Report No. R188 May 02, 199 6
OP E RATING MANU MANUA AL FOR A SINGL SIN GLE E PHASE F IRING IRING CIRCUIT CIRCUIT BOARD BOARD F CRO2 1 0 0
. 57 80 Th ornwood Drive, Drive, Goleta, Ca lif lifornia Phone: 805-68 3-2114 , Fax: 805-96 4-0798
Rev. 5-2-96
-1-
Report R188
TABLE OF CONTENTS Page INTRODUCTION
1
REFERENCES
1
ELE CTRICAL SP EC IFICATIONS
1
BOARD MOUNTED CONNECTORS
3
C o n t r o l a n d F e e d b a c k s i gn a l J 1
3
G a t e / C a t h o d e a n d P ow er S u p p ly C on n e ct o r J 2
4
F r e q u e n c y S e le c t io n C o n n e c t o r J 3
4
GATE DE LAY ANGLE TRANSF ER FUNC TION
4
DE LAY ANGLE CO MMAND
5
BIAS AND SP AN ADJ US TMENT
5
GATE INHIBIT INDICATOR LED PD2
6
In s t a n t a n e ou s In h ib it
6
Soft Inh ibit
6
Low signa l inh ibit
6
POWER-ON RESE T
6
GATE PULSE PROFILE
6
GATE PULSE AMPLIFIER
7
INSTALLATION INSTRU CTIONS
8
Rev. 5-2-96
-2-
Report R188
INTRODUCTION The general purpose firing board responds to a voltage or milliamp current signal to produce a delayed set of two 180° - a° high current SCR gate pulses for single phase AC/AC controller and AC/DC converters. The on board error amplifier provides a close loop feedback control for either voltage or current regulation All of the firing circuit logic is contained in a custom 22-pin CMOS LSI gate array and along with other industry standard components mounted in a printed circuit board which is fabricated from .093 inch thick G10 epoxy-glass and its dimensions are 4.50 inch by 5.40 inch. REFERENCES 1. 2.
Drawing E211, "Single Phase 2-SCR Firing Circuit/Regulator", Part No. FCRO2100. Bourbeau, F. J., "Phase Control Thyristor Firing Circuit: Theory and Applications", Power Quality '89, Oct. 17-19, Long Beach, California.
ELECTRICAL SPECIFICATIONS The electrical specifications of the General Purpose Firing Board are summarized in the table below. Characteristic 1. Board mounted power supply for control electronics and SCR gate drive. 2. SCR gate waveform.
Performance Requirement. Supporting Information Connect to mains at J2-7 6 VA 1ø 50/60 Hz fused board and J2-8 for 115/230V or mounted transformer T1. 240/480V. Center-tapped primary connected for 120V, 240V or 480V. Pulse Profile: 180 - a burst width and 32.6µs pulse width.
3. Input control signal.
0 Vdc to 5.0 Vdc control Option: a Shunt resistance signal. Input impedance is (R23) across signal input can 10.0 K. be selected for milliamp control signal. R23 = 249 Ω for 4 to 20 mAdc current control signal. Increase in command a max and amin change equally voltage produces a with change in R bias (R4). proportional decrease in (a max-amin) changes with gate delay angle, a. Rspan (R5). Attenuation = -3 dB at 67 Frequency response can be Hz. Phase shift = -45° @ modified by changing summing 57 Hz. amplifier parameters.
4. Gate delay steady-state transfer function. 5. Gate delay dynamic transfer function bandwidth. 6. Effect of frequency.
Rev. 5-2-96
Da/Df = 1.5°/Hz. For 50 Hz J3 for operation, compensate by operation removing R24. -3-
50/60
switchable
Report R188
7. Lock acquisition time.
Approximately 29 ms.
