Video Tutorials

Control Panel Quick Setup

Description:

Tutorial of the Quick Setup for a microFUSION SCR power controller using the Control Concepts Control Panel Software.

Transcript:

Today we’re going to show you how to quickly set up your MicroFusion power controller using the Control Concepts Control Panel Software.

To get started, we need to first wire our controller according to the wiring diagram found in the quick setup guide that came with your controller.

Next, we need to download the control panel software found at ccipower.com. Click Support. Then click software. Then click the red download link. When your download is finished, go ahead and install that software.

Next, connect your MicroFusion to the computer using a micro USB cable. For our demo today,  we have a 32 amp MicroFusion with a 120 volt light bulb.

Next, launch the control panel software. When it starts, you should see the MicroFusion in the upper left hand corner. It should automatically connect, but if it doesn’t, go ahead and click connect.

Now that we’re connected, we can use the quick setup guide to quickly configure your MicroFusion Controller. Click Action, then Quick Setup. The first menu allows you to set the feedback type for the controller. It can be RMS or average, and it can be voltage, current or power. For today, we’ll just pick RMS Voltage.

Next, we’re going to set our full scale settings for the controller. For voltage, we want the nominal line voltage, which, in this case, is 120 volts. For current, we want the full load current when nominal line voltage is applied. In this case, we’ll use 32 amps. And for power, we want the nominal voltage times the current. In this case, that’s 3.8 kW.

Next, we’ll set the voltage and current limits. For the voltage limit, we’ll leave it at 630 volts. For the current limit, we’ll set it to 105% of the frame rating. This can also be adjusted lower, to be 105% of your load, but no more than 105% of the frame.

This screen allows us to choose the firing mode of the power controller. For precision loads or for transformer-coupled loads, we recommend phase angle. For straight, resistive loads, we recommend zero cross. Additional firing modes can be found in the manual.

Next, we’ll set the control setpoint for the controller. This can be either an analog input, such as 0-5 volts or 4-20 milliamps, or it can be a fieldbus setpoint, such as ethernet ip, or profinet. You can also set a keypad setpoint that is either volatile or nonvolatile. For our demo today, we’re going to select Analog Input 1 and we’re going to select 0-5 volts D.C.

The summary page allows us to review all of our settings. Here we can click finish and we are ready to test our controller.

In order to operate the controller, we need to put it in a Run state. To put the controller in a Run state, we need to jumper pins 8 and 9 on the P1 connector. Next, apply 24 volts and your line voltage. Finally, select the Run/Stop slider and your power controller should now be operational.

Congratulations, you’ve set up your first power controller.

For more information, visit us at ccipower.com

The FUSION Control Panel is provided free with all our microprocessor-based controllers. This software allows you to conveniently monitor and adjust your controller settings.

In 2014, we are releasing our controllers with Control Panel 3.5, which is required to run Version 5.0 firmware.
Firmware 5.0 adds new features and made the control panel even more customizable. These include: 1) Custom display, 2) Zero Cross Transformer Mode, 3) User Lock, 4) Three Phase Load Imbalance, 5) monitor parameters, and the ability to name IP addresses

In this video, we will cover a few of these features, found under display control, and user settings.

First, connect to a powered controller via USB. Open the Control Panel and click "Connect" on the left side of the screen. Then click on the system tab, and on the right side of the screen you will find the Display Control Options and User Settings.

The display control options dictate what information will be available on your controller's digital display.

Clicking on "Default Screen List" returns the Control Panel to manufacturing defaults.

Selecting Custom Screen List opens a new window. From here you can choose what relevant data appears on your controller display, or create custom text.

The controller can display a maximum of 50 screens. Each screen contains up to two lines of text. The Screen List tells us which parameters are currently being displayed.

To add or remove screens, select a parameter from the Display List and select "Add," "Remove," or "Replace." For example, say I want "Control Loop Response" for Zone 1. I would like it to display above Feedback Zone 1, so I select that parameter and click "Add."

