Phasetronics EP1 Series Operation manual

Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com

Phasetronics
Page 2
Table of Contents
Chapter 1 - Introduction ............................................................................................................................. 3
1.1 General ......................................................................................................................................... 3
1.2 Receiving and Unpacking..............................................................................................................3
Chapter 2 - Specifications.......................................................................................................................... 4
2.1 Specification.................................................................................................................................. 4
2.2 Dimensions ................................................................................................................................... 5
2.3 Protective Networks ...................................................................................................................... 6
2.4 Ambient Temperature.................................................................................................................... 6
2.5 Cooling.......................................................................................................................................... 6
Chapter 3 - Installation............................................................................................................................... 7
3.1 Location ........................................................................................................................................ 7
3.2 Initial Unt Inspection......................................................................................................................7
3.3 Mounting and Cleaning.................................................................................................................. 8
3.4 Enclosure Ventilation..................................................................................................................... 8
Chapter 4 - Connections ............................................................................................................................9
4.1 Power Connections ....................................................................................................................... 9
4.2 Control Connections.................................................................................................................... 10
Chapter 5 - Options .................................................................................................................................. 11
5.1 Power-on Soft Start (Standard).................................................................................................... 11
5.2 ............................................................................................................ 11
5.3 .......................................................................................... 11
5.4 Command Signal Change Soft Start (Option ......................................................................... 11
5.5 ................................................................................................... 12
Chapter 6 - Start-Up.................................................................................................................................. 13
6.1 Manual Control............................................................................................................................ 13
6.2 Automatic Control........................................................................................................................ 14
6.3 -up............................................................................................... 14
6.4 -up................................................................................................. 15
6.5 Command Signal Change Soft Start (Option -up............................................................ 15
6.6 ....................................................................................... 15
Chapter 7 - Diagrams................................................................................................................................ 16
7.1 Main Logic Board for EP1 Series (10 thru 50 Amp Units) - EPCL1001 ......................................... 16
7.2 Main Logic Board for EP1 Series (85 thru 1000 Amp Units) - PCL1002........................................ 17
7.3 EP1 Series Option Board (10 thru 50 Amp Units) PCM1600 ..................................................... 18
7.4 EP1 Series Option Board (85 thru 1000 Amp Units) PCM1603 ................................................. 19
Chapter 8 - Troubleshooting .................................................................................................................... 20
8.1 SCR Testing Procedures............................................................................................................. 20
8.2 Replacing Printed Circuit Boards ................................................................................................. 21
8.3 Replacing SCR Devices .............................................................................................................. 21
8.4 Calibration Procedures................................................................................................................21
WARRANTY INFORMATION..................................................................................................................... 25
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com

Phasetronics
Page 3
Chapter 1 - Introduction
1.1 General
The EP1 series of power controls is a single phase control available in 120 thru 575vac with current
ratings from 10 to 1000A. It provides smooth, phase angle control of back to back SCRs for 0-100%
output power control. It comes standard with a selection of 3 automatic and one manual control signal
inputs. The integral offset and gain adjustments allow tailoring of the output power with respect to the
control signal input. Optional features such as Fusing, Current Limit, Current Trip and Control Signal Soft
Start are also available. The SCRs are protected by MOV and dv/dt networks as standard. The EP1
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 sources before
working on unit.
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com

Phasetronics
Page 4
Chapter 2 - Specifications
2.1 Specifications
External
Inputs
Milliamp Input 4-20 mA Input Impedance - 250 ohms
Analog Input 0-10 Vdc Signal / 0-5 Vdc Signal - 100k ohms input impedance
Manual Control 10k ohm, 2 watt potentiometer, linear taper (customer provided)
Output Current Rating (Model dependent) 10 to 1000 Amps
Output Stage Back to Back configuration (AC Switch)
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 Factory set for initial half-second of operation at power on. Field
adjustable via potentiometer from 0.5 seconds to 20 seconds.
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
Gain 4-20mA, 0-5 Vdc, 0-10 Volts
Offset 50% of gain maximum
Regulation
(Option R)
Optional Feature to provide Average Load Voltage regulation of
+/-2% over a +/-10 % line voltage input change.
Protective
Networks
Optional Fusing I²T fuse protects against short-circuit overloads (Option F)
Transient
Voltage
Suppressor
Integral MOV (Metal Oxide Varistor) protects against high
potential transient voltage
SCR Peak Inverse
Voltage (PIV Rating) 2.5 times line rating (minimum)
RC Snubber RC snubber networks prevent 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
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com

