USER MANUAL

PHASE ANGLE CONTROLLED

AC POWER CONTROLLER
CONTENTS :

CHAPTER 1 PRODUCT OVERVIEW :

DESCRIPTION 1-1
PRODUCT CODE 1-1
TECHNICAL SPECIFICATION 1-2
ENVIRONMENT 1-2
CHAPTER 2 INSTALLATION :
MECHANICAL INSTALLATION
1 & 2 PHASE PCU 2-1
3 PHASE PCU 2-2
ELECTRICAL INSTALLATION
WIRING GUIDELINES 2-3
CONTROL WIRING
1 & 2 PHASE WITH AP-13 2-3
1 & 2 PHASE WITH AP-29 2-4
3 PHASE WITH AP-12 2-5
POWER WIRING
1 & 2 PHASE 2-6
3 PHASE 2-7
CHAPTER 3 STANDARD FEATURE :
SWITCH SELECTION 3-1
POTENTIOMETER SETTING 3-2
SOFT STARTING 3-2
SYNCHRONISATION 3-2
DV / DT PROTECTION 3-2
ZERO SETTING 3-3
SPAN SETTING 3-3
CURRENT LIMIT 3-4
VOLTAGE REGULATION 3-4
CHAPTER 4 TROUBLE SHOOTING
NO OUTPUT 4-1
HIGH OUTPUT 4-2
APPENDIX A TEST CHART :

CONTENTS
CHAPTER 1 PRODUCT OVERVIEW

DESCRIPTION :
AMEE POWER AC POWER CONTROLLER UNIT ( PCU ) IS A COMPACT OPEN
EXCECUTION CHASSIS MOUNTED MODULE. IT CONSISTS OF MAINLY TWO
PARTS - POWER SECTION AND CONTROL SECTION. THE POWER SECTION
COMPRISES OF LAVISHLY RATED ANTI-PARALLEL CONNECTED SCRS MOUNTED
ON ELECTRICALLY ISOLATED HEAT SINKS (UPTO 500 AMPS) WHERE AS THE
CONTROL SECTION CONSISTS OF GATE FIRING AND TRIGGER CONTROL
CIRCUIT, POWER SUPPLY X-MER,CTS AND RC SNUBBER CIRCUITS.

PRODUCT CODE :
ALL PCUS ARE FULLY IDENTIFIED USING SIX BLOCK ALPHANUMERIC CODE.
THIS CODE DETAILS THE PCU CALIBRATION AND SETTINGS ON DESPATCH
FROM THE FACTORY. THE PRODUCT CODE APPEARS AS THE “ MODULE TYPE “ ON
THE RATING LABEL AT THE RIGHT SIDE OF THE UNIT. DETAILS OF EACH
BLOCK OF THE PRODUCT CODE ARE GIVEN BELOW :
1 2 3 4 5 6
MODULE TYPE :AP- 1 3 4 0 0 3 0 1

1 0 = ZERO FIRING 4 003 = 30 AMPS

1 = PHASE FIRING 005 = 50 AMPS
2 1 = SINGLE PHASE 007 = 70 AMPS
2 = TWO PHASE 009 = 90 AMPS
3 = THREE PHASE 015 = 150 AMPS
3 1 = 115 V 020 = 200 AMPS
2 = 230 V 025 = 250 AMPS
3 = OTHER VOLTAGES 035 = 350 AMPS
4 = 415 V 050 = 500 AMPS
5 0 = NONE 075 = 750 AMPS
1 = CURRENT REGULATION - CR 100 = 1000 AMPS
2 = POWER REGULATION - WR 135 = 1350 AMPS
3 = OVER CURRENT SHUT OFF - OC 170 = 1700 AMPS
4 = SEMI CONDUCTOR FUSES - SCF 210 = 2100 AMPS
5 = BLOWN FUSE MONITOR - FM 240 = 2400 AMPS
6 0= DC DRIVE 300 = 3000 AMPS
1 = RESISTIVE LOAD
2 = INDUCTIVE LOAD
PRODUCT OVERVIEW 1-1
TECHNICAL SPECIFICATION :

CONTROL METHOD : ZERO FIRING OR PHASE ANGLE FIRING OF

BACK TO BACK CONNECTED SCRS.