This third window tells us how the parameter will appear on the controller display: as "Slew Rate Z1." When we click "Program," these changes will be applied.

Custom text may be useful for naming a controller or giving instructions specific to your task. Enter the text you wish to display in the Custom Text fields, (maximum of 16 characters per line) highlight "Custom Text" from the end of the Display list and choose "Add" or "Replace."

Under "Analog Input Monitor Params" are options to specify titles and units for Monitor parameters. We will cover how to use analog inputs for general purpose in another tutorial.

Again, to approve changes, select "Program" and close the Custom Screen List dialog box. You must then reset the controller for the changes to take effect.

Many parameters can be edited from the controller display. Parameter lock prevents users from changing specific parameters unless they enter the right password. By default, this password is "4000."

From the parameter lock menu, select the parameters you wish to lock, enter your password, and click "Program" to make the change.  You may also choose to use the Lock All or Unlock All buttons.
Once the initial password is entered, you may also change the password by selecting the Change Password checkbox and entering a new 4-number combination into the field. 

An editable parameter will appear on the controller display with a dot preceding the text. Pressing the green checkmark key will allow you to edit the parameter value. When the parameter is locked, an asterik (*) appears instead, and the green checkmark key will prompt you to enter the password.

Use the arrow keys to enter the correct combination, pressing the green key to move forward to the next number. If the correct password is entered, parameters are unlocked and can be locked again by pressing and holding the plus sign (+) key.

Let's return to the Display Control options. If the "Auto-Scroll Enabled" checkbox is selected, the controller display will cycle through the approved parameters. Auto-scroll also resumes after ten minutes of inactivity, and can be turned on via the controller display panel by pressing and holding the Up Arrow key.

Moving on to User settings. These options are available in Firmware version 5.00 and later releases. Click Save to Backup after making changes to save your settings to your computer.

Restore From Backup allows you to restore previously-saved custom settings.

For more information, you can visit our website at www.ccipower.com, or contact the experts directly at Control Concepts, Inc.

Transcript:

Our FUSION SCR power controllers have a 100kA Short Circuit Current Rating (SCCR). Here's a behind-the-scenes look at our testing procedures.

The tests were conducted at Bussman Labs, in St. Louis, MO.

The controllers passed two tests: Standard Fault, and High Fault.

For the standard fault test, fuses are calibrated to have a let-through current of the peak let-through for the recommended fuse size. The high fault test uses the recommended fuse size: fast-acting, Class T fuses.

Here is the load and shorting contactor. The metal enclosure is to be connected to the phase of the source of supply which is connected to the pole judged as having the least risk of arcing to ground.

The controller is held in a wire mesh cage sized to 150% of controller size. This simulates the minimum requirement panel size for an end user. This cage is covered in cotton mesh that is considered highly flammable. Everything is installed according to manufacturer's recommendations.

To run the test, we initiate voltage to the controller and charge up the generator to a specific level determined by the fuse size. After counting down, the short is triggered by the contactor.

The contactor, located here, is sized to allow the peak let-through current of the fuses. A smaller contacter would not provide enough let-through and would void the test.

The noise heard is the contactor closing. The flash is the arc flash of the contactor when the short is being initiated.

In order to pass the tests, controller buswork, and ground wire must remain intact. The ground wire does not open or break, and nothing in or around the controller can have burn marks showing signs of a flame.

All FUSION and Compact FUSION units have received a 100kA short circuit current rating after passing these tests.
Contact Information onscreen

For more information about the rating and how SCCR impacts your business, visit www.ccipower.com/SCCR, or contact the experts directly and call Control Concepts, Inc.

Transcript:

Welcome. I'm Cory Watkins, President of Control Concepts. Today we're here to discuss how you can improve power factor for transformer-coupled loads.

Now, traditionally, zero cross SCR controllers are used for resistive loads. This is because zero cross operation reduces harmonics and maintains existing power factor. However, if a system design requires an isolation or step-down transformer, you would need to switch to phase angle operation in order to prevent saturation of the transformer. Switching to phase angle operation has the advantage of improved power control, but suffers from both increased harmonics and degraded power factor.

