Power-Tronics PC300B User manual

© 2021 Power-Tronics, Inc.
The Power-Tronics PC300B Phase control
is a self-contained complete Phase control
designed for continuous operation at up to
210vdc at 30Adc!
The PC300B is uniquely designed to sit in
a compact footprint while being passively
convection cooled for a long service life.
Because of its unique modular design, the
PC300B minimizes downtime should a
repair ever be necessary! All serviceable
parts are easily removable without the
need to remove the chassis from the
mounting cabinet or tray. The compact
design allows a wide variety of installation
methods, including installations where
space is at a premium.
Over 30 years of field use and design
refinement makes the PC300B a time-
proven design, utilizing high-reliability
components, and a unique modular design
to simplify repair. The PC300B is
designed to provide a lifetime of service
and is specifically built to minimize failures
and potential downtime!
The PCMG-B control module includes an
internal 0-10VDC or 4-20mA interface
module to allow a wide variety of VAR, PF,
or other PLC controls to remotely control
the unit. An optional motorized
potentiometer allows remote operation by
dry contact switching or older pulsed-DC
control schemes.
The PC300B Phase control is the latest
upgrade to the PC300B series of phase
controls.
PC300B
Phase Control
Specifications
Input Voltage: 208 - 240vac
Frequency: 50 or 60 Hz
Voltage Regulation: +/- .25% From NL to FL
Output Voltage Range: 0-210vdc @ 240vac input
Maximum Forcing Output: 210vdc @ 30adc
Rated Continuous Output: 125vdc @ 25adc
Minimum Field Resistance: 7Ω @ 210vdc output
Min Residual Build up Voltage: 5vac
Under Frequency Protection: Yes, VPH reduction
Physical Size: 10 x 10 x 4 in.
Weight: 4 lb.
Integrated Control Module: PCMG-B
Repairable: Yes
Internal Protection: Fuses, cartridge type
External Voltage Adjustment: Yes
System Operating Indicator: Yes
Optional External Controls Yes
Integrated 0-10VDC / 4-20mA Interface: Yes

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Table of Contents
Introduction and Functional Description:....................................................................3
Determining Application Sizing:...................................................................................4
Included Parts & Accessories:......................................................................................6
Mounting Dimensions & Chassis Ground:...................................................................7
Input Power & Field Connection Diagram:...................................................................8
PCMG-B Control Module:..............................................................................................9
Standard Control Wiring Diagram:..............................................................................10
Fully Automatic Remote Adjustment Wiring Diagram:.............................................11
Automatic / Manual Selectable Remote Adjustment Wiring Diagram:....................12
Initial Setup and Commissioning:...............................................................................13
Bench Check Procedures:...........................................................................................14
Installation Warranty Form:.........................................................................................15
Product Warranty Certificate:......................................................................................16

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Introduction and Functional Description
Caution: Read This Installation
Manual Carefully and Entirely!
Warning: Do not use digital equipment to read voltage, Hz, or amperage
during this installation. Use only Analog sensing equipment! Failure to do so
may result in damage to equipment or in personal injury!
ALWAYS perform all setup procedures off-line
ALWAYS wear eye protection
ALWAYS strip wire insulation properly or use insulated connectors
ALWAYS use analog metering equipment when setting up the regulator
ALWAYS ensure the static exciter receives ample airflow
ALWAYS use adequate fusing
NEVER hold the static exciter in your hand or lap when energized
NEVER install the static exciter in a place it can be exposed to the elements or moisture
NEVER mount the static exciter over a screw, bolt, rivet, seam, or other fastener
NEVER remove the regulator cover while the unit is in operation
NEVER insert a screwdriver or other object under the regulator cover
NEVER touch any exposed part of the PC300B during operation
NEVER install a switch in the DC portion of the static exciter’s wiring
NEVER USE A DIGITAL FREQUENCY METER (It can give a false reading!)
Functional Description
The PC300B Phase Control is the result of over 30 years of engineering efforts and offers high-
demand features at a competitive price point. The PC300B is a proven design and is engineered
to greatly simplify setup while offering extreme reliability. When properly installed, the PC300B
Phase Control is designed to provide a lifetime of service.
An automatic phase control has several automated tasks it must perform in order to provide
reliable, clean, and regulated electricity. It must maintain a preset setpoint and protect both itself
and the connected load should a fault situation arise.
The PC300B uses field-replaceable cartridge fuses to protect its internal circuitry should a fault
occur and the load current exceeds what the phase control is capable of delivering. It also
contains reliable circuitry that is designed to maintain a setpoint regardless of outside influences
or ambient temperature.
Due to its extreme simplicity, the PC300B Phase Control is uncommonly reliable and offers
features and accuracy usually only offered by much more complicated and often much more
expensive phase controls.

