Control Concepts Model 3629C 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 3629C 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 3629C TABLE OF CONTENTS DESCRIPTION 1 FEATURES 1 SPECIFICATIONS 3 INSTALLATION 5 INSTALLATION DRAWINGS 6 COMMAND CONNECTIONS 11 POWER CONNECTIONS 15 ADJUSTMENTS 18 TROUBLESHOOTING 20 REPLACEMENT PARTS 22 MANUFACTURED BY 22 MODEL NUMBER IDENTIFICATION 23 THEORY OF OPERATION 24 50 to 750 AMPS LISTED 3L32 FILE No: E136219 INDUSTRIAL CONTROL EQUIPMENT NOTE: THE 1000 or AMP UNIT IS NOT UL LISTED MODEL 3629C 04/10/2007
DESCRIPTION The model 3629C is a phase-angle SCR controller which linearly controls, with respect to a command signal, the voltage applied to a three phase electrical load. The controller can be connected either in-line or inside delta configuration. (See Figure 23 & Figure 24.) The 3629C can be configured to control a 4 wire wye load or with the addition of a 3-phase bridge can control a DC load. (See Figures 25 & Figure 27.
FEATURES (Continued) 14. Connection for a remote reset switch, which, if momentarily closed, resets the Over Current Trip relay and resets the circuit to allow the load voltage to ramp from zero to the desired value. The switch can also be used to provide remote "on-off" control. Closure of the switch immediately interrupts the SCR operation and removes load voltage. (See Figure 20.) 15. Eight status indicators provide the following information: A.
SPECIFICATIONS The following specifications apply over an ambient temperature range of 0 to 55°C and a supply voltage of 85% to 110% of the nominal supply voltage rating. Control Mode: Three-phase in line, Three-phase inside delta, 4-wire wye or DC. 6 SCR, phase angle control of the RMS or average load voltage. External feedback is available. See Power Connections section.
SPECIFICATIONS (Continued) SCR Surge Current: Peak 1 cycle surge current is: 50 Amp rating 80 Amp rating 120 Amp rating 160 Amp rating 200 Amp rating 250 Amp rating 300 Amp rating 380 Amp rating 425 Amp rating 500 Amp rating 600 Amp rating 750 Amp rating 1000 Amp rating - 1,750 A Surge 1,750 A Surge 1,900 A Surge 4,000 A Surge 5,200 A Surge 5,200 A Surge 7,000 A Surge 10,000 A Surge 13,000 A Surge 10,000 A Surge 13,000 A Surge 20,000 A Surge 26,000 A Surge SCR I2T Rating: 50 Amp rating 80 Amp rating 120
INSTALLATION MOUNTING The 50 Amp model 3629C controller is convection cooled and must be mounted with the fins aligned vertically on a flat surface so that air may pass over the fins. Although larger model 3629C controllers are forced air cooled, it is recommended that all controllers be mounted vertically with power terminals on top. Allow at least 3" of space between controllers for air to enter and exit.
9.5 MAX INSTALLATION DRAWINGS 9.85 14.0 1.0 6.0 UP 6.0 0.185 (6) 8.85 Figure 1. 50 Amp 3629C controller. Note: The 50 amp controller does not have a fan, and requires convection cooling. This unit must be mounted on a vertical panel with the fins oriented vertically, so that air may pass between the cooling fins without restriction. MAINTAIN 3" MINIMUM SPACE BETWEEN CONTROLLERS Figure 2. ORIENTATION OF FUSE IN HOLDER Fuse makes contact only when correctly installed.
9.5 MAX INSTALLATION DRAWINGS (Continued) 9.85 6.0 1.0 18.25 MAX 6.0 0.185 (6) 8.85 Figure 3. 80 Amp 3629C controller. Figure 4. ORIENTATION OF FUSE IN HOLDER Fuse makes contact only when correctly installed.
