1051 Series Product Manual - English

July 2013

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.

DANGER

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)

WARNING

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)

Caution

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)

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Table of Contents

Product Description ..................................................................................................... 1-1 Standard Features ............................................................................................... 1-2 Optional Features ................................................................................................ 1-3 Technical Specifications ...................................................................................... 1-4 Part Number ........................................................................................................ 1-6

Hardware........................................................................................................................ 2-1 Installation ........................................................................................................... 2-1 Enclosure ............................................................................................................. 2-1 Enclosure Temperature ....................................................................................... 2-1 Vibration .............................................................................................................. 2-2 Mounting .............................................................................................................. 2-3 Wiring .................................................................................................................. 2-3 Control and System Connections ........................................................................ 2-3 Digital Inputs ........................................................................................................ 2-8 Digital Outputs & Relay Output ............................................................................ 2-9 Important Digital Output Considerations ............................................................ 2-10 Analog I/O .......................................................................................................... 2-13 User Analog Inputs ............................................................................................ 2-14 User Analog Outputs ......................................................................................... 2-16 Temperature Measurement and Control ............................................................ 2-17 Voltage Attenuation ........................................................................................... 2-18 Current Transformers and Burden Resistors ..................................................... 2-18

Configuration and Monitoring .................................................................................... 3-1 Configuration Software ........................................................................................ 3-1 Configuration Application Overview ..................................................................... 3-2 Configuration Menu Bar ....................................................................................... 3-3 Off-line Configuration ........................................................................................... 3-7 The Setup Tab ................................................................................................... 3-8 The Operation Tab ........................................................................................... 3-11 The Fault/Alarm Tab ........................................................................................ 3-13 The Network Tab .............................................................................................. 3-13 Custom Tab ..................................................................................................... 3-15 Storing the Configuration ................................................................................... 3-18 On-line Operation .............................................................................................. 3-20 Set the Unit IP Address ..................................................................................... 3-27 Edit Ethernet Connection Parameters ............................................................... 3-32 Zero Crossover Control and Transformer-Coupled Loads ................................. 3-36

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Calibration ..................................................................................................................... 4-1 Load Calibration from File .................................................................................... 4-2 Save Calibration .................................................................................................. 4-3 Selective Calibration ............................................................................................ 4-4 Analog Input Calibration ...................................................................................... 4-8 Analog Output Calibration .................................................................................. 4-11

Local Digital Control .................................................................................................... 5-1 Status Bar ............................................................................................................ 5-1 Run Display ......................................................................................................... 5-3 Setpoint Display and Edit ..................................................................................... 5-4 Control Setup and Edit ......................................................................................... 5-6 Fault Display ........................................................................................................ 5-8 Alarm Display .................................................................................................... 5-10 Identity Display .................................................................................................. 5-11 Network Display ................................................................................................. 5-12 Flexible Display Capability ................................................................................. 5-13 Display Mismatch............................................................................................... 5-17

Network Communication Options ............................................................................. 6-1 Integrated Ethernet vs. Industrial Network Add-On.............................................. 6-1 Integrated Communication Protocol MODBUS TCP ......................................... 6-1 Industrial Network Communication .................................................................... 6-11

Settings .......................................................................................................................... 7-1 Voltage Output Feedback Range: ..................................................................... 7-38 Status Word bit OK to Run ............................................................................... 7-38 Startup Operation .............................................................................................. 7-38 Zero Crossover Automatic Power Synchronization............................................ 7-39 Scaling of Power Data ....................................................................................... 7-46 Timed Digital Input Selections ........................................................................... 7-46 Alarm Bits and the Alarm Filter Setting ............................................................ 7-46

Faults, Alarms, and Troubleshooting ........................................................................ 8-1 Fault and Alarm Codes ........................................................................................ 8-3 Fault Reset .......................................................................................................... 8-4 Fault History ........................................................................................................ 8-4 Alarm History ....................................................................................................... 8-4 Troubleshooting Guide ........................................................................................ 8-5 Fuse Replacement ............................................................................................. 8-15

Sample Web-Server Setup .......................................................................................... A-1 Mechanical Dimensions .............................................................................................. B-1 Electrical Characteristics ............................................................................................ C-1

Control Power VA Requirements ........................................................................ C-6

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Spang 1050 Series, 1051 Watt Losses ............................................................... C-7 Agency Approvals ............................................................................................... C-8

List of Figures

Figure 1-1 1051 Block Diagram, 15 - 400 Amps ..................................................... 1-1 Figure 1-2 1051 Block Diagram, 600 Amp .............................................................. 1-2 Figure 2-1 Typical Enclosed Package Access ........................................................ 2-4 Figure 2-2 Digital Output Connection .................................................................... 2-10 Figure 5-1 Local Digital Control............................................................................... 5-1 Figure 5-2 Run Display ........................................................................................... 5-3 Figure 5-3 Voltage Setpoint Display (Output On) .................................................... 5-4 Figure 5-4 Voltage Setpoint Display (Enter or Discard) .......................................... 5-5 Figure 5-5 Control Setup ......................................................................................... 5-6 Figure 5-6 Control Setup, Edit Mode ....................................................................... 5-7 Figure 5-7 Fault Display .......................................................................................... 5-8 Figure 5-8 Fault History .......................................................................................... 5-9 Figure 5-9 Alarm Display ...................................................................................... 5-10 Figure 5-10 Identity Display .................................................................................. 5-11 Figure 5-11 Network Information Display .............................................................. 5-12 Figure 5-13 Unit Selection Keys ........................................................................... 5-14 Figure 5-14 Select New Unit ................................................................................. 5-15 Figure 5-15 Unit IP Address and Description ........................................................ 5-16 Figure 7-1 Phase Angle Start Voltage Waveform ................................................. 7-39 Figure 7-3 Worst case, 100% overlap ................................................................... 7-39 Figure 7-4 50% Overlap ........................................................................................ 7-40 Figure 7-5 Improved Synchronization, 10% Overlap ............................................. 7-40 Figure 7-6 Synchronized, 0% Overlap .................................................................. 7-40 Figure 7-8 39 Zone Example ................................................................................ 7-41 Figure 7-7 12 Zone Example ................................................................................ 7-41 Figure 7-9 39 Zone Synchronization Performance................................................ 7-41 Figure 8-1 Control Board LEDs ............................................................................... 8-2 Figure C-1 1051 Electrical Schematic .................................................................... C-3 Figure C-2 1051, 600 Amp Schematic ................................................................... C-5

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List of Tables

Table 1-1 Technical Specifications ................................................................................ 1-4 Table 2-1 UL-Rated Maximum Ambient Temperature .................................................. 2-2 Table 2-2 UL Minimum Enclosure Size ......................................................................... 2-2 Table 2-3 1051 Connectors, Control Board 123011000 ............................................... 2-5 Table 2-4 1051 Connectors, Option Board 123012xxx ................................................. 2-6 Table 2-5 Lug Torque Specifications ............................................................................. 2-7 Table 2-6 Digital Inputs................................................................................................... 2-8 Table 2-7 Digital Outputs ................................................................................................ 2-9 Table 2-8 Digital Output De-Rating .............................................................................. 2-11 Table 2-9 Analog Input Connections ........................................................................... 2-13 Table 2-10 Analog Output Connections ...................................................................... 2-16 Table 6-1 MODBUS TCP Message Header ................................................................. 6-2 Table 6-2 Read Multiple Registers request (FC 3) ........................................................ 6-3 Table 6-3 Read Multiple Registers response ................................................................ 6-3 Table 6-4 Write Single Register request (FC 6) ............................................................ 6-4 Table 6-5 Write Single Register response ..................................................................... 6-4 Table 6-6 Write Multiple Registers request (FC 16) ...................................................... 6-5 Table 6-7 Write Multiple Registers response ................................................................ 6-5 Table 6-8 Read/Write Multiple Registers request (FC 23) ............................................ 6-6 Table 6-9 Read/Write Multiple Registers response....................................................... 6-7 Table 6-10 Read/Write Multiple Registers Example ..................................................... 6-8 Table 6-11 MODBUS Exception Response .................................................................. 6-9 Table 6-12 MODBUS Exception Codes ........................................................................ 6-9 Table 6-13 Little Endian Notation ............................................................................... 6-10 Table 6-14 Output Assembly - Poll Write Reference .................................................. 6-15 Table 6-15 Input Assembly - Poll Read Reference ..................................................... 6-15 Table 7-1 List of Settings ................................................................................................ 7-1 Table 8-1 Fault and Alarm Codes (1051 Single Phase) ............................................... 8-3 Table 8-2 Troubleshooting Guide .................................................................................. 8-6 Table C-1 Control Power VA Requirements ......................................................... C-6 Table C-2 1051 Watt Losses ................................................................................ C-7 Table C-3 Agency Approvals ................................................................................ C-8

