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

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

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

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

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

vi
List of Figures

Figure 1-1 853 DSPC Schematic Diagram................................................................... 1-1


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

vii
List of Tables

Table 1-1 Technical Specifications............................................................................... 1-8


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

viii
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 DSPC is designed for a three-phase application.
The 853 DSPC uses an advanced, dsp-based firing circuit to control a three phase, six SCR AC Switch.
The 853 DSPC is capable of firing into either direct or transformer coupled loads. The basic circuit
configuration is shown in the figure below.

Figure 1-1 853 DSPC Schematic Diagram

1-1
Product Description February 2004

Phase-Angle Control

In Phase-Angle control, the line is connected to the load for a portion of each half cycle. It is
disconnected from the load for the remainder of the half cycle. The period during which the load is
connected is varied in response to the control signal providing proportional control of power to the load. A
sample picture of Phase-Angle control is shown below.

Figure 1-2 Phase-Angle Control Half Cycles

1-2
February 2004 Product Description

Phase-Angle Control Method


The 853 DSPC controls its output based on regulation mode. The regulation modes are Open Loop,
Voltage Output, Current Output, and Power Output. Each mode regulates to within 1% of rated output.
The Current Input Limit is accomplished by comparing the Current Input to the Current Input Limit. If the
Current Input exceeds the Current Input Limit the Current Output setpoint is lowered, which in turn will
lower the Current Input. A flow diagram of the control is shown below.

Figure 1-3 Phase-Angle Duty Cycle Output

RFI
Phase-Angle control can generate Radio Frequency Interference (RFI). This may, depending upon the
installation and magnitude, affect other electronic equipment (computers, telephones, etc.). Where RFI
may be a problem, Zero-Crossover control can be used for many of the electric heating applications. The
source inductance, load inductance, and circuit impedances determine the amount of RFI generated by
Phase-Angle control. Additional components may be required to reduce or eliminate RFI, such as the
use of an isolation transformer between the line and the 853 DSPC or the addition of line filters.

1-3
Product Description February 2004

Zero-Crossover Control

In Zero-Crossover control, the line is connected to the load for a number of complete cycles. It is then
disconnected for a number of complete cycles. This on-off pattern is repeated continuously with the 853
DSPC turning on (and off) at the zero crossing of the sine wave. 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. The 853 DSPC has predefined the total number of cycles ON and OFF to be 100. This will
allow the output to be set to 1% or 1 cycle out of 100. A sample picture of the Zero-Crossover control is
shown below.

Figure 1-4 Zero-Crossover Control

Multiple 853 DSPC’s can achieve power leveling by using the Network Address and Node
Synchronization. This allows each independent 853 DSPC to start at a different time based on the
Network Address, which allows one 853 DSPC to turn on when the other unit is off, therefore causing
power leveling on the common AC power source.

Zero-Crossover Control Method


The Zero-Crossover control method is based on calculation. The actual voltage output, current output,
and power output are calculated every cycle and compared to each respective setpoint. The cycles
continue until the calculated feedback exceeds its respective setpoint and then the unit turns off after the
next cycle. 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.

1-4
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, and since the Zero-Crossover control is adaptive, the number of cycles will
automatically increase based on the voltage output, current output, and power output setpoints. 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. However, it does protect the load by limiting the current
that in some cases would be more important than the Zero-Crossover features. A sample picture of the
Zero-Crossover control with Current Input Limit is shown below.

Figure 1-5 Zero-Crossover Current Input Limit

Heating Loads
Resistance type heating loads fall into two general categories. The first category consists of heating
elements made from materials that exhibit relatively constant resistance whether hot or cold. These
include such elements as nichrome, calrod, chromolox and various steels. No particular precautions
need be taken in using such materials. The second category consists of elements made from materials
that exhibit low initial (cold) resistance such as tungsten, molybdenum, platinum, moly-disilicide, silicon
carbide (which ages) and quartz infrared lamps. 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.

Zero-Crossover Load Type


The very nature of Zero-Crossover control, firing full cycles of power, tends to cause large inrush currents
into the load. This is especially true when transformers are connected to the output. 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. In order to eliminate this problem from happening, the Load Type setting can be
set for Direct Coupled or Transformer Coupled loads. Transformer Coupled loads require two additional
settings; Magnetizing Sequence and Repetitive Pulse.

1-5
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. A sample picture of the Zero-
Crossover control magnetizing sequence is shown below.

Figure 1-6 Zero-Crossover Control Magnetizing Sequence

Repetitive Pulse
After the cycle has started, the Repetitive Pulse causes only the first cycle to start in Phase-Angle
control again in order to limit the current inrush. A sample picture of the Zero-Crossover control
Repetitive Pulse is shown below.

Figure 1-7 Zero-Crossover Control Repetitive Pulse

1-6
February 2004 Product Description

Standard Features

The 850 Series digital product family offers the following features:

• Flexibility. Configurable operating modes, ratings, limits, external inputs, and setpoints.

• On-Board Diagnostics. Fault memory (the last eight faults are available in fault buffer storage)
allows the user to record problems and, through the use of a computer, observe trends that could
indicate a need for process modification, troubleshooting or preventative maintenance.

• Computerized Setup and Calibration. RS-232 serial Configuration Tool for setup, digital calibration
and diagnostics

• Touch-Proof Mechanical Design prevents unintentional contact with hazardous voltage

• Advanced Process and Fault Monitoring. Real-time monitor of voltage, current, power and fault
conditions. Real-time adjustment of the setpoint. Changes can be made any of four different ways:

Locally, using an analog control signal.


Locally, using the Configuration Tool software.
Locally, with optional Local Digital Control feature.
Remotely, with optional Network Communications feature.

• Operates on universal line voltages, from 24 to 600 VAC and 50/60 Hz.

• DSP-based control

• 1600 Volt SCR's

• 20KHZ pulse transformer coupled SCR gating circuit

• 50KHZ digital firing control

• True RMS calculation of voltage, current, and power at 10KHZ sampling

• Simultaneous regulation of voltage, current, 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
Product Description February 2004

Optional Features

The following optional features are available for the 853 DSPC:

• Network Interface, allowing for remote control and monitoring of the 853. The networks supported
are DeviceNet™, MODBUS (MODBUS RTU protocol), Profibus, and Ethernet (MODBUS TCP
protocol).

• Local Digital Control. User has a 4-digit LED display, 12 independent status LEDs and 4
pushbuttons, which allow local control of the 853. The user can control unit output and change the
desired set point, as well as monitor voltage, current, or power on the LED display. Fault and alarm
conditions are displayed.

Technical Specifications

Table 1-1 Technical Specifications

Input Line Voltage 24 to 600 VAC RMS

Input Line Frequency 50/60 ± 2 HZ

Current Rating 40 to 350 A; consult factory for higher


ratings

Current Surge Rating 40A - 1,800A for 10 msec

90/175A - 8,000A for 10 msec

350A - 14,500A for 10 msec

Fuse I2t Rating 40A - 16,200 A2sec

90/175A - 320,000 A2sec

350A - 1,051,000 A2sec

Control Voltage 85 to 265 VAC

Control Power 50 VA

Analog Inputs (2) 0 to 5 VDC or 0 to 20mA (250Ω)

Analog Outputs (2) 0 to 5 VDC or 0 to 20mA (10V max)

Digital Inputs 0 to 5 VDC

Regulation 1%

Isolation to ground 2500 VAC

Ambient Temperature Range 0 to 50ºC

1-8
February 2004 Product Description

Part Number

The Part Number format for the 853 DSPC series product is 853-AAAA-00-00 and is described in detail
below.

853 AAAA 00 00
Product Options:
Current Rating:
Dx - DeviceNet™
40A SL – Special Lugs
Px - Profibus
Product Series 90A Reserved
Ex - Ethernet
175A for future use.
x1 - Local Control
350A
x2 - Remote Control

1-9
Chapter 2

Hardware
Installation

DANGER
The user is responsible for conforming to all applicable local, national, and international
codes; wiring practices, grounding, disconnects, and overcurrent protection are of
particular importance. Failure to observe this precaution could result in severe bodily injury
or loss of life.

Prior to installation, 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.

WARNING
The 853 DSPC is intended to be mounted in a protective enclosure to prevent the hazard
of electrical shock. Unless supplied with an enclosure, it is considered to be a component
that must be mounted in an enclosure by the user.

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. A NEMA 1 enclosure for providing
protection from electric shock is available as an option. If the 853 DSPC must be located in an area of
dust, falling debris, splashing or falling water, adequate protection must be supplied. These conditions
necessitate the use of a special NEMA enclosure. Custom NEMA enclosures for the afore-mentioned
conditions are also available.

WARNING
An incorrectly applied or installed system can result in component damage or reduction in
product life. Wiring or application errors, incorrect or inadequate AC supply, or excessive
ambient temperature may result in malfunction of the system.

Enclosure Temperature

The 853 DSPC is rated at 50°C maximum ambient temperature. If the 853 DSPC is mounted in an
enclosure other than one designed and built by Spang Power Electronics, care must be taken to allow
sufficient cooling air to the SCR heatsink. Consult the factory for enclosure temperatures above 50°C but
less than 65°C.

2-1
Hardware February 2004

Vibration

If the mounting site has a vibration concern, the 853 DSPC should be mounted using industry standard
shock mounting techniques.

Mounting

Allow four inches on each side and a minimum of four inches above and below the 853 DSPC for
adequate cooling. It is recommended that the enclosure exhaust vents be located above the top of the
heatsink. Allow additional room for wiring as required by the individual application.

Figure 2-1 Mounting Dimensions

Disconnect Means

It is required that a circuit breaker, fused disconnect or fuses be installed upstream of the 853 DSPC for
wire protection. Fuses are not necessary if the distribution system current surge rating is limited to below
the specification for the unit. Optional semiconductor fuses (externally mounted) are available to prevent
surge or transient currents from damaging the semiconductors. The semiconductor fuses are oversized
(90A for the 40A unit, 250A for the 90/175A unit and 500A for the 350A unit) to prevent nuisance fuse
blowing and, for this reason, cannot be used for steady state overload protection.

Wiring

Wire should be sized in accordance with the appropriate specific code guidelines. Ambient operating
temperature should be taken into account. All large cables should be routed to allow access to the 853
DSPC. It is up to the discretion of the installer to allow access room to service the unit.

2-2
February 2004 Hardware

The Phillips head cover


screws are located at the four
corners of the unit, and are
removed to open the covers
on their inside hinges,
providing access to the power
wiring terminals.

Figure 2-2 Cover screw locations

The input power lugs are located under the top cover. The output power lugs, the remote feedback
terminal block, and the chassis ground lug are located under the bottom cover as shown in the following
figure.

Figure 2-3 Input and Output Power Lug locations (175A unit)

2-3
Hardware February 2004

Table 2-1 Wiring Information

Unit Power Lugs Ground Lug Feedback Terminal


size
Wire Range Screw Head Wire Range Screw Head Wire Range Screw
Head

40A 14-2 [8*] AWG Slotted 14-2 [8*] AWG Slotted 8-24 [14*] AWG Slotted

90A 14-1/0 [4*] AWG Slotted 14-2 [8*] AWG Slotted 8-24 [14*] AWG Slotted

175A 6-250MCM[2/0*] AWG 5/16 inch hex 14-2 [4*] AWG Slotted 8-24 [14*] AWG Slotted

350A 4-500MCM 1/2 inch hex 6-3/0 [2*] AWG ¼ inch hex 8-24 [14*] AWG Slotted
[350MCM*] AWG

Note: Size in brackets [*] is recommended for 90ºC wire insulation.

Remote Feedback Wiring

If remote feedback is used,


the connections are made
to the Remote Feedback
Terminal. Current feedback
is connected to TB1
terminals 1 (+) and 2
(common), and voltage
feedback is connected to
TB2 terminals 1 (X1), 2 (X2)
and 3 (X3).

The current feedback signal


should be about 2.5 Vrms at
the rated output current,
and the voltage feedback
signal should be in the
same range as the input
voltage. Allowable ranges
are 300-600V, 150-300V,
75-150V, 37.5-75V and 24-
37.5V.

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.

2-4
February 2004 Hardware

Control Connections

Control connections are made using the pluggable


terminal blocks that are located on the right side of
the 853 DSPC. These terminals accept fine
stranded wire up to 12 AWG.

The 853 DSPC requires 85-265VAC 50/60Hz @


50VA control power for the circuit boards and
cooling fans. This must be wired to the two-
position plug labeled Control Power.

Figure 2-5 Control Connectors


The following figure shows a typical wiring diagram for control connections.

Figure 2-6 Typical Control Connections

2-5
Hardware February 2004

WARNING
This equipment is at line voltage when AC power is connected. Disconnect and lock out
all ungrounded conductors of the AC power line. Failure to observe these precautions
could result in severe bodily injury or loss of life.

Digital Inputs

The digital inputs (Remote/Local, Enable, and External Fault) provide power for each input designed for
low voltage contacts or switches. The voltage/current rating of the contact or switch should be 15V and
10mA. If interfacing to automated equipment, it is possible to connect a 10V signal directly into the input
without using the power connection.

The digital interface consists of the thirteen-position plug labeled Digital Interface. The following table
describes each terminal and its default operation. Terminals 1, 3, 5, 7 and 9 provide 15 volts through a
470 Ω resistor in order to develop a 10 volt, 10 mA signal into the appropriate digital input. A typical
schematic of the digital inputs follows the table.

Table 2-2 Digital Interface Plug

Terminal Terminal description Standard operation (see Note below)


Number

1 External Fault #1 power


Shorting 1 to 2 provides an external fault input. Open
indicates no remote fault.
2 External Fault #1 input

3 External Fault #2 power


Shorting 3 to 4 provides an external fault input. Open
indicates no remote fault.
4 External Fault #2 input

5 External Fault #3 power


Shorting 5 to 6 provides an external fault input. Open
indicates no remote fault.
6 External Fault #3 input

7 Remote/local power
Shorting 7 to 8 puts the unit into remote mode. Open
defaults to local mode.
8 Remote/local input

9 Enable power
Shorting 9 to 10 enables the unit. Open inhibits
operation.
10 Enable input

11 Fault common Fault relay common connection.

12 Fault NC Contact opens when a fault occurs.

13 Fault NO Contact closes when a fault occurs.


Note: The external faults are programmed by default as normally open (NO). Refer to the
Settings Chapter (Configuration Word) for more information on contacts.

