Novus PCW-3P-60 User manual

NOVUS AUTOMATION 1/4
Power Controller
– PCW / PCWE
INSTRUCTION MANUAL
– V1.0x F
PRESENTATION
The NOVUS power controller is a type of electronic equipment with
functions to control and limit the electric power delivered to a generic
electric load. These functions are executed with modern techniques,
in order to provide significant gains for the process, all with durability,
precision, efficiency and economy.
It also executes the important function of protecting the connected
load and the system as a whole, since it has ultra-fast fuses included
in all its versions.
There are two types of controller models: PCW and PCWE. The
PCWE model has a feature that limits the electric power delivered to
the load (Load Limit), the only difference between the two models.
SPECIFICATIONS
General Specifications
Load Voltage (MAIN POWER): .......................180~440 Vac; 50/60 Hz
Command Signal (INPUT):...................................... 0-20 mA, 4-20 mA
................................................................0-5 V, 1-5 V, 0-10 V e 2-10 V
..............................................................................10 k (Potentiometer)
Type of control:.................................................PWM and phase angle
Control feed (AUX. POWER):....................................220 Vac (PCWE)
.............................................................................. 220/380 Vac (PCW)
Alarm .......................................................... relay SPST; 3 A / 250 Vac
Dielectric rigidity between parts................................................ 2500 V
Operating Temperature: ................................................... -10 to 60 ºC
Plastic Cabinet.......................................................ABS+PC / UL-94V0
Monophase Models
MODEL PCW-1P-100 PCWE-1P-200
Load Current 100 A 200 A
Protection Fuse 100 A Fuse 200 A
Surge Current (10 ms) 1600 A 5400 A
Dimensions Figure 1 Figure 4
Fan 12 Vdc
Three Phase Models – Two controlled phases
MODEL PCW-2P-60 PCW-2P-100 PCW-2P-150
PCWE-2P-200
Load Current
60 A 100 A 150 A 200 A
Protections Fuse 60 A Fuse 100 A Fuse 150 A Fuse 200 A
Surge Current
(10 ms)
1200 A 1600 A 2250 A 5400 A
Dimensions Figure 1 Figure 2 Figure 3 Figure 5
Fan 12 Vdc 220 Vac
Three Phase Models – Three controlled phases
MODEL PCW-3P-60 PCWE-3P-100
PCWE-3P-160
PCWE-3P-200
Load Current
60 A 100 A 160 A 200 A
Protection Fuse 60 A Fuse 100 A Fuse 160 A Fuse 200 A
Surge Current
(10 ms) 1200 A 1600 A 2250 A 5400 A
Dimensions Figure 2 Figure 5
Fan 12 Vdc 220 Vac
INSTALLATION
The controller is made to be attached vertically, for instance, in the
rear of a control panel. It needs an open area for an appropriate air
circulation and the environment should meet the typical requirements
for electronic equipment.
DIMENSIONS
Figure 1
Figure 2

Power Controller
NOVUS AUTOMATION 2/4
Figure 3
Figure 4
Figure 5
ELECTRICAL CONNECTIONS
The available features of the connector bar for the power controller is
shown in Figure 6 and 7:
Figure 6 – Connector bar for the power controller, model PCW
Figure 7– Connector bar for the power controller, model PCWE
RECOMMENDATIONS FOR THE INSTALLATION
•To minimize the pick-up of electrical noise, the low voltage DC
connections and the sensor input wiring should be routed away
from high-current power conductors. If this is impractical, use
shielded cables. In general, keep cable lengths to a minimum.
•All electronic instruments must be powered by a clean mains
supply, proper for instrumentation.
•It is strongly recommended to apply RC'S FILTERS (noise
suppressor) to contactor coils, solenoids, etc.
•In any application it is essential to consider what can happen
when any part of the system fails. The controller features by
themselves can not assure total protection.
RESOURCES
CONTROL SIGNAL (INPUT)
The control signal is selected by the user during the configuration of
the power controller. There are (7) different types of control signals
accepted:
•4~20 mA
•0~20 mA
•1~5 V
•2~10 V
•0~5 V
•0~10 V
•10 k Power meter
The control signal should be applied in terminals 1, 2 and 3 of the
controller’s connector bar.
MANUAL CONTROL
Feature that allows the user to manually establish the percentage
value of the power delivered to the load. The options for a manual
control are:
- Via keypad adjustment. Available when following a
recommendation such as "Manual percentage value of the power
delivered to the load." See Mode of Operation later in this manual.
- Via power meter in Input.
- Via power meter in Limit. MANUAL digital entry, available in
terminals 6 and 7, selects the adoption of the manual control mode
when activated (closed switch). In the open switch position, the
Limit connected power meter begins to execute the Load Limit
function.
LOAD LIMIT (LIMIT)
Feature that determines the maximum power limit to be delivered to
the load, regardless of the value demonstrated by the control signal.
A potentiometer, of 10 k Ohms, installed in the Limit establishes this
maximum value. For this function to work, the MANUAL digital entry
should remain in the closed position (AUTO).
This limit is not in regards to the load current. It limits the portion
of the network cycle, or the network cycle number, applied to the
load. For the processes where the load does not have linear
behavior, the load current should be known and considered.
TYPE OF CONTROL
There are two types of possible controls in this power controller:
PWM control and Phase Angle control.

