Safety Information in this Manual
Danger, Warning, and Caution symbols are used throughout the manual to help identify and avoid hazardous situations. Examples of each symbol are shown and explained below.

DANGER
Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations. It may also be used to alert against unsafe practices. (Color: red)

WARNING
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. It may also be used to alert against unsafe practices or cause product failure. (Color: orange)

Caution
Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. (Color: yellow)

Table of Contents
Chapter 1...............................................................................1-1
Product Description......................................................................... 1-1 Phase-Angle Control..................................................................... 1-2 Zero-Crossover Control ................................................................ 1-4 Standard Features ........................................................................ 1-7 Optional Features ......................................................................... 1-8 Technical Specifications ............................................................... 1-8 Part Number ................................................................................. 1-9

Chapter 2...............................................................................2-1
Hardware ........................................................................................ 2-1 Installation..................................................................................... 2-1 Enclosure...................................................................................... 2-1 Enclosure Temperature ................................................................ 2-1 Vibration........................................................................................ 2-2 Mounting ....................................................................................... 2-2 Disconnect Means ........................................................................ 2-2 Wiring............................................................................................ 2-2 Remote Feedback Wiring ............................................................. 2-4 Control Connections ..................................................................... 2-5 Digital Inputs ................................................................................. 2-6 Digital Outputs .............................................................................. 2-7 Analog Inputs ................................................................................ 2-8 Analog Outputs ............................................................................. 2-9 Remote Feedback....................................................................... 2-10 Over-temperature Sensing.......................................................... 2-10

Chapter 3...............................................................................3-1
Configuration................................................................................... 3-1 Startup .......................................................................................... 3-1 Configuration Tool Installation ...................................................... 3-2 Running the Configuration Tool .................................................... 3-2 Configuration Tool Menu and Task Bar Descriptions.................... 3-5 Off-line Programming.................................................................. 3-10 On-line Programming.................................................................. 3-18 On-line Monitor ........................................................................... 3-23 Flash Programming..................................................................... 3-29

i

........7-1 Settings ................................................................................ 4-12 Manual Calibration ..................................... 4-5 Remote Voltage and Current Feedback.... 7-2 Voltage Input Actual................................. 5-7 Chapter 6.................................................................................................................................................................. 4-5 Voltage Rating ........................................................................................... 4-7 Saving Calibration.................................. 4-10 Analog Calibration..................... 7-1 Voltage L2-L3 Input Actual.... 6-1 Hardware ..................................... 4-17 Chapter 5................................................................................................................................................................. 7-1 Voltage Input Phase Unbalance Alarm ............................................. 6-3 Chapter 7............................................................................................................................................................ 4-9 Restoring Factory Calibration ....5-1 Local Digital Control Option ................................................................................................................................................................................................................................... 7-1 Voltage Input High Fault .................................................................................................................................................................................................... 4-1 Current Rating.................................... 7-1 Voltage L1-L2 Input Actual..................................6-1 Serial Communication .......................................... 7-1 Voltage Input Low Alarm...........................................................................................................................Loss of Communication ................. 4-15 Magnetizing Sequence Calibration ........................................................................................................................................................................................... 4-16 Repetitive Pulse Calibration.......................................... 7-2 ii ......................................................... 5-1 Normal Mode Operation.............. 5-1 Display and Status ..... 4-16 Node Synchronization....... 4-6 Calibration Procedure .......................... 3-30 Chapter 4................... 6-1 Serial Protocols................................................................. 7-2 Voltage L2-L3 Input Span .................. 7-2 Voltage L3-L1 Input Actual...................................................... 7-1 Voltage L1-L2 Input Span .......................................................................................................................... 7-2 Voltage L3-L1 Input Span ............. 5-3 Display Select Mode Operation................................................................................................................................................ 7-1 Voltage Input Rating .............................................................................4-1 Calibration..

............................................................. 7-2 Voltage Output Proportional Gain ................................................. 7-5 Current L2 Input Actual ................ 7-2 Voltage Output Setpoint.................................................................................................................................................... 7-4 Current Input Limit ............................................................................................................................................................................................. 7-3 Voltage X3-X1 Output Actual ............. 7-5 Current Input Actual .. 7-3 Voltage X3-X1 Output Zero........................................................................................... 7-2 Voltage Output Rating.......... 7-6 iii ..................................................................... 7-2 Voltage Output PT Secondary ....................................... 7-4 Current Input Overload Fault ................................................................ 7-5 Current L3 Input Span............... 7-5 Current L1 Input Actual ................................................... 7-4 Voltage Output Actual ....... 7-4 Current Input High Fault Retry Number ............... 7-4 Current Input Rating................................ 7-5 Current L2 Input Span......................................... 7-4 Current Input High Fault Retry Time ..................................... 7-3 Voltage X3-X1 Output Span.................................. 7-3 Voltage X1-X2 Output Zero............................................................. 7-5 Current L1 Input Zero................................................................................... 7-3 Voltage X2-X3 Output Zero.................... 7-3 Voltage Output Derivative Gain ............................................... 7-4 Current Input High Fault..............................................................Frequency Rating.................................... 7-2 Frequency Actual ........................... 7-5 Current L1 Input Span.................................................................................................................................................. 7-3 Voltage X2-X3 Output Actual ................................................................................................ 7-2 Voltage Output Limit ... 7-5 Current L2 Input Zero................................................................................................................................................................................................................................................. 7-4 Current Input Overload Time .................................................. 7-5 Current L3 Input Actual .......... 7-3 Voltage X2-X3 Output Span........................................................ 7-3 Voltage X1-X2 Output Actual ......................................................................... 7-4 Ground Fault Current ............................................................... 7-3 Voltage Output Integral Gain ...................................................................................... 7-5 Ground Fault Time ............ 7-5 Current L3 Input Zero................................................. 7-3 Voltage X1-X2 Output Span...........................................................................................................................................................

........................................ 7-7 KVA Input Rating .......................................................................................... 7-7 Current Output Actual .................................. 7-6 Current Output Derivative Gain..................... 7-7 Current X3 Output Actual................................................................................................ 7-8 Duty Cycle Output........... 7-10 iv ........................................................................................... 7-7 Power Output Setpoint.................................................................................. 7-6 Current Output Integral Gain............ 7-9 Primary Analog Setpoint Span .... 7-6 Current Output Rating.............................. 7-7 Current X2 Output Actual.............. 7-10 Analog Output #1 Span............................................... 7-9 Secondary Analog Setpoint Zero ............................. 7-6 Current Output Proportional Gain .......... 7-8 Power Factor .................................................................................................................................................................................................................................................................................................................................... 7-8 Primary Analog Setpoint Zero.......................................................................................................... 7-10 Analog Output #1 Bias ...........................................................................Current Input Threshold Load Failure ............................................................................................................ 7-8 Duty Cycle Setpoint ............................................................................................... 7-6 Current X1 Output Actual.............................................................................................................................................................................................. 7-8 Power Output Derivative Gain ............... 7-6 Current Output Setpoint ............... 7-7 KVA Input.......................................................... 7-8 Local Digital Control Setpoint............................................................................................. 7-8 Local Primary Analog Setpoint..................................................................................................................................................................................................................... 7-6 Current Output Limit................. 7-8 Power Output .............................................................................................. 7-10 Analog Output #1 ... 7-9 Analog Output #1 Selection .................. 7-9 Secondary Analog Setpoint Span .... 7-7 Power Output Integral Gain ....... 7-6 Current X1 Output Span ......................................................... 7-7 Power Output Proportional Gain ............... 7-6 Current X1 Output Zero ........................................................... 7-9 Local Secondary Analog Setpoint Selection ................................... 7-7 Power Output Rating........................... 7-9 Local Secondary Analog Setpoint ................ 7-7 Power Output Limit ......... 7-8 Local Digital Control Display Selection ................................................

................................................................................................ 7-15 Fault Code .................................................................. 7-13 Ramp Down Time .................................................................................. 7-16 Chapter 8.................................. 7-14 Network Loss ................................... 7-13 Control Strategy Selection ............................................................................................................................................................................ 7-10 Analog Output #2 Span.......................................................................................................................................................................................................... 7-14 Control Power Time On .......................Analog Output #2 Selection ............ 7-16 Fault Buffer #3 ................................................................................................................................................... 7-14 Output Time On .............................................................................................................. 7-14 Software Version...................................................... 7-15 Network Address............................................................................................................................................................................................................................................................. 7-16 Fault Buffer #8 ................................. 7-14 Repetitive Pulse Calibration......................................................................................................................................... 7-14 Serial Number ..................... 7-16 Fault Buffer #7 .............................................................................................................. 7-15 MODBUS Address ................................... 7-12 Ramp Up Time....... 7-10 Analog Output #2 Bias ...................................................... 7-15 MODBUS Baud Rate ............................................................................................. 7-15 Fault Buffer #2 ............... 7-15 Fault Index ................................................................ 7-14 Magnetizing Sequence Calibration .................................... 7-14 Load Type Selection ............................... 8-1 Control PCB LED Indicators .......... 7-11 Status Word ................................... 7-15 Network Type............................... 7-15 Network Baud Rate................................ 7-16 Fault Buffer #5 ............ 7-13 Configuration Word ..................................................................................................................... 7-14 KW-Hour ........................................ 7-14 Product Type .......................................................... 7-16 Fault Buffer #6 ..................................................... 8-2 v ........................................................................................................ 7-10 Analog Output #2 ............................................. 7-15 Fault Buffer #1 ...............................................................................................................................................................................................................8-1 Troubleshooting ........................ 7-10 Control Word........................ 7-16 Fault Buffer #4 ............

...................................................................................................... B-1 Electrical Drawings........ B-1 Glossary ............................................................................................................. A-1 Appendix B ...................... i vi .............................................................................................................................. 8-10 Appendix A ......................................................................................................................... 8-4 Fault Reset ................................................................ 8-9 Troubleshooting Guide....................................................... A-1 Mechanical Dimensions ....Local Digital Control Option LED Indicators......................... 8-9 Fault Buffer ............................. 8-3 Fault and Alarm Codes .....................................

............................................................................... 1-5 Figure 1-6 Zero-Crossover Control Magnetizing Sequence .......... 8-3 Figure A-1 Mechanical Dimensions.............List of Figures Figure 1-1 853 DSPC Schematic Diagram.................................................................................. 1-4 Figure 1-5 Zero-Crossover Current Input Limit............................................... 5-1 Figure 6-1 Nine Pin to Nine Pin Null Modem Cable Diagram .. 6-1 Figure 8-1 Control PCB LED indicator location ................................................................................................................................ 3-11 Figure 3-4 Ratings & Limits Tab................................ 1-1 Figure 1-2 Phase-Angle Control Half Cycles.......................................................B-6 Figure B-6 350A Wiring Diagram ....B-5 Figure B-5 175A Wiring Diagram ................................................................... 1-3 Figure 1-4 Zero-Crossover Control ................................................B-7 vii ...........................................................................................................................B-2 Figure B-2 Electrical Schematic Right Side................................................................................................................................................... 3-27 Figure 3-13 Fault History................................ 4-1 Figure 4-2 Voltage Calibration...................................................................................................................... 1-6 Figure 1-7 Zero-Crossover Control Repetitive Pulse........ 3-16 Figure 3-8 Network Tab..................................................................................................................................................................................................... 6-1 Figure 6-2 Twenty-five Pin to Nine Pin Null Modem Cable Diagram ....................... 3-17 Figure 3-9 Configuration Tool On-Line .......................................................................................................................................................................................................................................................................................................................................B-4 Figure B-4 90A Wiring Diagram .................. 2-3 Figure 2-6 Digital Input Schematic .................... 2-7 Figure 2-8 Analog Output Schematic ...................................................................................................................................................................................................................................................................... 3-1 Figure 3-3 Configuration Tool.................................................................................................................................................................................................................................................... 1-6 Figure 2-1 Mounting Dimensions ............................................................................................................................................................... 3-28 Figure 3-14 Flash Programming.................... 3-26 Figure 3-12 Monitor Status Tab. 8-2 Figure 8-2 Local Digital Control.....B-3 Figure B-3 40A Wiring Diagram ........................................................................ 3-12 Figure 3-5 Control Configuration Tab ........................................................................................................................ 3-29 Figure 4-1 Calibration (Voltage Tab) ........................................ 1-2 Figure 1-3 Phase-Angle Duty Cycle Output .............. 4-2 Figure 4-3 Current Calibration. 4-4 Figure 5-1 Local Digital Control Panel.............................................................................................................. 3-24 Figure 3-11 Monitor Control Tab ............................................................................................................................................................ 4-3 Figure 4-4 Analog Calibration............................................... 2-2 Figure 2-2 Cover screw locations ............................... 2-9 Figure 3-1 Control PCB LED Location..................... 3-19 Figure 3-10 Monitor Summary Tab ....... 3-15 Figure 3-7 PID Setup Tab ................................................. 3-14 Figure 3-6 Fault Setup Tab ........A-1 Figure B-1 Electrical Schematic Left Side .........................

.......................................................................................................................................................... 7-1 Table 8-1 Control PCB LED Indicators................. 6-2 Table 6-2 MODBUS RTU Query (from Master) ..................................................... 6-7 Table 7-1 List of Settings........................... 2-6 Table 2-3 Relay Contact Ratings ........................................ 8-4 Table 8-4 Troubleshooting Guide........................................................................................................................................... 5-2 Table 5-2 Digital Control Status .................. 3-20 Table 5-1 Display Selections..................................................................................... 8-3 Table 8-3 Fault and Alarm Codes ....... 5-8 Table 6-1 Serial Port Configuration .................................. 5-3 Table 5-3 Pushbutton function in Normal mode.............. 6-6 Table 6-8 General 8 Byte Response (from 853)............... Remote Control ..... 5-5 Table 5-5 Pushbutton function in Normal mode........................................ 1-8 Table 2-1 Wiring Information ...... 2-4 Table 2-2 Digital Interface Plug ................................................................List of Tables Table 1-1 Technical Specifications........... 6-5 Table 6-6 MODBUS RTU Exception Codes ............................. 5-6 Table 5-6 Pushbutton function in Display Select Mode.............. Remote Control ............................................................. 2-8 Table 3-1 Status Lamp Description ........................................ 6-4 Table 6-5 MODBUS RTU Exception Response (from 853 DSPC) ...................................... 6-3 Table 6-3 MODBUS RTU Read Response (from 853) .................. Local Control ...................................................................................................................................................................................................................................................................... 8-2 Table 8-2 Local Digital Control LED Indicators......... Local Analog Control ..... 5-4 Table 5-4 Pushbutton function in Normal mode............... Local Digital Control ................ 5-7 Table 5-7 Pushbutton function in Display Select Mode.............................................. 8-11 viii ............................................................................................................................................................................ 2-7 Table 2-4 Analog Interface Plug.................................................................... 6-5 Table 6-7 General 8 Byte Query (from Master) ....... 6-4 Table 6-4 MODBUS RTU Write Response (from 853) ........................................................................................................

Figure 1-1 853 DSPC Schematic Diagram 1-1 . dsp-based firing circuit to control a three phase. The basic circuit configuration is shown in the figure below. The 853 DSPC uses an advanced. The DSPC is designed for a three-phase application. six SCR AC Switch.Chapter 1 Product Description The 853 Digital SCR Power Controller (DSPC) from Spang Power Electronics offers the latest in Digital Signal Processing (DSP) technology and software. The 853 DSPC is capable of firing into either direct or transformer coupled loads.

A sample picture of Phase-Angle control is shown below. The period during which the load is connected is varied in response to the control signal providing proportional control of power to the load. Figure 1-2 Phase-Angle Control Half Cycles 1-2 .Product Description Phase-Angle Control February 2004 In Phase-Angle control. It is disconnected from the load for the remainder of the half cycle. the line is connected to the load for a portion of each half cycle.

Figure 1-3 Phase-Angle Duty Cycle Output RFI Phase-Angle control can generate Radio Frequency Interference (RFI). 1-3 . telephones. The Current Input Limit is accomplished by comparing the Current Input to the Current Input Limit. Zero-Crossover control can be used for many of the electric heating applications. and Power Output. depending upon the installation and magnitude. The regulation modes are Open Loop. etc.February 2004 Product Description Phase-Angle Control Method The 853 DSPC controls its output based on regulation mode. The source inductance.). which in turn will lower the Current Input. affect other electronic equipment (computers. Additional components may be required to reduce or eliminate RFI. Where RFI may be a problem. A flow diagram of the control is shown below. and circuit impedances determine the amount of RFI generated by Phase-Angle control. This may. Voltage Output. such as the use of an isolation transformer between the line and the 853 DSPC or the addition of line filters. Current Output. Each mode regulates to within 1% of rated output. If the Current Input exceeds the Current Input Limit the Current Output setpoint is lowered. load inductance.