1-1

Chapter 1

Product Description

The Spang Power Electronics 1051 Single Phase Controller is one of a series of products based on Spangs 1050 control design. The 1050 product family is well-suited for a wide variety of AC power applications. The 1050 family are multi-processor-based designs that drive SCRs that feed a variety of industrial heating loads. The 1051 design features short circuit protection, local or remote (networked) operation, a variety of user-definable inputs and outputs, and the precise regulation of power, voltage, current, temperature, or phase angle (duty cycle). The Spang Power Electronics 1050 power controller series represent the next generation of power control for AC applications that require dependability, flexibility and unmatched performance.

The 1051 Single Phase Controller has the following innovative features:

Low cost for premium feature set and performance Expandable I/O interface for sophisticated system applications, including thermocouple interface Browser based configuration tool for unit configuration, control, and monitoring Use of removable SD memory card for storage of configuration files Standard Ethernet MODBUS TCP network communication for unit configuration, control, and

monitoring plus a variety of optional industrial network interfaces (DeviceNet, Profibus, Ethernet/IP) Book shelf style package to minimize panel space consumption Integrated I2t fuse within touch proof package Optional color touch screen for local interface

Figure 1-1 1051 Block Diagram, 15 - 400 Amps

Product Description July 2013

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Figure 1-2 1051 Block Diagram, 600 Amp

Standard Features

The Spang 1051 Power Controller product offers the following features:

Flexibility. Configurable operating modes, ratings, limits, external inputs, and setpoints. It also offers multiple firing modes within the standard hardware package; phase angle and zero-crossover (burst firing).

On-Board Diagnostics. Fault and alarms memory (ten fault buffers and ten alarm buffers) provides data for analysis that may indicate a need for process modification, troubleshooting or preventative maintenance.

Computerized Setup and Calibration. Web-based configuration application for setup, calibration, monitoring, control and diagnostics

Mechanical Design. Touch-proof packaging prevents unintentional contact with hazardous voltage. A book-shelf style mechanical design allows efficient use of panel space when integrated into multi-unit system configurations.

Advanced Process and Fault Monitoring. Real-time monitor of voltage, current, power, temperature (optional) and fault/alarm conditions. Real-time adjustment of the setpoint. Communication methods include:

Local, using an analog control signal Local, using the configuration software application Local, with optional Local Digital Control feature Remote, using MODBUS TCP protocol over Ethernet and the standard Universal Comm port

Operates on universal line voltages, from 20 to 600 VAC and 50/60 Hz.

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DSP-based control

1600 Volt SCR's

20KHZ pulse transformer coupled SCR gating circuit

True RMS calculation of voltage, current, and power at 60KHZ sampling

Simultaneous regulation of voltage, current, and power

User-configurable analog inputs and outputs

User-configurable digital inputs and outputs

Non-volatile storage of settings and configuration

Web-hosted user configuration tool (stored on 1051 unit)

Compliance: CE, UL/ cUL (400A and under), RoHS

Optional Features

The following optional features are available for the 1051:

Expanded IO, including remote voltage, current and temperature (thermocouple) feedback as well as additional digital and analog I/O.

Network Interface, allowing for remote control and monitoring of the 1051.

Optional network interfaces include DeviceNet, Profibus, ETHERNET/IP, PROFINET, and Ethernet MODBUS TCP (a second Ethernet MODBUS TCP port provided on the network interface board).

Local Digital Control. Color touch-screen LCD display allows the user to control and monitor unit set points, output, and status.


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Technical Specifications

Table 1-1 Technical Specifications

Input voltage 20 to 600 VAC

Input line frequency 47 to 63 Hz.

Control power 115VAC or 230VAC, 50/60 Hz.

Output voltage rating 0 to 600 VAC maximum

Output current ratings See ordering information

Ambient temperature 0 to 50 C ambient

Humidity Up to 95% non-condensing

Maximum Elevation 1,000 m. above sea level

Cooling Fan power above 50A PCU; either 115VAC or 230VAC, 50/60 Hz

Regulation 1% (voltage, current, or power)

Analog control reference

Standard: One (1) configurable: current (4 20 mA; 249 ohm impedance), voltage (0 10 V; 1 Meg-ohm impedance), or potentiometer; 50V common-mode limit; 12 bit A/D achieves better than 1% accuracy

Optional: One (1) additional; same configurable functionality

Optional temperature reference

One (1) thermocouple input; 24 bit A/D achieves 0.25% accuracy

Digital control reference PC based configuration application, Remote Display, or network communication

Input voltage and current feedback (internal)

Contains voltage and current feedbacks for input voltage and current

Output voltage feedback (internal)

Contains voltage feedback for output voltage

Relay contact

One (1) Normally Open (N.O.) and One (1) Normally Closed (N.C.), Form C type selectable functionality

Rating: 0.5A @ 125VAC (general purpose); 2.0A max @ 0 - 30VDC (resistive) relay can only be used in a Class 2 transformer circuit or a low voltage limited energy circuit.

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Analog outputs Standard: Two (2) configurable voltage (0-5 V) or current (4-20 mA).

Optional: Four (4) additional; same configurable functionality.

Analog interface isolation Differential inputs for sink or source signals

Sourcing outputs, commons are tied common and ground referenced

Digital inputs

Standard: Enable / Inhibit, Remote / Local, Two (2) inputs configurable as alarm, fault, timed alarm, timed fault, fault reset, or output on.

Optional: Two (2) additional; same configurable functionality

Digital outputs

Standard: One (1) Form-C with dry-type contacts configurable as alarm, fault, no fault, OK to Run, or Run (firing output).

Optional: Three (3) open-collector outputs; same configurable functionality

LED indicators

POWER steady Green indicates Power Supply is okay

HEARTBEAT 1&2 flashing Green indicates processors are running

ENABLE steady Green indicates Unit Enabled

RUN steady Green indicates Output On

ALARM steady Yellow indicates alarm

FAULT steady Red indicates fault

Configuration port Ethernet port for PC based browser access, Display connection, or Ethernet MODBUS TCP network comm

Over temperature monitoring One (1) internally mounted thermal sensor.

Short circuit protection Integrally mounted I2t fuse SCCR rating: 15 - 400A, 100kA

Transient voltage protection RC networks across the SCRs (no MOVs)

Protection 15-600 Amps: IP20 with appropriately sized (user installed) power cable through power cable access holes. 1000 Amps and higher: IP00

Network connectivity

Ethernet MODBUS TCP via configuration port;

Optional network interface for DeviceNet, Profibus, Ethernet/IP, PROFINET, or Ethernet MODBUS TCP (a second Ethernet MODBUS TCP interface)

Certifications UL/cUL (400A and lower; 600A pending), CE, RoHS, WEEE


1-6

Part Number

The Part Number format for the 1051 Single Phase Controller is described below.

