Phasetronics 1P1 Series Operation manual

TM
PHASETRONICS
SCR Power Control Specialists
MANUAL - 1P120600-REV3
REV 05/23/19
OPERATION AND SERVICE MANUAL
20 to 600 Amp Models
Single Phase SCR
1P1
Series

Phasetronics
Page 2
Table of Contents
Chapter 1 - Introduction.............................................................................................................................4
1.1 General.........................................................................................................................................4
1.2 Receiving and Unpacking..............................................................................................................4
Chapter 2 - Specifications..........................................................................................................................5
2.1 Specification..................................................................................................................................5
2.2 Dimensions...................................................................................................................................6
2.3 Protective Networks ......................................................................................................................7
2.4 Ambient Temperature....................................................................................................................7
2.5 Cooling..........................................................................................................................................7
Chapter 3 - Installation...............................................................................................................................8
3.1 Location........................................................................................................................................8
3.2 Initial Unt Inspection......................................................................................................................8
3.3 Mounting and Cleaning..................................................................................................................9
3.4 Enclosure Ventilation.....................................................................................................................9
Chapter 4 - Connections ..........................................................................................................................10
4.1 Power Connections.....................................................................................................................10
4.2 Control Connections....................................................................................................................13
Chapter 5 - Options ..................................................................................................................................15
5.1 Option “B” (Standard on all 1P1 units) .........................................................................................15
5.2 Option "C" (Option B with the addition of Current Limit)................................................................15
5.3 Option “D” (Option B with the addition of Current Trip).................................................................15
5.4 Option “E” (Option B, C + D Combined).......................................................................................15
5.5 Option “KB” .................................................................................................................................16
5.6 K Series Option Soft Start............................................................................................................16
5.7 K Series Voltage and Current Feedback Signals (Efb and Ifb)......................................................16
5.8 Option “KC”: (Option KB with the addition of Current Limit ...........................................................16
5.9 Option “KD” (Option KB with the addition of Current Trip) ............................................................17
5.10 Option “KE” (Option KB, KC + KD Combined)..............................................................................17
5.11 Option “V” ...................................................................................................................................17
5.12 Option “T”....................................................................................................................................17
Chapter 6 - Start-Up..................................................................................................................................18
6.1 Manual Control (Options “B” and “KB”) ........................................................................................18
6.2 Automatic Control (Options (Options “B” and “KB”) ......................................................................19
6.3 Current Limit (Option “C” or “KC”) Start-up...................................................................................19
6.4 Current Trip (Option “E”) Start-up.................................................................................................20
6.5 Current Trip (Option “KE”) Start-up..............................................................................................20
6.6 Soft Start (Option “B-E” and “KB-KE”)..........................................................................................21
6.7 DC Voltage and Current Regulator (Option “V” or “T”)..................................................................22
Chapter 7 - Diagrams................................................................................................................................25
7.1 Option Board B, C, D & E...........................................................................................................25
7.2 Option Board KB, KC, KD & KE..................................................................................................27
7.3 Auto/Manual Switch for Options B, C, D, E, KB, KC, KD and KE..............................................26
7.4 Option Board V + T ....................................................................................................................28
7.5 Auto/Manual Switch for Option V or T..........................................................................................29

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Chapter 8 - Troubleshooting....................................................................................................................30
8.1 SCR Testing Procedure...............................................................................................................30
8.2 Replacing Printed Circuit Boards.................................................................................................31
8.3 Replacing SCR Devices..............................................................................................................32
8.4 Bench Calibration Procedure.......................................................................................................32
WARRANTY INFORMATION.....................................................................................................................35

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Chapter 1 - Introduction
1.1 General
The 1P1 series of power controls is a single phase controller available in 120 thru 575vac and with
current ratings from 20 to 600A. It provides smooth, phase angle control of back to back SCRs for 0-
100% output power control. It comes standard with an optically isolated 4-20ma signal input, a manual
potentiometer input and Load Voltage Regulation. The integral offset and gain adjustments allow tailoring
of the output power with respect to the control signal input. Optional features such as Current Limit and
Current Trip are also available. The SCRs are protected by MOVs (Metal Oxide Varistor) and a dv/dt
network as standard. The 1P1 series is well suited for a variety of loads including inductive, resistive and
high inrush.
1.2 –Receiving and unpacking
Upon receipt of this product you should immediately do the following:
•Inspect the unit for possible shipping damage (if damaged, you should notify the freight
carrier and file a claim immediately)
•Verify the model number on the unit matches your purchase order
Warning
DO NOT SERVICE EQUIPMENT WITH VOLTAGE APPLIED! Unit
can be a source of fatal electrical shocks!To avoid shock hazard,
disconnect all power sourcesbefore working on unit.

