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Siemens POWER CONTROL Series Operation Manual

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The use of an appropriate single-phase or three-phase fused disconnect or circuit breaker with this
Power Controller is required to ensure the safety of operating personnel.
HAZARDOUS VOLTAGES exist at the Power Controller Heat Sinks and at the Load, AT ALL
TIMES, when input voltage is connected. This condition exists even when the Power Controller is set
to deliver zero output.
The fused disconnect or circuit breaker must be open or OFF to perform maintenance of any kind,
including at the Load.
If this Handbook is not supplied to the End User, a WARNING statement identical to the
above should be prominently displayed in the Installation and Operation Instructions provided
to the End User.
s
Large Drives ROBICON
500 Hunt Valley Road, New Kensington, PA, USA 15068
P h o n e :
7 2 4 - 3 3 9 - 9 5 0 0
F a x :
7 2 4 - 3 3 9 - 9 5 6 2
We b :
https://www.robiconperfectharmony.com/
POWER CONTROL SERIES
SCR Power Controls
3PCI Series
25 A through 1200 A
Operation Manual
Manual Number: 19000325
Version 1.2
May 2006
WARNING
ORIGINAL EQUIPMENT MANUFACTURERS
—PLEASE NOTE—
Energy & Automation, Inc.
C u s t o m e r S u p p o r t P h o n e : 7 2 4 - 3 3 9 - 9 5 0 1 ( 2 4 - h o u r s )
C u s t o m e r S u p p o r t F a x : 7 2 4 - 3 3 9 - 4 3 9 4

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  • Page 1 POWER CONTROL SERIES SCR Power Controls 3PCI Series 25 A through 1200 A Operation Manual Manual Number: 19000325 Version 1.2 May 2006 WARNING The use of an appropriate single-phase or three-phase fused disconnect or circuit breaker with this Power Controller is required to ensure the safety of operating personnel.
  • Page 2 This manual applies to all 3PCI Series power controllers (25 A through 1200 A) manufactured by LD R and replaces manual 19000325 in its entirety. SCR Power Controls 3PCI Operation Manual (p/n 19000325) VERSION HISTORY Version 1.0 May 2003 Version 1.1 July 2003 Version 1.2 May 2006...

  • Page 3: Table Of Contents

    3PCI SCR Power Controller Series Manual Table of Contents TABLE OF CONTENTS CHAPTER 1: INTRODUCTION 1.1. Overview............................1-1 1.2. Operation ............................1-2 1.3. Three-phase Overcurrent (OC) Trip Feature .................. 1-2 1.4. Three-phase Current Limit (CL) Feature ..................1-3 1.5. Options ............................1-3 1.5.1.
  • Page 4 Table of Contents 3PCI SCR Power Controller Series Manual CHAPTER 6: SERVICE How to Contact s....................... 6-1 6.1. 6.2. Spare Parts............................6-1 6.3. Drawing List ............................. 6-4 ADDENDUM ..............................A-1 INDEX SUPPLEMENTS DRAWINGS ∇ ∇ ∇ Version 1.2 (19000325)
  • Page 5 3PCI SCR Power Controller Series Manual Table of Contents LIST OF FIGURES CHAPTER 1: INTRODUCTION Figure 1-1. Typical 3PCI Power Controller .................... 1-1 Figure 1-2. Front, Cutaway and Side Views of a Typical 25A to 225A 3PCI Controller......1-2 CHAPTER 2: INSTALLATION Figure 2-1.
  • Page 6 Table of Contents 3PCI SCR Power Controller Series Manual Version 1.2 (19000325)

  • Page 7: Chapter 1: Introduction

    3PCI SCR Power Controller Series Manual Introduction CHAPTER 1: INTRODUCTION In This Section: • Overview ..............1-1 • Operation .............1-2 • Three-phase Overcurrent (OC) Trip Feature..1-2 • Three-phase Current Limit (CL) Feature .....1-2 • Options..............1-3 • Technical Specifications ........1-3 1.1. Overview LD R.

  • Page 8: Operation

    Introduction 3PCI SCR Power Controller Series Manual Figure 1-2. Front, Cutaway and Side Views of a Typical 25A to 225A 3PCI Controller 1.2. Operation The 3PCI accomplishes phase fired control by the switching action of three pairs of inverse-parallel power SCRs.