2-6
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. The default state is for a normally open switch to indicate a “normal” condition. It may be
programmed by the user for a normally closed switch to indicate a “normal” condition.

Remote/Local Input
The Remote/Local Input is used to select the control mode. Remote control is selected to allow control
from the network (when present). The default state (open) is for local control.

Enable Input
The Enable Input is used to provide a local enable/inhibit function. The default state (open) inhibits the
unit (prevents the SCR from firing).

Digital Outputs

The digital outputs (Fault – Common, NC, and NO) are relay contacts from a miniature relay on the digital
control printed circuit board. It is very important to not exceed the contact ratings listed in the table below.

Table 2-3 Relay Contact Ratings

Load Type Voltage Current

Resistive 125VAC 0.30A

Resistive 30VDC 1.0A

Inductive 125VAC 0.20A

Inductive 30VDC 0.50A

2-7
Hardware February 2004

A pilot relay can be used to interface to larger relays or contactors if required.

Analog Inputs

The analog input (Analog Setpoint) is designed to accept potentiometer, voltage, or current inputs. The
potentiometer input is designed for a 10K potentiometer that is connected between the Analog Supply,
Analog Setpoint, and Analog Ground. The voltage input requires a 0 to 5VDC input to achieve 0 to 100%
setpoint. The current input requires a 0 to 20mA input to achieve 0 to 100% setpoint. In order to use the
current input, jumper JP2 must be shorted for the Primary Analog Input and jumper JP4 must be
shorted for the Secondary Analog Input. This connects a 249 ohm resistor into the circuit for the current
input to use. 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. Also, 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.

The analog interface consists of the ten-position plug labeled Analog Interface. The following table
describes each terminal and its default operation.

Table 2-4 Analog Interface Plug

Terminal
Terminal description Standard operation
Number

1 Analog #1 supply
Connecting a 10k potentiometer with JP2 OFF
2 Analog #1input
provides a local analog control.
3 Analog #1 ground

4 Analog #2 supply
Connecting a 10k potentiometer with JP4 OFF
5 Analog #2input
provides a local analog control.
6 Analog #2 ground

7 Analog #1 output
Provides a configurable analog output of 0-5
volts (JP3 on) or a mA output (JP3 off).
8 Analog #1ground

9 Analog #2 output
Provides a configurable analog output of 0-5
volts (JP5 on) or a mA output (JP5 off).
10 Analog #2ground

2-8
February 2004 Hardware

The Analog Input Circuit. If a mA


input signal is desired, Jumper JP2
(input #1) or JP4 (input #2) is inserted
to connect the 249 ohm burden
resistor. If a 0-5 volt signal is desired,
connect the signal source between
terminal 2 (+) and 3 (-) for input #1 or
5 (+) and 6 (-) for input #2.

Figure 2-7 Analog Input Schematic


Analog Outputs

The analog output (Analog Output) is designed to be a current or voltage output. The Primary or
Secondary Analog Output Selection defines what internal signal is connected to the Primary or
Secondary Analog Output. The analog output will generate 0 to 20mA for 0 to 100% of the selected
internal signal. To convert the analog output to voltage, jumper JP3 must be shorted for the Primary
Analog Output and jumper JP5 must be shorted for the Secondary Analog Output, which connects a
249 ohm resistor, that converts 0-20mA to 0-5VDC. Alternatively, a 500 ohm resistor can be connected
externally that converts 0-20mA to 0-10VDC. Just as on the analog input, 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.

The Analog Output Circuit. If a 5 volt


output signal is desired, Jumper JP3
(output #1) or JP5 (output #2) is
inserted to connect the 249 ohm
burden resistor. If a 10 volt signal is
desired, an external 500 ohm resistor
should be connected across the
appropriate output terminals.

Figure 2-8 Analog Output Schematic

2-9
Hardware February 2004

Remote Feedback

It is standard for the output voltage and current to be sensed internally. The 853 DSPC also provides for
a separate voltage and current feedback from a remote source, such as the secondary of a transformer
on the output of the 853 DSPC. An internal terminal board is provided for remote voltage and current
feedbacks. 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. The Voltage
Output PT Secondary setting is used to define the specific PT output connected as a remote voltage
feedback. The current transformer (CT) burden resistor must be selected such that 100% current output,
defined by Current Output Rating will equal 2.5V. For example, if a CT with a rating of 1000 to 1 is used
on a 350A 853 DSPC unit, the burden resistor would be 2.5V/.35A or 7.14 ohms.

Over-temperature Sensing

A temperature sensor is mounted on the heatsink of the 853 DSPC to detect and indicate an over
temperature condition. The standard temperature sensor is supplied with contacts that are normally
closed (NC).

2-10
Chapter 3

Configuration
Startup

WARNING
An incorrectly applied or installed system can result in component damage or reduction in
product life. Wiring or application errors, incorrect or inadequate AC supply, or excessive
ambient temperature may result in malfunction of the system.

Once the 853 is mounted, and the wiring is in place, apply control power to the unit. It is not necessary
for main power to be applied at this time.

DANGER
This equipment is at line voltage when AC power is connected. Disconnect and lock out all
ungrounded conductors of the AC power line. Failure to observe these precautions could
result in severe bodily injury or loss of life.

When control power is applied,


check the LED’s on the control
board to verify that the power
supplies are on and the DSP is
operating. At this time the red
FAULT LED will be on, the three
green power supply status LED’s
will be on, and the HEARTBEAT
LED will be blinking at about a 1
second rate.

Figure 3-1 Control PCB LED Location

With control power applied and status lights operating properly, the unit is ready for configuration.
Configuration consists of telling the unit what it is rated (power rating, input and output voltage and
current, etc.) and what type of control is to be used. Configuration is accomplished using the
Configuration Tool software running on a host computer, connected to the unit via the Serial Interface
Port. In most cases, the unit will be pre-configured at the factory, and only minor changes (such as limit
settings and/or control mode) will be made at the user site.

3-1
Configuration February 2004

The Serial Interface consists of a standard DB9 connector (9 pin male), which plugs into the host
computer’s serial port using a Null Modem cable. The wiring for typical Null Modem cables is illustrated
in the Serial Communication Chapter.

Configuration Tool Installation

The 853 Configuration Tool is a serial configuration/monitoring tool that runs on a Windows-based PC.
The minimum system requirements are:

Windows 95,
32MB ram,
10MB hard disk space,
an available serial port

The 853 Configuration Tool allows off-line editing and storage of configuration files. The Configuration
Tool also allows on-line, real-time changes to the 853 settings through the serial port. The capabilities of
the Configuration Tool include: on-line configuration, setpoint changes, operation, monitoring, calibration,
and file storage and retrieval.

The Configuration Tool is delivered on CD-Rom and includes ‘auto-run’ capability. However, should the
CD NOT run automatically once inserted into the cd-rom drive, browse for the cd-rom drive, and double-
click on the file ‘setup.exe’.

The Configuration Tool default install location is:

C:\Program Files\Spang Power Electronics\ 853 Configuration Tool vxxx

Once successfully installed, the Configuration Tool will be accessible via the Start Menu.

Note: The install process updates the computer’s system registry with the required
configuration information.

Running the Configuration Tool

Run the Configuration Tool from the start menu:

Start button -> Programs -> Spang Power Electronics -> Configuration Tool vxxx

3-2
February 2004 Configuration

Click on the [Start] button to continue the Configuration Tool startup (the program will automatically
continue after 10 seconds).

At this point the Configuration Tool is off-line, that is, the Tool is not communicating with the 853. The
setting values have been read from a setup (.csv) file stored on the computer running the configuration
tool. There are five settings 'tabs' which can be viewed off-line.

While off-line, settings can be modified two ways: either by opening an existing setup file, whose data is
read into the Configuration Tool, or by modifying the settings individually in the six “Settings” tabs of the
Configuration Tool.

3-3
Configuration February 2004

3-4
February 2004 Configuration

Configuration Tool Menu and Task Bar Descriptions

The 853 Configuration Tool menu bar is shown below, followed by a description of each option.

File Menu

File Menu including the ‘Save Calibration’ menu File Menu including the ‘Restore Calibration’ menu
choice. choice.

The ‘Save Calibration’ menu choice is visible only The ‘Restore Calibration’ menu choice is visible
under certain conditions, and should be used only only under certain conditions, and should be used
by authorized service personnel. only by authorized service personnel.

File Option Description

Open Open a standard dialog box listing the configuration files available for loading and
editing. (Configuration files are of the form <filename>.csv) and are read from
and saved to the host system.

Save Save and close changes made to the configuration file.

Print Open the Print Preview window; display 853 settings in tabular form.

Print Setup Open the standard dialog box that provides the selection of a printer and print
characteristics.

Save Calibration Save current calibration values as factory defaults in 853 eeprom.

Restore Restore calibration values from factory defaults stored in 853 eeprom.
Calibration

Exit Close the Configuration Tool

3-5
Configuration February 2004

Com Setup Menu

Com Options Description

Com1

Com2
The Com Setup menu is used to select the serial port on the host computer
available for use with the 853.
Com3

Com4

Window Menu

Window Options Description

Settings Open the Settings Pane. (This is the default upon program entry).

Monitor Establish on-line communication and open the Monitor pane to view 853 DSPC
operation.

Calibration Establish on-line communication and open the Calibrate pane.

Fault History Open the Fault History window (useful only if on-line).

Flash Open the Flash Programming window. Intended for use by authorized service
Programming personnel only.

3-6
February 2004 Configuration

Help Menu

Help Options Description

Manual Open (in a separate browser window) this product manual in pdf format.

About Display the version number of the Configuration Tool software.

3-7
Configuration February 2004

Taskbar
The Configuration Tool Taskbar provides shortcuts to frequently used options.

Taskbar Description
Items

Open Folder Same as the File->Open menu option

Floppy Same as the File->Save menu option.

Printer Same as the File->Print menu option.

Monitor Same as the Window->Monitor menu option.

Calibrate Same as the Window->Calibrate menu option.

Settings This button appears on the taskbar if either the Monitor or Calibration window is
visible. Same as the Window->Settings menu option.

Fault Same as the Window->Fault History menu option.

Offline/Online Toggle between Off-line programming and On-line communication with the 853.
The caption and color of the button indicate the current status of communication
between the configuration tool and the 853 DSPC.

A Red button with an Offline caption indicates No Communication between the


Configuration Tool and the 853 DSPC.

A Yellow button with an Online caption indicates one of two possibilities: the
853 DSPC is under Remote (network) Read Only control; or the 853 DSPC is
under Analog (vs Digital) control).

A Green button with an Online caption indicates Read/Write local


communication between the Configuration Tool and 853 DSPC.

3-8
February 2004 Configuration

Print Preview
The File->Print menu selection, or the printer icon on the Taskbar, opens the Print Preview window.
The Print Preview window displays a tabular summary of the settings stored in the Configuration Tool.

Figure 3-2 Print Preview Window

Click [Print] to send a copy of the table to the printer port of the host computer.

Click [Close] to exit the Print Preview window.

3-9
Configuration February 2004

Off-line Programming

Off-line programming allows the user to edit 853 settings without actually writing them to the controller.
All work is done on the host computer and can be saved.

The Configuration Tool starts in Off-Line Programming mode. The tool opens with the last settings file
saved. If there is no saved settings file, the default settings are loaded from the default.csv file ( included
with the configuration tool).

Load/Save the Configuration File


To load a configuration file from the host computer to the Configuration Tool,

● Select the File->Open menu option, (or click the file folder icon on the Taskbar)

● Browse the files in the ‘file open’ dialog, and select the desired configuration (*.csv) file.

The settings as defined in the configuration file are loaded into the Configuration Tool, and can be viewed
and/or modified.

To save settings to a .csv file on the host computer,

● Select the File->Save menu option, (or click the floppy icon on the Taskbar)

● Specify <filename>.csv .

The settings currently in the Configuration Tool are written to the specified file on the host computer.

3-10
February 2004 Configuration

Configuration Tool Settings Windows


The initial 853 Configuration Tool window is shown below.

Figure 3-3 Configuration Tool

The left pane is used for general status and control information related to the 853 DSPC. In Off-line
mode, only control information is visible in the left-hand pane:

‘Regulation Mode’ is a drop-down box containing the regulation choices.

‘Local Control’ is a button that toggles between Local Analog and Digital control.

On start up, the right-hand side of the window displays the Settings tab, as read from the latest (or
default) configuration file. Settings information is organized into several tabs: Ratings and Limits, Control
Configuration, Fault Setup, PID Setup, and Network. Offline programming allows edits to any writable
setting, as defined in the Settings Chapter. Read-only settings are indicated by a (cyan) shadowed
background and cannot be changed.

3-11
Configuration February 2004

Ratings and Limits Tab

The Ratings and Limits Tab holds the settings for

Voltage Input Rating Current Input Rating

*Voltage Output Rating Current Output Rating

Voltage Output Limit Current Input Limit

*Voltage Output PT Secondary Current Output Limit

Power Output Rating - Read Only Frequency Rating

Power Output Limit Ramp Up Time

KVA Input Rating – Read Only 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.

Figure 3-4 Ratings & Limits Tab

3-12
February 2004 Configuration

White fields indicate Read/Write

Cyan fields indicate Read Only information

3-13
Configuration February 2004

Control Configuration Tab

The Control Configuration Tab holds settings for

Control Strategy Primary Analog Output Selection

Load Type Secondary Analog Output Selection

* Magnetizing Sequence Secondary Analog Setpoint Selection

* Repetitive Pulse 1 and 2 Local Digital Display Selection

* Only used for Zero Crossover with transformer coupled load applications.