0.397 x 0.60 (6) 6.0 20.25 Max 6.0 8.5 7.5 7.0 FAN END INSTALLATION DRAWINGS (Continued) 4.0 Figure 5. Top view of 120 & 160 Amp 3629C controller. FAN END LINE 1 LOAD 1 LINE 2 LOAD 2 LINE 3 GROUND LOAD 3 11.5 Max COMMAND CONNECTOR Figure 6. Side view of 120 & 160 Amp 3629C controller. Figure 7. ORIENTATION OF FUSE IN HOLDER Fuse makes contact only when correctly installed. Place flat end of fuse in Cap. Place fuse & cap into fuseholder.
INSTALLATION DRAWINGS (Continued) 11.0 Max 16.25 16.25 17.5 Figure 8. End view of 200 to 425 Amp 3629C controller. 0.525 0.332 DAI. (6) 6.0 16.25 6.0 2.125 Figure 9. Top view of 200 to 425 Amp 3629C controller.
INSTALLATION DRAWINGS (Continued) 13.25 Max 22.0 Figure 10. End view of 500 to 1000 Amp 3629C controller. 1000 Amp controller has 4 wire lugs per terminal. 26.25 25.0 0.332 DAI. (8) 0.525 1.0 5.0 10.0 5.0 22.0 Figure 11. Top view of 500 to 1000 Amp 3629C controller.
COMMAND CONNECTIONS POSITIVE (+) VOLTAGE OR CURRENT COMMAND SIGNAL COMMON (-) 18 16 17 14 15 12 13 10 11 8 6 9 4 7 2 5 3 1 Figure 12. Voltage or current command connections. CW IK POT WIPER CCW 18 16 17 14 15 12 13 10 11 8 9 6 7 4 5 2 3 1 Figure 13. Potentiometer command connections. The Controller Ready signal is controlled by an open collector transistor which goes low with respect to Pin 12 when the controller is in the ready state.
COMMAND CONNECTIONS (Continued) 330 Ohms LED 18 16 17 14 15 12 13 Pin 12 - +5 Vdc Pin 11 - Ready 10 11 8 9 6 7 4 5 2 3 1 Figure 15. Sample LED Circuit. Pin 12 - +5 Vdc Pin 11 - Ready + 18 16 17 14 15 12 13 10 11 8 9 6 7 4 5 2 3 1 Figure 16. Sample Solid State Relay Circuit. Pin 11 - Ready Pin 10 - Common + SOURCE: 30 Vdc MAX Maximum load: 100mA 18 16 17 14 15 12 13 10 11 8 9 6 7 4 5 2 3 1 Figure 17. Example of switching an external voltage.
COMMAND CONNECTIONS (Continued) Note: to insure proper operation, isolation of the feedback source may be required. Contact the factory for further information. D.C. Feedback signal Positive 0 TO 5 Vdc Input Impedance = 200K Common 18 16 17 14 15 12 13 10 8 11 6 9 4 7 Determine that jumper P6 is in the EXTERNAL FEEDBACK position 2 5 3 1 IFB EFB P6 Figure 18. External voltage feedback.
COMMAND CONNECTIONS (Continued) + 1.75 POS METERING THE OVER CURRENT TRIP SETTING. Unless specified otherwise, the OVER CURRENT TRIP is set at 175% of the controller current rating at the factory. A reference output is available to assist in the recalibration of this setting if this adjustment is accidentally changed. POSITIVE 1.00 V output at terminal 18 with respect to terminal 14 equals 100% of controller current rating. POSITIVE 1.75 V output equals 175% of current rating.
POWER CONNECTIONS 2 X CLOSED 1 X Note: It is recommended that the load and controller be protected by 3 class "T" or "Semiconductor” fuses. Choose a fuse size approximately 120 to 125% of the current rating of the controller. See Replacement Parts sections. Mode Switch See Adjustments Section FUSES LINE 1 LOAD 1 LINE 2 LOAD 2 LINE 3 LOAD 3 B DELTA (OR WYE) LOAD TO 3 PHASE SUPPLY A C Figure 23. In-line power connections.