Power Controller
NOVUS AUTOMATION 3/4
PWM –
(on0
In this mode, the electric power controller is from the control of the
electrical network cycles delivered to the load. The activation always
occurs at zero voltage and the shutdown and zero current.
Figure 8– Different quantities of electric power delivered to the load with the
PWM type of control
Phase Angle –
(on1
With the phase angle control, the load activation occurs with each
semi-cycles of the electric network. The quantity of energy delivered
to the load depends on how much of each cycle of the electric
network is passed on to the load.
Figure 9– Different quantities of electric power delivered to the load with the
Phase Angle type of control
The shutdown always occurs at zero current, which does not cause
significant disturbances to the electrical network.
In this mode, it is possible to have more refined control over the
process. Low values for signal entry promotes low voltage values to
the load. This characteristic is important in a process where there is a
need to limit the electrical current during the first moments of the
activated process.
This is the type of control recommended for installation in the primary
side of transformers. In these applications, to avoid problems when
deactivating the load, electrical power values of under 25% should be
avoided.
The type of control is defined during the configuration of the
controller using the parameter
(on0
/
(on1
.
ALARM
As a protection feature, the controller also has an alarm that is
activated with:
•Lack of phase
•Fuse rupture
The alarm activates a relay that can be configured to operate in NA
or NF mode. The
Aln.0
configuration parameter defines the relay’s
operation mode.
SOFT START FUNCTION -
STR.0
Allows for a slow and gradual power increase delivered to the load.
The increase speed of the delivered power is determined by a time
interval that can be adjusted by the user in seconds. During this time
interval, the power delivered to the load varies from a minimum value
to a value defined by the control signal. The time interval is defined
in the
t.000
configuration parameter.
The value of the power delivered to the load continues to be defined
by the control signal. The Soft-start function simply limits the speed
on the increase of this power value during the time interval defined
by the user.
Associated with the Phase Angle control type, the Soft-start function
is normally used is processes that require a slow start, where the
instant application of 100% of the available power to the load could
damage system parts.
This function is disabled (
t.000
) when the time interval is set at 0
(zero).
KICK-START FUNCTION –
str.1
The kick-start function, as opposed to the soft-start function, begins
releasing maximum power to the process and then reduces until
reaching the value set by the entry signal.
This function is disabled (
t.000
) when the time interval is set at 0
(zero).
OFFSET
Percentage value added to the recommended value. Allows the user
to make a small adjustment to the process. Adjustable between -99
and 99 % in the
F.000
parameter.
OPERATION
The front panel of the controller, with their elements, can be seen in
the figures below:
Figure 10 - Identification of the frontal panel parts
Figure 11 - Identification of the frontal panel parts

Power Controller
NOVUS AUTOMATION 4/4
OPERATION MODE
In Operation mode, the controller applies an electrical power value to
the load that is proportional to the value of the control signal. In this
mode, the controller constantly shows on its display the Output
Indication that can show three different value options:
- Percentage value of the power delivered to the load
- Load current value
- Manual percentage value of the power delivered to the load
The selection of the desired recommendation type happens during
the configuration of the controller in Configuration Mode.
CONFIGURATION MODE
In this mode, the user configures the power controller to operate
according to their needs. The configuration defines each of the
various configuration parameters presented by the controller. The
user needs to understand the importance of each parameter, and for
each one, they must determine a valid condition or a valid value.
The configuration parameters are gathered in two groups:
Group 1
Accessed when the and keys are pressed simultaneously
for 3 seconds. The first parameter (
lcy.0
) of this group is shown.
The remaining parameters are presented with each new
compression of the key.
The following table shows all the parameters of group 1 in the order
they are presented in the controller display.
To alter the conditions of the parameters use the and .
PARAMETER
A.000
or
i.000
or
n.000
lcy.0
Configuration Protection:
lcy.0
Blocks alteration on all parameters
lcy.1
Allows for alteration in parameters of group 1.
lcy.2
Allows alteration on all parameters
A.
/
i.
/
n.
Selection of Output Indication type:
A.
Recommends Percentage value of the power
delivered to the load
i.
Recommends load current value.
n.
Recommends manual percentage value of the
power delivered to the load
1nt..0
Selection of the Control Signal:
1nt.0
4~20 mA
1nt.1
0~20 mA
1nt.2
1~5 V
1nt.3
2~10 V
1nt.4
0~5 V
1nt.5
0~10 V
1nt.6
10 k Power meter
(on..0
Type of control:
(on.0
Square Wave control type
(on.1
Phase Angle Control
Str..0
( * )
Soft-Start / Kick-Start Function:
Str..0
Adopts the Soft-start function
Str.1
Adopts the Kick-start function
( * ) To access the
Str0
/
Str1
, on
(on.0
/
(on.1
press
again for 3 seconds.
Group 2
Accessed when the key is pressed for 3 seconds. The first
parameter (
l.000
) of this group is shown. The remaining
parameters are presented with each new compression of the
key. The following table shows all the parameters of group 2 in the
order they are presented in the controller display.
To alter the conditions of the parameters use the and keys.
PARAMETER
A.000
or
i.000
or
n.000
l.000
Recommendation for the minimum amount for the signal
control. Defines the range for the power percentage value
type of recommendation.
k.000
Recommendation for the maximum amount for the signal
control. Defines the range for the power percentage value
type of recommendation.
i.99.9
Maximum value for load current. Defined the range for the
load current value type of recommendation.
t.000
Time interval for the Soft-Start and Kick-Start functions. In
seconds.
d.000
Non valid parameter for the PCW and PCWE models.
Maintain at
000
.
aLN.0
Operation mode for alarm relay:
Aln.0
Relay with Normally Open (NO) contact
Aln.1
Relay with Normally Closed (NC) contact
F.000
( * ) Offset percentage value.
( * ) To access the offset parameter (
f.000
), on
ALn.0
/
ALn.1
press again for 3 seconds.
FAILURE SIGNAL
NPER
Signals lack of phase or open fuse.
fnER
Fan Malfunction.
0hER
Controller Overheating
WARRANTY
Warranty conditions are available on our website
www.novusautomation.com/warranty.