The [Auto Set] function allows the 853 to automatically tune the repetitive pulses for the minimum
measured current pulses. To enable the [Auto Set] function, insert jumper JP1 with control power
applied to the unit.

Figure 3-5 Control Configuration Tab

White fields indicate Read/Write

Cyan fields indicate Read Only information

3-14
February 2004 Configuration

Fault Setup Tab

The Fault Setup Tab holds the settings for:

Voltage Input High Ground Fault Current

Voltage Input Low Ground Fault Time

Voltage Input Phase Unbalance Current Input Overload

Current Input High Current Input Overload Time

Current Input High Retries Current Input Threshold Load Failure

Current Input High Retry Time

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 Voltage Output Current Output

Proportional Gain Proportional Gain Proportional Gain

Integral Gain Integral Gain Integral Gain

Derivative Gain Derivative 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 MODBUS Address

Network Baud Rate MODBUS Baud Rate

Network Address 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
Configuration February 2004

On-line Programming

On-line programming involves actual serial communication between the configuration tool and the 853
DSPC. Settings are read from and written to the 853 DSPC using a serial protocol described in the
Serial Communication chapter. The On-line communication capability of the configuration tool allows
real-time monitoring and calibration of the 853 DSPC.

To establish on-line communication between the Configuration Tool and the 853 unit,

● Connect a standard, 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 following message will appear:

If settings have been modified offline, either


individually or by loading a .csv file, the user
has the option of transferring, or writing, the
settings stored in the 853 Configuration Tool to
the 853. If no modifications have been made,
the prompt will not appear.

Click Yes to write settings from the tool to the 853; click No if settings are NOT to be written to the 853.

Depending on the response, 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. In either case, online
communication is established. The On-line indicator turns green in the Tool Bar.
Note: If the serial link cannot be established, the following message appears:

Check both ends of the serial connection, make sure that power is applied to the 853
(check LEDs) and click [Online] again. If there is still no communication, with the serial cable
connected, cycle power to the unit, and click [Online].

3-18
February 2004 Configuration

When the Configuration Tool is communicating on-line with the 853 DSPC, status, control and setting
information is continuously read from the 853 DSPC and refreshed in the Configuration Tool. Additional
status and control information is visible in the left-hand pane.

Note that when only the control power is applied, a low voltage warning (A-34) is displayed. This is
normal, and will remain as long as the main power is off. 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. It is also
necessary for the Remote/Local switch to be in the Local position for the Configuration Tool to allow on-
line changes to the settings.

Figure 3-9 Configuration Tool On-Line

3-19
Configuration February 2004

Status indicators are described in the table below:

Table 3-1 Status Lamp Description

Lamp Color Description

Enable input Green The 853 DSPC is Enabled

Red The 853 DSPC in Inhibited

Output Status Green Output is ON

Red Output is OFF

Remote/Local input Green Local control is active

Red Remote (network) control is active

On/Off button Toggles the 853 output

Alert indicator Flashing Indicates an Alarm Condition (described in


Yellow the message box below the lamps)

Flashing Indicates a Fault Condition is present


Red (described in the lower message box)

Note: During normal operation, message


reads: No detected faults or alarms

Fault Reset button Click to send a ‘Fault Reset’ to the 853. The
853 will attempt to recover from the alert
condition. If recovery is accomplished, normal
operation will resume.

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, enter the desired setting value or click a choice from the drop down list
• Press [Tab], [Enter] or click outside setting
• Press [Escape] to cancel.

When a change is made to a setting, the following prompt appears:

3-20
February 2004 Configuration

A Yes response to the message prompts the Configuration Tool to write the setting to the 853 DSPC. If
unsuccessful, an error message may appear, and the setting reverts to its previous value.

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 Configuration Tool is considered to be a source of Local Digital control to the 853 DSPC. If the 853
DSPC is operating under Local Analog control, setpoints cannot be written from the Configuration Tool
to the 853 DSPC. The following prompt will appear:

In order to write a setpoint from the


Configuration Tool to the DSPC, the unit must
be under Local Digital control.

3-21
Configuration February 2004

The 853 DSPC settings related to actual 853 DSPC status, such as voltage out, power out, current out,
etc, are Read Only, and cannot be written under any circumstances.

Rating information, PT Secondary, frequency, Control strategy, Load Type, zero calibration, and magnetic
sequencing can be written only when the 853 DSPC output is off.

Voltage Output Span and Current Output Span can be written only when the 853 DSPC output is on.

When a setting cannot be written the following message appears:

Refer to the Settings Chapter for programming factors specific to each setting.

3-22
February 2004 Configuration

On-line Monitor

The Monitor mode provides a real-time view of 853 operation. Each setting in Monitor mode is updated
approximately every 2 seconds.

To access the on-line Monitor mode, select the Window Monitor menu item, or click [Monitor] on the
Taskbar.

Monitor information is organized into several tabs: Summary, Control, Status and Timing. Read-only
settings are indicated by a (cyan) shadowed background and cannot be changed.

3-23
Configuration February 2004

Summary Tab

The Monitor Summary Tab includes the following data

Duty Cycle Setpoint Current Input

Duty Cycle Output Current Output Setpoint

Power Output Setpoint Current Output

Power Output Analog Input

Voltage Input KVA Input

Voltage Output Setpoint Power Factor

Voltage Output Frequency Actual

The Duty Cycle Setpoint can be written ONLY under Open Loop regulation.

Figure 3-10 Monitor Summary Tab

3-24
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. The setpoint
associated with the selected regulation mode is displayed with a green background.

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.

• Setpoints can be modified only under Local DIGITAL control.


• Modified setpoints are italicized until written to the 853.
• Press the [Escape] key to cancel.
• The Duty Cycle Setpoint cannot be written unless Open Loop regulation mode is
selected.
• The setpoint associated with the selected regulation mode is the control setpoint. The
other setpoints become operating limits of their respective control loops.

3-25
Configuration February 2004

Control Tab

The Monitor Control Tab includes the following data for monitor only

Voltage L1-L2 Input Actual Voltage X1-X2 Output Actual

Voltage L2-L3 Input Actual Voltage X2-X3 Output Actual

Voltage L3-L1 Input Actual Voltage X3-X1 Output Actual

Voltage Input Actual Voltage Output Actual

Current L1 Input Actual Current X1 Output Actual

Current L2 Input Actual Current X2 Output Actual

Current L3 Input Actual Current X3 Output Actual

Current Input Actual Current Output Actual

Local Primary Analog Setpoint 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 Status Word Bit Number

At Setpoint Bit 9

Phase Rotation Bit 10

External Input #1 Bit 11

External Input #2 Bit 12

External Input #3 Bit 13

Regulation Limit Bits 6, 7, and 8

Calibration/Programming Jumper Bit 15

Figure 3-12 Monitor Status Tab

Green field indicates on status

3-27
Configuration February 2004

Fault History
The fault history lists the last eight faults recorded by the 853 DSPC. The information is read from the
853 DSPC and displayed in tabular form.

To access the on-line Fault History mode, select the Fault History menu item, or click [Fault] on the
Taskbar.

Figure 3-13 Fault History

Included in the Fault History table is the fault code, a description, and time (in hours) of the fault.

Click the [Print] button to send a copy of the information to the printer port of the host computer.

Click the [Close] button to close the Fault History window and return to the previous window.

With JP1 installed, click the [Zero] button to clear the fault buffers.

3-28
February 2004 Configuration

Flash Programming

WARNING
During flash programming, an interruption in the serial communication, either by loss of
power or a disconnected serial cable, will corrupt the 853 DSPC flash memory. This will
require the 853 DSPC to be sent back to the factory for programming.

The Flash Programming function is available to authorized service personnel only and is used to update
the 853 DSPC software.

Figure 3-14 Flash Programming

3-29
Configuration February 2004

Loss of Communication

Momentary loss of communication between the Configuration Tool and 853 DSPC results in the most-
recently-read setting to be displayed on a Red background. Subsequent communication recovery
restores the normal background color.

If serial communication is not recovered within a reasonable time, the configuration tool will go Offline.

3-30
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 L1-L2 Input Span

Voltage X2-X3 Output Zero and Span Voltage L2-L3 Input Span

Voltage X3-X1 Output Zero and Span Voltage L3-L1 Input Span

The [Zero] button, when clicked, uses the actual The [Set] button, when clicked, uses the actual
control reading and the zero adjustment, as control reading, the measured signal (meter
currently set, to calculate a new zero adjustment. reading), and the span adjustment, as currently set,
The result is an incremental change. The output to calculate a new span adjustment. The result is
must be off to zero the output voltages. 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 X1 Output Zero and Span

Current L2 Input Zero and Span

Current L3 Input Zero and Span

The [Zero] button, when clicked, uses the actual The [Set] button, when clicked, uses the actual
control reading and the zero adjustment, as control reading, the measured signal (meter
currently set, to calculate a new zero adjustment. reading), and the span adjustment, as currently set,
The result is an incremental change. 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 4-3 Current Calibration

White fields indicate Read/Write

Cyan fields indicate Read Only information

4-3
Calibration February 2004

Analog Calibration

The Calibration Analog Tab holds the calibration settings for

Primary Analog Setpoint Zero and Span Secondary Analog Setpoint Zero and Span

The [Zero] button, when clicked, uses the actual The [Set] button, when clicked, uses the actual
control reading and the zero adjustment, as control reading, the measured signal (meter
currently set, to calculate a new zero adjustment. reading), and the span adjustment, as currently set,
The result is an incremental change. to calculate a new span adjustment. The result is
an incremental change.

Check the Enable box for Analog Output Calibration. Use the slide bars to adjust Analog Output Bias
and Span. Uncheck the Enable box after Analog Output Calibration.

Analog Output #1 Bias and Span Analog Output #2 Bias 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 4-4 Analog Calibration

White fields indicate Read/Write

Cyan fields indicate Read Only information

4-4
February 2004 Calibration

Current Rating

The current feedback signal (at rated current) of the 853 must be between 1.25Vrms and 2.85Vrms. The
typical unit is setup for a current feedback signal level of 2.50Vrms using the burden resistor of the
current transformer. Standard units have the following burden resistors and feedback signals.

Unit Size CT Burden Resistor Feedback Signal

40A 800:1 62Ω 2.46Vrms

90A 1800:1 56.2Ω 2.53Vrms

175A 3500:1 41.2Ω 2.40Vrms

350A 7000:1 49.9Ω 2.50Vrms

Since the feedback signal on the standard unit is set to 2.5Vrms for the rating of the unit, changing the
rating to 50% would reduce the feedback signal to 1.25Vrms. This is the lowest that the rating can be
changed without also changing the current transformer burden resistor.

If, for example, it is desired to change the 40A unit to a 10A unit, the burden resistor should be changed
so that the current feedback signal will produce 2.5Vrms when the primary current is 10A. Since the
secondary current at 10A is 10/1000 = 10mA, the resistor should be:

2.5 / 10mA = 250Ω

The nearest standard value 1% resistor is 249Ω. The power in the resistor at rated current is (10mA)2 x
249 = 24.9mW, so a resistor with a power rating of 50mW or greater is required. A 1/4W or a 1/2W
resistor should be used so that it will properly fit in the connector (J10, terminals 1 and 4). The actual
voltage produced at rated current will be:

10/1000 x 249 = 2.49Vrms

Voltage Rating

The voltage feedback signal of a unit must be between 24Vrms and 600Vrms. 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

37.5 to 75

24 to 37.5

4-5
Calibration February 2004

Remote Voltage and Current Feedback

The standard unit uses the same current feedback signal for both the input and output current. If an
output current transformer is used with the 853, the jumpers connecting the input and output current
feedback signals together must be removed, and the output current signal connected to the remote
terminal provided on the 853. The internal voltage feedback signals must be removed and the remote
voltage feedback connected to the remote terminals. The remote feedback terminals are shown below.

Figure 4-5 Remote Feedback Terminals

If remote feedback is used, current feedback is connected to TB1 terminals 1 (+) and 2 (common), and
voltage feedback is connected to TB2 terminals 1 (X1), 2 (X2) and 3 (X3).
The Current Output feedback signal should be 2.5 Vrms at the rated output current. The Voltage Output
feedback signal should be in the same range as the Voltage Input feedback signal. Allowable ranges are
300-600V, 150-300V, 75-150V, 37.5-75V and 24-37.5V.

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.

4-6
February 2004 Calibration

Calibration Procedure

WARNING
An incorrectly applied or installed system can result in component damage or reduction in
product life. Wiring or application errors, or improper calibration may result in malfunction
of the system.

To calibrate the 853, the unit must be connected to its rated input source, have control power on, and
have a load attached to the unit. Connect your computer to the 853 serial port using a null modem cable
and open the 853 Configuration Tool program. Establish “ON line” communication with the unit and note
the existing 853 settings.

Click on the [Calibrate] button to open the 853 Calibration window. Click the [Cal Enable] button to
allow calibration. [Zero] is active when the unit output is off, [Set] is active when the unit output is on.
Click [Zero] to correct for any bias/noise; click [Set] to change the reading of non-zero voltage or current
values.

There are separate tabs for voltage, current, and analog calibration. To calibrate the voltage and/or
current, 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). Measure the
voltage and current and enter the values obtained in the column labeled “Meter Reading”, then click the
[Set] button next to the value entered.

4-7
Calibration February 2004

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

4-8
February 2004 Calibration

Saving Calibration

If desired, the new calibration may be saved in the 853 as the “Factory Default” calibration. The unit must
be on line, with the calibration window open. With control power turned on, install jumper JP1. JP1 is a
two-position jumper located immediately to the right of the dsp on the control board.

From the File menu, select “Save Calibration”.

4-9
Calibration February 2004

A dialog box will open asking if you want to replace the calibration defaults. Click [YES] to replace the
default calibration settings with the new calibration settings.

Remove the jumper (JP1), when the procedure is complete.

Restoring Factory Calibration

To recalibrate the unit using the stored calibration values, the unit must be on line, with the settings
window open. With control power turned on, install jumper JP1.