Phasetronics
Page 5
2.2 - Dimensions
C
A H
B
W
Model
EP1
AMPS
H
(inch.)
W
(Inch.)
D
(Inch.)
A
(Inch.)
B
(Inch.)
C
(dia)
(Inch.)
EP1-xx10(F) 10 6.0 5.75 4.75 5.53 5.28 .221
EP1-xx25(F) 25 6.0 5.75 4.75 5.53 5.28 .221
EP1-xx50(F) 50 9.0 7.0 5.5 8.25 6.37 .281
EP1-xx85(F) 85 11.5 9.88 6.25 9.5 9.00 .312
EP1-xx100(F) 100 11.5 9.88 6.25 9.5 9.00 .312
EP1-xx150(F) 150 11.5 10.75 10.0 8.0 8.00 .281
EP1-xx225(F) 225 11.5 10.75 10.0 8.0 8.0 .281
EP1-xx350(F) 350 13.0 11.0 10.0 8.0 8.0 .436
EP1-xx500(F) 500 21.0 11.0 10.0 19.25 9.25 .436
EP1-xx650(F) 650 21.0 11.0 10.0 19.25 9.25 .436
EP1-xx800(F) 800 25.625 15.625 13.5 23.875 13.875 .436
EP1-xx1000(F) 1000 CF CF CF CF CF CF
xx: 12 = 120 V, 20 = 208 V, 24 = 240 V, 38 = 380 V, 41 = 415 V, 48 = 480 V, 57=575 V
C = Mounting Hole Diameter
D = Depth of the unit
(Dimensions are subject to change.)
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com

Phasetronics
Page 6
2.3 - Protective Networks
Transient Voltage Suppressor (Standard): Integral MOV (Metal Oxide Varistor) is used to protect against
high potential transient voltage spikes.
RC Snubber Networks (Standard): RC snubbers 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 10 to 150A Amps are convection cooled. Units rated 225 Amps and above are fan cooled.
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com

Phasetronics
Page 7
(
)
(
)
Chapter 3 - Installation
3.1 - Location
Proper location of the EP1 Series is necessary to achieve specified performance and normal operation
lifetime. The EP1 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 excessive vibration (below 0.5G)
Open panel units must be mounted in the appropriate 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 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 EP1 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 EP1 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 EP1 Series unit is rated for the proper voltage and current for
the load.
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com

Phasetronics
Page 8
3.3 - Mounting and Cleaning
If mounting the EP1 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 EP1 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 the unit has a fan, install the 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 up the dust prior to using
compressed air on the unit.
WARNING!
Remove all sources of power before cleaning the unit.
3.4 Enclosure Ventilation
85, 100, 150, 225 and 350 Amp units require a 120 cfm box ventilation fan for NEMA 1 enclosures. 500
Amp and larger units require a 240 cfm vent fan (See example below).
Figure 1 - Enclosure
Note: Any box size should be selected in coordination with minimum
field wiring bending space requirements per local and National
Electrical Codes.
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com

Phasetronics
Page 9
Chapter 4 - Connections
4.1 - Power Connections
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 TB1 pin 6 on the EP1 unit.
If an option card is present connect the L2 wire to TB2 pin 7 on the option card.
See Figure 2 & 3 for connections with and without option cards.
Figure 2 - Power Connection (without option card)
Figure 3 - Power Connection (with option card)
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com