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Determining Correct Application Sizing
The PC300B Phase control is designed for use with 120-240VAC input. It contains internal
suppression for use with brush-type loads such as synchronous motors. Before installation, it is
necessary to verify that the PC300B is the correct product for your application.
To determine if the PC300B is the correct product for your load you need to know any two of the
following 3 specifications from the rating plate of your load:
1: Control Field Voltage (in DC Volts) [Generally given in full load Voltage on nameplates]
2: Control Field Resistance (in Ohms) [See Note Below]
3: Connected Load Amperage (in DC Amps) [Generally given in full load Amps on nameplates]
Using the specifications obtained from your connected load, verify
that your load fits the specifications below:
• Connected load full load voltage is 100VDC or less, and your control field
resistance is 3.5Ω or greater. Use 120VAC Input Voltage.
• Connected load full load voltage is 200VDC or less, and your control field
resistance is 7Ω or greater. Use 240VAC Input Voltage.
WARNING: BRUSH AND SLIP RING CONNECTION PROBLEMS ARE
THE #1 SOURCE OF VOLTAGE CONTROL PROBLEMS AND FAILURE OF PHASE
CONTROLS!!! DO NOT INSTALL THE PC300B IF THE BRUSHES AND/OR SLIP
RINGS ARE NOT IN EXCELLENT CONDITION!!!
STOP AND CORRECT BRUSH AND SLIP RING CONNECTION PROBLEMS IF ANY
OF THE FOLLOWING CONDITIONS ARE PRESENT:
• GROOVES IN SLIP RINGS
• ROUGH SLIP RING APPEARANCE OR GHOSTING (CHATTERING)
• OIL CONTAMINATION ON BRUSHES OR SLIP RINGS
• DULL, ROUGH, STRIPED, PITTED, OR METALLIC APPEARANCE OF BRUSH
FACES
• FIELD RESISTANCE MEASURED BETWEEN SLIP RING BRASS AND FIELD
RESISTANCE MEASURED BETWEEN FIELD LEADS EXCEEDS 1-2% DIFFERENCE

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Note about Field Resistance
When measuring field resistance on a brush-type device, such as
a synchronous motor, measure the resistance through both the
field leads as well as directly on the slip rings themselves.
The readings you obtain should ideally be the same, but no
more than 1% difference.
If you show more than 1% difference in reading your device has
brush and ring contact problems and will need cleaning or
maintenance before installing the PC300B.
Failure to correct brush and ring contact problems will
result in severe damage to the phase control as well
as possible PERMANENT damage to the slip rings
themselves!
NEVER use emery cloth, carborundum stones, “comm
sticks”, or Tuner cleaner to dress or clean slip rings!
They will make a bad problem much, much worse! Only use
Garnet or Flint sandpaper and clean with a clean rag soaked with
Acetone for best results!

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Included Parts & Accessories
The PC300B Static Exciter includes the following parts and
accessories to ensure a quick and easy installation:
Included Parts List:
• Vibration Isolators Qty: 4
• ¼-20 Self-Locking Nuts Qty: 8
• #16-14AWG Compression Terminal Qty: 1
• ¼” Bellville Washer Qty: 1
• 100K 2W Long-Life Potentiometer Qty: 1
• Panel Knob for Potentiometer Qty: 1
• #22-18AWG .250 Female Terminals Qty: 4
• Red Jumper Wire Qty: 1
• Orange Jumper Wire Qty: 1
• Purple Jumper Wire Qty: 1

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Mounting Dimensions & Chassis Ground
Chassis Should Be
Grounded
For Safety!!!
Use Supplied Compression Terminal
And Bellville Washer Provided In
Accessories Kit
Attach to Bottom Right Mounting Point.
Torque to 125 in•lbf (15N•M)
PCMG-B