4-10
February 2004 Calibration

From the File menu, select “Restore Calibration”.

A dialog box will open asking if you want to restore calibration using the stored defaults. Click [YES] to
write the default calibration settings to the unit.

Remove the jumper (JP1), when the procedure is complete.

4-11
Calibration February 2004

Analog Calibration

Analog signal settings are adjusted on-line in an iterative process to assure accurate signal readings and
optimal 853 performance.

If the analog input is used, it should be calibrated for the individual installation. To do this, both the
control power and the main input voltage must be present. In the Configuration Tool program, open the
Calibration window, and select the Analog Tab.

If the analog input is derived from a 10K potentiometer, simply turn the pot full counterclockwise and
“zero” the input by clicking the Primary or Secondary Analog In [Zero] button with the mouse pointer.
Then turn the pot full clockwise, enter the number 100 in the Gain Setting box, and click the Primary or
Secondary Analog In [Set] button. Alternately, click the Primary or Secondary Analog In [Zero] button
with the pot turned down, and the Primary or Secondary Analog In [Set] button with the pot turned up until
the readings are consistent.

If the analog input is a 4 – 20 mA signal, install jumper JP2 for 4 - 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, then set
the input to the minimum setting (4 mA) and click the Primary or Secondary Analog In [Zero] button.
Then set the input to the maximum setting (20 mA), enter 100 in the Gain Setting box, and click the
Primary or Secondary Analog In [Set] button. Again, repeat the minimum “Zero” and maximum “Set”
selections until the readings are consistent.

This calibration method causes the input to control to 100% of the rating with full input. If a control point
other than the rating is required at full input, then enter the percent of the control setpoint divided by the
rating. For example, if the analog input is a current setpoint, controlling 0-40A on a 50A unit, enter 80
(this equals 40/50*100) when maximum input signal is present.

4-12
February 2004 Calibration

To calibrate the analog output, set the analog output source to the Primary Analog Setpoint. It allows a
full range of signal settings without having to actually power up the unit. Once calibrated, the analog
output source may be changed to whichever variable is desired.

If the maximum analog output is less than the rating, set the analog reference (input) as the percentage of
the analog output variable divided by the rating. For example, if the analog output is output current,
controlling 0-35A on a 40A unit, set the analog reference to 75 (this equals 30/40*100) to represent
maximum current output.

4-13
Calibration February 2004

Check the Analog Output Enable box.

If the analog output is to be calibrated for a 0-5V output (as it may be for a typical digital meter), insert
jumper JP3 for the Primary Analog Output and jumper JP5 for the Secondary Analog Output, then turn on
the unit (both control power and main power). Since there is no “bias” setting, leave the “bias” adjustment
at zero. 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).

If the Analog Output is to be calibrated for a 4-20 mA signal, leave JP3 off for the Primary Analog Output
and JP5 off for the Secondary Analog Output, then terminate the output into a suitable burden (maybe a
milli-ammeter). With the analog input set at zero, adjust the appropriate “bias” slider until you read 4 mA
on your meter. Then set the analog input for 100%, and adjust the appropriate “gain” slider until you read
20 mA on your meter.

Other outputs (0 – 10V, 0 – 5V, 0 – 1mA, etc.) are done in the same fashion, using a suitable termination
for the signal required. The maximum output of the circuit is about 24 mA at 100% input.

Uncheck the Analog Output Enable box when calibration is complete.

4-14
February 2004 Calibration

Manual Calibration

WARNING
An incorrectly applied or installed system can result in component damage or reduction in
product life. Wiring or application errors, or improper calibration may result in malfunction
of the system.

Direct entry of calibration values is possible from the Manual Calibration window of the 853 Configuration
Tool. To open the Manual Calibration window, insert jumper JP1, select Calibration in the Config Tool,
and click the [Manual] button. 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.

READ from 853 Unit – read the current calibration values from the 853.

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.

CLOSE the manual calibration window.

4-15
Calibration February 2004

Magnetizing Sequence Calibration

Setting number 99 is the Magnetizing Sequence Calibration, which is used for zero-crossing control into a
transformer load.

The purpose of this setting is to soft start a transformer load when first powered up. The setting defines
the amount of phase control cycles which will occur during the first on cycle of zero-crossing control. A
minimum setting of 3 will usually keep the inrush current within acceptable limits. If the inrush current is
too high, increase the Magnetizing Sequence until the inrush current is within acceptable limits.

Repetitive Pulse Calibration

Setting number 100 is the repetitive pulse calibration, which is used for zero-crossing control into a
transformer load. In the 853, the Repetitive Pulse setting contains two values; bits 0 – 7 are the
Repetitive Pulse #1, and bits 8 – 15 are Repetitive Pulse #2.

Repetitive Pulse Calibration


The Repetitive Pulse Calibration is divided into
two separate bytes, allowing the first positive
Read/Write
zero crossing pulse to be set differently (Zero-
Condition: All
% Crossover control only).
Default:
100 Min: 10
Low Byte Low Byte – Bits 0 – 7
Max: 90
50 Repetitive Pulse #1
High Byte
30 High Byte – Bits 8 – 15
Repetitive Pulse #2

The repetitive pulse settings represent a delay in the firing of the SCRs during the first cycle of each
“burst” during zero-crossing control. This is necessary to avoid saturation of the load transformer and the
resulting over current shut down of the unit. The setting is expressed as the percentage of the total wave
passed through to the load.

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. To adjust the pulses
automatically, control power must be applied to the unit. Insert jumper JP1. On the Control Tab of the
Settings window of the Configuration Tool, click [Auto Set]. Note that if the system is sized close to the
operating limit of the transformers, the unit may trip before the program can determine the proper
settings. In such a case, it is necessary to manually “tune” the system.

In order to tune the settings, it is desirable to have some means of observing the line current. Using the
Configuration Tool program, turn the unit on with a duty cycle of between 10 and 50%. Start with both
pulse settings at about 50%. If the unit trips during start-up, adjust the #1 pulse setting for an observed
minimum peak current on the CФ line.

When a minimum peak current is observed, leave the #1 setting and adjust the #2 setting to further
reduce the observed peak current. It should be possible to adjust the two settings so that the unit will
operate without tripping.

Alternate between the two adjustments, until the minimum peak current is observed. As a check, monitor
the AФ and BФ currents as well. If excessive peak currents are observed, minor adjustments in the pulse
settings may be made to minimize the currents.

It should be noted that transformer saturation will occur more readily with higher line voltages and heavier
load currents. If possible, transformers should not be operated at higher than their design voltage ratings.

4-16
February 2004 Calibration

Node Synchronization

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, or the ratio of the “ON” vs. “OFF”
time. For duty cycles between 2% and 100% this simply means that the duty cycle is the ratio of on
cycles to 100. A 50% duty cycle would result in a unit being on for 50 cycles and off for 50 cycles. In
order to insure proper measurements, units are always on for at least 2 cycles.

The Network Address setting (setting 116) is used to determine the starting point of each unit’s power
cycle. An algorithm was developed to allow multiple units to be given sequential network nodes and
achieve power synchronization. Synchronization is achieved by applying power to, or enabling all the
controllers at the same time. The starting point cycle based on network number is listed in the table
below. Note that the synchronization calculation is valid for network addresses 1 – 63 only.

Network Address Starting point cycle


1 0
2 50
3 25
4 75
5 13
6 63
7 38
8 88
9 6
10 56
11 31
12 81
13 19
14 69
15 44
16 94
17 3
18 53
19 28
20 78
21 16
22 66
23 41
24 91
25 9
26 59
27 34
28 84
29 22
30 72
31 47
32 97
33 2
34 52
35 27
36 77
37 14
38 64

4-17
Calibration February 2004

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

4-18
Chapter 5

Local Digital Control Option


The Local Digital Control Option is an add-on display/control interface. It is used in one of two modes and
provides a four-digit numeric display, twelve LED’s and four pushbuttons that allow local control of the
853 DSPC. The Local Digital Control Panel is shown below.

Figure 5-1 Local Digital Control Panel

Display and Status

The four-digit numeric display is used to display a selected setpoint or output. It is also used to indicate
alert conditions and special programming modes. There are four LED's to the right of the numeric
display, and two below it. The LED’s describe the information shown on the numeric display, and are
summarized in the following table.

5-1
Local Digital Control Option February 2004

Table 5-1 Display Selections

If this LED is lit Setting #76


Display Selection Description
… equals …

Volts 1 Voltage Output (V) Voltage Output Actual in volts

Output

Amps 2 Current Output (A) Current Output Actual in amps

Output

Kilowatts 3 Power Output (KW) Power Output in kilowatts

Output

Setpoint 4 Regulation Mode Voltage Setpoint, Current Setpoint


Setpoint (unit) or Power Setpoint in appropriate
Volts, Amps, units
or Kilowatts

Volts 5 Voltage Output (%) Voltage Output Actual as % of rated


voltage
% of Rated
Output

Amps 6 Current Output (%) Current Output Actual as % of rated


current
% of Rated
Output

Kilowatts 7 Power Output (%) Power Output as % of rated power

% of Rated
Output

Setpoint 8 Regulation Mode Voltage Setpoint, Current Setpoint


Setpoint (%) or Power Setpoint as % of
% of Rated appropriate rating
Volts, Amps, or
Kilowatts

5-2
February 2004 Local Digital Control Option

The six status LED’s are summarized in the following table.

Table 5-2 Digital Control Status

LED Condition Description

Remote Status On The Remote/Local input is in the Remote state.

Off The Remote/Local input is in the Local state.

Analog Status On The Local mode is set to Analog, and the Remote/Local
input is in the Local state.

The Local mode is set to Digital, or the Remote/Local


Off input is in the Remote state.

Digital Status On The Local mode is set to Digital, and the Remote/Local
input is in the Local state.

The Local mode is set to Analog, or the Remote/Local


Off input is in the Remote state.

Enable Status On The Enable/Inhibit input is in the Enable state.

Off The Enable/Inhibit input is in the Inhibit state.

On Status On The DSPC output is active.

Off The DSPC output is off.

Alert Status On Either a fault or alarm is present.

Off No detected fault or alarm.

Normal Mode Operation

Normal mode operation depends on two factors: the Remote/Local input, and the Analog/Digital control
status. If the unit is under Local Digital Control, the four pushbuttons are used to increment/decrement
the regulation mode setpoint, toggle the unit output, and toggle the control mode from digital to analog
(and vice-versa). Normal operation under Local Digital Control is summarized in the following table:

5-3
Local Digital Control Option February 2004

Table 5-3 Pushbutton function in Normal mode, Local Digital Control

Display Selection Up/Down Button Select Button On/Off/Reset Button

Voltage Output (V) Display the Regulation Mode Press and Hold to toggle Toggle the unit On/Off
Setpoint in units; local Analog/Digital control
Increment/Decrement the
Regulation Mode Setpoint

Current Output (A) Display the Regulation Mode Press and Hold to toggle Toggle the unit On/Off
Setpoint in units; local Analog/Digital control
Increment/Decrement the
Regulation Mode Setpoint

Power Output (KW) Display the Regulation Mode Press and Hold to toggle Toggle the unit On/Off
Setpoint in units; local Analog/Digital control
Increment/Decrement the
Regulation Mode Setpoint

Regulation Mode Increment/Decrement the Press and Hold to toggle Toggle the unit On/Off
Setpoint (units) Regulation Mode Setpoint local Analog/Digital control

Voltage Output (%) Display the Regulation Mode Press and Hold to toggle Toggle the unit On/Off
Setpoint as % of rated; local Analog/Digital control
Increment/Decrement the
Regulation Mode Setpoint

Current Output (%) Display the Regulation Mode Press and Hold to toggle Toggle the unit On/Off
Setpoint as % of rated; local Analog/Digital control
Increment/Decrement the
Regulation Mode Setpoint

Power Output (%) Display the Regulation Mode Press and Hold to toggle Toggle the unit On/Off
Setpoint as % of rated; local Analog/Digital control
Increment/Decrement the
Regulation Mode Setpoint

Regulation Mode Increment/Decrement the Press and Hold to toggle Toggle the unit On/Off
Setpoint (%) Regulation Mode Setpoint local Analog/Digital control

Pushbutton functions vary slightly under Local Analog Control. The setpoint can be viewed but cannot
be changed. Normal operation under Local Analog Control is summarized in the following table:

5-4
February 2004 Local Digital Control Option

Table 5-4 Pushbutton function in Normal mode, Local Analog Control

Display Selection Up/Down Pushbutton Select Pushbutton On/Off/Reset Pushbutton

Voltage Output (V) Display the Regulation Mode Press and Hold to toggle Toggle the unit On/Off
Setpoint in units local Analog/Digital control

Current Output (A) Display the Regulation Mode Press and Hold to toggle Toggle the unit On/Off
Setpoint in units local Analog/Digital control

Power Output (KW) Display the Regulation Mode Press and Hold to toggle Toggle the unit On/Off
Setpoint in units local Analog/Digital control

Regulation Mode Display the Regulation Mode Press and Hold to toggle Toggle the unit On/Off
Setpoint (units) Setpoint in units local Analog/Digital control

Voltage Output (%) Display the Regulation Mode Press and Hold to toggle Toggle the unit On/Off
Setpoint as % of rated local Analog/Digital control

Current Output (%) Display the Regulation Mode Press and Hold to toggle Toggle the unit On/Off
Setpoint as % of rated local Analog/Digital control

Power Output (%) Display the Regulation Mode Press and Hold to toggle Toggle the unit On/Off
Setpoint as % of rated local Analog/Digital control

Regulation Mode Display the Regulation Mode Press and Hold to toggle Toggle the unit On/Off
Setpoint (%) Setpoint as % of rated local Analog/Digital control

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

On/Off/Reset
Display Selection Up/Down Pushbutton Select Pushbutton
Pushbutton

Voltage Output (V) No action No action No action

Current Output (A) No action No action No action

Power Output (KW) No action No action No action

Regulation Mode No action No action No action


Setpoint (units)

