853 Product Manual

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 shown and explained below.

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 be used to alert against unsafe practices. (Color: red)

Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. It may also be used to alert against unsafe practices or cause product failure. (Color: orange)

Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. (Color: yellow)

DANGER

WARNING

Caution

Table of Contents Chapter 1...............................................................................1-1

Product Description......................................................................... 1-1 Phase-Angle Control..................................................................... 1-2 Zero-Crossover Control ................................................................ 1-4 Standard Features ........................................................................ 1-7 Optional Features ......................................................................... 1-8 Technical Specifications ............................................................... 1-8 Part Number ................................................................................. 1-9

Chapter 2...............................................................................2-1

Hardware ........................................................................................ 2-1 Installation..................................................................................... 2-1 Enclosure...................................................................................... 2-1 Enclosure Temperature ................................................................ 2-1 Vibration........................................................................................ 2-2 Mounting ....................................................................................... 2-2 Disconnect Means ........................................................................ 2-2 Wiring............................................................................................ 2-2 Remote Feedback Wiring ............................................................. 2-4 Control Connections ..................................................................... 2-5 Digital Inputs ................................................................................. 2-6 Digital Outputs .............................................................................. 2-7 Analog Inputs................................................................................ 2-8 Analog Outputs ............................................................................. 2-9 Remote Feedback....................................................................... 2-10 Over-temperature Sensing.......................................................... 2-10

Chapter 3...............................................................................3-1

Configuration................................................................................... 3-1 Startup .......................................................................................... 3-1 Configuration Tool Installation ...................................................... 3-2 Running the Configuration Tool .................................................... 3-2 Configuration Tool Menu and Task Bar Descriptions.................... 3-5 Off-line Programming.................................................................. 3-10 On-line Programming.................................................................. 3-18 On-line Monitor ........................................................................... 3-23 Flash Programming..................................................................... 3-29

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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

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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

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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

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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

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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 advanced, 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 determine 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


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


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


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 Zero-Crossover 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


Standard Features

The 850 Series digital product family offers the following features:

• Flexibility. Configurable operating modes, ratings, limits, external inputs, and 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


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

40A - 1,800A for 10 msec

90/175A - 8,000A for 10 msec

Current Surge Rating

350A - 14,500A for 10 msec

40A - 16,200 A2sec

90/175A - 320,000 A2sec

Fuse I2t Rating

350A - 1,051,000 A2sec

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


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 hazard 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 nuisance 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


Table 2-1 Wiring Information

Power Lugs Ground Lug Feedback Terminal Unit size

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*] AWG 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

1/2 inch hex 6-3/0 [2*] AWG ¼ inch hex 8-24 [14*] AWG Slotted

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 24-37.5V.

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


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 two-position 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


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

Terminal description Standard operation (see Note below)

1 External Fault #1 power

2 External Fault #1 input

Shorting 1 to 2 provides an external fault input. Open indicates no remote fault.







7 Remote/local power

8 Remote/local input

Shorting 7 to 8 puts the unit into remote mode. Open defaults to local mode.

9 Enable power

10 Enable input

Shorting 9 to 10 enables the unit. Open inhibits operation.

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.

Note: The external faults are programmed by default as normally open (NO). Refer to the Settings Chapter (Configuration Word) for more information on contacts.

2-6


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


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 by 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 Standard operation

1 Analog #1 supply

2 Analog #1input

3 Analog #1 ground

Connecting a 10k potentiometer with JP2 OFF provides a local analog control.

4 Analog #2 supply

5 Analog #2input

6 Analog #2 ground

Connecting a 10k potentiometer with JP4 OFF provides a local analog control.

7 Analog #1 output

8 Analog #1ground

Provides a configurable analog output of 0-5 volts (JP3 on) or a mA output (JP3 off).

9 Analog #2 output

10 Analog #2ground

Provides a configurable analog output of 0-5 volts (JP5 on) or a mA output (JP5 off).

2-8


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

2-9


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


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 double-click 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

3-2

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.

3-3


3-4


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.

The ‘Save Calibration’ menu choice is visible only under certain conditions, and should be used only by authorized service personnel.

File Menu including the ‘Restore Calibration’ menu choice.

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 <filename>.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


Com Setup Menu

Com Options Description

Com1

Com2

Com3

Com4

The Com Setup menu is used to select the serial port on the host computer available for use with the 853.

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.

3-6


Help Menu

Help Options Description

Manual

About

Open (in a separate browser window) this product manual in pdf format.

Display the version number of the Configuration Tool software.

3-7


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


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.

3-9


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 <filename>.csv .

The settings currently in the Configuration Tool are written to the specified file on the host computer.

3-10


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.

