Table of Contents
Advertisement
Quick Links
Installation, Operation and Troubleshooting Instructions
The use of an appropriate single-phase or three-phase fused disconnect or circuit breaker with this Power
Controller is required to ensure the safety of operating personnel.
HAZARDOUS VOLTAGES exist at the Power Controller Heat Sinks and at the Load, AT ALL TIMES, when
input Voltage is connected. This condition exists even when the Power Controller is set to deliver zero output.
The fused disconnect or circuit breaker must be open or OFF to perform maintenance of any kind, including at
the Load.
If this Handbook is not supplied to the End User, a warning statement identical to the above should be
prominently displayed in the Installation and Operation Instructions provided to the End User.
PHASE/AMP SERIES DPA1 & DCPA1
POWER CONTROLLERS
ORIGINAL EQUIPMENT MANUFACTURERS
***PLEASE NOTE***
530 LAKEVIEW PLAZA BLVD, STE C
WORTHINGTON, OHIO 43085
TEL: 614-308-5500
TOLL FREE: 1-888-797-2685
FAX: 614-308-5506
Web: www.hdrpower.com
FOR
WARNING
Document: 9100030
Advertisement
Table of Contents
Troubleshooting
Related Manuals for Ametek DPA1 Series
Summary of Contents for Ametek DPA1 Series
- Page 1 Installation, Operation and Troubleshooting Instructions PHASE/AMP SERIES DPA1 & DCPA1 POWER CONTROLLERS WARNING The use of an appropriate single-phase or three-phase fused disconnect or circuit breaker with this Power Controller is required to ensure the safety of operating personnel. HAZARDOUS VOLTAGES exist at the Power Controller Heat Sinks and at the Load, AT ALL TIMES, when input Voltage is connected.
-
Page 3: Table Of Contents
MULTIPLE ZONE CONTROL WITH ONE TEMPERATURE CONTROLLER: .... 12 2-21. LINE VOLTAGE CHANGES: .................... 12 SECTION III - OPERATION ......................15 3-1. GENERAL........................... 15 3-3. STANDARD CONTROLS....................15 3-5. GAIN CONTROL........................ 15 Document 9100030 AMETEK HDR Power Systems... - Page 4 Figure 4-6 DPA-1 PHASE/AMP Waveforms ................27 4-33. SOFT START CIRCUIT..................... 28 4-35. SOFT START RESET CIRCUIT..................28 4-37. SCR FIRING CIRCUIT....................... 28 4-38. PULSE SHAPER CIRCUITS....................28 4-40. POWER SCR CIRCUITS....................29 AMETEK HDR Power Systems Document 9100030...
- Page 5 CORRECTING TYPICAL DPA-1 TROUBLE SYMPTOMS..........33 5-17. GENERAL TROUBLE SHOOTING PROCEDURES............34 SECTION VI -DIAGRAMS ......................39 6-1. GENERAL ........................... 39 6-3. QUICK INDEX TO DIAGRAMS..................39 Table 6-1 Quick Index To Diagrams ..................39 Document 9100030 AMETEK HDR Power Systems...
- Page 6 Table of Contents Phase/AMP Series DPA1/DCPA1 AMETEK HDR Power Systems Document 9100030...
-
Page 7: Section I - Description
Voltage is limited by firing-circuit design restrictions to 97% of the line Voltage. Refer to DCPA-1 outline and mounting dimension drawing 02C100259 for details on physical placement of components. Document 9100030 AMETEK HDR Power Systems... -
Page 8: Options And Accessories Available
OPTIONS AND ACCESSORIES AVAILABLE. 1-7. The options and accessories available for use with the DPA-1, DCPA-1 PHASE/AMPS are described in the paragraphs 1-8 through 1-25. The options and accessories desired should be specified at time of order. AMETEK HDR Power Systems Document 9100030... -
Page 9: Option A, Current Limit
The current limit portion is included to avoid operation that would result in excessive currents at low Voltages even though the load power rating is not exceeded. This option requires a 5VA Current Transformer. A Percent Power Indicator (option T, refer to paragraph 1-22) is also available. Document 9100030 AMETEK HDR Power Systems... -
Page 10: Option T, Percent Power Indicator
1-31. In the event that any question should arise concerning application or selection of available options and accessories, prompt assistance may be obtained by calling AMETEK HDR Power Systems Customer Support at 614-308-5500 Table 1-2 General Technical Specifications for DCPA-1/DPA-1 PHASE/AMPS... - Page 11 158°F (70°C) maximum. Metering Options RMS ammeter, accuracy (+5%) of full scale deflection RMS Voltmeter, accuracy (+5%) of full scale deflection Percent power meter, accuracy (+2%) of full scale deflection *With Current Limit option Installed Document 9100030 AMETEK HDR Power Systems...