VOLTAGE RATING : 115V , 230V OR 415 VAC, 50HZ.

CUURENT RATING : 30, 50, 70, 90, 150, 200, 275, 350, 500,
750, 1000, 1350, 1750, 2100,2400 & 3000 AMPS.

COMMAND SIGNAL : MOST STANDARD PROCESS SIGNALS LIKE :

0-5 V DC
0-10 V DC
0-20 mA DC
2-12 mA DC
4-20 mA DC
10-50 mA DC
VOLT PULSE

ISOLATION : 2500 VOLTS RMS FROM POWER CIRCUIT TO

COMMAND SIGNAL AND TO GROUND.

LINEARITY : AVERAGE OUTPUT VOLTAGE IS LINEAR TO

COMMAND SIGNAL.

ENVIRONMENT :

OPERATING TEMPERATURE : 0-50 * C

STORAGE TEMPERATURE : -10 * C TO 55 * C
SHIPPING TEMPERATURE : - 10 * C TO 70 * C
HUMIDITY : MAX. 85 % RH AT 40 * C

PRODUCT OVERVIEW 1-2

CHAPTER 2 INSTALLATION

MECHANICAL INSTALLATION :
MOUNTING
THE AMEE POWER PCU MUST BE MOUNTED VERTICALLY ON A SOLID FLAT
VERTICAL SURFACE. ALL PCUS ARE DIRECT WALL MOUNTABLE.

DIMENSIONS FOR 1 PH & 2PH PCU :

h1
h
w1 d
w
FRAME -1

ALL DIMENSIONS ARE IN MM

current h w d h1 w1 wt

25 .... 70A frame - 1 230 205 107 207 233 5 kgs

100A frame - 1

150A frame - 2

200A frame - 2

250...350A frame - 3

INSTALLATION 2-1
DIMENSIONS FOR 3 PH PCU:

h1
h
w1 d d d
w
FRAME -1 FRAME -2 FRAME -3

ALL DIMENSIONS ARE IN MM

current h w d h1 w1 wt

25 .... 70A frame - 1 345 270 190 330 230 10 kgs

100A frame - 1 345 270 230 330 230 11 kgs

150A frame - 2 460 270 300 418 175 13 kgs

200A frame - 2 510 270 300 468 175 14 kgs

250...350A frame - 3 400 270 270 360 242 15 kgs

NOTE: FRAME-3 COMES WITH ADDITIONAL 3PH 440V COOLING FAN

INSTALLATION 2-2
ELECTRICAL INSTALLATION
WIRING GUIDELINES
THE THREE PHASE AMEE POWER PCUS ARE DESIGNED TO ACCEPT 3 PHASE ,
3 WIRE 415 V +/- 10 % , 50 HZ +/- 5% AC INPUT SUPPLY. WHEREAS THE SINGLE
PHASE AMEE POWER PCUS ARE DESIGNED TO ACCEPT 1 PHASE / 2 PHASE
, 2 WIRE 230 / 415 V + / - 10 % , 50 HZ + / - 5 % AC INPUT SUPPLY.
WARNING : DO NOT CONNECT THE AC INPUT TO THE OUTPUT TERMINALS. IT
WILL DAMAGE THE PCU.
CAUTION : ENSURE ALL SCREWS ARE TIGHTENED PROPERLY.
PLEASE FOLLOW ALL LOCAL ELECTRICAL AND SAFETY CODES.

CONTROL WIRING

CONTROL WIRING FOR SINGLE OR TWO PHASE PCU :

THE DIAGRAM BELOW SHOWS THE TYPICAL CONTROL CONNECTIONS
REQUIRED FOR OPERATION AS A PCU.