  • Page 9: Options

    3PCI SCR Power Controller Series Manual Introduction transformers monitor the true rms current, and feed the information to option CL, which limits the true rms current regardless of the process control signal. 1.5. Options Several options are available on the 3PCI. Several of these options are listed below and explained in the subsections that follow.
  • Page 10 Introduction 3PCI SCR Power Controller Series Manual Item Description 0-1 mA (min) 0-3 mA (max) 0-3 mA (min) 0-30 mA (max) Control methods: 1. Potentiometer (5 kΩ, 0.5 watt) 2. Dry contact closure 3. Temperature or process controller Non isolated input (galvanic isolation); 250 Ω, 0.5 watt Control signal input impedance standard...

  • Page 11: Table 1-2. 3Pci Model Number Code Descriptions

    3PCI SCR Power Controller Series Manual Introduction Table 1-2. 3PCI Model Number Code Descriptions 3PCI-___ -_____ -CL/OC-D-__ -____________ -__________ -________ Voltage Current Input Type General Options Ramp Rate Optional (Volts) (Amps) Options Lug Kit 20=208 V 1=0-5 mA CID = Current FR =0.100 sec blank 24=240 V...
  • Page 12 Introduction 3PCI SCR Power Controller Series Manual Version 1.2 (19000325)

  • Page 13: Chapter 2: Installation

    3PCI SCR Power Controller Series Manual Installation CHAPTER 2: INSTALLATION In This Section: • Mounting the 3PCI ............2-1 • Fan Wiring (Models Rated at 90 A and Higher)...2-1 • Wiring Overtemperature Contacts .......2-1 • Input/Output Wiring ............2-1 • Adjusting the Overcurrent (OC) Feature......2-1 •...

  • Page 14: Figure 2-1. Typical 3Pci Line And Load Connections

    Installation 3PCI SCR Power Controller Series Manual Wiring rated at 75°C is required for all 3PCI model current ratings. The 3PCI is phase-rotation insensitive. That is, three-phase input power can be connected in any sequence to terminals , and , and will not cause an out-of-phase condition. Warning! Branch circuit overcurrent protection required is to be provided in accordance with the national and local codes of the inspecting authority.

  • Page 15: Figure 2-2. Input And Output Connections Overview For The 3Pci

    3PCI SCR Power Controller Series Manual Installation 4 (Gnd) 1 (Gnd) Figure 2-2. Input and Output Connections Overview for the 3PCI Table 2-2. Terminal Block Specifications Pin # Description Terminal Block Common Voltage input Shutdown 10 11 12 Common +15 VDC -15 VDC + mA input +10 VDC...

  • Page 16: Internal 3Pci Connections

    Installation 3PCI SCR Power Controller Series Manual 2.5. Internal 3PCI Connections Before operating the 3PCI, the customer must determine which control signal is used. The 3PCI will operate at 50/60 Hz with no circuit changes required. ∇ ∇ ∇ Version 1.2 (19000325)

  • Page 17: Chapter 3: Operation

    3PCI SCR Power Controller Series Manual Operation CHAPTER 3: OPERATION In This Section: • Introduction ..................3-1 • Internal Manual Control of Power Output ...........3-1 • Temperature Controller...............3-2 • Remote Manual Control (Only) with a Potentiometer ......3-2 • Auto/Manual Control with a Controller and Remote Potentiometer..3-3 •...

  • Page 18: Temperature Controller

    Operation 3PCI SCR Power Controller Series Manual 3.3. Temperature Controller A wide range of controller outputs can be used to drive the 3PCI. The range of acceptable full scale output voltages is from a minimum of 0-5 VDC to a maximum of 10 VDC. Since most controllers have a current output, the input impedance of the 3PCI on (-) and (+) is 0.05 to 10 VDC for voltage control.

  • Page 19: Auto/Manual Control With A Controller And Remote Potentiometer

    3PCI SCR Power Controller Series Manual Operation 3.5. Auto/Manual Control with a Controller and Remote Potentiometer Following the instructions detailed in the previous section (Section 3.4: Remote Manual Control (Only) with a Potentiometer), select and install the remote potentiometer. Install the AUTO/MAN switch in the same general location as the remote manual potentiometer.