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Input Power & Field Connection Diagram
(See page 10 for control wiring information)
WARNING: The PC300B Phase Control is NOT
Suitable for use on Electrical Generators Without a
Suitable Voltage Control Source!!!
The PC300B is a Full-Wave rectified phase control, which allows a maximum of 210VDC
@ 240VAC or 105VDC @120VAC at 30 ADC continuous.
This product is typically used on slip-ring synchronous motors or on inductive loads with
full load control field voltages of 125VDC or less and full load exciter field amperage
between 5 and 30ADC. Control fields with lower voltages can use the PC300B with
a 120VAC input voltage for a maximum output of 105VDC @ 30ADC.
Note that the maximum input voltage to the PC300B Phase control is 240VAC! DO
NOT input 277VAC into the PC300B! Severe damage to the unit will result! For use
on 480V or higher systems, connect the PC300B to an appropriate step-down
transformer to supply 240VAC to the PC300B.
Diagram Assumes a 208-240V
Input Voltage
For 480V Systems, use a 10KVA
(or larger) Transformer with a 240V
NOTE:
Diagram shows an isolation
transformer, which is
recommended for ALL
installations. An isolation
transformer will save your
bearings should the rotor ever
short to ground!
NEVER install a switch or
breaker on the DC or
Exciter side of the phase
control!
Only install a switch or
disconnect on the AC
Side of the phase control!
10KVA or Greater
240V Secondary
See Pages 10-12
for Control Wiring
Diagrams
Torque All Terminal
Connections to
125 in•lbf (15 N•M)
120-240VAC
From Power
Supply
Main Disconnect

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PCMG-B Control Module
The PCMG-B Control Module is an integrated device designed to replace multiple discrete
components in previous generations of Phase Controls. It incorporates a Phase Control
Module, AC Input Filtering, and integrated 0-10VDC / 4-20mA Interface Module.
The unitary design simplifies installation in the field, and greatly simplifies replacement if a fault
occurs with the control module. The unit has 5 color-coded wires with quick-connect terminals,
and can be quickly swapped out in less than 5 minutes without the need to remove the chassis
from its enclosure or tray.
Power
Status
Lamp
V/MA Jumper
Terminal Descriptions:
Colored Terminals:
Chassis Wiring (Color-Coded)
G1 & G2:
Gate Enable Pins
Short G1 & G2 To Operate
Switch or Relay Recommended
If No Switch, Install Red Jumper
R1 & R2:
Remote Adjustment Input
U- & U+:
Output From Internal Analog
Input Module
CV- & CV+:
Input for 0-10V or 4-20mA Signal
V/MA Jumper:
Installed for 4-20ma Signal
Remove for 0-10V Signal
Base Voltage
Trim Control
25 Turn Pot!

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Standard Control Wiring Diagram
This wiring diagram shows the default control wiring configuration for the PC300B and
assumes manual control with a remote potentiometer. Power wiring is shown on
Page 8.
NOTE:
It is not necessary
to jumper terminals
R1 and R2 if not
using the Remote
Voltage Adjustment!
NOTE:
If not using a switch,
Install Red Jumper
from Accessory Kit
100KΩ @ 2w

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Fully Automatic Remote Adjustment Wiring Diagram
This wiring diagram shows ONLY the control wiring configuration for fully-automatic
Remote Control of the PC300B. Control wiring is shown on Page 10.
+
-
0-10VDC
or
4-20mA
Control Signal
NOTE:
Purple and Orange
Jumpers are supplied in
the Accessory Parts Kit

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Automatic / Manual Selectable Remote Adjustment
Wiring Diagram
This wiring diagram shows ONLY the control wiring configuration for selectable fully-automatic
or manual Remote Control of the PC300B. Control wiring is shown on Page 10.
+
0-10VDC
or
4-20mA
Control Signal
100KΩ @ 2w
DPDT Switch
or Relay
Switch Position:
Automatic
é
Manual
ê
-

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Initial Setup and Commissioning
1. Install the PC300B and wire according to the correct wiring diagram and control wiring
diagram (Pages 8-12).
2. If installing the PC300B on a load containing slip rings and brushes, verify that the
brushes and brush riggings are isolated, ungrounded, and connected ONLY to the
PC300B.
3. Base Voltage and Manual Internal Voltage adjustments are preset from the factory for
use with a remote adjustment potentiometer or the internal 0-10V interface module.
4. If you are using a remote voltage adjustment, set it at 0% of adjustment.
5. If you are using the PC300B on a synchronous motor, bring the motor up to
operating speed and turn on the phase control switch (if used).
6. If you are using an external voltage adjustment potentiometer or the internal 0-
10V interface module, adjust the remote control until reaching the desired voltage
setting for the connected load.
7. Observe operation during no-load and full-load conditions. Once the voltage is
set and adjustment characteristics are satisfactory the installation procedure is
complete.
NOTE: Tolerances in remote potentiometers and control arrangements can cause the
base voltage to rise preventing the PC300B from reaching 0VDC output. If this
occurs, the base voltage can be adjusted using the BASE adjustment
potentiometer on the PCMG-B control module. Turn the external control to 0%.
If the PC300B is still outputting DC voltage, slowly turn the BASE adjustment
CCW until 0VDC output is achieved.

