Model 930 Power Control System Instruction Manual Publication No. A105328-001 Rev A December 2000 Another quality product from: 7128 Shady Oak Rd, Eden Prairie MN 55344 Phone: (952) 949-9009 Fax: (952) 949-9559 www.researchinc.
Dear Customer: Thank you for purchasing a Model 930 ControlIRTM Power Control System. We believe it is the finest system of its type and are confident you will think so too. For technical assistance, training, replacement parts and assemblies, or any other problems or questions, contact our Field Service specialists. They will do everything they can to help you or will put you in touch with someone who can.
Model 930 ControlIRTM Instruction Manual Section Contents page INTRODUCTION General Description Standard Features Optional Features SAFETY 1 1 2 3 INSTALLATION Mounting the System Wiring Connections Power Wiring Connections Line Connections Load Connections Control Connections Cooling Flow On/Off Relay Output Cooling Flow Switch Interlock Heater Over-Temperature Thermo-switch Interlock Remoter Interlock Switch Heater Open Switch Interlock Remote Setpoint Input Temperature Control Option Connections (
Model 930 ControlIRTM Instruction Manual Contents MAINTENANCE AND TROUBLE SHOOTING Routine Maintenance Troubleshooting Calibration Power Controller Panel Voltmeter Calibration Temperature Controller Option Line Voltage Re-Configuration 16 16 17 17 18 18 19 DIMENSIONS AND SPECIFICATIONS Specifications Dimensions Ordering Information Ordering Example Spare and Replacement Parts 20 22 24 24 25
Model 930 ControlIRTM Instruction Manual Introduction Introduction GENERAL DESCRIPTION Figure 1-1 The Model 930 power control system is a complete power ‘solution’ featuring a number of elements integrated into a single, ready-to-install package. The Model 930 is a three-phase power control system available in two configurations of 120 and 160 Amps at 480 Volts. These systems are ideally suited for many industrial power control applications and have been specifically optimized for use with Research Inc.
Model 930 ControlIRTM Instruction Manual Introduction • Fail safe operation of the heater contactor. The contactor will not automatically reenergize after a power failure, or an alarm condition that shuts down the heater. • Programmable Logic Controller for operating and alarm logic control.
Model 930 ControlIRTM Instruction Manual Operating Instructions Safety WARNING! Hazardous voltages are present at the main disconnect switch and load terminals. Setting the setpoint potentiometer or control signal to minimum does NOT eliminate these hazardous voltages. Always remove AC line voltage from the system before making contact with internal assemblies, line or load wiring, or fuses.
Model 930 ControlIRTM Instruction Manual Operating Instructions Installation This section describes how to install and wire the Model 930 power control system. The features and options mentioned here are identified in the model number found inside the enclosure. WARNING! Hazardous voltages are present at the main disconnect switch and load terminals. Setting the setpoint potentiometer or control signal to minimum does NOT eliminate these hazardous voltages.
Model 930 ControlIRTM Instruction Manual WIRING CONNECTIONS Operating Instructions Conduit entry into the system should be made near the right side of the cabinet for power wiring, near the center of the cabinet for load wiring, and near the left side for low voltage control wiring. Assure that metal fragments are not allowed to fall into the equipment while holes are made for conduit fittings. We suggest a separate conduit entry should be made for low level DC control wiring if used.
Model 930 ControlIRTM Instruction Manual Operating Instructions Power Wiring Connections Line Connections Referring to the wiring specification in Table 3-1, connect the external power lines to the top of the disconnect switch. Load Connections The model 930 power control system has 2 (3-pole) load fuseblocks for distributing the Three-phase power to your process. For the 120 Amp systems, do not exceed more than 60 amps – 3 phase per fuseblock.
Model 930 ControlIRTM Instruction Manual Cooling Flow Switch Interlock Operating Instructions This feature provides shutdown of the heater power in case of low or no cooling flow. This is accomplished by opening the heater power controller contactor. The cooling sensor may be a water flow or air flow switch. Use a switch with contacts that are open during the fault condition. Connect the flow switch to TB 100 pins 2 and 3.
Model 930 ControlIRTM Instruction Manual Remote Setpoint Input Operating Instructions This feature allows the power level of the system to be controlled from a remote location or device. This is accomplished by applying a 0-5 VDC or 0-20 mA signal input from a remote source. This feature is not available when the ‘Temperature Controller’ option is installed. If this feature is desired use the following procedure: 1. For a 0-5 VDC input, connect the source to TB 100 pins 16+ and 17-. 2.
Model 930 ControlIRTM Instruction Manual Temperature Control Option Connections (Option Codes TCT & TCP) Research, Inc. Operating Instructions Temperature control option ‘TCT’ is setup to use a ‘K’ type thermocouple for the temperature input. Temperature control option ‘TCP’ is setup to use a pyrometer for the temperature input. Alarm connections are provided if required for your process. The alarm contacts are ‘dry’ type rated for a maximum of 3 Amps resistive at 240 VAC.
Model 930 ControlIRTM Instruction Manual Operating Instructions Operating Instructions CONTROLS AND INDICATORS Figure 4-1 shows the location of the controls and indicators. Main Disconnect Switch The main disconnect switch turn on and off the power control system. Note the following: Before turning on the disconnect switch, check the following: 1. The load is wired and ready for power to be applied to it. 2. All safety precautions are observed.
Model 930 ControlIRTM Instruction Manual Operating Instructions The remote/local setpoint switch allows the operator to select the source for the power level setting to the load, lamps, or heaters. The selections include: 1. LOCAL: The power level is adjusted using the digital 10-Turn ‘LOCAL SETPOINT’ potentiometer. Remote/Local Setpoint Switch 2.