  • Page 20: Controlling Several 3Pcis In Parallel With One Controller

    Operation 3PCI SCR Power Controller Series Manual 3 (Shutdown) Controller 4 (Common) Figure 3-5. On/Off Control with Output Disabled by Contact Closure Calibrate the system as outlined in Section 3.3: Temperature Controller on page 3-2. Note that zero power demand is accomplished by closing the contacts with the controller, and maximum power demand is present when the contacts are open.

  • Page 21: Chapter 4: Options Setup

    3PCI SCR Power Controller Series Manual Options Setup CHAPTER 4: OPTIONS SETUP In This Section: • Introduction ........... 4-1 • Option CL (3-phase Current Limit) ....4-1 • Option CID (Current Imbalance Detector) ..4-1 • Reset Push-button ........4-1 •...
  • Page 22 Options Setup 3PCI SCR Power Controller Series Manual Version 1.2 (19000325)

  • Page 23: Chapter 5: Troubleshooting

    3PCI SCR Power Controller Series Manual Troubleshooting CHAPTER 5: TROUBLESHOOTING In This Section: • Customer Service Program ....5-1 • Troubleshooting Typical Symptoms..5-1 • Static Precautions When Servicing..5-1 • Environmental Problems..... 5-2 • Input Power and Load Connections..5-3 •...

  • Page 24: Environmental Problems

    Troubleshooting 3PCI SCR Power Controller Series Manual ESD Sensitive Equipment! Always be aware of electrostatic discharge (ESD) when working near or touching 3PCI components. Printed circuit boards contain components that are sensitive to static electricity. Handling and servicing of components that are sensitive to ESD should be done only by qualified personnel and only after reading and understanding proper ESD techniques.

  • Page 25: Excessive Vibration

    3PCI SCR Power Controller Series Manual Troubleshooting provide more cooling, or the 3PCI should be moved to a cooler location, or call the ROBICON service department. 5.4.4. Excessive Vibration A significant degree of pitched or unpitched vibration can cause numerous problems. If vibration is isolated as a probable cause of improper operation, standard vibration-isolation mounting techniques should be employed.

  • Page 26: Replacement Fuses

    Troubleshooting 3PCI SCR Power Controller Series Manual Symptom Possible Cause(s) Possible Solution(s) replace it. On units rated at 225 A and below: Remove the fuse and check the front-to- back SCR pairs by measuring resistance between terminals (of the SCR) and On the R×1 scale, the resistance should be infinite in both directions.

  • Page 27: Table 5-3. Torque Specifications Based On Conductor Sizes

    3PCI SCR Power Controller Series Manual Troubleshooting Attention! All input and output conductors should have a minimum temperature rating of 75°C. Table 5-3. Torque Specifications Based on Conductor Sizes Torque for Slot Torque for Slot Input/Output Torque for ≤ 0.25″ Conductor Size Width Width...
  • Page 28 Troubleshooting 3PCI SCR Power Controller Series Manual Version 1.2 (19000325)

  • Page 29: Chapter 6: Service

    Phone: (724) 339-9501 Fax: (724) 339-9507 Email: support@siemens.com Our telephone answering service will accept your messages during all off-hours, including weekends. We receive those messages at 8 am on the next normal work day. We will respond at the earliest time possible, within your time zone and normal work day.

  • Page 30: Chapter 6: Service

    Service 3PCI SCR Power Controller Series Manual Amps Item Description Item # 60 A Fuse, 125 A, 700 V 261277.30 PCB assembly, 3PCI trigger 460T41.00 PCB assembly, SCR module #1, *DVDT VAR* H023870 SCR/dual package, 92 A, 1400 V H011024 90 A Fan, axial, 115 Vac, 110 CFM H018659...