1-4 . The ratio of the number of cycles ON to the number OFF is varied in response to the control signal providing proportional control of the power to the load. This will allow the output to be set to 1% or 1 cycle out of 100. It is then disconnected for a number of complete cycles. The actual voltage output. This allows each independent 853 DSPC to start at a different time based on the Network Address. the line is connected to the load for a number of complete cycles.Product Description Zero-Crossover Control February 2004 In Zero-Crossover control. current output. and power output are calculated every cycle and compared to each respective setpoint. This necessitates a minimum of two cycles or 2% output since the first cycle is used for calculation and turn off does not occur until after the second cycle. The 853 DSPC has predefined the total number of cycles ON and OFF to be 100. Zero-Crossover Control Method The Zero-Crossover control method is based on calculation. Figure 1-4 Zero-Crossover Control Multiple 853 DSPC’s can achieve power leveling by using the Network Address and Node Synchronization. therefore causing power leveling on the common AC power source. The cycles continue until the calculated feedback exceeds its respective setpoint and then the unit turns off after the next cycle. This on-off pattern is repeated continuously with the 853 DSPC turning on (and off) at the zero crossing of the sine wave. which allows one 853 DSPC to turn on when the other unit is off. A sample picture of the Zero-Crossover control is shown below.

firing full cycles of power. Zero-Crossover Load Type The very nature of Zero-Crossover control. This is especially true when transformers are connected to the output. A sample picture of the Zero-Crossover control with Current Input Limit is shown below. These include such elements as nichrome. and since the Zero-Crossover control is adaptive. current output. Such elements require the use of the current limit option that prevents more than a preset value of current from flowing during the initial low resistance condition of the elements. 1-5 . moly-disilicide. silicon carbide (which ages) and quartz infrared lamps. Transformer Coupled loads require two additional settings. In order to eliminate this problem from happening.February 2004 Product Description Zero-Crossover Current Input Limit The Zero-Crossover control method controls cycles and can only control Current Input by applying Phase-Angle control to the individual cycles. The Phase-Angle control of the individual cycles will limit the input current. molybdenum. chromolox and various steels. the number of cycles will automatically increase based on the voltage output. calrod. tends to cause large inrush currents into the load. it does protect the load by limiting the current that in some cases would be more important than the Zero-Crossover features. Magnetizing Sequence and Repetitive Pulse. and power output setpoints. No particular precautions need be taken in using such materials. The Phase-Angle control of individual cycles does eliminate some of the features of the Zero-Crossover control such as high power factor and low RFI. This is because transformers rely on their magnetic field to limit the current. which is present only after current has been flowing for a short time. the Load Type setting can be set for Direct Coupled or Transformer Coupled loads. The second category consists of elements made from materials that exhibit low initial (cold) resistance such as tungsten. However. Figure 1-5 Zero-Crossover Current Input Limit Heating Loads Resistance type heating loads fall into two general categories. platinum. The first category consists of heating elements made from materials that exhibit relatively constant resistance whether hot or cold.

Product Description February 2004 Magnetizing Sequence The Magnetizing Sequence causes the specified number of cycles to start in Phase-Angle control in order to limit the current inrush when the 853 DSPC is first turned on. the Repetitive Pulse causes only the first cycle to start in Phase-Angle control again in order to limit the current inrush. Figure 1-6 Zero-Crossover Control Magnetizing Sequence Repetitive Pulse After the cycle has started. A sample picture of the Zero-Crossover control Repetitive Pulse is shown below. Figure 1-7 Zero-Crossover Control Repetitive Pulse 1-6 . A sample picture of the ZeroCrossover control magnetizing sequence is shown below.

troubleshooting or preventative maintenance. using an analog control signal. power and fault conditions. and power User-configurable analog input User-configurable analog outputs Non-volatile storage of all digital settings Support of MODBUS RTU protocol Support of multiple baud rates on the serial port 1-7 . On-Board Diagnostics. and setpoints. • • • • • • • • • • • • • • • Operates on universal line voltages. Configurable operating modes. Computerized Setup and Calibration. Locally. Remotely. current. through the use of a computer. RS-232 serial Configuration Tool for setup. ratings. limits. current. Changes can be made any of four different ways: Locally. with optional Network Communications feature. digital calibration and diagnostics Touch-Proof Mechanical Design prevents unintentional contact with hazardous voltage Advanced Process and Fault Monitoring. DSP-based control 1600 Volt SCR's 20KHZ pulse transformer coupled SCR gating circuit 50KHZ digital firing control True RMS calculation of voltage. using the Configuration Tool software. Fault memory (the last eight faults are available in fault buffer storage) allows the user to record problems and. with optional Local Digital Control feature. observe trends that could indicate a need for process modification. Real-time monitor of voltage. from 24 to 600 VAC and 50/60 Hz.February 2004 Standard Features The 850 Series digital product family offers the following features: • • Product Description Flexibility. current. external inputs. Real-time adjustment of the setpoint. Locally. and power at 10KHZ sampling Simultaneous regulation of voltage.

051.Product Description Optional Features The following optional features are available for the 853 DSPC: • February 2004 Network Interface. • Technical Specifications Table 1-1 Technical Specifications Input Line Voltage Input Line Frequency Current Rating 24 to 600 VAC RMS 50/60 ± 2 HZ 40 to 350 A.200 A2sec 90/175A . or power on the LED display. consult factory for higher ratings 40A . Local Digital Control.000 A2sec Control Voltage Control Power Analog Inputs (2) Analog Outputs (2) Digital Inputs Regulation Isolation to ground Ambient Temperature Range 85 to 265 VAC 50 VA 0 to 5 VDC or 0 to 20mA (250Ω) 0 to 5 VDC or 0 to 20mA (10V max) 0 to 5 VDC 1% 2500 VAC 0 to 50ºC Current Surge Rating 1-8 .14.16. which allow local control of the 853. 12 independent status LEDs and 4 pushbuttons.800A for 10 msec 90/175A . and Ethernet (MODBUS TCP protocol). User has a 4-digit LED display. MODBUS (MODBUS RTU protocol).500A for 10 msec Fuse I2t Rating 40A .000 A2sec 350A . current. Fault and alarm conditions are displayed. Profibus. allowing for remote control and monitoring of the 853.320.1.8. as well as monitor voltage. The user can control unit output and change the desired set point. The networks supported are DeviceNet™.000A for 10 msec 350A .1.

Profibus Ex . 1-9 .Local Control x2 .Ethernet x1 . 853 Product Series AAAA Current Rating: 40A 90A 175A 350A 00 Product Options: Dx .Remote Control 00 SL – Special Lugs Reserved for future use.DeviceNet™ Px .February 2004 Part Number Product Description The Part Number format for the 853 DSPC series product is 853-AAAA-00-00 and is described in detail below.

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the 853 DSPC should be carefully checked for shipping and/or handling damage such as loose or broken parts or wires. All covers and panels should be removed for internal inspection and any shipping braces should be removed. and international codes. Failure to observe this precaution could result in severe bodily injury or loss of life. splashing or falling water. Enclosure The 853 DSPC must be mounted in a protective enclosure to prevent the hazard of electrical shock and also to avoid exposing the circuitry to damaging contaminants. These conditions necessitate the use of a special NEMA enclosure. Wiring or application errors. care must be taken to allow sufficient cooling air to the SCR heatsink. incorrect or inadequate AC supply. A NEMA 1 enclosure for providing protection from electric shock is available as an option. grounding. WARNING The 853 DSPC is intended to be mounted in a protective enclosure to prevent the hazard of electrical shock. Prior to installation. adequate protection must be supplied.Chapter 2 Hardware Installation DANGER The user is responsible for conforming to all applicable local. wiring practices. WARNING An incorrectly applied or installed system can result in component damage or reduction in product life. Enclosure Temperature The 853 DSPC is rated at 50°C maximum ambient temperature. Custom NEMA enclosures for the afore-mentioned conditions are also available. If the 853 DSPC must be located in an area of dust. Unless supplied with an enclosure. disconnects. and overcurrent protection are of particular importance. it is considered to be a component that must be mounted in an enclosure by the user. If the 853 DSPC is mounted in an enclosure other than one designed and built by Spang Power Electronics. Consult the factory for enclosure temperatures above 50°C but less than 65°C. falling debris. or excessive ambient temperature may result in malfunction of the system. national. 2-1 .

Optional semiconductor fuses (externally mounted) are available to prevent surge or transient currents from damaging the semiconductors. Fuses are not necessary if the distribution system current surge rating is limited to below the specification for the unit. It is recommended that the enclosure exhaust vents be located above the top of the heatsink. 250A for the 90/175A unit and 500A for the 350A unit) to prevent nuisance fuse blowing and. for this reason. Figure 2-1 Mounting Dimensions Disconnect Means It is required that a circuit breaker. The semiconductor fuses are oversized (90A for the 40A unit. Ambient operating temperature should be taken into account. cannot be used for steady state overload protection. Mounting Allow four inches on each side and a minimum of four inches above and below the 853 DSPC for adequate cooling. Wiring Wire should be sized in accordance with the appropriate specific code guidelines. All large cables should be routed to allow access to the 853 DSPC.Hardware Vibration February 2004 If the mounting site has a vibration concern. 2-2 . It is up to the discretion of the installer to allow access room to service the unit. the 853 DSPC should be mounted using industry standard shock mounting techniques. fused disconnect or fuses be installed upstream of the 853 DSPC for wire protection. Allow additional room for wiring as required by the individual application.

and are removed to open the covers on their inside hinges. The output power lugs. providing access to the power wiring terminals. Figure 2-3 Input and Output Power Lug locations (175A unit) 2-3 . the remote feedback terminal block. and the chassis ground lug are located under the bottom cover as shown in the following figure.February 2004 Hardware The Phillips head cover screws are located at the four corners of the unit. Figure 2-2 Cover screw locations The input power lugs are located under the top cover.

the connections are made to the Remote Feedback Terminal.5-75V and 2437. 37. Remote Feedback Wiring If remote feedback is used. and the voltage feedback signal should be in the same range as the input voltage. 150-300V. Current feedback is connected to TB1 terminals 1 (+) and 2 (common). Allowable ranges are 300-600V. 2-4 . and voltage feedback is connected to TB2 terminals 1 (X1). 2 (X2) and 3 (X3). The current feedback signal should be about 2. 75-150V.5V.5 Vrms at the rated output current.Hardware February 2004 Table 2-1 Wiring Information Unit size Power Lugs Wire Range 40A 90A 175A 350A 14-2 [8*] AWG Screw Head Slotted Ground Lug Wire Range 14-2 [8*] AWG 14-2 [8*] AWG Screw Head Slotted Slotted Slotted Feedback Terminal Wire Range 8-24 [14*] AWG 8-24 [14*] AWG 8-24 [14*] AWG 8-24 [14*] AWG Screw Head Slotted Slotted Slotted Slotted 14-1/0 [4*] AWG Slotted 6-250MCM[2/0*] AWG 5/16 inch hex 14-2 [4*] AWG 4-500MCM [350MCM*] AWG 1/2 inch hex 6-3/0 [2*] AWG ¼ inch hex Note: Size in brackets [*] is recommended for 90ºC wire insulation. Figure 2-4 Remote Feedback Terminals Note: The existing current and voltage feedback connections must be removed and insulated before connecting new remote current and voltage feedback to the Remote Feedback Terminal.

Figure 2-5 Control Connectors The following figure shows a typical wiring diagram for control connections. The 853 DSPC requires 85-265VAC 50/60Hz @ 50VA control power for the circuit boards and cooling fans.February 2004 Control Connections Hardware Control connections are made using the pluggable terminal blocks that are located on the right side of the 853 DSPC. Figure 2-6 Typical Control Connections 2-5 . This must be wired to the twoposition plug labeled Control Power. These terminals accept fine stranded wire up to 12 AWG.

Table 2-2 Digital Interface Plug Terminal Number 1 2 3 4 5 6 7 8 9 10 11 12 13 Note: Terminal description External Fault #1 power External Fault #1 input External Fault #2 power External Fault #2 input External Fault #3 power External Fault #3 input Remote/local power Remote/local input Enable power Enable input Fault common Fault NC Fault NO Standard operation (see Note below) Shorting 1 to 2 provides an external fault input. Open indicates no remote fault. Shorting 3 to 4 provides an external fault input. and External Fault) provide power for each input designed for low voltage contacts or switches. Open inhibits operation.Hardware February 2004 WARNING This equipment is at line voltage when AC power is connected. Contact closes when a fault occurs. 10 mA signal into the appropriate digital input. Open indicates no remote fault. it is possible to connect a 10V signal directly into the input without using the power connection. The following table describes each terminal and its default operation. Contact opens when a fault occurs. The external faults are programmed by default as normally open (NO). Shorting 7 to 8 puts the unit into remote mode. The digital interface consists of the thirteen-position plug labeled Digital Interface. Fault relay common connection. Open defaults to local mode. Shorting 9 to 10 enables the unit. A typical schematic of the digital inputs follows the table. Digital Inputs The digital inputs (Remote/Local. Refer to the Settings Chapter (Configuration Word) for more information on contacts. 7 and 9 provide 15 volts through a 470 Ω resistor in order to develop a 10 volt. Open indicates no remote fault. If interfacing to automated equipment. Terminals 1. The voltage/current rating of the contact or switch should be 15V and 10mA. 5. Disconnect and lock out all ungrounded conductors of the AC power line. Enable. Failure to observe these precautions could result in severe bodily injury or loss of life. 3. Shorting 5 to 6 provides an external fault input. 2-6 .

It may be programmed by the user for a normally closed switch to indicate a “normal” condition. The default state (open) is for local control. Table 2-3 Relay Contact Ratings Load Type Resistive Resistive Inductive Inductive Voltage 125VAC 30VDC 125VAC 30VDC Current 0. Remote/Local Input The Remote/Local Input is used to select the control mode. It is very important to not exceed the contact ratings listed in the table below. NC. Remote control is selected to allow control from the network (when present).30A 1. Digital Outputs The digital outputs (Fault – Common. The default state (open) inhibits the unit (prevents the SCR from firing).February 2004 Hardware Figure 2-6 Digital Input Schematic External Fault Input One typical use for the External Fault Input would be the micro switch on an external semiconductor fuse.20A 0. and NO) are relay contacts from a miniature relay on the digital control printed circuit board.0A 0. Enable Input The Enable Input is used to provide a local enable/inhibit function.50A 2-7 . The default state is for a normally open switch to indicate a “normal” condition.

jumper JP2 must be shorted for the Primary Analog Input and jumper JP4 must be shorted for the Secondary Analog Input. voltage. other voltages and currents less than 5VDC and 20mA are acceptable by utilizing the Primary or Secondary Analog Setpoint Span calibration to set 100% setpoint. Analog Inputs February 2004 The analog input (Analog Setpoint) is designed to accept potentiometer. The current input requires a 0 to 20mA input to achieve 0 to 100% setpoint. It is possible to use a 4 to 20mA current input by utilizing the Primary or Secondary Analog Setpoint Zero calibration to offset the 4mA input to be 0% setpoint. In order to use the current input. Connecting a 10k potentiometer with JP4 OFF provides a local analog control. Standard operation Provides a configurable analog output of 0-5 volts (JP5 on) or a mA output (JP5 off). Table 2-4 Analog Interface Plug Terminal Number 1 2 3 4 5 6 7 8 9 10 Terminal description Analog #1 supply Analog #1input Analog #1 ground Analog #2 supply Analog #2input Analog #2 ground Analog #1 output Analog #1ground Analog #2 output Analog #2ground Provides a configurable analog output of 0-5 volts (JP3 on) or a mA output (JP3 off). The following table describes each terminal and its default operation. The analog interface consists of the ten-position plug labeled Analog Interface. 2-8 . Also. and Analog Ground. The voltage input requires a 0 to 5VDC input to achieve 0 to 100% setpoint. Connecting a 10k potentiometer with JP2 OFF provides a local analog control. This connects a 249 ohm resistor into the circuit for the current input to use. The potentiometer input is designed for a 10K potentiometer that is connected between the Analog Supply. or current inputs. Analog Setpoint.Hardware A pilot relay can be used to interface to larger relays or contactors if required.

Jumper JP2 (input #1) or JP4 (input #2) is inserted to connect the 249 ohm burden resistor. If a 10 volt signal is desired. To convert the analog output to voltage. the analog output can calibrate the output for different levels by using the Primary or Secondary Analog Output Bias and the Primary or Secondary Analog Output Span. connect the signal source between terminal 2 (+) and 3 (-) for input #1 or 5 (+) and 6 (-) for input #2. If a 0-5 volt signal is desired. which connects a 249 ohm resistor. Alternatively. The analog output will generate 0 to 20mA for 0 to 100% of the selected internal signal. Figure 2-8 Analog Output Schematic 2-9 . an external 500 ohm resistor should be connected across the appropriate output terminals. a 500 ohm resistor can be connected externally that converts 0-20mA to 0-10VDC. jumper JP3 must be shorted for the Primary Analog Output and jumper JP5 must be shorted for the Secondary Analog Output.February 2004 Hardware The Analog Input Circuit. The Primary or Secondary Analog Output Selection defines what internal signal is connected to the Primary or Secondary Analog Output. If a 5 volt output signal is desired. Figure 2-7 Analog Input Schematic Analog Outputs The analog output (Analog Output) is designed to be a current or voltage output. that converts 0-20mA to 0-5VDC. If a mA input signal is desired. The Analog Output Circuit. Just as on the analog input. Jumper JP3 (output #1) or JP5 (output #2) is inserted to connect the 249 ohm burden resistor.