Model 930 ControlIRTM Instruction Manual TEMPERATURE CONTROL OPTION Operating Instructions This section contains temperature controller configuration information for your system. Refer to the Model XT19 installation and instruction manual for operating the temperature controller.
Model 930 ControlIRTM Instruction Manual Operating Instructions Because an SCR is a type of diode, it can conduct only during every other half-cycle of the applied voltage. Therefore, SCRs used to control AC power are usually installed in pairs, connected in reverse-parallel, as shown in figure 4-3. One of the SCRs then can be fired during the positive half-cycle and the other can be fired during the negative half-cycle.
Model 930 ControlIRTM Instruction Manual Operating Instructions The average power a phase angle controller delivers to its load is determined by the number of electrical degrees by which the gating signal that turns on the SCRs is delayed past the beginnings of the half-cycles. The later in each half-cycle the SCRs fire, the less the time the SCRs conduct during each half-cycle and, therefore, the less power is delivered to the load (see figure 4-5).
Model 930 ControlIRTM Instruction Manual Operating Instructions The output voltage of a phase angle controller does not change linearly with respect to the number of degrees the SCR conduction phase angle changes. Therefore, the SCR controllers have a built-in load feedback circuit to linearize the relationship between the control signal and the voltage output.
Model 930 ControlIRTM Instruction Manual Maintenance and Trouble Shooting Maintenance and Trouble Shooting ROUTINE MAINTENANCE The following bi-monthly routine maintenance is suggested: 1. Remove power connection to the system. Lock out power if possible. Carefully vacuum any dust or dirt collecting within the enclosure. Use caution to not disturb the wiring. Service more often in dust locations. 2.
Model 930 ControlIRTM Instruction Manual Maintenance and Trouble Shooting Symptom No output to load, heaters or lamps. Setpoint switch is in REMOTE. Operation O.K. with Setpoint switch in LOCAL (if not see above). Action 1. Verify the polarity of the remote input. TB 100 pin 16 is positive, and 17 is negative. Full voltage cannot be obtained. 1. Verify the load, lamps, or heaters are not drawing current at full capacity of the system.
Model 930 ControlIRTM Instruction Manual Panel Voltmeter Calibration Maintenance and Trouble Shooting 2. Voltmeter Option or No Options: When REMOTE setpoint mode is selected, use a 0-5 VDC source for an input. Adjust the zero and span potentiometers on the power controller. The SPAN potentiometer is adjusted for 90 percent of rated line voltage for 4.5 VDC input. The ZERO potentiometer is adjusted for 0 Volts output when the local setpoint is set to 000 dial divisions. 3.
Model 930 ControlIRTM Instruction Manual LINE VOLTAGE RE-CONFIGURATION Maintenance and Trouble Shooting The AC line voltage for the Model 930 Power Control System may be re-configured. On transformer T100, a wire with wire number 1070 is connected to pins 3 or 4. Move this wire to the pin corresponding to the desired line voltage. Pin 3 Pin 4 240 VAC 480 VAC See Figure 5-1 below.
Model 930 ControlIRTM Instruction Manual Dimensions and Specifications Dimensions and Specifications SPECIFICATIONS Environmental Limits: Operating Temperature Storage Temperature Humidity Clearance 0-50 deg. C (32-122 deg. F) -40-70 deg. C (-10-158 deg. F) 0-90 %, non-condensing 4” (100mm) on right and left sides Weight: The system weight varies slightly with the options installed. The maximum weight of the system is ??? pounds (??? kg). Operating Voltage: 240 or 480-VAC +10%, -15% at 50 or 60 Hertz.
Model 930 ControlIRTM Instruction Manual Dimensions and Specifications Electrical Isolation: Heat sink to supply and load voltage: 2500 Volts peak. Command signal to supply and load voltage: 1400 Volts peak. Slew Rate: 200 ms. Slew rate is the time required for the load voltage to change 63% of the value represented by the command signal. The current limiting action will affect the slew rate if the load current is greater than the current rating of the SCRs.
Model 930 ControlIRTM Instruction Manual Dimensions and Specifications Specifications for Options Option Code TCT & TCP Temperature Controller Option Thermocouple type (TCT): Type ‘K’ Sensor Input (TCP): 4-20mA scaled 0-2500 deg. F Alarm relay rating: 5A @ 120VAC resistive, 3A @ 240VAC Sample rate: 10 HZ Calibration accuracy: +/- 0.
Model 930 ControlIRTM Instruction Manual Dimensions and Specifications Figure 6-2 shows the mounting dimensions using the supplied brackets. Figure 6-2 Wall Mounting Dimensions Research, Inc.
Model 930 ControlIRTM Instruction Manual Dimensions and Specifications Ordering Information Model Product Description 935 Three Phase SCR Power Control System Code Enclosure A Wall Mount(1) Code Line Voltage 240 240 Volts AC 480 480 Volts AC Code Current Capacity 120 120 Amps 160 160 Amps Code Options (2) Temperature Controller – 4/20 mA, Pyrometer Input (2) Temperature Controller – Thermocouple Input TCP TCT (2) VM Digital Voltmeter LL Lamp-out Detection 00 None (1) (2)
Model 930 ControlIRTM Instruction Manual Dimensions and Specifications Spare and Replacement Parts Description Fuse – 200 Amp 600 VAC (For use with 160 Amp version) Fuse – 150 Amp 600 VAC (For use with 120 Amp version) Fuse – 1 Amp Time Delay "CC" Fuse – 2 Amp 5x20 mm Fast Act.
