NuWave NWUPCM-1P Sereis User manual

Rev.1.3 12/13
COPYRIGHT 2013 NUWAVE TECHNOLOGIES,INC.
NWUPCM-1P SERIES USER MANUAL
PHASE ANGLE SCR POWER CONTROL DRIVER BOARD
FOR RESISTIVE LOADS

NWUPCM-1P User Manual
Copyright 2013 NUWAVE TECHNOLOGIES,INC.
TABLE OF CONTENTS
1. Ordering Codes...................................................................................................................3
2. Description..........................................................................................................................3
3. Installation / Safety Information...........................................................................................3
3.1 Mounting Instructions...................................................................................................4
3.2 Electrical Connections .................................................................................................4
3.3 SCR Output Snubbers and Transient Protection .........................................................4
3.3.1 Commutation Problems ........................................................................................4
3.3.2 dv/dt Problems......................................................................................................4
3.3.3 Snubber Sizing .....................................................................................................4
3.3.4 MOVs and TVSs...................................................................................................5
3.4 Limited Warranty..........................................................................................................5
4. Operation............................................................................................................................5
4.1 Power Supply...............................................................................................................5
4.2 24V Power Fusing........................................................................................................5
4.3 Command Input ...........................................................................................................5
4.4 PWM Command Input..................................................................................................6
4.4.1 PWM Input............................................................................................................6
4.4.2 Input Fail-safe Protection......................................................................................6
4.5 Line Voltage Compensation.........................................................................................6
4.5.1 Line Voltage Compensation Nominal Adjustment.................................................6
4.6 Soft Start......................................................................................................................6
4.7 Voltage Limit................................................................................................................7
4.7.1 Voltage Limit Adjustment Procedure.....................................................................7
4.8 Configuration Dipswitch ...............................................................................................7
4.9 SSR Drive Output (NWUPCM-1P- SSR)......................................................................8
4.10 Output LED..................................................................................................................8
4.11 Three Phase Operation................................................................................................9
4.12 Wiring Multiple Units in Single Phase or Three Phase Applications.............................9
4.12.1 Connecting Power & Commands In Parallel.........................................................9
5. Electrical Specifications ......................................................................................................9
6. Mechanical Dimensions....................................................................................................10
7. WIRING DIAGRAM - SINGLE PHASE (SSR OR SCR)....................................................11
8. WIRING DIAGRAM 3 INSIDE DELTA CONNECTION (SSR)...........................................12
9. WIRING DIAGRAM 3 PHASE 4 WIRE Y CONNECTION (SSR).......................................13
10. WIRING DIAGRAM 3 PHASE 4 WIRE Y CONNECTION (SCR)...................................14
11. WIRING DIAGRAM 3 PHASE INSIDE DELTA CONNECTION (SCR)..........................15

NWUPCM-1P User Manual
Copyright 2013 NUWAVE TECHNOLOGIES,INC.
1. Ordering Codes
Ordering Codes NWUPCM-1P-___-___
Power Control Module
Single Pole
Phase Angle
-XSS (Softstart Time, seconds)
-XSC (Soft Change Time, seconds)
-REV (Reverse Acting Output)
-PWM (PWM Input)
SCR or SSR
v
Part#
Description
NWUPCM-1P-SSR
Phase Angle Control Module SSR DRIVE
NWUPCM-1P-SCR
Phase Angle Control Module SCR GATE DRIVE
NWUPCM-1B-SSR
Burst Firing Control Module SSR DRIVE (see NWUPCM-1B User Manual)
NWUPCM-1B-SCR
Burst Firing Control Module SCR GATE DRIVE (see NWUPCM-1B User Manual)
NWUPCM-1B-SSR-LVC
Burst Firing Control Module SSR DRIVE (see NWUPCM-1B User Manual)
NWUPCM-1B-SCR-LVC
Burst Firing Control Module SCR GATE DRIVE (see NWUPCM-1B User Manual)
2. Description
The NWUPCM-1p is a Phase Angle SCR Power Control Driver Board designed for use
with Solid State Relays or high power back to back SCR modules. The power delivered
to the load is proportional to the command input signal.
Features:
•Provides true linear power output phase angle control and burst fire control
•Small 3.0”x2.5”module mounts in a snap track or a dinrail
•Command input accepts 4-20mA, 0-10V, 0-5V, Pot, PWM
•Configurable line voltage compensation increases stability of your process
•Configurable soft start for high inrush loads
•Wide frequency operation (30 to 90Hz)
•Adjustable Voltage Limit
•Drives multiple solid state relays
•Drives SCR gates directly
•Single phase and three phase control
3. Installation / Safety Information
Responsibility for determining suitability for use in any application / equipment lies solely on
the purchaser, OEM and end user. Suitability for use in your application is determined by
applicable standards such as UL, cUL and CE and the completed system involving this
component should be tested to those standards.
WARNING: FIRE HAZARD!! Even quality electronic components
CAN FAIL KEEPING FULL POWER ON! Provide a SEPARATE (redundant) OVER
TEMPERATURE SHUTDOWN DEVICE to switch the power off if safe temperatures are
exceeded.