63
64
62
61

02
1 2 3 4

01
FRC CABLE

FUSE LINK 1 2

FRC CABLE
P/S CARD
CONTROL CARD
TYPE : AP-13P
TYPE : AP-13
LED2

LED1

+ VCC
LED1 - +12V
LED2 - -12V
1 2 3 4 5 6 7 8

55

57
43

58
44

56
42
41
EXT. CL

mA I/P
V I/P
L/O GND CT
NC=ON SIGNAL

INSTALLATION 2-3
CONTROL WIRING :
CONTROL WIRING FOR SINGLE OR TWO PHASE PCU :
THE DIAGRAM BELOW SHOWS THE TYPICAL CONTROL CONNECTIONS
REQUIRED FOR OPERATION AS A PCU.

V
V

V
V

0V

G2
0V
0V
15

K2
15
0V

G1
10

K1
20
73
74
75
76
77
78
79
80

62
63
64
61
1 2 3 4 5 6 7 8 9 10 11 12

CONTROL CARD
TYPE : AP-29.01

+ VCC
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

42
43
44
45
46
47
48
49
50

52
53
54

58
59
60
41

51
+ - + -

LOGIC O/P

MA I/P
INCH I/P
VOLT I/P
GND
+ 12V

- 12V
V
FB CT1 L/O

EXT. CL
V CC
NC=ON

NOTE: CONNECT POT AT TERMINAL NO 5,6 & 7 ONLY WHEN RAMP CIRCUIT IS REQUIRED

INSTALLATION 2-4
CONTROL WIRING FOR THREE PHASE PCU :
THE DIAGRAM BELOW SHOWS THE TYPICAL CONTROL CONNECTIONS
REQUIRED FOR OPERATION AS A PCU.

V
V

V
V

0V

0V
G6
G5

0V
15
15
0V
G3

G4
G2

K4

10
K5

K6
K2

20
K3
G1
K1

73
74
75
76
77
78
79
80
62
63
64
65
66
67
68
69
70

72
61

71
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

CONTROL CARD
TYPE : AP-12

+ VCC
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

42
43
44
45
46
47
48
49
50

52
53
54
55
56

58
59
60
41

51
+ - - + -

LOGIC O/P

MA I/P
INCH I/P
VOLT I/P
GND
+ 12V

- 12V
V
FB CT1 CT2 L/O

EXT. CL
V CC
NC=ON

NOTE: CONNECT POT AT TERMINAL NO 5,6 & 7 ONLY WHEN RAMP CIRCUIT IS REQUIRED

INSTALLATION 2-5
POWER WIRING
POWER WIRING FOR SINGLE / TWO PHASE PCU :
ALWAYS CONNECT THE POWER SUPPLY LINE TO INPUT BUSBAR P & N. MAKE
SURE TO CONNECT THE NEUTRAL TO BUSBAR N VIA A MOLDED-CASE
CIRCUIT BREAKER ( MCCB) OR A FUSE. MAKE SURE TO GROUND THE GROUND
TERMINAL ACCORDING TO THE LOCAL GROUNDING CODE.

INPUT SUPPLY

P N
EXTERNAL
PROTECTIVE
DEVICE

P N

L1 L2

TO LOAD
NEUTRAL IS COMMON
FOR BOTH I/P & O/P

INSTALLATION 2-6
POWER WIRING FOR THREE PHASE PCU :
PRIOR TO CONNECT THE POWER TO THE MODULE VIA A MOLDED-CASE
CIRCUIT BREAKER ( MCCB) OR SEMI CONDUCTOR FUSE , PLEASE CHECK THE
SWITCH POSITION AND PHASE SEQUENCE AT THE THREE PHASE INPUT
SUPPLY. THE INPUT THREE PHASE SEQUENCE ROTATION MUST ALWAYS BE
CLOCKWISE. ANTI-CLOCKWISE INPUT PHASE SEQUENCE MAY RESULT IN
MALFUNCTIONING OF PCU AND HENCE THE UNCONTROLLED CURRENT
MAY CLEAR THE FUSES OR THYRISTOR. PLEASE MAKE SURE TO GROUND
THE GROUND TERMINAL ACCORDING TO THE LOCAL GROUNDING CODE.