For example.Hardware Remote Feedback February 2004 It is standard for the output voltage and current to be sensed internally.5V. The voltage potential transformer (PT) used for the remote voltage feedback must be designed such that the PT output voltage is close to the input voltage of the 853 DSPC.5V/. Over-temperature Sensing A temperature sensor is mounted on the heatsink of the 853 DSPC to detect and indicate an over temperature condition. The current transformer (CT) burden resistor must be selected such that 100% current output. such as the secondary of a transformer on the output of the 853 DSPC. The 853 DSPC also provides for a separate voltage and current feedback from a remote source. An internal terminal board is provided for remote voltage and current feedbacks. the burden resistor would be 2.35A or 7. The Voltage Output PT Secondary setting is used to define the specific PT output connected as a remote voltage feedback. defined by Current Output Rating will equal 2.14 ohms. 2-10 . if a CT with a rating of 1000 to 1 is used on a 350A 853 DSPC unit. The standard temperature sensor is supplied with contacts that are normally closed (NC).

etc. Configuration consists of telling the unit what it is rated (power rating. When control power is applied. and the wiring is in place. or excessive ambient temperature may result in malfunction of the system. Figure 3-1 Control PCB LED Location With control power applied and status lights operating properly. DANGER This equipment is at line voltage when AC power is connected. Once the 853 is mounted. Configuration is accomplished using the Configuration Tool software running on a host computer. Disconnect and lock out all ungrounded conductors of the AC power line. and only minor changes (such as limit settings and/or control mode) will be made at the user site. connected to the unit via the Serial Interface Port. check the LED’s on the control board to verify that the power supplies are on and the DSP is operating. and the HEARTBEAT LED will be blinking at about a 1 second rate.Chapter 3 Configuration Startup WARNING An incorrectly applied or installed system can result in component damage or reduction in product life. the unit is ready for configuration. apply control power to the unit.) and what type of control is to be used. the unit will be pre-configured at the factory. Failure to observe these precautions could result in severe bodily injury or loss of life. It is not necessary for main power to be applied at this time. In most cases. incorrect or inadequate AC supply. At this time the red FAULT LED will be on. 3-1 . the three green power supply status LED’s will be on. input and output voltage and current. Wiring or application errors.

operation. monitoring. and file storage and retrieval. browse for the cd-rom drive. However.Configuration February 2004 The Serial Interface consists of a standard DB9 connector (9 pin male). and doubleclick on the file ‘setup. Running the Configuration Tool Run the Configuration Tool from the start menu: Start button -> Programs -> Spang Power Electronics -> Configuration Tool vxxx 3-2 . setpoint changes. The minimum system requirements are: Windows 95. The Configuration Tool is delivered on CD-Rom and includes ‘auto-run’ capability. which plugs into the host computer’s serial port using a Null Modem cable. an available serial port The 853 Configuration Tool allows off-line editing and storage of configuration files. calibration. real-time changes to the 853 settings through the serial port. The Configuration Tool default install location is: C:\Program Files\Spang Power Electronics\ 853 Configuration Tool vxxx Once successfully installed. The wiring for typical Null Modem cables is illustrated in the Serial Communication Chapter. 32MB ram. Note: The install process updates the computer’s system registry with the required configuration information. should the CD NOT run automatically once inserted into the cd-rom drive. Configuration Tool Installation The 853 Configuration Tool is a serial configuration/monitoring tool that runs on a Windows-based PC. the Configuration Tool will be accessible via the Start Menu. The Configuration Tool also allows on-line. The capabilities of the Configuration Tool include: on-line configuration.exe’. 10MB hard disk space.

whose data is read into the Configuration Tool. At this point the Configuration Tool is off-line. The setting values have been read from a setup (. There are five settings 'tabs' which can be viewed off-line. or by modifying the settings individually in the six “Settings” tabs of the Configuration Tool. the Tool is not communicating with the 853. settings can be modified two ways: either by opening an existing setup file. that is. 3-3 . While off-line.February 2004 Configuration Click on the [Start] button to continue the Configuration Tool startup (the program will automatically continue after 10 seconds).csv) file stored on the computer running the configuration tool.

Configuration February 2004 3-4 .

and should be used only by authorized service personnel. The ‘Restore Calibration’ menu choice is visible only under certain conditions. followed by a description of each option. display 853 settings in tabular form. Open the standard dialog box that provides the selection of a printer and print characteristics. Open the Print Preview window.February 2004 Configuration Tool Menu and Task Bar Descriptions Configuration The 853 Configuration Tool menu bar is shown below. The ‘Save Calibration’ menu choice is visible only under certain conditions. File Menu File Menu including the ‘Save Calibration’ menu choice. (Configuration files are of the form <filename>. and should be used only by authorized service personnel. File Menu including the ‘Restore Calibration’ menu choice. Restore calibration values from factory defaults stored in 853 eeprom.csv) and are read from and saved to the host system. Save current calibration values as factory defaults in 853 eeprom. Save and close changes made to the configuration file. Close the Configuration Tool Save Print Print Setup Save Calibration Restore Calibration Exit 3-5 . File Option Open Description Open a standard dialog box listing the configuration files available for loading and editing.

Establish on-line communication and open the Monitor pane to view 853 DSPC operation. Window Menu Window Options Settings Monitor Calibration Fault History Flash Programming Description Open the Settings Pane. Intended for use by authorized service personnel only. Open the Flash Programming window.Configuration February 2004 Com Setup Menu Com Options Com1 Com2 Com3 Com4 Description The Com Setup menu is used to select the serial port on the host computer available for use with the 853. 3-6 . Establish on-line communication and open the Calibrate pane. Open the Fault History window (useful only if on-line). (This is the default upon program entry).

3-7 . Display the version number of the Configuration Tool software.February 2004 Configuration Help Menu Help Options Manual About Description Open (in a separate browser window) this product manual in pdf format.

This button appears on the taskbar if either the Monitor or Calibration window is visible. A Red button with an Offline caption indicates No Communication between the Configuration Tool and the 853 DSPC. or the 853 DSPC is under Analog (vs Digital) control). A Yellow button with an Online caption indicates one of two possibilities: the 853 DSPC is under Remote (network) Read Only control. Same as the Window->Fault History menu option. Same as the Window->Settings menu option. Same as the File->Print menu option. A Green button with an Online caption indicates Read/Write local communication between the Configuration Tool and 853 DSPC. Toggle between Off-line programming and On-line communication with the 853. Same as the Window->Calibrate menu option. Taskbar Items Open Folder Floppy Printer Monitor Calibrate Settings Fault Offline/Online Description Same as the File->Open menu option Same as the File->Save menu option. The caption and color of the button indicate the current status of communication between the configuration tool and the 853 DSPC. Same as the Window->Monitor menu option.Configuration February 2004 Taskbar The Configuration Tool Taskbar provides shortcuts to frequently used options. 3-8 .

opens the Print Preview window. Click [Close] to exit the Print Preview window. The Print Preview window displays a tabular summary of the settings stored in the Configuration Tool. or the printer icon on the Taskbar. 3-9 . Figure 3-2 Print Preview Window Click [Print] to send a copy of the table to the printer port of the host computer.February 2004 Configuration Print Preview The File->Print menu selection.

csv file ( included with the configuration tool). (or click the file folder icon on the Taskbar) Browse the files in the ‘file open’ dialog. The Configuration Tool starts in Off-Line Programming mode. ● ● Select the File->Save menu option. ● ● Select the File->Open menu option. and can be viewed and/or modified. 3-10 . If there is no saved settings file. The settings currently in the Configuration Tool are written to the specified file on the host computer. (or click the floppy icon on the Taskbar) Specify <filename>. To save settings to a .csv . The settings as defined in the configuration file are loaded into the Configuration Tool. All work is done on the host computer and can be saved. the default settings are loaded from the default. The tool opens with the last settings file saved.csv) file. and select the desired configuration (*.Configuration Off-line Programming February 2004 Off-line programming allows the user to edit 853 settings without actually writing them to the controller. Load/Save the Configuration File To load a configuration file from the host computer to the Configuration Tool.csv file on the host computer.

only control information is visible in the left-hand pane: ‘Regulation Mode’ is a drop-down box containing the regulation choices. the right-hand side of the window displays the Settings tab. In Off-line mode. Read-only settings are indicated by a (cyan) shadowed background and cannot be changed. Offline programming allows edits to any writable setting. 3-11 . On start up. PID Setup. Fault Setup. ‘Local Control’ is a button that toggles between Local Analog and Digital control. Control Configuration.February 2004 Configuration Configuration Tool Settings Windows The initial 853 Configuration Tool window is shown below. and Network. as defined in the Settings Chapter. as read from the latest (or default) configuration file. Settings information is organized into several tabs: Ratings and Limits. Figure 3-3 Configuration Tool The left pane is used for general status and control information related to the 853 DSPC.

Figure 3-4 Ratings & Limits Tab 3-12 .Configuration February 2004 Ratings and Limits Tab The Ratings and Limits Tab holds the settings for Voltage Input Rating *Voltage Output Rating Voltage Output Limit *Voltage Output PT Secondary Power Output Rating .Read Only Power Output Limit KVA Input Rating – Read Only Current Input Rating Current Output Rating Current Input Limit Current Output Limit Frequency Rating Ramp Up Time Ramp Down Time * For a direct-coupled load (Load Type) the Voltage Output Rating and the Voltage Output PT Secondary are Read Only and follow the Voltage Input Rating.

February 2004 Configuration White fields indicate Read/Write Cyan fields indicate Read Only information 3-13 .

The [Auto Set] function allows the 853 to automatically tune the repetitive pulses for the minimum measured current pulses. Figure 3-5 Control Configuration Tab White fields indicate Read/Write Cyan fields indicate Read Only information 3-14 . insert jumper JP1 with control power applied to the unit.Configuration February 2004 Control Configuration Tab The Control Configuration Tab holds settings for Control Strategy Load Type * Magnetizing Sequence * Repetitive Pulse 1 and 2 Primary Analog Output Selection Secondary Analog Output Selection Secondary Analog Setpoint Selection Local Digital Display Selection * Only used for Zero Crossover with transformer coupled load applications. To enable the [Auto Set] function.

February 2004 Configuration Fault Setup Tab The Fault Setup Tab holds the settings for: Voltage Input High Voltage Input Low Voltage Input Phase Unbalance Current Input High Current Input High Retries Current Input High Retry Time Ground Fault Current Ground Fault Time Current Input Overload Current Input Overload Time Current Input Threshold Load Failure Figure 3-6 Fault Setup Tab White fields indicate Read/Write Cyan fields indicate Read Only information 3-15 .

Configuration February 2004 PID Setup Tab The PID Setup Tab holds the PID settings for Power Output Proportional Gain Integral Gain Derivative Gain Voltage Output Proportional Gain Integral Gain Derivative Gain Current Output Proportional Gain Integral Gain Derivative Gain Figure 3-7 PID Setup Tab White fields indicate Read/Write Cyan fields indicate Read Only information 3-16 .

February 2004 Configuration Network Tab The Network Tab holds settings for Network Type Network Baud Rate Network Address MODBUS Address MODBUS Baud Rate Network Loss Option Software Version Serial Number Figure 3-8 Network Tab White fields indicate Read/Write Cyan fields indicate Read Only information 3-17 .

In either case. click No if settings are NOT to be written to the 853. the settings stored in the 853 Configuration Tool to the 853. Click Yes to write settings from the tool to the 853. If there is still no communication. 3-18 .csv file. Settings are read from and written to the 853 DSPC using a serial protocol described in the Serial Communication chapter. the following message appears: Check both ends of the serial connection. cycle power to the unit. with the serial cable connected. To establish on-line communication between the Configuration Tool and the 853 unit. The On-line indicator turns green in the Tool Bar. 9-pin null modem cable from the serial port of the host computer to the serial port of the 853 Assign the correct comm port to the configuration tool Click [Online/Offline] on the taskbar If any settings have been modified using the configuration tool offline. the user has the option of transferring. Note: If the serial link cannot be established. the prompt will not appear. The On-line communication capability of the configuration tool allows real-time monitoring and calibration of the 853 DSPC. Depending on the response. If no modifications have been made.Configuration On-line Programming February 2004 On-line programming involves actual serial communication between the configuration tool and the 853 DSPC. online communication is established. the configuration tool will either write its settings to the 853 and then read them all back. or will read all settings from the 853 into the configuration tool. ● ● ● Connect a standard. and click [Online]. make sure that power is applied to the 853 (check LEDs) and click [Online] again. or writing. either individually or by loading a . the following message will appear: If settings have been modified offline.

It is not necessary to be On-line to review and change the settings – but it is necessary to be On-line to write the changes to the unit. a low voltage warning (A-34) is displayed. It is also necessary for the Remote/Local switch to be in the Local position for the Configuration Tool to allow online changes to the settings.February 2004 Configuration When the Configuration Tool is communicating on-line with the 853 DSPC. and will remain as long as the main power is off. Figure 3-9 Configuration Tool On-Line 3-19 . status. control and setting information is continuously read from the 853 DSPC and refreshed in the Configuration Tool. Note that when only the control power is applied. Additional status and control information is visible in the left-hand pane. This is normal.

enter the desired setting value or click a choice from the drop down list Press [Tab]. On-Line Navigation and Changes To edit settings: • • • • • • Press [Tab] or [Enter] to move forward and select a setting Press [Shift+Tab] to move backward and select a setting Double-click the mouse over a setting to select it Once selected.Configuration Status indicators are described in the table below: February 2004 Table 3-1 Status Lamp Description Lamp Enable input Color Green Red Output Status Green Red Remote/Local input Green Red On/Off button Alert indicator Flashing Yellow Flashing Red Description The 853 DSPC is Enabled The 853 DSPC in Inhibited Output is ON Output is OFF Local control is active Remote (network) control is active Toggles the 853 output Indicates an Alarm Condition (described in the message box below the lamps) Indicates a Fault Condition is present (described in the lower message box) Note: During normal operation. the following prompt appears: 3-20 . When a change is made to a setting. The 853 will attempt to recover from the alert condition. [Enter] or click outside setting Press [Escape] to cancel. message reads: No detected faults or alarms Fault Reset button Click to send a ‘Fault Reset’ to the 853. normal operation will resume. If recovery is accomplished.

Factors Affecting Write Capability Write capability from the configuration tool to the 853 DSPC is affected by several factors: No writes are accepted from the configuration tool to the 853 DSPC if the Remote/Local input is in Remote. The 853 DSPC must be in Local mode to enable Configuration Tool control. The following prompt will appear: In order to write a setpoint from the Configuration Tool to the DSPC. setpoints cannot be written from the Configuration Tool to the 853 DSPC. If the 853 DSPC is operating under Local Analog control. an error message may appear. the unit must be under Local Digital control. The Configuration Tool is considered to be a source of Local Digital control to the 853 DSPC. and the setting reverts to its previous value. If unsuccessful. 3-21 .February 2004 Configuration A Yes response to the message prompts the Configuration Tool to write the setting to the 853 DSPC.

When a setting cannot be written the following message appears: Refer to the Settings Chapter for programming factors specific to each setting. Load Type. 3-22 . and cannot be written under any circumstances. power out. Control strategy. Voltage Output Span and Current Output Span can be written only when the 853 DSPC output is on. Rating information. PT Secondary. such as voltage out. current out. and magnetic sequencing can be written only when the 853 DSPC output is off.Configuration February 2004 The 853 DSPC settings related to actual 853 DSPC status. frequency. are Read Only. etc. zero calibration.

or click [Monitor] on the Monitor information is organized into several tabs: Summary. Monitor menu item. Each setting in Monitor mode is updated approximately every 2 seconds. 3-23 . select the Window Taskbar. Status and Timing.February 2004 On-line Monitor Configuration The Monitor mode provides a real-time view of 853 operation. Read-only settings are indicated by a (cyan) shadowed background and cannot be changed. To access the on-line Monitor mode. Control.

Figure 3-10 Monitor Summary Tab 3-24 .Configuration February 2004 Summary Tab The Monitor Summary Tab includes the following data Duty Cycle Setpoint Duty Cycle Output Power Output Setpoint Power Output Voltage Input Voltage Output Setpoint Voltage Output Current Input Current Output Setpoint Current Output Analog Input KVA Input Power Factor Frequency Actual The Duty Cycle Setpoint can be written ONLY under Open Loop regulation.

3-25 . To change a setpoint: ● ● Select the setpoint to change and enter the desired value Press [Enter] or click outside the field to write the new setpoint.February 2004 Configuration White fields indicate Read/Write Cyan fields indicate Read Only information Green field indicates regulation mode Amber field indicates alarm status The operating setpoint for each of the regulation modes is shown in the middle column. Modified setpoints are italicized until written to the 853. The other setpoints become operating limits of their respective control loops. The Duty Cycle Setpoint cannot be written unless Open Loop regulation mode is selected. The setpoint associated with the selected regulation mode is displayed with a green background. • • • • • Setpoints can be modified only under Local DIGITAL control. Press the [Escape] key to cancel. The setpoint associated with the selected regulation mode is the control setpoint.