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Bench Check Procedures
1. Wire the PC300B as shown in the figure below.
2. Connect two 120 volt 50 to 150 watt incandescent light bulbs in series to the F+ and F-
Terminals.
3. Install a temporary jumper wire between terminals G1 and G2 on the PCMG-B Control Module.
4. Input 208-240VAC fused at no more than 5A into the PC300B. The test light should be OFF.
5. Attach a 100KΩ potentiometer to R1 and R2 terminals on the PCMG-B Control Module.
6. Slowly turn the 100KΩ potentiometer Clockwise (Right) until the lights glow. The test light
should light to FULL Brightness. NOTE: Depending on the calibration of the PCMG-B
control module, it may take up to ¼ turn before the lights illuminate!
7. Slowly turn the 100KΩ potentiometer Counter-Clockwise (Left) until the lights go dark. The test
light should be OFF. NOTE: Lights should shut off without any flicker or flashing.
8. Turn off power and disconnect the PC300B from your power source. Inspect all electronic
components on the PC300B to ensure they are isolated from touching any part of the PC3000B
housing.
9. If you were able to successfully perform all of these tests, the PC300B is good.
2x 120V 50-150W
Incandescent
120-240VAC
Fuse Replacement Information:
PCMG-B:
Rating: 5A @ 250VAC
Qty: 2
PTI Part # 5R3-403
Cooper–Bussman Part # BK/GDB-5A
PC300B:
Rating: 30A @ 300VAC
Qty: 2
PTI Part # 5R3-466
Cooper–Bussman Part # JJS-30
Mersen Part # A6T-30
Jumper

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Installation Warranty Form
It is very important that you fill out this form completely when installing a voltage regulator. This form
serves as a history record on the application. This form also contains the information needed by Power-
Tronics, Inc., for repair and troubleshooting of any product you may be having problems with.
Failure to fill out this form during installation will result in a cancellation of your warranty
coverage! Filling out this form takes only minutes but will save hours or days later on if your
product should require service!
Problem Description/History (Please be detailed!!!):
Ship-To Address (City, State, Zip, Country):
Company Name:
Contact Person:
Telephone Number:
Email Address:
Primary Load (Please Explain):
Repair/Warranty Request Information
Generator Leads (Check One:) ☐12 ☐10 ☐6 ☐4 (3ø) ☐4 (1ø) ☐3
Generator Wiring Mode (Check One:) ☐High-Wye ☐Low-Wye ☐Series Delta
☐Zig-Zag ☐Double-Delta ☐Single-Phase ☐Other
Terminal Voltage:
Residual AC Voltage:
Rated KW:
Rated KVA:
Generator Wiring/Usage Information
This Section for Brushless Generators Only
Exciter Field Voltage:
Exciter Field Resistance:
This Section for Brush-Type Generators Only
Shunt-Field Voltage:
Shunt-Field Resistance:
Rotor Resistance @ Brush Leads:
Rotor Resistance on Slip-Rings:
Rotor Excitation Voltage:
Product Model:
Serial #:
Date of Installation:
Additional Module(s) or Options:

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PRODUCT WARRANTY
Power-Tronics, Inc., assumes no liability for damages due to incorrect voltage or other voltage
related damages resulting from either output of the generator or input to the generator exciter
system. These problems should be protected with external devices provided by the customer
such as fuses, surge suppressors, over/under voltage and frequency controls.
Power-Tronics, Inc., warranties only parts and workmanship of this product for a period of 3
years from the original date of purchase from Power-Tronics, Inc. Under warranty, Power-
Tronics, Inc. will replace, exchange or repair the defective product without labor or parts cost
to the customer. Remaining warranty of the original product will be transferred to the replaced
or repaired product. To obtain warranty, a copy of the original Installation Warranty Form must
be sent in with the defective product, which clearly shows the purchase date and serial number
of the defective part. A repair request form must be sent in with the product before repairs will
begin. You can obtain this form by contacting Power-Tronics, Inc.
Send repairs to: Power-Tronics, Inc., 2802 Cobbler Ln., Kerrville Texas USA 78028.
Send in repairs only by UPS or FedEx. USPS will NOT deliver to our facility!
Any one of the following conditions will void the warranty:
v Overheating of the power supply resistor on the printed circuit card.
v Overheating of the SCR or freewheeling diode.
v Physical damage to the printed circuit card, housing or components.
v Unauthorized repair or alteration of printed circuit card.
v Installation by anyone other than a qualified professional generator service technician.
v Conductive or corrosive contamination of the circuit card.
v Removal of our company identification from the product.
v Removal of any conformal coating of the printed circuit card or components.
v Overheating of foil on the printed circuit card.
v Inappropriate or infeasible application.
v Use with any external device other than manufactured by Power-Tronics, Inc.
v Failure to fill out the attached warranty card during installation
No other warranty is expressed or implied.