INPUT SUPPLY

R Y B
EXTERNAL
PROTECTIVE
DEVICE

R Y B

1 1 : + 12V
2 : - 12V
3 : G.P.S.
4 : SPAN
5 : ZERO
6
6 : C.L.

L1 L2 L3

TO LOAD

INSTALLATION 2-7
CHAPTER 3 STANDARD FEATURES

THE CONTROL CARD IS USED TO CONTROL THE THYRISTOR FIRING ANGLE ,

WHICH ALLOWS A SMOOTH VARIATION OF THE POWER THROUGHOUT THE
CONTROL RANGE. IT MAINTAINS CONSTANT POWER AT THE PRESELECTED
VALUE ( SET BY THE USER ) IRRESPECTIVE OF THE LOAD, TEMPERATURE OR
SUPPLY VOLTAGE VARIATION. IT CAN BE USED IN TWO MODES. AUTO AND
MANUAL MODE. IN AUTO MODE THIS CARD CAN ACCEPT INPUT SIGNALS
ANYWHERE FROM THE AUTOMATION SYSTEM LIKE : PLC , PID , DCS,
COMPUTER INTERFACE SYSTEM ETC. THE SIGNAL CAN BE 4 - 20 mA,
0 - 20mA, 10 - 50mA, 2 - 12 mA. WHERE AS IN MAUAL MODE IT CAN ACCEPT
0 TO 10V OR 0 TO 5V FROM AN EXTERNAL 10K,3W POTENTIOMETER.

SWITCH SELECTION ONLY FOR THREE PHASE PCU :

GENERALLY FOR AC POWER CONTROLLER APPLICATION , S/W - 2 ( J3 ) AND
S/W - 5 ( J7 ) ARE ON AND OTHERS SWITCHES ARE OFF.

WHERE AS FOR CERTAIN APPLICATIONS SWITCH POSITION HAS TO BE

RECONFIGURED AS UNDER. IF SWITCH IS ON OR JUMPER IS CLOSED, THE
REQUIRED FEATURE IS MADE AVAILABLE.

S/W NO JUMPER NO FUNCTION

S/W - 1 J1 RAMP GENERATOR
S/W - 2 J3 WITHOUT FEEDBACK
S/W - 3 J4 WITH FEEDBACK
S/W - 4 NOT USED
S/W - 5 J7 CURRENT LIMIT
S/W - 6 J6 CURRENT FEEDBACK
S/W - 7 J5 VOLTAGE FEEDBACK
S/W - 8 NOT USED

STANDARD FEATURES 3-1

POTENTIOMETER SETTINGS
AS SHOWN IN THE LAYOUT DIAGRAM THERE ARE FIVE SINGLE TURN TRIM
POTENTIOMETERS ARE MOUNTED ON THE CARD.

LEGEND FUNCTION OF THE POTENTIOMETER

P3 RAMP UP TIME
P4 RAMP DOWN TIME
P5 ZERO SETTING
P6 SPAN SETTING
P8 CURRENT LIMIT SETTING

SOFT STARTING
THE PCU HAS BUILT-IN FACILITY OF SOFT STARTTING. WHEN AC POWER IS
APPLIED TO THE PCU, A TIME DELAY OF APOPROXIMATELY 4 SECONDS
INHIBITS ALL GATE SIGNALS TO THE SCRS AFTER THIS INITIAL DELAY
THE SCRS ARE RAMPED ON TO THE LEVEL DETERMINED BY THE CONTROL
SIGNAL, THIS UNIQUE CIRCUITRY PREVENTS THE EXCESSIVE INRUSH
CURRENT TO THE LOAD.