Configuration February 2004 Control Tab The Monitor Control Tab includes the following data for monitor only Voltage L1-L2 Input Actual Voltage L2-L3 Input Actual Voltage L3-L1 Input Actual Voltage Input Actual Current L1 Input Actual Current L2 Input Actual Current L3 Input Actual Current Input Actual Local Primary Analog Setpoint Voltage X1-X2 Output Actual Voltage X2-X3 Output Actual Voltage X3-X1 Output Actual Voltage Output Actual Current X1 Output Actual Current X2 Output Actual Current X3 Output Actual Current Output Actual Local Secondary Analog Setpoint Figure 3-11 Monitor Control Tab Cyan fields indicate Read Only information 3-26 .

February 2004 Configuration Status Tab The Monitor Status Tab includes the following data Monitor Status Word At Setpoint Phase Rotation External Input #1 External Input #2 External Input #3 Regulation Limit Calibration/Programming Jumper Status Word Bit Number Bit 9 Bit 10 Bit 11 Bit 12 Bit 13 Bits 6. and 8 Bit 15 Figure 3-12 Monitor Status Tab Green field indicates on status 3-27 . 7.

To access the on-line Fault History mode. or click [Fault] on the Taskbar. With JP1 installed. Figure 3-13 Fault History Included in the Fault History table is the fault code. a description. click the [Zero] button to clear the fault buffers. The information is read from the 853 DSPC and displayed in tabular form. and time (in hours) of the fault. Click the [Close] button to close the Fault History window and return to the previous window.Configuration February 2004 Fault History The fault history lists the last eight faults recorded by the 853 DSPC. 3-28 . Click the [Print] button to send a copy of the information to the printer port of the host computer. select the Fault History menu item.

This will require the 853 DSPC to be sent back to the factory for programming. either by loss of power or a disconnected serial cable. Figure 3-14 Flash Programming 3-29 .February 2004 Flash Programming Configuration WARNING During flash programming. will corrupt the 853 DSPC flash memory. The Flash Programming function is available to authorized service personnel only and is used to update the 853 DSPC software. an interruption in the serial communication.

Subsequent communication recovery restores the normal background color. 3-30 . If serial communication is not recovered within a reasonable time. the configuration tool will go Offline.Configuration Loss of Communication February 2004 Momentary loss of communication between the Configuration Tool and 853 DSPC results in the mostrecently-read setting to be displayed on a Red background.

Chapter 4 Calibration
Proper calibration of the 853 validates the values displayed on the Local Digital Control panel and made available over the network interface. Unit calibration also validates the analog signal levels. The feedback signal levels correlate to the internal gain capability of the 853. Changing the Voltage/Current Ratings or the Analog Input/Output signal levels requires recalibration.

Figure 4-1 Calibration (Voltage Tab)

4-1

Calibration

February 2004

Voltage Calibration The [Cal Enable] button must be clicked to enable voltage calibration. Voltage X1-X2 Output Zero and Span Voltage X2-X3 Output Zero and Span Voltage X3-X1 Output Zero and Span The [Zero] button, when clicked, uses the actual control reading and the zero adjustment, as currently set, to calculate a new zero adjustment. The result is an incremental change. The output must be off to zero the output voltages. Voltage L1-L2 Input Span Voltage L2-L3 Input Span Voltage L3-L1 Input Span The [Set] button, when clicked, uses the actual control reading, the measured signal (meter reading), and the span adjustment, as currently set, to calculate a new span adjustment. The result is an incremental change.

The [Manual] button, when clicked, opens an input window for direct entry of calibration values. Jumper JP1 must be installed to enable Manual Calibration.

Figure 4-2 Voltage Calibration
White fields indicate Read/Write Cyan fields indicate Read Only information

4-2

February 2004

Calibration

Current Calibration The [Cal Enable] button must be clicked to enable current calibration. Current L1 Input Zero and Span Current L2 Input Zero and Span Current L3 Input Zero and Span The [Zero] button, when clicked, uses the actual control reading and the zero adjustment, as currently set, to calculate a new zero adjustment. The result is an incremental change. The [Set] button, when clicked, uses the actual control reading, the measured signal (meter reading), and the span adjustment, as currently set, to calculate a new span adjustment. The result is an incremental change. Current X1 Output Zero and Span

The [Manual] button, when clicked, opens an input window for direct entry of calibration values. Jumper JP1 must be installed to enable Manual Calibration.

Figure 4-3 Current Calibration
White fields indicate Read/Write Cyan fields indicate Read Only information

4-3

when clicked. and the span adjustment. Uncheck the Enable box after Analog Output Calibration. the measured signal (meter reading). opens an input window for direct entry of calibration values. Secondary Analog Setpoint Zero and Span The [Set] button. as currently set.Calibration February 2004 Analog Calibration The Calibration Analog Tab holds the calibration settings for Primary Analog Setpoint Zero and Span The [Zero] button. uses the actual control reading. uses the actual control reading and the zero adjustment. as currently set. when clicked. The result is an incremental change. The result is an incremental change. Use the slide bars to adjust Analog Output Bias and Span. Check the Enable box for Analog Output Calibration. when clicked. Figure 4-4 Analog Calibration White fields indicate Read/Write Cyan fields indicate Read Only information 4-4 . to calculate a new span adjustment. Analog Output #1 Bias and Span Analog Output #2 Bias and Span The [Manual] button. to calculate a new zero adjustment. Jumper JP1 must be installed to enable Manual Calibration.

5 4-5 . A 1/4W or a 1/2W resistor should be used so that it will properly fit in the connector (J10.40Vrms 2.50Vrms Since the feedback signal on the standard unit is set to 2.5Vrms when the primary current is 10A.50Vrms using the burden resistor of the current transformer.5Vrms for the rating of the unit. Standard units have the following burden resistors and feedback signals. Unit Size 40A 90A 175A 350A CT 800:1 1800:1 3500:1 7000:1 Burden Resistor 62Ω 56.9mW. The voltage sense circuit automatically sets the hardware gain of the sensed voltage in the following ranges: Voltage Rating 300 to 600 150 to 300 75 to 150 37.46Vrms 2. for example. This is the lowest that the rating can be changed without also changing the current transformer burden resistor.5 / 10mA = 250Ω The nearest standard value 1% resistor is 249Ω.9Ω Feedback Signal 2.53Vrms 2.85Vrms. The actual voltage produced at rated current will be: 10/1000 x 249 = 2. If. The power in the resistor at rated current is (10mA)2 x 249 = 24. the burden resistor should be changed so that the current feedback signal will produce 2. so a resistor with a power rating of 50mW or greater is required.25Vrms. The typical unit is setup for a current feedback signal level of 2. it is desired to change the 40A unit to a 10A unit. the resistor should be: 2. terminals 1 and 4).49Vrms Voltage Rating The voltage feedback signal of a unit must be between 24Vrms and 600Vrms.2Ω 41. Since the secondary current at 10A is 10/1000 = 10mA. changing the rating to 50% would reduce the feedback signal to 1.February 2004 Current Rating Calibration The current feedback signal (at rated current) of the 853 must be between 1.25Vrms and 2.2Ω 49.5 to 75 24 to 37.

The Current Output feedback signal should be 2. The internal voltage feedback signals must be removed and the remote voltage feedback connected to the remote terminals. the jumpers connecting the input and output current feedback signals together must be removed.Calibration Remote Voltage and Current Feedback February 2004 The standard unit uses the same current feedback signal for both the input and output current. 2 (X2) and 3 (X3). 37. current feedback is connected to TB1 terminals 1 (+) and 2 (common). and the output current signal connected to the remote terminal provided on the 853. The remote feedback terminals are shown below. Figure 4-5 Remote Feedback Terminals If remote feedback is used.5-75V and 24-37. Allowable ranges are 300-600V. 4-6 . 75-150V. Note: The existing current and voltage feedback connections must be removed and insulated before connecting new remote current and voltage feedback to the Remote Feedback Terminal. The Voltage Output feedback signal should be in the same range as the Voltage Input feedback signal. and voltage feedback is connected to TB2 terminals 1 (X1).5 Vrms at the rated output current.5V. If an output current transformer is used with the 853. 150-300V.

Click on the [Calibrate] button to open the 853 Calibration window. have control power on. then click the [Set] button next to the value entered. Measure the voltage and current and enter the values obtained in the column labeled “Meter Reading”. Wiring or application errors. Connect your computer to the 853 serial port using a null modem cable and open the 853 Configuration Tool program. and analog calibration. To calibrate the 853. Click [Zero] to correct for any bias/noise. 4-7 . or improper calibration may result in malfunction of the system. and have a load attached to the unit. it is recommended that the unit be turned on in “open loop” regulation mode at the highest practical operating point (set the duty cycle to 100% on the Monitor Screen if possible). Establish “ON line” communication with the unit and note the existing 853 settings. There are separate tabs for voltage. [Zero] is active when the unit output is off. To calibrate the voltage and/or current. current. Click the [Cal Enable] button to allow calibration.February 2004 Calibration Procedure Calibration WARNING An incorrectly applied or installed system can result in component damage or reduction in product life. the unit must be connected to its rated input source. click [Set] to change the reading of non-zero voltage or current values. [Set] is active when the unit output is on.

and that the unit is calibrated to the actual signals being measured. be sure that the Load Type is set to “Transformer-Coupled”.Calibration February 2004 If the (re)calibration is a result of adding remote monitoring. The output voltage may be different than the input voltage. 4-8 . as may the current.

The unit must be on line. JP1 is a two-position jumper located immediately to the right of the dsp on the control board. install jumper JP1. From the File menu.February 2004 Saving Calibration Calibration If desired. 4-9 . With control power turned on. select “Save Calibration”. with the calibration window open. the new calibration may be saved in the 853 as the “Factory Default” calibration.

Restoring Factory Calibration To recalibrate the unit using the stored calibration values. 4-10 . With control power turned on. with the settings window open. install jumper JP1. when the procedure is complete. the unit must be on line. Remove the jumper (JP1). Click [YES] to replace the default calibration settings with the new calibration settings.Calibration February 2004 A dialog box will open asking if you want to replace the calibration defaults.

when the procedure is complete. select “Restore Calibration”.February 2004 From the File menu. Click [YES] to write the default calibration settings to the unit. 4-11 . Calibration A dialog box will open asking if you want to restore calibration using the stored defaults. Remove the jumper (JP1).

If the analog input is used. open the Calibration window. enter the number 100 in the Gain Setting box. enter 100 in the Gain Setting box. If the analog input is derived from a 10K potentiometer. then enter the percent of the control setpoint divided by the rating. and select the Analog Tab. If the analog input is a 4 – 20 mA signal. Then turn the pot full clockwise. if the analog input is a current setpoint. repeat the minimum “Zero” and maximum “Set” selections until the readings are consistent. Again. and click the Primary or Secondary Analog In [Set] button. controlling 0-40A on a 50A unit. Then set the input to the maximum setting (20 mA). then set the input to the minimum setting (4 mA) and click the Primary or Secondary Analog In [Zero] button. In the Configuration Tool program. Alternately. both the control power and the main input voltage must be present.Calibration Analog Calibration February 2004 Analog signal settings are adjusted on-line in an iterative process to assure accurate signal readings and optimal 853 performance. If a control point other than the rating is required at full input. 4-12 . This calibration method causes the input to control to 100% of the rating with full input. and the Primary or Secondary Analog In [Set] button with the pot turned up until the readings are consistent. enter 80 (this equals 40/50*100) when maximum input signal is present. simply turn the pot full counterclockwise and “zero” the input by clicking the Primary or Secondary Analog In [Zero] button with the mouse pointer. For example. click the Primary or Secondary Analog In [Zero] button with the pot turned down.20 mA to the Primary Analog In on terminals 2 and 3 or jumper JP4 for 4 – 20mA to the Secondary Analog In on terminals 5 and 6. install jumper JP2 for 4 . To do this. and click the Primary or Secondary Analog In [Set] button. it should be calibrated for the individual installation.

Once calibrated. If the maximum analog output is less than the rating. It allows a full range of signal settings without having to actually power up the unit. set the analog reference (input) as the percentage of the analog output variable divided by the rating. controlling 0-35A on a 40A unit.February 2004 Calibration To calibrate the analog output. 4-13 . the analog output source may be changed to whichever variable is desired. For example. set the analog reference to 75 (this equals 30/40*100) to represent maximum current output. set the analog output source to the Primary Analog Setpoint. if the analog output is output current.

and adjust the appropriate “gain” slider until you read 20 mA on your meter. leave JP3 off for the Primary Analog Output and JP5 off for the Secondary Analog Output. adjust the appropriate “bias” slider until you read 4 mA on your meter. then terminate the output into a suitable burden (maybe a milli-ammeter). If the Analog Output is to be calibrated for a 4-20 mA signal. etc. 0 – 1mA. February 2004 If the analog output is to be calibrated for a 0-5V output (as it may be for a typical digital meter). leave the “bias” adjustment at zero.) are done in the same fashion. Then set the analog input for 100%. Since there is no “bias” setting. The maximum output of the circuit is about 24 mA at 100% input.Calibration Check the Analog Output Enable box. With the analog input set at zero. 0 – 5V. insert jumper JP3 for the Primary Analog Output and jumper JP5 for the Secondary Analog Output. 4-14 . Uncheck the Analog Output Enable box when calibration is complete. then turn on the unit (both control power and main power). Turn the analog reference signal to 100% and adjust the “gain” slider until you obtain exactly 5 volts on the analog output (terminals 7 to 8 for the Primary Analog Output and terminals 9 to 10 for the Secondary Analog Output on the analog interface plug). Other outputs (0 – 10V. using a suitable termination for the signal required.

and click the [Manual] button. READ from 853 Unit – read the current calibration values from the 853. CLOSE the manual calibration window. Calculate Defaults – Calculate new calibration values based on the voltage and current ratings. WRITE to 853 Unit – Write all of the displayed calibration values to the 853. Wiring or application errors. The Manual Calibration window looks like the following: Figure 4-6 Manual Calibration Window Note the choices available for manual calibration: READ from CSV File – open a .csv file stored on the host computer and read the calibration values. or improper calibration may result in malfunction of the system. To open the Manual Calibration window. Direct entry of calibration values is possible from the Manual Calibration window of the 853 Configuration Tool. select Calibration in the Config Tool.February 2004 Manual Calibration Calibration WARNING An incorrectly applied or installed system can result in component damage or reduction in product life. 4-15 . insert jumper JP1.

Start with both pulse settings at about 50%. adjust the #1 pulse setting for an observed minimum peak current on the CФ line. Repetitive Pulse Calibration Setting number 100 is the repetitive pulse calibration. minor adjustments in the pulse settings may be made to minimize the currents. transformers should not be operated at higher than their design voltage ratings.Calibration Magnetizing Sequence Calibration February 2004 Setting number 99 is the Magnetizing Sequence Calibration. The setting defines the amount of phase control cycles which will occur during the first on cycle of zero-crossing control. If excessive peak currents are observed. To adjust the pulses automatically. If the inrush current is too high. it is desirable to have some means of observing the line current. allowing the first positive zero crossing pulse to be set differently (ZeroCrossover control only). This is necessary to avoid saturation of the load transformer and the resulting over current shut down of the unit. and bits 8 – 15 are Repetitive Pulse #2. If possible. The setting is expressed as the percentage of the total wave passed through to the load. If the unit trips during start-up. It should be noted that transformer saturation will occur more readily with higher line voltages and heavier load currents. until the minimum peak current is observed. 4-16 . which is used for zero-crossing control into a transformer load. Repetitive Pulse Calibration Read/Write Condition: All Default: Low Byte 50 High Byte 30 The Repetitive Pulse Calibration is divided into two separate bytes. bits 0 – 7 are the Repetitive Pulse #1. the Repetitive Pulse setting contains two values. click [Auto Set]. it is necessary to manually “tune” the system. An automatic set function is built into the 853 power control unit. which will adjust the pulses at an accelerated rate and adjust for the minimum measured current pulses. When a minimum peak current is observed. In order to tune the settings. Low Byte – Bits 0 – 7 Repetitive Pulse #1 High Byte – Bits 8 – 15 Repetitive Pulse #2 100 % Min: 10 Max: 90 The repetitive pulse settings represent a delay in the firing of the SCRs during the first cycle of each “burst” during zero-crossing control. Insert jumper JP1. Using the Configuration Tool program. control power must be applied to the unit. leave the #1 setting and adjust the #2 setting to further reduce the observed peak current. A minimum setting of 3 will usually keep the inrush current within acceptable limits. Note that if the system is sized close to the operating limit of the transformers. The purpose of this setting is to soft start a transformer load when first powered up. In such a case. monitor the AФ and BФ currents as well. It should be possible to adjust the two settings so that the unit will operate without tripping. As a check. which is used for zero-crossing control into a transformer load. On the Control Tab of the Settings window of the Configuration Tool. the unit may trip before the program can determine the proper settings. increase the Magnetizing Sequence until the inrush current is within acceptable limits. Alternate between the two adjustments. In the 853. turn the unit on with a duty cycle of between 10 and 50%.