Voltage Output (%) No action No action No action

Current Output (%) No action No action No action

Power Output (%) No action No action No action

Regulation Mode No action No action No action


Setpoint (%)

5-6
February 2004 Local Digital Control Option

Display Select Mode Operation

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 Up/Down Pushbutton Select Pushbutton On/Off/Reset Pushbutton

Voltage Output (V) Increment/Decrement the Exit Display Select mode Toggle the unit On/Off; exit
display selection Display Select mode

Current Output (A) Increment/Decrement the Exit Display Select mode Toggle the unit On/Off; exit
display selection Display Select mode

Power Output (KW) Increment/Decrement the Exit Display Select mode Toggle the unit On/Off; exit
display selection Display Select mode

Regulation Mode Increment/Decrement the Exit Display Select mode Toggle the unit On/Off; exit
Setpoint (units) display selection Display Select mode

Voltage Output (%) Increment/Decrement the Exit Display Select mode Toggle the unit On/Off; exit
display selection Display Select mode

Current Output (%) Increment/Decrement the Exit Display Select mode Toggle the unit On/Off; exit
display selection Display Select mode

Power Output (%) Increment/Decrement the Exit Display Select mode Toggle the unit On/Off; exit
display selection Display Select mode

Regulation Mode Increment/Decrement the Exit Display Select mode Toggle the unit On/Off; exit
Setpoint (%) display selection Display Select mode

5-7
Local Digital Control Option February 2004

Table 5-7 Pushbutton function in Display Select Mode, Remote Control

Display Selection Up/Down Pushbutton Select Pushbutton On/Off/Reset Pushbutton

Voltage Output (V) Increment/Decrement the Exit Display Select mode Exit Display Select mode
display selection

Current Output (A) Increment/Decrement the Exit Display Select mode Exit Display Select mode
display selection

Power Output (KW) Increment/Decrement the Exit Display Select mode Exit Display Select mode
display selection

Regulation Mode Increment/Decrement the Exit Display Select mode Exit Display Select mode
Setpoint (units) display selection

Voltage Output (%) Increment/Decrement the Exit Display Select mode Exit Display Select mode
display selection

Current Output (%) Increment/Decrement the Exit Display Select mode Exit Display Select mode
display selection

Power Output (%) Increment/Decrement the Exit Display Select mode Exit Display Select mode
display selection

Regulation Mode Increment/Decrement the Exit Display Select mode Exit Display Select mode
Setpoint (%) display selection

5-8
Chapter 6

Serial Communication
Hardware

The serial port of the 853 DSPC is a standard, male, DB-9 connector. The hardware connection between
a standard PC COM port and the 853 DSPC’s serial port is a null modem style link, shown below. Only
pins 2, 3 and 5 (Receive, Transmit and Ground) of the DB-9 connector are needed to communicate; 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).

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
Serial Communication February 2004

The setup of the serial port is described below.

Table 6-1 Serial Port Configuration

Baud Rate 4800, 9600, or 19200 baud

Parity None

Length 8 bits

Stop 2 bits

Handshake None

The default serial baud rate is 19200. The baud rate is accessible as setting #117, and can be modified
either with the 853 Configuration Tool or through the (remote) network connection. In either case, the
new baud rate setting will take effect only after control power to the 853 DSPC is cycled.

The 853 Configuration Tool will detect baud rate automatically when on-line communication is established
with the 853 DSPC.

6-2
February 2004 Serial Communication

Serial Protocols

The 853 supports two serial protocols: MODBUS RTU and an 8-byte generic protocol. The 853
determines the protocol of each message sent. It looks for the start characters of a generic message
(described later in this chapter). If the start characters are present, the received message is treated as a
generic message. If the start characters are NOT present, the 853 will treat the received message as
MODBUS RTU. In either case, the appropriate response is generated and sent.

MODBUS RTU

The MODBUS RTU protocol is a query/response or master/slave protocol. The 853 acts as a slave in the
MODBUS master/slave relationship. The MODBUS query and response are summarized in the following
tables.

Table 6-2 MODBUS RTU Query (from Master)

Byte Field Name Description

1 Slave Address 853 MODBUS address, from setting #116, or 0


for a broadcast message.

2 Function MODBUS function code, 3 (read) or 6 (write).

3 Address High Always 0

4 Address Low 853 setting number.

5 # Points High (read) Always 0 (read);


Data High (write) High byte of 16-bit value to be written (write).

6 # Points Low (read) Always 1 (read);


Data Low Low byte of 16-bit value to be written (write).

7,8 Error Check 16-bit CRC, low byte first

6-3
Serial Communication February 2004

Table 6-3 MODBUS RTU Read Response (from 853)

Byte Field Name Description

1 Slave Address 853 MODBUS address, from setting #116.

2 Function MODBUS function code 3 (read).

3 Byte count Always 2

4 Data High High byte of 16-bit value read.

5 Data Low Low byte of 16-bit value read.

6,7 Error Check 16-bit CRC, low byte first

Table 6-4 MODBUS RTU Write Response (from 853)

Byte Field Name Description

1 Slave Address 853 MODBUS address, from setting #116.

2 Function MODBUS function code 6 (write).

3 Address High Always 0

4 Address Low 853 setting number.

5 Data High High byte of 16-bit value written (echo).

6 Data Low Low byte of 16-bit value written (echo).

7,8 Error Check 16-bit CRC, low byte first

6-4
February 2004 Serial Communication

When a message is received correctly (no communication errors, CRC checks out), but cannot be
executed, the 853 DSPC will generate an exception (error) response. No response is generated for a
message received incorrectly, or incompletely. No response is generated for broadcast messages.

Table 6-5 MODBUS RTU Exception Response (from 853 DSPC)

Byte Field Name Description

1 Slave Address 853 MODBUS address, from setting #116.

2 Function MODBUS function code plus exception


indication (80 hex).

3 Exception code MODBUS exception code.

4,5 Error Check 16-bit CRC, low byte first

The 853 DSPC supports the following MODBUS exception codes:

Table 6-6 MODBUS RTU Exception Codes

Exception Code Description

01 Illegal function

02 Illegal data address (setting number).

03 Illegal data value.

6-5
Serial Communication February 2004

General 8 Byte Protocol

The 853 DSPC supports a generic 8 byte query/response protocol. As in the MODBUS RTU protocol, the
853 DSPC is implemented as a slave in a master/slave communication relationship.

Table 6-7 General 8 Byte Query (from Master)

Byte Field Name Description

1 Start 1 Always 0xA5

2 Start 2 Always 0x5A

3 Command 0x00 (read), or


0x80 (write)

4 Setting 853 DSPC setting number.

5 Data High Unused (read);


High byte of 16-bit value to be written (write).

6 Data Low Unused (read);


Low byte of 16-bit value to be written (write).

7 Checksum Calculated from the sum of the Command byte,


Setting byte, Data high and Data low bytes.

8 End Always 0x7E

6-6
February 2004 Serial Communication

Each General Protocol query sent to the 853 DSPC will result in a response. Included in byte 3 of the
response is status information. The echo bit is set for all response messages. The error bit is set if an
error occurred during the reception or execution of the query. In the event of an error, the information in
the data bytes has no meaning.

Table 6-8 General 8 Byte Response (from 853)

Byte Field Name Description

1 Start 1 Always 0xA5

2 Start 2 Always 0x5A

3 Command Bit 0 - 3
reserved
Bit 4
1 - network offline
0 - network online
Bit 5
1- error bit
Bit 6
1- echo bit
Bit 7
1 - write operation
0 - read operation

4 Setting 853 DSPC setting number.

5 Data High High byte of 16-bit value read (read).


Unused (write);

6 Data Low Low byte of 16-bit value read (read).


Unused (write);

7 Checksum Calculated from the sum of the Command byte,


Setting byte, Data high and Data low bytes.

8 End Always 0x7E

Each serial message sent to the 853 DSPC results in a response message back. Byte 3 includes an
echo bit and an error bit. The echo bit is always set if the message has been received. The error bit is set
if the message has an error.

If an error occurs, the values returned in Bytes 5 and 6 are not meaningful.

6-7
Serial Communication February 2004

Additional Serial Information

Error responses do not stop 853 operation.

Message bytes are sent and received as binary values, and not as ASCII characters.

Floating point data (data containing a decimal point) are transferred as 16 bit integers. The floating point
value is scaled (multiplied) by 10 before transfer. Likewise, floating point data received by the controller
are adjusted (divided) by a factor of 10. For example, a voltage equal to 208.7 will be transferred as 2087

Settings that are longer than two bytes (such as Serial Number) must be read with two individual
transactions. The higher order word (2 bytes) is specified by the Setting number listed in the settings
table, and the lower order word is specified by the Setting number plus 1. Care must be taken when
reading four byte time values to check for lower order word overflow during the serial read operation,
which would result in an invalid time value.

Serial control of the unit is enabled when the Local/Remote switch is in LOCAL mode. 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 1.5 seconds.

The serial link can be used to monitor values when serial control is not enabled. This includes when the
unit is being controlled remotely under network control or when the unit is being controlled locally under
analog control.

6-8
Chapter 7

Settings

Caution

The 853 DSPC is configured using the programmable settings. Programming the settings
incorrectly can cause the 853 DSPC to exhibit intermittent or full output conditions.

The following table summarizes the settings of the 853.

Table 7-1 List of Settings

Settings No. Units Description


Voltage Input Rating
Vrms
The input rating of the voltage supplied to the
Read/Write 1 Min: 0.0
853.
Condition: Off Max: 600.0
Default: 480.0 V
Voltage Input High Fault
The level compared to Vinrms that causes a high
Vrms
voltage fault. It is limited to 125% of the Voltage
Read/Write 2 Min: 0.0
Input Rating. Fault operation is further
Condition: All Max: 750.0
described in the Troubleshooting Chapter.
Default: 576.0 V
Voltage Input Low Alarm
The level compared to Vinrms that causes a low
Vrms
voltage alarm. It is limited to 100% of the
Read/Write 3 Min: 0.0
Voltage Input Rating. Fault operation is further
Condition: All Max: 600.0
described in the Troubleshooting Chapter.
Default: 384.0 V
Voltage Input Phase
The difference between each Phase voltage and
Unbalance Alarm
the Voltage Input Actual expressed as a
%
positive percentage. Exceeding this limit value
Read/Write 4 Min: 2%
causes an unbalanced input voltage alarm. Fault
Condition: All Max: 100%
operation is further described in the
Default: 5.0 %
Troubleshooting Chapter.
Voltage L1-L2 Input Actual
5 Vrms Vinrms for Phase L1 to Phase L2.
Read only
Voltage L1-L2 Input Span
Bits Digital span adjustment of the voltage L1-L2
Read/Write 6 Min: 2000 input signal. Calibration is described in the
Condition: All Max: 16000 Calibration Chapter.
Default: Factory

7-1
Settings February 2004

Settings No. Units Description


Voltage L2-L3 Input Actual
7 Vrms Vinrms for Phase L2 to Phase L3.
Read only
Voltage L2-L3 Input Span
Bits Digital span adjustment of the voltage L2-L3
Read/Write 8 Min: 2000 input signal. Calibration is described in the
Condition: All Max: 16000 Calibration Chapter.
Default: Factory
Voltage L3-L1 Input Actual
Vinrms for Phases L3 to L1 calculated using L1-L2
9 Vrms
and L2-L3 voltages measured.
Read only
Voltage L3-L1 Input Span
Bits Digital span adjustment of the voltage L3-L1
Read/Write 10 Min: 2000 input signal. Calibration is described in the
Condition: All Max: 16000 Calibration Chapter.
Default: Factory
Voltage Input Actual
Average of Vinrms for Phases L1-L2, L2-L3 and
11 Vrms
L3-L1.
Read only
Frequency Rating
Hertz
Read/Write 12 Min: 50.0 The input line frequency rating.
Condition: Off Max: 60.0
Default: 60.0 Hz
Frequency Actual
13 Hertz Measured input line frequency.
Read only
Voltage Output Rating
Vrms
The output rating of the voltage being controlled
Read/Write 14 Min: 0.0
by the 853.
Condition: Off Max: 2000.0
Default: 480.0 V
Voltage Output PT
The secondary voltage of an external voltage
Secondary
Potential Transformer (PT). It is set equal to the
Vrms
Voltage Output Rating if no PT is used. It is
Read/Write 15 Min: 0.0
very important that this setting be in the same
Condition: Off Max: 600.0
calibration range as the Voltage Input Rating for
Default: 480.0 V
proper operation.
Voltage Output Limit
Vrms The maximum voltage the voltage output PID
Read/Write 16 Min: 0.0 control will limit to. It is limited to 125% of the
Condition: All Max: 2500.0 Voltage Output Rating.
Default: 528.0 V
Voltage Output Setpoint
Vrms
The setpoint for the voltage output PID control. It
Read/Write 17 Min: 0.0
is limited to 100% of the Voltage Output Limit.
Condition: Remote Max: 2500.0
Default: 480.0 V

7-2
February 2004 Settings

Settings No. Units Description


Voltage Output Proportional
Gain
%
18 Min: 0.0 Voltage output control proportional gain.
Read/Write
Max: 100.0
Condition: All
Default: 10.0 %
Voltage Output Integral Gain
%
Read/Write 19 Min: 0.0 Voltage output control integral gain.
Condition: All Max: 100.0
Default: 10.0 %
Voltage Output Derivative
Gain
%
20 Min: 0.0 Voltage output control derivative gain.
Read/Write
Max: 100.0
Condition: All
Default: 0.0 %
Voltage X1-X2 Output Actual
21 Vrms Voutrms for Phase X1 to Phase X2.
Read only
Voltage X1-X2 Output Zero
Bits Digital zero adjustment of the voltage X1-X2
Read/Write 22 Min: 0 output signal. Calibration is described in the
Condition: Off Max: 100 Calibration Chapter.
Default: Factory
Voltage X1-X2 Output Span
Bits Digital span adjustment of the voltage X1-X2
Read/Write 23 Min: 2000 output signal. Calibration is described in the
Condition: On Max: 16000 Calibration Chapter.
Default: Factory
Voltage X2-X3 Output Actual
24 Vrms Voutrms for Phase X2-X3.
Read only
Voltage X2-X3 Output Zero
Bits Digital zero adjustment of the voltage X2-X3
Read/Write 25 Min: 0 output signal. Calibration is described in the
Condition: Off Max: 100 Calibration Chapter.
Default: Factory
Voltage X2-X3 Output Span
Bits Digital span adjustment of the voltage X2-X3
Read/Write 26 Min: 2000 output signal. Calibration is described in the
Condition: On Max: 16000 Calibration Chapter.
Default: Factory
Voltage X3-X1 Output Actual
Voutrms for Phases X3-X1 calculated using Phase
27 Vrms
X1-X2 and Phase X2-X3 measurements.
Read only
Voltage X3-X1 Output Zero
Bits Digital zero adjustment of the voltage X3-X1
Read/Write 28 Min: 0 output signal. Calibration is described in the
Condition: Off Max: 100 Calibration Chapter.
Default: Factory