NWUPCM-1P User Manual
Copyright 2013 NUWAVE TECHNOLOGIES,INC.
WARNING: HIGH VOLTAGE!! This control module has high voltage on it.
This control must be installed in a GROUNDED enclosure by a qualified electrician in
accordance with applicable local and national codes including NEC and other applicable
codes. Provide a safety interlock on the door to remove power before gaining access to
the device.
The NWUPCM-1 contains fragile components that if damaged can cause
improper operation, failure or fire. While all units are inspected and tested at the factory,
damage can occur during shipping or installation. Before applying power, inspect each
module for damage paying specific attention to the pulse transformer drive coil. If there are
any abrasions or scratches on the coil wires, DO NOT APPLY POWER. The unit should be
sent back to the factory for repair.
3.1 Mounting Instructions
The NWUPCM-1 mounts in a 3.0” snap track and can be installed on a dinrail.
3.2 Electrical Connections
See the WIRING DIAGRAMS at the end of this document. Make sure the module ordered
is the correct module for the application before wiring. Before wiring the module all Dip
Switch settings for the command input and special features should be setup properly per
the Dipswitch Configuration Section.
3.3 SCR Output Snubbers and Transient Protection
3.3.1 Commutation Problems
When an SCR or TRIAC is used to control an inductive load, the load current lags the
mains voltage. When the device turns off at zero current, the rate of rise of the reapplied
voltage can retrigger the device and produce half cycling and blown fuses. To limit this rate
of rise and obtain reliable commutation, an R-C (resistor–capacitor) snubber circuit should
be connected in parallel with the SCR/TRIAC.
3.3.2 dv/dt Problems
When voltage transients occur on the mains supply or load of an SCR/TRIAC it can cause
the device to turn on unexpectedly due to the fast rate of rise of voltage (dv/dt). This can
result in false firing and half cycling of the load that can cause blown fuses when driving
inductive loads. An R-C snubber circuit will help to limit the dv/dt seen by the device and
will produce more reliable firing.
3.3.3 Snubber Sizing

NWUPCM-1P User Manual
Copyright 2013 NUWAVE TECHNOLOGIES,INC.
When an SCR/TRIAC using an R-C snubber turns on, the capacitor is discharged through
the resistor into the device resulting in high peak currents. It is critically important when
sizing your snubber to make sure that the resistor value does not become so low that the
ratings of the SCR/TRIAC are exceeded when the capacitor is discharged.
3.3.4 MOVs and TVSs
Metal Oxide Varistors and Transient Voltage Suppressors are both used on TRIACS/SCRs
to “clamp” voltage spikes that can occur across the devices and damage them. Snubbers
are not a substitute for MOVs/TVSs and vice versa. Snubbers and MOVs/TVs should be
used together to get reliable performance and long life from the SCR/TRIAC application.
External MOVs must be installed across the SCRs to limit peak voltages accepted by the
NWUPCM to ~ 850VDC.
3.4 Limited Warranty
NuWave Technologies, Inc. warrant this product to be free from defect in workmanship
and materials for a period of two (2) years from the date of purchase.
1. Should unit malfunction, return it to the factory. If defective it will be repaired or
replaced at no charge.
2. There are no user serviceable parts on this unit. This warranty is void if the unit shows
evidence of being tampered with or subjected to excessive heat, moisture, corrosion or
other misuse / misapplication.
3. Components which wear or damage with misuse are excluded, e.g. relays.
4. NuWave Technologies, Inc. shall not be responsible for any damage or losses however
caused, which may be experienced as a result of the installation or use of this product.
NuWave Technologies, Inc. liability for any breach of this agreement shall not exceed
the purchase price paid E. & O.E.
4. Operation
4.1 Power Supply
The NWUPCM-1 power supply requirement is 24V AC +/-10% 47-63Hz. The line
synchronization for phase angle and certain modes of burst firing has an input voltage
range of 100 to 600VAC, 30 to 90Hz.
4.2 24V Power Fusing
Fusing may be accomplished by fusing each module separately or fusing groups of the
modules with either primary or secondary fusing. The current draw of each NWUPCM-1
is 100mA max.
4.3 Command Input
The NWUPCM-1 can accept 4-20mA, 0-10V, 0-5V, and Potentiometer and PWM inputs.
All analog command inputs are not isolated from the 24V power Input. The type of
command input can be configured via the dipswitch. The default setting is 0-
5V/potentiometer.
The PWM digital command input (PLC Interface) is optically isolated from the power
supply.
When wiring multiple NWUPCM-1’s together, follow the guidelines in the Wiring Multiple
NWUPCM-1s section.