Gating is inhibited for 20 ms or longer at power-on. Inhibit period depends on SoftStart time constant. 8. Soft-Start Gating commences at Soft-Start time constant is set amax and exponentially by C3 and R13+R14. decays to the commanded T = (1.5k + (R13+R14))(C3)(0.579) delay when is T = msec, R = k Ω, C = µF R13+R14 ≥ 20.0kΩ ungrounded (J4-12). 9. Soft-Stop Gate-delay angle ramps to Soft-Stop time constant is set a max before being by C3 and R13. inhibited when is T = R13(C3)(1.84) T = msec, R = k Ω, C = µF grounded. R13 ≥ 1.0kΩ 10. Power-on inhibit. Inhibit circuit is activated at Same delay angle response as power-on. with phase loss inhibit. 11. Low Signal Inhibit circuit is activated if Eliminate this feature by Inhibit SIG HI < 0.49 Vdc. removing CR3. 12. Instantaneous Opening the connection of Gating is inhibited if P1 is inhibit. (P1-4) to +12V removed. instantly inhibits SCR gating. Closing the connection of to +12V instantly enables SCR gating. 13. Peak gate drive 15V With a 30 Vdc supply voltage open circuit voltage 14. Peak gate drive 2.0A Measured with a 30 Vdc supply short circuit voltage and a 1.0 Ω load resistor current. 15. Gate drive .5A in .5µs Measured with a 30 Vdc supply current rise voltage and a 1.0 Ω load resistor time(short circuit) 16. Frequency 2.6° el./Hz sensitivity 17. Temperature ±2° el. for 0° C
-4-
Report R188
rectifier and the +12 Vdc and +5 Vdc regulated outputs. Current or voltage feedback signal is provided by positions 9 and 5 of J1. If an AC current signal is used, a rectifier U7 and a burden resistor R3 must be installed and R3 is selected for 1.0 Vdc full load feedback signal. For a DC feedback signal, omit U7 and Jumper pads 1 and 4, 2 and 3 of U7. Table 1 below, illustrates pin designations. Positions of J1 Connections 1, 2 24 Vac 3
+30 Vdc
4
Instant Inhibit
5, 9 6 7 8 10 11 12
Feedback signal input +12 Vdc +5 Vdc Common Signal High Common Soft Inhibit
Supporting information The board AC power at the secondary of T1. Rectified from 24 Vac to provide circuit board power. Instant inhibit/enable: SCR gating inhibit is controlled by disconnecting pin 4 from, or connecting pin 4 to, +12 Vdc (pin 6) respectively. For closed loop control, apply the voltage or current feedback signal as shown on E211. Board power Board Power Board common 0 to +5.0 delay angle control signal Board common Soft start/stop: SCR gating inhibit is controlled by disconnecting pin 12 from, or connecting pin 12 to, COM (pin 8 or 11) respectively.
Gate/Cathode and Power Supply Connector J2 The SCR gate/cathode and power supply interface is provided by a 8-position MateN-Lok™ vertical header, J2, and mating plug P2. Positions 1 and 2 of J2 and P2 access the gates and cathodes of the SCR having load connected cathode when the SCR is arranged in the in-line ac controller or bridge converter configurations. Similarly, positions 4 and 5 access the gates and cathodes of the SCR having line connected cathodes. The board mounted 6 VA power supply transformer is normally energized by connecting the mains voltage to positions 7 and 8 of J2. The board power transformer also supplies the phase reference signal. Therefore, it is imperative that the board power be in-phase with the mains. The transformer with a center-tapped 115/230 Vac or 240/480 Vac primary winding is standard. The transformer output is rectified and filtered and used directly for gate drive +30 V power and is also applied to a +12 regulator for operation of the control electronics circuitry.
Rev. 5-2-96
-5-
Report R188
Table 2 below, illustrates pin designations. Positions of J2 Connections Supporting information 1, 2 Pin 1 to gate, pin 2 to +X SCR cathode 3, 6 No connections 4, 5 Pin 4 to gate, pin 5 to -X SCR cathode 7, 8 Board power supply Single phase 120/240 or 240/480 Vac and reference signal applied to the primary of transformer T1. input Frequency Selection Connector J3 A 3-position header, J3, is used to select between 50 Hz and 60 Hz operation. In 60 Hz operation R24 is connected in parallel with R12. In 50 Hz operation J3 removes R24 from the circuit in order to maintain TP4 at 5.0 Vdc. GATE DELAY ANGLE TRANSFER FUNCTION The gate delay angle in the open loop mode varies in negative proportion signal input voltage as shown on Fig. 1.
max.
