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
vii
List of Tables
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.
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.
1-2
February 2004 Product Description
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.
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.
1-4
February 2004 Product Description
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.
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.
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.
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
• 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:
• Operates on universal line voltages, from 24 to 600 VAC and 50/60 Hz.
• DSP-based control
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
Control Power 50 VA
Regulation 1%
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.
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 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
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
2-4
February 2004 Hardware
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.
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
2-6
February 2004 Hardware
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.
2-7
Hardware February 2004
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.
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 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.
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.
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.
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’.
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.
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
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.
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.
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
3-5
Configuration February 2004
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
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.
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
Manual Open (in a separate browser window) this product manual in pdf format.
3-7
Configuration February 2004
Taskbar
The Configuration Tool Taskbar provides shortcuts to frequently used options.
Taskbar Description
Items
Settings This button appears on the taskbar if either the Monitor or Calibration window is
visible. Same as the Window->Settings 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 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).
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.
Click [Print] to send a copy of the table to the printer port of the host computer.
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).
● 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.
● 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
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:
‘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
* 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.
3-12
February 2004 Configuration
3-13
Configuration February 2004
* 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.
3-14
February 2004 Configuration
3-15
Configuration February 2004
3-16
February 2004 Configuration
Network Tab
Software Version
Serial Number
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
If any settings have been modified using the configuration tool offline, the following message will 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.
3-19
Configuration February 2004
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.
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.
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:
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.
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 Duty Cycle Setpoint can be written ONLY under Open Loop regulation.
3-24
February 2004 Configuration
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:
● Press [Enter] or click outside the field to write the new setpoint.
3-25
Configuration February 2004
Control Tab
The Monitor Control Tab includes the following data for monitor only
3-26
February 2004 Configuration
Status Tab
At Setpoint Bit 9
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.
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.
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.
4-1
Calibration February 2004
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.
4-2
February 2004 Calibration
Current Calibration
Current L1 Input Zero and Span Current X1 Output 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.
4-3
Calibration February 2004
Analog Calibration
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.
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.
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:
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:
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
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.
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.
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.
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
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.
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
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.
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:
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.
4-15
Calibration February 2004
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.
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.
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.
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
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
Output
Output
Output
% of Rated
Output
5-2
February 2004 Local Digital Control Option
Analog Status On The Local mode is set to Analog, and the Remote/Local
input is in the Local state.
Digital Status On The Local mode is set to Digital, and the Remote/Local
input is in the Local state.
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
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
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.
On/Off/Reset
Display Selection Up/Down Pushbutton Select Pushbutton
Pushbutton
5-6
February 2004 Local Digital Control Option
To enter Display Select mode, press the [SEL] pushbutton. Entry into the Display Select mode is
indicated by the characters ‘SEL’ in the four-digit numeric display. In this mode, the [Up Arrow] and
[Down Arrow] pushbuttons increment/decrement the Local Digital Control Display Selection. Display
Select mode operation is summarized in the following tables:
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
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
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.
6-3
Serial Communication February 2004
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.
01 Illegal function
6-5
Serial Communication February 2004
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.
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.
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
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
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.
7-1
Settings February 2004
7-2
February 2004 Settings
7-3
Settings February 2004
7-4
February 2004 Settings
7-5
Settings February 2004
7-6
February 2004 Settings
7-7
Settings February 2004
7-8
February 2004 Settings
7-9
Settings February 2004
7-10
February 2004 Settings
7-11
Settings February 2004
7-12
February 2004 Settings
7-13
Settings February 2004
7-14
February 2004 Settings
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
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 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
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.
8-2
February 2004 Troubleshooting
The Local Digital Control Option has six LED’s used for status. The LED’s and their functions are listed
below.
8-3
Troubleshooting February 2004
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.
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.
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.
8-4
February 2004 Troubleshooting
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.
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.
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
Phase L1 Loss 11 The fault occurs when the following conditions are met.
Phase L2 Loss 12 The fault occurs when the following conditions are met.
Phase L3 Loss 13 The fault occurs when the following conditions are met.
8-6
February 2004 Troubleshooting
External Fault #1 14 The fault occurs when the following conditions are met.
External Fault #2 15 The fault occurs when the following conditions are met.
External Fault #3 16 The fault occurs when the following conditions are met.
Configuration Fault 17 The fault occurs when the 'check byte' of the onboard
EEPROM is not correct.
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.
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
Ground Fault 21 The fault occurs when all the following conditions are met.
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.
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.
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.
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
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.
● 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
+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
Heartbeat LED off DSP on main control PCB Check that jumper JP1 has been
failed removed before applying power
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.
8-11
Troubleshooting February 2004
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.
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
8-12
February 2004 Troubleshooting
F-07, F-08 – Internal Internal Fault contact state Check Configuration Word setting
Fault incorrect in Configuration
Word setting
8-13
Troubleshooting February 2004
F-14, F-15, F16 – External Fault contact state Check Configuration Word setting
External Fault incorrect in Configuration
Word setting
8-14
February 2004 Troubleshooting
8-15
Troubleshooting February 2004
8-16
February 2004 Troubleshooting
A-39 - Maximum Duty Cycle has reached Lower the control setpoint
Voltage Output 100%
Alarm
8-17
Troubleshooting February 2004
8-18
Appendix A
Mechanical Dimensions
A-1
Mechanical Dimensions February 2004
A-2
Appendix B
Electrical Drawings
B-1
Electrical Drawings February 2004
B-2
February 2004 Electrical Drawings
B-3
Electrical Drawings February 2004
B-4
February 2004 Electrical Drawings
B-5
Electrical Drawings February 2004
B-6
February 2004 Electrical Drawings
B-7
Glossary
Glossary of common terms and abbreviations used in SCR Power Controllers and their applications
CT Current Transformer
I/O Input/Output
i
Glossary February 2004
PT Potential Transformer
Rx Receive
Tx Transmit
ii