- Page 12 Description Phase/AMP Series DPA1/DCPA1 AMETEK HDR Power Systems Document 9100030...
-
Page 13: Section Ii - Installation
Other PHASE/AMPS on the same line will not be affected. The noise will not be transmitted back through any transformers or to any other windings on the same transformer. Document 9100030 AMETEK HDR Power Systems... -
Page 14: Radio Frequency Interference
Hazardous Voltages are present on the large, finned heat sinks and at most of the exposed terminals. Always remove electrical power from the unit before installing, removing, or performing service (replacing fuses, etc.) on the unit. AMETEK HDR Power Systems Document 9100030... - Page 15 100 watt light bulbs in series. The number of light bulbs required can be determined by dividing the full rated Voltage output of the unit by 120. Figure 2-1 Front View of Typical DPA-1 Document 9100030 AMETEK HDR Power Systems...
- Page 16 Connect the positive (+) terminal of the process controller to terminal 2 on terminal strip TB1. At this point, the milliammeter is connected to measure the control signal current from the process controller. AMETEK HDR Power Systems Document 9100030...
- Page 17 If the unit does have the Current Limit option, proceed as follows: (1) Position the CURRENT LIMIT control, on the Control Limit Module, to the center line or mid position. (2) Turn on main power. (3) Adjust the process controller to demand full power. Document 9100030 AMETEK HDR Power Systems...
-
Page 18: Multiple Zone Control With One Temperature Controller
Add a new jumper between terminals 3 and 15 on T1. e. Move the input wire (or wires) from terminal 16 of T1 to terminal 15. Locate transformer T2. It is the smaller one on the unit. AMETEK HDR Power Systems Document 9100030... - Page 19 Remove one end of the jumper connected to terminal 5 of %1 and re- connect to terminal 15. c. Change R105 to 2500 OHMS, 12 Watts. d. The unit will now operate from a 277 Volt line. Document 9100030 AMETEK HDR Power Systems...
- Page 20 Installation Phase/AMP Series DPA1/DCPA1 AMETEK HDR Power Systems Document 9100030...
-
Page 21: Section Iii - Operation
10 milliamperes. This will result in a reduced proportional band and potentially unstable operation of the control system. If the GAIN control is set low, full output of the PHASE/AMP will never be delivered to the load. Document 9100030 AMETEK HDR Power Systems... -
Page 22: Bias/Manual Control
2 milliamperes. Figure 3-2 Controller-Output Span with No Offset Bias Current Introduced Figure 3-3 Controller Output Span With A –2 Milliamperes of Offset Bias Current Introduced AMETEK HDR Power Systems Document 9100030... -
Page 23: Manual Function
125 percent of the rated current output of the PHASE/AMP, the optional current Limit device is required. The Current Limit will protect the unit from overload while the heating element is coming up to temperature. Document 9100030 AMETEK HDR Power Systems... - Page 24 Voltage and the Current Limit is used as a current control. Setting the CURRENT LIMIT control below the 6.5 percent point is a misapplication of the equipment, and may result in system oscillation and damage to the PHASE/AMP or the load. Consult the factory. AMETEK HDR Power Systems Document 9100030...
-
Page 25: Optional Current Indicator
3-27. OPTIONAL VOLTAGE INDICATOR. 3-28. The optional Voltage Indicator provides a direct indication of the RMS output Voltage across the load. Indicators are available to match the rated input Voltage of all DPA-1 models. Document 9100030 AMETEK HDR Power Systems... - Page 26 Operation Phase/AMP Series DPA1/DCPA1 AMETEK HDR Power Systems Document 9100030...
-
Page 27: Section Iv - Theory Of Operation
Controlling the Voltage across load Z corresponds to controlling the current through load Z and, therefore, the power delivered to load Z Figure 4-2 Comparison of Conduction Angles and Voltage Across Load Document 9100030 AMETEK HDR Power Systems... - Page 28 SCR’s and load Z for the positive and negative half cycles of the input Voltage. Figure 4-3 SCR’s Connected Back-to-Back to Obtain Full Wave Rectification Figure 4-4 Current Flow Through Back-to-Back SCR’s and Load AMETEK HDR Power Systems Document 9100030...
