SCR Power Controllers - Allied Instrument Service

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SCR PowerControllersInstructionManual

SCR POWER CONTROLLERSTABLE OF CONTENTSGeneral Descriptionand Specifications . . . . . . . . . . . . . . . . . 1Firing Modes. . . . . . . . . . . . . . . . . . . . . . . 2Installation and Wiring . . . . . . . . . . . . . . . 4Operation . . . . . . . . . . . . . . . . . . . . . . . . . 9Troubleshooting . . . . . . . . . . . . . . . . . . . . 15Parts Lists andOrdering Codes . . . . . . . . . . . . . . . . . . 18

OPERATING INSTRUCTIONSSeries 19 and 39 SCR Power ControllersSeries 91 and 93 SCR Power ControllersSection 1. General DescriptionIntroductionSCR Power Controllers are designed to regulate ac power to electricalheating processes, such as ovens, furnaces, heat sealers, etc. (Note:They are not designed to drive transformers, coils or other inductivetype loads.)The controller accepts an input signal, such as 4-20 mAdc from somesignal conditioning device, e.g., a temperature controller. For mostprocesses, the combination of a temperature controller and SCRpower controller will provide very accurate, automatic temperaturecontrol. For manual operation, a manual control option with a remotepotentiometer is available.General SpecificationsInputs:4-20 mAdc standard, or as ordered (seeserial number) minimum voltagerequirements 10 Vdc; all inputselectrically isolated via optical couplingSupply Voltage:110/120; 208/240; 440/480, 575/600Vac, or as ordered (Phase connectionnot critical on 3-phase units)50/60 HzFrequency:ooAmbient Temperature: 30 to 122 F for listed power ratingsCooling:ConvectionProtection:Sub-cycle, current-limiting fuse; transientvoltage suppresionLoadResistive, 1- or 3-phase - 3-wire Wye or DeltaAll specifications subject to change.1

Section 1. Firing ModesZero-Crossing ControlA zero-crossing switched (zer-switched or burst fired) SCRpower controller works by triggering at the moment when thevalue of the ac sine wave is at the baseline or “zero” voltagepoint (Figure 1.) This results in a “burst” of full line voltage withno RFI. SCR power controllers utilize a patented triggercircuit that turns on the SCRs as close as possible to the aczero voltage point. Proportioning action is obtained by varyingthe number of cycles on to the number of cycles off. Theoutput will vary from a few cycles on and a large number ofcycles off at low input, through halh the cycles on and half offat half input, to all cycles on at maximum input. This outputis integrated by the heaters which produce a smoothlyproportioning heat output that varies directly with the inputsignal.0.2 SecondTime BaseOffOnFigure 1. Time-proportioned, zero-cross burst.2

Phase-Angle ControlA phase-angle type SCR power controller works by delayingthe trigger pulse to some point in the half cycle of the acwave. This trigger point, from 0 to 180 degrees, is referred toas the phase angle (Figure 2). The SCR will turn on whentriggerred, and remain on for the rest of the half cycle.Increasing the control signal will cause the trigger pulse tooccur earlier in the half cycle, thus delivering a greater portionof the wave to the load.180 0 360 113 293 Phase angle 113 , 293 Power 25%Figure 2. Phase-angle changes and their effect on output power.Because it provides an extremely fast response, phase-anglecontrol should be used in low-mass element applications thatrequire high switching speeds, such as tungsten elements,quartz lamps, hot wires and other loads subject to high inrushcurrents. (Note: Some RFI can be generated from the phaseangle controller) SCR phase-angle power controllers are available with a soft-start timing option that provides a ramp topeak voltage, and are available with a voltage limit option that“clamps” output voltage to a level lower than the supplyvoltage.3

Section 3. Installation3.1 MountingMount the controller, with the heat sinks in a vertical position,ooin a reasonably cool location -- 50 C (122 F) maximum.Some space should be left above and below the unit to allowfor air circulation. If the controller must be placed in anoenvironment where the ambient temperature exceeds 50 Co(122 F), it will be necessary to derate the unit. If derating isnot possible, venting or an exhaust fan must be used to keepambient temperatures at an acceptable level. (See Figure 3for cooling calculations).Formula for minimum metal enclosure sizefor convection cooling.72 x AMPS x # of Controlled Legsoo122 F - Ambient F Min. ExposedSq. Ft.40 x AMPS x # of Controlled Legsoo50 C - Ambient C Min. ExposedSq. Ft.Formula for forced air cooling2.2 x AMPS x # of Controlled Legsoo50 C - Ambient C Min. CFM3.8 x AMPS x # of Controlled Legsoo122 F - Ambient F Min. CFMFigure 3. Calculations for determining cooling requirements4