Phasetronics
Page 10
4.2 - Control Connections
4.2.1 Manual Control
1. If the manual potentiometer is not used proceed to "Automatic Control". Manual potentiometer
does not have to be connected for unit to operate.
2. Connect manual potentiometer to TB2-3(wiper), TB2-4(high), and TB2-6(low) on the main board
per connection diagram. See illustration 7.1 + 7.2 for connection.
3. Manual potentiometer is 10K ohm, 2 watts linear resistance taper.
4. If you are using only manual pot control, proceed to chapter 5 + 6 Start-up.
10K
Ohm
2 Watt
Linear
Taper
TB2-4
(High)
TB2-3
(Wiper)
TB2-6
(Low)
CW
Figure 4 Potentiometer
4.2.2 Automatic Control
1. Connect the DC voltage or milliamp control signal to TB2 on the main board with pin 1 being
Positive and pin 2 being Negative. Note: You must configure the unit for the type of automatic
signal used by selecting the appropriate jumper (See illustrations 7.1 or 7.2 for configuration
information).
2. If both the manual and automatic control signals are needed, consider installing an auto/manual
switch. If both the manual and automatic signals are connected simultaneously the signal with the
larger input value will command the unit.
Figure 5 Analog Input
Figure 6 Auto / Manual Switch
Note: Soft start is active only when initial power is applied and a command signal is present. It has no
effect on control signal change (See Option S Section 5.4).If soft start is required on restart of mA signal
or when lockout is released.
MILLIAMP/
VOLTAGE
INPUT (+)
COMMON
MANUAL
OPTION
TB2 - 4
TB2 - 6
TB2 - 1
TB2 - 3
AUTO
MANUAL
TB2 - 6
TB2-1
TB2-2
+
-
4-20 mA
0-10 VDC
0-5 VDC
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com

Phasetronics
Page 11
Chapter 5 - Options
5.1 Power-on Soft Start (Standard)
This option is ideal for high inrush loads & delicate heater elements. The gradual ramp to the command
level eliminates inrush and prevents thermal shock. Here is how it works. When unit power is applied and
a Manual or Automatic command signal is present the unit will ramp the output voltage to the commanded
level. The ramp time is adjustable via potentiometer P3 on the main (mother) board. The 0-100% output
voltage ramp interval can be adjusted from a minimum of 0.5 seconds with P3 set fully counter clockwise,
to a maximum of 20 seconds with P3 set fully clockwise. This option can be disabled by removing X6
(PCL1002) or X7 (EPCL1001) on the mainboard. (See illustrations 7.1 or 7.2 for jumper location.)
Note: The overall ramp time is determined by the command level. For example; If the soft start time is set
to 20 seconds and the command level is 50%, the total ramp time to the command level will be 10
seconds.
5.2 Current Limit (Option "C")
The Current Limit option provides an additional layer of protection for dynamic and non-linear loads.
Adjustable from 0-110% of the units rating, this option will override the control signal to limit the output
current to a predetermined level. By adjusting the P4 potentiometer on the option card, the level can be
set to zero at the fully counter clockwise position to 110% of the units rating when at the fully clockwise
position. This feature is useful when the load can vary during process transitions or during a start-up
condition. This option can also be disabled by removing the X4 jumper on the option card. (See
illustrations 7.3 or 7.4 for jumper location.)
5.3
Load Voltage Regulation provides a means of stabilizing the output voltage when input voltage variations
are present. The unit monitors its output voltage thru the onboard feedback loop and compares it to the
command signal to provide regulation.
Output regulation of +/-2% over a +/-10% input voltage swing can be beneficial in heating or other critical
applications where stability and repeatability is of concern. This feature is factory set using the P1
potentiometer on the option card. Adjusting the P1 potentiometer should be avoided as it will affect the
units output voltage scaling and regulation.
5.4 Command Signal Change Soft Start (Option "S")
This option provides a soft start on Command signal Change, Current Trip Reset or when Lockout is
released. It protects fuses from inrush currents and is well suited for high inrush loads and delicate heater
elements. When power is applied and the command signal is brought to zero (0%) for more than 1
second, the unit resets its soft start circuitry and will ramp its output voltage when the commend signal is
increased to any value from zero. The ramp rate is adjusted by the P2 potentiometer on the option card.
When set at minimum (fully counter clockwise) the ramp time is ~0.75 seconds to 100% output. When set
at max (fully clockwise) the ramp time is ~12 seconds. This option can also be disabled by removing the
X2 jumper on the option card. (See illustration 7.3 or 7.4 for the jumper location.)
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com

Phasetronics
Page 12
5.5 Current Trip (Option "T")
The Current Trip option is over current protection that when activated will shut off the units current flow in
1/2 cycle of line power or less. Its peak current detector will initiate a shutdown sequence the instant any
current exceeds the current trip threshold set by potentiometer P3. The adjustment range is 50% to 200%
of unit rated current when going from fully counter clockwise to fully clockwise. The Current Trip is a
latched trip and requires a manual reset via a normally closed dry contact connected to TB1. Current
transformer is included as standard. This option can be disabled by removing jumper X3 on the option
card. (See illustrations 7.3 or 7.4 for Trip Reset terminal block and jumper location.)
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com