1 0 5 1 - n n n n - a a n - aaa - n - n n 1) 2) 3) 4) 5) 6) 7)

Product Identifier Current Rating (Amps) Communication Options Auxiliary IO Option Control Power

Note (1) Current Rating 0015 = 15 Amp

0025 = 25 amp 0050 = 50 Amp

0100 = 100 Amp 0200 = 200 Amp 0300 = 300 Amp 0400 = 400 Amp 0600 = 600 Amp * UL/cUL certification pending Note (2) Network Descriptor:

0 = No network comm D = DeviceNet P = PROFIBUS E = Ethernet MODBUS TCP I = Ethernet/IP N = PROFINET

Note (3) Network Redundancy 0 = Single network card R = Redundant network card

Note (4) Local Digital Control 0 = No Display 1 = Local Display

2 = Remote Display

Note (5) Auxiliary I/O Option 0 = No auxiliary I/O T = Auxiliary I/O board with thermocouple option TLV = Auxiliary I/O board with thermocouple option and low voltage feedback Note (6) Control Power 1 = 115V, single phase, 50/60 Hz. 2 = 230V, single phase, 50/60 Hz. Note (7) Special Configuration (00 = Standard configuration)

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Chapter 2

Hardware

WARNING

The 1051 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.

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.

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.

Installation

Prior to installation, the 1051 should be carefully checked for shipping and/or handling damage such as loose or broken parts or wires.

Enclosure

The 1051 must be mounted in a protective enclosure to prevent the hazard of electrical shock and also to avoid exposing the circuitry to damaging contaminants. If the 1051 will be located in an area of dust, falling debris, splashing or falling water, adequate protection must be supplied by a special NEMA or IP-rated enclosure; such enclosures are available as part of an integrated power system.

Enclosure Temperature

The 1051 is rated at 50C maximum ambient temperature inside of an enclosure. If the 1051 is mounted in an enclosure other than one designed and built by Spang Power Electronics, care must be taken to allow sufficient cooling/ventilation. Consult the factory for enclosure temperatures above 50C.

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Table 2-1 UL-Rated Maximum Ambient Temperature

UL-Rated Maximum Ambient Temperature (degrees Celcius) *

15 100 Amps 50C

200 400 Amp 40C

* The 600A unit is rated for 50C (non- UL).

Table 2-2 UL Minimum Enclosure Size

UL Minimum Enclosure Size *

Current Rating (Amps)

Height (inches) Width (inches) Depth (inches)

50 20 16 12

100 24 20 12

200 30 24 12

300 30 24 16

400 30 24 16

600 30 24 16

* Based on 150% dimensionally or to meet the wire-bending space, whichever is larger.

Vibration

If the mounting site has a vibration concern, the 1051 should be mounted using industry standard shock mounting techniques.

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Mounting

The 1051 power controller is designed to be mounted in a vertical orientation. Allow four inches above and below the 1051 for adequate cooling. Allow additional room for wiring as required by the individual application and applicable standards such as the National Electric Code.

The enclosed-package 1051 is designed for side by side mounting to minimize consumed panel space and may be mounted with zero clearance between adjacent units.

All enclosed-package 1050 Series power controllers require flush mounting against a flat panel surface. The flush mount provides a necessary and directed path for airflow to dissipate the expected watts generated by the power semiconductors.

For any other mounting considerations, contact Spang Power Electronics.

Wiring

Wire should be sized in accordance with the appropriate specific code guidelines. Ambient operating temperature should be taken into account.

DANGER

The user is responsible for conformance 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.

Control and System Connections

The 1051 uses a combination of Phoenix-style pluggable connectors, Molex crimp connectors, and quick connect terminals.

Caution

When using the internal power supply to provide power for analog references (i.e. pot control or shorting power to reference), the analog reference DIP switches must be positioned as voltage inputs (DIP switch in the Open position). If the DIP switches are not properly configured, the regulator/supply may not be able to achieve 100% reference. This condition may prove damaging to board-level components.

WARNING


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Figure 2-1 Typical Enclosed Package Access

Removable covers, allowing access to PCB connections.

Refer to the appropriate 1050 user drawings for PCB connections and layout.

Power wire connection (typical)

Control wireways (typical Top and Bottom)

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Table 2-3 1051 Connectors, Control Board 123011000

Usage Plug # Description Size AWG Wire Size*

IO Connectors Control board 123011000

Digital IO J15 6 pin vertical through-hole pluggable 3.81mm 28-16 AWG

Relay contacts J16 3 pin vertical through-hole pluggable 3.81mm 28-16 AWG

Analog IO J17 7 pin vertical through-hole pluggable 3.81mm 28-16 AWG

System Connectors - Control board 123011000

Neutral Voltage Sense

J1 2 pin vertical through-hole pluggable

earlier models 3.81mm 28-16 AWG

current production 5.08mm 24-12 AWG

Input Voltage Sense

J2 Quick Connect Terminal 0.187

Output Voltage Sense

J3 Quick Connect Terminal 0.187

Input Current Sense

J4 4 pin vertical through-hole pluggable 3.81mm 28-16 AWG

Heatsink Temperature

J5 3 pin vertical through-hole Molex friction lock header

0.1 centers

DSP JTAG J6 14 pin (2x7) vertical through-hole header 0.1 centers

microSD J7 8 pin microSD card slot surface mount

internal JTAG J8 10 pin (2x5) vertical through-hole header 0.05 centers

Ethernet J9 8 pin inverted Ethernet jack 8P8C modular

SCR1 gate drive J10 2 pin vertical through-hole Molex friction lock header

0.1 centers

SCR2 gate drive J11 2 pin vertical through-hole Molex friction lock header

0.1 centers

Network Option J12 16 pin (2x8) vertical through-hole header 0.1 centers

Digital option J13 20 pin (2x10) vertical through-hole header 0.1 centers

Analog option J14 20 pin (2x10) vertical through-hole header 0.1 centers

Control Power J18 2 pin vertical through-hole pluggable 5.08 mm 24-12 AWG

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Earth Ground J19 Quick Connect Terminal 0.187

Test points (internal use)

J20 J21

16 pin (2x8) right-angle through-hole header 0.1 centers

Display Power J22 2 pin vertical through-hole pluggable 3.81mm 28-16 AWG

Fan Power J23 J24

2 pin vertical through-hole pluggable 3.81mm 28-16 AWG

DSP Boot JP1 3 pin (1x3) vertical through-hole header 0.1 centers

*Standard Metric Equivalent Wire Size, from IEC 60228

28-16 AWG 0.5 mm2 1.5 mm2 22-30 AWG 0.5 mm2

24-12 AWG 0.5 mm2 4 mm2 22-18 AWG 0.5 mm2 0.75 mm2

Table 2-4 1051 Connectors, Option Board 123012xxx

IO Connectors - Option board 123012xxx

Digital IO (option)

J6 J8

3 pin vertical through-hole pluggable 6 pin vertical through-hole pluggable

3.81mm 28-16 AWG

Temperature (option)

J4 2 pin vertical through-hole pluggable 3.81mm 28-16 AWG

Analog IO (option)

J5 J7

4 pin vertical through-hole pluggable 6 pin vertical through-hole pluggable

3.81mm 28-16 AWG

System Connectors - Option board 123012xxx

Remote Vout J1 J2

2 pin vertical through-hole pluggable 3.81mm 28-16 AWG

Remote Iout J3 4 pin right-angle through-hole pluggable 3.81mm 28-16 AWG

Digital option J9 20 pin (2x10) receptacle 0.1 centers

Analog option J10 20 pin (2x10) receptacle 0.1 centers

Earth Ground J11 Quick Connect Terminal 0.187

*Standard Metric Equivalent Wire Size, from IEC 60228

28-16 AWG 0.5 mm2 1.5 mm2 22-30 AWG 0.5 mm2

24-12 AWG 0.5 mm2 4 mm2 22-18 AWG 0.5 mm2 0.75 mm2

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Table 2-5 Lug Torque Specifications