3.2 WiringThe wiring components of SCR power controllers consists ofline voltage, heater, load, and signal input. Follow the wiringdiagrams on the following pages (Figures 4 and 5) and theterminal labels on the unit. On three-phase controllers (Series39), it is not necessary to connect the phases to anyparticular terminal. Because the controllers arephase-to-phase controllers, either Wye or Delta connectedloads may be used.CAUTIONOn Wye connected loads, do not connect thecenter terminal to the line or to the ground.Wire gauge for power and load connections will vary depending on the size of the load. Standard electrical codeprocedures should be followed. Do not exceed the voltageand ampere ratings indicated on the controller’s label. Beforeconnecting the controller to a heater, we recommend that theheater be connected directly to the power line to ensure thatthe current rating is correct and that no shorts exist.5

CAUTION:Possible Shock Hazard -- Exposed high voltage exists on heatsinks and other parts of these units.To prevent possible electrocution, thecontroller must be locked in a secureenclosure during operation. Solidstate devices do not completelyremove power from the load, even inthe OFF state. This leakage currentpresents a potential shock hazard atall unit and load terminals. All powermust be completely off before servicing.Only qualified personnel should beallowed access.Possible Fire Hazard --Because SCR power controls andassociated equipment are not fail-safedevices, an approved temperatureand/or pressure safety control shouldbe used to ensure safe operation.6

3.21 Zero-CrossZero-cross mode power controllers may only be used withconstant resistance heating elements, such as Nichrome. Theyare NOT intended for high-inrush loads. Depending on the typeof element used, you can oversize the load controller.Figure 4b. Wiring scheme for Series 39Z.Figure 4a. Wiring scheme for Series 19Z.3.22 Phase-AnglePhase-Angle fired power controllers may be used with high-inrushloads if the "soft-start" option is installed.Figure 5b. Wiring scheme for Series 39P.Figure 5a. Wiring scheme for Series 19P.7

3.23 Fuses and Safety Warnings2Only I fuses should be used for protecting the powercontroller’s SCRs. These fuses are especially designed toprotect the solid state devices under short-circuit conditions;other fuses may not act quickly enough. If it becomesnecessary to replace a fuse, use only a Chase-ShawmutForm 101 or semiconductor fuse, or equivalent.IMPORTANT SAFETY WARNINGS - READ BEFOREOPERATING CONTROLLER.Standard fuses or a circuit breaker should be used onall power lines for safety and to meet electrical coderequirements. The supplied fuses are for protecting theSCRs only and are not acceptable as power line fuses.SCR power controllers do not satisfy electrical codedisconnect requirements in the non-conducting or OFFstate. Because they are semiconductor devices, thehave a leakage current in the OFF state on the order of10mA at rated line voltage. Therefore, the controllershould be connected to a circuit breaker or disconnectswitch.SCRs can fail in a “shorted-closed” mode, resulting infull application of power. Use of a seperate, thermallyprotected safety contactor is strongly recommended.8

Section 4. OperationSeries19/394.1 Series 19Z/39ZThe Series 19Z and 39Z power controllers are designed tocontrol ac power to electrical heating processes, such asovens, furnaces, heat sealers, etc. (Note: They are NOTintended to drive transformer coupled or inductive loads.)The controllers consist of power semiconductors (SCRs),properly sized heat sinks, and trigger circuitry. Thesecontrollers accept a control signal (e.g., 4-20 mAdc) from asignal conditioning device, such as a temperature controller.The “Z” suffix designates the controller as operating in theZero Cross, Zero Voltage Switched, or Zero Burst firing mode.A patented trigger circuit turns on the SCRs as close aspossible to the point at which the ac sine wave crossesthrough zero. In effect, this turns the line voltage on and offin full cycles. With an input of 4-20 mA , the output will beFULL OFF below 4 mA and FULL ON at 20 mA.Proportioning action is obtained by varying the number ofcycles ON to the number of cycles OFF. The resulting outputpower is integrated by the heaters to produce smoothlyproportional heating that varies directly with the input signal.9