Phasetronics
Page 13
Chapter 6 - Start-up
WARNING!
High Voltage present qualified personal only.
Equipment Required:
Digital Volt Meter
Clamp on Current Meter
Appropriately Rated Personal Protection Equipment
Non-metallic small flat blade screwdriver
6.1 Manual Control
The following procedure is used for manual control start-up of the EP1 Series Control.
1. If the unit has an automatic control signal connected, set it to zero or disconnect it.
2. If the unit has the current limit or current trip options, consider setting their adjustment
potentiometers P3 and P4 to fully clockwise setting to ensure they do not interfere with the start
up.
3. Set the digital meter to resistance and verify the manual pot is set to minimum by measuring the
resistance between terminals TB2-3 and TB2-6 on the main board. It should read less than1
If not, verify the manual pot connections before proceeding.
4. Place the Clamp on current meter over the cables connected to the T1 (Load) terminal on the
unit.
5. Set the digital volt meter to AC volts and connect it to the T1 output terminal and the L2
connection on the main board or option card if present.
6. Energize the main power and verify there is no current or voltage output.
7. Slowly rotate the manual pot clockwise while monitoring the voltage and current. The units output
should begin to gradually rise as the manual pot is turned.
8. Continue to turn the manual pot until it is at maximum.
9. Verify the units output voltage and current are at maximum.
10. Slowly reduce the manual pot to zero and verify the units output followed.
11. Remove the units power and disconnect the current and volt meters.
12. The unit is now ready to put into manual control service.
Note: If the unit is connected for manual control only and optional current limit is provided, proceed to
current limit start-up procedure (Section 6.3). If operating under manual control only, you have
completed start-up.
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com

Phasetronics
Page 14
6.2 Automatic Control
The following procedure is used for automatic control start-up of the EP1 Series Control.
1. Offset and Gain adjustments for Automatic signals are factory set for the 4-20ma input
configuration. If you are using a 4-20ma control signal, try the factory settings before
making any adjustments.
2. If the unit has the current limit or current trip options, consider setting the adjustment
potentiometers P3 and P4 to fully clockwise setting to ensure they do not interfere with
the start up.
3. If you are using a 4-20ma automatic signal proceed to step 6.
4. If you are using a 0-5 or 0-10vdc automatic signal, refer to section 7.1 or 7.2 for the
necessary jumper configuration for your signal.
5. Remove the jumper from the 4-20ma selection and place it on the selection that
matches your automatic signal.
6. Place the current meter around the T1 output lead from the unit.
7. Set the digital volt meter to AC volts and connect it to the T1 output terminal and the L2
connection on the main board or option card if present.
8. Energize the unit and verify there is no output voltage or current.
9. If you are using a 0-5 or 0-10vdc automatic signal, re-zero the unit output by adjusting
the Offset pot slowly counter clockwise to decrease the offset value until the unit starts
to output voltage; then back clockwise until the output drops back to its minimum value.
10. Increase the automatic signal gradually to 100% (Max), verify the unit output voltage
and current increase and follow the command signal level.
11. Verify the units output voltage and current are at maximum.
12. Slowly reduce the automatic signal to minimum and verify the units output followed.
13. Remove the units power and disconnect the current and volt meters.
14. The unit is now ready to put into automatic control service.
6.3 Current Limit (Option C ) Start-up
This section assumes the regular start up in sections 6.1 and/or 6.2 have been successfully completed
and the current/volt meters are still connected.
1. Verify the Current Limit potentiometer P4 is set fully clockwise (Maximum)
2. Energize the unit.
3. Increase the manual pot or automatic control signals to maximum.
4. Verify the units output is at maximum.
5. Monitor the Voltage and Current meters and simultaneously turn the current limit pot counter
clockwise (decrease) until the units output begins to decrease.
6. Continue to turn the current limit adjustment counter clockwise until the desired current limit point
is reached. This will establish the maximum current limit value.
7. If the unit is required to output full voltage, slowly increase the current limit pot until the units
voltage output reaches maximum again. This will set the current limit point above the full voltage
output value.
8. Swing the command signal down to minimum and then back up to maximum while monitoring the
output voltage and current.
9. Verify the current limit value is correct and the unit performs as needed.
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com