Lug Torque by Frame Size

Current Rating (Amps)

Wire Range Lug Range (SI) Torque Torque (SI) Set Screw

15, 25 1X 2-14 AWG 1X 35- 2.5mm2 25 Lbf-in 2.8 N-m .060 [1.5mm] Slot

50 1X 2-14 AWG 1X 35- 2.5mm2 35 Lbf-in 4.0 N-m .060 [1.5mm] Slot

100 1X 250-6 AWG 1X 120- 16mm2 225 Lbf-in 25.4 N-m 5/16 Hex

200 1X 500-1/0 AWG 1X 240- 50mm2 300 Lbf-in 33.9 N-m 3/8 Hex

300 2X 250-6 AWG 2X 120- 16mm2 225 Lbf-in 25.4 N-m 5/16 Hex



Control Terminal Boards

Connector Size Wire Range Lug Range (SI) Torque Torque (SI) Set Screw

3.81 mm 28-16 AWG 0.14 1.5 mm2 6 Lbf-in 0.7 N-m .025 [0.63mm] Slot

5.08 mm 24-12 AWG 0.20 2.0 mm2 6 Lbf-in 0.7 N-m .025 [0.63mm] Slot

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Digital Inputs

The 1051 provides two standard + two optional = four total user-configurable digital inputs. The digital inputs will indicate a true condition when tied to 1051 ground by direct connection or through a switch or relay rated for 15VDC and 10mA. Selectable functions are:

Not used Alarm when Closed Alarm when Opened Fault when Closed Fault when Opened Fault Reset Output On Timed Fault when Open Timed Fault when Closed Timed Alarm when Open Timed Alarm when Closed Local Control = Analog Firing Mode = Zero Cross

Table 2-6 Digital Inputs

Terminal Number

Terminal description Standard operation

J15 1 Enable Input Shorting 1 to digital common enables the unit. Open inhibits operation.

J15 2 Remote/Local Input Shorting 2 to digital common puts the unit into remote mode. Open is local mode.

J15 3 Digital Common

J15 4 Digital Input 0 User-configurable


J15 6 Digital Common

Option Board 123012xxx



J6 3 Digital Common

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Digital Outputs & Relay Output

The 1051 provides one relay output (standard), and three (optional) open-collector digital outputs. All digital outputs are user-configurable. The relay output may be configured in the same manner as the three optional digital outputs, which are open-collector outputs designed for driving externally powered relays. The user-configurable selections are:

Not used Run Alarm Fault Alarm or Fault Filtered Alarm OK to Run No Fault Local Control Analog Local Control Digital Firing Mode Phase Angle Firing Mode Zero Cross

NOTE for control pcb 123011000 revisions P and earlier: The relay and digital outputs will momentarily energize (switching state) during the initial power up or reset sequence. For control pcb 123011000 revisions Q and higher, the relay and digital outputs will remain in "shelf state" during initial power up and reset. For all revisions, all subsequent transitions are handled as a function of the defined user-configuration and real time status of the power controller.

Table 2-7 Digital Outputs

Terminal Number


J16 1 Normally Open User-configurable, closed when active

J16 2 Relay Common

J16 3 Normally Closed Open when active


J8 1 Digital Power Relay flyback power provided TO the 1051.

J8 2 Digital Out 1 User-configurable, pulled low when active


J8 4 Digital Ground


J8 6 Digital Ground

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A typical output connection is shown below.

Figure 2-2 Digital Output Connection

Important Digital Output Considerations

The digital output pin labeled as Digital Out n is to be fed as a common-source power connection, intended for relay coil diode suppression. It is NOT providing power. Digital Ground pins tie to GROUND within the control board circuitry.

WARNING: The digital outputs should NOT be connected to a 24Vdc power supply with the negative grounded at a different ground potential than the power controller.

WARNING: The digital outputs of multiple power controllers should NOT be tied to a common 24Vdc power supply if the power controllers are at differing ground potentials.

If a relay with a coil-suppression diode is used, correct polarity must be observed when wiring the relay coil; otherwise, the relays power supply could be shorted to ground.

Failure to wire the digital outputs properly will result in unrecoverable damage to the printed circuit board.

NEVER connect digital outputs or digital inputs to AC line voltages!

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Digital Output De-Rating Information

The external DC power supply should be less than 50VDC. The current output total MUST be limited to 80 mA, with no individual output drawing more than 40mA.

The 1051 digital outputs are organized into two groups; each group uses a common integrated circuit The particular integrated circuit used is a SN75468 (7 open collector Darlington transistors in a 16-pin SOIC surface mount package. The thermal de-rating graph from the SN75468 data sheet is shown below.

The current output should be restricted to about 80 mA.

Table 2-8 Digital Output De-Rating

# of Outputs Used Continuous current in each

switch Total current for package

1 360 mA 360 mA

2 220 mA 440 mA

3 160 mA 480 mA

The de-rating is based on a maximum junction temperature of 150C and a package thermal impedance of 73C/W.

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Approximate power dissipation with a current of 360 mA is about 1.25 x .36 = 450 mW which yields a junction temperature of about 73 x .45 + 70 = 103C.

A simplified method of assigning maximum loading would be to allow a maximum of 160 mA x 3 = 480 mA or 220 mA x 2 = 440 mA per group, with a maximum of 360 mA per output. This would mean that if one of three outputs in a group used 200 mA, there would be 480 200 = 180 mA available for the other two outputs in that group. The remaining available current can be split while not exceeding the 360 mA maximum single output limit.

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Analog I/O

The 1050 series analog inputs may be thought of as being in two categories, user I/O and system inputs. The user I/O consists of the analog inputs (one standard and one optional), and the analog outputs (six total; two are standard and four are optional).

The standard controller, therefore, has three system analog inputs, two voltage inputs and one current input. These inputs are pre-wired at the factory and connected for input voltage, output voltage, and current measurements. The Auxiliary I/O Option board adds one voltage and one current input; they are normally used for voltage and current feedback from the secondary of a voltage matching transformer.

Note: If the option board is present, the output voltage feedback comes from the option board, and the output voltage feedback on the base control board is not used.

One temperature input may be added to the Auxiliary I/O Option card (the standard Auxiliary I/O Option card does not include the temperature input feature).

Table 2-9 Analog Input Connections

Terminal Number


Control Board 123011000

J17 1 Analog Power (+10v)

J17 2 AIn1+ User-configurable

J17 3 AIn1- User-configurable

J17 4 Analog Common

J17 7 Analog Common


J5 1 Analog Power (+10v)

J5 2 AIn2+ User-configurable

J5 3 AIn2- User-configurable

J5 4 Analog Common

J7 3 Analog Common

J7 6 Analog Common

Hardware July 2013

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User Analog Inputs

The analog inputs (references) are designed to accept potentiometer, voltage, or current inputs.

The voltage input requires a 0 to 10VDC input to achieve 0 to 100% setpoint. The current input requires a 0 to 20mA input to achieve 0 to 100% setpoint. The inputs may also be calibrated by the user to non-standard configurations such as 0 to 5 VDC or 4 to 20 mADC input to achieve 0 to 100% setpoint.

Note: For (optional) temperature input, the Process Temperature Set Point Limit is the rating used for scaling the temperature input from 0 100%. The Process Temperature Set Point Limit is equal to 100% analog input.