3-11


Ratings and Limits Tab

The Ratings and Limits Tab holds the settings for

Voltage Input Rating

*Voltage Output Rating

Voltage Output Limit

*Voltage Output PT Secondary

Power Output Rating - Read Only

Power Output Limit

KVA Input Rating – Read Only

Current Input Rating

Current Output Rating

Current Input Limit

Current Output Limit

Frequency Rating

Ramp Up Time

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

3-12


White fields indicate Read/Write

Cyan fields indicate Read Only information

3-13


Control Configuration Tab

The Control Configuration Tab holds settings for

Control Strategy

Load Type

* Magnetizing Sequence

* Repetitive Pulse 1 and 2

Primary Analog Output Selection

Secondary Analog Output Selection

Secondary Analog Setpoint Selection

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



3-14


Fault Setup Tab

The Fault Setup Tab holds the settings for:

Voltage Input High

Voltage Input Low

Voltage Input Phase Unbalance

Current Input High

Current Input High Retries

Current Input High Retry Time

Ground Fault Current

Ground Fault Time

Current Input Overload

Current Input Overload Time

Current Input Threshold Load Failure

Figure 3-6 Fault Setup Tab



3-15


PID Setup Tab

The PID Setup Tab holds the PID settings for

Power Output Voltage Output Current Output

Proportional Gain

Integral Gain

Derivative Gain

Proportional Gain

Integral Gain

Derivative Gain

Proportional Gain

Integral Gain

Derivative Gain

Figure 3-7 PID Setup Tab



3-16


Network Tab

The Network Tab holds settings for

Network Type

Network Baud Rate

Network Address

MODBUS Address

MODBUS Baud Rate

Network Loss Option

Software Version

Serial Number

Figure 3-8 Network Tab



3-17


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].

3-18


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 on-line changes to the settings.

Figure 3-9 Configuration Tool On-Line

3-19


Status indicators are described in the table below:

Table 3-1 Status Lamp Description

Lamp Color Description

Enable input

Green

Red

The 853 DSPC is Enabled

The 853 DSPC in Inhibited

Output Status Green

Red

Output is ON

Output is OFF

Remote/Local input Green

Red

Local control is active

Remote (network) control is active

On/Off button Toggles the 853 output

Alert indicator Flashing Yellow

Flashing Red

Indicates an Alarm Condition (described in the message box below the lamps)

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:

3-20


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.

3-21


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.

3-22


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 Monitor menu item, or click [Monitor] on the Taskbar.

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.

3-23


Summary Tab

The Monitor Summary Tab includes the following data

Duty Cycle Setpoint

Duty Cycle Output

Power Output Setpoint

Power Output

Voltage Input

Voltage Output Setpoint

Voltage Output

Current Input

Current Output Setpoint

Current Output

Analog Input

KVA Input

Power Factor

Frequency Actual

The Duty Cycle Setpoint can be written ONLY under Open Loop regulation.

Figure 3-10 Monitor Summary Tab

3-24




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.

3-25


Control Tab

The Monitor Control Tab includes the following data for monitor only

Voltage L1-L2 Input Actual



Voltage Input Actual

Current L1 Input Actual



Current Input Actual

Local Primary Analog Setpoint

Voltage X1-X2 Output Actual



Voltage Output Actual

Current X1 Output Actual



Current Output Actual

Local Secondary Analog Setpoint

Figure 3-11 Monitor Control Tab


3-26


Status Tab

The Monitor Status Tab includes the following data

Monitor Status Word Status Word Bit Number

At Setpoint

Phase Rotation

External Input #1

External Input #2

External Input #3

Regulation Limit

Calibration/Programming Jumper

Bit 9

Bit 10

Bit 11

Bit 12

Bit 13

Bits 6, 7, and 8

Bit 15

Figure 3-12 Monitor Status Tab

Green field indicates on status

3-27


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.

3-28


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

3-29


Loss of Communication

Momentary loss of communication between the Configuration Tool and 853 DSPC results in the most-recently-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 network interface. Unit calibration also validates the analog signal levels. The feedback signal levels correlate to the internal gain capability of 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 February 2004

Voltage Calibration

The [Cal Enable] button must be clicked to enable voltage calibration.

Voltage X1-X2 Output Zero and Span



Voltage L1-L2 Input 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 output must be off to zero the output voltages.

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.

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 4-2 Voltage Calibration



4-2

February 2004 Calibration

Current Calibration

The [Cal Enable] button must be clicked to enable current calibration.

Current L1 Input Zero and Span



Current X1 Output 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.



Figure 4-3 Current Calibration



4-3


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.


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


Figure 4-4 Analog Calibration



4-4


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 unit 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 The nearest standard value 1% resistor is 249Ω. The power in the resistor at rated current is (10mA)2 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


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


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


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


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


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


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


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 potentiometer, 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


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


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


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


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 zero-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.


Read/Write Condition: All Default: Low Byte 50 High Byte 30

100 % Min: 10 Max: 90

The Repetitive Pulse Calibration is divided into two separate bytes, allowing the first positive zero crossing pulse to be set differently (Zero-Crossover control only).

