Phasetronics 36P1 Series Operation manual

TM
PHASETRONICS
SCR Power Control Specialists
MANUAL - 7091601MN-REV4
REV 05/23/19
OPERATION AND SERVICE MANUAL
20 to 600 Amp Models
Three Phase Controller
36P1
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....................................................................................................................11
Chapter 5 - Options ..................................................................................................................................13
5.1 Option “B” (Standard on all 36P1 units) .......................................................................................13
5.2 Option "G" (Option B with the addition of Current Limit)...............................................................13
5.3 Option “F” (Option B with the addition of Current Trip) .................................................................13
5.4 Option “H” (Options B, F and G combined)..................................................................................13
5.5 Option “KB” .................................................................................................................................14
5.6 K Series Option Soft Start............................................................................................................14
5.7 K Series Voltage and Current Feedback Signals (Efb and Ifb)......................................................14
5.8 Option “KG”: (Option KB with the addition of Current Limit)..........................................................14
5.9 Option “KF” (Option KB with the addition of Current Trip).............................................................15
5.10 Option “KH” (Options KB, KF and KG combined).........................................................................15
5.11 Option “V” ...................................................................................................................................15
5.12 Option “T”....................................................................................................................................15
Chapter 6 - Start-Up..................................................................................................................................16
6.1 Manual Control (Options “B” and “KB”) ........................................................................................16
6.2 Automatic Control (Options “B” and “KB”) ....................................................................................17
6.3 Current Limit (Option “G” and “KG”) Start-up................................................................................17
6.4 Current Trip (Option “F”) Start-up.................................................................................................17
6.5 Current Trip (Option “KF”) Start-up..............................................................................................18
6.6 Soft Start (Options “B”-“H” abd “KB-KH”) Start-up........................................................................18
6.7 DC Voltage and Current Regulator (Option "V" or "T") .................................................................20
Chapter 7 - Diagrams................................................................................................................................23
7.1 Option Board B, F, G & H...........................................................................................................23
7.2 Option Board KB, KF, KG & KH...................................................................................................24
7.3 Auto Manual Switch for Options B,F,G,H,KB,KF,KG & KH...........................................................25
7.4 Option Board V & T.....................................................................................................................26
7.5 Auto Manual Switch for Option V & T...........................................................................................27
7.6 PTR3000 Board ..........................................................................................................................28
7.7 PTR6000-I Board........................................................................................................................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..............................................................................................................33
8.4 Bench Calibration Procedure.......................................................................................................33
WARRANTY INFORMATION.....................................................................................................................35

Phasetronics
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Chapter 1 - Introduction
1.1 General
The 36P1 Series of power controls is a three phase controller available in 120 thru 575vac with current
ratings from 20 to 600A. Using six SCRs in a three phase AC switch configuration, it provides smooth
phase angle control for 0-100% output power. It comes standard with an 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.
Standard features include isolated heat sink design thru 75 amperes, semi conductor protection style
fuses, MOVs (Metal Oxide Varistor), dv/dt networks and high PIV rated SCRs. The 36P1 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 electricalshocks!To avoid shock hazard, disconnect all power sourcesbefore
working on unit.

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Chapter 2 - Specifications
2.1 - Specifications
AC Supply Voltage
Operates within 120, 208, 380, 415, 480, or 575VAC ±10%,
50/60 Hz. *
Output Current Rating
25 to 600 amps, model dependent (higher currents available, consult
factory)
Command Inputs
Signal
Input Impedance
Automatic: 4 - 20mA
10 - 50mA
1 - 5mA
0 - 10VDC
Manual: 10K, 2 Watt pot
510ohms
200 ohms
2K ohms
100K ohms minimum
Output Voltage
0 to 98% of input voltage
Output Stage
6 SCR (3 phase AC switch configuration)
Load Types
Resistive, Inductive, Transformer, and Lamp
Adjustments
Integral Offset and Gain Adjustments
Accommodates most milliamp signals
Current Limit
10 - 125% of controller rated current
Current Trip
75 - 200% of controller rated current
Regulation
Maintains output within 2% with a ±10% line variation
Ambient Temperature
0 to 40ºC at rated current
(From 50ºC to a maximum of 60ºC, the output rating decreases by 10% for
each 5ºC increase.)
Protective Features
I2t Fusing
Transient voltage suppressor (MOV)
dv/dt Networks
SCR Peak Inverse Voltage (PIV) 1500V
* Dependent on model configuration

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2.2 –Dimensions
Models 25 thru 75 Amps
Models 110 thru 600 Amps
Dimensions are in inches and are subject to change.

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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 (32 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 25 to 175 Amps are convection cooled. Units rated 225 Amps and above of fan cooled.

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Chapter 3 - Installation
3.1 - Location
Proper location of the 36P1 Seriesisnecessary to achieve specified performance and normal operation
lifetime. The 36P1 Series should always be installed inan area where the following conditions exist:
• Ambient operatingtemperature:
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 be mounted in the appropriate type of enclosure. Enclosure size and type
must be suitabletodissipate heat generatedbytheSCRpower control. (NEMA1 styleenclosures
can be forced ventilated to reduce size.) Use the following formulas for sizing 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 36P1 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 36P1 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 unit to function improperly.
Prior to beginning the installation, verify the 36P1 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 36P1 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 36P1 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 oriented vertically and running parallel to the
mounting surface. If theunit has a fan, 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
110 thru 175Amp unitsrequirea120cfmboxventilationfanfor NEMA 1 enclosures. 225Ampand 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
T1
L1
T2
L3
T3
L2
T1 T2 T3
L1 L2 L3
Fig 2a
Fig 2b