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Chapter 2 - Specifications
2.1 - Specifications
External Inputs
Milliamp Input
4-20 mA Input Impedance - 510 ohms.
Manual Control
10k ohm, 2 watt potentiometer, linear taper (customer provided).
Output Current Rating (Model dependent)
20 to 600 Amps.
AC Supply Voltage
120/208/240/380/415/480/575 Vac(+10% to -15%, 50/60 Hz) *
Type of Loads
Resistive / Inductive / Lamp.
Soft Start:
Options
B, C, D, E:
Set for initial half-second of operation at power on. Field
adjustable by potentiometer from 0.25 seconds to 60 seconds.
Ramp with DC signal change is factory set for 0.1 seconds
(adjustable with capacitor change.)
Options
KB, KC, KD & KE:
Set for initial half-second of operation at power on. Field
adjustable by potentiometer from 0.5 seconds to 25 seconds.
Ramp with DC signal change is factory set for 0.1 seconds
(adjustable with capacitor change.)
Options V & T:
Set for initial half-second of operation at power on. Field
adjustable by potentiometer from 1 second to 50 seconds.
Ramp with DC signal change is factory set for 0.1 seconds
(adjustable with capacitor change.)
Hard Firing Gate Pulse
A combination of a high-potential gate pulse and a rapid rise time
is used to prevent SCR damage due to di/dt stress.
Input Adjustments
(B,C,D,E,KB,KC,KD & KE)
Gain
4-20mA
Offset
50% of gain maximum
Regulation
Option:
B,C,D,E,KB,KC,KD & KE
Load voltage regulation of +/-2% over a +/-10 % line voltage
input change.
Option V & T
Specific to DC voltage applications, current and/or Voltage regulation
is 0.75%.
Protective
Networks
Fusing
Integral I²T fuse protects against short-circuit overloads.
Transient Voltage
Suppressor
Integral MOV (Metal Oxide Varistor) protects against
high potential transient voltage.
SCR Peak Inverse
Voltage (PIV Rating)
1500V
RC Snubber
RC snubber network prevents false firing due to dv/dt
characteristics
Ambient Temperature
Operating range is from 0°C thru 40°C (32°F thru 104°F)
* Dependent on model configuration

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2.2 - Dimensions
A H
B
W
DE
1P1 AMPS
H
(inch.)
W
(Inch.)
D
(Inch.)
E
(Inch.)
A
(Inch.)
B
(Inch.)
20-40
10.5
6.50
4.50
0.3125
9.875
5.875
75
10.5
6.50
6.00
0.3125
9.875
5.875
110-225
13.0
8.50
9.75
2.25
8.50
7.125
300-600
21.0
11.0
10.5
0.3125
19.25
9.25
C = Mounting Hole Diameter
D = Depth of the unit
Dimensionsaresubjecttochange

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2.3 - Protective Networks
Transient Voltage Suppressor (Standard): Integral MOV (Metal Oxide Varistor) protects against high
potential voltage spikes.
RC Snubber (Standard): RC Snubber networks are used to prevent false firing due to dv/dt
characteristics.
SCR Peak Inverse Voltage (PIV Rating) for line voltage 120 ~ 575V: 1500V for all models.
2.4 - Ambient Temperature
Ambient temperature operating range: 0 to 40 °C (32 to 104 °F).
Transportation and storage range: 0 to 65 °C (-30 to 149 °F).
Note: Output current rating decreases by 10% for each 5 °C rise (9 °F) in ambient temperature over 40 °C
(104 °F) to a maximum of 60 °C (140 ° F).
2.5 - Cooling
Units rated 20 to 225 Amps are convection cooled. Units rated 300 Amps and above arefan cooled.