Today, with the advent of digital SCR technology, we are able to combine phase angle and zero cross firing technlogies into a hybrid firing mode that we proudly introduce as "Zero Cross Transformer Mode," or ZCT Mode. 

This technology allows you to maintain a power factor of greater than 0.9 from 50-100% command signal, thereby eliminating the penalties you may see from your utilities.

So you may be wondering, are you a good candidate for ZCT Mode? Good candidates are those who are:

• Looking for improved power factor
• Have transformer-coupled loads
• Either require high thermal inertia, or require less stringent process control

So in summary, Zero Cross Transformer Mode can improve power factor by maintaining a power factor of 0.9 or greater from 50-100% command signal for transformer-coupled loads. 

If you'd like to learn more or talk to one of our application engineers about your project, give us a call at Control Concepts. Thank you.

Transcript:

Welcome. In this video, we will go over fuse replacement for a Compact FUSION SCR Power Controller.

You will need the following:

• A #2 Philips bit screwdriver
• A small flat head screwdriver
• If you are working with a 10 - 50A controller, you will also need a pair of fuse-pulling pliers.
• A 80 - 160A controller will call for a #3 philips bit and a torque wrench.
• You will also need some electrically-conductive anti-corrosive paste, like Penatrox A, and the replacement fuse or fuses - these are available for purchase from Control Concepts

Before replacing a fuse, you must turn off line power and control power. Then use a screwdriver to remove the controller lid. Disconnect the display wire and set the lid aside.

Now, remove the main wire harness by pulling very gently on the connectors - not the wire itself. 

You will also need to remove the flat flex cable as shown. Pull the key toward the cable from both edges of the connector. The key tabs will stay attached to the connector.

Remove the four screws in the corners of the gate driver board. Gently lift the board out of the controller.

Now the steps vary depending on your controller size. A 10-50A Compact FUSION is pretty straightforward: simply remove and replace the fuse. We will focus more on the 80 - 160A sizes.

These controllers have fuses attached to insulators. Here is a 160A controller - we remove the screws, paying attention to how the bus bars, wires, and lugs are oriented.

An 80A controller also has a DVDT board that must be removed from the SCR to get to the bus bar.

Once you've removed the bad fuse, take the new fuse and apply a thin layer of conductive anti-corrosive paste where it contacts the lug and the bus bar.

Insert the fuse, reattach the red wire with the ring terminal, and the lug. Torque the screws holding the fuse to 75 in-lbs.

For an 80A controller, you will do the same: torque the screws around the fuse to 75 in-lbs, and then re-attach the DVDT board and torque the stand offs to 25 in-lbs.

Now we continue working backward: Connect the leads from the current transformer. Re-insert the gate board with the 4 screws, and keep the board supported and not over-stressed while you connect the installation displacement connectors. Next, connect the flat flex cables, starting with the shortest. Be sure that you insert these cables into the key evenly - they should not be crooked or below the key altogether.Re-connect all the wiring to the correct headers, as well as any fan wires if present. (say 2x, once without) Reconnect the display cable. Re-attach the controller lids. Finally, apply control and line power and make sure a blown fuse indicator is NOT present.

For more information or assistance, download the Compact FUSION Installation manual from our website at www.ccipower.com or contact the experts directly by calling Control Concepts, Inc.

Transcript:

Welcome. This video series will provide an overview of advanced settings on your FUSION and Compact FUSION controller. We will start with the System tab and cover the Zone tabs in a second video.

Before we begin, you will need to install the Control Panel software, which is provided free with your controller. Then connect to your powered controller with a USB cable.

Open the Control Panel and click the Connect button. Now we'll go over the different advanced options under the System tab.

The run logic option controls polarity of pin 7 and 9. By default, the logic is set to closed for run. Toggling this option is the equivalent of opening and closing the run/reset.

This next option is specifically for 3-phase controllers with 4-wire wye or inside delta loads. Otherwise it will not appear on your Control Panel. This option is specified at order time as it requires a specific internal wire harness. Contact Control Concepts if you would like this option.