SYNCHRONIZATION CKT
THE MAINS SIGNAL REQUIRED FOR SYNCHRONIZING THE FIRING IS
DELIVERED FROM THE SECONDARY OF THE MAINS POWER SUPPLY
TRANSFORMER. THE DERIVED SIGNAL IS FIRST FILTERED TO PREVENT LINE
DISTURBANCES FROM AFFECTING THE RAMPS. THE FREQUIENCY OF THE
FILTERED SIGNAL WILL BE 50HZ.

DV/DT PROTECTION
A HIGH RATE OF CHANGE OF VOLTAGE ( DV / DT ) CAN CAUSE THE SCR TO
TURN ON. FOR DV/DT PROTECTION , SUITABLY RATED RC NETWORK ARE
CONNECTED ACROSS ALL THE SCRS.

STANDARD FEATURES 3-2

ZERO SETTING
ZERO ( BIAS ) POT ADJUSTMENT IS USED TO SET THE MINIMUM OUTPUT OF
THE PCU. WITH CONTROL SIGNAL AT ITS MINIMUM, THE BIAS SHOULD BE
ADJUSTED UNTIL OUTPUT VOLTAGE IS JUST AT ZERO SO THAT AS THE
CONTROL SIGNAL IS TURNED ON, THE OUTPUT VOLTAGE INCREASES.

EXAMPLE :

FOR 4 TO 20 mA INPUT SIGNAL :

SET THE ZERO ( BIAS ) POT SO THAT TILL THE 4mA SIGNAL SCR WILL NOT
FIRE AND AFTER THAT THE SCR JUST BEGINS TO FIRE.

FOR 0 TO 10 V DC INPUT SIGNAL :

SET THE COMMAND POTENTIOMETER AT MINIMUM POSITION, THEN
ADJUST THE ZERO ( BIAS ) POT SO THAT THE SCR JUST BEGIN TO FIRE.

SPAN SETTING
SPAN ( GAIN ) POT ADJUSTMENT IS USED TO SET THE MAXIMUM OUTPUT
OF THE PCU. AFTER SETTING ZERO , TURN THE CONTROL SIGNAL UPTO ITS
MAXIMUM VALUE AND ADJUST THE SPAN UNTIL THE OUTPUT VOLTAGE IS
JUST AT MAXIMUM VOLTAGE LEVEL WHICH YOU HAVE TO APPLY ACROSS
THE LOAD. SO BY THIS POT ONE CAN CLAMP THE UPPER LIMIT.

EXAMPLE :

FOR 4 TO 20 mA INPUT SIGNAL :

SET THE GAIN SO THAT THE SCRS ARE FULLY FIRED , WHEN PROCESS CON-
TROLLER GIVES MAXIMUM OUTPUT OF APPROX. 20mA SIGNAL

FOR 0 TO 10 V DC INPUT SIGNAL :

SET THE COMMAND POTENTIOMETER AT MAXIMUM POSITION, THEN
ADJUST THE SPAN ( GAIN ) POT SO THAT THE SCRS ARE FULLY FIRED.

STANDARD FEATURES 3-3

CURRENT LIMIT
NORMALLY CURRENT LIMIT ADJUSTMENT IS SET AT THE RATED OUTPUT
OF THE PCU. THIS IS ADJUSTABLE ANY WHERE FROM 20% TO 110% OF THE
RATED VALUE. TURNING THE POT CLOCKWISE WILL INCREASE THE CL SET
VALUE WHERE AS TURNING THE POT ANTICLOCKWISE WILL REDUCE THE
SET VALUE. IT IS RECOMMANDED TO SET THE CL VALUE AT YOUR REQUIRED
CURRENT LEVEL. BECAUSE THE CURRENT LIMIT TAKES PRECEDANCE OVER
THE CONTROL SIGNAL AND WILL PREVENT THE OUTPUT CURRENT FROM
INCREASING BEYOND THE SETTING EVEN THOUGH THE CONTROL SIGNAL IS
INCREASED.

