings
B-1
Electrical Drawings
February 2004
Figure B-1 Electrical Schematic Left Side
B-2
February 2004
Electrical Drawings
Figure B-2 Electrical Schematic Right Side
B-3
Electrical Drawings
February 2004
Figure B-3 40A Wiring Diagram
B-4
February 2004
Electrical Drawings
Figure B-4 90A Wiring Diagram
B-5
Electrical Drawings
February 2004
Figure B-5 175A Wiring Diagram
B-6
February 2004
Electrical Drawings
Figure B-6 350A Wiring Diagram
B-7
Glossary Glossary of common terms and abbreviations used in SCR Power Controllers and their applications
Term or Acronym
Description
ADR
Automatic Device Replacement
ASCII
American Standard Code for Information Interchange
Bias
Calibration factor to offset signal at zero output of control signal
CAN
Controller Area Network
CT
Current Transformer
DSP
Digital Signal Processor
DSPC
Digital SCR Power Controller
EDS
Electronic Data Sheet
Heatsink
Device to carry heat from power devices
2
It
Subcycle current characteristic of an SCR or fast clearing fuse
I/O
Input/Output
IRMS
Amps Root Mean Squared
KVA
One thousand volt amperes
LED
Light emitting diode
MOV
Metal Oxide Varistor – brand name of GE transient voltage suppressor
NC
Normally closed contact
NO
Normally open contact
NEC
National Electric Code
NEMA
National Electrical Manufacturers Association
ODVA
Open DeviceNet™ Vendors Association
PCB
Printed Circuit Board
PCMCIA
Personal Computer Memory Card International Association
PCU
Power Control Unit
i