DELAY ANGLE
min. 1
2
3
4
5
CONTROL VOLTAGE (Vdc)
Fig. 1. Gate Delay Angle Transfer Function The typical limits of the minimum and maximum delay angles, a min and a max, are 5° and 175°. Dynamic frequency response specifications are: 3 dB attenuation at 67 Hz, and 45° phase shift at 57 Hz. GATE DELAY COMMAND The gate delay command signal, SIG HI, may be a zero to 5.0 Vdc voltage signal or a current signal.
Rev. 5-2-96
-6-
Report R188
When the gate delay command is a current signal, R11 is selected to give a 5.0 Vdc level at the maximum delay command signal current. For typical 4-20 mAdc current signal input, R11 is select to 249 ohm. BIAS AND SPAN POTENTIOMETERS Two 5K potentiometers, designated R4 and R5, provide for delay angle bias and span ad ju s t m en t . Th es e p ot en tiom et er s a llow th e u s er t o "fin e t u n e" t h e board to m eet their sp ecific operationa l requ iremen ts. To adjus t th e BIAS potentiometer, R4, increase th e extern al comm an d s ign al until the inhibit LED, PD2, extinguishes. Then adjust R4 to obtain the d e s ir e d m i n im u m S C R ou t p u t . To adjust the SPAN potentiometer, R5, increase the external command signal to maximum. Then adjust R5 to obtain the desired maximum SCR output. It may be necessary to adjust both the BIAS and SPAN poten tiom eters a coup le of times to "fine tu n e" th e configur at ion.
GATE INHIBITS AND INHIBITS INDICATOR PD2
SCR gating is inhibited by making either or both of the inhibit signal points, d e s ign a t e d a s I 1 a n d I2 a n d a p p e a r in g a t p i n s 4 a n d 1 2 o f J 4 , a logic zero or by detecting a low sign al inpu t. In s t a n t a n e o u s In h i bi t
In th e case of th e ins tan tan eous inh ibit, I1, resistor RN4-7/ 8 on th e firin g boar d is pr ovided to pu ll th e I1 s ign al poin t low if th e conn ection b etween I1 an d +12 Vdc is open ed. Th is en su res th at SCR gatin g is in h ibited if plu g P1 is in advertently disconn ected. In ap plications wh ere th e in sta n tan eous gate inh ibit fu nction is n ot u tilized, a ju mp er wire is ins talled between pins 4 a nd 6 of P1 to hold I1 a t +12 Vdc when P1 is ins ta lled in J 1. S o ft I n h i b it
The soft inhibit signal, I2, is connected to +12 Vdc through pull-up resistor RN4-3/ 4 on th e firin g board. Wh en I2 is groun ded, th e gate delay an gle is ra m ped to th e m aximu m delay an gle before gating is inh ibited. Th is is termed th e "Soft-Stop" sh u tdown mode. Removin g the grou nd on I2 cau ses gating to be ena bled with th e delay angle set to th e maximu m limit. The delay an gle th en ram ps down to th e comm an ded an gle. Th is is termed the "Soft-Sta rt" tu rn -on m ode. Th e Soft-Stop an d Soft-Sta rt periods ar e determined b y timing resistors R14 a nd R13, an d capa citor C3.
Rev. 5-2-96
-7-
Report R188
Lo w S i g n a l In h i b i t
A 0.49 Vdc threshold signal and a comparator circuit provide the board inhibit function when command signal SIG HI is lower than 0.49 Vdc. To eliminate this feature, omit CR3. Inh ibit LED PD2
A red LED, PD2, will be on when an inh ibit s ign al is p resen t. POWER-ON RESET
A power-on reset circuit (Q1, Q2 and related components) is provided to inh ibit gating u n til the on -board p ower s u pply voltage h as estab lish ed. This circu it a lso inh ibits S CR gatin g du ring lin e volta ge dropou ts. GATE PULSE PR OFILE
The firing circuit uses a phase-locked loop (PLL) circuit locked to the single mains phase. The PLL oscillator output is counted down and decoded into two 0°-18 0° wide delayed logic sign als. Th e 0°-18 0° wide delayed logic signals are modulated by the 15,360 Hz PLL Voltage Controlled Oscillator (VCO) output signal. The modulated signals output to the darl intong transistor, U1, whose collectors are connected to +30 Vdc. The primaries of isolated pulse module transformers are connected to r esistors and capa citors to provide pu lse bu rsts of tran sformers. Th e tran sformers sa tu rate a fter app roxima tely 100µs bu t th is is of n o consequ ence becau se of the current limiting resistor in series with each of the transformer primary windings. Fig. 2 and Fig. 3 show the waveform of pulse transf ormer output into 1.0 ohm resistor load and the initial pulse detail respectively.