7-3
Settings February 2004

Settings No. Units Description


Voltage X3-X1 Output Span
Bits Digital span adjustment of the voltage X3-X1
Read/Write 29 Min: 2000 output signal. Calibration is described in the
Condition: On Max: 16000 Calibration Chapter.
Default: Factory
Voltage Output Actual
Average of Voutrms for Phases X1-X2, X2-X3,
30 Vrms
and X3-X1.
Read only
Current Input Rating
Irms
Read/Write 31 Min: 0.0 The input rating of the current to the 853.
Condition: Off Max: 1500.0
Default: 350.0 A
Current Input Limit
Irms The maximum Current Input Actual the 853 will
Read/Write 32 Min: 0.0 allow to run continuously. It is limited to 150% of
Condition: All Max: 2250.0 the Current Input Rating.
Default: 350.0 A
Current Input High Fault
The level compared to the peak current of each
phase individually. Exceeding this value causes
Read/Write Ipeak
an over current fault. The value is limited to
Condition: All 33 Min: 0.0
350% of the Current Input Rating. Fault
Default: 700.0 A Max: 5250.0
operation is described in the Troubleshooting
Chapter.
Current Input High Fault
Retry Number
Selection The number of retries for the Current Input High
34 Min: 0 Fault before the fault is latched. Fault operation
Read/Write
Max: 5 is described in the Troubleshooting Chapter.
Condition: All
Default: 0
Current Input High Fault
Retry Time
Seconds The time limit for fault retries before the fault will
35 Min: 10.0 latch. Fault operation is described in the
Read/Write
Max: 360.0 Troubleshooting Chapter.
Condition: All
Default: 10.0 Sec
Current Input Overload Fault
The level compared to the Current Input Actual
Irms that causes a timed current fault. It is limited to
Read/Write
36 Min: 0.0 250% of the Current Input Rating. Fault
Condition: All
Max: 3750.0 operation is described in the Troubleshooting
Default: 470.0 A
Chapter
Current Input Overload Time
Seconds The time limit on the current input overload level
Read/Write 37 Min: 0.0 before a fault occurs. Fault operation is
Condition: All Max: 360.0 described in the Troubleshooting Chapter.
Default: 10.0 Sec

7-4
February 2004 Settings

Settings No. Units Description


Ground Fault Current
The amount of current calculated to be flowing to
Amperes a ground (from phase current unbalances)
Read/Write
38 Min: 2.0 allowed before starting Ground Fault Time
Condition: All
Max: 1500.0 countdown. Fault operation is described in the
Default: 10.0 A
Troubleshooting Chapter.
Ground Fault Time
Seconds The amount of time required to generate a
Read/Write 40 Min: 0.0 ground fault. Fault operation is described in the
Condition: All Max: 360.0 Troubleshooting Chapter.
Default: 10.0 Sec
Current L1 Input Actual
41 Irms Iinrms for Phase L1.
Read only
Current L1 Input Zero
Bits Digital zero adjustment of the current L1 input
Read/Write 42 Min: 0 signal. Calibration is described in the
Condition: Off Max: 100 Calibration Chapter.
Default: Factory
Current L1 Input Span
Bits Digital span adjustment of the current L1 input
Read/Write 43 Min: 2000 signal. Calibration is described in the
Condition: On Max: 16000 Calibration Chapter.
Default: Factory
Current L2 Input Actual
44 Irms Iinrms for Phase L2.
Read only
Current L2 Input Zero
Bits Digital zero adjustment of the current L2 input
Read/Write 45 Min: 0 signal. Calibration is described in the
Condition: Off Max: 100 Calibration Chapter.
Default: Factory
Current L2 Input Span
Bits Digital span adjustment of the current L2 input
Read/Write 46 Min: 2000 signal. Calibration is described in the
Condition: On Max: 16000 Calibration Chapter.
Default: Factory
Current L3 Input Actual
47 Irms Iinrms for Phase L3.
Read only
Current L3 Input Zero
Bits Digital zero adjustment of the current L3 input
Read/Write 48 Min: 0 signal. Calibration is described in the
Condition: Off Max: 100 Calibration Chapter.
Default: Factory
Current L3 Input Span
Bits Digital span adjustment of the current L3 input
Read/Write 49 Min: 2000 signal. Calibration is described in the
Condition: On Max: 16000 Calibration Chapter.
Default: Factory

7-5
Settings February 2004

Settings No. Units Description


Current Input Actual
50 Irms Average of Iinrms for Phase L1, L2, and L3.
Read only
Current Input Threshold
Load Failure The individual phase current used to determine a
Irms
load failure. It is limited from 2% to 10% of the
51 Min: 0.0
Read/Write Current Input Rating. Fault operation is
Max: 1500.0
Condition: On described in the Troubleshooting Chapter.
Default: 10.0 A
Current Output Rating
Irms
The output rating of the current being controlled
Read/Write 52 Min: 0.0
by the 853.
Condition: Off Max: 3000.0
Default: 350.0 A
Current Output Limit
Irms The maximum current the current output PID
Read/Write 53 Min: 0.0 control will limit to. It is limited to 150% of the
Condition: All Max: 4500.0 Current Output Rating.
Default: 350.0 A
Current Output Setpoint
Irms
The setpoint for the current output PID control. It
Read/Write 54 Min: 0.0
is limited to 100% of the Current Output Limit.
Condition: Remote Max: 4500.0
Default: 350.0 A
Current Output Proportional
Gain
%
55 Min: 0.0 Current output control proportional gain.
Read/Write
Max: 100.0
Condition: All
Default: 10.0 %
Current Output Integral Gain
%
Read/Write 56 Min: 0.0 Current output control integral gain.
Condition: All Max: 100.0
Default: 10.0 %
Current Output Derivative
Gain
%
57 Min: 0.0 Current output control derivative gain.
Read/Write
Max: 100.0
Condition: All
Default: 0.0 %
Current X1 Output Actual
58 Irms Ioutrms for Phase X1 measured.
Read only
Current X1 Output Zero
Bits Digital zero adjustment of the Current X1
Read/Write 59 Min: 0 Output Actual signal. Calibration is described in
Condition: Off Max: 100 the Calibration Chapter.
Default: Factory

7-6
February 2004 Settings

Settings No. Units Description


Current X1 Output Span
Bits Digital span adjustment of the Current X1
Read/Write 60 Min: 2000 Output Actual signal. Calibration is described in
Condition: On Max: 16000 the Calibration Chapter.
Default: Factory
Current X2 Output Actual
61 Irms Ioutrms for Phase X2 calculated.
Read only
Current X3 Output Actual
62 Irms Ioutrms for Phase X3 calculated.
Read only
Current Output Actual
63 Irms Average of Ioutrms for Phases X1, X2, and X3.
Read only
KVA Input Rating
The KVA rating is the conversion factor that is
used to convert the KVA Input from percent to
Read only
KVA. It is calculated using the following
64 KVA equation.

(Voltage Input Rating * SQRT(3) * Current


Input Rating)/1000
KVA Input
The KVA input is calculated by the following
equation.
Read only
65 KVA
(Voltage Input Actual * SQRT(3) * Current
Input Actual.) /1000
Power Output Rating
The output rating of the Power being controlled
by the 853. It is calculated by the following
Read only
equation.
66 KW
(Voltage Output Rating * SQRT(3) * Current
Output Rating)/1000
Power Output Limit
KW The maximum power the power output PID
Read/Write 67 Min: 0.0 control will limit to. It is limited to 125% of the
Condition: All Max: 1125.0 Power Output Rating.
Default: 291.0 KW
Power Output Setpoint
KW
The setpoint for the power output PID control. It
Read/Write 68 Min: 0.0
is limited to 100% of the Power Output Limit.
Condition: Remote Max: 1125.0
Default: 291.0 KW
Power Output Proportional
Gain
%
69 Min: 0.0 Power output control proportional gain.
Read/Write
Max: 100.0
Condition: All
Default: 10.0 %

7-7
Settings February 2004

Settings No. Units Description


Power Output Integral Gain
%
Read/Write 70 Min: 0.0 Power output control integral gain.
Condition: All Max: 100.0
Default: 10.0 %
Power Output Derivative
Gain
%
71 Min: 0.0 Power output control derivative gain.
Read/Write
Max: 100.0
Condition: All
Default: 0.0 %
Power Output
(Vin * Iin)rms , calculated by using the
72 KW instantaneous product of the voltage and current
Read only
samples.
Power Factor
73 Power Output / KVA Input.
Read only
Duty Cycle Output
74 % On time / Off time * 100.0
Read only
Duty Cycle Setpoint
%
Read/Write 75 Min: 0.0 The setpoint for open loop control.
Condition: Remote Max: 100.0
Default: 100.0 %
Local Digital Control Display
Defines what the Local Digital Control displays
Selection
during operation. The Local Digital Control
option is described in the Local Digital Control
Read/Write
Option Chapter. The selection list is:
Condition: All
Default: 1 Selection 1 – Voltage Output (V)
76 Min: 1 2 – Current Output (A)
Max: 8 3 – Power Output (KW)
4 – Control Setpoint (units)
5 – Voltage Output (%)
6 – Current Output (%)
7 – Power Output (%)
8 – Control Setpoint (%)
Local Digital Control
KW The setpoint of the local digital control module. It
Setpoint
77 Vrms can be Vrms, Irms or KW depending on the
Irms setting of the regulation mode.
Read only
Local Primary Analog
KW The setpoint of the local primary analog input. It
Setpoint
78 Vrms can be KW, Vrms, or Irms depending on the
Irms setting of the regulation mode.
Read only

7-8
February 2004 Settings

Settings No. Units Description


Primary Analog Setpoint
Zero
Bits Digital zero adjustment of the Local Primary
79 Min: -100 Analog Setpoint input signal. Calibration is
Read/Write
Max: 500 described in the Calibration Chapter.
Condition: All
Default: Factory
Primary Analog Setpoint
Span
Bits Digital span adjustment of the Local Primary
80 Min: 2000 Analog Setpoint input signal. Calibration is
Read/Write
Max: 16000 described in the Calibration Chapter.
Condition: All
Default: Factory
Local Secondary Analog
Defines the operation of the Local Secondary
Setpoint Selection
Analog Setpoint during local analog control.
The selection list is:
Read/Write
Condition: All Selection 1 – Current Setpoint
Default: 1 81 Min: 1 2 – Voltage Setpoint
Max: 3 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
The setpoint of the Local Secondary Analog
Setpoint
Setpoint input. It is defined by the Local
KW
Secondary Analog Setpoint Selection. The
Read only 82 Vrms
secondary analog setpoint is
Irms
activated/deactivated in the Configuration
Word.
Secondary Analog Setpoint
Zero
Bits Digital zero adjustment of the Local Secondary
83 Min: -100 Analog Setpoint input signal. Calibration is
Read/Write
Max: 500 described in the Calibration Chapter.
Condition: All
Default: Factory
Secondary Analog Setpoint
Span
Bits Digital span adjustment of the Local Secondary
84 Min: 2000 Analog Setpoint input signal. Calibration is
Read/Write
Max: 16000 described in the Calibration Chapter.
Condition: All
Default: Factory

7-9
Settings February 2004

Settings No. Units Description


Analog Output #1 Selection
Defines the operation of the Analog Output #1.
The selection list is:
Read/Write
Condition: All 1 – Power Setpoint
Default: 2 2 – Power Output
Selection 3 – Voltage Setpoint
85 Min: 1 4 – Voltage Output
Max: 10 5 – Voltage Input
6 – Current Setpoint
7 – Current Output
8 – Current Input
9 –Analog Setpoint
10 – Duty Cycle Output
Analog Output #1
An analog output as defined by Analog Output
86 %
#1 Selection in percent.
Read only
Analog Output #1 Bias
Bits Digital zero adjustment of the Analog Output #1
Read/Write 87 Min: -100 signal. Calibration is described in the
Condition: All Max: 500 Calibration Chapter.
Default: Factory
Analog Output #1 Span
Bits Digital span adjustment of the Analog Output #1
Read/Write 88 Min: 2000 signal. Calibration is described in the
Condition: All Max: 6000 Calibration Chapter.
Default: Factory
Analog Output #2 Selection
Defines the operation of the Analog Output #2.
The selection list is:
Read/Write
Condition: All 1 – Power Setpoint
Default: 4 2 – Power Output
Selection 3 – Voltage Setpoint
89 Min: 1 4 – Voltage Output
Max: 10 5 – Voltage Input
6 – Current Setpoint
7 – Current Output
8 – Current Input
9 –Analog Setpoint
10 – Duty Cycle Output
Analog Output #2
An analog output as defined by Analog Output
90 %
#2 Selection in percent.
Read only
Analog Output #2 Bias
Bits Digital zero adjustment of the Analog Output #2
Read/Write 91 Min: -100 signal. Calibration is described in the
Condition: All Max: 500 Calibration Chapter.
Default: Factory
Analog Output #2 Span
Bits Digital span adjustment of the Analog Output #2
Read/Write 92 Min: 2000 signal. Calibration is described in the
Condition: All Max: 6000 Calibration Chapter.
Default: Factory