Ref # Voltage Current Differential Single-ended

1 SW1-1 O SW1-1 C SW1-2 O SW1-2 C

2 (OB)SW1-1 O (OB)SW1-1 C (OB)SW1-2 O (OB)SW1-2 C

O = Open C = Closed (OB) Option Board

Caution

When using the internal power supply to provide power for analog references (i.e. pot control or shorting power to reference), the analog reference DIP switches must be positioned as voltage inputs (DIP switch in the Open position). If the DIP switches are not properly configured, the regulator/supply may not be able to achieve 100% reference. This condition may prove damaging to board-level components.

July 2013 Hardware

2-15

Ain1 PWR (+10V) Ain1 Ref (+) Ain1 Ref () Acom (GND) Aout1 (+) Aout2 (+) Acom (GND)

1 2 3 4 5 6 7

1051 Analog Interface( J17 ) Control Board

Example: 4-20mAdc Reference Signal from Sourced (or Sinked) Current Controller

Customer Reference:PLC or Temperature Controller

SW1-1 = Closed (ON) Current SourceSW1-2 = Open (OFF) Differential

1 2 3 4

ON (closed) 4-20mAdc Ref (+) 4-20mAdc Ref ()

1051 Analog Dip Switch Settings( SW1 ) Control Board

Ain1 PWR (+10V) Ain1 Ref (+) Ain1 Ref () Acom (GND) Aout1 (+) Aout2 (+) Acom (GND)

1 2 3 4 5 6 7


Example: 0-10Vdc (or 0-5Vdc) Reference Signal from a Voltage Source

Customer Reference:PLC or Temperature Controller

SW1-1 = Open (OFF) Voltage SourceSW1-2 = Open (OFF) Differential

0-10Vdc Ref (+) 0-10Vdc Ref ()


1 2 3 4

ON (closed) Ain1 PWR (+10V) Ain1 Ref (+) Ain1 Ref () Acom (GND) Aout1 (+) Aout2 (+) Acom (GND)

1 2 3 4 5 6 7


Example: 10Turn, 10K, 2W Potentiometer Controlled Reference Signal

Customer Reference:Locally or Remotely Mounted Potentiometer

SW1-1 = Open (OFF) Voltage SourceSW1-2 = Closed (ON) Single Ended

Power (+10Vdc)

Wiper (Reference)

Common (GND)


1 2 3 4

ON (closed)

Hardware July 2013

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User Analog Outputs

The analog outputs are user-configurable. The Analog Output Selection defines which internal signal is assigned to each analog output. Each analog output will generate 0 to 20mA for 0 to 100% of the selected internal signal. An internal 249 Ohm resistor may be applied internally via dip switch selection to generate a 0 to 5 VDC signal. Note: The analog outputs momentarily range from zero to full output during the initial power up or reset sequence of the control board. The power controllers actual output is Off at this time.

Table 2-10 Analog Output Connections

Terminal Number


Control Board 123011000

J17 4 Analog Common

J17 5 Aout 1 User-configurable


J17 7 Analog Common


J5 4 Analog Common


J7 2 Aout4 User-configurable

J7 3 Analog Common



J7 6 Analog Common

July 2013 Hardware

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ANALOG OUTPUTS

Out # Voltage Current

1 SW1-3 C SW1-3 O

2 SW1-4 C SW1-4 O

3 (OB)SW2-1 C (OB)SW2-1 O




O = Open C = Closed (OB) Option Board

Temperature Measurement and Control

The 1050 series units have an option board analog (thermocouple) temperature channel and one standard digital temperature channel devoted to the SCR heatsink. The option board thermocouple channel uses an AD7793 24-bit A/D mounted on the Interface board, which communicates with the DSP via the SPI bus (note that this thermocouple provides two temperatures the cold-junction reading and the remote thermocouple reading. The cold junction temperature is labeled on-board temperature). There is no external interface to the on-board temperature sensor; it is monitored using the Spang Configuration Tool Application. The digital temperature sensor is internally mounted to the heat sink.

The option board (thermocouple) temperature channel has a common mode rejection at 50/60 Hz of 100 dB. The hardware has 150V (continuous) voltage isolation and is capable of sustaining 1000 VDC for 60 seconds.

Thermocouple Process Temperature Control (TC) is an optional outer control loop that acts as a master control around the standard control (regulation) mode. (TC) setup includes setting the Thermocouple Type, Process Temperature PID slow loop response, Process Temperature Setpoint, fault temperature, and alarm temperature. The Thermocouple Process Temperature Control (TC) has four (4) modes of operation:

1. Not used [default] -- There is no thermocouple connected; no alarm, fault, or control is available.

2. Monitor -- A thermocouple is connected but is used only to monitor the thermocouple temperature. Fault and/or alarm temperature level can be set.

3. Control -- A thermocouple is connected and Process Temperature Control is used as the outer (master) control loop.

4. Limit -- A thermocouple is connected and is used as a process limiting variable. If the measured temperature exceeds the Process Temperature Setpoint Limit, the controller output is reduced until the Process Temperature reaches the Process Temperature Setpoint Limit.

Hardware July 2013

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Setpoint ramping in degrees C per Hour is available with up-ramp and down-ramp controlled separately. Available thermal alarms and faults are:

Low temperature alarm High temperature alarm Time delayed high temperature fault High temperature fault

These alarms and faults typically would represent a layered safety net at increasing temperature values.

A feed-forward input to the thermal control loop allows for process and environmental control additions to the thermal loop, such as anticipation control.

The Process Temperature Set Point Limit is the rating used for scaling the temperature input from 0 100%. The Process Temperature Set Point Limit is equal to 100% analog input.

Voltage Attenuation

The gain control circuitry of the 1051 sets the gain of the input and output voltage sense channels to optimize the accuracy of the A to D conversion. The circuitry is dependent upon the voltage feedback range selection. The voltage feedback ranges are: 0 to 240 volts or 0 to 600 volts. An optional 0 to 40 volts and 0 to 115 volts remote feedback is available for low-voltage applications. Each range determines the gain of the signal path before the A to D converter.

Current Transformers and Burden Resistors

The current transformer (CT) burden resistors are specified and installed such that 100% current output, defined by the Current Output Rating, equals 2.5Vrms. For example, if a CT with a rating of 1000 to 1 is used on a unit rated at 350A, the burden resistor would be 2.5V/.35A or 7.14 ohms.

3-1

Chapter 3

Configuration and Monitoring

The 1051 Power Control units are shipped with a default configuration installed. Settings and calibration can be adjusted to fit specific application criteria. Spangs Configuration Tool software is a browser-based Adobe Flash application.

Configuration Software

The minimum system requirements are:

Web Browsing with Shockwave Flash version 10.3.185 or newer; 10BaseT or 100BaseT wired Ethernet connection, addressed to match the 1051 unit; Cat 5 network cable The 1051 Configuration Tool Application allows off-line editing and storage of configuration files. The Configuration app also allows on-line, real-time changes to the 1051 settings through the Ethernet connection. The capabilities of the Configuration Application include: offline file storage and retrieval, offline/online configuration, offline/online network configuration, calibration, operation, and monitoring.

The Configuration Tool App is delivered with the 1051 Power Control unit on an SD card, and web-served from the unit. The app may be copied to a PC and/or hosted from another web server (simple http web-server is needed; see Appendix). Users of the Firefox browser (version 19.02 or newer) can open the Configuration Tool Application directly from the PC without a web-server. Other browsers may have the same capability.

Unit Configuration July 2013

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Configuration Application Overview

Note: For optimal viewing when running the Configuration Tool, Spang recommends a screen resolution (on the host computer) of 1024 x 768 pixels.

Note: The default out-of-the-box IP address of the Spang 1051 Power Control unit is 192.168.0.101. The address is recorded on the SD card. To edit the address, refer to the section titled Edit Ethernet Connection Parameters in this chapter.