-
Page 29: Power Supply Circuit
This feature prevents the possible clearing of fuses when the unit is turned on. The output of the Soft Start circuit is supplied to the SCR Firing circuit. Document 9100030 AMETEK HDR Power Systems... -
Page 30: Soft Start Reset Circuit
The feedback signal is subtractive and will cause the Summing Amplifier to reduce its DC output signal so that the output current of the PHASE/AMP will remain at the value set by the CURRENT LIMIT control. AMETEK HDR Power Systems Document 9100030... -
Page 31: Bias/Manual Control
AMP-1 and to one end of the BIAS/MANUAL control. The –12 V dc is supplied to pin 6 on the Summing Amplifier and to the other end of the BIAS/MANUAL control. Filter capacitor C5, and zener diodes DZ2 and DZ3 insure constant supply Voltages during brief line interruptions. Document 9100030 AMETEK HDR Power Systems... -
Page 32: Bias/Manual Control
C1. When the optional Current Limit is used, its output is also summed with other signals at the summing point. The control signal from the process controller is negative, and the feedback signals are positive. The bias/manual signal may be positive, negative, or zero. AMETEK HDR Power Systems Document 9100030... - Page 33 Phase/AMP Series DPA1/DCPA1 Theory of Operation Figure 4-6 DPA-1 PHASE/AMP Waveforms Document 9100030 AMETEK HDR Power Systems...
-
Page 34: Soft Start Circuit
Power SCR Q2. The gate signal continues until an AC zero is reached on the line and the SCR Q5 turns off. On the next half cycle, SCR Q4 will fire, and the operation of the Pulse Shaper AMETEK HDR Power Systems Document 9100030... -
Page 35: Power Scr Circuits
The feedback signal is subtractive and will cause the Summing Amplifier to reduce its DC output signal so that the output current from the unit will remain at the value set by the CURRENT LIMIT control. Document 9100030 AMETEK HDR Power Systems... -
Page 36: Current Transformer
100 megohms at 500 V dc, dielectric strength 1500 VAC at 60 HZ for one minute) from the heat sink. Any standard alarm device or circuit may be connected to the contacts on the thermostat. Maximum ratings for the contacts are as follows: Voltage, 250 Volts AC, Current, 7 amperes AC. AMETEK HDR Power Systems Document 9100030... -
Page 37: Section V -Trouble Shooting
If full power output is not required, higher ambient temperature can be tolerated. For each 5% reduction of output current (from 100% max.), the allowable ambient temperature can be increased 1°C (from 50°C) to a maximum of 70°C. Document 9100030 AMETEK HDR Power Systems... - Page 38 The last two or three number digits must be same as those of the type listed. (4) A30X30 type may also be used. (5) Serial Numbers starting 77 or higher may use KAC30 fuse. (6) These models are no longer being produced. AMETEK HDR Power Systems Document 9100030...
-
Page 39: Correcting Typical Dpa-1 Trouble Symptoms
Check for proper firing pulses to power SCR’s as described in paragraphs 5-26 and 5-27. If the proper firing pulses are not present, proceed with the general trouble shooting procedures, paragraph 5-17. 5-14. Constant Full Output, No Control. a. Check power SCR’s Q1 and Q2 for anode to cathode short. Document 9100030 AMETEK HDR Power Systems... -
Page 40: General Trouble Shooting Procedures
5-20. If the multimeter does not indicate the specified value, check the following components. Observe previous WARNING; replace faulty components and repeat this test. Zener diodes DZ2 and DZ3. Resistors R14 and R15. Capacitor C5. Rectifiers D1 through D4. Power transformer T1. Associated Wiring. AMETEK HDR Power Systems Document 9100030... - Page 41 +7 Volts or more in approximately 200 (+20) milliseconds. If the oscilloscope display is as specified, proceed to paragraph 5-24. If the oscilloscope display is not as specified, check the following components. Observe previous WARNING; repeat test if any components are replaced. Capacitor C4. Resistor R7. Transistor Q7. Document 9100030 AMETEK HDR Power Systems...
- Page 42 5-27. If the oscilloscope dos not display the specified pulse train, check the following components. Repeat this test if faulty components are located and replaced. Silicon controlled rectifier Q5. Pulse transformer T3. Resistor R21 and R22. Capacitors C11 and C17. Power transformer T1. AMETEK HDR Power Systems Document 9100030...
- Page 43 SCR’s Q1 and Q2. Repeat this test if either is replaced. 5-29. Close the feedback loop by resoldering the wire to feedback transformer T2 (which was removed at paragraph 5-21). Document 9100030 AMETEK HDR Power Systems...
- Page 44 Trouble Shooting Phase/AMP Series DPA1/DCPA1 AMETEK HDR Power Systems Document 9100030...
-
Page 45: Section Vi -Diagrams
Schematic diagram, 30 and 50 AMP PA-1, plus all DPA-1 units 05C100123 Schematic diagram, PHASE/AMP Thyristor power amplifier 05D100260 DCPA-1 PC board assembly, 30 and 50 Amps PA-1 plus all DPA-1 units 26C100039 PC board assembly, DCPA-1 PHASE/AMP 26C100261 Document 9100030 AMETEK HDR Power Systems... - Page 46 Diagrams Phase/AMP Series DPA1/DCPA1 AMETEK HDR Power Systems Document 9100030...