NWUPCM-1P User Manual
Copyright 2013 NUWAVE TECHNOLOGIES,INC.
Any leg of the command input can tolerate shorts to the (0V) input. Connecting the 24V
power to the command input may cause damage to the unit.
4.4 PWM Command Input
The NWUPCM-1 PWM Command input is designed to accept a signal from a PLC or a
process/temperature controller’s SSR drive output. This logic signal is used to generate a
command setpoint.
4.4.1 PWM Input
The NWUPCM-1 accepts PWM signals from 500Hz-15KHz and logic voltages of 5VDC
(non isolated command input) or 24VDC (optically isolated PWM input). When using the
optically isolated PWM input, the PWM Dip Switch #6 must be set to “ON”. The PWM
input provides a low cost way to interface with a PLC or PC DAQ.
4.4.2 Input Fail-safe Protection
If the signal sent to the NWUPCM-1’s command input should become electrically open the
control output will be forced to an off state.
4.5 Line Voltage Compensation
The NWUPCM-1‘s line voltage compensation keeps the power constant on the load as
the line voltage changes. The line voltage is measured via the 24V power applied to the
NWUPCM-1 module. To use the Line Voltage Compensation feature properly, a 24VAC
power transformer should be fed from the same mains as the load circuit to be controlled
as per the wiring diagrams at the end of this document. Line Voltage Compensation can
be enabled or disabled using the configuration dipswitch. The default setting is enabled
(Switch # 1 is OFF). To disable the Line Voltage Compensation, set switch # 1 to the ON
position.
Without Line Voltage Compen sation
120VAC
108VAC
(-10%)
MAINS VOLTAGE
1KW
0.81KW
(~-20%)
LOAD POWER
NWUPCM-1 Line Voltage Compen sation
120VAC
108VAC
(-10%)
MAINS VOLTAGE
LOAD POWER
With a 10% drop in line voltage, NWUPCM-1 load power drops less than 2%
(120V, 1KW, 14.4 O hm Load )
E
R
P=
1KW
4.5.1 Line Voltage Compensation Nominal Adjustment
The nominal adjustment pot sets the nominal level of output for the current line voltage
being measured via the 24VAC input.
4.6 Soft Start

NWUPCM-1P User Manual
Copyright 2013 NUWAVE TECHNOLOGIES,INC.
The Soft Start feature ramps up to the command value over a period of approximately 5
seconds (at 60Hz). The soft start time resets if the command value goes to zero (less
than 4% of the input range) or power is cycled. Soft start is useful on high inrush heaters
such as Quartz, Molybdenum, Tungsten, or Graphite heaters.
Soft Start can be set on or off using the configuration dipswitch. The default setting is off.
Soft start times below 5 seconds are available and can be ordered by adding a “–XSS”to
the ordering code where X is the time in seconds.
Soft Start
Period
The Soft Start ramps the voltage up slowly over the soft start period.
Current
Time
High Inrush Load
Current
Time
Soft Start used to limit the inrush
4.7 Voltage Limit
The Voltage Limit feature is used in conjunction with the Line Voltage Compensation
feature to limit the actual voltage delivered to the load. The Voltage Limit is adjustable via
a potentiometer located just below the input terminal block. For this feature to work
properly Line Voltage Compensation must be turned on and the power transformer for the
NWUPCM-1 must be connected to the same mains as the load power is connected to.
This feature can be used without Line Voltage Compensation and will simply clip the
command signal to a set level.
4.7.1 Voltage Limit Adjustment Procedure
The Voltage Limit is adjustable from 25% to 100% of the max load voltage. Setting the
Voltage Limit potentiometer half way corresponds to a power limit of approximately 55%
or a voltage limit of 70% of the max load voltage. The best way to set the voltage limit is
using a voltmeter connected across the load. With the command input set to
approximately 100% (on startup) turn the pot fully CCW. Then just turn the pot CW until
the desired output voltage is achieved. For this feature to work as a true voltage limit, it is
important that the Line Voltage Compensation be enabled (this is the OFF position of
Switch # 1).
If the line voltage compensation is set to OFF the voltage limit will act as a percentage of
output limit and the absolute voltage limit will change with line voltage.
4.8 Configuration Dipswitch
The configuration dipswitch is used for setting up the command input, line voltage
compensation and soft start. Using a pen point gently push the switch up for on and
down for off according to the setup outlined in the table below.