4.2 Series 19P/39PThe Series 19P and 39P power controllers are designed tocontrol ac power to electrical heating processes, such asovens, furnaces, heat sealers, etc. (Note: They are NOTdesigned to drive transformer-coupled loads.) The controllersconsist of power semiconductors (SCRs), properly sized heatsinks, and trigger circuitry.These controllers accept a control signal (e.g., 4-20 mAdc)from a signal conditioning device, such as a temperaturecontroller.The “P” Suffix designates the controller as operating in thePhase-Angle firing mode. Providing full proportional control,SCRs are turned ON during each 1/2 cycle at apoint (phaseangle) of the ac sine wave, remaining ON for the rest of the1/2 cycle. By varying the phase angle setting, the amount ofvoltage reaching the load may be adjusted. The outputvoltage is proportional to the input signal. At 4 mA input, novoltage will be applied to the load; at 20 mA input, theoutput voltage will almost equal the line voltage.10

4.3 Voltage Limit Option (Phase-Angle Fired Units Only)The output voltage of the controller can be limited byadjusting the trimmer on the printed circuit board. Turningthe adjustment clockwise will increase the out put voltagelimit. This control will operate over a range of about 20% tofull output. Ordinarily, this adjustment is used to protectheaters that cannot operate on full line voltage, or to limit themaximum heating of a process.4.4 Soft Start Option (Phase-Angle Fired Units Only)The soft start circuitry is used to slowly turn on the voltagefrom the controller to the load. It is used to protect thecontroller when it is operating into loads having high-current,turn-on characteristics, e.g., quartz or tungsten heaters. Theoutput voltage will rise from zero to full output over varioustimes, depending on the time option selected.The soft start circuit presents an initial high impedance whichis inserted between the signal source and the controller. Thisimpedance decreases in value with time. Soft start actioncan be seen as the input signal slowly changes from 4-20 mAwhen full output is required.11

4.5 Manual OptionA module board is added to the standard controller whichconverts a variable resistance potentiometer to a 0-20 mAsignal. This signal is then applied to the input of the standardtrigger board and operates the controller in the standardmanner (Figure 6). The input potentiometer can be anythree-lead pot from 100 to 1000 ohms. The pot suppliedwith the manual option is 500 ohms. This pot has a 0-10scale and knob. There will be no output at the “0” settingand full output at the “10” setting.120/240/480/600Vac –RED0 -20 dcBLACKTRIGGERBOARD(1000 Ω MAX)Figure 6. Wiring diagram for manual control (Option module M required).12

4.6 Thermostat OptionThe module will also operate from a standard 135-ohmthermostat. Connect the three output wires to the controlleras shown on the drawing (Figure 7) and on the terminal strip.If the output terminals on the thermostat are not marked inthe same fashion, connect the center wire to the CT point onthe terminal strip, connect the other two wires to the CWand CCW points. The controller should then provide anoutput as the thermostat setpoint is increased. If the reverseaction occurs, interchange the CW and the CCW wires.120/240/480/600 Vac Cold–0 -20 dcTRIGGERBOARD(1000 Ω MAX)HotFigure 7. Wiring diagram for thermostatic control (Option H required).13

4.7 MaintenanceSCR power controllers require little, if any, maintenance.However, as with all products exposed to industrialenvironments, they should be cleaned periodically to preventcorrosion and to remove any surface dust, dirt, and oil. Wealso recommend inspecting, and re-tightening if necessary, allelectrical and mechanical connections (lugs, terminals, fuses,buss bars, etc.)WARNING: Before Touching Controller Parts,Make Sure Power Is Disconnected.14

4.8 TroubleshootingIf the power controller is not functioning properly, refer tothese troubleshooting procedures.Symptom: No heat or reduced heat output.Possible Cause(s)Action1. Loss of line voltage.Check powersupply.2. Line fuse or controller fuse blown.Check heater forshort circuit andcorrect problem.3. No input signal.Check signalconditioner.4. Malfunction on trigger board.Consult factory.5. Open SCRConsult factory.15