When Hero Mode is enabled, the controller will continue running in the event of an over-temp condition. By default, this feature is disabled, but you may enable it with SP-84 or with this field on the control panel. You will receive a warning that doing so will void controller warranty. Click OK if you wish to continue.

Now, from the Zone tabs, you can set different relay alarms. We'll go over this in detail in our next video. With regards to Hero Mode, just know that if a relay mask has "Heatsink Over Temp" selected, the relay will energize. Inhibit alarms will still indicate the over-temp condition. But your controller will stay in a run state, and the display and the indicator LEDs will register a warning alarm instead of an inhibit alarm.

Hero Mode is not available on all firmware versions. Contact Control Concepts with questions about this feature and new firmware releases.

If you are using Sync Guard, you may enable the sync guard resistor to do load balancing across multiple zero-cross controllers. Typically, customers with networks of controllers have this setting enabled on the master and disabled on the others.

We've covered analog setpoints in an earlier video. Let's move on to these relay alarms. These are processor or system level alarms, and you can map to either relay one or relay two.

For example, if we mark the checkbox for "PLL Lock Loss," an alarm is output to relay 1 if the controller is unable to synchronize with the mains line frequency.

"In Run State" indicates the controller is in a true run state as opposed to a Stop or Fault state. And "Run Enable" is a pass through for pin 9 - it mirrors its input. So if pin 9 is open, the relay is open, and vice versa.

Here in the corner, you'll find our contact information and a link to the Control Concepts website. And this icon opens WebEx, which is the tool we use for troubleshooting a controller online with a laptop connected to a controller in the field.

For more information, check out our other video tutorials, download the Control Panel manual from our website at www.ccipower.com, or contact the experts directly at Control Concepts Inc.

Transcript

Welcome. This video will walk through the basic set up of a FUSION or Compact FUSION SCR power controller. We will do so in four parts: first, mounting, wiring, and basic controller operation. And a second video will cover Full scale settings.

First, you will need to mount the controller. Be sure to do so at least 3 inches away from other devices in order to ensure proper ventilation. Next, ground the controller as shown.

Then we need to connect line power,  load connections, and control power. For single phase and three phase 2 leg controllers, you will also need to connect a reference voltage to the line ref input shown here.

On the side of the controller, locate the P1 connector, found here. Note that Pin 7 and Pin 9 are the run and reset - used to enable, disable, or reset the controller. These pins are commonly wired with a run/stop switch.

Please note that while opening the run/stop on Pin 7 and Pin 9 inhibits firing of the SCRs within one half-cycle, the only safe way to service the controller is by having the mains disconnected by mechanical means. SCRs are solid state devices and cannot be considered a mechanically safe disconnect.

You will see voltage on the load side of SCRS even when not firing

We will wire Pin 7 and Pin 9 closed to enable controller operation in the following examples.

Next we'll cover analog setpoints.

You can use the built-in display on the controller to monitor and change your controller settings. Scroll through the settings using the arrow keys to “Setpoint Type.” The display tells us that we are currently using analog control – this is the default setting, and means that Pin 7 and Pin 8 on P1 are open.

Use the arrow keys to view Setpoint Selection - we are using setpoint 1. On P1, this means that Pin 7 and Pin 10 are open. Then we can scroll down further on the display and see that Setpoint 1 is currently reading a 16.78 mA  analog command signal shown here connected to pins 2 & 3.

To switch to analog setpoint 2, simply close Pin 7 and 10 and move your analog command signal to pins 4 & 5.

Now let's go back and wire the controller for Digital Setpoint 1. To do so, close Pin 7 and Pin 8 to select the Digital Setpoint and make sure Pin 10 is left open to select setpoint 1. Then scroll to Digital Setpoint 1 on the display to see the digital setpoint command. We will come back and edit this setting in a minute.

First we'll go over basic controller operation. We've already mounted, grounded, and wired the controller. Let's take a closer look at our indicator LEDs.