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 and heavier load currents. If possible, transformers should not be operated at higher than their design voltage ratings.

4-16


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 Starting point cycle 1 0 2 50 3 25 4 75 5 13 6 63 7 38 8 88 9 6 10 56 11 31 12 81 13 19 14 69 15 44 16 94 17 3 18 53 19 28 20 78 21 16 22 66 23 41 24 91 25 9 26 59 27 34 28 84 29 22 30 72 31 47 32 97 33 2 34 52 35 27 36 77 37 14 38 64

4-17


39 39 40 89 41 8 42 58 43 33 44 83 45 20 46 70 47 45 48 95 49 5 50 55 51 30 52 80 53 17 54 67 55 42 56 92 57 11 58 61 59 36 60 86 61 23 62 73 63 48 64 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

Output

1 Voltage Output (V) Voltage Output Actual in volts

Amps

Output

2 Current Output (A) Current Output Actual in amps

Kilowatts

Output

3 Power Output (KW) Power Output in kilowatts

Setpoint

Volts, Amps, or Kilowatts

4 Regulation Mode Setpoint (unit)

Voltage Setpoint, Current Setpoint or Power Setpoint in appropriate units

Volts

% of Rated Output

5 Voltage Output (%) Voltage Output Actual as % of rated voltage

Amps

% of Rated Output

6 Current Output (%) Current Output Actual as % of rated current

Kilowatts

% of Rated Output

7 Power Output (%) Power Output as % of rated power

Setpoint

% of Rated Volts, Amps, or

Kilowatts

8 Regulation Mode Setpoint (%)

Voltage Setpoint, Current Setpoint or Power Setpoint as % of appropriate rating

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 Condition Description

Remote Status On

Off

The Remote/Local input is in the Remote state.

The Remote/Local input is in the Local state.

Analog Status On

Off

The Local mode is set to Analog, and the Remote/Local input is in the Local state.

The Local mode is set to Digital, or the Remote/Local input is in the Remote state.

Digital Status On

Off

The Local mode is set to Digital, and the Remote/Local input is in the Local state.

The Local mode is set to Analog, or the Remote/Local input is in the Remote state.

Enable Status On

Off

The Enable/Inhibit input is in the Enable state.

The Enable/Inhibit input is in the Inhibit state.

On Status On

Off

The DSPC output is active.

The DSPC output is off.

Alert Status On

Off

Either a fault or alarm is present.

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


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



Power Output (KW) Display the Regulation Mode Setpoint in units; Increment/Decrement the Regulation Mode Setpoint



Regulation Mode Setpoint (units)

Increment/Decrement the Regulation Mode Setpoint



Voltage Output (%) Display the Regulation Mode Setpoint as % of rated; Increment/Decrement the Regulation Mode Setpoint



Current Output (%) Display the Regulation Mode Setpoint as % of rated; Increment/Decrement the Regulation Mode Setpoint



Power Output (%) Display the Regulation Mode Setpoint as % of rated; Increment/Decrement the Regulation Mode Setpoint



Regulation Mode Setpoint (%)

Increment/Decrement the Regulation Mode Setpoint



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


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



Current Output (A) Display the Regulation Mode Setpoint in units



Power Output (KW) Display the Regulation Mode Setpoint in units




Display the Regulation Mode Setpoint in units



Voltage Output (%) Display the Regulation Mode Setpoint as % of rated



Current Output (%) Display the Regulation Mode Setpoint as % of rated



Power Output (%) Display the Regulation Mode Setpoint as % of rated




Display the Regulation Mode Setpoint as % of rated



5-5


If the unit is under Remote Control, the pushbuttons are inoperable, as summarized in the following table.

Table 5-5 Pushbutton function in Normal mode, Remote Control


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


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


No action No action No action

5-6


Display Select Mode Operation

To enter Display Select mode, press the [SEL] pushbutton. Entry into the Display Select mode is indicated by the characters ‘SEL’ in the four-digit numeric display. In this mode, the [Up Arrow] and [Down 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


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


Power Output (KW) Increment/Decrement the display selection



Increment/Decrement the display selection


Voltage Output (%) Increment/Decrement the display selection


Current Output (%) Increment/Decrement the display selection


Power Output (%) Increment/Decrement the display selection





5-7


Table 5-7 Pushbutton function in Display Select Mode, Remote Control


Voltage Output (V) Increment/Decrement the display selection

Exit Display Select mode Exit Display Select mode

Current Output (A) Increment/Decrement the display selection


Power Output (KW) Increment/Decrement the display selection





Voltage Output (%) Increment/Decrement the display selection


Current Output (%) Increment/Decrement the display selection


Power Output (%) Increment/Decrement the display selection





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 optional 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).

7,8 Error Check 16-bit CRC, low byte first

6-3


Table 6-3 MODBUS RTU Read Response (from 853)


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.