7-10
February 2004 Settings

Settings No. Units Description


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

7-11
Settings February 2004

Settings No. Units Description


Status Word
The status word is the digital outputs from the
853.
Read only
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
94 Bits 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

7-12
February 2004 Settings

Settings No. Units Description


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

7-13
Settings February 2004

Settings No. Units Description


Control Strategy Selection
Defines the type of control strategy that is being
Selection
run. The selection list is:
Read/Write 98 Min: 1
Condition: Off Max: 2 1 – Phase-Angle Control
Default: 1 2 – Zero-Crossover Control
Magnetizing Sequence
Calibration
Cycles
Number of cycles to ramp on in phase control –
99 Min: 5
Read/Write Zero-Crossover control only
Max: 20
Condition: Off
Default: 10 Cycles
Repetitive Pulse Calibration
The Repetitive Pulse Calibration is divided into
two separate bytes, which allows the first positive
Read/Write
zero crossing pulse to be set differently for the
Condition: All
% three phases – Zero-Crossover control only.
Default:
100 Min: 10
Low Byte Low Byte – Bits 0 – 7
Max: 90
50 Repetitive Pulse #1
High Byte
30 High Byte – Bits 8 – 15
Repetitive Pulse #2
Load Type Selection
Defines the type of load connected to the 853.
Selection
The selection list is:
Read/Write 101 Min: 1
Condition: Off Max: 2 1 – Direct Coupled
Default: 1 2 – Transformer Coupled
Product Type
102 The product type is 853.
Read only
Serial Number
The numeric serial number of the 853. The
103
Setting is read as two consecutive words
Read only 104
because of its size.
Factory set
Control Power Time On
The accumulated time control power has been
105 Hours
applied to the 853. The Setting is read as two
Read only 106 x.x
consecutive words because of its size.
Factory reset
Output Time On
The accumulated time the 853 output has been
107 Hours
on. The Setting is read as two consecutive
Read only 108 x.x
words because of its size.
Factory reset
KW-Hour
The accumulated Power Output in KW hours. It
109 KW- Hours can be reset remotely by writing a 1 to bit 3 of the
Read only
110 x.x Control Word. The Setting is read as two
consecutive words because of its size.
Software Version
112 The control software version read as xx.xxx.
Read only

7-14
February 2004 Settings

Settings No. Units Description


Network Loss
Defines the action that is taken by the 853
control when there is a network loss. The
Read/Write Selection
selection list is:
Condition: All 113 Min: 0
Default: 1 Max: 2 0 – Fault and Stop
1 – Ignore and Run
2 – Alarm and Run
Network Address
For the DeviceNet™ and Profibus network types,
defines the network interface card address. For
Read/Write Address
Ethernet, it defines the upper two octets of the
Condition: All 114 Min: 0
network address. Refer to the network interface
Default: 63 Max: 126
manual for a detailed description of the network
interface.
Network Baud Rate
For the DeviceNet™ and Profibus network types,
Selection defines the network baud rate. For Ethernet, it
Read/Write
115 Min: 0 defines the lower two octets of the network
Condition: All
Max: 2 address. Refer to the network interface manual
Default: 0
for a detailed description of the network interface.
MODBUS Address
Address
Read/Write Defines the device address for MODBUS
116 Min: 1
Condition: All messaging.
Max: 247
Default: 247

MODBUS Baud Rate


Selection Defines the serial baud rate. The selection list is:
Read/Write Min: 4800
117 4800
Condition: All Max: 19200
9600
Default: 19200 (baud)
19200
Network Type
Defines the selected network interface. The
selection list is:
Read/Write Selection
Condition: All 118 Min: 0 0 – DeviceNet™
Default: 0 Max: 2 1 – Profibus
2 – Ethernet

Fault Code
Fault condition code. Fault operation is
119
described in the Troubleshooting Chapter.
Read only
Fault Index
Index
120 Min: 1 Fault buffer index number.
Read only
Max: 8
Factory reset
Fault Buffer #1
Saved fault condition code with a time stamp of
121
time run.
Read only 122
Factory reset 123 Word 121 – Fault condition code
Word 122/123 – Output time on stamp

7-15
Settings February 2004

Settings No. Units Description


Fault Buffer #2
Saved fault condition code with a time stamp of
124
time run.
Read only 125
Factory reset 126 Word 124 – Fault condition code
Word 125/126 – Output time on stamp
Fault Buffer #3
Saved fault condition code with a time stamp of
127
time run.
Read only 128
Factory reset 129 Word 127 – Fault condition code
Word 128/129– Output time on stamp
Fault Buffer #4
Saved fault condition code with a time stamp of
130
time run.
Read only 131
Factory reset 132 Word 130 – Fault condition code
Word 131/132 – Output time on stamp
Fault Buffer #5
Saved fault condition code with a time stamp of
133
time run.
Read only 134
Factory reset 135 Word 133 – Fault condition code
Word 134/135 – Output time on stamp
Fault Buffer #6
Saved fault condition code with a time stamp of
136
time run.
Read only 137
Factory reset 138 Word 136 – Fault condition code
Word 137/138 – Output time on stamp
Fault Buffer #7
Saved fault condition code with a time stamp of
139
time run.
Read only 140
Factory reset 141 Word 139 – Fault condition code
Word 140/141 – Output time on stamp
Fault Buffer #8
Saved fault condition code with a time stamp of
142 time run.
Read only
143
Factory reset Word 142 – Fault condition code
144
Word 143/144 – Output time on stamp

7-16
Chapter 8

Troubleshooting

DANGER
Only qualified electrical personnel familiar with the construction and operation of the
equipment and the hazards involved should install, operate, and/or service this equipment.
Read and understand this manual and other applicable manuals in their entirety before
proceeding. Failure to observe this precaution could result in severe bodily injury or loss
of life.

DANGER
The user is responsible for conforming with all applicable local, national, and international
codes; wiring practices, grounding, disconnects, and overcurrent protection are of
particular importance. 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. Disconnect and lock out
all ungrounded conductors of the AC power line. Failure to observe these precautions
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. Voltages on many components are at incoming line potential.
to avoid electric shock hazard or damage to equipment, do not touch any component other
than those specified in the manual. Failure to observe these precautions could result in
severe injury or loss of life.

The 853 DSPC has a number of built in diagnostic features. 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.

8-1
Troubleshooting February 2004

Control PCB LED Indicators

The control printed circuit board has six LED’s. Remove the middle wiring cover of the 853 DSPC to view
these particular LED’s. The LED’s and their functions are listed in below.

Table 8-1 Control PCB LED Indicators

LED Color Description

+5V Green +5V power is present

+15V Green +15V power is present

-15V Green -15V power is present

On Green 853 DSPC output is active

Heartbeat Flashing Digital Signal Processor is operating


Green

Fault Red 853 DSPC has detected a fault condition

Figure 8-1 Control PCB LED indicator location

8-2
February 2004 Troubleshooting

Local Digital Control Option LED Indicators

The Local Digital Control Option has six LED’s used for status. The LED’s and their functions are listed
below.

Table 8-2 Local Digital Control LED Indicators

Status LED Color Description

Remote Green The Remote input is present.

Analog Green The Local mode is set to Analog.

Digital Green The Local mode is set to Digital.

Enable Green The Enable input is present.

On Green The 853 DSPC output is active.

Alert Amber Either a fault or alarm is present.

Figure 8-2 Local Digital Control

8-3
Troubleshooting February 2004

Fault and Alarm Codes

If there is a fault, the 853 DSPC automatically stops and holds the fault code for the user. The fault codes
are evaluated in their numeric order. This makes the lowest number codes the highest priority. The fault
code is displayed on the Local Digital Control module. 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 alarm code is also displayed on
the Local Digital Control module but not continuously. The display alternates between the selected
display variable and the alarm code. It can also be accessed as Setting #119 through either the serial or
network interface.

A fault will always override an alarm and stop the 853 DSPC. The following table lists the fault and alarm
codes.

Table 8-3 Fault and Alarm Codes

Fault/Alarm Code Description

Phase L1 Current 1 The fault occurs when the Current Input L1 Actual peak
Input High Fault exceeds the Current Input High Fault at any time during the
AC cycle for two consecutive samples. The fault will be reset
and automatically restart based on the following conditions.

1. The 853 will turn off and automatically restart based


on the Current Input High Retry Number.

2. The 853 will turn off and not automatically restart if


the number of restarts occur within the Current Input
High Retry Time.

Phase L2 Current 2 The fault occurs when the Current Input L2 Actual peak
Input High Fault exceeds the Current Input High Fault at any time during the
AC cycle for two consecutive samples. The fault will be reset
and automatically restart based on the following conditions.

1. The 853 will turn off and automatically restart based


on the Current Input High Retry Number.

2. The 853 will turn off and not automatically restart if


the number of restarts occur within the Current Input
High Retry Time.

8-4
February 2004 Troubleshooting

Fault/Alarm Code Description

Phase L3 Current 3 The fault occurs when the Current Input L3 Actual peak
Input High Fault exceeds the Current Input High Fault at any time during the
AC cycle for two consecutive samples. The fault will be reset
and automatically restart based on the following conditions.

1. The 853 will turn off and automatically restart based


on the Current Input High Retry Number.

2. The 853 will turn off and not automatically restart if


the number of restarts occur within the Current Input
High Retry Time.

Current Input Timed 5 The fault occurs when the following conditions are met.
Overload Fault
1. The Current Input Actual exceeds the Current
Input Overload Fault.

2. The accumulated time of condition #1 is greater than


the Current Input Overload Time.

Note: If the Current Input Actual goes below the Current


Input Overload Fault then the accumulated time resets back
to zero.

Over Temperature 6 The fault occurs when the thermostat input changes to the off
Fault state. The thermostat input is defined as NO (Normally
Open) or NC (Normally Closed) depending on bit 8 of the
Configuration Word.

Internal Fault #1 7 The fault occurs when internal fault input #1 changes to the
off state. The internal fault input #1 is defined as NO
(Normally Open) or NC (Normally Closed) depending on bit 6
of the Configuration Word.

Internal Fault #2 8 The fault occurs when internal fault input #2 changes to the
off state. The internal fault input #2 is defined as NO
(Normally Open) or NC (Normally Closed) depending on bit 7
of the Configuration Word.

Voltage Input High 9 The fault occurs when Voltage Input Actual (average of
Fault three phases) exceeds the Voltage High Fault.

Voltage Input Low 10 The fault occurs when Voltage Input Actual (average of
Fault three phases) is lower than 12.5% of the Voltage Input
Rating, and bit 9 of the Configuration Word is NOT set.

8-5
Troubleshooting February 2004

Fault/Alarm Code Description

Phase L1 Loss 11 The fault occurs when the following conditions are met.

1. 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.

2. Voltage L2-L3 Actual is greater than Voltage Input


Actual.

3. The accumulated time of condition #2 is greater than


100 milliseconds.

Note: If condition #2 is not met, then the accumulated time


resets back to zero.

Phase L2 Loss 12 The fault occurs when the following conditions are met.

1. 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.

2. Voltage L3-L1 Actual is greater than Voltage Input


Actual.

3. The accumulated time of condition #2 is greater than


100 milliseconds.

Note: If condition #2 is not met, then the accumulated time


resets back to zero.

Phase L3 Loss 13 The fault occurs when the following conditions are met.

1. 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.

2. Voltage L1-L2 Actual is greater than Voltage Input


Actual.

3. The accumulated time of condition #2 is greater than


100 milliseconds.

Note: If condition #2 is not met, then the accumulated time


resets back to zero.

8-6
February 2004 Troubleshooting

Fault/Alarm Code Description

External Fault #1 14 The fault occurs when the following conditions are met.

1. Configuration Word bit 12 is a one.

2. The External Fault Input #1 changes to the off state.

Note: External Fault Input #1 is defined as NO (Normally


Open) or NC (Normally Closed) depending on bit 3 of the
Configuration Word.

External Fault #2 15 The fault occurs when the following conditions are met.

1. Configuration Word bit 13 is a one.

2. The External Fault Input #2 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.

External Fault #3 16 The fault occurs when the following conditions are met.

1. Configuration Word bit 14 is a one.

2. The External Fault Input #3 changes to the off state.

Note: External Fault Input #3 is defined as NO (Normally


Open) or NC (Normally Closed) depending on bit 5 of the
Configuration Word.

Configuration Fault 17 The fault occurs when the 'check byte' of the onboard
EEPROM is not correct.

Note: [Reset] may clear this fault with no further action.

Watchdog Fault 18 The fault occurs when the digital signal processor does not
update the watchdog timer correctly.

SCR Shorted Fault 19 The fault occurs when the following conditions are met.

1. The Voltage Output Actual is greater than 75% of


the Voltage Output Rating for one second.

2. The 853 is off.

Network Loss Fault 20 The fault occurs if there is a network loss and the Network
Loss Selection is set to Fault and Stop.

8-7
Troubleshooting February 2004

Fault/Alarm Code Description

Ground Fault 21 The fault occurs when all the following conditions are met.

1. The calculated ground current exceeds the Ground


Fault Current.

2. The accumulated time of condition #1 is greater than


the Ground Fault Time.

Note: If the calculated ground current goes below the Ground


Fault Current then the accumulated time resets back to zero.

Frequency Alarm 30 The alarm occurs when the Frequency Actual is outside of a
2.0 Hertz band when compared to the Frequency Rating.

L1 Current Input 31 The alarm occurs when all of the following conditions are met.
Load Failure Alarm
1. The Current L1 Input Actual is less than the
Current Input Threshold Load Failure.

2. The Voltage Output Actual is greater than 10% of


the Voltage Output Rating

3. The setpoint has completed ramping up.

L2 Current Input 32 The alarm occurs when all of the following conditions are met.
Load Failure Alarm
1. The Current L2 Input Actual is less than the
Current Input Threshold Load Failure.