Fig. 2. 12 0° bur st of pulse outp u t (.5 A/ div)
Rev. 5-2-96
-8-
Report R188
Fig. 3. In itial pu lse deta il (.5 A/ div, 2 µs / div)
GATE PULSE AMPLIFIER
Circuitry shown in E211 consisting of transistor array U1, resistors R2 and R6, capacitor C4, and gate pulse isolation modules PM1 and PM2 amplify a n d s h a p e t h e t h y r is t o r ga t e c u r r e n t p u ls e s . E a c h p u ls e m o d u le c on s is t s o f a 2:1 ratio pulse transformer tested for 3500 Vrms isolation, two secondary diodes, noise suppression resistors across the primary and across the gate drive output, and a fuse in series with the output.
Rev. 5-2-96
-9-
Report R188
INSTALLATION INSTRUCTIONS
1.
Rem ove boa r d a n d con n e ct or p a ck a ge con t a in in g in terconn ectin g plu gs an d conta ct pin s from pa ckin g.
n e ces s a ry
2.
Th e F CRO 2 1 0 0 is p r o vid e d wit h AMP ™ Ma t e -N- Lok ™ c on n e ct or s o n the board with mating plugs and contact pins contained in the separate connector package.
3.
Th e c on t a c t p in s (AMP P# 3 5 0 5 3 6 -1 ) s u p p lie d fo r in t e r con n e ct io n wit h customer equipment are sized to be used with wire gauges from 16 to 20 AWG. It is recom m en ded th at AMP™ Ser vice Tool II (#2 90 04 -1) or a quality "U" Barrel crimping tool for the proper wire gauge range be u sed for mak ing these conn ections.
4.
Re fe r t o F IG 4 a t t h is t im e for a b r ie f d e s cr ip t io n s h o win g t h e lo ca t io n of th e prima ry con trol an d comma n d con nectors. A.
J 1 , 12 pos. connector, provides for customers SCR con trol sign als "Gate Delay Comm an d" an d "In h ibit". Th is con n ector also provides instant SCR gating by utilizing the jumper contained in th e conn ector packa ge (see J 4 note on Figu re 4). It is also possible to power the board through this connector with extern ally sou rced 24 Vac or 30 Vdc (see DWG. E211).
B.
J 2 , 8 pos. connector Pins 1-2 & 4-5 supply the actual gate sign als to drive th e cu st omer's SCR's. Pin s 7-8 of th is connector provides for input power to the onboard 24 Vac power supply.
5.
Th e FC RO 2 1 0 0 fir in g b oa r d m e a s u r e s 4 .5 "x 5 .3 " O .A. Th e 4 (# 8 S AE clearance) mounting holes provided measure 4.0" and 4.5" center to c en t e r . It is r e co m m e n d e d t h a t m o u n t i n g s p a c e r s a t le a s t 1 / 4 " lo n g be u tilized for pa n el m ou n ting th is d evice.
6.
Mou n t t h e b oa r d m e ch a n ica lly. It is r ecom m e n d ed th a t th e b oa r d b e physically mounted within 15" of the SCR's to be controlled to insure m in im al in du ctive n oise a n d p ositive gating of th e SCR's.
7.
Con n e ct ion * of t h e J 2 G a te/ Ca t h od e con t r ol lea d s s h ou ld b e m a de a t th is time. It is recomm ended th at the Gate an d Cathode leads from th e board to the SCR's be twisted pa irs with at least one tu rn per inch to m in imize in du ctive n oise an d possible false gat ing. Figur e 5 sh ows a typical DC converter conn ection diagram . Figur e 6 sh ows a typical AC contr oller con n ection d iagram .
Rev. 5-2-96
-10-
Report R188
*WARNING Check these connections very carefully before energizing the firing board. Im proper or misconn ections ca n s h ort circu it SCR line volta ge a n d r e s u l t in p r o d u c t a n d / o r c u s t o m e r e qu ip m e n t d a m a ge ! If yo u h a ve a n y questions concerning these connections, call 1-800-576-2114 (M-F, 7-4 Pacific) for assistance.