Table 6-4 MODBUS RTU Write Response (from 853)



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).


6-4


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)



2 Function MODBUS function code plus exception indication (80 hex).

3 Exception code MODBUS exception code.


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


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)


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


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)


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


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

Voltage Input Rating

Read/Write Condition: Off Default: 480.0 V

1 Vrms Min: 0.0 Max: 600.0

The input rating of the voltage supplied to the 853.

Voltage Input High Fault

Read/Write Condition: All Default: 576.0 V

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.

Voltage Input Low Alarm


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.

Voltage Input Phase Unbalance Alarm

Read/Write Condition: All Default: 5.0 %

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.


Read only 5 Vrms Vinrms for Phase L1 to Phase L2.


Read/Write Condition: All Default: Factory

6 Bits Min: 2000 Max: 16000

Digital span adjustment of the voltage L1-L2 input signal. Calibration is described in the Calibration Chapter.

7-1

Settings February 2004



Read only 7 Vrms Vinrms for Phase L2 to Phase L3.



8 Bits Min: 2000 Max: 16000



Read only 9 Vrms Vinrms for Phases L3 to L1 calculated using L1-L2

and L2-L3 voltages measured.



10 Bits Min: 2000 Max: 16000


Voltage Input Actual

Read only 11 Vrms Average of Vinrms for Phases L1-L2, L2-L3 and

L3-L1.

Frequency Rating

Read/Write Condition: Off Default: 60.0 Hz

12 Hertz Min: 50.0 Max: 60.0

The input line frequency rating.

Frequency Actual

Read only 13 Hertz Measured input line frequency.

Voltage Output Rating


14 Vrms Min: 0.0 Max: 2000.0

The output rating of the voltage being controlled by the 853.

Voltage Output PT Secondary


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.

Voltage Output Limit


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.

Voltage Output Setpoint

Read/Write Condition: Remote Default: 480.0 V

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.

7-2

February 2004 Settings


Voltage Output Proportional Gain


18 % Min: 0.0 Max: 100.0

Voltage output control proportional gain.

Voltage Output Integral Gain


19 % Min: 0.0 Max: 100.0

Voltage output control integral gain.

Voltage Output Derivative Gain


20 % Min: 0.0 Max: 100.0

Voltage output control derivative gain.


Read only 21 Vrms Voutrms for Phase X1 to Phase X2.

Voltage X1-X2 Output Zero

Read/Write Condition: Off Default: Factory

22 Bits Min: 0 Max: 100

Digital zero adjustment of the voltage X1-X2 output signal. Calibration is described in the Calibration Chapter.

Voltage X1-X2 Output Span

Read/Write Condition: On Default: Factory

23 Bits Min: 2000 Max: 16000

Digital span adjustment of the voltage X1-X2 output signal. Calibration is described in the Calibration Chapter.


Read only 24 Vrms Voutrms for Phase X2-X3.







26 Bits Min: 2000 Max: 16000



Read only 27 Vrms Voutrms for Phases X3-X1 calculated using Phase

X1-X2 and Phase X2-X3 measurements.





7-3





29 Bits Min: 2000 Max: 16000


Voltage Output Actual

Read only 30 Vrms Average of Voutrms for Phases X1-X2, X2-X3,

and X3-X1.

Current Input Rating

Read/Write Condition: Off Default: 350.0 A

31 Irms Min: 0.0 Max: 1500.0

The input rating of the current to the 853.

Current Input Limit

Read/Write Condition: All Default: 350.0 A

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.

Current Input High Fault


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.

Current Input High Fault Retry Number

Read/Write Condition: All Default: 0

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.

Current Input High Fault Retry Time

Read/Write Condition: All Default: 10.0 Sec

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.

Current Input Overload Fault


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

Current Input Overload Time



The time limit on the current input overload level before a fault occurs. Fault operation is described in the Troubleshooting Chapter.

7-4



Ground Fault Current


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.

Ground Fault Time



The amount of time required to generate a ground fault. Fault operation is described in the Troubleshooting Chapter.


Read only 41 Irms Iinrms for Phase L1.

Current L1 Input Zero



Digital zero adjustment of the current L1 input signal. Calibration is described in the Calibration Chapter.

Current L1 Input Span


43 Bits Min: 2000 Max: 16000

Digital span adjustment of the current L1 input signal. Calibration is described in the Calibration Chapter.









46 Bits Min: 2000 Max: 16000










49 Bits Min: 2000 Max: 16000


7-5



Current Input Actual

Read only 50 Irms Average of Iinrms for Phase L1, L2, and L3.

Current Input Threshold Load Failure

Read/Write Condition: On Default: 10.0 A

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.

Current Output Rating

Read/Write Condition: Off Default: 350.0 A

52 Irms Min: 0.0 Max: 3000.0

The output rating of the current being controlled by the 853.