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( )
( )
Chapter 3 - Installation
3.1 - Location
Proper location of the 1P1 Series isnecessary to achieve specified performance and normal operation
lifetime. The 1P1 Series should always be installed in an area where the following conditions exist:
• Ambient operating temperature:
0 to 40 degrees C (32 to 104 degrees F) - Type 1 ventilated enclosure
• Protected from rain and moisture
• Humidity: 5 to 95% non-condensing
• Free from metallic particles, conductive dust and corrosive gas
• Free from excessivevibration (below 0.5G)
• Open panel units must bemounted in theappropriate type of enclosure. Enclosure size and type must be
suitable to dissipate heat generated by the SCR power control. (NEMA 1 style enclosures can be forced
ventilated toreduce size.) Usethefollowingformulasforsizing non-ventilated enclosures:
Non-vented painted metal enclosures: FLA x 1.5 = sq. ft of exposed area
7
Non-vented stainless steel enclosures: FLA x 1.5 = sq. ft of exposed area
4
Mount units vertically so heat sink fins are parallel to vertical mounting surface. Non Fan cooled units
must be mounted with the power terminals located at the bottom to ensure proper cooling.
Notes:
- FLA is the 1P1 unit current rating.
- The area of the enclosure that is against the wall when mounted is not included in the "Exposed"
area for cooling considerations.
3.2 - Initial Unit Inspection
Prior to installing the 1P1 Series unit make a complete visual check of all the equipment for possible
damage in shipping and handling. Report damage immediately before attempting to run unit. Check for
loose mechanical assemblies or broken wires which may have occurred during transportation or
installation. Loose electrical connections will increase resistance and cause the unit to function
improperly. Prior to beginning the installation verify the 1P1 Series unit is rated for the proper voltage
and current for the load.
Warning
Do not service equipment with voltage applied! Unit can be source of fatal electrical
shocks! To avoid shock hazard, remove all sources of power before working on
controller. Warning labels must be attached to terminals, enclosure and control
panel to meet local codes.

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3.3 - Mounting and Cleaning
If mounting the 1P1 Series unit in an enclosure requires drilling or punching holes in the enclosure,
cover the electrical assembly to prevent metal filings from becoming lodged in areas which can cause
clearance reduction or actually short out electronics. After work is complete, thoroughly clean the area and
re-inspect the 1P1 Series unit for foreign material. Make sure to observe the required wire bending space
per NEC, NFPA and local codes when installing the unit. To maximize effective air flow and cooling, the
unit must be installed with its heat sink ribs orientedvertically and running parallel to themounting surface.
If theunit has afan,install unit so the fan blows upward vertically.
In dirty or contaminated atmospheres the unit should be cleaned on a regular basis to insure proper
cooling. Do not use any chemicals to clean the unit. To remove surface dust, use 80 to 100 psi clean dry
compressed air only. A three inch high quality dry paint brush is helpful to loosen the dust prior to using
compressed air on theunit.
WARNING!
Remove all sources of power before cleaning the unit.
3.4 –Enclosure Ventilation
75, 110 and 225Ampunitsrequire a 120cfmboxventilationfanforNEMA1 enclosures. 300Ampand
larger units require a 240 cfm vent fan. See example below.
Figure 1 - Enclosure
Note: Anybox sizeshouldbe selectedin coordination withminimum
field wiring bending space requirements per local and National
Electrical Codes.

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Chapter 4 - Connections
4.1 - Power Connections
4.1.1 - Options B, C, D, E, KB, KC, KD, KE
1. Connect the Line 1 input power cables to the terminal on the unit marked L1.
2. Connect the Load input power cable to the terminal on the unit marked T1.
3. Connect the Load output power cable and the L2 power cable together.
4. Using a 14awg, 600v wire, fused at 2A, connect the L2 power to TB2 pin 7 on the 1P1 unit option
card.
4.1.2 - Options V & T
1. Connect the L2 lead to TB4-4 on the PTR trigger card.
Note: The trigger card is located under the option card in units rated 20-75A.
See Fig 2a to 2c for overall wiring schemes.
Figure 2a: 20, 40, 75 AMP UNITS