Troubleshooting FlowchartSymptom: Heaters will not turn off.YesLine andload connectionsreversedReconnect properlyNoDisconnectinputsignal wiresYesSignal sourcedefectiveOutput off?NoTurn off powerand disconnectgate wiresTurn powerback onHeaterampspresent?YesShorted SCRNoTrigger boardmalfunction16

Input Signal Problems: In normal operation, the green LED willilluminate if an input signal of proper polarity is present. Itsbrightness indicates signal level.Symptom: Red or amber input LED is litRed: Polarity of input signal is reversed (Change polarity).Amber: AC on input signal (Check signal source).Output Signal Problems: In normal operation, the amber LEDwill illuminate if an output voltage is present. Its brightnessindicates output level.Symptom: Output LED lit with no input.YesLine and loadconnections reversed?Reconnect properlyNoHeaterampspresent?YesTurn off powerand disconnectgate wiresNoHeaterampspresent?Heater circuit openYesShorted SCRNoTrigger board malfunctionSymptom: Output LED is red or green with input.Check and correct the following conditions:1.2.3.4.Gate wire unplugged or brokenOpen SCRTrigger board malfunctionBalance pot misadjusted (Phase-angle controllers only)17

Section 5. Parts ListsSeries 19/39MODEL #FUSES(Voltage / Load)SCR MODULE(19P, 19Z, 39Z)SCR MODULE(39P)24040/12040A050F040IRKT 57-10IRKH 72-1024060/12060A050F060IRKT 57-10IRKH 72-1024080/12080A050URG080XAA IRKT 92-10IRKH 92-1048040A050F040IRKT 57-10IRKH 72-1048060A070F060IRKT 57-10IRKH 72-1048080A070URGC080WA IRKT 92-10IRKH 92-1018

Section 6. Model IdentificationOrdering Codes: Series 19/39Athena Model No:9PHASECode1 Single3 ThreeSWITCHING MODECode*P Phase angle firingZ Zero switchedLOAD CURRENT(AMPS)Code040 40 Amps060 60 Amps080 80 AmpsOPTIONSConsult Factory00 None0A FusesSOFT START / VOLTAGELIMIT P SERIES ONLYCode (Soft Start Timing0 NoneA 9 SecondsB 15 Seconds (Standard)C 30 SecondsD 60 Seconds*Specify voltage codeAC LINE VOLTAGE (50/60 HZ)24 02440/480 48110/120 12575/600 60208/240 24INPUTSCodeA 4-20 mAC 10-50 mAD Other mA or Voltage (Specify)P Pulsed dc (Z series only)Ordering Example:Model 39Z-24-040-P-0-00Three phase, zero switched,208/240 Vac line voltage, 40 amps,pulsed dc input, no options, no timing.(Use “0” for all spaces not used.)ACCESSORIESManual Station with Remote Potentiometer(Requires Input “A” on SCR unit)90M001-120 (120 Vac supply voltage)90M001-240 (240 Vac supply voltage)90M001-480 (480 Vac supply voltage)90M001-600 (600 Vac supply voltage)19

Section 7. DimensionsSeries D(in)DimensionsHxWxD(in)DimensionsHxWxD(in)7 x 4.75 x 47 x 4.75 x 47 x 9.62 x 47 x 14.37 x 4Notes: If fuses are added to unit, add 3 1/4". Overall depth is 4".WarrantyThis equipment is warranteed to be free from defects ofmaterial and workmanship. It is sold subject to our mutualagreement that the liability of the manufacturer is limited toreplacement and/or repair at its factory, provided theequipment is returned, transportation prepaid, within one (1)year of purchase.The purchaser agrees that the manufacturer shall assume noliability for consequential damages resulting from its use orfrom packaging of shipments returned to the factory.Components that wear or are damaged by misuse are notwarranted. These include contact points, fuses and triacs.Units that have been customer modified are not warranted.Specifications are subject to change without notice.20

900M019U00 REVISION “B”11-15-2004

Series 19 and 39 SCR Power Controllers Series 91 and 93 SCR Power Controllers Section 1. General Description Introduction SCRPower Controllers are designed to regulate ac power to electrical heating processes, such as ovens, furnaces, heat sealers, etc. (Note: They are not designed to drive transformers, coils or other inductive-type loads.)

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