Current Output Limit


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.

Current Output Setpoint

Read/Write Condition: Remote Default: 350.0 A

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.

Current Output Proportional Gain


55 % Min: 0.0 Max: 100.0

Current output control proportional gain.

Current Output Integral Gain


56 % Min: 0.0 Max: 100.0

Current output control integral gain.

Current Output Derivative Gain


57 % Min: 0.0 Max: 100.0

Current output control derivative gain.


Read only 58 Irms Ioutrms for Phase X1 measured.

Current X1 Output Zero



Digital zero adjustment of the Current X1 Output Actual signal. Calibration is described in the Calibration Chapter.

7-6



Current X1 Output Span


60 Bits Min: 2000 Max: 16000

Digital span adjustment of the Current X1 Output Actual signal. Calibration is described in the Calibration Chapter.


Read only 61 Irms Ioutrms for Phase X2 calculated.


Read only 62 Irms Ioutrms for Phase X3 calculated.

Current Output Actual

Read only 63 Irms Average of Ioutrms for Phases X1, X2, and X3.

KVA Input Rating

Read only

64 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.

(Voltage Input Rating * SQRT(3) * Current Input Rating)/1000

KVA Input

Read only 65 KVA

The KVA input is calculated by the following equation.

(Voltage Input Actual * SQRT(3) * Current Input Actual.) /1000

Power Output Rating

Read only 66 KW

The output rating of the Power being controlled by the 853. It is calculated by the following equation.

(Voltage Output Rating * SQRT(3) * Current Output Rating)/1000

Power Output Limit

Read/Write Condition: All Default: 291.0 KW

67 KW Min: 0.0 Max: 1125.0

The maximum power the power output PID control will limit to. It is limited to 125% of the Power Output Rating.

Power Output Setpoint

Read/Write Condition: Remote Default: 291.0 KW

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.

Power Output Proportional Gain


69 % Min: 0.0 Max: 100.0

Power output control proportional gain.

7-7



Power Output Integral Gain


70 % Min: 0.0 Max: 100.0

Power output control integral gain.

Power Output Derivative Gain


71 % Min: 0.0 Max: 100.0

Power output control derivative gain.

Power Output

Read only 72 KW (Vin * Iin)rms , calculated by using the instantaneous product of the voltage and current samples.

Power Factor

Read only 73 Power Output / KVA Input.

Duty Cycle Output

Read only 74 % On time / Off time * 100.0

Duty Cycle Setpoint

Read/Write Condition: Remote Default: 100.0 %

75 % Min: 0.0 Max: 100.0

The setpoint for open loop control.

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:

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 (%)

Local Digital Control Setpoint

Read only

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.

Local Primary Analog Setpoint

Read only

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



Primary Analog Setpoint Zero


79 Bits Min: -100 Max: 500

Digital zero adjustment of the Local Primary Analog Setpoint input signal. Calibration is described in the Calibration Chapter.

Primary Analog Setpoint Span


80 Bits Min: 2000 Max: 16000

Digital span adjustment of the Local Primary Analog Setpoint input signal. Calibration is described in the Calibration Chapter.

Local Secondary Analog Setpoint Selection

Read/Write Condition: All Default: 1 81

Selection Min: 1 Max: 3

Defines the operation of the Local Secondary Analog Setpoint during local analog control. The selection list is:

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.

Secondary Analog Setpoint Zero


83 Bits Min: -100 Max: 500

Digital zero adjustment of the Local Secondary Analog Setpoint input signal. Calibration is described in the Calibration Chapter.

Secondary Analog Setpoint Span


84 Bits Min: 2000 Max: 16000

Digital span adjustment of the Local Secondary Analog Setpoint input signal. Calibration is described in the Calibration Chapter.

7-9



Analog Output #1 Selection



Defines the operation of the Analog Output #1. The selection list is:

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

Analog Output #1

Read only 86 % An analog output as defined by Analog Output

#1 Selection in percent.

Analog Output #1 Bias


87 Bits Min: -100 Max: 500

Digital zero adjustment of the Analog Output #1 signal. Calibration is described in the Calibration Chapter.

Analog Output #1 Span


88 Bits Min: 2000 Max: 6000

Digital span adjustment of the Analog Output #1 signal. Calibration is described in the Calibration Chapter.

Analog Output #2 Selection



Defines the operation of the Analog Output #2. The selection list is:

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

Analog Output #2

Read only 90 % An analog output as defined by Analog Output

#2 Selection in percent.

Analog Output #2 Bias


91 Bits Min: -100 Max: 500

Digital zero adjustment of the Analog Output #2 signal. Calibration is described in the Calibration Chapter.

Analog Output #2 Span


92 Bits Min: 2000 Max: 6000

Digital span adjustment of the Analog Output #2 signal. Calibration is described in the Calibration Chapter.