To run the Configuration Tool from the host computer start menu, select:

Start button -> Programs -> Internet Explorer -> http:///ConfigTool.html

The Configuration Application will initially be off-line, that is, the Tool will not have established communication with the 1051. When off-line, it is possible to edit settings and configuration in a local environment, and save the information on the host computer.

The figures that follow feature the Spang 1051 single phase product.

July 2013 Unit Configuration

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Configuration Menu Bar

The 1051 Configuration Application menu bar is shown below. The older version included a menu item described as Factory Default; the text has been replaced with Default Files. The new version has additional selections.

File Menu

File Option Description (Offline)

Open

General Calibration data Network Setup All Three

Select and open a configuration file from the host system. Configuration files are of the form .xml.

Read only the ratings and other setup information from the selected xml file

Read only the calibration values from the selected xml file

Read only the network setup information from the selected xml file

Read all information from the selected xml file

Save Save current setup, calibration, and network information to a xml configuration file on the host system.

Print Open the standard dialog box that provides the selection of a printer and print characteristics.


3-4

Default Files Menu

In the following actions, the word Save refers to all available information in the PCU; the word Load refers to all configurable parameters in the PCU.

File Option Description

Load Factory Default

Load the factory default settings from a configuration file on the SD card to the PCU. For assistance, please contact Spang Power Electronics.

Save Factory Default

Save new factory default settings to the SD card from the PCU. This function is available to authorized Spang personnel only.

Load Customer Default

Note: The CUSTOMER.BIN file must exist on the micro SD card. Option 1 (Manual Load): Load the customer default settings from a configuration file on the SD card to the PCU. This action is accomplished via Configuration Software. Option 2 (Auto Load): Install jumper between positions 2-3 on JP1 (control board 123011000) prior to applying control power to the PCU. With the jumper in place, the customer defaults will be loaded to the PCU EVERY time control power is cycled.

Save Customer Default

Note: A new CUSTOMER.BIN file will be saved on the micro SD card. Save new customer default settings to the SD card from the PCU (password protected function). The default password is CUSTOMER. For assistance, or to change the password, please contact Spang Power Electronics.


3-5

Update Menu

Update Options Description

Calibration Open a new form allowing calibration of the unit (refer to the Calibration chapter)

Time Set the Date and/or Time of the 1050 unit based on the Date time of the computer running the configuration application. Date and time are based on UTC.

Temperature Menu

Temperature Description

Run Form Open a floating form to display temperature information.

Connection Menu

Connection Option

Description

Configure Enter the IP address of the target 1050 power control unit

Online Open a connection to the target 1050

Offline Close the connection with the target 1050


3-6

Help Menu

Help Options Description

Manual Open a web page with links to 1051 documents (including this manual) in pdf format.

Web Site Use the host computers internet browser to connect to the Spang website.

About Display information about the Configuration Tool application.

Menu Buttons

Button Description (Online)

Start/Stop Toggle the output of the 1050 unit (online only)

Fault Reset Send a Fault Reset input (online only; momentary input)


3-7

Off-line Configuration

Off-line configuration allows the user to edit the 1050 setup without actually writing information to the controller. All work is done on the host computer and can be saved in an xml file.

Configuration files are of the form .xml and are read from and saved to the host computer. A default configuration file is included in the documentation shipped with each 1050 product. To load a configuration file from the host computer to the Configuration Tool application,

Select the File->Open menu option

Browse the files in the file open dialog, and select the desired configuration (*.xml) file.

The setting values from the selected configuration file are loaded into the Configuration Tool application, and can be viewed and/or modified.

Note that real-time information, such as operating characteristics, calibration, and fault/alarm information is not valid when the Configuration Tool is offline. The information most useful for offline programming is included in the Setup, Fault/Alarm, Network, and Custom tabs.


3-8

The Setup Tab

The Setup tab includes sections for ratings and limits, control, PIDs, digital IO, and analog IO. The sections appear in the box on the left. Click on a section name to view its associated settings.

A bright blue-colored background on the form indicates a value that is read-only; ie, cannot be changed by the user.


3-9


3-10


3-11

The Operation Tab

The Operation tab includes operating setpoints and general real-time characteristics like input and output voltage, current and power, analog inputs and outputs, frequency, temperature and any existing fault or alarm. Most of the information on the Operation tab is read-only and undefined in the offline state.


3-12


3-13

The Fault/Alarm Tab

The Fault/Alarm tab includes the settings defining voltage, current and temperature fault/alarm levels.

The Network Tab

The Network tab contains the information necessary to set up the optional network interface. The Network tab includes address and network loss settings, the network map, read data, and write data. The sections appear in the box on the left. Click on a section name to view its associated settings.


3-14


3-15

Custom Tab

The Custom tab opens a new, blank form. Using the drag-and-drop method, the user can build a one-page summary of desired information.

Use drag-and-drop to add settings to the custom form.


3-16

Double-click the line to remove a setting from the custom form.


3-17


3-18

Storing the Configuration

To save the configuration (settings and data) to an xml file on the host computer,

Select the File->Save menu option


3-19

Browse for file location,

Specify .xml, and click Save


3-20

On-line Operation

DANGER


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.

On-line operation involves message exchange between the configuration application and the 1050. Settings are read from and written to the 1050 using ModbusTCP protocol. On-line communication allows real-time editing, monitoring and calibration of the 1050.

To establish on-line communication between the Configuration Tool application and the 1050 unit,

Establish a physical connection between the host computer and the 1050 unit using cat5 (wired Ethernet) cable.

From the taskbar, select Connection Configure Enter the IP address of the target 1050.

From the taskbar, select Connection Online

The status leds on the taskbar are described in the following table. The Heartbeat LED should ALWAYS flash at a 500msec rate IF the Configuration Tool application has established a connection with the 1050 product.

LED Color Description

Heartbeat Green, flashing flashing Green indicates healthy comm status

Enable Green, steady steady Green indicates the unit is (hardware) enabled

Run Green, steady steady Green indicates the unit output is energized

Remote Green, steady steady Green indicates the unit is under network control

Fault Red, steady steady Red indicates the presence of a fault

Alarm Amber, steady steady Amber indicates the presence of an alarm


3-21

If the Config Tool Heartbeat LED does not flash, make sure the IP address is properly set; if so, disconnect and reconnect the cable, close and restart the Config Tool and go on-line.

WARNING

Improper configuration of the settings can result in component damage or reduction in product life. Application errors or improper calibration may result in malfunction of the system.

When the Configuration Tool is communicating online with the 1050, status, control and setting information is continuously read from the 1050 and updated in the Configuration Tool.

Note: The green-colored background indicates the online status of communication.


3-22

When the Configuration Tool is communicating online with the 1050 unit, it is possible to make changes to settings and control information, but ONLY when the unit is under LOCAL CONTROL.

To edit a setting: Click the mouse in the spreadsheet cell to be changed. Only the value column may be edited. Once selected, enter the desired value or click a choice from the drop down list. Press [Tab] or [Enter], or Press [Escape] to cancel the edit.

Load Settings from a File

Configuration files are of the form .xml and are read from and saved to the host computer. A default configuration file is included in the documentation shipped with each 1050 product. To load a configuration file from the host computer to the Configuration Tool application,

Select the FileOpen menu option Browse the files in the file open dialog, and select the desired configuration (*.xml) file


3-23

The user has four options as described below. The selected information will be written directly to the target 1050 unit.

File Option Online Description

Open

General Calibration data Network Setup All Three

Select and open a configuration file from the host system. Configuration files are of the form .xml.

Load the ratings, limits, fault/alarm settings and other setup information from the selected xml file to the target 1050

Load only the calibration values from the selected xml file to the target 1050

Load only the network setup information from the selected xml file to the target 1050

Load all information from the selected xml file to the target 1050

Factors Affecting Write Capability

Write capability from the configuration application to the 1051 is affected by several factors:

Information cannot be written from the configuration application to the 1050 if the Remote/Local input is in Remote. Remote mode allows the 1050 to be controlled by a master device over an industrial network such as DeviceNet, PROFIBUS, or EthernetIP.