“OFF” time. units are always on for at least 2 cycles. In order to insure proper measurements. The starting point cycle based on network number is listed in the table below. Network Address 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 Starting point cycle 0 50 25 75 13 63 38 88 6 56 31 81 19 69 44 94 3 53 28 78 16 66 41 91 9 59 34 84 22 72 47 97 2 52 27 77 14 64 4-17 . For duty cycles between 2% and 100% this simply means that the duty cycle is the ratio of on cycles to 100. or enabling all the controllers at the same time. A 50% duty cycle would result in a unit being on for 50 cycles and off for 50 cycles. or the ratio of the “ON” vs.February 2004 Node Synchronization Calibration The 850 series zero-crossing mode of operation uses a 100 cycle period of time as a “power cycle”. Power delivered to the load is proportional to the duty cycle of the unit. Synchronization is achieved by applying power to. An algorithm was developed to allow multiple units to be given sequential network nodes and achieve power synchronization. Note that the synchronization calculation is valid for network addresses 1 – 63 only. The Network Address setting (setting 116) is used to determine the starting point of each unit’s power cycle.

Calibration February 2004 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 39 89 8 58 33 83 20 70 45 95 5 55 30 80 17 67 42 92 11 61 36 86 23 73 48 98 4-18 .

Figure 5-1 Local Digital Control Panel Display and Status The four-digit numeric display is used to display a selected setpoint or output. and two below it. It is used in one of two modes and provides a four-digit numeric display. 5-1 . The LED’s describe the information shown on the numeric display.Chapter 5 Local Digital Control Option The Local Digital Control Option is an add-on display/control interface. It is also used to indicate alert conditions and special programming modes. and are summarized in the following table. The Local Digital Control Panel is shown below. There are four LED's to the right of the numeric display. twelve LED’s and four pushbuttons that allow local control of the 853 DSPC.

or Kilowatts 8 Regulation Mode Setpoint (%) Voltage Setpoint. Current Setpoint or Power Setpoint as % of appropriate rating 7 Power Output (%) Power Output as % of rated power 6 Current Output (%) Current Output Actual as % of rated current 5 Voltage Output (%) 4 Regulation Mode Setpoint (unit) Voltage Setpoint. Amps.Local Digital Control Option February 2004 Table 5-1 Display Selections If this LED is lit … Volts Output Amps Output Kilowatts Output Setpoint Volts. Amps. Current Setpoint or Power Setpoint in appropriate units 3 Power Output (KW) Power Output in kilowatts 2 Current Output (A) Current Output Actual in amps Setting #76 equals … 1 Display Selection Voltage Output (V) Description Voltage Output Actual in volts Voltage Output Actual as % of rated voltage 5-2 . or Kilowatts Volts % of Rated Output Amps % of Rated Output Kilowatts % of Rated Output Setpoint % of Rated Volts.

and the Remote/Local input is in the Local state. Either a fault or alarm is present. the four pushbuttons are used to increment/decrement the regulation mode setpoint. The Local mode is set to Analog. and toggle the control mode from digital to analog (and vice-versa). Off Digital Status On Off Enable Status On Off On Status On Off Alert Status On Off Normal Mode Operation Normal mode operation depends on two factors: the Remote/Local input. The Local mode is set to Digital. or the Remote/Local input is in the Remote state. No detected fault or alarm. The Enable/Inhibit input is in the Enable state. and the Remote/Local input is in the Local state. The DSPC output is active. The Remote/Local input is in the Local state. or the Remote/Local input is in the Remote state. If the unit is under Local Digital Control. The Local mode is set to Digital. The Local mode is set to Analog.February 2004 The six status LED’s are summarized in the following table. The Enable/Inhibit input is in the Inhibit state. and the Analog/Digital control status. Normal operation under Local Digital Control is summarized in the following table: 5-3 . The DSPC output is off. Local Digital Control Option Table 5-2 Digital Control Status LED Remote Status Condition On Off Analog Status On Description The Remote/Local input is in the Remote state. toggle the unit output.

Increment/Decrement the Regulation Mode Setpoint Display the Regulation Mode Setpoint in units. Local Digital Control Display Selection Voltage Output (V) Up/Down Button Display the Regulation Mode Setpoint in units. Normal operation under Local Analog Control is summarized in the following table: 5-4 . Increment/Decrement the Regulation Mode Setpoint Increment/Decrement the Regulation Mode Setpoint Select Button Press and Hold to toggle local Analog/Digital control On/Off/Reset Button Toggle the unit On/Off Current Output (A) Press and Hold to toggle local Analog/Digital control Toggle the unit On/Off Power Output (KW) Press and Hold to toggle local Analog/Digital control Toggle the unit On/Off Regulation Mode Setpoint (units) Voltage Output (%) Press and Hold to toggle local Analog/Digital control Press and Hold to toggle local Analog/Digital control Toggle the unit On/Off Toggle the unit On/Off Current Output (%) Press and Hold to toggle local Analog/Digital control Toggle the unit On/Off Power Output (%) Press and Hold to toggle local Analog/Digital control Toggle the unit On/Off Regulation Mode Setpoint (%) Press and Hold to toggle local Analog/Digital control Toggle the unit On/Off Pushbutton functions vary slightly under Local Analog Control. Increment/Decrement the Regulation Mode Setpoint Display the Regulation Mode Setpoint as % of rated.Local Digital Control Option February 2004 Table 5-3 Pushbutton function in Normal mode. Increment/Decrement the Regulation Mode Setpoint Display the Regulation Mode Setpoint in units. The setpoint can be viewed but cannot be changed. Increment/Decrement the Regulation Mode Setpoint Display the Regulation Mode Setpoint as % of rated. Increment/Decrement the Regulation Mode Setpoint Increment/Decrement the Regulation Mode Setpoint Display the Regulation Mode Setpoint as % of rated.

February 2004 Local Digital Control Option Table 5-4 Pushbutton function in Normal mode. Local Analog Control Display Selection Voltage Output (V) Up/Down Pushbutton Display the Regulation Mode Setpoint in units Display the Regulation Mode Setpoint in units Display the Regulation Mode Setpoint in units Display the Regulation Mode Setpoint in units Display the Regulation Mode Setpoint as % of rated Display the Regulation Mode Setpoint as % of rated Display the Regulation Mode Setpoint as % of rated Display the Regulation Mode Setpoint as % of rated Select Pushbutton Press and Hold to toggle local Analog/Digital control Press and Hold to toggle local Analog/Digital control Press and Hold to toggle local Analog/Digital control Press and Hold to toggle local Analog/Digital control Press and Hold to toggle local Analog/Digital control Press and Hold to toggle local Analog/Digital control Press and Hold to toggle local Analog/Digital control Press and Hold to toggle local Analog/Digital control On/Off/Reset Pushbutton Toggle the unit On/Off Current Output (A) Toggle the unit On/Off Power Output (KW) Toggle the unit On/Off Regulation Mode Setpoint (units) Voltage Output (%) Toggle the unit On/Off Toggle the unit On/Off Current Output (%) Toggle the unit On/Off Power Output (%) Toggle the unit On/Off Regulation Mode Setpoint (%) Toggle the unit On/Off 5-5 .

Local Digital Control Option

February 2004

If the unit is under Remote Control, the pushbuttons are inoperable, as summarized in the following table.

Table 5-5 Pushbutton function in Normal mode, Remote Control
Display Selection Voltage Output (V) Current Output (A) Power Output (KW) Regulation Mode Setpoint (units) Voltage Output (%) Current Output (%) Power Output (%) Regulation Mode Setpoint (%) Up/Down Pushbutton No action No action No action No action Select Pushbutton No action No action No action No action On/Off/Reset Pushbutton No action No action No action No action

No action No action No action No action

No action No action No action No action

No action No action No action No action

5-6

February 2004 Display Select Mode Operation

Local Digital Control Option

To enter Display Select mode, press the [SEL] pushbutton. Entry into the Display Select mode is indicated by the characters ‘SEL’ in the four-digit numeric display. In this mode, the [Up Arrow] and [Down Arrow] pushbuttons increment/decrement the Local Digital Control Display Selection. Display Select mode operation is summarized in the following tables:

Table 5-6 Pushbutton function in Display Select Mode, Local Control
Display Selection Voltage Output (V) Up/Down Pushbutton Increment/Decrement the display selection Increment/Decrement the display selection Increment/Decrement the display selection Increment/Decrement the display selection Increment/Decrement the display selection Increment/Decrement the display selection Increment/Decrement the display selection Increment/Decrement the display selection Select Pushbutton Exit Display Select mode On/Off/Reset Pushbutton Toggle the unit On/Off; exit Display Select mode Toggle the unit On/Off; exit Display Select mode Toggle the unit On/Off; exit Display Select mode Toggle the unit On/Off; exit Display Select mode Toggle the unit On/Off; exit Display Select mode Toggle the unit On/Off; exit Display Select mode Toggle the unit On/Off; exit Display Select mode Toggle the unit On/Off; exit Display Select mode

Current Output (A)

Exit Display Select mode

Power Output (KW)

Exit Display Select mode

Regulation Mode Setpoint (units) Voltage Output (%)

Exit Display Select mode

Exit Display Select mode

Current Output (%)

Exit Display Select mode

Power Output (%)

Exit Display Select mode

Regulation Mode Setpoint (%)

Exit Display Select mode

5-7

Local Digital Control Option

February 2004

Table 5-7 Pushbutton function in Display Select Mode, Remote Control
Display Selection Voltage Output (V) Up/Down Pushbutton Increment/Decrement the display selection Increment/Decrement the display selection Increment/Decrement the display selection Increment/Decrement the display selection Increment/Decrement the display selection Increment/Decrement the display selection Increment/Decrement the display selection Increment/Decrement the display selection Select Pushbutton Exit Display Select mode On/Off/Reset Pushbutton Exit Display Select mode

Current Output (A)

Exit Display Select mode

Exit Display Select mode

Power Output (KW)

Exit Display Select mode

Exit Display Select mode

Regulation Mode Setpoint (units) Voltage Output (%)

Exit Display Select mode

Exit Display Select mode

Exit Display Select mode

Exit Display Select mode

Current Output (%)

Exit Display Select mode

Exit Display Select mode

Power Output (%)

Exit Display Select mode

Exit Display Select mode

Regulation Mode Setpoint (%)

Exit Display Select mode

Exit Display Select mode

5-8

Chapter 6 Serial Communication Hardware The serial port of the 853 DSPC is a standard. 3 and 5 (Receive. The hardware connection between a standard PC COM port and the 853 DSPC’s serial port is a null modem style link. male. Transmit and Ground) of the DB-9 connector are needed to communicate. DB-9 connector. Figure 6-1 Nine Pin to Nine Pin Null Modem Cable Diagram Figure 6-2 Twenty-five Pin to Nine Pin Null Modem Cable Diagram 6-1 . shown below. pins 7 and 8 (Request to Send and Clear to Send) are optional and provided for PC hardware handshake (fixed in the SEND OK state). Only pins 2.

9600.Serial Communication The setup of the serial port is described below. The 853 Configuration Tool will detect baud rate automatically when on-line communication is established with the 853 DSPC. February 2004 Table 6-1 Serial Port Configuration Baud Rate Parity Length Stop Handshake 4800. or 19200 baud None 8 bits 2 bits None The default serial baud rate is 19200. 6-2 . the new baud rate setting will take effect only after control power to the 853 DSPC is cycled. and can be modified either with the 853 Configuration Tool or through the (remote) network connection. In either case. The baud rate is accessible as setting #117.

The 853 determines the protocol of each message sent. Always 0 853 setting number. the appropriate response is generated and sent. Always 0 (read).8 6-3 . MODBUS RTU The MODBUS RTU protocol is a query/response or master/slave protocol. low byte first 2 3 4 5 Function Address High Address Low # Points High (read) Data High (write) # Points Low (read) Data Low Error Check 6 7. the received message is treated as a generic message. It looks for the start characters of a generic message (described later in this chapter). If the start characters are present. or 0 for a broadcast message. 16-bit CRC. the 853 will treat the received message as MODBUS RTU. from setting #116. The 853 acts as a slave in the MODBUS master/slave relationship. MODBUS function code. High byte of 16-bit value to be written (write). Table 6-2 MODBUS RTU Query (from Master) Byte 1 Field Name Slave Address Description 853 MODBUS address. In either case. The MODBUS query and response are summarized in the following tables. 3 (read) or 6 (write). Low byte of 16-bit value to be written (write). If the start characters are NOT present.February 2004 Serial Protocols Serial Communication The 853 supports two serial protocols: MODBUS RTU and an 8-byte generic protocol. Always 1 (read).

Low byte of 16-bit value written (echo). 16-bit CRC.Serial Communication February 2004 Table 6-3 MODBUS RTU Read Response (from 853) Byte 1 2 3 4 5 6. from setting #116. High byte of 16-bit value written (echo). MODBUS function code 3 (read). Low byte of 16-bit value read. Always 2 High byte of 16-bit value read. Always 0 853 setting number.8 Field Name Slave Address Function Address High Address Low Data High Data Low Error Check Description 853 MODBUS address. from setting #116. 16-bit CRC. low byte first Table 6-4 MODBUS RTU Write Response (from 853) Byte 1 2 3 4 5 6 7. MODBUS function code 6 (write).7 Field Name Slave Address Function Byte count Data High Data Low Error Check Description 853 MODBUS address. low byte first 6-4 .

6-5 . low byte first 3 4. MODBUS function code plus exception indication (80 hex). but cannot be executed.February 2004 Serial Communication When a message is received correctly (no communication errors. No response is generated for a message received incorrectly. from setting #116. MODBUS exception code. Table 6-5 MODBUS RTU Exception Response (from 853 DSPC) Byte 1 2 Field Name Slave Address Function Description 853 MODBUS address. or incompletely. Illegal data value.5 Exception code Error Check The 853 DSPC supports the following MODBUS exception codes: Table 6-6 MODBUS RTU Exception Codes Exception Code 01 02 03 Description Illegal function Illegal data address (setting number). No response is generated for broadcast messages. CRC checks out). 16-bit CRC. the 853 DSPC will generate an exception (error) response.

Data high and Data low bytes.Serial Communication February 2004 General 8 Byte Protocol The 853 DSPC supports a generic 8 byte query/response protocol. or 0x80 (write) 853 DSPC setting number. Low byte of 16-bit value to be written (write). Always 0x7E 4 5 Setting Data High 6 Data Low 7 Checksum 8 End 6-6 . Unused (read). Setting byte. As in the MODBUS RTU protocol. Calculated from the sum of the Command byte. Unused (read). the 853 DSPC is implemented as a slave in a master/slave communication relationship. High byte of 16-bit value to be written (write). Table 6-7 General 8 Byte Query (from Master) Byte 1 2 3 Field Name Start 1 Start 2 Command Description Always 0xA5 Always 0x5A 0x00 (read).

3 reserved Bit 4 1 . The error bit is set if the message has an error. the values returned in Bytes 5 and 6 are not meaningful. Always 0x7E 4 5 Setting Data High 6 Data Low 7 Checksum 8 End Each serial message sent to the 853 DSPC results in a response message back.network offline 0 . Unused (write). the information in the data bytes has no meaning. In the event of an error. If an error occurs.echo bit Bit 7 1 . Calculated from the sum of the Command byte. Table 6-8 General 8 Byte Response (from 853) Byte 1 2 3 Field Name Start 1 Start 2 Command Description Always 0xA5 Always 0x5A Bit 0 . Included in byte 3 of the response is status information.network online Bit 5 1. The echo bit is always set if the message has been received.error bit Bit 6 1.read operation 853 DSPC setting number. The echo bit is set for all response messages. High byte of 16-bit value read (read).February 2004 Serial Communication Each General Protocol query sent to the 853 DSPC will result in a response. Unused (write). The error bit is set if an error occurred during the reception or execution of the query. 6-7 . Byte 3 includes an echo bit and an error bit.write operation 0 . Setting byte. Low byte of 16-bit value read (read). Data high and Data low bytes.

5 seconds. Likewise. Care must be taken when reading four byte time values to check for lower order word overflow during the serial read operation. and not as ASCII characters. This includes when the unit is being controlled remotely under network control or when the unit is being controlled locally under analog control. The floating point value is scaled (multiplied) by 10 before transfer. For example. Serial control of the unit is enabled when the Local/Remote switch is in LOCAL mode. The serial link can be used to monitor values when serial control is not enabled.Serial Communication February 2004 Additional Serial Information Error responses do not stop 853 operation. Message bytes are sent and received as binary values. The higher order word (2 bytes) is specified by the Setting number listed in the settings table. 6-8 . and the lower order word is specified by the Setting number plus 1. 853’s without a local digital control option installed will revert to local Analog control unless serial messages are received at a rate of at least one message per every 1. a voltage equal to 208. floating point data received by the controller are adjusted (divided) by a factor of 10.7 will be transferred as 2087 Settings that are longer than two bytes (such as Serial Number) must be read with two individual transactions. which would result in an invalid time value. Floating point data (data containing a decimal point) are transferred as 16 bit integers.