7-10



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

93 Bits

The control word is the digital inputs to the 853.

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

7-11



Status Word

Read only

94 Bits

The status word is the digital outputs from the 853.

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

7-12



Ramp Up Time

Read/Write Condition: All Default: 10 Sec

95 Seconds Min: 0 Max: 360

The amount of time for the setpoint to go from 0 to100%.

Ramp Down Time

Read/Write Condition: All Default: 10 Sec

96 Seconds Min: 0 Max: 360

The amount of time for the setpoint to go from 100 to 0%.

Configuration Word

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

97 Bits

The configuration word configures the digital inputs to the 853.

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

7-13



Control Strategy Selection

Read/Write Condition: Off Default: 1


Defines the type of control strategy that is being run. The selection list is:

1 – Phase-Angle Control 2 – Zero-Crossover Control

Magnetizing Sequence Calibration

Read/Write Condition: Off Default: 10 Cycles

99 Cycles Min: 5 Max: 20

Number of cycles to ramp on in phase control – Zero-Crossover control only


Read/Write Condition: All Default: Low Byte 50 High Byte 30

100 % Min: 10 Max: 90

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.

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


Defines the type of load connected to the 853. The selection list is:

1 – Direct Coupled 2 – Transformer Coupled

Product Type

Read only 102 The product type is 853.

Serial Number

Read only Factory set

103 104

The numeric serial number of the 853. The Setting is read as two consecutive words because of its size.

Control Power Time On

Read only Factory reset

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.

Output Time On


107 108

Hours x.x

The accumulated time the 853 output has been on. The Setting is read as two consecutive words because of its size.

KW-Hour

Read only 109 110

KW- Hours x.x

The accumulated Power Output in KW hours. It can be reset remotely by writing a 1 to bit 3 of the Control Word. The Setting is read as two consecutive words because of its size.

Software Version

Read only 112 The control software version read as xx.xxx.

7-14



Network Loss



Defines the action that is taken by the 853 control when there is a network loss. The selection list is:

0 – Fault and Stop 1 – Ignore and Run 2 – Alarm and Run

Network Address


114 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 network interface manual for a detailed description of the network interface.

Network Baud Rate



For the DeviceNet™ and Profibus network types, defines the network baud rate. For Ethernet, it defines the lower two octets of the network address. Refer to the network interface manual for a detailed description of the network interface.

MODBUS Address


116 Address Min: 1 Max: 247

Defines the device address for MODBUS messaging.

MODBUS Baud Rate


117

Selection Min: 4800 Max: 19200 (baud)

Defines the serial baud rate. The selection list is:

4800 9600 19200

Network Type



Defines the selected network interface. The selection list is:

0 – DeviceNet™ 1 – Profibus 2 – Ethernet

Fault Code

Read only 119 Fault condition code. Fault operation is

described in the Troubleshooting Chapter.

Fault Index


120 Index Min: 1 Max: 8

Fault buffer index number.

Fault Buffer #1


121 122 123

Saved fault condition code with a time stamp of time run.

Word 121 – Fault condition code Word 122/123 – Output time on stamp

7-15



Fault Buffer #2


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 Saved fault condition code with a time stamp of

time run. 127 128 Read only 129 Word 127 – Fault condition code Factory reset

Word 128/129– Output time on stamp Fault Buffer #4 Saved fault condition code with a time stamp of

time run. 130 131 Read only

Factory reset 132 Word 130 – Fault condition code Word 131/132 – Output time on stamp

Fault Buffer #5


133 134 135


Fault Buffer #6


136 137 138



Read only 139 140




Fault Buffer #7

141 Factory reset

Fault Buffer #8 Saved fault condition code with a time stamp of time run. 142 Read only 143 Factory reset Word 142 – Fault condition code 144 Word 143/144 – Output time on stamp

7-16

Chapter 8

Troubleshooting

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.

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.


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.

DANGER

DANGER

DANGER

DANGER

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 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.

the Local Digital Control option

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

Green -15V power is present

On

-15V

Green 853 DSPC output is active

Flashing Green

Digital Signal Processor is operating Heartbeat

Red 853 DSPC has detected a fault condition Fault

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

Green The Remote input is present. Remote

Green The Local mode is set to Analog. Analog

Green The Local mode is set to Digital. Digital

Enable The Enable input is present.

On Green The 853 DSPC output is active.

Amber Either a fault or alarm is present.

Figure 8-2 Local Digital Control

Green

Alert

8-3


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 Description

Phase L1 Current Input High Fault

1

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.


Code


2


8-4


Fault/Alarm Description


Code


3


Current Input Timed Overload Fault

The fault occurs when the following conditions are met.

1. The Current Input Actual exceeds the Current Input Overload Fault.

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

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


5

2. The accumulated time of condition #1 is greater than the Current Input Overload Time.

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

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.

