Control Concepts Model 1029C Power Control System Instruction Manual Another quality product from: 7128 Shady Oak Road Eden Prairie, MN 55344 USA (952) 949-9009 Fax (952) 949-9559 www.researchinc.
CONTROL CONCEPTS INC. INSTALLATION MANUAL MODEL 1029C 7870 PARK DRIVE CHANHASSEN, MN 55317 (952) 474-6200 1-800-765-2799 FAX (952) 474-6070 www.ccipower.
CONTROL CONCEPTS, INC. 2 YEAR LIMITED WARRANTY CONTROL CONCEPTS, INC. warrants that the products delivered will be as described in the sales order or contract. CONTROL CONCEPTS, INC. warrants to the original user that CONTROL CONCEPTS, INC. products will be free from defects in materials and workmanship for a period of two (2) years after the date CONTROL CONCEPTS, INC. ships such products. If any CONTROL CONCEPTS, INC.
MODEL 1027 TABLE OF CONTENTS DESCRIPTION 1 FEATURES 1 SPECIFICATIONS 2 INSTALLATION 4 INSTALLATION DRAWINGS 5 COMMAND CONNECTIONS 8 POWER CONNECTIONS 12 FEEDBACK SELECTION 13 START-UP 13 ADJUSTMENTS 14 TROUBLESHOOTING 16 MANUFACTURED BY 16 REPLACEMENT PARTS 17 MODEL NUMBER IDENTIFICATION 18 THEORY OF OPERATION 19 50 to 750 AMPS LISTED 3L32 FILE No: E136219 INDUSTRIAL CONTROL EQUIPMENT NOTE: THE 1000 AMP UNIT IS NOT UL LISTED MODEL 1029C 10/19/2007
DESCRIPTION MODEL COVERED: This manual describes the Control Concepts model 1029C controller with the following ratings: CURRENT: 50 Amps to 750 Amps. VOLTAGE: 120 Vac to 575 Vac. @ 50/60 Hz. GENERAL DESCRIPTION: The model 1029C is a single-phase, phase-angle power controller that has selectable feedback, dual command signals, adjustable current limiting & over-current trip, shorted SCR detection, estimated output voltage metering and output current metering.
SPECIFICATIONS The following specifications apply over an ambient temperature of 0 to 55ºC and a supply voltage of 85% to 110% of the nominal supply voltage rating. CONTROL MODE: Single phase SCR phase-angle control. FRAME SIZE: The “[AMPS]A” term within the model number specifies the maximum continuous RMS current rating at the maximum operating ambient temperature of 55ºC.
SPECIFICATIONS (Continued) ZERO AND SPAN: Potentiometers on the circuit board allow zero and span adjustments of ± 25% of span for run and idle and are factory calibrated. CURRENT LIMITING: A potentiometer on the circuit board allows adjustment of the current limit setting from 20% to 105% of the controller rating. (The current limit potentiometer is factory set for 105% of the rated current unless otherwise specified.) VOLTAGE METER OUTPUT: A filtered metering signal equals 5.
INSTALLATION Potentiometer: A 1k ohm to 20k ohm potentiometer, 1/4 watt or more, may be used to adjust the load voltage. (A 1k ohm potentiometer provides the maximum linearity.) See Figure 8 or Figure 10. Consult factory for other options. TRANSFORMER TAP: Open lid and locate power transformer. Check voltage tap is on desired line voltage. MOUNTING AND LOCATION: Mount controllers on a vertical surface with the fins oriented so that air may flow vertically between them.
INSTALLATION DRAWINGS LOAD 0.60 10.6 10.6 10.0 8.27 0.288 X 0.50 (2) LINE 2 LINE 1 GROUND 1.125 0.50 7.65 6.65 0.29 (2) Figure 1. Installation drawing for 50, 80, 120 & 160 Amp units. NOTE: THE 50 and 80 AMP UNITS ARE NOT FAN COOLED. THEY MUST BE MOUNTED ON A VERTICAL SURFACE WITH THE FINS ORIENTED VERTICALLY SO THAT AIR MAY FLOW FREELY BETWEEN THE FINS. 120 and 160 AMP UNITS ARE FORCED AIR COOLED. THEY MAY BE MOUNTED IN ANY DIRECTION. Figure 2.