POWER CONNECTIONS (Continued) 2 0 CLOSED 1 X Note: It is recommended that the load and controller be protected by 3 class "T" or "Semiconductor” fuses. Choose a fuse size approximately 120 to 125% of the current rating of the controller. See Replacement Parts sections. Mode Switch See Adjustments Section LINE 1 LOAD 1 LINE 2 LOAD 2 LINE 3 LOAD 3 TO 3 PHASE SUPPLY A POS DC LOAD FUSES B C NEG Figure 25. DC power connections.
POWER CONNECTIONS (Continued) 2 X CLOSED 1 X Note: It is recommended that the load and controller be protected by 3 class "T" or "Semiconductor” fuses. Choose a fuse size approximately 120 to 125% of the current rating of the controller. See Replacement Parts sections. DELTA-WYE TRANSFORMER - With WYE load Using a Delta primary to a 3 wire Wye secondary transformer into a wye load with an SCR controller is not recommended.
ADJUSTMENTS The zero and span potentiometers are factory set, and generally do not require further adjustment. If adjustments become necessary, the following procedure should be followed. If you are using RMS feedback, you must use a true RMS meter for these measurements. 1. Set the command signal to minimum and adjust the zero potentiometer until the output is zero.
ADJUSTMENTS (Continued) Place a jumper across pins 1 & 2 on JP1 when you desire to use a 0 to 10 Vdc signal. No jumper for all other command signals. A 300 ohm resistor must be added in the R65 position when you use a 4/20mA command signal. Contact factory for more information. TP2 R65 P6 JP1 TP1 SW1 CONTROL CONCEPTS INC.
TROUBLESHOOTING CAUTION: High Voltage exists on controller, circuit board, and other equipment located near the controller. Use extreme caution to avoid electrical shock. Except for voltage and current measurements, remove power before attempting to service this equipment. Electrical measurements should be made by qualified personnel only. NOTES Control Concepts has field service engineers who can help to determine the cause of controller problems. Please call (952) 474-6200 with any questions you may have.
TROUBLESHOOTING (Continued) SYMPTOMS POSSIBLE CAUSES LOAD POWER AT MAXIMUM. 'COMMAND' LED IS ON OR OFF. SHORTED SCR. Check for illuminated "SHORTED SCR" LED. PROBLEM ON THE CIRCUIT BOARD. Remove or swap circuit board to determine if the problem exists on the circuit board. LOAD POWER AT MAXIMUM. 'COMMAND' LED IS ON PROBLEM WITH THE COMMAND SIGNAL. Remove the command connector. If load power and line current indicators go off, the problem is associated with the command signal. PROBLEM ON CIRCUIT BOARD.
REPLACEMENT PARTS FUSES The model 3629C does not have built-in line fuses. It is recommended that the load and controller be protected by using a class "T" or Semiconductor fuse in each of the three line leads. Bussmann type "JJN" (300 Volts) or "JJS" (600 Volts) are suitable for up to 600 Amp frames. On frame sizes larger than 600 Amps, a semiconductor type fuse is recommended. Choose a fuse having a current rating of approximately 120% - 125% of the maximum load current anticipated. Control Concepts, Inc.
MODEL NUMBER IDENTIFICATION 3629C-(FB)-(VOLTS)-(AMPS)-CS-IL(Amps)-(SC)-(OCT)-(SP-##) Basic Model Number Specifies Type of Feedback V specifies RMS voltage feedback. (Desired for heating applications.) A specifies Average voltage feedback. (Desired in some DC applications.) E specifies external feedback. Specifies Supply Voltage. Typical choices are: 208, 240, 380, 415, 480 or 575 Volts AC Other voltages may be available, call factory for details. Specifies: Current Rating of the Controller.
THEORY OF OPERATION THE SCR The heart of the SCR power controller is the SCR (silicon controlled rectifier, sometimes referred to as a thyristor). The SCR has two states, ON and OFF, and allows current to flow in only one direction when turned on. SCRs can remain in the off state even though the applied potential may be several thousand volts. In the on state, they can pass several thousand amperes.