9 Voltage Input High Fault

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


Fault/Alarm Description Code

Phase L1 Loss 11 The fault occurs when the following conditions are met.

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.

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.



Phase L3 Loss 13


Phase L2 Loss







8-6



14 The fault occurs when the following conditions are met. External Fault #1

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



External Fault #3 The fault occurs when the following conditions are met.




16



17 The fault occurs when the 'check byte' of the onboard EEPROM is not correct.

Configuration Fault

Note: [Reset] may clear this fault with no further action.

18 The fault occurs when the digital signal processor does not update the watchdog timer correctly.

Watchdog Fault

19 The fault occurs when the following conditions are met. SCR Shorted Fault

1. The Voltage Output Actual is greater than 75% of the Voltage Output Rating for one second.

2. The 853 is off.

Network Loss Fault 20 The fault occurs if there is a network loss and the Network Loss Selection is set to Fault and Stop.

8-7



21 The fault occurs when all the following conditions are met. Ground Fault

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.

The alarm occurs when the Frequency Actual is outside of a 2.0 Hertz band when compared to the Frequency Rating.

30 Frequency Alarm

31 The alarm occurs when all of the following conditions are met.L1 Current Input Load Failure Alarm

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 the Voltage Input Actual is lower than the Voltage Input Low Alarm.

34 Voltage Input Low Alarm

35 Voltage Output Limit Alarm

The alarm occurs when the Voltage Output Actual is being limited to the Voltage Output Limit by the voltage output control loop.

8-8



The alarm occurs when the Current Output Actual is being limited to the Current Output Limit by the current output control loop.

36 Current Output Limit Alarm

The alarm occurs when the Power Output Actual is being limited to the Power Output Limit by the power output control loop.

37 Power Output Limit Alarm

The alarm occurs when the Current Input Actual is being limited to the Current Input Limit.

38 Current Input Limit Alarm

39 The alarm occurs when the Duty Cycle of the controller reaches 100%.

Maximum Voltage Output Alarm

The alarm occurs if there is a network loss and the Network Loss Selection is set to Alarm and Run.

40 Network Loss Alarm

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).

41 L1-L2 Input Voltage Unbalanced


L2-L3 Input Voltage Unbalanced

42

L3-L1 Input Voltage Unbalanced


43

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 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.

momentarily

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


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.

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

DANGER

DANGERPower 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


Table 8-4 Troubleshooting Guide

Condition Probable Cause Corrective Action

No Control Power Insure the 853 DSPC has separate control power

+5V LED off

Power Supply connection open

Check Power Supply connections to main control PCB

+15V LED off

-15V LED off

Power Supply failed Replace Power Supply

Check that jumper JP1 has been removed before applying power

Heartbeat LED off DSP on main control PCB failed

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

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

853 DSPC will not turn on in Local Analog mode

Verify Local analog setpoint calibration

Local analog setpoint calibration incorrect

8-11



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.

853 DSPC will not turn on in Local Digital mode

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

853 DSPC will not turn on in Remote mode

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

Duty Cycle is at 100.0%.

Review the load to verify that 100.0% voltage will allow 100.0% power.

853 DSPC is full on and cannot provide any more power

Verify input voltage level to make sure it is not low

853 DSPC cannot provide full power to the load

Output wiring intermittent or disconnected

Check the output wiring

8-12


Probable Cause Corrective Action Condition

Improper fuse rating Refer to Hardware Installation Chapter for correct fuse rating

Nuisance Input Fuse blowing

Tighten the fuses Fuse improperly tightened


Current Input Rating setting incorrect

Check Current Input Rating setting

F-01, F-02, F-03 - Current Input High Fault

Current Input High Fault setting incorrect

Check Current Input High Fault setting

Intermittent short in load Check load




Current Input Overload Fault setting incorrect

Check Current Input Overload Fault setting

Current Input Overload Time setting incorrect

Check Current Input Overload Time setting

F-05 – Current Input Timed Over Current Fault

Verify size of output transformer Output transformer sized incorrectly

Thermostat contact state incorrect in Configuration Word setting

Check Configuration Word setting

Thermostat wiring open or shorted

F-06 – Over Temperature Fault

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 F-07, F-08 – Internal Fault

Check Internal Fault wiring Internal Fault wiring open or shorted

8-13




Voltage Input Rating setting incorrect

Check Voltage Input Rating setting

Check Voltage Input High Fault setting

Voltage Input High Fault setting incorrect

Check Voltage Output PT Secondary setting. Refer to Startup Chapter for details on correct setting

Voltage Output PT Secondary setting incorrect

F-09 – Voltage Input High Fault

Correct incoming voltage level Incoming voltage out of tolerance






Blown input fuse

Calibration incorrect Check calibration F-11, F-12, F-13 – Phase Loss

Blown input fuse Replace input fuse

External Fault contact state incorrect in Configuration Word setting

F-14, F-15, F16 – External Fault

External Fault wiring open or shorted

Check External Fault wiring

Try [Reset]

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.