The Configuration Tool application is considered to be a source of Local Digital control to the 1050. If the 1050 is operating under Local Analog control, setpoints cannot be written from the Configuration Tool to the 1050.

The 1050 settings related to real-time 1050 status, such as voltage out, power out, current out, etc, are Read Only, and cannot be written under any circumstances.

For safety and security, some setup and calibration information can be changed only when the unit output is OFF.


3-24

Default Files Menu

File Option Description

Load Factory Default

Load the factory default settings from a configuration file on the SD card to the PCU. For assistance, please contact Spang Power Electronics.

Save Factory Default

Save new factory default settings to the SD card from the PCU. This function is available to authorized Spang personnel only.

Load Customer Default

Note: The CUSTOMER.BIN file must exist on the micro SD card. Option 1 (Manual Load): Load the customer default settings from a configuration file on the SD card to the PCU. This action is accomplished via Configuration Software. Option 2 (Auto Load): Install jumper between positions 2-3 on JP1 prior to applying control power to the PCU. With the jumper in place, the customer defaults will be loaded to the PCU EVERY time control power is cycled.

Save Customer Default

Note: A new CUSTOMER.BIN file will be saved on the micro SD card. Save new customer default settings to the SD card from the PCU (password protected function). The default password is CUSTOMER. For assistance, or to change the password, please contact Spang Power Electronics.

Update Menu

Update Options Description

Calibration Open a new form allowing calibration of the unit (refer to the Calibration chapter)

Time Set the Date/Time of the 1050 unit to match the host computer (UTC).


3-25

Temperature Menu

To open the floating temperature display, select

Temperature Run Form

The temperature Run Form can be displayed anywhere on the form.


3-26

Connection Menu

Connection Option

Description

Configure Enter the IP address of the target 1050 power control unit

Online Open a connection to the target 1050

Offline Close the connection with the target 1050

Menu Buttons

Button Description

Start/Stop Toggle the output of the 1050 unit (online only)

Fault Reset Send a Fault Reset input (online only; momentary input)


3-27

Set the Unit IP Address

Each Spang 1050 power control unit must have a unique IP address on the Ethernet network.

The IP Address, subnet mask, and gateway address together determine the power controllers unique identifier on the Ethernet network segment. Indeterminate network behavior will result if each device on the Ethernet network does not have a unique IP address. Spang provides an industry-standard default address, subnet mask, and gateway in the TCPIPCFG.txt file.

The address is read by the unit from the TCPIPCFG.txt file on the micro SD memory card installed in the SD card slot on the 1050 power controller.

DANGER


WARNING

FOLLOW ALL FEDERAL, LOCAL, & PLANT SAFETY RULES & REGULATIONS.

To change the IP address of the power controller, the TCPIPCFG.txt file on the SD memory card can be edited using a computer, micro SD card reader and any standard text editor.

SD memory card slot (shown with SD card). The slot is labeled J7 on 1051 pcb.


3-28

To edit the SD card contents:

1. Turn off all main power / control power and lock out all related supply voltages.

2. Verify 1050 control power is off and remove the micro SD card from the 1050 power controller (push the card in to eject).

3. Using a micro SD card adapter, install (add as a drive) the micro SD card on the computer.

4. Open the TCPIPCFG.txt file.


3-29

5. As factory shipped, the text file should be displayed in a similar format to the image below.

NOTE: Subnet mask may also be 255.255.255.0.


3-30

6. To alter the IP address, mask, gateway, unit name, etc. alter numeric strings based on network scheme and application requirements. NOTE: When editing, use ONLY blank or space between the numeric entries and descriptions; do NOT use the tab character.

7. SAVE the TCPIPCFG.txt file. Do NOT change the filename. (For backup, copy the file to another drive on the computer. Once copied, the backup file can be renamed).

8. EXIT the text editor program.


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9. Safely remove (eject) the SD Card Hardware from the personal computer.

10. Physically remove the SD card adapter from the computer, and remove the SD card from the adapter.

11. Properly install the SD Card back into 1050 power controller (push until the card clicks into place).

12. Safely restore control / main power and verify the new address.


3-32

Edit Ethernet Connection Parameters

Both the Spang PCU and the LDC hardware include an 8 pin inverted Ethernet jack. The receptacle accepts standard Ethernet cable with 8P8C modular connectors. The default configuration of the Spang PCU is 100BaseT, Full-Duplex communication.

The configuration is read by the unit from the TCPIPCFG.txt file on the micro SD memory card installed in the SD card slot on the 1050 power controller.

DANGER


WARNING

FOLLOW ALL FEDERAL, LOCAL, & PLANT SAFETY RULES & REGULATIONS.

To change the network connection behavior of the power controller, the TCPIPCFG.txt file on the SD memory card can be edited using a computer, micro SD card reader and any standard text editor.

To edit the SD card contents:

1. Turn off all main power / control power and lock out all related supply voltages.

SD memory card slot (shown with SD card). The slot is labeled J7 on 1051 pcb.


3-33

2. Verify 1050 control power is off and remove the micro SD card from the 1050 power controller

(push the card in to eject).

3. Using a micro SD card adapter, install (add as a drive) the micro SD card on the computer.

4. Open the TCPIPCFG.txt file.


3-34

5. As factory shipped, the text file should be displayed in a similar format to the image below.

NOTE: Subnet mask may also be 255.255.255.0.


3-35

6. To change the Ethernet connection behavior from the default setup (100baseT, Full Duplex) to Auto-negotiate, replace the phrase100baseT with Auto in the first line of the TCPIPCFG.txt file (see image below). NOTE: When editing, use ONLY blank or space between the numeric entries and descriptions; do NOT use the tab character.

7. SAVE the TCPIPCFG.txt file. Do NOT change the filename. (For backup, copy the file to another drive on the computer. Once copied, the backup file can be renamed).

8. EXIT the text editor program.


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9. Safely remove (eject) the SD Card Hardware from the personal computer.

10. Physically remove the SD card adapter from the computer, and remove the SD card from the adapter.

11. Properly install the SD Card back into 1050 power controller (push until the card clicks into place).

12. Safely restore control / main power.

Zero Crossover Control and Transformer-Coupled Loads

Overview

If the 1051 directly controls a resistive load, standard zero cross firing is deployed. For transformer-coupled loads, a special tuning technique is used to avoid high peak current due to transformer core saturation which can occur if power is re-applied while residual core magnetization exists. The tuning process establishes a controlled soft startup of the transformer, avoiding high inrush; desired output operation, and a defined shutoff of the transformer. The settings used for tuning are: Initial Pulse, in percent, is the phase-on for the first cycle of each 100-AC-cycle firing period. This phase back of the first cycle is to limit the current of the magnetized transformer core. Magnetizing Ramp, in AC cycles, is the phase-on for the very first firing into a transformer used to limit the initial current surge caused by residual magnetization of the transformer core.


3-37

Tuning

Tuning the Initial Pulse and Magnetizing Ramp parameters for a transformer is best accomplished by viewing the current waveform on a storage oscilloscope connected to test point TP3 (Input Current) and ground. This is nominally a voltage signal of approximately 3 volts RMS. Set the Oscilloscope for 100 milliseconds per division, 5 volts per division. Initially set the 1051 unit to a regulation mode of Duty Cycle, the Firing Mode to Zero Cross and a duty cycle setpoint of 20%. Provide a load on the transformer of at least 30 % of its rated KVA. Set the Magnetizing Ramp to 10 AC cycles, and the Initial Pulse to 50%.

Duty Cycle control; Duty Cycle setpoint 20%.