0 Max: 750. Programming the settings incorrectly can cause the 853 DSPC to exhibit intermittent or full output conditions. Vinrms for Phase L1 to Phase L2.0 V Voltage Input Phase Unbalance Alarm Read/Write Condition: All Default: 5. The following table summarizes the settings of the 853. The difference between each Phase voltage and the Voltage Input Actual expressed as a positive percentage. Exceeding this limit value causes an unbalanced input voltage alarm.0 4 % Min: 2% Max: 100% 5 Read only Voltage L1-L2 Input Span Read/Write Condition: All Default: Factory 6 Vrms Bits Min: 2000 Max: 16000 7-1 . Units Vrms Min: 0.0 The level compared to Vinrms that causes a high voltage fault. 1 2 Vrms Min: 0.0 % Voltage L1-L2 Input Actual No. Calibration is described in the Calibration Chapter. Fault operation is further described in the Troubleshooting Chapter. Fault operation is further described in the Troubleshooting Chapter.0 V Voltage Input Low Alarm Read/Write Condition: All Default: 384. 3 Vrms Min: 0.0 Description The input rating of the voltage supplied to the 853.0 V Voltage Input High Fault Read/Write Condition: All Default: 576.Chapter 7 Settings Caution The 853 DSPC is configured using the programmable settings. Fault operation is further described in the Troubleshooting Chapter. Digital span adjustment of the voltage L1-L2 input signal.0 Max: 600. Table 7-1 List of Settings Settings Voltage Input Rating Read/Write Condition: Off Default: 480. It is limited to 100% of the Voltage Input Rating. It is limited to 125% of the Voltage Input Rating.0 Max: 600. The level compared to Vinrms that causes a low voltage alarm.

7-2 .0 12 Hertz Min: 50. Calibration is described in the Calibration Chapter. Average of Vinrms for Phases L1-L2.0 14 Vrms Min: 0. 13 Hertz Measured input line frequency. Digital span adjustment of the voltage L3-L1 input signal.0 Hz Frequency Actual Read only Voltage Output Rating Read/Write Condition: Off Default: 480.0 V Voltage Output Limit Read/Write Condition: All Default: 528. 17 Vrms Min: 0.Settings February 2004 Settings Voltage L2-L3 Input Actual No. L2-L3 and L3-L1.0 Max: 60. 15 Vrms Min: 0.0 V Voltage Output Setpoint Read/Write Condition: Remote Default: 480. Digital span adjustment of the voltage L2-L3 input signal. Units 7 Vrms Description Vinrms for Phase L2 to Phase L3. It is set equal to the Voltage Output Rating if no PT is used.0 Max: 2500.0 Max: 600. The output rating of the voltage being controlled by the 853.0 10 Bits Min: 2000 Max: 16000 8 Bits Min: 2000 Max: 16000 9 Vrms 11 Vrms The input line frequency rating. The maximum voltage the voltage output PID control will limit to.0 Max: 2500. It is limited to 125% of the Voltage Output Rating.0 The secondary voltage of an external voltage Potential Transformer (PT). Read only Voltage L2-L3 Input Span Read/Write Condition: All Default: Factory Voltage L3-L1 Input Actual Read only Voltage L3-L1 Input Span Read/Write Condition: All Default: Factory Voltage Input Actual Read only Frequency Rating Read/Write Condition: Off Default: 60.0 V Voltage Output PT Secondary Read/Write Condition: Off Default: 480.0 Max: 2000. Calibration is described in the Calibration Chapter.0 V 16 Vrms Min: 0.0 The setpoint for the voltage output PID control. It is very important that this setting be in the same calibration range as the Voltage Input Rating for proper operation. It is limited to 100% of the Voltage Output Limit. Vinrms for Phases L3 to L1 calculated using L1-L2 and L2-L3 voltages measured.

0 % Voltage Output Derivative Gain Read/Write Condition: All Default: 0.0 Description 18 Voltage output control proportional gain. Calibration is described in the Calibration Chapter. Digital zero adjustment of the voltage X1-X2 output signal. Calibration is described in the Calibration Chapter.0 Max: 100.0 Voltage output control integral gain. 21 Vrms Voutrms for Phase X1 to Phase X2. 25 Bits Min: 0 Max: 100 26 Bits Min: 2000 Max: 16000 Digital span adjustment of the voltage X2-X3 output signal. 24 Vrms Voutrms for Phase X2-X3. Voutrms for Phases X3-X1 calculated using Phase X1-X2 and Phase X2-X3 measurements.0 Voltage output control derivative gain. 19 % Min: 0. Calibration is described in the Calibration Chapter. 20 % Min: 0.February 2004 Settings Settings Voltage Output Proportional Gain Read/Write Condition: All Default: 10. Units % Min: 0.0 Max: 100. 22 Bits Min: 0 Max: 100 23 Bits Min: 2000 Max: 16000 Digital span adjustment of the voltage X1-X2 output signal.0 % Voltage X1-X2 Output Actual Read only Voltage X1-X2 Output Zero Read/Write Condition: Off Default: Factory Voltage X1-X2 Output Span Read/Write Condition: On Default: Factory Voltage X2-X3 Output Actual Read only Voltage X2-X3 Output Zero Read/Write Condition: Off Default: Factory Voltage X2-X3 Output Span Read/Write Condition: On Default: Factory Voltage X3-X1 Output Actual Read only Voltage X3-X1 Output Zero Read/Write Condition: Off Default: Factory No. 27 Vrms 28 Bits Min: 0 Max: 100 7-3 .0 Max: 100. Digital zero adjustment of the voltage X2-X3 output signal. Calibration is described in the Calibration Chapter. Digital zero adjustment of the voltage X3-X1 output signal. Calibration is described in the Calibration Chapter.0 % Voltage Output Integral Gain Read/Write Condition: All Default: 10.

0 Max: 3750. 37 Seconds Min: 0. 35 Seconds Min: 10.0 Sec No.0 Max: 1500. 32 Irms Min: 0.0 The input rating of the current to the 853. and X3-X1.0 The time limit for fault retries before the fault will latch. 29 30 Vrms 31 Irms Min: 0. 36 Irms Min: 0. Fault operation is described in the Troubleshooting Chapter The time limit on the current input overload level before a fault occurs. 33 Ipeak Min: 0.0 34 Selection Min: 0 Max: 5 The number of retries for the Current Input High Fault before the fault is latched.0 Sec Current Input Overload Fault Read/Write Condition: All Default: 470.0 The level compared to the Current Input Actual that causes a timed current fault.0 The maximum Current Input Actual the 853 will allow to run continuously. It is limited to 250% of the Current Input Rating.Settings February 2004 Settings Voltage X3-X1 Output Span Read/Write Condition: On Default: Factory Voltage Output Actual Read only Current Input Rating Read/Write Condition: Off Default: 350.0 Max: 2250. Fault operation is described in the Troubleshooting Chapter.0 A Current Input High Fault Read/Write Condition: All Default: 700.0 Max: 360.0 A Current Input High Fault Retry Number Read/Write Condition: All Default: 0 Current Input High Fault Retry Time Read/Write Condition: All Default: 10.0 Max: 5250. X2-X3. Fault operation is described in the Troubleshooting Chapter.0 7-4 . Exceeding this value causes an over current fault.0 A Current Input Limit Read/Write Condition: All Default: 350. Fault operation is described in the Troubleshooting Chapter. The level compared to the peak current of each phase individually. Units Bits Min: 2000 Max: 16000 Description Digital span adjustment of the voltage X3-X1 output signal.0 A Current Input Overload Time Read/Write Condition: All Default: 10. Fault operation is described in the Troubleshooting Chapter. It is limited to 150% of the Current Input Rating. The value is limited to 350% of the Current Input Rating. Average of Voutrms for Phases X1-X2.0 Max: 360. Calibration is described in the Calibration Chapter.

38 40 Seconds Min: 0. Calibration is described in the Calibration Chapter. Calibration is described in the Calibration Chapter. 48 Bits Min: 0 Max: 100 49 Bits Min: 2000 Max: 16000 Digital span adjustment of the current L3 input signal. 42 Bits Min: 0 Max: 100 43 Bits Min: 2000 Max: 16000 Digital span adjustment of the current L1 input signal. The amount of time required to generate a ground fault.0 41 Irms Iinrms for Phase L1.0 Max: 360. Fault operation is described in the Troubleshooting Chapter.0 Max: 1500. Digital zero adjustment of the current L2 input signal. Digital zero adjustment of the current L1 input signal. Calibration is described in the Calibration Chapter. Calibration is described in the Calibration Chapter. Calibration is described in the Calibration Chapter.0 A Ground Fault Time Read/Write Condition: All Default: 10. 44 Irms Iinrms for Phase L2.February 2004 Settings Settings Ground Fault Current Read/Write Condition: All Default: 10. 47 Irms Iinrms for Phase L3. Calibration is described in the Calibration Chapter. Units Amperes Min: 2. 45 Bits Min: 0 Max: 100 46 Bits Min: 2000 Max: 16000 Digital span adjustment of the current L2 input signal.0 Sec Current L1 Input Actual Read only Current L1 Input Zero Read/Write Condition: Off Default: Factory Current L1 Input Span Read/Write Condition: On Default: Factory Current L2 Input Actual Read only Current L2 Input Zero Read/Write Condition: Off Default: Factory Current L2 Input Span Read/Write Condition: On Default: Factory Current L3 Input Actual Read only Current L3 Input Zero Read/Write Condition: Off Default: Factory Current L3 Input Span Read/Write Condition: On Default: Factory No. Digital zero adjustment of the current L3 input signal.0 Description The amount of current calculated to be flowing to a ground (from phase current unbalances) allowed before starting Ground Fault Time countdown. 7-5 . Fault operation is described in the Troubleshooting Chapter.

0 A Current Output Setpoint Read/Write Condition: Remote Default: 350. 57 % Min: 0.0 Max: 100.0 A Current Output Limit Read/Write Condition: All Default: 350.0 A Current Output Rating Read/Write Condition: Off Default: 350.0 % Current Output Derivative Gain Read/Write Condition: All Default: 0.0 Max: 3000. Read only Current Input Threshold Load Failure Read/Write Condition: On Default: 10. Calibration is described in the Calibration Chapter.0 The maximum current the current output PID control will limit to. 55 % Min: 0.0 Max: 1500.0 The output rating of the current being controlled by the 853.0 52 Irms Min: 0. The individual phase current used to determine a load failure.0 Current output control integral gain.0 Max: 4500. Bits Min: 0 Max: 100 7-6 . 53 Irms Min: 0.Settings February 2004 Settings Current Input Actual No.0 Max: 100.0 % Current Output Integral Gain Read/Write Condition: All Default: 10.0 A Current Output Proportional Gain Read/Write Condition: All Default: 10.0 Max: 4500. Fault operation is described in the Troubleshooting Chapter. It is limited to 100% of the Current Output Limit. Digital zero adjustment of the Current X1 Output Actual signal. It is limited to 150% of the Current Output Rating. It is limited from 2% to 10% of the Current Input Rating. 54 Irms Min: 0.0 The setpoint for the current output PID control. L2.0 Current output control proportional gain.0 Current output control derivative gain. Units 50 Irms Description Average of Iinrms for Phase L1.0 Max: 100. and L3. 58 Irms Ioutrms for Phase X1 measured.0 % Current X1 Output Actual Read only Current X1 Output Zero Read/Write Condition: Off Default: Factory 59 51 Irms Min: 0. 56 % Min: 0.

(Voltage Input Rating * SQRT(3) * Current Input Rating)/1000 62 Read only Current Output Actual 63 Read only KVA Input Rating Read only 64 Irms Irms KVA KVA Input Read only 65 KVA The KVA input is calculated by the following equation.0 Max: 100.0 Max: 1125. Average of Ioutrms for Phases X1.0 The maximum power the power output PID control will limit to.0 Max: 1125. It is calculated by the following equation.0 KW Power Output Setpoint Read/Write Condition: Remote Default: 291. Units Bits Min: 2000 Max: 16000 Description Digital span adjustment of the Current X1 Output Actual signal. It is limited to 125% of the Power Output Rating. The KVA rating is the conversion factor that is used to convert the KVA Input from percent to KVA.0 Power output control proportional gain. 69 % Min: 0. 68 KW Min: 0. X2. (Voltage Input Actual * SQRT(3) * Current Input Actual. Calibration is described in the Calibration Chapter. and X3.) /1000 Power Output Rating Read only 66 KW The output rating of the Power being controlled by the 853.0 KW Power Output Proportional Gain Read/Write Condition: All Default: 10. 60 61 Irms Ioutrms for Phase X2 calculated.0 The setpoint for the power output PID control. It is limited to 100% of the Power Output Limit.February 2004 Settings Settings Current X1 Output Span Read/Write Condition: On Default: Factory Current X2 Output Actual Read only Current X3 Output Actual No. 7-7 . Ioutrms for Phase X3 calculated.0 % 67 KW Min: 0. (Voltage Output Rating * SQRT(3) * Current Output Rating)/1000 Power Output Limit Read/Write Condition: All Default: 291. It is calculated using the following equation.

Local Digital Control Setpoint Read only Local Primary Analog Setpoint Read only 77 KW Vrms Irms KW Vrms Irms 78 7-8 . Vrms. calculated by using the instantaneous product of the voltage and current samples.0 % Power Output Derivative Gain Read/Write Condition: All Default: 0. 72 KW (Vin * Iin)rms .0 Power output control derivative gain.0 Max: 100.0 % On time / Off time * 100. Irms or KW depending on the setting of the regulation mode. Defines what the Local Digital Control displays during operation. Power Output / KVA Input. The selection list is: Selection Min: 1 Max: 8 1 – Voltage Output (V) 2 – Current Output (A) 3 – Power Output (KW) 4 – Control Setpoint (units) 5 – Voltage Output (%) 6 – Current Output (%) 7 – Power Output (%) 8 – Control Setpoint (%) The setpoint of the local digital control module. It can be Vrms.0 Max: 100.0 % Power Output Read only Power Factor No.0 % Local Digital Control Display Selection Read/Write Condition: All Default: 1 76 75 % Min: 0. Units % Min: 0. 71 % Min: 0.0 Max: 100. The setpoint of the local primary analog input.0 Description 70 Power output control integral gain.Settings February 2004 Settings Power Output Integral Gain Read/Write Condition: All Default: 10.0 The setpoint for open loop control. or Irms depending on the setting of the regulation mode. The Local Digital Control option is described in the Local Digital Control Option Chapter. It can be KW. 73 Read only Duty Cycle Output 74 Read only Duty Cycle Setpoint Read/Write Condition: Remote Default: 100.

Secondary Analog Setpoint Zero Read/Write Condition: All Default: Factory Secondary Analog Setpoint Span Read/Write Condition: All Default: Factory 83 Bits Min: -100 Max: 500 Digital zero adjustment of the Local Secondary Analog Setpoint input signal. Calibration is described in the Calibration Chapter. 7-9 . 84 Bits Min: 2000 Max: 16000 Digital span adjustment of the Local Secondary Analog Setpoint input signal. Defines the operation of the Local Secondary Analog Setpoint during local analog control. It is defined by the Local Secondary Analog Setpoint Selection. 79 80 Bits Min: 2000 Max: 16000 Digital span adjustment of the Local Primary Analog Setpoint input signal. Calibration is described in the Calibration Chapter. Units Bits Min: -100 Max: 500 Description Digital zero adjustment of the Local Primary Analog Setpoint input signal. The secondary analog setpoint is activated/deactivated in the Configuration Word. Calibration is described in the Calibration Chapter. Calibration is described in the Calibration Chapter.February 2004 Settings Settings Primary Analog Setpoint Zero Read/Write Condition: All Default: Factory Primary Analog Setpoint Span Read/Write Condition: All Default: Factory Local Secondary Analog Setpoint Selection Read/Write Condition: All Default: 1 No. The selection list is: 81 Selection Min: 1 Max: 3 1 – Current Setpoint 2 – Voltage Setpoint 3 – Power Setpoint Note: The Local Secondary Analog Setpoint will be ignored if it is set to the same regulation mode as the Local Primary Analog Setpoint Local Secondary Analog Setpoint Read only 82 KW Vrms Irms The setpoint of the Local Secondary Analog Setpoint input.

Calibration is described in the Calibration Chapter. Defines the operation of the Analog Output #2. Digital zero adjustment of the Analog Output #2 signal. Calibration is described in the Calibration Chapter. Analog Output #2 90 Read only Analog Output #2 Bias Read/Write Condition: All Default: Factory Analog Output #2 Span Read/Write Condition: All Default: Factory 91 Bits Min: -100 Max: 500 % 92 Bits Min: 2000 Max: 6000 Digital span adjustment of the Analog Output #2 signal. 85 Selection Min: 1 Max: 10 Analog Output #1 86 Read only Analog Output #1 Bias Read/Write Condition: All Default: Factory Analog Output #1 Span Read/Write Condition: All Default: Factory Analog Output #2 Selection Read/Write Condition: All Default: 4 89 Selection Min: 1 Max: 10 87 Bits Min: -100 Max: 500 % 88 Bits Min: 2000 Max: 6000 Digital span adjustment of the Analog Output #1 signal. Calibration is described in the Calibration Chapter. Digital zero adjustment of the Analog Output #1 signal.Settings February 2004 Settings Analog Output #1 Selection Read/Write Condition: All Default: 2 No. Calibration is described in the Calibration Chapter. The selection list is: 1 – Power Setpoint 2 – Power Output 3 – Voltage Setpoint 4 – Voltage Output 5 – Voltage Input 6 – Current Setpoint 7 – Current Output 8 – Current Input 9 –Analog Setpoint 10 – Duty Cycle Output An analog output as defined by Analog Output #2 Selection in percent. The selection list is: 1 – Power Setpoint 2 – Power Output 3 – Voltage Setpoint 4 – Voltage Output 5 – Voltage Input 6 – Current Setpoint 7 – Current Output 8 – Current Input 9 –Analog Setpoint 10 – Duty Cycle Output An analog output as defined by Analog Output #1 Selection in percent. Units Description Defines the operation of the Analog Output #1. 7-10 .