NWUPCM-1P User Manual
Copyright 2013 NUWAVE TECHNOLOGIES,INC.
Command Input
2
4
5
6
0-5V (Default)
OFF
OFF
OFF
OFF
Potentiometer
OFF
OFF
OFF
OFF
0-10V
OFF
ON
OFF
OFF
4-20mA
ON
OFF
ON
OFF
1-5V
ON
OFF
OFF
OFF
2-10V
ON
ON
OFF
OFF
PWM (isolated input)
OFF
OFF
OFF
ON
Feature to Enable
1
3
Line Voltage Comp Enabled (default)
OFF
OFF
None
ON
OFF
Soft Start Only Enabled
ON
ON
Soft Start & Line Voltage Comp Enabled
OFF
ON
4.9 SSR Drive Output (NWUPCM-1P- SSR)
The NWUPCM-1’s SSR output drive is a DC-pulsed current limited 10V/15mA (nominal)
drive signal. This is more than enough current for driving most 3-32V standard SSRs,
however it is still important to review the data sheet for the SSR you would like to use for
compatibility with the NWUPCM-1’s output drive. The control output can tolerate a
momentary direct short. The following graph will allow you to verify the SSR’s
compatibility with the NWUPCM-1 over wide input voltage variations.
NWUPCM-1’s Output Drive Current vs. SSR Input Voltage Drop
4.10 Output LED
The NWUPCM-1’s RED output LED will turn on when the output is on and increase in
intensity as the power output is increased. Because the drive signal varies considerably
to give linear power output, the LED should only be used as a rough indication of
SSR/SCR Drive and not actual power output.

NWUPCM-1P User Manual
Copyright 2013 NUWAVE TECHNOLOGIES,INC.
4.11 Three Phase Operation
Three NWUPCM-1s can be used to control three poles of a three phase load for inside
delta, or grounded WYE configurations. The Module should be wired as shown in the
wiring diagrams.
4.12 Wiring Multiple Units in Single Phase or Three Phase Applications
If more than one NWUPCM-1 is to be used from a non-isolated or common command
signals:
1. A common power supply or transformer can be shared. If the input selected is 0-
10V or 0-5V, the inputs should be wired in parallel.
2. If multiple units must be powered from one power transformer and 4-20mA input is
selected, one module should be set for 4-20mA and the remaining modules should
be set for 1-5V and wired in parallel.
3. If the command is 4-20mA, and the command inputs are to be wired in series, a
separate power transformer or supply for each module is required to isolate the
inputs.
4.12.1 Connecting Power & Commands In Parallel
When multiple NWUPCM-1 power inputs and commands are wired in parallel, all of the
0V terminals must be connected together follows:
Power: Command:
0V-----0V-----0V-----> 0V-----0V-----0V----->
24V---24V---24V----> IN------IN-----IN------>
No crossing of the power input feed or command signal is permitted. If for some reason
the power should become crossed, it will cause a direct short in the system. If properly
fused, the fuse will blow and the NWUPCM-1 will not be damaged. If the command
inputs are wired improperly, damage to the NWUPCM-1 can result.
5. Electrical Specifications
Command Inputs 4-20mA, 0-10V, 0-5V, Pot, PWM
Input Impedance 10K (0-10V), 250(4-20mA), 100K(0-5V)
Control Output SSR Drive, DC pulse, nominally 10V at 15mA
Response Time <50mS
PWM Input Frequency 500Hz-15KHz
PWM Input Level 5 VDC (non isolated) or 24VDC (isolated)
Output Linearity +/-3%
External Potentiometer Res. 10K-25K
Line Voltage Comp. Range +15%/-15% up to 100% output
Regulation +/-3%
Soft Start Period 5 seconds to reach 100% output
Voltage Limit Range 25-100% of max load voltage.
Ambient Temperature Range 0 to 50 °C
Power Supply 24VAC +10/-10%, <100mA Current Draw.
Line Frequency Range 30 to 90Hz
Line Voltage Range 100-600VAC (External MOV must be installed across
SCRs to limit peak voltages to ~ 850VDC)
SCR Gate Drive Characteristics 16KHz Burst for 1.35mS every half cycle. Initial pulse
peak current of 600mA, maintain pulses, 300mA, 10uS
pulse width per pulse, rise time of 100nS.

NWUPCM-1P User Manual
Copyright 2013 NUWAVE TECHNOLOGIES,INC.
6. Mechanical Dimensions