3-38

Set the oscilloscope to single trigger and turn the 1051 output on. If an overcurrent fault occurs, increase the Magnetizing Ramp by 10 AC cycles and if possible, increase the Current High Fault Ratio to Rating. Look for current overshoots in the initial ramped set of AC waveforms. Increase the Magnetizing Ramp to remove any overshoot on the ramped waveform. Set the oscilloscope to 10milliseconds, and with the 1051 output on, continuous-trigger the oscilloscope. Look for current overshoots on the initial AC waveform of the set of 20, and adjust the Initial Pulse parameter (increase or decrease as needed) to eliminate any overshoot seen. If an oscilloscope is not available, contact Spang Power Electronics for assistance.

Zero Cross Firing Mode; Initial Pulse 50%; Magnetizing Ramp 10 cycles

4-1

Chapter 4

Calibration

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.

DANGER


DANGER

Power must be applied to the 1051 to perform certain calibration procedures. Voltages on many components are at incoming line or output voltage potentials. To avoid electric shock hazard or damage to equipment, do not touch any energized electrical component and set up all metering devices for measurements in a powered down/locked out state. Failure to observe these precautions could result in severe injury or loss of life.

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.

The 1050 power control unit is calibrated before shipment. Any re-calibration of the unit should be performed by authorized service personnel.

Note that all voltage calibrations should be performed in Duty Cycle regulation mode with as close to 100% output as possible, all voltage measurements should be made with a calibrated True RMS volt meter, and all calibrations should be performed while the unit is in a No Fault or Alarm state (i.e. NOT hindered by any limit settings, usually indicated by an alarm).

Calibration July 2013

4-2

NOTE: Turn main incoming power OFF, and open the Enable input. Control power must remain ON. If control power is linked to the input bus, it must be externally supplied for the calibration sequence. Load Calibration from File

Using the Configuration Tool, it is possible to load calibration information from an xml file. On the menu bar, select

File Open Calibration Data

Select the xml file to read calibration values from. The values will be written directly to the 1050 unit.

July 2013 Calibration

4-3

Save Calibration

Calibration information can be saved from the File menu using the Configuration Tool. On the menu bar, select

File Save

Specify a location and xml filename on the host computer.


4-4

Selective Calibration

Use the Configuration Tool to calibrate individual signals.

Offset

The Offset calibration exercise adjusts the raw A/D values.

Step Action Description

1 Check to verify that the unit Power is lit and the HB LEDs are blinking.

2 Establish on-line communication between the host computer and the 1051. The unit must be under LOCAL control.

3 Set the Local Control Mode to DIGITAL.

4 Set the Regulation Mode for Duty Cycle Control.

5 Turn main incoming power OFF. Check with a calibrated True RMS volt meter that there is no main incoming voltage (Phase to Phase and Phase to Ground).

6 On the Main form, select the Setup->Rating tab.

7 Check/set the Voltage and Current Ratings and select the Voltage Feedback Ranges.

8 On the menu bar, select Update Calibration. Click the [Main] tab as shown below.

9 With a calibrated True RMS meter, measure incoming voltage at the unit input terminals or other easily accessible location to the input voltage bus.

10 The measured voltage should be zero (0) Volts. If not, verify all connections in a de-energized state per the system/product schematics and repeat the previous steps.

11 Click the [Set Offsets for RMS readings] button in the table (lower right).


4-5

* Remote Current is applicable only when option board 123012xxx is used.


4-6

Input Zero




3 On the Main form, select the Operation->General tab. Set the Regulation Mode for Duty Cycle Control, and the Local Control Mode to DIGITAL.




8 On the menu bar, select Update Calibration. Select the [Main] tab as shown.

9 With a calibrated True RMS meter, measure incoming voltage at the unit input terminals or other easily accessible location to the input voltage bus.

With a calibrated True RMS meter, measure the incoming current (See system/product schematic).

10 The measured voltage/current should be zero (0). If not, verify all connections in a de-energized state per the system/product schematics and repeat the previous steps.

11 Increase the value of the Voltage/Current input zero cell until noise and measurement errors are sufficiently suppressed. (Note: setting these values too high may result in inaccurate behavior at lower operating levels)


4-7

Input Gain




3 On the Main form, select the Operation->General tab. Set the Regulation Mode for Duty Cycle Control, and the Local Control Mode to DIGITAL.

4 Verify that the Enable Input is open (Inhibited), preventing the SCRs from firing.




8 On the menu bar, select Update Calibration. Select the [Main] tab as shown.

9 Enter the numeric value for the measured True RMS voltage in the corresponding Meter (right-side) column of the table.

10 Click the corresponding [Set to Meter] button in the table (below the Meter column).

Note: If the Gain is at zero, the [Set to Meter] function will not work. Set the gain to a non-zero value and repeat steps 9 through 10.


4-8

Analog Input Calibration

All analog calibration percentages are based on rated values, specifically the rating of the selected reference (e.g. current or voltage). 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 0-40A on a 50A unit, set the analog reference to 80% (40/50*100) to represent maximum current output.

Set the analog reference DIP switches on the interface PCB in order to properly measure the values. On the menu bar, select Update Calibration. Select the [Analog In] tab.


4-9

Analog Input Zero





4 Verify that the output is OFF.

5 On the menu bar, select Update Calibration. Select the [Analog In] tab as shown.

6 Input the desired control reference from an external source to achieve 0% output into the corresponding terminals on the control or option board.

7 With a calibrated True RMS volt meter, measure and verify that the analog input reference signal is equivalent to your desired lower-end reference signal for 0% Output (i.e. 4mA, 0VDC, etc.). (If not, in a de-energized state, verify all connections to the 1051 and associated circuitry per the system/product schematics. Once completed, repeat the previous steps.)

8 Click the [Set Zero] button on the form to set the zero point of the reference


4-10

Analog Input Gain






5 On the menu bar, select Update Calibration. Select the [Analog In] tab as shown.

6 Input the desired control reference from an external source to achieve 100% output into the corresponding terminal jumpers on the control or option board

7 With a calibrated True RMS volt meter, measure and verify that the analog input reference signal is equivalent to your desired higher-end reference signal for 100% Output (i.e. 20mA, 5Vdc, etc.). (If not, in a de-energized state, verify all connections to the 1051 and associated circuitry per the system/product schematics. Once completed, repeat the previous steps.)

8 Set the value you want for the higher end reference (usually 100%) in the box next to the Set Value button.

9 Click the [Set Value] button on the form to set the analog gain.


4-11

Analog Output Calibration

All analog calibration percentages are based on rated values, specifically the rating of the selected reference (e.g. current or voltage). 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 0-40A on a 50A unit, set the analog reference to 80% (40/50*100) to represent maximum current output.

Set the Analog Output Selection to Calibration Setpoint, to allow a full range of signal settings without having to actually power up the unit. Once calibrated, re-set the Analog Output Selection to the desired operational setting.


4-12

Analog Output Offset and Span

Main form, Setup->Analog tab

On the menu bar, select Update Calibration. Select the [Analog Out] tab.






5 On the Main form, select the Setup->Analog tab.

6 Set the Analog Output Selection to Calibration Setpoint.

8 On the menu bar, select Update Calibration. Select the [Analog Out] tab as shown.

9 Set the [Calibration Setpoint] to a Value of 0.00%.

10 With a calibrated True RMS volt meter, measure and verify that the analog output reference signal is equivalent to your desired lower-end reference signal for 0% Output (i.e. 4mA, 0Vdc, etc.).

11 If the analog output is not at the desired signal level, adjust the offset slidebar until the correct output is reached/measured.

12 Set the [Calibration Setpoint] to a Value of 100.00%.

13 With a calibrated True RMS volt meter, measure and verify that the analog output reference signal is equivalent to your desired upper-end reference signal for 100% Outp

Documents

1051 Series Product Manual - English