Bit 0 – Maintained 1 – On 0 . Units Description The control word is the digital inputs to the 853.February 2004 Settings Settings Control Word Read/Write Condition: All Default: Bit 0 – 0 Off Bit 1 – 0 No Reset Bit 2 .Fault Reset 0 – No Reset Bit 3 – Momentary 1 – KW-hour Reset 0 – No Reset Bit 4 – Momentary 1 – Node synchronization 0 – No synchronization Bit 5 – Momentary 1 – Auto Set Repetitive Pulse 0 – No Auto Set Regulation Mode Bit 6 – 7 Maintained 0 – 0 No Regulation 1 – 0 Power Output Control 0 – 1 Voltage Output Control 1 – 1 Current Output Control Bit 8 – Momentary 1 – Save calibration data to eeprom 0 – No cal save Bit 9 – Momentary 1 – Restore calibration data from eeprom 0 – No cal restore 93 Bits 7-11 .Off Bit 1 – Momentary 1 .Reserved Bit 3 – 0 No Reset Bit 4 – 0 No Sync Bit 5 – 0 No Auto Set Bit 6 – 0 Bit 7 – 1 Voltage Bit 8 – 0 Save Calibration Bit 9 – 0 Restore Calibration Bit 10 – 15 Reserved No.

Units Description The status word is the digital outputs from the 853. Bit 0 1– On 0 – Off Bit 1 1 – Fault 0 – No Fault Bit 2 1 – Alarm 0 – No Alarm Bit 3 1 – Remote control selected 0 – Local control selected Bit 4 1 – Enable selected 0 – Inhibit selected Bit 5 1 – Local Digital control 0 – Local Analog control Regulation Limit Bit 6 – 7 – 8 0 – 0 – 0 No Limit 1 – 0 – 0 Power Output Limit 0 – 1 – 0 Voltage Output Limit 0 – 0 – 1 Current Output Limit 0 – 1 – 1 Current Input Limit 1 – 1 – 1 Maximum Voltage Output Bit 9 1 – At Setpoint 0 – Not at Setpoint Bit 10 1 – Phase Rotation L3-L2-L1 0 – Phase Rotation L1-L2-L3 Bit 11 1 – Ext Input #1 Closed 0 – Ext Input #1 Open Bit 12 1 – Ext Input #2 Closed 0 – Ext Input #2 Open Bit 13 1 – Ext Input #3 Closed 0 – Ext Input #3 Open Bit 14 Reserved Bit 15 1 – Program Jumper In 0 – Program Jumper Out 94 Bits 7-12 .Settings February 2004 Settings Status Word Read only No.

The configuration word configures the digital inputs to the 853. Units Seconds Min: 0 Max: 360 Description The amount of time for the setpoint to go from 0 to100%. 95 96 Seconds Min: 0 Max: 360 The amount of time for the setpoint to go from 100 to 0%.February 2004 Settings Settings Ramp Up Time Read/Write Condition: All Default: 10 Sec Ramp Down Time Read/Write Condition: All Default: 10 Sec Configuration Word Read/Write Condition: All Default: Bit 0 – 1 Digital Bit 1 – 0 Secondary Analog Disabled Bit 2 Reserved Bit 3 – 1 Ext Fault #1 NO Bit 4 – 1 Ext Fault #2 NO Bit 5 – 1 Ext Fault #3 NO Bit 6 – 1 Int Fault #1 NO Bit 7 – 1 Int Fault #2 NO Bit 8 – 0 Thermostat NC Bit 9 – 0 Low voltage Fault Bit 10 – 11 Reserved Bit 12 – 1 Ext #1 Input Bit 13 – 1 Ext #2 Input Bit 14 – 1 Ext #3 Input Bit 15 – 0 Auto Start Disabled No. Bit 0 – Maintained 1 – Local Digital control 0 – Local Analog control Bit 1 – Maintained 1 – Secondary Analog enabled 0 – Secondary Analog disabled Bit 2 – Reserved Bit 3 – Maintained 1 – External Fault #1 NO 0 – External Fault #1 NC Bit 4 – Maintained 1 – External Fault #2 NO 0 – External Fault #2 NC Bit 5 – Maintained 1 – External Fault #3 NO 0 – External Fault #3 NC Bit 6 – Maintained 1 – Internal Fault #1 NO 0 – Internal Fault #1 NC Bit 7 – Maintained 1 – Internal Fault #2 NO 0 – Internal Fault #2 NC Bit 8 – Maintained 1 – Thermostat NO 0 – Thermostat NC Bit 9 – Maintained 1 – Low voltage results in Alert 0 – Low voltage results in Fault Bit 12 – Maintained 1 – External #1 generates fault 0 – External #1 input only Bit 13 – Maintained 1 – External #2 generates fault 0 – External #2 input only Bit 14 – Maintained 1 – External #3 generates fault 0 – External #3 input only Bit 15 – Maintained 1 – Enable Auto Start on Power up 0 – Disable Auto Start on Power up 97 Bits 7-13 .

Settings

February 2004

Settings
Control Strategy Selection Read/Write Condition: Off Default: 1 Magnetizing Sequence Calibration Read/Write Condition: Off Default: 10 Cycles Repetitive Pulse Calibration Read/Write Condition: All Default: Low Byte 50 High Byte 30 Load Type Selection Read/Write Condition: Off Default: 1 Product Type Read only Serial Number Read only Factory set Control Power Time On Read only Factory reset Output Time On Read only Factory reset KW-Hour Read only Software Version

No. Units
Selection Min: 1 Max: 2

Description
Defines the type of control strategy that is being run. The selection list is: 1 – Phase-Angle Control 2 – Zero-Crossover Control

98

99

Cycles Min: 5 Max: 20

Number of cycles to ramp on in phase control – Zero-Crossover control only

100

% Min: 10 Max: 90

The Repetitive Pulse Calibration is divided into two separate bytes, which allows the first positive zero crossing pulse to be set differently for the three phases – Zero-Crossover control only. Low Byte – Bits 0 – 7 Repetitive Pulse #1 High Byte – Bits 8 – 15 Repetitive Pulse #2

101

Selection Min: 1 Max: 2

Defines the type of load connected to the 853. The selection list is: 1 – Direct Coupled 2 – Transformer Coupled The product type is 853. The numeric serial number of the 853. The Setting is read as two consecutive words because of its size.

102

103 104

105 106

Hours x.x

The accumulated time control power has been applied to the 853. The Setting is read as two consecutive words because of its size. The accumulated time the 853 output has been on. The Setting is read as two consecutive words because of its size. The accumulated Power Output in KW hours. It can be reset remotely by writing a 1 to bit 3 of the Control Word. The Setting is read as two consecutive words because of its size. The control software version read as xx.xxx.

107 108

Hours x.x

109 110

KW- Hours x.x

112 Read only

7-14

February 2004

Settings

Settings
Network Loss Read/Write Condition: All Default: 1 Network Address Read/Write Condition: All Default: 63 Network Baud Rate Read/Write Condition: All Default: 0 MODBUS Address Read/Write Condition: All Default: 247 MODBUS Baud Rate Read/Write Condition: All Default: 19200 Network Type Read/Write Condition: All Default: 0 Fault Code

No. Units

Description
Defines the action that is taken by the 853 control when there is a network loss. The selection list is: 0 – Fault and Stop 1 – Ignore and Run 2 – Alarm and Run For the DeviceNet™ and Profibus network types, defines the network interface card address. For Ethernet, it defines the upper two octets of the network address. Refer to the network interface manual for a detailed description of the network interface. For the DeviceNet™ and Profibus network types, defines the network baud rate. For Ethernet, it defines the lower two octets of the network address. Refer to the network interface manual for a detailed description of the network interface.

113

Selection Min: 0 Max: 2

114

Address Min: 0 Max: 126

115

Selection Min: 0 Max: 2

116

Address Min: 1 Max: 247

Defines the device address for MODBUS messaging.

117

Selection Min: 4800 Max: 19200 (baud)

Defines the serial baud rate. The selection list is: 4800 9600 19200 Defines the selected network interface. The selection list is: 0 – DeviceNet™ 1 – Profibus 2 – Ethernet Fault condition code. Fault operation is described in the Troubleshooting Chapter.

118

Selection Min: 0 Max: 2

119 Read only Fault Index Read only Factory reset Fault Buffer #1 Read only Factory reset 120 Index Min: 1 Max: 8

Fault buffer index number.

121 122 123

Saved fault condition code with a time stamp of time run. Word 121 – Fault condition code Word 122/123 – Output time on stamp

7-15

Settings

February 2004

Settings
Fault Buffer #2 Read only Factory reset Fault Buffer #3 Read only Factory reset Fault Buffer #4 Read only Factory reset Fault Buffer #5 Read only Factory reset Fault Buffer #6 Read only Factory reset Fault Buffer #7 Read only Factory reset Fault Buffer #8 Read only Factory reset

No. Units
124 125 126

Description
Saved fault condition code with a time stamp of time run. Word 124 – Fault condition code Word 125/126 – Output time on stamp Saved fault condition code with a time stamp of time run. Word 127 – Fault condition code Word 128/129– Output time on stamp Saved fault condition code with a time stamp of time run. Word 130 – Fault condition code Word 131/132 – Output time on stamp Saved fault condition code with a time stamp of time run. Word 133 – Fault condition code Word 134/135 – Output time on stamp Saved fault condition code with a time stamp of time run. Word 136 – Fault condition code Word 137/138 – Output time on stamp Saved fault condition code with a time stamp of time run. Word 139 – Fault condition code Word 140/141 – Output time on stamp Saved fault condition code with a time stamp of time run. Word 142 – Fault condition code Word 143/144 – Output time on stamp

127 128 129

130 131 132

133 134 135

136 137 138

139 140 141

142 143 144

7-16

The 853 DSPC has a number of built in diagnostic features. grounding. Failure to observe this precaution could result in severe bodily injury or loss of life. Failure to observe these precautions could result in severe bodily injury or loss of life. and international codes. 8-1 . Read and understand this manual and other applicable manuals in their entirety before proceeding.Chapter 8 Troubleshooting DANGER Only qualified electrical personnel familiar with the construction and operation of the equipment and the hazards involved should install. Voltages on many components are at incoming line potential. Disconnect and lock out all ungrounded conductors of the AC power line. DANGER This equipment is at line voltage when AC power is connected. and/or service this equipment. to avoid electric shock hazard or damage to equipment. wiring practices. These include LED indicators for quick visual indicators on the following: ● ● ● the Main Control printed circuit board (PCB) the Local Digital Control option the network interface option The four-digit display on the Local Digital Control option can be programmed to view key control signals and display fault or alarm codes. Failure to observe these precautions could result in severe injury or loss of life. do not touch any component other than those specified in the manual. DANGER The user is responsible for conforming with all applicable local. and overcurrent protection are of particular importance. operate. disconnects. national. Failure to observe this precaution could result in severe bodily injury or loss of life. DANGER Power must be applied to the 853 DSPC with the cover removed to perform certain troubleshooting procedures.

The LED’s and their functions are listed in below. Table 8-1 Control PCB LED Indicators LED +5V +15V -15V On Heartbeat Color Green Green Green Green Flashing Green Red Description +5V power is present +15V power is present -15V power is present 853 DSPC output is active Digital Signal Processor is operating Fault 853 DSPC has detected a fault condition Figure 8-1 Control PCB LED indicator location 8-2 . Remove the middle wiring cover of the 853 DSPC to view these particular LED’s.Troubleshooting Control PCB LED Indicators February 2004 The control printed circuit board has six LED’s.

The Local mode is set to Digital. The Local mode is set to Analog. The 853 DSPC output is active. The Enable input is present. Either a fault or alarm is present.February 2004 Local Digital Control Option LED Indicators Troubleshooting The Local Digital Control Option has six LED’s used for status. Table 8-2 Local Digital Control LED Indicators Status LED Remote Analog Digital Enable On Alert Color Green Green Green Green Green Amber Description The Remote input is present. Figure 8-2 Local Digital Control 8-3 . The LED’s and their functions are listed below.

2. 1. Table 8-3 Fault and Alarm Codes Fault/Alarm Phase L1 Current Input High Fault Code 1 Description The fault occurs when the Current Input L1 Actual peak exceeds the Current Input High Fault at any time during the AC cycle for two consecutive samples. 8-4 . The fault will be reset and automatically restart based on the following conditions. Phase L2 Current Input High Fault 2 The fault occurs when the Current Input L2 Actual peak exceeds the Current Input High Fault at any time during the AC cycle for two consecutive samples. The display alternates between the selected display variable and the alarm code. The 853 will turn off and automatically restart based on the Current Input High Retry Number.Troubleshooting Fault and Alarm Codes February 2004 If there is a fault. The 853 will turn off and automatically restart based on the Current Input High Retry Number. The alarm code is also displayed on the Local Digital Control module but not continuously. It can also be accessed as Setting #119 through either the serial or network interface. Alarm codes are warning conditions and do not stop the 853 DSPC. The 853 will turn off and not automatically restart if the number of restarts occur within the Current Input High Retry Time. 2. A fault will always override an alarm and stop the 853 DSPC. This makes the lowest number codes the highest priority. The 853 will turn off and not automatically restart if the number of restarts occur within the Current Input High Retry Time. 1. the 853 DSPC automatically stops and holds the fault code for the user. The fault will be reset and automatically restart based on the following conditions. The fault code is displayed on the Local Digital Control module. The fault codes are evaluated in their numeric order. It can also be accessed as Setting #119 through either the serial or network interface. The following table lists the fault and alarm codes.

Over Temperature Fault 6 The fault occurs when the thermostat input changes to the off state. The fault occurs when Voltage Input Actual (average of three phases) exceeds the Voltage High Fault. The fault will be reset and automatically restart based on the following conditions. The Current Input Actual exceeds the Current Input Overload Fault. The fault occurs when internal fault input #2 changes to the off state. 2. The thermostat input is defined as NO (Normally Open) or NC (Normally Closed) depending on bit 8 of the Configuration Word. Note: If the Current Input Actual goes below the Current Input Overload Fault then the accumulated time resets back to zero.5% of the Voltage Input Rating. The accumulated time of condition #1 is greater than the Current Input Overload Time. The fault occurs when internal fault input #1 changes to the off state. Internal Fault #1 7 Internal Fault #2 8 Voltage Input High Fault Voltage Input Low Fault 9 10 8-5 . 1. The 853 will turn off and not automatically restart if the number of restarts occur within the Current Input High Retry Time. 1. The internal fault input #1 is defined as NO (Normally Open) or NC (Normally Closed) depending on bit 6 of the Configuration Word. The 853 will turn off and automatically restart based on the Current Input High Retry Number. 2.February 2004 Troubleshooting Fault/Alarm Phase L3 Current Input High Fault Code 3 Description The fault occurs when the Current Input L3 Actual peak exceeds the Current Input High Fault at any time during the AC cycle for two consecutive samples. Current Input Timed Overload Fault 5 The fault occurs when the following conditions are met. and bit 9 of the Configuration Word is NOT set. The internal fault input #2 is defined as NO (Normally Open) or NC (Normally Closed) depending on bit 7 of the Configuration Word. The fault occurs when Voltage Input Actual (average of three phases) is lower than 12.

2. The phase difference between Voltage L1-L2 Input Actual and Voltage L2-L3 Input Actual is less than 45 degrees or greater than 135 degrees. Voltage L3-L1 Actual is greater than Voltage Input Actual. Note: If condition #2 is not met. The phase difference between Voltage L1-L2 Input Actual and Voltage L2-L3 Input Actual is less than 45 degrees or greater than 135 degrees. 1. The accumulated time of condition #2 is greater than 100 milliseconds. The phase difference between Voltage L1-L2 Input Actual and Voltage L2-L3 Input Actual is less than 45 degrees or greater than 135 degrees. Note: If condition #2 is not met. The accumulated time of condition #2 is greater than 100 milliseconds. 8-6 . 1. 2.Troubleshooting February 2004 Fault/Alarm Phase L1 Loss Code 11 Description The fault occurs when the following conditions are met. then the accumulated time resets back to zero. 3. The accumulated time of condition #2 is greater than 100 milliseconds. 3. then the accumulated time resets back to zero. 2. Voltage L1-L2 Actual is greater than Voltage Input Actual. Note: If condition #2 is not met. Phase L3 Loss 13 The fault occurs when the following conditions are met. Voltage L2-L3 Actual is greater than Voltage Input Actual. 3. Phase L2 Loss 12 The fault occurs when the following conditions are met. then the accumulated time resets back to zero. 1.