INSTALLATION DRAWINGS (Continued) 5.00 4.00 16 14 15 12 13 10 11 8 9 6 7 4 5 SHORTED SCR RELAY FB. BK. I. METER V. METER IDLE (+) W COM(-) CCW RUN (+) W +5V CW RUN/IDLE COMMON RESET 17 SHORTED SCR 2 3 1 OVER CURRENT RELAY 18 OVER CURRENT DANGER HIGH VOLTAGE INDICATOR INDICATOR 10.85 16.00 LOAD 17.40 COMMAND LOAD LINE 5/16 Dia. (4) Figure 3. Installation drawing for 200, 250, 300,380 and 425 Amp units. Figure 4.
INSTALLATION DRAWINGS (Continued) 16 14 15 12 13 10 11 8 9 6 7 4 5 SHORTED SCR RELAY FB. BK. I. METER V. METER IDLE (+) W COM(-) CCW RUN (+) W +5V CW RUN/IDLE COMMON RESET 17 SHORTED SCR 2 3 1 OVER CURRENT RELAY 18 OVER CURRENT 13.05 DANGER HIGH VOLTAGE INDICATOR INDICATOR 25.0 LOAD 26.1 COMMAND Figure 5. Installation drawing for 500 to 750 Amp units. 0.332 Dia. (4) Figure 6. ORIENTATION OF FUSE IN HOLDER Fuse makes contact only when correctly installed. 5.00 7.
COMMAND CONNECTIONS OVER CURRENT TRIP RESET SWITCH TO ALARM OR POWER DISCONNECT CIRCUIT TO ALARM OR POWER DISCONNECT CIRCUIT 16 15 12 13 10 11 8 9 6 7 4 5 2 3 SHORTED SCR RELAY FB. BK. I. METER V. METER IDLE (+) W COM(-) CCW RUN (+) W +5V CW RUN/IDLE COMMON RESET 17 14 1 OVER CURRENT RELAY 18 Figure 7.
COMMAND CONNECTIONS (Continued) POSITIVE(+) COMMON(-) 16 14 15 13 10 11 8 9 6 7 4 5 2 3 SHORTED SCR RELAY FB. BK. I. METER V. METER IDLE (+) W COM(-) CCW RUN (+) W +5V CW RUN/IDLE COMMON RESET 17 12 1 OVER CURRENT RELAY 18 RUN INPUT (VOLTAGE OR CURRENT COMMAND SIGNAL.) Figure 9. Single voltage or mA current applied to the run input connections (Terminals 10 & 11 must be connected to enable the run input.
COMMAND CONNECTIONS (Continued) POSITIVE(+) POSITIVE(+) COMMON(-) COMMON(-) 18 16 15 12 13 10 11 8 6 9 4 7 2 5 3 SHORTED SCR RELAY FB. BK. I. METER V. METER IDLE (+) W COM(-) CCW RUN (+) W +5V CW RUN/IDLE COMMON RESET 17 14 RUN INPUT (VOLTAGE OR CURRENT COMMAND SIGNAL.) 1 OVER CURRENT RELAY IDLE INPUT (VOLTAGE OR CURRENT* COMMAND SIGNAL.) Figure 11. Run and Idle voltage or current connections.
COMMAND CONNECTIONS (Continued) POSITIVE(+) IDLE POTENTIOMETER CCW COMMON(-) IK POT RUN INPUT (VOLTAGE OR CURRENT COMMAND SIGNAL.) WIPER RUN/IDLE SWITCH CLOSED ENABLES THE RUN INPUT OPEN ENABLES THE IDLE INPUT 16 15 12 13 10 11 8 6 9 7 FB. BK. I. METER V. METER IDLE (+) W COM(-) CCW RUN (+) W +5V CW RUN/IDLE COMMON RESET 17 14 4 5 2 3 SHORTED SCR RELAY 18 1 OVER CURRENT RELAY CW Figure 13. Combination command-signal/potentiomter input connections.