2. The Voltage Output Actual is greater than 10% of


the Voltage Output Rating

3. The setpoint has completed ramping up.

L3 Current Input 33 The alarm occurs when all of the following conditions are met.
Load Failure Alarm
1. The Current L3 Input Actual is less than the
Current Input Threshold Load Failure.

2. The Voltage Output Actual is greater than 10% of


the Voltage Output Rating

3. The setpoint has completed ramping up.

Voltage Input Low 34 The alarm occurs when the Voltage Input Actual is lower
Alarm than the Voltage Input Low Alarm.

Voltage Output 35 The alarm occurs when the Voltage Output Actual is being
Limit Alarm limited to the Voltage Output Limit by the voltage output
control loop.

8-8
February 2004 Troubleshooting

Fault/Alarm Code Description

Current Output 36 The alarm occurs when the Current Output Actual is being
Limit Alarm limited to the Current Output Limit by the current output
control loop.

Power Output Limit 37 The alarm occurs when the Power Output Actual is being
Alarm limited to the Power Output Limit by the power output
control loop.

Current Input Limit 38 The alarm occurs when the Current Input Actual is being
Alarm limited to the Current Input Limit.

Maximum Voltage 39 The alarm occurs when the Duty Cycle of the controller
Output Alarm reaches 100%.

Network Loss Alarm 40 The alarm occurs if there is a network loss and the Network
Loss Selection is set to Alarm and Run.

L1-L2 Input Voltage 41 The alarm occurs when the difference between the Voltage
Unbalanced 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).

L2-L3 Input Voltage 42 The alarm occurs when the difference between the Voltage
Unbalanced 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).

L3-L1 Input Voltage 43 The alarm occurs when the difference between the Voltage
Unbalanced 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).

Fault Reset

Faults can be cleared or reset by three different methods. Alarms are automatically cleared.

● Toggle the Enable/Inhibit switch from Enable to Inhibit.

● Press the Reset button on the Local Digital Control module.

● Use the fault reset bit (bit 1) of the Control Word. The bit must be momentarily set to enable a
fault reset. 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.

Fault Buffer

The last eight faults are stored in Fault Buffers #1 - #8 and can be accessed from the serial interface.
The fault buffer includes the Fault Code and a time stamp from Output Time On. Only faults that occur

8-9
Troubleshooting February 2004

when the unit is running are buffered. The Fault Index indicates which buffer will be written to next. The
fault buffers are connected in a circular fashion.

Troubleshooting Guide

DANGER
Only qualified electrical personnel familiar with the construction and operation of the
equipment and the hazards involved should install, operate, and/or service this equipment.
Read and understand this manual and other applicable manuals in their entirety before
proceeding. Failure to observe this precaution could result in severe bodily injury or loss
of life.

DANGER
The user is responsible for conforming with all applicable local, national, and international
codes; wiring practices, grounding, disconnects, and overcurrent protection are of
particular importance. 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. Disconnect and lock out
all ungrounded conductors of the AC power line. Failure to observe these precautions
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. Voltages on many components are at incoming line potential.
to avoid electric shock hazard or damage to equipment, do not touch any component other
than those specified in the manual. Failure to observe these precautions could result in
severe injury or loss of life.

The following table shows different conditions with probable cause and corrective action for each
condition.

8-10
February 2004 Troubleshooting

Table 8-4 Troubleshooting Guide

Condition Probable Cause Corrective Action

+5V LED off No Control Power Insure the 853 DSPC has separate
control power
+15V LED off
Power Supply connection Check Power Supply connections to
-15V LED off open main control PCB

Power Supply failed Replace Power Supply

Heartbeat LED off DSP on main control PCB Check that jumper JP1 has been
failed removed before applying power

Replace main control PCB

Local Digital Local Digital Control Check Local Digital Control


Control Display off connection open or connection to main control PCB
or scrambled intermittent

853 DSPC will not Enable not present Check that the Enable status LED is
turn on in Local on. The Output On status LED should
Analog mode also be on.

Local mode not selected Check that the Remote status LED is
off.

Analog mode not selected Select Analog mode on Local Digital


Control. Check that the Analog status
LED on

Local Analog setpoint set to Verify voltage at Analog Setpoint input


zero

Local analog setpoint Verify Local analog setpoint


calibration incorrect calibration

8-11
Troubleshooting February 2004

Condition Probable Cause Corrective Action

853 DSPC will not Enable not present Check that the Enable status LED is
turn on in Local on.
Digital mode
Local mode not selected Check that the Remote status LED is
off.

Digital mode not selected Select Digital mode on Local Digital


Control. Check that the Digital status
LED is on

Output On not selected Press the On/Off/Reset pushbutton


and check that the Output On LED is
on.

Digital setpoint set at zero Press the increase pushbutton to


increase the setpoint

853 DSPC will not Enable not present Check that the Enable status LED is
turn on in Remote on.
mode
Remote mode not selected Check that the Remote status LED is
on.

On/Off bit not set to one Set the On/Off bit to one in the
Control Word and check that the
Output On LED is on

Setpoint set at zero Verify that the setpoints for Voltage,


Current, Power and Remote Duty
Cycle are not zero

853 DSPC cannot Calibration incorrect Check calibration


provide full power
to the load Power is being limited by one Verify setpoints for the three control
of the three control loops loops

853 DSPC is full on and Duty Cycle is at 100.0%.


cannot provide any more
power
Review the load to verify that 100.0%
voltage will allow 100.0% power.

Verify input voltage level to make sure


it is not low

Output wiring intermittent or Check the output wiring


disconnected

8-12
February 2004 Troubleshooting

Condition Probable Cause Corrective Action

Nuisance Input Improper fuse rating Refer to Hardware Installation


Fuse blowing Chapter for correct fuse rating

Fuse improperly tightened Tighten the fuses

F-01, F-02, F-03 - Calibration incorrect Check calibration


Current Input High
Fault Current Input Rating setting Check Current Input Rating setting
incorrect

Current Input High Fault Check Current Input High Fault


setting incorrect setting

Intermittent short in load Check load

F-05 – Current Input Calibration incorrect Check calibration


Timed Over Current
Fault Current Input Rating setting Check Current Input Rating setting
incorrect

Current Input Overload Fault Check Current Input Overload Fault


setting incorrect setting

Current Input Overload Time Check Current Input Overload Time


setting incorrect setting

Output transformer sized Verify size of output transformer


incorrectly

F-06 – Over Thermostat contact state Check Configuration Word setting


Temperature Fault incorrect in Configuration
Word setting

Thermostat wiring open or Check thermostat wiring


shorted

Cabinet is overheating Provide more cabinet ventilation or


cooling

Unit is Overheating Check fan is functioning properly

F-07, F-08 – Internal Internal Fault contact state Check Configuration Word setting
Fault incorrect in Configuration
Word setting

Internal Fault wiring open or Check Internal Fault wiring


shorted

8-13
Troubleshooting February 2004

Condition Probable Cause Corrective Action

F-09 – Voltage Input Calibration incorrect Check calibration


High Fault
Voltage Input Rating setting Check Voltage Input Rating setting
incorrect

Voltage Input High Fault Check Voltage Input High Fault


setting incorrect setting

Voltage Output PT Secondary Check Voltage Output PT


setting incorrect Secondary setting. Refer to Startup
Chapter for details on correct setting

Incoming voltage out of Correct incoming voltage level


tolerance

F-10 – Voltage Input Calibration incorrect Check calibration


Low Fault
Voltage Input Rating setting Check Voltage Input Rating setting
incorrect

Voltage Output PT Secondary Check Voltage Output PT


setting incorrect Secondary setting. Refer to Startup
Chapter for details on correct setting

Blown input fuse Replace input fuse

F-11, F-12, F-13 – Calibration incorrect Check calibration


Phase Loss
Blown input fuse Replace input fuse

F-14, F-15, F16 – External Fault contact state Check Configuration Word setting
External Fault incorrect in Configuration
Word setting

External Fault wiring open or Check External Fault wiring


shorted

F-17 – Configuration Failed EEPROM memory Try [Reset]


Fault
If the fault remains, use the
configuration tool offline to modify a
setting or load a .csv file. Go online,
and respond to the Write prompt with
Yes.

Replace main control PCB

F-18 Watchdog Failed DSP Replace main control PCB


Fault

8-14
February 2004 Troubleshooting

Condition Probable Cause Corrective Action

F-19 – SCR Shorted Calibration incorrect Check calibration


Fault
Voltage Output Rating setting Check Voltage Output Rating setting
incorrect

Voltage Output PT Secondary Check Voltage Output PT


setting incorrect Secondary setting. See Startup
Chapter for details on correct setting

Shorted SCR Replace SCR

F-20 - Network Loss Network failure Check network connection


Fault
Verify presence of network

Change Network Loss Option to


allow device operation

F-21 – Ground Fault Calibration incorrect Check calibration

Current Input Rating setting Check Current Input Rating setting


incorrect

Ground Fault Current Check Ground Fault Current setting


setting incorrect

Intermittent short to ground Check for ground

A-30 – Frequency Frequency Rating setting Check Frequency Rating setting


Alarm incorrect

Incoming frequency out of Correct incoming frequency


tolerance

8-15
Troubleshooting February 2004

Condition Probable Cause Corrective Action

A-31, A-32, A-33 – Calibration incorrect Check calibration


Current Input Load
Failure Alarm Current Threshold Load Check Current Input Threshold
Failure setting incorrect Load Failure setting

Voltage Output Rating setting Check Voltage Output Rating setting


incorrect

Voltage Output PT Secondary Check Voltage Output PT


setting incorrect Secondary setting. Refer to Startup
Chapter for details on correct setting

Output load changed Verify output load

A-34 – Voltage Input Calibration incorrect Check calibration


Low Alarm
Voltage Input Rating setting Check Voltage Input Rating setting
incorrect

Voltage Input Low Alarm Check Voltage Input Low Alarm


setting incorrect setting

Voltage Output PT Secondary Check Voltage Output PT


setting incorrect Secondary setting. Refer to Startup
Chapter for details on correct setting

Incoming voltage out of Correct incoming voltage level


tolerance

A-35 – Voltage Calibration incorrect Check calibration


Output Limit Alarm
Voltage Output Rating setting Check Voltage Output Rating setting
incorrect

Voltage Output PT Secondary Check Voltage Output PT


setting incorrect Secondary setting. Refer to Startup
Chapter for details on correct setting

Voltage Output Setpoint Check Voltage Output Setpoint


setting incorrect setting

Controlling with Voltage Change Voltage Output Setpoint


Output PID

8-16
February 2004 Troubleshooting

Condition Probable Cause Corrective Action

A-36 – Current Calibration incorrect Check calibration


Output Limit Alarm
Current Output Rating setting Check Current Output Rating setting
incorrect

Current Output Setpoint Check Current Output Setpoint


setting incorrect setting

Controlling with Current Change Current Output Setpoint


Output PID

A-37 – Power Calibration incorrect Check calibration


Output Limit Alarm
Voltage Output Rating setting Check Voltage Output Rating setting
incorrect

Voltage Output PT Secondary Check Voltage Output PT


setting incorrect Secondary setting. Refer to Startup
Chapter for details on correct setting

Current Output Rating setting Check Current Output Rating setting


incorrect

Power Output Setpoint setting Check Power Output Setpoint


incorrect setting

Controlling with Power Output Change Power Output Setpoint


PID

A-38 – Current Input Calibration incorrect Check calibration


Limit Alarm
Current Input Rating setting Check Current Input Rating setting
incorrect

Current Input Limit setting Check Current Input Limit setting


incorrect

Controlling Current Input with Change Current Input Limit


Current Output PID

A-39 - Maximum Duty Cycle has reached Lower the control setpoint
Voltage Output 100%
Alarm

8-17
Troubleshooting February 2004

Condition Probable Cause Corrective Action

A-40- Network Loss Network failure Check network connection


Alarm
Verify presence of network

Change Network Loss Option to


allow device operation

A-41, A-42, A-43 – Calibration incorrect Check calibration


Input Voltage
Unbalance Alarm Voltage Input Phase Check Voltage Input Phase
Unbalance setting incorrect Unbalance Alarm setting

Voltage Input Rating setting Check Voltage Input Rating setting


incorrect

Voltage Input Supply not Check Voltage Input Supply


balanced

8-18
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
Glossary
Glossary of common terms and abbreviations used in SCR Power Controllers and their applications

Term or Acronym Description

ADR Automatic Device Replacement

ASCII American Standard Code for Information Interchange

Bias Calibration factor to offset signal at zero output of control signal

CAN Controller Area Network

CT Current Transformer

DSP Digital Signal Processor

DSPC Digital SCR Power Controller

EDS Electronic Data Sheet

Heatsink Device to carry heat from power devices

I2t Subcycle current characteristic of an SCR or fast clearing fuse

I/O Input/Output

IRMS Amps Root Mean Squared

KVA One thousand volt amperes

LED Light emitting diode

MOV Metal Oxide Varistor – brand name of GE transient voltage


suppressor

NC Normally closed contact

NO Normally open contact

NEC National Electric Code

NEMA National Electrical Manufacturers Association

ODVA Open DeviceNet™ Vendors Association

PCB Printed Circuit Board

PCMCIA Personal Computer Memory Card International Association

PCU Power Control Unit

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Glossary February 2004

Term or Acronym Description

Phase Angle Control by chopping each half cycle

PID Proportional, Integral Derivative Controller

PLC Programmable Logic Controller

PT Potential Transformer

RFI Radio Frequency Interference

RMS Root Mean Squared

Rx Receive

SCR Silicon Controlled Rectifier

Semiconductor Solid State device for controlling electric power

Setpoint Reference for PID control

Silicon Material from which semiconductors are made

Span Calibration signal to adjust maximum input of control signal

Thyristor Name of semiconductor family including SCR’s, TRIAC, etc.

Tx Transmit

TXID Transaction ID for Explicit Message Requests and Responses

VAC Volts Alternating Current

VDC Volts Direct Current

VRMS Volts Root Mean Squared

Zero Calibration signal to adjust minimum input of control signal to zero

Zero-Cross Control by integrating numbers of complete cycles

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