The External Fault Input #2 changes to the off state. 2. The 853 is off. The External Fault Input #1 changes to the off state. Note: External Fault Input #2 is defined as NO (Normally Open) or NC (Normally Closed) depending on bit 4 of the Configuration Word. Note: External Fault Input #1 is defined as NO (Normally Open) or NC (Normally Closed) depending on bit 3 of the Configuration Word. Network Loss Fault 20 The Voltage Output Actual is greater than 75% of the Voltage Output Rating for one second. 2. Note: [Reset] may clear this fault with no further action.February 2004 Troubleshooting Fault/Alarm External Fault #1 Code 14 Description The fault occurs when the following conditions are met. Configuration Word bit 12 is a one. The External Fault Input #3 changes to the off state. 1. Configuration Fault 17 The fault occurs when the 'check byte' of the onboard EEPROM is not correct. 2. 2. External Fault #2 15 The fault occurs when the following conditions are met. Watchdog Fault 18 The fault occurs when the digital signal processor does not update the watchdog timer correctly. External Fault #3 16 The fault occurs when the following conditions are met. 1. Configuration Word bit 13 is a one. 1. Note: External Fault Input #3 is defined as NO (Normally Open) or NC (Normally Closed) depending on bit 5 of the Configuration Word. Configuration Word bit 14 is a one. 1. 8-7 . SCR Shorted Fault 19 The fault occurs if there is a network loss and the Network Loss Selection is set to Fault and Stop. The fault occurs when the following conditions are met.

L3 Current Input Load Failure Alarm 33 The alarm occurs when all of the following conditions are met.0 Hertz band when compared to the Frequency Rating. Note: If the calculated ground current goes below the Ground Fault Current then the accumulated time resets back to zero. The accumulated time of condition #1 is greater than the Ground Fault Time. 2. 3. 3. 35 8-8 . L1 Current Input Load Failure Alarm 31 The alarm occurs when all of the following conditions are met. The alarm occurs when all of the following conditions are met. Frequency Alarm 30 The alarm occurs when the Frequency Actual is outside of a 2. The alarm occurs when the Voltage Output Actual is being limited to the Voltage Output Limit by the voltage output control loop. The Current L2 Input Actual is less than the Current Input Threshold Load Failure. The Current L3 Input Actual is less than the Current Input Threshold Load Failure. Voltage Input Low Alarm Voltage Output Limit Alarm 34 The alarm occurs when the Voltage Input Actual is lower than the Voltage Input Low Alarm. 2. 1. The Voltage Output Actual is greater than 10% of the Voltage Output Rating The setpoint has completed ramping up. The Voltage Output Actual is greater than 10% of the Voltage Output Rating The setpoint has completed ramping up. 1. 2. 3. The calculated ground current exceeds the Ground Fault Current. 2. The Voltage Output Actual is greater than 10% of the Voltage Output Rating The setpoint has completed ramping up.Troubleshooting February 2004 Fault/Alarm Ground Fault Code 21 Description The fault occurs when all the following conditions are met. 1. L2 Current Input Load Failure Alarm 32 The Current L1 Input Actual is less than the Current Input Threshold Load Failure. 1.

The fault buffer includes the Fault Code and a time stamp from Output Time On. Use the fault reset bit (bit 1) of the Control Word. The alarm occurs when the Power Output Actual is being limited to the Power Output Limit by the power output control loop. The bit must be momentarily set to enable a fault reset. Fault Buffer The last eight faults are stored in Fault Buffers #1 .February 2004 Troubleshooting Fault/Alarm Current Output Limit Alarm Code 36 Description The alarm occurs when the Current Output Actual is being limited to the Current Output Limit by the current output control loop. The alarm occurs when the difference between the Voltage L2-L3 Input Actual and the Voltage Input Actual exceeds the Voltage Input Phase Unbalance Alarm (expressed as a percentage of the Voltage Input Rating). Press the Reset button on the Local Digital Control module. The alarm occurs when the Current Input Actual is being limited to the Current Input Limit. The alarm occurs when the Duty Cycle of the controller reaches 100%. ● ● ● Toggle the Enable/Inhibit switch from Enable to Inhibit. The alarm occurs if there is a network loss and the Network Loss Selection is set to Alarm and Run. Power Output Limit Alarm 37 Current Input Limit Alarm Maximum Voltage Output Alarm Network Loss Alarm 38 39 40 L1-L2 Input Voltage Unbalanced 41 The alarm occurs when the difference between the Voltage L1-L2 Input Actual and the Voltage Input Actual exceeds the Voltage Input Phase Unbalance Alarm (expressed as a percentage of the Voltage Input Rating). The alarm occurs when the difference between the Voltage L3-L1 Input Actual and the Voltage Input Actual exceeds the Voltage Input Phase Unbalance Alarm (expressed as a percentage of the Voltage Input Rating).#8 and can be accessed from the serial interface. L2-L3 Input Voltage Unbalanced 42 L3-L1 Input Voltage Unbalanced 43 Fault Reset Faults can be cleared or reset by three different methods. Alarms are automatically cleared. The 853 automatically resets the bit after the fault has been cleared. It is very important not to leave the bit set in the control word. Only faults that occur 8-9 .

grounding. The following table shows different conditions with probable cause and corrective action for each condition. disconnects. Failure to observe these precautions could result in severe bodily injury or loss of life. The Fault Index indicates which buffer will be written to next. do not touch any component other than those specified in the manual. DANGER The user is responsible for conforming with all applicable local.Troubleshooting February 2004 when the unit is running are buffered. Voltages on many components are at incoming line potential. and overcurrent protection are of particular importance. Failure to observe this precaution could result in severe bodily injury or loss of life. Troubleshooting Guide DANGER Only qualified electrical personnel familiar with the construction and operation of the equipment and the hazards involved should install. to avoid electric shock hazard or damage to equipment. and international codes. Failure to observe these precautions could result in severe injury or loss of life. Read and understand this manual and other applicable manuals in their entirety before proceeding. DANGER Power must be applied to the 853 DSPC with the cover removed to perform certain troubleshooting procedures. Disconnect and lock out all ungrounded conductors of the AC power line. national. The fault buffers are connected in a circular fashion. and/or service this equipment. wiring practices. Failure to observe this precaution could result in severe bodily injury or loss of life. DANGER This equipment is at line voltage when AC power is connected. operate. 8-10 .

Check that the Remote status LED is off. The Output On status LED should also be on.February 2004 Troubleshooting Table 8-4 Troubleshooting Guide Condition +5V LED off +15V LED off -15V LED off Power Supply connection open Power Supply failed Heartbeat LED off DSP on main control PCB failed Check Power Supply connections to main control PCB Replace Power Supply Check that jumper JP1 has been removed before applying power Replace main control PCB Local Digital Control Display off or scrambled 853 DSPC will not turn on in Local Analog mode Local Digital Control connection open or intermittent Enable not present Check Local Digital Control connection to main control PCB Probable Cause No Control Power Corrective Action Insure the 853 DSPC has separate control power Check that the Enable status LED is on. Check that the Analog status LED on Verify voltage at Analog Setpoint input Local mode not selected Analog mode not selected Local Analog setpoint set to zero Local analog setpoint calibration incorrect Verify Local analog setpoint calibration 8-11 . Select Analog mode on Local Digital Control.

Check that the Remote status LED is off. Verify input voltage level to make sure it is not low Local mode not selected Digital mode not selected Output On not selected Digital setpoint set at zero 853 DSPC will not turn on in Remote mode Enable not present Remote mode not selected On/Off bit not set to one Setpoint set at zero 853 DSPC cannot provide full power to the load Calibration incorrect Power is being limited by one of the three control loops 853 DSPC is full on and cannot provide any more power Output wiring intermittent or disconnected Check the output wiring 8-12 .Troubleshooting February 2004 Condition 853 DSPC will not turn on in Local Digital mode Probable Cause Enable not present Corrective Action Check that the Enable status LED is on. Press the increase pushbutton to increase the setpoint Check that the Enable status LED is on.0% voltage will allow 100.0% power. Review the load to verify that 100.0%. Set the On/Off bit to one in the Control Word and check that the Output On LED is on Verify that the setpoints for Voltage. Check that the Remote status LED is on. Current. Check that the Digital status LED is on Press the On/Off/Reset pushbutton and check that the Output On LED is on. Power and Remote Duty Cycle are not zero Check calibration Verify setpoints for the three control loops Duty Cycle is at 100. Select Digital mode on Local Digital Control.

F-02. F-03 Current Input High Fault Calibration incorrect Current Input Rating setting incorrect Current Input High Fault setting incorrect Intermittent short in load F-05 – Current Input Timed Over Current Fault Calibration incorrect Current Input Rating setting incorrect Current Input Overload Fault setting incorrect Current Input Overload Time setting incorrect Output transformer sized incorrectly F-06 – Over Temperature Fault Thermostat contact state incorrect in Configuration Word setting Thermostat wiring open or shorted Cabinet is overheating Check Current Input High Fault setting Check load Check calibration Check Current Input Rating setting Check Current Input Overload Fault setting Check Current Input Overload Time setting Verify size of output transformer Check Configuration Word setting Check thermostat wiring Provide more cabinet ventilation or cooling Check fan is functioning properly Check Configuration Word setting Unit is Overheating F-07.February 2004 Troubleshooting Condition Nuisance Input Fuse blowing Probable Cause Improper fuse rating Corrective Action Refer to Hardware Installation Chapter for correct fuse rating Tighten the fuses Check calibration Check Current Input Rating setting Fuse improperly tightened F-01. F-08 – Internal Fault Internal Fault contact state incorrect in Configuration Word setting Internal Fault wiring open or shorted Check Internal Fault wiring 8-13 .

Replace main control PCB F-18 Watchdog Fault Failed DSP Replace main control PCB 8-14 . F16 – External Fault External Fault contact state incorrect in Configuration Word setting External Fault wiring open or shorted F-17 – Configuration Fault Failed EEPROM memory Check External Fault wiring Try [Reset] If the fault remains. Refer to Startup Chapter for details on correct setting Correct incoming voltage level Incoming voltage out of tolerance F-10 – Voltage Input Low Fault Calibration incorrect Voltage Input Rating setting incorrect Voltage Output PT Secondary setting incorrect Check calibration Check Voltage Input Rating setting Check Voltage Output PT Secondary setting. F-15. F-12. use the configuration tool offline to modify a setting or load a . Refer to Startup Chapter for details on correct setting Replace input fuse Check calibration Replace input fuse Check Configuration Word setting Blown input fuse F-11. F-13 – Phase Loss Calibration incorrect Blown input fuse F-14.csv file.Troubleshooting February 2004 Condition F-09 – Voltage Input High Fault Probable Cause Calibration incorrect Voltage Input Rating setting incorrect Voltage Input High Fault setting incorrect Voltage Output PT Secondary setting incorrect Corrective Action Check calibration Check Voltage Input Rating setting Check Voltage Input High Fault setting Check Voltage Output PT Secondary setting. and respond to the Write prompt with Yes. Go online.

February 2004 Troubleshooting Condition F-19 – SCR Shorted Fault Probable Cause Calibration incorrect Voltage Output Rating setting incorrect Voltage Output PT Secondary setting incorrect Corrective Action Check calibration Check Voltage Output Rating setting Check Voltage Output PT Secondary setting.Network Loss Fault Network failure F-21 – Ground Fault Calibration incorrect Current Input Rating setting incorrect Ground Fault Current setting incorrect Intermittent short to ground Check calibration Check Current Input Rating setting Check Ground Fault Current setting Check for ground Check Frequency Rating setting A-30 – Frequency Alarm Frequency Rating setting incorrect Incoming frequency out of tolerance Correct incoming frequency 8-15 . See Startup Chapter for details on correct setting Replace SCR Check network connection Verify presence of network Change Network Loss Option to allow device operation Shorted SCR F-20 .

Refer to Startup Chapter for details on correct setting Check Voltage Output Setpoint setting Change Voltage Output Setpoint Voltage Output Setpoint setting incorrect Controlling with Voltage Output PID 8-16 .Troubleshooting February 2004 Condition A-31. Refer to Startup Chapter for details on correct setting Verify output load Check calibration Check Voltage Input Rating setting Output load changed A-34 – Voltage Input Low Alarm Calibration incorrect Voltage Input Rating setting incorrect Voltage Input Low Alarm setting incorrect Voltage Output PT Secondary setting incorrect Check Voltage Input Low Alarm setting Check Voltage Output PT Secondary setting. A-32. Refer to Startup Chapter for details on correct setting Correct incoming voltage level Incoming voltage out of tolerance A-35 – Voltage Output Limit Alarm Calibration incorrect Voltage Output Rating setting incorrect Voltage Output PT Secondary setting incorrect Check calibration Check Voltage Output Rating setting Check Voltage Output PT Secondary setting. A-33 – Current Input Load Failure Alarm Probable Cause Calibration incorrect Current Threshold Load Failure setting incorrect Voltage Output Rating setting incorrect Voltage Output PT Secondary setting incorrect Corrective Action Check calibration Check Current Input Threshold Load Failure setting Check Voltage Output Rating setting Check Voltage Output PT Secondary setting.

February 2004 Troubleshooting Condition A-36 – Current Output Limit Alarm Probable Cause Calibration incorrect Current Output Rating setting incorrect Current Output Setpoint setting incorrect Controlling with Current Output PID Corrective Action Check calibration Check Current Output Rating setting Check Current Output Setpoint setting Change Current Output Setpoint A-37 – Power Output Limit Alarm Calibration incorrect Voltage Output Rating setting incorrect Voltage Output PT Secondary setting incorrect Check calibration Check Voltage Output Rating setting Check Voltage Output PT Secondary setting. Refer to Startup Chapter for details on correct setting Check Current Output Rating setting Current Output Rating setting incorrect Power Output Setpoint setting incorrect Controlling with Power Output PID A-38 – Current Input Limit Alarm Calibration incorrect Current Input Rating setting incorrect Current Input Limit setting incorrect Controlling Current Input with Current Output PID A-39 .Maximum Voltage Output Alarm Duty Cycle has reached 100% Check Power Output Setpoint setting Change Power Output Setpoint Check calibration Check Current Input Rating setting Check Current Input Limit setting Change Current Input Limit Lower the control setpoint 8-17 .

Network Loss Alarm Probable Cause Network failure Corrective Action Check network connection Verify presence of network Change Network Loss Option to allow device operation A-41.Troubleshooting February 2004 Condition A-40. A-43 – Input Voltage Unbalance Alarm Calibration incorrect Voltage Input Phase Unbalance setting incorrect Voltage Input Rating setting incorrect Voltage Input Supply not balanced Check calibration Check Voltage Input Phase Unbalance Alarm setting Check Voltage Input Rating setting Check Voltage Input Supply 8-18 . A-42.

Appendix A Mechanical Dimensions Figure A-1 Mechanical Dimensions A-1 .

Mechanical Dimensions February 2004 A-2 .

Appendix B Electrical Drawings B-1 .

Electrical Drawings February 2004 Figure B-1 Electrical Schematic Left Side B-2 .

February 2004 Electrical Drawings Figure B-2 Electrical Schematic Right Side B-3 .

Electrical Drawings February 2004 Figure B-3 40A Wiring Diagram B-4 .

February 2004 Electrical Drawings Figure B-4 90A Wiring Diagram B-5 .

Electrical Drawings February 2004 Figure B-5 175A Wiring Diagram B-6 .

February 2004 Electrical Drawings Figure B-6 350A Wiring Diagram B-7 .

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Glossary Glossary of common terms and abbreviations used in SCR Power Controllers and their applications Term or Acronym ADR ASCII Bias CAN CT DSP DSPC EDS Heatsink I2t I/O IRMS KVA LED MOV NC NO NEC NEMA ODVA PCB PCMCIA PCU Description Automatic Device Replacement American Standard Code for Information Interchange Calibration factor to offset signal at zero output of control signal Controller Area Network Current Transformer Digital Signal Processor Digital SCR Power Controller Electronic Data Sheet Device to carry heat from power devices Subcycle current characteristic of an SCR or fast clearing fuse Input/Output Amps Root Mean Squared One thousand volt amperes Light emitting diode Metal Oxide Varistor – brand name of GE transient voltage suppressor Normally closed contact Normally open contact National Electric Code National Electrical Manufacturers Association Open DeviceNet™ Vendors Association Printed Circuit Board Personal Computer Memory Card International Association Power Control Unit i .

Transmit Transaction ID for Explicit Message Requests and Responses Volts Alternating Current Volts Direct Current Volts Root Mean Squared Calibration signal to adjust minimum input of control signal to zero Control by integrating numbers of complete cycles ii . TRIAC. Integral Derivative Controller Programmable Logic Controller Potential Transformer Radio Frequency Interference Root Mean Squared Receive Silicon Controlled Rectifier Solid State device for controlling electric power Reference for PID control Material from which semiconductors are made Calibration signal to adjust maximum input of control signal Name of semiconductor family including SCR’s.Glossary February 2004 Term or Acronym Phase Angle PID PLC PT RFI RMS Rx SCR Semiconductor Setpoint Silicon Span Thyristor Tx TXID VAC VDC VRMS Zero Zero-Cross Description Control by chopping each half cycle Proportional. etc.

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