POWER CONNECTIONS LINE 2 LOAD VOLTAGE SUPPLY LINE 1 LINE 1 LOAD 1 LINE 2 GND Figure 15. Power Connections. LINE 1 LOAD LINE 2 LINE 1 VOLTAGE SUPPLY LOAD 1 LINE 2 1029C CONTROLLER Figure 16. Power Path.
FEEDBACK SELECTION START-UP Connector P2 on the circuit board allows the selection of feedback type. (See Figure 18). Determine that the selected transformer tap corresponds to the line voltage. True RMS is the default voltage feedback mode. Average voltage feedback mode may be requested when ordering the controller.
ADJUSTMENTS The I Span and V Span pots (and Power Span and Power Zero pots, when factory installed), are sealed at the factory. They are identified with an X in Figure 17. Under no circumstances should adjustment of these four pots be attempted. The setting of each of these potentiometers is critical to the proper operation of the controller. The potentiometers labeled Run Span, Run Zero, Idle Span & Idle Zero have been calibrated at the factory and readjustment should not be necessary.
ADJUSTMENTS (Continued) Run Span Pot. Run Zero Pot. THESE FOUR POTS, AND THE CURRENT LIMIT POT ARE MOUNTED ON THE BACK SIDE OF THE BOARD TO SHOW THROUGH LID Idle Span Pot. Idle Zero Pot. P2 FeedbackSelector. See Figure 18 Installed for power feedback only DO NOT CHANGE ADJUSTMENTS ON POTS MARKED WITH AN ‘X’ X X Current Limit Pot. (shows through lid.) Over Current Trip X X DO NOT CHANGE ADJUSTMENTS ON POTS MARKED WITH AN ‘X’ FEEDBACK SELECTION SUMMING JUNCTION EXTERNAL F.B. CURRENT F.B. VOLTAGE F.
TROUBLESHOOTING CAUTION: HIGH VOLTAGES ARE PRESENT ON THIS CONTROLLER AND ON PORTIONS OF THE PRINTED CIRCUIT BOARD. USE EXTREME CARE TO AVOID ELECTRICAL SHOCK. Notes: The LED's provide a convenient method of determining the general location of controller problems. The LOAD LED indicates that 10% or more of rated load current is present. The intensity of the LOAD LED should increase as the command signal is increased. The COMMAND LED indicates the presence of gate drive. The O.C.T.
REPLACEMENT PARTS SCHEMATIC DWG: CCI No. D1000954A ITS RECOMMENDED THAT THE CONTROLLER AND LOAD BE PROTECTED BY 600 VOLT, CLASS ‘T’ FUSES: TO ORDER A SPARE SCR MODULE: TO ORDER CLASS ‘T’ FUSES CONTROLLER CURRENT RAING Amps (A) CONTROL CONCEPTS PART No. CONTROLLER CURRENT RATING Amps (A) FUSE SIZE Amps (A) CONTROL CONCEPTS PART No.
MODEL NUMBER IDENTIFICATION 1029C-[X]-[XXX]V-[XXX]A-IL[XXX]-R[XXX]-I[XXX] 1029C The basic model number. [X] The type of feedback A - Specifies average voltage feedback. With average voltage feedback, the controller varies the conduction angle (or ON time) of the SCRs such that the average voltage applied to the load is proportional to the command signal. E - Specifies external feedback. The external feedback being proportional to some parameter such as speed, current, etc.
THEORY OF OPERATION THE SCR The heart of the Control Concepts, Inc. power controller is the SCR (silicon controlled rectifier, sometimes referred to as a thyristor). PHASE-ANGLE OPERATION In phase-angle control, each SCR of the back-to-back pair is turned on for a variable portion of the half-cycle that it conducts. (Figure 22). The SCR has two states, ON and OFF, and allows current to flow in only one direction when turned on.