  • Page 31: Drawing List

    3PCI SCR Power Controller Series Manual Service Amps Item Description Item # 800 A Fan, axial, 115 Vac, 350 CFM 074892 Fuse, 1000 A, 700 V 261277.42 Lug kit, single-phase .8-1.2kA, CSA certified H020760 PCB assembly, 3PCI trigger 460C17.xx PCB assembly, *DVDT VAR* H028607 SCR, 719 A, 1400 V H020037...
  • Page 32 Service 3PCI SCR Power Controller Series Manual Version 1.2 (19000325)
  • Page 33 3PCI SCR Power Controller Series Manual Warranty CHAPTER 7: WARRANTY In This Section: • Guarantee and Product Liability ........7-1 • In-House Repair Services..........7-1 • Field Service Repairs...........7-2 WARRANTY POLICY AND PRODUCT LIABILITY LD R products as well as product liability This chapter details the warranty policy of LD R’s standard warranty policy is listed below.
  • Page 34 Warranty 3PCI SCR Power Controller Series Manual Warranty Repairs: In addition to securing Repair Service Order (SO) number, please supply the System CO number (found on the system, usually on the tag inside the cabinet door). LD R. The price for Non-Warranty Repairs: Secure a Repair Service Order (SO) number from exchange or repair will be quoted for your purchase order when you receive the SO number.

  • Page 35: Addendum

    3PCI SCR Power Controller Series Manual Addendum TITLE: Instructions for Configuring the 3PCI Gate Trigger (GTU) Units P/N 460T2300, 460T23.10, 460T23.20, and 460T41.00 1.0 PURPOSE The purpose of this document is to define the necessary steps to configure the above 3PCI GTU’s. 2.0 SCOPE These instructions apply to the 460T23.00, 460T23.10, 460T23.20 and 460T41.00.
  • Page 36 Addendum 3PCI SCR Power Controller Series Manual Pos “C” (PR) Power Regulation J3, J4 Pos “A” RROCT J6 – Zero ohm resistor normally installed by PCB vendor Zero ohm resistor removed for remote reset OCT when required J7 – Normally in Pos “A” “Open”...
  • Page 37 3PCI SCR Power Controller Series Manual Addendum The following three (3) charts document which trigger circuits we have made in the past. Gate Trigger Circuit in a Stand-alone Frame (350-1200A) REPLACED BY: 460T23.10 Non-UL/CSA 460T23.20 UL/CSA Ramp Integrator Curr Reg Curr Reg RR OCT Vreg CR Ext.
  • Page 38 Addendum 3PCI SCR Power Controller Series Manual Gate Trigger Only (350-1200A) REPLACED BY: 460T23.00 Ramp Integrator Curr Reg Curr Reg RR OCT Vreg CR Ext. FB 10 x Ramp in "B" Position Item Part Number Description Open Closed "A" 460C33.01 ASSY GTU BRD 208V STD RAMP 460C33.02 ASSY GTU BRD 240V STD RAMP...
  • Page 39 3PCI SCR Power Controller Series Manual Addendum Gate Trigger Only (15-225amp) REPLACED BY: 460T41.00 Ramp Integrator Curr Reg Curr Reg RR OCT Vreg CR Ext. FB 10 x Ramp in "B" Position Item Part Number Rev Description Open Closed "A" 469196.01 ASSY GTU BRD 208V STD RAMP 469196.02...
  • Page 40 Addendum 3PCI SCR Power Controller Series Manual Version 1.2 (19000325)

  • Page 41: Index

    3PCI SCR Power Controller Series Manual Index INDEX Note that locator page numbers appear in regular type faces for standard index references (e.g., 7-10). For index references that correspond to items found in tables, the locator page numbers are shown in an italic type face (e.g., 6-24).
  • Page 42 Index 3PCI SCR Power Controller Series Manual fused disconnect, 3-1, 3-2, 3-3, 5-1 operating with an adequate load, 3-1, 5-1 fuses, 5-5, 5-6 current, 1-2 manufacturers and p, 5-6 lug kit, 1-5 replacement, 5-6 —M— —G— maintenance, 3-1, 5-4 manual control, 1-2, 3-1, 5-5 gain control, 1-2, 1-4, 2-2, 3-1, 3-2, 4-1, 5-5 galvanic isolation, 1-4 manual pot, 3-2, 3-3...
  • Page 43 3PCI SCR Power Controller Series Manual Index power output, 1-4 trip reset push-button, 1-2 power regulation, 1-5 troubleshooting, 5-1 power SCRs protection, 1-4 symptoms and solutions, 5-5 preset maximum current level, 1-3 process control signal, 1-3 —V— process controller, 1-4 vibration, 5-5 protection, 1-2, 1-4, 2-1, 2-2 voltage, 1-5...
  • Page 44 Index 3PCI SCR Power Controller Series Manual Version 1.2 (19000325)

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