The top LED will turn green after you've connected Universal Input power - this is what powers the controller's electronics. The second LED will turn green when the mains input power is present. The Status LED has three settings: green for a run state, orange for a warning alarm, and red for an inhibit alarm. If the Status LED is off completely, no alarms are present but the controller is not enabled

We've wired the controller for analog control, and we'll use an analog source to change our settings; in our case we've connected to our controller with a PLC.

From the display we can confirm that we're using analog control and setpoint 1. We can also scroll down using the arrow keys to view the output of both setpoints, and use our PLC to increase or decrease output between 4 - 20 mA.

Let's go back and try this using a Digital setpoint. To do so, Pin 7 and Pin 8 must be closed. Then we scroll on the display to Digital Setpoint. The dot next to the name indicates that we can edit the setting, so we press the green button and use the plus or minus keys to change the output from 0 to 100 percent. Once we reach the right value, we press the green button again and save the change - we are now operating with 85 % power.

For more information, visit our website at www.ccipower.com, or contact the experts at Control Concepts Incorporated.

Transcript:

Welcome. This video will demonstrate auxiliary I/O retransmit scaling.

Before we begin, we will need to install the Control Panel software, which is provided free with your controller. Connect power to the controller and connect to your computer with a USB cable. 

First, connect to the controller using the USB interface.

The auxiliary I/O card is an optional component on our FUSION and Compact FUSION controllers. The card is located on the controller here. If your controller has an auxiliary I/O card, relevant options will be available to you on the control panel software.

You will see a -1000 in its model number, and this tab, the Aux I/O tab, will be part of your control panel.

The card has 2 digital inputs, digital 2 outputs, and 2 analog retransmits. You can see their statuses here on the control panel screen.

When we click on the Aux I/O tab, we can see Meter 1 and Meter 2 at the bottom of the screen. By default, both are set to 0 - 5 V DC. The Meter 1 Signal is set to RMS Load Voltage A, and the signal for Meter 2 is set to RMS Load Current A.

Let's do a couple of scenarios with retransmit scaling.

SCENARIO 1: Output = power 4-20 mA = 0 - 100%

You can choose up to two signals from the drop-down menus to retransmit. For our demonstration, let's change our output type to current, have Meter 1 output Power, and use 4-20 mA as 0 - 100 percent of full scale power.

We can check the Zone 1 tab for information about our fullscale settings. Here we see that fullscale power is equal to 9.6 killowatts.

Let's look at one more scenario. You may want to use a Direct Out test for trouble shooting or system start up. We change meter 2's signal to direct out. Let's also change the output type on meter 2 to 4 - 20 mA current.

Now we can enter a mA value in the Meter 2 Direct Out field, and the controller will output at that value.

Welcome. This video will demonstrate setup and basic procedures for communicating with your FUSION Controller using the Modbus TCP Fieldbus over an Ethernet connection.

Modbus TCP is a fieldbus that allows digital communication between a PLC and the controller.

There are some advantages to using Modbus TCP over an analog interface: first, it allows access to all user parameters. It eliminates analog error, and lowers wiring installation costs.

Before we begin, you'll need to install the Control Panel software, provided free with your controller.

Connect power to the controller and connect to your computer with a USB cable.

Now, you will need to set up communication between your factory controller or PLC and the power controller. For this tutorial, we will use a laptop connected to the controller with an Ethernet cable.

Let's look at a few basic procedures. First, we will identify the IP address on our controller.

From the outside of the controller, you can use the up and down arrows to scroll through parameters and find the IP address. Your controller may display zeroes if it is using default factory settings.

Let's also open the Control Panel software. On the lefthand side of the screen, you should see USB selected as the interface. Click the "Connect" button.

Next choose the "Digital Communication" tab. You will see "Common Settings" - we'll come back to that later - and below that: TCP/IP Settings. Here we can view or change the IP address.

Now let's set our network IP address on the controller. First we enter the address here. You will need to consult your network administrator for the correct address.