Failed EEPROM memory

Replace main control PCB

F-18 Watchdog Fault

Failed DSP Replace main control PCB

F-10 – Voltage Input Low Fault

Replace input fuse

Check Configuration Word setting

F-17 – Configuration Fault

8-14




Voltage Output Rating setting incorrect

Check Voltage Output Rating setting


Check Voltage Output PT Secondary setting. See Startup Chapter for details on correct setting

Replace SCR

Check network connection

Verify presence of network

F-20 - Network Loss Fault

Network failure

Change Network Loss Option to allow device operation



Ground Fault Current setting incorrect

Check Ground Fault Current setting

F-21 – Ground Fault

Intermittent short to ground Check for ground

A-30 – Frequency Alarm

F-19 – SCR Shorted Fault

Shorted SCR


Check Frequency Rating setting Frequency Rating setting incorrect

Incoming frequency out of tolerance

Correct incoming frequency

8-15


Condition Corrective Action

Calibration incorrect

Current Threshold Load Failure setting incorrect

Check Current Input Threshold Load Failure setting





A-31, A-32, A-33 – Current Input Load Failure Alarm

Verify output load




Voltage Input Low Alarm setting incorrect

Check Voltage Input Low Alarm setting



A-34 – Voltage Input Low Alarm

Probable Cause

Check calibration

Output load changed

Check calibration

Incoming voltage out of tolerance

Correct incoming voltage level





Voltage Output Setpoint setting incorrect

Check Voltage Output Setpoint setting

Controlling with Voltage Output PID

Change Voltage Output Setpoint


A-35 – Voltage Output Limit Alarm

8-16


Probable Cause Corrective Action

Check calibration

Current Output Rating setting incorrect

Current Output Setpoint setting incorrect

Check Current Output Setpoint setting

A-36 – Current Output Limit Alarm

Controlling with Current Output PID

Change Current Output Setpoint


Condition


Check Current Output Rating setting



A-37 – Power Output Limit Alarm



Check Current Output Rating setting

Power Output Setpoint setting incorrect

Controlling with Power Output PID

Change Power Output Setpoint




Check Current Input Limit setting

A-38 – Current Input Limit Alarm

Controlling Current Input with Current Output PID

A-39 - Maximum Voltage Output Alarm

Duty Cycle has reached 100%

Lower the control setpoint

Current Output Rating setting incorrect

Check Power Output Setpoint setting

Current Input Limit setting incorrect

Change Current Input Limit

8-17



Check network connection A-40- Network Loss Alarm

Network failure

Verify presence of network

Change Network Loss Option to allow device operation

Check calibration

Voltage Input Phase Unbalance setting incorrect



A-41, A-42, A-43 – Input Voltage Unbalance Alarm

Voltage Input Supply not balanced

Check Voltage Input Supply


Check Voltage Input Phase Unbalance Alarm setting

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


Figure B-3 40A Wiring Diagram

B-4



B-5



B-6



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

American Standard Code for Information Interchange

Bias Calibration factor to offset signal at zero output of control signal

CAN Controller Area Network

CT

DSP Digital Signal Processor

Digital SCR Power Controller

EDS Electronic Data Sheet

Heatsink Device to carry heat from power devices

I t Subcycle current characteristic of an SCR or fast clearing fuse

I/O Input/Output

IRMS Amps Root Mean Squared

KVA

LED Light emitting diode

ASCII

Current Transformer

DSPC

2

One thousand volt amperes

Metal Oxide Varistor – brand name of GE transient voltage suppressor

MOV

Normally closed contact NC

Normally open contact NO

National Electric Code NEC

NEMA National Electrical Manufacturers Association

Open DeviceNet™ Vendors Association

Printed Circuit Board

Personal Computer Memory Card International Association

Power Control Unit

ODVA

PCB

PCMCIA

PCU

i

Glossary February 2004

ii

Term or Acronym Description

Phase Angle Control by chopping each half cycle

PID Proportional, Integral Derivative Controller

PLC Programmable Logic Controller

PT Potential Transformer

RFI Radio Frequency Interference

RMS Root Mean Squared

Rx Receive

SCR Silicon Controlled Rectifier

Semiconductor Solid State device for controlling electric power

Setpoint Reference for PID control

Silicon Material from which semiconductors are made

Span Calibration signal to adjust maximum input of control signal

Thyristor Name of semiconductor family including SCR’s, TRIAC, etc.

Tx Transmit

TXID Transaction ID for Explicit Message Requests and Responses

VAC Volts Alternating Current

VDC Volts Direct Current

VRMS Volts Root Mean Squared

Zero Calibration signal to adjust minimum input of control signal to zero

Zero-Cross Control by integrating numbers of complete cycles

853 Product Manual

Documents

Transcript of 853 Product Manual