8.
Con n e ct ion o f t h e J 1 Com m a n d a n d C on t r ol s ign a ls a n d / or clos u r es sh ould be made at this time. See Figures 5 and 3 for typical Comm an d an d Cont rol connections . J 1 also provides ins tan t SCR gating by u tilizin g the ju mp er contained in th e conn ector p acka ge (see J 1 n ote on Figure 4).
9.
Con n e ct ion o f b oa r d e xc it a t ion volt a ge a t J 2 (s e e J 2 n o t e on F IG 4 ) should be made after careful examination of steps 7 & 8 above. NOTE: If the mains voltage is present, applying board power will gate SCR's after a sh ort ( ≈ 20 m sec.) delay. It is importan t tha t the single phase control voltage signal applied at Pins 7-8 be "In Phase" with the voltage a pp lied t o th e SCR's (see Note #1 , Figs. 5 & 6).
10.
E n e r gize t h e b o a r d p o w er s u p p ly. Ve r ify t h a t t h e gr e en "P WR ON" LE D indicator is on.
11.
Adjust R4 "BIAS" for 0% SCR ou tpu t when "SIG HI" = 0 VDC.
12.
Adjust R5 "SPAN" for 100 % SCR outp u t when "SIG HI" = 5.0 VDC
13.
O p er a t e yo u r c on t r o lle r a s d e s ir e d . You r in s t a l la t io n w a s s u c ce s s fu l !
Rev. 5-2-96
-11-
Report R188
TO SCR'S WARNING Check these connections very carefully before energizing the firing board. Improper or misconnections will result in product and/or customer equipment damage! If you have any questions concerning these connections, call 1-800-576-2114 (M-F, 7-4 Pacific) for assistance
+X
4.0" Center to Center
-X
G
HI LINE
G
4.5" Center to Center
120/240VAC FACTORY SLECTED
FCRO2100
J2 1
2
3
4
PM1
5
6
7
8
PM2
"PWR ON" GREEN LED
T1
"INHIBIT Red LED
U2
J1
R4
Control Signals are supplied here. (See Figures 1 and 2. Also see Dwg. #E211)
R5
J1 BIA
10 7
SPAN
4
1
COM
"COMMON"
FIGURE 4
Rev. 5-2-96
-12-
Report R188
AC CONTROLLER (TYPICAL)
G
LINE HIGH
L1
K +X SCR G
LOAD K -X SCR
LINE L2 LOW (COM)
CUSTOMER SUPPLIED EQUIPMENT
line high K
G
K
+X
2
120/240 VAC
G -X
1
5
4
7
8
J2 7
J1 FCRO2100 SINGLE PHASE SCR FIRING/REGULATOR BOARD (Ref. dwg. E211)
10 8 12 11
SPAN
BIAS
2
4
3
6
+5 SIG HI
2K (TYP)
CURRENT COMMAND
COM
I2
ON OFF
SOFT START/STOP
COM
I1 +12
NOTES 1. J2 #7 LINE HIGH, must be in phase with L1. 2. Adjust SPAN potentiometer R5 for 100% dc output with +5 V CURRENT COMMAND input. 3. Adjust BIAS pot. R4 for 0% dc output with 0.5 V command.
FIGURE 5 Rev. 5-2-96
-13-
Report R188
CONVERTER (TYPICAL)
G
LINE HIGH
L1
K +X SCR
LOAD
G
LINE LOW (COM)
L2 K -X SCR CUSTOMER SUPPLIED EQUIPMENT
line high K
G +X
K
120/240 VAC
G -X
2 1 5 4
7
8
J2 7
J1 FCRO2100 SINGLE PHASE SCR FIRING/REGULATOR BOARD (Ref. dwg. E211)
10 8
+5 SIG HI
SPAN
BIAS
2
I2
6
ON OFF
SOFT START/STOP
COM
I1
4
3
CURRENT COMMAND
COM
12 11
2K (TYP)
+12
NOTES 1. J2 #7 LINE HIGH, must be in phase with L1. 2. Adjust SPAN potentiometer R5 for 100% dc output with +5 V CURRENT COMMAND input. 3. Adjust BIAS pot. R4 for 0% dc output with 0 V command.
FIGURE 6
Rev. 5-2-96
-14-
Report R188