FOR OPERATING THE PCU AT THE DESIRED MAXIMUM CURRENT, FIRST

TURN THE CL POT ANTI-CLOCKWISE UNTIL THE OUTPUT CURRENT JUST
BEGINS TO DECREASE, THEN TURN THE POT SLIGHTLY CLOCKWISE. AN
EXTERNAL CURRENT LIMIT POT ( 10K,3W ) MAY BE WIRED TO THE PCU.
FOR EXTERNAL CL CONNECT THE POT VARIABLE AT TERMINAL NO 20.

VOLTAGE REGULATION

THIS FEATURE IS VERY USEFULL WHERE CLOSE- LOOP CONTROL IS REQUIRED

WITHOUT SUDDEN OVERSHOOT OF VOLTAGE LEVEL. THE OUTPUT VOLTAGE
OF THE PCU IS MONITORED CONTINEOUSLY AND MAINTAINED WITHIN THE
TOLLARENCE OF + /- 2 % OF MAX. SET VALUE IRRESPECTIVE OF LINE AND
LOAD VARIATION. THE PERMISSIBLE LINE VARIATION IS + / - 10 % OF INPUT
SUPPLY VOLTAGE.

STANDARD FEATURES 3-4

TROUBLE SHOOTING GUIDE:

NO OUTPUT:

1: INPUT POWER NOT PRESENT OR OUT OF PHASE.

IF UNIT IS 3 PHASE, VERIFY CORRECT (CLOCKWISE) PHASE ROTATION.

2: CONTROL SIGNAL NOT PRESENT / POLARITY REVERSED.

CHECK THAT CORRECT CONTROL SIGNAL IS APPLIED TO PROPER
TERMINALS ON THE CONTROL AMPLIFIER AND THAT POLARITY OF
SIGNAL IS CORRECT.

3: ZERO AND / OR SPAN POT OUT OF ADJUSTMENT.

CHECK THAT CONTROL AMPLIFIER ZERO AND SPAN SETTING ARE NOT OUT
OF ADJUSTMENT

4: CL POT IS AT ZERO POSITION.

OUTPUT IS BLOCKED, SO INPUT IS HIGHER, BUT OUTPUT IS VERY LOW
HENCE CHECK THE CURRENT LIMIT POT.

TROUBLE SHOOTING 4-1

HIGH OUTPUT (NO CONTROL):

1: BIAS AND / OR GAIN OUT OF ADJUSTMENT.

CHECK THAT THE CONTROL AMPLIFIER ZERO AND SPAN SETTINGS ARE
NOT OUT OF ADJUSTMENT

2: SHORTED SCR.
CHECK THAT SCRS HAVE NOT FAILED SHOTED.

3: FAULT IN THE CARD

CHECK FOLLOWING LED STATES ON THE CONTROL CARD
LED 1 : -12V
LED 2 : +12V
LED 3 : GATE POWER SUPPLY
LED 5 : LOCKOUT
LED 6 : HIGH FREQUINCY

IF LED1 AND LED2 ARE NOT LIT, PLEASE CHECK ALL THE TEST POINT ON
THE CARD. IF LED5 IS NOT LIT, CHECK FOR LOCKOUT SIGNAL (INHIBIT
SIGNAL) IT IS NORMALLY OPEN / CLOSE CONTACT.

4: RAMP FUNCITION:
RAMP GENERATOR IS NORMALLY USED TO ACHIEVE THE REFERENCE AT
PRE DETERMINED RETE SO THAT THE SUDDEN JERKS AT STARTING CAN
BE AVOIDED. IT HAS TWO ADJUSTABLE POT RAMP UP SETTING (P3) AND
RAMP DOWN SETTING (P4) BY POT P3 YOU CAN ADJUST RAMP-UP
(ACCELERATION) TIME AND BY POT P4 YOU CAN ADJUST RAMP-DOWN
(DEACCELERATION) TIME.

TROUBLE SHOOTING 4-2

TEST CHART FOR CARD AP-12
REMARKS :

PLOT NO : 5303 , PHASE - 4

GIDC VATVA, AHMEDABAD
TELEFAX : 079-25840079, 25840578
email 1l : ameepower@ameepower.com
email 2 : mbg@ameepower.com