Phasetronics
Page 15
6.4 -up
This section assumes the regular start up in sections 6.1 and/or 6.2 have been successfully completed
and the current/volt meters are still connected.
1. Connect a normally closed dry contact to TB1 pins 1 & 2 on the option card.
2. Verify the Current Trip potentiometer P3 is set fully clockwise (Maximum)
3. Energize the unit.
4. Increase the manual pot or automatic control signals to maximum.
5. Verify the units output is at maximum.
6. Monitor the Voltage and Current meters and simultaneously turn the Current Trip Pot (P3)
counter clockwise (decrease) until the units output abruptly drops to zero.
7. Verify the RED Current Trip LED is lit.
8. Decrease the command signal to minimum.
9. Momentarily press the normally closed Trip Reset button connected to TB1 on the option card.
10. Verify the Red Current Trip LED is now out.
11. Increase the command signal again to maximum. If the unit trips again, increase the Current Trip
adjustment slightly and repeat the Reset process until the unit can reach full output.
NOTE: If Option S is not installed and a Current Trip is reset with the command signal present, the unit
will come on at the command signal level without a soft start. Option "S" is recommended when using
Option T to facilitate a controlled ramp back to the desired output power level.
6.5 -up
This section assumes the regular start up in sections 6.1 and/or 6.2 have been successfully completed
and the current/volt meters are still connected.
1. Preset the Option S potentiometer P2 on the option card to the mid-scale.
2. Energize the unit.
3. Increase the command signal to maximum.
4. Verify the units output voltage and current has reached maximum.
5. Decrease the command signal to zero and verify the yellow soft start LED is lit.
6. Step the command voltage from 0 to 100% and monitor the output voltage.
7. Verify the output voltage gradually increases and the yellow soft start LED slowly goes out.
8. Adjust the Soft Start pot P2 clockwise to increase ramp time or counter clockwise to decrease
ramp time as needed.
9. Repeat steps 5 - 9 until the Option S soft start is set to the desired time.
6.6
1. Option R is factory calibrated and does not require field start up adjustments.
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com

Phasetronics
Page 16
Chapter 7 - Diagrams
7.1 - Main Logic Board for EP1 Series (10 thru 50 Amp Units) - EPCL1001
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com

Phasetronics
Page 17
7.2 - Main Logic Board for EP1 Series (85 thru 1000 Amp Units) - PCL1002
Note: 380, 575 volt units are not dual connectable.415 volts is dual connectable (208/415).
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com

Phasetronics
Page 18
7.3 - EP1 Series Option Board (10 thru 50 Amp Units) PCM1600
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com

Phasetronics
Page 19
7.4 - EP1 Series Option Board (85 thru 1000 Amp Units) PCM1603
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com

Phasetronics
Page 20
Chapter 8 - Troubleshooting
8.1-SCR Testing Procedures
WARNING
Remove all power sources from the unit! Disconnect load and line leads. Observe
all lock out / tag out practices.
Equipment required: Digital Volt / Ohm meter
8.1.1 Anode to Cathode Measurement
1. Remove line power from the unit and lock out.
2. Disconnect the line and load leads.
3. Set the Volt/Ohm meter to ohms.
4. Connect the Red lead to the L1 power Lug on the unit.
5. Connect the Black lead to the T1 output lead of the unit.
6. Compare readings to the values in the table below.
+ Lead - Lead Good Consult Factory
L1 Lug T1 Lug Greater than 10k ohm Less than 10k ohm
8.1.2 Gate to Cathode Measurements
Phasetronics uses two possible configurations. The first is a 4 color scheme coded Black, Yellow, Gray,
White. The second is coded Red, White and Red White.
1. Using the Ohm meter, measure the resistance between the Black/Yellow pair.
2. Using the Ohm meter, measure the resistance between the Gray/White pair.
3. For units with two sets of Red/White wires, ohm each pair separately.
4. Compare your readings to the table below.
For wire that is color coded black, yellow, gray and white
+ Lead - Lead Good Bad
Black Yellow Between 5 and 32 ohm Less than 5 or greater than 32 ohm
Gray White Between 5 and 32 ohm Less than 5 or greater than 32 ohm
For wire that is color coded red, white, red and white
+ Lead - Lead Good Bad
Red White Between 5 and 32 ohm Less than 5 or greater than 32 ohm
Red White Between 5 and 32 ohm Less than 5 or greater than 32 ohm
Figure 7
Note: If any of the above readings are out of specification, the SCR may need to be replaced.
Contact the factory for technical support or a return material request.
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com