For operation with industrial systems, we recommend that you only use a static IP address. In DHCP, the server may re-assign addresses and the PLC will not be able to locate the correct controller.

Once you have entered a static IP address, click "Save." The controller display will let you know that the new IP address is being applied. It may take up to 60 seconds to change.

To test the connection between our PLC and the controller, we return to the Control Panel and select "Modbus TCP" as the interface, and then hit "Connect."Provided that the laptop or PLC is on the same network, the Control Panel will locate and display any FUSION controllers on the network. If there are more than one, you will receive a dialog box prompting you to choose one of the controllers.

We are now connected to the controller, and can begin viewing and adjusting our settings.

Next, we will discuss reading and writing parameters. 

We'll specifically look at two kinds of parameters: setup parameters, and monitor parameters.

Setup parameters are numbered 1 - 199, and can both be read and written to. For example - digital setpoint, firing modes, current limits ... these are all setup parameters.

Parameters 200 through 389 are Monitor parameters. These are read-only; they consist of process data you may want to monitor, like load voltage, or load current, or load power.

Ok, let's look at a very typical scenario: First, say we want to write a digital setpoint, then, read a monitor parameter, like Load Current A on phase 3, and finally process the information in order to update the setpoint. And then we'll repeat the process.

Writing the setpoint is accomplished with Modbus Function 6, or "Write Single Register" which requires the following information: Slave ID 1, Parameter # 100, and as a value, 50 % or 5000.

To read monitor parameters for Load Current A, we use Modbus Function 3, "Read Holding Registers." Enter 1 for the Slave ID, 222 for the parameter, and 1 for bytes. We recommend consulting your PLC documentation for specific instructions on how to implement Modbus for your particular controller.

You can also find modbus specifications online at www.modbus.org, under "Technical Resources."

The FUSION Control Panel program also has a nice feature for finding parameters. Just hover your cursor over the value or setting you're looking for, and the corresponding parameter number will appear under the cursor.

We will briefly talk about overloading. If you are reading or writing too many parameters at a time, the controller may become overloaded. To avoid overloading, use block reads to collect data more efficiently. A block read consists of up to 16 parameters. Furthermore, do not poll the controller more than four block reads per second.

Now let's address Digital Communication Failure. Under the digital communication tab on the Control Panel we see "Common Settings." If communication is interrupted, whether because of a cabling issue or your PLC has shut down, this is where you specify how your controller will react. It's known default state that you've defined.

The Comm Heartbeat is like a watchdog for your controller. The default factory setting is 0, which stands for an infinite timeout. When it is set to zero, if there is a communication failure, the controller will continue running as it has been based on your last command. But maybe you want to know, or take a specific action when you have a communication failure.

You have two options, indicated by these two radial buttons: continue, and stop. For our demonstration, our timeout will be set for 5 seconds. This means the controller expects a read or write from the fieldbus, at least every 5 seconds, and if communication has been interrupted, it does one of two things:

If you have the controller set to continue, it continues running at your last digital command until network communication is restored. We can demonstrate this by removing the cable. After 5 seconds, the controller displays a warning and holds the last command. So to restore communication, we correct the failure and make sure the factory controller or the PLC is communicating with the controller. Then the warning alarm will disappear.

If you select "stop" and communication is interrupted, the controller goes into an inhibit state and stops operating. This is a fault state, indicated on the control panel here. You may choose this option as a safety precaution, it all depends on your specific application and preferences.

Stop mode requires you to do two things to get the controller back to run state: First, restore digital communication - fix the problem, in our case restore the cable, and make sure there is communication between the factory controller or PLC and the controller. Then cycle run/reset on P1 to clear the fault. These two steps need to happen in sequence; first restore digital communication, and second cycle run/reset.

An additional option would be to have the controller notify an external signaling device, like a light tower or alarm system. You can find this option under the "System" tab on the control panel; choose "Communication Error" here to trigger Relay 1 or Relay 2 in the event of a communication failure.

For more detailed instructions, visit our website at www.ccipower.com or contact the experts at Control Concepts Inc.